Big Blue 400 CX

TM-4435C 2008−05
Eff. w/Serial Number LE341957 Thru

LJ140120E
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A) Cut-

ting and Gouging
Description
Engine Driven Welding Generator
Big Blue 400 CX

)
Effective With Serial Number LE341957 Thru LJ140120E
File: Engine Drive

Visit our website at
www.MillerWelds.com
INFORMATION ON OLDER UNITS
This manual includes operating information for current units. To obtain specific operating information for older models, download the applicable
Owner’s Manual from www.MillerWelds.com
This manual covers the Big Blue 400 CX CC/CV Flux Core model (907143)
from LE341957 thru LJ140120E and the Big Blue 400 CX CC/CV
model (907281) from LF410002E thru LH040123E. Eff w/LH040124E, the Big Blue 400 CX CC/CV became the Big Blue 400 PX CC/C
(OM-229979).
Eff w/LG440030E, the auto-idle assembly (optional) was changed and circuit breaker CB9 was added.
Eff w/LJ110231E, this unit was manufactured with the Tier III (emission standard) engine .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SECTION 2 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-2. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SECTION 3 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-2. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-3. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-4. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-5. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-6. AC Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-2. Mounting Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-4. Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-5. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-6. Activating The Dry Charge Battery (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-7. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-8. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-9. Connecting To Weld Output Terminals On CC/CV Flux Core Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-10. Connecting To Weld Output Terminals On CC/CV Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4-11. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-12. Connecting To Remote 14 Receptacle RC14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SECTION 5 − OPERATING WELDING GENERATOR
(CC/CV FLUX CORE MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-1. Front Panel Controls (See Section 5-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-2. Description Of Front Panel Controls On CC/CV Flux Core Models (See Section 5-1) . . . . . . . . . . . . . 21
5-3. Process/Contactor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-4. Lift-Arc Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5-5. Remote Voltage/Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
(CC/CV MODELS THRU LH040123E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6-1. Front Panel Controls (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6-2. Description Of Front Panel Controls (See Section 6-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6-3. Process/Contactor Switch On CC/CV Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6-4. Lift-Arc Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6-5. Remote Voltage/Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SECTION 7 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7-1. Auxiliary Power Receptacles On CC/CV Flux Core Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7-2. Auxiliary Power Receptacles On CC/CV Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
SECTION 8 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8-1. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8-2. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8-3. Caterpillar Customer Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8-4. Checking Generator Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8-5. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8-6. Inspecting And Cleaning Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8-7. Servicing Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8-8. Adjusting Engine Speed On Standard Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
TABLE OF CONTENTS
8-9. Adjusting Engine Speed On Models With Automatic Idle (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

8-10. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8-11. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8-12. Optional Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
SECTION 9 − THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
SECTION 10 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
10-1. Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
10-2. Troubleshooting Circuit Diagram For Welding Generator (Use With Section 10-3) . . . . . . . . . . . . . . . . 48
10-3. Troubleshooting Values For Circuit Diagram (Use With Section 10-2) . . . . . . . . . . . . . . . . . . . . . . . . . . 50
10-4. Waveforms For Sections 10-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
10-5. Filter Board PC6 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
10-6. Filter Board PC6 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
10-7. Module Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
10-8. Main Control Board PC1 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
10-9. Main Control Board PC1 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
10-10. Voltage Regulator Board PC3 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
10-11. Voltage Regulator Board PC3 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
10-12. Meter Display Board PC2 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
10-13. Meter Display Board PC2 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
10-14. Idle Module PC5 Testing Information And Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . . 60
10-15. Replacing Brushes And Cleaning Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
10-16. Checking Unit Output After Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
SECTION 11 − DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
11-1. Disassembly Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
11-2. Disassembly Of Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
11-3. Other Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
11-4. Replacing Rectifier SCR Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
SECTION 12 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
SECTION 13 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
13-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
13-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
13-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
SECTION 14 − PARTS LIST EFF w/LE341957 THRU LJ110230E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
SECTION 15 − PARTS LIST EFF w/LJ110231E THRU LJ140120E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Declaration of Conformity for
European Community (CE) Products
This information is provided for units with CE certification (see rating label on unit).
Manufacturer: European Contact:

Miller Electric Mg. Co. Mr. Danilo Fedolfi,
1635 W. Spencer St. Managing Director
Appleton, WI 54914 USA ITW Welding Products Italy S.r.l.
Phone: (920) 734-9821 Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39(02)98290-1
Fax: 39(02)98290203
European Contact Signature:
Declares that the product: Big Blue 400 CX

conforms to the following Directives and Standards:
Directives
Low Voltage Directive: 73/23/EEC
Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC
Machinery Directives: 98/37/EEC, 91/368/EEC, 92/31/EEC, 133/04, 93/68/EEC
Noise level of Welding Generators: 2000/14/EC
Standards
Arc Welding Equipment − Part 1: Welding Power Sources. IEC 60974-1 Ed. 2.1
Rotating Electrical Machines − Part 1: Rating and Performance.
IEC 60034-1 Ed. 10.2 1999-08
Rotating Electrical Machines − Part 5: Classification Of Degrees Of Protection Provided By Enclosure Of Rotating
Electrical Machines (IP Code) IEC 60034-5 2001-06
Insulation Coordination For Equipment Within Low-Voltage Systems:
Part 1: Principles, Requirements and Tests: IEC 60664-1 Ed. 1.1 2000-04
Arc Welding Equipment − Part 10: Electromagnetic Compatibility (EMC) Requirements. IEC 60974-10 August 2002
The product technical file is maintained by the responsible Business Unit(s) located at the manufacturing facility.
dec_rot_6/05
Declaration of Conformity for
European Community (CE) Products
This information is provided for units with CE certification (see rating label on unit).
Manufacturer: European Contact: Notified Body:

Miller Electric Mg. Co. Mr. Danilo Fedolfi, AV Technology Limited
1635 W. Spencer St. Managing Director AVTECH House
Appleton, WI 54914 USA ITW Welding Products Italy S.r.l. Birdhall Lane
Phone: (920) 734-9821 Via Privata Iseo 6/E Cheadle Heath
20098 San Giuliano Stockport, Chesire SK30XU
Milanese, Italy
Phone: 39(02)98290-1
Fax: 39(02)98290203
European Contact Signature:
The Manufacturer Declares the: Big Blue 400 CX

Conforms to Directive: 2000/14/EC, Noise Level of Welding Generators
Effective Date: 7/2004
Sound Level Information

Measured Sound Power Level: 96 dB
Guaranteed Sound Power Level: 96 dB
Sound power level requirements determined by the 30% duty cycle of 400 A, 23 V
Conforming assessment procedure 1 of Annex VI will be followed.
The product technical file is maintained by the responsible Business Unit(s) located at the manufacturing facility.
dec_rotsound_6/05
SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING
Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage

OM-4435L/M - 2007−05/2008−03, safety_rtm 2007−04
DANGER! − Indicates a hazardous situation which, if Indicates special instructions.

not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,

could result in death or serious injury. The possible This group of symbols means Warning! Watch Out! ELECTRIC
hazards are shown in the adjoining symbols or ex- SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
plained in the text. bols and related instructions below for necessary actions to avoid the
hazards.
NOTICE − Indicates statements not related to personal injury.
1-2. Servicing Hazards
The symbols shown below are used throughout this manual FLYING METAL or DIRT can injure eyes.
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions Wear safety glasses with side shields or face
to avoid the hazard. shield during servicing.
Be careful not to short metal tools, parts, or
Only qualified persons should test, maintain, and repair this wires together during testing and servicing.
unit.
During servicing, keep everybody, especially children, away. STATIC (ESD) can damage PC boards.
Put on grounded wrist strap BEFORE handling
ELECTRIC SHOCK can kill. boards or parts.
Do not touch live electrical parts. Use proper static-proof bags and boxes to
store, move, or ship PC boards.
Stop engine and remove input power plug from
receptacle (if applicable) before testing or re-
pairing unit unless the procedure specifically
requires an energized unit. Using a generator indoors CAN KILL
Insulate yourself from ground by standing or working on dry insu- YOU IN MINUTES.
lating mats big enough to prevent contact with the ground.
Generator exhaust contains carbon monoxide.
Do not leave live unit unattended. This is a poison you cannot see or smell.
If this procedure requires an energized unit, have only personnel NEVER use inside a home or garage, EVEN IF
familiar with and following standard safety practices do the job. doors and windows are open.
When testing live unit, use the one-hand method. Do not put both Only use OUTSIDE and far away from windows, doors, and
hands inside unit. Keep one hand free. vents.
SIGNIFICANT DC VOLTAGE exists after stopping

engine on inverters. FUEL can cause fire or explosion.
Stop engine and let it cool off before checking or
Stop engine on inverter and discharge input capacitors according
adding fuel.
to instructions in Troubleshooting Section before touching any
parts. Do not add fuel while smoking or if unit is near
any sparks or open flames.
Do not overfill tank; clean up any spilled fuel.
MOVING PARTS can cause injury.
FIRE OR EXPLOSION hazard.
Keep away from moving parts such as fans,
belts, and rotors. Do not place unit on, over, or near combustible surfaces.
Keep away from pinch points such as drive
rolls. Do not service unit near flammables.
Have only qualified people remove doors,
panels, covers, or guards for maintenance BATTERY EXPLOSION can BLIND.
and troubleshooting as necessary.
Keep hands, hair, loose clothing, and tools Always wear a face shield, rubber gloves, and
away from moving parts. protective clothing when working on a battery.
Stop engine before disconnecting or connect-
Before working on generator, remove spark plugs or injectors
ing battery cables.
to keep engine from kicking back or starting.
Do not allow tools to cause sparks when working on a battery.
Block flywheel so that it will not turn while working on genera-
tor components. Do not use welder to charge batteries or jump start vehicles.
Reinstall doors, panels, covers, or guards when servicing is Observe correct polarity (+ and −) on batteries.
finished and before starting engine. Disconnect negative (−) cable first and connect it last.
Big Blue 400 CX TM-4435 Page 1

BATTERY ACID can BURN SKIN and EYES. EXPLODING PARTS can cause injury.
Do not tip battery. Failed parts can explode or cause other parts to
Replace damaged battery. explode when power is applied to inverters.
Flush eyes and skin immediately with water. Always wear a face shield and long sleeves
when servicing inverters.
STEAM AND HOT COOLANT can burn.
If possible, check coolant level when engine is
cold to avoid scalding. H.F. RADIATION can cause interference.
Always check coolant level at overflow tank, if
present on unit, instead of radiator. High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
If the engine is warm, checking is needed, and there is no over- communications equipment.
flow tank, follow the next two statements. Have only qualified persons familiar with elec-
Wear safety glasses and gloves and put a rag over radiator cap. tronic equipment perform this installation.
Turn cap slightly and let pressure escape slowly before The user is responsible for having a qualified electrician prompt-
completely removing cap. ly correct any interference problem resulting from the installa-
tion.
MAGNETIC FIELDS can affect Implanted
If notified by the FCC about interference, stop using the equip-
Medical Devices.
ment at once.
Wearers of Pacemakers and other Implanted Have the installation regularly checked and maintained.
Medical Devices should keep away from serv-
Keep high-frequency source doors and panels tightly shut, keep
icing areas until consulting their doctor and the
spark gaps at correct setting, and use grounding and shielding to
device manufacturer.
minimize the possibility of interference.
FALLING UNIT can cause injury.
Use lifting eye to lift unit and properly installed OVERUSE can cause OVERHEATING.
accessories only, NOT gas cylinders. Do not
exceed maximum lift eye weight rating (see Allow cooling period; follow rated duty cycle.
Specifications).
Reduce current or reduce duty cycle before
Lift and support unit only with proper equip- starting to weld again.
ment and correct procedures.
Do not block or filter airflow to unit.
Securely attach components to lifting
equipment.
If using lift forks to move unit, be sure forks are long enough to SHOCK HAZARD from testing.
extend beyond opposite side of unit.
Stop engine or turn Off welding power source (if
HOT PARTS can cause severe burns. applicable) before making or changing meter
lead connections.
Do not touch hot engine parts bare-handed. Use at least one meter lead that has a self-
Allow cooling period before working on retaining spring clip such as an alligator clip.
equipment. Read instructions for test equipment.
To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
READ INSTRUCTIONS.
TILTING OR TIPPING can cause injury. Use Testing Booklet (Part No. 150 853) when
servicing this unit.
Do not put any body part under unit while lifting.
Consult the Owner’s Manual for welding safety
Always use proper equipment (hoists, slings,
precautions.
chains, blocks, etc.) of adequate capacity to lift
and support components (stator, rotor, engine, Use only genuine replacement parts from the
etc.) as needed during job. manufacturer.
PINCH POINTS can injure. Reinstall injectors and bleed air from fuel system according to
engine manual.
Be careful when working on stator and rotor assemblies.
1-3. California Proposition 65 Warnings

For Gasoline Engines:
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of
cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc-
Health & Safety Code Section 25249.5 et seq.) tive harm.
For Diesel Engines:
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of Diesel engine exhaust and some of its constituents are
California to cause cancer and birth defects or other known to the State of California to cause cancer, birth
reproductive harm. Wash hands after handling. defects, and other reproductive harm.
TM-4435 Page 2 Big Blue 400 CX

1-4. EMF Information
Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them, or using a
Electric And Magnetic Fields cable cover.
Welding current, as it flows through welding cables, will cause electro- 2. Arrange cables to one side and away from the operator.
magnetic fields. There has been and still is some concern about such 3. Do not coil or drape cables around your body.
fields. However, after examining more than 500 studies spanning 17
4. Keep welding power source and cables as far away from
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the operator as practical.
committee’s judgment, has not demonstrated that exposure to power- 5. Connect work clamp to workpiece as close to the weld as
frequency electric and magnetic fields is a human-health hazard.” possible.
However, studies are still going forth and evidence continues to be
About Implanted Medical Devices:
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when Implanted Medical Device wearers should consult their doctor and the
welding or cutting. device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
To reduce magnetic fields in the workplace, use the following If cleared by your doctor, then following the above procedures is recom-
procedures: mended.

SECTION 2 − DEFINITIONS
2-1. Warning Label Definitions
1 Remove unit from shipping

S-177 571
crate. Remove Owner’s
1
+
Manual from unit. Follow
instructions to install muffler.
2 Read Owner’s Manual. Read
labels on unit.
2 3 Use Diesel Fuel only, and fill
+ 4
fuel tank. Leave room for
expansion.
Warning! Watch Out! There
are possible hazards as
3 shown by the symbols. Read
DIESEL Owner’s Manual. Follow
instructions to activate
battery.
4 5 Check oil level. Add oil if
necessary.
6 During the first 50 hours of
operation, keep welding load
above 200 amperes. Do not
weld below 200 amperes of
output.
5 7 After the first 50 hours of
operation, change the oil and
oil filter.
0 − 50 h Std. 200A 0 − 200A
50 h Std.
API CD-MIL L 2104D,

CD/SE, CD/SF
3/96
Notes
Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

2-2. Symbols And Definitions
Some symbols are found only on CE products.
Fast (Run, Weld/

Stop Engine Slow (Idle) Start Engine
Power)
Starting Aid Engine Oil

Battery (Engine) Engine Oil
(Preheat) Pressure
Check Injectors/ Check Valve Protective Earth

Fuel
Pump Clearance (Ground)
Certified/Trained
Positive Negative Welding Arc
Mechanic
A Amperes
V Volts Panel/Local Remote
Air Temperature Or
Alternating
Engine Engine Output
Current
Temperature
Stick (SMAW) Constant Current MIG (GMAW) TIG (GTAW)

Welding (CC) Welding Welding
Time
h
Hours S Seconds
1 Single Phase
3
Read Operator’s Do Not Switch
Three Phase Circuit Protection
Manual While Welding
Engine-Driven,
Electrode
Connection
Work Connection G
3
Three-Phase
Alternator With
Rectifier
Hz Hertz
X Duty Cycle U0 Rated No Load

Voltage (Average) U2 Conventional
Load Voltage n Rated Load
Speed
n1 Rated Idle
Speed n0 Rated No Load
Speed I Current
I2 Rated Welding
Current
Remote Foot
Contactor On Arc Force (Dig) Lift-Arc TIG Control TIG
(GTAW)

SECTION 3 − SPECIFICATIONS
3-1. Weld, Power, And Engine Specifications
Maximum
Welding Weld Output Rated Welding Open- Fuel
Auxiliary Power Rating Engine
Mode Range Output Circuit Capacity
Voltage
Generator
300 A, 32 Volts DC Single-Phase,
20 − 410 A
CC/DC 60% Duty Cycle 10 kVA/kW, 91/46 A,
250 A, 30 Volts DC 110/220 V AC,
60 Hz Catepillar C1.5
100% Duty cycle Water−Cooled 11.5 gal
73
Three−Cylinder (43.5 L)
Receptacles
21.7 HP Diesel Engine
300 A, 29 Volts DC 110/55 V AC Receptacles
CV/DC 5.5 kVA/kW, 50/100 A
14 − 40 V 60% Duty Cycle
Flux Core
250 A, 26.5 Volts DC 220/110 V AC Receptacles
100% Duty cycle 11 kVA/kW, 50/20 A
3-2. Dimensions, Weights, And Operating Angles

Dimensions
32 in (813 mm)
Height 35-3/4 in (908 mm) G
(to top of lift eye)
26-1/4 in (667 mm)
(mtg. brackets turned in) ! Do not exceed tilt angles or engine could
Width be damaged or unit could tip.
28-3/4 in (730 mm)
(mtg. brackets turned out) ! Do not move or operate unit where it could
tip.
Depth 56 in (1422 mm)
A 56 in (1422 mm)
B 54 in (1372 mm) A
B C
C 52 in in (1321 mm)
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°

20°
9/16 in (14 mm) Dia. H
H
4 Holes Front Panel End 20°
Weight
D F
No fuel: 1100 lb (499 kg) E
w/ fuel: 1199 lb (544 kg)
Lifting Eye Weight Rating:

1500 lb (680 kg) Maximum

3-3. Volt-Ampere Curves
A. Stick Mode The volt-ampere curves show the
minimum and maximum voltage
100 and amperage output capabilities of
the welding generator. Curves of all
other settings fall between the
90 curves shown.
80
70
60
DC VOLTS
50
40
MAX
30
MIN 300
20
10
0
0 100 200 300 400 500
DC AMPERES
B. MIG Mode
100
80
DC VOLTS
60
40 MAX
20 MIN
0
0 100 200 300 400 500
DC AMPERES
C. TIG Mode
100
80
DC VOLTS
60
40
20 MIN 300 MAX
0
0 100 200 300 400 500
DC AMPERES
222 108 / 221 800 / 217 518

3-4. Fuel Consumption
The curve shows typical fuel use
under weld or power loads.
2.00
1.75
1.50
U.S. GAL/HR.
1.25
1.00
0.75
0.50
0.25 IDLE
0.00
0 50 100 150 200 250 300 350 400
DC WELD AMPERES AT 100% DUTY CYCLE
217 509
3-5. Duty Cycle And Overheating

1 100% Duty Cycle
1 Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
without overheating.
This unit is rated for welding at

250 amperes continuously.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
1000
800
600
WELD AMPERES
500
400
CC
300 CV
250
200
150
100
10 15 20 25 30 40 50 60 80 100
% DUTY CYCLE
217 515

3-6. AC Generator Power Curve
The AC power curve shows the
generator power in amperes.
240 120
200 100
160 80
AC VOLTS
120 60
80 40
40 20
0 0
0 20 40 60 80 100 120 140
AC AMPERES IN 110V MODE
0 10 20 30 40 50 60 70
AC AMPERES IN 220V MODE
220 346−B
Notes MATERIAL THICKNESS REFERENCE CHART
24 Gauge (.025 in)

22 Gauge (.031 in)
20 Gauge (.037 in)
18 Gauge (.050 in)
16 Gauge (.063 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)

SECTION 4 − INSTALLATION
4-1. Installing Welding Generator
! Do not move or operate unit
where it could tip.
! Always securely fasten weld-
Movement ing generator onto transport
vehicle or trailer and comply
with all DOT and other applica-
ble codes.
NOTICE − Do not install unit where
air flow is restricted or engine may
overheat.
OR OR
See Section 3-2 for lifting eye rat-
ing.
See Section 4-2 for mounting

information.
Location/Airflow Clearance
OR OR
18 in
(460 mm)
18 in
18 in (460 mm)
(460 mm)
18 in
18 in (460 mm)
(460 mm)
install3 2008-01 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712

4-2. Mounting Welding Generator
! Do not weld on base. Weld-
ing on base can cause fuel
tank fire or explosion. Weld
only on the four mounting
Supporting The Unit brackets or bolt unit down.
NOTICE − Do not mount unit by
supporting the base only at the four
mounting brackets. Use cross-
supports to adequately support unit
2 and prevent damage to base.
Mounting Surface:
1 Cross-Supports
2 Mounting Brackets (Supplied)
OR
Mount unit on flat surface or use
cross-supports to support base.
Secure unit with mounting brack-
ets.
1 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
1 four mounting brackets to the base.
Reverse brackets and reattach to
base with original hardware.
Mount unit to truck or trailer with 1/2
Using Mounting Brackets in (12 mm) or larger hardware (not
supplied).
To Weld Unit In Place:
Weld unit to truck or trailer only at
the four mounting brackets.
2
Welding Unit In Place

Bolting Unit In Place
2 3
Tools Needed:
9/16 in
install3 2008--01 803 274 / 200 864-A / 803 231

4-3. Grounding Generator To Truck Or Trailer Frame
! Always ground generator

frame to vehicle frame to pre-
vent electric shock and static
electricity hazards.
! Also see AWS Safety &
Health Fact Sheet No. 29,
Grounding of Portable And
Vehicle Mounted Welding
Generators.
! Bed liners, shipping skids,
and some running gear insu-
late the welding generator
from the vehicle frame. Al-
ways connect a ground wire
from the generator equip-
1 2 ment grounding terminal to
bare metal on the vehicle
GND/PE frame as shown.
! If unit does not have GFCI re-
ceptacles, use GFCI-pro-
tected extension cord.
1 Equipment Grounding
Terminal (On Front Panel)
3 2 Grounding Cable (Not
Supplied)
3 Metal Vehicle Frame
Connect cable from equipment
ground terminal to metal vehicle
frame. Use #10 AWG or larger
insulated copper wire.
Electrically bond generator

frame to vehicle frame by met-
al-to-metal contact.
rot_grnd 2008-01 − 800 652-D
4-4. Rating Label Location

1 Rating Label − Typical
Locate rating label on unit. Label pro-
1
vides information such as weld output
ratings, generator ratings, and engine
information.
Evidence of label tampering voids

warranty.
rot_label 2008-01 − 804 712

4-5. Installing Exhaust Pipe
! Stop engine and let cool.
Point exhaust pipe in desired di-
rection but always away from front
panel and direction of travel.
Tools Needed:
1/2 in 803 582 / Ref. 217 357-A
Notes
Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

4-6. Activating The Dry Charge Battery (If Applicable)
! Always wear a face shield,
rubber gloves and protective
clothing when working on a
battery.
3
Remove battery from unit.
1 Vent Caps
2 2 Sulfuric Acid Electrolyte
(1.265 Specific Gravity)
1 3 Well
Fill each cell with electrolyte to
bottom of well (maximum).
! Do not overfill battery cells.
Wait ten minutes and check electro-
lyte level. If necessary, add electro-
lyte to raise to proper level. Reins-
tall vent caps.
4 Battery Charger
! Read and follow all instruc-
tions supplied with battery
charger.
5 5 Amperes For 30 Minutes
Charge Time
5 6 30 Amperes For 12 Minutes
4 Charge Time
Charge battery. Disconnect charg-
ing cables and install battery.
When electrolyte is low, add

only distilled water to cells to
5A maintain proper level.
+
6
−
Tools Needed: 30 A
drybatt 12008−01 − S-0886
4-7. Connecting The Battery

! Connect negative (−) battery
cable last.
Close door after connecting

battery.
Tools Needed:
1/2 in
803 563 / Ref. 217 357-A / S-0756-C

4-8. Engine Prestart Checks
Check radiator coolant

level when fluid is low in
recovery tank.
Full
Full
Diesel
Capacity:
6 qt (5.7 L)
Coolant Recovery Tank
Hot Full
Cold Full
Full
Ref. 804 009−C
Check all engine fluids daily. Do not run out of fuel or air will enter fuel sys- freeze to mixture if using the unit in tempera-
tem and cause starting problems. See en- tures below −34° F (−37° C).
Engine must be cold and on a level surface. gine manual to bleed air from fuel system.
Unit is shipped with 20W break-in oil.
Automatic shutdown system stops engine if Oil Keep radiator and air intake clean and free
oil pressure is too low or coolant tempera- of dirt.
After fueling, check oil with unit on level sur-
ture is too high.
face. If oil is not up to full mark on dipstick, NOTICE − Incorrect engine temperature
This unit has a low oil pressure shut- add oil (see maintenance label).
can damage engine. Do not run engine with-
down switch. However, some condi- out a properly working thermostat and ra-
tions may cause engine damage before Coolant
diator cap.
the engine shuts down. Check oil level Check coolant level in radiator before start-
often and do not use the oil pressure ing unit the first time. If necessary, add cool-
shutdown system to monitor oil level. ant to radiator until coolant level is at bottom To improve cold weather starting:
Follow run-in procedure in engine manual. of filler neck.
If unburned fuel and oil collect in exhaust Use Preheat switch (see Section 5-1).
pipe during run-in, see Section 13. Check coolant level in recovery tank daily.
Fuel If necessary, add coolant to recovery tank Keep battery in good condition. Store
until coolant level is between Cold Full and battery in warm area.
NOTICE − Do not use gasoline. Gasoline Hot Full levels. If recovery tank coolant level
will damage engine. was low, also check coolant level in radiator. Use fuel formulated for cold weather
The unit is shipped with enough fuel to pre- Add coolant if level is below bottom of radia- (diesel fuel can gel in cold weather).
vent air from entering fuel system. Add fresh tor filler neck. Contact local fuel supplier for fuel in-
diesel fuel before starting (see engine main- formation.
tenance label for fuel specifications). Leave Unit is shipped with an engine coolant mix-
filler neck empty to allow room for ture of water and ethylene glycol base anti- Use correct grade oil for cold weather
expansion. freeze rated to −34° F (−37° C). Add anti- (see Section 8-1).

4-9. Connecting To Weld Output Terminals On CC/CV Flux Core Models
Stick and TIG Welding MIG and FCAW Welding

For Stick and TIG welding Direct Current Elec- For MIG and FCAW welding Direct Current
trode Positive (DCEP), connect electrode Electrode Positive (DCEP), connect wire
holder cable to Positive (+) terminal and work feeder cable to Positive (+) terminal and work
cable to Negative (−) terminal on left. cable to Negative (−) terminal on left. Use Pro-
cess switch to select type of weld output (see
For Direct Current Electrode Negative
Section 5-3).
(DCEN), reverse cable connections.
Use Process switch to select type of weld out-
put (see Section 5-3).
! Stop engine.
1 Work (−) Weld Output Terminal
2 Positive (+) Weld Output Terminal(s)
! Failure to properly connect weld
cables may cause excessive heat and
start a fire, or damage your machine.
3 Weld Output Terminal
4 Supplied Weld Output Terminal Nut
5 Weld Cable Terminal
6 Copper Bar
Remove supplied nut from weld output termi-
nal. Slide weld cable terminal onto weld output
terminal and secure with nut so that weld cable
terminal is tight against copper bar. Do not
place anything between weld cable termi-
nal and copper bar. Make sure that the sur-
faces of the weld cable terminal and cop-
per bar are clean.
1
2
6
3
Do not place
anything between
weld cable terminal
and copper bar.
Tools Needed:
3/4 in
Correct Installation Incorrect Installation
Ref.804 009-C / Ref. 226 386 / 803 778-A

4-10. Connecting To Weld Output Terminals On CC/CV Models
Stick and TIG Welding MIG and FCAW Welding

For Stick and TIG welding Direct Current Elec- For MIG and FCAW welding Direct Current
trode Positive (DCEP), connect electrode Electrode Positive (DCEP), connect wire
holder cable to Positive (+) terminal and work feeder cable to Positive (+) terminal and work
cable to Negative (−) terminal on left. cable to Negative (−) terminal on left. Use Pro-
cess switch to select type of weld output (see
Section 6-3).
Use Process switch to select type of weld out-
put (see Section 6-3).
! Stop engine.
CC/CV model shown.
1 Work (−) Weld Output Terminal
2 Positive (+) Weld Output Terminal(s)
! Failure to properly connect weld
cables may cause excessive heat and
start a fire, or damage your machine.
3 Weld Output Terminal
4 Supplied Weld Output Terminal Nut
5 Weld Cable Terminal
6 Copper Bar
Remove supplied nut from weld output termi-
nal. Slide weld cable terminal onto weld output
terminal and secure with nut so that weld cable
terminal is tight against copper bar. Do not
place anything between weld cable termi-
nal and copper bar. Make sure that the sur-
faces of the weld cable terminal and cop-
per bar are clean.
1
2
6
3
Do not place
anything between
weld cable terminal
and copper bar.
Tools Needed:
3/4 in
Correct Installation Incorrect Installation
Ref.804 009-C / Ref. 226 386 / 803 778-A

4-11. Selecting Weld Cable Sizes*
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
Weld Output
Terminals
! Stop engine before
connecting to weld
output terminals.
150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
! Do not use worn, 100 ft (30 m) or Less
(45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
damaged, under-
sized, or poorly
spliced cables.
10 − 60% 60 − 100%
Welding
Duty Duty 10 − 100% Duty Cycle
Amperes
Cycle 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)
2 ea. 2/0 2 ea. 2/0

250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x70)
2 ea. 2/0 2 ea. 3/0 2 ea. 3/0

300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x95)
2 ea. 2/0 2 ea. 3/0 2 ea. 3/0 2 ea. 4/0

350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x95) (2x120)
2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 2 ea. 4/0

400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x120) (2x120)
2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 3/0 3 ea. 3/0
500 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x120) (3x95) (3x95)
* This chart is a general guideline and may not suit all applications. If cables overheat, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use S-0007-F
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.
Notes

4-12. Connecting To Remote 14 Receptacle RC14
Socket* Socket Information
A 24 volts AC. Protected by sup-

plementary protector CB8.
24 VOLTS AC
B Contact closure to A completes
24 volt AC contactor control
circuit.
C Output to remote control:+10

volts DC in MIG mode; 0 to +10
volts DC in Stick or TIG mode.
REMOTE D Remote control circuit common.

OUTPUT
CONTROL E DC input command signal: 0 to
+10 volts from min. to max. of
remote control with Voltage/
Amperage Adjust control at
max.
Current feedback: 1 volt per

F 100 amperes.
H Voltage feedback: 1 volt per 10

OR arc volts.
GND K Chassis common.
NEUTRAL G Circuit common for 24 volt AC

Ref 804 009-C
circuit.
*The remaining sockets are not used.
Notes
Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

(CC/CV FLUX CORE MODELS)
5-1. Front Panel Controls (See Section 5-2)
9 10
6 7 8 1 2 4 5
Stop
226 390−A / 804 009−C

5-2. Description Of Front Panel Controls On CC/CV Flux Core Models (See Section 5-1)
Engine Starting Controls Engine Gauges, Meters, And Lights 7 Process/Contactor Switch
1 Preheat Switch 4 Fuel Gauge/Hourmeter See Section 5-3 for Process/Contactor
Use gauge to check fuel level or total engine switch information.
Use switch to energize starting aid for cold
weather starting (see starting instructions fol- operating hours. 8 Voltage/Amperage Control
lowing). To check fuel level or engine hours when en-
gine is not running, turn Engine Control switch With Process/Contactor switch in any Stick or
2 Engine Control Switch to Run or Auto (optional) position. TIG setting, use control to adjust amperage.
With Process/Contactor switch in any Wire
Use switch to start engine, select engine 5 Engine Indicator Light (MIG) position, use control to adjust voltage.
speed (if unit has auto idle option), and stop Light goes on and engine stops if engine tem- With Voltage/Amperage Adjust Switch in Re-
engine. perature exceeds 230° F (110° C) or engine mote position, control limits the remote am-
oil pressure is below 10 psi (69 kPa). perage in Stick or TIG mode, but has no effect
In Run position, engine runs at weld/power
in Wire (MIG) modes.
speed. In Auto position (optional), engine Normal engine temperature is 180 - 203
runs at idle speed at no load and weld speed F (82 - 95 C). Normal oil pressure is 30 Weld Meters (Optional)
with load applied. - 60 psi (207 - 414 kPa).
3 Engine Stop Lever
Weld meters also work in combination to
NOTICE − Do not run engine until trouble is display troubleshooting help codes (see
Use lever to stop engine if Engine Control fixed. Section 8-12).
switch does not work. Weld Controls
9 DC Voltmeter
6 Remote Control Receptacle
The Engine Stop lever shuts off the fuel Voltmeter displays preset voltage (MIG weld-
supply. However, the Engine Stop lever Use receptacle to connect remote controls,
ing) with contactor off, and actual output volt-
will not stop the engine if the engine can wire feeders, and tools.
age with the contactor on. Voltmeter displays
draw fuel-rich air from the surrounding When a remote control is connected to the voltage at the weld output terminals, but not
atmosphere (oil refineries). Remote receptacle, the Auto Sense Remote necessarily the welding arc due to resistance
feature automatically switches voltage/am- of cable and connections.
To Start: perage control to the remote control (see Sec-
tion 4-12). To set voltage, turn contactor off and turn Pro-
NOTICE − Do not use ether. cess/Contactor switch to Wire position. Turn
With remote control connected, weld output is V/A control until desired voltage is displayed
If engine does not start, let engine come determined by a combination of front panel on Voltmeter. When welding is finished, volt-
to a complete stop before attempting re- and remote control voltage/amperage set- meter displays weld voltage and then defaults
start. tings. to preset voltage.
Above 325 F (05 C): turn Engine Control If no remote control is connected to the Re-
10 DC Ammeter
switch to Start. Release Engine Control mote receptacle, the front panel Voltage/Am-
switch when engine starts. perage control adjusts voltage and amper- Ammeter displays preset amperage (Stick
age. and TIG only) when not welding, and actual
Below 325 F (05 C): turn engine control switch output amperage when welding.
to Auto position. Push Preheat switch up for If a remote device connected to Remote
60 seconds. Turn Engine Control switch to Receptacle RC14 is faulty or is discon- To set amperage, turn Process/Contactor
Start. Release Engine Control switch and nected, the meters display Help 25 (see switch to Stick or TIG position. Turn V/A con-
Preheat switch when engine starts. Section 8-12). Clear fault by stopping trol until desired amperage is displayed on
and restarting the unit or by turning Pro- Ammeter. When welding is finished, ammeter
To Stop: turn Engine Control switch to Off cess/Contactor switch to another posi- displays weld amperage and then defaults to
position. tion. preset amperage.

5-3. Process/Contactor Switch
! Weld output terminals are ener-
gized when Process/Contactor
switch is in a Weld Terminals Al-
ways On position and the engine
is running.
1 1 Process/Contactor Switch
2 Weld Terminals Always On − TIG
Lift Arc Position
3 Remote On/Off Switch Required −
TIG HF Required Or Scratch Start
Position
4 Remote On/Off Switch Required −
Wire (Flux Core) Position
6
5 Weld Terminals Always On − Wire
(Flux Core) Position
6 Weld Terminals Always On − Stick
5 − Position
2
Use switch to select weld process and
weld output on/off control (see table be-
3
4 low).
Place switch in Remote On/Off Switch
Required positions to turn weld output on
and off with a device connected to the
Remote 14 receptacle.
Place switch in Weld Terminals Always
On positions for weld output to be on
whenever the engine is running.
Use the Lift-Arc TIG mode for TIG
(GTAW) welding using the Lift-Arc TIG
starting procedure (see Section 5-4).
Ref 804 444−A / Ref 226 390−A
Process/Contactor Switch Settings
Switch Setting Process Output On/Off Control Engine Auto Idle (Optional)
Weld Terminals
TIG Lift-Arc (GTAW) Electrode Hot Active
Always On − TIG Lift Arc −
Remote On/Off Switch Required − GTAW With HF Unit, Pulsing Device,

At Remote 14 Receptacle Active
TIG HF Required Or Scratch Start Or Remote Control
Remote On/Off Switch Required − Flux Core

At Remote 14 Receptacle Active
Wire (Flux Core) w/Constant Speed Feeder
Weld Terminals Always On − Wire Flux Core

Electrode Hot Active
(Flux Core) w/Voltage Sensing Feeder
Stick (SMAW),
Weld Terminals Always On − Stick Air Carbon Arc (CAC-A) Cutting And Electrode Hot Active
Gouging

5-4. Lift-Arc™ Start Procedure
Lift-Arc TIG
With Lift-Arc TIG selected, start
arc as follows:
1 TIG Electrode
Lift-Arc Start Method 2 Workpiece

1 2 Turn gas on. Touch tungsten
electrode to workpiece at weld start
point. Hold electrode to
workpiece for 1-2 seconds, and
slowly lift electrode. Arc is formed
when electrode is lifted.
Normal open-circuit voltage is not
1−2 present before tungsten electrode
“Touch” Seconds touches workpiece; only a low
sensing voltage is present between
electrode and workpiece. The
solid-state output contactor does
not energize until after electrode is
touching workpiece. This allows
electrode to touch workpiece
without overheating, sticking, or be-
ing contaminated.
Application:
Lift-Arc is used for the DCEN
GTAW process when HF Start
method is not permitted, or to
Do NOT Strike Like A Match! replace the scratch method.
Notes
Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

5-5. Remote Voltage/Amperage Control
1 Remote 14 Receptacle RC14
Connect optional remote control to RC14 (see
Section 4-12).
When a remote control is connected to the

Remote receptacle, the Auto Sense Re-
1 mote feature automatically switches volt-
age/amperage control to the remote con-
trol. When a device is connected to the Re-
mote receptacle, remote voltage/amper-
age control is always available regardless
of the position of the Process/Contactor
switch.
Example: Combination Remote Amperage Control (FCAW) In Example:

Process = Remote FCAW
Min = 20 A DC
Max = 205 A DC
Max (205 A DC)
Min (20 A DC)
Connect Remote Set Remote Process Set V/A Control Adjust Optional Remote Control
Control To Remote (Only If Remote On/Off Mid-Range: About 205A
Receptacle RC14 Control Is Desired)
Example: Combination Remote Amperage Control (TIG) In Example:

Process =Remote TIG
Min = 20 A DC
Max = About 205 A DC
Max (205 A DC)
Min (20 A DC)

Connect Remote Set Remote Process Set V/A Control
Adjust Optional Remote Control
Control To Remote (Only If Remote On/Off Mid-Range: About 205 A
Receptacle RC14 Control Is Desired)
0774 / Ref.226 390−A / Ref 804 444−A

Notes

(CC/CV MODELS THRU LH040123E)
6-1. Front Panel Controls (See Section 6-2)
8 9 10
6 7 1 2 4 5
Stop
226 386-B / 804 009-C

6-2. Description Of Front Panel Controls (See Section 6-1)
Engine Starting Controls Engine Gauges, Meters, And Lights 7 Process/Contactor Switch
1 Preheat Switch 4 Fuel Gauge/Hourmeter See Section 6-3 for Process/Contactor
Use gauge to check fuel level or total engine switch information.
Use switch to energize starting aid for cold
weather starting (see starting instructions fol- operating hours. 8 Voltage/Amperage Control
lowing). To check fuel level or engine hours when en-
gine is not running, turn Engine Control switch With Process/Contactor switch in any Stick or
2 Engine Control Switch to Run or Auto (optional) position. TIG setting, use control to adjust amperage.
With Process/Contactor switch in any Wire
Use switch to start engine, select engine 5 Engine Indicator Light (MIG) position, use control to adjust voltage.
speed (if unit has auto idle option), and stop Light goes on and engine stops if engine tem- With Voltage/Amperage Adjust Switch in Re-
engine. perature exceeds 230° F (110° C) or engine mote position, control limits the remote am-
oil pressure is below 10 psi (69 kPa). perage in Stick or TIG mode, but has no effect
In Run position, engine runs at weld/power
in Wire (MIG) modes.
speed. In Auto position (optional), engine Normal engine temperature is 180 - 203
runs at idle speed at no load and weld speed F (82 - 95 C). Normal oil pressure is 30 Weld Meters
with load applied. - 60 psi (207 - 414 kPa).
3 Engine Stop Lever
Weld meters also work in combination to
NOTICE − Do not run engine until trouble is display troubleshooting help codes (see
Use lever to stop engine if Engine Control fixed. Section 8-12).
switch does not work. Weld Controls
9 DC Voltmeter
6 Remote Control Receptacle
The Engine Stop lever shuts off the fuel Voltmeter displays preset voltage (MIG weld-
supply. However, the Engine Stop lever Use receptacle to connect remote controls,
ing) with contactor off, and actual output volt-
will not stop the engine if the engine can wire feeders, and tools.
age with the contactor on. Voltmeter displays
draw fuel-rich air from the surrounding When a remote control is connected to the voltage at the weld output terminals, but not
atmosphere (oil refineries). Remote receptacle, the Auto Sense Remote necessarily the welding arc due to resistance
feature automatically switches voltage/am- of cable and connections.
To Start: perage control to the remote control (see Sec-
tion 4-12). To set voltage, turn contactor off and turn Pro-
NOTICE − Do not use ether. cess/Contactor switch to Wire position. Turn
With remote control connected, weld output is V/A control until desired voltage is displayed
If engine does not start, let engine come determined by a combination of front panel on Voltmeter. When welding is finished, volt-
to a complete stop before attempting re- and remote control voltage/amperage set- meter displays weld voltage and then defaults
start. tings. to preset voltage.
Above 325 F (05 C): turn Engine Control If no remote control is connected to the Re-
10 DC Ammeter
switch to Start. Release Engine Control mote receptacle, the front panel Voltage/Am-
switch when engine starts. perage control adjusts voltage and amper- Ammeter displays preset amperage (Stick
age. and TIG only) when not welding, and actual
Below 325 F (05 C): turn engine control switch output amperage when welding.
to Auto position. Push Preheat switch up for If a remote device connected to Remote
60 seconds. Turn Engine Control switch to Receptacle RC14 is faulty or is discon- To set amperage, turn Process/Contactor
Start. Release Engine Control switch and nected, the meters display Help 25 (see switch to Stick or TIG position. Turn V/A con-
Preheat switch when engine starts. Section 8-12). Clear fault by stopping trol until desired amperage is displayed on
and restarting the unit or by turning Pro- Ammeter. When welding is finished, ammeter
To Stop: turn Engine Control switch to Off cess/Contactor switch to another posi- displays weld amperage and then defaults to
position. tion. preset amperage.

6-3. Process/Contactor Switch On CC/CV Models
1 1 Process/Contactor Switch
! Weld output terminals are ener-
gized when Process/Contactor
switch is in a Weld Terminals Al-
ways On position and the engine
is running.
Use switch to select weld process and
weld output on/off control (see table be-
low).
Place switch in Remote On/Off Switch
Required positions to turn weld output on
and off with a device connected to the
Remote 14 receptacle.
Place switch in Weld Terminals Always
On positions for weld output to be on
whenever the engine is running.
Use Stick mode for air carbon arc
(CAC-A) cutting and gouging.
When switch is in Stick mode, select one
of four arc drive (dig) settings to provide
additional amperage during low voltage
(short arc length) conditions and prevent
“sticking” electrodes. Turn control from A
to D to increase arc drive (dig) from min
to max.
Use the Lift-Arc TIG mode for TIG
(GTAW) welding using the Lift-Arc TIG
starting procedure (see Section 6-4).
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-

GTAW With HF Unit, Pulsing
quired −TIG HF Required Or At Remote 14 Receptacle Active
Device, Or Remote Control
Scratch Start
Remote On/Off Switch

Stick (SMAW) With Remote On/Off At Remote 14 Receptacle Active
Required − Stick
Remote On/Off Switch

MIG (GMAW)
Required − CV Feeder At Remote 14 Receptacle Active
w/Constant Speed Feeder
Using Remote
Weld Terminals Always On − MIG (GMAW)

Electrode Hot Active
Wire w/Voltage Sensing Feeder
Stick (SMAW),
Weld Terminals Always On −
Air Carbon Arc (CAC-A) Cutting Electrode Hot Active
Stick
And Gouging
Weld Terminals Always On −

TIG Lift-Arc (GTAW) Electrode Hot Active
TIG Lift-Arc

6-4. Lift-Arc™ Start Procedure
Lift-Arc TIG
With Lift-Arc TIG selected, start
arc as follows:
1 TIG Electrode
Lift-Arc Start Method 2 Workpiece

1 2 Turn gas on. Touch tungsten
electrode to workpiece at weld start
point. Hold electrode to
workpiece for 1-2 seconds, and
slowly lift electrode. Arc is formed
when electrode is lifted.
Normal open-circuit voltage is not
1−2 present before tungsten electrode
“Touch” Seconds touches workpiece; only a low
sensing voltage is present between
electrode and workpiece. The
solid-state output contactor does
not energize until after electrode is
touching workpiece. This allows
electrode to touch workpiece
without overheating, sticking, or be-
ing contaminated.
Application:
Lift-Arc is used for the DCEN
GTAW process when HF Start
method is not permitted, or to
Do NOT Strike Like A Match! replace the scratch method.
Notes
Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

6-5. Remote Voltage/Amperage Control
1 Remote 14 Receptacle RC14
Connect optional remote control to RC14 (see
Section 4-12).
When a remote control is connected to the

Remote receptacle, the Auto Sense Re-
1 mote feature automatically switches volt-
age/amperage control to the remote con-
trol. When a device is connected to the Re-
mote receptacle, remote voltage/amper-
age control is always available regardless
of the position of the Process/Contactor
switch.
In Example:
Min = 20 A DC
Max = 205 A DC
Connect Remote Set V/A Control

Control To Remote To Desired Maximum
Adjust Optional Remote Weld Output Using Weld
Receptacle RC14 Control to 100% Meters
Set TIG or STICK Process
Max (205 A DC)
Min (20 A DC)
Adjust Optional Remote

Control to desired
weld output
Weld meters will always

show the combined main
Adjust Optional Remote and remote control setting
Control to desired and machine welds at
Connect Remote
weld output nominal output setting of
Control To Remote
the meter.
Receptacle RC14
Weld meters show preset
Set WIRE Process output when not welding.
0774 / Ref.226 386-B / 804 009-C

SECTION 7 − OPERATING AUXILIARY EQUIPMENT
7-1. Auxiliary Power Receptacles On CC/CV Flux Core Models
1 2 3 4 5 6
Ref. 217 359-A
1 220V 16 A AC Receptacle RC12 tacle does not work. Press button to reset. Receptacles GFCI1, RC11, and RC12
supply 60 Hz single-phase power at weld/
2 110V 20 A AC Receptacle GFCI1 4 Earth Leakage Circuit Breaker ELCB1 power speed.
If a ground fault is detected, GFCI Reset Maximum combined output of all recep-
5 Earth Leakage Circuit Breaker ELCB2 tacles is 10 kVa/kW.
button pops out and receptacle does not
work. Check for faulty equipment plugged in
receptacle. Press button to reset GFCI re-
ELCB1 protects RC12 and ELCB2 protects At least once a month, run engine at
RC11 from overload and earth leakage weld/power speed and press test but-
ceptacle.
fault. If a circuit breaker opens, the recep- ton to verify ELCB1, ELCB2, and GFCI
3 Supplementary Protector CB5 tacle does not work. Place switch in On are working properly.
position to reset circuit breaker.
CB5 protects GFCI1 from overload. If a Generator power decreases as weld
supplementary protector opens, the recep- 6 220V 32A AC Receptacle RC11 output increases.
7-2. Auxiliary Power Receptacles On CC/CV Models
1 2 3 4
226 386
1 110 V 16 A AC Receptacle RC12 fault. If a circuit breaker opens, the recep- 4 110 V 32 A AC Receptacle RC11
tacle does not work. Place switch in On
2 Earth Leakage Circuit Breaker RC11 and RC12 supply 60 Hz single-phase
position to reset circuit breaker.
ELCB1 power at weld/power speed.
3 Earth Leakage Circuit Breaker
At least once a month, run engine at Generator power decreases as weld
ELCB2 output increases.
weld/power speed and press test but-
ELCB1 protects RC12 and ELCB2 protects ton to verify ELCB1 and ELCB2 are Combined output of all receptacles is limit-
RC11 from overload and earth leakage working. ed to the 10 kVA/kw rating of the generator.

SECTION 8 − MAINTENANCE
8-1. Maintenance Label

8-2. Routine Maintenance
! Stop engine before maintaining.
Recycle engine
See Engine Manual and Maintenance Label
for important start-up, service, and storage
fluids.
information. Service engine more often if
used in severe conditions.
= Check = Change = Clean = Replace Reference

* To be done by Factory Authorized Service Agent
Every Section 4-8,
8 8-10
Hours
Coolant Level Fuel Level Oil Level Oil, Fuel Spills

Every
50
Hours
Weld Terminals
Every Section 8-5
100
Hours
Battery Terminals Air Cleaner Hoses Air Cleaner Element

Every Engine
250 1/2 in.
(13 mm) Manual,
Hours Section 8-6,
8-10
Unreadable Labels Fan Belt Tension Oil Oil Filter Spark Arrestor
Every
500
Hours
Weld Cables Fuel Filter Inline Fuel Filter Radiator Thermostat

Every Section 4-8,
FUEL
1000 8-4, 8-7,
OR
Hours 8-10, and
Engine
SLUDGE Manual
Radiator Fluid Level Inside Unit Valve Clearance* Drain Sludge
Slip Rings*
Brushes*
Every
2000
Hours
Injectors*

8-3. Caterpillar Customer Assistance
Service 2 If your problem cannot be resolved at Please follow the above steps in sequence
the dealer level without additional if a problem arises.
When a problem arises concerning the op-
assistance, call a Field Service
eration or service of the engine, the prob- Website Address
Coordinator at 1-800-447-4986.
lem will normally be managed by the dealer
in your area. 3 If your needs still have not been met, www.caterpillar.com
submit the matter in writing to:
Your satisfaction is a primary concern to
Caterpillar and to Caterpillar dealers. If you Altitude
Caterpillar Inc.
have a problem that has not been handled Manager, Customer Service, Contact the Caterpillar applications depart-
to your complete satisfaction, follow these Engine Division ment for information on the effect of ambient
steps: Mossville Bldg A conditions on Caterpillar 3024 engines.
1 Discuss your problem with a manager P.O. Box 600
from the dealership. Peoria, IL 61552-0600
8-4. Checking Generator Brushes

1 Generator Brush With Spring
Mark and disconnect leads at brush hold-
er cap. Remove brushes.
Replace brushes if damaged or if brush
material is at or near minimum length.
5/16 in. (8 mm)

Minimum Length
9/16 in. (14.3 mm)

New Length
Replace
Damaged Brushes
Ref 226 386-B / S−0233−A

8-5. Servicing Air Cleaner
! Stop engine.
NOTICE − Do not run engine without air
1 3 4 cleaner or with dirty element. Engine
2
damage caused by using a damaged ele-
ment is not covered by the warranty.
The air cleaner primary element can

be cleaned but the dirt holding capac-
ity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while clean-
ing and the possibility of filter damage
makes cleaning a risk. Consider the
Optional risk of unwarrantable equipment
5 damage when determining whether
to clean or replace the primary ele-
ment.
If you decide to clean the primary ele-

ment, we strongly recommend instal-
ling an optional safety element to pro-
vide additional engine protection.
Never clean a safety element. Re-
place the safety element after servic-
ing the primary element three times.
Clean or replace primary element if dirty
(see note above before cleaning). Re-
place primary element if damaged. Re-
place primary element yearly or after six
cleanings.
1 Housing
Keep nozzle
2 in (51 mm) 2 Safety Element (Optional)
from element. 3 Primary Element
4 Dust Cap
5 Dust Ejector
To clean air filter:
Wipe off cap and housing. Remove cap
and dump out dust. Remove element(s).
Wipe dust from inside cap and housing
with damp cloth. Reinstall safety element
Blow Inspect (if present). Reinstall cap.
NOTICE − Do not clean housing with air
hose.
Clean primary element with compressed
air only.
Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in (3 mm) nozzle and
keep nozzle at least 2 in (51 mm) from
inside of element. Replace primary ele-
ment if it has holes or damaged gaskets.
Reinstall primary element and cap (dust
ejector down).
aircleaner1 2/01− ST-153 929-B / ST-153 585 / Ref. S-0698-B / Ref. 226 386-B

8-6. Inspecting And Cleaning Spark Arrestor Muffler

1 Spark Arrestor Muffler
2 Cleanout Plug
Remove plug and remove any dirt
covering cleanout hole.
3 Exhaust Pipe
Start engine and run at idle speed to
blow out cleanout hole. If nothing
3 blows out of hole, briefly cover end
of exhaust pipe with fireproof
material.
Reinstall cleanout plug.
Tools Needed:
3/8 in
803 582-F / Ref. 226 386-B
8-7. Servicing Engine Cooling System

1 Radiator Draincock
2 Radiator Cap Cover
Change coolant according to engine
manual. Add coolant according to Sec-
tion 4-8).
Run engine until engine reaches normal
operating temperature. Check coolant
level in recovery tank. Add coolant if nec-
essary.
After engine cools, check coolant level
again and add coolant if necessary.
2
804 009−C / Ref 226 386-B

8-8. Adjusting Engine Speed On Standard Models

Engine speed is factory set and
should not require adjustment. Af-
ter tuning engine, check engine
Engine Speed speed with tachometer or frequen-
(No Load) RPM (Hz) cy meter. See table for proper no
load speed. If necessary, adjust
speed as follows:
1880 (61.7)
Weld/Power
Maximum Start engine and run until warm.
Turn Process/Contactor switch to
Weld Terminals Always On − Stick
position.
3 1 Lock Nut
2 Adjustment Screw
Loosen nut. Turn screw until engine
runs at weld/power speed. Tighten
nut.
Do not set engine speed higher

than specified. Tampering with
adjustments other than shown
may affect engine warranty
3 Engine Stop Lever
! Stop engine.
Close door.
Tools Needed:
803 563

8-9. Adjusting Engine Speed On Models With Automatic Idle (Optional)
Engine Speed Adjustment

Engine Speed
After tuning engine, check en-
(No Load)
gine speed with tachometer or
1880 rpm max frequency meter. See table for
(62.6 Hz) proper no load speed. If neces-
sary, adjust speed as follows:
1500 rpm
(50 Hz) Start engine and run until warm.
Turn Process/Contactor switch
to Stick − Weld Terminals Al-
ways On position.
1 Throttle Rod / Plunger
4 2 Lock Nut
3 Rubber Boot
4 Adjustment Screw
Adjustment screw is not used to
adjust engine speed when auto-
matic idle option is installed.
To prevent solenoid dam-

age, be sure a 1/8 in (3 mm)
gap exists between the en-
gine low speed screw and
throttle lever when the sole-
noid is held in the energized
position.
Unhook rubber boot from the so-
lenoid housing but leave con-
nected to plunger.
Loosen lock nut. Place Engine
Control Switch in Auto position.
Turn throttle rod and plunger un-
til engine runs at idle speed.
Tighten lock nut.
Hook rubber boot back onto so-
lenoid housing.
Be sure solenoid plunger

pulls all the way in (“bot-
toms”) when energized.
2 Weld/Power Speed
Adjustment
1
Weld/power speed adjust-
ment must be done by the
engine manufacturer’s fac-
tory authorized service
agent.
Tampering with adjustments
other than shown may affect
engine warranty.
! Stop engine.
803 563

8-10. Servicing Fuel And Lubrication Systems

! After servicing, start engine
and check for fuel leaks.
Stop engine, tighten connec-
tions as necessary, and wipe
up spilled fuel.
1 Oil Filter
2 Oil Drain Valve And Hose
3 Oil Fill Cap
4 Primary (Canister) Fuel Filter
5 Secondary (In-Line) Fuel
Filter
6 Fuel Tank Sludge Drain Valve
To change oil and filter:
Route oil drain hose and valve
through hole in base. See engine
manual and engine maintenance
label for oil/filter change in-
formation.
To replace primary (canister) fuel
filter:
Turn filter counterclockwise. Re-
move filter.
Fill new filter with fresh fuel. Apply
thin coat of fuel to gasket on new fil-
ter. Install new filter and turn clock-
wise.
Inspect fuel lines, and replace if
cracked or worn.
2 To drain water from fuel system:
See engine manual.
6
To replace secondary (in-line)
fuel filter:
Note direction of fuel flow as indi-
cated by arrow on side of filter. Re-
move fuel line clamps and discon-
nect fuel lines from fuel filter. Re-
place filter, reconnect fuel lines, and
4 reinstall clamps.
3 To drain sludge from fuel tank:
! Beware of fire. Do not smoke
and keep sparks and flames
away from drained fuel. Dis-
pose of drained fuel in an en-
vironmentally-safe manner.
Do not leave unit unattended
while draining fuel tank.
5 ! Properly lift unit and secure
in a level position. Use ade-
quate blocks or stands to
support unit while draining
fuel tank.
Attach 1/2 ID hose to drain valve.
Put metal container under drain,
and use screwdriver to open
sludge drain valve. Close valve
when sludge has drained. Remove
hose.
Close door.
Tools Needed:
1
Ref 226 386-B / 804 009−C

8-11. Overload Protection
! Stop engine.
1 Fuse F1
F1 protects the stator exciter wind-
ing from overload. If F1 opens, weld
and generator power is low or stops
entirely.
If F1 continues to open, check volt-
age regulator board PC3.
If PC3 senses an overload con-

dition (shorted rotor), it protects
itself by stopping weld output.
Check rotor and brushes before
replacing PC3.
2 Circuit Breaker CB1 (Not
Shown)
3 Supplementary Protector CB2
6 Circuit Breaker CB9 (Optional)
CB1 protects the engine battery cir-
cuit. If CB1 opens, the engine will not
crank. CB1 automatically resets
1 when the fault is corrected. If CB1
continues to open, check fuel sole-
noid FS1, the fuel pump, throttle so-
lenoid TS1, integrated rectifier SR1,
engine alternator, glow plug, and cir-
cuit boards PC2, PC3, and PC5.
CB2 protects the engine wiring har-
3
6 ness. If CB2 opens, the engine will
not crank. Press button to reset If
CB2 continues to open, check fuel
solenoid FS1, the fuel pump, throttle
solenoid TS1, integrated rectifier
SR1, and circuit board PC5 and Fuel
4 Gauge/Hour Meter.
CB3 protects part of the weld control
wiring harness. If CB3 opens, weld
and generator power output stops. If
CB3 continues to open, check circuit
boards PC1, PC2, and PC3.
CB8 protects the 24 volt AC output to
remote receptacle RC14. If CB8
opens, 24 volt output to RC14 stops.
If CB8 continues to open, check re-
mote controls connected to Remote
5 receptacle RC14, and circuit board
PC6.
CB9 protects the throttle solenoid
against overload. If CB9 opens, the
engine does not automatically idle
down. Check the linkage and sole-
noid. CB9 automatically resets.
Ref. 226 386-B / 803 566-E / 804 009-C

8-12. Optional Voltmeter/Ammeter Help Displays
Use the Voltmeter/Ammeter help

displays to diagnose and correct
fault conditions.
1
When a help code is displayed To reset help displays, stop
normally weld output has
HL.P 20 stopped but generator power out- unit and then restart. See item
put may be okay. Auxiliary power 6 below to reset Help 25 dis-
must be available and correct be- play.
2 fore continuing. If auxiliary output 1 Help 20 Display
is not correct, disregard help Indicates a failure of meter display
codes until auxiliary power prob- module PC2, or the wiring between
21
lem is corrected. If both weld out-
HL.P put and auxiliary power are not
available, see Section 10-7 for
module testing information.
PC2 and main control module PC1.
If this display is shown, check PC1,
PC2, and the wiring between PC1
and PC2.
3
2 Help 21 Display
Indicates thermistor TH1 on the
HL.P 22 main rectifier heat sink has failed.

If this display is shown, check TH1,
and the wiring between TH1 and
4 PC1.
3 Help 22 Display
HL.P 23
Indicates the rectifier heat sink has
overheated. If this display is shown,
check generator cooling system
and/or reduce duty cycle. Keep en-
5 gine access door closed when run-
ning to maintain proper cooling air
flow past rectifier. Allow unit to cool
HL.P 24
before restarting.
4 Help 23 Display
Indicates one of the rectifier output
6 SCRs has failed. If this display is
shown, check the rectifier SCRs.
25
5 Help 24 Display
HL.P Indicates weld open circuit voltage
(OCV) is too high (above 41 volts
DC).
Verify engine speed is correct by
checking frequency at 115 volt AC
duplex receptacle (should be
approximately 62 Hertz with Engine
Control switch in the Run position).
If engine speed is correct and weld
open circuit voltage (OCV) is too
high (above 41 volts DC), check
main control module PC1.
6 Help 25 Display
Indicates a remote device con-
nected to Remote Receptacle
RC14 may be faulty. Help 25 is also
displayed whenever a remote de-
vice has been connected to RC14
and then disconnected. Clear fault
by stopping and restarting the unit
or by turning Process/Contactor
switch to another position. If prob-
lem continues, check the remote
device, filter board PC6, and main
control module PC1.
If no remote control device is
plugged in to Remote receptacle
RC14 and the corrective action
above has been followed, discon-
nect filter board PC6. If the help
code is still displayed, main control
module PC1 may be at fault. If the
help code clears, replace PC6.
Ref. 804 009-C

SECTION 9 − THEORY OF OPERATION
1 Engine
Supplies force to turn revolving fields. 10
2 Throttle Solenoid TS1 Voltage

(Pull To Idle) Regulator
Board PC3
Decreases engine speed to idle rpm.
3 Control Relay CR4 9
CR4 energizes at no load to supply pow-
er to throttle solenoid TS1 Fuse F1
4 Circuit Breaker CB9 Current
Protects throttle solenoid TS1 from Feedback
overload.
5 Idle Module PC5
Controls engine speed. Without a signal
from CT1 and PC1 it lowers engine
speed to idle rpm. 1 7 8
3φ
6 Current Transformer CT1 Revolving Exciter
Senses output from auxiliary power Engine Fields
Weld
(Rotor) Stator Windings
windings and signals idle module to in-
crease to or maintain weld speed. Generator Power
2♦
7 Revolving Fields (Rotor)
Throttle
Turn at 1885 rpm maximum for weld and Solenoid TS1
power. The speed and excitation current (Pull To Idle)
of the field coils determine voltages in
stator windings. 3♦
8 Stator Windings
Control Relay
Supply power to exciter, generator pow- CR4
er, and weld circuits.
9 Fuse F1 4♦
Protects exciter windings from over-
load. Circuit Breaker
CB9 6♦
10 Voltage Regulator Board PC3
Current
Changes AC output of stator windings to 5♦ Transformer
DC to supply excitation current to the ex- CT1
citer revolving field. Idle Module
Controls field current in response to PC5
changes in output load. 12 11
If PC3 senses an overload condition AC Supplementary
(shorted rotor), it protects itself by stop- Receptacles Protector CB5
ping excitation current (weld and gener-
ator power output stops).
11 Supplementary Protector CB5 14
Protect AC receptacles from overload.
12 AC Receptacles
Provide connection points and power for
auxiliary equipment. Filter Board 13
PC6/Remote Supplementary
AC receptacles and circuit protec- Receptacle 24 VAC
Protector
tion varies by model. RC14 CB8
17
Provides overload protection for 24 volt
AC portion of Remote 14 receptacle
RC14. +10 VDC Output
Command Voltage Control
14 Filter Board PC6/Remote Recep- Board
tacle RC14 PC1
PC6 protects unit from high frequency,
and RC14 connects remote amperage/
voltage and contactor controls to unit.
When a remote control is connected to
the Remote receptacle, the Auto Sense
Remote feature automatically switches
voltage/amperage control to the remote
control.

15 Voltage/Amperage Control R2
AC Or DC Control Circuits Adjusts weld output amperage or
voltage level.
Weld Current Circuit 16 Process/Contactor Switch R1
External Circuits Selects weld process and weld out-
put on/off control.
3φ Power 17 Control Board PC1
Controls weld output by changing
main rectifier SCR gate pulses
♦ Optional (conduction times) after comparing
amperage (CC) or voltage (CV)
feedback to selected voltage/am-
perage signal.
18 Thermistor TH1
Signals PC1 to stop weld output if
CC/CV Model Shown. CC/CV Flux Core main rectifier overheats.
model does not have capacitor bank C10 or 19 Meter Board PC2
CV weld output terminal.
Displays preset and actual (rectified
and filtered) values of the weld volt-
age and amperage.
23 25 20 Main Rectifier
CC
Changes AC weld current to DC.
Stabilizer CC Weld
Z1 Output Works with PC1 (item 17) to control
21 Terminal weld output by changing rectifier
CV
SCR gate pulses (conduction
Burden
times) after comparing voltage (CV)
Resistor R3
or amperage (CC) feedback to se-
Electrode lected voltage or amperage signal.
21 Burden Resistor R3
20 24 25
Provides a path for a minimum SCR
CV Weld holding current to flow.
Main Capacitor
Bank C10 Output 22 Hall Device HD1
Rectifier Terminal
Provides current feedback signal to
PC1.
23 Stabilizer Z1
Smooths (filters) weld output
current.
24 Capacitor Bank C10
22 25
Filters the DC output voltage of
Hall Device Work (−) Weld main rectifier.
Output
HD1 Terminal 25 Work (−), CC, And CV Weld
Output Terminals
Provide weld output and allow
SCR CC or CV manual changing of output polarity.
Gating Voltage Current
Signals Feedback Feedback Work CC/CV Flux Core models do
not have capacitor bank C10
and a CV weld output terminal.
15 16 18 19
Voltage/ Process/
Thermistor Meter
Amperage Contactor Board PC2
Control R2 Switch R1 TH1

SECTION 10 − TROUBLESHOOTING
10-1. Troubleshooting Tables
See Section 10-2 for test points and values
and Section 14 and following for parts location.
Use MILLER Testing Booklet (Part No. 150

853) when servicing this unit.
See the Miller Extranet for service memos that

may aid in the repair of this product.
Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 8-12).
A. Welding
Trouble Remedy
No weld output; generator power output Place Process/Contactor switch in a Weld Terminals Always On position, or place switch in a Remote
okay at AC receptacles. On/Off Switch Required position and turn remote contactor on (see Section 4-12).
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 4-12).
Check resistance and connections of Voltage/Amperage Adjust control R2; R2 is 1000 ohms ±10%.
Replace R2 if necessary.
Check reactor Z1 for signs of winding failure. Check continuity across windings, and check for proper
connections. Replace Z1 if necessary.
Check Voltmeter/Ammeter help displays (see Section 8-12).
No weld output, or generator power out- Disconnect equipment from generator power receptacles during start-up.
put at AC receptacles.
Reset supplementary protector CB3 (see Section 8-11).
Check fuse F1, and replace if open (see Section 8-11). If F1 is open, check the voltage regulator board
PC3. If PC3 senses an overload condition (shorted rotor), it protects itself by stopping weld output. Check
rotor and brushes before replacing PC3.
Clean slip rings, and install new brushes if necessary (see Section 10-15).
Disconnect leads 105 and 108 from the rotor, and check continuity across slip rings. Replace rotor if nec-
essary.
Disconnect stator excitation leads 100 and 101, and check continuity between leads. Replace stator if
necessary.
Determine if main control board PC1 or voltage regulator board PC3 is causing the lack of output (see
Section 10-7).
Check voltage regulator board PC3 and connections, and replace PC3 if necessary (see Section 10-10).
If PC3 senses an overload condition (shorted rotor), it protects itself by stopping weld output. Check rotor
and brushes before replacing PC3.
Check main control board PC1 and connections, and replace PC1 if necessary (see Sections 10-8 and
10-9).
Erratic weld output. Check and tighten connections inside and outside unit. Be sure connection to work piece is clean and
tight.
Be sure weld cables have no nicks or gouges and no kinks.
Use dry, properly stored electrodes.
Remove excessive coils from weld cables.
Disconnect leads 105 and 108 from the rotor, and check continuity across slip rings. Replace rotor if
necessary.

Trouble Remedy
High weld output. Repair or replace remote control device.
Check hall device HD1, and replace if necessary (see Section 10-2).
10-9).
Low weld output. Check engine speed, and adjust if necessary (see Section 8-8 or 8-9).
Increase Voltage/Amperage Adjust control R2 setting.
Check fuse F1, and replace if open (see Section 8-11).
Repair or replace remote control device.
essary.
Low open-circuit voltage. Check engine speed, and adjust if necessary (see Section 8-8 or 8-9).
10-9).
Check SCRs in main rectifier, and replace if necessary (see Section 11-4). If any SCRs are replaced,
check capacitors C1 through C9 for a short or open, and check for proper connections. Replace 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 4-12).
No 24 volt AC output at Remote recep- Reset circuit breaker CB8 (24 volt) (see Section 8-11).
tacle RC14.
Check filter board PC6, and replace if necessary.
B. Generator Power
Trouble Remedy
No generator power output at AC recep- Reset receptacle supplementary protectors (see Section 7-1).
tacles; weld output okay.
Check resistance of generator power windings between leads 84 and 99. Replace stator if necessary.
No generator power or weld output. Disconnect equipment from generator power receptacles during start-up.
PC3 (see Section 10-10). If PC3 senses an overload condition (shorted rotor), it protects itself by stop-
ping weld output. Check rotor and brushes before replacing PC3.
Reset circuit breaker CB3 (see Section 8-11).
Clean slip rings, and install new brushes if necessary (see Section 10-15).
essary.
Disconnect stator excitation leads 100 and 101, and check continuity between leads. Replace stator if
necessary.
Determine if main control board PC1 or voltage regulator board PC3 is causing the lack of output (see
Section 10-7).
10-9).

Trouble Remedy
High output at generator power AC Check voltage regulator board PC3 and connections, and replace PC3 if necessary (see Section 10-10).
receptacles. If PC3 senses an overload condition (shorted rotor), it protects itself by stopping weld output. Check rotor
Check connections at isolation transformer T1. Check T1 continuity and replace if necessary.
Voltage feedback signal not present. Check and tighten/repair connections.
Low output at generator power AC Check engine speed, and adjust if necessary (see Section 8-8 or 8-9).
receptacles.
PC3 (see Section 10-10). If PC3 senses an overload condition (shorted rotor), it protects itself by stop-
ping weld output. Check rotor and brushes before replacing PC3.
C. Engine
Trouble Remedy
Engine will not crank. Check battery, and replace if necessary.
Check battery connections and tighten if necessary.
Circuit breaker CB1 may be open. CB1 automatically resets when fault is corrected (see Section 8-11).
Check engine wiring harness and components.
Reset supplementary protector CB2 (see Section 8-11).
Check engine wiring harness plug connections.
Check continuity of Engine Control switch S1, and replace if necessary.
Check Fuel Gauge/Hourmeter Fuel/HM and connections, and replace FUEL/HM if necessary.
Check control relay CR1 for proper coil voltage and connections. Check continuity of coil and condition
of contacts. Replace CR1 if necessary.
Engine cranks but does not start. Check fuel level.
Check battery and replace if necessary. Check engine charging system according to engine manual.
Check fuel solenoid FS1 for proper coil voltage and connections. Check continuity of coil. Replace
FS1 if necessary.
Check fuel pump according to engine manual.
Air in fuel system. See engine manual.
Engine hard to start in cold weather. Use Preheat switch (see Section 5-2).
Keep battery in good condition. Store battery in warm area off cold surface.
Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier for
fuel information.
Use correct grade oil for cold weather (see Section 8-1).
Check continuity of Preheat switch S4, and replace if necessary.
Check glow plug for proper operation, and replace if necessary.
Engine suddenly stops. Check oil and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolant
temperature is too high (see Section 4-8 ).
Reset circuit breaker CB1 and/or CB2 (see Section 8-11). Check engine alternator, engine harness,
throttle solenoid TS1, fuel solenoid FS1, and the fuel pump.
Check continuity of Engine Control switch S1, and replace if necessary.

Trouble Remedy
Engine suddenly stops (continued). Check control relay CR1 for proper coil voltage and connections. Check continuity of coil and condition
Check integrated rectifier SR2, and replace if necessary.
Check fuel solenoid FS1 for proper coil voltage and connections. Check continuity of coil. Replace
FS1 if necessary.
Check fuel pump according to engine manual.
Check engine wiring harness and plug connections.
See engine manual.
Engine slowly stopped and cannot be Check fuel level.

restarted.
Check engine air and fuel filters (see Sections 8-5 and 8-10).
See engine manual.
Battery discharges between uses. Turn Engine Control switch S1 off when unit is not running.
Clean top of battery with baking soda and water solution; rinse with clear water.
Recharge or replace battery if necessary.
Periodically recharge battery (approximately every 3 months).
Engine idles, but does not come up to Check for obstructed throttle solenoid TS1
weld speed (units with idle option only).
Check idle module PC5, and replace if necessary.
Check current transformer CT1 for continuity and proper connections. Replace CT1 if necessary.
Engine does not run at idle speed Check for obstructed throttle solenoid TS1.
(units with idle option only).
Eff w/LG440003E, reset circuit breaker CB9 (see Section 8-11).
Check idle module PC5, and replace if necessary.
Engine uses oil during run-in period; Dry engine according to run-in procedure (see Section 13).
wetstacking occurs.
Notes

10-2. Troubleshooting Circuit Diagram For Welding Generator (Use With Section 10-3)
The circuit for the CC/CV model is shown below. See Sec-
tion 12 for the circuit for CC/CV Flux core models.
V5,R5
V4,
R4
R10
V6,R6
V1,R1 E
V7, E
V1,R1 E
R7
I1
V1,R1
V1,R1
V2,R2
See Section 10-10

for PC3 data
V3,R3
See Section
10-12 for PC2
Throttle Solenoid Circuit Breaker data
CB9 Eff w/LG440030E V21
Starter control
Engine
relay CR2
V23 control
relay CR1
V22
V24
R9
V10 V8,
R8
V25,
R12
V9
Glow plug
relay CR3

V16,
B,D
V15,
A,C
E E
E
E E E
V19
V20 V17
V18
V11, R11 V12 V13 V14

See Section 10-4
for waveforms
A,B,C,D,E
See Section
10-5 for
PC6 data
See Section
4-12 for RC14
information
226 566-D

10-3. Troubleshooting Values For Circuit Diagram (Use With Section 10-2)
Test Equipment Needed:
Voltage Readings
a) Tolerance − ±10% unless specified
b) Condition − 70°F (21°C); cold machine
(no warm-up); no load; weld/power rpm
unless noted
c) Reference − single arrow: reference to
circuit common (lead 42); double
arrow: reference to points indicated
d) Process/Contactor switch R1 in Weld Resistance Values
Terminals Always On − Stick (Dig-B) a) Tolerance − ±10% unless specified
position (Stick 30 postion on Flux Core
units) unless noted. b) Condition − 70°F (21°C); cold
e) Wiring Connections − see Section 12 machine (no warm-up)
V1 49 − 60 volts AC c) Wiring Connections − see Section
12
V2 158 volts AC
d) Stop engine before checking
V3 24 volts AC
resistance
V4 46 volts AC
R1 thru R6 Less than 1 ohm
V5 46 volts AC
R7 22 ohms
V6 46 volts AC R8 14.2 ohms
V7 + 61 volts DC R9 Empty fuel tank: 250 ohms
V8 +12 volts DC Full tank: 0 ohms
R10 30k ohms cold, drops as
V9 +12 volts DC unit heats up
V10 +12 volts DC R11 Increases in 1K ohm
V11 0 to +5 volts DC from Weld Terminals increments up to 11K ohms,
Always On−Wire position to Remote−Wire then resets to zero
position of Process Contactor switch R1 (in R12 14.2 ohms
0.45 volt increments). On Flux Core units,
rotate R1 from Min to 20 position.
V12 +5 volts DC
V13 0 to +5 volts DC from min to max of Amperage Readings
Voltage/Amperage control R2 a) Tolerance − ±5% unless specified
V14 +5 volts DC
b) Condition − 70°F (21°C); cold
V15 +41 volts DC with Process/Contactor machine (no warm-up); no load;
switch R1 in Weld Terminals Always On − weld/power rpm unless noted
Stick position (Eff w/LH030117E: +59 volts
DC); +20 volts DC with R1 in TIG position c) Process/Contactor switch R1 in
V16 14 to +40 volts DC with Process/Contactor Weld Terminals Always On − Stick
switch R1 in Weld Terminals Always (Dig-B) position (or Stick 30
On−Wire position position on Flux Core units)
V17 Circuit common unless noted
V18 1 volt DC per 100 amperes of weld output I1 3.1 amps DC
4.6 amps at 20 volt, 200 amp load
V19 − 15 volts DC
V20 +15 volts DC
V21 +12 volts DC
V22 +12 volts DC input with Engine Control
switch S1 in Start position
V23 +12 volts DC input with Engine Control
switch S1 in Start or Run position
V24 Ground path for CR1:
Normal operation: 0 volts DC
Fault shutdown: +12 volts DC
V25 +12 volts DC

10-4. Waveforms For Sections 10-2
The waveforms represent the output of the welding power source. When operating properly, the power source waveforms match those shown.
2 ms 50 V 2 ms 20 V
gnd gnd
A. CC/DC Open-Circuit Voltage, Process/Contactor B. CV/DC Open-Circuit Voltage, Process/Con-

Switch R1 In Weld Terminals Always On − Stick tactor Switch R1 In Weld Terminals Always
(Dig B) Position (Stick 30 postion on Flux Core On − Wire Position, Voltage/Amperage Con-
units), Voltage/Amperage Control R2 At Max trol R2 At Max
2 ms 50 V 2 ms 20 V
gnd gnd
C. CC/DC Output, 30 Volts DC, 250 Amperes, Pro- D. CV/DC Output, 30 Volts DC, 250 Amperes, Pro-
cess/Contactor Switch R1 In Weld Terminals Al- cess/Contactor Switch R1 In Weld Terminals
ways On − Stick (Dig B) Position (Stick 30 Always On − Wire Position, (Resistive Load)
postion on Flux Core units), (Resistive Load)
5 ms 2 V
gnd
E. SCR Gate Pulses w/Respect To Cathode At No Load, Pro-

cess/Contactor Switch R1 In Weld Terminals Always On −
Stick (Dig B) Position (Stick 30 postion on Flux Core
units), Voltage/Amperage Control R2 At Max

10-5. Filter Board PC6 Testing Information
! Stop engine.
See Section 10-6 for specific val-
ues during testing. Voltage read-
1 ings tolerance ±10%.
1 Filter Board PC6
2 Receptacle RC2
Ref. 804 492−A / 217 008
10-6. Filter Board PC6 Test Point Values
a) Tolerance − ±10% unless

specified
PC6 Voltage Readings b) Reference − to circuit common
(lead 42) unless noted
c) Condition − no load; weld/pow-
er rpm unless noted
d) Process/Contactor switch S6
in Weld Terminals Always On −
Stick position
Receptacle Pin Value

RC2 1 24 volt AC input with respect to pin RC2-5
2 Not used on this model
3 115 volts AC input with respect to pin RC2-5
4 Voltage feedback: 1 volt DC per 10 arc volts
5 Circuit common for 24 and 115 volt AC contactor control circuits
6 Command reference: +10 volt DC input
7 Contactor control circuit: 24 volt AC input with respect to pin RC2-5 and closure on RC14 between
pins A and B
8 Command common
9 Remote command signal input: 0 to +10 volts DC input from min to max of remote voltage/amperage
control
10 Current feedback: 1 volt DC per 100 arc amperes

10-7. Module Testing Information
If there is no weld output and no
auxiliary power output, use this
testing information to determine
which circuit board module may be
at fault.
1 Main Control Board PC1
2 Plug PLG6
3 Jumper Wires
Locate 30−pin plug PLG6 and dis-
connect from PC1 module. Install
jumper wires at the following pins:
G3 (Lead No. 117) to H3 (Lead No.
113)
D2 (Lead No. 107) to J3 (Lead No.
1 130)
3
Start engine with these jumpers
installed and check for auxiliary
power.
If auxiliary power is present, PC1
2 could be at fault. Use Sections 10-8
and 10-9 to troubleshoot PC1.
If auxiliary power is not present,
voltage regulator board PC3 could
be at fault. Be sure PC3 is supply-
ing the following voltages at PC1
module:
4 Plug PLG7
4
Check for +14 volts DC at PLG7 pin
E1 (lead no. 120)
Check for +15 volts DC at PLG6 pin
E3 (lead no. 109)
Check for −15 volts DC at PLG6 pin
F3 (lead no. 106).
Use Sections 10-10 and 10-11 to
troubleshoot PC3.
Remove jumper wires before con-
tinuing troubleshooting.
Ref. 804 492-A

10-8. Main Control Board PC1 Testing Information
! Stop engine.
ings tolerance ±10%.
1 Main Control Board PC1
2 Plug PLG6
3 Plug PLG7
4 Plug PLG11
If no weld output and no auxilia-
ry power are available, see
Section 10-7 for module testing
information before trouble-
shooting PC1.
4
1
803 930−A

10-9. Main Control Board PC1 Test Point Values
specified
er rpm unless noted
d) Process/Contactor switch R1
Stick position

PLG6 A1 Serial data line
A2 +5 volts DC output
A3 CV weld feedback with respect to pin PLG6-B3: same as OCV or load voltage
B2 Command signal input: 0 to +5 volts DC input from min to max of Voltage/Amperage control R2
B3 Voltage feedback reference
C1 Serial data line
C2 Circuit common for Voltage/Amperage control R2
C3 CC weld feedback with respect to pin PLG6-B3; same as OCV or load voltage
D2 Frequency to voltage signal: +10 volts DC input at 1860 rpm
D3 Not used on this model
E2 Synchronization signal
E3 Power supply input: +15 volts DC
F1 Not used on this model
F2 Voltage feedback: 1 volt DC per 10 arc volts
F3 Power supply input: −15 volts DC
G1 Not used on this model
G2 Command reference: +10 volt DC input
G3 Shutoff command output (field current); normal condition: 0 volts DC, fault condition: 0.7 volts DC
H1 Not used on this model
H2 Remote command signal input: 0 to +10 volts DC input from min to max of remote voltage/amperage
control
H3 Circuit common
J1 Not used on this model
J3 +10 volts DC output
K1 +5 volts DC output
K3 24 volts AC input
PLG7 A1 0 to +5 volts DC from Weld Terminals Always On−Wire position to Remote−Wire position of Process
Contactor switch R1 (in 0.45 volt increments). (On Flux Core units, rotate R1 from Min to 20 position.)
A2 1 volt DC input per 100 amperes of weld output with respect to pin PLG7-C2
B1 Circuit common for Process/Contactor switch R1
B2 +15 volts DC output with respect to pin PLG7-C2
B3 Contactor control circuit: 24 volt AC input with respect to circuit common and closure on RC14 be-
tween pins A and B
C1 +5 volts DC output
C2 Circuit common
C3 SCR fault signal; +5 volts DC output if any SCR fails

D1 +2 volts DC input at 77° F
D2 −15 volts DC with respect to pin PLG7-C2
E1 +13 volts DC input
F1 Command common
F2 Weld idle control signal: 0 volts DC output when welding; 3.5 volts DC input when not welding
F3 Current feedback: 0 volts DC input per 100 arc amperes
PLG11 A1 Gate Pulse to SCR1 with respect to pin PLG11-A2
A2 Reference for gate pulse to SCR1
A3 Gate Pulse to SCR2 with respect to pin PLG11-B3
B1 Reference for gate pulse to SCR3
B2 Gate Pulse to SCR3 with respect to pin PLG11-B1
B3 Gate Pulse to SCR2 with respect to pin PLG11-A3
C1 Gate Pulse to SCR4 with respect to pin PLG11-C2
C2 Reference for gate pulse to SCR4
C3 Reference for gate pulse to SCR5
D1 Reference for gate pulse to SCR6
D2 Gate Pulse to SCR6 with respect to pin PLG11-D1
D3 Gate Pulse to SCR5 with respect to pin PLG11-C3
E1 Gate Pulse to SCR7 with respect to pin PLG11-E2
E2 Reference for gate pulse to SCR7
E3 Gate Pulse to SCR8 with respect to pin PLG11-F3
F1 Reference for gate pulse to SCR9
F2 Gate Pulse to SCR9 with respect to pin PLG11-F1
F3 Reference for gate pulse to SCR8

10-10. Voltage Regulator Board PC3 Testing Information
! Stop engine.
1 Voltage Regulator Board PC3
2 Receptacle RC1
3 Receptacle RC2
If no weld output and no auxilia-
1 ry power are available, see
Section 10-7 for module testing
information before trouble-
shooting PC3.
803 930−A

10-11. Voltage Regulator Board PC3 Test Point Values

specified
er rpm unless noted
Stick position

RC1 1 14 volts DC input with respect to pin RC1-3
2 +13 volts DC output
3 Circuit common
4 Circuit common
5 Power supply output: +15 volts DC
6 Power supply output: −15 volts DC
7 +10 volts DC input
8 Shutoff command input (field current): normal condition: 0 volts DC, fault condition: 0.7 volts DC
9 Frequency to voltage signal: +10 volts DC output at 1860 rpm
10 SCR fault signal; +5 volts DC input if SCR fails
11 Synchronization signal
12 Not used
RC2 1 120 volts AC input with respect to pin RC1-3
3 Not used
4 Not used
6 +61 volts DC with respect to pin RC2-7
7 +61 volts DC with respect to pin RC2-6
8 158 volts AC with respect to pin RC2-5
9 Not used
10 Not used
11 Not used
12 Not used

10-12. Meter Display Board PC2 Testing Information
! Stop engine.
1 1 Meter Display Board PC2
804 492-A / 214 536
10-13. Meter Display Board PC2 Test Point Values

specified
er rpm unless noted
Stick position

RC1 1 +12 volts DC input with respect to pin RC1-2
2 Circuit common
3 Serial data line
4 Serial data line

10-14. Idle Module PC5 Testing Information And Troubleshooting Flow Chart
Voltage readings tolerance ±10%.

1 Idle Module PC5
Engine starts and remains at idle

speed until a power or weld load is
applied.
Verify engine speeds are correct

before testing idle module.
J C
G E
B H
A
803 566-E

Engine does not go to idle speed (1250 rpm; Engine does not go to weld/power speed
1500 rpm Eff w/LH030117E) with no weld or (1880 rpm) under power or weld load .
power load applied.
Connect meter (DC) between Connect meter between

terminal H and terminal E. terminal H and terminal E.
Start engine, and place Engine Start engine, and place Engine
Control switch S1 in Auto position. Control switch S1 in Auto position.
Place Process/Contactor switch Place Process/Contactor switch
R1 in Weld Terminals R1 in Weld Terminals
Always On − Stick position. Always On − Stick position.
Check Engine Check Engine

NO NO
Control switch S1, Control switch S1,
+12 volts dc present? and ground con- +12 volts dc present? and ground con-
nection (lead 42). nection (lead 42).
YES YES
Connect meter DC between

Connect meter between
terminal B (+) and terminal E (−).
terminal G and terminal E.
Check Engine
NO Control switch S1, Connect a 100 watt light bulb to
+12 volts dc present? control relay CR1, 120 volts ac duplex receptacle.
and ground con-
nection (lead 42).
YES
NO Check connections
Connect meter between Minimum of 0.75 volt AC present? to current
terminal G and terminal E.
transformer.
YES
Disconnect load
NO from generator Connect meter between
0 (zero) volts ac present? power receptacles. terminal J and terminal E.
Check current
transformer.
NO Check main
Connect meter between 0 Volts DC present? control board
terminal J and terminal E.
PC1.
YES
NO Check main Connect meter between

3.5 volts dc present? control board terminal C (+) and terminal E (−).
PC1.
YES
NO
Connect meter between 0 (zero) volts dc present? Replace
terminal C (+) and terminal E (−). idle module.
YES
NO Check control relay CR4

Replace and throttle solenoid
About 10 volts DC present?
idle module. TS1.
YES
Check circuit breaker CB9, control Disconnect 100 watt light bulb
relay CR4, throttle solenoid TS1, and meter leads.
and connections.
Reinstall cover. Reinstall cover.

10-15. Replacing Brushes And Cleaning Slip Rings

1 Brush Holder Bracket
Remove brush holder bracket.
Keep hardware for reinstallation.
2 Brush Holder
3 Brush With Spring
4 Brush Holder Cap
5 Brush Holder Retaining Bar
Mark and disconnect leads at caps
and remove retaining bar. Unscrew
caps and remove brushes from
bracket.
Replace brushes if damaged, or if
brush is at or near minimum length.
6 Slip Rings
Inspect slip rings. Under normal
use, rings turn dark brown.
If slip rings are corroded or surface
is uneven, insulate brush leads,
start engine, and clean rings with a
commutator stone. Remove as little
material as possible.
! Stop engine.
Install brushes, caps, bar, bracket,
and brush leads. Tighten bracket
hardware.
2
1 3
4 5
5/16 in (8 mm)
Minimum Length
9/16 in (14.3 mm)

New Length
Tools Needed:
Replace
Damaged Brushes
804 493-A

10-16. Checking Unit Output After Servicing
Also use output waveforms to

check unit output after servic-
ing (see Section 10-4).
Check engine speeds, and adjust if
necessary (see Section 8-8 or 8-9).
Place Process/Contactor switch
R1 in Weld Terminals Always Hot −
Stick position.
1 AC Power Receptacles RC11
And RC12
2 Positive (+) Weld Output
Terminal
3 Work (−) Weld Output
Terminal
Start engine and run at weld/power
speed (1880 rpm).
Check voltage at each receptacle.
With no load applied, there should
be approximately 220 volts AC
present at RC11 and RC12.
If correct voltage is not present, re-
peat troubleshooting procedures in
Section 10-1.
3 Check open-circuit voltage across
weld output terminals according to
Section 10-2. If correct voltages are
not present, repeat troubleshooting
procedures in Section 10-1.
! Stop engine.
1
Allow engine to cool, and then com-
plete pre-operational checks in
table.
Pre-Operational Checks
Wipe engine surfaces clean.
Check labels; replace labels that are unreadable or damaged.

Test Equipment Needed: Tools Needed:
Check fuel and oil (see Section 4-7).
Check and correct any fluid leaks.
Clean weld output and battery terminals. Tighten connections.
Clean outside of entire unit.
Ref 804 009−A

SECTION 11 − DISASSEMBLY AND REASSEMBLY
11-1. Disassembly Of Unit
! Stop engine and let cool. Dis-

connect battery negative (−)
cable.
Use Section 10-1 to determine if trouble
is in stator, rotor, engine or combination
of these components.
1 Engine Manifold Screw
2 Generator Mounting Screws
3 Engine Mounting Screw
4 Engine Lifting Eyes
Remove side panels, covers, and
doors. Retain all hardware.
Drain radiator according to Section 8-7
and engine manual. Disconnect hoses
at radiator.
Remove rear upright, right fan guard,
and radiator assembly.
Disconnect flexible exhaust pipe at en-
gine manifold.
Disconnect fuel line at engine.
To aid in reassembly, mark leads

before disconnecting. See lead list
summary in Section 12 for con-
nection information.
Disconnect:
generator cables from rectifier
assembly
generator power leads from termi-
nal strip TE1
1 engine wiring harness at in-line
connector
engine ground strap from base.
Use a hoist to evenly lift and remove
engine/generator assembly.
Go to Section 11-2.
Remove brushes
before removing
endbell or rotor.
Ref 804 494-A

11-2. Disassembly Of Generator
Generator
Torques: D
A 20 ft lb (27 N.m)
B 10 ft lb (14 N.m)
C 60 in lb (7 N.m) 4
D 30 ft lb ( 41N.m)
3
B
C 1
803 686-B
! Do not damage stator or rotor win- Remove brushes from brushholder assembly Reinstall engine/generator assembly in unit.
dings during this procedure. before disassembling generator. Reinstall mounting hardware.
! Use hoist and lifting strap to carefully Remove engine and rotor by removing nuts Reconnect fuel line and exhaust pipe
remove generator components. from studs and separating stator from engine
Reinstall radiator and rear upright. Refill ra-
adapter. With engine properly supported, re-
diator with coolant (see Section 8-7 and en-
1 Brushes move hardware securing endbell to stator.
gine manual).
2 Stator Reassembly Instructions:
Reconnect all leads. Use cable ties to secure
3 Endbell Reinstall engine and generator parts as leads in existing wiring harness and away
needed using torque values in table. from moving and hot parts.
4 Rotor
Reinstall brushes in brushholder assembly. Reconnect negative (−) battery cable. Rein-
5 Stud
stall cover, panels, and doors.
11-3. Other Torque Values

Location Hardware Torque
Engine Mounting Bracket to Engine Screw, 312−18x .75 Hexwhd.66d Stl Pld Slffmg Tap−rw 100 ft lb (135 N.m)
Upright to Base Screw, 375−16x1.00 Hexwhd.66d Stl Pld Slffmg 30 ft lb (41 N.m)
Rotor to Flywheel 20 ft lb (27 N.m)
Exhaust Pipe to Manifold Screw, M10−1.5x25 Hex Hd−pln 8.8 Pln 30 ft lb (41 N.m)
Engine and Generator Mounting Bolts Screw, 500−13 Hex Flange−Hd Gr8 Pln 50 ft lb +10/−0 (68 N.m)

11-4. Replacing Rectifier SCR Modules
! Stop engine and let cool. Dis-
connect battery negative (−)
cable.
Be sure to follow torque specifica-

tions in table when installing and
SCR Module Torques: connecting SCR module. Retorque
mounting hardware after four
SCR Mounting Screw SCR Connection Screw Terminal hours.
45 in lb, ±5 in lb 1 Rectifier Assembly

(5 N⋅m, ±0.5 N⋅m) 45 in lb, ±5 in lb 2 SCR Module 4, 5, 6
(5 N⋅m, ±0.5 N⋅m)
After four hours re-torque to 3 SCR Module 1, 2, 3
45 in lb, ±5 in lb
(5 N⋅m, ±0.5 N⋅m) 4 SCR Connection Screw
5 SCR Mounting Screw
Remove left side panel. Remove rectifi-
er assembly screws and slowly tilt as-
sembly out.
Remove defective SCR module.
Clean mounting surface where module
will be installed
Apply a thin layer of supplied heat sink
compound to mounting surface of
module.
Install new SCR module. Follow torque
specifications in table when installing
part. Remember to re-torque hard-
ware as specified.
Remove protective foam from SCR ter-
minals (if applicable) before connecting
leads.
2
5
1
803 703-B

SECTION 12 − ELECTRICAL DIAGRAMS
The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit inside
machine case or contact distributor for more information.
The following is a list of all diagrams for models covered by this manual.
Circuit Wiring
Model Serial Or Style Number
Diagram Diagram
Big Blue 400 CX CC/CV Flux LE341957 Thru LF350568 219 557−B
Core Models
LF350569 And Following 226 564-C See Table 12-1
Big Blue 400 CX CC/CV Models LF350569 Thru LH040123E 226 566-D See Table 12-2
Circuit Board PC6 LE341957 And Following 217 005-A

(HF Filter Board)
Circuit Board PC2 LE341957 And Following 214 535-B

(Meter Display)

Figure 12-1. Circuit Diagram For Big Blue 400 CX Flux Core Eff w/ LE341957 Thru LF350568
219 557−B

Figure 12-2. Circuit Diagram For Big Blue 400 CX CC/CV Flux Core Eff w/LF350569 And Following
226 564-C

Figure 12-3. Circuit Diagram For Big Blue 400 CX CC/CV Eff w/LF350569 Thru LH040123E
226 566-D

217 005-A
Figure 12-4. Circuit Board PC6 (HF Filter) Effective w/LE341957 And Following
214 535-B
Figure 12-5. Circuit Board PC2 (Meter Display) Effective w/LE341957 And Following
Table 12-1. Lead List Summary For Big Blue 400CX CC/CV Flux Core Models Eff w/LF350569
Table shows physical lead connections and should be used with circuit diagram (table replaces wiring diagram).
Apply small amount of dielectric grade, nonconductive electric grease (Miller Part No. 146 557) to connectors where factory-applied
grease had been present.
Lead Connections Lead Connections

−−−− PLG1 TO G1 52A CR4 (87) TO R4
−−−− PLG1 TO G2 52B R4 TO CR1 (4)
−−−− PLG1 TO K1 52C CR1 (4) TO SR2
−−−− PLG1 TO K2 52D SR2 TO CR2
11A STATOR TO RECT. 52E CR2 TO PC5 (B)
16A PLG6 (A3) TO R−3 RIGHT 53A FS1 (1) TO SR2
16B SCR CV (+) TO R3 (RIGHT) 53B SR2 TO FUEL PUMP
17A Z1 TO SCR’S CC (+) 54A CR1 (1) TO PLG1 (7)
19A PLG6 (C3) TO R−3 LEFT 55A CR1 (0) TO CR1 (2)
19A Z1 (CC) TO CC OUTPUT STUD 55B CR1 (0) TO S4 (NO)
19B Z1 TO R3 (LEFT) 55C CR1 (2) TO S1 (B)
21A STATOR TO RECT. 55D S4 (NO) TO PLG1 (4)
30A PLG6 (B3) TO R−3 CENTER 56A S2 (2) TO PLG1 (2)
30A SCR’S (−) TO NEGATIVE OUTPUT STUD 57A S3 (2) TO PLG1 (3)
30B HEAT SINK (−) TO R3 (CENTER) 58A CR3 (86) TO S4 (WIPER)
31A STATOR TO RECT. 60A CR4 (30) TO SR3
40A CR1 (8) TO PLG5 (1) 60B SR3 TO TS1
40B CR1 (8) TO PLG9 (1) 61A PC5 (C) TO SR3
41A CB1 (BAT) TO STARTER 61B SR3 TO CR4 (86)
42A GROUND STUD TO TE1 62A PC5 (H) TO S1 (D)
42A GROUND TERMINAL TO PLG9 (3) 67A PC5 (G) TO CT
42A S2 (1) TO GROUND TERMINAL 70A PLG7 (F2) TO PC5 (J)
42AA GROUND STUD TO RC11 (PE) 71A FUEL SENDER TO PLG1 (5)
42AB GROUND STUD TO RC12 (PE)
80 PC6 − EXIT
42AC GROUND STUD TO TE2
80A STATOR TO TE1
42B GROUND TERMINAL TO PLG5 (2)
80B TEI TO PC6 80 LEAD
42B S3 (1) TO GROUND TERMINAL
81A PLG6 (K3) TO CB8
42B TE1 TO BASE GROUND
81A STATOR TO CB8
42C GROUND TERMINAL TO TS1
82A STATOR TO TE1
42C PC6 TO FRT PANEL GROUND
82C TE1 TO CB5
42C PLG6 (J1) TO EXIT
82D CB6 TO CB5
42D FS1 (2) TO GROUND TERMINAL
83A STATOR TO TE1
42E FUEL PUMP TO GROUND TERMINAL
84A STATOR TO TE1
42F SR2 TO GROUND TERMINAL
84B STATOR TO T2−1
42G SR3 TO GROUND TERMINAL
42H PC5 (E) TO GROUND TERMINAL 85A STATOR TO TE1
42J CR4 (85) TO GROUND TERMINAL 87A PC6 − CB7
42K CR3 (85) TO GROUND TERMINAL 87A RC12 (L) TO CB6
42L PC5 (E) TO CT 88A STATOR TO TE1
42M GROUND TERMINAL TO GROUND TERMINAL 89A STATOR TO TE1
42N FUEL LEVEL SENDER TO GROUND TERMINAL 91B PLG10 (1) TO #91 STATOR LEAD
42P FUEL SENDER GROUND TO PLG1 (8) 92B PLG10 (2) TO #92 STATOR LEAD
42Q ENGINE BLOCK GROUND TO GROUND TERMINAL 94B RC11 (L) TO CB5
42R GROUND TERMINAL TO CR2 95B CB5 TO RC11
42TG T1−5 TO TE−1 98A STATOR TO TE1
42Y FRONT PANEL GROUND STUD TO TE1 99A CB5 TO RC12
43A ALT (B) TO CB1 (AUX) 99A STATOR TO TE1
43B CB1 (AUX) TO CB2 99B STATOR TO T1−3
43C CB2 TO CB3 99B TE1 TO CB5
43D CR3 (87) TO CB1 (AUX) 100A STATOR TO SPLICE (PC3)
44A CR3 (30) TO GLOW PLUG 100B PLG10 (5) TO STATOR 100A
45A CB3 TO CR1 (6) 101A STATOR TO FUSE 1
47A CR2 TO STARTER 103A PLG10 (4) TO T1−6
48A CB2 TO S1 (A) 104A PLG10 (3) TO T1−4
49A SR1 TO R4 105A PLG10 (6) TO BRUSH
50A ALT TO SR1 (+) 106A PLG6 (F3) TO PLG9 (6)
51A CR2 TO S1 (C) 107A PLG6 (D2) TO PLG9 (9)
51B CR2 TO PLG1 (6) 108A PLG10 (7) TO BRUSH
Table 12−1. Lead List Summary For Big Blue 400CX CC/CV Flux Core Models Eff w/LF350569 (Continued)
109A PLG6 (E3) TO PLG9 (5) 150A PLG7 (B3) TO PC6 (7)
112A PLG6 (E2) TO PLG9 (11) 160A PLG7 (B1) TO PLG3 (4)
113A PLG6 (H3) TO PLG9 (4) 161A PLG7 (A1) TO PLG3 (5)
114A PLG10 (8) TO F1 162A PLG6 (K1) TO PLG3 (6)
117A PLG6 (G3) TO PLG9 (8) 165A PLG6 (C2) TO PLG2 (1)
120A PLG7 (E1) TO PLG9 (2) 166A PLG6 (B2) TO PLG2 (2)
121A PLG7 (C3) TO PLG9 (10)
167A PLG6 (A2) TO PLG2 (3)
130A PLG6 (J3) TO PLG9 (7)
180A PLG6 (F1) TO EXIT
132A PC6 − CB8
135A PLG6 (G2) TO PC6 (6) 181A PLG6 (G1) TO EXIT
136A PLG7 (F1) TO PC6 (8) 182A PLG6 (H1) TO EXIT
137A PLG6 (H2) TO PC6 (9) 188A PLG7 (C1) TO PLG4 (1)
140A PLG7 (F3) TO PC6 (10) 189A PLG7 (D1) TO PLG4 (2)
141A PLG6 (F2) TO PC6 (4) 190A PLG6 (A1) TO PLG5 (3)
148A PLG6 (D3) TO PC6 (2) 191A PLG6 (C1) TO PLG5 (4)

Table 12-2. Lead List Summary For Big Blue 400CX CC/CV Models Eff w/LF350569
Table shows physical lead connections and should be used with circuit diagram (table replaces wiring diagram).
Apply small amount of dielectric grade, nonconductive electric grease (Miller Part No. 146 557) to connectors where factory-applied
grease had been present.

−−−− PLG1 TO G1 55A CR1 (0) TO CR1 (2)
−−−− PLG1 TO G2 55B CR1 (0) TO S4 (NO)
−−−− PLG1 TO K1 55C CR1 (2) TO S1 (B)
−−−− PLG1 TO K2 55D S4 (NO) TO PLG1 (4)
11A STATOR TO RECT. 56A S2 (2) TO PLG1 (2)
16A PLG6 (A3) TO R−3 RIGHT 57A S3 (2) TO PLG1 (3)
16B SCR CV (+) TO R3 (RIGHT) 58A CR3 (86) TO S4 (WIPER)
17A Z1 TO SCR’S CC (+) 60A CR4 (30) TO SR3
19A PLG6 (C3) TO R−3 LEFT 60B SR3 TO TS1
19A Z1 (CC) TO CC OUTPUT STUD 61A PC5 (C) TO SR3
19B Z1 TO R3 (LEFT) 61B SR3 TO CR4 (86)
21A STATOR TO RECT. 62A PC5 (H) TO S1 (D)
30A PLG6 (B3) TO R−3 CENTER 67A PC5 (G) TO CT
30A SCR’S (−) TO NEGATIVE OUTPUT STUD 70A PLG7 (F2) TO PC5 (J)
30B HEAT SINK (−) TO R3 (CENTER) 71A FUEL SENDER TO PLG1 (5)
31A STATOR TO RECT. 80 PC6 − EXIT
40A CR1 (8) TO PLG5 (1) 80A STATOR TO TE1
40B CR1 (8) TO PLG9 (1) 81A PLG6 (K3) TO CB8
41A CB1 (BAT) TO STARTER 81A STATOR TO CB8
42A GROUND STUD TO TE1 82A STATOR TO TE1
42A GROUND TERMINAL TO PLG9 (3) 82C TE1 TO ELCB1−LINE
42A S2 (1) TO GROUND TERMINAL 82D TE1 TO ELCB2 − LINE
42AA GROUND STUD TO RC11 (PE) 83A STATOR TO TE1
42AB GROUND STUD TO RC12 (PE) 84A STATOR TO TE1
42AC GROUND STUD TO TE2 84B STATOR TO T2−1
42AD GFCI−1 (GRND) TO GROUND STUD 84B TE1 TO CB5
42B GROUND TERMINAL TO PLG5 (2) 85A STATOR TO TE1
42B S3 (1) TO GROUND TERMINAL 87A PC6 − CB7
42B TE1 TO BASE GROUND 87A RC11 (L) TO ELCB2−LOAD
42C GROUND TERMINAL TO TS1 88A STATOR TO TE1
42C PC6 TO FRT PANEL GROUND 89A STATOR TO TE1
42C PLG6−J1 TO EXIT 90D CB5 TO GFCI1 (H)
42D FS1 (2) TO GROUND TERMINAL 91B PLG10 (1) TO #91 STATOR LEAD
42E FUEL PUMP TO GROUND TERMINAL 92B PLG10 (2) TO #92 STATOR LEAD
42F SR2 TO GROUND TERMINAL 94B RC12 (L) TO ELCB1−LOAD
42G SR3 TO GROUND TERMINAL 95B ELCB1−LOAD (N) TO RC12
42H PC5 (E) TO GROUND TERMINAL 96A ELCB2−LOAD (N) TO RC11
42J CR4 (85) TO GROUND TERMINAL 98A STATOR TO TE1
42K CR3 (85) TO GROUND TERMINAL 99A STATOR TO TE1
42L PC5 (E) TO CT 99B STATOR TO T1−3
42M GROUND TERMINAL TO GROUND TERMINAL 99B TE1 TO ELCB1 −LINE (N)
42N FUEL LEVEL SENDER TO GROUND TERMINAL 99C TE1 TO ELCB2 − LINE (N)
42P FUEL SENDER GROUND TO PLG1 (8) 99D TE1 TO GFCI−1 (N)
42Q ENGINE BLOCK GROUND TO GROUND TERMINAL 100A STATOR TO SPLICE (PC3)
42R GROUND TERMINAL TO CR2 100B PLG10 (5) TO STATOR 100A
42S PERSONALITY CONNECTION 101A STATOR TO FUSE 1
42T PERSONALITY CONNECTION 103A PLG10 (4) TO T1−6
42TG T1−5 TO TE−1 104A PLG10 (3) TO T1−4
42W PERSONALITY CONNECTION 105A PLG10 (6) TO BRUSH
42X PERSONALITY CONNECTION 106A PLG6 (F3) TO PLG9 (6)
42Y FRONT PANEL GROUND STUD TO TE1 107A PLG6 (D2) TO PLG9 (9)
43A ALT (B) TO CB1 (AUX) 108A PLG10 (7) TO BRUSH
43B CB1 (AUX) TO CB2 109A PLG6 (E3) TO PLG9 (5)
43C CB2 TO CB3 112A PLG6 (E2) TO PLG9 (11)
43D CR3 (87) TO CB1 (AUX) 113A PLG6 (H3) TO PLG9 (4)
44A CR3 (30) TO GLOW PLUG 114A PLG10 (8) TO F1
45A CB3 TO CR1 (6) 117A PLG6 (G3) TO PLG9 (8)
47A CR2 TO STARTER 120A PLG7 (E1) TO PLG9 (2)
48A CB2 TO S1 (A) 121A PLG7 (C3) TO PLG9 (10)
49A SR1 TO R4 130A PLG6 (J3) TO PLG9 (7)
50A ALT (D+) TO SR1 (+) 132A PC6 − CB8
51A CR2 TO S1 (C) 135A PLG6 (G2) TO PC6 (6)
51B CR2 TO PLG1 (6) 136A PLG7 (F1) TO PC6 (8)
52A CR4 (87) TO R4 137A PLG6 (H2) TO PC6 (9)
52B R4 TO CR1 (4) 140A PLG7 (F3) TO PC6 (10)
52C CR1 (4) TO SR2 141A PLG6 (F2) TO PC6 (4)
52D SR2 TO CR2 148A PLG6 (D3) TO PC6 (2)
52E CR2 TO PC5 (B) 150A PLG7 (B3) TO PC6 (7)
53A FS1 (1) TO SR2 160A PLG7 (B1) TO PLG3 (4)
53B SR2 TO FUEL PUMP 161A PLG7 (A1) TO PLG3 (5)
54A CR1 (1) TO PLG1 (7) 162A PLG6 (K1) TO PLG3 (6)
Table 12−2. Lead List Summary For Big Blue 400CX CC/CV Models Eff w/LF350569 (Continued)
165A PLG6 (C2) TO PLG2 (1) 182A PLG6 (H1) TO EXIT
166A PLG6 (B2) TO PLG2 (2) 188A PLG7 (C1) TO PLG4 (1)
167A PLG6 (A2) TO PLG2 (3) 189A PLG7 (D1) TO PLG4 (2)
180A PLG6 (F1) TO EXIT 190A PLG6 (A1) TO PLG5 (3)
181A PLG6 (G1) TO EXIT 191A PLG6 (C1) TO PLG5 (4)

SECTION 13 − RUN-IN PROCEDURE
run_in1 2007−04
13-1. Wetstacking
NOTICE − Do not perform run-in
procedure at less than 20 volts
weld output and do not exceed duty
cycle or equipment damage may
occur.
1 Welding Generator
2 Run diesel engines near rated volt-
age and current during run-in period
to properly seat piston rings and
prevent wetstacking. See name-
plate, rating label, or specifications
section in this manual to find rated
voltage and current.
NOTICE − Do not idle engine longer
than necessary. Piston rings seat
faster if engine runs at weld/power
rpm, and the welding generator is
kept loaded during run-in.
1
2 Engine Exhaust Pipe
Wetstacking is unburned fuel and
oil in the exhaust pipe and occurs
during run-in if the engine is run too
long at light load or idle rpm.
If exhaust pipe is coated with a wet,
black, tar-like substance, dry the
engine using one of the following
run-in procedures.
See the engine manual for addition-
al engine run-in information.

13-2. Run-In Procedure Using Load Bank
! Stop engine.
! Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
4 ! Keep exhaust and pipe away
from flammables.
2 NOTICE − Do not perform run-in
procedure at less than 20 volts weld
1 output and do not exceed duty
occur.
1 Load Bank
Turn all load bank switches Off. If
needed, connect load bank to 115
volts ac wall receptacle or genera-
tor auxiliary power receptacle.
2 Welding Generator
Place A/V range switch in maxi-
mum position, A/V control in mini-
mum position, and Output Selector
switch (if present) in either DC
position.
3 Weld Cables
Connect load bank to generator
weld output terminals using proper
size weld cables with correct
connectors. Observe correct
polarity.
Start engine and run for several
3 minutes.
Set load bank switches and then
adjust generator A/V control so
load equals rated voltage and
current of generator (see name-
plate, rating label, or the specifi-
cations section in this manual).
Check generator and load bank
meters after first five minutes then
every fifteen minutes to be sure
generator is loaded properly.
NOTICE − Check oil level frequent-
ly during run-in; add oil if needed.
It is recommended to run the weld-
ing generator for two hours mini-
mum and up to four hours under
load. Place A/V control in minimum
position, then turn off load bank to
remove load. Run engine several
minutes at no load.
Repeat procedure if wetstacking is
present.
S-0683

13-3. Run-In Procedure Using Resistance Grid
! Stop engine.
! Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
6
! Keep exhaust and pipe away
from flammables.
2
NOTICE − Do not perform run-in
procedure at less than 20 volts weld
output and do not exceed duty
occur.
1 Resistance Grid
Use grid sized for generator rated
1 output.
Turn Off grid.
2 Welding Generator
Place A/V range switch in maxi-
mum position, A/V control in mini-
mum position, and Output Selector
switch (if present) in either DC
position.
3 Weld Cables
Connect grid to generator weld
output terminals using proper size
weld cables with correct connec-
tors (polarity is not important).
4 Voltmeter
5 Clamp-On Ammeter
Connect voltmeter and ammeter as
3 5 shown, if not provided on generator.
Start engine and run for several
minutes.
Set grid switches and then ad-
just generator A/V control so
load equals rated voltage and
4 current of the generator (see
nameplate, rating label, or the
specifications section in this
manual).
+ Check generator and meters after
first five minutes then every fifteen
minutes to be sure generator is
loaded properly.
NOTICE − Check oil level frequent-
ly during run-in; add oil if needed.
It is recommended to run the weld-
ing generator for two hours mini-
mum and up to four hours under
load. Place A/V control in minimum
position, then shut down grid to
remove load. Run engine several
minutes at no load.
Repeat procedure if wetstacking is
present.
S-0684

TM-4435C 2008−05
LJ140120E
Processes
TIG (GTAW) Welding
MIG (GMAW) Welding

ting and Gouging
Description
Big Blue 400 CX

)
Eff w/LE341957 Thru LJ110230E

For OM-4435 (218 759) Revision A Thru L

www.MillerWelds.com
SECTION 14 − PARTS LIST EFF w/LE341957 THRU LJ110230E
Hardware is common and not
available unless listed.
Wiring harnesses are listed at

the end of parts section.
8
9
10
11 13
12
6
7 14 23
15
5
16
103 17 24
105 22
106 102
104 21
19 20
25
4−Fig.14-6 or 14-7
101 18
100 91
1 90 92
89
2−Fig.14-4 84
98
97−Fig.14-2 or 14-3 99 83
85 82
86
88 81
87
93
80
94
95
96
Figure 14-1. Main Assembly (CC/CV Model Shown)

30 31
28
27 32 42
29 41
40
110 35
26 39
34
33
38
37
69 68
43
70 67 36
66 44
65 45
71
64 50 52
63 51
78 61
46 49 46
48
62
47 53
79 77 72−Fig.14-5 60
59
76 58 54
57
56
73
55
75 55
74
Optional Auto Idle
109
108
107
804 012−B / Ref. 803 683-D

Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 14-1. Main Assembly
. . . 1 . . . . HD1 . . . . 168829 . . Transducer, Current 1000a Module Max Open Loop . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . Figure 14-5 . . Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . 217070 . . Bracket, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . Figure 14-7, Figure 14-8 Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 181853 . . Insulator, Screw (For Rectifier Mtg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 5 . . . . . Z1 . . . . . 213929 . . Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 192303 . . Angle, Mtg Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . . . . . . . . . . 215522 . . Bracket, Vault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . +213488 . . Panel, Engine Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . PC1 . . . . 228727 . . Module, Main Control/Scr Gating (Prior to LH030117E) . . . . . . . . . . . . . . . 1
. . . 8 . . . . PC1 . . . . 231705 . . Module, Main Control/Scr Gating (Eff w/LH030117E) . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . PC3 . . . . 214770 . . Module, Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . 213493 . . Upright, Center Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . 189464 . . Seal, Weather Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . 213501 . . Bracket, Fuel Pump/Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . . . . . . . . . . . Bracket, Fuel Filter Mtg. (Order Thru Engine Manufacturer) . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . 217687 . . Filter, Fuel Spin−on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 207721 . . Pump, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . *213858 . . Filter, Fuel In−line 5/16x5/16 Mic 125 −175 . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . 214753 . . Bracket, Holddown Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . 213602 . . Gasket, Exhaust Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . 212621 . . Pipe, Exhaust Flexible Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . 183314 . . Clamp, Muffler 1.625 Dia U Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . 21 . . . . . . . . . . . . . . 212604 . . Baffle, Air Lower Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . 201528 . . Muffler, Exhaust Engine (Prior to LF350569) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . 226018 . . Muffler, Exhaust Engine (Eff w/LF350569) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . 213580 . . Pipe, Exhaust Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . 088528 . . Spark Arretsor, Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . 201399 . . Pipe, Exhaust Extension 5.0” Long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . +213470 . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 049525 . . Nut, 312−18 U−nut Multi−thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . 27 . . . . . . . . . . . . . . 189052 . . Grommet, Plastic Neck Filler Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . 190198 . . Cap, Tank Screw−on 3.500 In W/Vent W/Lanyard 8” . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . 176104 . . Label, Warning Falling Equipment Can Cause Serious (Prior to LF310974)1
. . . 29 . . . . . . . . . . . . . . 222513 . . Label, Warning Falling Equipment Can Cause Serious (Eff w/LF310974) 1
. . . 30 . . . . . . . . . . . . . . 201851 . . Cover, Radiator Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . 214604 . . Pipe, Exhaust Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . 176230 . . Label, Hot Exhaust Parts Do Not Touch (Prior to LF310974) . . . . . . . . . . . 2
. . . 32 . . . . . . . . . . . . . . 224265 . . Label, Warning Hot Exhaust Parts Do Not Touch (Eff w/LF310974) . . . . . 2
. . . 32 . . . . . . . . . . . . . . 224265 . . Label, Warning Hot Exhaust Parts Do Not Touch (Eff w/LF350569) . . . . . 1
. . . 33 . . . . . . . . . . . . . . 176103 . . Label, Use Diesel Fuel Only (Prior to LF310974) . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . . 192041 . . Label, Use Diesel Fuel Only (Eff w/LF310974) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . 213472 . . Keeper, Latch Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . 213471 . . Bracket, Cover Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 36 . . . . . . . . . . . . . . 217387 . . Baffle, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . . 213503 . . Guard, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . . +212607 . . Shroud, Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . . 212606 . . Radiator, W/14# Cap 3 Row Core (Prior to LF350569) . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . . 226121 . . Radiator, W/14# Cap 3 Row Core (Eff w/LF350569 Thru LH190115E) . . 1
. . . 39 . . . . . . . . . . . . . . 233256 . . Radiator, W/14# Cap 3 Row Core (Eff w/LH190116E)) . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . . 212603 . . Baffle, Air Upper Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . +220954 . . Upright, Rear (Prior to LF350569) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . +225400 . . Upright, Rear (Eff w/LF350569) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . . . 225412 . . Cover, Radiator Access (Eff w/LF350569) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . . . 220295 . . Bracket, Stiffener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . . 190190 . . Tank, Coolant Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . . . 213502 . . Guard, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Item Dia. Part
Figure 14-1. Main Assembly (Continued)
. . . 46 . . . . . . . . . . . . . . 176106 . . Label, Warning Moving Parts Can Cause Serious (Prior to LF310974) . . 4
. . . 46 . . . . . . . . . . . . . . 225120 . . Label, Warning Moving Parts Can Cause Injury (Eff w/LF310974) . . . . . . 4
. . . 47 . . . . . . . . . . . . . . 217698 . . Label, Help Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . . . . . . . . . . 176108 . . Label, Warning Battery Explosion Can Blind
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Prior to LF310974 and Eff w/LF350569) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . . . . . . . . . . 168385 . . Label, Warning Battery Explosion Can Blind
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Eff w/LF310974 thru LF350568) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . . . . . . . . . . . 176109 . . Label, Caution Using Ether To Aid Engine Etc (Prior to LF310974) . . . . . 1
. . . 49 . . . . . . . . . . . . . . 203260 . . Label, Caution Do Not Use Ether (Eff w/LF310974) . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . . . . . . . . . . 215268 . . Label, Diesel Engine Maintenance Cat 3013c . . . . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . . . . . . . . . . . 199592 . . Latch, Paddle Series 20 (Black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 52 . . . . . . . . . . . . . +213487 . . Door, Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 191626 . . Bumper, Door Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 53 . . . . . . . . . . . . . . 189975 . . Hinge, Door Access 180 Deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 54 . . . . . . . . . . . . . . 087341 . . Bumper, Door 1.000 Od X .750 High Rbr 50 Duro W/O . . . . . . . . . . . . . . 2
. . . 55 . . . . . . . . . . . . . . 213486 . . Panel, Rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 56 . . . . . . . . . . . . . . 213266 . . Mount, Engine/Generator Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 57 . . . . . . . . . . . . . . 197506 . . Screw, M14−1.5x 30 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 58 . . . . . . . . . . . . . . 213480 . . Bracket, Mtg Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 59 . . . . . . . . . . . . . . 083883 . . Washer, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 199505 . . Hose Assy, Oil Drain 32.000 Lg (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 61 . . . . . . . . . . . . . . 113854 . . . . Hose, Sae .500 Id X .780 Od Xcoil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 Ft.
. . . 62 . . . . . . . . . . . . . . 176529 . . . . Ftg, Hose Brs Barbed Fem 1/2 Tbg X 3/8 Npt . . . . . . . . . . . . . . . . . . . . . 1
. . . 63 . . . . . . . . . . . . . . 165271 . . . . Valve, Oil Drain 3/8−18 Nptf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 197448 . . Ftg, Hose Brs Barbed Elbow M 1/2 Tbg X 3/8 Npt . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 212612 . . Ftg, Adapter Oil Drain Cat 3013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 64 . . . . . . . . . . . . . . 212614 . . Hose, Radiator Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 65 . . . . . . . . . . . . . . 217686 . . Belt, Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 66 . . . . . . . . . . . . . . 210792 . . Engine, Cat Dsl Elec 3013c (1800) Series . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *202166 . . Filter, Oil Cat−150−4140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 217695 . . Switch, Coolant Temp N.C. 110c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 67 . . . . . . . . . . . . . . 212613 . . Hose, Radiator Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 68 . . . . . . . . . . . . . . 216811 . . Clip, Nut Retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 69 . . . . . . . . . . . . . . 197613 . . Air Cleaner, Intake 5.250 In (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 197675 . . . . Dust Ejector, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *197676 . . . . Element, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 197677 . . . . Cover Assy, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 197678 . . . . Body, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦*197679 . . . . Element, Air Cleaner Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 197829 . . . . Bracket, Mtg Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 70 . . . . . . . . . . . . . . 212617 . . Hose, Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 71 . . . . . . . . . . . . . . 217696 . . Switch, Lubricating Oil Pressure N.O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 72 . . . . . . . . . . Figure 14-6 . . Generator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 73 . . . . . . . . . . . . . . 213461 . . Bracket, Mtg Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 212623 . . Tank, Fuel (Includes Fuel Cap And Items Below) . . . . . . . . . . . . . . . . . . . . 1
. . . 74 . . . . . . . . . . . . . . 189908 . . . . Valve, Drain Fuel 180 Deg Zinc Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 75 . . . . . . . . . . . . . . 181572 . . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 77 . . . . . . . . . . . . . . 212611 . . . . Hose, Fuel Stand Pipe W/3/16 In Ftg (Return) . . . . . . . . . . . . . . . . . . . . . 1
. . . 78 . . . . . . . . . . . . . . 212610 . . . . Hose, Fuel Stand Pipe W/5/16 In Ftg (Supply) . . . . . . . . . . . . . . . . . . . . . 1
. . . 79 . . SENDER . . 213265 . . . . Sender, Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 172071 . . Clamp, Hose .520 − .605 Clp Dia Slfttng Black . . . . . . . . . . . . . . . . . . . . . . 8
. . . . . . . . . . . . . . . . . . . . 134835 . . Hose, Sae .312 Id X .560 Od (order by foot) . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 145054 . . Hose, Sae .187 Id X .410 Od X 26.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 80 . . . . . . . . . . . . . . 213465 . . Bolt, J Stl .312−18 X 7.250 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 81 . . . . . . . . . . . . . . 213466 . . Bracket, Battery Holddown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Item Dia. Part
. . . 82 . . . . BATT . . . . 111352 . . Battery, Stor 12v 585 Crk 95 Rsv Gp 55 Maint Free . . . . . . . . . . . . . . . . . 1
. . . 83 . . . . . . . . . . . . . . 190207 . . Cable, Bat Pos 45 In Lg No 1 Awg W/Clamp & .406 Rng . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 190206 . . Cable, Bat Neg 42 In Lg 2 Awg W/Clamp & .375 Rng . . . . . . . . . . . . . . . . 1
. . . 84 . . . . . . . . . . . . . . 213668 . . Bracket, Mtg Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 85 . . . . . . . . . . . . . . 200864 . . Label, Warning Do Not Weld On Base (Prior to LF310974) . . . . . . . . . . . . 2
. . . 85 . . . . . . . . . . . . . . 224266 . . Label, Warning Do Not Weld On Base (Eff w/LF310974) . . . . . . . . . . . . . . 2
. . . 86 . . . . . . . . . . . . . . 213458 . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 87 . . . . . . . . . . . . . . 213460 . . Crossmember, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 88 . . . . . . . . . . . . . . 213463 . . Spacer/Snubber, Generator Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 89 . . . . . . . . . . . . . . 213462 . . Pad, Mtg Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 90 . . . . . . . . . . . . . . 213459 . . Crossmember, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 213670 . . Screw, 500−13x2.25 Hex Flange−hd Gr8 Pln Chem/Phys . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 071731 . . Washer, Flat .656idx2.250odx.187t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 213600 . . Screw, 500−13x3.00 Hex Flange−hd Gr8 Pln . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 213464 . . Bracket, Battery Locator (In Base − Not Shown) . . . . . . . . . . . . . . . . . . . . . 1
. . . 91 . . . . . . . . . . . . . . 213485 . . Support, Engine Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 92 . . . . . . . . . . . . . . 213483 . . Support, Engine Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 93 . . . . . . . . . . . . . . 200865 . . Label, Ce Sound Power Level 98db (Prior to LF350569) . . . . . . . . . . . . . . 1
. . . 93 . . . . . . . . . . . . . . 226150 . . Label, Ce Sound Power Level 96db (Eff w/LF350569) . . . . . . . . . . . . . . . . 1
. . . 94 . . . . . . . . . . . . . +220953 . . Upright, Front (Prior to LF350569) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 94 . . . . . . . . . . . . . +226104 . . Upright, Front (Eff w/LF350569) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 95 . . . . . . . . . . . . . . 176105 . . Label, Warning General Precautionary (Prior to LF310974) . . . . . . . . . . . . 1
. . . 95 . . . . . . . . . . . . . . 223379 . . Label, Warning General Precautionary (Eff w/LF310974 thru LF350568) 1
. . . 95 . . . . . . . . . . . . . . 223378 . . Label, Warning General Precautionary (Eff w/LF350569 thru LH190058E) 1
. . . 95 . . . . . . . . . . . . . . 223952 . . Label, Warning General Precautionary (Eff w/LH190059E) . . . . . . . . . . . . 1
. . . 96 . . . . . . . . . . . . . . 220955 . . Panel, Front Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 97 . . . . . . Figure 14-3, Figure 14-4 Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 98 . . . . CT1 . . ♦105370 . . Xfmr, Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 99 . . . . . . . . . . . . . . 218449 . . Label, Rating Card Code 154 (Prior to LF350569) . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 173216 . . Label, CE European Community Mark (Prior to LF350659) . . . . . . . . . . . . 1
. . . 99 . . . . . . . . . . . . . . 226163 . . Label, Rating Card Ce 907143 (CC Model) (Eff w/LF350569) . . . . . . . . . . 1
. . . 99 . . . . . . . . . . . . . . 226422 . . Label, Rating Card Ce 907281 (CC/CV Model) (Eff w/LF350569) . . . . . . 1
. . 100 . . . . . . . . . . . . . 213504 . . Tray, Reactor&Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 101 . . . . . . . . . . . . . 213500 . . Brkt, Beam Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 102 . . . . T1 . . . . . 220887 . . Xfmr, Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 103 . . . TE1 . . . . 172661 . . Block, Stud Connection 6 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 104 . . . . C11 . . . . 217054 . . Capacitor, Cer Disc .0047 Uf 3000 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . 1
. . 105 . . . . . . . . . . . . . 214742 . . Capacitor Assy, (CC/CV Model) (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 213489 . . . . Bus Bar,Capacitor Bank Negative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 213490 . . . . Bus Bar,Capacitor Bank Positive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . C10 . . . . 163535 . . . . Capacitor,Elctlt 16000 Uf 60 Vdc Can 1.75 Dia . . . . . . . . . . . . . . . . . . . . 6
. . 106 . . . . R3 . . . . . 213027 . . Resistor, WW Tap 300 W 40 Ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 173734 . . Link, Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Item Dia. Part
. . . . . . . . . . . . . . . . . . ♦214887 . . Idle, Solenoid Assy (Prior to LG440030E) (Includes) . . . . . . . . . . . . . . 1

. . 107 . . . . . . . . . . . ♦213505 . . . . Bracket, Mtg Solenoid Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 108 . . . TS1 . . ♦080517 . . . . Solenoid,12vdc Pull Type Tubular . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦049839 . . . . Bracket, Adjustment Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦605277 . . . . Pin,Cotter .093 X .750 Zinc Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦198370 . . . . Rod,Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦206209 . . . . Ball Joint,.250−28 Thd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦198609 . . . . Arm,Throttle 104.22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦085963 . . . . Spring, Ext .375 Od X .041 Wire X 2.000 . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦230637 . . Idle, Solenoid Assy (Eff w/LG440030E) (consisting of) . . . . . . . . . . . . 1
. . 107 . . . . . . . . . . . ♦230828 . . . . Bracket, Mtg Solenoid Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 108 . . . TS1 . . ♦230634 . . . . Solenoid, Throttle W/4−8.4 Lb Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦198109 . . . . Screw, Shld Stl Sch .250−20 X .437 X .500 Shld . . . . . . . . . . . . . . . . . . . 1
. . 109 . . . . . . . . . . . ♦198018 . . . . Linkage, Throttle Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦230830 . . . . Arm, Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 110 . . . . . . . . . . . . . 233088 . . Label, Danger Using A Generator Indoors Can Kill You In Minutes
(Eff w/LH190057E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 213506 . . Bracket, Hold−Down Fuel Tank (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 218460 . . Kit, Label (Includes Safety And Informational Labels) . . . . . . . . . . . . . . . . . 1
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
* Recommended Spare Parts. ♦Optional
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

11
10 Hardware is common and not
12 available unless listed.
8 9 Wirng harnesses are listed at

13
7 14
15
6
16
23
22
5
4 24
17 21
3
1 2 18 20
36
35 19
34
25
29 26
28
27
33
31 30
32
804 011−A
Figure 14-2. Panel, Front w/Components (CC/CV Flux Core) (Prior To LF350569)
Item Dia. Part

Figure 14-2. Panel, Front w/Components (CC/CV Flux Core) Prior To LF350569 (Figure 14-1 Item 97 )
... 1 . . . . . . . . . . . . . . 097926 . . Knob, Pointer 2.375 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . . 1

... 2 . . . . . . . . . . . . . . 072590 . . Lock, Shaft Pot .375−32 X .250 Dia Shaft Tall . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 . . . . . . . . . . . . . . 170391 . . Conn, Circ Ms Protective Cap Size 20 Nylon . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . . . . . . . . . . . . . . 206795 . . Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 . . . . . . . . . . . . . . 097922 . . Knob, Pointer .875 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . . . 1
... 6 ........................ Nameplate, Control (Order By Model & Serial No.) . . . . . . . . . . . . . . . . . . . 1
... 7 . . . . PC6 . . . . 229949 . . Circuit Card Assy, Connector/Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . CB8 . . . . 083432 . . Circuit Breaker, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . . . . . 1
... 9 . . . . . . . . . . . . . . 214864 . . Panel, Front Engine/Weld Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 . . . . . . . . . . . . . . 214762 . . Bracket, Meter Hole Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 . . . . . . . . . . . . ♦214543 . . Enclosure, Circuit Card Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 11 . . . . . . . . . . . . ♦134201 . . Stand−off Support, Pc Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . . . 4
... 12 . . . . PC2 . . ♦214660 . . Circuit Card Assy, Display W/Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 . . . . . R1 . . . . . 214760 . . Switch, Rotary 12 Posn 1p 200ma 28vdc W/Resistors . . . . . . . . . . . . . . . 1
... 14 . . . . . R2 . . . . . 193118 . . Pot, Cp Flat 1t 2. W 1k Ohm Linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 . . . . . S4 . . . . . 021467 . . Switch, Tgl Spst 3a 250v Off−none−(On) Spd Term . . . . . . . . . . . . . . . . . . 1

Item Dia. Part
Figure 14-2. Panel, Front w/Components (CC/CV Flux Core) Prior To LF350569 (Continued)
... 16 . . . . . S1 . . . . . 212436 . . Switch, Ignition 4 Position (Includes Knob) . . . . . . . . . . . . . . . . . . . . . . . . 1

... 17 . . . . . . . . . . . . . . 039047 . . Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 18 . . . . . . . . . . . . . . 010381 . . Connector, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 19 . . . C13, 14 . . . 128750 . . Capacitor, Cer Disc .1 Uf 500 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . . . . . 2
... 20 . . . . RC12 . . . . 176355 . . Rcpt, Str 2p3w 16a 220v Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 21 . . . . CB6 . . . . 201083 . . Circuit Breaker,Man Reset 2p 20a 250vac . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 22 ........................ Nameplate, Generator Power (Order By Model & Serial No.) . . . . . . . . . . 1
... 23 . . . . . . . . . . . . . . 213478 . . Panel, Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 24 . . . . CB5 . . . . 202683 . . Supplementary Protector, Man Reset 2p 40a 240vac (Prior to LE409822) 1
... 24 . . . . CB5 . . . . 222187 . . Supplementary Protector, Man Reset 2p 35a 240vac (Eff w/LE409822) 1
... 25 . . . . GRD . . . . 083030 . . Stud, Brs .250−20 X 1.750 W/Hex Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 26 . . . . . . . . . . . . . . 010915 . . Washer, Flat .257idx0.640odx.031t Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 27 . . . . . . . . . . . . . . 601836 . . Nut, 250−20 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 28 . . . . RC11 . . . . 156831 . . Rcpt,Str 2p3w 32a 220v Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 29 . . . . . . . . . . . . . . 209056 . . Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 30 ........................ Nameplate, Weld Terminal (Order By Model & Serial No.) . . . . . . . . . . . . . 1
... 31 . . . . . . . . . . . . . . 181169 . . Spacer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 32 . . . . . . . . . . . . . . 186621 . . Boot, Generic Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 33 . . . . . . . . . . . . . . 180735 . . Washer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 34 . . . . . . . . . . . . . . 039046 . . Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 35 . . FUEL/HM . . 214768 . . Gauge, Fuel Elec/Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 36 . . . . . . . . . . . . . . 021385 . . Boot, Toggle Switch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦Optional
+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 218 460


11 Wiring harnesses are listed at

10 the end of parts section.
12
8 9
13 25
7 14 23
22 24
15 26 27
28
6 21
16
20 29
5
4
17
3
1 2 18
41 19
40 30
31
34 33 32
39
38
36 35
804 011−B
37
Figure 14-3. Panel, Front w/Components (CC/CV Flux Core) Effective W/LF350569
Item Dia. Part

Figure 14-3. Panel, Front w/Components (CC/Cv Flux Core) Effective W/LF350569 (Figure 14-1 Item 97)

... 8 . . . . CB8 . . . . 083432 . . Supplementary Pro, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . 1

Item Dia. Part
Figure 14-3. Panel, Front w/Components (CC Model) Effective W/LF350569 (Continued)

... 21 . . . . . . . . . . . . . . 206795 . . Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 23 . . . . . . . . . . . . . . 224428 . . Panel, Power CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 24 . . . GFCI1 . . . 151981 . . Rcpt, Str Dx Grd 2p3w 15/20a 125v *5−20r Gfi . . . . . . . . . . . . . . . . . . . . . . 1
... 25 . . . C11, 12 . . . 217054 . . Capacitor, Cer Disc .0047 Uf 3000 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . 2
... 27 . . . ELCB1 . . . 222991 . . Circuit Breaker, Elcb 20a 220v 0.030a Trip . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 29 . . . . . . . . . . . . . . 144844 . . Stand−off, No 6−32 X .875 Lg .250 Hex Al Fem . . . . . . . . . . . . . . . . . . . . . 4
... 32 . . . . . . . . . . . . . . 601836 . . Nut, 250−20 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
♦Optional


11 available unless listed.
10
9
8
13
7 14
15
6
16
5
17 23
4 24
25
1
3 18 22
2
19
37
21
36
26
20
35
27
28
30 29
31
34
32
804 443-A
33
Figure 14-4. Panel, Front w/Components (CC/CV Model) Eff w/LF350569 Thru LH040123E
Item Dia. Part
Figure 14-4. Panel, Front w/Components (CC/CV Model) Eff w/LF350569 Thru LH040123E
(Figure 14-1 Item 97)
... 6 . . . . . . . . . . . . . . . . . . . . . . . . Nameplate, Control (Order By Model & Serial No.) . . . . . . . . . . . . . . . . . . . 1

Item Dia. Part
Figure 14-4. Panel, Front w/Components (CC/CV Model) Effective w/LF350569 Thru LH040123E
(Continued)
... 23 . . . . . . . . . . . . . . 224428 . . Panel, Power CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 29 . . . . . . . . . . . . . . 601836 . . Nut, 250−20 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
♦Optional

Hardware is common and not 5
4
Wirng harnesses are listed at
3
2
6
1
9
10
11
12
13
14
803 689-D
15
Figure 14-5. Control Panel
Item Dia. Part

Figure 14-5. Control Panel (Figure 14-1 Item 2)
... 1 . . . . . . . . . . . . . . 220981 .. Bracket, Mtg Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 . . . . . . . . . . . . . . 129524 .. Term, Frict 250x032 Uninsul Male .130 Stud Mtg 3pr . . . . . . . . . . . . . . . . 2
... 3 . . . . CR2 . . . . 214876 .. Relay, Encl 6vdc Spst 35a/14vdc 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . . . . CB1 . . . . 190374 .. Circuit Breaker, Auto Reset 12vdc 40 Amp . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 . . . . CR1 . . . . 199999 .. Relay, Encl 12vdc Dpst−no 30a 6pin Flange (Prior to LF065150) . . . . . . . 1
... 5 . . . . CR1 . . . . 223669 .. Relay Assy, (Eff w/LF065150 Thru LF310974) . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 . . . . CR1 . . . . 223710 .. Relay, Encl 12vdc Dpst−no 25a 6pin Flange (Eff w/LF310974) . . . . . . . . . 1
... 6 . . . . . . . . . . . . . . 046432 .. Holder, Fuse Mintr .250 X 1.250 Panel Mtg . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . . . F1 . . . . . 085874 .. Fuse, Mintr Cer Slo−blo 10. Amp 250 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . . R4 . . . . . 217335 .. Resistor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 . . . . CR4 . . ♦090104 .. Relay, Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg . . . . . . . . . . . . . . . . . . 1
... 10 . . . . CR3 . . . . 197325 .. Relay, Encl 12vdc Spst 70a 4pin Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . 1
... 11 . . . . SR3 . . ♦035704 .. Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 . . SR1, SR2 . . 035704 .. Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 13 . . . . PC5 . . ♦214761 .. Module, Pull To Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 14 . . CB2, CB3 . . 083432 .. Supplementary Pro, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . 2
... 15 . . . . CB9 . . ♦230635 .. Circuit Breaker, Auto Reset 12vdc 8 Amp (Eff w/LG440030E) . . . . . . . . . 1
♦Optional

5
4 6
the end of parts section. 7
3
1
8
9
10
11
12
13
14
20 19 18
17
16 803 686-A
15
Figure 14-6. Generator

Item Dia. Part
Figure 14-6. Generator (Figure 14-1 Item 72)
... 1 . . . ROTOR . . . 212474 . . Rotor, Generator 4 Pole (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 .............. 053390 . . . . Bearing, Ball Rdl Sgl Row 1.370 X 2.830 X .6 . . . . . . . . . . . . . . . . . . . . . 1
... 3 .............. 192600 . . . . Fan, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 .............. 159918 . . Baffle, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 .............. 212126 . . Adapter, Engine Machined Cat 3013c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 .............. 602211 . . Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . . 6
... 7 .............. 192686 . . Screw, M 8−1.25x 25 Hex Hd−pln 8.8 Pld Din933 . . . . . . . . . . . . . . . . . . . 6
... 10 .............. 212641 . . Stud, Stl .375−16 1.625x 19.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 11 . . STATOR . . 219920 . . Stator, Generator 4 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 .............. 160943 . . Endbell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 .............. 167788 . . Nut, 375−16 .56hex .34h Stl Pld Sem Cone Wshr.88d . . . . . . . . . . . . . . . 4
... 14 .............. 218552 . . Brush, Assembly 2 Pole (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 .............. 047879 . . . . Bar, Retaining Brushholder 2 Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 16 .............. 161306 . . . . Cap, Brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 17 .............. 126984 . . . . Brush w/Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 18 .............. 005614 . . . . Holder, Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 19 .............. 125548 . . . . Holder, Brush Elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 20 .............. 158832 . . Screw, 010−32x .50 Hex Hd−slt Stl Pld Sq Cone Sems . . . . . . . . . . . . . . 2

2
4
5
804 010−A
Figure 14-7. Rectifier Assembly For CC/CV Flux Core Models
Item Dia. Part

Figure 14-7. Rectifier Assembly For CC/CV Flux Core Models (Figure 14-1 Item 4)
.................... 217082 . . Rectifier, Assembly (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 1 .............. 211984 . . . . Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 2 .............. 212601 . . . . Insulator, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . MOD1,2,3 . . 196760 . . . . Thyristor, Scr Module 190a 400v Dual . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 4 .............. 217085 . . . . Bus Bar, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . C1−6 . . . . 215611 . . . . Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 6 . . . . TH1 . . . . 213930 . . . . Thermistor, Ntc 30k Ohm @ 25 Deg C 8.5in Lead . . . . . . . . . . . . . . . . . 1
.................... 181853 . . Insulator, Screw (For Mounting Rectifier) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

available unless listed. 6
1
3
2
10
9
803 685-A
Figure 14-8. Rectifier Assembly For CC/CV Models
Item Dia. Part

Figure 14-8. Rectifier Assembly For CC/CV Models (Figure 14-1 Item 4)

... 1 .............. 211984 . . . . Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . MOD1,2,3 . . 218296 . . . . Kit, Module SCR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 3 . . MOD4,5,6 . . 218292 . . . . Kit, Module SCR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 8 . . . . C1−6 . . . . 215611 . . . . Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 9 . . . C7,8,9 . . . 048420 . . . . Capacitor, Cer Disc .01 Uf 1000 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . 3
. . . 10 . . . . . . . . . . . . . . 217085 . . . . Bus Bar, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Some wiring harness components (switches, relays, circuit breakers) are also referenced elsewhere in this parts list. Purchase components sepa-
rately or as part of the associated wiring harness.
Item Dia. Part

Wiring Harnesses
.................... 219231 . . Harness, Engine CAT (Prior to LG440030E) (Includes) . . . . . . . . . . . . 1

. . . . . . . . . . . S4 . . . . . 021467 . . . . Switch, Tgl Spst 3a 250v Off−none−(On) Spd Term . . . . . . . . . . . . . . . . 1
. . . . . . . . SR1, SR2 . . 035704 . . . . Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . CB1 . . . . 190374 . . . . Circuit Breaker, Auto Reset 12vdc 40 Amp . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . CB2, CB3 . . 083432 . . . . Supplementary Pro, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . 2
. . . . . . . . . . CR3 . . . . 197325 . . . . Relay, Encl 12vdc Spst 70a 4pin Flange Mtg . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CR2 . . . . 214876 . . . . Relay, Encl 6vdc Spst 35a/14vdc 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 217335 . . . . Resistor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 148850 . . . . Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 212116 . . . . Conn, Deutsch 2p 1row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
.................... 212117 . . . . Conn, Deutsch Wedge Lock 2 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . PLG1 . . . . 214932 . . . . Conn, Rect Univ 039 8p/S 2row Plug Cable Lkg Seal . . . . . . . . . . . . . . 1
.................... 214933 . . . . Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
.................... 214934 . . . . Seal, Plug Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . For S1 . . . 211292 . . . . Conn, Pack 4p 1row Female . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . For S1 . . . 211293 . . . . Conn, Pack Terminal Position Assurance (Lock) . . . . . . . . . . . . . . . . . . . 1
.................... 129524 . . . . Term, Frict 250x032 Uninsul Male .130 Stud Mtg 3pr . . . . . . . . . . . . . . . 1
.................... 231122 . . Harness, Engine CAT (Eff w/ LG440030E) (Includes) . . . . . . . . . . . . . . 1

. . . . . . . . CB2, CB3 . . 083432 . . . . Circuit Breaker, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . R4 . . . . . 217335 . . . . Resistor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 148850 . . . . Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 214933 . . . . Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
.................... 214934 . . . . Seal, Plug Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . For S1 . . . 211293 . . . . Conn, Pack Terminal Position Assurance(Lock) . . . . . . . . . . . . . . . . . . . 1
.................... 221864 . . Harness, Weld Control CE (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG2 . . . . 150316 . . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1
.................... 214933 . . . . Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
.................... 214934 . . . . Seal, Plug Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . PLG8 . . . . 147992 . . . . Conn, Rect Univ 039 10p/S 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG6 . . . . 193184 . . . . Conn, Rect Cinch 30 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG9 . . . . 215261 . . . . Conn, Deutsch 12p 2row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG10 . . . 215262 . . . . Conn, Deutsch 12p 2row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 215265 . . . . Conn, Deutsch Wedge Lock 12 Position . . . . . . . . . . . . . . . . . . . . . . . . . . 2
.................... 215343 . . . . Seal, Plug Deutsch 12−16 Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
. . . . . . . . . . PLG5 . . . . 113750 . . . . Conn, Rect Mini 045 4skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . 1
.................... 217000 . . . . Cable, Lem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 215340 . . . . Conn, Rect Univ 039 2p/S 1row Rcpt Cable/Pnl Lkg S . . . . . . . . . . . . . 1
.................... 214933 . . . . Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . . . . . . . . . . . . 214982/214984 . . Harness, Rectifier (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG11 . . . 193183 . . . . Conn, Rect Cinch 18 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 207716 . . . . Conn, Faston Mini Polarized 2 Skt G1k1 . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . . . . . 217010 . . Harness, Receptacle Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Notes

TM-4435C 2008−05
LJ140120E
Processes
TIG (GTAW) Welding
MIG (GMAW) Welding

ting and Gouging
Description
Big Blue 400 CX

)
Eff w/LJ110230E Thru LJ140120E

For OM-4435 (218 759) Revision M

www.MillerWelds.com
SECTION 15 − PARTS LIST EFF w/LJ110231E THRU LJ140120E

8
9
10
11 13
12
6
7 14 23
15
5
16
103 17 24
105 22
106 102
104 21
19 20
25
4−Fig.15-5
101 18
100 91
1 90 92
89
2−Fig.15-3 84
98
97−Fig.15-2 99 83
85 82
86
88 81
87
93
80
94
95
96

30 31
28
27 32 42
29 41
40
110 35
26 39
34
33
38
37
69 68
43
70 67 36
66 44
65 45
71
64 50 52
63 51
78 61
46 49 46
48
62
47 53
79 77 72−Fig.15-4 60
59
76 58 54
57
56
73
55
75 55
74
Optional Auto Idle
109
107
108 804 012−A / Ref. 803 683-F

Item Dia. Part
. . . 1 . . . . HD1 . . . . 168829 . . Transducer, Current 1000a Module Max Open Loop . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . Figure 15-3 . . Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . 217070 . . Bracket, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . Figure 15-5 . . Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 181853 . . Insulator, Screw (For Rectifier Mtg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 5 . . . . . Z1 . . . . . 213929 . . Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 192303 . . Angle, Mtg Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . . . . . . . . . . 215522 . . Bracket, Vault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . +213488 . . Panel, Engine Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . PC1 . . . . 231705 . . Module, Main Control/Scr Gating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . PC3 . . . . 214770 . . Module, Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . 213493 . . Upright, Center Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . 189464 . . Seal, Weather Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . 213501 . . Bracket, Fuel Pump/Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . . . . . . . . . . . Bracket, Fuel Filter Mtg. (Order Thru Engine Manufacturer) . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . 217687 . . Filter, Fuel Spin−on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 207721 . . Pump, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . *213858 . . Filter, Fuel In−line 5/16x5/16 Mic 125 −175 . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . 214753 . . Bracket, Holddown Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . 213602 . . Gasket, Exhaust Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . 212621 . . Pipe, Exhaust Flexible Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . 183314 . . Clamp, Muffler 1.625 Dia U Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . 21 . . . . . . . . . . . . . . 212604 . . Baffle, Air Lower Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . 226018 . . Muffler, Exhaust Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . 213580 . . Pipe, Exhaust Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . 088528 . . Spark Arretsor, Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . 201399 . . Pipe, Exhaust Extension 5.0” Long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . +213470 . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 049525 . . Nut, 312−18 U−nut Multi−thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . 27 . . . . . . . . . . . . . . 189052 . . Grommet, Plastic Neck Filler Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . 190198 . . Cap, Tank Screw−on 3.500 In W/Vent W/Lanyard 8” . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . 222513 . . Label, Warning Falling Equipment Can Cause Serious . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . 201851 . . Cover, Radiator Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . 214604 . . Pipe, Exhaust Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . 224265 . . Label, Warning Hot Exhaust Parts Do Not Touch . . . . . . . . . . . . . . . . . . . . 2
. . . 33 . . . . . . . . . . . . . . 192041 . . Label, Use Diesel Fuel Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . 213472 . . Keeper, Latch Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . 213471 . . Bracket, Cover Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 36 . . . . . . . . . . . . . . 217387 . . Baffle, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . . 213503 . . Guard, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . . +212607 . . Shroud, Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . . 233256 . . Radiator, W/14# Cap 3 Row Core 1.25 In Inlet/Outlet . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 187120 . . . . Cap, Radiator Pressure 14 Lb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . . 212603 . . Baffle, Air Upper Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . +225400 . . Upright, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . . . 225412 . . Cover, Radiator Access ........................................ 1
. . . 43 . . . . . . . . . . . . . . 220295 . . Bracket, Stiffener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . . 190190 . . Tank, Coolant Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . . . 213502 . . Guard, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . . . . . . . . . . 225120 . . Label, Warning Moving Parts Can Cause Injury . . . . . . . . . . . . . . . . . . . . . . 4
. . . 47 . . . . . . . . . . . . . . 217698 . . Label, Help Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . . . . . . . . . . 176108 . . Label, Warning Battery Explosion Can Blind . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . . . . . . . . . . . 203260 . . Label, Caution Do Not Use Ether . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . . . . . . . . . . 237382 . . Label, Diesel Engine Maintenance Cat C1.5 . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . . . . . . . . . . . 199592 . . Latch, Paddle Series 20 (Black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 52 . . . . . . . . . . . . . +213487 . . Door, Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 191626 . . Bumper, Door Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Item Dia. Part
. . . 53 . . . . . . . . . . . . . . 189975 . . Hinge, Door Access 180 Deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 54 . . . . . . . . . . . . . . 087341 . . Bumper, Door 1.000 Od X .750 High Rbr 50 Duro W/O . . . . . . . . . . . . . . 2
. . . 55 . . . . . . . . . . . . . . 213486 . . Panel, Rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 56 . . . . . . . . . . . . . . 213266 . . Mount, Engine/Generator Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 58 . . . . . . . . . . . . . . 237218 . . Bracket, Mtg Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 59 . . . . . . . . . . . . . . 083883 . . Washer, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 199505 . . Hose Assy, Oil Drain 32.000 Lg (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 61 . . . . . . . . . . . . . . 113854 . . . . Hose, Sae .500 Id X .780 Od Xcoil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 Ft.
. . . 62 . . . . . . . . . . . . . . 176529 . . . . Ftg, Hose Brs Barbed Fem 1/2 Tbg X 3/8 Npt . . . . . . . . . . . . . . . . . . . . . 1
. . . 63 . . . . . . . . . . . . . . 165271 . . . . Valve, Oil Drain 3/8−18 Nptf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 197448 . . Ftg, Hose Brs Barbed Elbow M 1/2 Tbg X 3/8 Npt . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 212612 . . Ftg, Adapter Oil Drain Cat 3013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 64 . . . . . . . . . . . . . . 212614 . . Hose, Radiator Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 65 . . . . . . . . . . . . . . 217686 . . Belt, Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 66 . . . . . . . . . . . . . . 237008 . . Engine, Cat Dsl Elec C1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *202166 . . Filter, Oil Cat−150−4140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 217695 . . Switch, Coolant Temp N.C. 110c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 67 . . . . . . . . . . . . . . 212613 . . Hose, Radiator Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 68 . . . . . . . . . . . . . . 216811 . . Clip, Nut Retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 69 . . . . . . . . . . . . . . 197613 . . Air Cleaner, Intake 5.250 In (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 197675 . . . . Dust Ejector, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *197676 . . . . Element, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 197677 . . . . Cover Assy, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 197678 . . . . Body, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦*197679 . . . . Element, Air Cleaner Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 197829 . . . . Bracket, Mtg Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 70 . . . . . . . . . . . . . . 212617 . . Hose, Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 71 . . . . . . . . . . . . . . 217696 . . Switch, Lubricating Oil Pressure N.O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 72 . . . . . . . . . . Figure 15-4 . . Generator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 73 . . . . . . . . . . . . . . 213461 . . Bracket, Mtg Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 212623 . . Tank, Fuel (Includes Fuel Cap And Items Below) . . . . . . . . . . . . . . . . . . . . 1
. . . 74 . . . . . . . . . . . . . . 189908 . . . . Valve, Drain Fuel 180 Deg Zinc Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 77 . . . . . . . . . . . . . . 212611 . . . . Hose, Fuel Stand Pipe W/3/16 In Ftg (Return) . . . . . . . . . . . . . . . . . . . . . 1
. . . 78 . . . . . . . . . . . . . . 212610 . . . . Hose, Fuel Stand Pipe W/5/16 In Ftg (Supply) . . . . . . . . . . . . . . . . . . . . . 1
. . . 79 . . SENDER . . 213265 . . . . Sender, Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 172071 . . Clamp, Hose .520 − .605 Clp Dia Slfttng Black . . . . . . . . . . . . . . . . . . . . . . 8
. . . . . . . . . . . . . . . . . . . . 134835 . . Hose, Sae .312 Id X .560 Od (order by foot) . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 145054 . . Hose, Sae .187 Id X .410 Od X 26.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 80 . . . . . . . . . . . . . . 213465 . . Bolt, J Stl .312−18 X 7.250 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 81 . . . . . . . . . . . . . . 213466 . . Bracket, Battery Holddown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 82 . . . . BATT . . . . 111352 . . Battery, Stor 12v 585 Crk 95 Rsv Gp 55 Maint Free . . . . . . . . . . . . . . . . . 1
. . . 83 . . . . . . . . . . . . . . 190207 . . Cable, Bat Pos 45 In Lg No 1 Awg W/Clamp & .406 Rng . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 190206 . . Cable, Bat Neg 42 In Lg 2 Awg W/Clamp & .375 Rng . . . . . . . . . . . . . . . . 1
. . . 84 . . . . . . . . . . . . . . 213668 . . Bracket, Mtg Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 85 . . . . . . . . . . . . . . 224266 . . Label, Warning Do Not Weld On Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 86 . . . . . . . . . . . . . . 213458 . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 87 . . . . . . . . . . . . . . 213460 . . Crossmember, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 88 . . . . . . . . . . . . . . 213463 . . Spacer/Snubber, Generator Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 89 . . . . . . . . . . . . . . 213462 . . Pad, Mtg Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 90 . . . . . . . . . . . . . . 213459 . . Crossmember, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 213670 . . Screw, 500−13x2.25 Hex Flange−hd Gr8 Pln Chem/Phys . . . . . . . . . . . . 2

Item Dia. Part
. . . . . . . . . . . . . . . . . . . . 213600 . . Screw, 500−13x3.00 Hex Flange−hd Gr8 Pln . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 213464 . . Bracket, Battery Locator (In Base − Not Shown) . . . . . . . . . . . . . . . . . . . . . 1
. . . 91 . . . . . . . . . . . . . . 213485 . . Support, Engine Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 92 . . . . . . . . . . . . . . 213483 . . Support, Engine Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 93 . . . . . . . . . . . . . . 226150 . . Label, Ce Sound Power Level 96db . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 94 . . . . . . . . . . . . . +226104 . . Upright, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 95 . . . . . . . . . . . . . . 233952 . . Label, Warning General Precautionary (Wordless) . . . . . . . . . . . . . . . . . . . 1
. . . 96 . . . . . . . . . . . . . . 220955 . . Panel, Front Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 97 . . . . . . . . . . Figure 15-2 . . Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 98 . . . . CT1 . . ♦105370 . . Xfmr, Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 99 . . . . . . . . . . . . . . 226163 . . Label, Rating Card Ce 907143 (CC Model) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 99 . . . . . . . . . . . . . . 226422 . . Label, Rating Card Ce 907281 (CC/CV Model) . . . . . . . . . . . . . . . . . . . . . . 1
. . 100 . . . . . . . . . . . . . 213504 . . Tray, Reactor&Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 101 . . . . . . . . . . . . . 213500 . . Brkt, Beam Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 102 . . . . T1 . . . . . 220887 . . Xfmr, Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 103 . . . TE1 . . . . 172661 . . Block, Stud Connection 6 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 104 . . . . C11 . . . . 217054 . . Capacitor, Cer Disc .0047 Uf 3000 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . 1
. . 105 . . . . . . . . . . . . . 214742 . . Capacitor Assy, (CC/CV Model) (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 213489 . . . . Bus Bar,Capacitor Bank Negative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 213490 . . . . Bus Bar,Capacitor Bank Positive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . C10 . . . . 163535 . . . . Capacitor,Elctlt 16000 Uf 60 Vdc Can 1.75 Dia . . . . . . . . . . . . . . . . . . . . 6
. . 106 . . . . R3 . . . . . 213027 . . Resistor, WW Tap 300 W 40 Ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 173734 . . Link, Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . ♦235023 . . Idle, Solenoid Assy (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 107 . . . . . . . . . . . ♦234691 . . . . Bracket, Mtg Solenoid Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 108 . . . TS1 . . ♦230634 . . . . Solenoid, Throttle W/4−8.4 Lb Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦198109 . . . . Screw, Shld Stl Sch .250−20 X .437 X .500 Shld . . . . . . . . . . . . . . . . . . . 1
. . 109 . . . . . . . . . . . ♦235056 . . . . Linkage, Throttle Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 601868 . . . . Nut, 250−28 .44hex .26h Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . ♦234689 . . . . Arm, Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 604224 . . . . Screw, 250−20x .75 Hexwhd.50d Stl Pld Slffmg Tap−rw . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 152461 . . . . Nut, 250−20 .44hex .23h Stl Pld Sem Cone Wshr.65d . . . . . . . . . . . . . . 3
. . 110 . . . . . . . . . . . . . 233088 . . Label, Danger Using A Generator Indoors Can Kill You In Minutes . . . . . 1
. . . . . . . . . . . . . . . . . . . . 213506 . . Bracket, Hold−Down Fuel Tank (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 218460 . . Kit, Label (Includes Safety And Informational Labels) . . . . . . . . . . . . . . . . . 1
* Recommended Spare Parts.
♦Optional



10 the end of parts section.
12
8 9
13 25
7 14 23
22 24
15 26 27
28
6 21
16
20 29
5
4
17
3
1 2 18
41 19
40 30
31
34 33 32
39
38
36 35
804 011−B
37
Figure 15-2. Panel, Front w/Components
Item Dia. Part

Figure 15-2. Panel, Front w/Components (Figure 15-1 Item 97 )


Item Dia. Part
Figure 15-2. Panel, Front w/Components (Continued)

... 21 . . . . . . . . . . . . . . 206795 . . Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 23 . . . . . . . . . . . . . . 224428 . . Panel, Power CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 24 . . . GFCI1 . . . 151981 . . Rcpt, Str Dx Grd 2p3w 15/20a 125v *5−20r Gfi . . . . . . . . . . . . . . . . . . . . . . 1
... 25 . . . C11, 12 . . . 217054 . . Capacitor, Cer Disc .0047 Uf 3000 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . 2
... 32 . . . . . . . . . . . . . . 601836 . . Nut, 250−20 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
♦Optional

Hardware is common and not 5
4
2
6
1
9
10
11
12
13
14
803 689-D
15
Figure 15-3. Control Panel
Item Dia. Part

Figure 15-3. Control Panel (Figure 15-1 Item 2)
... 1 . . . . . . . . . . . . . . 220981 .. Bracket, Mtg Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 . . . . . . . . . . . . . . 129524 .. Term, Frict 250x032 Uninsul Male .130 Stud Mtg 3pr . . . . . . . . . . . . . . . . 2
... 3 . . . . CR2 . . . . 214876 .. Relay, Encl 6vdc Spst 35a/14vdc 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . . . . CB1 . . . . 190374 .. Circuit Breaker, Auto Reset 12vdc 40 Amp . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 . . . . CR1 . . . . 223710 .. Relay, Encl 12vdc Dpst−no 25a 6pin Flange . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 . . . . . . . . . . . . . . 046432 .. Holder, Fuse Mintr .250 X 1.250 Panel Mtg . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . . . F1 . . . . . 085874 .. Fuse, Mintr Cer Slo−blo 10. Amp 250 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . . R4 . . . . . 217335 .. Resistor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 . . . . CR4 . . ♦090104 .. Relay, Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg . . . . . . . . . . . . . . . . . . 1
... 10 . . . . CR3 . . . . 197325 .. Relay, Encl 12vdc Spst 70a 4pin Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . 1
... 11 . . . . SR3 . . ♦035704 .. Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 . . SR1, SR2 . . 035704 .. Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 13 . . . . PC5 . . ♦214761 .. Module, Pull To Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 14 . . CB2, CB3 . . 083432 .. Circuit Breaker, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . . . . . 2
... 15 . . . . CB9 . . ♦230635 .. Circuit Breaker, Auto Reset 12vdc 8 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦Optional

5
4 6
3
1
8
9
10
11
12
13
14
20 19 18
17
16 803 686-A
15
Figure 15-4. Generator

Item Dia. Part
Figure 15-4. Generator (Figure 15-1 Item 72)
... 1 . . . ROTOR . . . 212474 . . Rotor, Generator 4 Pole (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 .............. 053390 . . . . Bearing, Ball Rdl Sgl Row 1.370 X 2.830 X .6 . . . . . . . . . . . . . . . . . . . . . 1
... 3 .............. 192600 . . . . Fan, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 .............. 159918 . . Baffle, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 .............. 212126 . . Adapter, Engine Machined Cat 3013c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 .............. 212641 . . Stud, Stl .375−16 1.625x 19.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 11 . . STATOR . . 219920 . . Stator, Generator 4 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 .............. 160943 . . Endbell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 .............. 167788 . . Nut, 375−16 .56hex .34h Stl Pld Sem Cone Wshr.88d . . . . . . . . . . . . . . . 4
... 14 .............. 218552 . . Brush, Assembly 2 Pole (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 .............. 047879 . . . . Bar, Retaining Brushholder 2 Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 16 .............. 161306 . . . . Cap, Brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 17 .............. 126984 . . . . Brush w/Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 18 .............. 005614 . . . . Holder, Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 19 .............. 125548 . . . . Holder, Brush Elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 20 .............. 158832 . . Screw, 010−32x .50 Hex Hd−slt Stl Pld Sq Cone Sems . . . . . . . . . . . . . . 2

2
4
5
804 010−A
Figure 15-5. Rectifier Assembly
Item Dia. Part

Figure 15-5. Rectifier Assembly (Figure 15-1 Item 4)

... 1 .............. 211984 . . . . Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . MOD1,2,3 . . 196760 . . . . Thyristor, Scr Module 190a 400v Dual . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 5 . . . . C1−6 . . . . 215611 . . . . Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Some wiring harness components (switches, relays, circuit breakers) are also referenced elsewhere in this parts list. Purchase components sepa-
rately or as part of the associated wiring harness.
Item Dia. Part

Wiring Harnesses
.................... 231122 . . Harness, Engine CAT (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . CB2, CB3 . . 083432 . . . . Circuit Breaker, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . R4 . . . . . 217335 . . . . Resistor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 148850 . . . . Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 214933 . . . . Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
.................... 214934 . . . . Seal, Plug Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . For S1 . . . 211293 . . . . Conn, Pack Terminal Position Assurance(Lock) . . . . . . . . . . . . . . . . . . . 1
.................... 221864 . . Harness, Weld Control CE (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . PLG2 . . . . 150316 . . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1
.................... 214933 . . . . Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
.................... 214934 . . . . Seal, Plug Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . PLG8 . . . . 147992 . . . . Conn, Rect Univ 039 10p/S 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG9 . . . . 215261 . . . . Conn, Deutsch 12p 2row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG10 . . . 215262 . . . . Conn, Deutsch 12p 2row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 215265 . . . . Conn, Deutsch Wedge Lock 12 Position . . . . . . . . . . . . . . . . . . . . . . . . . . 2
.................... 215343 . . . . Seal, Plug Deutsch 12−16 Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
. . . . . . . . . . PLG5 . . . . 113750 . . . . Conn, Rect Mini 045 4skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . 1
.................... 217000 . . . . Cable, Lem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 215340 . . . . Conn, Rect Univ 039 2p/S 1row Rcpt Cable/Pnl Lkg S . . . . . . . . . . . . . 1
.................... 214933 . . . . Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . 214982 / 214984 . Harness, Rectifier (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . PLG11 . . . 193183 . . . . Conn, Rect Cinch 18 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 217010 . . Harness, Receptacle Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Notes
Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
PRINTED IN USA © 2008 Miller Electric Mfg. Co.

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Big Blue 400 CX

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TM-4435C 2008−05

Eff. w/Serial Number LE341957 Thru

TIG (GTAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Air Carbon Arc (CAC-A) Cut-

Engine Driven Welding Generator

Big Blue 400 CX

Effective With Serial Number LE341957 Thru LJ140120E

File: Engine Drive

SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8-9. Adjusting Engine Speed On Models With Automatic Idle (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Manufacturer: European Contact:

European Contact Signature:

Declares that the product: Big Blue 400 CX

Manufacturer: European Contact: Notified Body:

European Contact Signature:

The Manufacturer Declares the: Big Blue 400 CX

Effective Date: 7/2004

Sound Level Information

1-1. Symbol Usage

DANGER! − Indicates a hazardous situation which, if Indicates special instructions.

Indicates a hazardous situation which, if not avoided,

1-2. Servicing Hazards

SIGNIFICANT DC VOLTAGE exists after stopping

Big Blue 400 CX TM-4435 Page 1

1-3. California Proposition 65 Warnings

TM-4435 Page 2 Big Blue 400 CX

Big Blue 400 CX TM-4435 Page 3

2-1. Warning Label Definitions

1 Remove unit from shipping

API CD-MIL L 2104D,

Work like a Pro!

TM-4435 Page 4 Big Blue 400 CX

Fast (Run, Weld/

Starting Aid Engine Oil

Check Injectors/ Check Valve Protective Earth

Stick (SMAW) Constant Current MIG (GMAW) TIG (GTAW)

X Duty Cycle U0 Rated No Load

Big Blue 400 CX TM-4435 Page 5

3-2. Dimensions, Weights, And Operating Angles

G 27-3/4 in (705 mm) 30°

Lifting Eye Weight Rating:

TM-4435 Page 6 Big Blue 400 CX

20 MIN 300 MAX

Big Blue 400 CX TM-4435 Page 7

3-5. Duty Cycle And Overheating

This unit is rated for welding at

TM-4435 Page 8 Big Blue 400 CX

Notes MATERIAL THICKNESS REFERENCE CHART

24 Gauge (.025 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)

Big Blue 400 CX TM-4435 Page 9

See Section 4-2 for mounting

TM-4435 Page 10 Big Blue 400 CX

Welding Unit In Place

Big Blue 400 CX TM-4435 Page 11

! Always ground generator

Electrically bond generator