Bigblue400cxce (Lj140121e)

TM-4435F 2011−06
Eff. w/Serial Number LJ140121E And

Following
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 CE

)
Eff w/Serial Number LJ140121E And Following
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) eff w/LH140121E.
See TM-4435C for information on the Big Blue 400 CX CC/CV (Flux Core) model (907143) prior to LH140121E, and the Big Blue 400 PX CC/CV
model (907281) prior to LH040124E.
See TM-229979 for information on the Big Blue 400 PX CC/CV (907281) model eff w/LH040124E.
Eff w/ LJ480119E, implementation of a new Engine Control switch changed the method to display engine maintenance information on the Fuel/
Hour gauge. See the Owner’s Manual or the Fuel/Hour Gauge Descriptions label on the unit for specific information.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SECTION 2 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-2. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SECTION 3 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-1. Important Information Regarding CE Products (Sold Within The EU) . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-2. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-3. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-4. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-5. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-6. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-7. AC Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-2. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-3. Mounting Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-4. Grounding Generator To Truck Or Trailer Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-10. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4-11. Connecting To Remote 14 Receptacle RC14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SECTION 5 − OPERATING WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-1. Front Panel Controls (See Section 5-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-2. Description Of Front Panel Controls (See Section 5-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-3. Process/Contactor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-4. Lift-Arct TIG With Crater-Out And Auto-Stopt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5-5. Remote Voltage/Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-6. Fuel/Hour Gauge Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SECTION 6 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6-1. Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SECTION 7 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7-1. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7-2. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7-3. Caterpillar Customer Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7-4. Checking Generator Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7-5. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7-6. Inspecting And Cleaning Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7-7. Servicing Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7-8. Adjusting Engine Speed On Standard Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7-9. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7-10. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7-11. Optional Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
SECTION 8 − THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
TABLE OF CONTENTS
SECTION 9 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9-1. Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9-2. Troubleshooting Circuit Diagram For Welding Generator (Use With Section 9-3) . . . . . . . . . . . . . . . . 42
9-3. Troubleshooting Values For Circuit Diagram (Use With Section 9-2) . . . . . . . . . . . . . . . . . . . . . . . . . . 44
9-4. Waveforms For Sections 9-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9-5. Filter Board PC6 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
9-6. Filter Board PC6 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
9-7. Main Control Board PC1 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9-8. Main Control Board PC1 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
9-9. Meter Display Board PC2 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
9-10. Meter Display Board PC2 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
9-11. Fuel/Hourmeter Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9-12. Replacing Brushes And Cleaning Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
9-13. Checking Unit Output After Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
SECTION 10 − DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
10-1. Disassembly Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
10-2. Disassembly Of Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
10-3. Other Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
10-4. Replacing Rectifier SCR Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
SECTION 11 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
SECTION 12 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
12-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
12-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
12-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
SECTION 13 − PARTS EFF W/LJ140121E AND FOLLOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING
Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage

OM-4435AE - 2011−06, safety_rtm 2010−03
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 STATIC (ESD) can damage PC boards.
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions Put on grounded wrist strap BEFORE handling
to avoid the hazard. boards or parts.
Use proper static-proof bags and boxes to
Only qualified persons should test, maintain, and repair this store, move, or ship PC boards.
unit.
During servicing, keep everybody, especially children, away.
ELECTRIC SHOCK can kill. Using a generator indoors CAN KILL

Do not touch live electrical parts. YOU IN MINUTES.
Stop engine and remove input power plug from
Generator exhaust contains carbon monoxide.
receptacle (if applicable) before testing or re-
This is a poison you cannot see or smell.
pairing unit unless the procedure specifically
requires an energized unit. NEVER use inside a home or garage, EVEN IF
Insulate yourself from ground by standing or working on dry insu- doors and windows are open.
lating mats big enough to prevent contact with the ground. Only use OUTSIDE and far away from windows, doors, and
Do not leave live unit unattended. vents.
If this procedure requires an energized unit, have only personnel
familiar with and following standard safety practices do the job.
When testing live unit, use the one-hand method. Do not put both FUEL can cause fire or explosion.
hands inside unit. Keep one hand free.
Stop engine and let it cool off before checking or
SIGNIFICANT DC VOLTAGE exists in inverter power adding fuel.
sources AFTER stopping engine. Do not add fuel while smoking or if unit is near
Stop engine on inverter and discharge input capacitors according any sparks or open flames.
to instructions in Troubleshooting Section before touching any Do not overfill tank; clean up any spilled fuel.
parts.
FIRE OR EXPLOSION hazard.
MOVING PARTS can injure.
Do not place unit on, over, or near combustible surfaces.
Keep away from moving parts such as fans,
belts, and rotors. Do not service unit near flammables.
Keep away from pinch points such as drive
rolls.
Have only qualified people remove doors,
BATTERY EXPLOSION can BLIND.
panels, covers, or guards for maintenance Always wear a face shield, rubber gloves, and
and troubleshooting as necessary. protective clothing when working on a battery.
Keep hands, hair, loose clothing, and tools Stop engine before disconnecting or connect-
away from moving parts. ing battery cables.
Before working on generator, remove spark plugs or injectors Do not allow tools to cause sparks when working on a battery.
to keep engine from kicking back or starting. Do not use welder to charge batteries or jump start vehicles.
Block flywheel so that it will not turn while working on genera- Observe correct polarity (+ and −) on batteries.
tor components.
Disconnect negative (−) cable first and connect it last.
Reinstall doors, panels, covers, or guards when servicing is
finished and before starting engine.
FLYING METAL or DIRT can injure eyes. BATTERY ACID can BURN SKIN and EYES.
Wear safety glasses with side shields or face Do not tip battery.
shield during servicing.
Replace damaged battery.
Be careful not to short metal tools, parts, or
Flush eyes and skin immediately with water.
wires together during testing and servicing.
Big Blue 400 CX TM-4435 Page 1

STEAM AND HOT COOLANT can burn. H.F. RADIATION can cause interference.
If possible, check coolant level when engine is High-frequency (H.F.) can interfere with radio
cold to avoid scalding. navigation, safety services, computers, and
communications equipment.
Always check coolant level at overflow tank, if
present on unit, instead of radiator. Have only qualified persons familiar with elec-
tronic equipment perform this installation.
If the engine is warm, checking is needed, and there is no over-
The user is responsible for having a qualified electrician prompt-
flow tank, follow the next two statements.
ly correct any interference problem resulting from the installa-
Wear safety glasses and gloves and put a rag over radiator cap. tion.
Turn cap slightly and let pressure escape slowly before If notified by the FCC about interference, stop using the equip-
completely removing cap. ment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
ELECTRIC AND MAGNETIC FIELDS (EMF) spark gaps at correct setting, and use grounding and shielding to
can affect Implanted Medical Devices. minimize the possibility of interference.
Wearers of Pacemakers and other Implanted
Medical Devices should keep away from serv- OVERUSE can cause OVERHEATING.
icing areas until consulting their doctor and the
device manufacturer. Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
starting to weld again.
FALLING EQUIPMENT can injure. Do not block or filter airflow to unit.
Use lifting eye to lift unit and properly installed

accessories only, NOT gas cylinders. Do not SHOCK HAZARD from testing.
exceed maximum lift eye weight rating (see
Stop engine or turn Off welding power source (if
Specifications).
applicable) before making or changing meter
Use equipment of adequate capacity to lift and lead connections.
support unit.
Use at least one meter lead that has a self-
If using lift forks to move unit, be sure forks are long enough to
retaining spring clip such as an alligator clip.
extend beyond opposite side of unit.
Read instructions for test equipment.
Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manu-
ally lifting heavy parts or equipment. READ INSTRUCTIONS.
Use Testing Booklet (Part No. 150 853) when
HOT PARTS can burn. servicing this unit.
Do not touch hot engine parts bare-handed. Consult the Owner’s Manual for welding safety
precautions.
Allow cooling period before working on
Use only genuine replacement parts from the manufacturer.
equipment.
Read and follow all labels and the Technical Manual carefully be-
To handle hot parts, use proper tools and/or fore installing, operating, or servicing unit. Read the safety in-
wear heavy, insulated welding gloves and formation at the beginning of the manual and in each section.
clothing to prevent burns.
Reinstall injectors and bleed air from fuel system according to
engine manual.
TILTING OR TIPPING can injure.
Do not put any body part under unit while lifting.
HYDRAULIC EQUIPMENT can injure
or kill.
Always use proper equipment (hoists, slings,
chains, blocks, etc.) of adequate capacity to lift Before working on hydraulic system, turn off
and support components (stator, rotor, engine, and lockout/tagout unit, release pressure, and
etc.) as needed during job. be sure hydraulic pressure cannot be accident-
ally applied.
PINCH POINTS can injure.
Be careful when working on stator and rotor assemblies. Do not work on hydraulic system with unit running unless you are a
qualified person and following the manufacturer’s instructions.
Do not modify or alter hydraulic pump or manufacturer-supplied
EXPLODING PARTS can injure. equipment. Do not disconnect, disable, or override any safety
equipment in the hydraulic system.
Failed parts can explode or cause other parts to Keep away from potential pinch points or crush points created by
explode when power is applied to inverters. equipment connected to the hydraulic system.
Always wear a face shield and long sleeves Do not work under or around any equipment that is supported only
when servicing inverters. by hydraulic pressure. Properly support equipment by mechanical
means.
TM-4435 Page 2 Big Blue 400 CX

Do not work on compressed air system with unit running unless
HYDRAULIC FLUID can injure or kill. you are a qualified person and following the manufacturer’s in-
structions.
Before working on hydraulic system, turn off and Do not modify or alter compressor or manufacturer-supplied
lockout/tagout unit, release pressure, and be sure equipment. Do not disconnect, disable, or override any safety
hydraulic pressure cannot be accidentally applied. equipment in the compressed air system.
Relieve pressure before disconnecting or con- Keep away from potential pinch points or crush points created by
necting hydraulic lines. equipment connected to the compressed air system.
Check hydraulic system components and all con- Do not work under or around any equipment that is supported only
nections and hoses for damage, leaks, and wear by air pressure. Properly support equipment by mechanical
before operating unit. means.
Wear protective equipment such as safety
glasses, leather gloves, heavy shirt and trousers, COMPRESSED AIR can injure or kill.
high shoes, and a cap when working on hydraulic
system. Before working on compressed air system,
turn off and lockout/tagout unit, release pres-
Use a piece of paper or cardboard to search for leaks−−never use sure, and be sure air pressure cannot be acci-
bare hands. Do not use equipment if leaks are found. dentally applied.
HYDRAULIC FLUID is FLAMMABLE−−do not work on hydraulics Relieve pressure before disconnecting or con-
near sparks or flames; do not smoke near hydraulic fluid. necting air lines.
Reinstall doors, panels, covers, or guards when servicing is Check compressed air system components
finished and before starting unit. and all connections and hoses for damage,
If ANY fluid is injected into the skin, it must be surgically removed leaks, and wear before operating unit.
within a few hours by a doctor familiar with this type of injury or gan- Do not direct air stream toward self or others.
grene may result. Wear protective equipment such as safety glasses, hearing pro-
tection, leather gloves, heavy shirt and trousers, high shoes, and
a cap when working on compressed air system.
COMPRESSED AIR EQUIPMENT can Use soapy water or an ultrasonic detector to search for
injure or kill. leaks−−never use bare hands. Do not use equipment if leaks are
found.
Before working on compressed air system, turn Reinstall doors, panels, covers, or guards when servicing is
off and lockout/tagout unit, release pressure, finished and before starting unit.
and be sure air pressure cannot be accidentally If ANY air is injected into the skin or body seek medical help im-
applied. mediately.
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.
Battery posts, terminals and related accessories contain lead For Diesel Engines:
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.
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
1-4. EMF Information

Electric current flowing through any conductor causes localized electric 4. Keep head and trunk as far away from the equipment in the
and magnetic fields (EMF). Welding current creates an EMF field welding circuit as possible.
around the welding circuit and welding equipment. EMF fields may inter-
fere with some medical implants, e.g. pacemakers. Protective 5. Connect work clamp to workpiece as close to the weld as
measures for persons wearing medical implants have to be taken. For possible.
example, access restrictions for passers−by or individual risk assess-
ment for welders. All welders should use the following procedures in 6. Do not work next to, sit or lean on the welding power source.
order to minimize exposure to EMF fields from the welding circuit:
7. Do not weld whilst carrying the welding power source or wire
feeder.
1. Keep cables close together by twisting or taping them, or using a
cable cover. About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
2. Do not place your body between welding cables. Arrange cables device manufacturer before performing or going near arc welding, spot
to one side and away from the operator. welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom-
3. Do not coil or drape cables around your body. 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
h s 1
Time Hours Seconds 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. Important Information Regarding CE Products (Sold Within The EU)
A. Information On Electromagnetic Fields (EMF)
! This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding.
This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public
access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.
Wire feeders and ancillary equipment (such as torches, liquid cooling systems and arc striking and stabilizing devices) as part of the welding
circuit may not be a major contributor to the EMF. See the Owner’s Manuals for all components of the welding circuit for additional EMF exposure
information.
The EMF assessment on this equipment was conducted at 0.5 meter.
At a distance of 1 meter the EMF exposure values were less than 20% of the permissible values.
B. Information On Electromagnetic Compatibility (EMC)
! This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low−
voltage supply system. There may be potential difficulties in ensuring electromagnetic compatibility in those locations, due to
conducted as well as radiated disturbances.
ce-emc 3 2010−10
3-2. Weld, Power, And Engine Specifications

Maximum
Welding Weld Output Rated Welding Open- Fuel
Auxiliary Power Rating Engine
Mode Range Output Circuit Capacity
Voltage
300 A, 32 Volts DC Generator

60% Duty Cycle Single-Phase,
20 − 410 A
CC/DC 10 kVA/kW, 91/46 A,
250 A, 30 Volts DC 110/220 V AC,
100% Duty cycle 60 Hz Caterpillar C1.5
Water−Cooled 11.5 gal
73
Receptacles Three−Cylinder (43.5 L)
300 A, 29 Volts DC
110/55 V AC Receptacles 21.7 HP Diesel Engine
CV/DC 60% Duty Cycle
14 − 40 V 5.5 kVA/kW, 50/100 A
Flux Core 250 A, 26.5 Volts DC
220/110 V AC Receptacles
100% Duty cycle
11 kVA/kW, 50/20 A
3-3. Dimensions, Weights, And Operating Angles

Dimensions
32 in. (813 mm) G
Height 35-3/4 in. (908 mm)
(to top of lift eye)
26-1/4 in. (667 mm)
(mtg. brackets turned in)
Width
28-3/4 in. (730 mm) ! Do not exceed tilt angles or engine could
(mtg. brackets turned out) be damaged or unit could tip.
Depth 56 in. (1422 mm) ! Do not move or operate unit where it could
tip.
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)
H 30°
H 9/16 in. (14 mm) Dia. 4 Holes
Front Panel End 20°
Weight 20°
No fuel: 1128 lb (512 kg) D F
w/ fuel: 1210 lb (549 kg) E
Lifting Eye Weight Rating:
1500 lb (680 kg) Maximum

3-4. Volt-Ampere Curves
C. Stick Mode The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
100 other settings fall between the
90 curves shown.
80
70
60
DC Volts
50
Max
40
Min
30
20
10
0
0 100 200 300 400 500 600
DC Amperes
D. MIG Mode
100
90
80
70
60
DC Volts
50
Max
40
30
20 Min
10
0
0 100 200 300 400 500 600
DC Amperes
E. TIG Mode
100
90
80
70
60
DC Volts
50
40
30
20
10
0
0 100 200 300 400 500
DC Amperes
237 466 / 237 468 / 237 470

3-5. 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
237 471
3-6. 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

3-7. 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. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the front. Use rating label to determine input power requirements and/or rated
output. For future reference, write serial number in space provided on back cover of this manual.
4-2. 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 3-3 for lifting eye rat-
ing.
See Section 4-3 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

4-3. 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

4-4. 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-
ment grounding terminal to
bare metal on the vehicle
frame as shown.
1 2
! Use GFCI protection when
GND/PE operating auxiliary equip-
ment. If unit does not have
GFCI receptacles, use GFCI-
protected extension cord.
1 Equipment Grounding
Terminal (On Front Panel)
2 Grounding Cable (Not
3 Supplied)
3 Metal Vehicle Frame
Connect cable from equipment
ground terminal to metal vehicle
frame. Use #8 AWG or larger insu-
lated copper wire.
Electrically bond generator

frame to vehicle frame by met-
al-to-metal contact.
rot_grnd1 2011−04 − 800 652-D

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. 287 125-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. 287 125-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)
Engine stops if fuel level is low.
Coolant Recovery Tank
Hot Full
Cold Full
Full
Ref. 804 009−C
Check all engine fluids daily. Engine stops if fuel level is low. freeze to mixture if using the unit in tempera-
tures below −34° F (−37° C).
Engine must be cold and on a level surface.
Oil
Automatic shutdown system stops engine if Keep radiator and air intake clean and free
oil pressure is too low or coolant tempera- After fueling, check oil with unit on level sur- of dirt.
ture is too high. face. If oil is not up to full mark on dipstick,
add oil (see maintenance label).
This unit has a low oil pressure shut- NOTICE − Incorrect engine temperature
down switch. However, some condi- can damage engine. Do not run engine with-
Coolant out a properly working thermostat and ra-
tions may cause engine damage before
the engine shuts down. Check oil level diator cap.
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 12. 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 7-1).

4-9. Connecting To Weld Output Terminals
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.
For Direct Current Electrode Negative
Use Process switch to select type of weld out-
(DCEN), reverse cable connections.
put (see Section 5-3).
! Stop engine.
! Failure to properly connect weld
cables may cause excessive heat and
start a fire, or damage your machine.
Do not place anything between weld cable

terminal and copper bar. Make sure that
the surfaces of the weld cable terminal
and copper bar are clean.
1 Correct Weld Cable Connection
2 Incorrect Weld Cable Connection
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.
7 Work (−) Weld Output Terminal
8 Positive (+) Weld Output Terminal(s)
1
7 8
2
6
3
Tools Needed:
3/4 in.
Ref.804 009-F / Ref. 287 125-A / 803 778-B

4-10. Selecting Weld Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is
100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable
size.
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 cable overheats, 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
***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).
Ref. S-0007-H 2011−05
Notes

4-11. 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-F
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.

Notes

SECTION 5 − OPERATING WELDING GENERATOR
5-1. Front Panel Controls (See Section 5-2)
9 10
7 8 2 4 5
1
Stop
287 125−B / 804 009−F

5-2. Description Of Front Panel Controls (See Section 5-1)
Engine Starting Controls Engine Gauges, Meters, And Lights 7 Process/Contactor Switch
1 Preheat Switch See Section 5-6 for complete fuel/hour See Section 5-3 for Process/Contactor
gauge information. switch information.
Use switch to energize starting aid for cold 4 Fuel Gauge/Hourmeter
weather starting (see starting instructions fol- 8 Voltage/Amperage Control
Use gauge to check fuel level or total engine
lowing). With Process/Contactor switch in any Stick or
operating hours, or hours to oil change..
TIG setting, use control to adjust amperage.
2 Engine Control Switch To check fuel level or engine hours when en-
With Process/Contactor switch in any Wire
gine is not running, turn Engine Control switch
(MIG) position, use control to adjust voltage.
Use switch to start engine, select engine run, to Run position.
With Voltage/Amperage Adjust Switch in Re-
and stop engine. 5 Engine Indicator Light mote position, control limits the remote am-
Light goes on and engine stops if engine tem- perage in Stick or TIG mode, but has no effect
In Run position, engine runs at weld/power perature exceeds 230° F (110° C) or engine in Wire (MIG) modes.
speed. oil pressure is below 10 psi (69 kPa).
Weld Meters (Optional)
3 Engine Stop Lever Normal engine temperature is 180 - 203
Use lever to stop engine if Engine Control
F (82 - 95 C). Normal oil pressure is 30 Weld meters also work in combination to
- 60 psi (207 - 414 kPa). display troubleshooting help codes (see
switch does not work.
NOTICE − Do not run engine until trouble is Section 7-11).
fixed.
The Engine Stop lever shuts off the fuel Weld Controls
9 DC Voltmeter
supply. However, the Engine Stop lever
will not stop the engine if the engine can 6 Remote Control Receptacle Voltmeter displays preset voltage (MIG weld-
draw fuel-rich air from the surrounding Use receptacle to connect remote controls, ing) with contactor off, and actual output volt-
wire feeders, and tools. age with the contactor on. Voltmeter displays
atmosphere (oil refineries).
voltage at the weld output terminals, but not
When a remote control is connected to the necessarily the welding arc due to resistance
To Start: Remote receptacle, the Auto Sense Remote of cable and connections.
feature automatically switches voltage/am-
NOTICE − Do not use ether. perage control to the remote control (see Sec- To set voltage, turn contactor off and turn Pro-
tion 4-11). cess/Contactor switch to Wire position. Turn
If engine does not start, let engine come With remote control connected, weld output is V/A control until desired voltage is displayed
to a complete stop before attempting re- determined by a combination of front panel on Voltmeter. When welding is finished, volt-
start. and remote control voltage/amperage set- meter displays weld voltage and then defaults
tings. to preset voltage.
Above 325 F (05 C): turn Engine Control If no remote control is connected to the Re-
switch to Start. Release Engine Control 10 DC Ammeter
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 Run 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 during operation, the meters dis- switch to Stick or TIG position. Turn V/A con-
Preheat switch when engine starts. play Help 25 (see Section 7-11). Clear trol until desired amperage is displayed on
fault by stopping and restarting the unit or Ammeter. When welding is finished, ammeter
To Stop: turn Engine Control switch to Off by turning Process/Contactor switch to displays weld amperage and then defaults to
position. another position. preset amperage.

5-3. Process/Contactor Switch
! Weld output terminals are en-
ergized when Process/Con-
tactor switch is in a Weld Ter-
minals Always On position
and the engine is running.
1 Process/Contactor Switch
2 Weld Terminals Always On −
1 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 Wire (Flux Core) Position
Stick − Position
5 Use switch to select weld process
2 and weld output on/off control (see
table below).
3
4 Place switch in Remote On/Off
Switch Required positions to turn
weld output on and off with a device
connected to the Remote 14 recep-
tacle.
Place switch in Weld Terminals Al-
ways On positions for weld output to
be on whenever the engine is run-
ning.
Use the Lift-Arc TIG mode for TIG
(GTAW) welding using the Lift-Arc
TIG starting procedure (see Section
5-4).
Ref 804 444−C / Ref 287 125−A
Process/Contactor Switch Settings
Switch Setting Process Output On/Off Control
Weld Terminals
TIG Lift-Arc (GTAW) Electrode Hot
Always On − TIG Lift Arc −
Remote On/Off Switch Required − TIG HF GTAW With HF Unit, Pulsing Device, Or Remote
At Remote 14 Receptacle
Required Or Scratch Start Control
Remote On/Off Switch Required − Wire (Flux Flux Core

At Remote 14 Receptacle
Core) w/Constant Speed Feeder
Flux Core
Weld Terminals Always On − Wire (Flux Core) Electrode Hot
w/Voltage Sensing Feeder
Stick (SMAW),
Weld Terminals Always On − Stick Electrode Hot
Air Carbon Arc (CAC-A) Cutting And Gouging

5-4. Lift-Arct TIG With Crater-Out And Auto-Stopt
Arc Start With Lift-Arc TIG
Lift-Arc is used for the DCEN
GTAW process when HF Start
method is not permitted.
Select Lift-Arc at Process/Contac-
tor switch.
Arc Start With Lift-Arc
Turn gas on.
1 2 1 Touch or scratch.
2 Lift at any angle.
Touch tungsten electrode to
workpiece at weld start point.
Slowly lift electrode. Arc is started
when electrode is lifted.
Maintain shielding gas coverage
and eliminate tungsten and work-
piece contamination by using
Auto-Crater or Auto-Stop to end
the arc.
Arc End With Crater-Out:
Momentary contact switch re-

quired to start crater-out.
1 While welding.
Arc End With Crater-Out 2 Close momentary contact
switch to start Crater-out end
1 2 3 (current is reduced).
3 Shielding gas continues until
shut off.
Arc End With Auto-Stop:
1 While welding.
2 Lift torch to start Auto-Stop.
Arc stops.
3 Move torch back down to
maintain gas coverage and
prevent contamination.
OR
Arc End With Auto-Stop
1 2 3
WM Marketing

5-5. Remote Voltage/Amperage Control
1 Remote 14 Receptacle RC14

Connect optional remote control to
RC14 (see Section 4-11).
When a remote control is con-

nected to the Remote receptacle,
1 the Auto Sense Remote feature
automatically switches voltage/
amperage control to the remote
control. When a device is con-
nected to the Remote receptacle,
remote voltage/amperage con-
trol is always available regard-
less of the position of the Pro-
cess/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.287 125−A / Ref 804 444−A

5-6. Fuel/Hour Gauge Descriptions

SECTION 6 − OPERATING AUXILIARY EQUIPMENT
6-1. Auxiliary Power Receptacles
1 2 3 4 5 6
Ref. 287 125-A
1 220V 16 A AC Receptacle RC12 4 Earth Leakage Circuit Breaker ELCB1 Maximum combined output of all recep-
tacles is 10 kVa/kW.
2 110V 20 A AC Receptacle GFCI1 5 Earth Leakage Circuit Breaker ELCB2
If a ground fault is detected, GFCI Reset ELCB1 protects RC12 and ELCB2 protects At least once a month, run engine at
button pops out and receptacle does not RC11 from overload and earth leakage weld/power speed and press test but-
work. Check for faulty equipment plugged in fault. If a circuit breaker opens, the recep- ton to verify ELCB1, ELCB2, and GFCI
receptacle. Press button to reset GFCI re- tacle does not work. Place switch in On are working properly.
ceptacle. position to reset circuit breaker. If a supplementary protector or circuit
3 Supplementary Protector CB5 6 220V 32A AC Receptacle RC11 breaker continues to open, contact
Factory Authorized Service Agent.
CB5 protects GFCI1 from overload. If a Receptacles GFCI1, RC11, and RC12
supplementary protector opens, the recep- supply 60 Hz single-phase power at weld/ Generator power decreases as weld
tacle does not work. Press button to reset. power speed. output increases.

SECTION 7 − MAINTENANCE
7-1. Maintenance Label

7-2. 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 7-9
Hours
Coolant Level Fuel Level Oil Level Oil, Fuel Spills

Every
50
Hours
Weld Terminals
Every Section 7-5
100
Hours
Battery Terminals Air Cleaner Hoses Air Cleaner Element

Every NOTICE − Change engine Engine
250 1/2 in.
(13 mm) oil and filter after initial 50 to Manual,
Hours 75 hours of use. Section 7-6,
7-9
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 7-4, 7-7,
OR
Hours 7-9, and
Engine
SLUDGE Manual
Radiator Fluid Level Inside Unit Valve Clearance* Drain Sludge
Slip Rings*
Brushes*
Every
2000
Hours
Injectors*

7-3. 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
7-4. 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 287 125-A / S−0233−A

7-5. 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

7-6. 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. 287 125-A
7-7. 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−F / Ref 287 125-A

7-8. 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

7-9. 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 287 125-A / 804 009−C

7-10. Overload Protection
! Stop engine.
When a circuit breaker, supple-

mentary protector, or fuse
opens, it usually indicates a
more serious problem exists.
Contact Factory Authorized
Service Agent.
1 Fuse F1
F1 protects the stator exciter wind-
ing from overload. If F1 opens, weld
and generator power is low or stops
entirely.
2 Circuit Breaker CB1 (Not
Shown)
3 Supplementary Protector CB2
1 5 Supplementary Protector CB8
CB1 protects the engine battery cir-
cuit. If CB1 opens, the engine will not
crank. CB1 automatically resets
when the fault is corrected.
CB2 protects the engine wiring har-
ness. If CB2 opens, the engine will
not crank.
CB3 protects part of the weld control
wiring harness. If CB3 opens, weld
and generator power output stops.
CB8 protects the 24 volt AC output to
remote receptacle RC14. If CB8
3 opens, 24 volt output to RC14 stops.
6
Press button to reset supplementary
protector.
6 Circuit Breaker CB9
CB9 protects the throttle solenoid
4 against overload. If CB9 opens, the
engine does not automatically idle
down. Check the linkage and sole-
noid. CB9 automatically resets.
Ref. 287 125-A / 803 566 / 804 009-F

7-11. Optional Voltmeter/Ammeter Help Displays
Use the Voltmeter/Ammeter help

displays to diagnose and correct
fault conditions.
When a help code is displayed

normally weld output has
stopped but generator power
output may be okay.
To reset help displays, stop

1 unit and then restart. See item
5 below to reset Help 25 dis-
HL.P 20
play.
1 Help 20 Display
Indicates a failure of meter display
2 module PC2, or the wiring between
PC2 and main control module PC1.
If this display is shown, have Facto-
HL.P 21 ry Authorized Service Agent check

PC1, PC2, and the wiring between
PC1 and PC2.
3 2 Help 21 Display
Indicates thermistor TH1 on the
main rectifier heat sink has failed.
HL.P 22 If this display is shown, have Facto-

ry Authorized Service Agent check
TH1, and the wiring between TH1
4
and PC1.
3 Help 22 Display
HL.P 23
Indicates the rectifier heat sink has
overheated. If this display is shown,
check generator cooling system
5 and/or reduce duty cycle. Keep en-
gine access door closed when run-
ning to maintain proper cooling air
flow past rectifier. Allow unit to cool
HL.P 25 before restarting. If problem contin-

ues, have Factory Authorized Ser-
vice Agent check unit.
4 Help 23 Display
Can indicate a complete loss of
generator excitation, auxiliary pow-
er output, and weld output or a fail-
ure of one of the rectifier output
SCRs. If generator output is lost,
see trouble “No generator power or
weld output.” in section 9-1B. If gen-
erator output is okay, have Factory
Authorized Service Agent check
the rectifier SCRs.
5 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, have Factory Autho-
rized Service Agent check the re-
mote device, filter board PC6, and
main control module PC1.
Ref. 804 009-F

SECTION 8 − THEORY OF OPERATION
1 Engine
Supplies force to turn revolving fields. 10
2 Throttle Solenoid TS1 Transformer

(Pull To Idle) T1
Decreases engine speed to idle rpm.
3 Control Relay CR4 9
+12 V DC Current
CR4 energizes at no load to supply pow- Feedback
er to throttle solenoid TS1 Fuse F1
4 Circuit Breaker CB9 7 11
Protects throttle solenoid TS1 from Integrated Integrated
overload. Rectifier SR4 Rectifier
(Flashing Diode) SR5
5 Current Transformer CT1
Senses output from auxiliary power
windings and signals idle module to in-
crease to or maintain weld speed. 1 6 8
3φ
6 Revolving Fields (Rotor) Revolving Exciter
Turn at 1885 rpm maximum for weld and Engine Fields
Weld
(Rotor) Stator Windings
power. The speed and excitation current
of the field coils determine voltages in Generator Power
stator windings. 2♦
7 Integrated Rectifier SR4 (Flashing Throttle
Diode) Solenoid TS1
Acts as check valve in field flashing cir- (Pull To Idle)
cuit. During start-up, battery voltage
passes through SR4 diode to flash ex- 3♦
citer field. When exciter field is estab- 4♦
5 ♦
lished, SR4 diode blocks exciter winding Control Relay Circuit Breaker Current
voltage from feeding back into battery. CR4 CB9 Transformer
8 Stator Windings CT1
Supply power to exciter, generator pow-
er, and weld circuits.
+12 V DC
9 Fuse F1
Protects exciter windings from over-
load. 12
10 Transformer T1 Supplementary
Boosts excitation current to exciter re- Protector CB5
volving field (rotor) through integrated
rectifier SR5 in response to weld or pow-
er load.
11 Integrated Rectifier SR5 13
Changes AC output of stator exciter AC
windings to DC. 15 Receptacles
GFCI1, RC11,
12 Supplementary Protector CB5 RC12
Protects AC receptacles from overload.
13 AC Receptacles GFCI1, RC11, Filter Board 14
RC12 PC6/Remote 24 VAC
Supplementary
Provide connection points and power for Receptacle Protector
auxiliary equipment. RC14 CB8
Provides overload protection for 24 volt 18
AC portion of Remote 14 receptacle
RC14. +10 VDC Output
Command Voltage Control
15 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.

16 Voltage/Amperage Control R2
AC Or DC Control Circuits Adjusts weld output amperage or
voltage level.
Weld Current Circuit 17 Process/Contactor Switch R1
External Circuits Selects weld process and weld out-
put on/off control.
3φ Power 18 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.
Controls engine speed. Without a
signal from CT1 or HD1 it lowers en-
gine speed to idle rpm.
19 Thermistor TH1
Signals PC1 to stop weld output if
main rectifier overheats.
20 Meter Board PC2
24 25 Displays preset and actual (rectified
CC
and filtered) values of the weld volt-
Stabilizer CC Weld age and amperage.
Z1 Output
Terminal 21 Main Rectifier
22
Changes AC weld current to DC.
Burden
Resistor R3 Works with PC1 (item 18) to control
weld output by changing rectifier
Electrode SCR gate pulses (conduction
times) after comparing amperage
21
(CC) feedback to selected amper-
age signal.
Main
Rectifier 22 Burden Resistor R3
Provides a path for a minimum SCR
holding current to flow.
23 Hall Device HD1
Provides current feedback signal to
PC1.
24 Stabilizer Z1
23 25 Smooths (filters) weld output
Hall Device Work (−) Weld current.
Output 25 Work (−) And CC Weld Out-
HD1 Terminal put Terminals
Provide weld output and allow
manual changing of output polarity.
SCR CC
Gating Voltage Current
Feedback Work
Signals Feedback
16 17 19 20
Voltage/ Process/
Thermistor Meter
Amperage Contactor Board PC2
Control R2 Switch R1 TH1

SECTION 9 − TROUBLESHOOTING
9-1. Troubleshooting Tables
See Section 9-2 for test points and values and
Section 13 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 7-11).
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 Sections 4-11 and 5-3).
Check and secure connections to Remote Control receptacle RC14 (see Section 4-11).
Reset supplementary protector CB8 (see Section 7-10). Check for faulty remote device connected to
RC14.
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 7-11).
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 7-10).
Check fuse F1, and replace if open (see Section 7-10). If F1 is open, check integrated rectifier SR5, trans-
former T1, and rotor and brushes.
Clean slip rings, and install new brushes if necessary (see Section 9-12).
Disconnect leads 42 and 105 from the rotor, and check continuity across slip rings. Replace rotor if neces-
sary.
Disconnect stator excitation leads 100 and 101, and check continuity between leads. Replace stator if
necessary.
Check main control board PC1 and connections, and replace PC1 if necessary (see Sections 9-7 and
9-8).
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 42 and 105 from the rotor, and check continuity across slip rings. Replace rotor if
necessary.
High weld output. Repair or replace remote control device.
Check hall device HD1, and replace if necessary (see Section 9-2).
9-8).

Trouble Remedy
Low weld output. Check engine speed, and adjust if necessary (see Section 7-8).
Increase Voltage/Amperage Adjust control R2 setting.
Check fuse F1, and replace if open (see Section 7-10).
Check hall device HD1, and replace if necessary (see Section 9-2).
Repair or replace remote control device.
sary.
Low open-circuit voltage. Check engine speed, and adjust if necessary (see Section 7-8).
9-8).
Disconnect 24 volt AC exciter leads 80 and 81, and check continuity between leads. Replace stator if
necessary.
Check SCRs and gate leads in main rectifier, and replace if necessary (see Section 10-4). If any
SCRs are replaced, check capacitors C1 through C6 for a short or open, and check for proper con-
nections. Replace C1 through C6 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 4-11).
No 24 volt AC output at Remote recep- Reset circuit breaker CB8 (24 volt) (see Section 7-10).
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 6-1).
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.
Reset circuit breaker CB3 (see Section 7-10).
Clean slip rings, and install new brushes if necessary (see Section 9-12).
sary.
Disconnect stator excitation leads 100 and 101, and check continuity between leads. Replace stator if
necessary.
9-8).
High output at generator power AC Check connections at transformer T1. Check T1 continuity and replace if necessary.
receptacles.
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 7-8).
receptacles.

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 7-10).
Check engine wiring harness and components.
Reset supplementary protector CB2 (see Section 7-10).
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 (see
Section 9-11).
Check control relay CR1: Check all connections, check coil continuity, check for proper coil voltage, and
check contact voltage (input to common and output to common) to ensure contacts are operating. Re-
place 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.
Section 9-11).
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 7-1).
Check continuity of Preheat switch S4, and replace if necessary.
Check glow plug for proper operation, and replace if necessary.
Engine slowly stopped and cannot be Check fuel level.

restarted.
Section 9-11).
Check engine air and fuel filters (see Sections 7-5 and 7-9).
See engine manual.
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 7-10). 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 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.
Section 9-11).
Check fuel pump according to engine manual.
Check engine wiring harness and plug connections.
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 current transformer CT1 for continuity and proper connections. Replace CT1 if necessary.
9-8).
Engine does not run at idle speed Check for obstructed throttle solenoid TS1.
(units with idle option only).
Reset circuit breaker CB9 (see Section 7-10).
9-8).
Engine uses oil during run-in period; Dry engine according to run-in procedure (see Section 12).
wetstacking occurs.
Notes

9-2. Troubleshooting Circuit Diagram For Welding Generator (Use With Section 9-3)
V5,R5
V4,
R4
V6
R6
V1,R1
R10
V1,R1
V1,R1
V7,R7
V1,R1
V26
I1
V2,R2
V27
V3,R3
See Section
9-9 for PC2
data
V21
Engine
Starter control relay CR2 V23 control
relay CR1
V22
V24
R9
V10 V8,
R8
V25,
R12
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 9-4

for waveforms
A,B,C,D,E
See Section
9-5 for
PC6 data
See Section
4-11 for RC14
information
240 674-B

9-3. Troubleshooting Values For Circuit Diagram (Use With Section 9-2)
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 30 postion a) Tolerance − ±10% unless specified
unless noted.
e) Wiring Connections − see Section 11 b) Condition − 70°F (21°C); cold
machine (no warm-up)
V1 59 volts AC
c) Wiring Connections − see Section
V2 164 volts AC 11
V3 24 volts AC
d) Stop engine before checking
V4 49 volts AC resistance
V5 49 volts AC R1 thru R6 Less than 1 ohm
V6 49 volts AC R7 22 ohms
V7 + 66 volts DC R8 14.2 ohms
V8 +12 volts DC R9 Empty fuel tank: 250 ohms
Full tank: 0 ohms
V9* +12 volts DC R10 30k ohms cold, drops as
V10 +12 volts DC unit heats up
V11 0 to +5 volts DC from Min to 20 position. of R11 Increases in 1K ohm
Process/Contactor switch R1 (in 0.45 volt increments up to 11K ohms,
increments). then resets to zero
R12 14.2 ohms
V12 +5 volts DC
V13 0 to +5 volts DC from min to max of
Voltage/Amperage control R2
V14 +5 volts DC Amperage Readings
V15 +63 volts DC with Process/Contactor
switch R1 in Weld Terminals Always On −
a) Tolerance − ±5% unless specified
Stick position b) Condition − 70°F (21°C); cold
V16 14 to +40 volts DC with Process/Contactor machine (no warm-up); no load;
switch R1 in Weld Terminals Always weld/power rpm unless noted
On−Wire position
c) Process/Contactor switch R1 in
V17 Circuit common Weld Terminals Always On−Stick
V18 1 volt DC per 100 amperes of weld output 30 position unless noted
V19 − 15 volts DC I1 3.8 amps DC, no load
V20 +15 volts DC 4.8 amps DC at 20 volt, 100 amp load
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
V26 2.1 volts AC at 100 amp load
*V9 is measured across the throttle solenoid TS1
V27 121 volts AC at 100 amp load on models with auto idle option (no longer dis-
played on circuit diagram).

9-4. Waveforms For Sections 9-2
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/Contac- B. CV/DC Open-Circuit Voltage, Process/Con-

tor Switch R1 In Weld Terminals Always On − tactor Switch R1 In Weld Terminals Always
Stick 30 postion, Voltage/Amperage Control R2 On − Wire Position, Voltage/Amperage Con-
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 30 postion, (Resistive Load) Always On − Wire Position, (Resistive Load)
5 ms 2 V
gnd
E. SCR Gate Pulses w/Respect To Cathode At No

Load, Process/Contactor Switch R1 In Weld
Terminals Always On − Stick Stick 30 postion,
Voltage/Amperage Control R2 At Max

9-5. Filter Board PC6 Testing Information
! Stop engine.
See Section 9-6 for specific values
during testing. Voltage readings tol-
1 erance ±10%.
1 Filter Board PC6
2 Receptacle RC2
Ref. 804 492 / 217 008
9-6. 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

9-7. Main Control Board PC1 Testing Information
! Stop engine.
See Section 9-8 for specific values
during testing. Voltage readings tol-
erance ±10%.
1 Main Control Board PC1
2 Plug PLG6
3 Plug PLG7
4 Plug PLG11
4
1
804 492

9-8. 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 Not used
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 Not used
D3 Not used
E1 Not used
E2 Not used
E3 Not used
F1 + 5 volts DC
F2 Voltage feedback: 1 volt DC per 10 arc volts
F3 +14 volts DC
G1 Not used
G2 Command reference: +10 volt DC input
G3 Not used
H1 Not used
H2 Remote command signal input: 0 to +10 volts DC input from min to max of remote voltage/amperage
control
H3 Circuit common
J1 Ground
J2 Not used
J3 Remote control circuit common
K1 +5 volts DC output
K2 Not used
K3 24 volts AC input
PLG7 A1 0 to +5 volts DC from Min to 20 position of Process Contactor switch R1 (in 0.45 volt increments).
A2 1 volt DC input per 100 amperes of weld output with respect to pin PLG7-C2
B1 Circuit common for Process/Contactor switch R1
B2 +15 volts DC output with respect to pin PLG7-C2
B3 Contactor control circuit: 24 volt AC input with respect to circuit common and closure on RC14 be-
tween pins A and B

C1 +5 volts DC output
C2 Circuit common
C3 +12 volts DC at idle rpm
D1 +2 volts DC input at 77° F
D2 −15 volts DC with respect to pin PLG7-C2
E1 +14 volts DC input
F1 Not used
F2 Not used
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 Not used
E2 Not used
E3 Not used
F1 Not used
F2 Not used
F3 Not used

9-9. Meter Display Board PC2 Testing Information
! Stop engine.
See Section 9-10 for specific val-
ues during testing. Voltage read-
ings tolerance ±10%.
1 1 Meter Display Board PC2
804 492 / 214 536
9-10. Meter Display Board PC2 Test Point Values

specified
er rpm unless noted
d) Process/Contactor switch R1
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

9-11. Fuel/Hourmeter Testing Information
Pin Description 1 Rear of Fuel/Hourmeter
1 +12 Volts DC Input S1 In Run/Idle; FUEL/HM
Open (No Output) With S1 in Run 1 See Section 5-6 for explanation of
meter functions.
2 Input From Temperature Switch S2
Wiring harness plug PLG1 con-
3 Input From Oil Pressure Switch S3
nects to receptacle on rear of meter.
4 +12 Volts DC Input (S1 In Any Position
Test meter functions by checking
But Off)
pin inputs and outputs as specified
5 Input From Fuel Level Sender in the table below.
6 +12 volts DC (S1 In Start) Voltage readings tolerance ±10%.
7 Output To Relay CR1 (Engine Latch)
8 Negative (−) Battery Voltage (Ground)
hm1 2010−08 232 111 / Ref. 804 492
Fuel/Hourmeter Input/Output Information

hm1 2010−08
Oil High
Low Oil View Hours
Hourmeter Maintenance Coolant View Engine Low Fuel Shut-
Pressure Until Next Oil Fuel Gauge
Counts Hours Temp Hours down
Pin Shutdown Change
Countdown Shutdown
Engine Running Engine Not Running Any Engine Mode
1 n/a n/a n/a n/a Open +12 volts DC n/a n/a
2 Ground Ground Ground Open Ground Ground Ground Ground
3 Ground Ground Open n/a Open Open n/a n/a
4 +12 volts DC +12 volts DC +12 volts DC +12 volts DC +12 volts DC +12 volts DC +12 volts DC +12 volts DC
28 to 33 ohms 28 to 33 ohms 28 to 33 ohms 28 to 33 ohms

w/fuel tank w/fuel tank w/fuel tank w/fuel tank
Greater than 235 Less than 235
5 full; 235 ohms full; 235 ohms full; 235 ohms full; 235 ohms n/a n/a
ohms ohms
starts shut- starts shut- starts shut- starts shut-
down down down down
+12 volts DC +12 volts DC

applied during applied during
engine crank- engine crank-
ing and then ing and then
6 Open Open removed (fault removed n/a n/a n/a n/a
shutdown in- (fault shut-
hibited for 30 down inhibited
sec. after for 30 sec. af-
startup) ter startup)
30 second 30 second
delay after delay after Open after 10
start-up start-up sec. delay (shuts
7 Ground Ground Ground Ground Ground
(deenergizes (deenergizes off CR1 which
CR1 which CR1 which stops unit)
stops unit) stops unit)
8 Ground Ground Ground Ground Ground Ground Ground Ground

9-12. 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

9-13. Checking Unit Output After Servicing
Also use output waveforms to

check unit output after servic-
ing (see Section 9-4).
Check engine speeds, and adjust if
necessary (see Section 7-8).
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 9-1.
3 Check open-circuit voltage across
weld output terminals according to
Section 9-2. If correct voltages are
not present, repeat troubleshooting
procedures in Section 9-1.
Perform a load bank test to en-

1 sure welding generator oper-
ates properly after servicing.
Be sure load bank is capable of
handling the rated output of the
welding generator being tested
(see load bank Owner’s manu-
al).
The load bank will simulate a
2
weld load and the electrical de-
mand on the unit. See Specific-
ations for rated load.
If unit does not perform at rated
load, repeat troubleshooting
procedures.
! Stop engine.
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 10 − DISASSEMBLY AND REASSEMBLY
10-1. Disassembly Of Unit
! Stop engine and let cool. Dis-

connect battery negative (−)
cable.
Use Section 9-1 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 7-7
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 11 for connec-
tion information.
Disconnect:
generator cables from rectifier
assembly
generator power leads from termi-
nal strip TE1
engine wiring harness at in-line
1 connector
engine ground strap from base.
Use a hoist to evenly lift and remove
engine/generator assembly.
Go to Section 10-2.
Remove brushes
before removing
endbell or rotor.
Ref 804 494

10-2. 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)
5
Prior To MB180121E
Eff w/MB180121E
2 1
3 2
B
C 3
B
C 1
803 686-B / Ref. 803 686-C
! Do not damage stator or rotor win- Remove brushes from brushholder assembly Reinstall engine/generator assembly in unit.
dings during this procedure. or remove brushholder before disassembling Reinstall mounting hardware.
generator.
! Use hoist and lifting strap to carefully Reconnect fuel line and exhaust pipe
remove generator components. Remove engine and rotor by removing nuts
Reinstall radiator and rear upright. Refill ra-
from studs and separating stator from engine
diator with coolant (see Section 7-7 and en-
1 Brushes adapter. With engine properly supported, re-
gine manual).
2 Stator move hardware securing endbell to stator.
Reconnect all leads. Use cable ties to secure
Reassembly Instructions:
3 Endbell leads in existing wiring harness and away
Reinstall engine and generator parts as from moving and hot parts.
4 Rotor
needed using torque values in table.
Reconnect negative (−) battery cable. Rein-
5 Stud
Reinstall brushes in brushholder assembly or stall cover, panels, and doors.
reinstall brushholder.
10-3. 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)

10-4. 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 1, 2, 3
(5 N⋅m, ±0.5 N⋅m)
After four hours re-torque to 3 SCR Connection Screw
45 in lb, ±5 in lb
(5 N⋅m, ±0.5 N⋅m) 4 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.
4
1
805 265

SECTION 11 − 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 Models LJ140121E Thru LJ480118E 237 150-B
LJ480119E And Following 240 674-B See Table 11-1
Circuit Board PC6 LE140121E And Following 217 005-A

(HF Filter Board)
Circuit Board PC2 LE140121E And Following 214 535-B

(Meter Display)

Figure 11-1. Circuit Diagram For Big Blue 400 CX CC/CV Eff w/LJ140121E Thru LJ480 118E
237 150-B

Figure 11-2. Circuit Diagram For Big Blue 400 CX CC/CV Eff w/LJ480119E And Following
240 674-B

217 005-A
Figure 11-3. Circuit Board PC6 (HF Filter) Effective w/LJ140121E And Following
214 535-B
Figure 11-4. Circuit Board PC2 (Meter Display) Effective w/LJ140121E And Following
Table 11-1. Lead List Summary For Big Blue 400 CX CC/CV Models Eff w/MB110164E
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 57A S3 (2) TO PLG1 (3)
−−−− PLG1 TO G2 58A CR3 (86) TO S4 (WIPER)
−−−− PLG1 TO K1 60A CR4 (30) TO SR3 (AC)
−−−− PLG1 TO K2 60B SR3 (AC) TO TS1
−−−−− 106A TO BRUSHBLOCK 62A PLG 1 (1) TO SPLICE
−−−−− 42DD TO BRUSHBLOCK 62B S1 (D) TO SPLICE
10A T1 TO RECT 62C JOINS WITH 62D TO PLG6 (F3)
11A STATOR TO T1 62D 62C TO SPLICE
17A Z1 TO SCR’S CC (+) 65A CB9 TO CR4 (87)
18A PLG6 (A3) TO Z1 66A PLG 6 (E3) TO CT LEAD
19A PLG6 (C3) TO R−3 LEFT 67A PLG 6 (G3) TO CT LEAD
19A Z1 (CC) TO CC OUTPUT STUD 70A PLG7 (C3) TO CR4−85)
19B Z1 TO R3 (LEFT) 71A FUEL SENDER TO PLG1 (5)
21A STATOR TO RECT. 80 PC6−80 TO TE1−80
30A PLG6 (B3) TO R−3 CENTER 80A STATOR TO TE1 (E)
30A SCR’S (−) TO NEGATIVE OUTPUT STUD 81A STATOR TO CB8
30B HEAT SINK (−) TO R3 (CENTER) 81A PLG6 (K3) TO CB8
31A STATOR TO RECT. 83A STATOR TO TE1
40A CR1 (3) TO PLG5 (1) 84A STATOR TO TE1 OR TE2(DEPENDS ON MODEL)
40B CR1 (3) TO SR 4 (−) 84B TE1−C TO CB5
40C SR 4 (−)TO PLG7 (E1) 85A STATOR TO TE1
41A CB1 (BAT) TO STARTER 87 PC6−87 TO CB7
42A S2 (1) TO GROUND TERMINAL 87A RC11 (L) TO ELCB2−LOAD
42AA GROUND STUD TO RC11 (PE) 88A STATOR TO TE1
42AB GROUND STUD TO RC12 (PE) 89A STATOR TO TE1 OR TE2 (DEPENDS ON MODEL)
42AC GROUND STUD TO TE2 90D CB5 TO GFCI1 (H)
42AD GFCI−1 (GRND) TO GROUND STUD 91A STATOR TO TE2
42B S3 (1) TO GROUND TERMINAL 91A ELCB2−LOAD (N) TO RC11
42B TE1 (F) TO BASE GROUND 92A STATOR TO TE2
42BB GROUND TERMINAL TO PLG5 (2) 94B RC12 (L) TO ELCB1−LOAD
42C PLG6 (J1) TO EXIT 95B ELCB1−LOAD (N) TO RC12
42D FS1 (2) TO GROUND TERMINAL 96C TE2−C TO ELCB1−LINE
42DD SR 5 (−) TO BRUSH 96D TE2−C TO ELCB2 − LINE
42E FUEL PUMP TO GROUND TERMINAL 97B TE2−D TO ELCB1 −LINE (N)
42EE SR 5 (−) TO GROUND TERMINAL 97C TE2−D TO ELCB2 − LINE (N)
42F SR2 TO GROUND TERMINAL 97D TE2−D TO GFCI−1 (N)
42G SR3 (−) TO GROUND TERMINAL 97E TE1−E TO TE2−D
42K CR3 (85) TO GROUND TERMINAL 98A STATOR TO TE1
42M GROUND TERMINAL TO GROUND TERMINAL 100A STATOR TO TE1 (B)
42N FUEL LEVEL SENDER TO GROUND TERMINAL 100B TE1 (B) TO SR5 (AC)
42P FUEL SENDER GROUND TO PLG1 (8) 101A STATOR TO FUSE 1
42P RING ASSY TO ROTOR COILS 105A SR 5 (+) TO BRUSH
42Q ENGINE BLOCK GROUND TO GROUND TERMINAL 105B SR 5 (+) SR 4 (AC)
42R GROUND TERMINAL TO CR2 109B RING ASSY TO ROTOR COILS
42W GROUND TERMINAL TO PLG6 (H3) 114A TE2 (E) TO (114 FROM F1)
42X ENGINE BLOCK GROUND TO TS1 115A TE2 (F) TO 115 (FROM SR5AC)
42Y WORK (−) TO TE1 (F) 132 PC6−132 − CB8
43A ALT (B) TO CB1 (AUX) 135 PC6−135 TO RC2−6
43B CB1 (AUX) TO CB2 135A PLG6 (G2) TO PLG8 (6)
43C CB2 TO CB3 135A PC6−135A TO RC13 (1)
43D CR3 (87) TO CB1 (AUX) 136 PC6−136 TO RC2−8
43E CB1 (AUX) TO CB9 136A PLG6 (J3) TO PLG8 (8)
44A CR3 (30) TO GLOW PLUG 136A PC6−136A TO RC13 (3)
45A CB3 TO CR1 4 137 PC6−137 TO RC2−9
47A CR2 TO STARTER 137A PLG6 (H2) TO PLG8 (9)
48A CB2 TO S1 (A) 140 PC6−140 TO RC2−10
50A ALT (D+) TO SR1 (+) 140A PLG7 (F3) TO PLG8 (10)
51A CR2 TO S1 (C) 141 PC6−141 TO RC2−4
51B CR2 TO PLG1 (6) 141A PLG6 (F2) TO PLG8 (4)
52B SR1 TO CR1 (1) 148 PC6−148 TO RC2−2
52C CR1 (1) TO SR2 148A PLG6 (D3) TO PLG8 (2)
52D SR2 TO CR2 148A PC6−148A TO RC13 (2)
53A FS1 (1) TO SR2 (+) 150 PC6−150 TO RC2−7
53B SR2 (+) TO FUEL PUMP 150A PLG7 (B3) TO PLG8 (7)
53C CR4 (86) TO SR2 (+) 160A PLG7 (B1) TO PLG3 (4)
54A CR1 (6) TO PLG1 (7) 161A PLG7 (A1) TO PLG3 (5)
55A CR1 (5) TO CR1 (2) 162A PLG6 (K1) TO PLG3 (6)
55B CR1 (2) TO S4 (NO) 165A PLG6 (C2) TO PLG2 (1)
55C CR1 (5) TO S1 (B) 166A PLG6 (B2) TO PLG2 (2)
55D S4 (NO) TO PLG1 (4) 167A PLG6 (A2) TO PLG2 (3)
56A S2 (2) TO PLG1 (2) 180A PLG6 (F1) TO EXIT
Table 11-1. Lead List Summary For Big Blue 400 CX CC/CV Models Eff w/MB110164E (Continued)
Lead Connections Lead Connections
181A PLG6 (G1) TO EXIT 189A PLG7 (D1) TO PLG4 (2)
182A PLG6 (H1) TO EXIT 190A PLG6 (A1) TO PLG5 (3)
183A PLG 6 (E1) TO EXIT 191A PLG6 (C1) TO PLG5 (4)
188A PLG7 (C1) TO PLG4 (1)

SECTION 12 − RUN-IN PROCEDURE
run_in1 2007−04
12-1. 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.

12-2. 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

12-3. 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-4435F 2011−06
Eff. w/Serial Number LJ140121E And
Following
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

)
Eff w/LJ140121E And Following

For OM-4435 (218 759) Revisions N Thru AE
Visit our website at

www.MillerWelds.com
SECTION 13 − PARTS EFF W/LJ140121E AND FOLLOWING
Hardware is common and not
available unless listed.
Wiring harnesses are listed at

the end of parts section.
10
9 13
11
12
7 14 23
5 15
16
102 24
17 22
105
104 103 110
21
19 20
25
4−Fig.13-5
101
18 91
100 92
1 90
89
2−Fig.13-3 84
98
83
99
97−Fig.13-2
85 82
86
88 81
87
93
80
94
95
96
Figure 13-1. Main Assembly

28 30 31
42
27 32
29 41
40
26 35
34 39
38
109 33 37
69
68
43
70 67
66 36 45 111 44
65
71 64 50 51 52
61 63
78 46 46
49
48
62 53
79 47
77
76 54
73 72−Fig.13-4
55
75 55
74
Optional Auto Idle
108
106
107
804 012−H1 / 804 012-G2 / Ref. 803 683-F

Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 13-1. Main Assembly
. . . 1 . . . . HD1 . . . . 168829 . . Transducer, Current 1000a Module Max Open Loop . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . Figure 13-4 . . Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . 217070 . . Bracket, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . Figure 13-7 . . Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 181853 . . Insulator, Screw (For Rectifier Mtg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 5 . . . . . Z1 . . . . . 236580 . . Stabilizer (Prior to LK400015E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . Z1 . . . . . 245553 . . Stabilizer (Eff w/LK400015E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 192303 . . Angle, Mtg Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . . . . . . . . . . 232425 . . Bracket, Vault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . +213488 . . Panel, Engine Side (Prior to MB180121E) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . +243709 . . Panel, Engine Side (Eff w/MB180121E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . PC1 . . . . 232746 . . Module, Main Control/SCR Gating (Prior to MB110164E) . . . . . . . . . . . . . 1
. . . 8 . . . . PC1 . . . . 250280 . . Module, Main Control/SCR Gating (Eff w/MB110164E) . . . . . . . . . . . . . . . 1
. . . 9 . . . . . T1 . . . . . 232445 . . Xfmr, Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 (Prior to MB040167E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . +249656 . . Cover, Top (Eff w/MB040167E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 (Prior to MA320152E)1
. . . 39 . . . . . . . . . . . . . . 244812 . . Radiator, w/14# Cap 1 Row Core 1.25 In Inlet/Outlet (Eff w/MA320152E) 1
. . . . . . . . . . . . . . . . . . . . 187120 . . . . Cap, Radiator Pressure 14 Lb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . . 212603 . . Baffle, Air Upper Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . +225400 . . Upright, Rear (Prior to MB180121E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . +243710 . . Upright, Rear (Eff w/MB180121E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . . . 225412 . . Cover, Radiator Access (Prior to MB180121E) . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . . . 243711 . . Cover, Radiator Access (Eff w/MB180121E) . . . . . . . . . . . . . . . . . . . . . . . . 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
Item Dia. Part
Figure 13-1. Main Assembly (Continued)
. . . 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
. . . 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 (Prior to MB180121E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 55 . . . . . . . . . . . . . . 243708 . . Panel, Rocker (Eff w/MB180121E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 56 . . . . . . . . . . . . . . 213266 . . Mount, Engine/Generator Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 57 . . . . . . . . . . . . . . 197506 . . Screw, M14−1.5x 30 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 58 . . . . . . . . . . . . . . 237218 . . Bracket, Mtg Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 59 . . . . . . . . . . . . . . 083883 . . Washer, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . . . . 2
. . . 60 . . . . . . . . . . . . . . 049026 . . Screw, M10−1.5x 25 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . . . . 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) (Prior to MB040167E) . . . . . . . . . . 1
. . . 69 . . . . . . . . . . . . . . 249657 . . Air Cleaner, Intake 5.250 In (Includes) (Eff w/MB040167E) . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 197675 . . . . Dust Ejector, Air Cleaner (Prior to MB040167E) . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 249661 . . . . Dust Ejector, Air Cleaner (Eff w/MB040167E) . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *197676 . . . . Element, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 197677 . . . . Cover Assy, Air Cleaner(Prior to MB040167E) . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 249659 . . . . Cover Assy, Air Cleaner (Eff w/MB040167E) . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 197678 . . . . Body, Air Cleaner (Prior to MB040167E) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 249658 . . . . Body, Air Cleaner (Eff w/MB040167E) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 249664 . . . . Latch, Air Cleaner (Eff w/MB040167E) . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 13-5, Figure 13-6 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
. . . 76 . . . . . . . . . . . . . . 124253 . . . . 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

Item Dia. Part
Figure 13-1. Main Assembly (Continued)
. . . 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
. . . . . . . . . . . . . . . . . . . . 071731 . . Washer, Flat .656idx2.250odx.187t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 213600 . . Screw, 500−13x3.00 Hex Flange−hd Gr8 Pln . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 071731 . . Washer, Flat .656idx2.250odx.187t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 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 13-2, Figure 13-3 Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 98 . . . . CT1 . . ♦105370 . . Xfmr, Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 99 . . . . . . . . . . . . . . . . . . . . . . . . Label, Rating Card Ce 907143 (CC Model) (Order By Model And Serial No.) . . . 1
. . . 99 . . . . . . . . . . . . . . . . . . . . . . . . Label, Rating Card Ce 907281 (CC/CV Model) (Order By Model And Serial No.) . 1
. . 100 . . . . . . . . . . . . . 213504 . . Tray, Reactor&Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 101 . . . . . . . . . . . . . 213500 . . Brkt, Beam Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 102 . TE1, TE2 . . 172661 . . Block, Stud Connection 6 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 103 . . . . C11 . . . . 217054 . . Capacitor, Cer Disc .0047 Uf 3000 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . 1
. . 104 . . . . . . . . . . . . . 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
. . 105 . . . . R3 . . . . . 213027 . . Resistor, WW Tap 300 W 40 Ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 173734 . . Link, Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . ♦235023 . . Idle, Solenoid Assy (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 106 . . . . . . . . . . . ♦234691 . . . . Bracket, Mtg Solenoid Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 107 . . . TS1 . . ♦230634 . . . . Solenoid, Throttle W/4−8.4 Lb Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦198109 . . . . Screw, Shld Stl Sch .250−20 X .437 X .500 Shld . . . . . . . . . . . . . . . . . . . 1
. . 108 . . . . . . . . . . . ♦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
. . 109 . . . . . . . . . . . . . 233088 . . Label, Danger Using A Generator Indoors Can Kill You In Minutes . . . . . 1
. . 110 . . . . . . . . . . . . . 285297 . . Adapter, Terminal Block (Eff w/LJ470079E) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 111 . . . . . . . . . . . . . 237013 . . Label, Hour/Fuel Meter Usage (Prior to LJ480119E) . . . . . . . . . . . . . . . . . . 1
. . 111 . . . . . . . . . . . . . 238650 . . Label, Hour/Fuel Meter Usage (Eff w/LJ480119E) . . . . . . . . . . . . . . . . . . . . 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 Wiring harnesses are listed at
10
12
8 9
13 14 25
7 23 24
22 26 27
28
15
6 21
16
20 29
5
4
17
3
1 2 18
41 19
40 30
31
34 33
32
39
38
36 35
37 804 011−C
Figure 13-2. Panel, Front w/Components (Prior to LJ480119E)
Item Dia. Part

Figure 13-2. Panel, Front w/Components (Prior to LJ480119E) (Figure 13-1 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 . . Supplementary Pro, 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

Item Dia. Part
Figure 13-2. Panel, Front w/Components (Prior to LJ480119E) (Figure 13-1 Item 97 )
... 15 . . . . . S4 . . . . . 021467 . . Switch, Tgl Spst 3a 250v Off−none−(On) Spd Term . . . . . . . . . . . . . . . . . . 1

... 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 . . . . . . . . . . . . . . 206795 . . Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 22 ........................ Nameplate, Generator Power (Order By Model & Serial No.) . . . . . . . . . . 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
... 28 . . . ELCB2 . . . 222992 . . Circuit Breaker, Elcb 30a 220v 0.030a Trip . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 29 . . . . . . . . . . . . . . 144844 . . Stand−off, No 6−32 X .875 Lg .250 Hex Al Fem . . . . . . . . . . . . . . . . . . . . . 4
... 30 . . . . GRD . . . . 083030 . . Stud, Brs .250−20 X 1.750 W/Hex Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 31 . . . . . . . . . . . . . . 010915 . . Washer, Flat .257idx0.640odx.031t Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 32 . . . . . . . . . . . . . . 601836 . . Nut, 250−20 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 33 . . . . RC11 . . . . 156831 . . Rcpt,Str 2p3w 32a 220v Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 34 . . . . . . . . . . . . . . 209056 . . Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 35 ........................ Nameplate, Weld Terminal (Order By Model & Serial No.) . . . . . . . . . . . . . 1
... 36 . . . . . . . . . . . . . . 181169 . . Spacer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 37 . . . . . . . . . . . . . . 186621 . . Boot, Generic Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 38 . . . . . . . . . . . . . . 180735 . . Washer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 39 . . . . . . . . . . . . . . 039046 . . Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 40 . . FUEL/HM . . 232111 . . Gauge, Fuel Elec/Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 41 . . . . . . . . . . . . . . 021385 . . Boot, Toggle Switch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦Optional

11
10 available unless listed.
12 Wiring harnesses are listed at
9 the end of parts section.
8
13 14 25
7 23 24
22
26 27
28
15
6 21
16
20 29
5
4
17
3
1 2 18
41
40 19
30
31
34 33 32
39
38
36 35
37
804 011−D
Figure 13-3. Panel, Front w/Components (Eff w/LJ480119E)
Item Dia. Part

Figure 13-3. Panel, Front w/Components (Eff w/LJ480119E) (Figure 13-1 Item 97 )
... 1 . . . . . . . . . . . . . . 097926 . . Knob, Pointer 2.375 Dia X .250 Id (Prior To MB230150E) . . . . . . . . . . . . . 1

... 1 . . . . . . . . . . . . . . 218764 . . Knob, Pointer 1.625 Dia (Eff w/MB230150E) . . . . . . . . . . . . . . . . . . . . . . . . 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 (Prior To MB230150E) . . . . . . . . . . . . . . 1
... 5 . . . . . . . . . . . . . . 207080 . . Knob, Pointer 1.125 Dia (Eff w/MB230150E) . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 ........................ Nameplate, Control (Order By Model & Serial No.) . . . . . . . . . . . . . . . . . . . 1
... 7 . . . . PC6 . . . . 229949 . . Circuit Card Assy, Connector/Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 . . . . . . . . . . . . . . 240672 . . 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
Item Dia. Part
Figure 13-3. Panel, Front w/Components (Eff w/LJ480119E) (Continued)
. . . 15 . . . . . S4 . . . . . 021467 . . Switch, Tgl Spst 3a 250v Off−none−(On) Spd Term . . . . . . . . . . . . . . . . . . 1

. . . 16 . . . . . S1 . . . . . 217680 . . Switch, Ignition 4 Position W/Out Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 207073 . . Lever, Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 201244 . . Washer, Tooth.728idx1.166odx.050t Stl Pld Int.688 . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . 241432 . . 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 . . . . . . . . . . . . . . 206795 . . Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . . . . . . . . . . . Nameplate, Generator Power (Order By Model & Serial No.) . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . 224428 . . Panel, Power CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . GFCI1 . . . 151981 . . Rcpt, Str Dx Grd 2p3w 15/20a 125v *5−20r Gfi (Prior To MA130015E) . . 1
. . . 24 . . . GFCI1 . . . 246865 . . Rcpt, Str Dx Grd 2p3w 20a 125v *5−20r Gfi (Eff w/MA130015E) . . . . . . . 1
. . . 25 . . . C11, 12 . . . 217054 . . Capacitor, Cer Disc .0047 Uf 3000 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . 2
. . . 26 . . . . CB5 . . . . 093996 . . Supplementary Pro, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . 1
. . . 27 . . . ELCB1 . . . 222991 . . Circuit Breaker, Elcb 20a 220v 0.030a Trip . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . ELCB2 . . . 222992 . . Circuit Breaker, Elcb 30a 220v 0.030a Trip . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . 144844 . . Stand−off, No 6−32 X .875 Lg .250 Hex Al Fem . . . . . . . . . . . . . . . . . . . . . 4
. . . 30 . . . . GRD . . . . 083030 . . Stud, Brs .250−20 X 1.750 W/Hex Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . 010915 . . Washer, Flat .257idx0.640odx.031t Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 32 . . . . . . . . . . . . . . 601836 . . Nut, 250−20 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 33 . . . . RC11 . . . . 156831 . . Rcpt,Str 2p3w 32a 220v Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 34 . . . . . . . . . . . . . . 209056 . . Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 35 . . . . . . . . . . . . . . . . . . . . . . . . Nameplate, Weld Terminal (Order By Model & Serial No.) . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . . 181169 . . Spacer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 37 . . . . . . . . . . . . . . 186621 . . Boot, Generic Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 38 . . . . . . . . . . . . . . 180735 . . Washer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 39 . . . . . . . . . . . . . . 241433 . . Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . FUEL/HM . . 232111 . . Gauge, Fuel Elec/Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . . 021385 . . Boot, Toggle Switch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦Optional

available unless listed. 5
Wirng harnesses are listed at 4
3
2
6
1
8
10
11
12
13
14
803 689-E
Figure 13-4. Control Panel
Item Dia. Part

Figure 13-4. Control Panel (Figure 13-1 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 . . . . CR4 . . ♦090104 .. Relay, Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg . . . . . . . . . . . . . . . . . . 1
... 9 . . . . CR3 . . . . 197325 .. Relay, Encl 12vdc Spst 70a 4pin Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 . . SR5, SR4 . . 035704 .. Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 11 . . . . SR3 . . ♦035704 .. Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 . . SR2, SR1 . . 035704 .. Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 13 . . CB2, CB3 . . 083432 .. Supplementary Pro, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . 2
... 14 . . . . CB9 . . ♦230635 .. Supplementary Pro, Auto Reset 1p 8a 12vdc Frict . . . . . . . . . . . . . . . . . . . 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 13-5. Generator (Prior To MB180121E)

Item Dia. Part
Figure 13-5. Generator (Figure 13-1 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 . . 237062 . . 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

Wiring harnesses are listed at 5

4 6
7
3
1
8
9
10
12
13
15
11
16
14
803 686-C
Figure 13-6. Generator (Eff w/MB180121E)

Item Dia. Part
Figure 13-6. Generator (Figure 13-1 Item 72)
... 1 . . . ROTOR . . . 243820 . . Rotor, Generator 4 Pole (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 .............. 181143 . . . . Bearing, Ball Rdl Sgl Row .984 X 2.047 X .591 . . . . . . . . . . . . . . . . . . . . 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 . . 251062 . . Stator, Generator 4 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 .............. 183336 . . Endbell (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 .............. 183419 . . . . O-Ring, 1.984 Id X .139 Cs 70 Duro Viton . . . . . . . . . . . . . . . . . . . . . . . . 1
... 14 .............. 167788 . . Nut, 375−16 .56hex .34h Stl Pld Sem Cone Wshr.88d . . . . . . . . . . . . . . . 4
... 15 .............. 244290 . . Brushholder Assembly, Generator w/Leads . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 16 .............. 136343 . . . . Screw, K50x 20 Pan Hd-phl Stl Pld Pt Thread Forming . . . . . . . . . . . . . 2

2
the end of parts section. 1
4
5
804 010−A
Figure 13-7. Rectifier Assembly
Item Dia. Part

Figure 13-7. Rectifier Assembly (Figure 13-1 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
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.

Some wiring harness components (switches, relays, supplementary protectors) are also referenced elsewhere in this parts list. Purchase compo-
nents separately or as part of the associated wiring harness.
Item Dia. Part

Wiring Harnesses
.................... 235012 . . Harness, Engine (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . S4 . . . . . 021467 . . . . Switch, Tgl Spst 3a 250v Off−none−(On) Spd Term . . . . . . . . . . . . . . . . 1
. . . . . SR1, SR2, SR3 035704 . . . . Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . 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
.................... 148850 . . . . Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 212116 . . . . Conn, Deutsch 2p 1row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
.................... 212117 . . . . Conn, Deutsch Wedge Lock 2 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . PLG6 . . . . 214932 . . . . Conn, Rect Univ 039 8p/S 2row Plug Cable Lkg Seal . . . . . . . . . . . . . . 1
.................... 214933 . . . . Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
.................... 147995 . . . . Conn, Rect Univ 039 Skt 22−18ga .094od Gold . . . . . . . . . . . . . . . . . . . 7
. . . . . . . . . For S1 . . . 211292 . . . . Conn, Pack 4p 1row Female (Prior to LJ480119E) . . . . . . . . . . . . . . . . . 1
. . . . . . . . . For S1 . . . 211293 . . . . Conn, Pack Terminal Position (Lock) (Prior to LJ480119E) . . . . . . . . . . 1
. . . . . . . . . For S1 . . . 177859 . . . . Conn, Body 5 Terminal (Eff w/LJ480119E) . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 129524 . . . . Term, Frict 250x032 Uninsul Male .130 Stud Mtg 3pr . . . . . . . . . . . . . . . 2
.................... 235018 . . Harness, Weld Control (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . PLG2 . . . . 150316 . . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG3 . . . . 214951 . . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg Seal . . . . . . . . . . . . . . 1
.................... 214933 . . . . Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
.................... 214934 . . . . Seal, Plug Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
.................... 235021 . . . . Connector, w/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG6 . . . . 193184 . . . . Conn, Rect Cinch 30 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG7 . . . . 193183 . . . . Conn, Rect Cinch 18 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG5 . . . . 113750 . . . . Conn, Rect Mini 045 4skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . 1
.................... 217000 . . . . Cable, Lem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG4 . . . . 215340 . . . . Conn, Rect Univ 039 2p/S 1row Rcpt Cable/Pnl Lkg S . . . . . . . . . . . . . 1
.................... 214933 . . . . Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . SR4, SR5 . . 035704 . . . . Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
.................... 214984 . . Harness, Rectifier Cc/Cv (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . PLG11 . . . 193183 . . . . Conn, Rect Cinch 18 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 207716 . . . . Conn, Faston Mini Polarized 2 Skt G1k1 . . . . . . . . . . . . . . . . . . . . . . . . . 6
.................... 207718 . . . . Conn, Faston Mini Polarized 2 Skt G2k2 . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . 217010 . . Harness, Receptacle Auxiliary Power (Includes) . . . . . . . . . . . . . . . . . . 1

. . . . . . . . CB4, CB6 . . 093996 . . . . Supplementary Pro, Man Reset 1p 20a 250vac Fric . . . . . . . . . . . . . . . . 2

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
For International Locations Visit
www.MillerWelds.com
ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2011 Miller Electric Mfg. Co.

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Copyright:

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Bigblue400cxce (Lj140121e)

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TM-4435F 2011−06

Eff. w/Serial Number LJ140121E And

TIG (GTAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Air Carbon Arc (CAC-A) Cut-

Engine Driven Welding Generator

Big Blue 400 CX CE

Eff w/Serial Number LJ140121E And Following

File: Engine Drive

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

1-1. Symbol Usage

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

Indicates a hazardous situation which, if not avoided,

During servicing, keep everybody, especially children, away.

ELECTRIC SHOCK can kill. Using a generator indoors CAN KILL

Big Blue 400 CX TM-4435 Page 1

Use lifting eye to lift unit and properly installed

TM-4435 Page 2 Big Blue 400 CX

1-3. California Proposition 65 Warnings

1-4. EMF Information

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

The EMF assessment on this equipment was conducted at 0.5 meter.

3-2. Weld, Power, And Engine Specifications

300 A, 32 Volts DC Generator

3-3. Dimensions, Weights, And Operating Angles

TM-4435 Page 6 Big Blue 400 CX

237 466 / 237 468 / 237 470

Big Blue 400 CX TM-4435 Page 7

3-6. 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

4-2. Installing Welding Generator

See Section 4-3 for mounting

TM-4435 Page 10 Big Blue 400 CX

Welding Unit In Place

Big Blue 400 CX TM-4435 Page 11

Electrically bond generator

rot_grnd1 2011−04 − 800 652-D

TM-4435 Page 12 Big Blue 400 CX

Work like a Pro!

Big Blue 400 CX TM-4435 Page 13

When electrolyte is low, add

4-7. Connecting The Battery

= Check = Change = Clean = Replace Reference

Coolant Level Fuel Level Oil Level Oil, Fuel Spills

Battery Terminals Air Cleaner Hoses Air Cleaner Element

Weld Cables Fuel Filter Inline Fuel Filter Radiator Thermostat