Miller Bobcat 250 NT Owner`s manual

OM-4403
200 291E
April 2002
Processes
Stick (SMAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Non-Critical TIG (GTAW)
Welding
Description
Engine Driven Welding Generator

Bobcat 250 NT
Visit our website at
www.MillerWelds.com
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001 Quality System Warranty and service information for your
Standard.
particular model are also provided.
Working as hard as you do
– every power source from
Miller is backed by the most
hassle-free warranty in the
business.
Miller offers a Technical
Manual which provides
more detailed service and
parts information for your
unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMAW-P.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog orindividual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
TABLE OF CONTENTS
WARNING
This product, when used
for welding or cutting,
produces fumes or
gases which contain
chemicals known to the
State of California to
cause birth defects and,
in some cases, cancer.
(California Health &
Safety Code Section
25249.5 et seq.)
WARNING
Battery posts, terminals
and related accessories
contain lead and lead
compounds, chemicals
known to the State of
California to cause
cancer and birth defects
or other reproductive
harm. Wash hands after
handling.
WARNING
The engine exhaust from
this product contains
chemicals known to the
State of California to
cause cancer, birth
defects, or other
reproductive harm.
The following terms are
used interchangeably
throughout this manual:
TIG = GTAW
Stick = SMAW
MIG = GMAW
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . .
1-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Weld, Power, and Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Dimensions, Weights, and Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Fuel Consumption (Onan-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Fuel Consumption (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Engine Prestart Checks (Onan-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Engine Prestart Checks (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Activating The Dry Charge Battery (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Connecting the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Connecting to Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 – OPERATING THE WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Typical Stick Welding Connections And Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Typical MIG Welding Connections And Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Typical MIG Connections And Settings Using Weld Control And Spoolgun . . . . . . . . . . . . . .
SECTION 6 – OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Standard Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Optional Generator Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Wiring Optional 240 Volt Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 – MAINTENANCE (ONAN-POWERED UNITS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Routine Maintenance (Onan-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Maintenance Label (Onan-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Servicing Air Cleaner (Onan-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Overload Protection (Onan-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5. Changing Engine Oil, Oil Filter, and Fuel Filter (Onan-Powered Units) . . . . . . . . . . . . . . . . . .
7-6. Adjusting Engine Speed (Onan-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-7. Servicing Optional Spark Arrestor (Onan-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 – MAINTENANCE – (KOHLER-POWERED UNITS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Routine Maintenance (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Maintenance Label (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Servicing Air Cleaner (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Changing Engine Oil, Oil Filter, and Fuel Filter (Kohler-Powered Units) . . . . . . . . . . . . . . . . .
8-5. Adjusting Engine Speed (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6. Overload Protection (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-7. Servicing Optional Spark Arrestor (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS
SECTION 9 – TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 – GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 – STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 13 – MIG WELDING (GMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-1. Typical MIG Process Connections Using A Voltage-Sensing Wire Feeder . . . . . . . . . . . . . .
13-2. Typical MIG Process Connections Using A Constant Speed Wire Feeder . . . . . . . . . . . . . .
13-3. Typical MIG Process Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-4. Holding And Positioning Welding Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-5. Conditions That Affect Weld Bead Shape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-6. Gun Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-7. Poor Weld Bead Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-8. Good Weld Bead Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-9. Troubleshooting – Excessive Spatter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-10. Troubleshooting – Porosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-11. Troubleshooting – Excessive Penetration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-12. Troubleshooting – Lack Of Penetration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-13. Troubleshooting – Incomplete Fusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-14. Troubleshooting – Burn-Through . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-15. Troubleshooting – Waviness Of Bead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-16. Troubleshooting – Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-17. Common MIG Shielding Gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 14 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPTIONS AND ACCESSORIES
WARRANTY
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59
59
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SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING
rom _nd_4/02
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Marks a special safety message.
Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-5. Read and follow all
Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
Do not touch live electrical parts.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists in inverters after
stopping engine.
Stop engine on inverter and discharge input capacitors according
to instructions in Maintenance Section before touching any parts.
ARC RAYS can burn eyes and skin.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
Use AC output ONLY if required for the welding process.
If AC output is required, use remote output control if present on
unit.
Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
Always verify the supply ground – check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
When making input connections, attach proper grounding conductor first – double-check connections.
Frequently inspect input power cord for damage or bare wiring –
replace cord immediately if damaged – bare wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes from arc rays and sparks when welding or
watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards).
Wear approved safety glasses with side shields under your
helmet.
Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
If ventilation is poor, use an approved air-supplied respirator.
Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
OM-4403 Page 1
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
Protect yourself and others from flying sparks and hot metal.
Do not weld where flying sparks can strike flammable material.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
HOT PARTS can cause severe burns.
Allow cooling period before maintaining.
Wear protective gloves and clothing when
working on a hot engine.
Do not touch hot engine parts or just-welded
parts bare-handed.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
Wear approved ear protection if noise level is
high.
Watch for fire, and keep a fire extinguisher nearby.
Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
Do not use welder to thaw frozen pipes.
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
MAGNETIC FIELDS can affect pacemakers.
Pacemaker wearers keep away.
Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
CYLINDERS can explode if damaged.
Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
FLYING METAL can injure eyes.
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
Shut off shielding gas supply when not in use.
Always ventilate confined spaces or use approved air-supplied respirator.
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder – explosion will result.
Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
1-3. Engine Hazards
FUEL can cause fire or explosion.
Stop engine and let it cool off before checking or
adding fuel.
Do not add fuel while smoking or if unit is near
any sparks or open flames.
Do not overfill tank – allow room for fuel to expand.
Do not spill fuel. If fuel is spilled, clean up before starting engine.
Dispose of rags in a fireproof container.
OM-4403 Page 2
STEAM AND HOT COOLANT can burn.
If possible, check coolant level when engine is
cold to avoid scalding.
Always check coolant level at overflow tank, if
present on unit, instead of radiator (unless told
otherwise in maintenance section or engine
manual).
If the engine is warm, checking is needed, and
there is no overflow tank, follow the next two
statements.
Wear safety glasses and gloves and put a rag over radiator cap.
Turn cap slightly and let pressure escape slowly before completely
removing cap.
MOVING PARTS can cause injury.
Keep away from fans, belts, and rotors.
Keep all doors, panels, covers, and guards
closed and securely in place.
Stop engine before installing or connecting unit.
Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary.
To prevent accidental starting during servicing, disconnect
negative (–) battery cable from battery.
Keep hands, hair, loose clothing, and tools away from moving
parts.
Reinstall panels or guards and close doors when servicing is
finished and before starting engine.
Before working on generator, remove spark plugs or injectors to
keep engine from kicking back or starting.
Block flywheel so that it will not turn while working on generator
components.
BATTERY ACID can BURN SKIN and
EYES.
Do not tip battery.
Replace damaged battery.
Flush eyes and skin immediately with water.
ENGINE EXHAUST GASES can kill.
Use equipment outside in open, well-ventilated
areas.
If used in a closed area, vent engine exhaust
outside and away from any building air intakes.
ENGINE HEAT can cause fire.
BATTERY EXPLOSION can BLIND.
Always wear a face shield, rubber gloves, and
protective clothing when working on a battery.
Stop engine before disconnecting or connecting battery cables or servicing battery.
Do not allow tools to cause sparks when working on a battery.
Do not use welder to charge batteries or jump start vehicles.
Observe correct polarity (+ and –) on batteries.
Disconnect negative (–) cable first and connect it last.
Do not locate unit on, over, or near combustible
surfaces or flammables.
Keep exhaust and exhaust pipes way from
flammables.
EXHAUST SPARKS can cause fire.
Do not let engine exhaust sparks cause fire.
Use approved engine exhaust spark arrestor in
required areas – see applicable codes.
1-4. Additional Symbols For Installation, Operation, And Maintenance
FALLING UNIT can cause injury.
Use lifting eye to lift unit only, NOT running
gear, gas cylinders, trailer, or any other
accessories.
Use equipment of adequate capacity to lift and
support unit.
If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
FLYING SPARKS can cause injury.
Wear a face shield to protect eyes and face.
Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
Sparks can cause fires — keep flammables away.
OVERUSE can cause OVERHEATING.
Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
starting to weld again.
Do not block or filter airflow to unit.
STATIC (ESD) can damage PC boards.
Put on grounded wrist strap BEFORE handling
boards or parts.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
TILTING OF TRAILER can cause injury.
Use tongue jack or blocks to support weight.
Properly install welding generator onto trailer
according to instructions supplied with trailer.
OVERHEATING can damage motors.
Turn off or unplug equipment before starting or
stopping engine.
Do not let low voltage and frequency caused by
low engine speed damage electric motors.
Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle
where applicable.
READ INSTRUCTIONS.
Use only genuine MILLER replacement parts.
Perform engine maintenance and service
according to this manual and the engine
manual.
OM-4403 Page 3
H.F. RADIATION can cause interference.
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
ARC WELDING can cause interference.
Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-5. Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face
Protection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
1-6. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
1. Keep cables close together by twisting or taping them.
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
2. Arrange cables to one side and away from the operator.
OM-4403 Page 4
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from
operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT
UTILISATION
rom _nd_fre 11/98
1-1. Signification des symboles
Signifie Mise en garde ! Soyez vigilant ! Cette procédure
présente des risques de danger ! Ceux-ci sont identifiés
par des symboles adjacents aux directives.
Identifie un message de sécurité particulier.
Signifie NOTA ; n’est pas relatif à la sécurité.
Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des
risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN
MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous aux symboles
et aux directives ci-dessous afin de connaître les mesures à prendre pour
éviter tout danger.
1-2. Dangers relatifs au soudage à l’arc
Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne font
que résumer l’information contenue dans les normes de sécurité énumérées à la section 1-5. Veuillez lire et respecter toutes
ces normes de sécurité.
L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées.
Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrement les enfants.
Une tension DC importante subsiste à l’intérieur
des onduleurs après avoir coupé l’alimentation.
Couper l’alimentation du poste et décharger les condensateurs d’entrée
comme indiqué dans la Section Maintenance avant de toucher des composants.
LES RAYONS DE L’ARC peuvent provoquer des brûlures dans les yeux et
sur la peau.
UN CHOC ÉLECTRIQUE peut tuer.
Un simple contact avec des pièces électriques peut
provoquer une électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension dès
que l’appareil est sur ON. Le circuit d’entrée et les circuits
internes de l’appareil sont également sous tension à ce
moment-là. En soudage semi-automatique ou automatique, le fil, le dévidoir, le
logement des galets d’entraînement et les pièces métalliques en contact avec
le fil de soudage sont sous tension. Des matériels mal installés ou mal mis à la
terre présentent un danger.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-champ
les pièces endommagées. Entretenir l’appareil conformément à ce
manuel.
Porter un harnais de sécurité quand on travaille en hauteur.
Maintenir solidement en place tous les panneaux et capots.
Fixer le câble de retour de façon à obtenir un bon contact métal-métal avec
la pièce à souder ou la table de travail, le plus près possible de la soudure.
Isoler la pince de masse quand pas mis à la pièce pour éviter le contact
avec tout objet métallique.
Le rayonnement de l’arc du procédé de soudage génère
des rayons visibles et invisibles intenses (ultraviolets et
infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la
peau. Des étincelles sont projetées pendant le soudage.
Ne jamais toucher les pièces électriques sous tension.
Porter des gants et des vêtements de protection secs ne comportant pas
de trous.
S’isoler de la pièce et de la terre au moyen de tapis ou d’autres moyens isolants suffisamment grands pour empêcher le contact physique éventuel
avec la pièce ou la terre.
Ne pas se servir de source électrique àcourant électrique dans les zones
humides, dans les endroits confinés ou là où on risque de tomber.
Se servir d’une source électrique àcourant électrique UNIQUEMENT si le
procédé de soudage le demande.
Si l’utilisation d’une source électrique àcourant électrique s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé.
Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation,
à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation
selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).
Installer et mettre à la terre correctement cet appareil conformément à son
manuel d’utilisation et aux codes nationaux, provinciaux et municipaux.
Toujours vérifier la terre du cordon d’alimentation – Vérifier et s’assurer que
le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre
du sectionneur ou que la fiche du cordon est raccordée à une prise
correctement mise à la terre.
En effectuant les raccordements d’entrée fixer d’abord le conducteur de
mise à la terre approprié et contre-vérifier les connexions.
Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas endommagé ou dénudé – remplacer le cordon immédiatement s’il est
endommagé – un câble dénudé peut provoquer une électrocution.
Mettre l’appareil hors tension quand on ne l’utilise pas.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou
mal épissés.
Ne pas enrouler les câbles autour du corps.
Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct – ne pas utiliser le connecteur de pièce ou le câble de retour.
Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou
une électrode provenant d’une autre machine.
Porter un casque de soudage muni d’un écran de filtre approprié pour protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir
ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
Porter des protections approuvés pour les oreilles si le niveau sondre est
trop élevé.
Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair et de
l’éblouissement; demander aux autres personnes de ne pas regarder l’arc.
Porter des vêtements de protection constitué dans une matière durable, résistant au feu (laine ou cuir) et une protection des pieds.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz. Leur inhalation
peut être dangereux pour votre santé.
Eloigner votre tête des fumées. Ne pas respirer les fumées.
À l’interieur, ventiler la zone et/ou utiliser un échappement au niveau de
l’arc pour l’évacuation des fumées et des gaz de soudage.
Si la ventilation est insuffisante, utiliser un respirateur à alimentation d’air
homologué.
Lire les spécifications de sécurité des matériaux (MSDSs) et les instructions du fabricant concernant les métaux, les consommables, les
revêtements, les nettoyants et les dégraisseurs.
Travailler dans un espace fermé seulement s’il est bien ventilé ou en portant un respirateur à alimentation d’air. Demander toujours à un surveillant
dûment formé de se tenir à proximité. Des fumées et des gaz de soudage
peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des
blessures ou des accidents mortels. S’assurer que l’air de respiration ne
présente aucun danger.
Ne pas souder dans des endroits situés à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de
l’arc peuvent réagir en présence de vapeurs et former des gaz hautement
toxiques et irritants.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été
enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et si nécessaire, en portant un respirateur à alimentation d’air. Les revêtements et
tous les métaux renfermant ces éléments peuvent dégager des fumées
toxiques en cas de soudage.
OM-4403 Page 5
LE SOUDAGE peut provoquer un incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels que
des réservoirs, tambours ou des conduites peut provoquer
leur éclatement. Des étincelles peuvent être projetées de
l’arc de soudure. La projection d’étincelles, des pièces chaudes et des
équipements chauds peut provoquer des incendies et des brûlures. Le contact
accidentel de l’électrode avec des objets métalliques peut provoquer des
étincelles, une explosion, un surchauffement ou un incendie. Avant de
commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de
danger.
Le soudage, l’écaillement, le passage de la pièce
à la brosse en fil de fer, et le meulage génèrent
des étincelles et des particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier.
Prévoir une période de refroidissement avant d’effectuer des travaux d’entretien.
Porter des gants et des vêtements de protection pour
travailler sur un moteur chaud.
Ne pas toucher à mains nues les parties chaudes du moteur ni les pièces
récemment soudées.
LE BRUIT peut affecter l’ouïe.
Le bruit des processus et des équipements peut affecter
l’ouïe.
Fermer l’alimentation du gaz protecteur en cas de
non utilisation.
Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué.
Porter des protections approuvés pour les oreilles si
le niveau sondre est trop élevé.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
Porteurs de stimulateur cardiaque, restez à distance.
Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur médecin avant de s’approcher
des opérations de soudage à l’arc, de gougeage ou
de soudage par points.
Si des BOUTEILLES sont endommagées, elles pourront exploser.
Des bouteilles de gaz protecteur contiennent du gaz sous
haute pression. Si une bouteille est endommagée, elle peut
exploser. Du fait que les bouteilles de gaz font normalement partie du procédé de soudage, les manipuler avec
précaution.
Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des
chocs mécaniques, du laitier, des flammes ouvertes, des étincelles et des
arcs.
Placer les bouteilles debout en les fixant dans un support stationnaire ou
dans un porte-bouteilles pour les empêcher de tomber ou de se renverser.
Tenir les bouteilles éloignées des circuits de soudage ou autres circuits
électriques.
Ne jamais placer une torche de soudage sur une bouteille à gaz.
Une électrode de soudage ne doit jamais entrer en contact avec une bouteille.
Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou
même la mort.
Se protéger et d’autres personnes de la projection d’étincelles et de métal
chaud.
Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des
substances inflammables.
Déplacer toutes les substances inflammables à une distance de 10,7 m de
l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec
des protections homologués.
Des étincelles et des matériaux chauds du soudage peuvent facilement
passer dans d’autres zones en traversant de petites fissures et des
ouvertures.
Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.
Le soudage effectué sur un plafond, plancher, paroi ou séparation peut déclencher un incendie de l’autre côté.
Ne pas effectuer le soudage sur des conteneurs fermés tels que des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été préparés
correctement conformément à AWS F4.1 (voir les normes de sécurité).
Brancher le câble sur la pièce le plus près possible de la zone de soudage
pour éviter le transport du courant sur une longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution et
d’incendie.
Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
En cas de non utilisation, enlever la baguette d’électrode du porte-électrode ou couper le fil à la pointe de contact.
Porter des vêtements de protection dépourvus d’huile tels que des gants
en cuir, une chemise en matériau lourd, des pantalons sans revers, des
chaussures hautes et un couvre chef.
Avant de souder, retirer toute substance combustible de vos poches telles
qu’un allumeur au butane ou des allumettes.
DES PARTICULES VOLANTES
peuvent blesser les yeux.
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
Ne jamais souder une bouteille pressurisée – risque d’explosion.
Utiliser seulement des bouteilles de gaz protecteur, régulateurs, tuyaux et
raccords convenables pour cette application spécifique; les maintenir ainsi
que les éléments associés en bon état.
Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la bouteille.
Maintenir le chapeau de protection sur la soupape, sauf en cas d’utilisation
ou de branchement de la bouteille.
Lire et suivre les instructions concernant les bouteilles de gaz comprimé,
les équipements associés et les publication P-1 CGA énumérées dans les
normes de sécurité.
1-3. Dangers existant en relation avec le moteur
LE CARBURANT MOTEUR peut provoquer un incendie ou une explosion.
LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT CHAUD peuvent
provoquer des brûlures.
Arrêter le moteur avant de vérifier le niveau de carburant ou de faire le plein.
Ne pas faire le plein en fumant ou proche d’une source d’étincelles ou d’une flamme nue.
Ne pas faire le plein de carburant à ras bord; prévoir de l’espace pour son
expansion.
Faire attention de ne pas renverser de carburant. Nettoyer tout carburant renversé avant de faire démarrer le moteur.
Jeter les chiffons dans un récipient ignifuge.
OM-4403 Page 6
Il est préférable de vérifier le liquide de
refroidissement une fois le moteur refroidi pour éviter
de se brûler.
Toujours vérifier le niveau de liquide de refroidissement dans le vase
d’expansion (si présent), et non dans le radiateur (sauf si précisé autrement dans la section maintenance du manuel du moteur).
Si le moteur est chaud et que le liquide doit être vérifié, opérer comme
suivant :
Mettre des lunettes de sécurité et des gants, placer un torchon sur le
bouchon du radiateur.
Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant
d’enlever le bouchon.
DES ORGANES MOBILES peuvent
provoquer des blessures.
L’ACIDE DE LA BATTERIE peut provoquer des brûlures dans les YEUX et
sur la PEAU.
Ne pas approcher les mains des ventilateurs, courroies et autres pièces en mouvement.
Maintenir fermés et fixement en place les portes,
panneaux, recouvrements et dispositifs de
protection.
Arrêter le moteur avant d’installer ou brancher l’appareil.
Demander seulement à un personnel qualifié d’enlever les dispositifs de
sécurité ou les recouvrements pour effectuer, s’il y a lieu, des travaux
d’entretien et de dépannage.
Pour empêcher tout démarrage accidentel pendant les travaux d’entretien, débrancher le câble négatif (–) de batterie de la borne.
Ne pas approcher les mains, cheveux, vêtements lâches et outils des organes mobiles.
Remettre en place les panneaux ou les dipositifs de protection et fermer
les portes à la fin des travaux d’entretien et avant de faire démarrer le
moteur.
Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la mise
en route accidentelle du moteur.
Bloquer le volant moteur pour éviter sa rotation lors d’une intervention
sur le générateur.
L’EXPLOSION DE LA BATTERIE peut
RENDRE AVEUGLE.
Toujours porter une protection faciale, des gants en
caoutchouc et vêtements de protection lors d’une intervention sur la batterie.
Arrêter le moteur avant de débrancher ou de brancher les câbles de
batterie.
Eviter de provoquer des étincelles avec les outils en travaillant sur la
batterie.
Ne pas utiliser le poste de soudage pour charger les batteries ou des véhicules de démarrage rapide.
Observer la polarité correcte (+ et –) sur les batteries.
Débrancher le câble négatif (–) en premier lieu. Le rebrancher en dernier
lieu.
Ne pas renverser la batterie.
Remplacer une batterie endommagée.
Rincer immédiatement les yeux et la peau à l’eau.
LES GAZ D’ÈCHAPPEMENT DU
MOTEUR peuvent provoquer des
accidents mortels.
Utiliser l’équipement à l’extérieur dans des zones ouvertes et bien ventilées.
En cas d’utilisation dans un endroit fermé évacuer les gaz d’échappement du moteur vers l’extérieur à distance des entrées d’air dans les bâtiments.
LA CHALEUR DU MOTEUR peut provoquer un incendie.
Ne pas placer l’appareil sur, au-dessus ou à proximité
de surfaces inflammables.
Tenir à distance les produits inflammables de
l’échappement.
LES ÉTINCELLES À L’ÉCHAPPEMENT
peuvent provoquer un incendie.
Empêcher les étincelles d’échappement du moteur
de provoquer un incendie.
Utiliser uniquement un pare-étincelles approuvé –
voir codes en vigueur.
1-4. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance
LA CHUTE DE L’APPAREIL peut
blesser.
Utiliser l’anneau de levage uniquement pour soulever
l’appareil lui-même ; sans chariot, de bouteilles de
gaz, remorque, ou autres accessoires.
Utiliser un équipement de levage de capacité suffisante pour lever l’appareil.
En utilisant des fourches de levage pour déplacer l’unité, s’assurer
que les fourches sont suffisamment longues pour dépasser du côté
opposé de l’appareil.
LES ÉTINCELLES VOLANTES risquent de provoquer des blessures.
Porter un écran facial pour protéger le visage et les
yeux.
Affuterr l’électrode au tungstène uniquement à la meuleuse dotée de protecteurs. Cette manoeuvre est à exécuter dans un endroit sûr lorsque
l’on porte l’équipement homologué de protection du visage, des mains et
du corps.
Les étincelles risquent de causer un incendie – éloigner toute substance
inflammable.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
LES
CHARGES
ÉLECTROSTATIQUES
peuvent
endommager les circuits imprimés.
Établir la connexion avec la barrette de terre avant de
manipuler des cartes ou des pièces.
Utiliser des pochettes et des boîtes antistatiques
pour stocker, déplacer ou expédier des cartes de
circuits imprimes.
UNE REMORQUE QUI BASCULE peut
entraîner des blessures.
LE SURCHAUFFEMENT peut endommager le moteur électrique.
Laisser l’équipement refroidir ; respecter le facteur de
marche nominal.
Réduire le courant ou le facteur de marche avant de
poursuivre le soudage.
Ne pas obstruer les passages d’air du poste.
Utiliser les supports de la remorque ou des blocs
pour soutenir le poids.
Installer convenablement le poste sur la remorque
comme indiqué dans le manuel s’y rapportant.
Arrêter ou déconnecter l’équipement avant de démarrer ou d’arrêter le moteur.
Ne pas laisser tourner le moteur trop lentement sous
risque d’endommager le moteur électrique à cause
d’une tension et d’une fréquence trop faibles.
Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz, s’il y a
lieu.
LIRE LES INSTRUCTIONS.
Utiliser seulement les pièces de rechange d’origine.
Effecteur la maintenance et la mise en service
d’après le manuel et celui du moteur.
OM-4403 Page 7
LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer
des interférences.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipements
de radio–navigation et de communication, les
services de sécurité et les ordinateurs.
Demander seulement à des personnes qualifiées familiarisées avec des
équipements électroniques de faire fonctionner l’installation.
L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement l’appareil.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
Maintenir soigneusement fermés les portes et les panneaux des sources
de haute fréquence, maintenir les éclateurs à une distance correcte et
utiliser une terre et et un blindage pour réduire les interférences
éventuelles.
L’énergie électromagnétique risque de provoquer
des interférences pour l’équipement électronique
sensible tel que les ordinateurs et l’équipement commandé par ordinateur tel que les robots.
Veiller à ce que tout l’équipement de la zone de soudage soit compatible
électromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de soudage aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que
le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.
1-5. Principales normes de sécurité
Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126
Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme AWS
F4.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL
33126
National Electrical Code, NFPA Standard 70, de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de la Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Règles de sécurité en soudage, coupage et procédés connexes, norme
CSA W117.2, de l’Association canadienne de normalisation, vente de
normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face Protection, norme ANSI Z87.1, de l’American National Standards Institute,
1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, norme NFPA 51B, de la National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
1-6. Information sur les champs électromagnétiques
Données sur le soudage électrique et sur les effets, pour l’organisme,
des champs magnétiques basse fréquence
Afin de réduire les champs électromagnétiques dans l’environnement
de travail, respecter les consignes suivantes :
1
Le courant de soudage, pendant son passage dans les câbles de soudage, causera des champs électromagnétiques. Il y a eu et il y a encore
un certain souci à propos de tels champs. Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de
recherche de 17 ans, un comité spécial ruban bleu du National Research Council a conclu: “L’accumulation de preuves, suivant le
jugement du comité, n’a pas démontré que l’exposition aux champs
magnétiques et champs électriques à haute fréquence représente un
risque à la santé humaine”. Toutefois, des études sont toujours en cours
et les preuves continuent à être examinées. En attendant que les conclusions finales de la recherche soient établies, il vous serait
souhaitable de réduire votre exposition aux champs électromagnétiques pendant le soudage ou le coupage.
OM-4403 Page 8
2
3
4
5
Garder les câbles ensembles en les torsadant ou en les
attachant avec du ruban adhésif.
Mettre tous les câbles du côté opposé de l’opérateur.
Ne pas courber pas et ne pas entourer pas les câbles autour de
votre corps.
Garder le poste de soudage et les câbles le plus loin possible de
vous.
Relier la pince de masse le plus près possible de la zone de
soudure.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur docteur. Si vous êtes déclaré apte par votre docteur, il est
alors recommandé de respecter les consignes ci–dessus.
SECTION 2 – DEFINITIONS
2-1. Symbol Definitions
h
Stop Engine
Fast
(Run, Weld/Power)
Start Engine
Read Operator’s
Manual
Engine Oil
Fuel
Battery (Engine)
Engine
Engine Choke
Check Valve
Clearance
Do not switch while
welding
Work Connection
Positive
Negative
Alternating Current
(AC)
Output
Welding Arc
(Electrode)
MIG (GMAW),
Wire
Stick (SMAW)
TIG (GTAW)
Seconds
Time
Protective Earth
(Ground)
Hours
s
Circuit Breaker
Fast/Slow
(Run/Idle)
A
Amperes
Slow (Idle)
V
Volts
Temperature
SECTION 3 – SPECIFICATIONS
3-1. Weld, Power, and Engine Specifications
Note
This unit uses either an Onan Performer OHV or a Kohler CH-20 engine.
Differences between models are noted throughout this manual.
Welding
Mode
Weld Output
Range
Rated
Welding
Output
Maximum
Open Circuit
Voltage
CC/AC
40 – 250 A
250 A, 25 V,
100% Duty
Cycle
80
40 – 250 A
250 A, 25 V,
100% Duty
Cycle
Generator Power Rating
Fuel
Capacity
Peak: 10 kVA/kW
CC/DC
CV/DC
17 – 28 V
275 A, 25 V,
60% Duty
Cycle
250 A, 28 V,
100% Duty
Cycle
72
Continuous: 9.5 kVA/kW,
Single-Phase,
84/42 A, 120/240 V AC,
60 Hz
(while not welding)
Engine
Onan Performer OHV
Air-Cooled, Two-Cylinder,
Four-Cycle, 20.5 HP
Gasoline Engine
10 gal
(38 L) Tank
or
Kohler CH-20
Air-Cooled, Two-Cylinder,
Four-Cycle, 20 HP
Gasoline Engine
41
OM-4403 Page 9
3-2. Dimensions, Weights, and Operating Angles
Dimensions
Height
33-1/2 in (851 mm)
Width
18-3/4 in (476 mm)
Depth
46 in (1164 mm)
A
18 in (457 mm)
B
16-1/2 in (419 mm)
C
3/4 in (19 mm)
A
B
C
Do not exceed tilt angles or engine could
be damaged or unit could tip.
D
G
4 Holes
Do not move or operate unit where it could
tip.
E
F
D
3-1/8 in (79 mm)
E
32-3/4 in (832 mm)
F
45-1/2 in (1156 mm)
G
13/32 in (10 mm) Dia.
25°
25°
25°
25°
Weight
Onan-Powered Unit: 525 lb (238 kg)
Engine End
800 426
Kohler-Powered Unit: 519 lb (235 kg)
3-3. Generator Power Curve
The generator power curve shows
the generator power in amperes
available at the receptacles.
200 294
OM-4403 Page 10
3-4. Fuel Consumption (Onan-Powered Units)
206 148
3-5. Fuel Consumption (Kohler-Powered Units)
200 299
OM-4403 Page 11
3-6. Volt-Ampere Curves
A. For CC/AC Mode
The volt-ampere curve shows the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
other settings fall between the
curves shown.
B. For CC/DC Mode
C. For CV/DC Mode
200 296 / 200 297 / 200 298
OM-4403 Page 12
3-7. Duty Cycle
Duty cycle is the percentage of 10
minutes that unit can weld at rated
load without overheating.
Exceeding duty cycle can
damage unit and void
warranty.
Continuous Welding
100% Duty Cycle at 250 Amperes
200 293
SECTION 4 – INSTALLATION
4-1. Installing Welding Generator
Movement
Do not weld on base. Welding on base can cause fuel
tank fire or explosion. Bolt
unit down using holes provided in base.
Airflow Clearance
Do not lift unit from end.
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
OR
Always securely fasten
welding generator onto
transport vehicle or trailer
and comply with all DOT and
other applicable codes.
Always ground generator
frame to vehicle frame to prevent electric shock and static
electricity hazards.
18 in
(460 mm)
18 in
(460 mm)
1
2
3
Grounding
Location
4
3
1
GND/PE
Use #10 AWG or larger insulated
copper wire.
4
If unit does not have GFCI receptacles,
use
GFCIprotected extension cord.
OR
OR
2
Electrically bond generator frame to vehicle frame
by metal-to-metal contact.
Generator Base
Metal Vehicle Frame
Equipment Grounding
Terminal
Grounding Cable
2
install1 10/00 – Ref. 800 652 / Ref. 800 477-A / 158 936-A / S-0854
OM-4403 Page 13
4-2. Engine Prestart Checks (Onan-Powered Units)
Check all fluids daily. Engine must
be cold and on a level surface. Unit
is shipped with 10W30 engine oil.
Full
Follow run-in procedure in engine manual.
This unit has a low oil pressure
Gasoline
shutdown switch. However,
some conditions may cause
engine damage before the engine shuts down. Check oil level often and do not use the oil
pressure shutdown system to
monitor oil level.
Fuel
Add fresh fuel before starting
engine the first time (see maintenance label for specifications). Always leave filler neck empty to allow room for expansion. Check fuel
level on a cold engine before use
each day.
Oil
After fueling, check oil with unit on
level surface. If oil is not up to full
mark on dipstick, add oil (see maintenance label).
To
improve
starting:
cold
weather
Keep battery in good condition.
Store battery in warm area off
concrete surface.
Oil Check
Oil Fill
Use correct grade oil for cold
weather.
Full
800 392-J
OM-4403 Page 14
4-3. Engine Prestart Checks (Kohler-Powered Units)
Check all fluids daily. Engine must
be cold and on a level surface. Unit
is shipped with 10W30 engine oil.
Full
Follow run-in procedure in engine manual.
This unit has a low oil pressure
Gasoline
shutdown switch. However,
some conditions may cause
engine damage before the engine shuts down. Check oil level often and do not use the oil
pressure shutdown system to
monitor oil level.
Fuel
Add fresh fuel before starting
engine the first time (see maintenance label for specifications). Always leave filler neck empty to allow room for expansion. Check fuel
level on a cold engine before use
each day.
Oil
After fueling, check oil with unit on
level surface. If oil is not up to full
mark on dipstick, add oil (see maintenance label).
To
improve
starting:
cold
weather
Keep battery in good condition.
Store battery in warm area off
concrete surface.
Use correct grade oil for cold
weather.
Full
Ref. 801 188-D / Ref. 801 221-A
OM-4403 Page 15
4-4. Activating The Dry Charge Battery (If Applicable)
Remove battery from unit.
1
5
4
1
2
3
4
5
Eye Protection – Safety
Glasses Or Face Shield
Rubber Gloves
Vent Caps
Sulfuric Acid Electrolyte
(1.265 Specific Gravity)
Well
Fill each cell with electrolyte to
bottom of well (maximum).
3
Do not overfill battery cells.
Wait ten minutes and check electrolyte level. If necessary, add electrolyte to raise to proper level. Reinstall vent caps.
6
Battery Charger
Read and follow all instructions supplied with battery
charger.
2
Charge battery for 12 minutes at 30
amperes or 30 minutes at 5 amperes. Disconnect charging cables
and install battery.
When electrolyte
is low, add
only distilled water to cells to
maintain proper level.
6
5 A For 30 Minutes
Tools Needed:
OR
+
–
rubbergloves
30 A For 12 Minutes
glasses
drybatt1 1/98 – S-0886
OM-4403 Page 16
4-5. Connecting the Battery
Connect negative (–)
cable last.
–
+
Tools Needed:
3/8, 1/2 in
Ref. 800 394-C / Ref. 200 017 / Ref. S-0756-D
4-6. Installing Exhaust Pipe
Engine backfire can cause severe burns or other injuries. Do
not point exhaust pipe toward
control panel. Keep away from
exhaust outlet.
Point exhaust pipe in desired di-
rection but always away from front
panel and direction of travel.
Be sure to tighten exhaust clamp
nuts.
Tools Needed:
1/2 in
801 681 / Ref. 200 017
OM-4403 Page 17
4-7. Connecting to Weld Output Terminals
See Section 5 for examples of
1
2
typical weld connections and
control settings.
Work Weld Output Terminal
Electrode Weld Output Terminal
Connect work cable to Work terminal.
Connect electrode holder cable or
electrode weld cable to Electrode terminal for Stick and MIG welding.
Connect torch cable to Electrode terminal for TIG welding.
1
2
Use Process Selector switch to
select type of weld output (see
Section 5-1).
See Sections 5-2 thru 5-4 for typical process connections and
control settings.
Tools Needed:
3/4 in
800 396-B / Ref. 200 017
4-8. Selecting Weld Cable Sizes*
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
100 ft (30 m) or Less
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
400 ft
(105 m) (120 m)
Weld Output
Terminals
Turn off power before
connecting to weld output terminals.
Welding
Amperes
10 – 60%
Duty
Cycle
60 – 100%
Duty
Cycle
100
4 (20)
4 (20)
4 (20)
3 (30)
2 (35)
1 (50)
1/0 (60)
1/0 (60)
150
3 (30)
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
200
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
4/0 (120)
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 2/0
(2x70)
300
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
350
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
400
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
2 ea. 4/0
(2x120)
500
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
3 ea. 3/0
(3x95)
Do not use worn, damaged, undersized, or
poorly spliced cables.
10 – 100% Duty Cycle
* This
chart is a general guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), 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 representative at 920-735-4505.
OM-4403 Page 18
S-0007-E
SECTION 5 – OPERATING THE WELDING GENERATOR
5-1. Front Panel Controls
5
6
1
2
3
Shown with optional
receptacle covers.
4
Ref. 200 017
1 Engine Control Switch
Use switch to start engine, select speed, and
stop engine. In Run/Idle position, engine runs
at idle speed at no load, and weld/power speed
under load. In Run position, engine runs at
weld/power speed.
Place switch in Run position to operate
most MIG equipment.
2 Engine Choke Control
Use control to change engine air-fuel mix.
To Start: pull out choke and turn Engine Control switch to Start position. Release switch
and slowly push choke in when engine starts.
If the engine does not start, let engine
come to a complete stop before attempting restart.
To Stop: turn Engine Control switch to Off
position.
3
Engine Hour Meter
4
Weld Process Selector Switch
Do not switch under load.
Use switch to select type of weld output.
Use a positive (+) position for Direct Current
Electrode Positive (DCEP) and a negative (–)
position for Direct Current Electrode Negative.
Use AC position for alternating current.
5
Coarse Range Switch
Do not switch under load.
Use switch to select weld amperage range
when Weld Process Selector switch is in Stick/
Tig position, or voltage range when switch is in
Wire position.
For best arc starts and when using weld
and generator power together, use a low
Coarse Range setting with the Fine control set at 7 or higher.
6 Fine Control
Use control to select weld amperage (Stick/
Tig) or voltage (Wire) within the range selected
by the Coarse Range switch. Control may be
adjusted while welding.
Set control at 10 for maximum generator power.
Weld output would be about 124 A DC based
on control settings shown (80% of 60 to 140
A). Settings shown are typical for welding with
a 7018 (1/8) electrode.
See Sections 5-2 thru 5-4 for typical process connections and control settings.
OM-4403 Page 19
5-2. Typical Stick Welding Connections And Control Settings
Stop engine.
This section provides general guide-
lines and may not suit all applications.
For best arc starts and best
results using weld and generator
power together, use a low
Coarse Range setting and the
Fine control set at 7 or higher.
The control panel shows the typical
1
2
settings for welding with a 7018 (1/8 in)
electrode. Consult the amperage
selection tables below if welding with
other electrodes.
Work Clamp
Electrode Holder
Connect Work cable to Work terminal and
Electrode holder cable to Electrode terminal on welding generator.
Be sure to use the correct size weld
cables (see Section 4-8).
For best performance,
set the Coarse
Range switch to the lowest range that
covers the desired weld amperage.
Use the Fine control to select the desired amperage within the range selected. When properly set, the Fine
control is normally set at 7 or higher.
Typical Settings For 7018 (1/8 in)
Electrode:
Typical Settings For 7018 (1/8 in) Electrode
1
>
2
>
>
Set Weld Process Selector switch to
+ Stick position.
Set Coarse Range switch to 60-140
(1/8”) position.
Set Fine control at 7 or higher for
best results.
6013
7014
7018
7024
Ni-Cl
308L
OM-4403 Page 20
USAGE
POSITION
AC
DC*
450
400
350
300
AMPERAGE
RANGE
250
200
150
100
50
ELECTRODE
3/32
1/8
5/32
3/16
7/32
1/4
1/16
5/64
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
3/32
1/8
5/32
PENETRATION
6010
&
6011
DIAMETER
ELECTRODE
Electrode Selection Tables
6010
EP
ALL
6011
EP
ALL
DEEP MIN. PREP, ROUGH
HIGH SPATTER
DEEP
6013
EP,EN
ALL
LOW
GENERAL
ALL
MED
ALL
LOW
SMOOTH, EASY,
FAST
LOW HYDROGEN,
STRONG
7014
EP,EN
7018
EP
7024
EP,EN
NI-CL
EP
FLAT
HORIZ
FILLET
ALL
308L
EP
ALL
LOW
SMOOTH, EASY,
FASTER
LOW
CAST IRON
LOW
STAINLESS
*EP = ELECTRODE POSITIVE (REVERSE POLARITY)
EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)
Tools Needed:
3/4 in
Ref. 800 395 / 200 017 / 087 985-A / Ref. S-0653
5-3. Typical MIG Welding Connections And Settings
A. Solid Wire Applications
Stop engine.
This section provides general guide-
lines and may not suit all applications.
Typical Control Settings For .035 (ER70S-3)
Solid Wire – Short Circuit Transfer
The control panel shows the typical
Note Coarse Range,
Fine Control, and
Weld Process switch
settings.
1
2
3
settings for welding with .035
(ER70S-3) solid wire. Use Argonbased shielding gas.
Work Clamp
Wire Feeder
MIG Gun
4
Gun Trigger Plug
5
Voltage Sensing Clamp
6
Gas Cylinder:
75/25 Argon-Based Gas for Short
Circuit Transfer
80% Argon (Or Higher) For Spray
Transfer
6
7
Gas Hose
Connect work cable to welding generator
Work terminal. Connect cable from wire
feeder to cable from welding generator
Electrode terminal.
7
Be sure to use the correct size weld
cables (see Section 4-8).
Loosen MIG gun securing knob. Insert
gun end through opening in feeder and
position as close as possible to drive rolls
without touching. Tighten knob.
See wire feeder manual for wire threading procedure.
Insert gun trigger plug (item 4) into
matching receptacle and tighten
threaded collar.
Connect gas hose from feeder to regulator on cylinder.
Typical Control Settings For Short
Circuit Transfer Using .035 (ER70S-3)
Solid Wire And 75/25 Argon-Based
Gas:
Quick connector
>
2
3
>
>
>
Set Weld Process Selector switch
to Wire + (DCEP) position.
Set Coarse Range switch to Wire/
Low Range (17-22 volts) position.
Set Fine Control to obtain minimum
spatter.
Set wire feed speed between
150-300 ipm.
Typical Control Settings For Spray
Transfer Using .035 (ER70S-3) Solid
Wire And 80% Or Higher ArgonBased Gas:
5
>
4
>
Work
Tools Needed:
>
1
3/4 in
>
802 766 / 200 017
Set Weld Process Selector switch
to Wire + position.
Set Coarse Range switch to Wire/
High Range (20-28 volts) position.
Set wire feed speed between
320-500 ipm.
Set Fine control to 3 and increase
for longer arc length.
OM-4403 Page 21
B. Self-Shielded Flux Core Wire Applications
Stop engine.
This
Typical Control Settings For .045 (71T-11) Self-Shielded Flux Core Wire
Note Coarse Range,
Fine Control, and
Weld Process switch
settings.
section provides general
guidelines and may not suit all
applications.
The control panel shows the typi1
2
3
cal settings for welding with .045
(71T-11) self-shielded flux core
wire.
Work Clamp
Wire Feeder
MIG Gun
4
Gun Trigger Plug
5
Voltage Sensing Clamp
Connect work cable to welding generator Work terminal. Connect cable
from wire feeder to cable from welding generator Electrode terminal.
Be sure to use the correct size
weld cables (see Section 4-8).
Loosen MIG gun securing knob. Insert gun end through opening in feeder and position as close as possible
to drive rolls without touching. Tighten knob.
See wire feeder manual for wire
threading procedure.
Insert gun trigger plug (item 4) into
matching receptacle and tighten
threaded collar.
Typical Control Settings Using
.045 (71T-11) Self-Shielded Flux
Core Wire :
>
>
>
Quick connector
>
2
3
>
Set Weld Process Selector
switch to Wire – position
(DCEN).
Set Coarse Range switch to
Wire/Low Range (17-22 volts)
position.
Set Fine Control near minimum
setting.
Set wire feed speed between
125-200 ipm.
Do a test weld. To increase arc
length, increase Fine Control
setting. To shorten arc length,
reduce fine control setting or increase wire feed speed.
5
4
Work
1
Tools Needed:
3/4 in
OM-4403 Page 22
802 766 / 200 017
5-4. Typical MIG Connections And Settings Using Weld Control And Spoolgun
Typical Settings For 4043 (.035)
Aluminum On 1/8 in Material:
Tools Needed:
3/4 in
Note Coarse Range and Weld
Process switch settings.
10
9
8
Connect to unused
contactor terminal.
Work
12
5
Plug and sensing lead not
used in this application.
6
Left Side View
2
1
3
11
4
This section
provides general guidelines and may not suit all applications.
1
2
Weld Control
Spoolgun
3
4
Optional Contactor (Recommended)
Reed Switch
5
6
7
Weld Cable (Customer-Supplied)
Weld Control Weld Terminal
Weld Power Cable From Spoolgun
8
9
Work Clamp
Gas Hose
10 Argon Cylinder
11 Trigger Control Cord
12 Input Power Cord
5
Be sure to use the correct size weld
cables (see Section 4-8).
Route weld cable from welding generator
Electrode terminal through reed switch to
unused contactor terminal. Connect weld
cable from spoolgun to weld control weld terminal (item 6).
Connect work cable to welding generator
Work terminal.
Insert trigger control plug (item 11) into weld
control receptacle. Tighten threaded collar.
Connect ac power cord (item 12) to 120 volt
ac receptacle on welding generator.
Connect gas hose from spoolgun to regulator on Argon bottle.
Reinstall weld control wrapper.
6
7
802 750 / 200 017
Typical Settings For 4043 (.035)
Aluminum On 1/8 in Material:
>
>
>
>
Set Weld Process Selector switch to
Wire + (DCEP) position.
Set Coarse Range switch to Wire/Low
(17-22 volts) position.
Set Fine Control to desired voltage
(arc length). Start with a low voltage
setting (about 4) to prevent burnback.
Set wire feed speed between 240-270
ipm. For 1/4 in. and thicker materials,
set Coarse Range switch to Wire/High
and Fine Control to 6. Increase/decrease Fine Control setting to increase/decrease arc length.
OM-4403 Page 23
SECTION 6 – OPERATING AUXILIARY EQUIPMENT
6-1. Standard Receptacles
If unit does not have GFCI receptacles, use GFCI-protected
extension cord.
Generator power decreases as
weld current increases.
3
2
1
4
5
6
1
Set Fine Control R1 at 10 for full
generator power.
240 V 50 A AC Receptacle RC1
RC1 supplies 60 Hz single-phase
power at weld/power speed. Maximum output is 10 kVA/kW.
2
120 V 20 A AC Duplex Receptacle RC2
3
120 V 20 A AC Duplex Receptacle RC3
RC2 and RC3 supply 60 Hz singlephase power at weld/power speed.
Maximum output from RC2 or RC3 is
2.4 kVA/kW.
4
Circuit Breakers CB1 and CB2
CB1 and CB2 protect RC1 from overload. If CB1 or CB2 opens, RC1 and
one of the 120 volt receptacles does
not work. 120 volts may still be present at RC1.
Power is still present at the 240
volt receptacle when only one
circuit breaker trips.
Unplug power cord before attempting to service accessories or tools.
5
Circuit Breaker CB3
6
Circuit Breaker CB4
CB3 protects RC2 and CB4 protects
RC3 from overload. If a circuit breaker opens, the receptacle does not
work.
Press
button to reset circuit
breaker. If breaker continues to
open,
contact
Factory
Authorized Service Agent.
Combined output of all receptacles
limited to 10 kVA/kW rating of the generator.
EXAMPLE: If 20 A is drawn from
each 120 V duplex receptacle, only
21 A is available at the 240V
receptacle:
2 x (120 V x 20 A) + (240 V x 21 A) =
10 kVA/kW
Ref. 200 017
OM-4403 Page 24
6-2. Optional Generator Power Receptacles
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Generator power
decreases as weld
current increases.
1
Set Fine Control R1 at 10 for full generator power.
Combined output of all receptacles limited to
10 kVA/kW rating of the generator.
CSA Receptacle Option
Receptacles supply 60 Hz single-phase
power at weld/power speed. Receptacles
and generator power output are the same as
on standard unit (see Section 6-1).
1
Circuit Breaker CB1
CB1 protects RC1 from overload. If CB1
opens, the receptacles do not work. Push
switch up to reset breaker. Circuit breaker
protection for remaining receptacles is the
same as on standard unit (see Section 6-1).
GFCI Receptacle Option
2
2
120 V 20 A AC GFCI Receptacles
GFCI-2 and GFCI-3
GFCI2 and GFCI3 supply 60 Hz singlephase power at weld/power speed. Maximum output from GFCI-2 or GFCI-3 is 2.4
kVA/kW. Circuit breaker protection is the
same as standard receptacles.
If a ground fault is detected, the GFCI Reset
button pops out and the circuit opens to disconnect the faulty equipment. Check for
damaged tools, cords, plugs, etc. connected to the receptacle. Press button to reset receptacle and resume operation.
5
Power is still present at the 240 volt
receptacle when only one circuit
breaker trips.
Unplug power cord before attempting to service accessories or tools.
At least once a month, run engine at
6
weld/power speed and press Test button to verify GFCI is working properly.
South African And Australian Receptacle Options
3
240 V 16 A AC South African Receptacles RC1, RC2, and RC3
4
240 V 15 A AC Australian Receptacles RC1, RC2, and RC3
3
Receptacles supply 60 Hz single-phase
power at weld/power speed. Maximum output from each receptacle is 3.6 kVA/kW.
5
5
Circuit Breakers CB1, CB2, CB3
CB1, CB2, and CB3 protect RC1, RC2, and
RC3 from overload. If a circuit breaker
opens, the receptacle does not work.
6
6
Circuit Breaker CB4
CB4 protects all the receptacles from overload. If CB4 opens, none of the receptacles
work.
Press button to reset circuit breaker. If
breaker continues to open, contact Factory Authorized Service Agent.
4
Ref. 205 903 / 200 017 / Ref. 172 782-B / Ref. 172 113-A
OM-4403 Page 25
6-3. Wiring Optional 240 Volt Plug
1
The plug can be wired for a 240 V,
2-wire load or a 120/240V, 3-wire
load. See circuit diagram.
3
4
1
7
Current Available in Amperes
240 V
Receptacle*
Each 120 V Duplex
Receptacle
42
37
32
27
22
0
5
10
15
20
Plug Wired for 120/240 V,
3-Wire Load
When wired for 120 V loads, each
duplex receptacle shares a load
with one half of 240 V receptacle.
120V
120V
5
240V
6
2
3
V x A = Watts
*One 240 V load or two 120 V loads.
4
2
Plug Wired for 240 V, 2-Wire
Load
3
Neutral (Silver) Terminal
4
Load 1 (Brass)Terminal
5
Load 2 (Brass) Terminal
6
Ground (Green) Terminal
7
Amperes Available Using
120/240 V Plug
240V
Tools Needed:
6
5
120 813-D
SECTION 7 – MAINTENANCE (ONAN-POWERED UNITS)
7-1. Routine Maintenance (Onan-Powered Units)
Note
Follow the storage procedure in the engine owner’s manual if the unit will not be used for an
extended period.
Stop engine before maintaining.
Recycle
engine
fluids.
See also Engine Manual and maintenance label.
*
Service engine more often if used in severe conditions.
To be done by Factory Authorized Service Agent.
8h
Check fluid levels.
See Section 4-2.
Wipe up spills.
20 h
Check and clean
spark arrestor screen.
See Section 4-2.
25 h
Service
air
cleaner wrapper
(foam element).
See Section 7-3.
Continued
OM-4403 Page 26
50 h
Clean and
tighten weld
terminals.
100 h
Change oil. See
Section 7-5 and
maintenance label.
Clean cooling system.
See Engine Manual.
Service
air
cleaner element.
See Section 7-3.
Clean
and
tighten battery
connections.
200 h
Replace fuel
filter.
See
Section 7-5.
Change oil filter. See
Section 7-5 and
maintenance label.
Check
spark
plugs.
Replace
unreadable
labels.
500 h
Service welding generator
brushes and slip rings. Service
more often in dirty conditions.*
Repair or
replace cracked
cables.
Check
valve
clearance.*
1000 h
Blow out or
vacuum inside.
During heavy
service, clean
monthly.
OR
OM-4403 Page 27
7-2. Maintenance Label (Onan-Powered Units)
OM-4403 Page 28
7-3. Servicing Air Cleaner (Onan-Powered Units)
Stop engine.
1
Do not run engine without air
cleaner or with dirty element.
1
2
Wrapper (Foam Element)
Wash wrapper with soap and water
solution. Allow wrapper to air dry
completely.
Spread 1 tablespoon SAE 30 oil
evenly into wrapper. Squeeze out
excess oil.
2
Element
Replace element if dirty, oily, or
damaged.
aircleaner5 1/97 – 803 070 / Ref. 200 017 / S-0759
7-4. Overload Protection (Onan-Powered Units)
Stop engine. Disconnect
negative (–) battery cable.
1
Fuse F1 (See Parts List)
F1 protects the weld excitation
winding from overload. If F1 opens,
weld output stops or is low.
1
2
2
Fuse F2 (See Parts List)
F2 protects the generator power
excitation winding from overload. If
F2 opens, generator power output
stops or is low.
3
Fuse F6 (See Parts List)
F6 protects the engine wiring system from overload. If F6 opens,
engine will not crank.
Replace any open fuses. Reinstall
cover before operating.
If a fuse opens, it usually indi-
cates a more serious problem
exists. Contact a Factory Authorized Service Agent.
Tools Needed:
3/8 in
3
802 921-B
OM-4403 Page 29
7-5. Changing Engine Oil, Oil Filter, and Fuel Filter (Onan-Powered Units)
Stop engine and let cool.
1
Oil Drain Valve
2
1/2 ID x 12 in Hose
3
Oil Filter
Change engine oil and filter according to engine owner’s manual.
Close valve and valve cap
before adding oil and
running engine.
Fill crankcase with new oil to full
mark on dipstick (see Section 7-2).
Oil Check
Oil Fill
4
Fuel Filter
5
Fuel Line
Replace line if cracked or worn.
Install new filter. Wipe up any spilled
fuel.
Start engine, and check for fuel
leaks.
Full
Stop engine, tighten connections as necessary, and wipe
up fuel.
4
5
3
2
1
Tools Needed:
802 921-A / S-0842
OM-4403 Page 30
7-6. Adjusting Engine Speed (Onan-Powered Units)
2200 ± 100 rpm
3700 ± 50 rpm
After tuning engine, check engine
speeds with a tachometer (see
table). If necessary, adjust speeds
as follows:
Start engine and run until warm.
Remove wrapper to access speed
adjustments.
Idle Speed Adjustment
Move Engine Control switch to
Run/Idle position.
1
1
3
Throttle Solenoid
2
Mounting Screws
3
Idle Speed Screw
Loosen mounting screws. Adjust
solenoid position so engine runs at
idle speed. If necessary, back out
idle speed screw so solenoid can
be moved to correct position. Tighten mounting screws. Be sure solenoid linkage works smoothly.
Turn idle speed screw for fine
adjustments.
Weld/Power Speed Adjustment
Move Engine Control switch to Run
position.
4
Jam Nut
5
Lock Nut
6
Weld/Power Speed
Adjustment Screw
Loosen jam nut and lock nut. Turn
adjustment screw until engine runs
at weld/power speed. Tighten jam
nut, and then tighten lock nut.
2
Stop engine.
Reinstall wrapper.
4
6
5
Tools Needed:
10 mm
8 mm
800 392-J / 802 457
OM-4403 Page 31
7-7. Servicing Optional Spark Arrestor (Onan-Powered Units)
Stop engine and let cool.
1
Spark Arrestor Screen
Clean and inspect screen. Replace
spark arrestor if screen wires are
broken or missing.
1
Tools Needed:
1/4 in
Ref. 801 682-A / Ref. 183 175–A
SECTION 8 – MAINTENANCE – (KOHLER-POWERED UNITS)
8-1. Routine Maintenance (Kohler-Powered Units)
Note
Follow the storage procedure in the engine owner’s manual if the unit will not be used for an
extended period.
Stop engine before maintaining.
Recycle
engine
fluids.
See also Engine Manual and maintenance label. Ser*
vice engine more often if used in severe conditions.
To be done by Factory Authorized Service Agent.
8h
Check fluid levels.
See Section 4-3.
Wipe up spills.
20 h
Check and clean optional
spark arrestor screen. See
Section 8-7.
25 h
Service
air
cleaner
wrapper (foam element).
See Section 8-3.
50 h
Clean and tighten weld
terminals.
OM-4403 Page 32
100 h
Change oil. See Section 8-4
and maintenance label.
Check air cleaner element.
See Section 8-3.
Clean cooling system. See
Engine Manual.
Clean and tighten battery
connections.
200 h
Change oil filter. See Section
8-4 and maintenance label.
Replace fuel
Section 8-4.
Check spark plugs.
filter.
See
Replace unreadable labels.
500 h
Service welding generator
brushes and slip rings. Service
more often in dirty conditions.*
Repair or replace cracked
cables.
1000 h
Blow out or vacuum inside.
During heavy service, clean
monthly.
OR
Notes
OM-4403 Page 33
8-2. Maintenance Label (Kohler-Powered Units)
8-3. Servicing Air Cleaner (Kohler-Powered Units)
Stop engine.
1
Do not run engine without air
cleaner or with dirty element.
1
2
Wrapper (Foam Element)
Wash wrapper with soap and water
solution. Allow wrapper to air dry
completely.
Spread 1 tablespoon SAE 30 oil
evenly into wrapper. Squeeze out
excess oil.
2
Element
Replace element if dirty, oily, or
damaged.
aircleaner4 1/97 – 802 822 / Ref. 200 017 / S-0759
OM-4403 Page 34
8-4. Changing Engine Oil, Oil Filter, and Fuel Filter (Kohler-Powered Units)
Stop engine and let cool.
1
Oil Drain Valve
2
1/2 ID x 12 in Hose
3
Oil Filter
Change engine oil and filter according to engine owner’s manual.
Close valve and valve cap
before adding oil and
running engine.
Full
Fill crankcase with new oil to full
mark on dipstick (see Section 8-2).
4
Fuel Filter
5
Fuel Line
Replace line if cracked or worn.
Install new filter. Wipe up any spilled
fuel.
Start engine, and check for fuel
leaks.
Stop engine, tighten connections as necessary, and wipe
up fuel.
4
5
3
2
1
Tools Needed:
Ref. 801 188-D / Ref. 200 017 / 800 395 / S-0842
OM-4403 Page 35
8-5. Adjusting Engine Speed (Kohler-Powered Units)
After tuning engine, check engine
speeds with a tachometer (see
table). If necessary, adjust speeds
as follows:
2200 ± 50 rpm
3700 ± 50 rpm
Start engine and run until warm.
Turn Fine Control to 10.
Remove top cover to access speed
adjustments.
Idle Speed Adjustment
Move Engine Control switch to
Run/Idle position.
1
1
5
2
4
Throttle Solenoid
2
Mounting Screws
3
Idle Speed Screw
Loosen mounting screws. Adjust
solenoid position so engine runs at
idle speed. If necessary, back out
idle speed screw so solenoid can
be moved to correct position. Tighten mounting screws. Be sure solenoid linkage works smoothly.
Turn idle speed screw for fine adjustments.
Weld/Power Speed Adjustment
Move Engine Control switch to Run
position.
4
Weld/Power Speed
Adjustment Nut
5
Lock Nut
Loosen lock nut. Turn adjustment
nut until engine runs at weld/power
speed. Tighten lock nut.
3
Reinstall top cover.
Stop engine.
Top View
Tools Needed:
1/4, 3/8 in
OM-4403 Page 36
Ref. 801 188-D / 801 209-A
8-6. Overload Protection (Kohler-Powered Units)
Stop engine. Disconnect
negative (–) battery cable.
1
Fuse F1 (See Parts List)
F1 protects the weld excitation
winding from overload. If F1 opens,
weld output stops or is low.
1
2
2
Fuse F2 (See Parts List)
F2 protects the generator power
excitation winding from overload. If
F2 opens, generator power output
stops or is low.
3
Fuse F6 (See Parts List)
F6 protects the engine wiring system from overload. If F6 opens,
engine will not crank.
Replace any open fuses. Reinstall
cover before operating.
If a fuse opens, it usually indi-
cates a more serious problem
exists. Contact a Factory Authorized Service Agent.
3
Tools Needed:
3/8 in
801 683 / Ref. 801 221-A / Ref. 183 175–A
8-7. Servicing Optional Spark Arrestor (Kohler-Powered Units)
Stop engine and let cool.
1
Spark Arrestor Screen
Clean and inspect screen. Replace
spark arrestor if screen wires are
broken or missing.
1
Tools Needed:
1/4 in
Ref. 801 695-A / Ref. 200 017
OM-4403 Page 37
SECTION 9 – TROUBLESHOOTING
9-1. Welding Troubleshooting
Trouble
Low or no weld output; generator power output okay at ac receptacles.
Remedy
Check control settings.
Check weld connections.
Check fuse F1, and replace if open (see Section 7-4 or 8-6).
Have Factory Authorized Service Agent check brushes, slip rings, and integrated rectifiers SR2 and
SR3.
No weld output or generator power output at ac receptacles.
Be sure all equipment is disconnected from receptacles when starting unit.
Check fuses F1 and F2, and replace if open (see Section 7-4 or 8-6).
Check plug PLG6 connection.
Have Factory Authorized Service Agent check brushes, slip rings, and integrated rectifiers SR2, SR3.
Low weld output.
Check fuse F1, and replace if open (see Section 7-4 or 8-6).
Check control settings.
Check engine speed, and adjust if necessary (see Section 7-6 or 8-5).
Service air cleaner according to engine manual.
Have Factory Authorized Service Agent check brushes, slip rings, and integrated rectifiers SR2, SR3.
High weld output.
Check control settings.
Check engine speed, and adjust if necessary (see Section 7-6 or 8-5).
Erratic weld output.
Check control settings.
Tighten and clean connections to electrode and workpiece.
Use dry, properly-stored electrodes for Stick and TIG welding.
Remove excessive coils from weld cables.
Clean and tighten connections both inside and outside welding generator.
Check engine speed, and adjust if necessary (see Section 7-6 or 8-5).
Have Factory Authorized Service Agent check brushes, slip rings, and integrated rectifiers SR2, SR3.
9-2. Generator Power Troubleshooting
Trouble
No or low generator power output at ac
receptacles; weld output okay.
Remedy
Reset circuit breakers (see Section 6-1 or 6-2).
Press optional GFCI receptacle Reset button (see Section 6-2).
Check fuse F2, and replace if open (see Section 7-4 or 8-6).
Check plug PLG6 connection.
Have Factory Authorized Service Agent check brushes, slip rings, and integrated rectifier SR3.
No generator power or weld output.
Be sure all equipment is disconnected from receptacles when starting unit.
Check fuses F1 and F2, and replace if open (see Section 7-4 or 8-6).
Check plug PLG6 connection.
Have Factory Authorized Service Agent check brushes, slip rings, and integrated rectifiers SR2 and
SR3.
OM-4403 Page 38
Trouble
Low power output at ac receptacles.
Remedy
Check fuse F2, and replace if open (see Section 7-4 or 8-6).
Increase Fine control R1 setting to max.
High power output at ac receptacles.
Check engine speed, and adjust if necessary (see Section 7-6 or 8-5).
Erratic power output at ac receptacles.
Check fuel level.
Check engine speed, and adjust if necessary (see Section 7-6 or 8-5).
Check receptacle wiring and connections.
Have Factory Authorized Service Agent check brushes and slip rings.
9-3. Engine Troubleshooting
Trouble
Engine will not crank.
Remedy
Check fuse F6, and replace if open (see Section 7-4 or 8-6).
Check battery voltage.
Check battery connections and tighten if necessary.
Check plug PLG4 and plug PLG8 connections.
Have Factory Authorized Service Agent check Engine Control switch S2.
Engine will not start.
Check fuel level.
Check battery voltage.
Check battery connections and tighten if necessary.
Check oil level (see Section 4-2 or 4-3).
Check low oil pressure shutdown switch (see Parts List for location).
Have Factory Authorized Service Agent check fuel shutoff solenoid FS1 (FS1 optional on Onan-powered
units).
Engine starts but stops when Engine
Control switch returns to Run position.
Check oil level.
Check and refill crankcase with proper viscosity oil for operating temperature, if necessary.
Check low oil pressure shutdown switch (see Parts List for location).
Engine stopped during normal
operation.
Check fuel level.
Check oil level (see Section 4-2 or 4-3).
Check low oil pressure shutdown switch (see Parts List for location)
Periodically recharge battery (approximately every 3 months).
Replace battery.
Check voltage regulator and connections according to engine manual.
Have Factory Authorized Service Agent check fuel shutoff solenoid FS1 (FS1 optional on Onan-powered
units).
Battery Discharges between uses.
Clean battery, terminals, and posts with baking soda and water solution; rinse with clear water.
Periodically recharge battery (approximately every 3 months).
Replace battery.
Check voltage regulator and connections according to engine manual.
Engine idles but does not come up to
weld speed.
Have Factory Authorized Service Agent check auto idle module PC1, and current transformer CT1.
OM-4403 Page 39
Trouble
Unstable or sluggish engine speeds.
Remedy
Readjust throttle linkage if necessary. Check throttle solenoid TS1 for smooth operation.
Tune-up engine according to engine manual.
Engine does not return to idle speed.
Remove weld and generator power loads.
Check throttle linkage for smooth, non-binding operation.
Have Factory Authorized Service Agent check idle module PC1, current transformer CT1, Engine Control
switch S2, and throttle solenoid TS1.
Notes
OM-4403 Page 40
Notes
OM-4403 Page 41
SECTION 10 – ELECTRICAL DIAGRAMS
Figure 11-1. Circuit Diagram For Welding Generator
OM-4403 Page 42
202 547-D
OM-4403 Page 43
SECTION 11 – GENERATOR POWER GUIDELINES
11-1. Selecting Equipment
1
2
3
Generator Power Receptacles
– Neutral Bonded To Frame
3-Prong Plug From Case
Grounded Equipment
2-Prong Plug From Double
Insulated Equipment
1
2
3
Be sure equipment
has this symbol
and/or wording.
OR
gen_pwr 4/02 – Ref. ST-159 730 / ST-800 577
11-2. Grounding Generator To Truck Or Trailer Frame
Always ground generator
frame to vehicle frame to prevent electric shock and static
electricity hazards.
1
2
3
4
3
1
Use #10 AWG or larger insulated
copper wire.
4
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
GND/PE
OR
2
Generator Base
Metal Vehicle Frame
Equipment Grounding
Terminal
Grounding Cable
2
Electrically bond generator
frame to vehicle frame by
metal-to-metal contact.
S-0854
OM-4403 Page 44
11-3. Grounding When Supplying Building Systems
1
1
2
2
GND/PE
Equipment Grounding
Terminal
Grounding Cable
Use #10 AWG or larger insulated
copper wire.
3
Ground Device
Ground generator to system
earth ground if supplying
power to a premises (home,
shop, farm) wiring system.
Use ground device as stated
in electrical codes.
2
3
ST-800 576-B
11-4. How Much Power Does Equipment Require?
1
3
2
1
VOLTS 115
AMPS 4.5
Hz
60
Resistive Load
A light bulb is a resistive load and
requires a constant amount of power.
2
Non-Resistive Load
Equipment with a motor is a non-resistive load and requires approximately six times more power while
starting the motor than when running (see Section 11-8).
3
3
Rating Data
Rating shows volts and amperes,
or watts required to run equipment.
AMPERES x VOLTS = WATTS
EXAMPLE 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power
requirement in watts.
4.5 A x 115 V = 520 W
The load applied by the drill is 520 watts.
EXAMPLE 2: If three 200 watt flood lamps are used with the drill from Example 1,
add the individual loads to calculate total load.
(200 W + 200 W + 200 W) + 520 W = 1120 W
The total load applied by the three flood lamps and drill is 1120 watts.
S-0623
OM-4403 Page 45
11-5. Approximate Power Requirements For Industrial Motors
Industrial Motors
Split Phase
Capacitor Start-Induction Run
Capacitor Start-Capacitor Run
Fan Duty
Rating
Starting Watts
Running Watts
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
800
1225
1600
2100
3175
2020
3075
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
1000
1400
1850
2400
3500
300
500
600
700
875
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
400
550
650
800
1100
11-6. Approximate Power Requirements For Farm/Home Equipment
Farm/Home Equipment
Stock Tank De-Icer
Grain Cleaner
Portable Conveyor
Grain Elevator
Milk Cooler
Milker (Vacuum Pump)
FARM DUTY MOTORS
Std. (e.g. Conveyors,
Feed Augers, Air
Compressors)
High Torque (e.g. Barn
Cleaners, Silo Unloaders,
Silo Hoists, Bunk Feeders)
3-1/2 cu. ft. Mixer
High Pressure 1.8 Gal/Min
Washer 2 gal/min
2 gal/min
Refrigerator or Freezer
Shallow Well Pump
Sump Pump
OM-4403 Page 46
Rating
1/4 HP
1/2 HP
3/4 HP
2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/2 HP
500 PSI
550 PSI
700 PSI
1/3 HP
1/2 HP
1/3 HP
1/2 HP
Starting Watts
Running Watts
1000
1650
3400
4400
2900
10500
1720
2575
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
3300
3150
4500
6100
3100
2150
3100
2100
3200
1000
650
1000
1400
1100
2800
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
1000
950
1400
1600
800
750
1000
800
1050
11-7. Approximate Power Requirements For Contractor Equipment
Contractor
Hand Drill
Circular Saw
Table Saw
Band Saw
Bench Grinder
Air Compressor
Electric Chain Saw
Electric Trimmer
Electric Cultivator
Elec. Hedge Trimmer
Flood Lights
Submersible Pump
Centrifugal Pump
Floor Polisher
High Pressure Washer
55 gal Drum Mixer
Wet & Dry Vac
Rating
Starting Watts
Running Watts
1/4 in
3/8 in
1/2 in
6-1/2 in
7-1/4 in
8-1/4 in
9 in
10 in
14 in
6 in
8 in
10 in
1/2 HP
1 HP
1-1/2 HP
2 HP
1-1/2 HP, 12 in
2 HP, 14 in
Standard 9 in
Heavy Duty 12 in
1/3 HP
18 in
HID
Metal Halide
Mercury
Sodium
Vapor
400 gph
900 gph
3/4 HP, 16 in
1 HP, 20 in
1/2 HP
3/4 HP
1 HP
1/4 HP
1.7 HP
2-1/2 HP
350
400
600
500
900
1400
4500
6300
2500
1720
3900
5200
3000
6000
8200
10500
1100
1100
350
500
2100
400
125
313
1000
1400
1250
600
900
4500
6100
3150
4500
6100
1900
900
1300
350
400
600
500
900
1400
1500
1800
1100
720
1400
1600
1000
1500
2200
2800
1100
1100
350
500
700
400
100
250
1000
200
500
1400
1600
950
1400
1600
700
900
1300
OM-4403 Page 47
11-8. Power Required To Start Motor
4
1
3
AC MOTOR
VOLTS 230
AMPS 2.5
CODE M
Hz
60
HP
1/4
PHASE 1
1
2
3
4
2
Motor Start Code
Running Amperage
Motor HP
Motor Voltage
To find starting amperage:
Step 1: Find code and use table to
find kVA/HP. If code is not listed,
multiply running amperage by six to
find starting amperage.
Step 2: Find Motor HP and Volts.
Step 3: Determine starting amperage (see example).
Welding generator amperage output must be at least twice the
motor’s running amperage.
Single-Phase Induction Motor Starting Requirements
Motor Start
Code
G
H
J
K
L
M
N
P
KVA/HP
6.3
7.1
8.0
9.0
10.0
11.2
12.5
14.0
kVA/HP x HP x 1000
VOLTS
= STARTING AMPERAGE
EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4
HP motor with a motor start code of M.
Volts = 230
HP = 1/4
Using Table, Code M results in kVA/HP = 11.2
11.2 x 1/4 x 1000
= 12.2 A Starting the motor requires 12.2 amperes.
230
S-0624
11-9. How Much Power Can Generator Supply?
1
Limit Load To 90% Of
Generator Output
Always start non-resistive (motor)
loads in order from largest to smallest, and add resistive loads last.
2
1
2
5 Second Rule
If motor does not start within 5
seconds, turn off power to prevent
motor damage. Motor requires
more power than generator can
supply.
Ref. ST-800 396-A / S-0625
OM-4403 Page 48
11-10. Typical Connections To Supply Standby Power
Have only qualified persons
perform these connections
according to all applicable
codes and safety practices.
Customer-supplied equipment is required if
generator is to supply standby power during
emergencies or power outages.
Properly install and ground
this equipment according to
its Owner’s Manual and natioanl, state, and local codes.
1
240 V
1
120/240 Volt
60 Hz
Three-Wire
Service
120 V
2
120 V
5
3
Power Company Service
Meter
Main and Branch Overcurrent
Protection
Double-Pole, Double-Throw
Transfer Switch
Obtain and install correct switch.
Switch rating must be same as or
greater than the branch overcurrent
protection.
Neutral
4
2
3
240 V
Obtain and install the correct
switchable circuit breakers or fused
switch.
5
120 V
Load
Generator Power Disconnect
Switch
Utility Power Emergency
Disconnect
Allows the utility power to be quickly
disconnected from the building
electrical system.
120 V
6
4
7
7
CB
or
F1
6
7
Extension Cord
Select as shown in Section 11-11.
Generator Connections
Connect terminals or plug of adequate amperage capacity to cord.
Follow all applicable codes and
safety practices.
Turn off or unplug all equipment
connected to generator before
starting or stopping engine. When
starting or stopping, the engine has
low speed which causes low voltLocate switch where
age and frequency.
readily accessible.
8 Load Connections
240 V
120/240 Volt
Single-Phase
Three-Wire
Generator Output
Connection
120 V
120 V
Ground
S-0405-A
OM-4403 Page 49
11-11. Selecting Extension Cord (Use Shortest Cord Possible)
Cord Lengths for 120 Volt Loads
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)
Load (Watts)
5
600
7
840
10
1200
15
4
6
8
10
12
14
350 (106)
225 (68)
137 (42)
100 (30)
400 (122)
250 (76)
150 (46)
100 (30)
62 (19)
400 (122)
275 (84)
175 (53)
112 (34)
62 (19)
50 (15)
1800
300 (91)
175 (53)
112 (34)
75 (23)
37 (11)
30 (9)
20
2400
225 (68)
137 (42)
87 (26)
50 (15)
30 (9)
25
3000
175 (53)
112 (34)
62 (19)
37 (11)
30
3600
150 (46)
87 (26)
50 (15)
37 (11)
35
4200
125 (38)
75 (23)
50 (15)
40
4800
112 (34)
62 (19)
37 (11)
45
5400
100 (30)
62 (19)
50
6000
87 (26)
50 (15)
*Conductor size is based on maximum 2% voltage drop
Cord Lengths for 240 Volt Loads
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)
Load (Watts)
5
1200
7
1680
10
2400
15
4
8
10
12
14
700 (213)
450 (137)
225 (84)
200 (61)
800 (244)
500 (152)
300 (91)
200 (61)
125 (38)
800 (244)
550 (168)
350 (107)
225 (69)
125 (38)
100 (31)
3600
600 (183)
350 (107)
225 (69)
150 (46)
75 (23)
60 (18)
20
4800
450 (137)
275 (84)
175 (53)
100 (31)
60 (18)
25
6000
350 (107)
225 (69)
125 (38)
75 (23)
30
7000
300 (91)
175 (53)
100 (31)
75 (23)
35
8400
250 (76)
150 (46)
100 (31)
40
9600
225 (69)
125 (38)
75 (23)
45
10,800
200 (61)
125 (38)
50
12,000
175 (53)
100 (31)
*Conductor size is based on maximum 2% voltage drop
OM-4403 Page 50
6
SECTION 12 – STICK WELDING (SMAW) GUIDELINES
12-1. Stick Welding Procedure
Weld current starts when
electrode touches workpiece.
Weld current can damage
electronic parts in vehicles.
Disconnect both battery
cables before welding on a
vehicle. Place work clamp as
close to the weld as possible.
1
5
2
3
4
2
Work Clamp
Electrode
A small diameter electrode requires
less current than a large one. Follow electrode manufacturer’s
instructions when setting weld amperage (see Section 12-2).
3
6
1
Workpiece
Make sure workpiece is clean before welding.
7
4
5
6
Insulated Electrode Holder
Electrode Holder Position
Arc Length
Arc length is the distance from the
electrode to the workpiece. A short
arc with correct amperage will give
a sharp, crackling sound.
7
Slag
Use a chipping hammer and wire
brush to remove slag. Remove slag
and check weld bead before making another weld pass.
Tools Needed:
stick 12/96 – ST-151 593
OM-4403 Page 51
7014
7018
7024
Ni-Cl
308L
ALL
DEEP
EP
ALL
DEEP
6013
EP,EN
ALL
LOW
GENERAL
7014
EP,EN
ALL
MED
7018
EP
ALL
LOW
SMOOTH, EASY,
FAST
LOW HYDROGEN,
STRONG
7024
EP,EN
NI-CL
EP
FLAT
HORIZ
FILLET
ALL
308L
EP
ALL
USAGE
PENETRATION
EP
6011
AC
3/32
1/8
5/32
3/16
7/32
1/4
1/16
5/64
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
3/32
1/8
5/32
DC*
450
400
350
300
AMPERAGE
RANGE
250
200
150
POSITION
6013
6010
ELECTRODE
6010
&
6011
100
50
DIAMETER
ELECTRODE
12-2. Electrode and Amperage Selection Chart
MIN. PREP, ROUGH
HIGH SPATTER
LOW
SMOOTH, EASY,
FASTER
LOW
CAST IRON
LOW
STAINLESS
*EP = ELECTRODE POSITIVE (REVERSE POLARITY)
EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)
Ref. S-087 985-A
12-3. Striking an Arc – Scratch Start Technique
1
1
2
3
Electrode
Workpiece
Arc
Drag electrode across workpiece
like striking a match; lift electrode
slightly after touching work. If arc
goes out electrode was lifted to
high. If electrode sticks to workpiece, use a quick twist to free it.
2
3
S-0049
12-4. Striking an Arc – Tapping Technique
1
1
2
3
2
Electrode
Workpiece
Arc
Bring electrode straight down to
workpiece; then lift slightly to start
arc. If arc goes out, electrode was
lifted too high. If electrode sticks to
workpiece, use a quick twist to free it.
3
S-0050
OM-4403 Page 52
12-5. Positioning Electrode Holder
10°-30°
90°
90°
End View of Work Angle
Side View of Electrode Angle
GROOVE WELDS
10°-30°
45°
45°
End View of Work Angle
Side View of Electrode Angle
FILLET WELDS
S-0060
12-6. Poor Weld Bead Characteristics
1
2
3
4
5
Large Spatter Deposits
Rough, Uneven Bead
Slight Crater During Welding
Bad Overlap
Poor Penetration
1
2
4
3
5
S-0053-A
12-7. Good Weld Bead Characteristics
1
2
3
Fine Spatter
Uniform Bead
Moderate Crater During
Welding
Weld a new bead or layer for each
1/8 in. (3.2 mm) thickness in metals
being welded.
4
5
1
2
3
4
No Overlap
Good Penetration into Base
Metal
5
S-0052-B
OM-4403 Page 53
12-8. Conditions That Affect Weld Bead Shape
NOTE
Weld bead shape is affected by electrode angle, arc length, travel speed, and
thickness of base metal.
Angle Too Small
Correct Angle
10° - 30°
Angle Too Large
Drag
ELECTRODE ANGLE
Spatter
Normal
Too Short
Too Long
ARC LENGTH
Normal
Slow
Fast
TRAVEL SPEED
S-0061
12-9. Electrode Movement During Welding
NOTE
Normally, a single stringer bead is satisfactory for most narrow groove weld joints;
however, for wide groove weld joints or bridging across gaps, a weave bead or
multiple stringer beads work better.
1
2
1
2
3
Stringer Bead – Steady
Movement Along Seam
Weave Bead – Side to Side
Movement Along Seam
Weave Patterns
Use weave patterns to cover a wide
area in one pass of the electrode.
Do not let weave width exceed
2-1/2 times diameter of electrode.
3
S-0054-A
OM-4403 Page 54
12-10. Butt Joints
1
1
2
Tack Welds
Prevent edges of joint from drawing
together ahead of electrode by tack
welding the materials in position before final weld.
2
Square Groove Weld
Good for materials up to 3/16 in (5
mm) thick.
3
1/16 in
(1.6 mm)
30°
Single V-Groove Weld
Good for materials 3/16 – 3/4 in
(5-19 mm) thick. Cut bevel with oxyacetylene or plasma cutting equipment. Remove scale from material
after cutting. A grinder can also be
used to prepare bevels.
4
3
Create 30 degree angle of bevel on
materials in V-groove welding.
4
Double V-Groove Weld
Good for materials thicker than 3/16
in (5 mm).
S-0662
12-11. Lap Joint
30°
Or Less
30°
Or Less
1
1
1
2
Move electrode in circular motion.
3
Single-Layer Fillet Weld
Multi-Layer Fillet Weld
Weld a second layer when a heavier fillet is needed. Remove slag before making another weld pass.
Weld both sides of joint for maximum strength.
3
2
Electrode
Single-Layer Fillet Weld
Multi-Layer Fillet Weld
S-0063 / S-0064
12-12. Tee Joint
1
2
Keep arc short and move at definite
rate of speed. Hold electrode as
shown to provide fusion into the
corner. Square edge of the weld
surface.
1
2
45°
Or Less
Electrode
Fillet Weld
For maximum strength weld both
sides of upright section.
2
3
Multi-Layer Deposits
Weld a second layer when a heavier fillet is needed. Use any of the
weaving patterns shown in Section
12-9. Remove slag before making
another weld pass.
1
3
S-0060 / S-0058-A / S-0061
OM-4403 Page 55
12-13. Weld Test
1
2
3
3
Strike weld joint in direction shown.
A good weld bends over but does
not break.
3
2 To 3 in
(51-76 mm)
1/4 in
(6.4 mm)
Vise
Weld Joint
Hammer
2 To 3 in
(51-76 mm)
2
2
1
1
S-0057-B
12-14. Troubleshooting – Porosity
Porosity – small cavities or holes resulting from gas
pockets in weld metal.
Possible Causes
Corrective Actions
Arc length too long.
Reduce arc length.
Damp electrode.
Use dry electrode.
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
12-15. Troubleshooting – Excessive Spatter
Excessive Spatter – scattering of molten metal particles
that cool to solid form near weld bead.
Possible Causes
Corrective Actions
Amperage too high for electrode.
Decrease amperage or select larger electrode.
Arc length too long or voltage too high.
Reduce arc length or voltage.
OM-4403 Page 56
12-16. Troubleshooting – Incomplete Fusion
Incomplete Fusion – failure of weld metal to fuse completely with
base metal or a preceeding weld bead.
Possible Causes
Corrective Actions
Insufficient heat input.
Increase amperage. Select larger electrode and increase amperage.
Improper welding technique.
Place stringer bead in proper location(s) at joint during welding.
Adjust work angle or widen groove to access bottom during welding.
Momentarily hold arc on groove side walls when using weaving technique.
Keep arc on leading edge of weld puddle.
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
12-17. Troubleshooting – Lack Of Penetration
Lack Of Penetration – shallow fusion between weld metal and
base metal.
Lack of Penetration
Good Penetration
Possible Causes
Corrective Actions
Improper joint preparation.
Material too thick. Joint preparation and design must provide access to bottom of groove.
Improper weld technique.
Keep arc on leading edge of weld puddle.
Insufficient heat input.
Increase amperage. Select larger electrode and increase amperage.
Reduce travel speed.
12-18. Troubleshooting – Excessive Penetration
Excessive Penetration – weld metal melting through base metal and
hanging underneath weld.
Excessive Penetration
Possible Causes
Excessive heat input.
Good Penetration
Corrective Actions
Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
OM-4403 Page 57
12-19. Troubleshooting – Burn-Through
Burn-Through – weld metal melting completely through base metal resulting
in holes where no metal remains.
Possible Causes
Excessive heat input.
Corrective Actions
Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
12-20. Troubleshooting – Waviness Of Bead
Waviness Of Bead – weld metal that is not parallel and does not cover
joint formed by base metal.
Possible Causes
Unsteady hand.
Corrective Actions
Use two hands. Practice technique.
12-21. Troubleshooting – Distortion
Distortion – contraction of weld metal during welding that forces base
metal to move.
Base metal moves
in the direction of
the weld bead.
Possible Causes
Excessive heat input.
Corrective Actions
Use restraint (clamp) to hold base metal in position.
Make tack welds along joint before starting welding operation.
Select lower amperage for electrode.
Increase travel speed.
Weld in small segments and allow cooling between welds.
OM-4403 Page 58
SECTION 13 – MIG WELDING (GMAW) GUIDELINES
13-1. Typical MIG Process Connections Using A Voltage-Sensing Wire Feeder
Constant
Current (CC)
Or Constant
Voltage (CV)
Power Source
Weld current can damage
electronic parts in vehicles.
Disconnect both battery
cables before welding on a
vehicle. Place work clamp as
close to the weld as possible.
Voltage sensing wire feeders are
used with constant current (CC) or
constant voltage (CV) power
sources (14 pin receptacle not required).
If using a CC or CV welding power
source without a weld output contactor, use optional secondary contactor.
Gun
Workpiece
Work Clamp
For GMAW, use optional gas valve.
Voltage
Sensing Wire
Feeder
Electrode Lead
Voltage
Sensing Clamp
Work Lead
802 488
13-2. Typical MIG Process Connections Using A Constant Speed Wire Feeder
Weld current can damage
electronic parts in vehicles.
Disconnect both battery
cables before welding on a
vehicle. Place work clamp as
close to the weld as possible.
Regulator/
Flowmeter
115V/24V
Constant
Speed
Wire Feeder
Contactor
Constant
Voltage
(CV)
Welding
Power
Source
Constant speed wire feeders are
used with constant voltage (CV)
power sources having a 14-pin receptacle.
Shielding
Gas
Gun
Gas
Workpiece
Work Clamp
Electrode Lead
Work Lead
mig 9/99 / ST-800 357-A
OM-4403 Page 59
13-3. Typical MIG Process Control Settings
NOTE
These settings are guidelines only. Material and wire type, joint design, fitup,
position, shielding gas, etc. affect settings. Test welds to be sure they comply to
specifications.
Material thickness determines weld
parameters.
1/8 or
.125 in
Convert Material
Thickness to
Amperage (A)
(.001 in = 1 ampere)
.125 in = 125 A
.035 in
Wire Size
Amperage Range
.030 in
.035 in
.045 in
40 – 145 A
50 – 180 A
75 – 250 A
Select Wire Size
Wire
Size
Recommendation
Wire Speed
(Approx.)
Select Wire Speed
(Amperage)
.030 in
.035 in
.045 in
2 in per ampere
1.6 in per ampere
1 in per ampere
2 x 125 A = 250 ipm
1.6 x 125 A = 200 ipm
1 x 125 A = 125 ipm
125 A based on 1/8 in
material thickness
ipm = inch per minute
Low voltage: wire stubs into work
High voltage: arc is unstable (spatter)
Select Voltage
Set voltage midway between high/low voltage.
Wire speed (amperage) controls weld penetration (wire speed = burn-off rate)
Voltage controls height and width of
weld bead.
Ref. ST-801 865
OM-4403 Page 60
13-4. Holding And Positioning Welding Gun
NOTE
Welding wire is energized when gun trigger is pressed. Before lowering helmet and
pressing trigger, be sure wire is no more than 1/2 in (13 mm) past end of nozzle,
and tip of wire is positioned correctly on seam.
1
1
3
2
2
3
4
5
Hold Gun and Control Gun
Trigger
Workpiece
Work Clamp
Electrode Extension (Stickout)
1/4 to 1/2 in (6 To 13 mm)
Cradle Gun and Rest Hand on
Workpiece
5
4
0°-15°
90°
90°
End View Of Work Angle
Side View Of Gun Angle
GROOVE WELDS
0°-15°
45°
45°
End View Of Work Angle
Side View Of Gun Angle
FILLET WELDS
S-0421-A
OM-4403 Page 61
13-5. Conditions That Affect Weld Bead Shape
NOTE
Weld bead shape depends on gun angle, direction of travel, electrode extension
(stickout), travel speed, thickness of base metal, wire feed speed (weld current),
and voltage.
10°
Push
Perpendicular
10°
Drag
GUN ANGLES AND WELD BEAD PROFILES
Short
Normal
Long
ELECTRODE EXTENSIONS (STICKOUT)
Short
Normal
Long
FILLET WELD ELECTRODE EXTENSIONS (STICKOUT)
Slow
Normal
GUN TRAVEL SPEED
OM-4403 Page 62
Fast
S-0634
13-6. Gun Movement During Welding
NOTE
Normally, a single stringer bead is satisfactory for most narrow groove weld joints;
however, for wide groove weld joints or bridging across gaps, a weave bead or
multiple stringer beads works better.
1
1
2
2
3
Stringer Bead – Steady
Movement Along Seam
Weave Bead – Side To Side
Movement Along Seam
Weave Patterns
Use weave patterns to cover a wide
area in one pass of the electrode.
3
S-0054-A
13-7. Poor Weld Bead Characteristics
1
2
3
1
2
3
4
5
Large Spatter Deposits
Rough, Uneven Bead
Slight Crater During Welding
Bad Overlap
Poor Penetration
4
5
S-0053-A
13-8. Good Weld Bead Characteristics
1
2
3
1
Fine Spatter
Uniform Bead
Moderate Crater During
Welding
Weld a new bead or layer for each
1/8 in (3.2 mm) thickness in metals
being welded.
4
5
2
3
4
No Overlap
Good Penetration into Base
Metal
5
S-0052-B
OM-4403 Page 63
13-9. Troubleshooting – Excessive Spatter
Excessive Spatter – scattering of molten metal particles that
cool to solid form near weld bead.
S-0636
Possible Causes
Corrective Actions
Wire feed speed too high.
Select lower wire feed speed.
Voltage too high.
Select lower voltage range.
Electrode extension (stickout) too long.
Use shorter electrode extension (stickout).
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.
Insufficient shielding gas at welding arc.
Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.
Dirty welding wire.
Use clean, dry welding wire.
Eliminate pickup of oil or lubricant on welding wire from feeder or liner.
13-10. Troubleshooting – Porosity
Porosity – small cavities or holes resulting from gas pockets
in weld metal.
S-0635
Possible Causes
Insufficient shielding gas at welding arc.
Corrective Actions
Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.
Remove spatter from gun nozzle.
Check gas hoses for leaks.
Place nozzle 1/4 to 1/2 in (6-13 mm) from workpiece.
Hold gun near bead at end of weld until molten metal solidifies.
Wrong gas.
Use welding grade shielding gas; change to different gas.
Dirty welding wire.
Use clean, dry welding wire.
Eliminate pick up of oil or lubricant on welding wire from feeder or liner.
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before welding.
Use a more highly deoxidizing welding wire (contact supplier).
Welding wire extends too far out of nozzle.
Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.
13-11. Troubleshooting – Excessive Penetration
Excessive Penetration – weld metal melting through base metal
and hanging underneath weld.
Excessive Penetration Good Penetration
S-0639
Possible Causes
Excessive heat input.
Corrective Actions
Select lower voltage range and reduce wire feed speed.
Increase travel speed.
OM-4403 Page 64
13-12. Troubleshooting – Lack Of Penetration
Lack Of Penetration – shallow
fusion between weld metal and
base metal.
Lack of Penetration
Good Penetration
S-0638
Possible Causes
Corrective Actions
Improper joint preparation.
Material too thick. Joint preparation and design must provide access to bottom of groove while
maintaining proper welding wire extension and arc characteristics.
Improper weld technique.
Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.
Keep arc on leading edge of weld puddle.
Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.
Insufficient heat input.
Select higher wire feed speed and/or select higher voltage range.
Reduce travel speed.
13-13. Troubleshooting – Incomplete Fusion
Incomplete Fusion – failure of weld metal to fuse completely with
base metal or a preceeding weld bead.
S-0637
Possible Causes
Corrective Actions
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before
welding.
Insufficient heat input.
Select higher voltage range and/or adjust wire feed speed.
Improper welding technique.
Place stringer bead in proper location(s) at joint during welding.
Adjust work angle or widen groove to access bottom during welding.
Momentarily hold arc on groove side walls when using weaving technique.
Keep arc on leading edge of weld puddle.
Use correct gun angle of 0 to 15 degrees.
13-14. Troubleshooting – Burn-Through
Burn-Through – weld metal melting completely through base metal
resulting in holes where no metal remains.
S-0640
Possible Causes
Excessive heat input.
Corrective Actions
Select lower voltage range and reduce wire feed speed.
Increase and/or maintain steady travel speed.
OM-4403 Page 65
13-15. Troubleshooting – Waviness Of Bead
Waviness Of Bead – weld metal that is not parallel and does not cover
joint formed by base metal.
S-0641
Possible Causes
Corrective Actions
Welding wire extends too far out of nozzle.
Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.
Unsteady hand.
Support hand on solid surface or use two hands.
13-16. Troubleshooting – Distortion
Distortion – contraction of weld metal during welding that forces
base metal to move.
Base metal moves
in the direction of
the weld bead.
S-0642
Possible Causes
Excessive heat input.
Corrective Actions
Use restraint (clamp) to hold base metal in position.
Make tack welds along joint before starting welding operation.
Select lower voltage range and/or reduce wire feed speed.
Increase travel speed.
Weld in small segments and allow cooling between welds.
OM-4403 Page 66
13-17. Common MIG Shielding Gases
This is a general chart for common gases and where they are used. Many different combinations (mixtures) of
shielding gases have been developed over the years. The most commonly used shielding gases are listed in the
following table.
Application
Gas
Spray Arc Steel
Short Circuiting
Steel
Spray Arc
Stainless Steel
Short Circuiting
Stainless Steel
Argon
Argon + 1% O2
Flat & Horizontal5
Fillet
Flat & Horizontal5
Fillet
Argon + 2% O2
Flat & Horizontal5
Fillet
Flat & Horizontal5
Fillet
Argon + 5% O2
Flat & Horizontal5
Fillet
Argon + 8% CO2
Flat & Horizontal5
Fillet
All Positions
Argon + 25%
CO2
Flat & Horizontal1
Fillet
All Positions
Argon + 50%
CO2
CO2
Spray Arc
Aluminum
Short Circuiting
Aluminum
All Positions5
All Positions
All Positions3
All Positions
Flat & Horizontal1
Fillet
All Positions
Helium
All Positions2
Argon + Helium
All Positions2
Tri-Mix4
1
Globular Transfer
2
Heavy Thicknesses
3
Single Pass Welding Only
4
90% HE + 7-1/2% AR + 2-1/2% CO2
5
Also for GMAW-P, All Positions
All Positions
OM-4403 Page 67
SECTION 14 – PARTS LIST
19
Hardware is common and
24
41
40
39
46
43
42 – FIG 14-3
51
52
1
2
50
44
3
45
4
49
47
48
46
48
5
38
37
6
8
32
10
31
33
11
9
36
34
12
35
30
13
29
28
18
21
22
27
23
14
16
17
20 – FIG 14-2
26
25
15
not available unless listed.
Figure 14-1. Main Assembly (Onan OHV Engine Shown)
OM-4403 Page 68
802 920-D
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 14-1. Main Assembly
. . . 1 . . . . . . . . . . . . . 181 881
. . . 2 . . . . . . . . . . . . . 147 601
. . . 3 . . . . . . . . . . . . . 200 795
. . . 4 . . . . . . . . . . . . . 203 994
. . . 5 . . . . . . . . . . . . +205 762
. . . 5 . . . . . . . . . . . . +205 762
. . . 6 . . . . . . . . . . . . . 182 365
. . . 7 . . . . . . . . . . . . . . Deleted
. . . 8 . . . . . . . . . . . . . 201 278
. . . . . . . . . . . . . . . . . . . 187 502
. . . . . . . . . . . . . . . . . . . 124 253
. . . . . . . . . . . . . . . . . . . 182 922
. . . . . . . . . . . . . . . . . . . 182 925
. . . 9 . . . . . . . . . . . . . 121 652
. . . 10 . . . . . R2 . . . . 200 518
. . . 11 . . . . . . . . . . . . . 205 736
. . . 12 . . . . . . . . . . . . . 205 734
. . . 13 . . . . . . . . . . . . . 186 667
. . . 14 . . . . . . . . . . . . . 209 057
. . Grommet, Neck Filler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Cap, Tank Screw-on W/Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Label,Warning Gen. Precautionary Csa . . . . . . . . . . . . . . . . . . . . . . . 1
. . Pipe, Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Cover, Top (Onan OHV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Cover, Top (Kohler CH-20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Panel, Rear Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
....................................................................
. . Tank, Fuel 10gal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Fitting, Stand Pipe Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Bushing, Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Bushing, Fuel Tank 1.210 Id . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Gauge, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Filter Kit, Fuel W/Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Resistor, Ww Fxd 225 W 3.15 Ohm W/2.85 Ta . . . . . . . . . . . . . . . . . . . . . . 1
. . Upright, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Seal, Weather Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Panel, Rear Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Clamp, Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . +198 552 . . Engine, Kohler CH-20 Gas Elec Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . . . . 183 435 . . . . Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . . . . . . . . . . . 189 477 . . . . Muffler Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 18 . . . . TS1 . . . 199 530 . . . . Solenoid, throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bracket, Mtg Solenoid (see engine parts List) . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . F6 . . . . *021 718 . . . . Fuse, Mintr Gl 30a, 32v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 180 096 . . Tune Up & Filter Kit, (Kohler CH-20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 066 698 . . . . Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 121 652 . . . . Filter/Clamps, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 067 272 . . . . Element, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 067 273 . . . . Air Filter, Wrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 067 007 . . . . Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . ♦192 093 . . Pump, Electric Fuel (Kohler CH-20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
1
1
1
1
1
1
1
1
2
1
. . . 15 . . . . . . . . . . . . +206 245
. . . 16 . . . . . . . . . . . . . 204 841
. . . 17 . . . . . . . . . . . . . 065 313
. . . . . . . . . . . . . . . . . . . *198 754
. . . . . . . . . . . . . . . . . . . *198 755
. . . . . . . . . . . . . . . . . . . 198 756
. . . . . . . . . . . S5 . . . . 198 757
. . . . . . . . . . . . . . . . . . . *121 652
. . . . . . . . . . . . . . . . . . . *198 777
. . . 18 . . . . TS1 . . . 206 573
. . . . . . . . . . . F6 . . . . *021 718
. . . . . . . . . . . . . . . . . . . 198 778
. . . . . . . . . . . . . . . . . . . 190 827
. . . . . . . . . . . . . . . . . . . 137 046
. . . . . . . . . . . . . . . . . . . 065 251
. . . . . . . . . . . . . . . . . . . 121 652
. . . . . . . . . . . . . . . . . . . 064 617
. . . . . . . . . . . . . . . . . . . 065 709
. . Engine, Onan OHV (OHV) Gas Elec Start (consisting of) . . . . . . . . . . . . .
. . . . Muffler, Exhaust Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Gasket, muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Filter, oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Element, air cleaner w/precleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Pump, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Switch, low oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Filter, fuel w/clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Plug, spark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Solenoid, throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Fuse, Mintr Gl 30a, 32v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Regulator, voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Boot, solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Tune-up & Filter Kit, (Onan OHV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Filter/Clamps, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Element, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
2
. . . . . . . . . . . . . . . . . . . 147 551
. . . . . . . . . . . . . . . . . . . 177 126
. . . 19 . . . . . . . . . . . . . 165 271
. . . 20 . . . . . . . . . . Figure 14-2
. . . 21 . . . . . . . . . . . . . 204 317
. . . 21 . . . . . . . . . . . . . 173 043
..
..
..
..
..
..
1
1
1
1
1
1
Tool, Puller Rotor (Onan OHV and Kohler CH-20) . . . . . . . . . . . . . . . . . .
Tool, Puller Rotor (Kohler CH-20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve, Oil Drain 3/8-18nptf (Included W/Engine) . . . . . . . . . . . . . . . . . . . . .
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, Mtg Engine (Onan OHV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, Mtg Engine (Kohler CH-20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-4403 Page 69
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 14-1. Main Assembly (Continued)
. . . 22 . . . . . . . . . . . . . 082 319 . . Cable, Cable, Bat Neg 17.750 (Battery To Engine Block)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Onan OHV & Kohler CH-20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 172 669 . . Cable, Cable, Bat Neg 11.000 (Engine Block To Case)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Onan OHV & Kohler CH-20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . 182 935 . . Hold Down, Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . +201 174 . . Door, Access Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . 168 385 . . Label, Warning Battery Explosion Can Blind . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . 173 921 . . Cable, Bat Pos 28.000 (Onan OHV & Kohler CH-20) . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . 168 037 . . Battery, Stor 12v 430 Crk 75 Rsv Gp 58 Dry . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . 201 280 . . Pan, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . 194 074 . . Label, Engine Maintenance (Onan OHV) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . 173 088 . . Label, Engine Maintenance (Kohler CH-20) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . 197 930 . . Label, Warning Do Not Weld On Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 31 . . . . . . . . . . . . . 181 057 . . Cover, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 32 . . . . . . . . . . . . . . 200 011 . . Stab/Reactor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . AC-Z . . . 200 012 . . . . Reactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . DC-Z . . . 183 179 . . . . Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 164 920 . . . . Bracket, Mtg Stab/Reactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 35 . . . . . . . . . . . . . 182 928 . . Bracket, Mtg Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . . Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 37 . . . . . 1T . . . . 172 661 . . Block, Term 20a 8p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . . 173 734 . . Link, Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 39 . . . . SR1 . . . 142 503 . . Rectifier, Si 1 Ph 300a 400piv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . 172 625 . . Bracket, Mtg Rec/Comp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . 180 628 . . Panel, Front Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . Figure 14-3 . . Panel, Front W/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . CT1 . . . 201 784 . . Transformer, Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . 177 136 . . Clamp, Capacitor 1.375dia Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . C1 . . . . 199 979 . . Capacitor, Elctlt 1500uf 75vdc Can 1.40 Dia . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . D4 . . . . 135 184 . . Diode Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 47 . . . . . . . . . . . . . 172 731 . . Holder, Fuse Mintr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 48 . . . F1, F2 . . *169 296 . . Fuse, Mintr Gl 25A 125v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 49 . . SR2, SR3 . 035 704 . . Rectifier, Integ 40A 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 50 . . . . . . . . . . . . . 182 367 . . Panel, Side Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC4 . . . . 116 045 . . Connector & Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . . . . . . . . . . 182 366 . . Panel, Side Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 52 . . . . . . . . . . . . . 192 042 . . Label, Warning Engine Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 204 374 . . Label Kit (Onan OHV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 204 377 . . Label Kit (Kohler CH-20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 200 025 . . Harness, Wiring Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 167 640 . . Connector, Pins/Soc (Onan OHV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC6 . . . 168 844 . . Connector, Rect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC7 . . . . . . . . . . . . . . Connector, Part Of TS1 (See Engine Parts List) . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG5 . . . . 116 045 . . Connector & Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG6 . . . 136 810 . . Connector & Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG7 . . . . . . . . . . . . . . Connector, (See Engine Parts List) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC5 . . . . . . . . . . . . . . Connector, (See Engine Parts List) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG8 . . . 177 859 . . Connector, Body 5 Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered. Labels
available separately or as part of label kit 204 374 (Onan OHV) or 204 377 (Kohler).
♦Optional
* Recommended Spare Parts.
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.
OM-4403 Page 70
5
4
1
6
8
2
9
7
10
11
3
802 930
Figure 14-2. Generator
Item
No.
Part
No.
Description
Quantity
Figure 14-2. Generator (Figure 14-1 Item 20)
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
6
7
8
9
10
11
. . . . . +202 986
. . . . . . 183 419
. . . . . . 167 632
. . . . . . 013 367
. . . . . . 185 148
. . . . . . 142 156
. . . . . . 186 083
. . . . . . 198 461
. . . . . . 181 134
. . . . . . 181 143
. . . . . . 205 725
. . . . . . 142 156
. . Housing, Generator Front (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . O–ring, 1.984 Id X .139 Cs 70 Duro Viton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Screw, 375–16x1.50 Hexwhd.66d Stl Pld Slffmg Tap–rw . . . . . . . . . . . . . . . . . . .
. . Label, Warning Moving Parts Can Cause Serious Etc . . . . . . . . . . . . . . . . . . . . . . .
. . Housing, Generator Rear (Onan OHV & Kohler CH-20) . . . . . . . . . . . . . . . . . . . .
. . Screw, 375–16x1.75 Hexwhd.81d Gr8 Pld (Onan OHV) . . . . . . . . . . . . . . . . . . . . .
. . Screw, 437–14x1.75 Hexwhd.93d Gr8 Pld (Kohler CH-20) . . . . . . . . . . . . . . . . . .
. . Rotor, Generator (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Fan, Rotor Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bearing, Ball Rdl Sgl Row .984 X 2.047 X .59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Brushholder Assy, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Screw, 375–16x1.75 Hexwhd.81d Gr8 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
4
4
1
1
1
1
4
+When ordering a component originally displaying a precautionary label, the label should also be ordered. Labels
available separately or as part of label kit 204 374 (Onan OHV) or 204 377 (Kohler CH-20).
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.
OM-4403 Page 71
5
4
1
2
3
6
7
8
9
10
25
11
24
23
22
21
15
17
14
13
12
18
19
20
16
ST-801 747-B
Figure 14-3. Panel, Front w/Components
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 14-3. Panel, Front w/Components (Figure 14-1 Item 42)
. . . 1 . . . . . . S1 . . . . . 198 700 . .
... 2 ..........................
. . . 3 . . . . . . . . . . . . . . . 207 845 . .
. . . 3 . . . . . . . . . . . . . ♦207 846 . .
. . . 3 . . . . . . . . . . . . . ♦201 785 . .
. . . 3 . . . . . . . . . . . . . ♦209 154 . .
. . . 4 . . . . . . . . . . . . . . . 186 058 . .
. . . 5 . . . . . . S3 . . . . . 199 992 . .
. . . 6 . . . . . PC1 . . . . 201 936 . .
. . . 7 . . . . . . R1 . . . . . 200 657 . .
. . . 8 . . . . . . S2 . . . . . 176 606 . .
. . . 9 . . . . RC2,3 . . . 141 432 . .
. . . 9 . . . GFCI 2,3 ♦151 981 . .
. . . 10 . . . . CB1,2 . . . . 195 955 . .
. . . 10 . . . . . CB1 . . ♦200 929 . .
. . . . . . . . . . . . . . . . . . . ♦202 631 . .
. . . . . . . . . . . . . . . . . . . ♦202 630 . .
. . . 11 . . . . CB3,4 . . . . 093 996 . .
. . . 11 . . . . CB3,4 . . ♦093 995 . .
. . . 12 . . . . . . Hm . . . . . 145 247 . .
. . . 13 . . . . . . . . . . . . . . . 204 895 . .
. . . 13 . . . . . . . . . . . . . . . 203 993 . .
. . . 14 . . . . . . . . . . . . . . . 119 014 . .
. . . 15 . . . . R3,VR1 . . . 046 819 . .
. . . 16 . . Work, Elect . 099 255 . .
. . . 17 . . . . . . . . . . . . . . . 083 030 . .
OM-4403 Page 72
Switch, Polarity 5 Position With Leads And Jumpers . . . . . . . . . . . . . . . .
Nameplate (Order By Model And Serial Number) . . . . . . . . . . . . . . . . . . .
Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, Front (CSA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, Front (W/Battery Charger Option) . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, Front (W/Australian Or South African Receptacle Option) . . . . .
Cover, Dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, Range 6 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Module, Pull To Idle 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rheostat, Ww 150w 14 Ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Receptacle, Str Dx Grd 2p3w 20a 125vac . . . . . . . . . . . . . . . . . . . . . . . . .
Receptacle, Str Dx Grd 2p3w 15/20a 125vac Gfci . . . . . . . . . . . . . . . . . .
Circuit Breaker, 1p 50a 125vac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Breaker, Man Reset 2p 50A 240 vac Screw 90 (CSA) . . . . . . . . .
Cover, Circuit Breaker (CSA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, Mtg Circuit Breaker (CSA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Breaker, 1p 20a 250vac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Breaker, 1p 15a 250vac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Meter, Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control, Push/Pull Snap–in 42.000 W/1.750 Ext (Onan OHV) . . . . . . . .
Control, Push/Pull Snap–in 36.000 W/1.750 Ext (Kohler CH-20) . . . . .
Lever, Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Suppressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminal, Pwr Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stud, Brs .250-20 X 1.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
2
1
1
1
1
2
2
2
1
1
1
2
2
1
1
1
1
1
2
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 14-3. Panel, Front w/Components (Figure 14-1 Item 42) (Continued)
. . . 18 . . . . . . . . . . . . . . . 010 915 . . Washer, Flat .250 Id Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 19 . . . . . . . . . . . . . . . 601 836 . . Nut, .250-20 Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 20 . . . . . . . . . . . . . . . 159 921 . . Bezel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . . 147 195 . . Nut, .375-27 Nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 22 . . . . . RC1 . . . . 182 954 . . Receptacle, Str 3p4w 50a 125/250vac . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . ♦119 172 . . Plug, Str 50a 125/250v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . ♦188 039 . . Cover, Receptacle (CSA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . . 148 956 . . Handle, Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 25 . . . . . . . . . . . . . . . 097 924 . . Knob, Pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦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.
OM-4403 Page 73
Effective January 1, 2001
(Equipment with a serial number preface of “LB” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
*
LIMITED WARRANTY – Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants
to its original retail purchaser that new Miller equipment sold
after the effective date of this limited warranty is free of defects
in material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such defects in material or workmanship. Miller must be
notified in writing within thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that
the equipment was delivered to the original retail purchaser, or
one year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to an
International distributor.
1.
5 Years Parts – 3 Years Labor
*
*
2.
3 Years — Parts and Labor
*
*
*
*
*
*
3.
Original main power rectifiers
Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Supplies
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year — Parts and Labor
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources
Water Coolant Systems
HF Units
Grids
Maxstar 140
Spot Welders
Load Banks
Miller Cyclomatic Equipment
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
4.
6 Months — Batteries
5.
90 Days — Parts
*
*
MIG Guns/TIG Torches
Induction Heating Coils and Blankets
*
*
*
*
*
APT, ZIPCUT & PLAZCUT Model Plasma Cutting
Torches
Remote Controls
Accessory Kits
Replacement Parts (No labor)
Spoolmate Spoolguns
Canvas Covers
Miller’s True Blue Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.
2.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE
AND MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods
at customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
DISCLAIMED BY MILLER.
Some states in the U.S.A. do not allow limitations of how long
an implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty
provides specific legal rights, and other rights may be
available, but may vary from state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may
be available, but may vary from province to province.
miller_warr 10/01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters–USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters –
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
www.MillerWelds.com
Contact the Delivering Carrier for:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims,
contact your distributor and/or equipment
manufacturer’s Transportation Department.
PRINTED IN USA
 2002 Miller Electric Mfg. Co.
1/02