Miller Electric BLUE STAR 6000 TM-499C Owner`s manual

OM-499
197 850H
March 2004
Processes
Stick (SMAW) Welding
Description
Engine Driven Welding Generator
Blue Star 6000
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
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-7. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-8. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . .
2-6. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Fuel Consumption (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Fuel Consumption (Honda-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Generator Power Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Grounding Generator To Truck Or Trailer Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Grounding Generator When Supplying Building Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Engine Prestart Checks (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Engine Prestart Checks (Honda-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Connecting The Battery (Electric-Start Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − OPERATING THE WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Controls (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Controls (Honda-Powered Units) (See Section 6-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Description Of Controls (Honda-Powered Units) (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Generator Power Panel 495 218 (USA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Optional Generator Power Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Generator Power Panel Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Wiring Instructions For Optional 120/240 Volt Twistlock Plug (NEMA L14-30P) . . . . . . . . . . . . . . . . . .
SECTION 8 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Overload Protection (Honda-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Adjusting Engine Speed (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5. Adjusting Engine Speed (Honda-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 − STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 13 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
rom _nd_8/03
Warning: Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
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.
Marks a special safety message.
Means “Note”; not safety related.
1-2. Arc Welding Hazards
Use only well-maintained equipment. Repair or replace damaged parts at
once. Maintain unit according to manual.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Only qualified persons should install, operate, maintain, and repair this unit.
Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical.
During operation, keep everybody, especially children, away.
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.
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 1-7. Read and follow all Safety Standards.
SIGNIFICANT DC VOLTAGE exists in inverters after stopping engine.
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 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.
Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp locations or while wearing
wet clothing; on metal structures such as floors, gratings, or scaffolds;
when in cramped positions such as sitting, kneeling, or lying; or when there
is a high risk of unavoidable or accidental contact with the workpiece or
ground. For these conditions, use the following equipment in order presented: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most
situations, use of a DC, constant voltage wire welder is recommended.
And, do not work alone!
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing these fumes
and gases can be hazardous to your health.
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.
Stop engine on inverter and discharge input capacitors according to
instructions in Maintenance Section before touching any parts.
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 airsupplied 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.
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.
ARC RAYS can burn eyes and skin.
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.
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OM-499 Page 1
WELDING can cause fire or explosion.
HOT PARTS can cause severe burns.
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.
NOISE can damage hearing.
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.
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.
Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.
Remove any combustibles, such as a butane lighter or matches, from your
person before doing any welding.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot
work and have a fire watcher and extinguisher nearby.
Noise from some processes or equipment can damage
hearing.
Wear approved ear protection if noise level is high.
MAGNETIC FIELDS can affect pacemakers.
FLYING METAL can injure eyes.
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.
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.
Pacemaker wearers keep away.
Wearers should consult their doctor before going
near arc welding, gouging, or spot welding operations.
CYLINDERS can explode if damaged.
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.
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.
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
MOVING PARTS can cause injury.
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.
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.
Always keep nozzle in contact with tank when fueling.
OM-499 Page 2
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.
Return To Table Of Contents
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.
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.
BATTERY ACID can BURN SKIN and EYES.
Do not tip battery.
Replace damaged battery.
Flush eyes and skin immediately with water.
ENGINE HEAT can cause fire.
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. Compressed Air Hazards
BREATHING COMPRESSED AIR can
cause serious injury or death.
Do not use compressed air for breathing.
Use only for cutting, gouging, and tools.
COMPRESSED AIR can cause injury.
Wear approved safety goggles.
Do not direct air stream toward self or others.
TRAPPED AIR PRESSURE AND WHIPPING
HOSES can cause injury.
HOT METAL from air arc cutting and
gouging can cause fire or explosion.
Release air pressure from tools and system before
servicing, adding or changing attachments, or opening compressor oil drain or oil fill cap.
Do not cut or gouge near flammables.
Watch for fire; keep extinguisher nearby.
HOT PARTS can cause burns and injury.
Do not touch hot compressor or air system parts.
Let system cool down before touching or servicing.
READ INSTRUCTIONS.
Read Owner’s Manual before using or servicing unit.
Stop engine and release air pressure before
servicing.
1-5. 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.
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.
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.
Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where
applicable.
Put on grounded wrist strap BEFORE handling
boards or parts.
Use proper static-proof bags and boxes to store,
move, or ship PC boards.
FLYING SPARKS can cause injury.
TILTING OF TRAILER 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.
Use tongue jack or blocks to support weight.
Properly install welding generator onto trailer according to instructions supplied with trailer.
Sparks can cause fires — keep flammables away.
Return To Table Of Contents
OM-499 Page 3
READ INSTRUCTIONS.
ARC WELDING can cause interference.
Use only genuine MILLER/Hobart replacement
parts.
Perform engine and air compressor (if applicable)
maintenance and service according to this manual
and the engine/air compressor (if applicable) manuals.
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.
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.
Electromagnetic energy can interfere with sensitive
electronic equipment such as microprocessors,
computers, and computer-driven equipment such as
robots.
Be sure all equipment in the welding area is electromagnetically compatible.
1-6. California Proposition 65 Warnings
Welding or cutting equipment 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.)
For Gasoline Engines:
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
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.
For Diesel Engines:
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
1-7. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(phone: 305-443-9353, website: www.aws.org).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard
AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (phone: 305-443-9353, website: www.aws.org).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269-9101 (phone: 617-770-3000, website: www.nfpa.org and www.
sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202-4102 (phone: 703-412-0900, website:
www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale Bou-
levard, Rexdale, Ontario, Canada M9W 1R3 (phone: 800-463-6727 or
in Toronto 416-747-4044, website: www.csa-international.org).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036–8002 (phone: 212-642-4900,
website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (phone:
617-770-3000, website: www.nfpa.org and www. sparky.org).
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Offices—phone for Region 5, Chicago, is
312-353-2220, website: www.osha.gov).
1-8. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
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.
OM-499 Page 4
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away 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.
Return To Table Of Contents
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
rom_fre 8/03
Avertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions.
2-1. 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.
2-2. 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 2-6 . 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.
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.
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.
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.
Une tension DC importante subsiste à l’intérieur
des onduleurs après avoir coupé l’alimentation.
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.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Ne pas se servir de source électrique àcourant électrique dans les zones
humides, dans les endroits confinés ou là où on risque de tomber.
Le soudage génère des fumées et des gaz. Leur inhalation
peut être dangereux pour votre santé.
Se servir d’une source électrique àcourant électrique UNIQUEMENT si le
procédé de soudage le demande.
Eloigner votre tête des fumées. Ne pas respirer les fumées.
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.
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.
Des précautions de sécurité supplémentaires sont requises dans des envi-
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.
ronnements à risque comme: les endroits humides ou lorsque l’on porte
des vêtements mouillés; sur des structures métalliques au sol, grillages et
échafaudages; dans des positions assises, à genoux et allongées; ou
quand il y a un risque important de contact accidentel avec la pièce ou le
sol. Dans ces cas utiliser les appareils suivants dans l’ordre de préférence:
1) un poste à souder DC semi−automatique de type CV (MIG/MAG), 2) un
poste à souder manuel (électrode enrobée) DC, 3) un poste à souder manuel AC avec tension à vide réduite. Dans la plupart des cas, un poste
courant continu de type CV est recommandé. Et, ne pas travailler seul!
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.
Couper l’alimentation du poste et décharger les condensateurs d’entrée
comme indiqué dans la Section Maintenance avant de toucher des composants.
Revenez à la table des matières
OM-499 Page 5
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou
même la mort.
Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et NFPA 51B
pour les travaux à chaud et avoir de la surveillance et un extincteur à proximité.
DES PARTICULES VOLANTES
peuvent blesser les yeux.
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.
LES RAYONS DE L’ARC peuvent provoquer des brûlures dans les yeux et
sur la peau.
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.
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
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.
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.
Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.
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.
LE SOUDAGE peut provoquer un incendie ou une explosion.
Porter des protections approuvés pour les oreilles si
le niveau sondre est trop élevé.
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.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
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.
Si des BOUTEILLES sont endommagées, elles pourront exploser.
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.
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.
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.
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.
2-3. Dangers existant en relation avec le moteur
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou
même la mort.
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.
OM-499 Page 6
Revenez à la table des matières
L’ACIDE DE LA BATTERIE peut provoquer des brûlures dans les YEUX et
sur la PEAU.
Ne pas renverser la batterie.
Remplacer une batterie endommagée.
Rincer immédiatement les yeux et la peau à l’eau.
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.
LE CARBURANT MOTEUR peut provoquer un incendie ou une explosion.
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.
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.
LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT CHAUD peuvent
provoquer des brûlures.
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.
LA CHALEUR DU MOTEUR peut provoquer un incendie.
DES ORGANES MOBILES peuvent
provoquer des blessures.
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.
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.
Il est préférable de vérifier le liquide de
refroidissement une fois le moteur refroidi pour éviter
de se brûler.
Empêcher les étincelles d’échappement du moteur
de provoquer un incendie.
Utiliser uniquement un pare-étincelles approuvé −
voir codes en vigueur.
2-4. Dangers liés à l’air comprimé
RESPIRER L’AIR COMPRIMÉ peut provoquer des blessures graves ou causer
la mort.
Le METAL CHAUD lors du coupage et
gougeage plasma peut provoquer un incendie ou une explosion.
Ne pas utiliser l’air comprimé pour respirer.
Utiliser l’air comprimé seulement pour le coupage, gougeage et les outils pneumatiques.
Ne pas couper ou gouger à proximité de produits
inflammables.
Surveillez et garder un extincteur à proximité.
L’AIR COMPRIMÉ peut provoquer
des blessures.
DES PIECES CHAUDES peuvent provoquer des brûlures et blessures.
Porter des lunettes de sécurité approuvées.
Ne pas diriger le jet d’air vers d’autres ou soi−
même.
Ne pas toucher le compresseur ou d’autres éléments du circuit air comprimé chauds.
Laisser l’ensemble se refroidir avant de toucher
ou d’effectuer la maintenance.
L’AIR COMPRIME EMMAGASINE ET DES
TUYAUX SOUS PRESSION peuvent provoquer des blessures.
LIRE LES INSTRUCTIONS.
Relâcher la pression d’air de l’outillage ou du système avant d’effectuer la maintenance, avant de
changer ou de rajouter des éléments ou avant
d’ouvrir la purge ou le bouchon de remplissage
d’huile.
Lisez le manuel d’instructions avant l’utilisation
ou la maintenance de l’appareil.
Arrêter le moteur et relâcher la pression avant
d’effectuer la maintenance.
2-5. 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.
Revenez à la table des matières
OM-499 Page 7
LE SURCHAUFFEMENT peut endommager le moteur électrique.
LIRE LES INSTRUCTIONS.
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.
LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer
des interférences.
LES ÉTINCELLES VOLANTES risquent de provoquer des blessures.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
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 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.
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.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les
circuits imprimés.
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.
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.
Utiliser seulement les pièces de rechange d’origine.
Effectuer la maintenance du moteur et du compresseur (si applicable) suivant ce manuel et le manuel du
moteur/compresseur (si applicable).
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
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.
2-6. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, de
l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (téléphone : (305) 443−9353, site Web : www.aws.org).
Recommended Safe Practices for the Preparation for Welding and Cutting
of Containers and Piping, norme American Welding Society AWS F4.1, de
l’American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (téléphone : (305) 443−9353, site Web : www.aws.org).
National Electrical Code, norme NFPA 70, de la National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101
(téléphone : (617) 770−3000, sites Web : www.nfpa.org et www.sparky.org).
Safe Handling of Compressed Gases in Cylinders, brochure CGA P−1, de
la Compressed Gas Association, 1735 Jefferson Davis Highway, Suite
1004, Arlington, VA 22202−4102 (téléphone : (703) 412−0900, site Web :
www.cganet.com).
Code for Safety in Welding and Cutting, norme CSA W117.2, de la Canadian Standards Association, Standards Sales, 178 boulevard Rexdale,
Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) 463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−international.org).
Practice For Occupational And Educational Eye And Face Protection,
norme ANSI Z87.1, de l’American National Standards Institute, 11 West
42nd Street, New York, NY 10036−8002 (téléphone : (212) 642−4900, site
Web : www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot Work,
norme NFPA 51B, de la National Fire Protection Association, P.O. Box
9101, 1 Battery March Park, Quincy, MA 02269−9101 (téléphone : (617)
770−3000, site Web : www.nfpa.org et www.sparky.org).
OSHA, Occupational Safety and Health Standards for General Industry,
Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and
Part 1926, Subpart J, de l’U.S. Government Printing Office, Superintendent
of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10 bureaux
régionaux − Téléphone pour la Région 5, Chicago : (312) 353−2220, site
Web : www.osha.gov).
2-7. Information sur les champs électromagnétiques
Données sur le soudage électrique et les effets des champs magnétiques
basse fréquence sur l’organisme
En parcourant les câbles de soudage, le courant crée des champs électromagnétiques. Les effets potentiels de tels champs restent préoccupants.
Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de recherche de 17 ans, un comité de spécialistes du
National Research Council a conclu : « L’accumulation de preuves n’a pas
démontré que l’exposition aux champs magnétiques et aux champs électriques à haute fréquence constitue un risque pour la santé humaine ».
Toutefois, les études et l’examen des preuves se poursuivent. En attendant
les conclusions finales de la recherche, il serait souhaitable de réduire l’exposition aux champs électromagnétiques pendant le soudage ou le
coupage.
OM-499 Page 8
Afin de réduire les champs électromagnétiques en milieu de travail, respecter les consignes suivantes :
1. Garder les câbles ensemble en les torsadant ou en les fixant avec du
ruban adhésif.
2. Mettre tous les câbles du côté opposé à l’opérateur.
3. Ne pas s’enrouler les câbles autour du corps.
4. Garder le poste de soudage et les câbles le plus loin possible de soi.
5. Placer la pince de masse le plus près possible de la zone de soudage.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur médecin. Si ce dernier les déclare aptes, il leur est recommandé de respecter les consignes ci-dessus.
Revenez à la table des matières
SECTION 3 − DEFINITIONS
3-1. Symbol Definitions
A
V
Engine Choke
Read Operator’s
Manual
Engine Oil
Fuel
Battery (Engine)
Engine
Positive
Negative
Alternating Current
(AC)
Output
Seconds
Time
Protective Earth
(Ground)
s
Hours
h
Circuit Breaker
Amperes
Volts
Temperature
SECTION 4 − SPECIFICATIONS
NOTE
This unit uses either a Kohler or a Honda engine. Differences between models are
noted throughout this manual.
4-1. Weld, Power, And Engine Specifications
Welding
Mode
CC/DC
Weld Output
Range
40 − 180 A
(60 Hz)
40 − 160 A
(50 Hz)
Rated
Welding
Output
180 A, 25 V,
30% Duty
Cycle
130 A, 25 V,
60% Duty
Cycle
100 A, 25 V,
100% Duty
Cycle
Maximum
Open Circuit
Voltage
80
(60 Hz)
70
(50 Hz)
Generator Power
Rating
Single-Phase,
6 kVA/kW (Peak)
5.5 kVA/kW
(Continuous)
50/25 A,
110/220 V AC, 50 Hz
120/240 V AC, 60 Hz
Return To Table Of Contents
Fuel Capacity
Kohler:
1.8 gal (6.9 L) Tank
Honda:
1.7 gal (6.4 L) Tank
Engine
Kohler CS12STG
Air-Cooled,
One-Cylinder,
Four-Cycle,
12 HP (360 CC),
Gasoline Engine
OR
Honda GX390
Air-Cooled,
One-Cylinder,
Four-Cycle,
13 HP (390 CC),
Gasoline Engine
OM-499 Page 9
4-2. Dimensions, Weights, And Operating Angles
Dimensions
Height
20-3/4 in (527 mm)
Width
22-3/4 in (577 mm)
Depth
31-1/4 in (793 mm)
A
31-1/4 in (793 mm)
B
10-1/2 in (268 mm)
C
13-45/64 in (348 mm)
D
22-3/4 in (577 mm)
E
1-3/4 in (44 mm)
F
19-1/2 in (495 mm)
G
13/32 in (10 mm) Dia.
D
Do not exceed tilt angles or engine could
be damaged or unit could tip.
B
Do not move or operate unit where it
could tip.
A
C
15°
G
4
Holes
Kohler: 265 lb (120 kg)
Honda Electric-Start Model:
278 lb (126 kg)
Honda Recoil-Start Model:
253 lb (114 kg)
15°
15°
Weight
E
15°
F
Engine End
802 524-A
802 096
4-3. Fuel Consumption (Kohler-Powered Units)
Fuel
consumption at low idle
(2000 rpm): 0.2 U.S. gal/hr.
60 HZ−WELD
60 HZ−AUX
50 HZ−AUX
50 HZ−WELD
HIGH IDLE
198 575
OM-499 Page 10
Return To Table Of Contents
4-4. Fuel Consumption (Honda-Powered Units)
802 122
4-5. 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 100 Amperes CC/DC
802 093
Return To Table Of Contents
OM-499 Page 11
4-6. Generator Power Curves
The generator power curves show
the ac power available in amperes
at the receptacles.
A. 60 Hz Model
250
225
200
LOAD VOLTS
175
150
125
100
75
50
25
0
0
5
10
15
20
25
30
35
25
30
35
LOAD AMPS
B. 50 Hz Model
250
225
200
LOAD VOLTS
175
150
125
100
75
50
25
0
0
5
10
15
20
LOAD AMPS
198 570
OM-499 Page 12
Return To Table Of Contents
4-7. Volt-Ampere Curves
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.
A. 60 Hz Model
80
70
LOAD VOLTS
60
50
40
MAX
30
MID
20
MIN
10
0
0
25
50
75
100
125
150
LOAD AMPS
175
200
225
250
225
250
B. 50 Hz Model
80
70
LOAD VOLTS
60
50
40
MAX
30
MID
20
MIN
10
0
0
25
50
75
100
125
150
LOAD AMPS
175
200
198 570
Return To Table Of Contents
OM-499 Page 13
SECTION 5 − INSTALLATION
5-1. Installing Welding Generator
Always securely fasten welding
generator onto transport vehicle
or trailer and comply with all DOT
and other applicable codes.
Movement
Airflow Clearance
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
Location
OR
install1 10/00*− 802 524-A / Ref. 151 556 / 158 936-A / S-0854
5-2. 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
3
1
GND/PE
4
4
Generator Base
Metal Vehicle Frame
Equipment Grounding
Terminal
Grounding Cable
Use #10 AWG or larger insulated
copper wire.
If unit does not have GFCI receptacles,
use
GFCIprotected extension cord.
OR
Electrically bond generator frame to
vehicle frame by metal-to-metal contact.
2
2
install1 10/00* − Ref. 151 556 / S-0854
OM-499 Page 14
Return To Table Of Contents
5-3. Grounding Generator When Supplying Building Systems
1
1
Equipment Grounding
Terminal
2
Grounding Cable
2
GND/PE
Use #10 AWG or larger insulated
copper wire.
3
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
Ground Device
3
800 576-B
5-4. Engine Prestart Checks (Kohler-Powered Units)
Follow run-in procedure in engine
manual.
1/2 in
(13 mm)
Check all fluids daily. Engine must be
cold and on a level surface. Unit is
shipped with 10W30 engine oil.
Full
Engine stops if oil level gets too low.
This unit has a low oil level shut-
down switch. However, some conditions may cause engine damage
before the engine shuts down.
Check oil level often and do not use
the oil level shutdown system to
monitor oil level.
Gasoline
1 Fuel Valve
Open valve by turning lever to vertical
position.
Close fuel valve before moving unit
or carburetor may flood and make
starting difficult.
1
Fuel
Add fresh fuel before starting engine the
first time (see maintenance label for
specifications). Fill fuel tank up to 1/2 in.
(13 mm) from top to allow room for expansion. Check fuel level on a cold engine before use each day.
Closed
Closed
Oil
Open
After fueling, check oil with unit on level
surface. If oil is not up to full mark on dipstick, add oil (see maintenance label).
Full
To improve cold weather starting:
Keep battery in good condition.
Store battery in warm area.
Use correct grade oil for cold
weather.
802 511-A
Return To Table Of Contents
OM-499 Page 15
5-5. Engine Prestart Checks (Honda-Powered Units)
Check all fluids daily. Engine must
be cold and on a level surface. Unit
is shipped with 10W30 engine oil.
Engine stops if oil level gets too low.
1/2 in
(13 mm)
Follow run-in procedure in en-
Full
gine manual.
1 Fuel Valve
Open valve.
Gasoline
Close fuel valve before moving
unit or carburetor may flood
and make starting difficult.
Fuel
Add fresh fuel before starting
engine the first time (see maintenance label for specifications). Fill
fuel tank up to 1/2 in. (13 mm) from
top 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
1
improve
starting:
Open
cold
weather
Keep battery in good condition.
Store battery in warm area.
Use correct grade oil for cold
weather.
Full
802 094-A
5-6. Connecting The Battery (Electric-Start Models Only)
Turn Engine Switch to Off
(electric-start models only).
Connect negative (−)
cable last.
+
Tools Needed:
3/8, 1/2 in
OM-499 Page 16
−
802 524 / Ref. S-0756-D
Return To Table Of Contents
5-7. Connecting To Weld Output Terminals
1
2
Positive (+) Weld Output
Terminal
Negative (−) Weld Output
Terminal
For Direct Current Electrode Positive (DCEP), connect work cable to
Negative (−) terminal and electrode
holder to Positive (+) terminal.
For Direct Current Electrode negative (DCEN), reverse cable connections.
1
2
Tools Needed:
3/4 in
196 914 / 495 178
5-8. 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
Stop engine 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)
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
S-0007-E
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.
Return To Table Of Contents
OM-499 Page 17
SECTION 6 − OPERATING THE WELDING GENERATOR
6-1. Controls (Kohler-Powered Units)
6
2
3
50 Hz
60 Hz
1
5
7
4
802 511-A / 802 0511 / 495 178
Weld and generator power output stops if
To Start (Electric): open fuel valve (see Section 5-4), move throttle lever to Idle, set choke,
and turn engine switch to Start position. Open
choke as engine warms. If engine does not
crank, use recoil starting procedure following
to start engine.
5
6
Use switch to open ignition circuit, and to stop
engine.
If engine does not start, let engine
come to a complete stop before attempting restart.
7
2
4
generator overheats or engine speed is
too low.
1
Engine Switch
Throttle Control Lever
Use lever to select engine speed. Use 50 Hz
or 60 Hz position for 50 or 60 Hz generator
power. Use 60 Hz position for maximum weld
output.
Starter Handle
To Start (Recoil): open fuel valve (see Section 5-4), move throttle lever to Idle, set choke,
and pull starter handle. Open choke as engine
warms.
To Stop: turn engine switch to Off.
3
Choke Control Lever
Use lever to change engine air/fuel mix. Move
lever to right if starting a cold engine. Move lever to left if starting a warm engine.
OM-499 Page 18
Always close fuel valve after stopping
unit. Moving unit with fuel valve open may
cause carburetor flooding and make
starting difficult.
Return To Table Of Contents
Engine Hour Meter
Welding Range Label
Use label to determine correct weld amperage based on electrode size, type, and material thickness.
Current Control
Use control to select weld amperage. Control
may be adjusted while welding.
To Set Current Control: Use label to determine correct size electrode for material thickness. Select electrode type and set current
control to corresponding amperage range.
Adjust control to obtain desired weld
performance.
EXAMPLE:
Material Thickness: 1/8 to 1/4 in
Electrode Diameter: 1/8
Electrode Type: E-6013
Current Control Setting: 90 − 120 A
6-2. Controls (Honda-Powered Units) (See Section 6-3)
3
4
Recoil-Start
1
2
Electric-Start
60 Hz
50 Hz
1
6
5
7
802 094-A / 802 095 / 495 187
Return To Table Of Contents
OM-499 Page 19
6-3. Description Of Controls (Honda-Powered Units) (See Section 6-2)
Weld and generator power output stops if
generator overheats or engine speed is
too low.
1 Engine Switch
On models with recoil-start, use switch to
open ignition circuit, and to stop engine.
On models with electric-start, use switch to
open ignition circuit, and to start and stop engine.
2 Throttle Control Lever
Use lever to select engine speed. Use 50 Hz
or 60 Hz position for generator power. Use 60
Hz position for maximum weld output.
3 Choke Control Lever
Use lever to change engine air/fuel mix. Move
lever to left if starting a cold engine. Move lever to right if starting a warm engine.
4 Starter Handle (Recoil-Start Models
Only)
To Start (Recoil): open fuel valve, turn engine
switch to On, move throttle lever to Idle, set
choke, and pull starter handle. Open choke as
engine warms.
To Start (Electric): open fuel valve, move
throttle lever to Idle, set choke, and turn engine switch to Start position. Open choke as
engine warms.
If engine does not start, let engine
come to a complete stop before attempting restart.
To Stop: turn engine switch to Off.
Always close fuel valve after stopping
5
6
7
Current Control
Use control to select weld amperage. Control
may be adjusted while welding.
To Set Current Control: Use label to determine correct size electrode for material thickness. Select electrode type and set current
control to corresponding amperage range on
nameplate. Adjust control within selected
range to obtain desired weld performance.
EXAMPLE:
unit. Moving unit with fuel valve open may
cause carburetor flooding and make
starting difficult.
Material Thickness: 1/8 to 1/4 in
Engine Hour Meter
Welding Range Label
Electrode Type: E-6013
Notes
OM-499 Page 20
Use label to determine correct weld amperage based on electrode size, type, and material thickness.
Return To Table Of Contents
Electrode Diameter: 1/8
Current Control Setting: 90 − 120 A
SECTION 7 − OPERATING AUXILIARY EQUIPMENT
NOTE
The welding generator provides power while welding and with the Current control
in any position. However, under these conditions equipment connected to the
welding generator may be subject to larger than normal voltage fluctuations. It is
recommended that only lamps be powered under these conditions.
7-1. Generator Power Panel 495 218 (USA)
4
1
2
3
5
495 218
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
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.
Generator power decreases as weld
RC1 supplies 60 Hz single-phase power at
weld/power speed. Maximum output is 3.5
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 single-phase
power at weld/power speed. Maximum
output from RC2 or RC3 is 2.4 kVA/kW.
current increases.
Each receptacle of the duplex can pro-
Set Amperage control at max. for full
generator power.
Do not parallel the two 120V duplex
vide 15A/1800W.
Place throttle lever in Run position (far
right) for generator power.
1
120 V AC Twistlock Receptacle RC1
receptacles.
4 Circuit Breaker CB1
CB1 protects RC1 from overload. If CB1
opens, RC1 does not work.
Return To Table Of Contents
5
Circuit Breakers CB2 And CB3
CB2 protects RC2 and CB3 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 6 kVA/kW rating of the generator (See
Section 11 − Generator Power Guidelines).
EXAMPLE: If 10 A is drawn from each 120
volt duplex receptacle, only 9 A is available
from the 120 V twistlock receptacle.
2 x (120 V x 10 A) + (240 V x 9 A) = 3.5 kVA/
KW.
OM-499 Page 21
7-2. Optional Generator Power Panels
Generator Power Panel 495 315
(USA)
Generator Power Panel 495 219
(USA)
Generator Power Panel 495 278
(Canada−CSA)
Generator Power Panel 495 253
(South Africa)
Generator Power Panel 495 288
(South America)
Generator Power Panel 495 289
(Australia)
Generator Power Panel 495 290
(Europe)
Generator Power Panel 495 283
(S.E. Asia)
Ref. ST-802 124 / H-495 290 / H-495 283 / 495 277
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Power may still be present at a receptacle when a circuit breaker
trips.
Unplug power cord before attempting to service accessories or tools.
OM-499 Page 22
Generator power decreases as weld
current increases.
Set Amperage control at max. for full
generator power.
Place throttle lever in Run position (far
right) for generator power.
Return To Table Of Contents
Circuit breakers protect the generator from
overload.
Press button to reset circuit breaker. If
breaker continues to open, contact
Factory Authorized Service Agent.
7-3. Generator Power Panel Ratings
NOTE
Unless otherwise stated, the rating of duplex outlets is the combined load of all
receptacles.
Total power from generator NOT to exceed 5500 Watts (60 Hz) or 5000 Watts (50 Hz)
Receptacle
Protected
By
Panel
495 218
(USA)
Panel
495 315
(USA)
Panel
495 219
(USA)
Panel
495 278
(CanadaCSA)
Panel
495 253
(S. Africa)
Panel
495 288
(South
America)
Panel
495 289
(Australia)
Panel
495 290
(Europe)
Panel
495 283
(S.E. Asia)
60 Hz
60 Hz
60 Hz
60 Hz
50 Hz
50 Hz
50 Hz
50 Hz
50 Hz
25A/
5500W
See
Note 2
25A/
5500W
See
Note 2
240 V
Twist Lock
CB1,2
240 V
Duplex
CB1,2
240 V
Duplex
CB3,4
230 V
Single
CB1
15A/
3600W
15A/
3600W
15A/
3600W
230 V
Single
CB2
15A/
3600W
15A/
3600W
15A/
3600W
230 V
Single
CB1,2
15A/
3600W
230 V
Single
CB3,4
15A/
3600W
120 V
Twist Lock
CB1
120 V
Duplex
CB1,3/
CB2,4
120 V
Duplex
CB2
20A/
2400W
120 V
Duplex
CB3
20A/
2400W
120 V
Duplex
CB4
5000W
5000W
Total
Power NOT
to exceed
15A/
3600W
See
Note 2
15A/
3600W
15A/
3600W
30A/
3500W
30A/
3600W
See
Note 1
5500W
20A/
2400W
See
Note 3
20A/
2400W
See
Note 3
20A/
2400W
See
Note 3
20A/
2400W
See
Note 3
5500W
5500W
5500W
5000W
5000W
5000W
Notes: 1. Each receptacle of the duplex can provide 15A/1800W. Do not parallel the two 120V duplex receptacles.
2. Do not parallel the two 120V circuits.
3. Do not parallel the two duplex outlets.
For example, for the 495 218 Generator Power Panel,
Calculating total power provided by generator.
(See Section 11 − Generator Power Guidelines)
Each receptacle can provide the watts or amps as shown
above. However, the total power can not exceed 5500W.
The rating plate on electrical apparatus will contain the watts
consumed or the rated input amps. Watts may be calculated by
multiplying the rated voltage by the rated input amps.
watts = volts x amps
120V, 3000W heater
120V, 10A chain saw
120V, 500W halogen lamp
Total
3000W
1200W
500W
4700W
120V, 3000W heater
120V, 10A chain saw
120V, 5A router
120V, 1000W halogen lamp
Total
3000W
1200W
600W
1000W
5800W
Return To Table Of Contents
This loading is OK.
This loading is not OK.
It exceeds 5500W.
OM-499 Page 23
7-4. Wiring Instructions For Optional 120/240 Volt Twistlock Plug (NEMA L14-30P)
2
1
1
3
Tools Needed:
When wired for 120 V loads, each duplex receptacle shares a load with
one half of the 240 V receptacle.
4
120V
240 V
6
5
120 V
Plug Wired For 120/240 V,
3-Wire Load
2
Neutral (Silver) Terminal
3
Load 1 (Brass) Terminal
4
Load 2 (Brass) Terminal
5
6
Ground (Green) Terminal
Cord Grip
Strip cord jacket back enough to separate conductors.
Strip conductors enough to make
good contact with plug terminals.
Make plug connections and reinstall
outer shell and cord grip.
Tighten assembly screws onto shell.
Do not overtighten.
plug3-11/99 − 802 527
SECTION 8 − MAINTENANCE
NOTE
Follow the storage procedure in the engine owner’s manual if the unit will not be
used for an extended period.
8-1. Maintenance Label
ENGINE MAINTENANCE
100 h
°C
°F
+40
+104
+30
+86
+59
+10
8h
1.1 l (1.2 US qt,
1.94 lmp qt)
0
+32
-10
-15
-20
-10
10W-30
+20
SG-SF/CC-CD
Unleaded
86 + Octane
6.5 l (1.7 US Gal,
11.4 lmp pt)
50 h
0.7 − 0.8 mm
(0.028 − 0.031 in)
200 h
Ref. S-175 679-A
OM-499 Page 24
Return To Table Of Contents
8-2. Routine Maintenance
Stop engine before maintaining.
Recycle
engine
fluids.
See Engine Manual and Maintenance Label. Service more often if used in severe conditions.
*
To be done by Factory Authorized Service Agent.
8h
Check fluid
levels. See
Section 5-4
or 5-5
20 h
Check and clean
spark arrestor screen.
See engine manual.
Wipe up spills.
50 h
Service air cleaner
element. See engine
manual.
Clean and
tighten weld
terminals.
100 h
Check
spark
plugs.
Change oil. See
engine manual and
maintenance label.
Clean and tighten battery
connections
(Electric
-Start models only).
Clean Fuel
sediment cup.
200 h
Clean fuel
tank and
strainer.
Replace
unreadable
labels.
300 h
Check valve
clearance.*
500 h
Repair or
replace cracked
cables.
Service welding generator
brushes and slip rings. Service
more often in dirty conditions.*
1000 h
Blow out or
vacuum inside.
During heavy
service, clean
monthly.
OR
Return To Table Of Contents
OM-499 Page 25
8-3. Overload Protection (Honda-Powered Units)
1
Ignition Circuit Breaker
(Electric-Start Models Only)
The circuit breaker protects the engine battery charging circuit. A
short circuit or a battery connected
in reverse polarity will trip the circuit
breaker.
Press button to reset breaker.
If a switch or breaker opens, it
usually indicates a more serious problem exists. Contact a
Factory Authorized Service
Agent.
1
Ref. 802 094-A
8-4. Adjusting Engine Speed (Kohler-Powered Units)
After tuning engine, check engine
speeds. See table for proper no
load speeds. If necessary, adjust
speeds as follows:
2000 ± 150 rpm
Start engine and run until warm.
3720 ± 50 rpm (60 Hz)
3250 ± 50 rpm (50 Hz)
Tools Needed:
Weld/Power Speed
Adjustment
1
Throttle Control Lever
2
Adjustment Screw
Move lever to Run (far right) position. To increase speed, turn screw
out (counterclockwise) while lightly
pushing lever to the right. To decrease speed, turn screw in (clockwise).
Idle Speed Adjustment
3
Adjustment Screw
Move lever to idle (far left) position.
To increase idle speed, turn screw
in (clockwise). To decrease idle
speed, turn screw out (counterclockwise).
Stop engine. Close fuel
valve.
Top View
Top View
3
2
1
802 511-A / Kohler Dwg.
OM-499 Page 26
Return To Table Of Contents
8-5. Adjusting Engine Speed (Honda-Powered Units)
1400 ± 150 rpm
3720 ± 50 rpm (60 Hz)
3250 ± 50 rpm (50 Hz)
After tuning engine, check engine
speeds. See table for proper no
load speeds. If necessary, adjust
speeds as follows:
Start engine and run until warm.
Weld/Power Speed
Adjustment
1
Throttle Control Lever
2
Adjustment Screw
Move lever to Run (60 Hz) position.
Turn screw and move lever until engine runs at weld/power speed.
Idle Speed Adjustment
3
4
Pilot Screw
Throttle Stop Screw
Move lever to idle position. Turn pilot screw until engine runs at highest idle speed. Turn stop screw until
engine runs at rated idle speed
(normally about 2-1/4 turns out.)
Stop engine. Close fuel
valve.
2
1
3
4
Tools Needed:
1/4, 3/8 in
802 097-A
Return To Table Of Contents
OM-499 Page 27
SECTION 9 − TROUBLESHOOTING
9-1. Troubleshooting
A. Welding
Trouble
No weld output.
Remedy
Check Amperage control setting.
Check weld connections.
Check engine speed, and adjust if necessary (see Section 8-4 or 8-5). Output stops if engine speed is
too low.
Be sure all equipment is disconnected from receptacles when starting unit.
Have Factory Authorized Service Agent check brushes, slip rings, capacitor C1, integrated rectifiers
SR1 and SR2, resistor R3 (Kohler only), and circuit board PC1.
Low weld output.
Check Amperage control and throttle lever settings.
Check engine speed, and adjust if necessary (see Section 8-4 or 8-5).
Service air cleaner according to engine manual.
Check weld cable size and length.
Have Factory Authorized Service Agent check brushes, slip rings, capacitor C1, integrated rectifiers
SR1 and SR2, resistor R3 (Kohler only), and circuit board PC1.
High weld output.
Check Amperage control setting.
Check engine speed, and adjust if necessary (see Section 8-4 or 8-5).
Have Factory Authorized Service Agent check brushes, slip rings, capacitor C1, integrated rectifiers
SR1 and SR2, suppressor VR1/R2, resistor R3 (Kohler only), and circuit board PC1.
Erratic weld output.
Check Amperage control setting.
Tighten and clean connections to electrode and workpiece.
Use dry, properly-stored electrodes for Stick 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 8-4 or 8-5).
Check throttle/governor linkage for smooth, non-binding operation.
Have Factory Authorized Service Agent check brushes, slip rings, capacitor C1, integrated rectifiers
SR1 and SR2, resistor R3 (Kohler only), and circuit board PC1.
B. Generator Power
Trouble
No output at generator power ac
receptacles.
Remedy
Reset circuit breakers (see Sections 7-1 and 7-2).
Check receptacle wiring and connections.
Check engine speed, and adjust if necessary (see Section 8-4 or 8-5). Output stops if engine speed is
too low.
Have Factory Authorized Service Agent check brushes, slip rings, capacitor C1, integrated rectifiers
SR1 and SR2, resistor R3 (Kohler only), and circuit board PC1.
High power output at generator power
ac receptacles.
Check engine speed, and adjust if necessary (see Section 8-4 or 8-5).
Move throttle lever to 50 Hz position for 50 Hz equipment (see Section 6-1 or 6-2).
Have Factory Authorized Service Agent check capacitor C1, resistor R3 (Kohler only), and circuit
board PC1.
OM-499 Page 28
Return To Table Of Contents
Trouble
Remedy
Low power output at generator power ac Check Amperage control setting.
receptacles.
Check engine speed, and adjust if necessary (see Section 8-4 or 8-5). Output stops if engine speed is
too low.
Move throttle lever to 60 Hz position for 60 Hz equipment (see Section 6-1 or 6-2).
Erratic power output at generator
power ac receptacles.
Check fuel level.
Check receptacle wiring and connections.
Check throttle/governor linkage for smooth, non-binding operation.
Service air cleaner according to engine manual.
Check engine speed, and adjust if necessary (see Section 8-4 or 8-5). Output stops if engine speed is
too low.
Have Factory Authorized Service Agent check brushes, slip rings, resistor R3 (Kohler only), and
circuit board PC1.
C. Engine
Trouble
Engine will not crank (electric-start
models only).
Remedy
Reset ignition circuit breaker (see Section 8-3).
Check battery voltage.
Check battery connections and tighten if necessary.
Have Factory Authorized Service Agent check engine ignition circuit.
Engine will not start.
Check fuel level (see Section 5-4 or 5-5).
Move choke lever to correct position (see Section 6-1 or 6-2).
Open fuel valve (see Section 5-4 or 5-5). Close fuel valve before moving unit or carburetor may flood and
make starting difficult.
Check battery voltage (electric-start models only).
Check battery connections and tighten if necessary (electric-start models only).
Check oil level (see Section 5-4 or 5-5). Engine stops if oil level is too low. Refill crankcase with proper
viscosity oil for operating temperature.
Have Factory Authorized Service Agent check low oil level shutdown switch.
Engine stopped during normal
operation.
Check fuel level (see Section 5-4 or 5-5).
Open fuel valve (see Section 5-4 or 5-5). Close fuel valve before moving unit or carburetor may flood and
make starting difficult.
Check oil level (see Section 5-4 or 5-5). Engine stops if oil level is too low.
Have Factory Authorized Service Agent check low oil level shutdown switch.
Check unit operating angle. Low oil level shutdown switch may stop engine if unit is tilted.
Battery discharges between uses (elec- Clean battery, terminals, and posts with baking soda and water solution; rinse with clear water.
tric-start models only).
Periodically recharge battery (approximately every 3 months).
Replace battery.
Check voltage regulator and connections according to engine manual.
Unstable or sluggish engine speeds.
Check engine speed, and adjust if necessary (see Section 8-4 or 8-5).
Check throttle/governor linkage for smooth, non-binding operation.
Tune-up engine according to engine manual.
Return To Table Of Contents
OM-499 Page 29
SECTION 10 − ELECTRICAL DIAGRAMS
197 857-E
Figure 10-1. Circuit Diagram For Welding Generator (1 Of 2)
OM-499 Page 30
Return To Table Of Contents
197 857-E
Figure 10-2. Circuit Diagram For Welding Generator (2 Of 2)
Return To Table Of Contents
OM-499 Page 31
201 026-A
Figure 10-3. Wiring Diagram For Auxiliary Power Panels (1 Of 2)
OM-499 Page 32
Return To Table Of Contents
201 026-A
Figure 10-4. Wiring Diagram For Auxiliary Power Panels (2 Of 2)
Return To Table Of Contents
OM-499 Page 33
SECTION 11 − GENERATOR POWER GUIDELINES
NOTE
The views in this section are intended to be representative of all engine-driven
welding generators. Your unit may differ from those shown.
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
Do not use 2-prong plug unless equipment is double insulated.
1
2
3
Be sure equipment
has this symbol
and/or wording.
OR
gen_pwr 11/02 − 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
1
GND/PE
3
Equipment Grounding
Terminal (On Front Panel)
Grounding Cable (Not
Supplied)
Metal Vehicle Frame
Connect cable from equipment
ground terminal to metal vehicle
frame. Use #10 AWG or larger
insulated copper wire.
2
3
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Electrically bond generator
frame to vehicle frame by
metal-to-metal contact.
Bed liners, shipping skids, and some running
gear insulate the welding generator from the vehicle frame. Always connect a ground wire from
the generator equipment grounding terminal to
bare metal on the vehicle frame as shown.
OM-499 Page 34
Return To Table Of Contents
S-0854
11-3. Grounding When Supplying Building Systems
1
1
2
Equipment Grounding
Terminal
Grounding Cable
2
GND/PE
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
Return To Table Of Contents
OM-499 Page 35
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-499 Page 36
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
Return To Table Of Contents
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
Return To Table Of Contents
1000
200
500
1400
1600
950
1400
1600
700
900
1300
OM-499 Page 37
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-499 Page 38
Return To Table Of Contents
11-10. Typical Connections To Supply Standby Power
Properly install and ground this equipment according to
its Owner’s Manual and national, state, and local codes.
1
2
Utility
Electrical
Service
3
Transfer Switch
4
Fused
Disconnect
Switch
(If Required)
Welding
Generator
Output
5
Essential
Loads
Have only qualified persons perform
these connections according to all
applicable codes and safety practices.
Switch transfers the electrical load from
electric utility service to the generator. Transfer load back to electric utility when service is
restored.
Properly install and ground this
equipment according to its Owner’s
Manual and national, state, and local
codes.
Install correct switch (customer-supplied).
Switch rating must be same as or greater
than the branch overcurrent protection.
Customer-supplied
equipment is required if generator will supply standby
power during emergencies or power outages.
1 Utility Electrical Service
2 Transfer Switch (Double-Throw)
3 Fused Disconnect Switch
Install correct switch (customer-supplied) if
required by electrical code.
4 Welding Generator Output
Generator output voltage and wiring must be
consistent with regular (utility) system voltage and wiring.
Connect generator with temporary or permanent wiring suitable for the installation.
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 voltage and
frequency.
5 Essential Loads
Generator output may not meet the electrical
requirements of the premises. If generator
does not produce enough output to meet all
requirements, connect only essential loads
(pumps, freezers, heaters, etc. − See Section 11-4).
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
Return To Table Of Contents
OM-499 Page 39
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
6
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-499 Page 40
Return To Table Of Contents
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
Return To Table Of Contents
OM-499 Page 41
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-499 Page 42
Return To Table Of Contents
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
Return To Table Of Contents
OM-499 Page 43
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-499 Page 44
Return To Table Of Contents
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
Return To Table Of Contents
OM-499 Page 45
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-499 Page 46
Return To Table Of Contents
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.
Return To Table Of Contents
OM-499 Page 47
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-499 Page 48
Return To Table Of Contents
SECTION 13 − PARTS LIST
13
Hardware is common and
26
50
39
40
41
44
43
42
38
37
36
35
34
33
32
45 46 47
31
3
4
5
6
7
1
8
49
9
30
23
29
10
28
11
22
25
21
20
27
19
18
17
16
15
14
12
not available unless listed.
802 509-A
Figure 13-1. Main Assembly
Return To Table Of Contents
OM-499 Page 49
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 13-1. Main Assembly
. . . 1 . . . . . . . . . . . . . . +495 247 . . TOP, control box (specify color) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . SR1 . . . . . 035 704 . . RECTIFIER, integ bridge 40 amp 800 v . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . SHUNT . . . . 028 747 . . SHUNT, meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . PC1 . . . . . 198 449 . . BOARD, PC assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . 134 201 . . STAND-OFF, support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 7 . . . . . . . . . . . . . . . 494 613 . . TERMINAL, output 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 7 . . . . . . . . . . . . . . . 129 525 . . TERMINAL, output Dinse 50/70 series (European models) . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . 129 527 . . PLUG, weld cable (European models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . . . . PC2 . . . . . 148 608 . . BOARD, PC filter (CSA only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . L1 . . . . . . 198 472 . . REACTOR, stabilizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . . 211 297 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . . 493 509 . . BRUSHHOLDER, assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . . 204 138 . . LABEL, warning fuel (also supplied with engine) . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . +195 771 . . ENGINE, Kohler 12HP (electric start) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . *203 952 . . FILTER, air Kohler cs 8.5 & 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . *203 954 . . FILTER, air pre Kohler cs 8.5 & 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . *203 955 . . CAP, fuel Kohler cs 8.5 & 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . *203 956 . . TANK, fuel Kohler cs 8.5 & 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . *203 957 . . STRAINER, fuel Kohler cs 8.5 & 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . *203 958 . . MUFFLER, exhaust engine Kohler cs 8.5 & 12 . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . *203 959 . . GASKET, muffler Kohler cs 8.5 & 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . *203 960 . . SPARK PLUG, Kohler cs 8.5 & 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . +495 055 . . ENGINE, Honda 13HP (recoil start) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . +495 053 . . ENGINE, Honda 13HP (electric start) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . . 494 606 . . ADAPTER, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . . 494 629 . . GUARD, generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . . 194 509 . . FAN, generator (Kohler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . . 493 868 . . FAN, generator (Honda) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . . 204 469 . . GENERATOR, w/stator assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . . 495 197 . . ROTOR, assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 495 154 . . . . BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . . 495 349 . . SCREW, 1/4-20 HWH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 20 . . . . . . . . . . . . . . . 494 587 . . CARRIER, bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . . 495 348 . . SCREW, 5/16-24 HWH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . +494 628 . . PANEL, end generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . . 495 257 . . MOUNT, shock w/bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 24 . . . . . . . . . . . . . . . Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 25 . . . . . . . . . . . . . . . 494 039 . . COVER, battery cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . . 495 111 . . LEAD, battery pos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . . 493 057 . . CLAMP, battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . . 494 604 . . BOLT, hold down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . . . . . . . . . . . . . BATTERY, 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . . 495 112 . . LEAD, battery neg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . . 495 256 . . MOUNT, shock generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . . 194 504 . . FRAME, mtg assembly (Kohler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . . 495 132 . . FRAME, mtg assembly (Honda) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . . . 495 255 . . DUCT, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . . 495 214 . . SEAL, air duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . R1 . . . . . . 207 083 . . POTENTIOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . . . 207 077 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, overlay (order by model & serial number) . . . . . . . . . . . . 1
. . . 38 . . . . . HM . . . . . . 176 365 . . METER, hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . Figure 13-2 . . PANEL, gen power assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . . . 495 236 . . BASE, control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-499 Page 50
Return To Table Of Contents
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 13-1. Main Assembly (Continued)
...
...
...
...
...
...
...
...
...
...
41
42
43
44
45
46
47
48
49
50
. . . . . 1T . . . . . .
...............
. . . R2/VR1 . . . .
. . . . SR2 . . . . .
. . . . . R3 . . . . . .
. . . . . C1 . . . . . .
...............
...............
...............
...............
172 661
495 193
046 819
495 189
197 795
176 007
494 915
201 223
495 187
188 039
..
..
..
..
..
..
..
..
..
..
BLOCK, terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET, mtg terminal block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUPPRESSOR, assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECTIFIER, assembly (w/mtg hardware) . . . . . . . . . . . . . . . . . . . . . . . . .
RESISTOR ASSEMBLY (Kohler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLAMP, capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL, warning electric shock power still present (CSA) . . . . . . . . . . . .
LABEL, current selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COVER, receptacle w/gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
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.
Return To Table Of Contents
OM-499 Page 51
3
4
5
Hardware is common and not available unless listed.
6
1
7
2
8
10
9
11
Generator Power Panel 495 315 (USA)
Generator Power Panel 495 218 (USA)
12
13
14
13
15
15
Generator Power Panel 495 253 (South Africa)
Generator Power Panel 495 289 (Australia)
22
16
18
17
23
19
20
21
Generator Power Panel 495 219 (USA)
Generator Power Panel 495 290 (Europe)
26
27
24
25
Generator Power Panel 495 288 (S. America)
28
Generator Power Panel 495 283 (S.E. Asia)
30
33
35
34
37
29
31
32
36
Generator Power Panel 495 298 (USA)
Generator Power Panel 495 278 (Canada−CSA)
Figure 13-2. Generator Power Panels
OM-499 Page 52
Return To Table Of Contents
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 13-2. Generator Power Panels (Figure 13-1, Item 39)
Generator Power Panel 495 218 (USA)
. . . 1 . . . . . . . . . . . . . . . 495 220 . . PANEL, generator power assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . 495 216 . . OVERLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . CB1 . . . . . 495 183 . . CIRCUIT BREAKER, 30A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . . 007 467 . . RECEPTACLE, twistlock grd 2P3W 30A 125 V . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . 408 898 . . RECEPTACLE, duplex 115 V 20 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . CB2, CB3 . . . 495 246 . . CIRCUIT BREAKER, 20A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Generator Power Panel 495 315 (USA)
. . . 7 . . . . . . . . . . . . . . . 495 314 . . PANEL, generator power assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . CB1, CB2 . . . 495 245 . . CIRCUIT BREAKER, 15A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . . . . . . . . . . . . 404 089 . . RECEPTACLE, Duplex 230 V S. American . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . CB3, CB4 . . . 495 246 . . CIRCUIT BREAKER, 20A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 11 . . . . . . . . . . . . . . . 408 898 . . RECEPTACLE, Duplex 115 V 20 A U.S. . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Generator Power Panel 495 253 (South Africa)
. . . 12 . . . . . . . . . . . . . . . 495 252 . . PANEL, generator power assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . CB1, CB2 . . . 495 245 . . CIRCUIT BREAKER, 15A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Generator Power Panel 495 289 (Australia)
. . . 14 . . . . . . . . . . . . . . . 495 254 . . PANEL, generator power assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . CB1 - CB4 . . 495 245 . . CIRCUIT BREAKER, 15A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Generator Power Panel 495 219 (USA)
. . . 16 . . . . . . . . . . . . . . . 495 220 . . PANEL, generator power assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . CB1, CB2 . . . 495 182 . . CIRCUIT BREAKER, 25A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 18 . . CB3, CB4 . . . 495 246 . . CIRCUIT BREAKER, 20A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 19 . . . . . . . . . . . . . . . 495 217 . . OVERLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . RC1 . . . . . 129 067 . . RECEPTACLE, tw lk grd 3P4W 30A 125/250V . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 088 898 . . PLUG, tw lk grd 3P4W 30A 125/250V
. . . 21 . . RC2, RC3 . . . 141 432 . . RECEPTACLE, str dx grd 2P3W 20A 125V . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . 073 690 . . PLUG, str grd armd 2P3W 15A 125V
Generator Power Panel 495 290 (Europe)
. . . 22 . . . . . . . . . . . . . . . 495 282 . . PANEL, generator power assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . CB1, CB2 . . . 495 245 . . CIRCUIT BREAKER, 15A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Generator Power Panel 495 288 (S. America)
. . . 24 . . . . . . . . . . . . . . . 495 287 . . PANEL, generator power assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . CB1-4 . . . . 495 245 . . CIRCUIT BREAKER, 15A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Generator Power Panel 495 283 (S.E. Asia)
. . . 26 . . . . . . . . . . . . . . . 495 282 . . Panel, generator power assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . CB1, CB2 . . . 495 245 . . CIRCUIT BREAKER, 15A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Generator Power Panel 495 298 (USA)
. . . 28 . . . . . . . . . . . . . . . 495 220 . . PANEL, generator power assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . CB1 . . . . . 495 183 . . CIRCUIT BREAKER, 30A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . CB2, CB3 . . . 495 246 . . CIRCUIT BREAKER, 20A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 31 . . . . RC1 . . . . . 007 467 . . RECEPTACLE, tw lk grd 2P3W 30A 125V . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 605 797 . . PLUG, tw lk 3P3W 20A 125V
. . . 32 . . RC2, RC3 . . . 141 432 . . RECEPTACLE, str dx grd 2P3W 20A 125V . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . 073 690 . . PLUG, str grd armd 2P3W 15A 125V
Generator Power Panel 495 278 (Canada−CSA)
. . . 33 . . . . . . . . . . . . . . . 495 277 . . PANEL, generator power assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . CB1 . . . . . 203 095 . . CIRCUIT BREAKER, 25A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 202 631 . . COVER, circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 202 630 . . BRACKET, mtg circuit breaker cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . CB2, CB3 . . . 495 246 . . CIRCUIT BREAKER, 20A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 36 . . . . RC1 . . . . . 129 067 . . RECEPTACLE, tw lk grd 3P4W 30A 125/250V . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 088 898 . . PLUG, tw lk grd 3P4W 30A 125/250V
. . . 37 . . . . RC2 . . . . . 141 432 . . RECEPTACLE, str dx grd 2P3W 20A 125V . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 073 690 . . PLUG, str grd armd 2P3W 15A 125V
NOTE: Replacement receptacles not listed can be found at your local hardware or electrical supply store.
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.
Return To Table Of Contents
OM-499 Page 53
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
Effective January 1, 2003
(Equipment with a serial number preface of “LC” 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.
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.
Your distributor also gives
you ...
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.
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.
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
Maxstar 150
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
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
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Maxstar 85, 140
Spot Welders
Load Banks
Racks
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 & SAF 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.
(Exception: brushes, slip rings, and relays are
covered on Bobcat, Trailblazer, and Legend models.)
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 8/03
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 to:
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
 2004 Miller Electric Mfg. Co.
1/04