Miller | LE246322 | Owner Manual | Miller TRAILBLAZER 302 GAS User manual

Miller TRAILBLAZER 302 GAS User manual
OM-4426
215 348F
October 2004
Processes
MIG (GMAW) Welding
Flux Cored (FCAW)
Stick (SMAW) Welding
TIG (GTAW) Welding
Air Plasma Cutting and Gouging
with Spectrum Unit
Air Carbon Arc (CAC-A) Cutting
and Gouging
Description
Engine Driven Welding Generator
(AC Available On AC/DC Models Only)
Trailblazer 302
Trailblazer 275 DC
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 9001:2000 Quality Warranty and service information for your
System Standard.
particular model are also provided.
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 or individual 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.
Mil_Thank 7/03
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
1-4. Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
1-5. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
4
1-7. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
1-8. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
5
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
2-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
2-4. Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . .
7
7
2-6. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
2-7. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
9
3-1. Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-2. Dimensions, Weights, and Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-3. Fuel Consumption Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-4. Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-5. Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-6. Stick And MIG Mode Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-7. TIG Mode Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-2. Engine Prestart Checks (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-3. Engine Prestart Checks (Robin-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-4. Activating The Dry Charge Battery (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-5. Connecting the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5-6. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5-7. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-8. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-9. Remote Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-10. Adjusting Wire (MIG) Weld Puddle Consistency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SECTION 6 − OPERATING WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-1. Front Panel Controls (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-2. Description Of Front Panel Controls (See Section 6-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6-3. Process/Contactor Switch On AC/DC Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6-4. Stick Start Procedure − Scratch Start Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6-5. TIG Lift-ArcE Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6-6. Remote Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SECTION 7 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7-1. Generator Power Receptacles And Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7-2. Optional GFCI Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7-3. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P) . . . . . . . . . . . . . . . . . . . 30
TABLE OF CONTENTS
SECTION 8 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Servicing Optional Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5. Changing Engine Oil, Oil Filter, And Fuel Filter (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . .
8-6. Changing Engine Oil, Oil Filter, and Fuel Filter (Robin-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . .
8-7. Adjusting Engine Speed (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-8. Adjusting Engine Speed (Robin-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-9. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-10. Welding Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-11. Generator Power Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-12. Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
31
31
32
33
34
35
36
37
38
39
40
41
41
43
50
54
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.
Marks a special safety message.
Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Arc Welding Hazards
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.
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!
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.
SIGNIFICANT DC VOLTAGE exists in inverters after stopping engine.
Stop engine on inverter and discharge input capacitors according to
instructions in Maintenance Section before touching any parts.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing these fumes
and gases can be hazardous to your health.
Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use exhaust at the arc to remove welding
fumes and gases.
If ventilation is poor, use an approved air-supplied respirator.
Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s
instructions for metals, consumables, coatings, cleaners, and degreasers.
Work in a confined space only if it is well ventilated, or while wearing an 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.
OM-4426 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.
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.
FLYING METAL can injure eyes.
Welding, chipping, wire brushing, and grinding cause
sparks and flying metal. As welds cool, they can
throw off slag.
Wear approved safety glasses with side shields even
under your welding helmet.
Allow cooling period before maintaining.
Wear protective gloves and clothing when working on
a hot engine.
Do not touch hot engine parts or just-welded parts
bare-handed.
NOISE can damage hearing.
Noise from some processes or equipment can damage
hearing.
Wear approved ear protection if noise level is high.
MAGNETIC FIELDS can affect pacemakers.
Pacemaker wearers keep away.
Wearers should consult their doctor before going
near arc welding, gouging, or spot welding operations.
CYLINDERS can explode if damaged.
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-4426 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.
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.
Release air pressure from tools and system before
servicing, adding or changing attachments, or opening compressor oil drain or oil fill cap.
HOT METAL from air arc cutting and
gouging can cause fire or explosion.
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.
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.
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.
FLYING SPARKS can cause injury.
OVERUSE can cause OVERHEATING.
Put on grounded wrist strap BEFORE handling
boards or parts.
Use proper static-proof bags and boxes to store,
move, or ship PC boards.
TILTING OF TRAILER can cause injury.
Use tongue jack or blocks to support weight.
Properly install welding generator onto trailer according to instructions supplied with trailer.
Sparks can cause fires — keep flammables away.
OM-4426 Page 3
READ INSTRUCTIONS.
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.
H.F. RADIATION can cause interference.
ARC WELDING 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.
To reduce possible interference, keep weld cables as short as possible,
close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic
equipment.
Be sure this welding machine is installed and grounded according to this
manual.
If interference still occurs, the user must take extra measures such as
moving the welding machine, using shielded cables, using line filters, or
shielding the work area.
1-6. 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-4426 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.
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.
Couper l’alimentation du poste et décharger les condensateurs d’entrée
comme indiqué dans la Section Maintenance avant de toucher des composants.
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.
OM-4426 Page 5
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.
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.
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.
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.
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.
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-4426 Page 6
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.
LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT CHAUD peuvent
provoquer des brûlures.
Il est préférable de vérifier le liquide de
refroidissement une fois le moteur refroidi pour éviter
de se brûler.
Toujours vérifier le niveau de liquide de refroidissement dans le vase d’expansion (si présent), et non dans le radiateur (sauf si précisé autrement
dans la section maintenance du manuel du moteur).
Si le moteur est chaud et que le liquide doit être vérifié, opérer comme suivant :
Mettre des lunettes de sécurité et des gants, placer un torchon sur le bouchon du radiateur.
Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant
d’enlever le bouchon.
LA CHALEUR DU MOTEUR peut provoquer un incendie.
DES ORGANES MOBILES peuvent
provoquer des blessures.
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.
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.
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.
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.
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.
OM-4426 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.
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.
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.
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-4426 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.
SECTION 3 − DEFINITIONS
3-1. Symbol Definitions
Stop Engine
Fast
(Run, Weld/Power)
Fast/Slow
(Run/Idle)
Slow (Idle)
Start Engine
Panel/Local
Temperature
Fuel
Engine Oil
Engine Choke
Check Valve
Clearance
Battery (Engine)
Engine
Read Operator’s
Manual
MIG (GMAW),
Wire
Stick (SMAW)
TIG (GTAW)
Lift Arc TIG
Positive
Negative
Alternating Current
(AC)
Output
Seconds
Protective Earth
(Ground)
Time
h
Hours
A
s
V
Amperes
Volts
Do not switch while
welding
Remote
Receptacle
Work Connection
CC
Constant
Current
Wire Feed
Electrode
Positive
Electrode Negative
CV
Constant
Voltage
Circuit Breaker
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-4426 Page 9
SECTION 4 − SPECIFICATIONS
4-1. Weld, Power, And Engine Specifications
Welding
Mode
Rated
Welding
Output
Maximum
Open-Circuit
Voltage
Weld
Output
Range
CC/DC
280 A, 25 V, 100%
Duty Cycle
48
20 − 300 A
CV/DC
300 A, 25 V, 100%
Duty Cycle
35
Generator
Power Rating
Fuel
Capacity
Continuous: 9.5 kVA/
kW, 80/40 A,
120/240 V AC, 60 Hz,
Single-Phase,
13 − 35 V
12 gal
(45 L)
Tank
Peak: 10 kVA/kW
(w/Weld Contactor Off)
CC/AC*
200 A, 25 V, 60%
Duty Cycle
78
35 − 225 A
Engine
Robin EH65
Air-Cooled,
Two-Cylinder, FourCycle,
y ,
22 HP
Gasoline Engine
or
Kohler CH-20
Air-Cooled,
Two-Cylinder,
Four-Cycle,
20 HP Gasoline Engine
AC/DC Models Only.
*
4-2. Dimensions, Weights, and Operating Angles
Dimensions
A
B
Height
33−1/2 in (851 mm)
(To Top Of Exhaust)
Width
20 in (508 mm)
Depth
45-3/8 in (1153 mm)
A
20 in (508 mm)
B
16-1/2 in (419 mm)
C
1-3/4 in (44 mm)
D
6−1/16 in (154 mm)
E
32-3/4 in (832 mm)
F
45−3/8 in (1153 mm)
20°
G
13/32 in (10 mm) Dia.
20°
C
Do not exceed tilt angles or engine could
be damaged or unit could tip.
D
G
4 Holes
F
Do not move or operate unit where it could
tip.
E
20°
20°
Weight
Onan: 580 lb (263 kg)
Kohler: 580 lb (263 kg)
OM-4426 Page 10
E i End
Engine
E d
800 426
803 572−A
4-3. Fuel Consumption Curves
1.75
6.62
DC Weld
5.68
US GAL/HR.
1.25
4.73
1.00
3.79
Generator
Power
0.75
2.84
1.89
0.50
Idle
0.25
0.00
LITERS/HR.
1.50
0.95
0.00
0
50
100
150
200
250
300
DC WELD AMPERES AT 100% DUTY CYCLE
0
2
4
6
8
10
KW AT 100% DUTY CYCLE
206 135 / 206 136
4-4. Generator Power Curve
The ac generator power curve
shows the generator power available in amperes at the receptacles.
300 150
264 132
+/− 10%
VOLTS
250 125
216 108
200 100
150
75
100
50
50
25
0
0
10,000 WATTS
0
20
40
60
80
100
120
140
AC AMPERES At 120 V
160
180
200
0
10
20
30
40
50
60
70
AC AMPERES AT 240 V
80
90
100
Ref. 220 807−A
OM-4426 Page 11
4-5. Duty Cycle
Duty cycle is the percentage of 10
minutes that unit can weld at rated
load without overheating.
100% Duty Cycle at 280 Amperes DC
Exceeding duty cycle can
damage unit and void
warranty.
AC output is not available on all
Continuous Welding
models.
350
MIG/FCAW
WELDING AMPERES
300
STICK
250
200
AC WELD
150
100
0
10
20
30
40
50
% DUTY CYCLE
OM-4426 Page 12
60
70
80
90
100
4-6. Stick And MIG Mode Volt-Ampere Curves
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of
other settings fall between the
curves shown.
A. CC/DC Stick Mode
120
DC VOLTS
100
80
60
MAX
40
MIN
20
MAX DIG
MIN DIG
0
0
200
400
DC AMPERES
600
800
B. CV/DC MIG Mode
40
35
MAX
DC VOLTS
30
25
MID
20
15
MIN
10
5
0
0
200
400
600
800
DC AMPERES
C. CC/AC STICK Mode
AC output is not available on all models.
80
AC VOLTS
70
60
50
MAX
40
30
MIN
20
MIN
DIG
10
0
0
100
200
AC AMPERES
MAX DIG
300
400
220 310−A / 220 313−A / 220 309−A
OM-4426 Page 13
4-7. TIG Mode Volt-Ampere Curves
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of
other settings fall between the
curves shown.
A. CC/AC TIG Mode
80
AC output is not available on all
models.
AC VOLTS
70
60
50
MAX
40
MIN
30
20
10
0
0
50
100
150
AC AMPERES
200
250
B. CC/DC TIG Mode
45
40
MAX
DC VOLTS
35
30
MIN
25
20
15
10
5
0
0
50
100
150
200
250
300
DC AMPERES
220 312−A / 220 311−A
OM-4426 Page 14
SECTION 5 − INSTALLATION
5-1. Installing Welding Generator
Do not weld on base. Welding
on base can cause fuel tank fire
or explosion. Bolt unit down
using holes provided in base.
Movement
Always securely fasten welding generator onto transport
vehicle or trailer and comply
with all DOT and other applicable codes.
Do not lift unit from end.
OR
Do not mount unit by supporting the base only at the four
mounting holes. Use crosssupports to adequately support unit and prevent damage
to base.
Location
Always ground generator
frame to vehicle frame to prevent electric shock and static
electricity hazards.
OR
If unit does not have GFCI receptacles, use GFCI-protected
extension cord.
OR
Mounting:
1
Mounting
Cross-Supports
Mount unit on flat surface or use
cross-supports to support base.
Grounding:
2
3
4
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.
OR
Inadequate support.
Do not use flexible mounts.
1
2
Grounding
3
GND/PE
Electrically bond generator frame to
vehicle frame by metal-to-metal contact.
4
Airflow Clearance
Bed liners, shipping skids, and some running
gears 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.
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
install2 6/04 − Ref. 800 652 / Ref. 800 477-A / 803 274
OM-4426 Page 15
5-2. Engine Prestart Checks (Kohler-Powered Units)
Check all fluids daily. Engine must be
cold and on a level surface. Unit is
shipped with 10W30 engine oil.
Follow run-in procedure in engine manual.
This unit has a low oil pressure
shutdown switch. However,
some conditions may cause engine damage before the engine
shuts down. Check oil level often
and do not use the oil pressure
shutdown system to monitor oil
level.
Open top service door
Full
Empty
Oil Check/Fill
Fuel
Add fresh fuel before starting engine
the first time (see maintenance label
for specifications). Always leave filler
neck empty to allow room for expansion. Check fuel level on a cold engine before use each day.
To check fuel level, turn Engine Control switch to Run/Idle position.
LED’s indicate fuel level in tank.
Full
Oil Fill
Oil
Do not
exceed the ”Full” mark on
the oil level dipstick. The fuel
pump may operate erratically if
crankcase is overfilled.
After fueling, check oil with unit on
level surface. If oil is not up to full
mark on dipstick, add oil (see maintenance label).
Use front panel meters to determine
hours until next recommended oil
change (see Section 6-1).
To
improve
starting:
cold
weather
Keep battery in good condition.
Store battery in warm area.
Use correct grade oil for cold
weather.
Close top service door
Full
Gasoline
Ref. 803 571−A / Ref. 803 573−A
OM-4426 Page 16
5-3. Engine Prestart Checks (Robin-Powered Units)
Check all fluids daily. Engine must be
cold and on a level surface. Unit is
shipped with 10W30 engine oil.
Follow run-in procedure in engine manual.
This unit has a low oil pressure
shutdown switch. However,
some conditions may cause engine damage before the engine
shuts down. Check oil level often
and do not use the oil pressure
shutdown system to monitor oil
level.
Open top service door.
Full
Empty
Oil Check
Oil Fill
Fuel
Add fresh fuel before starting engine
the first time (see maintenance label
for specifications). Always leave filler
neck empty to allow room for expansion. Check fuel level on a cold engine before use each day.
To check fuel level, turn Engine Control switch to Run/Idle position.
LED’s indicate fuel level in tank.
Full
Oil
Do not
exceed the ”Full” mark on
the oil level dipstick. The fuel
pump may operate erratically if
crankcase is overfilled.
After fueling, check oil with unit on
level surface. If oil is not up to full
mark on dipstick, add oil (see maintenance label).
Use front panel meters to determine
hours until next recommended oil
change (see Section 6-1).
To
improve
starting:
cold
weather
Keep battery in good condition.
Store battery in warm area.
Use correct grade oil for cold
weather.
Close top service door.
Full
Gasoline
Ref. 803 571−A / Ref. 803 572−A
OM-4426 Page 17
5-4. Activating The Dry Charge Battery (If Applicable)
Remove battery from unit.
1
5
4
1
2
3
4
5
Eye Protection − Safety
Glasses Or Face Shield
Rubber Gloves
Vent Caps
Sulfuric Acid Electrolyte
(1.265 Specific Gravity)
Well
Fill each cell with electrolyte to
bottom of well (maximum).
3
Do not overfill battery cells.
Wait ten minutes and check electrolyte level. If necessary, add electrolyte to raise to proper level. Reinstall vent caps.
6
Battery Charger
Read and follow all instructions supplied with battery
charger.
2
Charge battery for 12 minutes at 30
amperes or 30 minutes at 5 amperes. Disconnect charging cables
and install battery.
When electrolyte
is low, add
only distilled water to cells to
maintain proper level.
6
5 A For 30 Minutes
Tools Needed:
OR
+
−
rubbergloves
30 A For 12 Minutes
glasses
drybatt1 1/98 − S-0886
OM-4426 Page 18
5-5. Connecting the Battery
Connect negative (−)
cable last.
+
Tools Needed:
1/2 in
−
Ref. 803−573−A / Ref. 202 069-A / Ref. S-0756-D
5-6. Installing Exhaust Pipe
Stop engine and let cool.
Engine backfire can cause severe burns or other injuries.
Do not point exhaust pipe toward control panel. Keep away
from exhaust outlet.
Do not point exhaust pipe toward LP fuel tank (if equipped).
Do not point exhaust pipe towards shielding gas tank (if
equipped).
Point exhaust pipe in desired di-
rection but always away from
front panel and direction of travel.
Tools Needed:
1/2 in
803 891/ Ref. 216 170
OM-4426 Page 19
5-7. Connecting To Weld Output Terminals
Stop engine.
Do not connect to CC and CV
terminals at the same time.
AC/DC Models:
1
2
3
Work Weld Output Terminal
Stick/TIG (CC) Weld Output
Terminal
Wire /CV Weld Output Terminal
For MIG welding, connect work cable
to Work terminal and wire feeder
cable to Wire (CV) terminal.
For Stick/TIG welding, connect work
cable to Work terminal and electrode
holder/TIG torch cable to Stick/TIG
(CC) terminal.
DC Models:
4
5
6
Negative (−) Weld Output
Terminal
Stick/TIG (+) Weld Output
Terminal
Wire (+) Weld Output Terminal
For MIG welding, connect work cable
to Negative (−) terminal and wire
feeder cable to CV (Wire) terminal.
1
2
For Stick welding, connect work
cable to Negative (−) terminal and
electrode holder cable to CC (Stick/
TIG) terminal.
3
For TIG welding, connect work cable
to CC (Stick/TIG) terminal and electrode holder cable to Negative (−)
terminal.
Weld output terminals on
units with AC/DC output.
4
5
6
Weld output terminals on
units with DC output only.
803 571 / Ref. 216 170 / 204 353 / Ref. 216 169-A
OM-4426 Page 20
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)
300
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
350
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
400
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
2 ea. 4/0
(2x120)
Do not use worn, damaged, undersized, or
poorly spliced cables.
* This chart
10 − 100% Duty Cycle
is a general guideline and may not suit all applications. If cables overheat, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
S-0007-F
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.
Notes
MATERIAL THICKNESS REFERENCE CHART
24 Gauge (.025 in)
22 Gauge (.031 in)
20 Gauge (.037 in)
18 Gauge (.050 in)
16 Gauge (.063 in)
14 Gauge (.078 in)
1/8 in (.125 in)
3/16 in (.188 in)
1/4 in (.25 in)
5/16 in (.313 in)
3/8 in (.375 in)
1/2 in (.5 in)
OM-4426 Page 21
5-9. Remote Receptacle Information
NOTE
Engine runs at weld/power speed whenever a device connected to the remote
receptacle is running.
Socket*
24 VOLTS AC
A
B
K
J
I
115 VOLTS AC
H
C L N
M
D
G
E F
REMOTE
OUTPUT
CONTROL
803 571
GND
Socket Information
A
24 volts ac.
B
Contact closure to A completes 24 volt ac contactor control circuit and keeps engine at Run speed
in all modes. Protected by circuit breaker CB4.
I
115 volts ac. Protected by circuit breaker CB3.
J
Contact closure to I completes 115 volts ac
contactor control circuit.
C
+10 volts dc output to remote control.
D
Remote control circuit common.
E
0 to +10 volts dc input command signal from
remote control.
F
Current feedback: 1 volt per 100 amperes.
H
Voltage feedback: 1 volt per 10 arc volts.
G
Circuit common for 24 and 115 volts ac circuits.
K
Chassis common.
*The remaining sockets are not used.
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-4426 Page 22
5-10. Adjusting Wire (MIG) Weld Puddle Consistency
Stop engine and let cool.
Stabilizer DC-Z is factory connected to suit
most Wire (MIG) welding applications.
To change Wire (MIG) weld puddle consistency, proceed as follows:
Remove right side panels.
1
Stabilizer DC-Z
2
Stabilizer Tabs 1, 2, and 3
Tab 3 − provides stiffest weld puddle
(for aluminum and mild steel)
Tab 2 − provides wetter weld puddle
(for mild steel)
Tab 1 − provides wettest weld puddle
(for stainless steel)
Lead 28 is connected between the Wire/CV
weld output terminal and Tab 3 at the
factory.
For wetter weld puddle (for mild steel):
Remove insulated sleeving from Tab 2. Disconnect Lead 28 from Tab 3. Connect lead
28 to Tab 2, reusing hardware. Insulate Tab
3 with sleeving removed from Tab 2. Secure
sleeving with cable ties.
For wettest weld puddle
(for stainless steel):
Remove insulated sleeving from Tab 1. Disconnect Lead 28 from Tab 3. Connect lead
28 to Tab 1, reusing hardware. Insulate Tab
3 with sleeving removed from Tab 1. Secure
sleeving with cable ties.
Reinstall side panel.
1
2
Tools Needed:
3/8, 7/16 in
803 574−B
OM-4426 Page 23
SECTION 6 − OPERATING WELDING GENERATOR
6-1. Front Panel Controls (See Section 6-2)
1
2
3
4
5
6
9
7
8
Ref. 216 170
OM-4426 Page 24
6-2. Description Of Front Panel Controls (See Section 6-1)
1 Process/Contactor Switch
See Section 6-3 for Process/Contactor
switch information.
2
Remote Receptacle
Use receptacle to connect remote control or
wire feeder.
When a remote voltage/amperage control is
connected to the Remote receptacle, the
Auto Sense Remote feature automatically
switches voltage/amperage control to the remote control (see Sections 5-9 and 6-6).
With remote voltage/amperage control connected, weld output in CC mode is determined by a combination of front panel and remote control voltage/amperage settings. In
CV mode, weld output is controlled through
remote control only.
If no remote voltage/amperage control is
connected to the Remote receptacle, the
front panel Voltage/Amperage control adjusts voltage and amperage.
3 And 4
Displays
age and amperage when welding and for five
seconds after welding has stopped.
Meter Engine Maintenance Functions:
Meters display engine hours when Engine
Control switch is in Run position but engine
is not running.
Engine Control Switch
Use switch to start engine, select speed, and
stop engine. In Run/Idle position, engine
runs at idle speed at no load, and weld/power
speed under load. In Run position, engine
runs at weld/power speed.
Meter Oil Change Countdown: With engine off, place Engine Control switch in Run/
Idle position to see hours before next recommended oil change. Oil change hours start at
100 (fresh oil) and count down to 0 (oil
change due). The meters display negative
(−) hours if 100 hours is exceeded. After
changing oil, reset counter by flipping Engine Control switch from Run/Idle to Run
three times.
Use switch in combination with meters to determine total engine hours and hours until
next recommended oil change (see items 3
and 4 earlier in this section).
Place Engine Control switch in Off position
after reading meters.
8
5
Fuel Level Indicator
With Engine running or Engine Control
switch in Run or Run/Idle position, LED’s indicate fuel left in tank.
Displays can show weld process information
(voltage and amperage) or maintenance information (hourmeter or oil change countdown).
6
Meter Weld Functions: In Wire modes,
Voltmeter displays preset weld voltage
when not welding. Meters display actual voltage and amperage when welding and for five
seconds after welding has stopped.
With Process/Contactor switch in any Stick
or TIG setting, use control to adjust amperage. With Process/Contactor switch in any
Wire position, use control to adjust voltage.
When a remote voltage/amperage control is
connected to Remote receptacle RC4, control sets the maximum amperage in Stick and
TIG modes, but has no effect in MIG modes.
In Stick and TIG modes, Voltmeter reads
ON and Ammeter displays preset amperage
when not welding. Meters display actual volt-
7
Voltage/Amperage Control
Use control to select weld voltage or
amperage. Control may be adjusted while
welding.
The unit
will not return to idle speed
when the remote contactor is on and
Process/Contactor switch is in any Wire
position. The unit will return to idle
speed in all other modes.
Engine Choke Control
Use control to change engine air-fuel mix
when starting engine.
To Start: pull out choke and turn Engine
Control switch to Start position. Release
switch and slowly push choke in when
engine starts.
If
the engine does not start, let the
engine come to a complete stop before
attempting restart.
To Stop: turn Engine Control switch to Off
position.
9 DC Polarity/AC Switch (AC/DC Models
Only)
Do not switch under load.
Use switch to select AC weld output or polarity of DC weld output.
OM-4426 Page 25
6-3. Process/Contactor Switch On AC/DC Models
1
803 571−A / 216 170−A
1 Process/Contactor Switch
Weld output terminals are energized
when Process/Contactor switch is
in an Electrode Hot position and the
engine is running.
Stick Positions:
Use Stick positions for stick (SMAW) and
air carbon arc (CAC-A) cutting and
gouging.
The unit will not return to idle speed
When switch is in a Stick mode, select one
of four dig settings to provide additional amperage during short arc length conditions
and help prevent electrodes from “sticking”.
See Stick position descriptions following
(reading L to R):
Use switch to select weld process and weld
output on/off control (see table below and
Section 5-9).
Soft Arc (E 7018) (Position 1) - This setting
provides a low dig/arc force setting for
smooth weld performance. A stable weld
puddle with little arc “snap” gives excellent
weld bead appearance with minimal
spatter.
when Process/Contactor switch is in a
Wire position and the remote contactor
is on (closure between pins A and B on
remote receptacle).
Place switch in Remote positions to turn
weld output on and off with a device connected to the remote receptacle.
Place switch in Electrode Hot positions for
weld output to be on whenever the engine
is running.
Wire Positions:
Use Wire positions for MIG welding using a
voltage sensing wire feeder (Electrode Hot)
or wire feeder using remote control.
Medium Soft Arc (Position 2) - This setting
provides a low to medium dig/arc force that
gives a slightly more fluid weld puddle,
more arc “snap”, and reduces the potential
for electrode sticking at shorter arc lengths.
Medium Stiff Arc (Position 3) - This setting
provides medium dig/arc force for open root
vertical up joints or joints that do not require
additional current for fit up inconsistencies.
Stiff Arc (E6010) (Position 4) - This setting
provides a high dig/arc force for open root
vertical down joints where additional
current is needed to compensate for tight
joint fit up without the need to increase
overall welding current. This setting is recommended for those who prefer a very stiff
arc with 6010 electrodes.
The dig circuit is disabled when switch is in
Wire or TIG positions.
TIG Positions :
TIG − Remote On/Off − Use this position for
TIG welding using remote on/off control.
Electrode Hot − Lift-Arc/Scratch Start TIG
(Provides great DC starts with either starting method) - With switch in this position,
normal open-circuit voltage is not present
between the electrode and workpiece. A
solid-state contactor energizes after the
electrode touches
the
workpiece,
preventing overheating, sticking, or contamination of the electrode (see Sections
6-4 and 6-5).
Process/Contactor Switch Settings
Switch Setting
Process
Output On/Off Control
Electrode Hot − Wire
MIG (GMAW)
Electrode Hot
Electrode Hot − Stick
Stick (SMAW)
Select Preferred Dig
Electrode Hot
Electrode Hot − Stick
Air Carbon Arc (CAC-A) Cutting And Gouging
Select Any Dig
Electrode Hot
Electrode Hot − Lift Arc/
Scratch Start TIG
Lift Arc/Scratch Start TIG (GTAW)
Electrode Hot
Remote − TIG
GTAW With HF Unit, Pulsing Device, Or
Remote Control
At Remote Receptacle
Remote − Stick
Stick (SMAW) With Remote On/Off
At Remote Receptacle
Remote − Wire
MIG (GMAW)
At Remote Receptacle
OM-4426 Page 26
6-4.
Stick Start Procedure − Scratch Start Technique
With Stick selected, start arc as
follows:
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.
1
2
3
6-5. TIG Lift-Arc Start Procedure
Select Lift-Arc/Scratch Start TIG at
Process/Contactor switch to achieve
great arc starts with either procedure.
Perform Lift-Arc starting method as
follows:
Lift-Arc TIG
Lift-Arc Start Method
1
“Touch”
1
Second
2
1
TIG Electrode
2
Workpiece
Turn gas on. Touch tungsten
electrode to workpiece at weld start
point. Hold electrode to workpiece
for 1 second, and slowly lift electrode.
Arc is started when electrode is lifted.
Normal open-circuit voltage is not
present before tungsten electrode
touches workpiece; only a low sensing
voltage is present between electrode
and workpiece. The solid-state output
contactor does not energize until after
electrode is touching workpiece. This
allows electrode to touch workpiece
without overheating, sticking, or
getting contaminated.
Application:
Lift-Arc is used for the DCEN GTAW
process when HF Start method is not
permitted.
Do NOT Strike Like A Match!
OM-4426 Page 27
6-6. Remote Amperage Control
1
Remote Receptacle RC4
Connect optional remote voltage/
amperage (V/A) control to RC4
(see Section 5-9).
With remote control connected,
weld output in a CC mode (Stick,
TIG) is determined by a combination of front panel and remote control voltage/amperage settings. In
CV mode (Wire), weld output is
controlled through remote control
only.
1
2
3
Remote Hand Control
(Optional)
Remote Foot Control
(Optional)
Engine
runs at weld/power
speed in Wire mode whenever
a device connected to the remote receptacle makes closure between pins A and B. In
all other modes, the engine
runs at idle speed until a load is
applied.
In Example:
Process = Stick (Using Remote On/Off)
Min = 25 A CC/DC
Max = 160 A CC/DC
3
Switch
present on
AC/DC
models
only.
2
Max (160 A DC)
Min (25 A DC)
Connect Remote
V/A Control To
Remote
Receptacle RC4
Select Polarity By
Using DC Polarity/AC
Switch (If Present) Or
By Changing Cable
Connections
Set V/A Control
(Mid-Range: About 160 A)
Adjust Remote V/A Control
(Stick Welding Only)
803 571−A / 216 170−A / S-0769 / S-0774
OM-4426 Page 28
SECTION 7 − OPERATING AUXILIARY EQUIPMENT
7-1. Generator Power Receptacles And Circuit Breakers
1
4
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Generator power decreases as weld
current increases.
1
240 V 50 A AC Receptacle RC1
RC1 supplies 60 Hz single-phase power at
weld/power speed. Maximum output is 9.5
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 (20 A
x 120 V).
4 Circuit Breaker CB1
CB1 protects receptacles RC1, RC2, RC3,
and 115 volt ac output to Remote Receptacle RC4 from overload. If CB1 opens, the
receptacles do not work and 115 volt ac output to Remote Receptacle RC4 stops.
Place switch in On position to reset breaker.
5 Circuit Breaker CB2
6 Circuit Breaker CB3
CB2 protects RC2 from overload. CB3 protects RC3 and the 115 volt ac output to Re-
5
6
2
3
Ref. 216 170
mote Receptacle RC4 from overload. If
CB2 opens, RC2 does not work. If CB3
opens, RC3 does not work and the 115 volt
ac output to RC4 stops. Press button to reset breaker.
If
circuit breaker continues to open,
contact Factory Authorized Service
Agent.
Combined output of all receptacles limited
to 10 kVA/kW rating of the generator.
EXAMPLE: If 20 A is drawn from each 120
V duplex receptacle, only 20 A is available
at the 240 V receptacle:
2 x (120 V x 20 A) + (240 V x 20 A) = 9.6
kVA/kW
7-2. Optional GFCI Receptacles
1
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Generator power decreases as weld
current increases.
Combined output of all receptacles limited
to 10 kVA/kW rating of the generator.
GFCI Receptacle Option
1
120 V 20 A AC GFCI Receptacles
GFCI-2 and GFCI-3
GFCI2 and GFCI3 supply 60 Hz singlephase power at weld/power speed. Maximum output from GFCI-2 or GFCI-3 is 2.4
kVA/kW. Circuit breaker protection is the
same as standard receptacles.
If a ground fault is detected, the GFCI Reset button pops out and the circuit opens to
disconnect the faulty equipment. Check for
damaged tools, cords, plugs, etc. connected to the receptacle. Press button to
reset receptacle and resume operation.
At least once a month, run engine at
weld/power speed and press Test button to verify GFCI is working properly.
Ref. 216 170
OM-4426 Page 29
7-3. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P)
The plug can be wired for a 240 V,
2-wire load or a 120/240V, 3-wire
load. See circuit diagram.
1
7
When wired for 120 V loads, each
duplex receptacle shares a load
with one half of 240 V receptacle.
Current Available in Amperes
240 V
Each 120 V Duplex
Receptacle*
Receptacle
0
5
10
15
20
25
30
35
40
20
20
20
20
20
15
10
5
0
V x A = Watts
Plug Wired for 120/240 V,
3-Wire Load
3
4
120V
2
Plug Wired for 240 V, 2-Wire
Load
3
Neutral (Silver) Terminal
4
Load 1 (Brass)Terminal
1
5
Load 2 (Brass) Terminal
6
Ground (Green) Terminal
7
Amperes Available using
120/240 V Plug
5
120V
240V
6
Tools Needed:
2
*One 240 V load or two 120 V loads.
3
4
240V
6
5
240 V AC
120 V AC
120 V AC
plug1 11/03 − 120 813-D
OM-4426 Page 30
SECTION 8 − MAINTENANCE & TROUBLESHOOTING
8-1. Maintenance Label
220 407
OM-4426 Page 31
8-2. Routine Maintenance
Note
Also see Voltmeter/Ammeter displays to assist in scheduling maintenance (see Section
6-1). The Voltmeter and Ammeter display total engine operating hours at start-up.
Note
Follow the storage procedure in the engine owner’s manual if the unit will not be used for an
extended period.
Stop engine before maintaining.
See Engine Manual and maintenance label for important
Recycle
engine
fluids.
start-up, service, and storage information. Service engine more often if used in severe conditions.
Every 8 h
Check fluid levels.
See Section 5-2 or
5-3.
Check meters for
next oil change. See
Section 6-1.
Wipe up spills.
Every 25 h
Service
air
cleaner
wrapper (foam element).
See Section 8-4.
Check and clean optional spark
arrestor screen. See Section
8-3.
Every 50 h
Clean and
tighten weld
terminals.
Every 100 h
Change oil. See Section 8-5 or
8-6 and maintenance label.
(Use meters to check last oil
change. See Section 6-1.)
Clean cooling system.
See Engine Manual.
Service air cleaner element. See Section 8-4.
Clean and tighten
battery connections.
OM-4426 Page 32
Every 200 h
Replace fuel
filter.
See
Section 8-5
or 8-6.
Change oil filter. See
Section 8-5 or 8-6
and maintenance
label.
Check
spark
plugs.
Replace
unreadable
labels.
Every 500 h
Service welding
generator brushes
and slip rings.
Service more often in
dirty conditions.
To be done by Factory Authorized Service Agent.
Check valve clearance
(Robin EH65 Only).
Repair or
replace cracked
cables.
Every 1000 h
Blow out or
vacuum inside.
During heavy
service, clean
monthly.
OR
8-3. Servicing Optional Spark Arrestor
Stop engine and let cool.
1
Spark Arrestor Screen
Clean and inspect screen. Replace
spark arrestor if screen wires are
broken or missing.
1
Tools Needed:
1/4 in
Ref. 803 572−A / Ref. 183 175−A
OM-4426 Page 33
8-4. Servicing Air Cleaner
Kohler−Powered Units
Stop engine.
Do not run engine without air
cleaner or with dirty element.
1
1
Wrapper (Foam Element)
Wash wrapper with soap and water
solution. Allow wrapper to air dry
completely.
2
Spread 1 tablespoon SAE 30 oil
evenly into wrapper. Squeeze out
excess oil.
2
Element
Replace element if dirty, oily, or
damaged.
Robin−Powered Units
1
2
oil
aircleaner3 9/00 − 802 772 / Ref. 185 095-A / S-0759
OM-4426 Page 34
8-5. Changing Engine Oil, Oil Filter, And Fuel Filter (Kohler-Powered Units)
Stop engine and let cool.
1
Oil Drain Valve
2
Oil Filter
Change engine oil and filter according to engine manual.
Close valve and valve cap
before adding oil and running engine.
Full
Fill crankcase with new oil to full
mark on dipstick (see Section 5-2).
3
Fuel Filter
4
Fuel Line
Replace line if cracked or worn.
Install new filter. Wipe up any spilled
fuel.
Start engine, and check for fuel
leaks.
Stop engine, tighten connections as necessary, and wipe
up fuel.
Reset oil maintenance countdown
by flipping Engine Control switch
from Run/Idle to Run three times.
3
2
4
1
Tools Needed:
Ref. 803 573−A / S-0842
OM-4426 Page 35
8-6. Changing Engine Oil, Oil Filter, and Fuel Filter (Robin-Powered Units)
Stop engine and let cool.
1
Oil Drain Valve
2
Oil Filter
Change engine oil and filter according to engine owner’s manual.
Oil Fill
Close valve and valve cap
before adding oil and
running engine.
Oil Check
Fill crankcase with new oil to full
mark on dipstick (see Section 5-3).
3
Fuel Filter
4
Fuel Line
Replace line if cracked or worn.
Install new filter. Wipe up any spilled
fuel.
Full
Start engine, and check for fuel
leaks.
Stop engine, tighten connections as necessary, and wipe
up fuel.
2
Reset oil maintenance countdown
by flipping Engine Control switch
from Run/Idle to Run three times.
3
4
Tools Needed:
1
803 572 / S-0842
OM-4426 Page 36
8-7. Adjusting Engine Speed (Kohler-Powered Units)
2200 − 2300 rpm
(36.6 − 38.3 Hz)
3675 − 3750 rpm
(61.3 − 62.5 Hz)
After tuning engine, check engine
speeds with a tachometer (see
table). If necessary, adjust speeds
as follows:
Start engine and run until warm.
Turn A/V control to 10.
Open top cover access panel to access speed adjustments.
Idle Speed Adjustment
1
Move Engine Control switch to
Run/Idle position.
5
2
4
1
Throttle Solenoid
2
Mounting Screws
3
Idle Speed Screw
Loosen mounting screws. Adjust
solenoid position so engine runs at
idle speed. If necessary, back out
idle speed screw so solenoid can
be moved to correct position. Tighten mounting screws. Be sure solenoid linkage works smoothly.
Turn idle speed screw for fine
adjustments.
Weld/Power Speed Adjustment
Move Engine Control switch to Run
position.
3
4
Weld/Power Speed
Adjustment Nut
5
Lock Nut
Loosen lock nut. Turn adjustment
nut until engine runs at weld/power
speed. Tighten lock nut.
Close and secure top cover access
panel.
Stop engine.
Tools Needed:
1/4, 3/8 in
803 573 / 801 209-A
OM-4426 Page 37
8-8. Adjusting Engine Speed (Robin-Powered Units)
After tuning engine, check engine
speeds with a tachometer (see
table). If necessary, adjust speeds
as follows:
Start engine and run until warm.
Open top cover access panel to access speed adjustments.
Idle Speed Adjustment
2
1
Move Engine Control switch to
Run/Idle position.
1
Throttle Solenoid
2
Mounting Screws
3
Idle Speed Screw
Loosen mounting screws. Adjust
solenoid position so engine runs at
idle speed. If necessary, back out
idle speed screw so solenoid can
be moved to correct position. Tighten mounting screws. Be sure solenoid linkage works smoothly.
4
Turn idle speed screw for fine
adjustments.
6
Weld/Power Speed Adjustment
Move Engine Control switch to Run
position.
5
3
4
Jam Nut
5
Lock Nut
6
Weld/Power Speed
Adjustment Screw
Loosen jam nut and lock nut. Turn
adjustment screw until engine runs
at weld/power speed. Tighten jam
nut, and then tighten lock nut.
Stop engine.
Close and secure top cover access
panel.
2200 − 2300 rpm
(36.6 − 38.3 Hz)
3675 − 3750 rpm
(61.3 − 62.5 Hz)
Tools Needed:
10 mm
8 mm
OM-4426 Page 38
803 572−A
8-9. Overload Protection
Stop engine.
Open left side door.
When a circuit breaker or fuse
opens, it usually indicates a
more serious problem exists.
Contact a Factory Authorized
Service Agent.
1
Circuit Breaker CB4
CB4 protects the stator winding
supplying 24 volt ac output to Remote receptacle RC4. If CB4
opens, 24 volt ac output to RC4
stops.
Circuit breakers CB1 and CB3
protect the stator winding supplying 115 volt ac output to Remote Receptacle RC4 (see
Section 7-1).
Press button to reset breaker.
2
Fuse F6 (See Parts List)
F6 protects the engine wiring system from overload. If F6 opens,
engine will not crank.
Replace fuse if open.
Close left side door.
1
2
803 773−A / Ref. 216 170
OM-4426 Page 39
8-10. Welding Troubleshooting
Trouble
No weld output.
Remedy
Check weld control settings.
Check weld connections.
Disconnect equipment from generator power receptacles during start-up.
Increase front panel and/or remote voltage/amperage control settings (see Sections 5-9 and 6-1).
Check and secure connections to Remote receptacle RC4 (see Sections 5-9).
Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.
Low weld output.
Check control settings.
Increase front panel and/or remote voltage/amperage control settings (see Sections 5-9 and 6-1).
Check and clean air cleaner as necessary (see Section 8-4).
Check engine speed, and adjust if necessary (see Section 8-7 or 8-8).
Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.
See engine manual.
High weld output.
Check control settings.
Check and adjust engine speed (see Section 8-8 or 8-7).
Check for obstructed movement of solenoid linkage (see Section 8-7 or 8-8).
Have Factory Authorized Service Agent check circuit boards PC1 and PC2.
Weld output cannot be adjusted.
Have Factory Authorized Service Agent check field current control board PC2.
Erratic weld output.
Check control settings.
Clean and tighten connections both inside and outside unit.
Check and secure lead connections to remote control.
Be sure connection to work piece is clean and tight.
Remove excessive coils from weld cables.
Use dry, properly stored electrodes.
Check and adjust engine speed (see Section 8-7 or 8-8).
Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.
Check shielding gas, ensure proper shielding gas coverage while welding.
No remote voltage/amperage control.
Check and tighten connections to Remote receptacle RC4 (see Section 5-9). Check and secure lead
connections to remote control.
No front panel voltage/amperage control.
Disconnect remote control from Remote receptacle RC4 if not needed for weld process (see Section
5-9).
No 24 volt ac power output at Remote
receptacle RC4.
Reset circuit breaker CB4 (see Section 8-9).
No 115 volt ac power output at Remote
receptacle RC4.
Reset circuit breaker(s) CB1 and/or CB3 (see Section 7-1).
OM-4426 Page 40
Trouble
Lack of high frequency; difficulty in
establishing Gas Tungsten Arc Welding arc.
Remedy
Use proper size tungsten for welding amperage.
Reduce leakage of high frequency from torch or work cable (check grounding, remove excessive
coils from weld cables, use shorter weld cables, etc.).
Check cables and torch for cracked or deteriorated insulation or bad connections. Repair or replace
necessary parts.
Wandering arc − poor control of arc
direction.
Reduce gas flow rate.
Select proper size tungsten. Properly prepare tungsten.
Tungsten electrode oxidizing and not
remaining bright after conclusion of
weld.
Shield weld zone from drafts.
Increase postflow time.
Check and tighten all gas fittings.
Properly prepare tungsten.
8-11. Generator Power Troubleshooting
Trouble
No power output.
Remedy
Reset circuit breakers CB1, CB2 and/or CB3 (see Section 7-1).
Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.
Low power output.
Check and clean air cleaner as necessary.
Check engine speed, and adjust if necessary (see Section 8-7 or 8-8).
See engine manual.
High power output.
Check engine speed, and adjust if necessary (see Section 8-7 or 8-8).
Erratic power output.
Have Factory Authorized Service Agent check brushes, slip rings, and field current control board PC2.
Check receptacle wiring and connections.
Check governor according to engine manual.
8-12. Engine Troubleshooting
Trouble
Engine will not crank.
Remedy
Check fuse F6, and replace if open (see Section 8-9).
Check battery voltage.
Check battery connections and tighten if necessary.
Check plug PLG5 and plug PLG8 connections.
Have Factory Authorized Service Agent check Engine Control switch S2.
OM-4426 Page 41
Trouble
Engine does not start.
Remedy
Check fuel level (see Section 5-2 or 5-3).
Check battery and replace if necessary.
Check engine charging system according to engine manual.
Have Factory Authorized Service Agent check fuel shutoff solenoid FS1 according to engine manual.
See engine manual.
Engine starts but stops when Engine
Control switch returns to Run/Idle
position.
Check oil level (see Section 5-2 or 5-3). Low oil pressure shutdown stops engine if oil pressure is too
low.
Use correct grade oil for operating temperature. (see Section 8-1).
Have Factory Authorized Service Agent check low oil pressure shutdown switch S5.
Battery discharges between uses.
Place Engine Control switch in Off position when unit is not running.
Clean top of battery with baking soda and water solution; rinse with clear water.
Periodically recharge battery (approximately every 3 months).
Replace battery.
Check voltage regulator according to engine manual.
Engine stopped during normal
operation.
Check fuel level (see Section 5-2 or 5-3).
Check oil level (see Section 5-2 or 5-3). Low oil pressure shutdown stops engine if oil pressure is too
low. Oil level too high reduces capacity of the fuel pump.
Have Factory Authorized Service Agent check fuel shutoff solenoid FS1 according to engine manual.
Have Factory Authorized Service Agent check low oil pressure shutdown switch S5.
Engine does not return to idle speed.
Be sure Engine Control switch S2 is in Run/Idle position.
Remove all weld and generator power loads.
Place Process/Contactor switch in Electrode Hot position or turn off remote contactor. The unit will not
return to idle speed when Process/Contactor switch is in a remote position and the remote contactor
is on.
Turn off remote device connected to Remote receptacle RC4 (see Section 5-9).
Check for obstructed movement of solenoid linkage (see Section 8-7 or 8-8).
Have Factory Authorized Service Agent check circuit board PC1 and current transformer CT1.
Engine does not remain at weld/power
speed when power or weld load is
applied with Engine Control switch in
Run/Idle position.
Place Engine Control switch in the Run position for small loads.
Check for obstructed movement of solenoid linkage (see Section 8-7 or 8-8).
OM-4426 Page 42
SECTION 9 − 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.
9-1. 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
9-2. 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.
S-0854
OM-4426 Page 43
9-3. 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.
2
Use ground device as stated
in electrical codes.
3
ST-800 576-B
9-4. 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 9-8).
3
3
Rating Data
Rating shows volts and amperes, or
watts required to run equipment.
AMPERES x VOLTS = WATTS
EXAMPLE 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power
requirement in watts.
4.5 A x 115 V = 520 W
The load applied by the drill is 520 watts.
EXAMPLE 2: If three 200 watt flood lamps are used with the drill from Example 1,
add the individual loads to calculate total load.
(200 W + 200 W + 200 W) + 520 W = 1120 W
The total load applied by the three flood lamps and drill is 1120 watts.
S-0623
OM-4426 Page 44
9-5. 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
9-6. 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
Rating
1/4 HP
1/2 HP
3/4 HP
2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/2 HP
500 PSI
550 PSI
700 PSI
1/3 HP
1/2 HP
1/3 HP
1/2 HP
Starting Watts
Running Watts
1000
1650
3400
4400
2900
10500
1720
2575
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
3300
3150
4500
6100
3100
2150
3100
2100
3200
1000
650
1000
1400
1100
2800
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
1000
950
1400
1600
800
750
1000
800
1050
OM-4426 Page 45
9-7. 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
OM-4426 Page 46
Rating
Starting Watts
Running Watts
1/4 in
3/8 in
1/2 in
6-1/2 in
7-1/4 in
8-1/4 in
9 in
10 in
14 in
6 in
8 in
10 in
1/2 HP
1 HP
1-1/2 HP
2 HP
1-1/2 HP, 12 in
2 HP, 14 in
Standard 9 in
Heavy Duty 12 in
1/3 HP
18 in
HID
Metal Halide
Mercury
Sodium
Vapor
400 gph
900 gph
3/4 HP, 16 in
1 HP, 20 in
1/2 HP
3/4 HP
1 HP
1/4 HP
1.7 HP
2-1/2 HP
350
400
600
500
900
1400
4500
6300
2500
1720
3900
5200
3000
6000
8200
10500
1100
1100
350
500
2100
400
125
313
1000
1400
1250
600
900
4500
6100
3150
4500
6100
1900
900
1300
350
400
600
500
900
1400
1500
1800
1100
720
1400
1600
1000
1500
2200
2800
1100
1100
350
500
700
400
100
250
1000
200
500
1400
1600
950
1400
1600
700
900
1300
9-8. 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
9-9. 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-4426 Page 47
9-10. 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 9-4).
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-4426 Page 48
9-11. 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-4426 Page 49
SECTION 10 − ELECTRICAL DIAGRAMS
Figure 10-1. Circuit Diagram For Welding Generator Models With AC/DC Output
OM-4426 Page 50
218 722-C
OM-4426 Page 51
Figure 10-2. Circuit Diagram For Welding Generator Models With DC Output Only
OM-4426 Page 52
217 544-D
OM-4426 Page 53
SECTION 11 − PARTS LIST
Hardware is common and
not available unless listed.
7
8
9
12
10 11
6
13
28
14
15
17
4
30
27
16
5
29
22
18 21
19
20
3
26 − Figure 11-2
23
31
25
24
32
2
1
33
62
61
63
57
59
60
56
56
34
35
58
31
55
42
52
51 − Figure 11-3
53
36
38
39
40
41
54
44
46
37
43
45
47
48
50
49
803 889
Figure 11-1. Main Assembly (Kohler Engine Shown)
OM-4426 Page 54
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-1. Main Assembly
. . . 1 . . . . . . . . . . . . . . 211366 . . Panel, Side RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . . . 219329 . . Label, Use Gasoline Fuel Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . . . . . 200795 . . Label, Warning General Precautionary Csa . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . . . . . . . . . . 211367 . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . . . . . . . . . . 211365 . . Panel, Side LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . . . . . . . . . . 217395 . . Bumper, Rubber Press−in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . . . . . . . . . . . 211370 . . Latch, Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . . . . . . . . . . . . 211368 . . Door, Access Engine Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . . . . . . . . . . . 211398 . . Grommet, Plastic Neck Filler Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 10 . . . . . . . . . . . . . . 220711 . . Cap, Tank Screw−on W/Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . . . . . . . . . . . 220414 . . Pipe, Exhaust Elbow Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . . . . . . . . . . . . 211369 . . Door Assy, Access Engine Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . . . . 220407 . . Label, Engine Maintenance Robin & Kohler . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 14 . . . . . . . . . . . . . . 217952 . . Label, Function Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 15 . . . . . . . . . . . . . . 211368 . . Door, Access Engine Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . . . . . 215799 . . Cover, PC Board Bkt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . . PC1 . . . . 213257 . . Circuit Card Assy, Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 18 . . . . . . . . . . . . . . 215797 . . Bracket, Mtg Pc Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 19 . . . . C39 . . . . 217631 . . Capacitor, Elctlt 1500 Uf 75 Vdc Can 1.40 Dia . . . . . . . . . . . . . . . . . . . . . .
. . . 20 . . . . . R1 . . . . . 188067 . . Resistor, Ww Fxd 100 W 200 Ohm W/Clips (AC/DC Units Only) . . . . . .
. . . 21 . . . . . . . . . . . . . . 211360 . . Upright, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 22 . . . . . . . . . . . . . . 205734 . . Seal, Weather Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 23 . . . . CB4 . . . . 083432 . . Circuit Breaker, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . . . . .
. . . 24 . . . . . . . . . . . . . . 211209 . . Cover, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 25 . . . . . . . . . . . . . . 179276 . . Bushing, Snap−in Nyl 1.000 Id X 1.375 Mtg Hole Cent . . . . . . . . . . . . . . . .
. . . 26 . . . . . . . . . . . Figure 11-2 . . Generator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 27 . . . . . . . . . . . . . . 211402 . . Muffler, Exhaust Engine (Kohler Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 27 . . . . . . . . . . . . . . 211404 . . Muffler, Exhaust Engine (Robin Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 28 . . . . . . . . . . . . . . 209057 . . Clamp, Muffler 1.625 Dia U Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 29 . . . . . . . . . . . . . . 217441 . . Muffler Gasket, (Robin Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 29 . . . . . . . . . . . . . . 189477 . . Muffler Gasket, (Kohler Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 30 . . . . . . . . . . . . . . 214531 . . Engine, Gas Elec Start (Kohler) (includes) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . F6 . . . . *021718 . . . . Fuse, Mintr Gl 30, Amp 32 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . VOLT REG . *190249 . . . . Regulator, Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . TS1 . . . . 199530 . . . . Solenoid, Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bracket, Mtg Solenoid (See Engine Parts List) . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 180096 . . Tune−up & Filter Kit (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . *067272 . . . . Air Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . *066698 . . . . Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . *215985 . . . . Filter/Clamps, Fuel 1/4 in Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . *067007 . . . . Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . *067273 . . . . Air Filter Wrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 30 . . . . . . . . . . . . . . 214530 . . Engine, Gas Elec Start (Robin) (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . F6 . . . . *021718 . . . . Fuse, Mintr Gl 30, Amp 32 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . *198756 . . . . Pump, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . VOLT REG . *198778 . . . . Regulator, Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . S5 . . . . . 198757 . . . . Switch, Low Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 190827 . . . . Boot, Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . *206473 . . . . Washer, Seal Oil Copper M14id x M19.500d . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 199062 . . Tune−up & Filter Kit (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . *198755 . . . . Element, Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . *198754 . . . . Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . *215985 . . . . Filter/Clamps, Fuel 1/4 in Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . *198777 . . . . Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 31 . . . . . . . . . . . . . . 167788 . . Nut, 375−16 .56hex .34h Stl Pld Sem Cone Wshr.88d . . . . . . . . . . . . . . .
. . . 32 . . . . . . . . . . . . . . 208003 . . Hose, Oil W/Fittings And Valve (Kohler Engine) . . . . . . . . . . . . . . . . . . . . . .
. . . 32 . . . . . . . . . . . . . . 208004 . . Hose, Oil W/Fittings And Valve (Robin Engine) . . . . . . . . . . . . . . . . . . . . . .
. . . 33 . . . . . . . . . . . . . . 211364 . . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 34 . . . . . . . . . . . . . . 082319 . . Cable, Bat Neg 17.750 No 4 Awg W/Clamp & .343 Rng . . . . . . . . . . . . . .
. . . 35 . . . . . . . . . . . . . . 173921 . . Cable, Bat Pos 28.000 No 4 Awg W/Clamp & .312 Rng . . . . . . . . . . . . . .
. . . 36 . . . . . . . . . . . . . . 182935 . . Hold Down, Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
10
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
2
3
1
1
1
1
1
2
OM-4426 Page 55
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-1. Main Assembly (Continued)
. . . 37 . . . . . . . . . . . . . . 167677
. . . 38 . . . . . . . . . . . . . . 211394
. . . 39 . . . . . . . . . . . . . . 216641
. . . 40 . . . . . . . . . . . . . . 215984
. . . 41 . . . . . . . . . . . . . . 215035
. . . . . . . . . . . . . . . . . . . . 124253
. . . . . . . . . . . . . . . . . . . . 219972
. . . . . . . . . . . . . . . . . . . . 216308
. . . 42 . . . . . . . . . . . . . . 219654
. . . 43 . . . . . . . . . . . . . . 211356
. . . 44 . . . . . . . . . . . . . . 217015
. . . 45 . . . . . . . . . . . . . . 211355
. . . 46 . . . . DC−Z . . . . 212699
. . . 47 . . . . . . . . . . . . . . 214814
. . . 48 . . . . . . . . . . . . . . 211091
. . . 49 . . . . SR1 . . . . 202222
. . . 50 . . . . . . . . . . . . . . 211092
. . . 51 . . . . . . . . . . . Figure 11-3
. . . 52 . . . . CT1 . . . . 217844
. . . 53 . . . . PC3 . . . . 148021
. . . 54 . . . . PC5 . . . . 148030
. . . 55 . . . . . . . . . . . . . . 211358
. . . 56 . . . . . . . . . . . . . . 010954
. . . 57 . . . . . . . . . . . . . . 214556
. . . 58 . . . . . . . . . . . . . . 127595
. . . 59 . . . . . . . . . . . . . . 211210
. . . 59 . . . . . . . . . . . . . . 211213
. . . 60 . . . . . . . . . . . . . . 215798
. . . 61 . . . . . . . . . . . . . . 215800
. . . 62 . . . . C 41 . . . . 217632
. . . 63 . . . . . . . . . . . . . . 215873
. . Battery, Stor 12v 430 Crk 75 Rsv Gp 58 Maint Free . . . . . . . . . . . . . . . . . 1
. . Baffle, Engine Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Seal, Engine Air Baffle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Tank, Fuel 12.0 Gal W/Sender (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Ftg, Stand Pipe .250 X 6.125 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Sender, Fuel Gauge 7.875 Deep Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Warning Battery Explosion Can Blind . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Pan, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Warning Do Not Weld On Base/Fuel Level . . . . . . . . . . . . . . . . . . . 2
. . Cover, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Stabilizer Assy, (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Plate, Mtg Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Mtg Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Rectifier, Si 3ph 300 Amp 400 Piv 100% Duty Cycle . . . . . . . . . . . . . . . . . 1
. . Baffle, Stab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Panel, Front w/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Xfmr, Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Circuit Card Assy, Filter Hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Circuit Card Assy, Filter Hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Mtg Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Washer, Flat .406idx1.250odx.125t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . Mount, Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . Screw, 375−16x2.50 Hex Hd−pln Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Bracket, Mtg Engine (Kohler Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Mtg Engine (Robin Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Capacitor Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Gasket, Capacitor Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Capacitor, Elctlt 1200 Uf 300 Vdc Can 2.00 Dia . . . . . . . . . . . . . . . . . . . . . 1
. . Shroud, Air Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
*Recommended Spare Parts.
+
When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 217221.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-4426 Page 56
Item
No.
Part
No.
Description
Quantity
Figure 11-2. Generator (Figure 11-1 Item 26)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
. . . . . . . . . . . . . +218739
. . . . . . . . . . . . . . 182092
. . . . . . . . . . . . . . 215346
. . . . . . . . . . . . . . 181143
. . . . . . . . . . . . . . 215344
. . . . . . . . . . . . . . 212161
. . . . . . . . . . . . . . 202771
. . . . . . . . . . . . . . 142156
. . . . . . . . . . . . . . 170861
. . . . . . . . . . . . . . 205725
. . . . . . . . . . . . . . 010910
. . . . . . . . . . . . . . 010909
. . . . . . . . . . . . . . 136343
. . . . . . . . . . . . . . 218049
. . . . . . . . . . . . . . 183419
. . . . . . . . . . . . . . 214017
. . . . . . . . . . . . . . 172661
. . . . . . . . . . . . . . 173734
. . Stator, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Warning Moving Parts Can Cause Serious Etc . . . . . . . . . . . . . . . . 1
. . Rotor, Generator (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Bearing, Ball Rdl Sgl Row .984 X 2.047 X .591 . . . . . . . . . . . . . . . . . . . . 1
. . . . Fan, Rotor Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Adapter, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Baffle, Engine Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Screw, 375−16x1.75 Hexwhd.81d Gr8 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . Stud, Stl .375−16 X 17.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . Brushholder Assy, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Washer, Flat .406idx0.812odx.065t Stl Pld Ansi.375 . . . . . . . . . . . . . . . . . . 4
. . Nut, 375−16 .56hex .46h Stl Pld Elastic Stop Nut . . . . . . . . . . . . . . . . . . . . 4
. . Screw, K50x 20 Pan Hd−phl Stl Pld Pt Thread Forming . . . . . . . . . . . . . . . 4
. . Endbell (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . O−ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Terminal Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Block, Stud Connection 6 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Link, Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hardware is common and
7
not available unless listed.
6
3
18
5
2
4
17
1
8
16
9
14
15
10
11
13
12
803 887
Figure 11-2. Generator
+
When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 217221.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-4426 Page 57
Hardware is common and
not available unless listed.
3
8
6
5
2
7
4
1
9
10
7
29
28
27
26
12
14
16
25
11
13
15
18
17
24
23
22
19
21
20
803 888−A
Figure 11-3. Panel, Front w/Components
OM-4426 Page 58
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-3. Panel, Front w/Components (Figure 11-1 Item 51)
. . . 1 . . . . . . . . . . . . . . . . . . . . . . . . Nameplate (Order By Model & Serial Number) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . 190512 . . Stand−off, No 6−32 X .640 Lg .250 Hex Al Fem . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . PC2 . . . . 220982 . . Circuit Card Assy, Control (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 206794 . . . . Shield, PCB Protective Anti Static 4.813x12.750 . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . RC4 . . . . 134735 . . Conn, Circ Ms/Cpc 14skt Size 20 Rcpt Panel Pushin . . . . . . . . . . . . . . . . .
. . . 5 . . . . . S1 . . . . . 213440 . . Switch, Changeover (AC/DC Units Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . 086075 . . Bus Bar (AC/DC Units Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 CC, CV, WORK 099255 . . Terminal, Pwr Output Neutral (AC/DC Units Only) . . . . . . . . . . . . . . . . . . . . 3
. . . 7 . . . . POS . . . . 039047 . . Terminal, Pwr Output Red (DC Units Only) . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 7 . . . WORK . . . 039046 . . Terminal, Pwr Output Black (DC Units Only) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . LEM . . . . 168829 . . Transducer, Current 1000a Module Max Open Loop . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . CB1 . . . . 218591 . . Circuit Breaker,Man Reset 2p 50a 240vac Screw−90 . . . . . . . . . . . . . . . . 1
. . . 10 . . . . CB2 . . . . 093996 . . Circuit Breaker, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . CB3 . . . . 093996 . . Circuit Breaker, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . RC2 , RC3 . 141432 . . Rcpt, Str Dx Grd 2p3w 20a 125v *5−20r . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 11 GFCI2, GFCI3 ♦220332 . Rcpt, Str Dx Grd 2p3w 20a 125v GFCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . . . S2 . . . . . 217680 . . Switch, Ignition 4 Position W/Out Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . 218606 . . Handle, Switch Range (AC/DC Units Only) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . 220804 . . Screw, 010−32x .50 Btn Hd−soc Stl Pld Patch (AC/DC Units Only) . . . . . 1
. . . 15 . . . . . . . . . . . . . . 211452 . . Control, Push/Pull Snap−in 42.000 W/1.750 Extension (Robin) . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 221516 . . Control,Push/Pull Snap−in 36.000 W/1.750 Extension (Kohler) . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . 207073 . . Lever, Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . 212977 . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . RC1 . . . . 182954 . . Rcpt, Str 3p4w 50a 125/250v Flush Mtg *14−50 . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . 211416 . . Bezel, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . 216775 . . Cover, Output Stud Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . 213914 . . Cover, Output Stud Stick/Tig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . 216773 . . Cover, Receptacle Duplex 120v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . 216774 . . Cover, Receptacle Full Kva 120/240v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . 216772 . . Cover, Output Stud Work (AC/DC Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . 216771 . . Cover, Output Stud Negative (DC Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . 211405 . . Pin, Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . 170391 . . Conn, Circ Ms Protective Cap Size 20 Nylon . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . 197203 . . Grounding Stud Assy, Brass (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 083030 . . . . Stud, Brs .250−20 X 1.750 W/Hex Collar . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 010915 . . . . Washer, Flat .257idx0.640odx.031t Brs . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 163167 . . . . Washer, Lock .254idx0.489odx.062t Sst Split.250 . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 601836 . . . . Nut, 250−20 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . 207075 . . Knob, Pointer 1.625 Dia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . 207080 . . Knob, Pointer 1.125 Dia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦ Optional
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-4426 Page 59
Note
Item
No.
Some wiring harness components (switches, relays, circuit breakers) are also referenced
elsewhere in this parts list. Purchase components separately or as part of the associated
wiring harness.
Dia.
Mkgs.
Part
No.
Description
Quantity
Wiring Harnesses
....................
. . . . . . . . . PLG 15 . . .
. . . . . . . . . . RC 5 . . . .
. . . . . . . . . PLG 24 . . .
. . . . . . . . . PLG 8 . . .
....................
217875
113752
113634
117865
177859
202660
..
..
..
..
..
..
Harness, Wrg Ignition (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conn, Rect Mini 045 10skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . .
Conn, Rect Univ 084 6p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . . .
Conn, Rect Mini 045 14skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . .
Conn, Body 5 Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conn, Push 4 Wire 12−16strnd 12−18sld 16−22tinstrnd . . . . . . . . . . . . . .
1
1
1
1
1
1
....................
. . . . . . . . . . RC 4 . . . .
. . . . . . . . . PLG 14 . . .
. . . . . . . . . . CB 4 . . . .
218733
134735
113751
083432
..
..
..
..
Harness, Remote Control 14Pin (includes) . . . . . . . . . . . . . . . . . . . . . . .
Conn, Circ Ms/Cpc 14skt Size 20 Rcpt Panel Pushin . . . . . . . . . . . . . . . .
Conn, Rect Mini 045 8skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . .
Circuit Breaker, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
....................
. . . . . . . . . PLG 27 . . .
. . . . . . . . . PLG 25 . . .
. . . . . . . . . PLG 31 . . .
. . . . . . . . . PLG 26 . . .
218729
176121
114063
114063
066104
..
..
..
..
..
Harness, Wrg Power Board (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conn, Rect Univ 084 2p/S 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . .
Conn, Rect Univ 084 4p/S 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . .
Conn, Rect Univ 084 4p/S 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . .
Conn, Rect Univ 084 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
....................
. . . . . . . . . PLG 17 . . .
. . . . . . . . . PLG 23 . . .
. . . . . . . . . PLG 21 . . .
. . . . . . . . . PLG 16 . . .
218732
117037
117037
113752
116513
..
..
..
..
..
Harness, Wrg Interconnecting (includes) . . . . . . . . . . . . . . . . . . . . . . . . .
Conn, Rect Mini 045 2skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . .
Conn, Rect Mini 045 2skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . .
Conn, Rect Mini 045 10skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . .
Conn, Rect Mini 045 12skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
. . . . . . . . . . . . . . . . . . . . 217747 . . Plugs, w/Leads (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG 6 . . . 113750 . . Conn, Rect Mini 045 4skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG13 . . . 113750 . . Conn, Rect Mini 045 4skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 217305 . . Harness, Wrg Interconnecting (AC/DC Units) (includes) . . . . . . . . . . . . 1
. . . . . . . . . PLG 12 . . . 130693 . . Conn,Rect Mini 045 5skt 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG5 . . . . 135556 . . Plug, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-4426 Page 60
Effective January 1, 2004
(Equipment with a serial number preface of “LE” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
*
Induction Heating Coils and Blankets
*
APT & SAF Model Plasma Cutting Torches
*
Remote Controls
*
Accessory Kits
*
Replacement Parts (No labor)
*
Spoolmate Spoolguns
*
Canvas Covers
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.
Miller’s True Blue Limited Warranty shall not apply to:
1.
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.
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.
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 Sources (Unless Otherwise Stated)
*
Water Coolant Systems (Integrated)
*
*
*
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 and Coolers
Water Coolant Systems (Non-Integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Maxstar 85, 140
Spot Welders
Load Banks
Arc Stud Power Sources & Arc Stud Guns
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
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 6/04
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
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