Miller BOBCAT 3 PHASE Owners manual (REAR ENGINE)

OM-4436 220 542C

January 2005

Processes

Stick (SMAW) Welding

MIG (GMAW) Welding
Flux Cored (FCAW) Welding

Non-Critical TIG (GTAW)
Welding

Description

Engine Driven Welding Generator



Bobcat 3 Phase

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
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001:2000 Quality
System Standard.

parts list will then help you to decide the
exact part you may need to fix the problem.
Warranty and service information for your
particular model are also provided.

Working as hard as you do

− every power source from
Miller is backed by the most
hassle-free warranty in the
business.

Miller 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

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Arc Welding Hazards 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Engine Hazards 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. Compressed Air Hazards 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Additional Symbols For Installation, Operation, And Maintenance 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6. California Proposition 65 Warnings 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-7. Principal Safety Standards 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-8. EMF Information 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Signification des symboles 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 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance 7 . . . . . .

2-6. Principales normes de sécurité 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-7. Information sur les champs électromagnétiques 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − DEFINITIONS 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − SPECIFICATIONS 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Weld, Power, and Engine Specifications 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Dimensions, Weights, and Operating Angles 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Fuel Consumption 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Generator Power Curves 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Volt-Ampere Curves 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Duty Cycle 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − INSTALLATION 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Installing Welding Generator 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Engine Prestart Checks 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Activating The Dry Charge Battery (If Applicable) 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Connecting Or Replacing the Battery 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Installing Exhaust Pipe 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. Connecting to Weld Output Terminals 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7. Selecting Weld Cable Sizes* 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − OPERATING THE WELDING GENERATOR 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Front Panel Controls 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Typical Stick Welding Connections And Control Settings 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Typical MIG Welding Connections And Settings 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. Typical MIG Connections And Settings Using Weld Control And Spoolgun 23 . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − OPERATING AUXILIARY EQUIPMENT 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Standard Receptacles 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Wiring Optional 240 Volt Plug 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − MAINTENANCE 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1. Maintenance Label (Kohler-Powered Units) 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2. Routine Maintenance 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3. Servicing Air Cleaner 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-4. Changing Engine Oil, Oil Filter, and Fuel Filter 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-5. Adjusting Engine Speed 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-6. Overload Protection 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-7. Servicing Optional Spark Arrestor 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − TROUBLESHOOTING 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 − ELECTRICAL DIAGRAMS 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 − GENERATOR POWER GUIDELINES 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 12 − STICK WELDING (SMAW) GUIDELINES 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 13 − MIG WELDING (GMAW) GUIDELINES 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-1. Typical MIG Process Connections Using A Voltage-Sensing Wire Feeder 51 . . . . . . . . . . . . . . . . . . . . . .

13-2. Typical MIG Process Connections Using A Constant Speed Wire Feeder 51 . . . . . . . . . . . . . . . . . . . . . .

13-3. Typical MIG Process Control Settings 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-4. Holding And Positioning Welding Gun 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-5. Conditions That Affect Weld Bead Shape 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-6. Gun Movement During Welding 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-7. Poor Weld Bead Characteristics 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-8. Good Weld Bead Characteristics 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-9. Troubleshooting − Excessive Spatter 56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-10. Troubleshooting − Porosity 56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-11. Troubleshooting − Excessive Penetration 56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-12. Troubleshooting − Lack Of Penetration 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-13. Troubleshooting − Incomplete Fusion 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-14. Troubleshooting − Burn-Through 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-15. Troubleshooting − Waviness Of Bead 58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-16. Troubleshooting − Distortion 58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-17. Common MIG Shielding Gases 59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 14 − PARTS LIST 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING

rom _nd_10/04

 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.

1-2. Arc Welding Hazards

 The symbols shown below are used throughout this manual to

call attention to and identify possible hazards. When you see the
symbol, watch out, and follow the related instructions to avoid the
hazard. The safety information given below is only a summary of
the more complete safety information found in the Safety Stan­dards listed in Section 1-7. Read and follow all Safety Standards.

 Only qualified persons should install, operate, maintain, and re-

pair this unit.

 During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or
severe burns. The electrode and work circuit is electrically

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 electri-

cally 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 sep-

arate cable.

 Do not touch electrode if you are in contact with the work, ground, or anoth-

er electrode from a different machine.

live whenever the output is on. The input power circuit and

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.

 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.
 Clamp work cable with good metal-to-metal contact to workpiece or work-

table as near the weld as practical.

 Insulate work clamp when not connected to workpiece to prevent contact

with any metal object.

 Do not connect more than one electrode or work cable to any single weld

output terminal.

SIGNIFICANT DC VOLTAGE exists in inverters after stop­ping engine.

 Stop engine on inverter and discharge input capacitors according to

instructions in Maintenance Section before touching any parts.

FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing these fumes
and gases can be hazardous to your health.

 Keep your head out of the fumes. Do not breathe the fumes.
 If inside, ventilate the area and/or use exhaust at the arc to remove welding

fumes and gases.

 If ventilation is poor, use an approved air-supplied respirator.
 Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s

instructions for metals, consumables, coatings, cleaners, and degreasers.

 Work in a confined space only if it is well ventilated, or while wearing an air-

supplied respirator. Always have a trained watchperson nearby. Welding
fumes and gases can displace air and lower the oxygen level causing injury
or death. Be sure the breathing air is safe.

 Do not weld in locations near degreasing, cleaning, or spraying operations.

The heat and rays of the arc can react with vapors to form highly toxic and
irritating gases.

 Do not weld on coated metals, such as galvanized, lead, or cadmium plated

steel, unless the coating is removed from the weld area, the area is well
ventilated, and if necessary, while wearing an air-supplied respirator. The
coatings and any metals containing these elements can give off toxic fumes
if welded.

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-4436 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

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, cuf-

fless 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.

welding arc. The flying sparks, hot workpiece, and hot

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 de-

signed 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

BATTERY EXPLOSION can BLIND.

 Always wear a face shield, rubber gloves, and protec-

tive clothing when working on a battery.

 Stop engine before disconnecting or connecting bat-

tery 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 add-

ing 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-4436 Page 2

MOVING PARTS can cause injury.

 Keep away from fans, belts, and rotors.
 Keep all doors, panels, covers, and guards closed

and securely in place.

 Stop engine before installing or connecting unit.
 Have only qualified people remove guards or covers for maintenance

and troubleshooting as necessary.

 To prevent accidental starting during servicing, disconnect negative (−)

battery cable from battery.

 Keep hands, hair, loose clothing, and tools away from moving parts.
 Reinstall panels or guards and close doors when servicing is finished

and before starting engine.

 Before working on generator, remove spark plugs or injectors to keep

engine from kicking back or starting.

 Block flywheel so that it will not turn while working on generator compo-

nents.

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 pres-

ent 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 re-

moving cap.

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 flam-

mables.

ENGINE EXHAUST GASES can kill.

 Use equipment outside in open, well-ventilated ar-

eas.

 If used in a closed area, vent engine exhaust outside

and away from any building air intakes.

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.

EXHAUST SPARKS can cause fire.

 Do not let engine exhaust sparks cause fire.
 Use approved engine exhaust spark arrestor in re-

quired areas — see applicable codes.

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 and properly installed acces-

sories only. Do not exceed maximum lift eye weight
rating (see Specifications).

 Lift and support unit only with proper equipment and

correct procedures.

 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 stop-

ping engine.

 Do not let low voltage and frequency caused by low

engine speed damage electric motors.

 Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where

applicable.

FLYING SPARKS can cause injury.

 Wear a face shield to protect eyes and face.
 Shape tungsten electrode only on grinder with proper

guards in a safe location wearing proper face, hand,
and body protection.

 Sparks can cause fires — keep flammables away.

OVERUSE can cause OVERHEATING.

 Allow cooling period; follow rated duty cycle.
 Reduce current or reduce duty cycle before starting

to weld again.

 Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

 Put on grounded wrist strap BEFORE handling

boards or parts.

 Use proper static-proof bags and boxes to store,

move, or ship PC boards.

TILTING OF TRAILER can cause injury.

 Use tongue jack or blocks to support weight.
 Properly install welding generator onto trailer accord-

ing to instructions supplied with trailer.

OM-4436 Page 3

READ INSTRUCTIONS.

ARC WELDING can cause interference.

 Use only genuine MILLER/Hobart replacement

parts.

 Perform engine and air compressor (if applicable)

maintenance and service according to this manual
and the engine/air compressor (if applicable) manu­als.

H.F. RADIATION can cause interference.

 High-frequency (H.F.) can interfere with radio naviga-

tion, 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.

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.)

 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.

 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 electro-

magnetically 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.

For Gasoline Engines:
 Engine exhaust contains chemicals known to the State of

California to cause cancer, birth defects, or other reproductive
harm.

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 i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(phone: [phone], 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: [phone], 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: [phone], 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: [phone], website:
www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale Bou-

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.

levard, Rexdale, Ontario, Canada M9W 1R3 (phone: [phone] 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: [phone],
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).

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.

OM-4436 Page 4

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT

UTILISATION

rom_fre 10/04

 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.

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.

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

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.

 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 iso-

lants suffisamment grands pour empêcher le contact physique éventuel
avec la pièce ou la terre.

 Ne pas se servir de source électrique à courant électrique dans les zones

humides, dans les endroits confinés ou là où on risque de tomber.

 Se servir d’une source électrique à courant électrique UNIQUEMENT si le

procédé de soudage le demande.

 Si l’utilisation d’une source électrique à courant électrique s’avère néces-

saire, se servir de la fonction de télécommande si l’appareil en est équipé.

 Des précautions de sécurité supplémentaires sont requises dans des envi-

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.

internes de l’appareil sont également sous tension à ce

Ce groupe de symboles si­gnifie Mise en garde !
Soyez vigilant ! Il y a des

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.

 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 en-

dommagé 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.

risques de danger reliés

Une tension DC importante subsiste à l’intérieur
des onduleurs après avoir coupé l’alimentation.

 Couper l’alimentation du poste et décharger les condensateurs d’entrée

comme indiqué dans la Section Maintenance avant de toucher des compo­sants.

LES FUMÉES ET LES GAZ peuvent
être dangereux.

Le soudage génère des fumées et des gaz. Leur inhalation
peut être dangereux pour votre santé.

 Eloigner votre tête des fumées. Ne pas respirer les fumées.
 À l’intérieur, ventiler la zone et/ou utiliser un échappement au niveau de

l’arc pour l’évacuation des fumées et des gaz de soudage.

 Si la ventilation est insuffisante, utiliser un respirateur à alimentation d’air

homologué.

 Lire les spécifications de sécurité des matériaux (MSDSs) et les instruc-

tions 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 por-

tant 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 dé-

graissage, 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 galvani-

sé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été
enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et si néces­saire, en portant un respirateur à alimentation d’air. Les revêtements et
tous les métaux renfermant ces éléments peuvent dégager des fumées
toxiques en cas de soudage.

OM-4436 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 respi-

rateur d’adduction d’air homologué.

LES RAYONS DE L’ARC peuvent pro­voquer des brûlures dans les yeux et
sur la peau.

Le rayonnement de l’arc du procédé de soudage génère

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 pro-

téger 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 sonore 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, ré-

sistant au feu (laine ou cuir) et une protection des pieds.

des rayons visibles et invisibles intenses (ultraviolets et

LE SOUDAGE peut provoquer un in­cendie ou une explosion.

Le soudage effectué sur des conteneurs fermés tels que
des réservoirs, tambours ou des conduites peut provoquer

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.

 Se protéger et d’autres personnes de la projection d’étincelles et de métal

chaud.

 Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des

substances inflammables.

 Déplacer toutes les substances inflammables à une distance de 10,7 m de

l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec
des protections homologués.

 Des étincelles et des matériaux chauds du soudage peuvent facilement

passer dans d’autres zones en traversant de petites fissures et des
ouvertures.

 Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.
 Le soudage effectué sur un plafond, plancher, paroi ou séparation peut dé-

clencher un incendie de l’autre côté.

 Ne pas effectuer le soudage sur des conteneurs fermés tels que des réser-

voirs, 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-électro-

de 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.

leur éclatement. Des étincelles peuvent être projetées de

 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.

 Le soudage, l’écaillement, le passage de la pièce

à la brosse en fil de fer, et le meulage génèrent

lantes. Pendant la période de refroidissement des soudures, elles ris­quent de projeter du laitier.

 Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.

des étincelles et des particules métalliques vo-

DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.

 Prévoir une période de refroidissement avant d’effec-

tuer 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.

 Porter des protections approuvés pour les oreilles si

le niveau sonore est trop élevé.

LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.

 Porteurs de stimulateur cardiaque, restez à distance.
 Les porteurs d’un stimulateur cardiaque doivent

d’abord consulter leur médecin avant de s’approcher
des opérations de soudage à l’arc, de gougeage ou
de soudage par points.

Si des BOUTEILLES sont endomma­gées, elles pourront exploser.

Des bouteilles de gaz protecteur contiennent du gaz sous
haute pression. Si une bouteille est endommagée, elle peut
exploser. Du fait que les bouteilles de gaz font normale­ment partie du procédé de soudage, les manipuler avec
précaution.

 Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des

chocs mécaniques, du laitier, des flammes ouvertes, des étincelles et des
arcs.

 Placer les bouteilles debout en les fixant dans un support stationnaire ou

dans un porte-bouteilles pour les empêcher de tomber ou de se renverser.

 Tenir les bouteilles éloignées des circuits de soudage ou autres circuits

électriques.

 Ne jamais placer une torche de soudage sur une bouteille à gaz.
 Une électrode de soudage ne doit jamais entrer en contact avec une bou-

teille.

 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 respi-

rateur d’adduction d’air homologué.

OM-4436 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 véhi-

cules 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 carbu-

rant ou de faire le plein.

 Ne pas faire le plein en fumant ou proche d’une sour-

ce 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 carbu-

rant renversé avant de faire démarrer le moteur.

 Jeter les chiffons dans un récipient ignifuge.

DES ORGANES MOBILES peuvent
provoquer des blessures.

 Ne pas approcher les mains des ventilateurs, cour-

roies et autres pièces en mouvement.

 Maintenir fermés et fixement en place les portes,

panneaux, recouvrements et dispositifs de
protection.

 Arrêter le moteur avant d’installer ou brancher l’appareil.
 Demander seulement à un personnel qualifié d’enlever les dispositifs de

sécurité ou les recouvrements pour effectuer, s’il y a lieu, des travaux d’en­tretien et de dépannage.

 Pour empêcher tout démarrage accidentel pendant les travaux d’entretien,

débrancher le câble négatif (−) de batterie de la borne.

 Ne pas approcher les mains, cheveux, vêtements lâches et outils des orga-

nes mobiles.

 Remettre en place les panneaux ou les dispositifs de protection et fermer

les portes à la fin des travaux d’entretien et avant de faire démarrer le mo­teur.

 Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la mise en

route accidentelle du moteur.

 Bloquer le volant moteur pour éviter sa rotation lors d’une intervention sur le

générateur.

LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT CHAUD peuvent
provoquer des brûlures.

 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’ex-

pansion (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 sui-

vant :

 Mettre des lunettes de sécurité et des gants, placer un torchon sur le bou-

chon 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.

 Ne pas placer l’appareil sur, au-dessus ou à proximité

de surfaces inflammables.

 Tenir à distance les produits inflammables de

l’échappement.

LES ÉTINCELLES À L’ÉCHAPPEMENT
peuvent provoquer un incendie.

 Empêcher les étincelles d’échappement du moteur

de provoquer un incendie.

 Utiliser uniquement un pare-étincelles approuvé −

voir codes en vigueur.

2-4. Dangers liés à l’air comprimé

RESPIRER L’AIR COMPRIMÉ peut pro­voquer des blessures graves ou causer
la mort.

 Ne pas utiliser l’air comprimé pour respirer.
 Utiliser l’air comprimé seulement pour le coupa-

ge, gougeage et les outils pneumatiques.

L’AIR COMPRIMÉ peut provoquer
des blessures.

 Porter des lunettes de sécurité approuvées.
 Ne pas diriger le jet d’air vers d’autres ou soi−

même.

L’AIR COMPRIME EMMAGASINE ET DES
TUYAUX SOUS PRESSION peuvent provo­quer des blessures.

 Relâcher la pression d’air de l’outillage ou du sys-

tème 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.

Le METAL CHAUD lors du coupage et
gougeage plasma peut provoquer un in­cendie ou une explosion.

 Ne pas couper ou gouger à proximité de produits

inflammables.

 Surveillez et garder un extincteur à proximité.

DES PIECES CHAUDES peuvent provo­quer des brûlures et blessures.

 Ne pas toucher le compresseur ou d’autres élé-

ments du circuit air comprimé chauds.

 Laisser l’ensemble se refroidir avant de toucher

ou d’effectuer la maintenance.

LIRE LES INSTRUCTIONS.

 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 un œilleton de levage pour lever l’appareil

et les accessoires correctement installés. Ne pas
dépasser le poids nominal maximal de l’œilleton
(voir les spécifications).

 Ne lever et ne soutenir l’appareil qu’avec de l’équipement approprié et

en suivant les procédures adéquates.

 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-4436 Page 7

LE SURCHAUFFEMENT peut endom­mager le moteur électrique.

 Arrêter ou déconnecter l’équipement avant de dé-

marrer 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.

LES ÉTINCELLES VOLANTES ris­quent de provoquer des blessures.

 Porter un écran facial pour protéger le visage et les

yeux.

 Affûter l’électrode au tungstène uniquement à la meuleuse dotée de pro-

tecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque
l’on porte l’équipement homologué de protection du visage, des mains et
du corps.

 Les étincelles risquent de causer un incendie − éloigner toute substance

inflammable.

L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.

 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.

 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.

 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.

LIRE LES INSTRUCTIONS.

 Utiliser seulement les pièces de rechange d’origine.
 Effectuer la maintenance du moteur et du compres-

seur (si applicable) suivant ce manuel et le manuel du
moteur/compresseur (si applicable).

LE RAYONNEMENT HAUTE FRÉ­QUENCE (H.F.) risque de provoquer
des interférences.

 Le rayonnement haute fréquence (H.F.) peut

provoquer des interférences avec les équipements
de radio−navigation et de communication, les
services de sécurité et les ordinateurs.

 Demander seulement à des personnes qualifiées familiarisées avec des

équipements électroniques de faire fonctionner l’installation.

 L’utilisateur est tenu de faire corriger rapidement par un électricien quali-

fié 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 un blindage pour réduire les interférences
éventuelles.

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 souda-

ge 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 élec-

tronique sensible.

 Veiller à ce que ce poste de soudage soit posé et mis à la terre conformé-

ment à ce mode d’emploi.

 En cas d’interférences après avoir pris les mesures précédentes, il in-

combe 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-4436 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.

3-1. Symbol Definitions

SECTION 3 − DEFINITIONS

h

Stop Engine

Start Engine

Engine Oil Fuel Battery (Engine) Engine

Engine Choke

Positive Negative

Welding Arc

(Electrode)

Hours

Fast

(Run, Weld/Power)

Read Operator’s

Manual A

Check Valve

Clearance

MIG (GMAW),

Wire

Seconds Time

Fast/Slow
(Run/Idle)

Amperes

Do not switch while

welding

Alternating Current

(AC)

Stick (SMAW) TIG (GTAW)

V

Slow (Idle)

Volts

Work Connection

Output

Protective Earth

(Ground)

s

Circuit Breaker Temperature

SECTION 4 − SPECIFICATIONS

4-1. Weld, Power, and Engine Specifications

Welding

Mode

CC/AC 50 − 225 A

CC/DC 50 − 210 A

CV/DC 19 − 28 V

Weld Output

Range

Rated

Welding

Output

225 A, 25 V,

100% Duty

Cycle

210 A, 25 V,

100% Duty

Cycle

200 A, 20 V,

100% Duty

Cycle

Maximum

Open Circuit

Voltage

80

72

33

Generator Power Rating

84/42A 120/240V AC

Single−Phase

10kVA/kW

60 Hz

Three−Phase

11 kVA/kW

13A, 480 V AC

60 Hz

(while not welding)

Fuel

Capacity

12 gal

(45 L) Tank

Engine

Kohler CH-20

Air-Cooled, Two-Cylinder,

Four-Cycle, 20 HP

Gasoline Engine

OM-4436 Page 9

4-2. Dimensions, Weights, and Operating Angles

 gg
 Do not move or operate unit where it could

4 Holes

F

25

800 426

Engine End

Dimensions

Height

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)

G 13/32 in (10 mm) Dia.

Kohler-Powered Unit: 562 lb (254 kg)

33-1/2 in (851 mm)

(To Top Of Exhaust)

Weight

Lifting Eye Weight Rating:

1280 lb (580 kg)

4-3. Fuel Consumption

A

B

C

 Do not exceed tilt angles or engine could

D

G

4 Holes

E

F

Engine End

800 426

be damaged or unit could tip.

tip.

25°
25°

25°

25°

OM-4436 Page 10

179 939

4-4. Generator Power Curves

A. 10 kVA/kW Single-Phase Power

The generator power curves show
the generator power in amperes
available at the receptacles.

B. 11 kVA/kW Three-Phase Power

200 294 / 210 724

OM-4436 Page 11

4-5. Volt-Ampere Curves

A. For CC/AC Mode

B. For CC/DC Mode

The volt-ampere curve shows the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
other settings fall between the
curves shown.

C. For CV/DC Mode

OM-4436 Page 12

166 024-A / 166 025-A / 166 026-A

4-6. Duty Cycle

Duty cycle is the percentage of 10
minutes that unit can weld at rated
load without overheating.

 Exceeding duty cycle can

damage unit and void
warranty.

100% Duty Cycle at 225 Amperes CC/AC, 210 Amperes CC/DC, 200 Amperes CV/DC

Notes

Continuous Welding

119 454-A

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-4436 Page 13

SECTION 5 − INSTALLATION

5

-1. Installing Welding Generator

 Do not weld on base. Welding

Movement

Location / Airflow Clearance

Mounting

 Do not lift unit from end.

OR

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

OR

18 in

(460 mm)

18 in

(460 mm)

on base can cause fuel tank fire
or explosion. Bolt unit down
using holes provided in base.

 Always securely fasten weld-

ing generator onto transport
vehicle or trailer and comply
with all DOT and other applica­ble codes.

 Do not mount unit by support-

ing the base only
mounting holes. Use cross­supports to adequately sup­port unit and prevent damage
to base.

 Always ground generator

frame to vehicle frame to pre­vent electric shock and static
electricity hazards.

 If unit does not have GFCI re-

ceptacles, use GFCI-protected
extension cord.

Mounting:

1 Cross-Supports
Mount unit on flat surface or use

cross-supports to support base.

Grounding:

2 Equipment Grounding Terminal

(On Front Panel)
3 Grounding Cable (Not Supplied)
4 Metal Vehicle Frame
Connect cable from equipment

ground terminal to metal vehicle
frame. Use #10 AWG or larger insu­lated copper wire.

at the four

Inadequate support.

Grounding

GND/PE

OM-4436 Page 14

 Do not use flexible mounts.

2

3

Electrically bond generator frame to
vehicle frame by metal-to-metal contact.

4

OR

1

 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.

install2 11/04 − Ref. 800 652 / Ref. 800 477-A / 803 274

5-2. Engine Prestart Checks

Full

Gasoline

Full

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 en-

gine 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.

Fuel

To help prime the fuel system at ini­tial start-up, fill tank with fresh fuel
(see maintenance label for specifi­cations). Always leave filler neck
empty to allow room for expansion.
Check fuel level on a cold engine
before use each day.

Oil

 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).

 To improve cold weather

starting:
Keep battery in good condition.

Store battery in warm area.
Use correct grade oil for cold

weather.

803 847 / 217 015-A

OM-4436 Page 15

5-3. Activating The Dry Charge Battery (If Applicable)

5

4

1

3

2

Remove battery from unit.
1 Eye Protection − Safety

Glasses Or Face Shield
2 Rubber Gloves
3 Vent Caps
4 Sulfuric Acid Electrolyte

(1.265 Specific Gravity)
5 Well
Fill each cell with electrolyte to

bottom of well (maximum).

 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 instruc-

tions supplied with battery

charger.

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.

5 A For 30 Minutes

30 A For 12 Minutes

OM-4436 Page 16

OR

6

Tools Needed:

+

−

rubbergloves

glasses

drybatt1 1/98 − S-0886

5-4. Connecting Or Replacing the Battery

Connecting The Battery

 Connect negative (−)

cable last.

+

−

−

+

Replacing The Battery

Tools Needed:

3/8, 1/2 in

5-5. Installing Exhaust Pipe

 Remove end panel to replace battery.

 Connect negative (−)

cable last.

+

−

−

+

803 847 / 803 849 / Ref. S-0756-D

 Engine backfire can cause se-

vere burns or other injuries. Do
not point exhaust pipe toward
control panel. Keep away from
exhaust outlet.

 Point exhaust pipe in desired di-

rection but always away from front
panel and direction of travel.

 Be sure to tighten exhaust clamp

nuts. Exhaust clamp supplied with
muffler.

Tools Needed:

1/2 in

803 847 / Ref 801 681 / Ref. 218 646-A-A

OM-4436 Page 17

5-6. Connecting to Weld Output Terminals

1 2

 See Section 6 for examples of

typical weld connections and
control settings.

1 Work Weld Output Terminal
2 Electrode Weld Output Terminal
Connect work cable to Work terminal.

Connect electrode holder cable or
electrode weld cable to Electrode ter­minal for Stick and MIG welding.

Connect torch cable to Electrode ter­minal for TIG welding.

Use Process Selector switch to
select type of weld output (see
Section 6-1).

 See Sections 6-2 thru 6-4 for typi-

cal process connections and
control settings.

Tools Needed:

3/4 in

803 847 / Ref. 218 646-A

5-7. Selecting Weld Cable Sizes*

100 ft (30 m) or Less

Weld Output

Terminals

 Turn off power before

connecting to weld out­put terminals.

 Do not use worn, dam-

aged, undersized, or
poorly spliced cables.

Welding

Amperes

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)

300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)

350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)

10 − 60%

Duty

Cycle

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit

Not Exceeding***

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

300 ft

(90 m)

350 ft

(105 m)

60 − 100%

Duty

10 − 100% Duty Cycle

Cycle

2 ea. 2/0

(2x70)

2 ea. 2/0

(2x70)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 3/0

(2x95)

2 ea. 3/0

(2x95)

400 ft

(120 m)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)

500 2/0 (70) 3/0 (95) 4/0 (120)

* This chart is a general guideline and may not suit all applications. If cables overheat, use next size larger cable.

**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use S-0007-F

***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.

OM-4436 Page 18

2 ea. 2/0

(2x70)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

2 ea. 4/0

(2x120)

3 ea. 3/0

(3x95)

2 ea. 4/0

(2x120)

3 ea. 3/0

(3x95)

SECTION 6 − OPERATING THE WELDING GENERATOR

6-1. Front Panel Controls

4

5

36

1 Engine Control Switch
Use switch to start engine, select speed, and

stop engine. In Run/Idle position, engine runs
at idle speed at no load, and weld/power speed
under load. In Run position, engine runs at
weld/power speed.

 Place switch in Run position to operate

most MIG equipment.

2 Engine Choke Control
Use control to change engine air-fuel mix.
To Start: pull out choke and turn Engine Con-

trol switch to Start position. Release switch
and slowly push choke in when engine starts.

 If the engine does not start, let engine

come to a complete stop before attempt­ing restart.

To Stop: turn Engine Control switch to Off
position.

1

3 Engine Hour Meter
4 Weld Process Selector Switch

 Do not switch under load.

Use switch to select type of weld output.
Wire (GMAW) Welding: Use a positive (+)

position for Direct Current Electrode Positive
(DCEP) and a negative (−) position for Direct
Current Electrode Negative.

Stick (SMAW) and TIG (GTAW Welding): Use
a positive (+) position for Direct Current Elec­trode Positive (DCEP) and a negative (−) posi-
tion for Direct Current Electrode Negative.
Use AC position for alternating current.

5 Coarse Range Switch

 Do not switch under load.

Use switch to select weld amperage range
when Weld Process Selector switch is in Stick/

2

Ref. 219 760−A

Tig position, or voltage range when switch is in
Wire position.

 For best arc starts and when using weld

and generator power together, use a low
Coarse Range setting with the Fine con­trol set at 7 or higher.

6 Fine Control
Use control to select weld amperage (Stick/

Tig) or voltage (Wire) within the range selected
by the Coarse Range switch. Control may be
adjusted while welding.

Set control at 10 for maximum generator
power.

Weld output would be about 110 A DC based
on control settings shown (80% of 70 to 150
A). Settings shown are typical for welding with
a 7018 (1/8) electrode.

 See Sections 6-2 thru 6-4 for typical pro-

cess connections and control settings.

OM-4436 Page 19

6-2. Typical Stick Welding Connections And Control Settings

For best arc starts and best
results using weld and generator
power together, use a low
Coarse Range setting and the
Fine control set at 7 or higher.

Typical Settings For 7018 (1/8 in) Electrode

1

 Stop engine.

 This section provides general

guidelines and may not suit all
applications.

 The control panel shows the typi-

cal settings for welding with a
7018 (1/8 in) electrode. Consult
the amperage selection tables
below if welding with other elec­trodes.

1 Work Clamp
2 Electrode Holder
Connect Work cable to Work terminal

and Electrode holder cable to Elec­trode terminal on welding generator.

 Be sure to use the correct size

weld cables (see Section 5-7).

 For best performance, set the

Coarse Range switch to the low­est range that covers the desired

weld amperage. Use the Fine
control to select the desired am­perage within the range se­lected. When properly set, the
Fine control is normally set at 7
or higher.

Typical Settings For 7018 (1/8 in)
Electrode:

> Set Weld Process Selector

switch to + Stick position.

> Set Coarse Range switch to

70-150 (1/8”) position.

> Set Fine control at 7 or higher

for best results.

AC

DC*

ELECTRODE

6010
6011
6013

7014

7018

7024

NI-CL

308L

*EP = ELECTRODE POSITIVE (REVERSE POLARITY)
EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)

EP
EP

EP,EN

EP,EN

EP

EP,EN

EP
EP

POSITION

ALL
ALL
ALL

ALL

ALL

FLAT

HORIZ

FILLET

ALL
ALL

PENETRATION

DEEP

MIN. PREP, ROUGH

DEEP

LOW

MED

LOW HYDROGEN,

LOW

LOW

LOW
LOW

USAGE

HIGH SPATTER

GENERAL

SMOOTH, EASY,

FAST

STRONG

SMOOTH, EASY,

FASTER

CAST IRON
STAINLESS

2

Tools Needed:

3/4 in

803 847 / 218 646-A / 087 985-A / Ref. S-0653

OM-4436 Page 20

6-3. Typical MIG Welding Connections And Settings

A. Solid Wire Applications

Typical Control Settings For .035 (ER70S-3)

Solid Wire − Short Circuit Transfer

Note Coarse Range,

Fine Control, and

Weld Process switch

settings.

6

7

Quick connector

2

3

 Stop engine.

 This section provides general guide-

lines and may not suit all ap­plications.

 The control panel shows the typical

settings for welding with .035
(ER70S-3) solid wire. Use Argon­based shielding gas.

1 Work Clamp
2 Wire Feeder
3 MIG Gun
4 Gun Trigger Plug

5 Voltage Sensing Clamp
6 Gas Cylinder:

75/25 Argon-Based Gas for Short
Circuit Transfer

80% Argon (Or Higher) For Spray

Transfer
7 Gas Hose
Connect work cable to welding generator

Work terminal. Connect cable from wire
feeder to cable from welding generator
Electrode terminal.

 Be sure to use the correct size weld

cables (see Section 5-7).

Loosen MIG gun securing knob. Insert
gun end through opening in feeder and
position as close as possible to drive rolls
without touching. Tighten knob.

See wire feeder manual for wire thread­ing procedure.

Insert gun trigger plug (item 4) into
matching receptacle and tighten
threaded collar.

Connect gas hose from feeder to regula­tor on cylinder.

Typical Control Settings For Short
Circuit Transfer Using .035 (ER70S-3)
Solid Wire And 75/25 Argon-Based
Gas:

> Set Weld Process Selector switch

to Wire + (DCEP) position.

> Set Coarse Range switch to Wire

19-28 volts position.

> Set Fine Control to obtain minimum

spatter.

> Set wire feed speed between

150-300 ipm.

Tools Needed:

3/4 in

5

1

4

Work

803 847 / 802 766 / 218 646-A

OM-4436 Page 21

B. Self-Shielded Flux Core Wire Applications

Typical Control Settings For .045 (71T-11) Self-Shielded Flux Core Wire

Note Coarse Range,

Fine Control, and

Weld Process switch

settings.

Quick connector

2

 Stop engine.

 This section provides general

guidelines and may not suit all
applications.

 The control panel shows the typi-

cal settings for welding with .045
(71T-11) self-shielded flux core

wire.
1 Work Clamp
2 Wire Feeder
3 MIG Gun

4 Gun Trigger Plug
5 Voltage Sensing Clamp
Connect work cable to welding gen-

erator Work terminal. Connect cable
from wire feeder to cable from weld­ing generator Electrode terminal.

 Be sure to use the correct size

weld cables (see Section 5-7).

Loosen MIG gun securing knob. In­sert gun end through opening in feed­er and position as close as possible
to drive rolls without touching. Tight­en knob.

See wire feeder manual for wire
threading procedure.

Insert gun trigger plug (item 4) into
matching receptacle and tighten
threaded collar.

Typical Control Settings Using
.045 (71T-11) Self-Shielded Flux
Core Wire :

> Set Weld Process Selector

switch to Wire − position

(DCEN).

> Set Coarse Range switch to

Wire 19-28 volts position.

> Set Fine Control near minimum

setting.

> Set wire feed speed between

125-200 ipm.

3

> Do a test weld. To increase arc

length, increase Fine Control

setting. To shorten arc length,

reduce fine control setting or in-

crease wire feed speed.

Tools Needed:

OM-4436 Page 22

3/4 in

5

4

Work

1

803 847 / 802 766 / 218 646-A

6-4. Typical MIG Connections And Settings Using Weld Control And Spoolgun

Typical Settings For 4043 (.035)
Aluminum On 1/8 in Material:

Note Coarse Range and Weld

Process switch settings.

Tools Needed:

3/4 in

9

8

10

Work

2

 This section provides general guide-

lines and may not suit all applications.

1 Weld Control
2 Spoolgun
3 Optional Contactor (Recommended)
4 Reed Switch
5 Weld Cable (Customer-Supplied)
6 Weld Control Weld Terminal
7 Weld Power Cable From Spoolgun
8 Work Clamp
9 Gas Hose
10 Argon Cylinder
11 Trigger Control Cord

Connect to unused
contactor terminal.

6

11

12 Input Power Cord

 Be sure to use the correct size weld

Route weld cable from welding generator
Electrode terminal through reed switch to
unused contactor terminal. Connect weld
cable from spoolgun to weld control weld ter­minal (item 6).

Connect work cable to welding generator
Work terminal.

Insert trigger control plug (item 11) into weld
control receptacle. Tighten threaded collar.

Connect ac power cord (item 12) to 120 volt
ac receptacle on welding generator.

1

4 5 7

cables (see Section 5-7).

Left Side View

12

5

Plug and sensing lead not
used in this application.

3

6

Connect gas hose from spoolgun to regula­tor on Argon bottle.

Reinstall weld control wrapper.

Typical Settings For 4043 (.035)
Aluminum On 1/8 in Material:

802 847 / 218 646-A

> Set Weld Process Selector switch to

Wire + (DCEP) position.

> Set Coarse Range switch to Wire

19-28 volts position.

> Set Fine Control to desired voltage

(arc length). Start with a low voltage
setting (about 4) to prevent burnback.

> Set wire feed speed between 240-270

ipm.

OM-4436 Page 23

SECTION 7 − OPERATING AUXILIARY EQUIPMENT

7-1. Standard Receptacles

1

23

4

6

 Generator power decreases

as weld current increases.

Set Fine Control R1 at 10 for full

generator power.

1 120/240 V 50 A Single-Phase

AC Receptacle RC1
2 120 V 20 A AC GFCI Recep-

tacles GFCI2 and GFCI3
3 480 V 30 A Three-Phase AC

Receptacle RC4
RC1 supplies 60 Hz single-phase

power at weld/power speed. Maxi­mum output is 10 kVA/kW.

GFCI2 and GFCI3 supply 60 Hz
single-phase power at weld/power
speed. Maximum output from
GFCI2 or GFCI3 is 2.4 kVA/kW.

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

5

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.

RC4 supplies 60 Hz three-phase
power at weld/power speed. Maxi­mum output is 11 kVA/kW.

4 Circuit Breaker CB2
5 Circuit Breaker CB3
CB2 protects GFCI2 and CB3 pro-

tects GFCI3 from overload. If a cir­cuit breaker opens, the receptacle
does not work.

 Press button to reset circuit

breaker . I f breaker continues to

open, contact Factory

Authorized Service Agent.

6 Circuit Breaker CB1
CB1 protects RC1 from overload. If

CB1 opens, RC1 does not work.
7 Circuit Breaker CB4

7

CB4 protects RC4 from overload. If
CB4 opens, RC4 does not work.

Combined output of all receptacles
limited to 11 kVA/kW three-phase
rating of the generator.

OM-4436 Page 24

Ref. 208 296

7-2. Wiring Optional 240 Volt Plug

Current Available in Amperes

240 V

Receptacle*

0

5
10
15
20
25
30
35
40

*One 240 V load or two 120 V loads.

Each 120 V Duplex

Receptacle

20
20
20
20
20
15
10

5
0

V x A = Watts

The plug can be wired for a 240 V,
2-wire load or a 120/240V, 3-wire
load. See circuit diagram.

1 Plug Wired for 120/240 V,

7

1

3

4

120V

120V

240V

4

6

2

3

3-Wire Load

When wired for 120 V loads, each
duplex receptacle shares a load
with one half of 240 V receptacle.

2 Plug Wired for 240 V, 2-Wire

Load
3 Neutral (Silver) Terminal
4 Load 1 (Brass)Terminal
5 Load 2 (Brass) Terminal
6 Ground (Green) Terminal
7 Amperes Available using

120/240 V Plug

5

Tools Needed:

240V

240 V AC

120 V AC 120 V AC

56

plug1 11/03 − 120 813-D

OM-4436 Page 25

SECTION 8 − MAINTENANCE

8-1. Maintenance Label (Kohler-Powered Units)

8-2. Routine Maintenance

Note

Wipe up spills.

Follow the storage procedure in the engine owner’s manual if the unit will not be used for an
extended period.

Every 20 h Every 25 h

Check and clean optional
spark arrestor screen. See
Section 8-7.

OM-4436 Page 26

Recycle

engine

fluids.

Every 8 h

Check fluid levels.
See Section 5-2.

Service air cleaner
wrapper (foam element).
See Section 8-3.

 Stop engine before maintaining.

 See Engine Manual and Maintenance Label for impor-

tant start-up, service, and storage information. Ser­vice engine more often if used in severe conditions.

* To be done by Factory Authorized Service Agent.

Clean and tighten weld
terminals.

Every 50 h

Every 100 h

Change oil. See Section 8-4
and maintenance label.

Clean cooling system. See
Engine Manual.

Change oil filter. See Section
8-4 and maintenance label.

Repair or replace cracked
cables.

Check air cleaner element.
See Section 8-3.

Clean and tighten battery
connections.

Every 200 h

Replace fuel filter. See
Section 8-4.

Replace unreadable labels.Check spark plugs.

Every 500 h

Service welding generator
brushes and slip rings. Service
more often in dirty conditions.*

Every 1000 h

Blow out or vacuum inside.
During heavy service, clean
monthly.

OR

OM-4436 Page 27

8-3. Servicing Air Cleaner

 Stop engine.
 Do not run engine without air

cleaner or with dirty element.

1 Precleaner
Wash precleaner with soap and wa-

ter solution. Allow precleaner to air
dry completely.

1

2

Spread 1 tablespoon SAE 30 oil
evenly into precleaner. Squeeze
out excess oil.

2 Element
Replace element if damaged, dirty,

or oily.

Notes

oil

aircleaner3 11/04 − 802 772 / S-0759

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-4436 Page 28

8-4. Changing Engine Oil, Oil Filter, and Fuel Filter

Full

 Stop engine and let cool.

1 Oil Drain Valve
2 1/2 ID x 12 in Hose
3 Oil Filter
Change engine oil and filter accord-

ing to engine owner’s manual.

 Close valve and valve cap

before adding oil and
running engine.

Fill crankcase with new oil to full
mark on dipstick (see Section 8-1).

4 Fuel Filter
5 Fuel Line
Replace line if cracked or worn.

Install new filter. Wipe up any spilled
fuel.

Start engine, and check for fuel
leaks.

 Stop engine, tighten connec-

tions as necessary, and wipe

4

up fuel.

5

3

2

1

Tools Needed:

803 847 / S-0842

OM-4436 Page 29

8-5. Adjusting Engine Speed

5

4

3

After tuning engine, check engine
speeds with a tachometer (see
table). If necessary, adjust speeds

2200 − 2300 rpm

(36.6 − 38.3 Hz)

3675 − 3750 rpm

(61.3 − 62.5 Hz)

1

2

as follows:
Start engine and run until warm.

Turn Fine Control to 10.
Remove rear panel to access idle

speed adjustments.

Idle Speed Adjustment

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.

Turn idle speed screw for fine ad­justments.

Weld/Power Speed Adjustment

Move Engine Control switch to Run
position.

4 Weld/Power Speed

Adjustment Nut
5 Lock Nut
Loosen lock nut. Turn adjustment

nut until engine runs at weld/power
speed. Tighten lock nut.

Reinstall end panel.

 Stop engine.

Top View

Tools Needed:

1/4, 3/8 in

803 849 / 801 209-A

OM-4436 Page 30

8-6. Overload Protection

21

 Fuses F1, F2 located on

bracket behind left side
panel.

 Fuse F6 located in

engine harness on
left side.

3

 Stop engine. Disconnect

negative (−) battery cable.

1 Fuse F1 (See Parts List)
F1 protects the weld excitation

winding from overload. If F1 opens,
weld output stops or is low.

2 Fuse F2 (See Parts List)
F2 protects the generator power

excitation winding from overload. If
F2 opens, generator power output
stops or is low.

3 Fuse F6 (See Parts List)
F6 protects the engine wiring sys-

tem from overload. If F6 opens,
engine will not crank.

Replace any open fuses. Reinstall
cover before operating.

 If a fuse opens, it usually indi-

cates a more serious problem
exists. Contact a Factory Au­thorized Service Agent.

Tools Needed:

8-7. Servicing Optional Spark Arrestor

1

3/8 in

803 847

 Stop engine and let cool.

1 Spark Arrestor Screen
Clean and inspect screen. Replace

spark arrestor if screen wires are
broken or missing.

Tools Needed:

1/4 in

803 847 / Ref. 801 682-A

OM-4436 Page 31

SECTION 9 − TROUBLESHOOTING

9-1. Welding Troubleshooting

Trouble Remedy

Low or no weld output; generator pow­er output okay at ac receptacles.

No weld output or generator power out­put at ac receptacles.

Low weld output. Check fuse F1, and replace if open (see Section 8-6).

High weld output. Check control settings.

Erratic weld output. Check control settings.

Check control settings.

Check weld connections.

Check fuse F1, and replace if open (see Section 8-6).

Have Factory Authorized Service Agent check brushes, slip rings, capacitor C1, and integrated rectifi­ers SR2 and SR3.

Be sure all equipment is disconnected from receptacles when starting unit.

Check fuses F1 and F2, and replace if open (see Section 8-6).

Check plug PLG6 connection.

Have Factory Authorized Service Agent check brushes, slip rings, capacitor C1, and integrated rectifi­ers SR2 and SR3.

Check control settings.

Check engine speed, and adjust if necessary (see Section 8-5).

Service air cleaner according to engine manual.

Have Factory Authorized Service Agent check brushes, slip rings, capacitor C1, and integrated rectifi­ers SR2 and SR3.

Check engine speed, and adjust if necessary (see Section 8-5).

Tighten and clean connections to electrode and workpiece.

Use dry, properly-stored electrodes for Stick and TIG welding.

Remove excessive coils from weld cables.

Clean and tighten connections both inside and outside welding generator.

Check engine speed, and adjust if necessary (see Section 8-5).

Have Factory Authorized Service Agent check brushes, slip rings, and integrated rectifiers SR2, SR3.

9-2. Generator Power Troubleshooting

Trouble Remedy

No or low generator power output at ac
receptacles; weld output okay.

OM-4436 Page 32

Reset circuit breakers (see Section 7-1).
Press GFCI receptacle Reset button (see Section 7-1).
Check fuse F2, and replace if open (see Section 8-6).

Check plug PLG6 connection.

Have Factory Authorized Service Agent check brushes, slip rings, and integrated rectifier SR3.

Trouble Remedy

C

No generator power or weld output. Be sure all equipment is disconnected from receptacles when starting unit.

Check fuses F1 and F2, and replace if open (see Section 8-6).

Check plug PLG6 connection.

Have Factory Authorized Service Agent check brushes, slip rings, capacitor C1, and integrated rectifi­ers SR2 and SR3.

Low power output at ac receptacles. Check fuse F2, and replace if open (see Section 8-6).

Increase Fine control R1 setting to max.

High power output at ac receptacles. Check engine speed, and adjust if necessary (see Section 8-5).

Erratic power output at ac receptacles. Check fuel level.

Check engine speed, and adjust if necessary (see Section 8-5).

Check receptacle wiring and connections.

Have Factory Authorized Service Agent check brushes and slip rings.

9-3. Engine Troubleshooting

Trouble Remedy

Engine will not crank. Check fuse F6, and replace if open (see Section 8-6).

Check battery voltage.

Check battery connections and tighten if necessary.

Check plug PLG4 and plug PLG8 connections.

Have Factory Authorized Service Agent check Engine Control switch S2.

Engine will not start. Check fuel level.

Check battery voltage.

Check battery connections and tighten if necessary.

Check oil level (see Section 5-2).

Check low oil pressure shutdown switch (see Parts List for location).

Have Factory Authorized Service Agent check fuel shutoff solenoid FS1 and diode D8. (FS1 optional on
Robin-powered units.)

Engine starts but stops when Engine

ontrol switch returns to Run position.

Engine stopped during normal
operation.

Check oil level.

Check and refill crankcase with proper viscosity oil for operating temperature, if necessary.

Check low oil pressure shutdown switch (see Parts List for location).

Check fuel level.

Check oil level (see Section 5-2).

Check low oil pressure shutdown switch (see Parts List for location)

Periodically recharge battery (approximately every 3 months).

Replace battery.

Check voltage regulator and connections according to engine manual.

Have Factory Authorized Service Agent check fuel shutoff solenoid FS1 (FS1 optional on Robin-powered
units).

OM-4436 Page 33

Trouble Remedy

Battery Discharges between uses. Clean battery, terminals, and posts with baking soda and water solution; rinse with clear water.

Periodically recharge battery (approximately every 3 months).

Replace battery.

Check voltage regulator and connections according to engine manual.

Engine idles but does not come up to
weld speed.

Unstable or sluggish engine speeds. Readjust throttle linkage if necessary. Check throttle solenoid TS1 for smooth operation.

Engine does not return to idle speed. Remove weld and generator power loads.

Have Factory Authorized Service Agent check auto idle module PC1, and current transformer CT1.

Check oil level. Oil level should not exceed Full mark on dipstick. Fuel pump will operate erratically if
crankcase is overfilled.

Tune-up engine according to engine manual.

Check throttle linkage for smooth, non-binding operation.

Have Factory Authorized Service Agent check idle module PC1, current transformer CT1, Engine Control
switch S2, and throttle solenoid TS1.

Notes

OM-4436 Page 34

SECTION 10 − ELECTRICAL DIAGRAMS

Figure 10-1. Circuit Diagram For Welding Generator

219 009-B

OM-4436 Page 35

SECTION 11 − GENERATOR POWER GUIDELINES

NOTE

The views in this section are intended to be representative of all engine-driven
welding generators. Your unit may differ from those shown.

11-1. Selecting Equipment

1

1 Generator Power Receptacles

− Neutral Bonded To Frame

2 3-Prong Plug From Case

Grounded Equipment

3 2-Prong Plug From Double

Insulated Equipment

 Do not use 2-prong plug un-

less equipment is double in­sulated.

2

3

OR

11-2. Grounding Generator To Truck Or Trailer Frame

1

GND/PE

2

Be sure equipment
has this symbol
and/or wording.

3

gen_pwr 11/02 − Ref. ST-159 730 / ST-800 577

 Always ground generator

frame to vehicle frame to pre­vent electric shock and static
electricity hazards.

1 Equipment Grounding

Terminal (On Front Panel)

2 Grounding Cable (Not

Supplied)
3 Metal Vehicle Frame
Connect cable from equipment

ground terminal to metal vehicle
frame. Use #10 AWG or larger
insulated copper wire.

 If unit does not have GFCI re-

ceptacles, use GFCI-pro-

tected extension cord.

OM-4436 Page 36

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

11-3. Grounding When Supplying Building Systems

1 2

GND/PE

Use ground device as stated

2

3

in electrical codes.

1 Equipment Grounding

Terminal
2 Grounding Cable
Use #10 AWG or larger insulated

copper wire.
3 Ground Device

 Ground generator to system

earth ground if supplying

power to a premises (home,

shop, farm) wiring system.

11-4. How Much Power Does Equipment Require?

3

2

1

3

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.

VOLTS 115
AMPS
Hz

4.5
60

ST-800 576-B

1 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-re-

sistive load and requires approxi­mately six times more power while
starting the motor than when running
(see Section 11-8).

3 Rating Data
Rating shows volts and amperes, or

watts required to run equipment.

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-4436 Page 37

11-5. Approximate Power Requirements For Industrial Motors

Industrial Motors Rating Starting Watts Running Watts

Split Phase 1/8 HP 800 300

1/6 HP 1225 500
1/4 HP 1600 600
1/3 HP 2100 700
1/2 HP 3175 875

Capacitor Start-Induction Run 1/3 HP 2020 720

1/2 HP 3075 975
3/4 HP 4500 1400

1 HP 6100 1600

1-1/2 HP 8200 2200

2 HP 10550 2850
3 HP 15900 3900
5 HP 23300 6800

Capacitor Start-Capacitor Run 1-1/2 HP 8100 2000

5 HP 23300 6000

7-1/2 HP 35000 8000

10 HP 46700 10700

Fan Duty 1/8 HP 1000 400

1/6 HP 1400 550
1/4 HP 1850 650
1/3 HP 2400 800
1/2 HP 3500 1100

11-6. Approximate Power Requirements For Farm/Home Equipment

Farm/Home Equipment Rating Starting Watts Running Watts

Stock Tank De-Icer 1000 1000
Grain Cleaner 1/4 HP 1650 650
Portable Conveyor 1/2 HP 3400 1000
Grain Elevator 3/4 HP 4400 1400
Milk Cooler 2900 1100
Milker (Vacuum Pump) 2 HP 10500 2800
FARM DUTY MOTORS 1/3 HP 1720 720
Std. (e.g. Conveyors, 1/2 HP 2575 975
Feed Augers, Air 3/4 HP 4500 1400
Compressors) 1 HP 6100 1600

1-1/2 HP 8200 2200

2 HP 10550 2850
3 HP 15900 3900

5 HP 23300 6800
High Torque (e.g. Barn 1-1/2 HP 8100 2000
Cleaners, Silo Unloaders, 5 HP 23300 6000
Silo Hoists, Bunk Feeders) 7-1/2 HP 35000 8000

10 HP 46700 10700
3-1/2 cu. ft. Mixer 1/2 HP 3300 1000
High Pressure 1.8 Gal/Min 500 PSI 3150 950
Washer 2 gal/min 550 PSI 4500 1400
2 gal/min 700 PSI 6100 1600
Refrigerator or Freezer 3100 800
Shallow Well Pump 1/3 HP 2150 750

1/2 HP 3100 1000

Sump Pump 1/3 HP 2100 800

1/2 HP 3200 1050

OM-4436 Page 38

11-7. Approximate Power Requirements For Contractor Equipment

Contractor Rating Starting Watts Running Watts

Hand Drill 1/4 in 350 350

3/8 in 400 400
1/2 in 600 600

Circular Saw 6-1/2 in 500 500

7-1/4 in 900 900
8-1/4 in 1400 1400

Table Saw 9 in 4500 1500

10 in 6300 1800
Band Saw 14 in 2500 1100
Bench Grinder 6 in 1720 720

8 in 3900 1400

10 in 5200 1600
Air Compressor 1/2 HP 3000 1000

1 HP 6000 1500

1-1/2 HP 8200 2200

2 HP 10500 2800
Electric Chain Saw 1-1/2 HP, 12 in 1100 1100

2 HP, 14 in 1100 1100

Electric Trimmer Standard 9 in 350 350

Heavy Duty 12 in 500 500
Electric Cultivator 1/3 HP 2100 700
Elec. Hedge Trimmer 18 in 400 400
Flood Lights HID 125 100

Metal Halide 313 250

Mercury 1000

Sodium 1400

Vapor 1250 1000
Submersible Pump 400 gph 600 200
Centrifugal Pump 900 gph 900 500
Floor Polisher 3/4 HP, 16 in 4500 1400

1 HP, 20 in 6100 1600

High Pressure Washer 1/2 HP 3150 950

3/4 HP 4500 1400

1 HP 6100 1600
55 gal Drum Mixer 1/4 HP 1900 700
Wet & Dry Vac 1.7 HP 900 900

2-1/2 HP 1300 1300

OM-4436 Page 39

11-8. Power Required To Start Motor

4
1

VOLTS AMPS

3

Single-Phase Induction Motor Starting Requirements

Motor Start

Code GHJ KLMNP

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

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
230

= 12.2 A

CODE 60

HP

Starting the motor requires 12.2 amperes.

AC MOTOR

230 2.5

M

1/4

= STARTING AMPERAGE

Hz
PHASE

1

2

1 Motor Start Code
2 Running Amperage
3 Motor HP
4 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 amper-

age (see example).
Welding generator amperage out-

put must be at least twice the
motor’s running amperage.

S-0624

11-9. How Much Power Can Generator Supply?

1

2

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 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.

OM-4436 Page 40

Ref. ST-800 396-A / S-0625

11-10. Typical Connections To Supply Standby Power

 Properly install and ground this equipment according to

its Owner’s Manual and national, state, and local codes.

1234

Utility

Electrical

Service

Transfer Switch

5

Essential

Loads

Fused

Disconnect

Switch

(If Required)

Welding

Generator

Output

 Have only qualified persons perform

these connections according to all
applicable codes and safety practic­es.

 Properly install and ground this

equipment according to its Owner’s
Manual and national, state, and local
codes.

 Customer-supplied equipment is re-

quired if generator will supply standby
power during emergencies or power out­ages.

1 Utility Electrical Service
2 Transfer Switch (Double-Throw)

Notes

Switch transfers the electrical load from
electric utility service to the generator. Trans­fer load back to electric utility when service is
restored.

Install correct switch (customer-supplied).
Switch rating must be same as or greater
than the branch overcurrent protection.

3 Fused Disconnect Switch
Install correct switch (customer-supplied) if

required by electrical code.
4 Welding Generator Output
Generator output voltage and wiring must be

consistent with regular (utility) system volt­age and wiring.

Connect generator with temporary or perma­nent wiring suitable for the installation.

Turn off or unplug all equipment connected to
generator before starting or stopping engine.
When starting or stopping, the engine has
low speed which causes low voltage and
frequency.

5 Essential Loads

Generator output may not meet the electrical
requirements of the premises. If generator
does not produce enough output to meet all
requirements, connect only essential loads
(pumps, freezers, heaters, etc. − See Sec­tion 11-4).

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-4436 Page 41

11-11. Selecting Extension Cord (Use Shortest Cord Possible)

Cord Lengths for 120 Volt Loads
 If unit does not have GFCI receptacles, use GFCI-protected extension cord.

Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*

Current

(Amperes)

5 600 350 (106) 225 (68) 137 (42) 100 (30)

7 840 400 (122) 250 (76) 150 (46) 100 (30) 62 (19)

10 1200 400 (122) 275 (84) 175 (53) 112 (34) 62 (19) 50 (15)

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.

Load (Watts) 4 6 8 10 12 14

Current

(Amperes)

5 1200 700 (213) 450 (137) 225 (84) 200 (61)

7 1680 800 (244) 500 (152) 300 (91) 200 (61) 125 (38)

10 2400 800 (244) 550 (168) 350 (107) 225 (69) 125 (38) 100 (31)

15 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

Load (Watts) 4 6 8 10 12 14

Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*

OM-4436 Page 42

SECTION 12 − STICK WELDING (SMAW) GUIDELINES

12-1. Stick Welding Procedure

 Weld current starts when

electrode touches work­piece.

 Weld current can damage

electronic parts in vehicles.
Disconnect both battery
cables before welding on a
vehicle. Place work clamp as
close to the weld as possible.

1 Workpiece
Make sure workpiece is clean be-

5

4

2

3

6

1

7

fore welding.
2 Work Clamp
3 Electrode
A small diameter electrode requires

less current than a large one. Fol­low electrode manufacturer’s
instructions when setting weld am­perage (see Section 12-2).

4 Insulated Electrode Holder
5 Electrode Holder Position
6 Arc Length
Arc length is the distance from the

electrode to the workpiece. A short
arc with correct amperage will give
a sharp, crackling sound.

7 Slag
Use a chipping hammer and wire

brush to remove slag. Remove slag
and check weld bead before mak­ing another weld pass.

Tools Needed:

stick 12/96 − ST-151 593

OM-4436 Page 43

12-2. Electrode and Amperage Selection Chart

RANGE

AMPERAGE

ELECTRODE

6010

&

6011

6013

7014

7018

7024

Ni-Cl

308L

DIAMETER

3/32

1/8
5/32
3/16
7/32

1/4
1/16
5/64
3/32

1/8
5/32
3/16
7/32

1/4
3/32

1/8
5/32
3/16
7/32

1/4
3/32

1/8
5/32
3/16
7/32

1/4
3/32

1/8
5/32
3/16
7/32

1/4
3/32

1/8
5/32
3/16
3/32

1/8
5/32

50

100

150

200

250

300

350

400

450

AC

DC*

ELECTRODE

EP

6010

EP

6011

EP,EN

6013

EP,EN

7014

EP

7018

EP,EN

7024

EP

NI-CL

EP

308L

*EP = ELECTRODE POSITIVE (REVERSE POLARITY)
EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)

POSITION

ALL
ALL
ALL

ALL

ALL

FLAT

HORIZ

FILLET

ALL
ALL

PENETRATION

DEEP
DEEP

LOW

MED

LOW

LOW

LOW
LOW

USAGE

MIN. PREP, ROUGH

HIGH SPATTER

GENERAL

SMOOTH, EASY,

FAST

LOW HYDROGEN,

STRONG

SMOOTH, EASY,

FASTER

CAST IRON
STAINLESS

Ref. S-087 985-A

12-3. Striking an Arc − Scratch Start Technique

1

3

12-4. Striking an Arc − Tapping Technique

1

3

1 Electrode
2 Workpiece
3 Arc
Drag electrode across workpiece

2

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.

S-0049

1 Electrode
2 Workpiece
3 Arc
Bring electrode straight down to

workpiece; then lift slightly to start

2

arc. If arc goes out, electrode was
lifted too high. If electrode sticks to
workpiece, use a quick twist to free it.

S-0050

OM-4436 Page 44

12-5. Positioning Electrode Holder

90° 90°

End View of Work Angle Side View of Electrode Angle

10°-30°

GROOVE WELDS

45°

45°

End View of Work Angle Side View of Electrode Angle

12-6. Poor Weld Bead Characteristics

FILLET WELDS

2

3

10°-30°

S-0060

1 Large Spatter Deposits
2 Rough, Uneven Bead
3 Slight Crater During Welding
4 Bad Overlap
5 Poor Penetration

1

4

12-7. Good Weld Bead Characteristics

5

1 Fine Spatter
2 Uniform Bead
3 Moderate Crater During

Welding

Weld a new bead or layer for each
1/8 in. (3.2 mm) thickness in metals
being welded.

1

5234

4 No Overlap
5 Good Penetration into Base

Metal

OM-4436 Page 45

S-0053-A

S-0052-B

12-8. Conditions That Affect Weld Bead Shape

NOTE

Weld bead shape is affected by electrode angle, arc length, travel speed, and
thickness of base metal.

Angle Too Small

Too Short

Slow

Correct Angle

10° - 30°

Drag

ELECTRODE ANGLE

Normal Too Long

ARC LENGTH

Normal Fast

TRAVEL SPEED

Angle Too Large

Spatter

S-0061

12-9. Electrode Movement During Welding

NOTE

1

Normally, a single stringer bead is satisfactory for most narrow groove weld joints;
however, for wide groove weld joints or bridging across gaps, a weave bead or
multiple stringer beads work better.

3

1 Stringer Bead − Steady

Movement Along Seam

2

2 Weave Bead − Side to Side

Movement Along Seam
3 Weave Patterns
Use weave patterns to cover a wide

area in one pass of the electrode.
Do not let weave width exceed
2-1/2 times diameter of electrode.

S-0054-A

OM-4436 Page 46

12-10. Butt Joints

1

12-11. Lap Joint

2

Single-Layer Fillet Weld

1 Tack Welds

2

1/16 in

(1.6 mm)

3

30°
Or Less

11

30°

4

30°
Or Less

3

Multi-Layer Fillet Weld

Prevent edges of joint from drawing
together ahead of electrode by tack
welding the materials in position be­fore final weld.

2 Square Groove Weld
Good for materials up to 3/16 in (5

mm) thick.
3 Single V-Groove Weld
Good for materials 3/16 − 3/4 in

(5-19 mm) thick. Cut bevel with oxy­acetylene or plasma cutting equip­ment. Remove scale from material
after cutting. A grinder can also be
used to prepare bevels.

Create 30 degree angle of bevel on
materials in V-groove welding.

4 Double V-Groove Weld
Good for materials thicker than 3/16

in (5 mm).

S-0662

1 Electrode
2 Single-Layer Fillet Weld
Move electrode in circular motion.
3 Multi-Layer Fillet Weld
Weld a second layer when a heavi-

er fillet is needed. Remove slag be­fore making another weld pass.
Weld both sides of joint for maxi­mum strength.

S-0063 / S-0064

12-12. Tee Joint

2

1

45°

Or Less

1 Electrode
2 Fillet Weld
Keep arc short and move at definite

rate of speed. Hold electrode as
shown to provide fusion into the
corner. Square edge of the weld
surface.

For maximum strength weld both

2

1

3

sides of upright section.
3 Multi-Layer Deposits
Weld a second layer when a heavi-

er fillet is needed. Use any of the
weaving patterns shown in Section
12-9. Remove slag before making
another weld pass.

S-0060 / S-0058-A / S-0061

OM-4436 Page 47

12-13. Weld Test

3

2 To 3 in

(51-76 mm)

2 To 3 in

(51-76 mm)

1/4 in

(6.4 mm)

2
1

2

12-14. Troubleshooting − Porosity

Porosity − small cavities or holes resulting from gas
pockets in weld metal.

Possible Causes Corrective Actions

Arc length too long. Reduce arc length.

1 Vise
2 Weld Joint
3 Hammer

3

1

Strike weld joint in direction shown.
A good weld bends over but does
not break.

S-0057-B

Damp electrode. Use dry electrode.

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before

welding.

12-15. Troubleshooting − Excessive Spatter

Excessive Spatter − scattering of molten metal particles
that cool to solid form near weld bead.

Possible Causes Corrective Actions

Amperage too high for electrode. Decrease amperage or select larger electrode.

Arc length too long or voltage too high. Reduce arc length or voltage.

OM-4436 Page 48

12-16. Troubleshooting − Incomplete Fusion

Incomplete Fusion − failure of weld metal to fuse completely with
base metal or a preceeding weld bead.

Possible Causes Corrective Actions

Insufficient heat input. Increase amperage. Select larger electrode and increase amperage.

Improper welding technique. Place stringer bead in proper location(s) at joint during welding.

Adjust work angle or widen groove to access bottom during welding.

Momentarily hold arc on groove side walls when using weaving technique.

Keep arc on leading edge of weld puddle.

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before

welding.

12-17. Troubleshooting − Lack Of Penetration

Lack Of Penetration − shallow fusion between weld metal and
base metal.

Lack of Penetration Good Penetration

Possible Causes Corrective Actions

Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove.

Improper weld technique. Keep arc on leading edge of weld puddle.

Insufficient heat input. Increase amperage. Select larger electrode and increase amperage.

Reduce travel speed.

12-18. Troubleshooting − Excessive Penetration

Excessive Penetration − weld metal melting through base metal and
hanging underneath weld.

Excessive Penetration

Possible Causes Corrective Actions

Excessive heat input. Select lower amperage. Use smaller electrode.

Good Penetration

Increase and/or maintain steady travel speed.

OM-4436 Page 49

12-19. Troubleshooting − Burn-Through

Burn-Through − weld metal melting completely through base metal resulting
in holes where no metal remains.

Possible Causes Corrective Actions

Excessive heat input. Select lower amperage. Use smaller electrode.

Increase and/or maintain steady travel speed.

12-20. Troubleshooting − Waviness Of Bead

Waviness Of Bead − weld metal that is not parallel and does not cover
joint formed by base metal.

Possible Causes Corrective Actions

Unsteady hand. Use two hands. Practice technique.

12-21. Troubleshooting − Distortion

Distortion − contraction of weld met­al during welding that forces base
metal to move.

Base metal moves

in the direction of

the weld bead.

Possible Causes Corrective Actions

Excessive heat input. Use restraint (clamp) to hold base metal in position.

Make tack welds along joint before starting welding operation.

Select lower amperage for electrode.

Increase travel speed.

Weld in small segments and allow cooling between welds.

OM-4436 Page 50

SECTION 13 − MIG WELDING (GMAW) GUIDELINES

13-1. Typical MIG Process Connections Using A Voltage-Sensing Wire Feeder

 Weld current can damage

electronic parts in vehicles.
Disconnect both battery
cables before welding on a
vehicle. Place work clamp as
close to the weld as possible.

Voltage sensing wire feeders are
used with constant current (CC) or
constant voltage (CV) power
sources (14 pin receptacle not re­quired).

If using a CC or CV welding power
source without a weld output con­tactor, use optional secondary con­tactor.

For GMAW, use optional gas valve.

Gun

Workpiece

Work Clamp Voltage

Sensing Clamp

Voltage

Sensing Wire

Feeder

Constant

Current (CC)

Or Constant

Voltage (CV)

Power Source

Electrode Lead

Work Lead

13-2. Typical MIG Process Connections Using A Constant Speed Wire Feeder

 Weld current can damage

electronic parts in vehicles.
Disconnect both battery
cables before welding on a
vehicle. Place work clamp as
close to the weld as possible.

Constant speed wire feeders are
used with constant voltage (CV)
power sources having a 14-pin re­ceptacle.

Gun

Workpiece

Work Clamp

Constant

Speed

Wire Feeder

115V/24V

Contactor

Gas

Regulator/
Flowmeter

Shielding

Electrode Lead

Work Lead

Constant

Voltage

(CV)

Welding

Power

Source

Gas

802 488

mig 9/99 / ST-800 357-A

OM-4436 Page 51

13-3. Typical MIG Process Control Settings

NOTE

These settings are guidelines only. Material and wire type, joint design, fitup,
position, shielding gas, etc. affect settings. Test welds to be sure they comply to
specifications.

Material thickness determines weld
parameters.

.035 in

Wire Size Amperage Range

.030 in
.035 in
.045 in 75 − 250 A

1/8 or

.125 in

40 − 145 A
50 − 180 A

Convert Material

Thickness to

Amperage (A)

(.001 in = 1 ampere)

.125 in = 125 A

Select Wire Size

Wire
Size (Approx.)

.030 in
.035 in

.045 in 1 in per ampere 1 x 125 A = 125 ipm

Wire speed (amperage) controls weld pe­netration (wire speed = burn-off rate)

Voltage controls height and width of
weld bead.

Recommendation

2 in per ampere

1.6 in per ampere

Low voltage: wire stubs into work

High voltage: arc is unstable (spatter)

Set voltage midway between high/low voltage.

Wire Speed

2 x 125 A = 250 ipm

1.6 x 125 A = 200 ipm

Select Wire Speed

(Amperage)

125 A based on 1/8 in

material thickness

ipm = inch per minute

Select Voltage

OM-4436 Page 52

Ref. ST-801 865

13-4. Holding And Positioning Welding Gun

NOTE

Welding wire is energized when gun trigger is pressed. Before lowering helmet and
pressing trigger, be sure wire is no more than 1/2 in (13 mm) past end of nozzle,
and tip of wire is positioned correctly on seam.

1

2

5

4

0°-15°

90° 90°

End View Of Work Angle Side View Of Gun Angle

GROOVE WELDS

1 Hold Gun and Control Gun

Trigger

2 Workpiece

3

3 Work Clamp
4 Electrode Extension (Stickout)

1/4 to 1/2 in (6 To 13 mm)

5 Cradle Gun and Rest Hand on

Workpiece

45°

45°

End View Of Work Angle Side View Of Gun Angle

FILLET WELDS

0°-15°

S-0421-A

OM-4436 Page 53

13-5. Conditions That Affect Weld Bead Shape

NOTE

Weld bead shape depends on gun angle, direction of travel, electrode extension
(stickout), travel speed, thickness of base metal, wire feed speed (weld current),
and voltage.

10°

Push

Perpendicular Drag

GUN ANGLES AND WELD BEAD PROFILES

Short Normal Long

10°

ELECTRODE EXTENSIONS (STICKOUT)

Short Normal Long

FILLET WELD ELECTRODE EXTENSIONS (STICKOUT)

Slow Normal Fast

GUN TRAVEL SPEED

S-0634

OM-4436 Page 54

13-6. Gun Movement During Welding

NOTE

Normally, a single stringer bead is satisfactory for most narrow groove weld joints;
however, for wide groove weld joints or bridging across gaps, a weave bead or
multiple stringer beads works better.

1 2

3

13-7. Poor Weld Bead Characteristics

1 Stringer Bead − Steady

Movement Along Seam

2 Weave Bead − Side To Side

Movement Along Seam
3 Weave Patterns
Use weave patterns to cover a wide

area in one pass of the electrode.

S-0054-A

2

13-8. Good Weld Bead Characteristics

2

4

3

1 Large Spatter Deposits

1

4

3

5

1

2 Rough, Uneven Bead
3 Slight Crater During Welding
4 Bad Overlap
5 Poor Penetration

S-0053-A

1 Fine Spatter
2 Uniform Bead
3 Moderate Crater During

Welding
Weld a new bead or layer for each

1/8 in (3.2 mm) thickness in metals
being welded.

4 No Overlap
5 Good Penetration into Base

Metal

5

OM-4436 Page 55

S-0052-B

13-9. Troubleshooting − Excessive Spatter

Excessive Spatter − scattering of molten metal particles that
cool to solid form near weld bead.

S-0636

Possible Causes Corrective Actions

Wire feed speed too high. Select lower wire feed speed.

Voltage too high. Select lower voltage range.

Electrode extension (stickout) too long. Use shorter electrode extension (stickout).

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.

Insufficient shielding gas at welding arc. Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.

Dirty welding wire. Use clean, dry welding wire.

Eliminate pickup of oil or lubricant on welding wire from feeder or liner.

13-10. Troubleshooting − Porosity

Porosity − small cavities or holes resulting from gas pockets
in weld metal.

S-0635

Possible Causes Corrective Actions

Insufficient shielding gas at welding arc. Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.

Remove spatter from gun nozzle.

Check gas hoses for leaks.

Place nozzle 1/4 to 1/2 in (6-13 mm) from workpiece.

Hold gun near bead at end of weld until molten metal solidifies.

Wrong gas. Use welding grade shielding gas; change to different gas.

Dirty welding wire. Use clean, dry welding wire.

Eliminate pick up of oil or lubricant on welding wire from feeder or liner.

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before welding.

Use a more highly deoxidizing welding wire (contact supplier).

Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.

13-11. Troubleshooting − Excessive Penetration

Excessive Penetration − weld metal melting through base metal
and hanging underneath weld.

Excessive Penetration

Possible Causes Corrective Actions

Excessive heat input. Select lower voltage range and reduce wire feed speed.

OM-4436 Page 56

Good Penetration

Increase travel speed.

S-0639

13-12. Troubleshooting − Lack Of Penetration

Lack Of Penetration − shallow
fusion between weld metal and
base metal.

Lack of Penetration Good Penetration

Possible Causes Corrective Actions

S-0638

Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while

maintaining proper welding wire extension and arc characteristics.

Improper weld technique. Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.

Keep arc on leading edge of weld puddle.

Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.

Insufficient heat input. Select higher wire feed speed and/or select higher voltage range.

Reduce travel speed.

13-13. Troubleshooting − Incomplete Fusion

Incomplete Fusion − failure of weld metal to fuse completely with
base metal or a preceeding weld bead.

Possible Causes Corrective Actions

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before

welding.

Insufficient heat input. Select higher voltage range and/or adjust wire feed speed.

S-0637

Improper welding technique. Place stringer bead in proper location(s) at joint during welding.

Adjust work angle or widen groove to access bottom during welding.

Momentarily hold arc on groove side walls when using weaving technique.

Keep arc on leading edge of weld puddle.

Use correct gun angle of 0 to 15 degrees.

13-14. Troubleshooting − Burn-Through

Burn-Through − weld metal melting completely through base metal
resulting in holes where no metal remains.

Possible Causes Corrective Actions

Excessive heat input. Select lower voltage range and reduce wire feed speed.

Increase and/or maintain steady travel speed.

S-0640

OM-4436 Page 57

13-15. Troubleshooting − Waviness Of Bead

Waviness Of Bead − weld metal that is not parallel and does not cover
joint formed by base metal.

Possible Causes Corrective Actions

Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.

Unsteady hand. Support hand on solid surface or use two hands.

13-16. Troubleshooting − Distortion

Distortion − contraction of weld metal during welding that forces
base metal to move.

Base metal moves

in the direction of

the weld bead.

Possible Causes Corrective Actions

Excessive heat input. Use restraint (clamp) to hold base metal in position.

S-0641

S-0642

Make tack welds along joint before starting welding operation.

Select lower voltage range and/or reduce wire feed speed.

Increase travel speed.

Weld in small segments and allow cooling between welds.

OM-4436 Page 58

13-17. Common MIG Shielding Gases

This is a general chart for common gases and where they are used. Many different combinations (mixtures) of
shielding gases have been developed over the years. The most commonly used shielding gases are listed in the
following table.

Application

Gas

Spray Arc Steel

Short Circuiting

Steel

Spray Arc

Stainless Steel

Short Circuiting

Stainless Steel

Spray Arc

Aluminum

Argon All Positions

Argon + 1% O

Argon + 2% O

Argon + 5% O

Argon + 8% CO

Argon + 25%

CO

2

Argon + 50%

CO

2

CO

2

Flat & Horizontal

2

Flat & Horizontal

2

Flat & Horizontal

2

Flat & Horizontal

2

Flat & Horizontal

Flat & Horizontal

Fillet

Fillet

Fillet

Fillet

Fillet

Fillet

5

Flat & Horizontal

Fillet

5

Flat & Horizontal

Fillet

5

5

All Positions

1

All Positions All Positions

All Positions

1

All Positions

5

5

3

Helium All Positions

Argon + Helium All Positions

Short Circuiting

5

2

2

Aluminum

All Positions

4

Tri-Mix

1 Globular Transfer
2 Heavy Thicknesses
3 Single Pass Welding Only
4 90% HE + 7-1/2% AR + 2-1/2% CO
5 Also for GMAW-P, All Positions

All Positions

2

OM-4436 Page 59

SECTION 14 − PARTS LIST

5

8

7

6

9

 Hardware is common and

not available unless listed.

29

24

35

27

26

31

28

30

32

33

34

23

10

15

18

16

17

42

41

14

4

3

2

1

48−FIG. 14−3

49

46

45

50

44

13

12

11

53

52

51

43

19

20

40

39

25

21

22−FIG. 14−2

36

37

38

OM-4436 Page 60

47

803 971−B

Figure 14-1. Main Assembly (Kohler Engine Shown)

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 14-1. Main Assembly

1 +211366 Panel, Side Rh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 +211367 Cover, Top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 222324 Label, Warning General Precautionary Csa 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 +211365 Panel, Side Lh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 217654 Bezel, Side Engine Access 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 211398 Grommet, Plastic Neck Filler Fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 220711 Cap, Tank Screw−on W/Vent 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 211527 Pipe, Exhaust Elbow 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 217653 Bezel, Top Cover Engine Access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 219329 Label, Use Gasoline Fuel Only 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 C1 210639 Capacitor, Elctlt 1500 Uf 75 Vdc Can 1.40 Dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 177136 Clamp, Capacitor 1.375 Dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 F1, F2 169296 Fuse, Mintr Gl 25. Amp 125 Volt 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 172731 Holder, Fuse Mintr .250 X 1.250 Clip Anti−pivot 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 D4 135184 Diode Board 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 SR2, SR3 035704 Rectifier, Integ Bridge 40. Amp 800 Volt 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 1T 172661 Block, Stud Connection 6 Position 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

173734 Link, Jumper 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 211376 Bracket, Mtg Component 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 205734 Seal, Weather Lift Eye 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 211360 Upright, Base 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 211359 Cover, Tank Fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 Figure14-2 Generator Assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 209057 Clamp, Muffler 1.625 Dia U Pld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 218634 Engine, Gas Elec Start Kohler (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 218635 Muffler, Exhaust Engine 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 165271 Valve, Oil Drain 3/8−18 Nptf 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 *215984 Filter, Fuel In−line .250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F6 *021718 Fuse, Mintr Gl 30. Amp 32 Volt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*180096 Tune−up & Filter Kit, Kohler (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

067272 Air Filter Element, Kohler 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

066698 Oil Filter, Kohler 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

215985 Filter, Fuel w/Clamps & 1/4 in Fuel Line 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

067007 Spark Plug 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*067273 Air Filter Wrapper 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 217067 Stiffener, Rear Panel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 213952 Baffle, Engine Air Assy 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 +211364 Panel, Rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 217848 Cable, Bat Neg 15.000 No 4 Awg W/Clamp & .343 Rng 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 217847 Cable, Bat Neg 8.000 6ga W/.250 Rng & .375 Rng 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 219811 Cable, Bat Pos 25.000 No 4 Awg W/Clamp & .312 Rng 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 182935 Hold Down, Battery 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 BATT 168037 Battery, Stor 12 Volt 430 Crk 75 Rsv Gp 58 Dry 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 199052 Tank, Fuel 12.0 Gal 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

214843 Hose, Sae .250 Id X .500 Od X 10.250 Kohler 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 +211356 Pan, Base 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 219654 Label, Warning Battery Explosion Can Blind 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 215939 Label, Engine Maintenance Robin & Kohler 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 217015 Label, Warning Do Not Weld On Base/Fuel Level 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 211210 Bracket, Mtg Engine Kohler 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 127595 Screw, 375−16x2.50 Hex Hd−pln Gr5 Pld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 010954 Washer, Flat .406idx1.250odx.125t Stl Pld 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 214556 Mount, Vibration 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

167788 Nut, 375−16 .56hex .34h Stl Pld Sem Cone Wshr.88d 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 211358 Bracket, Mtg Generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 211355 Cover, Base 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46 DC-Z 218497 Reactor, Stabilizer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47 SR1 220782 Rectifier, Si 1 Ph, 400 Amp, 400 Piv 60% Duty Cycle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48 Figure14-3 Front Panel Assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-4436 Page 61

Quantity

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 14-1. Main Assembly (Continued)

49 CT1 218664 Xfmr, Current Sensing 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 219980 Bracket, Mtg Components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51 C2, C3, C4 210720 Capacitor, Ac 370v 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52 210719 Clamp, Capacitor 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53 R2 200518 Resistor, WW Fxd 225 W 3.15 Ohm W/2.85 Ta 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

147551 Tool, Puller Rotor (Service Item) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

177126 Tool, Puller Rotor (Service Item) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

167640 Housing Plug Pins+Skts, (Service Kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

218952 Kit, Label ‘1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+When ordering a component originally displaying a precautionary label, the label should also be ordered. Labels
available separately or as part of label kit 219008.
♦Optional
* Recommended Spare Parts.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-4436 Page 62

11

10

9

5

8

7

2

1

3

4

12

6

13

14

Figure 14-2. Generator

Item

No.

Part

No.

Description

Figure14-2. Generator (Figure 14-1 Item 22)

1 142156 Screw, 375−16x1.75 Hexwhd.81d Gr8 Pld 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 STATOR +223231 Generator Assy, Front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 183419 O-Ring 1.984 Id X .139 cs 70 Duro Viton 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 013367 Label, Warning Moving Parts Can Cause Serious Etc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 ROTOR 217681 Rotor, Generator (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 181143 Bearing, Ball Rdl Sgl Row .984 X 2.047 X .591 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 181135 Ring, Collector Rotor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 216444 Fan, Rotor Gen 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 211357 Housing, Generator Rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 213979 Guard, Fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 604224 Screw, 250−20x .75 Hexwhd.50d Stl Pld Slffmg Tap−rw 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 186083 Screw, 437−14x1.75 Hexwhd.93d Gr8 Pld 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 205725 Brushholder Assy, Generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 136343 Screw, K50x 20 Pan Hd−phl Stl Pld Pt Thread Forming 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

803 882

Quantity

+When ordering a component originally displaying a precautionary label, the label should also be ordered. Labels
available separately or as part of label kit 219008.

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-4436 Page 63

26

27

28

4

3

2

1

5

6

7

8

9

10

11

12

24

Item

No.

23

25

22

21

Dia.

Mkgs.

15

18

16

17

20

19

Figure 14-3. Panel, Front w/Components

Part

No.

Description

Figure 14-3. Panel, Front w/Components (Figure 14-1 Item 48)

14

13

803 972−A

Quantity

1 Nameplate (Order By Model And Serial No.) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 219522 Panel, Front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 186058 Cover, Dust 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 S1 222520 Switch, Polarity 5 Position W/Leads & Jumpers 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 S3 183148 Switch, Range 4 Position 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 PC1 201936 Module, Pull To Idle 5 Pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 R1 207177 Rheostat, WW 150. W 14. Ohm Frict Term 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 S2 217680 Switch, Ignition 4 Position W/Out Handle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 CB2, CB3 093996 Circuit Breaker, Man Reset 1p 20a 250vac Frict 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 GFCI2, GFCI3 151981 Rcpt, Str Dx Grd 2p3w 15/20a 125v *5−20r Gfi 2. . . . . . . . . . . . . . . . . . . . . . . . . . .

11 CB1 218591 Circuit Breaker, Man Reset 2p 50a 240vac Screw−90 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 HM 145247 Meter, Hour 12−24vdc 1.25 X 2.12 Rect 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 207077 Knob, Pointer 1.625 Dia. Push On 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 203993 Control, Push/Pull Snap−in 45.000 W/1.750 Extension Kohler 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

15 207073 Lever, Ignition Switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 RC4 210707 Rcpt, Tw Lk 3p4w 30a 480v 3p L16−30r 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 CB4 210641 Circuit Breaker, Man Reset 3p 15a 277vac Screw−90 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 RC1 182954 Rcpt, Str 3p4w 50a 125/250v Flush Mtg *14−50 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦119172 Plug, str grd 3p4w 50a 125/250v *14−50p 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-4436 Page 64

Item

No.

19 211416 Bezel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 216776 Cover, Output Stud Electrode 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 213637 Cover, Output Stud 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 216773 Cover, Receptacle Duplex 120v 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 216774 Cover, Receptacle Full Kva 120/240v 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 216772 Cover, Output Stud Work 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 211405 Pin, Hinge 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 207074 Handle, Switch 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 GRD 197203 Grounding Stud Assy, Brass 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28

♦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.

Dia.

Mkgs.

ELECT, WORK 099255 Terminal, Pwr Output Neutral 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Part

No.

Figure 14-3. Panel, Front w/Components (Continued)

217346 Bezel Assy (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description

Quantity

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.

PLG8 177859 Conn, Body 5 Terminal 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC4/PLG4 116045 Conn, Rect Univ 084 6p/S 3row Rcpt Cable/Pane (Service Kit) 1. . . . . . . . . . . . . . . . . .

RC6/PLG6 136810 Conn, Rect Univ 084 4p/S 1row Plug Cable Lkg (Service Kit) 1. . . . . . . . . . . . . . . . . . . .

Part

No.

Wiring Harnesses

219016 Harness, Wrg Unit (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description

Quantity

OM-4436 Page 65

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.

Effective January 1, 2005

(Equipment with a serial number preface of “LF” or newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other

LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.

Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that the
equipment was delivered to the original retail purchaser, or one
year after the equipment is sent to a North American distributor
or eighteen months after the equipment is sent to an
International distributor.

1. 5 Years Parts — 3 Years Labor

* Original main power rectifiers
* Inverters (input and output rectifiers only)

2. 3 Years — Parts and Labor

* 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.)

3. 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

guarantees or warranties expressed or implied.

* Induction Heating Coils and Blankets
* APT & SAF Model Plasma Cutting Torches
* Remote Controls
* Accessory Kits
* Replacement Parts (No labor)
* Spoolmate Spoolguns
* Canvas Covers

Miller’s True Blue Limited Warranty shall not apply to:

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)

2. Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.

3. Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for the
equipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.

Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary
from state to state.

In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may be
available, but may vary from province to province.

miller_warr 1/05

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

Contact 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
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information

and Parts)
Circuit Diagrams
Welding Process Handbooks

To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller

Miller Electric Mfg. Co.

An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA

International Headquarters−USA

USA Phone: [phone] Auto-Attended
USA & Canada FAX: [phone]
International FAX: [phone]

European Headquarters −
United Kingdom

Phone: [phone]
FAX: [phone]

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  2005 Miller Electric Mfg. Co. 1/05