Miller Electric Blue Star 6000 User Manual

OM-499 197 850H

March 2004

Processes

Stick (SMAW) Welding

Description

Engine Driven Welding Generator



Blue Star 6000

Visit our website at

www.MillerWelds.com

From Miller to You

Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.

That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.

Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.

This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.

We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The

Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 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 orindividual catalog sheets. To locate your nearest

distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.

Miller offers a Technical
Manual which provides
more detailed service and
parts information for your
unit. T o obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMA W-P.

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 (Kohler-Powered Units) 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Fuel Consumption (Honda-Powered Units) 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Duty Cycle 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Generator Power Curves 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Volt-Ampere Curves 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

5-2. Grounding Generator To Truck Or Trailer Frame 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Grounding Generator When Supplying Building Systems 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Engine Prestart Checks (Kohler-Powered Units) 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Engine Prestart Checks (Honda-Powered Units) 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. Connecting The Battery (Electric-Start Models Only) 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7. Connecting To Weld Output Terminals 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-8. Selecting Weld Cable Sizes* 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − OPERATING THE WELDING GENERATOR 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Controls (Kohler-Powered Units) 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Controls (Honda-Powered Units) (See Section 6-3) 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Description Of Controls (Honda-Powered Units) (See Section 6-2) 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − OPERATING AUXILIAR Y EQUIPMENT 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Generator Power Panel 495 218 (USA) 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Optional Generator Power Panels 2 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3. Generator Power Panel Ratings 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-4. Wiring Instructions For Optional 120/240 Volt Twistlock Plug (NEMA L14-30P) 24 . . . . . . . . . . . . . . . . . .

SECTION 8 − MAINTENANCE 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1. Maintenance Label 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2. Routine Maintenance 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3. Overload Protection (Honda-Powered Units) 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-4. Adjusting Engine Speed (Kohler-Powered Units) 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-5. Adjusting Engine Speed (Honda-Powered Units) 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − TROUBLESHOOTING 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 − ELECTRICAL DIAGRAMS 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 − GENERATOR POWER GUIDELINES 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 12 − STICK WELDING (SMAW) GUIDELINES 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 13 − PARTS LIST 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING

rom _nd_8/03

 Warning: Protect yourself and others from injury — read and follow these precautions.

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.

 Marks a special safety message.

 Means “Note”; not safety related.

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

Return To Table Of Contents

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-499 Page 1

WELDING can cause fire or explosion.

HOT PARTS can cause severe burns.

Welding on closed containers, such as tanks, drums, or
pipes, can cause them to blow up. Sparks can fly off from the

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-499 Page 2

 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.

Return To Table Of Contents

MOVING PARTS can cause injury.

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

and securely in place.

STEAM AND HO T C OOLANT can burn.

BREATHING COMPRESSED AIR can

.

TRAPPED AIR PRESSURE AND WHIPPING

 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

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.

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 only, NOT running gear, gas

cylinders, trailer, or any other accessories.

 Use equipment of adequate capacity to lift and

support unit.

 If using lift forks to move unit, be sure forks are long

enough to extend beyond opposite side of unit.

OVERHEATING can damage motors.

 Turn off or unplug equipment before starting or 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,

 Sparks can cause fires — keep flammables away.

and body protection.

Return To Table Of Contents

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-499 Page 3

READ INSTRUCTIONS.

ARC WELDING can cause interference.

 Use only genuine MILLER/Hobart replacement

parts.

 Perform engine and air compressor (if applicable)

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

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

 W elding 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, o r
shielding the work area.

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

California t o 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 Ma g netic 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, NFP A 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-499 Page 4

Return To Table Of Contents

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT

UTILISATION

rom_fre 8/03

 Avertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions.

2-1. Signification des symboles

Signifie Mise en garde ! Soyez vigilant ! Cette procédure
présente des risques de danger ! Ceux-ci sont identifiés par
des symboles adjacents aux directives.

 Identifie un message de sécurité particulier.

 Signifie NOTA ; n’est pas relatif à la sécurité.

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 e t 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 l a 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 àcourant électrique dans les zones

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

 Se servir d’une source électrique àcourant électrique UNIQUEMENT si le

procédé de soudage le demande.

 Si l’utilisation d’une source électrique àcourant électrique s’avère 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

Revenez à la table des matières

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’interieur, ventiler la zone et/ou utiliser un échappement au niveau de

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

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

homologué.

 Lire les spécifications de sécurité des matériaux (MSDSs) et les 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-499 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 sondre est

trop élevé.

 Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair et de

l’éblouissement; demander aux autres personnes de ne pas regarder l’arc.

 Porter des vêtements de protection constitué dans une matière durable, 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 pa ssage 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 sondre est trop élevé.

LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.

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

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

Si des BOUTEILLES sont endomma­gées, elles pourront exploser.

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

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

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

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

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

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

électriques.

 Ne jamais placer une torche de soudage sur une bouteille à gaz.
 Une électrode de soudage ne doit jamais entrer en contact avec une 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-499 Page 6

Revenez à la table des matières

L’ACIDE DE LA BATTERIE peut pro­voquer des brûlures dans les YEUX et
sur la PEAU.

 Ne pas renverser la batterie.
 Remplacer une batterie endommagée.
 Rincer immédiatement les yeux et la peau à l’eau.

L’EXPLOSION DE LA BATTERIE peut

-

r

r

-

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.

 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 dipositifs de protection et fermer les

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

 Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la mise e n

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.

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.

2-4. Dangers liés à l’air comprimé

RESPIRER L’AIR COMPRIMÉ peut pro
voquer des blessures graves ou cause
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 provoque
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 provo
quer des blessures.

 Relâcher l a 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.

 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.

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 l’anneau de levage uniquement pour soulever

l’appareil lui-même ; sans chariot, de bouteilles de
gaz, remorque, ou autres accessoires.

Revenez à la table des matières

 Utiliser un équipement de levage de capacité suffisante pour lever

l’appareil.

 En utilisant des fourches de levage pour déplacer l’unité, s’assurer

que les fourches sont suffisamment longues pour dépasser du côté
opposé de l’appareil.

OM-499 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.

 Affuterr l’électrode au tungstène uniquement à la meuleuse dotée de pro-

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

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

inflammable.

L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.

 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 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 c e 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 s ouder à une distance de 100 mètres de tout équipement élec-

tronique sensible.

 Veiller à c e 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 qu e
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 W e b : w w w.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 F i r e P r e v e n t i o n During Welding, Cutting, and Other Hot Work,
norme NFPA 51B, de la National Fire Protection Association, P.O. Box
9101, 1 Battery March Park, Quincy, MA 02269−9101 (téléphone : (617)
770−3000, site Web : www.nfpa.org et www.sparky.org).
OSHA, Occupational Safety and Health Standards for General Industry,
Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and
Part 1926, Subpart J, de l’U.S. Government Printing Office, Superintendent
of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10 bureaux
régionaux − Téléphone pour la Région 5, Chicago : (312) 353−2220, site
Web : www.osha.gov).

2-7. Information sur les champs électromagnétiques

Données sur le soudage électrique et les effets des champs magnétiques
basse fréquence sur l’organisme
En parcourant les câbles de soudage, le courant crée des champs électro­magnétiques. Les effets potentiels de tels champs restent préoccupants.
Cependant, après avoir examiné plus de 500 études qui ont été faites pen­dant une période de recherche de 17 ans, un comité de spécialistes du
National Research Council a conclu : « L’accumulation de preuves n’a pas
démontré que l’exposition aux champs magnétiques et aux champs électri­ques à haute fréquence constitue un risque pour la santé humaine ».
Toutefois, les études et l’examen des preuves se poursuivent. En attendant
les conclusions finales de la recherche, il serait souhaitable de réduire l’ex­position aux champs électromagnétiques pendant le soudage ou le
coupage.

OM-499 Page 8

Revenez à la table des matières

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

h

s

SECTION 3 − DEFINITIONS

NOTE

Engine Choke

Engine Oil Fuel Battery (Engine) Engine

Positive Negative

Hours

Circuit Breaker Temperature

Read Operator’s

Manual A

Alternating Current

Seconds Time

Amperes

(AC)

V

Output

Protective Earth

(Ground)

SECTION 4 − SPECIFICATIONS

This unit uses either a Kohler or a Honda engine. Differences between models are
noted throughout this manual.

Volts

4-1. Weld, Power, And Engine Specifications

Welding

Mode

CC/DC

Weld Output

Range

40 − 180 A

(60 Hz)

40 − 160 A

(50 Hz)

Rated

Welding

Output

180 A, 25 V ,

30% Duty

Cycle

130 A, 25 V ,

60% Duty

Cycle

100 A, 25 V ,

100% Duty

Cycle

Maximum

Open Circuit

Voltage

80

(60 Hz)

70

(50 Hz)

Generator Power

Rating

Single-Phase,

6 kVA/kW (Peak)

5.5 kVA/kW

(Continuous)

50/25 A,
110/220 V AC, 50 Hz
120/240 V AC, 60 Hz

Fuel Capacity Engine

Kohler CS12STG

Air-Cooled,

One-Cylinder,

Kohler:

1.8 gal (6.9 L) Tank
Honda:

1.7 gal (6.4 L) Tank

Four-Cycle,
12 HP (360 CC),
Gasoline Engine

Honda GX390

Air-Cooled,

One-Cylinder,

Four-Cycle,
13 HP (390 CC),
Gasoline Engine

OR

Return To T able Of Contents

OM-499 Page 9

4-2. Dimensions, Weights, And Operating Angles

D

B

be damaged or unit could tip.

 Do not move or operate unit where it

G

15°

15°

G

15°

Holes

4-3. Fuel Consumption (Kohler-Powered Units)

Dimensions

Height 20-3/4 i n (527 mm)

Width 22-3/4 i n (577 mm)
Depth 31-1/4 in (793 mm)

A 31-1/4 i n (793 mm)
B 10-1/2 i n (268 mm)
C 13-45/64 in (348 mm)
D 22-3/4 in (577 mm)
E 1-3/4 in (44 mm)
F 19-1/2 in (495 mm)
G 13/32 in (10 mm) Dia.

Weight

Kohler: 265 lb (120 kg)

Honda Electric-Start Model:

278 lb (126 kg)

Honda Recoil-Start Model:

253 lb (114 kg)

A

C

E

D

F

Engine End

4

Holes

802 096

 Do not exceed tilt angles or engine could

could tip.

°

°

°

15°

802 524-A

HIGH IDLE

 Fuel consumption at low idle

(2000 rpm): 0.2 U.S. gal/hr.

60 HZ−WELD

60 HZ−AUX

50 HZ−AUX

50 HZ−WELD

OM-499 Page 10

Return To T able Of Contents

198 575

4-4. Fuel Consumption (Honda-Powered Units)

4-5. Duty Cycle

Continuous Welding

100% Duty Cycle at 100 Amperes CC/DC

802 122

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.

Return To T able Of Contents

802 093

OM-499 Page 11

4-6. Generator Power Curves

A. 60 Hz Model

250

225

200

175

150

125

LOAD VOLTS

100

75

50

25

0

0 5 10 15 20 25 30 35

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

LOAD AMPS

B. 50 Hz Model

250

225

200

175

150

125

LOAD VOLTS

100

75

50

25

0

0 5 10 15 20 25 30 35

LOAD AMPS

OM-499 Page 12

198 570

Return To T able Of Contents

4-7. Volt-Ampere Curves

f
l

A. 60 Hz Model

80

70

60

50

40

LOAD VOLTS

30

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

MAX

MID

20

10

0

0 25 50 75 100 125 150 175 200 225 250

MIN

LOAD AMPS

B. 50 Hz Model

80

70

60

50

40

LOAD VOLTS

30

MID

20

MIN

MAX

10

0

0 25 50 75 100 125 150 175 200 225 250

LOAD AMPS

Return To Table Of Contents

198 570

OM-499 Page 13

SECTION 5 − INSTALLATION

5-1. Installing Welding Generator

Movement Airflow Clearance

(460 mm)

18 in

(460 mm)

 Always securely fasten welding

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

18 in

18 in

(460 mm)

18 in

(460 mm)

Location

OR

5-2. Grounding Generator To Truck Or Trailer Frame

1

GND/PE

OR

3

18 in

(460 mm)

install1 10/00*− 802 524-A / Ref. 151 556 / 158 936-A / S-0854

 Always ground generator

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

1 Generator Base
2 Metal Vehicle Frame
3 Equipment Grounding

Terminal

4

4 Grounding Cable
Use #10 AWG or larger insulated

copper wire.

 If unit does not have GFCI re-

ceptacles, use GFCI­protected extension cord.

OM-499 Page 14

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

2

Return To Table Of Contents

2

install1 10/00* − Ref. 151 556 / S-0854

5-3. Grounding Generator When Supplying Building Systems

5

GND/PE

Use ground device as
stated in electrical codes.

1 2

1 Equipment Grounding

Terminal
2 Grounding Cable
Use #10 AWG or larger insulated

copper wire.
3 Ground Device

 Ground generator to sys-

tem earth ground if supply-

ing power to a premises

(home, shop, farm) wiring

system.

2

3

800 576-B

-4. Engine Prestart Checks (Kohler-Powered Units)

 Follow run-in procedure in engine

1/2 in

(13 mm)

Full

manual.

Check all fluids daily. Engine must be
cold and on a level surface. Unit is
shipped with 10W30 engine oil.

Engine stops if oil level gets too low.

 This unit has a low oil level shut-

Gasoline

down switch. However, some con­ditions may cause engine damage
before the engine shuts down.
Check oil level often and do not use
the oil level shutdown system to
monitor oil level.

1 Fuel Valve
Open valve by turning lever to vertical

position.

 Close fuel valve before moving unit

1

Closed

Closed

Open

Full

or carburetor may flood and make
starting difficult.

Fuel

Add fresh fuel before starting engine the
first time (see maintenance label for
specifications). Fill fuel tank up to 1/2 in.
(13 mm) from top to allow room for ex­pansion. Check fuel level on a cold en­gine before use each day.

Oil

After fueling, check oil with unit on level
surface. I f oil is not up to full mark on dip­stick, add oil (see maintenance label).

 T o improve cold weather starting:

Return To Table Of Contents

Keep battery in good condition.
Store battery in warm area.

Use correct grade oil for cold
weather.

802 511-A

OM-499 Page 15

5

-5. Engine Prestart Checks (Honda-Powered Units)

f

Check all fluids daily. Engine must
be cold and on a level surface. Unit
is shipped with 10W30 engine oil.

1/2 in

(13 mm)

Gasoline

1

Open

Full

Full

Engine stops if oil level gets too low.

 Follow run-in procedure in en-

gine manual.

1 Fuel Valve
Open valve.

 Close fuel valve before moving

unit or carburetor may flood
and make starting difficult.

Fuel

Add fresh fuel before starting
engine the first time (see mainte­nance label for specifications). Fill
fuel tank up to 1/2 in. (13 mm) from
top to allow room for expansion.
Check fuel level on a cold engine
before use each day.

Oil

After fueling, check oil with unit on
level surface. If oil is not up to full
mark on dipstick, add oil (see main­tenance label).

 To improve cold weather

starting:
Keep battery in good condition.

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

weather.

5-6. Connecting The Battery (Electric-Start Models Only)

 Connect negative (−)

cable last.

+

Tools Needed:

3/8, 1/2 in

−

802 094-A

 Turn Engine Switch to Of

(electric-start models only).

802 524 / Ref. S-0756-D

OM-499 Page 16

Return To Table Of Contents

5-7. Connecting To Weld Output Terminals

12

1 Positive (+) W eld Output

Terminal

2 Negative (−) Weld Output

Terminal

For Direct Current Electrode Posi­tive (DCEP), connect work cable to
Negative (−) terminal and electrode
holder to Positive (+) terminal.

For Direct Current Electrode nega­tive (DCEN), reverse cable con­nections.

Tools Needed:

3/4 in

5-8. Selecting Weld Cable Sizes*

100 ft (30 m) or Less

Weld Output

Terminals

 Stop engine before

connecting t o 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)

10 − 60%

Duty

Cycle

196 914 / 495 178

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

400 ft

(120 m)

250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)

* This chart is a general guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), use next size larger

cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.

( ) = mm2 for metric use S-0007-E
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.

Return To T able Of Contents

2 ea. 2/0

(2x70)

2 ea. 2/0

(2x70)

OM-499 Page 17

SECTION 6 − OPERATING THE WELDING GENERATOR

6-1. Controls (Kohler-Powered Units)

3

50 Hz

60 Hz

1

6

2

4

 Weld and generator power output stops if

generator overheats or engine speed is
too low.

1 Engine Switch
Use switch to open ignition circuit, and to stop

engine.

2 Throttle Control Lever

Use lever to select engine speed. Use 50 Hz
or 60 Hz position for 50 or 60 Hz generator
power. Use 60 Hz position for maximum weld
output.

3 Choke Control Lever

Use lever to change engine air/fuel mix. Move
lever to right if starting a cold engine. Move le­ver to left if starting a warm engine.

To Start (Electric): open fuel valve (see Sec­tion 5-4 ), move throttle lever to Idle, set choke,
and turn engine switch to Start position. Open
choke as engine warms. If engine does not
crank, use recoil starting procedure following
to start engine.

 If engine does not start, let engine

come to a complete stop before at­tempting restart.

4 Starter Handle
To Start (Recoil): open fuel valve (see Sec-

tion 5-4 ), move throttle lever to Idle, set choke,
and pull starter handle. Open choke as engine
warms.

To Stop: turn engine switch to Off.

 Always close fuel valve after stopping

unit. Moving unit with fuel valve open may
cause carburetor flooding and make
starting difficult.

5

7

802 511-A / 802 0511 / 495 178

5 Engine Hour Meter
6 Welding Range Label
Use label to determine correct weld amper-

age based on electrode size, type, and mate­rial thickness.

7 Current Control
Use control to select weld amperage. Control

may be adjusted while welding.
To Set Current Control: Use label to deter-

mine correct size electrode for material thick­ness. Select electrode type and set current
control to corresponding amperage range.
Adjust control to obtain desired weld
performance.

EXAMPLE:
Material Thickness: 1/8 to 1/4 in
Electrode Diameter: 1/8
Electrode Type: E-6013
Current Control Setting: 90 − 120 A

OM-499 Page 18

Return To T able Of Contents

6-2. Controls (Honda-Powered Units) (See Section 6-3)

3

6

60 Hz

4

Recoil-Start

1

2

50 Hz

Electric-Start

1

5

7

802 094-A / 802 095 / 495 187

Return To T able Of Contents

OM-499 Page 19

6-3. Description Of Controls (Honda-Powered Units) (See Section 6-2)

Notes

 Weld and generator power output stops if

generator overheats or engine speed is
too low.

1 Engine Switch
On models with recoil-start, use switch to

open ignition circuit, and to stop engine.
On models with electric-start, use switch to

open ignition circuit, and to start and stop en­gine.

2 Throttle Control Lever
Use lever to select engine speed. Use 50 Hz

or 60 Hz position for generator power. Use 6 0
Hz position for maximum weld output.

3 Choke Control Lever
Use lever to change engine air/fuel mix. Move

lever to left if starting a cold engine. Move le­ver to right if starting a warm engine.

4 Starter Handle (Recoil-Start Models

Only)

To Start (Recoil): open fuel valve, turn engine
switch to On, move throttle lever to Idle, set
choke, and pull starter handle. Open choke as
engine warms.

To Start (Electric): open fuel valve, move
throttle lever to Idle, set choke, and turn en­gine switch to Start position. Open choke as
engine warms.

 If engine does not start, let engine

come to a complete stop before at­tempting restart.

To Stop: turn engine switch to Off.

 Always close fuel valve after stopping

unit. Moving unit with fuel valve open may
cause carburetor flooding and make
starting difficult.

5 Engine Hour Meter
6 Welding Range Label

Use label to determine correct weld amper­age based on electrode size, type, and mate­rial thickness.

7 Current Control
Use control to select weld amperage. Control

may be adjusted while welding.
To Set Current Control: Use label to deter-

mine correct size electrode for material thick­ness. Select electrode type and set current
control to corresponding amperage range o n
nameplate. Adjust control within selected
range to obtain desired weld performance.

EXAMPLE:
Material Thickness: 1/8 to 1/4 in
Electrode Diameter: 1/8
Electrode Type: E-6013
Current Control Setting: 90 − 120 A

OM-499 Page 20

Return To T able Of Contents

SECTION 7 − OPERATING AUXILIARY EQUIPMENT

NOTE

The welding generator provides power while welding and with the Current control
in any position. However, under these conditions equipment connected to the
welding generator may be subject to larger than normal voltage fluctuations. It is
recommended that only lamps be powered under these conditions.

7-1. Generator Power Panel 495 218 (USA)

1234 5

 If unit does not have GFCI recep-

tacles, use GFCI-protected exten­sion cord.

 Power i s still present at the 240 volt

receptacle when only one circuit
breaker trips.

Unplug power cord before attempt­ing to service accessories or tools.

 Generator power decreases as weld

current increases.
Set Amperage control at max. for full

generator power.

 Place throttle lever in Run position (far

right) for generator power.

1 120 V AC Twistlock Receptacle RC1

RC1 supplies 60 Hz single-phase power at
weld/power speed. Maximum output is 3.5
kVA/kW.

2 120 V 20 A AC Duplex Receptacle

RC2

3 120 V 20 A AC Duplex Receptacle

RC3

RC2 and RC3 supply 60 Hz single-phase
power at weld/power speed. Maximum
output from RC2 or RC3 is 2.4 kVA/kW.

 Each receptacle of the duplex can pro-

vide 15A/1800W.

 Do not parallel the two 120V duplex

receptacles.

4 Circuit Breaker CB1
CB1 protects RC1 from overload. If CB1

opens, RC1 does not work.

Return To T able Of Contents

495 218

5 Circuit Breakers CB2 And CB3
CB2 protects RC2 and CB3 protects RC3

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

 Press button to reset circuit breaker. I f

breaker continues to open, contact
Factory Authorized Service Agent.

Combined output of all receptacles limited
to 6 kVA/kW rating of the generator (See
Section 11 − Generator Power Guide­lines).

EXAMPLE: I f 1 0 A i s drawn from each 120
volt duplex receptacle, only 9 A is available
from the 120 V twistlock receptacle.

2 x (120 V x 10 A) + (240 V x 9 A) = 3.5 kVA/
KW.

OM-499 Page 21

7-2. Optional Generator Power Panels

Generator Power Panel 495 315

Generator Power Panel 495 278

(Canada−CSA)

Generator Power Panel 495 219

(USA)

Generator Power Panel 495 253

(South Africa)

(USA)

Generator Power Panel 495 288

(South America)

Generator Power Panel 495 289

(Australia)

 If unit does not have GFCI recep-

tacles, use GFCI-protected exten­sion cord.

 Power may still be present at a re-

ceptacle when a circuit breaker
trips.

Unplug power cord before attempt­ing to service accessories or tools.

OM-499 Page 22

Generator Power Panel 495 290

(Europe)

 Generator power decreases as weld

current increases.
Set Amperage control at max. for full

generator power.

 Place throttle lever in Run position (far

right) for generator power.

Return To Table Of Contents

Generator Power Panel 495 283

(S.E. Asia)

Ref. ST-802 124 / H-495 290 / H-495 283 / 495 277

Circuit breakers protect the generator from
overload.

 Press button to reset circuit breaker. If

breaker continues to open, contact
Factory Authorized Service Agent.

7-3. Generator Power Panel Ratings

.

NOTE

Receptacle

240 V

Twist Lock

240 V

Duplex

240 V

Duplex

230 V
Single

230 V
Single

230 V
Single

230 V
Single

120 V

Twist Lock

120 V

Duplex

120 V

Duplex

120 V

Duplex

120 V

Duplex

Total

Power NOT

to exceed

Unless otherwise stated, the rating of duplex outlets is the combined load of all
receptacles.

Total power from generator NOT to exceed 5500 Watts (60 Hz) or 5000 Watts (50 Hz)

Protected

By

CB1,2

CB1,2

CB3,4

CB1

CB2

CB1,2

CB3,4

CB1

CB1,3/

CB2,4

CB2

CB3

CB4

Panel

495 218

(USA)

60 Hz 60 Hz 60 Hz 60 Hz 50 Hz 50 Hz 50 Hz 50 Hz 50 Hz

30A/

3500W

20A/

2400W

20A/

2400W

5500W 5500W 5500W 5500W 5000W 5000W 5000W 5000W 5000W

Panel

495 315

(USA)

15A/

3600W

See

Note 2

20A/

2400W

See

Note 3

20A/

2400W

See

Note 3

Panel

495 219

(USA)

25A/

5500W

See

Note 2

20A/

2400W

See

Note 3

20A/

2400W

See

Note 3

Panel

495 278

(Canada-

CSA)

25A/

5500W

See

Note 2

30A/

3600W

See

Note 1

Panel

495 253

(S. Africa)

15A/

3600W

15A/

3600W

Panel

495 288

(South

America)

15A/

3600W

15A/

3600W

Panel

495 289

(Australia)

15A/

3600W

15A/

3600W

Panel

495 290

(Europe)

15A/

3600W

15A/

3600W

Panel

495 283

(S.E. Asia)

15A/

3600W

15A/

3600W

Notes: 1. Each receptacle of the duplex can provide 15A/1800W . Do not parallel the two 120V duplex receptacles.

2. Do not parallel the two 120V circuits.

3. Do not parallel the two duplex outlets.

Calculating total power provided by generator.
(See Section 11 − Generator Power Guidelines)

Each receptacle can provide the watts or amps as shown
above. However, the total power can not exceed 5500W.

The rating plate on electrical apparatus will contain the watts
consumed or the rated input amps. Watts may be calculated by
multiplying the rated voltage by the rated input amps.

watts = volts x amps

For example, for the 495 218 Generator Power Panel,
120V, 3000W heater 3000W

120V, 10A chain saw 1200W
120V, 500W halogen lamp 500W

Total 4700W This loading is OK.

120V, 3000W heater 3000W
120V, 10A chain saw 1200W
120V, 5A router 600W
120V, 1000W h a l o g e n l a m p 1000W

Total 5800W This loading is not OK

Return To Table Of Contents

It exceeds 5500W.

OM-499 Page 23

7-4. Wiring Instructions For Optional 120/240 Volt Twistlock Plug (NEMA L14-30P)

2

Tools Needed:

6

120 V

1

3

120V

240 V

5

1 Plug Wired For 120/240 V,

3-Wire Load

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

4

2 Neutral (Silver) Terminal
3 Load 1 (Brass) Terminal
4 Load 2 (Brass) Terminal
5 Ground (Green) Terminal
6 Cord Grip
Strip cord jacket back enough to sep-

arate conductors.
Strip conductors enough to make

good contact with plug terminals.
Make plug connections and reinstall
outer shell and cord grip.

Tighten assembly screws onto shell.
Do not overtighten.

plug3-11/99 − 802 527

SECTION 8 − MAINTENANCE

NOTE

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

8-1. Maintenance Label

ENGINE MAINTENANCE

8 h

1.1 l (1.2 US qt,

1.94 lmp qt)

50 h

Unleaded
86 + Octane

6.5 l (1.7 US Gal,

11.4 lmp pt)

100 h

SG-SF/CC-CD

+40°C+104

+86+30

+20

+59

+10

+32

0

-10

-15

-20

-10

°F

10W-30

OM-499 Page 24

0.7 − 0.8 mm

(0.028 − 0.031 in)

200 h

Ref. S-175 679-A

Return To Table Of Contents

8-2. Routine Maintenance

Recycle

engine

fluids.

 Stop engine before maintaining.

 See Engine Manual and Maintenance Label. Ser-

vice more often if used in severe conditions.

* To be done by Factory Authorized Service Agent.

Check fluid
levels. See
Section 5-4
or 5-5

Service air cleaner
element. See engine
manual.

Change oil. See
engine manual and
maintenance label.

Clean Fuel
sediment cup.

8 h

Wipe up spills.

20 h

Check and clean
spark arrestor screen.
See engine manual.

50 h

Clean and
tighten weld
terminals.

100 h

Check
spark
plugs.

Clean an d t i g h ten battery
connections (Electric

-Start models only).

Clean fuel
tank and
strainer.

Repair or
replace cracked
cables.

Check valve
clearance.*

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

200 h

Replace
unreadable
labels.

300 h

500 h

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

1000 h

OR

Return To T able Of Contents

OM-499 Page 25

8-3. Overload Protection (Honda-Powered Units)

1

8-4. Adjusting Engine Speed (Kohler-Powered Units)

2000 ± 150 rpm

3720 ± 50 rpm (60 Hz)
3250 ± 50 rpm (50 Hz)

Tools Needed:

1 Ignition Circuit Breaker

(Electric-Start Models Only)

The circuit breaker protects the en­gine battery charging circuit. A
short circuit or a battery connected
in reverse polarity will trip the circuit
breaker.

Press button to reset breaker.

 If a switch or breaker opens, it

usually indicates a more seri­ous problem exists. Contact a
Factory Authorized Service
Agent.

Ref. 802 094-A

After tuning engine, check engine
speeds. See table for proper no
load speeds. If necessary, adjust
speeds as follows:

Start engine and run until warm.

Weld/Power Speed
Adjustment

1 Throttle Control Lever
2 Adjustment Screw
Move lever to Run (far right) posi-

tion. To increase speed, turn screw
out (counterclockwise) while lightly
pushing lever to the right. To de­crease speed, turn screw in (clock­wise).

Idle Speed Adjustment

3 Adjustment Screw
Move lever to idle (far left) position.

To increase idle speed, turn screw
in (clockwise). To decrease idle
speed, turn screw out (counter­clockwise).

 Stop engine. Close fuel

valve.

Top V iew

3

OM-499 Page 26

Return To Table Of Contents

Top V iew

2

1

802 511-A / Kohler Dwg.

8-5. Adjusting Engine Speed (Honda-Powered Units)

1400 ± 150 rpm

3720 ± 50 rpm (60 Hz)
3250 ± 50 rpm (50 Hz)

2

1

After tuning engine, check engine
speeds. See table for proper no
load speeds. If necessary, adjust
speeds as follows:

Start engine and run until warm.

Weld/Power Speed
Adjustment

1 Throttle Control Lever
2 Adjustment Screw
Move lever to Run (60 Hz) position.

Turn screw and move lever until en ­gine runs at weld/power speed.

Idle Speed Adjustment

3 Pilot Screw
4 Throttle Stop Screw
Move lever to idle position. T urn pi-

lot screw until engine runs at high­est idle speed. Turn stop screw until
engine runs at rated idle speed
(normally about 2-1/4 turns out.)

 Stop engine. Close fuel

valve.

Tools Needed:

3

4

1/4, 3/8 in

Return To T able Of Contents

802 097-A

OM-499 Page 27

SECTION 9 − TROUBLESHOOTING

9-1. Troubleshooting

A. Welding

Trouble Remedy

No weld output. Check Amperage control setting.

Check weld connections.
Check engine speed, and adjust if necessary (see Section 8-4 or 8-5). Output stops if engine speed is

too low.
Be sure all equipment is disconnected from receptacles when starting unit.
Have Factory Authorized Service Agent check brushes, slip rings, capacitor C1, integrated rectifiers

SR1 and SR2, resistor R3 (Kohler only), and circuit board PC1.

Low weld output. Check Amperage control and throttle lever settings.

Check engine speed, and adjust if necessary (see Section 8-4 or 8-5).
Service air cleaner according to engine manual.
Check weld cable size and length.
Have Factory Authorized Service Agent check brushes, slip rings, capacitor C1, integrated rectifiers

SR1 and SR2, resistor R3 (Kohler only), and circuit board PC1.

High weld output. Check Amperage control setting.

Check engine speed, and adjust if necessary (see Section 8-4 or 8-5).
Have Factory Authorized Service Agent check brushes, slip rings, capacitor C1, integrated rectifiers

SR1 and SR2, suppressor VR1/R2, resistor R3 (Kohler only), and circuit board PC1.

Erratic weld output. Check Amperage control setting.

Tighten and clean connections to electrode and workpiece.
Use dry, properly-stored electrodes for Stick welding.
Remove excessive coils from weld cables.
Clean and tighten connections both inside and outside welding generator.
Check engine speed, and adjust if necessary (see Section 8-4 or 8-5).
Check throttle/governor linkage for smooth, non-binding operation.
Have Factory Authorized Service Agent check brushes, slip rings, capacitor C1, integrated rectifiers

SR1 and SR2, resistor R3 (Kohler only), and circuit board PC1.

B. Generator Power

Trouble Remedy

No output at generator power ac
receptacles.

High power output at generator power
ac receptacles.

OM-499 Page 28

Reset circuit breakers (see Sections 7-1 and 7-2).

Check receptacle wiring and connections.
Check engine speed, and adjust if necessary (see Section 8-4 or 8-5). Output stops if engine speed is

too low.
Have Factory Authorized Service Agent check brushes, slip rings, capacitor C1, integrated rectifiers

SR1 and SR2, resistor R3 (Kohler only), and circuit board PC1.
Check engine speed, and adjust if necessary (see Section 8-4 or 8-5).

Move throttle lever to 50 Hz position for 50 Hz equipment (see Section 6-1 or 6-2).
Have Factory Authorized Service Agent check capacitor C1, resistor R3 (Kohler only), and circuit

board PC1.

Return To T able Of Contents

Trouble Remedy

Low power output at generator power ac
receptacles.

Erratic power output at generator
power ac receptacles.

C. Engine

Trouble Remedy

Engine will not crank (electric-start
models only).

Check Amperage control setting.

Check engine speed, and adjust if necessary (see Section 8-4 or 8-5). Output stops if engine speed is
too low.

Move throttle lever to 60 Hz position for 60 Hz equipment (see Section 6-1 or 6-2).
Check fuel level.

Check receptacle wiring and connections.
Check throttle/governor linkage for smooth, non-binding operation.
Service air cleaner according to engine manual.
Check engine speed, and adjust if necessary (see Section 8-4 or 8-5). Output stops if engine speed is

too low.
Have Factory Authorized Service Agent check brushes, slip rings, resistor R3 (Kohler only), and

circuit board PC1.

Reset ignition circuit breaker (see Section 8-3).

Check battery voltage.
Check battery connections and tighten if necessary.
Have Factory Authorized Service Agent check engine ignition circuit.

Engine will not start. Check fuel level (see Section 5-4 or 5-5).

Move choke lever to correct position (see Section 6-1 or 6-2).
Open fuel valve (see Section 5-4 o r 5-5). Close fuel valve before moving unit or carburetor may flood and

make starting difficult.
Check battery voltage (electric-start models only).
Check battery connections and tighten if necessary (electric-start models only).
Check oil level (see Section 5-4 or 5-5). Engine stops if oil level is too low. Refill crankcase with proper

viscosity oil for operating temperature.
Have Factory Authorized Service Agent check low oil level shutdown switch.

Engine stopped during normal
operation.

Battery discharges between uses (elec­tric-start models only).

Check fuel level (see Section 5-4 or 5-5).

Open fuel valve (see Section 5-4 o r 5-5). Close fuel valve before moving unit or carburetor may flood and
make starting difficult.

Check oil level (see Section 5-4 or 5-5). Engine stops if oil level is too low.
Have Factory Authorized Service Agent check low oil level shutdown switch.
Check unit operating angle. Low oil level shutdown switch may stop engine if unit is tilted.
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.

Unstable or sluggish engine speeds. Check engine speed, and adjust if necessary (see Section 8-4 or 8-5).

Check throttle/governor linkage for smooth, non-binding operation.
Tune-up engine according to engine manual.

Return To Table Of Contents

OM-499 Page 29

SECTION 10 − ELECTRICAL DIAGRAMS

OM-499 Page 30

197 857-E

Figure 10-1. Circuit Diagram For Welding Generator (1 Of 2)

Return To T able Of Contents

Figure 10-2. Circuit Diagram For Welding Generator (2 Of 2)

Return To Table Of Contents

197 857-E

OM-499 Page 31

OM-499 Page 32

201 026-A

Figure 10-3. Wiring Diagram For Auxiliary Power Panels (1 Of 2)

Return To Table Of Contents

Figure 10-4. Wiring Diagram For Auxiliary Power Panels (2 Of 2)

Return To Table Of Contents

201 026-A

OM-499 Page 33

SECTION 11 − GENERATOR POWER GUIDELINES

s

-

-

1

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 Receptacle

− 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 in

sulated.

2

3

OR

Be sure equipment
has this symbol
and/or wording.

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

1-2. Grounding Generator To Truck Or Trailer Frame

 Always ground generator

frame t o vehicle frame to pre-

1

GND/PE

2

3

vent 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-499 Page 34

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

 Bed liners, shipping skids, and some running

gear in s u late the welding generator from the v e­hicle frame. Always connect a ground wire from
the generator equipment grounding terminal to
bare metal on the vehicle frame as shown.

Return To Table Of Contents

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 1 1-8).

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.

Return To T able Of Contents

S-0623

OM-499 Page 35

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-499 Page 36

Return To T able Of Contents

11-7. Approximate Power Requirements For Contractor Equipment

Contractor Rating Starting W atts 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

Return To T able Of Contents

OM-499 Page 37

11-8. Power Required To Start Motor

4
1

VOLTS AMPS

3

Single-Phase Induction Motor Starting Requirements

Motor Start

Code GHJKLMNP

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-499 Page 38

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

Return To T able Of Contents

11-10. Typical Connections To Supply Standby Power

 Properly install and ground this equipment according to

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

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 produ c e enough output to meet all
requirements, connect only essential loads
(pumps, freezers, heaters, etc. − See Sec­tion 11-4).

Return To Table Of Contents

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-499 Page 39

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

Cord Lengths for 120 V olt 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-499 Page 40

Return To Table Of Contents

SECTION 12 − STICK WELDING (SMAW) GUIDELINES

12-1. Stick Welding Procedure

 Weld current starts when

electrode touches work­piece.

 Weld current can damage

electronic parts in vehicles.
Disconnect both battery
cables before welding on a
vehicle. P lace work clamp as
close t o 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 t o 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:

Return To T able Of Contents

stick 12/96 − ST-151 593

OM-499 Page 41

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-499 Page 42

Return To T able Of Contents

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

Return To Table Of Contents

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 w elded.

1

5234

4 No Overlap
5 Good Penetration into Base

Metal

OM-499 Page 43

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-499 Page 44

Return To T able Of Contents

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 W eld
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 3 0 degree angle of bevel on
materials in V-groove welding.

4 Double V-Groove W eld
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

2

1

3

Return To T able Of Contents

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
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-499 Page 45

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-499 Page 46

Return To T able Of Contents

12-16.Troubleshooting − Incomplete Fusion

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

Possible Causes Corrective Actions

Insufficient heat input. Increase amperage. Select larger electrode and increase amperage.
Improper welding technique. Place stringer bead in proper location(s) at joint during welding.

Adjust work angle or widen groove to access bottom during welding.
Momentarily hold arc on groove side walls when using weaving technique.
Keep arc on leading edge of weld puddle.

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

welding.

12-17.Troubleshooting − Lack Of Penetration

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

Lack of Penetration Good Penetration

Possible Causes Corrective Actions

Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove.
Improper weld technique. Keep arc on leading edge of weld puddle.
Insufficient heat input. Increase amperage. Select larger electrode and increase amperage.

Reduce travel speed.

12-18.Troubleshooting − Excessive Penetration

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

Excessive Penetration

Possible Causes Corrective Actions

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

Good Penetration

Increase and/or maintain steady travel speed.

Return To T able Of Contents

OM-499 Page 47

12-19.Troubleshooting − Burn-Through

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

Possible Causes 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 O f 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 t o 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-499 Page 48

Return To T able Of Contents

SECTION 13 − PARTS LIST

12

13

14

15

16

17

18

19

20

21

 Hardware i s common and

not available unless listed.

26

25

22

27

11

28

10

9

49

8

1

6

5

4

3

47

46
45

37

38

39

40

444243

41

23

7

31

32

33

34

35

36

50

29

30

802 509-A

Figure 13-1. Main Assembly

Return To T able Of Contents

OM-499 Page 49

Part

Dia.

Item

ty

No.

Mkgs.

No.

Description

Figure 13-1. Main Assembly

1 +495 247 TOP, control box (specify color) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Deleted. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 SR1 035 704 RECTIFIER, integ bridge 40 amp 800 v 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 SHUNT 028 747 SHUNT, meter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 PC1 198 449 BOARD, PC assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 134 201 STAND-OFF, support 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 494 613 TERMINAL, output 250V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 129 525 TERMINAL, output Dinse 50/70 series (European models) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

129 527 PLUG, weld cable (European models) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 PC2 148 608 BOARD, PC filter (CSA only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 L1 198 472 REACTOR, stabilizing 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 211 297 LABEL, warning general precautionary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 493 509 BRUSHHOLDER, assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 204 138 LABEL, warning fuel (also supplied with engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 +195 771 ENGINE, Kohler 12HP (electric start) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*203 952 FILTER, air Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*203 954 FILTER, air pre Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*203 955 CAP, fuel Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*203 956 TANK, fuel Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*203 957 STRAINER, fuel Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*203 958 MUFFLER, exhaust engine Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*203 959 GASKET, muffler Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*203 960 SPARK PLUG, Kohler cs 8.5 & 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 +495 055 ENGINE, Honda 13HP (recoil start) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 +495 053 ENGINE, Honda 13HP (electric start) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 494 606 ADAPTER, engine 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 494 629 GUARD, generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 194 509 FAN, generator (Kohler) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 493 868 FAN, generator (Honda) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 204 469 GENERATOR, w/stator assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 495 197 ROTOR, assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

495 154 BEARING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 495 349 SCREW, 1/4-20 HWH 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 494 587 CARRIER, bearing 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 495 348 SCREW, 5/16-24 HWH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 +494 628 PANEL, end generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 495 257 MOUNT, shock w/bushing 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 Deleted. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 494 039 COVER, battery cable 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 495 111 LEAD, battery pos 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 493 057 CLAMP, battery 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 494 604 BOLT, hold down 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 BATTERY, 12V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 495 112 LEAD, battery neg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 495 256 MOUNT, shock generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 194 504 FRAME, mtg assembly (Kohler) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 495 132 FRAME, mtg assembly (Honda) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 495 255 DUCT, air 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 495 214 SEAL, air duct 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 R1 207 083 POTENTIOMETER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 207 077 KNOB, pointer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 NAMEPLATE, overlay (order by model & serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 HM 176 365 METER, hour 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 Figure 13-2 PANEL, gen power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 495 236 BASE, control box 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-499 Page 50

Return To Table Of Contents

Quanti

Part

Dia.

Item

No.

ty

Mkgs.

No.

Description

Quanti

Figure 13-1. Main Assembly (Continued)

41 1T 172 661 BLOCK, terminal 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 495 193 BRACKET, mtg terminal block 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 R2/VR1 046 819 SUPPRESSOR, assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 SR2 495 189 RECTIFIER, assembly (w/mtg hardware) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 R3 197 795 RESISTOR ASSEMBLY (Kohler) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46 C1 176 007 CAPACITOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47 494 915 CLAMP, capacitor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48 201 223 LABEL, warning electric shock power still present (CSA) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49 495 187 LABEL, current selection 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 188 039 COVER, receptacle w/gasket 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.

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

Return To T able Of Contents

OM-499 Page 51

4536

1

 Hardware is common and not available unless listed.

7

2

Generator Power Panel 495 218 (USA)

12

13

8

9 11

Generator Power Panel 495 315 (USA)

14

13

15

Generator Power Panel 495 253 (South Africa) Generator Power Panel 495 289 (Australia)

16
17

20

18
19

22
23

10

15

21

Generator Power Panel 495 219 (USA)

24

25

Generator Power Panel 495 288 (S. America)

28

29

31

30

Generator Power Panel 495 290 (Europe)

26
27

Generator Power Panel 495 283 (S.E. Asia)

33

34

36

35

37

32

OM-499 Page 52

Generator Power Panel 495 298 (USA)

Generator Power Panel 495 278 (Canada−CSA)

Figure 13-2. Generator Power Panels

Return To Table Of Contents

Part

Dia.

Item

ty

No.

Mkgs.

No.

Description

Quanti

Figure 13-2. Generator Power Panels (Figure 13-1, Item 39)

Generator Power Panel 495 218 (USA)

1 495 220 PANEL, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 495 216 OVERLAY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 CB1 495 183 CIRCUIT BREAKER, 30A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 007 467 RECEPTACLE, twistlock grd 2P3W 30A 125 V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 408 898 RECEPTACLE, duplex 115 V 20 A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 CB2, CB3 495 246 CIRCUIT BREAKER, 20A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator Power Panel 495 315 (USA)

7 495 314 PANEL, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 CB1, CB2 495 245 CIRCUIT BREAKER, 15A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 404 089 RECEPTACLE, Duplex 230 V S. American 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 CB3, CB4 495 246 CIRCUIT BREAKER, 20A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 408 898 RECEPTACLE, Duplex 115 V 20 A U.S. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator Power Panel 495 253 (South Africa)

12 495 252 PANEL, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 CB1, CB2 495 245 CIRCUIT BREAKER, 15A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator Power Panel 495 289 (Australia)

14 495 254 PANEL, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 CB1 - CB4 495 245 CIRCUIT BREAKER, 15A 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator Power Panel 495 219 (USA)

16 495 220 PANEL, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 CB1, CB2 495 182 CIRCUIT BREAKER, 25A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 CB3, CB4 495 246 CIRCUIT BREAKER, 20A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 495 217 OVERLAY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 RC1 129 067 RECEPTACLE, tw lk grd 3P4W 30A 125/250V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

088 898 PLUG, tw lk grd 3P4W 30A 125/250V. . . . . . . . . . . . . . . . . . . . . . .

21 RC2, RC3 141 432 RECEPTACLE, str dx grd 2P3W 20A 125V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

073 690 PLUG, str grd armd 2P3W 15A 125V. . . . . . . . . . . . . . . . . . . . . . .

Generator Power Panel 495 290 (Europe)

22 495 282 PANEL, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 CB1, CB2 495 245 CIRCUIT BREAKER, 15A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator Power Panel 495 288 (S. America)

24 495 287 PANEL, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 CB1-4 495 245 CIRCUIT BREAKER, 15A 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator Power Panel 495 283 (S.E. Asia)

26 495 282 Panel, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 CB1, CB2 495 245 CIRCUIT BREAKER, 15A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator Power Panel 495 298 (USA)

28 495 220 PANEL, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 CB1 495 183 CIRCUIT BREAKER, 30A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 CB2, CB3 495 246 CIRCUIT BREAKER, 20A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 RC1 007 467 RECEPTACLE, tw lk grd 2P3W 30A 125V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

605 797 PLUG, tw lk 3P3W 20A 125V. . . . . . . . . . . . . . . . . . . . . . .

32 RC2, RC3 141 432 RECEPTACLE, str dx grd 2P3W 20A 125V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

073 690 PLUG, str grd armd 2P3W 15A 125V. . . . . . . . . . . . . . . . . . . . . . .

Generator Power Panel 495 278 (Canada−CSA)

33 495 277 PANEL, generator power assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 CB1 203 095 CIRCUIT BREAKER, 25A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

202 631 COVER, circuit breaker 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

202 630 BRACKET, mtg circuit breaker cover 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 CB2, CB3 495 246 CIRCUIT BREAKER, 20A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 RC1 129 067 RECEPTACLE, tw lk grd 3P4W 30A 125/250V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

088 898 PLUG, tw lk grd 3P4W 30A 125/250V. . . . . . . . . . . . . . . . . . . . . . .

37 RC2 141 432 RECEPTACLE, str dx grd 2P3W 20A 125V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

073 690 PLUG, str grd armd 2P3W 15A 125V. . . . . . . . . . . . . . . . . . . . . . .

NOTE: Replacement receptacles not listed can be found at your local hardware or electrical supply store.

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

Return To Table Of Contents

OM-499 Page 53

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

Warranty Questions?

Call
1-800-4-A-MILLER
for your local
Miller distributor.

Y our distributor also gives
you ...

Service

Y ou 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, 2003

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

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

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 Supplies
* 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
* Water Coolant Systems
* Flowgauge and Flowmeter Regulators (No Labor)
* HF Units
* Grids
* Maxstar 85, 140
* Spot Welders
* Load Banks
* Racks
* Running Gear/Trailers
* Plasma Cutting Torches (except APT & SAF

Models)
* Field Options

(NOTE: Field options are covered under True

Blue for the remaining warranty period of the

product they are installed in, or for a minimum of

one year — whichever is greater.)

4. 6 Months — Batteries

5. 90 Days — Parts

* MIG Guns/TIG Torches

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 B o b cat, 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 bas e d u p o n a c tual 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. I N N O EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.

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

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

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

miller_warr 8/03

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

For Service

Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information

and Parts)
Circuit Diagrams
Welding Process Handbooks

Miller Electric Mfg. Co.

An Ill inoi s Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA

International Headquarte rs− USA

USA Phone: [phone] Auto-At t ended
USA & Canada FAX: [phone]
International FAX: [phone]

European Headquarte rs −
United Kingdom

Phone: [phone]
FAX: [phone]

www.MillerWelds.com

Contact the Delivering Carrier to:

PRINTED IN USA  2004 Miller Electric Mfg. Co. 1/04

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.