Miller Electric Trailblazer DC User Manual

OM-4407 203 236U

May 2004

Processes

MIG (GMAW) Welding
Flux Cored (FCAW)
Stick (SMAW) Welding

TIG (GTAW) Welding

Air Plasma Cutting and Gouging
with Spectrum Unit

Air Carbon Arc (CAC-A) Cutting
and Gouging

Description

Engine Driven Welding Generator
(AC Available On AC/DC Models Only)



Trailblazer 301 G



Trailblazer DC

Visit our website at

www.MillerWelds.com

From Miller to You

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

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

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

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

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

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

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

Working as hard as you do

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

Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual catalog sheets. To locate your nearest

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

Mil_Thank 7/03

TABLE OF CONTENTS

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

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

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

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

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

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

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

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

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

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

2-1. Signification des symboles 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Dangers relatifs au soudage à l’arc 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Dangers existant en relation avec le moteur 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4. Dangers liés à l’air comprimé 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

3-1. Symbol Definitions 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − SPECIFICATIONS 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Weld, Power, And Engine Specifications 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

4-3. Fuel Consumption While Welding 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Fuel Consumption While Using Generator Power 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Generator Power Curve 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Duty Cycle 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Stick And MIG Mode Volt-Ampere Curves 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. TIG Mode Volt-Ampere Curves 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − INSTALLATION 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Installing Welding Generator 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Engine Prestart Checks (Robin EH64-Powered Units) 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Engine Prestart Checks (Kohler-Powered Units) 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Activating The Dry Charge Battery (If Applicable) 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Connecting The Battery 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. Installing Exhaust Pipe 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7. Connecting To Weld Output Terminals 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-8. Selecting Weld Cable Sizes* 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-9. Remote Receptacle Information 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-10. Adjusting Wire (MIG) Weld Puddle Consistency 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − OPERATING WELDING GENERATOR 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Front Panel Controls 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Process/Contactor Switch On CC/CV Models 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Remote Amperage/Voltage Control 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − OPERATING AUXILIARY EQUIPMENT 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Generator Power Receptacles And Circuit Breakers 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Optional Generator Power Receptacles 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P) 28 . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS

SECTION 8 − MAINTENANCE (Robin EH64-POWERED UNITS) 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1. Maintenance Label (Robin EH64-Powered Units) 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2. Routine Maintenance (Robin EH64-Powered Units) 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3. Servicing Air Cleaner (Robin EH64-Powered Units) 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-4. Servicing Optional Spark Arrestor (Robin EH64-Powered Units) 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-5. Overload Protection (Robin EH64-Powered Units) 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-6. Changing Engine Oil, Oil Filter, and Fuel Filter (Robin EH64-Powered Units) 34 . . . . . . . . . . . . . . . . . . . .

8-7. Adjusting Engine Speed (Robin EH64-Powered Units) 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − MAINTENANCE (KOHLER-POWERED UNITS) 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1. Routine Maintenance (Kohler-Powered Units) 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-2. Maintenance Label (Kohler-Powered Units) 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3. Servicing Air Cleaner (Kohler-Powered Units) 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-4. Servicing Optional Spark Arrestor (Kohler-Powered Units) 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-5. Changing Engine Oil, Oil Filter, And Fuel Filter (Kohler-Powered Units) 39 . . . . . . . . . . . . . . . . . . . . . . . . .

9-6. Adjusting Engine Speed (Kohler-Powered Units) 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-7. Overload Protection (Kohler-Powered Units) 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 − TROUBLESHOOTING 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-1. Welding Troubleshooting 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-2. Generator Power Troubleshooting 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-3. Engine Troubleshooting 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 − ELECTRICAL DIAGRAMS 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 12 − GENERATOR POWER GUIDELINES 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 13 − PARTS LIST 58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPTIONS AND ACCESSORIES
WARRANTY

SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING

rom _nd_10/02

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

1-1. Symbol Usage

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

 Marks a special safety message.

 Means “Note”; not safety related.

1-2. Arc Welding Hazards

 The symbols shown below are used throughout this manual to

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

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

pair this unit.

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

ELECTRIC SHOCK can kill.

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

machine internal circuits are also live when power is on. In semiautomatic or
automatic wire welding, the wire, wire reel, drive roll housing, and all metal
parts touching the welding wire are electrically live. Incorrectly installed or
improperly grounded equipment is a hazard.

 Do not touch live electrical parts.
 Wear dry, hole-free insulating gloves and body protection.
 Insulate yourself from work and ground using dry insulating mats or covers

big enough to prevent any physical contact with the work or ground.

 Do not use AC output in damp areas, if movement is confined, or if there is a

danger of falling.

 Use AC output ONLY if required for the welding process.
 If AC output is required, use remote output control if present on unit.
 Additional safety precautions are required when any of the following electri-

cally hazardous conditions are present: in damp locations or while wearing
wet clothing; on metal structures such as floors, gratings, or scaffolds;
when in cramped positions such as sitting, kneeling, or lying; or when there
is a high risk of unavoidable or accidental contact with the workpiece or
ground. For these conditions, use the following equipment in order present­ed: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most
situations, use of a DC, constant voltage wire welder is recommended.
And, do not work alone!

 Disconnect input power or stop engine before installing or servicing this

equipment. Lockout/tagout input power according to OSHA 29 CFR

1910.147 (see Safety Standards).

 Properly install and ground this equipment according to its Owner’s Manual

and national, state, and local codes.

 Always verify the supply ground — check and be sure that input power cord

ground wire is properly connected to ground terminal in disconnect box or
that cord plug is connected to a properly grounded receptacle outlet.

 When making input connections, attach proper grounding conductor first −

double-check connections.

 Frequently inspect input power cord for damage or bare wiring — replace

cord immediately if damaged — bare wiring can kill.

 Turn off all equipment when not in use.
 Do not use worn, damaged, undersized, or poorly spliced cables.
 Do not drape cables over your body.
 If earth grounding of the workpiece is required, ground it directly with a sep-

arate cable.

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

er electrode from a different machine.

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

This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.

 Use only well-maintained equipment. Repair or replace damaged parts at

once. Maintain unit according to manual.

 Wear a safety harness if working above floor level.
 Keep all panels and covers securely in place.
 Clamp work cable with good metal-to-metal contact to workpiece or work-

table as near the weld as practical.

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

with any metal object.

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

output terminal.

SIGNIFICANT DC VOLTAGE exists in inverters after stop­ping engine.

 Stop engine on inverter and discharge input capacitors according to

instructions in Maintenance Section before touching any parts.

FUMES AND GASES can be hazardous.

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

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

fumes and gases.

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

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

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

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

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

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

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

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

BUILDUP OF GAS can injure or kill.

 Shut off shielding gas supply when not in use.
 Always ventilate confined spaces or use approved

air-supplied respirator.

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense visible
and invisible (ultraviolet and infrared) rays that can burn eyes
and skin. Sparks fly off from the weld.

 Wear a welding helmet fitted with a proper shade of filter to protect your face

and eyes from arc rays and sparks when welding or watching (see ANSI
Z49.1 and Z87.1 listed in Safety Standards).

 Wear approved safety glasses with side shields under your helmet.
 Use protective screens or barriers to protect others from flash and glare;

warn others not to watch the arc.

 Wear protective clothing made from durable, flame-resistant material (wool

and leather) and foot protection.

OM-4407 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-4407 Page 2

MOVING PARTS can cause injury.

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

and securely in place.

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

and troubleshooting as necessary.

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

battery cable from battery.

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

and before starting engine.

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

engine from kicking back or starting.

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

nents.

STEAM AND HOT COOLANT can burn.

 If possible, check coolant level when engine is cold to

avoid scalding.

 Always check coolant level at overflow tank, if pres-

ent on unit, instead of radiator (unless told otherwise
in maintenance section or engine manual).

 If the engine is warm, checking is needed, and there is no overflow tank,

follow the next two statements.

 Wear safety glasses and gloves and put a rag over radiator cap.
 Turn cap slightly and let pressure escape slowly before completely re-

moving cap.

BATTERY ACID can BURN SKIN and EYES.

 Do not tip battery.
 Replace damaged battery.
 Flush eyes and skin immediately with water.

ENGINE HEAT can cause fire.

 Do not locate unit on, over, or near combustible

surfaces or flammables.

 Keep exhaust and exhaust pipes way from flam-

mables.

ENGINE EXHAUST GASES can kill.

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

eas.

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

and away from any building air intakes.

1-4. Compressed Air Hazards

BREATHING COMPRESSED AIR can
cause serious injury or death.

 Do not use compressed air for breathing.
 Use only for cutting, gouging, and tools.

COMPRESSED AIR can cause injury.

 Wear approved safety goggles.
 Do not direct air stream toward self or others.

TRAPPED AIR PRESSURE AND WHIPPING
HOSES can cause injury.

 Release air pressure from tools and system before

servicing, adding or changing attachments, or open­ing compressor oil drain or oil fill cap.

EXHAUST SPARKS can cause fire.

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

quired areas — see applicable codes.

HOT METAL from air arc cutting and
gouging can cause fire or explosion.

 Do not cut or gouge near flammables.
 Watch for fire; keep extinguisher nearby.

HOT PARTS can cause burns and injury.

 Do not touch hot compressor or air system parts.
 Let system cool down before touching or servicing.

READ INSTRUCTIONS.

 Read Owner’s Manual before using or servicing unit.
 Stop engine and release air pressure before

servicing.

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

FALLING UNIT can cause injury.

 Use lifting eye to lift unit 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,
and body protection.

 Sparks can cause fires — keep flammables away.

OVERUSE can cause OVERHEATING.

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

to weld again.

 Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

 Put on grounded wrist strap BEFORE handling

boards or parts.

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

move, or ship PC boards.

TILTING OF TRAILER can cause injury.

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

ing to instructions supplied with trailer.

OM-4407 Page 3

READ INSTRUCTIONS.

ARC WELDING can cause interference.

 Use only genuine MILLER/Hobart replacement

parts.

 Perform engine and air compressor (if applicable)

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

H.F. RADIATION can cause interference.

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

tion, safety services, computers, and communica­tions equipment.

 Have only qualified persons familiar with electronic

equipment perform this installation.

 The user is responsible for having a qualified electrician

promptly correct any interference problem resulting from the installation.

 If notified by the FCC about interference, stop using the equipment at

once.

 Have the installation regularly checked and maintained.
 Keep high-frequency source doors and panels tightly shut, keep spark

gaps at correct setting, and use grounding and shielding to minimize the
possibility of interference.

1-6. California Proposition 65 Warnings

 Welding or cutting equipment produces fumes or gases which

contain chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)

 Battery posts, terminals and related accessories contain lead

and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.

 Electromagnetic energy can interfere with sensitive

electronic equipment such as microprocessors,
computers, and computer-driven equipment such as
robots.

 Be sure all equipment in the welding area is electro-

magnetically compatible.

 To reduce possible interference, keep weld cables as short as possible,

close together, and down low, such as on the floor.

 Locate welding operation 100 meters from any sensitive electronic

equipment.

 Be sure this welding machine is installed and grounded according to this

manual.

 If interference still occurs, the user must take extra measures such as

moving the welding machine, using shielded cables, using line filters, or
shielding the work area.

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

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

For Diesel Engines:
 Diesel engine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects, and
other reproductive harm.

1-7. Principal Safety Standards

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

Recommended Safe Practices for the Preparation for Welding and Cut­ting of Containers and Piping, American Welding Society Standard

AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Mi­ami, FL 33126 (phone: [phone], website: www.aws.org).

National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269-9101 (phone: [phone], website: www.nfpa.org and www.
sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202-4102 (phone: [phone], website:
www.cganet.com).

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

1-8. EMF Information

Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields

Welding current, as it flows through welding cables, will cause electro­magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power­frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.

levard, Rexdale, Ontario, Canada M9W 1R3 (phone: [phone] or
in Toronto 416-747-4044, website: www.csa-international.org).

Practice For Occupational And Educational Eye And Face Protection,

ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036–8002 (phone: [phone],
website: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,

P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (phone:
617-770-3000, website: www.nfpa.org and www. sparky.org).

OSHA, Occupational Safety and Health Standards for General Indus­try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super­intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Offices—phone for Region 5, Chicago, is
312-353-2220, website: www.osha.gov).

To reduce magnetic fields in the workplace, use the following
procedures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep welding power source and cables as far away from
operator as practical.

5. Connect work clamp to workpiece as close to the weld as
possible.

About Pacemakers:

Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.

OM-4407 Page 4

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 et suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne font
que résumer l’information contenue dans les normes de sécu­rité énumérées à la section 2-6 . Veuillez lire et respecter toutes
ces normes de sécurité.

 L’installation, l’utilisation, l’entretien et les réparations ne

doivent être confiés qu’à des personnes qualifiées.

 Au cours de l’utilisation, tenir toute personne à l’écart et plus

particulièrement les enfants.

UN CHOC ÉLECTRIQUE peut tuer.

Un simple contact avec des pièces électriques peut
provoquer une électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension dès
que l’appareil est sur ON. Le circuit d’entrée et les circuits

moment-là. En soudage semi-automatique ou automatique, le fil, le dévidoir, le
logement des galets d’entraînement et les pièces métalliques en contact avec
le fil de soudage sont sous tension. Des matériels mal installés ou mal mis à la
terre présentent un danger.

 Ne jamais toucher les pièces électriques sous tension.
 Porter des gants et des vêtements de protection secs ne comportant pas

de trous.

 S’isoler de la pièce et de la terre au moyen de tapis ou d’autres moyens iso-

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

 Ne pas se servir de source électrique 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

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-4407 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 passage de la pièce

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

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

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

des étincelles et des particules métalliques vo-

DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.

 Prévoir une période de refroidissement avant d’effec-

tuer des travaux d’entretien.

 Porter des gants et des vêtements de protection pour

travailler sur un moteur chaud.

 Ne pas toucher à mains nues les parties chaudes du moteur ni les pièces

récemment soudées.

LE BRUIT peut affecter l’ouïe.

Le bruit des processus et des équipements peut affecter
l’ouïe.

 Porter des protections approuvés pour les oreilles si

le niveau 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-4407 Page 6

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

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

L’EXPLOSION DE LA BATTERIE peut
RENDRE AVEUGLE.

 Toujours porter une protection faciale, des gants en

caoutchouc et vêtements de protection lors d’une in­tervention sur la batterie.

 Arrêter le moteur avant de débrancher ou de brancher les câbles de

batterie.

 Eviter de provoquer des étincelles avec les outils en travaillant sur la

batterie.

 Ne pas utiliser le poste de soudage pour charger les batteries ou des véhi-

cules de démarrage rapide.

 Observer la polarité correcte (+ et −) sur les batteries.
 Débrancher le câble négatif (–) en premier lieu. Le rebrancher en dernier

lieu.

LE CARBURANT MOTEUR peut pro­voquer un incendie ou une explosion.

 Arrêter le moteur avant de vérifier le niveau de carbu-

rant ou de faire le plein.

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

ce d’étincelles ou d’une flamme nue.

 Ne pas faire le plein de carburant à ras bord; prévoir de l’espace pour son

expansion.

 Faire attention de ne pas renverser de carburant. Nettoyer tout carbu-

rant renversé avant de faire démarrer le moteur.

 Jeter les chiffons dans un récipient ignifuge.

 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 en

route accidentelle du moteur.

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

générateur.

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

 Il est préférable de vérifier le liquide de

refroidissement une fois le moteur refroidi pour éviter
de se brûler.

 Toujours vérifier le niveau de liquide de refroidissement dans le vase d’ex-

pansion (si présent), et non dans le radiateur (sauf si précisé autrement
dans la section maintenance du manuel du moteur).

 Si le moteur est chaud et que le liquide doit être vérifié, opérer comme sui-

vant :

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

chon du radiateur.

 Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant

d’enlever le bouchon.

LA CHALEUR DU MOTEUR peut pro­voquer un incendie.

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 pro­voquer des blessures graves ou causer
la mort.

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

ge, gougeage et les outils pneumatiques.

L’AIR COMPRIMÉ peut provoquer
des blessures.

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

même.

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

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

tème avant d’effectuer la maintenance, avant de
changer ou de rajouter des éléments ou avant
d’ouvrir la purge ou le bouchon de remplissage
d’huile.

 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.

 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-4407 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 ce que tout l’équipement de la zone de soudage soit compatible

électromagnétiquement.

 Pour réduire la possibilité d’interférence, maintenir les câbles de souda-

ge aussi courts que possible, les grouper, et les poser aussi bas que pos­sible (ex. par terre).

 Veiller à souder à une distance de 100 mètres de tout équipement élec-

tronique sensible.

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

ment à ce mode d’emploi.

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

combe à l’utilisateur de prendre des mesures supplémentaires telles que
le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de fil­tres de ligne ou la pose de protecteurs dans la zone de travail.

2-6. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, de
l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (télé­phone : (305) 443−9353, site Web : www.aws.org).
Recommended Safe Practices for the Preparation for Welding and Cutting
of Containers and Piping, norme American Welding Society AWS F4.1, de
l’American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (télé­phone : (305) 443−9353, site Web : www.aws.org).
National Electrical Code, norme NFPA 70, de la National Fire Protection As­sociation, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101
(téléphone : (617) 770−3000, sites Web : www.nfpa.org et www.sparky.org).
Safe Handling of Compressed Gases in Cylinders, brochure CGA P−1, de
la Compressed Gas Association, 1735 Jefferson Davis Highway, Suite
1004, Arlington, VA 22202−4102 (téléphone : (703) 412−0900, site Web :
www.cganet.com).
Code for Safety in Welding and Cutting, norme CSA W117.2, de la Cana­dian Standards Association, Standards Sales, 178 boulevard Rexdale,

Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) 463−6727 ou à To­ronto : (416) 747−4044, site Web : www.csa−international.org).
Practice For Occupational And Educational Eye And Face Protection,
norme ANSI Z87.1, de l’American National Standards Institute, 11 West
42nd Street, New York, NY 10036−8002 (téléphone : (212) 642−4900, site
Web : www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot Work,
norme NFPA 51B, de la National Fire Protection Association, P.O. Box
9101, 1 Battery March Park, Quincy, MA 02269−9101 (téléphone : (617)
770−3000, site Web : www.nfpa.org et www.sparky.org).
OSHA, Occupational Safety and Health Standards for General Industry,
Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and
Part 1926, Subpart J, de l’U.S. Government Printing Office, Superintendent
of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10 bureaux
régionaux − Téléphone pour la Région 5, Chicago : (312) 353−2220, site
Web : www.osha.gov).

2-7. Information sur les champs électromagnétiques

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

OM-4407 Page 8

Afin de réduire les champs électromagnétiques en milieu de travail, respec­ter les consignes suivantes :

1. Garder les câbles ensemble en les torsadant ou en les fixant avec du

ruban adhésif.

2. Mettre tous les câbles du côté opposé à l’opérateur.

3. Ne pas s’enrouler les câbles autour du corps.

4. Garder le poste de soudage et les câbles le plus loin possible de soi.

5. Placer la pince de masse le plus près possible de la zone de soudage.

Consignes relatives aux stimulateurs cardiaques :

Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur médecin. Si ce dernier les déclare aptes, il leur est recom­mandé de respecter les consignes ci-dessus.

3-1. Symbol Definitions

SECTION 3 − DEFINITIONS

Stop Engine

Start Engine Panel/Local Temperature Fuel

Engine Oil Engine Choke

Engine

MIG (GMAW),

Wire

Positive Negative

Time

h

Fast

(Run, Weld/Power)

Read Operator’s

Manual

Stick (SMAW) TIG (GTAW) Circuit Breaker

Hours

A

s

Fast/Slow
(Run/Idle)

Check Valve

Clearance

Amperes

Alternating Current

(AC)

Seconds

V

Slow (Idle)

Battery (Engine)

Volts

Output

Protective Earth

(Ground)

Do not switch while

Notes

welding

Wire Feed

Remote

Receptacle

Electrode

Positive

Work Connection

Electrode Negative

Work like a Pro!

Constant

CC

CV

Current

Constant

Voltage

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-4407 Page 9

SECTION 4 − SPECIFICATIONS

,

/

(w/

Cycle

(w/Weld Contactor

A

C

D

gp

tip

25°

Robin: 591 lb (268 kg)

4-1. Weld, Power, And Engine Specifications

Welding

Mode

CC/DC

CV/DC

CC/AC*

* AC/DC Models Only.

Rated

Welding

Output

280 A, 25 V, 100%

Duty Cycle

300 A, 25 V, 100%

Duty Cycle

200 A, 25 V, 60%

Duty Cycle

Maximum

Open-Circuit

Voltage

80 20 − 300 A

50

75 35 − 225 A

Amperage

Range In
CC Mode

10 − 33 V

Min − 325 A

Voltage
Range In
CV Mode

10 − 34 V

4-2. Dimensions, Weights, and Operating Angles

Dimensions

Height 33 in (838 mm)

Width 18-3/4 in (476 mm)

Depth 45-1/2 in (1156 mm)

A 18 in (457 mm)

B 16-1/2 in (419 mm)

D

A

B

Generator

Power Rating

Continuous: 9.5 kVA/

kW, 80/40 A,

120/240 V AC, 60

Hz, Single-Phase,

Peak: 10 kVA/kW

Weld Contactor

Off)

 Do not exceed tilt angles or engine could

be damaged or unit could tip.

G

4 Holes

 Do not move or operate unit where it could

tip.

.

Fuel

Capacity

10 gal
(38 L)

Tank

Engine

Robin EH64

Performer OHV

Air-Cooled,

Two-Cylinder, Four-

Cycle

,

20.5 HP

Gasoline Engine

or

Kohler CH-20

Air-Cooled,

Two-Cylinder,

Four-Cycle,

20 HP Gasoline

Engine

C 3/4 in (19 mm)

D 3-1/8 in (79 mm)

E 32-3/4 in (832 mm)

F 45-1/2 in (1156 mm)

G 13/32 in (10 mm) Dia.

Weight

Robin: 591 lb (268 kg)

Kohler: 567 lb (257 kg)

E

F

°

25°

802 848-A

Engine End

25°
25°

800 426

OM-4407 Page 10

4-3. Fuel Consumption While Welding

US GAL/HR.

LITERS/HR.

2.258.51

2.00

7.57

1.75

6.62

1.50

5.68

4.73

3.79

2.84

1.89

0.95

0.00

1.25

1.00

0.75

0.50

0.25

0.00

IDLE − KOHLER AND ROBIN

050

DC WELD AMPERES AT 100% DUTY CYCLE

ROBIN

100 150 200 250 300

KOHLER

4-4. Fuel Consumption While Using Generator Power

US GAL/HR.

LITERS/HR.

2.258.51

2.00

7.57

1.75

6.62

1.50

5.68

4.73

3.79

2.84

1.89

0.95

0.00

1.25

1.00

0.75

0.50

0.25

0.00

IDLE − KOHLER AND ROBIN

0246810

ROBIN

KOHLER

KW AT 100% DUTY CYCLE

206 136

OM-4407 Page 11

4-5. Generator Power Curve

300

The ac generator power curve
shows the generator power avail­able in amperes at the receptacles.

250

216
200

150

AC VOLTS

100

50

0

0 102030405060708090

4-6. Duty Cycle

10,000 watts

AC AMPERES

100% Duty Cycle at 280 Amperes DC

Continuous Welding

Ref. 204 922

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.

 AC output is not available on all

models.

WELDING AMPERES

OM-4407 Page 12

350

300

MIG/FCAW

STICK

250

200

AC WELD

150

100

0 102030405060708090100

% DUTY CYCLE

4-7. Stick And MIG Mode Volt-Ampere Curves

A. CC/AC Stick Mode

80

70

60

50

40

AC VOLTS

30

20

10

0

0 50 100 150 200 250 300 350

AC AMPERES

B. CC/DC Stick Mode

80

70

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

 AC output is not available on all

models.

60

50

40

DC VOLTS

30

20

10

0

0 50 100 150 200 250 300 350 400 450

C. CV/DC MIG Mode

45
40
35
30
25
20

DC VOLTS

15

DC AMPERES

10

5
0

0 100 200 300 400 500 600 700

DC AMPERES

204 923 / 204 928 / 204 935

OM-4407 Page 13

4-8. TIG Mode Volt-Ampere Curves

A. CC/AC TIG Mode

80

70

60

50

40

AC VOLTS

30

20

10

0

0 50 100 150 200 250 300 350

AC AMPERES

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

 AC output is not available on all

models.

B. CC/DC TIG Mode

50
45
40
35
30
25
20

DC VOLTS

15
10

5
0

0 50 100 150 200 250 300 350

DC AMPERES

OM-4407 Page 14

204 934 / 204 930

SECTION 5 − INSTALLATION

5-1. Installing Welding Generator

Movement

 Do not lift unit from end.

OR

Location

OR

Mounting

Inadequate support.

OR

OR

 Do not weld on base. Welding

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

 Always securely fasten weld-

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

 Do not mount unit by support-

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

 Always ground generator

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

 If unit does not have GFCI re-

ceptacles, use GFCI-protected
extension cord.

Mounting:

1 Cross-Supports
Mount unit on flat surface or use

cross-supports to support base.

Grounding:

2 Equipment Grounding Terminal

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

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

at the four

Grounding

Airflow Clearance

 Do not use flexible mounts.

2

GND/PE

18 in

(460 mm)

18 in

(460 mm)

3

4

18 in

(460 mm)

1

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

 Bed liners, shipping skids, and some running

gears insulate the welding generator from the
vehicle frame. Always connect a ground wire
from the generator equipment grounding termi­nal to bare metal on the vehicle frame as shown.

18 in

(460 mm)

18 in

(460 mm)

install2 5/03 − Ref. 800 652 / Ref. 800 477-A / 803 274

OM-4407 Page 15

5-2. Engine Prestart Checks (Robin EH64-Powered Units)

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

 Follow run-in procedure in en-

gine manual.

 This unit has a low oil pressure

shutdown switch. However,

some conditions may cause en-

gine damage before the engine

shuts down. Check oil level often

and do not use the oil pressure

shutdown system to monitor oil

level.

Fuel

Add fresh fuel before starting engine
the first time (see maintenance label
for specifications). Always leave filler
neck empty to allow room for expan­sion. Check fuel level on a cold en­gine before use each day.

Oil

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

 To improve cold weather

starting:

Gasoline

Keep battery in good condition.

Store battery in warm area.

Use correct grade oil for cold

weather.

Oil Check Oil Fill

Full

Full

OM-4407 Page 16

803 098 / 800 392-J

5-3. Engine Prestart Checks (Kohler-Powered Units)

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

 Follow run-in procedure in engine

manual.

 This unit has a low oil pressure

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

Fuel

Add fresh fuel before starting engine
the first time (see maintenance label for
specifications). Always leave filler
neck empty to allow room for expan­sion. Check fuel level on a cold engine
before use each day.

Oil

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.

Gasoline

Use correct grade oil for cold
weather.

Full

Full

801 221 / 802 849-A

OM-4407 Page 17

5-4. Activating The Dry Charge Battery (If Applicable)

5

4

1

3

2

Remove battery from unit.
1 Eye Protection − Safety

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

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

bottom of well (maximum).

 Do not overfill battery cells.

Wait ten minutes and check electro­lyte level. If necessary, add electro­lyte to raise to proper level. Reins­tall vent caps.

6 Battery Charger

 Read and follow all instruc-

tions supplied with battery

charger.

Charge battery for 12 minutes at 30
amperes or 30 minutes at 5 am­peres. Disconnect charging cables
and install battery.

 When electrolyte is low, add

only distilled water to cells to

maintain proper level.

5 A For 30 Minutes

30 A For 12 Minutes

OM-4407 Page 18

OR

6

Tools Needed:

+

−

rubbergloves

glasses

drybatt1 1/98 − S-0886

5-5. Connecting The Battery

 Connect negative (−)

cable last.

+

−

Tools Needed:

3/8, 1/2 in

5-6. Installing Exhaust Pipe

Ref. 800 394-C / Ref. 206 422 / Ref. S-0756-D

 Stop engine and let cool.
 Engine backfire can cause se-

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

 Point exhaust pipe in desired di-

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

Tools Needed:

1/2 in

801 681 / Ref. 206 422

OM-4407 Page 19

5-7. Connecting To Weld Output Terminals

 Stop engine.
 Do not connect to CC and CV

terminals at the same time.
AC/DC Models:

1 Work Weld Output Terminal
2 Stick/TIG (CC) Weld Output

Terminal
3 Wire /CV Weld Output Terminal
For MIG welding, connect work cable

to Work terminal and wire feeder
cable to Wire (CV) terminal.

For Stick/TIG welding, connect work
cable to Work terminal and electrode
holder cable to Stick/TIG (CC)
terminal.

DC Only Models:

4 Negative (−) Weld Output

Terminal
5 Stick/TIG (+) Weld Output

Terminal
6 Wire (+) Weld Output Terminal
For MIG welding, connect work cable

to Negative (−) terminal and wire
feeder cable to CV (Wire) terminal.

For Stick welding, connect work
cable to Negative (−) terminal and
electrode holder cable to CC (Stick/
TIG) terminal.

321

For TIG welding, connect work cable
to CC (Stick/TIG) terminal and elec­trode holder cable to Negative (−)
terminal.

OR

Weld output terminals on
units with AC/DC output.

654

Weld output terminals on
units with DC output only.

802 850 / Ref. 206 422 / 204 353

OM-4407 Page 20

5-8. Selecting Weld Cable Sizes*

24 VOLTS AC

B

115 VOLTS AC

D

M

G

REMOTE

100 ft (30 m) or Less

Weld Output

Terminals

 Stop engine before

connecting to weld out­put terminals.

 Do not use worn, dam-

aged, undersized, or
poorly spliced cables.

Welding

Amperes

100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)

150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)

200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)

10 − 60%

Duty

Cycle

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

Not Exceeding***

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

300 ft

(90 m)

350 ft

(105 m)

60 − 100%

Duty

10 − 100% Duty Cycle

Cycle

400 ft

(120 m)

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

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

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

400 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 overheats, use next size larger cable.

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

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

2 ea. 2/0

(2x70)

2 ea. 2/0

(2x70)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 3/0

(2x95)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

2 ea. 4/0

(2x120)

5-9. Remote Receptacle Information

NOTE

AJ

K

B

L

NH

C

M

D

F

E

I

G

Engine runs at weld/power speed whenever a device connected to the remote
receptacle is running.

Socket* Socket Information

A 24 volts ac.

B Contact closure to A completes 24 volt ac contac-

tor control circuit and keeps engine at Run speed
in all modes. Protected by circuit breaker CB5.

115 VOLTS AC

I 115 volts ac. Protected by fuse F2.

J Contact closure to I completes 115 volts ac

contactor control circuit.

C 0 to +10 volts dc output to remote control in Stick

and TIG modes. +10 volts dc output to remote
control in Wire mode.

*The remaining sockets are not used.

OUTPUT

CONTROL

GND

D Remote control circuit common.

E 0 to +10 volts dc input command signal from

remote control. Voltage is dependent on front pan­el Voltage/Amperage control setting.

G Circuit common for 24 and 115 volts ac circuits.

K Chassis common.

OM-4407 Page 21

5-10. Adjusting Wire (MIG) Weld Puddle Consistency

 Stop engine and let cool.

Stabilizer DC-Z is factory connected to suit
most Wire (MIG) welding applications.

To change Wire (MIG) weld puddle consis­tency, proceed as follows:

Remove cover and right side panel.
1 Stabilizer DC-Z
2 Wire /CV Weld Output Terminal
3 Stabilizer Leads 29, 28, And 27

Lead 29 − provides stiffest weld
puddle

Lead 28 − provides wetter weld
puddle (for mild steel)

Lead 27 − provides wettest weld
puddle (for stainless steel)

Lead 29 is connected to the Wire/CV weld
output terminal at the factory.

Disconnect lead 29 from the Wire/CV weld
output terminal.

For wetter weld puddle (for mild steel):

Remove insulated sleeving from lead 28.
Connect lead 28 to Wire/CV weld output ter­minal, reusing hardware. Insulate lead 29
with sleeving removed from lead 28. Secure
sleeving with cable ties.

For wettest weld puddle
(for stainless steel):

Remove insulated sleeving from lead 27.
Connect lead 27 to Wire/CV weld output ter­minal, reusing hardware. Insulate lead 29
with sleeving removed from lead 27. Secure
sleeving with cable ties.

Reinstall side panel.

2

Tools Needed:

OM-4407 Page 22

3/8, 7/16 in

1

3

803 099

SECTION 6 − OPERATING WELDING GENERATOR

6-1. Front Panel Controls

421

7

63

5

1 Process/Contactor Switch
See Section 6-2 for Process/Contactor

switch information.
2 Voltage/Amperage Adjust Switch And

Remote Receptacle

Use switch to select front panel or remote
voltage/amperage control. For remote con­trol, place switch in Remote position and
connect remote control to Remote recep­tacle RC4 (see Sections 5-9 and 6-3).

3 A/V Control
Use control to select weld voltage or

amperage. Control may be adjusted while
welding.

With Process/Contactor switch in any Stick
or TIG setting, use control to adjust amper­age. With Process/Contactor switch in any
Wire position, use control to adjust voltage.

With V/A Adjust Switch in Remote position,
control limits the remote amperage in Stick
and TIG modes, but has no effect in MIG
modes.

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

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

 Place switch in Run position for TIG

(GTAW) welding using a high frequency
device.

 The unit will not return to idle speed

when the remote contactor is on.

5 Engine Choke Control

Use control to change engine air-fuel mix
when starting engine.

To Start: pull out choke and turn Engine
Control switch to Start position. Release
switch and slowly push choke in when
engine starts.

 If the engine does not start, let the

engine come to a complete stop before
attempting restart.

To Stop: turn Engine Control switch to Off
position.

6 Engine Hour Meter
7 DC Polarity/AC Switch (AC/DC Models

Only)

 Do not switch under load.

Use switch to select AC weld output or polar­ity of DC weld output.

Ref. 206 422

OM-4407 Page 23

6-2. Process/Contactor Switch On CC/CV Models

1

1 Process/Contactor Switch

 Weld output terminals are ener-

gized when Process/Contactor
switch is in an Electrode Hot posi­tion and the engine is running.

 The unit will not return to idle speed

when Process/Contactor switch is in
a Wire or TIG mode and the remote
contactor is on (closure between
pins A and B on remote receptacle).

Use switch to select weld process and
weld output on/off control (see table be­low and Section 5-9).

Place switch in Remote positions to turn
weld output on and off with a device con­nected to the remote receptacle.

Place switch in Electrode Hot positions
for weld output to be on whenever the en­gine is running.

Use Stick positions for air carbon arc
(CAC-A) cutting and gouging.

When switch is in a Stick position, the dig
circuit provides additional amperage
during low voltage (short arc length con­ditions) to prevent “sticking” electrodes.

The dig circuit is disabled when switch is
in Wire or TIG positions.

Process/Contactor Switch Settings

Switch Setting Process Output On/Off Control

Remote − TIG

Remote − Stick Stick (SMAW) With Remote On/Off At Remote Receptacle

Remote − Wire MIG (GMAW) At Remote Receptacle

Electrode Hot − Wire MIG (GMAW) Electrode Hot

Electrode Hot − Stick

Electrode Hot − Scratch

Start TIG

GTAW With HF Unit, Pulsing Device, Or

Remote Control

Stick (SMAW),

Air Carbon Arc (CAC-A) Cutting And Gouging

Scratch Start TIG (GTAW) Electrode Hot

At Remote Receptacle

Electrode Hot

802 850

OM-4407 Page 24

6-3. Remote Amperage/Voltage Control

1

1 Remote Receptacle RC4
Connect optional remote control to

RC4 (see Section 5-9).
2 Remote Hand Control (Optional)
3 Remote Foot Control (Optional)

 Engine runs at weld/power speed

in Wire and TIG modes whenever
a device connected to the remote
receptacle makes closure be­tween pins A and B (exam­ple:trigger pull on MIG gun).

Set V/A Adjust

Switch

Select Polarity By

Using DC Polarity/AC

Switch (If Present) Or

By Changing Cable

Connections

Switch
present on
AC/DC
models
only.

Set

A/V Control

Process = Stick (Using Remote On/Off)

In Example:

Min = 40 A CC/DC

Max = 180 A CC/DC

3

2

Max (180 A DC)

Min (40 A DC)

Adjust Remote Control

(Stick Welding Only)

802 850 / 206 422 / S-0769 / S-0774

OM-4407 Page 25

SECTION 7 − OPERATING AUXILIARY EQUIPMENT

7-1. Generator Power Receptacles And Circuit Breakers

5

1

4

2

3

 If unit does not have GFCI re-

ceptacles, use GFCI­protected extension cord.

 Generator power decreases as

6

weld current increases.

1 240 V 50 A AC Receptacle

RC1

RC1 supplies 60 Hz single-phase
power at weld/power speed. Maxi­mum output is 9.5 kVA/kW.

2 120 V 20 A AC Duplex

Receptacle RC2

3 120 V 20 A AC Duplex

Receptacle RC3

RC2 and RC3 supply 60 Hz single­phase power at weld/power speed.
Maximum output from RC2 or RC3 is

2.4 kVA/kW.
4 Circuit Breaker CB1
CB1 protects receptacles RC1, RC2,

RC3, and 115 volt ac output to Re­mote Receptacle RC4 from over­load. If CB1 opens, the receptacles
do not work and 115 volt ac output to
Remote Receptacle RC4 stops.
Place switch in On position to reset
breaker.

5 Circuit Breaker CB3
6 Circuit Breaker CB4
CB3 protects RC2 and CB4 protects

RC3 from overload. If a circuit break­er opens, the receptacle does not
work. Press button to reset breaker.

 If circuit breaker continues to

open, contact Factory
Authorized Service Agent.

Combined output of all receptacles
limited to 10 kVA/kW rating of the
generator.

EXAMPLE: If 20 A is drawn from
each 120 V duplex receptacle, only
20 A is available at the 240 V
receptacle:

2 x (120 V x 20 A) + (240 V x 20 A) =

9.6 kVA/kW

OM-4407 Page 26

Ref. 206 422

7-2. Optional Generator Power Receptacles

 If unit does not have GFCI re-

ceptacles, use GFCI-

1

protected extension cord.

 Generator power decreases as

weld current increases.

Combined output of all receptacles
limited to 8 kVA/kW rating of the
generator.

GFCI Receptacle Option

1 120 V 20 A AC GFCI Recep-

tacles GFCI-2 and GFCI-3

GFCI2 and GFCI3 supply 60 Hz
single-phase power at weld/power
speed. Maximum output from
GFCI-2 or GFCI-3 is 2.4 kVA/kW.
Circuit breaker protection is the
same as standard receptacles.

If a ground fault is detected, the
GFCI Reset button pops out and
the circuit opens to disconnect the
faulty equipment. Check for
damaged tools, cords, plugs, etc.
connected to the receptacle. Press
button to reset receptacle and
resume operation.

 At least once a month, run

engine at weld/power speed
and press Test button to verify
GFCI is working properly.

Notes

Ref. 206 422

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-4407 Page 27

7-3. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P)

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

1 Plug Wired for 120/240 V,

3-Wire Load

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

2 Plug Wired for 240 V, 2-Wire

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

120/240 V Plug

5

Tools Needed:

Current Available in Amperes

240 V

Receptacle*

0

5
10
15
20
25
30
35
40

Each 120 V Duplex

Receptacle

20
20
20
20
20
15
10

5
0

V x A = Watts

*One 240 V load or two 120 V loads.

7

1

3

4

120V

120V

240V

4

6

2

3

240V

240 V AC

120 V AC 120 V AC

56

OM-4407 Page 28

plug1 11/03 − 120 813-D

SECTION 8 − MAINTENANCE (Robin EH64-POWERED UNITS)

8-1. Maintenance Label (Robin EH64-Powered Units)

OM-4407 Page 29

8-2. Routine Maintenance (Robin EH64-Powered Units)

Note

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

 Stop engine before maintaining.

 See also Engine Manual and Maintenance Label for im-

Recycle

engine

fluids.

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

* To be done by Factory Authorized Service Agent.

Every 8 h

Check fluid levels.
See Section 5-2.

Every 20 h

Check and clean
spark arrestor screen.
See Section 8-4.

Wipe up spills.

Every 25 h

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

Every 50 h

Change oil. See
Section 8-6 and
maintenance label.

Service air
cleaner element.
See Section 8-3.

Clean and
tighten weld
terminals.

Every 100 h

Clean cooling system.
See Engine Manual.

Clean and
tighten battery
connections.

OM-4407 Page 30

Every 200 h

Change oil filter. See
Section 8-6 and
maintenance label.

Repair or
replace cracked
cables.

Replace fuel
filter. See
Section 8-6.

Check
spark
plugs.

Replace
unreadable
labels.

Every 500 h

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

Check
valve
clearance.*

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

Every 1000 h

OR

OM-4407 Page 31

8-3. Servicing Air Cleaner (Robin EH64-Powered Units)

 Stop engine.

1

2

 Do not run engine without air

cleaner or with dirty element.

1 Wrapper (Foam Element)
Wash wrapper with soap and water

solution. Allow wrapper to air dry
completely.

2 Element
Replace element if dirty, oily, or

damaged.

aircleaner5 1/97 − 803 070 / Ref. 200 017 / S-0759

8-4. Servicing Optional Spark Arrestor (Robin EH64-Powered Units)

 Stop engine and let cool.

1 Spark Arrestor Screen
Clean and inspect screen. Replace

spark arrestor if screen wires are
broken or missing.

1

Tools Needed:

OM-4407 Page 32

1/4 in

Ref. 803 098 / Ref. 183 175−A

8-5. Overload Protection (Robin EH64-Powered Units)

2

Located behind front panel.

Tools Needed:

3/8 in

4

 Stop engine.

 When a circuit breaker or fuse

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

1 Circuit Breaker CB5
CB5 protects the 24 volt ac output

to Remote receptacle RC4. If CB5
opens, 24 volt ac output to RC4
stops.

Press button to reset breaker.
2 Fuse F2 (See Parts List)
3 Fuse F6 (See Parts List)

F2 is located behind the front panel.
F2 protects the 115 volt output to
Remote Receptacle RC4. If F2
opens, 115 volt ac output to RC4
stops.

F6 protects the engine wiring sys­tem from overload. If F6 opens,
engine will not crank.

4 Fuse F1 (See Parts List)
Remove side panel.
F1 protects the exciter excitation

winding from overload. If F1 opens,
weld and generator power output
stops.

Replace any open fuses. Reinstall
cover before operating unit.

3

1

803 100 / Ref. 206 422

OM-4407 Page 33

8-6. Changing Engine Oil, Oil Filter, and Fuel Filter (Robin EH64-Powered Units)

 Stop engine and let cool.

1 Oil Drain Valve
2 Oil Filter
Change engine oil and filter accord-

ing to engine owner’s manual.

 Close valve and valve cap

before adding oil and
running engine.

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

3 Fuel Filter

Oil Check Oil Fill

Full

4 Fuel Line
Replace line if cracked or worn.

Install new filter. Wipe up any spilled
fuel.

Start engine, and check for fuel
leaks.

 Stop engine, tighten connec-

tions as necessary, and wipe
up fuel.

3

4

2

Tools Needed:

OM-4407 Page 34

1

803 098 / S-0842

8-7. Adjusting Engine Speed (Robin EH64-Powered Units)

2200 ± 100 rpm

3700 ± 50 rpm

1

3

2

4

6

5

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

Start engine and run until warm.
Remove wrapper to access speed

adjustments.

Idle Speed Adjustment

Move Engine Control switch to
Run/Idle position.

1 Throttle Solenoid
2 Mounting Screws
3 Idle Speed Screw
Loosen mounting screws. Adjust

solenoid position so engine runs at
idle speed. If necessary, back out
idle speed screw so solenoid can
be moved to correct position. Tight­en mounting screws. Be sure sole­noid linkage works smoothly.

Turn idle speed screw for fine
adjustments.

Weld/Power Speed Adjustment

Move Engine Control switch to Run
position.

4 Jam Nut
5 Lock Nut
6 Weld/Power Speed

Adjustment Screw

Loosen jam nut and lock nut. Turn
adjustment screw until engine runs
at weld/power speed. Tighten jam
nut, and then tighten lock nut.

 Stop engine.

Reinstall wrapper.

Tools Needed:

8 mm

10 mm

803 098

OM-4407 Page 35

SECTION 9 − MAINTENANCE (KOHLER-POWERED UNITS)

9-1. Routine Maintenance (Kohler-Powered Units)

 Stop engine before maintaining.

Check fluid levels.
See Section 5-3.

Check and clean
spark arrestor screen.
See Section 9-4.

Change oil. See
Section 9-5 and
maintenance
label.

Recycle

engine

fluids.

 See also Engine Manual and Maintenance Label for im-

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

* To be done by Factory Authorized Service Agent.

Every 8 h

Wipe up spills.

OIL
Full

Every 20 h Every 25 h

Service air filter wrapper
(foam element). See
Section 9-3.

Every 50 h

Clean and tighten
weld terminals.

Every 100 h

Service air filter element.
See Section 9-3.

Clean cooling system. See
engine manual.

Change oil filter.
See Section 9-5
and maintenance
label.

Check spark plugs.

Repair or
replace cracked
cables.

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

Clean and
tighten battery
connections.

Every 200 h

Replace fuel
filter. See
Section 9-5.

Replace
unreadable
labels.

Every 500 h

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

Every 1000 h

OR

OM-4407 Page 36

9-2. Maintenance Label (Kohler-Powered Units)

NOTE

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

OM-4407 Page 37

9-3. Servicing Air Cleaner (Kohler-Powered Units)

 Stop engine.
 Do not run engine without air

1

2

cleaner or with dirty element.

1 Wrapper (Foam Element)
Wash wrapper with soap and water

solution. Allow wrapper to air dry
completely.

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

2 Element
Replace element if damaged, dirty,

or oily.

oil

aircleaner3 9/00 − 802 772 / Ref. 185 095-A / S-0759

9-4. Servicing Optional Spark Arrestor (Kohler-Powered Units)

1

 Stop engine and let cool.

1 Spark Arrestor Screen
Clean and inspect screen. Replace

spark arrestor if screen wires are
broken or missing.

Tools Needed:

OM-4407 Page 38

1/4 in

802 849-A / Ref. 206 422

9-5. Changing Engine Oil, Oil Filter, And Fuel Filter (Kohler-Powered Units)

 Stop engine and let cool.

1 Oil Drain Valve
2 Oil Filter
Change engine oil and filter accord-

ing to engine manual.

 Close valve and valve cap

before adding oil and run­ning engine.

Full

Fill crankcase with new oil to full
mark on dipstick (see Section 9-2).

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

Install new filter. Wipe up any spilled
fuel.

Start engine, and check for fuel
leaks.

 Stop engine, tighten connec-

tions as necessary, and wipe
up fuel.

3

4

2

1

Tools Needed:

802 849-A / S-0842

OM-4407 Page 39

9-6. Adjusting Engine Speed (Kohler-Powered Units)

1

5

4

3

2

2200 ± 50 rpm
3700 ± 50 rpm

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

Start engine and run until warm.
Turn A/V control to 10.

Remove top cover to access speed
adjustments.

Idle Speed Adjustment

Move Engine Control switch to
Run/Idle position.

1 Throttle Solenoid
2 Mounting Screws
3 Idle Speed Screw
Loosen mounting screws. Adjust

solenoid position so engine runs at
idle speed. If necessary, back out
idle speed screw so solenoid can
be moved to correct position. Tight­en mounting screws. Be sure sole­noid linkage works smoothly.

Turn idle speed screw for fine
adjustments.

Weld/Power Speed Adjustment

Move Engine Control switch to Run
position.

4 Weld/Power Speed

Adjustment Nut
5 Lock Nut
Loosen lock nut. Turn adjustment

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

Reinstall top cover.

 Stop engine.

Tools Needed:

1/4, 3/8 in

Top View

802 849-A / 801 209-A

OM-4407 Page 40

9-7. Overload Protection (Kohler-Powered Units)

2

Located behind front panel.

Tools Needed:

3/8 in

4

 Stop engine.

 When a circuit breaker or fuse

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

1 Circuit Breaker CB5
CB5 protects the 24 volt ac output

to Remote receptacle RC4. If CB5
opens, 24 volt ac output to RC4
stops.

Press button to reset breaker.
2 Fuse F2 (See Parts List)
3 Fuse F6 (See Parts List)

F2 is located behind the front panel.
F2 protects the 115 volt output to
Remote Receptacle RC4. If F2
opens, 115 volt ac output to RC4
stops.

F6 protects the engine wiring sys­tem from overload. If F6 opens,
engine will not crank.

4 Fuse F1 (See Parts List)
Remove side panel.
F1 protects the exciter excitation

winding from overload. If F1 opens,
weld and generator power output
stops.

Replace any open fuses. Reinstall
cover before operating unit.

3

1

802 851-A / Ref. 206 422

OM-4407 Page 41

SECTION 10 − TROUBLESHOOTING

10-1. Welding Troubleshooting

Trouble Remedy

No weld output. Check control settings.

Check weld connections.

Disconnect equipment from generator power receptacles during start-up.

Place V/A Adjust switch in Panel position, or move switch to Remote position and connect remote
control to Remote receptacle RC4 (see Sections 5-9 and 6-1).

Check and secure connections to Remote receptacle RC4 (see Sections 5-9).

Check fuse F1, and replace if necessary (see Section 8-5 or 9-7).

Have Factory Authorized Service Agent check brushes, slip rings, integrated rectifier SR2, and circuit
boards PC1 and PC2.

Low weld output. Check control settings.

Place V/A Adjust switch in Panel position, or move switch to Remote position and connect remote
control to Remote receptacle RC4 (see Sections 5-9 and 6-1).

Check and clean air cleaner as necessary (see Section 8-3 or 9-3).

Check engine speed, and adjust if necessary (see Section 8-7 or 9-6).

Have Factory Authorized Service Agent check brushes, slip rings, integrated rectifier SR2, and circuit
boards PC1 and PC2.

See engine manual.

High weld output. Check control settings.

Check and adjust engine speed (see Section 8-7 or 9-6).

Check for obstructed movement of solenoid linkage (see Section 8-7 or 9-6).

Have Factory Authorized Service Agent check circuit boards PC1 and PC2.

Weld output cannot be adjusted. Check position of V/A Adjust switch (see Section 6-1).

Have Factory Authorized Service Agent check field current control board PC2.

Erratic weld output. Check control settings.

Clean and tighten connections both inside and outside unit.

Check and secure lead connections to A/V control.

Be sure connection to work piece is clean and tight.

Remove excessive coils from weld cables.

Use dry, properly stored electrodes.

Check and adjust engine speed (see Section 8-7 or 9-6).

Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.

No remote fine amperage control. Place V/A Adjust switch in correct position (see Section 6-1).

Check and tighten connections to Remote receptacle RC4 (see Section 5-9).

No 24 volt ac power output at Remote
receptacle RC4.

No 115 volt ac power output at Remote
receptacle RC4.

OM-4407 Page 42

Reset circuit breaker CB5 (see Section 8-5 or 9-7).

Check fuse F2, and replace if necessary (see Section 8-5 or 9-7).

Reset circuit breaker CB1 (see Section 7-1).

Trouble Remedy

Lack of high frequency; difficulty in
establishing Gas Tungsten Arc Weld­ing arc.

Use proper size tungsten for welding amperage.

Reduce leakage of high frequency from torch or work cable (check grounding, remove excessive
coils from weld cables, use shorter weld cables, etc.).

Check cables and torch for cracked or deteriorated insulation or bad connections. Repair or replace
necessary parts.

Wandering arc − poor control of arc
direction.

Tungsten electrode oxidizing and not
remaining bright after conclusion of
weld.

Reduce gas flow rate.

Select proper size tungsten. Properly prepare tungsten.

Shield weld zone from drafts.

Increase postflow time.

Check and tighten all gas fittings.

Properly prepare tungsten.

10-2. Generator Power Troubleshooting

Trouble Remedy

No power output. Reset circuit breakers CB1, CB3 and/or CB4 (see Section 7-1).

Check fuse F1, and replace if necessary (see Section 8-5 or 9-7).

Have Factory Authorized Service Agent check brushes, slip rings, integrated rectifier SR2, and circuit
boards PC1 and PC2.

Low power output. Check and clean air cleaner as necessary.

Check engine speed, and adjust if necessary (see Section 8-7 or 9-6).

See engine manual.

High power output. Check engine speed, and adjust if necessary (see Section 8-7 or 9-6).

Erratic power output. Have Factory Authorized Service Agent check brushes, slip rings, and field current control board PC2.

Check receptacle wiring and connections.

Check governor according to engine manual.

10-3. Engine Troubleshooting

Trouble Remedy

Engine will not crank. Check fuse F6, and replace if open (see Section 8-5 or 9-7).

Check battery voltage.

Check battery connections and tighten if necessary.

Check plug PLG5 and plug PLG8 connections.

Have Factory Authorized Service Agent check Engine Control switch S2.

OM-4407 Page 43

Trouble Remedy

Engine does not start. Check fuel level (see Section 5-2 or 5-3).

Check battery and replace if necessary.

Check engine charging system according to engine manual.

Have Factory Authorized Service Agent check fuel shutoff solenoid GS1 according to engine manual
(GS1 standard on Kohler-powered units; optional on Robin-powered, LP-fueled units).

See engine manual.

Engine starts but stops when Engine
Control switch returns to Run/Idle
position.

Battery discharges between uses. Place Engine Control switch in Off position when unit is not running.

Engine stopped during normal
operation.

Check oil level (see Section 5-2 or 5-3). Low oil pressure shutdown stops engine if oil pressure is too
low.

Use correct grade oil for operating temperature. (see Section 8-1 or 9-2).

Have Factory Authorized Service Agent check low oil pressure shutdown switch S5.

Clean top of battery with baking soda and water solution; rinse with clear water.

Periodically recharge battery (approximately every 3 months).

Replace battery.

Check voltage regulator according to engine manual.

Check fuel level (see Section 5-2 or 5-3).

Check oil level (see Section 5-2 or 5-3). Low oil pressure shutdown stops engine if oil pressure is too
low.

Have Factory Authorized Service Agent check fuel shutoff solenoid GS1 according to engine manual
(GS1 standard on Kohler-powered units; optional on Robin-powered, LP-fueled units).

Have Factory Authorized Service Agent check low oil pressure shutdown switch S5.

Engine does not return to idle speed. Be sure Engine Control switch S2 is in Run/Idle position.

Remove all weld and generator power loads.

Place Process/Contactor switch in Electrode Hot position or turn off remote contactor. The unit will not
return to idle speed when Process/Contactor switch is in a remote position and the remote contactor
is on.

Turn off remote device connected to Remote receptacle RC4 (see Section 5-9).

Check for obstructed movement of solenoid linkage (see Section 8-7 or 9-6).

Have Factory Authorized Service Agent check circuit board PC1 and current transformer CT1.

Engine does not remain at weld/power
speed when power or weld load is
applied with Engine Control switch in
Run/Idle position.

Place Engine Control switch in the Run position for small loads.

Check for obstructed movement of solenoid linkage (see Section 8-7 or 9-6).

OM-4407 Page 44

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-4407 Page 45

SECTION 11 − ELECTRICAL DIAGRAMS

OM-4407 Page 46

Figure 11-1. Circuit Diagram For Welding Generator Models With AC/DC Output

OM-4407 Page 47

209 625-C

Figure 11-2. Circuit Diagram For Welding Generator Models With DC Output Only (Kohler Only)

OM-4407 Page 48

OM-4407 Page 49

209 620-B

SECTION 12 − GENERATOR POWER GUIDELINES

NOTE

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

12-1. Selecting Equipment

1

1 Generator Power Receptacles

− Neutral Bonded To Frame

2 3-Prong Plug From Case

Grounded Equipment

3 2-Prong Plug From Double

Insulated Equipment

 Do not use 2-prong plug un-

less equipment is double in­sulated.

2

3

OR

12-2. Grounding Generator To Truck Or Trailer Frame

1

GND/PE

2

Be sure equipment
has this symbol
and/or wording.

3

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

 Always ground generator

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

1 Equipment Grounding

Terminal (On Front Panel)

2 Grounding Cable (Not

Supplied)
3 Metal Vehicle Frame
Connect cable from equipment

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

 If unit does not have GFCI re-

ceptacles, use GFCI-pro-

tected extension cord.

OM-4407 Page 50

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

 Bed liners, shipping skids, and some running

gear insulate the welding generator from the ve­hicle frame. Always connect a ground wire from
the generator equipment grounding terminal to
bare metal on the vehicle frame as shown.

S-0854

12-3. 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.

12-4. 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 12-8).

3 Rating Data
Rating shows volts and amperes, or

watts required to run equipment.

EXAMPLE 2: If three 200 watt flood lamps are used with the drill from Example 1,
add the individual loads to calculate total load.

(200 W + 200 W + 200 W) + 520 W = 1120 W

The total load applied by the three flood lamps and drill is 1120 watts.

S-0623

OM-4407 Page 51

12-5. 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

12-6. 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-4407 Page 52

12-7. Approximate Power Requirements For Contractor Equipment

Contractor Rating Starting Watts Running Watts

Hand Drill 1/4 in 350 350

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

Circular Saw 6-1/2 in 500 500

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

Table Saw 9 in 4500 1500

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

8 in 3900 1400

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

1 HP 6000 1500

1-1/2 HP 8200 2200

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

2 HP, 14 in 1100 1100

Electric Trimmer Standard 9 in 350 350

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

Metal Halide 313 250

Mercury 1000

Sodium 1400

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

1 HP, 20 in 6100 1600

High Pressure Washer 1/2 HP 3150 950

3/4 HP 4500 1400

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

2-1/2 HP 1300 1300

OM-4407 Page 53

12-8. Power Required To Start Motor

4
1

VOLTS AMPS

3

Single-Phase Induction Motor Starting Requirements

Motor Start

Code GH J K LMNP

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

12-9. 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-4407 Page 54

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

12-10. Typical Connections To Supply Standby Power

 Properly install and ground this equipment according to

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

1234

Utility

Electrical

Service

Transfer Switch

5

Essential

Loads

Fused

Disconnect

Switch

(If Required)

Welding

Generator

Output

 Have only qualified persons perform

these connections according to all
applicable codes and safety practic­es.

 Properly install and ground this

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

 Customer-supplied equipment is re-

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

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

Notes

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

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

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

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

consistent with regular (utility) system volt­age and wiring.

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

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

5 Essential Loads

Generator output may not meet the electrical
requirements of the premises. If generator
does not produce enough output to meet all
requirements, connect only essential loads
(pumps, freezers, heaters, etc. − See Sec­tion 12-4).

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-4407 Page 55

12-11. Selecting Extension Cord (Use Shortest Cord Possible)

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

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

Current

(Amperes)

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

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

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

15 1800 300 (91) 175 (53) 112 (34) 75 (23) 37 (11) 30 (9)

20 2400 225 (68) 137 (42) 87 (26) 50 (15) 30 (9)

25 3000 175 (53) 112 (34) 62 (19) 37 (11)

30 3600 150 (46) 87 (26) 50 (15) 37 (11)

35 4200 125 (38) 75 (23) 50 (15)

40 4800 112 (34) 62 (19) 37 (11)

45 5400 100 (30) 62 (19)

50 6000 87 (26) 50 (15)

*Conductor size is based on maximum 2% voltage drop

Cord Lengths for 240 Volt Loads
 If unit does not have GFCI receptacles, use GFCI-protected extension cord.

Load (Watts) 4 6 8 10 12 14

Current

(Amperes)

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

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

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

15 3600 600 (183) 350 (107) 225 (69) 150 (46) 75 (23) 60 (18)

20 4800 450 (137) 275 (84) 175 (53) 100 (31) 60 (18)

25 6000 350 (107) 225 (69) 125 (38) 75 (23)

30 7000 300 (91) 175 (53) 100 (31) 75 (23)

35 8400 250 (76) 150 (46) 100 (31)

40 9600 225 (69) 125 (38) 75 (23)

45 10,800 200 (61) 125 (38)

50 12,000 175 (53) 100 (31)

*Conductor size is based on maximum 2% voltage drop

Load (Watts) 4 6 8 10 12 14

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

OM-4407 Page 56

Notes

OM-4407 Page 57

SECTION 13 − PARTS LIST

20

21

23

22

16

19−Fig.13-3

24

25

18

17

26

27

28

29

 Hardware is common and

not available unless listed.

30

31

32

33

36

59

40

37

38

58

41

42

43

44

54

45

46

35

55

47

48

60

53

34

49

50

51

52

15

14

11

10

9

8

7

6

5

4

3

2

1

OM-4407 Page 58

57−Fig.13-2

Figure 13-1. Main Assembly (Kohler Engine Shown)

56

802 951

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 13-1. Main Assembly

1 182367 Panel, Side Rh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 ♦185352 Panel, Side Rh Stainless Steel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 182366 Panel, Side Lh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ♦185353 Panel, Side Lh Stainless Steel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 +205762 Cover, Top (Robin EH64, Kohler) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 +206758 Cover, Top Stainless Steel (Robin EH64, Kohler) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦163175 Screw, 250−20x .75 Hex Hd−pln Stainless Steel Pln T18−8 302−305 18. . . . . . . . . . . . . . . . . . . . . . .

♦163167 Washer, Lock .254idx0.489odx.062t Stainless Steel Split.250 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦163174 Washer, Flat .281idx0.625odx.050t Stainless Steel 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 205605 Label, Power While Welding 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 192042 Label, Use Gasoline Only 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 181881 Grommet, Plastic Neck Filler Fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 166608 Cap, Tank Screw−on W/Vent 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 182761 Label, Warning General Precautionary Csa 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 183433 Pipe, Exhaust Elbow 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 183314 Clamp, Muffler 1.625 Dia U Pld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 182365 Panel, Rear Upper 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 ♦185351 Panel, Rear Upper Stainless Steel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 & 13 Deleted. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 205736 Upright, Base (Robin EH64, Kohler) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 205734 Seal, Weather Lift Eye (Robin EH64, Kohler) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 181789 Seal, Barrel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 186667 Cover, Tank Fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 204317 Bracket, Mtg. Engine (Robin EH64) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 173043 Bracket, Mtg Engine (Kohler) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 Figure 13-3 Generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 215939 Label, Engine Maintenance (Robin EH64, Kohler) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

202807 Shield, Heat Muffler (Kohler) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

205713 Hose, Oil w/Fittings (Robin EH64, Kohler) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 208006 Engine, Robin EH64 Gas Elect Start (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 204841 Muffler, Exhaust Engine 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

065313 Gasket, Muffler 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

198756 Pump, Fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S5 198757 Switch, Low Oil Pressure 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 TS1 206573 Solenoid, Throttle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

190827 Boot, Solenoid 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

198778 Regulator, Voltage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

215984 Filter, Fuel Inline .250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 208004 Valve, Oil Drain 3/8−18 Nptf (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

207490 Hose, Oil W/Fitting 9.750 Lg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

206472 Ftg, Hose Brs Barbed M 1/2 Tbg X M14x1.25 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

206473 Washer, Seal oil copper M14 ID x M19.500 OD (Robin EH64) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 209023 Engine, Kohler CH20S-PS−64635 Gas Elec Start (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 207458 Muffler,Exhaust Engine 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

189477 Gasket, Muffler 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 TS1 199530 Solenoid, Throttle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bracket, Mtg Solenoid (See Engine Parts List) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

215984 Filter,Fuel Inline .250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 208003 Valve,Oil Drain 3/8−18 Nptf (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

207490 Hose, Oil W/Fitting 9.750 Lg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

206402 Ftg, Hose Brs Barbed M 1/2 Tbg X 3/8 Npt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

*215985 Filter/Clamps, Fuel 1/4” Line 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

OM-4407 Page 59

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Description

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Figure 13-1. Main Assembly (Continued)

25 168385 Label, Warning Battery Explosion Can Blind 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 +201174 Door, Access Battery 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 182935 Hold Down, Battery 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 082319 Cable, Bat Neg 17.750l lg no 4 awg w/clamp & .343 rng. . . . . . . . . . . . . . . . . . .

(Kohler, Robin EH64) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 172 669 Cable, Bat Neg 11.000 lg 6ga w/.250 rng & .375 rng. . . . . . . . . . . . . . . . . .

(Kohler, Robin EH64) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 173 921 Cable, Bat Pos 28.000 lg no 4 awg w/clamp & .312 rng. . . . . . . . . . . . . . . . . .

(Kohler, Robin EH64) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 167677 Battery, Stor 12v 430 Crk 75 Rsv Gp 58 Maint Free 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 +201280 Pan, Base 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 197930 Label, Warning Do Not Weld On Base 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 207864 Label, Engine Maintenance (Kohler) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 181057 Cover, Base 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 DC-Z 202337 Stabilizer, Assy (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

202338 Plate, Rect/Stab Mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 +182928 Bracket, Mtg Generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 121652 Filter/Clamps, Fuel (Part Of Tune-Up & Filter Kits) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 173766 Hose, Sae .250 Id X .500 Od X 11.500 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 Deleted. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

084173 Clamp, Hose .460 − .545 Clp Dia Slfttng 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 182079 Tank, Fuel 10.0 Gal (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

124253 Bushing, Tank Fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187502 Ftg, Stand Pipe .250 X 7.375 Lg 90 Degree 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

182922 Bushing, Tank Fuel 1.210id 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

182925 Gauge, Fuel Float Type 5.50 Float Travel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 PC1 212708 Circuit Card Assy, Power 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 097132 Stand−off, No 6−32 X .375 Lg .250 Hex Brs M&f 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 204148 Bracket, Mtg Pc Board 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 119148 Bushing, Snap−in Nyl 1.968 Id X 2.500 Mtg Hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 200263 Label, Warning Electric Shock Hazard 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46 172731 Holder, Fuse Mintr .250 X 1.250 Clip Anti−pivot 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47 F1 169296 Fuse, Mintr Gl 25. Amp 125 Volt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48 SR2 200759 Rectifier, Integ Bridge 35. Amp 600v 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49 1T 172661 Block, Stud Connection 6 Position 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

173734 Link, Jumper 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 165437 Clip, Snap In .472 Bundle .250hole .020−.197 Thk 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51 C12 176007 Capacitor, Elctlt 1200 Uf 300 Vdc Can 1.37 Dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52 C1 199979 Capacitor, Elctlt 1500 Uf 75 Vdc Can 1.40 Dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53 204166 Bracket, Capacitor Support 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

202331 Gasket, Capacitor Support 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54 R1 188067 Resistor, Ww Fxd 100 W 200 Ohm W/Clips (AC/DC Units Only) 1. . . . . . . . . . . . . . . . . . . . . .

55 CT1 206 369 Xfmr, Current Sensing 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

56 +180628 Panel, Front Lower 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57 Figure 13-2 Panel, Front w/Components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58 SR1 202222 Rectifier, Si 3ph 300 Amp 400 Piv 100% Duty Cycle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59 202339 Baffle, Air 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60 196180 Insulator, Terminal Block 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC29, 30, PLG6 209831 Receptacles, W/Leads 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

202883 Harness, Control Power Board Interconnecting (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG16 115093 Conn, Rect Mini 045 6skt 2row Plug Cable Lkg (Service Kit) 1. . . . . . . . . . . . . . . . . . . . . . . . .

PLG12, PLG27 131054 Conn, Rect Mini 045 2skt 2row Plug Cable Lkg (Service Kit) 2. . . . . . . . . . . . . . . . . . .

PLG21 115094 Conn, Rect Mini 045 4skt 2row Plug Cable Lkg (Service Kit) 1. . . . . . . . . . . . . . . . . . . . . . . . .

206534 Harness, Wrg Interconnecting (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG25 115091 Conn, Rect Mini 045 10skt 2row Plug Cable Lkg (Service Kit) 1. . . . . . . . . . . . . . . . . . . . . . . .

RC9 174823 Conn, Rect Comm 093 2p/S 1row Rcpt Cable Lkg (Service Kit) 1. . . . . . . . . . . . . . . . . . . . . . . .

RC7 130204 Conn, Rect Univ 084 3p/S 1row Plug Cable Lkg (Service Kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . .

PLG18 204773 Plug, W/Leads (AC/DC Units Only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-4407 Page 60

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206537 Harness, Wrg Ignition (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG15 115092 Conn, Rect Mini 045 8skt 2row Plug Cable Lkg (Service Kit) 1. . . . . . . . . . . . . . . . . . . . . . . . .

RC5 116045 Conn, Rect Univ 084 6p/S 3row Rcpt Cable/Panel Lkg (Service Kit) 1. . . . . . . . . . . . . . . . . . . .

PLG7 168165 Conn, Rect Comm 084 3p/S 1row Recpt Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

202660 Conn, Push 4 Wire 12−16strnd 12−18sld 16−22tinstrnd 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG5 135556 Conn, Rect Univ 084 6p/S 3row Plug (Service Kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

206123 Tune-Up & Filter Kit (Robin EH64) (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*198755 Element, Air Cleaner w/Precleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*198754 Oil Filter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*121652 Filter/Clamps, Fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*198777 Spark Plug 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

180096 Tune-up & Filter Kit (Kohler) (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*067272 Element, Air Cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*066698 Filter, Oil 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

121652 Filter/Clamps, Fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

*067272 Air Filter Wrapper 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

206122 Kit, Label (Robin EH64) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

205650 Kit, Label (Kohler) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦Optional
*Recommended Spare Parts.

Description

Figure 13-1. Main Assembly (Continued)

Quantity

+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order

label individually or as part of Label Kit 206122 (Robin EH64), or 205650 (Kohler).

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

OM-4407 Page 61

 Hardware is common and

not available unless listed.

33

32

34

35

29

31

30

28

36

10

7

9

13

11

12

16

17

19

15

18

14

4

3

2

1

23

24

5

21
22

6

8

25

26

27

Figure 13-2. Panel, Front w/Components

20

802 952

OM-4407 Page 62

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No.

Description

Figure 13-2. Panel, Front w/Components (Figure 13-1 Item 57)

1 206854 Panel, Front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 115 440 Stand−off, No 6−32 X .625 Lg .250 Hex Al Fem 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 203401 Stand−off Support, Pc Card .187 Dia W/P&l .625 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 PC2 212867 Circuit Card Assy, Control (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

206794 Bag, Protective Anti Static 5:00x12:00 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 S1 204641 Switch, Changeover Assy W/Leads (AC/DC Units Only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 187189 Bracket, Mtg Shunt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 LEM 168829 Transducer, Current 1000a Module Max Open Loop 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

209618 Harness, Remote Control 14pin (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 RC4 143976 Conn, Circ Ms/Cpc 14skt Size 20 Rcpt Panel Pushin (Service Kit) 1. . . . . . . . . . . . . . . . . .

9 209617 Holder, Fuse w/10a Fuse (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F2 085874 Fuse, Mintr Cer Slo-Blo 10 a 250 Volt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG23 115093 Conn, Rect Mini 045 6skt 2row Plug Cable Lkg (Service Kit) 1. . . . . . . . . . . . . . . . . . . . . . . . .

PLG24 131054 Conn, Rect Mini 045 2skt 2row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

202884 Harness, Switch Control (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG20 131204 Conn, Rect Mini 045 3skt 1row Plug Cable Lkg (Service Kit) 1. . . . . . . . . . . . . . . . . . . . . . . . .

10 S3 011609 Switch, Tgl Spdt 15a 125vac On−none−on Spd Term Chr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 CB5 083432 Circuit Breaker, Man Reset 1p 10a 250vac Frict 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 S2 176606 Switch, Ignition 4 Position W/Out Handle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 RC2, RC3 141432 Rcpt, Str Dx Grd 2p3w 20a 125v *5−20r 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GFCI2, GFCI3 ♦151981 Rcpt, Str Dx Grd 2p3w 20a 125v GFCI 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

14 CB3, CB4 093996 Circuit Breaker, Man Reset 1p 20a 250vac Frict 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 CB1 217858 Circuit Breaker, Man Reset 2p 50a 240vac Screw−90 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 PC5 148030 Circuit Card Assy, Filter Hf 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 PC3 148021 Circuit Card Assy, Filter Hf 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

134201 Stand−off Support, Pc Card .312/.375w/Post&lock .43 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 211452 Control, Push/Pull Snap−in 42.000 W/1.750 Extension 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 119014 Lever, Switch Black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 CC, CV, WORK 099255 Terminal, Pwr Output Neutral (AC/DC Units Only) 3. . . . . . . . . . . . . . . . . . . . . . . . . . .

POS 039047 Terminal, Pwr Output Red (DC Units Only) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NEG 039046 Terminal, Pwr Output Black (DC Units Only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG30 204777 Plug, w/ Leads (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

174824 Conn,Rect Comm 093 2p/S 1row Plug Cable Lkg (Service Kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG28 204664 Plug, w/Leads (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

130203 Conn,Rect Mini 045 12skt 2row Plug Cable Lkg (Service Kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 083030 Stud, Brs .250−20 X 1.750 W/Hex Collar 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 010915 Washer, Flat .257idx0.640odx.031t Brs 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 602207 Washer, Lock .255idx0.489odx.062t Stl Pld Split.250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 601836 Nut, 250−20 .50hex .19h Brs 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 188039 Cover, Receptacle W/Gasket 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 203016 Boot, Circuit Breaker 2 Pole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 159921 Bezel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

29 021385 Boot, Toggle Switch Lever 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

31 207075 Knob, Pointer 1.625 Dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 010647 Pin, Spring Cs .156 X 1.250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 115493 Handle, Switch Range (AC/DC Units Only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 170391 Conn, Circ Ms Protective Cap Size 20 Nylon 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 207080 Knob, Pointer 1.125 Dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 Nameplate (Order By Model & Serial Number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

♦Optional
+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order

label individually or as part of Label Kit 206122 (Robin EH64), or 205650 (Kohler).

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

OM-4407 Page 63

Item

No.

Part

No.

Description

Figure 13-3. Generator (Figure 13-1 Item 19)

1 +206 406 Stator, Generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 182092 Label, Warning Moving Parts Can Caue Serious Injury 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 202346 Rotor, Generator (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 181143 Bearing, Ball Rdl Sgl Row .984 X 2.047 X .591 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 160566 Fan, Rotor Gen 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 212161 Adapter, Engine (Kohler, Robin EH64) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 202771 Baffle, Engine Adapter (Kohler, Robin EH64) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 170861 Stud, Stl .375−16 X 17.375 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 205725 Brushholder Assy, Generator 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG17 203387 Harness, Brushholder (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

202511 Conn,Rect Univ 084 6p/S 3row Plug Cable Lkg (Service Kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 010909 Washer, Flat .406idx0.812odx.065t Stl Pld Ansi.375 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 010910 Nut, 375−16 .56hex .46h Stl Pld Elastic Stop Nut 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 218049 Endbell (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 183419 O-Ring 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG10 130204 Connector, Rect Univ 084 3 P/S 1 Row Plug Cable Lkg (Service Kit) 1. . . . . . . . . . . . . . . . .

Quantity

 Hardware is common and

not available unless listed.

1

12

7

6

3

5

4

2

8

9

13

11

10

802 999

Figure 13-3. Generator

+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order

label individually or as part of Label Kit 206122 (Robin EH64), or 205650 (Kohler).

*Recommended Spare Parts.

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

OM-4407 Page 64

Warranty Questions?

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

Your distributor also gives
you ...

Service

You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.

Support

Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.

Effective January 1, 2004

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

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

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 (Unless Otherwise Stated)
* 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
* Arc Stud Power Sources & Arc Stud Guns
* Racks
* Running Gear/Trailers
* Plasma Cutting Torches (except APT & SAF

Models)
* Field Options

(NOTE: Field options are covered under True

Blue for the remaining warranty period of the

product they are installed in, or for a minimum of

one year — whichever is greater.)

4. 6 Months — Batteries

5. 90 Days — Parts

* MIG Guns/TIG Torches

guarantees or warranties expressed or implied.

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

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

1. Consumable components; such as contact tips,

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

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

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

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

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

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

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

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

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

miller_warr 3/04

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

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

Distributor

Address

City

State Zip

For Service

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

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

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

and Parts)
Circuit Diagrams
Welding Process Handbooks

Miller Electric Mfg. Co.

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

International Headquarters−USA

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

European Headquarters −
United Kingdom

Phone: [phone]
FAX: [phone]

www.MillerWelds.com

Contact the Delivering Carrier to:

PRINTED IN USA  2003 Miller Electric Mfg. Co. 1/03

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.