OM-498
197 849F
March 2004
Processes
Stick (SMAW) Welding
Description
Engine Driven Welding Generator
R
Blue Star 3500
Visit our website at
Download from Www.Somanuals.com. All Manuals Search And Download.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-7. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-8. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . .
2-6. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-3. Fuel Consumption (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-4. Fuel Consumption (Honda-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-5. Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-6. Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-7. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5-2. Grounding Generator To Truck Or Trailer Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5-3. Grounding Generator When Supplying Building Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5-4. Engine Prestart Checks (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5-5. Engine Prestart Checks (Honda-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-6. Connecting The Battery (Honda Electric-Start Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-7. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-8. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SECTION 6 − OPERATING THE WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6-1. Controls (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6-2. Controls (Honda-Powered Units) (See Section 6-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6-3. Description Of Controls (Honda-Powered Units) (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SECTION 7 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7-1. Generator Power Panel 495 218 (USA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7-2. Optional Generator Power Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7-3. Generator Power Panel Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7-4. Wiring Instructions For Optional 120/240 Volt Twistlock Plug (NEMA L14-30P) . . . . . . . . . . . . . . . . . . 23
SECTION 8 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8-2. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8-3. Overload Protection (Honda-Powered Units Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8-4. Adjusting Engine Speed (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
8-5. Adjusting Engine Speed (Honda-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SECTION 9 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SECTION 10 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SECTION 11 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
SECTION 12 − STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
SECTION 13 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Download from Www.Somanuals.com. All Manuals Search And Download.
Download from Www.Somanuals.com. All Manuals Search And Download.
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
rom _nd_8/03
Y
Warning: Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
This group of symbols means Warning! Watch Out! possible
Y
Marks a special safety message.
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
.
M
e
a
n
s
“
N
o
t
e
”
;
n
o
t
s
a
f
e
t
y
r
e
l
a
t
e
d
.
1-2. Arc Welding Hazards
D
Use only well-maintained equipment. Repair or replace damaged parts at
once. Maintain unit according to manual.
Y
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 Stan-
D
D
D
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.
Y
Y
Only qualified persons should install, operate, maintain, and re-
pair this unit.
D
D
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.
During operation, keep everybody, especially children, away.
SIGNIFICANT DC VOLTAGE exists in inverters after stop-
ping engine.
ELECTRIC SHOCK can kill.
D
Stop engine on inverter and discharge input capacitors according to
instructions in Maintenance Section before touching any parts.
Touching live electrical parts can cause fatal shocks or
severe burns. The electrode and work circuit is electrically
live whenever the output is on. The input power circuit and
machine internal circuits are also live when power is on. In semiautomatic or
automatic wire welding, the wire, wire reel, drive roll housing, and all metal
parts touching the welding wire are electrically live. Incorrectly installed or
improperly grounded equipment is a hazard.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing these fumes
and gases can be hazardous to your health.
D
D
D
Do not touch live electrical parts.
D
D
Keep your head out of the fumes. Do not breathe the fumes.
Wear dry, hole-free insulating gloves and body protection.
If inside, ventilate the area and/or use exhaust at the arc to remove welding
fumes and gases.
Insulate yourself from work and ground using dry insulating mats or covers
big enough to prevent any physical contact with the work or ground.
D
D
If ventilation is poor, use an approved air-supplied respirator.
D
Do not use AC output in damp areas, if movement is confined, or if there is a
danger of falling.
Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s
instructions for metals, consumables, coatings, cleaners, and degreasers.
D
D
D
Use AC output ONLY if required for the welding process.
D
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.
If AC output is required, use remote output control if present on unit.
Additionalsafety 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 present-
ed: 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!
D
D
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.
D
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).
BUILDUP OF GAS can injure or kill.
D
D
Shut off shielding gas supply when not in use.
D
D
Properly install and ground this equipment according to its Owner’s Manual
and national, state, and local codes.
Always ventilate confined spaces or use approved
air-supplied respirator.
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.
ARC RAYS can burn eyes and skin.
D
D
When making input connections, attach proper grounding conductor first −
double-check connections.
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.
Frequently inspect input power cord for damage or bare wiring — replace
cord immediately if damaged — bare wiring can kill.
D
D
D
D
Turn off all equipment when not in use.
D
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).
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
D
D
Wear approved safety glasses with side shields under your helmet.
If earth grounding of the workpiece is required, ground it directly with a sep-
arate cable.
Use protective screens or barriers to protect others from flash and glare;
warn others not to watch the arc.
D
Do not touch electrode if you are in contact with the work, ground, or anoth-
er electrode from a different machine.
D
Wear protective clothing made from durable, flame-resistant material (wool
and leather) and foot protection.
OM-498 Page 1
Download from Www.Somanuals.com. All Manuals Search And Download.
WELDING can cause fire or explosion.
HOT PARTS can cause severe burns.
D
D
Allow cooling period before maintaining.
Welding on closed containers, such as tanks, drums, or
pipes, can cause them to blow up. Sparks can fly off from the
welding arc. The flying sparks, hot workpiece, and hot
equipment can cause fires and burns. Accidental contact of electrode to metal
objects can cause sparks, explosion, overheating, or fire. Check and be sure
the area is safe before doing any welding.
Wear protective gloves and clothing when working on
a hot engine.
D
Do not touch hot engine parts or just-welded parts
bare-handed.
D
D
D
Protect yourself and others from flying sparks and hot metal.
Do not weld where flying sparks can strike flammable material.
NOISE can damage hearing.
Noise from some processes or equipment can damage
hearing.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not
possible, tightly cover them with approved covers.
D
Wear approved ear protection if noise level is high.
D
Be alert that welding sparks and hot materials from welding can easily go
through small cracks and openings to adjacent areas.
MAGNETIC FIELDS can affect pacemakers.
D
D
Watch for fire, and keep a fire extinguisher nearby.
D
D
Pacemaker wearers keep away.
Be aware that welding on a ceiling, floor, bulkhead, or partition can cause
fire on the hidden side.
Wearers should consult their doctor before going
near arc welding, gouging, or spot welding opera-
tions.
D
D
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.
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.
D
D
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.
D
D
Protect compressed gas cylinders from excessive heat, mechanical
shocks, slag, open flames, sparks, and arcs.
D
D
D
Wear oil-free protective garments such as leather gloves, heavy shirt, cuf-
fless trousers, high shoes, and a cap.
Install cylinders in an upright position by securing to a stationary support or
cylinder rack to prevent falling or tipping.
Remove any combustibles, such as a butane lighter or matches, from your
person before doing any welding.
D
D
D
D
D
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot
work and have a fire watcher and extinguisher nearby.
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.
FLYING METAL can injure eyes.
D
Welding, chipping, wire brushing, and grinding cause
sparks and flying metal. As welds cool, they can
throw off slag.
D
D
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.
D
Wear approved safety glasses with side shields even
under your welding helmet.
D
Read and follow instructions on compressed gas cylinders, associated
equipment, and CGA publication P-1 listed in Safety Standards.
1-3. Engine Hazards
MOVING PARTS can cause injury.
BATTERY EXPLOSION can BLIND.
D
D
Keep away from fans, belts, and rotors.
D
D
Always wear a face shield, rubber gloves, and protec-
tive clothing when working on a battery.
Keep all doors, panels, covers, and guards closed
and securely in place.
Stop engine before disconnecting or connecting bat-
tery cables or servicing battery.
D
Stop engine before installing or connecting unit.
D
D
D
D
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.
D
Have only qualified people remove guards or covers for maintenance
and troubleshooting as necessary.
D
To prevent accidental starting during servicing, disconnect negative (−)
battery cable from battery.
Disconnect negative (−) cable first and connect it last.
D
D
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.
FUEL can cause fire or explosion.
D
D
Before working on generator, remove spark plugs or injectors to keep
engine from kicking back or starting.
D
D
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.
Block flywheel so that it will not turn while working on generator compo-
nents.
D
D
D
D
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-498 Page 2
Download from Www.Somanuals.com. All Manuals Search And Download.
BATTERY ACID can BURN SKIN and EYES.
STEAM AND HOT COOLANT can burn.
D
D
D
Do not tip battery.
D
D
If possible, check coolant level when engine is cold to
avoid scalding.
Replace damaged battery.
Always check coolant level at overflow tank, if pres-
ent on unit, instead of radiator (unless told otherwise
in maintenance section or engine manual).
Flush eyes and skin immediately with water.
D
If the engine is warm, checking is needed, and there is no overflow tank,
follow the next two statements.
ENGINE HEAT can cause fire.
D
D
Wear safety glasses and gloves and put a rag over radiator cap.
D
Do not locate unit on, over, or near combustible
surfaces or flammables.
Turn cap slightly and let pressure escape slowly before completely re-
moving cap.
D
Keep exhaust and exhaust pipes way from flam-
mables.
ENGINE EXHAUST GASES can kill.
EXHAUST SPARKS can cause fire.
D
Use equipment outside in open, well-ventilated ar-
eas.
D
D
Do not let engine exhaust sparks cause fire.
Use approved engine exhaust spark arrestor in re-
quired areas — see applicable codes.
D
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.
HOT METAL from air arc cutting and
gouging can cause fire or explosion.
D
D
Do not use compressed air for breathing.
Use only for cutting, gouging, and tools.
D
D
Do not cut or gouge near flammables.
Watch for fire; keep extinguisher nearby.
HOT PARTS can cause burns and injury.
COMPRESSED AIR can cause injury.
D
D
Do not touch hot compressor or air system parts.
Let system cool down before touching or servicing.
D
D
Wear approved safety goggles.
Do not direct air stream toward self or others.
TRAPPED AIR PRESSURE AND WHIPPING
HOSES can cause injury.
READ INSTRUCTIONS.
D
D
Read Owner’s Manual before using or servicing unit.
D
Release air pressure from tools and system before
servicing, adding or changing attachments, or open-
ing compressor oil drain or oil fill cap.
Stop engine and release air pressure before
servicing.
1-5. Additional Symbols For Installation, Operation, And Maintenance
OVERUSE can cause OVERHEATING.
FALLING UNIT can cause injury.
D
D
Allow cooling period; follow rated duty cycle.
D
D
D
Use lifting eye to lift unit only, NOT running gear, gas
cylinders, trailer, or any other accessories.
Reduce current or reduce duty cycle before starting
to weld again.
Use equipment of adequate capacity to lift and
support unit.
D
Do not block or filter airflow to 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.
STATIC (ESD) can damage PC boards.
D
Turn off or unplug equipment before starting or stop-
ping engine.
D
D
Put on grounded wrist strap BEFORE handling
boards or parts.
D
Do not let low voltage and frequency caused by low
engine speed damage electric motors.
Use proper static-proof bags and boxes to store,
move, or ship PC boards.
D
Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where
applicable.
FLYING SPARKS can cause injury.
TILTING OF TRAILER can cause injury.
D
D
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.
D
D
Use tongue jack or blocks to support weight.
Properly install welding generator onto trailer accord-
ing to instructions supplied with trailer.
D
Sparks can cause fires — keep flammables away.
OM-498 Page 3
Download from Www.Somanuals.com. All Manuals Search And Download.
READ INSTRUCTIONS.
ARC WELDING can cause interference.
D
Use only genuine MILLER/Hobart replacement
parts.
D
Electromagnetic energy can interfere with sensitive
electronic equipment such as microprocessors,
computers, and computer-driven equipment such as
robots.
D
Perform engine and air compressor (if applicable)
maintenance and service according to this manual
and the engine/air compressor (if applicable) manu-
als.
D
Be sure all equipment in the welding area is electro-
magnetically compatible.
D
D
D
D
To reduce possible interference, keep weld cables as short as possible,
close together, and down low, such as on the floor.
H.F. RADIATION can cause interference.
Locate welding operation 100 meters from any sensitive electronic
equipment.
D
High-frequency (H.F.) can interfere with radio naviga-
tion, safety services, computers, and communica-
tions equipment.
Be sure this welding machine is installed and grounded according to this
manual.
D
Have only qualified persons familiar with electronic
equipment perform this installation.
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.
D
D
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.
D
D
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
Y
Welding or cutting equipment produces fumes or gases which
contain chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)
For Gasoline Engines:
Y
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
For Diesel Engines:
Y
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
reproductiveharm. Wash hands after handling.
Y
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 inWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(phone: 305-443-9353, website: www.aws.org).
levard, Rexdale, Ontario, Canada M9W 1R3 (phone: 800-463-6727 or
in Toronto 416-747-4044, website: www.csa-international.org).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036–8002 (phone: 212-642-4900,
website: www.ansi.org).
RecommendedSafe Practices for the Preparation for Welding and Cut-
ting of Containers and Piping, American Welding Society Standard
AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Mi-
ami, FL 33126 (phone: 305-443-9353, website: www.aws.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:
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202-4102 (phone: 703-412-0900, website:
www.cganet.com).
OSHA, Occupational Safety and Health Standards for General Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
intendent 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).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
CanadianStandards Association, Standards Sales, 178 Rexdale Bou-
1-8. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
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.
Welding current, as it flows through welding cables, will cause electro-
magnetic 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 power-
frequency 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.
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-498 Page 4
Download from Www.Somanuals.com. All Manuals Search And Download.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
rom_fre 8/03
Y
A
v
e
r
t
i
s
s
e
m
e
n
t
:
P
r
o
t
é
g
e
z
v
o
u
s
e
t
l
e
s
a
u
t
r
e
s
d
e
s
b
l
e
s
s
u
r
e
s
−
l
i
s
e
z
e
t
s
u
i
v
e
z
c
e
s
p
r
é
c
a
u
t
i
o
n
s
.
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.
Ce groupe de symboles si-
gnifie Mise en garde
Soyez vigilant ! Il y a des
risques de danger reliés
!
Y
Identifie un message de sécurité particulier.
aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux
PIÈCES CHAUDES. Reportez-vous aux symboles et aux directives ci-des-
sous afin de connaître les mesures à prendre pour éviter tout danger.
.
S
i
g
n
i
f
i
e
N
O
T
A
;
n
’
e
s
t
p
a
s
r
e
l
a
t
i
f
à
l
a
s
é
c
u
r
i
t
é
.
2-2. Dangers relatifs au soudage à l’arc
D
D
En effectuant les raccordements d’entrée fixer d’abord le conducteur de
mise à la terre approprié et contre-vérifier les connexions.
Y
Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les ris-
ques 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 sécu-
ces normes de sécurité.
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.
D
D
Mettre l’appareil hors tension quand on ne l’utilise pas.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou
mal épissés.
D
D
Ne pas enrouler les câbles autour du corps.
Y
Y
L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées.
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.
D
D
Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou
une électrode provenant d’une autre machine.
Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrement les enfants.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-champ
les pièces endommagées. Entretenir l’appareil conformément à ce
manuel.
UN CHOC ÉLECTRIQUE peut tuer.
D
D
D
Porter un harnais de sécurité quand on travaille en hauteur.
Maintenir solidement en place tous les panneaux et capots.
Un simple contact avec des pièces électriques peut
provoquer une électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension dès
que l’appareil est sur ON. Le circuit d’entrée et les circuits
internes de l’appareil sont également sous tension à ce
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.
D
Isoler la pince de masse quand pas mis à la pièce pour éviter le contact
avec tout objet métallique.
moment-là. En soudage semi-automatique ou automatique, le fil, le dévidoir, le
logement des galets d’entraînement et les pièces métalliques en contact avec
le fil de soudage sont sous tension. Des matériels mal installés ou mal mis à la
terre présentent un danger.
Une tension DC importante subsiste à l’intérieur
des onduleurs après avoir coupé l’alimentation.
D
Couper l’alimentation du poste et décharger les condensateurs d’entrée
comme indiqué dans la Section Maintenance avant de toucher des compo-
sants.
D
D
Ne jamais toucher les pièces électriques sous tension.
Porter des gants et des vêtements de protection secs ne comportant pas
de trous.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
D
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.
Le soudage génère des fumées et des gaz. Leur inhalation
peut être dangereux pour votre santé.
D
D
D
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.
D
D
Eloigner votre tête des fumées. Ne pas respirer les fumées.
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.
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.
D
D
Si la ventilation est insuffisante, utiliser un respirateur à alimentation d’air
homologué.
D
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 ma-
nuel 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!
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.
D
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.
D
D
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.
D
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).
D
D
Installer et mettre à la terre correctement cet appareil conformément à son
manuel d’utilisation et aux codes nationaux, provinciaux et municipaux.
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 néces-
saire, 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.
Toujours vérifier la terre du cordon d’alimentation − Vérifier et s’assurer que
le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre
du sectionneur ou que la fiche du cordon est raccordée à une prise
correctement mise à la terre.
OM-498 Page 5
Download from Www.Somanuals.com. All Manuals Search And Download.
D
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 proxi-
mité.
LES ACCUMULATIONS DE GAZ ris-
quent de provoquer des blessures ou
même la mort.
DES PARTICULES VOLANTES
peuvent blesser les yeux.
D
Fermer l’alimentation du gaz protecteur en cas de
non utilisation.
D
Le soudage, l’écaillement, le passage de la pièce
à la brosse en fil de fer, et le meulage génèrent
des étincelles et des particules métalliques vo-
D
Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi-
rateur d’adduction d’air homologué.
lantes. Pendant la période de refroidissement des soudures, elles ris-
quent de projeter du laitier.
LES RAYONS DE L’ARC peuvent pro-
voquer des brûlures dans les yeux et
sur la peau.
D
Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
Le rayonnement de l’arc du procédé de soudage génère
des rayons visibles et invisibles intenses (ultraviolets et
infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la
peau. Des étincelles sont projetées pendant le soudage.
D
Prévoir une période de refroidissement avant d’effec-
tuer des travaux d’entretien.
D
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).
D
Porter des gants et des vêtements de protection pour
travailler sur un moteur chaud.
D
Ne pas toucher à mains nues les parties chaudes du moteur ni les pièces
récemment soudées.
D
D
D
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.
LE BRUIT peut affecter l’ouïe.
Porter des vêtements de protection constitué dans une matière durable, ré-
sistant au feu (laine ou cuir) et une protection des pieds.
Le bruit des processus et des équipements peut affecter
l’ouïe.
LE SOUDAGE peut provoquer un in-
cendie ou une explosion.
D
Porter des protections approuvés pour les oreilles si
le niveau sondre est trop élevé.
Le soudage effectué sur des conteneurs fermés tels que
des réservoirs, tambours ou des conduites peut provoquer
leur éclatement. Des étincelles peuvent être projetées de
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
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.
D
D
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.
D
D
D
Se protéger et d’autres personnes de la projection d’étincelles et de métal
chaud.
Si des BOUTEILLES sont endomma-
gées, 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 normale-
ment partie du procédé de soudage, les manipuler avec
précaution.
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.
D
Des étincelles et des matériaux chauds du soudage peuvent facilement
passer dans d’autres zones en traversant de petites fissures et des
ouvertures.
D
Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des
chocs mécaniques, du laitier, des flammes ouvertes, des étincelles et des
arcs.
D
D
Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.
D
D
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.
Le soudage effectué sur un plafond, plancher, paroi ou séparation peut dé-
clencher un incendie de l’autre côté.
Tenir les bouteilles éloignées des circuits de soudage ou autres circuits
électriques.
D
D
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).
D
D
Ne jamais placer une torche de soudage sur une bouteille à gaz.
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 che-
mins inconnus éventuels en provoquant des risques d’électrocution et
d’incendie.
Une électrode de soudage ne doit jamais entrer en contact avec une bou-
teille.
D
D
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.
D
D
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.
D
D
Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la bouteille.
D
D
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.
Maintenir le chapeau de protection sur la soupape, sauf en cas d’utilisation
ou de branchement de la bouteille.
D
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.
Avant de souder, retirer toute substance combustible de vos poches telles
qu’un allumeur au butane ou des allumettes.
2-3. Dangers existant en relation avec le moteur
LES ACCUMULATIONS DE GAZ ris-
quent de provoquer des blessures ou
même la mort.
L’ACIDE DE LA BATTERIE peut pro-
voquer des brûlures dans les YEUX et
sur la PEAU.
D
Fermer l’alimentation du gaz protecteur en cas de
non utilisation.
D
D
D
Ne pas renverser la batterie.
Remplacer une batterie endommagée.
Rincer immédiatement les yeux et la peau à l’eau.
D
Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi-
rateur d’adduction d’air homologué.
OM-498 Page 6
Revenez à la table des matières
Download from Www.Somanuals.com. All Manuals Search And Download.
D
D
D
D
D
Pour empêcher tout démarrage accidentel pendant les travaux d’entretien,
débrancher le câble négatif (−) de batterie de la borne.
L’EXPLOSION DE LA BATTERIE peut
RENDRE AVEUGLE.
Ne pas approcher les mains, cheveux, vêtements lâches et outils des orga-
nes mobiles.
D
Toujours porter une protection faciale, des gants en
caoutchouc et vêtements de protection lors d’une in-
tervention sur la batterie.
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.
D
D
D
Arrêter le moteur avant de débrancher ou de brancher les câbles de
batterie.
Bloquer le volant moteur pour éviter sa rotation lors d’une intervention sur le
générateur.
Eviter de provoquer des étincelles avec les outils en travaillant sur la
batterie.
LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT CHAUD peuvent
provoquer des brûlures.
Ne pas utiliser le poste de soudage pour charger les batteries ou des véhi-
cules de démarrage rapide.
D
D
Observer la polarité correcte (+ et −) sur les batteries.
Débrancher le câble négatif (–) en premier lieu. Le rebrancher en dernier
lieu.
D
Il est préférable de vérifier le liquide de
refroidissement une fois le moteur refroidi pour éviter
de se brûler.
LE CARBURANT MOTEUR peut pro-
voquer un incendie ou une explosion.
D
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).
D
D
Arrêter le moteur avant de vérifier le niveau de carbu-
rant ou de faire le plein.
D
D
D
Si le moteur est chaud et que le liquide doit être vérifié, opérer comme sui-
vant :
Ne pas faire le plein en fumant ou proche d’une sour-
ce d’étincelles ou d’une flamme nue.
Mettre des lunettes de sécurité et des gants, placer un torchon sur le bou-
chon du radiateur.
D
Ne pas faire le plein de carburant à ras bord; prévoir de l’espace pour son
expansion.
Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant
d’enlever le bouchon.
D
D
Faire attention de ne pas renverser de carburant. Nettoyer tout carbu-
rant renversé avant de faire démarrer le moteur.
LA CHALEUR DU MOTEUR peut pro-
voquer un incendie.
Jeter les chiffons dans un récipient ignifuge.
D
Ne pas placer l’appareil sur, au-dessus ou à proximité
de surfaces inflammables.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D
Tenir
à
distance les produits inflammables de
l’échappement.
D
Ne pas approcher les mains des ventilateurs, cour-
roies et autres pièces en mouvement.
LES ÉTINCELLES À L’ÉCHAPPEMENT
peuvent provoquer un incendie.
D
Maintenir fermés et fixement en place les portes,
panneaux, recouvrements et dispositifs de
protection.
D
D
Empêcher les étincelles d’échappement du moteur
de provoquer un incendie.
D
Arrêter le moteur avant d’installer ou brancher l’appareil.
D
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’en-
tretien et de dépannage.
Utiliser uniquement un pare-étincelles approuvé −
voir codes en vigueur.
2-4. Dangers liés à l’air comprimé
Le METAL CHAUD lors du coupage et
gougeage plasma peut provoquer un in-
cendie ou une explosion.
RESPIRER L’AIR COMPRIMÉ peut pro-
voquer des blessures graves ou causer
la mort.
D
Ne pas utiliser l’air comprimé pour respirer.
D
Ne pas couper ou gouger à proximité de produits
inflammables.
D
Utiliser l’air comprimé seulement pour le coupa-
ge, gougeage et les outils pneumatiques.
D
Surveillez et garder un extincteur à proximité.
L’AIR COMPRIMÉ peut provoquer
des blessures.
DES PIECES CHAUDES peuvent provo-
quer des brûlures et blessures.
D
Porter des lunettes de sécurité approuvées.
D
D
Ne pas toucher le compresseur ou d’autres élé-
ments du circuit air comprimé chauds.
D
Ne pas diriger le jet d’air vers d’autres ou soi−
même.
Laisser l’ensemble se refroidir avant de toucher
ou d’effectuer la maintenance.
L’AIR COMPRIME EMMAGASINE ET DES
TUYAUX SOUS PRESSION peuvent provo-
quer des blessures.
LIRE LES INSTRUCTIONS.
D
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.
D
D
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
D
Utiliser un équipement de levage de capacité suffisante pour lever
l’appareil.
LA CHUTE DE L’APPAREIL peut
blesser.
D
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.
D
Utiliser l’anneau de levage uniquement pour soulever
l’appareil lui-même ; sans chariot, de bouteilles de
gaz, remorque, ou autres accessoires.
OM-498 Page 7
Download from Www.Somanuals.com. All Manuals Search And Download.
LE SURCHAUFFEMENT peut endom-
mager le moteur électrique.
LIRE LES INSTRUCTIONS.
D
D
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).
D
Arrêter ou déconnecter l’équipement avant de dé-
marrer ou d’arrêter le moteur.
D
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.
LE RAYONNEMENT HAUTE FRÉ-
QUENCE (H.F.) risque de provoquer
des interférences.
D
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 ris-
quent de provoquer des blessures.
D
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.
D
Porter un écran facial pour protéger le visage et les
yeux.
D
D
Demander seulement à des personnes qualifiées familiarisées avec des
équipements électroniques de faire fonctionner l’installation.
D
D
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.
L’utilisateur est tenu de faire corriger rapidement par un électricien quali-
fié les interférences résultant de l’installation.
D
D
D
Si le FCC signale des interférences, arrêter immédiatement l’appareil.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
Les étincelles risquent de causer un incendie − éloigner toute substance
inflammable.
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.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
D
D
D
Laisser l’équipement refroidir ; respecter le facteur de
marche nominal.
Réduire le courant ou le facteur de marche avant de
poursuivre le soudage.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
Ne pas obstruer les passages d’air du poste.
D
L’énergie électromagnétique risque de provoquer
des interférences pour l’équipement électronique
sensible tel que les ordinateurs et l’équipement com-
mandé par ordinateur tel que les robots.
LES CHARGES ÉLECTROSTATI-
QUES peuvent endommager les
circuits imprimés.
D
D
Veiller à ce que tout l’équipement de la zone de soudage soit compatible
électromagnétiquement.
D
Établir la connexion avec la barrette de terre avant de
manipuler des cartes ou des pièces.
Pour réduire la possibilité d’interférence, maintenir les câbles de souda-
ge aussi courts que possible, les grouper, et les poser aussi bas que pos-
sible (ex. par terre).
D
Utiliser des pochettes et des boîtes antistatiques
pour stocker, déplacer ou expédier des cartes de
circuits imprimes.
D
D
D
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.
UNE REMORQUE QUI BASCULE peut
entraîner des blessures.
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 fil-
tres de ligne ou la pose de protecteurs dans la zone de travail.
D
Utiliser les supports de la remorque ou des blocs
pour soutenir le poids.
D
Installer convenablement le poste sur la remorque
comme indiqué dans le manuel s’y rapportant.
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 (télé-
phone : (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 (télé-
phone : (305) 443−9353, site Web : www.aws.org).
Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) 463−6727 ou à To-
ronto : (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)
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).
National Electrical Code, norme NFPA 70, de la National Fire Protection As-
sociation, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101
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 Cana-
dian Standards Association, Standards Sales, 178 boulevard Rexdale,
2-7. Information sur les champs électromagnétiques
Données sur le soudage électrique et les effets des champs magnétiques
basse fréquence sur l’organisme
Afin de réduire les champs électromagnétiques en milieu de travail, respec-
ter les consignes suivantes :
En parcourant les câbles de soudage, le courant crée des champs électro-
magnétiques. Les effets potentiels de tels champs restent préoccupants.
Cependant, après avoir examiné plus de 500 études qui ont été faites pen-
dant 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 électri-
ques 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’ex-
position aux champs électromagnétiques pendant le soudage ou le
coupage.
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 recom-
mandé de respecter les consignes ci-dessus.
OM-498 Page 8
Revenez à la table des matières
Download from Www.Somanuals.com. All Manuals Search And Download.
SECTION 3 − DEFINITIONS
3-1. Symbol Definitions
Read Operator’s
Amperes
Engine Choke
Volts
Manual
Fuel
A
V
Engine Oil
Positive
Battery (Engine)
Engine
Output
Alternating Current
(AC)
Negative
Protective Earth
(Ground)
Hours
Seconds
Time
s
h
Circuit Breaker
Temperature
SECTION 4 − SPECIFICATIONS
This unit uses either a Kohler or a Honda engine. Differences between models are
noted throughout this manual.
NOTE
4-1. Weld, Power, And Engine Specifications
Weld
Output
Range
Maximum
Open Circuit
Voltage
Welding
Mode
Rated
Welding Output
Generator
Power Rating
Fuel
Capacity
Engine
Kohler CS8.5TG
Air-Cooled,
One-Cylinder,
Four-Cycle,
8.5 HP (300 CC),
Gasoline Engine
OR
Honda GX270
Air-Cooled,
One-Cylinder,
Four-Cycle,
140 A, 25 V,
30% Duty Cycle
Kohler:
1.8 gal (6.9 L)
Tank
Single-Phase,
3.5 kVA/kW
30/15 A,
120/240 V AC,
60 Hz
100 A, 25 V,
60% Duty Cycle
CC/DC
40 − 140 A
70
Honda:
1.6 gal (6 L)
Tank
80 A, 25 V
100% Duty Cycle
9 HP (270 CC),
Gasoline Engine
Download from Www.Somanuals.com. All Manuals Search And Download.
OM-498 Page 9
4-2. Dimensions, Weights, And Operating Angles
Dimensions
Height
20-3/4 in (527 mm)
22-3/4 in (577 mm)
31-1/4 in (793 mm)
31-1/4 in (793 mm)
10-1/2 in (268 mm)
13-45/64in (348 mm)
22-3/4 in (577 mm)
1-3/4 in (44 mm)
D
Width
Depth
Y
Y
Do not exceed tilt angles or engine could
be damaged or unit could tip.
B
A
B
C
D
E
F
Do not move or operate unit where it
could tip.
A
C
19-1/2 in (495 mm)
13/32 in (10 mm) Dia.
G
15°
15°
15°
Weight (Kohler-Powered Units)
222 lb (101 kg)
G
4
15°
Holes
Weight (Honda-Powered Units)
Electric-Start Model: 226 lb (103 kg)
Recoil-Start Model: 201 lb (91 kg)
F
E
Engine End
802 096
802 512-A
4-3. Fuel Consumption (Kohler-Powered Units)
.
F
u
e
l
c
o
n
s
u
m
p
t
i
o
n
a
t
l
o
w
i
d
l
e
(2000 rpm): 0.17 U.S. gal/hr.
AUX POWER
WELD
HIGH IDLE
198 573
OM-498 Page 10
Download from Www.Somanuals.com. All Manuals Search And Download.
4-4. Fuel Consumption (Honda-Powered Units)
802 121
4-5. Duty Cycle
Duty cycle is the percentage of 10
minutes that unit can weld at rated
load without overheating.
Y
Exceeding duty cycle can
damage unit and void
warranty.
ContinuousWelding
100% Duty Cycle at 80 Amperes CC/DC
3 Minutes Welding
7 Minutes Resting
30% Duty Cycle at 140 Amperes CC/DC
802 092
Download from Www.Somanuals.com. All Manuals Search And Download.
OM-498 Page 11
4-6. Generator Power Curve
generator power curves
generator power available
es at the receptacles.
802 129
4-7. Volt-Ampere Curves
The volt-ampere curve shows the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
other settings fall between the
curves shown.
80
70
60
50
40
MAX
30
MID
MIN
20
10
0
0
25
50
75
100
LOAD AMPS
125
150
175
200
198 453
Download from Www.Somanuals.com. All Manuals Search And Download.
OM-498 Page 12
SECTION 5 − INSTALLATION
5-1. Installing Welding Generator
Movement
Airflow Clearance
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
Location
OR
install1 5/02 − 802 512-A / Ref. 151 556 / 158 936-A / 800 652-A / S-0854
5-2. Grounding Generator To Truck Or Trailer Frame
Y
Always ground generator
frame to vehicle frame to pre-
vent electric shock and static
electricity hazards.
1
2
Metal Vehicle Frame
Equipment Grounding
Terminal
3
Grounding Cable
2
Use #10 AWG or larger insulated
copper wire.
3
GND/PE
Y
If unit does not have GFCI
receptacles, use GFCI-
protected extension cord.
Electrically bond generator frame
to vehicle frame by metal-to-metal
contact.
1
install1 5/02* − Ref. 151 556 / S-0854
OM-498 Page 13
Download from Www.Somanuals.com. All Manuals Search And Download.
5-3. Grounding Generator When Supplying Building Systems
1
2
EquipmentGrounding
Terminal
1
2
GND/PE
Grounding Cable
Use #10 AWG or larger insulated
copper wire.
3
Ground Device
Y
Ground generator to sys-
tem earth ground if supply-
ing power to a premises
(home, shop, farm) wiring
system.
Use ground device as
stated in electrical codes.
2
3
800 576-B
5-4. Engine Prestart Checks (Kohler-Powered Units)
.
F
o
l
l
o
w
r
u
n
-
i
n
p
r
o
c
e
d
u
r
e
i
n
e
n
-
gine manual.
Check all fluids daily. Engine must be
cold and on a level surface. Unit is
shipped with 10W30 engine oil.
1/2 in
(13 mm)
Full
Engine stops if oil level gets too low.
. This unit has a low oil level shut-
down switch. However, some
conditions may cause engine
damagebefore the engine shuts
down. Check oil level often and
do not use the oil level shutdown
system to monitor oil level.
Gasoline
1
Fuel Valve
Open valve by turning lever to verti-
cal position.
. Close fuel valve before moving
unit or carburetor may flood and
make starting difficult.
1
Fuel
Add fresh fuel before starting engine
the first time (see maintenance label
for specifications). Fill fuel tank up to
1/2 in. (13 mm) from top to allow room
for expansion. Check fuel level on a
cold engine before use each day.
Closed
Closed
Oil
After fueling, check oil with unit on
level surface. If oil is not up to full
mark on dipstick, add oil (see mainte-
nance label).
Open
.
T
o
i
m
p
r
o
v
e
c
o
l
d
w
e
a
t
h
e
r
Full
starting:
Keep battery in good condition.
Store battery in warm area off
concrete surface.
Use correct grade oil for cold
weather.
Ref. 802 512-A
OM-498 Page 14
Download from Www.Somanuals.com. All Manuals Search And Download.
5-5. Engine Prestart Checks (Honda-Powered Units)
Check all fluids daily. Engine must
be cold and on a level surface. Unit
is shipped with 10W30 engine oil.
Engine stops if oil level gets too low.
1/2 in
(13 mm)
1
Fuel Valve
Full
Open valve.
. Close fuel valve before moving
unit or carburetor may flood
and make starting difficult.
Gasoline
Fuel
Add fresh fuel before starting
engine the first time (see mainte-
nance label for specifications). Fill
fuel tank up to 1/2 in. (13 mm) from
top to allow room for expansion.
Check fuel level on a cold engine
before use each day.
Oil
After fueling, check oil with unit on
level surface. If oil is not up to full
mark on dipstick, add oil (see main-
tenance label).
.
T
o
i
m
p
r
o
v
e
c
o
l
d
w
e
a
t
h
e
r
starting:
1
Keep battery in good condition.
Store battery in warm area off
concrete surface.
Open
Use correct grade oil for cold
weather.
Full
Ref. 802 099-A
5-6. Connecting The Battery (Honda Electric-Start Models Only)
Y
Turn Engine Switch to Off
(electric-startmodels only).
Y
Connect negative (−)
cable last.
−
+
Tools Needed:
3/8, 1/2 in
802 100-A / Ref. S-0756-D
OM-498 Page 15
Download from Www.Somanuals.com. All Manuals Search And Download.
5-7. Connecting To Weld Output Terminals
1
2
Positive (+) Weld Output
Terminal
Negative (−) Weld Output
Terminal
For Direct Current Electrode Posi-
tive (DCEP), connect work cable to
Negative (−) terminal and electrode
holder to Positive (+) terminal.
For Direct Current Electrode nega-
tive (DCEN), reverse cable con-
nections.
1
2
Tools Needed:
3/4 in
196 921 / 495 179
5-8. Selecting Weld Cable Sizes*
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
150 ft
(45 m)
200 ft
250 ft
300 ft
350 ft
400 ft
100 ft (30 m) or Less
(60 m) (70 m) (90 m) (105 m) (120 m)
Weld Output
Terminals
Y
Y
Stop engine before
connectingto weld out-
put terminals.
10 − 60% 60 − 100%
Welding
Amperes
Duty
Duty
10 − 100% Duty Cycle
Cycle
Cycle
Do not use worn, dam-
aged, undersized, or
poorly spliced cables.
100
150
200
4 (20)
3 (30)
3 (30)
4 (20)
3 (30)
2 (35)
4 (20)
2 (35)
1 (50)
3 (30)
1 (50)
2 (35)
1/0 (60)
2/0 (70)
1 (50)
1/0 (60)
3/0 (95)
1/0 (60)
3/0 (95)
2/0 (70)
1/0 (60)
3/0 (95) 4/0 (120) 4/0 (120)
2 ea. 2/0 2 ea. 2/0
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95) 4/0 (120)
(2x70)
(2x70)
* This chart is a general guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), use next size larger
cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm for metric use
2
S-0007-E
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.
OM-498 Page 16
Download from Www.Somanuals.com. All Manuals Search And Download.
SECTION 6 − OPERATING THE WELDING GENERATOR
6-1. Controls (Kohler-Powered Units)
5
2
3
60 Hz
6
4
1
802 512-A / 495 179
Use lever to change engine air/fuel mix. Move
lever to right if starting a cold engine. Move le-
ver to left if starting a warm engine.
6
Current Control
. Weld and generator power output stops if
generator overheats or engine speed is
too low.
Use control to select weld amperage. Control
may be adjusted while welding.
4
Starter Handle
1
Engine Switch
To Set Current Control: Use label to deter-
mine correct size electrode for material thick-
ness. Select electrode type and set current
control to corresponding amperage range.
Adjust control to obtain desired weld
performance.
turn engine switch to On, move throttle lever
to Idle, set choke, and pull starter handle.
Open choke as engine warms.
Use switch to open ignition circuit, and to stop
engine.
2
Throttle Control Lever
To Stop: turn engine switch to Off.
Use lever to select engine speed. Move lever
to idle position (far left) for idle speed. Move le-
ver to Run position (far right) for weld/power
speed.
.
A
l
w
a
y
s
c
l
o
s
e
f
u
e
l
v
a
l
v
e
a
f
t
e
r
s
t
o
p
p
i
n
g
EXAMPLE:
unit. Moving unit with fuel valve open may
cause carburetor flooding and make
starting difficult.
Material Thickness: 1/8 to 1/4 in
Electrode Diameter: 1/8
Electrode Type: E-6013
Current Control Setting: 90 − 120 A
. Always place lever in Run position (far
right) for generator power and for maxi-
mum weld output.
5
Welding Range Label
Use label to determine correct weld amper-
age based on electrode size, type, and mate-
rial thickness.
3
Choke Control Lever
OM-498 Page 17
Download from Www.Somanuals.com. All Manuals Search And Download.
lever to left if starting a cold engine. Move le-
ver to right if starting a warm engine.
5
Welding Range Label
. Weld and generator power output stops if
generator overheats or engine speed is
too low.
Use label to determine correct weld amper-
age based on electrode size, type, and mate-
rial thickness.
4
Starter Handle (Recoil-Start Models
Only)
1
Engine Switch
To Start (Recoil): open fuel valve, turn engine
switch to On, move throttle lever to Idle, set
choke, and pull starter handle. Open choke as
engine warms.
6
Current Control
On models with recoil-start, use switch to
open ignition circuit, and to stop engine.
Use control to select weld amperage. Control
may be adjusted while welding.
On models with electric-start, use switch to
open ignition circuit, and to start and stop en-
gine.
To Set Current Control: Use label to deter-
mine correct size electrode for material thick-
ness. Select electrode type and set current
control to corresponding amperage range on
nameplate. Adjust control within selected
range to obtain desired weld performance.
To Start (Electric): open fuel valve, move
throttle lever to Idle, set choke, and turn en-
gine switch to Start position. Open choke as
engine warms.
2
Throttle Control Lever
Use lever to select engine speed. Move lever
to idle position (far right) for idle speed. Move
lever to Run position (far left) for weld/power
speed.
Y
If the engine does not start, let engine
come to a complete stop before at-
tempting restart.
EXAMPLE:
To Stop: turn engine switch to Off.
. Always place lever in Run position (far
left) for generator power and for maxi-
mum weld output.
Material Thickness: 1/8 to 1/4 in
Electrode Diameter: 1/8
Electrode Type: E-6013
Current Control Setting: 90 − 120 A
. Always close fuel valve after stopping
unit. Moving unit with fuel valve open may
cause carburetor flooding and make
starting difficult.
3
Choke Control Lever
Use lever to change engine air/fuel mix. Move
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-498 Page 19
Download from Www.Somanuals.com. All Manuals Search And Download.
SECTION 7 − OPERATING AUXILIARY EQUIPMENT
The welding generator provides power while welding and with the Current control
NOTE
in any position. However, under these conditions equipment connected to the
welding generator may be subject to larger than normal voltage fluctuations. It is
recommended that only lamps be powered under these conditions.
7-1. Generator Power Panel 495 218 (USA)
4
1
2
3
5
495 218
Y
Y
If unit does not have GFCI recep-
tacles, use GFCI-protected exten-
sion cord.
RC1 supplies 60 Hz single-phase power at
weld/powerspeed. Maximum output is 3.5
kVA/kW.
5
Circuit Breakers CB2 And CB3
CB2 protects RC2 and CB3 protects RC3
from overload. If a circuit breaker opens,
the receptacle does not work.
2
120 V 20 A AC Duplex Receptacle
RC2
Power is still present at the 240 volt
receptacle when only one circuit
breaker trips.
3
120 V 20 A AC Duplex Receptacle
RC3
. Press button to reset circuit breaker. If
breaker continues to open, contact
Factory Authorized Service Agent.
Unplug power cord before attempt-
ing to service accessories or tools.
RC2 and RC3 supply 60 Hz single-phase
power at weld/power speed. Maximum
output from RC2 or RC3 is 2.4 kVA/kW.
Combinedoutput of all receptacles limited
to 3.5 kVA/kW rating of the generator (See
lines).
.
G
e
n
e
r
a
t
o
r
p
o
w
e
r
d
e
c
r
e
a
s
e
s
a
s
w
e
l
d
current increases.
.
E
a
c
h
r
e
c
e
p
t
a
c
l
e
o
f
t
h
e
d
u
p
l
e
x
c
a
n
p
r
o
-
vide 15A/1800W.
Set Amperage control at max. for full
generatorpower.
.
D
o
n
o
t
p
a
r
a
l
l
e
l
t
h
e
t
w
o
1
2
0
V
d
u
p
l
e
x
EXAMPLE:If 10 A is drawn from each 120
volt duplex receptacle, only 9 A is available
from the 120 V twistlock receptacle.
receptacles.
.
P
l
a
c
e
t
h
r
o
t
t
l
e
l
e
v
e
r
i
n
R
u
n
p
o
s
i
t
i
o
n
(
f
a
r
4
Circuit Breaker CB1
right) for generator power.
CB1 protects RC1 from overload. If CB1
opens, RC1 does not work.
2 x (120 V x 10 A) + (240 V x 9 A) = 3.5 kVA/
KW.
1
120 V AC Twistlock Receptacle RC1
OM-498 Page 20
Download from Www.Somanuals.com. All Manuals Search And Download.
7-2. Optional Generator Power Panels
Generator Power Panel 495 315
(USA)
Generator Power Panel 495 298
(USA)
Generator Power Panel 495 279
(Canada)
Generator Power Panel 495 253 Generator Power Panel 495 288
(South Africa)
(South America)
Generator Power Panel 495 289
(Australia)
Generator Power Panel 495 290
(Europe)
Generator Power Panel 495 283
(S.E. Asia)
Ref. ST-802 124 / H-495 290 / H-495 283
Y
Y
If unit does not have GFCI recep-
tacles, use GFCI-protected exten-
sion cord.
Circuit breakers protect the generator from
overload.
.
G
e
n
e
r
a
t
o
r
p
o
w
e
r
d
e
c
r
e
a
s
e
s
a
s
w
e
l
d
current increases.
. Press button to reset circuit breaker. If
breaker continues to open, contact
Factory Authorized Service Agent.
Power may still be present at a re-
ceptacle when a circuit breaker
trips.
Set Amperage control at max. for full
generatorpower.
.
P
l
a
c
e
t
h
r
o
t
t
l
e
l
e
v
e
r
i
n
R
u
n
p
o
s
i
t
i
o
n
(
f
a
r
Unplug power cord before attempt-
ing to service accessories or tools.
right) for generator power.
OM-498 Page 21
Download from Www.Somanuals.com. All Manuals Search And Download.
7-3. Generator Power Panel Ratings
Unless otherwise stated, the rating of duplex outlets is the combined load of all
receptacles.
NOTE
Total power from generator NOT to exceed 3500 Watts (60 Hz)
Panel
495 279
(Canada-
CSA)
Panel
495 288
(South
Panel
495 218
(USA)
Panel
495 315
(USA)
Panel
495 298
(USA)
Panel
495 253
(S. Africa)
Panel
495 289
(Australia)
Panel
495 290
(Europe)
Panel
495 283
(S.E. Asia)
Protected
Receptacle
By
America)
60 Hz
60 Hz
60 Hz
60 Hz
60 Hz
60 Hz
60 Hz
60 Hz
60 Hz
240 V
Twist Lock
30A/
3600W
CB1,2
CB1,2
15A/
3500W
See
240 V
Duplex
15A/
3500W
Note 2
240 V
Duplex
15A/
3500W
CB3,4
CB1
230 V
Single
15A/
3500W
15A/
3500W
15A/
3500W
230 V
Single
15A/
3500W
15A/
3500W
15A/
3500W
CB2
230 V
Single
15A/
3500W
CB1,2
CB3,4
CB1
230 V
Single
15A/
3500W
120 V
Twist Lock
30A/
3500W
30A/
3500W
120 V
Duplex
CB1,2
CB1,3
30A/
3500W
120 V
Duplex
20A/
2400W
CB2
20A/
2400W
See
120 V
Duplex
20A/
2400W
20A/
2400W
CB3
Note 3
20A/
2400W
See
120 V
Duplex
20A/
2400W
CB4
Note 3
Total
Power NOT
to exceed
3500W
3500W
3500W
3500W
3500W
3500W
3500W
3500W
3500W
Notes: 1. Each receptacle of the duplex can provide 15A/1800W. Do not parallel the two 120V duplex receptacles.
2. Do not parallel the two 120V circuits.
3. Do not parallel the two duplex outlets.
Calculating total power provided by generator.
(See Section 11 − Generator Power Guidelines)
For example, for the 495 218 Generator Power Panel,
120V, 1500W heater
120V, 10A chain saw
120V, 500W halogen lamp
Total
1500W
1200W
500W
Each receptacle can provide the watts or amps as shown
above. However, the total power can not exceed 3500W.
3200W
This loading is OK.
The rating plate on electrical apparatus will contain the watts
consumed or the rated input amps. Watts may be calculated by
multiplying the rated voltage by the rated input amps.
120V, 1500W heater
120V, 10A chain saw
120V, 5A router
1500W
1200W
600W
watts = volts x amps
120V, 500W halogen lamp
Total
500W
3800W
This loading is not OK.
It exceeds 3500W.
OM-498 Page 22
Download from Www.Somanuals.com. All Manuals Search And Download.
7-4. Wiring Instructions For Optional 120/240 Volt Twistlock Plug (NEMA L14-30P)
1
Plug Wired For 120/240 V,
3-Wire Load
When wired for 120 V loads, each du-
plex receptacle shares a load with
one half of the 240 V receptacle.
2
1
3
2
3
4
5
6
Neutral (Silver) Terminal
Load 1 (Brass) Terminal
Load 2 (Brass) Terminal
Ground (Green) Terminal
Cord Grip
4
120V
Strip cord jacket back enough to sep-
arate conductors.
240 V
6
Strip conductors enough to make
good contact with plug terminals.
Make plug connections and reinstall
outer shell and cord grip.
5
120 V
Tighten assembly screws onto shell.
Do not overtighten.
Tools Needed:
plug3-11/99 − 802 527
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
Download from Www.Somanuals.com. All Manuals Search And Download.
OM-498 Page 23
SECTION 8 − MAINTENANCE
8-1. Routine Maintenance
Y
Stop engine before maintaining.
.
S
e
e
E
n
g
i
n
e
M
a
n
u
a
l
a
n
d
M
a
i
n
t
e
n
a
n
c
e
L
a
b
e
l
.
Recycle
engine
fluids.
Service more often if used in severe conditions.
*
To be done by Factory Authorized Service Agent.
8 h
20 h
Check fluid
levels. See
Section 5-4
Check and clean
spark arrestor screen.
See engine manual.
Wipe up spills.
50 h
Service air cleaner
element. See engine
manual.
Clean and
tighten weld
terminals.
100 h
Check
spark
plugs.
Change oil. See
engine manual and
maintenancelabel.
Clean and tighten battery
connections (Electric
-Start models only).
Clean Fuel
sediment cup.
200 h
Clean fuel
tank and
strainer.
Replace
unreadable
labels.
300 h
Check valve
clearance.*
500 h
Service welding generator
brushes and slip rings. Service
more often in dirty conditions.*
Repair or
replace cracked
cables.
1000 h
Blow out or
vacuum inside.
During heavy
service, clean
monthly.
OR
OM-498 Page 24
Download from Www.Somanuals.com. All Manuals Search And Download.
Follow the storage procedure in the engine owner’s manual if the unit will not be
used for an extended period.
NOTE
8-2. Maintenance Label
°C
+40
°F
+104
ENGINE MAINTENANCE
100 h
+30
+20
+10
0
+86
+59
+32
-10
8 h
-10
-15
-20
SG-SF/CC-CD
1.1 l (1.2 US qt,
1.94 lmp qt)
Unleaded
86 + Octane
6.5 l (1.7 US Gal,
11.4 lmp pt)
50 h
0.7 − 0.8 mm
(0.028 − 0.031 in)
200 h
Ref. S-175 679-A
8-3. Overload Protection (Honda-Powered Units Only)
1
Ignition Circuit Breaker
(Electric-Start Models Only)
The circuit breaker protects the en-
gine battery charging circuit. A
short circuit or a battery connected
in reverse polarity will trip the circuit
breaker.
Press button to reset breaker.
.
I
f
a
s
w
i
t
c
h
o
r
b
r
e
a
k
e
r
o
p
e
n
s
,
i
t
usually indicates a more seri-
ous problem exists. Contact a
Factory Authorized Service
Agent.
1
Ref. 802 099-A
OM-498 Page 25
Download from Www.Somanuals.com. All Manuals Search And Download.
8-4. Adjusting Engine Speed (Kohler-Powered Units)
After tuning engine, check engine
speeds. See table for proper no
load speeds. If necessary, adjust
speeds as follows:
2000 150 rpm
Start engine and run until warm.
Weld/Power Speed
Adjustment
3720 50 rpm (60 Hz)
1
2
Throttle Control Lever
Adjustment Screw
Move lever to Run (far right) posi-
tion. To increase speed, turn screw
out (counterclockwise) while lightly
pushing lever to the right. To de-
crease speed, turn screw in (clock-
wise).
Idle Speed Adjustment
3
Adjustment Screw
Move lever to idle (far left) position.
To increase idle speed, turn screw
in (clockwise). To decrease idle
speed, turn screw out (counter-
clockwise).
Y
Stop engine. Close fuel
valve.
Top View
Top View
3
2
1
Tools Needed:
802 512-A / Kohler Dwg.
OM-498 Page 26
Download from Www.Somanuals.com. All Manuals Search And Download.
8-5. Adjusting Engine Speed (Honda-Powered Units)
After tuning engine, check engine
speeds. See table for proper no
load speeds. If necessary, adjust
speeds as follows:
1400 150 rpm
Start engine and run until warm.
Weld/Power Speed
Adjustment
3720 50 rpm (60 Hz)
1
2
Throttle Control Lever
Adjustment Screw
Move lever to Run (far left) position.
Turn screw and move lever until en-
gine runs at weld/power speed.
Idle Speed Adjustment
3
4
Pilot Screw
Throttle Stop Screw
Move lever to idle (far right) posi-
tion. Turn pilot screw until engine
runs at highest idle speed. Turn
stop screw until engine runs at
rated idle speed (normally about
2-1/4 turns out.)
2
Y
Stop engine. Close fuel
valve.
1
4
3
Tools Needed:
1/4, 3/8 in
802 101-A
Download from Www.Somanuals.com. All Manuals Search And Download.
OM-498 Page 27
SECTION 9 − TROUBLESHOOTING
9-1. Troubleshooting
A. Welding
Trouble
Remedy
No weld output.
Check Amperage control setting.
Check weld connections.
Be sure all equipment is disconnected from receptacles when starting unit.
Have Factory Authorized Service Agent check brushes, slip rings, rotor, stator, reactor L2, output
rectifier CR3, stabilizer L3, integrated rectifiers CR1 and CR2, and amperage control R1.
Low weld output.
Check Amperage control and throttle lever settings.
Service air cleaner according to engine manual.
Check weld cable size and length.
Have Factory Authorized Service Agent check brushes, slip rings, capacitor C1, reactor L2, and recti-
fier CR2.
High weld output.
Check Amperage control setting.
Check Amperage control setting.
Erratic weld output.
Tighten and clean connections to electrode and workpiece.
Use dry, properly-stored electrodes for Stick welding.
Remove excessive coils from weld cables.
Clean and tighten connections both inside and outside welding generator.
Check throttle/governor linkage for smooth, non-binding operation.
B. Generator Power
Trouble
Remedy
No output at generator power ac
receptacles.
Check receptacle wiring and connections.
Check engine speed, and adjust if necessary (see Section 8-4 or 8-5). Output stops if engine speed is
too low.
Have Factory Authorized Service Agent check stator windings.
High output at generator power ac
receptacles.
Low output at generator power ac Check Amperage control setting.
receptacles.
Check engine speed, and adjust if necessary (see Section 8-4 or 8-5). Output stops if engine speed is
too low.
OM-498 Page 28
Download from Www.Somanuals.com. All Manuals Search And Download.
Trouble
Remedy
Erratic output at generator power ac
receptacles.
Check fuel level.
Check receptacle wiring and connections.
Check throttle/governor linkage for smooth, non-binding operation.
Service air cleaner according to engine manual.
Check engine speed, and adjust if necessary (see Section 8-4 or 8-5). Output stops if engine speed is
too low.
C. Engine
Trouble
Remedy
Engine will not crank (Honda electric-
start models only).
Check battery voltage.
Check battery connections and tighten if necessary.
Have Factory Authorized Service Agent check engine ignition circuit.
Engine will not start.
Open fuel valve (see Section 5-4 or 5-5). Close fuel valve before moving unit or carburetor may flood and
make starting difficult.
Check battery voltage (Honda electric-start models only).
Check battery connections and tighten if necessary (Honda electric-start models only).
Check oil level (see Section 5-4 or 5-5). Engine stops if oil level is too low. Refill crankcase with proper
viscosity oil for operating temperature.
Have Factory Authorized Service Agent check low oil level shutdown switch.
Engine stopped during normal
operation.
Open fuel valve (see Section 5-4 or 5-5). Close fuel valve before moving unit or carburetor may flood and
make starting difficult.
Battery discharges between uses (elec- Clean battery, terminals, and posts with baking soda and water solution; rinse with clear water.
tric-start models only).
Periodically recharge battery (approximately every 3 months).
Replace battery.
Check voltage regulator and connections according to engine manual.
Unstable or sluggish engine speeds.
Check throttle/governor linkage for smooth, non-binding operation.
Tune-up engine according to engine manual.
OM-498 Page 29
Download from Www.Somanuals.com. All Manuals Search And Download.
201 026-A
Figure 10-2. Wiring Diagram For Generator Power Panels (1 Of 2)
OM-498 Page 31
Download from Www.Somanuals.com. All Manuals Search And Download.
201 026-A
Figure 10-3. Wiring Diagram For Generator Power Panels (2 Of 2)
OM-498 Page 32
Download from Www.Somanuals.com. All Manuals Search And Download.
SECTION 11 − GENERATOR POWER GUIDELINES
The views in this section are intended to be representative of all engine-driven
welding generators. Your unit may differ from those shown.
NOTE
11-1. Selecting Equipment
1
Generator Power Receptacles
− Neutral Bonded To Frame
2
3-Prong Plug From Case
Grounded Equipment
3
2-Prong Plug From Double
Insulated Equipment
Y
Do not use 2-prong plug un-
less equipment is double in-
sulated.
1
2
3
Be sure equipment
has this symbol
and/or wording.
OR
gen_pwr 11/02 − Ref. ST-159 730 / ST-800 577
11-2. Grounding Generator To Truck Or Trailer Frame
Y
Always ground generator
frame to vehicle frame to pre-
vent electric shock and static
electricity hazards.
1
2
3
Equipment Grounding
Terminal (On Front Panel)
Grounding Cable (Not
Supplied)
1
Metal Vehicle Frame
Connect cable from equipment
ground terminal to metal vehicle
frame. Use #10 AWG or larger
insulated copper wire.
2
GND/PE
Y
If unit does not have GFCI re-
ceptacles, use GFCI-pro-
tected extension cord.
3
Electrically bond generator
frame to vehicle frame by
metal-to-metalcontact.
Y
Bed liners, shipping skids, and some running
gear insulate the welding generator from the ve-
hicle frame. Always connect a ground wire from
the generator equipment grounding terminal to
bare metal on the vehicle frame as shown.
S-0854
OM-491 Page 33
Download from Www.Somanuals.com. All Manuals Search And Download.
11-3. Grounding When Supplying Building Systems
1
2
EquipmentGrounding
Terminal
1
2
Grounding Cable
GND/PE
Use #10 AWG or larger insulated
copper wire.
3
Ground Device
Y
Ground generator to system
earth ground if supplying
power to a premises (home,
shop, farm) wiring system.
Use ground device as stated
in electrical codes.
2
3
ST-800 576-B
11-4. How Much Power Does Equipment Require?
1
Resistive Load
3
A light bulb is a resistive load and
requires a constant amount of power.
VOLTS 115
AMPS 4.5
Hz 60
2
2
Non-Resistive Load
1
Equipment with a motor is a non-re-
sistive load and requires approxi-
mately six times more power while
starting the motor than when running
3
Rating Data
3
Rating shows volts and amperes, or
watts required to run equipment.
AMPERES x VOLTS = WATTS
EXAMPLE 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power
requirementin watts.
4.5 A x 115 V = 520 W
The load applied by the drill is 520 watts.
EXAMPLE 2: If three 200 watt flood lamps are used with the drill from Example 1,
add the individual loads to calculate total load.
(200 W + 200 W + 200 W) + 520 W = 1120 W
The total load applied by the three flood lamps and drill is 1120 watts.
S-0623
OM-491 Page 34
Download from Www.Somanuals.com. All Manuals Search And Download.
11-5. Approximate Power Requirements For Industrial Motors
Industrial Motors
Rating
Starting Watts
Running Watts
Split Phase
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
800
1225
1600
2100
3175
2020
3075
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
1000
1400
1850
2400
3500
300
500
600
700
875
Capacitor Start-Induction Run
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
400
1-1/2 HP
2 HP
3 HP
5 HP
Capacitor Start-Capacitor Run
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
Fan Duty
550
650
800
1100
11-6. Approximate Power Requirements For Farm/Home Equipment
Farm/HomeEquipment
Stock Tank De-Icer
Rating
Starting Watts
Running Watts
1000
1650
3400
4400
2900
10500
1720
2575
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
3300
3150
4500
6100
3100
2150
3100
2100
3200
1000
650
Grain Cleaner
1/4 HP
1/2 HP
3/4 HP
Portable Conveyor
Grain Elevator
1000
1400
1100
2800
720
Milk Cooler
Milker (Vacuum Pump)
FARM DUTY MOTORS
Std. (e.g. Conveyors,
Feed Augers, Air
Compressors)
2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
1000
950
1-1/2 HP
2 HP
3 HP
5 HP
High Torque (e.g. Barn
1-1/2 HP
5 HP
Cleaners, Silo Unloaders,
Silo Hoists, Bunk Feeders)
7-1/2 HP
10 HP
1/2 HP
500 PSI
550 PSI
700 PSI
3-1/2 cu. ft. Mixer
High Pressure 1.8 Gal/Min
Washer 2 gal/min
2 gal/min
1400
1600
800
Refrigerator or Freezer
Shallow Well Pump
1/3 HP
1/2 HP
1/3 HP
1/2 HP
750
1000
800
Sump Pump
1050
OM-491 Page 35
Download from Www.Somanuals.com. All Manuals Search And Download.
11-7. Approximate Power Requirements For Contractor Equipment
Contractor
Rating
Starting Watts
Running Watts
Hand Drill
1/4 in
3/8 in
350
400
350
400
1/2 in
600
600
Circular Saw
Table Saw
6-1/2 in
7-1/4 in
8-1/4 in
9 in
500
500
900
900
1400
4500
6300
2500
1720
3900
5200
3000
6000
8200
10500
1100
1100
350
1400
1500
1800
1100
720
10 in
Band Saw
14 in
Bench Grinder
6 in
8 in
1400
1600
1000
1500
2200
2800
1100
1100
350
10 in
Air Compressor
1/2 HP
1 HP
1-1/2 HP
2 HP
Electric Chain Saw
Electric Trimmer
Electric Cultivator
1-1/2 HP, 12 in
2 HP, 14 in
Standard 9 in
Heavy Duty 12 in
1/3 HP
500
500
2100
400
700
Elec. Hedge Trimmer
Flood Lights
18 in
400
HID
125
100
Metal Halide
Mercury
Sodium
Vapor
313
250
1000
1400
1250
600
1000
200
Submersible Pump
Centrifugal Pump
Floor Polisher
400 gph
900 gph
3/4 HP, 16 in
1 HP, 20 in
1/2 HP
900
500
4500
6100
3150
4500
6100
1900
900
1400
1600
950
High Pressure Washer
3/4 HP
1400
1600
700
1 HP
55 gal Drum Mixer
Wet & Dry Vac
1/4 HP
1.7 HP
900
2-1/2 HP
1300
1300
OM-491 Page 36
Download from Www.Somanuals.com. All Manuals Search And Download.
11-8. Power Required To Start Motor
1
2
3
4
Motor Start Code
Running Amperage
Motor HP
4
AC MOTOR
VOLTS 230 AMPS 2.5
Hz 60
PHASE 1
2
1
3
CODE
HP
M
Motor Voltage
1/4
To find starting amperage:
Step 1: Find code and use table to
find kVA/HP. If code is not listed,
multiplyrunning 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.
Single-Phase Induction Motor Starting Requirements
Motor Start
Code
G
H
J
K
L
M
N
P
KVA/HP
6.3
7.1
8.0
9.0
10.0
11.2
12.5
14.0
kVA/HP x HP x 1000
VOLTS
= STARTING AMPERAGE
EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4
HP motor with a motor start code of M.
Volts = 230 HP = 1/4 Using Table, Code M results in kVA/HP = 11.2
11.2 x 1/4 x 1000
= 12.2 A
Starting the motor requires 12.2 amperes.
230
S-0624
11-9. How Much Power Can Generator Supply?
1
Limit Load To 90% Of
Generator Output
Always start non-resistive (motor)
loads in order from largest to small-
est, and add resistive loads last.
2
5 Second Rule
1
If motor does not start within 5
seconds, turn off power to prevent
motor damage. Motor requires
more power than generator can
supply.
2
Ref. ST-800 396-A / S-0625
Download from Www.Somanuals.com. All Manuals Search And Download.
OM-491 Page 37
11-10. Typical Connections To Supply Standby Power
Y
Properly install and ground this equipment according to
its Owner’s Manual and national, state, and local codes.
1
2
3
4
Fused
Disconnect
Switch
Utility
Electrical
Service
Welding
Generator
Output
Transfer Switch
(If Required)
5
Essential
Loads
Y
Y
Have only qualified persons perform Switch transfers the electrical load from Connect generator with temporary or perma-
these connections according to all electric utility service to the generator. Trans- nent wiring suitable for the installation.
applicable codes and safety practic- fer load back to electric utility when service is
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.
es.
restored.
Properly install and ground this Install correct switch (customer-supplied).
equipment according to its Owner’s Switch rating must be same as or greater
Manual and national, state, and local
codes.
than the branch overcurrent protection.
3 Fused Disconnect Switch
5 Essential Loads
. Customer-supplied equipment is re-
quired if generator will supply standby
power during emergencies or power out-
ages.
Install correct switch (customer-supplied) if
required by electrical code.
Generatoroutput may not meet the electrical
requirements of the premises. If generator
does not produce enough output to meet all
4 Welding Generator Output
Generator output voltage and wiring must be requirements, connect only essential loads
consistent with regular (utility) system volt- (pumps, freezers, heaters, etc. − See Sec-
1 Utility Electrical Service
2 Transfer Switch (Double-Throw)
age and wiring.
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
Download from Www.Somanuals.com. All Manuals Search And Download.
OM-491 Page 38
11-11. Selecting Extension Cord (Use Shortest Cord Possible)
Cord Lengths for 120 Volt Loads
Y
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)
Load (Watts)
4
6
8
10
12
14
5
600
350 (106)
250 (76)
175 (53)
112 (34)
87 (26)
62 (19)
50 (15)
50 (15)
37 (11)
225 (68)
150 (46)
112 (34)
75 (23)
50 (15)
37 (11)
37 (11)
137 (42)
100 (30)
62 (19)
37 (11)
30 (9)
100 (30)
62 (19)
50 (15)
30 (9)
7
840
400 (122)
275 (84)
175 (53)
137 (42)
112 (34)
87 (26)
10
15
20
25
30
35
40
45
50
1200
1800
2400
3000
3600
4200
4800
5400
6000
400 (122)
300 (91)
225 (68)
175 (53)
150 (46)
125 (38)
112 (34)
100 (30)
87 (26)
75 (23)
62 (19)
62 (19)
50 (15)
*Conductor size is based on maximum 2% voltage drop
Cord Lengths for 240 Volt Loads
Y
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)
Load (Watts)
4
6
8
10
12
14
5
1200
1680
2400
3600
4800
6000
7000
8400
9600
10,800
12,000
700 (213)
500 (152)
350 (107)
225 (69)
175 (53)
125 (38)
100 (31)
100 (31)
75 (23)
450 (137)
300 (91)
225 (69)
150 (46)
100 (31)
75 (23)
225 (84)
200 (61)
125 (38)
75 (23)
200 (61)
125 (38)
100 (31)
60 (18)
7
800 (244)
550 (168)
350 (107)
275 (84)
225 (69)
175 (53)
150 (46)
125 (38)
125 (38)
100 (31)
10
15
20
25
30
35
40
45
50
800 (244)
600 (183)
450 (137)
350 (107)
300 (91)
250 (76)
225 (69)
200 (61)
175 (53)
60 (18)
75 (23)
*Conductor size is based on maximum 2% voltage drop
Download from Www.Somanuals.com. All Manuals Search And Download.
OM-491 Page 39
SECTION 12 − STICK WELDING (SMAW) GUIDELINES
12-1. Stick Welding Procedure
Y
Y
Weld current starts when
electrode touches work-
piece.
Weld current can damage
electronic parts in vehicles.
Disconnect both battery
cables before welding on a
vehicle. Place work clamp as
close to the weld as possible.
1
Workpiece
Make sure workpiece is clean be-
fore welding.
5
2
3
Work Clamp
Electrode
4
2
A small diameter electrode requires
less current than a large one. Fol-
low electrode manufacturer’s
instructions when setting weld am-
4
5
6
Insulated Electrode Holder
Electrode Holder Position
Arc Length
3
Arc length is the distance from the
electrodeto the workpiece. A short
arc with correct amperage will give
a sharp, crackling sound.
6
1
7
7
Slag
Use a chipping hammer and wire
brush to remove slag. Remove slag
and check weld bead before mak-
ing another weld pass.
Tools Needed:
stick 12/96 − ST-151 593
Download from Www.Somanuals.com. All Manuals Search And Download.
OM-498 Page 40
12-2. Electrode and Amperage Selection Chart
3/32
1/8
5/32
3/16
7/32
6010
&
6011
1/4
1/16
5/64
3/32
6010
6011
EP
EP
ALL
ALL
ALL
DEEP
DEEP
LOW
MIN. PREP, ROUGH
HIGH SPATTER
6013 EP,EN
GENERAL
1/8
5/32
3/16
7/32
SMOOTH, EASY,
FAST
6013
7014 EP,EN
ALL
MED
LOW
LOW HYDROGEN,
STRONG
7018
EP
ALL
FLAT
1/4
3/32
1/8
5/32
3/16
SMOOTH, EASY,
FASTER
7024 EP,EN
HORIZ LOW
FILLET
NI-CL
308L
EP
EP
ALL
ALL
LOW
LOW
CAST IRON
STAINLESS
7014
7/32
1/4
3/32
1/8
*EP = ELECTRODE POSITIVE (REVERSE POLARITY)
EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)
5/32
3/16
7018
7/32
1/4
3/32
1/8
5/32
3/16
7024
7/32
1/4
3/32
1/8
5/32
Ni-Cl
3/16
3/32
1/8
308L
5/32
Ref. S-087 985-A
12-3. Striking an Arc − Scratch Start Technique
1
1
2
3
Electrode
Workpiece
Arc
Drag electrode across workpiece
like striking a match; lift electrode
slightly after touching work. If arc
goes out electrode was lifted to
high. If electrode sticks to work-
piece, use a quick twist to free it.
2
3
S-0049
12-4. Striking an Arc − Tapping Technique
1
1
2
3
Electrode
Workpiece
Arc
Bring electrode straight down to
workpiece; then lift slightly to start
arc. If arc goes out, electrode was
lifted too high. If electrode sticks to
workpiece, use a quick twist to free it.
2
3
S-0050
OM-498 Page 41
Download from Www.Somanuals.com. All Manuals Search And Download.
12-5. Positioning Electrode Holder
10°-30°
90°
90°
End View of Work Angle
Side View of Electrode Angle
GROOVE WELDS
10°-30°
45°
45°
End View of Work Angle
Side View of Electrode Angle
S-0060
FILLET WELDS
12-6. Poor Weld Bead Characteristics
1
2
3
4
5
Large Spatter Deposits
Rough, Uneven Bead
Slight Crater During Welding
Bad Overlap
Poor Penetration
1
2
4
3
5
S-0053-A
12-7. Good Weld Bead Characteristics
1
Fine Spatter
2
3
Uniform Bead
Moderate Crater During
Welding
Weld a new bead or layer for each
1/8 in. (3.2 mm) thickness in metals
being welded.
4
5
No Overlap
1
3
Good Penetration into Base
Metal
2
4
5
S-0052-B
Download from Www.Somanuals.com. All Manuals Search And Download.
OM-498 Page 42
12-8. Conditions That Affect Weld Bead Shape
Weld bead shape is affected by electrode angle, arc length, travel speed, and
thickness of base metal.
NOTE
Correct Angle
Angle Too Large
Angle Too Small
10° - 30°
Drag
ELECTRODE ANGLE
Spatter
Normal
Too Long
Too Short
ARC LENGTH
Normal
Fast
Slow
TRAVEL SPEED
S-0061
12-9. Electrode Movement During Welding
Normally, a single stringer bead is satisfactory for most narrow groove weld joints;
however, for wide groove weld joints or bridging across gaps, a weave bead or
multiple stringer beads work better.
NOTE
1
2
3
Stringer Bead − Steady
Movement Along Seam
Weave Bead − Side to Side
Movement Along Seam
2
1
Weave Patterns
Use weave patterns to cover a wide
area in one pass of the electrode.
Do not let weave width exceed
2-1/2 times diameter of electrode.
3
S-0054-A
OM-498 Page 43
Download from Www.Somanuals.com. All Manuals Search And Download.
12-10. Butt Joints
1
Tack Welds
1
Prevent edges of joint from drawing
together ahead of electrode by tack
welding the materials in position be-
fore final weld.
2
2
Square Groove Weld
Good for materials up to 3/16 in (5
mm) thick.
3
Single V-Groove Weld
Good for materials 3/16 − 3/4 in
(5-19 mm) thick. Cut bevel with oxy-
acetylene or plasma cutting equip-
ment. Remove scale from material
after cutting. A grinder can also be
used to prepare bevels.
30°
1/16 in
(1.6 mm)
4
Create 30 degree angle of bevel on
materials in V-groove welding.
3
4
Double V-Groove Weld
Good for materials thicker than 3/16
in (5 mm).
S-0662
12-11. Lap Joint
30°
1
2
Electrode
30°
Or Less
Or Less
1
Single-LayerFillet Weld
Move electrode in circular motion.
Multi-Layer Fillet Weld
1
3
Weld a second layer when a heavi-
er fillet is needed. Remove slag be-
fore making another weld pass.
Weld both sides of joint for maxi-
mum strength.
3
2
Single-Layer Fillet Weld
Multi-Layer Fillet Weld
S-0063 / S-0064
12-12. Tee Joint
1
2
Electrode
Fillet Weld
Keep arc short and move at definite
rate of speed. Hold electrode as
shown to provide fusion into the
corner. Square edge of the weld
surface.
1
45°
Or Less
For maximum strength weld both
sides of upright section.
2
2
3
Multi-Layer Deposits
Weld a second layer when a heavi-
er fillet is needed. Use any of the
weaving patterns shown in Section
12-9. Remove slag before making
another weld pass.
1
3
S-0060 / S-0058-A / S-0061
Download from Www.Somanuals.com. All Manuals Search And Download.
OM-498 Page 44
12-13. Weld Test
1
2
3
Vise
Weld Joint
Hammer
3
Strike weld joint in direction shown.
A good weld bends over but does
not break.
3
2 To 3 in
(51-76 mm)
2 To 3 in
(51-76 mm)
2
2
1
1/4 in
(6.4 mm)
1
S-0057-B
12-14. Troubleshooting − Porosity
Porosity − small cavities or holes resulting from gas
pockets in weld metal.
Possible Causes
Arc length too long.
Corrective Actions
Reduce arc length.
Use dry electrode.
Damp electrode.
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
12-15. Troubleshooting − Excessive Spatter
Excessive Spatter − scattering of molten metal particles
that cool to solid form near weld bead.
Possible Causes
Corrective Actions
Amperage too high for electrode.
Decrease amperage or select larger electrode.
Reduce arc length or voltage.
Arc length too long or voltage too high.
OM-498 Page 45
Download from Www.Somanuals.com. All Manuals Search And Download.
12-16. Troubleshooting − Incomplete Fusion
IncompleteFusion − failure of weld metal to fuse completely with
base metal or a preceeding weld bead.
Possible Causes
Insufficient heat input.
Corrective Actions
Increase amperage. Select larger electrode and increase amperage.
Improper welding technique.
Place stringer bead in proper location(s) at joint during welding.
Adjust work angle or widen groove to access bottom during welding.
Momentarily hold arc on groove side walls when using weaving technique.
Keep arc on leading edge of weld puddle.
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
12-17. Troubleshooting − Lack Of Penetration
Lack Of Penetration − shallow fusion between weld metal and
base metal.
Lack of Penetration
Possible Causes
Good Penetration
Corrective Actions
Improper joint preparation.
Improper weld technique.
Insufficient heat input.
Material too thick. Joint preparation and design must provide access to bottom of groove.
Keep arc on leading edge of weld puddle.
Increase amperage. Select larger electrode and increase amperage.
Reduce travel speed.
12-18. Troubleshooting − Excessive Penetration
Excessive Penetration − weld metal melting through base metal and
hangingunderneath weld.
Excessive Penetration
Good Penetration
Possible Causes
Excessive heat input.
Corrective Actions
Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
OM-498 Page 46
Download from Www.Somanuals.com. All Manuals Search And Download.
12-19. Troubleshooting − Burn-Through
Burn-Through− weld metal melting completely through base metal resulting
in holes where no metal remains.
Possible Causes
Excessive heat input.
Corrective Actions
Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
12-20. Troubleshooting − Waviness Of Bead
Waviness Of Bead − weld metal that is not parallel and does not cover
joint formed by base metal.
Possible Causes
Unsteady hand.
Corrective Actions
Use two hands. Practice technique.
12-21. Troubleshooting − Distortion
Distortion− contraction of weld met-
al during welding that forces base
metal to move.
Base metal moves
in the direction of
the weld bead.
Possible Causes
Corrective Actions
Excessive heat input.
Use restraint (clamp) to hold base metal in position.
Make tack welds along joint before starting welding operation.
Select lower amperage for electrode.
Increase travel speed.
Weld in small segments and allow cooling between welds.
OM-498 Page 47
Download from Www.Somanuals.com. All Manuals Search And Download.
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 13-1. Main Assembly
. . . 1 . . . . . . . . . . . . . . +495 247 . . TOP, control box (specify color) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . CR1, CR2 . . . 035 704 . . RECTIFIER, integ bridge 40 amp 800 v . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . . . . . . . . . . . . 134 201 . . STAND-OFF, support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 5 . . . . . . . . . . . . . . . 495 236 . . BASE, control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . L3 . . . . . . 495 200 . . REACTOR, stabilizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . . 211 297 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . . 493 509 . . BRUSHHOLDER, assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . . 204 138 . . LABEL, warning fuel (also supplied with engine) . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . +195 557 . . ENGINE, gas Kohler 8.5HP (recoil start) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . *203 952 . . FILTER, air Kohler cs 8.5 & 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . *203 954 . . FILTER, air pre Kohler cs 8.5 & 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . *203 955 . . CAP, fuel Kohler cs 8.5 & 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . *203 956 . . TANK, fuel Kohler cs 8.5 & 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . *203 957 . . STRAINER, fuel Kohler cs 8.5 & 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . *203 958 . . MUFFLER, exhaust engine Kohler cs 8.5 & 12 . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . *203 959 . . GASKET, muffler Kohler cs 8.5 & 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . *203 960 . . SPARK PLUG, Kohler cs 8.5 & 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . +184 556 . . ENGINE, Honda 9HP (recoil start) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . +184 555 . . ENGINE, Honda 9HP (electric start) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . . 494 606 . . ADAPTER, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . . 494 629 . . GUARD, generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . . 194 509 . . FAN, generator (Kohler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . . 493 868 . . FAN, generator (Honda) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . . 209 320 . . GENERATOR, w/stator assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . L1-D . . . . . 494 574 . . ROTOR, assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . . 495 349 . . SCREW, 1/4-20 HWH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 17 . . . . . . . . . . . . . . . 494 587 . . CARRIER, bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . . 495 348 . . SCREW, 5/16-24 HWH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . +494 628 . . PANEL, end generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . . Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 21 . . . . . . . . . . . . . . . 495 257 . . MOUNT, shock w/bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 22 . . . . . . . . . . . . . . . 495 256 . . MOUNT, shock generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . . 194 504 . . FRAME, mtg assembly (Kohler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . . 495 132 . . FRAME, mtg assembly (Honda) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . PC1 . . . . . 148 608 . . BOARD, PC filter (CSA only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . . 494 613 . . TERMINAL, output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 26 . . . . . R1 . . . . . . 494 618 . . RHEOSTAT, 35 ohm 100W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . . 495 214 . . SEAL, air duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . . 495 255 . . DUCT, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . . 097 924 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, overlay (order by model and serial number) . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . Figure 13-2 . . PANEL, aux power assembly (CSA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . 1T . . . . . . 172 661 . . BLOCK, terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . . . 495 193 . . BRACKET, mtg terminal block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . L2 . . . . . . 495 202 . . REACTOR, weld assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . R2/VR1 . . . . 046 819 . . SUPPRESSOR, assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . CR3 . . . . . 495 188 . . RECTIFIER, assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . . . 201 223 . . LABEL, warning electric shock power still present . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . . . . 494 976 . . LABEL, current selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . . . 495 112 . . LEAD, battery neg (electric start) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . . . . . . . . . . . . . . BATTERY, 12V (electric start) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . . . 494 604 . . BOLT, hold down (electric start) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . . . . 493 057 . . CLAMP, battery (electric start) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . . . . 495 111 . . LEAD, battery pos (electric start) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . . . 494 039 . . COVER, battery cable (electric start) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a part displaying a precautionary label, order label also.
*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-498 Page 49
Download from Www.Somanuals.com. All Manuals Search And Download.
2
4
5
.
H
a
r
d
w
a
r
e
i
s
c
o
m
m
o
n
a
n
d
n
o
t
a
v
a
i
l
a
b
l
e
u
n
l
e
s
s
l
i
s
t
e
d
.
1
6
7
3
8
Generator Power Panel 495 298
(USA)
Generator Power Panel 495 315 (USA)
9
13
14
11
12
15
10
Generator Power Panel 495 218
(USA)
Generator Power Panel 495 279
(Canada)
16
17
18
19
17
19
Generator Power Panel 495 253
(South Africa)
Generator Power Panel 495 289
(Australia)
20
21
22
23
Generator Power Panel 495 290
(Europe)
Generator Power Panel 495 288
(S. America)
24
25
Generator Power Panel 495 283
(S.E. Asia)
196 921
Figure 13-2. Generator Power Panels
OM-498 Page 50
Download from Www.Somanuals.com. All Manuals Search And Download.
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Generator Power Panel 495 298 (USA)
. . . 1 . . . . . . . . . . . . . . . 495 220 . . PANEL, generator power assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . CB1, CB2 . . . 495 245 . . CIRCUIT BREAKER, 15A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . CB3, CB4 . . . 495 246 . . CIRCUIT BREAKER, 20A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . RC1 . . . . . 407 749 . . RECEPTACLE, twistlock 230 V U.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . RC2, RC3 . . . 408 898 . . RECEPTACLE, duplex 115 V 20 A U.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Generator Power Panel 495 315 (USA)
. . . 6 . . . . . . . . . . . . . . . 495 314 . . PANEL, generator power assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . CB1, CB2 . . . 495 245 . . CIRCUIT BREAKER, 15A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . . CB3, CB4 . . . 495 246 . . CIRCUIT BREAKER, 20A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Generator Power Panel 495 218 (USA)
. . . 9 . . . . . . . . . . . . . . . 495 220 . . PANEL, generator power assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . . 495 216 . . OVERLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . CB1 . . . . . 495 183 . . CIRCUIT BREAKER, 30A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . CB2, CB3 . . . 495 246 . . CIRCUIT BREAKER, 20A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Generator Power Panel 495 279 (Canada)
. . . 13 . . . . . . . . . . . . . . . 495 284 . . PANEL, generator power assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . CB1 . . . . . 495 183 . . CIRCUIT BREAKER, 30A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . CB2, CB3 . . . 495 246 . . CIRCUIT BREAKER, 20A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Generator Power Panel 495 253 (South Africa)
. . . 16 . . . . . . . . . . . . . . . 495 252 . . PANEL, generator power assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . CB1, CB2 . . . 495 245 . . CIRCUIT BREAKER, 15A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Generator Power Panel 495 289 (Australia)
. . . 18 . . . . . . . . . . . . . . . 495 254 . . PANEL, generator power assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . CB1 - CB4 . . 495 245 . . CIRCUIT BREAKER, 15A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Generator Power Panel 495 290 (Europe)
. . . 20 . . . . . . . . . . . . . . . 495 282 . . PANEL, generator power assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . CB1,CB2 . . . 495 245 . . CIRCUIT BREAKER, 15A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Generator Power Panel 495 288 (S. America)
. . . 22 . . . . . . . . . . . . . . . 495 287 . . PANEL, generator power assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . CB1-4 . . . . 495 245 . . CIRCUIT BREAKER, 15A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Generator Power Panel 495 283 (S.E. Asia)
. . . 24 . . . . . . . . . . . . . . . 495 282 . . PANEL, generator power assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . CB1,CB2 . . . 495 245 . . CIRCUIT BREAKER, 15A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
*Recommended Spare Parts.
NOTE: Replacement receptacles not listed can be found at your local hardware or electrical supply store.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-498 Page 51
Download from Www.Somanuals.com. All Manuals Search And Download.
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
Return To Table Of Contents
Download from Www.Somanuals.com. All Manuals Search And Download.
OM-498 Page 52
Notes
Download from Www.Somanuals.com. All Manuals Search And Download.
Notes
MATERIAL THICKNESS REFERENCE CHART
24 Gauge (.025 in)
22 Gauge (.031 in)
20 Gauge (.037 in)
18 Gauge (.050 in)
16 Gauge (.063 in)
14 Gauge (.078 in)
1/8 in (.125 in)
3/16 in (.188 in)
1/4 in (.25 in)
5/16 in (.313 in)
3/8 in (.375 in)
1/2 in (.5 in)
Invision 354MP
TM-188 304 Page 54
Download from Www.Somanuals.com. All Manuals Search And Download.
Effective January 1, 2003
(Equipment with a serial number preface of “LC” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants
to its original retail purchaser that new Miller equipment sold
after the effective date of this limited warranty is free of defects
in material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
*
*
*
*
*
*
*
Induction Heating Coils and Blankets
APT & SAF Model Plasma Cutting Torches
Remote Controls
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Accessory Kits
Replacement Parts (No labor)
Spoolmate Spoolguns
Canvas Covers
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such defects in material or workmanship. Miller must be
notified in writing within thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.
Your distributor also gives
you ...
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.)
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
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.
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.
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.
3. Equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.
1. 5 Years Parts — 3 Years Labor
*
*
Original main power rectifiers
Inverters (input and output rectifiers only)
2. 3 Years — Parts and Labor
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.
*
*
*
*
*
*
*
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Supplies
Intellitig
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.
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)
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.
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
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
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
Grids
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
Maxstar 85, 140
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.
Spot Welders
Load Banks
Racks
Running Gear/Trailers
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.
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.)
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.
4. 6 Months — Batteries
5. 90 Days — Parts
*
MIG Guns/TIG Torches
miller_warr 8/03
Download from Www.Somanuals.com. All Manuals Search And Download.
Owner’s Record
Please complete and retain with your personal records.
Model Name
Purchase Date
Distributor
Address
Serial/Style Number
(Date which equipment was delivered to original customer.)
City
State
Zip
For Service
to locate a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA
2004 Miller Electric Mfg. Co. 1/04
Download from Www.Somanuals.com. All Manuals Search And Download.
|