Miller Electric Welding System Bobcat 250 User Manual
OM-4419  
211 392M  
2007−05  
Processes  
Stick (SMAW) Welding  
MIG (GMAW) Welding  
Flux Cored (FCAW) Welding  
Non-Critical TIG (GTAW)  
Welding  
Description  
Engine Driven Welding Generator  
™
Bobcat 250  
File: Engine Drive  
Visit our website at  
www.MillerWelds.com  
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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. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
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6
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11  
2-7. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11  
2-8. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
11  
12  
12  
4-1. Weld, Power, and Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12  
4-2. Dimensions, Weights, and Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13  
4-3. Dimensions For Units With Optional Running Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13  
4-4. Fuel Consumption (Robin-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14  
4-5. Fuel Consumption (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14  
4-6. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15  
4-7. Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16  
4-8. Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16  
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
17  
5-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17  
5-2. Engine Prestart Checks (Robin-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18  
5-3. Engine Prestart Checks (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19  
5-4. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20  
5-5. Connecting Or Replacing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20  
5-6. Connecting to Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21  
5-7. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22  
SECTION 6 − OPERATING THE WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
23  
6-1. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23  
6-2. Cold Weather Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24  
6-3. Typical Stick Welding Connections And Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25  
6-4. Typical MIG Welding Connections And Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26  
6-5. Typical MIG Connections And Settings Using Weld Control And Spoolgun . . . . . . . . . . . . . . . . . . . . . 28  
SECTION 7 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
29  
7-1. Generator Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29  
7-2. Simultaneous Weld And Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30  
7-3. Wiring Optional 240 Volt Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30  
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TABLE OF CONTENTS  
SECTION 8 − MAINTENANCE (ROBIN-POWERED UNITS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
31  
8-1. Routine Maintenance (Robin-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31  
8-2. Maintenance Label (Robin-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32  
8-3. Servicing Air Cleaner (Robin-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33  
8-4. Overload Protection (Robin-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33  
8-5. Changing Engine Oil, Oil Filter, and Fuel Filter (Robin-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . 34  
8-6. Adjusting Engine Speed (Robin-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35  
8-7. Servicing Optional Spark Arrestor (Robin-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36  
SECTION 9 − MAINTENANCE − (KOHLER-POWERED UNITS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
37  
9-1. Routine Maintenance (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37  
9-2. Maintenance Label (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38  
9-3. Servicing Air Cleaner (Kohler−Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39  
9-4. Changing Engine Oil, Oil Filter, and Fuel Filter (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . 40  
9-5. Adjusting Engine Speed (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41  
9-6. Overload Protection (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42  
9-7. Servicing Optional Spark Arrestor (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42  
SECTION 10 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
43  
10-1. Welding Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43  
10-2. Generator Power Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43  
10-3. Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44  
SECTION 11 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
45  
11-1. Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45  
SECTION 12 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
SECTION 13 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
SECTION 14 − STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
SECTION 15 − MIG WELDING (GMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
46  
48  
55  
63  
15-1. Typical MIG Process Connections Using A Voltage-Sensing Wire Feeder . . . . . . . . . . . . . . . . . . . . . 63  
15-2. Holding And Positioning Welding Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63  
15-3. Conditions That Affect Weld Bead Shape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64  
15-4. Gun Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65  
15-5. Poor Weld Bead Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65  
15-6. Good Weld Bead Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65  
15-7. Troubleshooting − Excessive Spatter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66  
15-8. Troubleshooting − Porosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66  
15-9. Troubleshooting − Excessive Penetration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66  
15-10. Troubleshooting − Lack Of Penetration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67  
15-11. Troubleshooting − Incomplete Fusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67  
15-12. Troubleshooting − Burn-Through . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67  
15-13. Troubleshooting − Waviness Of Bead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68  
15-14. Troubleshooting − Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68  
15-15. Common MIG Shielding Gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69  
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SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING  
rom_2007−04  
Protect yourself and others from injury — read and follow these precautions.  
1-1. Symbol Usage  
DANGER! − Indicates a hazardous situation which, if  
not avoided, will result in death or serious injury. The  
possible hazards are shown in the adjoining symbols  
or explained in the text.  
.
I
n
d
i
c
a
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s
p
e
c
i
a
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i
n
s
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u
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s
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Indicates a hazardous situation which, if not avoided,  
could result in death or serious injury. The possible  
hazards are shown in the adjoining symbols or ex-  
plained in the text.  
This group of symbols means Warning! Watch Out! ELECTRIC  
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-  
bols and related instructions below for necessary actions to avoid the  
hazards.  
NOTICE − Indicates statements not related to personal injury.  
1-2. Arc Welding Hazards  
D
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  
groundedreceptacle outlet.  
When making input connections, attach proper grounding conduc-  
tor first − double-check connections.  
Keep cords dry, free of oil and grease, and protected from hot metal  
and sparks.  
Frequentlyinspect input power cord for damage or bare wiring —  
replace cord immediately if damaged — bare wiring can kill.  
Turn off all equipment when not in use.  
Do not use worn, damaged, undersized, or poorly spliced cables.  
Do not drape cables over your body.  
The symbols shown below are used throughout this manual  
to call attention to and identify possible hazards. When you  
see the symbol, watch out, and follow the related instructions  
to avoid the hazard. The safety information given below is  
only a summary of the more complete safety information  
found in the Safety Standards listed in Section 1-7. Read and  
follow all Safety Standards.  
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D
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Only qualified persons should install, operate, maintain, and  
repair this unit.  
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D
D
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During operation, keep everybody, especially children, away.  
If earth grounding of the workpiece is required, ground it directly  
with a separate cable.  
ELECTRIC SHOCK can kill.  
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D
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Do not touch electrode if you are in contact with the work, ground,  
or another electrode from a different machine.  
Use only well-maintained equipment. Repair or replace damaged  
parts at once. Maintain unit according to manual.  
Do not touch electrode holders connected to two welding ma-  
chines at the same time since double open-circuit voltage will be  
present.  
Wear a safety harness if working above floor level.  
Keep all panels and covers securely in place.  
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 equip-  
ment is a hazard.  
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Do not touch live electrical parts.  
Clamp work cable with good metal-to-metal contact to workpiece  
or worktable as near the weld as practical.  
Wear dry, hole-free insulating gloves and body protection.  
Insulate yourself from work and ground using dry insulating mats  
or covers big enough to prevent any physical contact with the work  
or ground.  
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.  
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Do not use AC output in damp areas, if movement is confined, or if  
there is a danger of falling.  
SIGNIFICANT DC VOLTAGE exists in inverters after stop-  
ping engine.  
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Use AC output ONLY if required for the welding process.  
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Stop engine on inverter and discharge input capacitors according  
to instructions in Maintenance Section before touching any parts.  
If AC output is required, use remote output control if present on  
unit.  
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Additionalsafety precautions are required when any of the follow-  
ing electrically hazardous conditions are present: in damp  
locations or while wearing wet clothing; on metal structures such  
as floors, gratings, or scaffolds; when in cramped positions such  
as sitting, kneeling, or lying; or when there is a high risk of unavoid-  
able or accidental contact with the workpiece or ground. For these  
conditions, use the following equipment in order presented: 1) a  
semiautomaticDC constant voltage (wire) welder, 2) a DC manual  
(stick) welder, or 3) an AC welder with reduced open-circuit volt-  
age. In most situations, use of a DC, constant voltage wire welder  
is recommended. And, do not work alone!  
HOT PARTS can cause severe burns.  
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Do not touch hot parts bare handed.  
Allow cooling period before working on equip-  
ment.  
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To handle hot parts, use proper tools and/or wear heavy, insu-  
lated welding gloves and clothing to prevent burns.  
FLYING METAL or DIRT can injure eyes.  
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Welding, chipping, wire brushing, and grinding  
cause sparks and flying metal. As welds cool,  
they can throw off slag.  
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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).  
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Wear approved safety glasses with side shields even under your  
welding helmet.  
Properly install and ground this equipment according to its  
Owner’s Manual and national, state, and local codes.  
OM-4419 Page 1  
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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).  
FUMES AND GASES can be hazardous.  
Welding produces fumes and gases. Breathing these  
fumes and gases can be hazardous to your health.  
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Do not weld where the atmosphere may contain flammable dust,  
gas, or liquid vapors (such as gasoline).  
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Keep your head out of the fumes. Do not breathe the fumes.  
If inside, ventilate the area and/or use local forced ventilation at the  
arc to remove welding fumes and gases.  
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, sparks, and fire haz-  
ards.  
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If ventilation is poor, wear an approved air-supplied respirator.  
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Do not use welder to thaw frozen pipes.  
Read and understand the Material Safety Data Sheets (MSDSs)  
and the manufacturer’s instructions for metals, consumables,  
coatings, cleaners, and degreasers.  
Remove stick electrode from holder or cut off welding wire at  
contact tip when not in use.  
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Wear oil-free protective garments such as leather gloves, heavy  
shirt, cuffless trousers, high shoes, and a cap.  
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Work in a confined space only if it is well ventilated, or while  
wearing an air-supplied respirator. Always have a trained watch-  
person nearby. Welding fumes and gases can displace air and  
lower the oxygen level causing injury or death. Be sure the breath-  
ing air is safe.  
Do not weld in locations near degreasing, cleaning, or spraying op-  
erations. 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  
cadmiumplated steel, unless the coating is removed from the weld  
area, the area is well ventilated, and while wearing an air-supplied  
respirator. The coatings and any metals containing these elements  
can give off toxic fumes if welded.  
Remove any combustibles, such as a butane lighter or matches,  
from your person before doing any welding.  
After completion of work, inspect area to ensure it is free of sparks,  
glowing embers, and flames.  
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Use only correct fuses or circuit breakers. Do not oversize or by-  
pass them.  
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B  
for hot work and have a fire watcher and extinguisher nearby.  
NOISE can damage hearing.  
Noise from some processes or equipment can dam-  
age hearing.  
BUILDUP OF GAS can injure or kill.  
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Shut off shielding gas supply when not in use.  
Always ventilate confined spaces or use ap-  
proved air-supplied respirator.  
D
Wear approved ear protection if noise level is  
high.  
MAGNETIC FIELDS can affect Implanted  
Medical Devices.  
ARC RAYS can burn eyes and skin.  
D
Wearers of Pacemakers and other Implanted  
Medical Devices should keep away.  
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.  
D
ImplantedMedical Device wearers should consult their doctor  
and the device manufacturer before going near arc welding, spot  
welding, gouging, plasma arc cutting, or induction heating  
operations.  
D
Wear an approved welding helmet fitted with a proper shade of filter  
lenses to protect your face and eyes from arc rays and sparks  
when welding or watching (see ANSI Z49.1 and Z87.1 listed in  
Safety Standards).  
Wear approved safety glasses with side shields under your  
helmet.  
Use protective screens or barriers to protect others from flash,  
glare, and sparks; warn others not to watch the arc.  
Wear protective clothing made from durable, flame-resistant mate-  
rial (leather, heavy cotton, or wool) and foot protection.  
CYLINDERS can explode if damaged.  
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Shielding gas cylinders contain gas under high pres-  
sure. If damaged, a cylinder can explode. Since gas  
cylinders are normally part of the welding process, be  
sure to treat them carefully.  
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Protect compressed gas cylinders from excessive heat, mechani-  
cal shocks, physical damage, slag, open flames, sparks, and arcs.  
Install cylinders in an upright position by securing to a stationary  
support or cylinder rack to prevent falling or tipping.  
WELDING can cause fire or explosion.  
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Keep cylinders away from any welding or other electrical circuits.  
Never drape a welding torch over a gas cylinder.  
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,  
Never allow a welding electrode to touch any cylinder.  
Never weld on a pressurized cylinder — explosion will result.  
and hot equipment can cause fires and burns. Accidental contact of  
electrodeto metal objects can cause sparks, explosion, overheating,  
or fire. Check and be sure the area is safe before doing any welding.  
Use only correct shielding gas cylinders, regulators, hoses, and fit-  
tings designed for the specific application; maintain them and  
associated parts in good condition.  
D
Remove all flammables within 35 ft (10.7 m) of the welding arc. If  
this is not possible, tightly cover them with approved covers.  
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Turn face away from valve outlet when opening cylinder valve.  
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Do not weld where flying sparks can strike flammable material.  
Protect yourself and others from flying sparks and hot metal.  
Keep protective cap in place over valve except when cylinder is in  
use or connected for use.  
Be alert that welding sparks and hot materials from welding can  
easily go through small cracks and openings to adjacent areas.  
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Use the right equipment, correct procedures, and sufficient num-  
ber of persons to lift and move cylinders.  
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Watch for fire, and keep a fire extinguisher nearby.  
Read and follow instructions on compressed gas cylinders,  
associated equipment, and Compressed Gas Association (CGA)  
publication P-1 listed in Safety Standards.  
Be aware that welding on a ceiling, floor, bulkhead, or partition can  
cause fire on the hidden side.  
OM-4419 Page 2  
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1-3. Engine Hazards  
STEAM AND HOT COOLANT can burn.  
BATTERY EXPLOSION can BLIND.  
D
If possible, check coolant level when engine is  
cold to avoid scalding.  
D
Always wear a face shield, rubber gloves, and  
protective clothing when working on a battery.  
D
Always check coolant level at overflow tank, if  
present on unit, instead of radiator (unless told  
otherwise in maintenance section or engine  
manual).  
D
Stop engine before disconnecting or connect-  
ing battery cables or servicing battery.  
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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
If the engine is warm, checking is needed, and there is no over-  
flow tank, follow the next two statements.  
Disconnect negative (−) cable first and connect it last.  
D
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Wear safety glasses and gloves and put a rag over radiator cap.  
Turn cap slightly and let pressure escape slowly before  
completely removing cap.  
FUEL can cause fire or explosion.  
D
Stop engine and let it cool off before checking or  
adding fuel.  
D
Do not add fuel while smoking or if unit is near  
any sparks or open flames.  
Using a generator indoors CAN KILL  
YOU IN MINUTES.  
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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.  
D
Generator exhaust contains carbon monoxide.  
This is a poison you cannot see or smell.  
Always keep nozzle in contact with tank when fueling.  
D
NEVER use inside a home or garage, EVEN IF  
doors and windows are open.  
D
Only use OUTSIDE and far away from windows, doors, and  
vents.  
MOVING PARTS can cause injury.  
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Keep away from fans, belts, and rotors.  
Keep all doors, panels, covers, and guards  
closed and securely in place.  
BATTERY ACID can BURN SKIN and EYES.  
D
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Stop engine before installing or connecting unit.  
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Do not tip battery.  
Replace damaged battery.  
Flush eyes and skin immediately with water.  
Have only qualified people remove doors, panels, covers, or  
guards for maintenance and troubleshooting as necessary.  
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To prevent accidental starting during servicing, disconnect  
negative (−) battery cable from battery.  
Keep hands, hair, loose clothing, and tools away from moving  
parts.  
ENGINE HEAT can cause fire.  
Reinstall doors, panels, covers, or guards when servicing is  
finished and before starting engine.  
D
Do not locate unit on, over, or near combustible  
surfaces or flammables.  
Before working on generator, remove spark plugs or injectors to  
keep engine from kicking back or starting.  
D
Keep exhaust and exhaust pipes way from  
flammables.  
Block flywheel so that it will not turn while working on generator  
components.  
HOT PARTS can cause severe burns.  
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Do not touch hot parts bare handed.  
Allow cooling period before working on equip-  
ment.  
To handle hot parts, use proper tools and/or  
wear heavy, insulated welding gloves and  
clothing to prevent burns.  
EXHAUST SPARKS can cause fire.  
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Do not let engine exhaust sparks cause fire.  
Use approved engine exhaust spark arrestor in  
required areas — see applicable codes.  
D
1-4. Compressed Air Hazards  
TRAPPED AIR PRESSURE AND WHIPPING  
HOSES can cause injury.  
BREATHING COMPRESSED AIR can  
cause serious injury or death.  
D
Release air pressure from tools and system be-  
fore servicing, adding or changing attach-  
ments, or opening compressor oil drain or oil fill  
cap.  
D
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Do not use compressed air for breathing.  
Use only for cutting, gouging, and tools.  
COMPRESSED AIR can cause injury.  
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Wear approved safety goggles.  
Do not direct air stream toward self or others.  
OM-4419 Page 3  
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HOT METAL from air arc cutting and  
gouging can cause fire or explosion.  
READ INSTRUCTIONS.  
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Read Owner’s Manual before using or servic-  
ing unit.  
Stop engine and release air pressure before  
servicing.  
Use only genuine replacement parts from the  
manufacturer.  
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Do not cut or gouge near flammables.  
Watch for fire; keep extinguisher nearby.  
HOT PARTS can cause burns and injury.  
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Do not touch hot compressor or air system  
parts.  
Let system cool down before touching or ser-  
vicing.  
1-5. Additional Symbols For Installation, Operation, And Maintenance  
FIRE OR EXPLOSION hazard.  
WELDING WIRE can cause injury.  
D
Do not install or place unit on, over, or near  
combustiblesurfaces.  
D
Do not press gun trigger until instructed to do  
so.  
D
Do not install unit near flammables.  
D
Do not point gun toward any part of the body,  
other people, or any metal when threading  
welding wire.  
D
Do not overload building wiring − be sure power supply system is  
properly sized, rated, and protected to handle this unit.  
FALLING UNIT can cause injury.  
OVERUSE can cause OVERHEATING.  
D
Use lifting eye to lift unit and properly installed  
accessories only, NOT gas cylinders. Do not  
exceed maximum lift eye weight rating (see  
Specifications).  
Lift and support unit only with proper equipment  
and correct procedures.  
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Allow cooling period; follow rated duty cycle.  
Reduce current or reduce duty cycle before  
starting to weld again.  
D
Do not block or filter airflow to unit.  
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If using lift forks to move unit, be sure forks are long enough to  
extend beyond opposite side of unit.  
STATIC (ESD) can damage PC boards.  
D
Put on grounded wrist strap BEFORE handling  
boards or parts.  
OVERHEATING can damage motors.  
D
Use proper static-proof bags and boxes to  
store, move, or ship PC boards.  
D
Turn off or unplug equipment before starting or  
stopping engine.  
D
Do not let low voltage and frequency caused by  
low engine speed damage electric motors.  
TILTING OF TRAILER can cause injury.  
D
Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle  
where applicable.  
D
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Use tongue jack or blocks to support weight.  
Properly install welding generator onto trailer  
according to instructions supplied with trailer.  
FLYING SPARKS can cause injury.  
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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.  
READ INSTRUCTIONS.  
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Read Owner’s Manual before using or servic-  
ing unit.  
Use only genuine replacement parts from the  
manufacturer.  
Perform engine and air compressor mainte-  
nance and service according to this manual  
and the engine/air compressor (if applicable)  
manuals.  
D
Sparks can cause fires — keep flammables away.  
MOVING PARTS can cause injury.  
D
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Keep away from moving parts.  
Keep away from pinch points such as drive  
rolls.  
OM-4419 Page 4  
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H.F. RADIATION can cause interference.  
ARC WELDING can cause interference.  
D
High-frequency (H.F.) can interfere with radio  
navigation, safety services, computers, and  
communicationsequipment.  
Have only qualified persons familiar with  
electronic equipment perform this installation.  
D
Electromagnetic energy can interfere with  
sensitive electronic equipment such as micro-  
processors, computers, and computer-driven  
equipmentsuch as robots.  
Be sure all equipment in the welding area is  
electromagneticallycompatible.  
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The user is responsible for having a qualified electrician  
promptly correct any interference problem resulting from the  
installation.  
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To reduce possible interference, keep weld cables as short as  
possible, close together, and down low, such as on the floor.  
If notified by the FCC about interference, stop using the  
equipmentat once.  
Locate welding operation 100 meters from any sensitive elec-  
tronic equipment.  
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Have the installation regularly checked and maintained.  
Be sure this welding machine is installed and grounded  
according to this manual.  
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.  
If interference still occurs, the user must take extra measures  
such as moving the welding machine, using shielded cables,  
using line filters, or shielding the work area.  
1-6. California Proposition 65 Warnings  
For Gasoline Engines:  
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.)  
Engine exhaust contains chemicals known to the State of  
California to cause cancer, birth defects, or other reproduc-  
tive harm.  
For Diesel Engines:  
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.  
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 Global Engineering Documents (phone: 1-877-413-5184, website:  
www.global.ihs.com).  
Ontario, Canada L4W 5NS (phone: 800-463-6727 or in Toronto  
416-747-4044,website: www.csa-international.org).  
Safe Practice For Occupational And Educational Eye And Face Protec-  
tion, ANSI Standard Z87.1, from American National Standards Institute,  
25 West 43rd Street, New York, NY 10036–8002 (phone:  
212-642-4900,website: www.ansi.org).  
Standard for Fire Prevention During Welding, Cutting, and Other Hot  
Work, NFPA Standard 51B, from National Fire Protection Association,  
P.O. Box 9101, Quincy, MA 02269-9101 (phone: 617-770-3000, web-  
site: www.nfpa.org.  
Recommended Safe Practices for the Preparation for Weldingand Cut-  
ting of Containers and Piping, American Welding Society Standard  
AWS F4.1, from Global Engineering Documents (phone:  
1-877-413-5184,website: www.global.ihs.com).  
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-  
tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (phone:  
617-770-3000,website: www.nfpa.org and www. sparky.org).  
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-  
intendentof Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954  
(phone: 1-866-512-1800) (there are 10 Regional Offices—phone for  
Region 5, Chicago, is 312-353-2220, website: www.osha.gov).  
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,  
from Compressed Gas Association, 4221 Walney Road, 5th Floor,  
Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).  
Code for Safety in Welding and Cutting, CSA Standard W117.2, from  
CanadianStandards Association, Standards Sales, 5060 Mississauga,  
1-8. EMF Information  
Considerations About Welding And The Effects Of Low Frequency  
Electric And Magnetic Fields  
1. Keep cables close together by twisting or taping them, or using a  
cable cover.  
2. Arrange cables to one side and away from the operator.  
3. Do not coil or drape cables around your body.  
4. Keep welding power source and cables as far away from  
operator as practical.  
5. Connect work clamp to workpiece as close to the weld as  
possible.  
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.  
About Implanted Medical Devices:  
ImplantedMedical Device wearers should consult their doctor and the  
device manufacturer before performing or going near arc welding, spot  
welding, gouging, plasma arc cutting, or induction heating operations.  
If cleared by your doctor, then following the above procedures is recom-  
mended.  
To reduce magnetic fields in the workplace, use the following  
procedures:  
OM-4419 Page 5  
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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT  
UTILISATION  
rom_2007−04fre  
Se protéger, ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud.  
2-1. Signification des symboles  
DANGER! − Indique une situation dangereuse qui si on  
l’évite pas peut donner la mort ou des blessures graves.  
Les dangers possibles sont montrés par les symboles  
joints ou sont expliqués dans le texte.  
.
I
n
d
i
q
u
e
d
e
s
i
n
s
t
r
u
c
t
i
o
n
s
s
p
é
c
i
f
i
q
u
e
s
.
Indique une situation dangereuse qui si on l’évite pas  
peut donner la mort ou des blessures graves. Les dan-  
gers possibles sont montrés par les symboles joints ou  
sont expliqués dans le texte.  
Ce groupe de symboles veut dire Avertissement! Attention! DANGER  
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES  
CHAUDES. Consulter les symboles et les instructions ci-dessous y  
afférant pour les actions nécessaires afin d’éviter le danger.  
NOTE − Indique des déclarations pas en relation avec des blessures  
personnelles.  
2-2. Dangers relatifs au soudage à l’arc  
souder DC semi−automatique de type CV (MIG/MAG), 2) un poste  
à souder manuel (électrode enrobée) DC, 3) un poste à souder  
manuelAC avec tension à vide réduite. Dans la plupart des cas, un  
poste courant continu de type CV est recommandé. Et, ne pas tra-  
vailler seul!  
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  
sécurité énumérées à la section 2-7. Veuillez lire et respecter  
toutes ces normes de sécurité.  
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 conformé-  
ment à son manuel d’utilisation et aux codes nationaux,  
provinciaux et municipaux.  
L’installation, l’utilisation, l’entretien et les réparations ne  
doivent être confiés qu’à des personnes qualifiées.  
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.  
Au cours de l’utilisation, tenir toute personne à l’écart et plus  
particulièrementles enfants.  
UN CHOC ÉLECTRIQUE peut tuer.  
D
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En effectuant les raccordements d’entrée fixer d’abord le conduc-  
teur de mise à la terre approprié et contre-vérifier les connexions.  
Un simple contact avec des pièces électriques peut  
provoquerune électrocution ou des blessures graves.  
L’électrode et le circuit de soudage sont sous tension  
Les câbles doivent être exempts d’humidité, d’huile et de graisse;  
protégez−les contre les étincelles et les pièces métalliques chau-  
des.  
dès que l’appareil est sur ON. Le circuit d’entrée et les circuits  
internes de l’appareil sont également sous tension à ce moment-là.  
En soudage semi-automatique ou automatique, le fil, le dévidoir, le  
logement des galets d’entraînement et les pièces métalliques en  
contact avec le fil de soudage sont sous tension. Des matériels mal  
installés ou mal mis à la terre présentent un danger.  
D
Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est  
pas endommagé ou dénudé − remplacer le cordon immédiatement  
s’il est endommagé − un câble dénudé peut provoquer une électro-  
cution.  
D
D
Mettre l’appareil hors tension quand on ne l’utilise pas.  
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-  
sante ou mal épissés.  
D
D
Ne jamais toucher les pièces électriques sous tension.  
Porter des gants et des vêtements de protection secs ne compor-  
tant pas de trous.  
D
D
Ne pas enrouler les câbles autour du corps.  
Si la pièce soudée doit être mise à la terre, le faire directement  
avec un câble distinct − ne pas utiliser le connecteur de pièce ou le  
câble de retour.  
D
D
S’isoler de la pièce et de la terre au moyen de tapis ou d’autres  
moyens isolants suffisamment grands pour empêcher le contact  
physique éventuel avec la pièce ou la terre.  
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.  
Ne pas se servir de source électrique à courant électrique dans les  
zones humides, dans les endroits confinés ou là où on risque de  
tomber.  
Ne pas toucher des porte électrodes connectés à deux machines  
en même temps à cause de la présence d’une tension à vide dou-  
blée.  
D
D
Se servir d’une source électrique à courant électrique UNIQUE-  
MENT si le procédé de soudage le demande.  
D
N’utiliser qu’un matériel en bon état. Réparer ou remplacer  
sur-le-champ les pièces endommagées. Entretenir l’appareil  
conformémentà ce manuel.  
Si l’utilisation d’une source électrique à courant électrique s’avère  
nécessaire, se servir de la fonction de télécommande si l’appareil  
en est équipé.  
D
D
D
Porter un harnais de sécurité quand on travaille en hauteur.  
Maintenir solidement en place tous les panneaux et capots.  
D
Des précautions de sécurité supplémentaires sont requises dans  
des environnements à risque comme: les endroits humides ou  
lorsque l’on porte des vêtements mouillés; sur des structures mé-  
talliques 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  
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.  
OM-4419 Page 6  
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Une tension DC importante subsiste à l’intérieur  
des onduleurs après avoir coupé l’alimentation.  
LES RAYONS DE L’ARC peuvent pro  
voquer des brûlures dans les yeux e  
sur la peau.  
D
Couper l’alimentation du poste et décharger les condensateurs  
d’entrée comme indiqué dans la Section Maintenance avant de  
toucher des composants.  
Le rayonnement de l’arc du procédé de soudage  
génère des rayons visibles et invisibles intense  
(ultraviolets et infrarouges) susceptibles de provoquer des brûlure  
dans les yeux et sur la peau. Des étincelles sont projetées pendant le  
soudage.  
DES PIÈCES CHAUDES peuvent  
provoquer des brûlures graves.  
D
Ne pas toucher à mains nues les parties chau-  
des.  
Prévoir une période de refroidissement avant de  
travailler à l’équipement.  
D
Porter un casque de soudage approuvé muni de verres filtrants  
approprié pour protéger visage et yeux pendant le soudage  
(voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).  
D
D
D
Porter des lunettes de sécurité avec écrans latéraux même sous  
votre casque.  
D
Ne pas toucher aux pièces chaudes, utiliser les outils recomman-  
dés et porter des gants de soudage et des vêtements épais pour  
éviter les brûlures.  
Avoir recours à des écrans protecteurs ou à des rideaux pour  
protéger les autres contre les rayonnements les éblouissements  
et les étincelles ; prévenir toute personne sur les lieux de ne pas  
regarder l’arc.  
D
Porter des vêtements confectionnés avec des matières résistan-  
tes et ignifuges (cuir, coton lourd ou laine) et des bottes de  
protection.  
DES PIECES DE METAL ou DES SA-  
LETES peuvent provoquer des bles-  
sures dans les yeux.  
LE SOUDAGE peut provoquer un in  
cendie ou une explosion.  
D
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  
métalliquesvolantes. Pendant la période de refroidissement des  
soudures, elles risquent de projeter du laitier.  
Le soudage effectué sur des conteneurs fermés tel  
que des réservoirs, tambours ou des conduites peu  
provoquer leur éclatement. Des étincelles peuven  
être projetées de l’arc de soudure. La projection d’étincelles, des pièce  
chaudes et des équipements chauds peut provoquer des incendies e  
des brûlures. Le contact accidentel de l’électrode avec des objet  
métalliquespeut provoquer des étincelles, une explosion, un surchauf  
fement ou un incendie. Avant de commencer le soudage, vérifier e  
s’assurer que l’endroit ne présente pas de danger.  
Porter des lunettes de sécurité avec écrans latéraux ou un écran  
facial.  
LES FUMÉES ET LES GAZ peuvent être  
dangereux.  
D
Déplacer toutes les substances inflammables à une distance de  
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir  
soigneusementavec des protections homologués.  
Le soudage génère des fumées et des gaz. Leur  
inhalationpeut être dangereux pour votre santé.  
D
D
D
Ne pas souder dans un endroit là où des étincelles peuvent tomber  
sur des substances inflammables.  
D
Eloigner votre tête des fumées. Ne pas respirer les fumées.  
D
D
D
À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au  
niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.  
Se protéger et d’autres personnes de la projection d’étincelles et  
de métal chaud.  
Des étincelles et des matériaux chauds du soudage peuvent  
facilement passer dans d’autres zones en traversant de petites  
fissures et des ouvertures.  
Si la ventilation est médiocre, porter un respirateur anti-vapeurs  
approuvé.  
Lire et comprendre les spécifications de sécurité des matériaux  
(MSDS) et les instructions du fabricant concernant les métaux, les  
consommables, les revêtements, les nettoyants et les dégraisseurs.  
D
D
D
Surveiller tout déclenchement d’incendie et tenir un extincteur à  
proximité.  
Le soudage effectué sur un plafond, plancher, paroi ou séparation  
peut déclencher un incendie de l’autre côté.  
D
Travailler dans un espace fermé seulement s’il est bien ventilé ou  
en portant un respirateur à alimentation d’air. Demander toujours à  
un surveillant dûment formé de se tenir à proximité. Des fumées et  
des gaz de soudage peuvent déplacer l’air et abaisser le niveau  
d’oxygène provoquant des blessures ou des accidents mortels.  
S’assurer que l’air de respiration ne présente aucun danger.  
Ne pas effectuer le soudage sur des conteneurs fermés tels que  
des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été  
préparés correctement conformément à AWS F4.1 (voir les nor-  
mes de sécurité).  
D
D
Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou va-  
peurs inflammables (vapeur d’essence, par exemple).  
D
D
Ne pas souder dans des endroits situés à proximité d’opérations  
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et  
les rayons de l’arc peuvent réagir en présence de vapeurs et for-  
mer des gaz hautement toxiques et irritants.  
Brancher le câble de masse sur la pièce le plus près possible de la  
zone de soudage pour éviter le transport du courant sur une  
longue distance par des chemins inconnus éventuels en provo-  
quant des risques d’électrocution, d’étincelles et d’incendie.  
Ne pas souder des métaux munis d’un revêtement, tels que l’acier  
galvanisé, plaqué en plomb ou au cadmium à moins que le revête-  
ment n’ait été enlevé dans la zone de soudure, que l’endroit soit  
bien ventilé, et en portant un respirateur à alimentation d’air. Les  
revêtementset tous les métaux renfermant ces éléments peuvent  
dégager des fumées toxiques en cas de soudage.  
D
D
D
Ne pas utiliser le poste de soudage pour dégeler des conduites ge-  
lées.  
En cas de non utilisation, enlever la baguette d’électrode du porte-  
électrode ou couper le fil à la pointe de contact.  
Porter des vêtements de protection dépourvus d’huile tels que des  
gants en cuir, une chemise en matériau lourd, des pantalons sans  
revers, des chaussures hautes et un couvre chef.  
LES ACCUMULATIONS DE GAZ ris  
quent de provoquer des blessures ou  
même la mort.  
D
D
D
Avant de souder, retirer toute substance combustible de vos po-  
ches telles qu’un allumeur au butane ou des allumettes.  
D
Fermer l’alimentation du gaz protecteur en cas de  
non utilisation.  
Une fois le travail achevé, assurez−vous qu’il ne reste aucune tra-  
ce d’étincelles incandescentes ni de flammes.  
D
Veiller toujours à bien aérer les espaces confinés ou se servir d’un  
respirateurd’adduction d’air homologué.  
Utiliser exclusivement des fusibles ou coupe−circuits appropriés.  
Ne pas augmenter leur puissance; ne pas les ponter.  
OM-4419 Page 7  
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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 proximité.  
D
D
D
Protéger les bouteilles de gaz comprimé d’une chaleur excessive,  
des chocs mécaniques, des dommages physiques, du laitier, des  
flammes ouvertes, des étincelles et des arcs.  
Placer les bouteilles debout en les fixant dans un support station-  
naire ou dans un porte-bouteilles pour les empêcher de tomber ou  
de se renverser.  
LE BRUIT peut affecter l’ouïe.  
Le bruit des processus et des équipements peut affec  
l’ouïe.  
Tenir les bouteilles éloignées des circuits de soudage ou autres  
circuits électriques.  
D
Porter des protections approuvés pour les ore  
les si le niveau sonore est trop élevé.  
D
D
Ne jamais placer une torche de soudage sur une bouteille à gaz.  
Une électrode de soudage ne doit jamais entrer en contact avec  
une bouteille.  
LES CHAMPS MAGNETIQUES peuv-  
ent affecter des implants médicaux.  
D
D
Ne jamais souder une bouteille pressurisée − risque d’explosion.  
D
Porteur de simulateur cardiaque ou autre im-  
plants médicaux, rester à distance.  
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
Les porteurs d’implants doivent d’abord consulter leur médecin  
avant de s’approcher des opérations de soudage à l’arc, de sou-  
dage par points, de gougeage, du coupage plasma ou de chauf-  
fage par induction.  
D
D
D
D
Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la  
bouteille.  
Si des BOUTEILLES sont endomma  
gées, elles pourront exploser.  
Maintenir le chapeau de protection sur la soupape, sauf en cas  
d’utilisationou de branchement de la bouteille.  
Utiliser les équipements corrects, les bonnes procédures et suffi-  
samment de personnes pour soulever et déplacer les bouteilles.  
Des bouteilles de gaz protecteur contiennent du ga  
sous haute pression. Si une bouteille est endomma  
gée, elle peut exploser. Du fait que les bouteilles de gaz fon  
normalement partie du procédé de soudage, les manipuler ave  
précaution.  
Lire et suivre les instructions sur les bouteilles de gaz comprimé,  
l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas  
Association) mentionné dans les principales normes de sécurité.  
2-3. Dangers existant en relation avec le moteur  
D
Seules des personnes qualifiées sont autorisées à enlever les por-  
tes, panneaux, recouvrements ou dispositifs de protection pour  
effectuer, s’il y a lieu, des travaux d’entretien et de dépannage.  
L’EXPLOSION DE LA BATTERIE peu  
RENDRE AVEUGLE.  
D
D
D
Pour empêcher tout démarrage accidentel pendant les travaux  
d’entretien,débrancher le câble négatif (−) de batterie de la borne.  
D
Toujours porter une protection faciale, des gants  
en caoutchouc et vêtements de protection lors  
d’une intervention sur la batterie.  
Ne pas approcher les mains, cheveux, vêtements lâches et outils  
des organes mobiles.  
D
D
D
Arrêter le moteur avant de débrancher ou de brancher les câbles  
de batterie.  
Remettreen place les panneaux ou les dispositifs de protection et  
fermer les portes à la fin des travaux d’entretien et avant de faire  
démarrer le moteur.  
Eviter de provoquer des étincelles avec les outils en travaillant sur  
la batterie.  
D
D
Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la  
mise en route accidentelle du moteur.  
Ne pas utiliser le poste de soudage pour charger les batteries ou  
des véhicules de démarrage rapide.  
Bloquerle volant moteur pour éviter sa rotation lors d’une interven-  
tion sur le générateur.  
D
D
Observer la polarité correcte (+ et −) sur les batteries.  
Débrancher le câble négatif (–) en premier lieu. Le rebrancher en  
dernier lieu.  
DES PIÈCES CHAUDES peuvent  
provoquer des brûlures graves.  
LE CARBURANT MOTEUR peut provo  
quer un incendie ou une explosion.  
D
Ne pas toucher à mains nues les parties chau-  
des.  
D
Prévoir une période de refroidissement avant de  
travailler à l’équipement.  
D
Arrêter le moteur avant de vérifier le niveau de  
carburant ou de faire le plein.  
D
Ne pas toucher aux pièces chaudes, utiliser les outils recomman-  
dés et porter des gants de soudage et des vêtements épais pour  
éviter les brûlures.  
D
Ne pas faire le plein en fumant ou proche d’une source d’étincelles  
ou d’une flamme nue.  
D
D
Ne pas faire le plein de carburant à ras bord; prévoir de l’espace  
pour son expansion.  
LA VAPEUR ET LE LIQUIDE DE  
REFROIDISSEMENT CHAUD peuvent  
provoquer des brûlures.  
Faire attention de ne pas renverser de carburant. Nettoyer tout  
carburant renversé avant de faire démarrer le moteur.  
D
D
Jeter les chiffons dans un récipient ignifuge.  
D
Il est préférable de vérifier le liquide de refroi-  
dissementune fois le moteur refroidi pour éviter  
de se brûler.  
Toujours garder le pistolet en contact avec le réservoir lors du  
remplissage.  
DES ORGANES MOBILES peuvent pro  
voquer des blessures.  
D
Toujours vérifier le niveau de liquide de refroidissement dans le  
vase d’expansion (si présent), et non dans le radiateur (sauf si pré-  
cisé autrement dans la section maintenance du manuel du  
moteur).  
D
Ne pas approcher les mains des ventilateurs,  
courroies et autres pièces en mouvement.  
D
D
Si le moteur est chaud et que le liquide doit être vérifié, opérer com-  
me suivant.  
D
Maintenirfermés et fixement en place les portes, panneaux, re-  
couvrements et dispositifs de protection.  
Mettre des lunettes de sécurité et des gants, placer un torchon sur  
le bouchon du radiateur.  
D
Arrêter le moteur avant d’installer ou brancher l’appareil.  
OM-4419 Page 8  
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D
Dévisser le bouchon légèrement et laisser la vapeur s’échapper  
avant d’enlever le bouchon.  
LA CHALEUR DU MOTEUR peut pro-  
voquer un incendie.  
L’utilisation d’un groupe autonome  
à l’intérieur PEUT VOUS TUER EN  
QUELQUES MINUTES.  
D
Ne pas placer l’appareil sur, au-dessus ou à  
proximité de surfaces inflammables.  
D
Tenir à distance les produits inflammables de l’échappement.  
D
Les fumées d’un groupe autonome contient du  
monoxyde de carbone. C’est un poison invisi-  
ble et inodore.  
LES ÉTINCELLES À L’ÉCHAPPEMENT  
peuvent provoquer un incendie.  
D
JAMAIS utiliser dans une maison ou garage,  
même avec les portes et fenêtres ouvertes.  
D
Empêcher les étincelles d’échappement du  
moteur de provoquer un incendie.  
D
Uniquementutiliser à l’EXTERIEUR, loin des portes, fenêtres et  
bouches aération.  
D
Utiliser uniquement un pare-étincelles  
approuvé − voir codes en vigueur.  
L’ACIDE DE LA BATTERIE peut pro-  
voquer des brûlures dans les YEUX et  
sur la PEAU.  
D
D
Ne pas renverser la batterie.  
Remplacer une batterie endommagée.  
D
Rincer immédiatement les yeux et la peau à l’eau.  
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 couper ou gouger à proximité de pro-  
duits inflammables.  
Surveillez et garder un extincteur à proximité.  
D
D
Ne pas utiliser l’air comprimé pour respirer.  
Utiliser l’air comprimé seulement pour le cou-  
page, gougeage et les outils pneumatiques.  
D
DES PIECES CHAUDES peuvent provo-  
quer des brûlures et blessures.  
L’AIR COMPRIMÉ peut provoquer  
des blessures.  
D
Ne pas toucher le compresseur ou d’autres  
éléments du circuit air comprimé chauds.  
D
D
Porter des lunettes de sécurité approuvées.  
Ne pas diriger le jet d’air vers d’autres ou  
soi-même.  
D
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
Lisez le manuel d’instructions avant l’utilisation  
ou la maintenance de l’appareil.  
D
Relâcher la pression d’air de l’outillage ou du  
système avant d’effectuer la maintenance,  
avant de changer ou de rajouter des éléments  
ou avant d’ouvrir la purge ou le bouchon de  
remplissaged’huile.  
D
Arrêter le moteur et relâcher la pression avant  
d’effectuer la maintenance.  
D
N’utiliser que les pièces de rechange recommandées par le  
constructeur.  
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance  
Risque D’INCENDIE OU D’EXPLO-  
SION.  
LA CHUTE DE L’APPAREIL peut blesser.  
D
Utiliser l’anneau de levage pour lever l’appareil et  
les accessoires correctement installées seuls,  
PAS les bouteilles de gaz. Ne pas dépasser le  
poids nominal maximal de l’œilleton (voir les spé-  
cifications).  
D
Ne pas placer l’appareil sur, au-dessus ou  
à proximité de surfaces inflammables.  
D
Ne pas installer l’appareil à proximité de pro-  
duits inflammables.  
D
Ne lever et ne soutenir l’appareil qu’avec de  
l’équipement approprié et en suivant les  
procédures adéquates.  
D
Ne pas surcharger l’installation électrique − s’assurer que l’ali-  
mentationest correctement dimensionnée et protégée avant de  
mettre l’appareil en service.  
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.  
OM-4419 Page 9  
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UNE REMORQUE QUI BASCULE peut  
entraîner des blessures.  
LE SURCHAUFFEMENT peut endom-  
mager le moteur électrique.  
D
Utiliser les supports de la remorque ou des  
blocs pour soutenir le poids.  
D
Arrêter ou déconnecter l’équipement avant de  
démarrer ou d’arrêter le moteur.  
D
Installer convenablement le poste sur la remor-  
que comme indiqué dans le manuel s’y rappor-  
tant.  
D
D
Ne pas laisser tourner le moteur trop lentement sous risque d’en-  
dommagerle moteur électrique à cause d’une tension et d’une fré-  
quence trop faibles.  
Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz,  
s’il y a lieu.  
LIRE LES INSTRUCTIONS.  
D
Lisez le manuel d’instructions avant l’utilisation  
ou la maintenance de l’appareil.  
D
N’utiliser que les pièces de rechange recom-  
mandées par le constructeur.  
LES ÉTINCELLES VOLANTES ris-  
quent de provoquer des blessures.  
D
Effectuer la maintenance et le service du moteur et du compres-  
seur d’air suivant les instructions dans ce manuel ou le manuel  
du moteur/compresseur (si applicable).  
D
Porter un écran facial pour protéger le visage et  
les yeux.  
D
Affûter l’électrode au tungstène uniquement à la  
meuleuse dotée de protecteurs. Cette manœuv-  
re est à exécuter dans un endroit sûr lorsque l’on  
porte l’équipement homologué de protection du  
visage, des mains et du corps.  
LE RAYONNEMENT HAUTE FRÉ-  
QUENCE (H.F.) risque de provoquer  
des interférences.  
D
Le rayonnement haute fréquence (H.F.) peut  
provoquer des interférences avec les équipe-  
ments de radio−navigation et de communica-  
tion, les services de sécurité et les ordinateurs.  
D
Les étincelles risquent de causer un incendie − éloigner toute sub-  
stance inflammable.  
D
Demander seulement à des personnes qualifiées familiarisées  
avec des équipements électroniques de faire fonctionner l’instal-  
lation.  
DES ORGANES MOBILES peuvent  
provoquer des blessures.  
D
Ne pas s’approcher des organes mobiles.  
Ne pas s’approcher des points de coincement  
tels que des rouleaux de commande.  
D
D
L’utilisateurest tenu de faire corriger rapidement par un électri-  
cien qualifié les interférences résultant de l’installation.  
D
Si le FCC signale des interférences, arrêter immédiatement l’ap-  
pareil.  
D
D
Effectuer régulièrement le contrôle et l’entretien de l’installation.  
LES FILS DE SOUDAGE peuvent  
provoquer des blessures.  
Maintenirsoigneusement fermés les portes et les panneaux des  
sources de haute fréquence, maintenir les éclateurs à une dis-  
tance correcte et utiliser une terre et un blindage pour réduire les  
interférences éventuelles.  
D
Ne pas appuyer sur la gâchette avant d’en  
avoir reçu l’instruction.  
D
Ne pas diriger le pistolet vers soi, d’autres per-  
sonnes ou toute pièce mécanique en enga-  
geant le fil de soudage.  
LE SOUDAGE À L’ARC risque de  
provoquer des interférences.  
D
L’énergie électromagnétique risque de provo-  
quer des interférences pour l’équipement élec-  
tronique sensible tel que les ordinateurs et  
l’équipementcommandé par ordinateur tel que  
les robots.  
L’EMPLOI EXCESSIF peut  
SURCHAUFFER L’ÉQUIPEMENT.  
D
D
D
Laisser l’équipement refroidir ; respecter le fac-  
teur de marche nominal.  
Réduire le courant ou le facteur de marche  
avant de poursuivre le soudage.  
D
D
Veiller à ce que tout l’équipement de la zone de soudage soit  
compatibleélectromagnétiquement.  
Pour réduire la possibilité d’interférence, maintenir les câbles de  
soudage aussi courts que possible, les grouper, et les poser  
aussi bas que possible (ex. par terre).  
Ne pas obstruer les passages d’air du poste.  
D
D
D
Veiller à souder à une distance de 100 mètres de tout équipe-  
ment électronique sensible.  
LES CHARGES ÉLECTROSTATI-  
QUES peuvent endommager les  
circuits imprimés.  
Veiller à ce que ce poste de soudage soit posé et mis à la terre  
conformément à ce mode d’emploi.  
En cas d’interférences après avoir pris les mesures précéden-  
tes, il incombe à l’utilisateur de prendre des mesures supplé-  
mentairestelles que le déplacement du poste, l’utilisation de câ-  
bles blindés, l’utilisation de filtres de ligne ou la pose de protec-  
teurs dans la zone de travail.  
D
Établir la connexion avec la barrette de terre  
avant de manipuler des cartes ou des pièces.  
D
Utiliser des pochettes et des boîtes antistatiques pour stocker,  
déplacer ou expédier des cartes de circuits imprimes.  
OM-4419 Page 10  
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2-6. Proposition californienne 65 Avertissements  
Pour les moteurs à essence :  
Les équipements de soudage et de coupage produisent des  
fumées et des gaz qui contiennent des produits chimiques  
dont l’État de Californie reconnaît qu’ils provoquent des mal-  
formations congénitales et, dans certains cas, des cancers.  
(Code de santé et de sécurité de Californie, chapitre 25249.5  
et suivants)  
Les gaz d’échappement des moteurs contiennent des pro-  
duits chimiques dont l’État de Californie reconnaît qu’ils  
provoquent des cancers et des malformations congénitales  
ou autres problèmes de procréation.  
Pour les moteurs diesel :  
Les batteries, les bornes et autres accessoires contiennent  
du plomb et des composés à base de plomb, produits chimi-  
ques dont l’État de Californie reconnaît qu’ils provoquent des  
cancers et des malformations congénitales ou autres  
problèmesde procréation. Se laver les mains après manipu-  
lation.  
Les gaz d’échappement des moteurs diesel et certains de  
leurs composants sont reconnus par l’État de Californie com-  
me provoquant des cancers et des malformations  
congénitalesou autres problèmes de procréation.  
2-7. Principales normes de sécurité  
Safety inWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,  
de Global Engineering Documents (téléphone : 1-877-413-5184, site  
Internet : www.global.ihs.com).  
L4W 5NS (téléphone : 800-463-6727 ou à Toronto 416-747-4044, site  
Internet : www.csa-international.org).  
Safe Practice For Occupational And Educational Eye And Face Protec-  
tion, ANSI Standard Z87.1, de American National Standards Institute,  
11 West 43rd Street, New York, NY 10036-8002 (téléphone :  
212-642-4900,site Internet : www.ansi.org).  
RecommendedSafe Practices for the Preparation for Welding and Cut-  
ting of Containers and Piping, American Welding Society Standard  
AWS F4.1 de Global Engineering Documents (téléphone  
1-877-413-5184,site Internet : www.global.ihs.com).  
:
Standard for Fire Prevention During Welding, Cutting, and Other Hot  
Work, NFPA Standard 51B, de National Fire Protection Association,  
P.O. Box 9101, Quincy, MA 02269-9101 (téléphone : 617-770-3000,  
site Internet : www.nfpa.org).  
National Electrical Code, NFPA Standard 70, de National Fire Protec-  
tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (téléphone :  
617-770-3000, site Internet : www.nfpa.org).  
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, de U.S. Government Printing Office, Superin-  
tendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954  
(téléphone: 1-866-512-1800) (il y a 10 bureaux régionaux−−le télépho-  
ne de la région 5, Chicago, est 312-353-2220, site Internet :  
www.osha.gov).  
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,  
de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chan-  
tilly, VA 20151 (téléphone  
www.cganet.com).  
:
703-788-2700, site Internet  
:
Code for Safety in Welding and Cutting, CSA Standard W117.2, de  
CanadianStandards Association, 5060 Mississauga, Ontario, Canada  
2-8. Information EMF  
Considérationssur le soudage et les effets de basse fréquence et des  
champs magnétiques et électriques.  
1. Garder les câbles ensemble, les torsader, les scotcher, ou les  
recouvrir d’une housse.  
2. Disposer les câbles d’un côté et à distance de l’opérateur.  
3. Ne pas courber pas et ne pas entourer pas les câbles autour de  
votre corps.  
Le courant de soudage, pendant son passage dans les câbles de sou-  
dage, causera des champs électromagnétiques. Il y a eu et il y a encore  
un certain souci à propos de tels champs. Cependant, après avoir exa-  
miné plus de 500 études qui ont été faites pendant une période de  
recherche de 17 ans, un comité spécial ruban bleu du National  
Research Council a conclu : « L’accumulation de preuves, suivant le  
jugement du comité, n’a pas démontré que l’exposition aux champs  
magnétiqueset champs électriques à haute fréquence représente un  
risque à la santé humaine ». Toutefois, des études sont toujours en  
cours et les preuves continuent à être examinées. En attendant que les  
conclusions finales de la recherche soient établies, il vous serait  
souhaitablede réduire votre exposition aux champs électromagnéti-  
ques pendant le soudage ou le coupage.  
4. Garder le poste de soudage et les câbles le plus loin possible de  
vous.  
5. Connecter la pince sur la pièce aussi près que possible de la  
soudure.  
En ce qui concerne les implants médicaux :  
Les porteurs d’implants doivent d’abord consulter leur médecin avant  
de s’approcher des opérations de soudage à l’arc, de soudage par  
points, de gougeage, du coupage plasma ou de chauffage par induc-  
tion. Si le médecin approuve, il est recommandé de suivre les  
procédures précédentes.  
Pour réduire les champs magnétiques sur le poste de travail, appliquer  
les procédures suivantes :  
OM-4419 Page 11  
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SECTION 3 − DEFINITIONS  
3-1. Symbol Definitions  
Fast  
Fast/Slow  
(Run/Idle)  
Stop Engine  
Slow (Idle)  
Volts  
(Run, Weld/Power)  
Read Operator’s  
Manual  
Start Engine  
Engine Oil  
Amperes  
A
V
Fuel  
Battery (Engine)  
Engine  
Check Valve  
Clearance  
Do not switch while  
welding  
Engine Choke  
Positive  
Work Connection  
Alternating Current  
(AC)  
Negative  
Output  
Welding Arc  
(Electrode)  
MIG (GMAW),  
Wire  
Stick (SMAW)  
Time  
TIG (GTAW)  
Protective Earth  
(Ground)  
Hours  
Seconds  
s
h
Circuit Protector  
Temperature  
SECTION 4 − SPECIFICATIONS  
4-1. Weld, Power, and Engine Specifications  
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Rated  
Welding  
Output  
Maximum  
Open Circuit  
Voltage  
Welding  
Mode  
Weld Output  
Range  
Fuel  
Capacity  
Generator Power Rating  
Engine  
250 A, 25 V,  
100% Duty  
Cycle  
CC/AC  
CC/DC  
40 − 250 A  
80  
Peak: 10.5 kVA/kW  
Robin EH-65  
Air-Cooled, Two-Cylinder,  
Four-Cycle, 22 HP  
Gasoline Engine  
Continuous: 9.5 kVA/kW,  
Single-Phase,  
84/42 A, 120/240 V AC,  
60 Hz  
(while not welding)  
250 A, 25 V,  
100% Duty  
Cycle  
40 − 250 A  
80  
12 gal  
(45 L) Tank  
or  
Kohler CH-23  
Air-Cooled, Two-Cylinder,  
Four-Cycle, 23 HP  
Gasoline Engine  
275 A, 25 V,  
60% Duty  
Cycle  
CV/DC  
17 − 28 V  
41  
250 A, 28 V,  
100% Duty  
Cycle  
OM-4419 Page 12  
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4-2. Dimensions, Weights, and Operating Angles  
Dimensions  
33-1/2 in (851 mm)  
(To Top Of Exhaust)  
A
B
Height  
C
Width  
20 in (508 mm)  
Do not exceed tilt angles or engine could  
be damaged or unit could tip.  
Depth  
45-3/8 in (1153 mm)  
20 in (508 mm)  
D
A
B
C
D
E
F
Do not move or operate unit where it could  
tip.  
G
16-1/2 in (419 mm)  
1-3/4 in (44 mm)  
6-1/16 in (154 mm)  
32-3/4 in (832 mm)  
45-3/8 in (1153 mm)  
13/32 in (10 mm) Dia.  
Weight  
4 Holes  
E
F
25°  
25°  
25°  
25°  
G
Robin-Powered Unit: 560 lb (254 kg)  
Kohler-PoweredUnit: 562 lb (254 kg)  
Engine End  
800 426  
Lifting Eye Weight Rating: 1280 lbs  
(580 kg)  
4-3. Dimensions For Units With Optional Running Gear  
Dimensions  
All Running Gear Options:  
42-1/2 in (1079 mm)  
Height  
(To Top Of Handle  
Assembly)  
C
Protective Cage Width:  
D
A
26 in (660 mm)  
Running Gear Width:  
B
32 in (813 mm)  
Protective Cage Length:  
C
48 in (1219 mm)  
A
B
B
Running Gear Length:  
45−1/2 in (1156 mm)  
D
OM-4419 Page 13  
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4-4. Fuel Consumption (Robin-Powered Units)  
On a typical job using 1/8 in 7018  
electrodes (125 amps, 20% duty  
cycle), expect about 20 hours of op-  
eration.  
Welding at 150 amps at 40% duty  
cycle uses approximately 3/4 gal-  
lon per hour, or about 16 hours of  
operation.  
220 571  
4-5. Fuel Consumption (Kohler-Powered Units)  
On a typical job using 1/8 in 7018  
electrodes (125 amps, 20% duty  
cycle), expect about 20 hours of op-  
eration.  
Welding at 150 amps at 40% duty  
cycle uses approximately 3/4 gal-  
lon per hour, or about 16 hours of  
operation.  
220 181  
OM-4419 Page 14  
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4-6. 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.  
A. For CC/AC Mode  
B. For CC/DC Mode  
C. For CV/DC Mode  
200 296 / 200 297 / 200 298  
OM-4419 Page 15  
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4-7. Generator Power Curve  
The generator power curve shows  
the generator power in amperes  
available at the receptacles.  
200 294  
4-8. Duty Cycle  
Duty cycle is the percentage of 10  
minutes that unit can weld at rated  
load without overheating.  
NOTICE − Exceeding duty cycle  
can damage unit and void warranty.  
Continuous Welding  
100% Duty Cycle at 250 Amperes  
200 293  
OM-4419 Page 16  
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SECTION 5 − INSTALLATION  
5-1. Installing Welding Generator  
!
!
Do not weld on base. Welding  
on base can cause fuel tank fire  
or explosion. Bolt unit down  
using holes provided in base.  
Movement  
Do not lift unit from end.  
Always securely fasten weld-  
ing generator onto transport  
vehicle or trailer and comply  
with all DOT and other applica-  
ble codes.  
OR  
!
Do not mount unit by support-  
ing the base only at the four  
mounting holes. Use cross-  
supports to adequately sup-  
port unit and prevent damage  
to base.  
Location / Airflow Clearance  
!
!
Always ground generator  
frame to vehicle frame to pre-  
vent electric shock and static  
electricity hazards.  
If unit does not have GFCI re-  
ceptacles, use GFCI-protected  
extension cord.  
OR  
NOTICE− Do not install unit where air  
flow is restricted or engine may  
overheat.  
18 in  
(460 mm)  
18 in  
(460 mm)  
Mounting:  
18 in  
(460 mm)  
1
Cross-Supports  
Mount unit on flat surface or use  
cross-supports to support base.  
Grounding:  
18 in  
(460 mm)  
2
Equipment Grounding Terminal  
(On Front Panel)  
18 in  
(460 mm)  
3
4
Grounding Cable (Not Supplied)  
Metal Vehicle Frame  
Mounting  
Connect cable from equipment  
ground terminal to metal vehicle  
frame. Use #10 AWG or larger insu-  
lated copper wire.  
OR  
Inadequatesupport.  
1
!
Do not use flexible mounts.  
Grounding  
2
!
Bed liners, shipping skids, and some running gears in-  
3
sulate the welding generator from the vehicle frame. Al-  
ways connect a ground wire from the generator equip-  
ment grounding terminal to bare metal on the vehicle  
frame as shown.  
GND/PE  
Electrically bond generator frame to  
vehicle frame by metal-to-metal contact.  
install2 12/06 − Ref. 800 652 / Ref. 800 477-A / 803 274-A / 804 712  
4
OM-4419 Page 17  
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5-2. Engine Prestart Checks (Robin-Powered Units)  
Check all fluids daily. Engine must  
be cold and on a level surface. Unit  
is shipped with 10W30 engine oil.  
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NOTICE − This unit has a low oil  
pressure shutdown switch. Howev-  
er, some conditions may cause en-  
gine damage before the engine  
shuts down. Check oil level often  
and do not use the oil pressure  
shutdown system to monitor oil  
level.  
Oil Fill  
Oil Check  
Open top service door.  
Fuel  
To help prime the fuel system at ini-  
tial start-up, fill tank with fresh fuel  
(see maintenance label for specifi-  
cations). Always leave filler neck  
empty to allow room for expansion.  
Check fuel level on a cold engine  
before use each day.  
Full  
Full  
Oil  
. Do not exceed the ”Full” mark  
on the oil level dipstick. The  
fuel pump may operate errati-  
cally if crankcase is overfilled.  
Gasoline  
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).  
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starting:  
Keep battery in good condition.  
Store battery in warm area.  
Use correct grade oil for cold  
weather.  
Close top service door.  
1/2  
0
1
0000  
H
803 755-C / 217 015-A  
OM-4419 Page 18  
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5-3. Engine Prestart Checks (Kohler-Powered Units)  
Check all fluids daily. Engine must  
be cold and on a level surface. Unit  
is shipped with 10W30 engine oil.  
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NOTICE − This unit has a low oil  
pressure shutdown switch. Howev-  
er, some conditions may cause en-  
gine damage before the engine  
shuts down. Check oil level often  
and do not use the oil pressure  
shutdown system to monitor oil  
level.  
Full  
Full  
Open top service door.  
Gasoline  
Fuel  
To help prime the fuel system at ini-  
tial start-up, fill tank with fresh fuel  
(see maintenance label for specifi-  
cations). Always leave filler neck  
empty to allow room for expansion.  
Check fuel level on a cold engine  
before use each day.  
Oil  
. Do not exceed the ”Full” mark  
on the oil level dipstick. The  
fuel pump may operate errati-  
cally if crankcase is overfilled.  
After fueling, check oil with unit on  
level surface. If oil is not up to full  
mark on dipstick, add oil (see main-  
tenance label).  
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starting:  
Keep battery in good condition.  
Store battery in warm area.  
Use correct grade oil for cold  
weather.  
Close top service door.  
1/2  
0
1
0000  
H
803 754-C / 217 015-A  
OM-4419 Page 19  
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5-4. Installing Exhaust Pipe  
!
Engine backfire can cause se-  
vere burns or other injuries.  
Do not point exhaust pipe to-  
ward control panel. Keep  
away from exhaust outlet.  
Point exhaust pipe in desired  
direction but always away  
from front panel and direction  
of travel.  
. Be sure to tighten exhaust clamp  
nuts. Exhaust clamp supplied  
with muffler.  
Tools Needed:  
1/2 in  
803 751 / Ref. 228 201-B  
5-5. Connecting Or Replacing the Battery  
Connecting The Battery  
Connect negative (−)  
cable last.  
−
+
−
+
Replacing The Battery  
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Tools Needed:  
3/8, 1/2 in  
Connect negative (−)  
cable last.  
−
+
−
+
803 754-C / Ref. S-0756-D / Ref. 228 201-B  
OM-4419 Page 20  
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5-6. Connecting to Weld Output Terminals  
!
Stop engine.  
1
Work Weld Output Terminal  
Electrode Weld Output Terminal  
2
Connect work cable to Work terminal.  
Connect electrode holder cable or  
electrodeweld cable to Electrode ter-  
minal for Stick and MIG welding.  
Connect torch cable to Electrode ter-  
minal for TIG welding.  
Use Process Selector switch to  
select type of weld output (see  
Section 6-1).  
.
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5
f
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cal process connections and  
control settings.  
!
Failure to properly connect  
weld cables may cause exces-  
sive heat and start a fire, or  
damage your machine.  
3
4
Weld Output Terminal  
Supplied Weld Output Terminal  
Nut  
1
2
5
6
Weld Cable Terminal  
Copper Bar  
Remove supplied nut from weld out-  
put terminal. Slide weld cable terminal  
onto weld output terminal and secure  
with nut so that weld cable terminal is  
tight against copper bar. Do not  
place anything between weld cable  
terminal and copper bar. Make  
sure that the surfaces of the weld  
cable terminal and copper bar are  
clean.  
Tools Needed:  
3/4 in  
6
3
Do not place  
anything between  
weld cable terminal  
and copper bar.  
4
5
Correct Installation  
Incorrect Installation  
803 750-B / Ref. 228 201-B / 803 778-A  
OM-4419 Page 21  
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5-7. Selecting Weld Cable Sizes*  
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit  
Not Exceeding***  
Weld Output  
Terminals  
!
Turn off power before  
connecting to weld  
output terminals.  
150 ft  
(45 m)  
200 ft  
250 ft  
300 ft  
350 ft  
400 ft  
100 ft (30 m) or Less  
Do not use worn,  
damaged, under-  
sized, or poorly  
spliced cables.  
(60 m) (70 m) (90 m) (105 m) (120 m)  
10 − 60% 60 − 100%  
Welding  
Amperes  
Duty  
Duty  
10 − 100% Duty Cycle  
Cycle  
Cycle  
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  
300  
350  
400  
500  
2 (35)  
1 (50)  
1 (50)  
1/0 (60)  
2/0 (70)  
3/0 (95)  
3/0 (95)  
4/0 (120)  
2/0 (70)  
3/0 (95) 4/0 (120)  
(2x70)  
(2x70)  
2 ea. 2/0 2 ea. 3/0 2 ea. 3/0  
(2x70) (2x95) (2x95)  
1/0 (60)  
2/0 (70)  
2/0 (70)  
3/0 (95)  
3/0 (95) 4/0 (120)  
2 ea. 2/0 2 ea. 3/0 2 ea. 3/0 2 ea. 4/0  
(2x70) (2x95) (2x95) (2x120)  
1/0 (60)  
1/0 (60)  
2/0 (70)  
4/0 (120)  
4/0 (120)  
2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 2 ea. 4/0  
(2x70) (2x95) (2x120) (2x120)  
2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 3/0 3 ea. 3/0  
(2x70)  
(2x95)  
(2x120)  
(3x95)  
(3x95)  
* This chart is a general guideline and may not suit all applications. If cables overheat, use next size larger cable.  
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.  
2
( ) = mm for metric use  
S-0007-F  
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.  
Notes  
OM-4419 Page 22  
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SECTION 6 − OPERATING THE WELDING GENERATOR  
6-1. Front Panel Controls  
6
3
5
4
2
1
Ref. 228 201-B  
1
Engine Control Switch  
Hour Meter: With engine off, place Engine  
Control switch in Run/Idle position to view en-  
gine hours.  
5
Coarse Range Switch  
Use switch to start engine, select speed, and  
stop engine. In Run/Idle position, engine runs  
at idle speed at no load, and weld/power speed  
under load. In Run position, engine runs at  
weld/power speed.  
NOTICE − Do not switch under load.  
Use switch to select weld amperage range  
whenWeld Process Selector switch is in Stick/  
Tig position, or voltage range when switch is in  
Wire position.  
Oil Change Interval: With engine off, place En-  
gine Control switch in the Run position to see  
hours before next oil change. Oil hours start at  
100 and count down to 0 (zero) (oil change  
due).  
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. For best arc starts and when using weld  
and generator power together, use a low  
Coarse Range setting with the Fine con-  
trol set at 7 or higher.  
most MIG equipment.  
Engine Choke Control  
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ommendedoil change interval.  
Use control to change engine air-fuel mix.  
To reset, cycle Engine Control switch from  
Run/Idle to Run three times within five sec-  
onds (engine off).  
6
Fine Control  
To Start: pull out choke and turn Engine Con-  
trol switch to Start position. Release switch  
and slowly push choke in when engine starts.  
Use control to select weld amperage (Stick/  
Tig) or voltage (Wire) within the range selected  
by the Coarse Range switch. Control may be  
adjusted while welding.  
4
Weld Process Selector Switch  
NOTICE − Do not switch under load.  
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come to a complete stop before attempt- Use switch to select type of weld output.  
ing restart.  
Set control at 10 for maximum generator  
power.  
Wire (GMAW) Welding: Use a positive (+)  
position for Direct Current Electrode Positive  
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(DCEP) and a negative (−) position for Direct  
gines encounter difficulties that are easily  
remedied.See Section 6-2 and 10-3.  
Weld output would be about 124 A DC based  
on control settings shown (80% of 60 to 140  
A). Settings shown are typical for welding with  
a 7018 (1/8) electrode.  
Current Electrode Negative.  
Stick (SMAW) and TIG (GTAW Welding): Use  
To Stop: turn Engine Control switch to Off  
a positive (+) position for Direct Current Elec-  
position.  
trode Positive (DCEP) and a negative (−) posi-  
tion for Direct Current Electrode Negative.  
Use AC position for alternating current.  
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Engine Hour Meter/Fuel Gauge/Idle  
Control  
cess connections and control settings.  
OM-4419 Page 23  
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6-2. Cold Weather Engine Operation  
1
Engine Control Switch  
Carburetor Icing  
Carburetoricing causes the unit to drop below the normal idle speed and then  
stall. This condition occurs when the temperature is near freezing and the rela-  
tive humidity is high. Ice forms on the throttle plate and inner bore of the carbu-  
retor. The engine typically restarts without problems but soon stalls again.  
1
Infrequently  
Loaded  
S
S
S
Treat gasoline with a fuel de−icer product (isopropyl alcohol).  
Place the Engine Control switch in the Run position.  
Run engine only when expecting to frequently load it.  
Breather Icing  
Oil breather/pulse line icing occurs in severe cold (continuously below 0_F).  
Moisture accumulates in the oil from piston ring blow−by if the engine is exten-  
sively idled. This may cause vacuum line freezing, oil breather tube freezing  
or ice in the carburetor. All of these cause operating problems. Due to ice in  
the lines, the engine may not restart until it is warmed to above freezing.  
Frequently  
Loaded  
S
S
S
Load engine and reduce idle times to prevent engine shutdowns.  
Use an electric fuel pump to avoid pulse line freezing.  
Install engine cold−weather kit.  
Both Kohler (1-800-544-2444) and Robin (1-800-277-6246) offer kits for cold  
weather operation. The user can install these kits. Both kits pull heated air from  
the muffler surface into the carburetor and shut the cold air off. This increases  
engine temperature during operation in both idle and high speed.  
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flow will have to be returned to normal.  
Ref. 228 201-B  
Notes  
Work like a Pro!  
Pros weld and cut  
safely. Read the  
safety rules at  
the beginning  
of this manual.  
OM-4419 Page 24  
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6-3. Typical Stick Welding Connections And Control Settings  
Stop engine.  
. This section provides general  
guidelines and may not suit all  
applications.  
For best arc starts and best  
results using weld and generator  
power together, use a low  
Coarse Range setting and the  
Fine control set at 7 or higher.  
. The control panel shows the typi-  
cal settings for welding with a  
7018 (1/8 in) electrode. Consult  
the amperage selection tables  
below if welding with other elec-  
trodes.  
1
2
Work Clamp  
Electrode Holder  
ConnectWork cable to Work terminal  
and Electrode holder cable to Elec-  
trode terminal on welding generator.  
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weld cables (see Section 5-7).  
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Typical Settings For 7018 (1/8 in) Electrode  
Coarse Range switch to the low-  
est range that covers the desired  
weld amperage. Use the Fine  
control to select the desired am-  
perage within the range se-  
lected. When properly set, the  
Fine control is normally set at 7  
or higher.  
1
2
Typical Settings For 7018 (1/8 in)  
Electrode:  
>
>
>
Set Weld Process Selector  
switch to + Stick position.  
Set Coarse Range switch to  
60-140 (1/8”) position.  
Electrode Selection Table (Beneath Cover)  
Set Fine control at 7 or higher  
for best results.  
3/32  
1/8  
6010  
5/32  
6010  
6011  
EP  
EP  
ALL  
ALL  
ALL  
DEEP  
&
MIN. PREP, ROUGH  
3/16  
7/32  
1/4  
6011  
HIGH SPATTER  
DEEP  
1/16  
6013 EP,EN  
LOW  
GENERAL  
5/64  
3/32  
1/8  
SMOOTH, EASY,  
FAST  
LOW HYDROGEN,  
STRONG  
7014 EP,EN  
ALL  
MED  
6013  
5/32  
7018  
EP  
ALL  
LOW  
3/16  
7/32  
1/4  
3/32  
1/8  
FLAT  
HORIZ LOW  
FILLET  
SMOOTH, EASY,  
FASTER  
7024 EP,EN  
5/32  
NI-CL  
308L  
EP  
EP  
ALL  
ALL  
LOW  
LOW  
CAST IRON  
STAINLESS  
7014  
7018  
7024  
3/16  
7/32  
1/4  
3/32  
1/8  
5/32  
3/16  
7/32  
1/4  
3/32  
1/8  
5/32  
3/16  
7/32  
1/4  
*EP = ELECTRODE POSITIVE (REVERSE POLARITY)  
EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)  
Tools Needed:  
3/4 in  
3/32  
1/8  
Ni-Cl  
308L  
5/32  
3/16  
3/32  
1/8  
803 750-B / 228 201-B / 087 985-A / Ref. S-0653  
5/32  
OM-4419 Page 25  
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6-4. Typical MIG Welding Connections And Settings  
A. Solid Wire Applications  
Stop engine.  
. This section provides general guide-  
lines and may not suit all ap-  
plications.  
Typical Control Settings For .035 (ER70S-3)  
. The control panel shows the typical  
settings for welding with .035  
(ER70S-3) solid wire. Use Argon-  
based shielding gas.  
Solid Wire − Short Circuit Transfer  
Note Coarse Range,  
Fine Control, and  
Weld Process switch  
settings.  
1
2
3
4
Work Clamp  
Wire Feeder  
MIG Gun  
Gun Trigger Plug  
5
6
Voltage Sensing Clamp  
Gas Cylinder:  
75/25 Argon-Based Gas for Short  
Circuit Transfer  
80% Argon (Or Higher) For Spray  
Transfer  
7
Gas Hose  
6
Connect work cable to welding generator  
Work terminal. Connect cable from wire  
feeder to cable from welding generator  
Electrode terminal.  
7
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cables (see Section 5-7).  
Loosen MIG gun securing knob. Insert  
gun end through opening in feeder and  
positionas close as possible to drive rolls  
without touching. Tighten knob.  
See wire feeder manual for wire thread-  
ing procedure.  
Insert gun trigger plug (item 4) into  
matching receptacle and tighten  
threaded collar.  
Connect gas hose from feeder to regula-  
tor on cylinder.  
Typical Control Settings For Short  
Circuit Transfer Using .035 (ER70S-3)  
Solid Wire And 75/25 Argon-Based  
Gas:  
Quick connector  
2
3
>
>
>
>
Set Weld Process Selector switch  
to Wire + (DCEP) position.  
Set Coarse Range switch to Wire/  
Low Range (17-22 volts) position.  
Set Fine Control to obtain minimum  
spatter.  
Set wire feed speed between  
150-300 ipm.  
Typical Control Settings For Spray  
Transfer Using .035 (ER70S-3) Solid  
Wire And 80% Or Higher Argon-  
Based Gas:  
4
5
>
>
>
>
Set Weld Process Selector switch  
to Wire + position.  
Work  
Set Coarse Range switch to Wire/  
High Range (20-28 volts) position.  
1
Tools Needed:  
3/4 in  
Set wire feed speed between  
320-500 ipm.  
Set Fine control to 3 and increase  
for longer arc length.  
803 750-B / 802 766 / 228 201-B  
OM-4419 Page 26  
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B. Self-Shielded Flux Core Wire Applications  
!
Stop engine.  
. This section provides general  
guidelines and may not suit all  
applications.  
Typical Control Settings For .045 (71T-11) Self-Shielded Flux Core Wire  
. The control panel shows the typi-  
cal settings for welding with .045  
(71T-11) self-shielded flux core  
wire.  
Note Coarse Range,  
Fine Control, and  
Weld Process switch  
settings.  
1
2
3
4
Work Clamp  
Wire Feeder  
MIG Gun  
Gun Trigger Plug  
5
Voltage Sensing Clamp  
Connect work cable to welding gen-  
erator Work terminal. Connect cable  
from wire feeder to cable from weld-  
ing generator Electrode terminal.  
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weld cables (see Section 5-7).  
Loosen MIG gun securing knob. In-  
sert gun end through opening in feed-  
er and position as close as possible  
to drive rolls without touching. Tight-  
en knob.  
See wire feeder manual for wire  
threadingprocedure.  
Insert gun trigger plug (item 4) into  
matching receptacle and tighten  
threaded collar.  
Typical Control Settings Using  
.045 (71T-11) Self-Shielded Flux  
Core Wire :  
>
Set Weld Process Selector  
switch to Wire − position  
(DCEN).  
>
Set Coarse Range switch to  
Wire/Low Range (17-22 volts)  
position.  
Quick connector  
>
>
>
Set Fine Control near minimum  
setting.  
2
Set wire feed speed between  
125-200 ipm.  
3
Do a test weld. To increase arc  
length, increase Fine Control  
setting. To shorten arc length,  
reduce fine control setting or in-  
crease wire feed speed.  
5
4
Work  
1
Tools Needed:  
3/4 in  
803 750-B / 802 766 / 228 201-B  
OM-4419 Page 27  
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6-5. Typical MIG Connections And Settings Using Weld Control And Spoolgun  
Typical Settings For 4043 (.035)  
Aluminum On 1/8 in Material:  
Tools Needed:  
3/4 in  
Note Coarse Range and Weld  
Process switch settings.  
10  
9
8
Connect to unused  
contactor terminal.  
Work  
12  
5
Plug and sensing lead not  
used in this application.  
6
Left Side View  
2
1
3
11  
6
4
5
7
802 750-B / 228 201-B  
Typical Settings For 4043 (.035)  
Aluminum On 1/8 in Material:  
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lines and may not suit all applications.  
cables (see Section 5-7).  
Route weld cable from welding generator  
Electrode terminal through reed switch to  
unused contactor terminal. Connect weld  
cable from spoolgun to weld control weld ter-  
minal (item 6).  
1
2
3
4
5
6
7
8
9
Weld Control  
>
>
>
Set Weld Process Selector switch to  
Wire + (DCEP) position.  
Spoolgun  
Optional Contactor (Recommended)  
Reed Switch  
Set Coarse Range switch to Wire/Low  
(17-22 volts) position.  
Connect work cable to welding generator  
Work terminal.  
Weld Cable (Customer-Supplied)  
Weld Control Weld Terminal  
Weld Power Cable From Spoolgun  
Work Clamp  
Set Fine Control to desired voltage  
(arc length). Start with a low voltage  
setting (about 4) to prevent burnback.  
Insert trigger control plug (item 11) into weld  
control receptacle. Tighten threaded collar.  
>
Set wire feed speed between 240-270  
ipm. For 1/4 in. and thicker materials,  
set Coarse Range switch to Wire/High  
and Fine Control to 6. Increase/de-  
crease Fine Control setting to in-  
crease/decrease arc length.  
Connect ac power cord (item 12) to 120 volt  
ac receptacle on welding generator.  
Gas Hose  
10 Argon Cylinder  
Connect gas hose from spoolgun to regula-  
tor on Argon bottle.  
11 Trigger Control Cord  
12 Input Power Cord  
Reinstall weld control wrapper.  
OM-4419 Page 28  
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SECTION 7 − OPERATING AUXILIARY EQUIPMENT  
7-1. Generator Power Receptacles  
If unit does not have GFCI recep-  
tacles, use GFCI-protected extension  
cord.  
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current increases.  
Set Fine Control R1 at 10 for full genera-  
tor power.  
1
240 V 50 A AC Receptacle RC1  
RC1 supplies 60 Hz single-phase power at  
weld/power speed. Maximum output is 10.5  
kVA/kW.  
2
120 V 20 A AC Duplex Receptacle  
RC2  
3
120 V 20 A AC Duplex Receptacle  
RC3  
RC2 and RC3 supply 60 Hz single-phase  
power at weld/power speed. Maximum out-  
put from RC2 or RC3 is 2.4 kVA/kW.  
4
Supplementary Protector CB1  
CB1 protects receptacles RC1, RC2, and  
RC3 from overload. If CB1 opens, the recep-  
tacles do not work. Place switch in On posi-  
tion to reset.  
1
5
2
6
3
5
6
Supplementary Protector CB2  
Supplementary Protector CB3  
CB2 protects RC2 and CB3 protects RC3  
from overload. If a supplementary protector  
opens, the receptacle does not work.  
. Press button to reset supplementary  
protector. If supplementary protector  
continues to open, contact Factory  
Authorized Service Agent.  
7
Optional 120 V 20 A AC GFCI Recep-  
tacles GFCI-2 and GFCI-3  
GFCI2 and GFCI3 supply 60 Hz single-  
phase power at weld/power speed. Maxi-  
mum output from GFCI-2 or GFCI-3 is 2.4  
kVA/kW. Circuit protection is the same as  
standard receptacles.  
If a ground fault is detected, the GFCI Reset  
button pops out and the circuit opens to dis-  
connect the faulty equipment. Check for  
damagedtools, cords, plugs, etc. connected  
to the receptacle. Press button to reset re-  
ceptacle and resume operation.  
4
Power is still present at the 240 volt  
receptacle when only one supple-  
mentary protector trips.  
7
Unplug power cord before attempting  
to service accessories or tools.  
. At least once a month, run engine at  
weld/powerspeed and press Test button  
to verify GFCI is working properly.  
Combinedoutput of all receptacles limited to  
10.5 kVA/kW rating of the generator.  
EXAMPLE: If 20 A is drawn from each 120  
V duplex receptacle, only 23 A is available at  
the 240V receptacle:  
2 x (120 V x 20 A) + (240 V x 23 A) = 10.5  
kVA/kW  
803 750-B / Ref. 228 201-B  
OM-4419 Page 29  
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7-2. Simultaneous Weld And Power  
Weld Current in Amperes  
Total Power in Watts  
120 V Full kVA Receptacle  
Amperes  
240 V Full kVA Receptacle  
Amperes  
250  
180  
125  
90  
2200  
3500  
18  
29  
43  
66  
87  
9
14  
21  
33  
43  
5200  
8000  
0
10,500  
7-3. Wiring Optional 240 Volt Plug  
The plug can be wired for a 240 V,  
2-wire load or a 120/240V, 3-wire  
load. See circuit diagram.  
1
Plug Wired for 120/240 V,  
3-Wire Load  
7
Current Available in Amperes  
When wired for 120 V loads, each  
duplex receptacle shares a load  
with one half of 240 V receptacle.  
240 V  
Receptacle*  
Each 120 V Duplex  
Receptacle  
2
Plug Wired for 240 V, 2-Wire  
Load  
0
5
20  
20  
20  
20  
20  
15  
10  
5
1
3
3
4
5
6
7
Neutral (Silver) Terminal  
Load 1 (Brass)Terminal  
Load 2 (Brass) Terminal  
Ground (Green) Terminal  
4
10  
15  
20  
25  
30  
35  
40  
Amperes Available using  
120/240 V Plug  
120V  
5
120V  
0
240V  
6
2
V x A = Watts  
*One 240 V load or two 120 V loads.  
Tools Needed:  
3
4
240V  
6
5
240 V  
AC  
120 V  
AC  
120 V  
AC  
plug1 11/03 − 120 813-D  
OM-4419 Page 30  
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. A complete Parts List is available at www.MillerWelds.com  
SECTION 8 − MAINTENANCE (ROBIN-POWERED UNITS)  
8-1. Routine Maintenance (Robin-Powered Units)  
Stop engine before maintaining.  
. See Engine Manual and Maintenance Label  
for important start-up, service, and storage  
information. Service engine more often if  
used in severe conditions.  
Recycle engine  
fluids.  
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Reference  
Section 5-2  
* To be done by Factory Authorized Service Agent  
Every  
8
Hours  
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Every  
20  
Section 8-7  
Section 8-3  
Hours  
n
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c
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e
n
Every  
25  
Hours  
~
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r
a
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r
Every  
50  
Hours  
~
W
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T
e
r
m
i
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a
l
s
Every  
100  
Hours  
Engine  
Manual,  
Section 8-3,  
8-5  
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Every  
200  
Hours  
Engine  
Manual,  
Section 8-5  
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F
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F
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F
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Every  
500  
Hours  
Engine  
Manual  
n
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a
b
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n
~ Slip Rings*  
Brushes*  
n
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*
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8-2. Maintenance Label (Robin-Powered Units)  
OM-4419 Page 32  
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8-3. Servicing Air Cleaner (Robin-Powered Units)  
!
Stop engine.  
NOTICE − Do not run engine with-  
out air cleaner or with dirty element.  
1
Precleaner  
Wash precleaner with soap and wa-  
ter solution. Allow precleaner to air  
dry completely.  
1
2
Spread 1 tablespoon SAE 30 oil  
evenly into precleaner. Squeeze  
out excess oil.  
2
Element  
Replace element if damaged, dirty,  
or oily.  
oil  
aircleaner3 11/04 − 803 070 / S-0759  
8-4. Overload Protection (Robin-Powered Units)  
!
Stop engine. Disconnect  
negative (−) battery cable.  
1
Fuse F1 (See Section 11-1)  
. Fuse F6 located in  
harness behind left  
side door.  
1
2
F1 protects the weld excitation  
winding from overload. If F1 opens,  
weld output stops or is low.  
2
Fuse F2 (See Section 11-1)  
F2 protects the generator power  
excitation winding from overload. If  
F2 opens, generator power output  
stops or is low.  
3
3
Fuse F6 (See Section 11-1)  
F6 protects the engine wiring sys-  
tem from overload. If F6 opens,  
engine will not crank.  
. Fuses F1, F2 located on  
bracket behind left side  
panel.  
Replace any open fuses. Reinstall  
cover before operating.  
. If a fuse opens, it usually indi-  
cates a more serious problem  
exists. Contact a Factory Au-  
thorized Service Agent.  
Tools Needed:  
3/8 in  
803 753-B  
OM-4419 Page 33  
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8-5. Changing Engine Oil, Oil Filter, and Fuel Filter (Robin-Powered Units)  
!
1
Stop engine and let cool.  
Oil Drain Valve  
2
3
1/2 ID x 7 in Hose  
Oil Filter  
Change engine oil and filter accord-  
ing to engine owner’s manual.  
!
Close valve and valve cap  
before adding oil and  
running engine.  
Oil Fill  
Fill crankcase with new oil to full  
mark on dipstick (see Section 8-2).  
Oil Check  
4
5
Fuel Filter  
Fuel Line  
Replace line if cracked or worn.  
Install new filter. Wipe up any spilled  
fuel.  
Full  
Start engine, and check for fuel  
leaks.  
Stop engine, tighten connec-  
tions as necessary, and wipe  
up fuel.  
4
5
3
2
1
Tools Needed:  
803 755-C / 802 921-A / S-0842  
OM-4419 Page 34  
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8-6. Adjusting Engine Speed (Robin-Powered Units)  
After tuning engine, check engine  
speeds with a tachometer (see  
table). If necessary, adjust speeds  
as follows:  
2200 − 2300 rpm  
(36.6 − 38.3 Hz)  
Start engine and run until warm.  
Remove rear panel and air cleaner  
to access idle speed adjustments.  
Remove top cover to access weld/  
power speed adjustments.  
3675 − 3750 rpm  
(61.3 − 62.5 Hz)  
Idle Speed Adjustment  
Move Engine Control switch to  
Run/Idle position.  
1
2
3
Throttle Solenoid  
Mounting Screws  
Idle Speed Screw  
Loosen mounting screws. Adjust  
solenoid position so engine runs at  
idle speed. If necessary, back out  
idle speed screw so solenoid can  
be moved to correct position. Tight-  
en mounting screws. Be sure sole-  
noid linkage works smoothly.  
1
3
Turn idle speed screw for fine  
adjustments.  
Weld/Power Speed Adjustment  
Move Engine Control switch to Run  
position.  
4
5
6
Jam Nut  
Lock Nut  
Weld/Power Speed  
Adjustment Screw  
Loosen jam nut and lock nut. Turn  
adjustmentscrew until engine runs  
at weld/power speed. Tighten jam  
nut, and then tighten lock nut.  
2
Stop engine.  
4
Reinstall air cleaner, end panel, and  
top cover.  
6
5
Tools Needed:  
10 mm  
8 mm  
803 755-C / 802 457  
OM-4419 Page 35  
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8-7. Servicing Optional Spark Arrestor (Robin-Powered Units)  
Stop engine and let cool.  
1
Spark Arrestor Screen  
Clean and inspect screen. Replace  
spark arrestor if screen wires are  
broken or missing.  
1
Tools Needed:  
1/4 in  
Ref. 801 682-A / Ref. 183 175−A  
Notes  
MATERIAL THICKNESS REFERENCE CHART  
24 Gauge (.025 in)  
22 Gauge (.031 in)  
20 Gauge (.037 in)  
18 Gauge (.050 in)  
16 Gauge (.063 in)  
14 Gauge (.078 in)  
1/8 in (.125 in)  
3/16 in (.188 in)  
1/4 in (.25 in)  
5/16 in (.313 in)  
3/8 in (.375 in)  
1/2 in (.5 in)  
OM-4419 Page 36  
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SECTION 9 − MAINTENANCE − (KOHLER-POWERED UNITS)  
9-1. Routine Maintenance (Kohler-Powered Units)  
!
Stop engine before maintaining.  
. See Engine Manual and Maintenance Label  
for important start-up, service, and storage  
information. Service engine more often if  
used in severe conditions.  
Recycle engine  
fluids.  
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Reference  
Section 5-3  
* To be done by Factory Authorized Service Agent  
Every  
8
Hours  
n
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Every  
20  
Section 9-7  
Section 9-3  
Hours  
n
~
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p
a
r
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A
r
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t
o
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S
c
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e
e
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Every  
25  
Hours  
~
A
i
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C
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e
a
n
e
r
W
r
a
p
p
e
r
Every  
50  
Hours  
~
W
e
l
d
T
e
r
m
i
n
a
l
s
Every  
100  
Hours  
Engine  
Manual,  
Section 9-3,  
9-4  
~
B
a
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T
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~
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Every  
200  
Hours  
Engine  
Manual,  
Section 9-4  
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F
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F
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Every  
500  
Hours  
Engine  
Manual  
n
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~ Slip Rings*  
Brushes*  
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OM-4419 Page 37  
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9-2. Maintenance Label (Kohler-Powered Units)  
OM-4419 Page 38  
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9-3. Servicing Air Cleaner (Kohler−Powered Units)  
!
Stop engine.  
NOTICE − Do not run engine with-  
out air cleaner or with dirty element.  
1
Precleaner  
Wash precleaner with soap and wa-  
ter solution. Allow precleaner to air  
dry completely.  
1
2
Spread 1 tablespoon SAE 30 oil  
evenly into precleaner. Squeeze  
out excess oil.  
2
Element  
Replace element if damaged, dirty,  
or oily.  
oil  
aircleaner3 11/04 − 802 772 / S-0759  
Notes  
Work like a Pro!  
Pros weld and cut  
safely. Read the  
safety rules at  
the beginning  
of this manual.  
OM-4419 Page 39  
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9-4. Changing Engine Oil, Oil Filter, and Fuel Filter (Kohler-Powered Units)  
!
1
Stop engine and let cool.  
Oil Drain Valve  
2
3
1/2 ID x 7 in Hose  
Oil Filter  
Change engine oil and filter accord-  
ing to engine owner’s manual.  
!
Close valve and valve cap  
before adding oil and  
running engine.  
Full  
Fill crankcase with new oil to full  
mark on dipstick (see Section 5-3).  
4
5
Fuel Filter  
Fuel Line  
Replace line if cracked or worn.  
Install new filter. Wipe up any spilled  
fuel.  
Start engine, and check for fuel  
leaks.  
Stop engine, tighten connec-  
tions as necessary, and wipe  
up fuel.  
4
5
3
2
1
Tools Needed:  
803 754 / S-0842  
OM-4419 Page 40  
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9-5. Adjusting Engine Speed (Kohler-Powered Units)  
After tuning engine, check engine  
speeds with a tachometer (see  
table). If necessary, adjust speeds  
as follows:  
2200 − 2300 rpm  
(36.6 − 38.3 Hz)  
Start engine and run until warm.  
Turn Fine Control to 10.  
3675 − 3750 rpm  
(61.3 − 62.5 Hz)  
Remove rear panel and air cleaner  
to access idle speed adjustments.  
Remove top cover to access weld/  
power speed adjustments.  
1
Idle Speed Adjustment  
Move Engine Control switch to  
Run/Idle position.  
1
2
3
Throttle Solenoid  
Mounting Screws  
Idle Speed Screw  
5
Loosen mounting screws. Adjust  
solenoid position so engine runs at  
idle speed. If necessary, back out  
idle speed screw so solenoid can  
be moved to correct position. Tight-  
en mounting screws. Be sure sole-  
noid linkage works smoothly.  
2
4
Turn idle speed screw for fine ad-  
justments.  
Weld/Power Speed Adjustment  
Move Engine Control switch to Run  
position.  
4
Weld/Power Speed  
Adjustment Nut  
5
Lock Nut  
3
Loosen lock nut. Turn adjustment  
nut until engine runs at weld/power  
speed. Tighten lock nut.  
Stop engine.  
Reinstall air cleaner, end panel, and  
top cover.  
Top View  
Tools Needed:  
1/4, 3/8 in  
803 752 / 801 209-A  
OM-4419 Page 41  
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9-6. Overload Protection (Kohler-Powered Units)  
Stop engine. Disconnect  
negative (−) battery cable.  
1
Fuse F1 (See Section 11-1)  
F1 protects the weld excitation  
winding from overload. If F1 opens,  
weld output stops or is low.  
2
1
. Fuse F6 located in  
harness behind left  
side door.  
2
Fuse F2 (See Section 11-1)  
F2 protects the generator power  
excitation winding from overload. If  
F2 opens, generator power output  
stops or is low.  
3
3
Fuse F6 (See Section 11-1)  
F6 protects the engine wiring sys-  
tem from overload. If F6 opens,  
engine will not crank.  
. Fuses F1, F2 located on  
bracket behind left side  
panel.  
Replace any open fuses. Reinstall  
cover before operating.  
. If a fuse opens, it usually indi-  
cates a more serious problem  
exists. Contact a Factory Au-  
thorized Service Agent.  
Tools Needed:  
3/8 in  
803 753-B  
9-7. Servicing Optional Spark Arrestor (Kohler-Powered Units)  
Stop engine and let cool.  
1
Spark Arrestor Screen  
Clean and inspect screen. Replace  
spark arrestor if screen wires are  
broken or missing.  
1
Tools Needed:  
1/4 in  
803 755 / Ref. 801 682-A  
OM-4419 Page 42  
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SECTION 10 − TROUBLESHOOTING  
10-1. Welding Troubleshooting  
Trouble  
Remedy  
Low or no weld output; generator pow- Check control settings.  
er output okay at ac receptacles.  
Check weld connections.  
Check fuse F1, and replace if open (see Section 8-4 or 9-6).  
Have Factory Authorized Service Agent check brushes, slip rings, and integrated rectifiers SR2 and  
SR3.  
No weld output or generator power out- Be sure all equipment is disconnected from receptacles when starting unit.  
put at ac receptacles.  
Check fuses F1 and F2, and replace if open (see Section 8-4 or 9-6).  
Check plug PLG6 connection.  
Have Factory Authorized Service Agent check brushes, slip rings, and integrated rectifiers SR2, SR3.  
Check fuse F1, and replace if open (see Section 8-4 or 9-6).  
Check control settings.  
Low weld output.  
Check engine speed, and adjust if necessary (see Section 8-6 or 9-5).  
Service air cleaner according to engine manual.  
Have Factory Authorized Service Agent check brushes, slip rings, and integrated rectifiers SR2, SR3.  
Check control settings.  
High weld output.  
Check engine speed, and adjust if necessary (see Section 8-6 or 9-5).  
Check control settings.  
Erratic weld output.  
Tighten and clean connections to electrode and workpiece.  
Use dry, properly-stored electrodes for Stick and TIG welding.  
Remove excessive coils from weld cables.  
Clean and tighten connections both inside and outside welding generator.  
Check engine speed, and adjust if necessary (see Section 8-6 or 9-5).  
Have Factory Authorized Service Agent check brushes, slip rings, and integrated rectifiers SR2, SR3.  
10-2. Generator Power Troubleshooting  
Trouble  
Remedy  
No or low generator power output at ac Reset supplementary protector(s) (see Section 7-1).  
receptacles; weld output okay.  
Press optional GFCI receptacle Reset button (see Section 7-1).  
Check fuse F2, and replace if open (see Section 8-4 or 9-6).  
Check plug PLG6 connection.  
Have Factory Authorized Service Agent check brushes, slip rings, and integrated rectifier SR3.  
Be sure all equipment is disconnected from receptacles when starting unit.  
No generator power or weld output.  
Check fuses F1 and F2, and replace if open (see Section 8-4 or 9-6).  
Check plug PLG6 connection.  
Have Factory Authorized Service Agent check brushes, slip rings, and integrated rectifiers SR2 and  
SR3.  
OM-4419 Page 43  
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Trouble  
Remedy  
Low power output at ac receptacles.  
Check fuse F2, and replace if open (see Section 8-4 or 9-6).  
Increase Fine control R1 setting to max.  
High power output at ac receptacles.  
Check engine speed, and adjust if necessary (see Section 8-6 or 9-5).  
Erratic power output at ac receptacles. Check fuel level.  
Check engine speed, and adjust if necessary (see Section 8-6 or 9-5).  
Check receptacle wiring and connections.  
Have Factory Authorized Service Agent check brushes and slip rings.  
10-3. Engine Troubleshooting  
Trouble  
Engine will not crank.  
Remedy  
Check fuse F6, and replace if open (see Section 8-4 or 9-6).  
Check battery voltage.  
Check battery connections and tighten if necessary.  
Check plug PLG4 and plug PLG8 connections.  
Have Factory Authorized Service Agent check Engine Control switch S2.  
Check fuel level.  
Engine will not start.  
Check battery voltage.  
Check battery connections and tighten if necessary.  
Check oil level (see Section 5-2 or 5-3).  
Check low oil pressure shutdown switch.  
Have Factory Authorized Service Agent check fuel shutoff solenoid FS1 (FS1 optional on Robin-powered  
units).  
Check oil level.  
Engine starts but stops when Engine  
Control switch returns to Run position.  
Check and refill crankcase with proper viscosity oil for operating temperature, if necessary.  
Check low oil pressure shutdown switch.  
Engine stopped during normal  
operation.  
Check fuel level.  
Check oil level (see Section 5-2 or 5-3).  
Check low oil pressure shutdown switch.  
Periodically recharge battery (approximately every 3 months).  
Replace battery.  
Check voltage regulator and connections according to engine manual.  
Have Factory Authorized Service Agent check fuel shutoff solenoid FS1 (FS1 optional on Robin-powered  
units).  
Battery Discharges between uses.  
Clean battery, terminals, and posts with baking soda and water solution; rinse with clear water.  
Periodically recharge battery (approximately every 3 months).  
Replace battery.  
Check voltage regulator and connections according to engine manual.  
Engine idles but does not come up to  
weld speed.  
Have Factory Authorized Service Agent check fuel gauge/hourmeter/idle control, and current trans-  
former CT1.  
OM-4419 Page 44  
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Trouble  
Remedy  
Unstable or sluggish engine speeds.  
Readjust throttle linkage if necessary. Check throttle solenoid TS1 for smooth operation.  
Check oil level. Oil level should not exceed Full mark on dipstick. Fuel pump will operate erratically if  
crankcase is overfilled.  
Tune-up engine according to engine manual.  
Remove weld and generator power loads.  
Engine does not return to idle speed.  
Check throttle linkage for smooth, non-binding operation.  
Have Factory Authorized Service Agent check idle module PC1, current transformer CT1, Engine Control  
switch S2, and throttle solenoid TS1.  
During operation in near freezing tem-  
peratures, engine starts and goes to  
idle but stalls after a few minutes.  
Treat fuel with isopropyl alcohol de-icer product.  
Place Engine Control switch in the Run position until unit has been in operation and loaded for a peri-  
od of time.  
During operation in severe cold weath- Install engine manufacturer’s kit for cold-weather operation.  
er, engine starts and goes to idle but  
stalls after a few minutes.  
SECTION 11 − PARTS LIST  
11-1. Recommended Spare Parts  
Dia.  
Mkgs.  
Part  
No.  
Description  
Quantity  
Recommended Spare Parts  
. . . . . . . . . F1, F2 . . . 169296 . . Fuse, Mintr Gl 25. Amp 125 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . . . . . . . . . F6 . . . . . 021718 . . Fuse, Mintr Gl 30. Amp 32 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . 215984 . . Filter, Fuel In−line .250 (Kohler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . 230015 . . Tune−up & Filter Kit, Kohler (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . 230016 . . . . Air Filter Element, Kohler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . 066698 . . . . Oil Filter, Kohler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . 215985 . . . . Filter, Fuel w/Clamps & 1/4 in Fuel Line . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . 067007 . . . . Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . . . . . . . . . . . . . . . . . . 230017 . . . . Air Filter Wrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . 066113 . . Filter, Fuel In−line .250 (Robin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . 199062 . . Tune−up & Filter Kit, Robin (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . 198755 . . . . Element, Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . 198754 . . . . Filter, Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . 215985 . . . . Filter, Fuel w/Clamps & 1/4 Fuel Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . 198777 . . . . Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
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OM-4419 Page 45  
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SECTION 12 − ELECTRICAL DIAGRAMS  
Figure 12-1. Circuit Diagram For Welding Generator  
OM-4419 Page 46  
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228 460-A  
OM-4419 Page 47  
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SECTION 13 − 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.  
13-1. Selecting Equipment  
1
2
3
Generator Power Receptacles  
− Neutral Bonded To Frame  
3-Prong Plug From Case  
Grounded Equipment  
2-Prong Plug From Double  
Insulated Equipment  
. Be sure equipment has double  
insulated symbol and/or word-  
ing on it.  
1
2
!
Do not use 2-prong plug un-  
less equipment is double in-  
sulated.  
3
OR  
gen_pwr 2007−04 − Ref. ST-159 730 / ST-800 577  
13-2. Grounding Generator To Truck Or Trailer Frame  
Always ground generator  
frame to vehicle frame to pre-  
vent electric shock and static  
electricity hazards.  
Also see AWS Safety  
&
Health Fact Sheet No. 29,  
Grounding of Portable And  
Vehicle Mounted Welding  
Generators.  
1
2
3
EquipmentGrounding  
Terminal (On Front Panel)  
Grounding Cable (Not  
Supplied)  
1
Metal Vehicle Frame  
2
GND/PE  
Connect cable from equipment  
ground terminal to metal vehicle  
frame. Use #10 AWG or larger  
insulated copper wire.  
. Electrically bond generator  
frame to vehicle frame by met-  
al-to-metal contact.  
3
!
Bed liners, shipping skids,  
and some running gear insu-  
late the welding generator  
from the vehicle frame. Al-  
ways connect a ground wire  
from the generator equip-  
ment grounding terminal to  
bare metal on the vehicle  
frame as shown.  
If unit does not have GFCI re-  
ceptacles, use GFCI-pro-  
tected extension cord.  
S-0854  
OM-4419 Page 48  
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13-3. 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  
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electrical codes.  
Ground generator to system  
earth ground if supplying  
power to a premises (home,  
shop, farm) wiring system.  
Also see AWS Safety  
&
Health Fact Sheet No. 29,  
Grounding of Portable And  
Vehicle Mounted Welding  
Generators.  
2
3
ST-800 576-B  
13-4. How Much Power Does Equipment Require?  
1
Resistive Load  
A light bulb is a resistive load and  
requires a constant amount of power.  
2
Non-Resistive Load  
3
VOLTS 115  
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  
(see Section 13-8).  
2
AMPS 4.5  
Hz  
60  
1
3
Rating Data  
Rating shows volts and amperes, or  
watts required to run equipment.  
3
Amperes x Volts = Watts  
Example 1: If a drill uses 4.5 am-  
peres at 115 volts, calculate its run-  
ning power requirement in watts.  
4.5 A x 115 V = 520 W  
The load applied by the drill is 520  
watts.  
Example 2: If three 200 watt flood  
lamps are used with the drill from Ex-  
ample 1, add the individual loads to  
calculate total load.  
(3 x 200W) + 520 W = 1120 W  
The total load applied by the three  
flood lamps and drill is 1120 watts.  
S-0623  
OM-4419 Page 49  
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13-5. 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  
Fan Duty  
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  
550  
650  
800  
1100  
13-6. 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-4419 Page 50  
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13-7. 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-4419 Page 51  
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13-8. Power Required To Start Motor  
Single-PhaseInduction 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  
1
2
3
4
Motor Start Code  
Running Amperage  
Motor HP  
4
1
3
AC MOTOR  
2
Motor Voltage  
VOLTS 230  
AMPS 2.5  
To find starting amperage:  
CODE  
HP  
M
Hz  
60  
Step 1: Find code and use table to  
find kVA/HP. If code is not listed,  
multiplyrunning amperage by six to  
find starting amperage.  
1/4  
PHASE 1  
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.  
(kVA/HP x HP x 1000) / Volts =  
Starting Amperage  
Example: Calculate starting amper-  
age required for a 230 V, 1/4 HP mo-  
tor with a motor start code of M.  
Volts = 230, HP = 1/4, kVA/HP =  
11.2  
(11.2 x 1/4 x 1000) / 230 = 12.2A  
Starting the motor requires 12.2  
amperes.  
S-0624  
13-9. 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  
OM-4419 Page 52  
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13-10. Typical Connections To Supply Standby Power  
!
!
Have only qualified persons  
perform these connections  
according to all applicable  
codes and safety practices.  
4
1
2
3
Fused  
Disconnect  
Switch  
Properly install and ground  
this equipment according to  
its Owner’s Manual and na-  
tional, state, and local codes.  
Welding  
Generator  
Output  
Utility  
Electrical  
Service  
Transfer Switch  
(If Required)  
. Customer-supplied equipment  
is required if generator will sup-  
ply standby power during  
emergencies or power out-  
ages.  
5
1 Utility Electrical Service  
Essential  
Loads  
2 Transfer Switch (Double-Throw)  
Switch transfers the electrical load  
from electric utility service to the  
generator. Transfer load back to  
electric utility when service is re-  
stored.  
Install correct switch (customer-  
supplied). Switch rating must be  
same as or greater than the branch  
overcurrent protection.  
3 Fused Disconnect Switch  
Install correct switch (customer-  
supplied) if required by electrical  
code.  
4 Welding Generator Output  
Generator output voltage and wir-  
ing must be consistent with regular  
(utility) system voltage and wiring.  
Connect generator with temporary  
or permanent wiring suitable for the  
installation.  
Turn off or unplug all equipment  
connected to generator before  
starting or stopping engine. When  
starting or stopping, the engine has  
low speed which causes low volt-  
age and frequency.  
5 Essential Loads  
Generator output may not meet the  
electrical requirements of the prem-  
ises. If generator does not produce  
enough output to meet all require-  
ments, connect only essential  
loads (pumps, freezers, heaters,  
etc. − See Section 13-4).  
OM-4419 Page 53  
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13-11. Selecting Extension Cord (Use Shortest Cord Possible)  
Cord Lengths for 120 Volt Loads  
If unit does not have GFCI receptacles, use GFCI-protected extension cord.  
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*  
Current  
(Amperes)  
Load (Watts)  
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  
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  
OM-4419 Page 54  
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SECTION 14 − STICK WELDING (SMAW) GUIDELINES  
14-1. Stick Welding Procedure  
!
!
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  
5
Make sure workpiece is clean be-  
fore welding.  
4
2
3
Work Clamp  
Electrode  
2
A small diameter electrode re-  
quires less current than a large  
one. Follow electrode manufactur-  
er’s instructions when setting weld  
amperage (see Section 14-2).  
4
5
6
Insulated Electrode Holder  
Electrode Holder Position  
Arc Length  
3
6
Arc length is the distance from the  
electrode to the workpiece. A short  
arc with correct amperage will give  
a sharp, crackling sound.  
1
7
7
Slag  
Use a chipping hammer and wire  
brush to remove slag. Remove  
slag and check weld bead before  
making another weld pass.  
Tools Needed:  
stick 2007−04 − ST-151 593  
OM-4419 Page 55  
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14-2. Electrode and Amperage Selection Chart  
3/32  
1/8  
6010  
&
6011  
5/32  
3/16  
7/32  
1/4  
6010  
6011  
EP  
EP  
ALL  
ALL  
ALL  
DEEP  
DEEP  
LOW  
MIN. PREP, ROUGH  
HIGH SPATTER  
1/16  
5/64  
3/32  
1/8  
5/32  
3/16  
7/32  
1/4  
3/32  
1/8  
5/32  
3/16  
6013 EP,EN  
GENERAL  
SMOOTH, EASY,  
FAST  
LOW HYDROGEN,  
STRONG  
6013  
7014 EP,EN  
ALL  
MED  
LOW  
7018  
EP  
ALL  
FLAT  
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  
7/32  
1/4  
3/32  
1/8  
5/32  
3/16  
7/32  
1/4  
7018  
7024  
3/32  
1/8  
Ni-Cl  
308L  
5/32  
3/16  
3/32  
1/8  
5/32  
Ref. S-087 985-A  
14-3. 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  
14-4. 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  
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14-5. 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  
14-6. 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
3
4
5
S-0053-A  
14-7. 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  
OM-4419 Page 57  
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14-8. Conditions That Affect Weld Bead Shape  
.
W
e
l
d
b
e
a
d
s
h
a
p
e
i
s
a
f
f
e
c
t
e
d
b
y
e
l
e
c
t
r
o
d
e
a
n
g
l
e
,
a
r
c
l
e
n
g
t
h
,
t
r
a
v
e
l
s
p
e
e
d
,
a
n
d
t
h
i
c
k
n
e
s
s
o
f
b
a
s
e
m
e
t
a
l
.
Correct Angle  
Angle Too Large  
10° - 30°  
Angle Too Small  
Drag  
ELECTRODE ANGLE  
Spatter  
Normal  
Too Long  
Too Short  
ARC LENGTH  
Normal  
Fast  
Slow  
TRAVEL SPEED  
S-0061  
14-9. Electrode Movement During Welding  
.
N
o
r
m
a
l
l
y
,
a
s
i
n
g
l
e
s
t
r
i
n
g
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r
b
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a
d
i
s
s
a
t
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f
a
c
t
o
r
y
f
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t
n
a
r
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o
w
g
r
o
o
v
e
w
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l
d
j
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n
t
s
;
h
o
w
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v
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r
,
f
o
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w
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g
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o
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l
d
j
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s
o
r
b
r
i
d
g
i
n
g
a
c
r
o
s
s
g
a
p
s
,
a weave bead or multiple stringer beads work better.  
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 elec-  
trode. Do not let weave width ex-  
ceed 2-1/2 times diameter of  
electrode.  
3
S-0054-A  
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14-10. Butt Joints  
1
Tack Welds  
1
Prevent edges of joint from draw-  
ing together ahead of electrode by  
tack welding the materials in posi-  
tion before 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  
oxyacetylene or plasma cutting  
equipment. 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  
14-11. Lap Joint  
30°  
1
2
Electrode  
30°  
Or Less  
Or Less  
1
Single-Layer Fillet 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  
14-12. Tee Joint  
1
2
Electrode  
Fillet Weld  
Keep arc short and move at defi-  
nite 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  
14-9. Remove slag before making  
another weld pass.  
1
3
S-0060 / S-0058-A / S-0061  
OM-4419 Page 59  
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14-13. 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  
14-14. 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.  
14-15. 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-4419 Page 60  
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14-16. Troubleshooting − Incomplete Fusion  
Incomplete Fusion − failure of weld metal to fuse completely with  
base metal or a preceeding weld bead.  
Possible Causes  
Insufficient heat input.  
Improper welding technique.  
Corrective Actions  
Increase amperage. Select larger electrode and increase amperage.  
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.  
14-17. 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.  
14-18. Troubleshooting − Excessive Penetration  
Excessive Penetration − weld metal melting through base metal  
and hanging underneath 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-4419 Page 61  
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14-19. 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.  
14-20. 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.  
14-21. Troubleshooting − Distortion  
Distortion − contraction of weld  
metal during welding that forces  
base metal to move.  
Base metal moves  
in the direction of  
the weld bead.  
Possible Causes  
Corrective Actions  
Excessive heat input.  
Use restraint (clamp) to hold base metal in position.  
Make tack welds along joint before starting welding operation.  
Select lower amperage for electrode.  
Increase travel speed.  
Weld in small segments and allow cooling between welds.  
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SECTION 15 − MIG WELDING (GMAW) GUIDELINES  
15-1. Typical MIG Process Connections Using A Voltage-Sensing Wire Feeder  
Weld current can damage  
electronic parts in vehicles.  
Disconnect both battery  
cables before welding on a  
vehicle. Place work clamp as  
close to the weld as possible.  
Constant  
Current (CC)  
Or Constant  
Voltage (CV)  
Power Source  
Voltage sensing wire feeders are  
used with constant current (CC) or  
constant voltage (CV) power  
sources (14 pin receptacle not re-  
quired).  
If using a CC or CV welding power  
source without a weld output con-  
tactor, use optional secondary con-  
tactor.  
Gun  
For GMAW, use optional gas valve.  
Voltage  
Sensing Wire  
Feeder  
Workpiece  
Work Clamp  
Electrode Lead  
Work Lead  
Voltage  
Sensing Clamp  
802 488  
15-2. Holding And Positioning Welding Gun  
.
W
e
l
d
i
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g
w
i
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.
B
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o
m
o
r
e
t
h
a
n
1
/
2
i
n
(
1
3
m
m
)
past end of nozzle, and tip of wire is positioned correctly on seam.  
1
Hold Gun and Control Gun  
Trigger  
1
2
3
4
Workpiece  
Work Clamp  
3
Electrode Extension (Stickout)  
1/4 to 1/2 in (6 To 13 mm)  
2
5
Cradle Gun and Rest Hand on  
Workpiece  
5
4
0°-15°  
0°-15°  
45°  
90°  
90°  
45°  
End View Of Work Angle  
Side View Of Gun Angle  
End View Of Work Angle  
Side View Of Gun Angle  
FILLET WELDS  
GROOVE WELDS  
S-0421-A  
OM-4419 Page 63  
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15-3. Conditions That Affect Weld Bead Shape  
.
W
e
l
d
b
e
a
d
s
h
a
p
e
d
e
p
e
n
d
s
o
n
g
u
n
a
n
g
l
e
,
d
i
r
e
c
t
i
o
n
o
f
t
r
a
v
e
l
,
e
l
e
c
t
r
o
d
e
e
x
t
e
n
s
i
o
n
(
s
t
i
c
k
o
u
t
)
,
t
r
a
v
e
l
s
p
e
e
d
,
t
h
i
c
k
n
e
s
s
o
f
b
a
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e
m
e
t
a
l
,
w
i
r
e
f
e
e
d
s
p
e
e
d
(weld current), and voltage.  
10°  
Push  
10°  
Perpendicular  
Drag  
GUN ANGLES AND WELD BEAD PROFILES  
Short  
Normal  
Long  
ELECTRODE EXTENSIONS (STICKOUT)  
Short  
Normal  
Long  
FILLET WELD ELECTRODE EXTENSIONS (STICKOUT)  
Slow  
Normal  
Fast  
GUN TRAVEL SPEED  
S-0634  
OM-4419 Page 64  
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15-4. Gun Movement During Welding  
.
N
o
r
m
a
l
l
y
,
a
s
i
n
g
l
e
s
t
r
i
n
g
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e
a
d
i
s
s
a
t
i
s
f
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o
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f
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a
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r
o
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g
r
o
o
v
e
w
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j
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t
s
;
h
o
w
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v
e
r
,
f
o
r
w
i
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e
g
r
o
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v
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l
d
j
o
i
n
t
s
o
r
b
r
i
d
g
i
n
g
a
c
r
o
s
s
g
a
p
s
,
a weave bead or multiple stringer beads works better.  
1
2
3
Stringer Bead − Steady  
Movement Along Seam  
1
2
Weave Bead − Side To Side  
Movement Along Seam  
Weave Patterns  
Use weave patterns to cover a wide  
area in one pass of the electrode.  
3
S-0054-A  
15-5. Poor Weld Bead Characteristics  
1
2
3
4
5
Large Spatter Deposits  
Rough, Uneven Bead  
1
Slight Crater During Welding  
Bad Overlap  
Poor Penetration  
2
4
3
5
S-0053-A  
15-6. Good Weld Bead Characteristics  
1
2
3
Fine Spatter  
Uniform Bead  
Moderate Crater During  
Welding  
1
Weld a new bead or layer for each  
1/8 in (3.2 mm) thickness in metals  
being welded.  
4
5
No Overlap  
Good Penetration into Base  
Metal  
2
4
3
5
S-0052-B  
OM-4419 Page 65  
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15-7. Troubleshooting − Excessive Spatter  
Excessive Spatter − scattering of molten metal particles that  
cool to solid form near weld bead.  
S-0636  
Possible Causes  
Wire feed speed too high.  
Corrective Actions  
Select lower wire feed speed.  
Select lower voltage range.  
Use shorter electrode extension (stickout).  
Voltage too high.  
Electrode extension (stickout) too long.  
Workpiece dirty.  
Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.  
Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.  
Use clean, dry welding wire.  
Insufficient shielding gas at welding arc.  
Dirty welding wire.  
Eliminate pickup of oil or lubricant on welding wire from feeder or liner.  
15-8. Troubleshooting − Porosity  
Porosity − small cavities or holes resulting from gas pockets  
in weld metal.  
S-0635  
Possible Causes  
Corrective Actions  
Insufficient shielding gas at welding arc.  
Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.  
Remove spatter from gun nozzle.  
Check gas hoses for leaks.  
Place nozzle 1/4 to 1/2 in (6-13 mm) from workpiece.  
Hold gun near bead at end of weld until molten metal solidifies.  
Use welding grade shielding gas; change to different gas.  
Use clean, dry welding wire.  
Wrong gas.  
Dirty welding wire.  
Eliminate pick up of oil or lubricant on welding wire from feeder or liner.  
Workpiece dirty.  
Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before welding.  
Use a more highly deoxidizing welding wire (contact supplier).  
Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.  
15-9. Troubleshooting − Excessive Penetration  
Excessive Penetration − weld metal melting through base metal  
and hanging underneath weld.  
Excessive Penetration Good Penetration  
S-0639  
Possible Causes  
Excessive heat input.  
Corrective Actions  
Select lower voltage range and reduce wire feed speed.  
Increase travel speed.  
OM-4419 Page 66  
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15-10. Troubleshooting − Lack Of Penetration  
Lack Of Penetration − shallow  
fusion between weld metal and  
base metal.  
Lack of Penetration Good Penetration  
S-0638  
Possible Causes  
Corrective Actions  
Improper joint preparation.  
Improper weld technique.  
Material too thick. Joint preparation and design must provide access to bottom of groove while  
maintaining proper welding wire extension and arc characteristics.  
Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.  
Keep arc on leading edge of weld puddle.  
Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.  
Select higher wire feed speed and/or select higher voltage range.  
Reduce travel speed.  
Insufficient heat input.  
15-11. Troubleshooting − Incomplete Fusion  
Incomplete Fusion − failure of weld metal to fuse completely with  
base metal or a preceeding weld bead.  
S-0637  
Possible Causes  
Workpiece dirty.  
Corrective Actions  
Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before  
welding.  
Insufficient heat input.  
Select higher voltage range and/or adjust wire feed speed.  
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.  
Improper welding technique.  
Use correct gun angle of 0 to 15 degrees.  
15-12. Troubleshooting − Burn-Through  
Burn-Through− weld metal melting completely through base metal  
resulting in holes where no metal remains.  
S-0640  
Possible Causes  
Excessive heat input.  
Corrective Actions  
Select lower voltage range and reduce wire feed speed.  
Increase and/or maintain steady travel speed.  
OM-4419 Page 67  
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15-13. Troubleshooting − Waviness Of Bead  
Waviness Of Bead − weld metal that is not parallel and does not cover  
joint formed by base metal.  
S-0641  
Possible Causes  
Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.  
Unsteady hand. Support hand on solid surface or use two hands.  
Corrective Actions  
15-14. Troubleshooting − Distortion  
Distortion − contraction of weld metal during welding that forces  
base metal to move.  
Base metal moves  
in the direction of  
the weld bead.  
S-0642  
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 voltage range and/or reduce wire feed speed.  
Increase travel speed.  
Weld in small segments and allow cooling between welds.  
OM-4419 Page 68  
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15-15. Common MIG Shielding Gases  
This is a general chart for common gases and where they are used. Many different combinations (mixtures) of  
shielding gases have been developed over the years. The most commonly used shielding gases are listed in the  
following table.  
Application  
Gas  
Short Circuiting  
Steel  
Spray Arc  
Stainless Steel  
Short Circuiting  
Stainless Steel  
Spray Arc  
Aluminum  
Short Circuiting  
Aluminum  
Spray Arc Steel  
5
Argon  
All Positions  
All Positions  
5
5
Flat & Horizontal  
Fillet  
Flat & Horizontal  
Fillet  
Argon + 1% O  
2
2
2
5
5
5
1
5
Flat & Horizontal  
Fillet  
Flat & Horizontal  
Fillet  
Argon + 2% O  
Argon + 5% O  
Flat & Horizontal  
Fillet  
Flat & Horizontal  
Fillet  
Argon + 8% CO  
Argon + 25%  
All Positions  
All Positions  
All Positions  
All Positions  
2
Flat & Horizontal  
Fillet  
3
All Positions  
CO  
2
Argon + 50%  
CO  
2
1
Flat & Horizontal  
Fillet  
CO  
2
2
2
Helium  
All Positions  
Argon + Helium  
All Positions  
4
Tri-Mix  
All Positions  
1
2
3
4
5
Globular Transfer  
Heavy Thicknesses  
Single Pass Welding Only  
90% HE + 7-1/2% AR + 2-1/2% CO  
Also for GMAW-P, All Positions  
2
OM-4419 Page 69  
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Effective January 1, 2007  
(Equipment with a serial number preface of “LH” 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, Cables, and  
Non-Electronic Controls  
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:  
Service  
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.)  
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 delivery date of the  
equipment to the original end-user purchaser, and not to exceed  
one year after the equipment is shipped to a North American  
distributor or eighteen months after the equipment is shipped 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  
2. 3 Years — Parts and Labor  
*
*
*
*
*
*
*
*
Transformer/Rectifier Power Sources  
Plasma Arc Cutting Power Sources  
Process Controllers  
Semi-Automatic and Automatic Wire Feeders  
Inverter Power Sources (Unless Otherwise Stated)  
Water Coolant Systems (Integrated)  
Intellitig  
Engine Driven Welding Generators  
(NOTE: Engines are warranted separately by the  
engine manufacturer.)  
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND  
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS  
TRAINED AND EXPERIENCED IN THE USE AND  
MAINTENANCE OF WELDING EQUIPMENT.  
In the event of a warranty claim covered by this warranty, the  
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)  
replacement; or, where authorized in writing by Miller in  
appropriate cases, (3) the reasonable cost of repair or  
replacement at an authorized Miller service station; or (4)  
payment of or credit for the purchase price (less reasonable  
depreciation based upon actual use) upon return of the goods at  
customer’s risk and expense. Miller’s option of repair or  
replacement will be F.O.B., Factory at Appleton, Wisconsin, or  
F.O.B. at a Miller authorized service facility as determined by  
Miller. Therefore no compensation or reimbursement for  
transportation costs of any kind will be allowed.  
3. 1 Year — Parts and Labor Unless Specified  
*
Motor Driven Guns (w/exception of Spoolmate  
Spoolguns)  
Positioners and Controllers  
Automatic Motion Devices  
RFCS Foot Controls  
Induction Heating Power Sources, Coolers, and  
Electronic  
Controls/Recorders  
*
*
*
*
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.  
*
*
*
*
*
*
*
*
*
*
Water Coolant Systems (Non-Integrated)  
Flowgauge and Flowmeter Regulators (No Labor)  
HF Units  
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND  
Grids  
ANY  
IMPLIED  
WARRANTY,  
GUARANTY  
OR  
REPRESENTATION AS TO PERFORMANCE, AND ANY  
REMEDY FOR BREACH OF CONTRACT TORT OR ANY  
OTHER LEGAL THEORY WHICH, BUT FOR THIS  
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION  
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,  
Spot Welders  
Load Banks  
Arc Stud Power Sources & Arc Stud Guns  
Racks  
Running Gear/Trailers  
Plasma Cutting Torches (except APT & SAF  
Models)  
Field Options  
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.  
*
(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.)  
Bernard-Branded Mig Guns (No Labor)  
Weldcraft-Branded TIG Torches (No Labor)  
Subarc Wire Drive Assemblies  
Some states in the U.S.A. do not allow limitations of how long an  
implied warranty lasts, or the exclusion of incidental, indirect,  
special or consequential damages, so the above limitation or  
exclusion may not apply to you. This warranty provides specific  
legal rights, and other rights may be available, but may vary from  
state to state.  
*
*
*
In Canada, legislation in some provinces provides for certain  
additional warranties or remedies other than as stated herein,  
and to the extent that they may not be waived, the limitations and  
exclusions set out above may not apply. This Limited Warranty  
provides specific legal rights, and other rights may be available,  
4. 6 Months — Batteries  
5. 90 Days — Parts  
*
MIG Guns/TIG Torches and Subarc (SAW) Guns  
but may vary from province to province.  
miller_warr 2007−01  
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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  
Contact a DISTRIBUTOR or SERVICE AGENCY near you.  
Always provide Model Name and Serial/Style Number.  
Contact your Distributor for:  
Welding Supplies and Consumables  
Options and Accessories  
Personal Safety Equipment  
Service and Repair  
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  
To locate a Distributor or Service Agency visit  
www.millerwelds.com or call 1-800-4-A-Miller  
www.MillerWelds.com  
Contact the Delivering Carrier to:  
File a claim for loss or damage during  
shipment.  
For assistance in filing or settling claims, contact  
your distributor and/or equipment manufacturer’s  
Transportation Department.  
PRINTED IN USA  
© 2007 Miller Electric Mfg. Co.2007−01  
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