OM-4415
209 416F
2007−05
Processes
Stick (SMAW) Welding
Description
Engine Driven Welding Generator
R
Blue Star 185
R
Blue Star 185 DX
File: Engine Drive
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2-8. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-2. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-3. Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-4. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-5. Fuel Consumption Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-6. Generator Power Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-2. Grounding Generator When Supplying Building Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-3. Engine Prestart Checks − Standard Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-4. Engine Prestart Checks − DX Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5-5. Connecting The Battery (DX Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5-6. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-7. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SECTION 6 − OPERATING THE WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Controls (Standard Models) (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6-2. Description Of Controls (Standard Models) (See Section 6-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6-3. Controls (DX Models) (See Section 6-4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-4. Description Of Controls (DX Models) (See Section 6-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SECTION 7 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8-2. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8-3. Adjusting Engine Speed (Honda-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8-4. Adjusting Engine Speed (Kohler−Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SECTION 9 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1. Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
SECTION 11 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 13 − STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
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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.
.
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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
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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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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D
D
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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
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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.
D
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.
D
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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.
D
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.
D
D
Do not touch hot parts bare handed.
Allow cooling period before working on equip-
ment.
D
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.
D
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D
D
Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D
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.
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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.
D
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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.
D
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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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D
D
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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.
D
D
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.
D
D
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.
D
D
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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.
D
D
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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D
D
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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.
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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.
D
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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-4415 Page 2
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1-3. Engine Hazards
STEAM AND HOT COOLANT can burn.
BATTERY EXPLOSION can BLIND.
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If possible, check coolant level when engine is
cold to avoid scalding.
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Always wear a face shield, rubber gloves, and
protective clothing when working on a battery.
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Always check coolant level at overflow tank, if
present on unit, instead of radiator (unless told
otherwise in maintenance section or engine
manual).
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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.
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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.
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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.
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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.
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Generator exhaust contains carbon monoxide.
This is a poison you cannot see or smell.
Always keep nozzle in contact with tank when fueling.
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NEVER use inside a home or garage, EVEN IF
doors and windows are open.
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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.
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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.
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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.
D
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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.
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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.
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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.
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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.
D
D
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.
D
D
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
D
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.
D
D
Wear a face shield to protect eyes and face.
Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
READ INSTRUCTIONS.
D
D
D
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
D
Keep away from moving parts.
Keep away from pinch points such as drive
rolls.
OM-4415 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.
D
D
D
D
The user is responsible for having a qualified electrician
promptly correct any interference problem resulting from the
installation.
D
D
D
D
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
If notified by the FCC about interference, stop using the
equipmentat once.
Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
D
D
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-
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:
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-4415 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
D
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-4415 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-4415 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 peuvent affec-
ter 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-4415 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-4415 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-4415 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.
Des 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-4415 Page 11
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SECTION 3 − DEFINITIONS
3-1. Symbol Definitions
Read Operator’s
Manual
Engine Choke
Amperes
Volts
A
V
Engine Oil
Positive
Fuel
Battery (Engine)
Engine
Output
Alternating Current
(AC)
Negative
Protective Earth
(Ground)
Hours
Seconds
Time
s
h
Circuit Protector
Temperature
SECTION 4 − SPECIFICATIONS
4-1. Weld, Power, And Engine Specifications
Weld
Output
Range
Maximum
Open Circuit
Voltage
Welding
Mode
Rated
Welding Output
Generator
Power Rating
Fuel
Capacity
Engine
Standard Model:
Honda GX390
Air-Cooled,
One-Cylinder,
Four-Cycle,
13 HP (390 CC),
Gasoline Engine
(Recoil-Start)
Single-Phase,
6 kVA/kW (Peak)
5.5 kVA/kW
(Continuous)
40/23 A,
120/240 V AC,
60 Hz
185 A, 25 V,
Standard Model:
1.7 gal (6.9 L)
Tank
20% Duty Cycle
130 A, 25 V,
60% Duty Cycle
CC/DC
55 − 185 A
80
DX Model:
5 gal (19 L)
Tank
DX Model:
Kohler CS12.75
Air-Cooled,
One-Cylinder,
Four-Cycle,
100 A, 25 V
100% Duty Cycle
12.75 HP (360 CC),
Gasoline Engine
(Electric-Start)
OM-4415 Page 12
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4-2. Dimensions, Weights, And Operating Angles
Dimensions
Height
22-3/4 in (578 mm)
22-3/4 in (577 mm)
31-5/8 in (803 mm)
31-5/8 in (803 mm)
10-9/16 in (268 mm)
13-25/64 in (340 mm)
22-3/4 in (577 mm)
1-9/16 in (40 mm)
19-5/8 in (498 mm)
13/32 in (10 mm) Dia.
Weight
D
Width
Depth
Do not move or operate unit
where it could tip.
B
C
A
B
C
D
E
F
Do not exceed tilt angles or en-
gine could be damaged or unit
could tip.
A
G
15°
15°
15°
G
DX Model: 315 lb (143 kg)
4
15°
Holes
Standard Model: 267 lb (121 kg)
F
E
Optional Lifting Eye
Weight Rating
Engine End
803 403
803 597−B
430 lb (195 kg)
4-3. 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 100 Amperes CC/DC
2 Minutes Welding
8 Minutes Resting
20% Duty Cycle at 185 Amperes CC/DC
200
180
160
140
120
100
80
60
40
20
0
0
10
20
30
40
50
60
70
80
90
100
% DUTY CYCLE
220 626−A
OM-4415 Page 13
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4-4. 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. Standard Model (Honda Engine)
80
70
60
50
40
30
20
10
0
MAX
MIN
MID
0
50
100
150
200
250
300
AMPERES
B. DX Model (Kohler Engine)
80
70
60
50
40
30
20
10
0
MAX
MIN
MID
0
50
100
150
AMPERES
200
250
300
220 603−A / 220 605−A
OM-4415 Page 14
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4-5. Fuel Consumption Curves
A. Weld Output Standard
Model (Honda Engine)
1.00
B. Weld Output DX Model
(Kohler Engine)
1.00
0.80
0.60
0.40
0.20
0.00
0.80
0.60
0.40
0.20
0.00
Idle
0
25 50 75 100 125 150 175 200
0
25 50 75 100 125 150 175 200
DC Weld Amperes At Rated Duty Cycle
DC Weld Amperes At Rated Duty Cycle
1.20
1.00
0.80
0.60
0.40
0.20
C. Auxiliary Power Standard
Model (Honda Engine)
0.00
0
1
2
3
4
5
6
7
8
Aux Power kW At 100% Duty Cycle
1.00
0.80
0.60
0.40
0.20
D. Auxiliary Power DX Model
(Kohler Engine)
Idle
0.00
0
1
2
3
4
5
6
7
8
Aux Power kW At 100% Duty Cycle
220 638−A / 220 639−A
OM-4415 Page 15
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4-6. Generator Power Curves
The ac generator power curves
show the generator power available
in amperes at the receptacles.
A. Power Output Standard
Model (Honda Engine)
300
250
200
150
100
240 VOLT
120 VOLT
50
0
0
10
20
30
40
50
60
70
80
AMPERES
B. Power Output DX Model
(Kohler Engine)
300
250
200
150
100
240 VOLT
120 VOLT
50
0
0
10
20
30
40
50
60
70
80
220 589−A / 220 594−A
AMPERES
OM-4415 Page 16
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SECTION 5 − INSTALLATION
5-1. Installing Welding Generator
Movement
Airflow Clearance
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
Location
Do not install unit where air
flow is restricted or engine
may overheat.
OR
Always securely fasten welding
generator onto transport vehicle
or trailer and comply with all
DOT and other applicable codes
Always ground generator frame
to vehicle frame to prevent elec-
tric shock and static electricity
hazards.
2
1
2
Metal Vehicle Frame
3
GND/PE
Equipment Grounding
Terminal
3
Grounding Cable
Bed liners, shipping skids, and
some running gear insulate the
welding generator from the ve-
hicle frame. Always connect a
ground wire from the generator
equipment grounding terminal
to bare metal on the vehicle
frame as shown.
Use #10 AWG or larger insulated
copper wire to make metal-to-met-
al grounding connection.
1
If unit does not have GFCI
receptacles,
use
GFCI-
protected extension cord.
Ref 151 556 / Ref. 800 652 / 803 597-B / S-0854
OM-4415 Page 17
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5-2. Grounding Generator When Supplying Building Systems
1
2
Ground generator to system
earth ground if supplying power
to a premises (home, shop,
farm) wiring system.
GND/PE
1
EquipmentGrounding
Terminal
2
Grounding Cable
Use #10 AWG or larger insulated
copper wire.
3
Ground Device
. Use ground device as stated
2
3
in electrical codes.
800 576-B
5-3. Engine Prestart Checks − Standard Model
Check all fluids daily. Engine must
be cold and on a level surface. Unit
is shipped with 10W30 engine oil.
1/2 in
(13 mm)
1
Fuel Valve
Full
Open valve.
. Fuel valve is shown in the open
position. Always close fuel
valve after stopping unit. Mov-
ing unit with fuel valve open
may cause carburetor flooding
and make starting difficult.
Gasoline
Fuel
Add fresh fuel before starting
engine the first time (see engine
manual for specifications). Fill fuel
tank up to 1/2 in. (13 mm) from top
to allow room for expansion. Check
fuel level on a cold engine before
use each day.
1
Oil
After fueling, check oil with unit on
level surface. If oil is not up to full
mark on dipstick, add oil (see en-
gine manual).
Unit stops if oil level is too low. Unit
cannot be restarted until sufficient
oil is added.
Full
Ref. 803 597−B / Ref. 802 099
OM-4415 Page 18
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5-4. Engine Prestart Checks − DX Model
Check all fluids daily. Engine must
be cold and on a level surface. Unit
is shipped with 10W30 engine oil.
1/2 in
(13 mm)
1
Fuel Valve
Full
Open valve.
. Close fuel valve before moving
unit or carburetor may flood
and make starting difficult.
Gasoline
Fuel
Add fresh fuel before starting
engine the first time (see engine
manual for specifications). Fill fuel
tank up to 1/2 in. (13 mm) from top
to allow room for expansion. Check
fuel level on a cold engine before
use each day.
1
Oil
After fueling, check oil with unit on
level surface. If oil is not up to full
mark on dipstick, add oil (see en-
gine manual).
Unit stops if oil level is too low. Unit
cannot be restarted until sufficient
oil is added.
. To improve cold weather
starting:
. Fuel valve is shown in the
open position. Always close
fuel valve after stopping unit.
Moving unit with fuel valve
Keep battery in good condition.
Store battery in warm area off
concrete surface.
Full
open may cause carburetor
flooding and make starting
difficult.
Use correct grade oil for cold
weather.
803 595−B
5-5. Connecting The Battery (DX Models Only)
Turn Engine Switch to Off (DX
models only).
+
−
Connect negative (−) cable last.
Tools Needed:
1/2 in
803 596−B / 803 466
OM-4415 Page 19
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5-6. Connecting To Weld Output Terminals
1
2
Positive (+) Weld Output
Terminal
Negative (−) Weld Output
Terminal
For Direct Current Electrode Posi-
tive (DCEP), connect work cable to
Negative (−) terminal and electrode
holder to Positive (+) terminal.
1
2
For Direct Current Electrode nega-
tive (DCEN), reverse cable con-
nections.
Failure to properly connect weld
cables may cause excessive
heat and start a fire, or damage
your machine.
3
4
Weld Output Terminal
Supplied Weld Output
Terminal Nut
5
6
Weld Cable Terminal
Copper Bar
6
Remove supplied nut from weld
output terminal. Slide weld cable
terminal onto weld output terminal
and secure with nut so that weld
cable terminal is tight against cop-
per 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.
3
Do not place
anything between
weld cable terminal
and copper bar.
4
5
Tools Needed:
3/4 in
Correct Installation
Incorrect Installation
803 596−B / 803 778-A
5-7. Selecting Weld Cable Sizes*
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
150 ft
(45 m)
200 ft
250 ft
300 ft
350 ft
400 ft
100 ft (30 m) or Less
(60 m) (70 m) (90 m) (105 m) (120 m)
10 − 60% 60 − 100%
Welding
Amperes
Duty
Duty
10 − 100% Duty Cycle
Cycle
Cycle
Weld Output
Terminals
Stop engine before
connecting to weld
output terminals.
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
Do not use worn, dam-
aged, undersized, or
poorly spliced cables.
250
300
2 (35)
1 (50)
1 (50)
1/0 (60)
2/0 (70)
2/0 (70)
3/0 (95) 4/0 (120)
(2x70)
(2x70)
2 ea. 2/0 2 ea. 3/0 2 ea. 3/0
(2x70)
1/0 (60)
3/0 (95) 4/0 (120)
(2x95)
(2x95)
* 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.
OM-4415 Page 20
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Notes
OM-4415 Page 21
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1
Engine Switch
D
D
Set choke.
Pull starter handle. Open choke as en-
gine warms.
5
Weld Output Control
Use switch to control ignition circuit. Turn
switch to On position when starting engine.
Turn switch to Off position to stop engine. En-
gine cannot be started with switch in the Off
position.
Enginestops if oil level is too low. Engine can-
not be restarted until sufficient oil is added.
. Set control at maximum for full generator
power output at AC receptacles
If the engine does not start, let
engine come to a complete stop
before attempting restart.
Use control to select weld amperage. Control
may be adjusted while welding.
To Set Weld Output Control: Use table to
determinecorrect size electrode for weld am-
perage. Select electrode type and set control
to corresponding amperage range on name-
plate. Adjust control to obtain desired weld
performance.
To Stop:
2
3
Starter Handle
Choke Control
D
Turn Engine switch to Off.
. Always close fuel valve after stopping
unit. Moving unit with fuel valve open may
cause carburetor flooding and make
starting difficult.
Use control to change engine air/fuel mix.
Move control to far right if starting a cold en-
gine. Move control to far left if starting a warm
engine.
EXAMPLE:
4
Welding Range Table
Electrode Diameter: 1/8
Electrode Type: E-6013
Current Control Setting: 90 − 120 A
To Start:
Use table to determine correct weld amper-
age based on electrode size, type, and mate-
rial thickness.
D
D
Turn Engine switch to On.
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-4415 Page 23
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1
Engine Switch
To Start:
6
Run / Idle Switch
Use switch to control ignition circuit. Turn
switch to Start position for electric start. Turn
switch to On position to start engine using
starter handle (recoil). Turn switch to Off posi-
tion to stop engine.
Use switch to select whether the engine stays
at run speed continuously or whether the auto
idle feature is enabled so engine speed re-
turns to idle speed after start−up or after weld
or generator load is removed.
D
D
D
Set choke.
Electric-Start: Turn Engine switch to
Start position.
Recoil: Turn Engine switch to On posi-
tion. Pull starter handle until engine
starts.
2
Low Oil Level Light
7
Weld Output Control
Light goes on and engine stops if engine oil
level is too low.
Engine cannot be restarted until sufficient oil
is added.
. Set control at maximum for full generator
power output at AC receptacles.
D
Open choke as engine warms.
Use control to select weld amperage. Control
may be adjusted while welding.
If the engine does not start, let
engine come to a complete stop
before attempting restart.
Stop engine and add oil if light
To Set Weld Output Control: Use table to
determinecorrect size electrode for weld am-
perage. Select electrode type and set control
to corresponding amperage range on name-
plate. Adjust control to obtain desired weld
performance.
3
Starter Handle
To Stop:
Use starter handle to start unit if electric start
does not work.
D
Turn Engine switch to Off.
4
Choke Control
. Always close fuel valve after stopping
unit. Moving unit with fuel valve open may
cause carburetor flooding and make
starting difficult.
Use control to change engine air/fuel mix.
Move control to far right if starting a cold en-
gine. Move control to far left if starting a warm
engine.
The engine starts at weld/power speed and
runs at weld/power speed under weld or gen-
EXAMPLE:
Electrode Diameter: 1/8
Electrode Type: E-6013
Current Control Setting: 90 − 120 A
5
Welding Range Table
8
Hourmeter
erator power load. The engine returns to idle Use table to determine correct weld amper-
speed 12 seconds after start-up or after weld age based on electrode size, type, and mate-
Use hourmeter to help schedule routine main-
tenance.
or generator power load is removed.
rial thickness.
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-4415 Page 25
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SECTION 7 − OPERATING AUXILIARY EQUIPMENT
7-1. Generator Power Panel Receptacles
5
4
1
2
3
218 611−B
3
120 V 20 A AC Duplex Receptacle
RC3
tector opens, the receptacle does not
work. Press button to reset.
If unit does not have GFCI recep-
tacles, use GFCI-protected exten-
sion cord.
RC2 and RC3 supply 60 Hz single-phase
power at weld/power speed. Maximum
output from RC2 or RC3 is 2.4 kVA/kW.
. If supplementary protector continues
to open, contact Factory Authorized
Service Agent.
. Generator power decreases as weld
current increases. Set Weld Output
control to maximum for full generator
power output at AC receptacles.
NOTICE − Do not parallel the two 120V du-
plex receptacles.
Combinedoutput of all receptacles limited
to 5.5 kVA/kW continuous rating of the
Power Guidelines).
4
Supplementary Protector CB1
1
240 V AC Receptacle RC1
CB1 protects the receptacles from over-
load. If CB1 opens, the receptacles do not
work. Move switch to the On position to re-
set.
RC1 supplies 60 Hz single-phase power at
weld/power speed. Maximum output is 6
kVA/kW (peak) or 5.5 kVA/kW (continu-
ous).
EXAMPLE:If 10 A is drawn from each 120
volt duplex receptacle, only 13 A is avail-
able from the 240 V receptacle.
5
SupplementaryProtectors CB2, CB3
2
120 V 20 A AC Duplex Receptacle
RC2
CB2 protects RC2 and CB3 protects RC3
from overload. If the supplementary pro-
2 x (120 V x 10 A) + (240 V x 13 A) = 5.5
kVA/KW.
OM-4415 Page 26
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SECTION 8 − MAINTENANCE
.
F
o
l
l
o
w
t
h
e
s
t
o
r
a
g
e
p
r
o
c
e
d
u
r
e
i
n
t
h
e
e
n
g
i
n
e
o
w
n
e
r
’
s
m
a
n
u
a
l
i
f
t
h
e
u
n
i
t
w
i
l
l
n
o
t
b
e
u
s
e
d
f
o
r
a
n
e
x
t
e
n
d
e
d
p
e
r
i
o
d
.
8-1. Routine Maintenance
Stop engine before maintaining.
. See Engine Manual and Maintenance Label
Recycle engine
fluids.
for important start-up, service, and storage
information. Service engine more often if
used in severe conditions.
n
=
C
h
e
c
k
Z
=
C
h
a
n
g
e
~
=
C
l
e
a
n
l
=
R
e
p
l
a
c
e
Reference
* To be done by Factory Authorized Service Agent
Every
8
Hours
n
F
u
e
l
L
e
v
e
l
n
O
i
l
L
e
v
e
l
~
O
i
l
,
F
u
e
l
S
p
i
l
l
s
Every
25
Hours
~
A
i
r
C
l
e
a
n
e
r
P
r
e
c
l
e
a
n
e
r
Every
50
Hours
~
W
e
l
d
T
e
r
m
i
n
a
l
s
Every
100
Hours
Engine
Manual,
Z
O
i
l
n
n
l
A
i
r
C
l
e
a
n
e
r
E
l
e
m
e
n
t
~
C
o
o
l
i
n
g
S
y
s
t
e
m
n
S
p
a
r
k
P
l
u
g
G
a
p
~ Battery Terminals (DX
Models)
~
S
p
a
r
k
A
r
r
e
s
t
o
r
S
c
r
e
e
n
(Optional on DX Models)
Every
200
Hours
l
U
n
r
e
a
d
a
b
l
e
L
a
b
e
l
s
Every
300
Hours
Engine
Manual
n
V
a
l
v
e
C
l
e
a
r
a
n
c
e
*
Every
500
Hours
Engine
Manual
n
l
W
e
l
d
C
a
b
l
e
s
n
n
~ Slip Rings*
Brushes*
l
OM-4415 Page 27
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8-2. Servicing Air Cleaner
Stop engine.
NOTICE − Do not run engine with-
out air cleaner or with dirty element.
1
2
Precleaner
Paper Element
. Do not wash paper element or
clean with compressed air.
Remove cover.
Wash precleaner with soap and wa-
ter solution. Allow precleaner to air
dry completely.
Dip precleaner in clean engine oil.
Squeeze out excess oil. The engine
will smoke if precleaner contains
too much oil.
1
2
Replace paper element if dirty, oily,
or damaged.
Standard Model Shown
oil
aircleaner6 9/00 − 803 404
OM-4415 Page 28
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8-3. Adjusting Engine Speed (Honda-Powered Units)
After tuning engine, check engine
speeds. See table for proper no
load speeds. If necessary, adjust
speeds as follows:
1400 150 rpm
Start engine and run until warm.
Weld/Power Speed
Adjustment
3750 30 rpm (62 Hz)
1
2
Throttle Control Lever
Adjustment Screw
Move lever to Run (far left) position.
Turn screw and move lever until en-
gine runs at weld/power speed.
Idle Speed Adjustment
3
4
Pilot Screw
Throttle Stop Screw
Move lever to idle (far right) posi-
tion. Turn pilot screw until engine
runs at highest idle speed. Turn
stop screw until engine runs at
rated idle speed (normally about
2-1/4 turns out.)
2
1
!
Stop engine. Close fuel
valve.
4
3
Tools Needed:
1/4, 3/8 in
803 597−B / Ref. 802 101-A
OM-4415 Page 29
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8-4. Adjusting Engine Speed (Kohler−Powered Units)
After tuning engine, check engine
speed. See table for proper no load
speed. If necessary, adjust speed
as follows:
2500 100 rpm (42 Hz)
3750 30 rpm (62Hz)
Start engine and run until warm.
Set Weld Output Control to Max.
Weld/Power Speed Adjustment
1
Adjustment Screw
To increase speed, turn screw out
(counterclockwise). To decrease
speed, turn screw in (clockwise).
Idle Speed Adjustment
2
3
Throttle Solenoid TS1
Adjustment Screw
Loosen two screws on side of
throttle solenoid TS1. Adjust TS1
until idle speed is approximately
2500 rpm. Use adjustment screw
to fine tune idle speed. Be sure TS1
plunger bottoms at idle. Tighten
two screws on TS1.
!
Stop engine. Close fuel
valve.
1
2
3
Tools Needed:
803 595-B
OM-4415 Page 30
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SECTION 9 − TROUBLESHOOTING
9-1. Troubleshooting
A. Welding
Trouble
Remedy
No weld output or generator power out- Be sure all equipment is disconnected from receptacles when starting unit.
put at ac receptacles.
Have Factory Authorized Service Agent check brushes, slip rings, rotor, stator, integrated rectifier
SR2, and Weld Output control R1.
No weld output; generator power out-
put okay at ac receptacles.
Check Weld Output control setting.
Check weld connections.
Have Factory Authorized Service Agent check Weld Output control R1, stator, integrated rectifier
SR2, stabilizer DC-Z, main rectifier SR1, and reactor AC-Z
Low weld output.
Check Weld Output control setting.
Service engine air cleaner.
Check weld cable size and length.
Have Factory Authorized Service Agent check Weld Output control R1, stator, integrated rectifier
SR2, stabilizer DC-Z, main rectifier SR1, and reactor AC-Z
High weld output.
Check Weld Output control setting.
Check Weld Output control setting.
Erratic weld output.
Tighten and clean connections to electrode and workpiece.
Use dry, properly-stored electrodes for Stick welding.
Remove excessive coils from weld cables.
Clean and tighten connections both inside and outside welding generator.
Check throttle/governor linkage for smooth, non-binding operation.
B. Generator Power
Trouble
Remedy
No output at generator power ac re-
ceptacles; no weld output.
Be sure all equipment is disconnected from receptacles when starting unit.
Have Factory Authorized Service Agent check brushes, slip rings, rotor, stator, integrated rectifier
SR2, and Weld Output control R1.
No output at generator power ac re-
ceptacles; weld output okay.
Check receptacle wiring and connections.
Have Factory Authorized Service Agent check stator windings and connections at terminal block 1T.
High output at generator power ac
receptacles.
OM-4415 Page 31
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Trouble
Remedy
Low output at generator power ac Check Weld Output control setting.
receptacles.
Check engine speed, and adjust if necessary (see Section 8-3 or 8-4). Open circuit voltage is reduced
as engine speed drops.
Erratic output at generator power ac Check fuel level.
receptacles.
Have Factory Authorized Service Agent check connections at terminal block 1T.
Check receptacle supplementary protector(s), wiring, and connections.
Check throttle linkage for smooth, non-binding operation.
Service air cleaner according to engine manual.
C. Engine
Trouble
Engine will not crank (DX models only).
Remedy
Reset ignition circuit breaker (see engine manual).
Check and replace ignition fuse (see engine manual).
Check battery voltage.
Check battery connections and tighten if necessary.
Have Factory Authorized Service Agent check engine ignition circuit.
Engine will not start.
Open fuel valve (see Section 5-3 or 5-4). Close fuel valve before moving unit or carburetor may flood and
make starting difficult.
Check battery voltage (DX models only).
Check battery connections and tighten if necessary (DX models only).
Check oil level (see Section 5-3 or 5-4). Engine stops if oil level is too low. Refill crankcase with proper
viscosity oil for operating temperature.
Have Factory Authorized Service Agent check low oil level shutdown switch.
Engine stopped during normal
operation.
Open fuel valve (see Section 5-3 or 5-4). Close fuel valve before moving unit or carburetor may flood and
make starting difficult.
Battery discharges between uses (DX Clean battery, terminals, and posts with baking soda and water solution; rinse with clear water.
models only).
Periodically recharge battery (approximately every 3 months).
Replace battery.
Check engine battery charging circuit and connections according to engine manual.
Unstable or sluggish engine speeds.
Check throttle/governor linkage for smooth, non-binding operation.
Tune-up engine according to engine manual.
OM-4415 Page 32
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SECTION 10 − PARTS LIST
10-1. Recommended Spare Parts
Dia.
Mkgs.
Part
No.
Description
Quantity
Recommended Spare Parts
. . . . . . . . . . . . . . . . . . . 220305 . . Tune−up & Filter Kit, Honda (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 190108 . . . . Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 220303 . . . . Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 220304 . . . . Air Filter, Pre Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 221584 . . Tune−up & Filter Kit, Kohler CS 10 & 12 Electric (includes) . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 203960 . . . . Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 221582 . . . . Filter, Air Kohler CS 10 & 12 Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 221583 . . . . Filter, Air Pre Cleaner Kohler CS 10 & 12 Electric . . . . . . . . . . . . . . . . . . . 1
OM-4415 Page 33
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226 738-A
Figure 11-2. Circuit Diagram for DX Models
OM-4415 Page 35
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SECTION 12 − 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.
12-1. 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
12-2. 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.
3
. Electrically bond generator
frame to vehicle frame by met-
al-to-metal contact.
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-4415 Page 36
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12-3. 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
.
U
s
e
g
r
o
u
n
d
d
e
v
i
c
e
a
s
s
t
a
t
e
d
i
n
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
12-4. 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
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-4415 Page 37
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12-5. 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
12-6. 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-4415 Page 38
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12-7. 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-4415 Page 39
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12-8. 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
12-9. 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-4415 Page 40
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12-10. 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)
.
C
u
s
t
o
m
e
r
-
s
u
p
p
l
i
e
d
e
q
u
i
p
m
e
n
t
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,
OM-4415 Page 41
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12-11. Selecting Extension Cord (Use Shortest Cord Possible)
Cord Lengths for 120 Volt Loads
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)
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-4415 Page 42
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SECTION 13 − STICK WELDING (SMAW) GUIDELINES
13-1. Stick Welding Procedure
Weld current starts when elec-
trode touches workpiece.
Weld current can damage elec-
tronic parts in vehicles. Discon-
nect both battery cables before
welding on a vehicle. Place work
clamp as close to the weld as
possible.
1
Workpiece
Make sure workpiece is clean be-
fore welding.
5
2
3
Work Clamp
Electrode
4
2
A small diameter electrode requires
less current than a large one. Fol-
low electrode manufacturer’s
instructions when setting weld am-
4
5
6
Insulated Electrode Holder
Electrode Holder Position
Arc Length
3
Arc length is the distance from the
electrodeto the workpiece. A short
arc with correct amperage will give
a sharp, crackling sound.
6
1
7
7
Slag
Use a chipping hammer and wire
brush to remove slag. Remove slag
and check weld bead before mak-
ing another weld pass.
Tools Needed:
stick 2007−04 − ST-151 593
OM-4415 Page 43
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13-2. 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
6013 EP,EN
GENERAL
1/8
SMOOTH, EASY,
FAST
LOW HYDROGEN,
STRONG
6013
7014 EP,EN
ALL
MED
LOW
5/32
3/16
7/32
1/4
3/32
1/8
7018
EP
ALL
FLAT
HORIZ LOW
FILLET
ALL
ALL
SMOOTH, EASY,
FASTER
7024 EP,EN
NI-CL
308L
EP
EP
LOW
LOW
CAST IRON
STAINLESS
5/32
3/16
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
5/32
3/16
3/32
1/8
Ni-Cl
308L
5/32
Ref. S-087 985-A
13-3. 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
13-4. Striking an Arc − Tapping Technique
1
1
2
3
Electrode
Workpiece
Arc
Bring electrode straight down to
workpiece; then lift slightly to start
arc. If arc goes out, electrode was
lifted too high. If electrode sticks to
workpiece, use a quick twist to free it.
2
3
S-0050
OM-4415 Page 44
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13-5. 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
13-6. Poor Weld Bead Characteristics
1
2
3
4
5
Large Spatter Deposits
Rough, Uneven Bead
Slight Crater During Welding
Bad Overlap
Poor Penetration
1
2
4
3
5
S-0053-A
13-7. 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-4415 Page 45
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13-8. 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
Angle Too Small
10° - 30°
Drag
ELECTRODE ANGLE
Spatter
Normal
Too Long
Too Short
ARC LENGTH
Normal
Fast
Slow
TRAVEL SPEED
S-0061
13-9. 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
e
r
b
e
a
d
i
s
s
a
t
i
s
f
a
c
t
o
r
y
f
o
r
m
o
s
t
n
a
r
r
o
w
g
r
o
o
v
e
w
e
l
d
j
o
i
n
t
s
;
h
o
w
e
v
e
r
,
f
o
r
w
i
d
e
g
r
o
o
v
e
w
e
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 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 electrode.
Do not let weave width exceed
2-1/2 times diameter of electrode.
3
S-0054-A
OM-4415 Page 46
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13-10. Butt Joints
1
Tack Welds
1
Prevent edges of joint from drawing
together ahead of electrode by tack
welding the materials in position be-
fore final weld.
2
2
Square Groove Weld
Good for materials up to 3/16 in (5
mm) thick.
3
Single V-Groove Weld
Good for materials 3/16 − 3/4 in
(5-19 mm) thick. Cut bevel with oxy-
acetylene or plasma cutting equip-
ment. Remove scale from material
after cutting. A grinder can also be
used to prepare bevels.
30°
1/16 in
(1.6 mm)
4
Create 30 degree angle of bevel on
materials in V-groove welding.
3
4
Double V-Groove Weld
Good for materials thicker than 3/16
in (5 mm).
S-0662
13-11. Lap Joint
30°
1
2
Electrode
30°
Or Less
Or Less
1
Single-LayerFillet Weld
Move electrode in circular motion.
Multi-Layer Fillet Weld
1
3
Weld a second layer when a heavi-
er fillet is needed. Remove slag be-
fore making another weld pass.
Weld both sides of joint for maxi-
mum strength.
3
2
Single-Layer Fillet Weld
Multi-Layer Fillet Weld
S-0063 / S-0064
13-12. Tee Joint
1
2
Electrode
Fillet Weld
Keep arc short and move at definite
rate of speed. Hold electrode as
shown to provide fusion into the
corner. Square edge of the weld
surface.
1
45°
Or Less
For maximum strength weld both
sides of upright section.
2
2
3
Multi-Layer Deposits
Weld a second layer when a heavi-
er fillet is needed. Use any of the
weaving patterns shown in Section
13-9. Remove slag before making
another weld pass.
1
3
S-0060 / S-0058-A / S-0061
OM-4415 Page 47
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13-13. 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
13-14. 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.
13-15. 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-4415 Page 48
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13-16. Troubleshooting − Incomplete Fusion
IncompleteFusion − failure of weld metal to fuse completely with
base metal or a preceeding weld bead.
Possible Causes
Insufficient heat input.
Corrective Actions
Increase amperage. Select larger electrode and increase amperage.
Improper welding technique.
Place stringer bead in proper location(s) at joint during welding.
Adjust work angle or widen groove to access bottom during welding.
Momentarily hold arc on groove side walls when using weaving technique.
Keep arc on leading edge of weld puddle.
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
13-17. 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.
13-18. Troubleshooting − Excessive Penetration
Excessive Penetration − weld metal melting through base metal and
hangingunderneath weld.
Excessive Penetration
Good Penetration
Possible Causes
Excessive heat input.
Corrective Actions
Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
OM-4415 Page 49
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13-19. 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.
13-20. 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.
13-21. Troubleshooting − Distortion
Distortion− contraction of weld met-
al during welding that forces base
metal to move.
Base metal moves
in the direction of
the weld bead.
Possible Causes
Corrective Actions
Excessive heat input.
Use restraint (clamp) to hold base metal in position.
Make tack welds along joint before starting welding operation.
Select lower amperage for electrode.
Increase travel speed.
Weld in small segments and allow cooling between welds.
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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
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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