OM-4407
May 2004
203 236U
Processes
MIG (GMAW) Welding
Flux Cored (FCAW)
Stick (SMAW) Welding
TIG (GTAW) Welding
Air Plasma Cutting and Gouging
R
with Spectrum Unit
Air Carbon Arc (CAC-A) Cutting
and Gouging
Description
Engine Driven Welding Generator
(AC Available On AC/DC Models Only)
R
Trailblazer 301 G
R
Trailblazer DC
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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. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-2. Dimensions, Weights, and Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-3. Fuel Consumption While Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-4. Fuel Consumption While Using Generator Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-5. Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-6. Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-7. Stick And MIG Mode Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-8. TIG Mode Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-2. Engine Prestart Checks (Robin EH64-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-3. Engine Prestart Checks (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-4. Activating The Dry Charge Battery (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-5. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5-6. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5-7. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-8. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-9. Remote Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-10. Adjusting Wire (MIG) Weld Puddle Consistency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SECTION 6 − OPERATING WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6-1. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6-2. Process/Contactor Switch On CC/CV Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-3. Remote Amperage/Voltage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SECTION 7 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7-1. Generator Power Receptacles And Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7-2. Optional Generator Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7-3. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P) . . . . . . . . . . . . . . . . . . . 28
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TABLE OF CONTENTS
SECTION 8 − MAINTENANCE (Robin EH64-POWERED UNITS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8-1. Maintenance Label (Robin EH64-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8-2. Routine Maintenance (Robin EH64-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8-3. Servicing Air Cleaner (Robin EH64-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8-4. Servicing Optional Spark Arrestor (Robin EH64-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8-5. Overload Protection (Robin EH64-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8-6. Changing Engine Oil, Oil Filter, and Fuel Filter (Robin EH64-Powered Units) . . . . . . . . . . . . . . . . . . . . 34
8-7. Adjusting Engine Speed (Robin EH64-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
SECTION 9 − MAINTENANCE (KOHLER-POWERED UNITS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9-1. Routine Maintenance (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9-2. Maintenance Label (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9-3. Servicing Air Cleaner (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9-4. Servicing Optional Spark Arrestor (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9-5. Changing Engine Oil, Oil Filter, And Fuel Filter (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . 39
9-6. Adjusting Engine Speed (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9-7. Overload Protection (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
SECTION 10 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
10-1. Welding Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
10-2. Generator Power Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
10-3. Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
SECTION 11 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
SECTION 12 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
SECTION 13 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
OPTIONS AND ACCESSORIES
WARRANTY
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SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
rom _nd_10/02
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Warning: Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
This group of symbols means Warning! Watch Out! possible
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Marks a special safety message.
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
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1-2. Arc Welding Hazards
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Use only well-maintained equipment. Repair or replace damaged parts at
once. Maintain unit according to manual.
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The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see the
symbol, watch out, and follow the related instructions to avoid the
hazard. The safety information given below is only a summary of
the more complete safety information found in the Safety Stan-
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Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece or work-
table as near the weld as practical.
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Only qualified persons should install, operate, maintain, and re-
pair this unit.
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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.
During operation, keep everybody, especially children, away.
SIGNIFICANT DC VOLTAGE exists in inverters after stop-
ping engine.
ELECTRIC SHOCK can kill.
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Stop engine on inverter and discharge input capacitors according to
instructions in Maintenance Section before touching any parts.
Touching live electrical parts can cause fatal shocks or
severe burns. The electrode and work circuit is electrically
live whenever the output is on. The input power circuit and
machine internal circuits are also live when power is on. In semiautomatic or
automatic wire welding, the wire, wire reel, drive roll housing, and all metal
parts touching the welding wire are electrically live. Incorrectly installed or
improperly grounded equipment is a hazard.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing these fumes
and gases can be hazardous to your health.
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Do not touch live electrical parts.
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Keep your head out of the fumes. Do not breathe the fumes.
Wear dry, hole-free insulating gloves and body protection.
If inside, ventilate the area and/or use exhaust at the arc to remove welding
fumes and gases.
Insulate yourself from work and ground using dry insulating mats or covers
big enough to prevent any physical contact with the work or ground.
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If ventilation is poor, use an approved air-supplied respirator.
Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s
instructions for metals, consumables, coatings, cleaners, and degreasers.
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Do not use AC output in damp areas, if movement is confined, or if there is a
danger of falling.
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Use AC output ONLY if required for the welding process.
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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 watchperson nearby. Welding
fumes and gases can displace air and lower the oxygen level causing injury
or death. Be sure the breathing air is safe.
If AC output is required, use remote output control if present on unit.
Additionalsafety precautions are required when any of the following electri-
cally hazardous conditions are present: in damp locations or while wearing
wet clothing; on metal structures such as floors, gratings, or scaffolds;
when in cramped positions such as sitting, kneeling, or lying; or when there
is a high risk of unavoidable or accidental contact with the workpiece or
ground. For these conditions, use the following equipment in order present-
ed: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most
situations, use of a DC, constant voltage wire welder is recommended.
And, do not work alone!
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Do not weld in locations near degreasing, cleaning, or spraying operations.
The heat and rays of the arc can react with vapors to form highly toxic and
irritating gases.
Do not weld on coated metals, such as galvanized, lead, or cadmium plated
steel, unless the coating is removed from the weld area, the area is well
ventilated, and if necessary, while wearing an air-supplied respirator. The
coatings and any metals containing these elements can give off toxic fumes
if welded.
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Disconnect input power or stop engine before installing or servicing this
equipment. Lockout/tagout input power according to OSHA 29 CFR
1910.147 (see Safety Standards).
BUILDUP OF GAS can injure or kill.
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Shut off shielding gas supply when not in use.
Always ventilate confined spaces or use approved
air-supplied respirator.
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Properly install and ground this equipment according to its Owner’s Manual
and national, state, and local codes.
Always verify the supply ground — check and be sure that input power cord
ground wire is properly connected to ground terminal in disconnect box or
that cord plug is connected to a properly grounded receptacle outlet.
ARC RAYS can burn eyes and skin.
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When making input connections, attach proper grounding conductor first −
double-check connections.
Arc rays from the welding process produce intense visible
and invisible (ultraviolet and infrared) rays that can burn eyes
and skin. Sparks fly off from the weld.
Frequently inspect input power cord for damage or bare wiring — replace
cord immediately if damaged — bare wiring can kill.
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Turn off all equipment when not in use.
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Wear a welding helmet fitted with a proper shade of filter to protect your face
and eyes from arc rays and sparks when welding or watching (see ANSI
Z49.1 and Z87.1 listed in Safety Standards).
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
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Wear approved safety glasses with side shields under your helmet.
If earth grounding of the workpiece is required, ground it directly with a sep-
arate cable.
Use protective screens or barriers to protect others from flash and glare;
warn others not to watch the arc.
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Do not touch electrode if you are in contact with the work, ground, or anoth-
er electrode from a different machine.
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Wear protective clothing made from durable, flame-resistant material (wool
and leather) and foot protection.
OM-4407 Page 1
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WELDING can cause fire or explosion.
HOT PARTS can cause severe burns.
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Allow cooling period before maintaining.
Wear protective gloves and clothing when working on
a hot engine.
Do not touch hot engine parts or just-welded parts
bare-handed.
Welding on closed containers, such as tanks, drums, or
pipes, can cause them to blow up. Sparks can fly off from the
welding arc. The flying sparks, hot workpiece, and hot
equipment can cause fires and burns. Accidental contact of electrode to metal
objects can cause sparks, explosion, overheating, or fire. Check and be sure
the area is safe before doing any welding.
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Protect yourself and others from flying sparks and hot metal.
Do not weld where flying sparks can strike flammable material.
NOISE can damage hearing.
Noise from some processes or equipment can damage
hearing.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not
possible, tightly cover them with approved covers.
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Wear approved ear protection if noise level is high.
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Be alert that welding sparks and hot materials from welding can easily go
through small cracks and openings to adjacent areas.
MAGNETIC FIELDS can affect pacemakers.
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Watch for fire, and keep a fire extinguisher nearby.
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Pacemaker wearers keep away.
Be aware that welding on a ceiling, floor, bulkhead, or partition can cause
fire on the hidden side.
Wearers should consult their doctor before going
near arc welding, gouging, or spot welding opera-
tions.
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Do not weld on closed containers such as tanks, drums, or pipes, unless
they are properly prepared according to AWS F4.1 (see Safety Standards).
Connect work cable to the work as close to the welding area as practical to
prevent welding current from traveling long, possibly unknown paths and
causing electric shock and fire hazards.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high pressure. If
damaged, a cylinder can explode. Since gas cylinders are
normally part of the welding process, be sure to treat them
carefully.
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Do not use welder to thaw frozen pipes.
Remove stick electrode from holder or cut off welding wire at contact tip
when not in use.
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Protect compressed gas cylinders from excessive heat, mechanical
shocks, slag, open flames, sparks, and arcs.
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Wear oil-free protective garments such as leather gloves, heavy shirt, cuf-
fless trousers, high shoes, and a cap.
Install cylinders in an upright position by securing to a stationary support or
cylinder rack to prevent falling or tipping.
Remove any combustibles, such as a butane lighter or matches, from your
person before doing any welding.
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Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot
work and have a fire watcher and extinguisher nearby.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder — explosion will result.
Use only correct shielding gas cylinders, regulators, hoses, and fittings de-
signed for the specific application; maintain them and associated parts in
good condition.
FLYING METAL can injure eyes.
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Welding, chipping, wire brushing, and grinding cause
sparks and flying metal. As welds cool, they can
throw off slag.
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Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is in use or
connected for use.
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Wear approved safety glasses with side shields even
under your welding helmet.
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Read and follow instructions on compressed gas cylinders, associated
equipment, and CGA publication P-1 listed in Safety Standards.
1-3. Engine Hazards
MOVING PARTS can cause injury.
BATTERY EXPLOSION can BLIND.
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Keep away from fans, belts, and rotors.
Keep all doors, panels, covers, and guards closed
and securely in place.
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Always wear a face shield, rubber gloves, and protec-
tive clothing when working on a battery.
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Stop engine before disconnecting or connecting bat-
tery cables or servicing battery.
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Stop engine before installing or connecting unit.
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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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Have only qualified people remove guards or covers for maintenance
and troubleshooting as necessary.
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To prevent accidental starting during servicing, disconnect negative (−)
battery cable from battery.
Disconnect negative (−) cable first and connect it last.
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Keep hands, hair, loose clothing, and tools away from moving parts.
Reinstall panels or guards and close doors when servicing is finished
and before starting engine.
FUEL can cause fire or explosion.
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Before working on generator, remove spark plugs or injectors to keep
engine from kicking back or starting.
D
Stop engine and let it cool off before checking or add-
ing fuel.
D
Do not add fuel while smoking or if unit is near any
sparks or open flames.
Block flywheel so that it will not turn while working on generator compo-
nents.
D
D
D
D
Do not overfill tank — allow room for fuel to expand.
Do not spill fuel. If fuel is spilled, clean up before starting engine.
Dispose of rags in a fireproof container.
Always keep nozzle in contact with tank when fueling.
OM-4407 Page 2
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BATTERY ACID can BURN SKIN and EYES.
STEAM AND HOT COOLANT can burn.
D
D
D
Do not tip battery.
Replace damaged battery.
D
If possible, check coolant level when engine is cold to
avoid scalding.
D
Always check coolant level at overflow tank, if pres-
ent on unit, instead of radiator (unless told otherwise
in maintenance section or engine manual).
Flush eyes and skin immediately with water.
D
If the engine is warm, checking is needed, and there is no overflow tank,
follow the next two statements.
ENGINE HEAT can cause fire.
D
D
Wear safety glasses and gloves and put a rag over radiator cap.
D
Do not locate unit on, over, or near combustible
surfaces or flammables.
Turn cap slightly and let pressure escape slowly before completely re-
moving cap.
D
Keep exhaust and exhaust pipes way from flam-
mables.
ENGINE EXHAUST GASES can kill.
EXHAUST SPARKS can cause fire.
D
Use equipment outside in open, well-ventilated ar-
eas.
D
D
Do not let engine exhaust sparks cause fire.
Use approved engine exhaust spark arrestor in re-
quired areas — see applicable codes.
D
If used in a closed area, vent engine exhaust outside
and away from any building air intakes.
1-4. Compressed Air Hazards
BREATHING COMPRESSED AIR can
cause serious injury or death.
HOT METAL from air arc cutting and
gouging can cause fire or explosion.
D
D
Do not use compressed air for breathing.
Use only for cutting, gouging, and tools.
D
D
Do not cut or gouge near flammables.
Watch for fire; keep extinguisher nearby.
HOT PARTS can cause burns and injury.
COMPRESSED AIR can cause injury.
D
D
Do not touch hot compressor or air system parts.
Let system cool down before touching or servicing.
D
D
Wear approved safety goggles.
Do not direct air stream toward self or others.
TRAPPED AIR PRESSURE AND WHIPPING
HOSES can cause injury.
READ INSTRUCTIONS.
D
D
Read Owner’s Manual before using or servicing unit.
Stop engine and release air pressure before
servicing.
D
Release air pressure from tools and system before
servicing, adding or changing attachments, or open-
ing compressor oil drain or oil fill cap.
1-5. Additional Symbols For Installation, Operation, And Maintenance
OVERUSE can cause OVERHEATING.
FALLING UNIT can cause injury.
D
D
Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before starting
to weld again.
D
D
D
Use lifting eye to lift unit only, NOT running gear, gas
cylinders, trailer, or any other accessories.
Use equipment of adequate capacity to lift and
support unit.
If using lift forks to move unit, be sure forks are long
enough to extend beyond opposite side of unit.
D
Do not block or filter airflow to unit.
OVERHEATING can damage motors.
STATIC (ESD) can damage PC boards.
D
Turn off or unplug equipment before starting or stop-
ping engine.
Do not let low voltage and frequency caused by low
engine speed damage electric motors.
D
Put on grounded wrist strap BEFORE handling
boards or parts.
D
D
Use proper static-proof bags and boxes to store,
move, or ship PC boards.
D
Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where
applicable.
FLYING SPARKS can cause injury.
TILTING OF TRAILER can cause injury.
D
D
Wear a face shield to protect eyes and face.
Shape tungsten electrode only on grinder with proper
guards in a safe location wearing proper face, hand,
and body protection.
D
D
Use tongue jack or blocks to support weight.
Properly install welding generator onto trailer accord-
ing to instructions supplied with trailer.
D
Sparks can cause fires — keep flammables away.
OM-4407 Page 3
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READ INSTRUCTIONS.
ARC WELDING can cause interference.
D
Use only genuine MILLER/Hobart replacement
parts.
D
Electromagnetic energy can interfere with sensitive
electronic equipment such as microprocessors,
computers, and computer-driven equipment such as
robots.
Be sure all equipment in the welding area is electro-
magnetically compatible.
D
Perform engine and air compressor (if applicable)
maintenance and service according to this manual
and the engine/air compressor (if applicable) manu-
als.
D
D
D
D
D
To reduce possible interference, keep weld cables as short as possible,
close together, and down low, such as on the floor.
H.F. RADIATION can cause interference.
Locate welding operation 100 meters from any sensitive electronic
equipment.
D
High-frequency (H.F.) can interfere with radio naviga-
tion, safety services, computers, and communica-
tions equipment.
Be sure this welding machine is installed and grounded according to this
manual.
D
Have only qualified persons familiar with electronic
equipment perform this installation.
If interference still occurs, the user must take extra measures such as
moving the welding machine, using shielded cables, using line filters, or
shielding the work area.
D
D
The user is responsible for having
a
qualified electrician
promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the equipment at
once.
D
D
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep spark
gaps at correct setting, and use grounding and shielding to minimize the
possibility of interference.
1-6. California Proposition 65 Warnings
Y
Welding or cutting equipment produces fumes or gases which
contain chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)
For Gasoline Engines:
Y
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
For Diesel Engines:
Y
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductiveharm. Wash hands after handling.
Y
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
1-7. Principal Safety Standards
Safety inWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(phone: 305-443-9353, website: www.aws.org).
RecommendedSafe Practices for the Preparation for Welding and Cut-
ting of Containers and Piping, American Welding Society Standard
AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Mi-
ami, FL 33126 (phone: 305-443-9353, website: www.aws.org).
levard, Rexdale, Ontario, Canada M9W 1R3 (phone: 800-463-6727 or
in Toronto 416-747-4044, website: www.csa-international.org).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036–8002 (phone: 212-642-4900,
website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (phone:
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202-4102 (phone: 703-412-0900, website:
www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
CanadianStandards Association, Standards Sales, 178 Rexdale Bou-
OSHA, Occupational Safety and Health Standards for General Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Offices—phone for Region 5, Chicago, is
312-353-2220,website: www.osha.gov).
1-8. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
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 Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
OM-4407 Page 4
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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
rom_fre 8/03
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.
2-1. Signification des symboles
Signifie Mise en garde ! Soyez vigilant ! Cette procédure
présente des risques de danger ! Ceux-ci sont identifiés par
des symboles adjacents aux directives.
Ce groupe de symboles si-
gnifie Mise en garde
Soyez vigilant ! Il y a des
risques de danger reliés
!
Y
Identifie un message de sécurité particulier.
aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux
PIÈCES CHAUDES. Reportez-vous aux symboles et aux directives ci-des-
sous afin de connaître les mesures à prendre pour éviter tout danger.
.
S
i
g
n
i
f
i
e
N
O
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A
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i
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a
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é
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i
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é
.
2-2. Dangers relatifs au soudage à l’arc
D
D
En effectuant les raccordements d’entrée fixer d’abord le conducteur de
mise à la terre approprié et contre-vérifier les connexions.
Y
Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les ris-
ques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne font
que résumer l’information contenue dans les normes de sécu-
ces normes de sécurité.
Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas en-
dommagé ou dénudé − remplacer le cordon immédiatement s’il est
endommagé − un câble dénudé peut provoquer une électrocution.
D
D
Mettre l’appareil hors tension quand on ne l’utilise pas.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou
mal épissés.
D
D
Ne pas enrouler les câbles autour du corps.
Y
Y
L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées.
Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct − ne pas utiliser le connecteur de pièce ou le câble de retour.
D
D
Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou
une électrode provenant d’une autre machine.
Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrement les enfants.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-champ
les pièces endommagées. Entretenir l’appareil conformément à ce
manuel.
UN CHOC ÉLECTRIQUE peut tuer.
D
D
D
Porter un harnais de sécurité quand on travaille en hauteur.
Maintenir solidement en place tous les panneaux et capots.
Un simple contact avec des pièces électriques peut
provoquer une électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension dès
que l’appareil est sur ON. Le circuit d’entrée et les circuits
internes de l’appareil sont également sous tension à ce
Fixer le câble de retour de façon à obtenir un bon contact métal-métal avec
la pièce à souder ou la table de travail, le plus près possible de la soudure.
D
Isoler la pince de masse quand pas mis à la pièce pour éviter le contact
avec tout objet métallique.
moment-là. En soudage semi-automatique ou automatique, le fil, le dévidoir, le
logement des galets d’entraînement et les pièces métalliques en contact avec
le fil de soudage sont sous tension. Des matériels mal installés ou mal mis à la
terre présentent un danger.
Une tension DC importante subsiste à l’intérieur
des onduleurs après avoir coupé l’alimentation.
D
Couper l’alimentation du poste et décharger les condensateurs d’entrée
comme indiqué dans la Section Maintenance avant de toucher des compo-
sants.
D
D
Ne jamais toucher les pièces électriques sous tension.
Porter des gants et des vêtements de protection secs ne comportant pas
de trous.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
D
S’isoler de la pièce et de la terre au moyen de tapis ou d’autres moyens iso-
lants suffisamment grands pour empêcher le contact physique éventuel
avec la pièce ou la terre.
Le soudage génère des fumées et des gaz. Leur inhalation
peut être dangereux pour votre santé.
D
D
D
Ne pas se servir de source électrique àcourant électrique dans les zones
humides, dans les endroits confinés ou là où on risque de tomber.
Se servir d’une source électrique àcourant électrique UNIQUEMENT si le
procédé de soudage le demande.
D
D
Eloigner votre tête des fumées. Ne pas respirer les fumées.
Si l’utilisation d’une source électrique àcourant électrique s’avère néces-
saire, se servir de la fonction de télécommande si l’appareil en est équipé.
À l’interieur, ventiler la zone et/ou utiliser un échappement au niveau de
l’arc pour l’évacuation des fumées et des gaz de soudage.
D
D
Si la ventilation est insuffisante, utiliser un respirateur à alimentation d’air
homologué.
D
Des précautions de sécurité supplémentaires sont requises dans des envi-
ronnements à risque comme: les endroits humides ou lorsque l’on porte
des vêtements mouillés; sur des structures métalliques au sol, grillages et
échafaudages; dans des positions assises, à genoux et allongées; ou
quand il y a un risque important de contact accidentel avec la pièce ou le
sol. Dans ces cas utiliser les appareils suivants dans l’ordre de préférence:
1) un poste à souder DC semi−automatique de type CV (MIG/MAG), 2) un
poste à souder manuel (électrode enrobée) DC, 3) un poste à souder ma-
nuel AC avec tension à vide réduite. Dans la plupart des cas, un poste
courant continu de type CV est recommandé. Et, ne pas travailler seul!
Lire les spécifications de sécurité des matériaux (MSDSs) et les instruc-
tions du fabricant concernant les métaux, les consommables, les
revêtements, les nettoyants et les dégraisseurs.
D
Travailler dans un espace fermé seulement s’il est bien ventilé ou en por-
tant un respirateur à alimentation d’air. Demander toujours à un surveillant
dûment formé de se tenir à proximité. Des fumées et des gaz de soudage
peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des
blessures ou des accidents mortels. S’assurer que l’air de respiration ne
présente aucun danger.
D
D
Ne pas souder dans des endroits situés à proximité d’opérations de dé-
graissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de
l’arc peuvent réagir en présence de vapeurs et former des gaz hautement
toxiques et irritants.
D
Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation,
à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation
selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).
D
D
Installer et mettre à la terre correctement cet appareil conformément à son
manuel d’utilisation et aux codes nationaux, provinciaux et municipaux.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier galvani-
sé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été
enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et si néces-
saire, en portant un respirateur à alimentation d’air. Les revêtements et
tous les métaux renfermant ces éléments peuvent dégager des fumées
toxiques en cas de soudage.
Toujours vérifier la terre du cordon d’alimentation − Vérifier et s’assurer que
le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre
du sectionneur ou que la fiche du cordon est raccordée à une prise
correctement mise à la terre.
OM-4407 Page 5
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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 proxi-
mité.
LES ACCUMULATIONS DE GAZ ris-
quent de provoquer des blessures ou
même la mort.
DES PARTICULES VOLANTES
peuvent blesser les yeux.
D
Fermer l’alimentation du gaz protecteur en cas de
non utilisation.
D
Le soudage, l’écaillement, le passage de la pièce
à la brosse en fil de fer, et le meulage génèrent
des étincelles et des particules métalliques vo-
D
Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi-
rateur d’adduction d’air homologué.
lantes. Pendant la période de refroidissement des soudures, elles ris-
quent de projeter du laitier.
LES RAYONS DE L’ARC peuvent pro-
voquer des brûlures dans les yeux et
sur la peau.
Le rayonnement de l’arc du procédé de soudage génère
des rayons visibles et invisibles intenses (ultraviolets et
D
Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la
peau. Des étincelles sont projetées pendant le soudage.
D
Prévoir une période de refroidissement avant d’effec-
tuer des travaux d’entretien.
D
Porter un casque de soudage muni d’un écran de filtre approprié pour pro-
téger votre visage et vos yeux pendant le soudage ou pour regarder (voir
ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
D
Porter des gants et des vêtements de protection pour
travailler sur un moteur chaud.
D
Ne pas toucher à mains nues les parties chaudes du moteur ni les pièces
récemment soudées.
D
D
D
Porter des protections approuvés pour les oreilles si le niveau sondre est
trop élevé.
Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair et de
l’éblouissement; demander aux autres personnes de ne pas regarder l’arc.
LE BRUIT peut affecter l’ouïe.
Porter des vêtements de protection constitué dans une matière durable, ré-
sistant au feu (laine ou cuir) et une protection des pieds.
Le bruit des processus et des équipements peut affecter
l’ouïe.
LE SOUDAGE peut provoquer un in-
cendie ou une explosion.
D
Porter des protections approuvés pour les oreilles si
le niveau sondre est trop élevé.
Le soudage effectué sur des conteneurs fermés tels que
des réservoirs, tambours ou des conduites peut provoquer
leur éclatement. Des étincelles peuvent être projetées de
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
l’arc de soudure. La projection d’étincelles, des pièces chaudes et des
équipements chauds peut provoquer des incendies et des brûlures. Le contact
accidentel de l’électrode avec des objets métalliques peut provoquer des
étincelles, une explosion, un surchauffement ou un incendie. Avant de
commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de
danger.
D
D
Porteurs de stimulateur cardiaque, restez à distance.
Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur médecin avant de s’approcher
des opérations de soudage à l’arc, de gougeage ou
de soudage par points.
D
D
D
Se protéger et d’autres personnes de la projection d’étincelles et de métal
chaud.
Si des BOUTEILLES sont endomma-
gées, elles pourront exploser.
Des bouteilles de gaz protecteur contiennent du gaz sous
haute pression. Si une bouteille est endommagée, elle peut
exploser. Du fait que les bouteilles de gaz font normale-
ment partie du procédé de soudage, les manipuler avec
précaution.
Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des
substances inflammables.
Déplacer toutes les substances inflammables à une distance de 10,7 m de
l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec
des protections homologués.
D
Des étincelles et des matériaux chauds du soudage peuvent facilement
passer dans d’autres zones en traversant de petites fissures et des
ouvertures.
D
Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des
chocs mécaniques, du laitier, des flammes ouvertes, des étincelles et des
arcs.
Placer les bouteilles debout en les fixant dans un support stationnaire ou
dans un porte-bouteilles pour les empêcher de tomber ou de se renverser.
Tenir les bouteilles éloignées des circuits de soudage ou autres circuits
électriques.
Ne jamais placer une torche de soudage sur une bouteille à gaz.
Une électrode de soudage ne doit jamais entrer en contact avec une bou-
teille.
Ne jamais souder une bouteille pressurisée − risque d’explosion.
Utiliser seulement des bouteilles de gaz protecteur, régulateurs, tuyaux et
raccords convenables pour cette application spécifique; les maintenir ainsi
que les éléments associés en bon état.
Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la bouteille.
Maintenir le chapeau de protection sur la soupape, sauf en cas d’utilisation
ou de branchement de la bouteille.
Lire et suivre les instructions concernant les bouteilles de gaz comprimé,
les équipements associés et les publication P-1 CGA énumérées dans les
normes de sécurité.
D
D
Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.
D
D
Le soudage effectué sur un plafond, plancher, paroi ou séparation peut dé-
clencher un incendie de l’autre côté.
D
D
Ne pas effectuer le soudage sur des conteneurs fermés tels que des réser-
voirs, tambours, ou conduites, à moins qu’ils n’aient été préparés
correctement conformément à AWS F4.1 (voir les normes de sécurité).
D
D
Brancher le câble sur la pièce le plus près possible de la zone de soudage
pour éviter le transport du courant sur une longue distance par des che-
mins inconnus éventuels en provoquant des risques d’électrocution et
d’incendie.
D
D
D
D
Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
En cas de non utilisation, enlever la baguette d’électrode du porte-électro-
de ou couper le fil à la pointe de contact.
D
D
D
D
Porter des vêtements de protection dépourvus d’huile tels que des gants
en cuir, une chemise en matériau lourd, des pantalons sans revers, des
chaussures hautes et un couvre chef.
D
Avant de souder, retirer toute substance combustible de vos poches telles
qu’un allumeur au butane ou des allumettes.
2-3. Dangers existant en relation avec le moteur
LES ACCUMULATIONS DE GAZ ris-
quent de provoquer des blessures ou
même la mort.
L’ACIDE DE LA BATTERIE peut pro-
voquer des brûlures dans les YEUX et
sur la PEAU.
D
Fermer l’alimentation du gaz protecteur en cas de
non utilisation.
D
D
D
Ne pas renverser la batterie.
Remplacer une batterie endommagée.
Rincer immédiatement les yeux et la peau à l’eau.
D
Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi-
rateur d’adduction d’air homologué.
OM-4407 Page 6
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D
D
D
D
D
Pour empêcher tout démarrage accidentel pendant les travaux d’entretien,
L’EXPLOSION DE LA BATTERIE peut
RENDRE AVEUGLE.
débrancher le câble négatif (−) de batterie de la borne.
Ne pas approcher les mains, cheveux, vêtements lâches et outils des orga-
nes mobiles.
D
Toujours porter une protection faciale, des gants en
caoutchouc et vêtements de protection lors d’une in-
tervention sur la batterie.
Remettre en place les panneaux ou les dipositifs de protection et fermer les
portes à la fin des travaux d’entretien et avant de faire démarrer le moteur.
Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la mise en
route accidentelle du moteur.
D
D
D
Arrêter le moteur avant de débrancher ou de brancher les câbles de
batterie.
Bloquer le volant moteur pour éviter sa rotation lors d’une intervention sur le
générateur.
Eviter de provoquer des étincelles avec les outils en travaillant sur la
batterie.
LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT CHAUD peuvent
provoquer des brûlures.
Ne pas utiliser le poste de soudage pour charger les batteries ou des véhi-
cules de démarrage rapide.
D
D
Observer la polarité correcte (+ et −) sur les batteries.
Débrancher le câble négatif (–) en premier lieu. Le rebrancher en dernier
lieu.
D
Il est préférable de vérifier le liquide de
refroidissement une fois le moteur refroidi pour éviter
de se brûler.
LE CARBURANT MOTEUR peut pro-
voquer un incendie ou une explosion.
D
Toujours vérifier le niveau de liquide de refroidissement dans le vase d’ex-
pansion (si présent), et non dans le radiateur (sauf si précisé autrement
dans la section maintenance du manuel du moteur).
D
Arrêter le moteur avant de vérifier le niveau de carbu-
rant ou de faire le plein.
D
D
D
Si le moteur est chaud et que le liquide doit être vérifié, opérer comme sui-
vant :
D
Ne pas faire le plein en fumant ou proche d’une sour-
ce d’étincelles ou d’une flamme nue.
Mettre des lunettes de sécurité et des gants, placer un torchon sur le bou-
chon du radiateur.
D
Ne pas faire le plein de carburant à ras bord; prévoir de l’espace pour son
expansion.
Faire attention de ne pas renverser de carburant. Nettoyer tout carbu-
rant renversé avant de faire démarrer le moteur.
Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant
d’enlever le bouchon.
D
D
LA CHALEUR DU MOTEUR peut pro-
voquer un incendie.
Jeter les chiffons dans un récipient ignifuge.
D
Ne pas placer l’appareil sur, au-dessus ou à proximité
de surfaces inflammables.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D
Tenir
à
distance les produits inflammables de
l’échappement.
D
Ne pas approcher les mains des ventilateurs, cour-
roies et autres pièces en mouvement.
LES ÉTINCELLES À L’ÉCHAPPEMENT
peuvent provoquer un incendie.
D
Maintenir fermés et fixement en place les portes,
panneaux, recouvrements et dispositifs de
protection.
D
Empêcher les étincelles d’échappement du moteur
de provoquer un incendie.
Utiliser uniquement un pare-étincelles approuvé −
voir codes en vigueur.
D
Arrêter le moteur avant d’installer ou brancher l’appareil.
D
Demander seulement à un personnel qualifié d’enlever les dispositifs de
sécurité ou les recouvrements pour effectuer, s’il y a lieu, des travaux d’en-
tretien et de dépannage.
D
2-4. Dangers liés à l’air comprimé
Le METAL CHAUD lors du coupage et
gougeage plasma peut provoquer un in-
cendie ou une explosion.
RESPIRER L’AIR COMPRIMÉ peut pro-
voquer des blessures graves ou causer
la mort.
D
Ne pas utiliser l’air comprimé pour respirer.
D
Ne pas couper ou gouger à proximité de produits
inflammables.
D
Utiliser l’air comprimé seulement pour le coupa-
ge, gougeage et les outils pneumatiques.
D
Surveillez et garder un extincteur à proximité.
L’AIR COMPRIMÉ peut provoquer
des blessures.
DES PIECES CHAUDES peuvent provo-
quer des brûlures et blessures.
D
Porter des lunettes de sécurité approuvées.
D
Ne pas toucher le compresseur ou d’autres élé-
ments du circuit air comprimé chauds.
D
Ne pas diriger le jet d’air vers d’autres ou soi−
même.
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
Relâcher la pression d’air de l’outillage ou du sys-
tème avant d’effectuer la maintenance, avant de
changer ou de rajouter des éléments ou avant
d’ouvrir la purge ou le bouchon de remplissage
d’huile.
D
Lisez le manuel d’instructions avant l’utilisation
ou la maintenance de l’appareil.
Arrêter le moteur et relâcher la pression avant
d’effectuer la maintenance.
D
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la
maintenance
D
Utiliser un équipement de levage de capacité suffisante pour lever
l’appareil.
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.
LA CHUTE DE L’APPAREIL peut
blesser.
D
D
Utiliser l’anneau de levage uniquement pour soulever
l’appareil lui-même ; sans chariot, de bouteilles de
gaz, remorque, ou autres accessoires.
OM-4407 Page 7
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LE SURCHAUFFEMENT peut endom-
mager le moteur électrique.
LIRE LES INSTRUCTIONS.
D
D
Utiliser seulement les pièces de rechange d’origine.
Effectuer la maintenance du moteur et du compres-
seur (si applicable) suivant ce manuel et le manuel du
moteur/compresseur (si applicable).
D
Arrêter ou déconnecter l’équipement avant de dé-
marrer ou d’arrêter le moteur.
D
Ne pas laisser tourner le moteur trop lentement sous
risque d’endommager le moteur électrique à cause
d’une tension et d’une fréquence trop faibles.
LE RAYONNEMENT HAUTE FRÉ-
QUENCE (H.F.) risque de provoquer
des interférences.
D
Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz, s’il y a
lieu.
LES ÉTINCELLES VOLANTES ris-
quent de provoquer des blessures.
D
Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipements
de radio−navigation et de communication, les
services de sécurité et les ordinateurs.
D
Porter un écran facial pour protéger le visage et les
yeux.
D
D
Demander seulement à des personnes qualifiées familiarisées avec des
équipements électroniques de faire fonctionner l’installation.
L’utilisateur est tenu de faire corriger rapidement par un électricien quali-
fié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement l’appareil.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
Maintenir soigneusement fermés les portes et les panneaux des sources
de haute fréquence, maintenir les éclateurs à une distance correcte et
utiliser une terre et et un blindage pour réduire les interférences
éventuelles.
D
D
Affuterr l’électrode au tungstène uniquement à la meuleuse dotée de pro-
tecteurs. Cette manoeuvre est à exécuter dans un endroit sûr lorsque
l’on porte l’équipement homologué de protection du visage, des mains et
du corps.
Les étincelles risquent de causer un incendie − éloigner toute substance
inflammable.
D
D
D
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
D
D
D
Laisser l’équipement refroidir ; respecter le facteur de
marche nominal.
Réduire le courant ou le facteur de marche avant de
poursuivre le soudage.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
Ne pas obstruer les passages d’air du poste.
D
L’énergie électromagnétique risque de provoquer
des interférences pour l’équipement électronique
sensible tel que les ordinateurs et l’équipement com-
mandé par ordinateur tel que les robots.
LES CHARGES ÉLECTROSTATI-
QUES peuvent endommager les
circuits imprimés.
D
D
Veiller à ce que tout l’équipement de la zone de soudage soit compatible
électromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de souda-
ge aussi courts que possible, les grouper, et les poser aussi bas que pos-
sible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement élec-
tronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre conformé-
ment à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il in-
combe à l’utilisateur de prendre des mesures supplémentaires telles que
le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de fil-
tres de ligne ou la pose de protecteurs 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.
D
D
D
UNE REMORQUE QUI BASCULE peut
entraîner des blessures.
D
Utiliser les supports de la remorque ou des blocs
pour soutenir le poids.
D
Installer convenablement le poste sur la remorque
comme indiqué dans le manuel s’y rapportant.
2-6. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, de
l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (télé-
phone : (305) 443−9353, site Web : www.aws.org).
Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) 463−6727 ou à To-
Practice For Occupational And Educational Eye And Face Protection,
norme ANSI Z87.1, de l’American National Standards Institute, 11 West
42nd Street, New York, NY 10036−8002 (téléphone : (212) 642−4900, site
Web : www.ansi.org).
Recommended Safe Practices for the Preparation for Welding and Cutting
of Containers and Piping, norme American Welding Society AWS F4.1, de
l’American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (télé-
phone : (305) 443−9353, site Web : www.aws.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot Work,
norme NFPA 51B, de la National Fire Protection Association, P.O. Box
9101, 1 Battery March Park, Quincy, MA 02269−9101 (téléphone : (617)
National Electrical Code, norme NFPA 70, de la National Fire Protection As-
sociation, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101
Safe Handling of Compressed Gases in Cylinders, brochure CGA P−1, de
la Compressed Gas Association, 1735 Jefferson Davis Highway, Suite
1004, Arlington, VA 22202−4102 (téléphone : (703) 412−0900, site Web :
www.cganet.com).
OSHA, Occupational Safety and Health Standards for General Industry,
Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and
Part 1926, Subpart J, de l’U.S. Government Printing Office, Superintendent
of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10 bureaux
régionaux − Téléphone pour la Région 5, Chicago : (312) 353−2220, site
Web : www.osha.gov).
Code for Safety in Welding and Cutting, norme CSA W117.2, de la Cana-
dian Standards Association, Standards Sales, 178 boulevard Rexdale,
2-7. Information sur les champs électromagnétiques
Données sur le soudage électrique et les effets des champs magnétiques
basse fréquence sur l’organisme
Afin de réduire les champs électromagnétiques en milieu de travail, respec-
ter les consignes suivantes :
En parcourant les câbles de soudage, le courant crée des champs électro-
magnétiques. Les effets potentiels de tels champs restent préoccupants.
Cependant, après avoir examiné plus de 500 études qui ont été faites pen-
dant une période de recherche de 17 ans, un comité de spécialistes du
National Research Council a conclu : « L’accumulation de preuves n’a pas
démontré que l’exposition aux champs magnétiques et aux champs électri-
ques à haute fréquence constitue un risque pour la santé humaine ».
Toutefois, les études et l’examen des preuves se poursuivent. En attendant
les conclusions finales de la recherche, il serait souhaitable de réduire l’ex-
position aux champs électromagnétiques pendant le soudage ou le
coupage.
1. Garder les câbles ensemble en les torsadant ou en les fixant avec du
ruban adhésif.
2. Mettre tous les câbles du côté opposé à l’opérateur.
3. Ne pas s’enrouler les câbles autour du corps.
4. Garder le poste de soudage et les câbles le plus loin possible de soi.
5. Placer la pince de masse le plus près possible de la zone de soudage.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur médecin. Si ce dernier les déclare aptes, il leur est recom-
mandé de respecter les consignes ci-dessus.
OM-4407 Page 8
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SECTION 3 − DEFINITIONS
3-1. Symbol Definitions
Fast
Fast/Slow
(Run/Idle)
Stop Engine
Slow (Idle)
Fuel
(Run, Weld/Power)
Start Engine
Engine Oil
Engine
Panel/Local
Temperature
Check Valve
Clearance
Engine Choke
Battery (Engine)
Volts
Read Operator’s
Manual
Amperes
A
V
MIG (GMAW),
Wire
Stick (SMAW)
Negative
TIG (GTAW)
Circuit Breaker
Output
Alternating Current
(AC)
Positive
Time
Protective Earth
(Ground)
Hours
Seconds
s
h
Do not switch while
welding
Remote
Constant
Current
Work Connection
Receptacle
CC
CV
Electrode
Positive
Constant
Voltage
Wire Feed
Electrode Negative
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-4407 Page 9
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SECTION 4 − SPECIFICATIONS
4-1. Weld, Power, And Engine Specifications
Rated
Welding
Output
Maximum
Open-Circuit
Voltage
Amperage
Range In
CC Mode
Voltage
Range In
CV Mode
Welding
Mode
Generator
Power Rating
Fuel
Capacity
Engine
Robin EH64
Performer OHV
Air-Cooled,
Two-Cylinder, Four-
Cycle,
20.5 HP
Gasoline Engine
280 A, 25 V, 100%
Duty Cycle
CC/DC
CV/DC
CC/AC*
80
50
75
20 − 300 A
Continuous: 9.5 kVA/
kW, 80/40 A,
120/240 V AC, 60
Hz, Single-Phase,
10 gal
(38 L)
Tank
300 A, 25 V, 100%
Duty Cycle
10 − 33 V
Min − 325 A
10 − 34 V
or
Peak: 10 kVA/kW
(w/Weld Contactor
Off)
Kohler CH-20
Air-Cooled,
Two-Cylinder,
Four-Cycle,
20 HP Gasoline
Engine
200 A, 25 V, 60%
Duty Cycle
35 − 225 A
*
AC/DC Models Only.
4-2. Dimensions, Weights, and Operating Angles
Dimensions
A
B
Height
33 in (838 mm)
18-3/4 in (476 mm)
45-1/2 in (1156 mm)
18 in (457 mm)
C
Width
Y
Y
Do not exceed tilt angles or engine could
be damaged or unit could tip.
Depth
D
Do not move or operate unit where it could
tip.
A
B
C
D
E
F
G
4 Holes
16-1/2 in (419 mm)
3/4 in (19 mm)
E
F
3-1/8 in (79 mm)
32-3/4 in (832 mm)
45-1/2 in (1156 mm)
13/32 in (10 mm) Dia.
Weight
25°
25°
25°
25°
G
Robin: 591 lb (268 kg)
Kohler: 567 lb (257 kg)
Engine End
800 426
802 848-A
OM-4407 Page 10
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4-3. Fuel Consumption While Welding
8.51 2.25
7.57 2.00
1.75
6.62
5.68 1.50
1.25
ROBIN
4.73
KOHLER
3.79 1.00
2.84 0.75
0.50
1.89
0.95 0.25
0.00
IDLE − KOHLER AND ROBIN
0.00
0
50
100
150
200
250
300
DC WELD AMPERES AT 100% DUTY CYCLE
4-4. Fuel Consumption While Using Generator Power
8.51 2.25
7.57 2.00
6.62 1.75
1.50
5.68
ROBIN
4.73 1.25
3.79 1.00
KOHLER
0.75
0.50
0.25
2.84
1.89
0.95
IDLE − KOHLER AND ROBIN
0.00 0.00
0
2
4
6
8
10
KW AT 100% DUTY CYCLE
206 136
OM-4407 Page 11
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4-5. Generator Power Curve
The ac generator power curve
shows the generator power avail-
able in amperes at the receptacles.
300
250
10,000 watts
216
200
150
100
50
0
0
10
20
30
40
50
60
70
80
90
AC AMPERES
Ref. 204 922
4-6. Duty Cycle
Duty cycle is the percentage of 10
minutes that unit can weld at rated
load without overheating.
100% Duty Cycle at 280 Amperes DC
Y
Exceeding duty cycle can
damage unit and void
warranty.
.
A
C
o
u
t
p
u
t
i
s
n
o
t
a
v
a
i
l
a
b
l
e
o
n
a
l
l
Continuous Welding
models.
350
300
250
200
150
MIG/FCAW
STICK
AC WELD
100
0
10
20
30
40
50
60
70
80
90
100
% DUTY CYCLE
OM-4407 Page 12
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4-7. Stick And MIG Mode Volt-Ampere Curves
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of
other settings fall between the
curves shown.
A. CC/AC Stick Mode
80
70
60
50
40
30
20
10
0
.
A
C
o
u
t
p
u
t
i
s
n
o
t
a
v
a
i
l
a
b
l
e
o
n
a
l
l
models.
0
50
100
150
200
250
300
350
450
700
AC AMPERES
B. CC/DC Stick Mode
80
70
60
50
40
30
20
10
0
0
50
100
150
200
DC AMPERES
250
300
350
400
C. CV/DC MIG Mode
45
40
35
30
25
20
15
10
5
0
0
100
200
300
400
500
600
DC AMPERES
204 923 / 204 928 / 204 935
OM-4407 Page 13
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4-8. TIG Mode Volt-Ampere Curves
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of
other settings fall between the
curves shown.
A. CC/AC TIG Mode
80
70
60
50
40
30
20
10
0
.
A
C
o
u
t
p
u
t
i
s
n
o
t
a
v
a
i
l
a
b
l
e
o
n
a
l
l
models.
0
50
100
150
200
250
300
350
AC AMPERES
B. CC/DC TIG Mode
50
45
40
35
30
25
20
15
10
5
0
0
50
100
150
200
250
300
350
DC AMPERES
204 934 / 204 930
OM-4407 Page 14
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SECTION 5 − INSTALLATION
5-1. Installing Welding Generator
Y
Y
Do not weld on base. Welding
on base can cause fuel tank fire
or explosion. Bolt unit down
using holes provided in base.
Movement
Always securely fasten weld-
ing generator onto transport
vehicle or trailer and comply
with all DOT and other applica-
ble codes.
Y
Do not lift unit from end.
OR
Y
Do not mount unit by support-
ing the base only at the four
mounting holes. Use cross-
supports to adequately sup-
port unit and prevent damage
to base.
Location
Y
Y
Always ground generator
frame to vehicle frame to pre-
vent electric shock and static
electricity hazards.
If unit does not have GFCI re-
ceptacles, use GFCI-protected
extension cord.
OR
OR
Mounting:
1
Cross-Supports
Mounting
Mount unit on flat surface or use
cross-supports to support base.
Grounding:
2
Equipment Grounding Terminal
(On Front Panel)
3
4
Grounding Cable (Not Supplied)
Metal Vehicle Frame
Connect cable from equipment
ground terminal to metal vehicle
frame. Use #10 AWG or larger insu-
lated copper wire.
OR
Inadequatesupport.
1
Y
Do not use flexible mounts.
2
Grounding
3
GND/PE
Electrically bond generator frame to
vehicle frame by metal-to-metal contact.
Y
Bed liners, shipping skids, and some running
gears insulate the welding generator from the
vehicle frame. Always connect a ground wire
from the generator equipment grounding termi-
nal to bare metal on the vehicle frame as shown.
4
Airflow Clearance
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
install2 5/03 − Ref. 800 652 / Ref. 800 477-A / 803 274
OM-4407 Page 15
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5-2. Engine Prestart Checks (Robin EH64-Powered Units)
Check all fluids daily. Engine must be
cold and on a level surface. Unit is
shipped with 10W30 engine oil.
.
F
o
l
l
o
w
r
u
n
-
i
n
p
r
o
c
e
d
u
r
e
i
n
e
n
-
gine manual.
.
T
h
i
s
u
n
i
t
h
a
s
a
l
o
w
o
i
l
p
r
e
s
s
u
r
e
shutdown switch. However,
some conditions may cause en-
gine damage before the engine
shuts down. Check oil level often
and do not use the oil pressure
shutdown system to monitor oil
level.
Fuel
Add fresh fuel before starting engine
the first time (see maintenance label
for specifications). Always leave filler
neck empty to allow room for expan-
sion. Check fuel level on a cold en-
gine before use each day.
Oil
After fueling, check oil with unit on
level surface. If oil is not up to full
mark on dipstick, add oil (see mainte-
nance label).
.
T
o
i
m
p
r
o
v
e
c
o
l
d
w
e
a
t
h
e
r
starting:
Keep battery in good condition.
Store battery in warm area.
Use correct grade oil for cold
weather.
Oil Check
Oil Fill
Full
Full
Gasoline
803 098 / 800 392-J
OM-4407 Page 16
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5-3. Engine Prestart Checks (Kohler-Powered Units)
Check all fluids daily. Engine must be
cold and on a level surface. Unit is
shipped with 10W30 engine oil.
.
F
o
l
l
o
w
r
u
n
-
i
n
p
r
o
c
e
d
u
r
e
i
n
e
n
g
i
n
e
manual.
.
T
h
i
s
u
n
i
t
h
a
s
a
l
o
w
o
i
l
p
r
e
s
s
u
r
e
shutdown switch. However, some
conditions may cause engine
damage before the engine shuts
down. Check oil level often and do
not use the oil pressure shutdown
system to monitor oil level.
Fuel
Add fresh fuel before starting engine
the first time (see maintenance label for
specifications). Always leave filler
neck empty to allow room for expan-
sion. Check fuel level on a cold engine
before use each day.
Oil
Check oil with unit on level surface. If
oil is not up to full mark on dipstick, add
oil (see maintenance label).
.
T
o
i
m
p
r
o
v
e
c
o
l
d
w
e
a
t
h
e
r
s
t
a
r
t
i
n
g
:
Keep battery in good condition.
Store battery in warm area.
Use correct grade oil for cold
weather.
Full
Full
Gasoline
801 221 / 802 849-A
OM-4407 Page 17
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5-4. Activating The Dry Charge Battery (If Applicable)
Remove battery from unit.
1
Eye Protection − Safety
Glasses Or Face Shield
2
3
4
Rubber Gloves
Vent Caps
5
Sulfuric Acid Electrolyte
(1.265 Specific Gravity)
5
Well
4
1
Fill each cell with electrolyte to
bottom of well (maximum).
3
Y
Do not overfill battery cells.
Wait ten minutes and check electro-
lyte level. If necessary, add electro-
lyte to raise to proper level. Reins-
tall vent caps.
6
Battery Charger
Y
Read and follow all instruc-
tions supplied with battery
charger.
2
Charge battery for 12 minutes at 30
amperes or 30 minutes at 5 am-
peres. Disconnect charging cables
and install battery.
. When electrolyte is low, add
only distilled water to cells to
maintainproper level.
6
5 A For 30 Minutes
OR
Tools Needed:
rubbergloves
+
−
30 A For 12 Minutes
glasses
drybatt1 1/98 − S-0886
OM-4407 Page 18
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5-5. Connecting The Battery
Y
Connect negative (−)
cable last.
−
+
Tools Needed:
3/8, 1/2 in
Ref. 800 394-C / Ref. 206 422 / Ref. S-0756-D
5-6. Installing Exhaust Pipe
Y
Y
Stop engine and let cool.
Engine backfire can cause se-
vere burns or other injuries.
Do not point exhaust pipe to-
ward control panel. Keep away
from exhaust outlet.
. Point exhaust pipe in desired di-
rection but always away from
front panel and direction of travel.
Tools Needed:
1/2 in
801 681 / Ref. 206 422
OM-4407 Page 19
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5-7. Connecting To Weld Output Terminals
Y
Y
Stop engine.
Do not connect to CC and CV
terminals at the same time.
AC/DC Models:
1
2
Work Weld Output Terminal
Stick/TIG (CC) Weld Output
Terminal
3
Wire /CV Weld Output Terminal
For MIG welding, connect work cable
to Work terminal and wire feeder
cable to Wire (CV) terminal.
For Stick/TIG welding, connect work
cable to Work terminal and electrode
holder cable to Stick/TIG (CC)
terminal.
DC Only Models:
4
5
6
Negative (−) Weld Output
Terminal
Stick/TIG (+) Weld Output
Terminal
Wire (+) Weld Output Terminal
For MIG welding, connect work cable
to Negative (−) terminal and wire
feeder cable to CV (Wire) terminal.
For Stick welding, connect work
cable to Negative (−) terminal and
electrode holder cable to CC (Stick/
TIG) terminal.
For TIG welding, connect work cable
to CC (Stick/TIG) terminal and elec-
trode holder cable to Negative (−)
terminal.
1
2
3
Weld output terminals on
units with AC/DC output.
OR
4
5
6
Weld output terminals on
units with DC output only.
802 850 / Ref. 206 422 / 204 353
OM-4407 Page 20
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5-8. Selecting Weld Cable Sizes*
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
150 ft
(45 m)
200 ft
250 ft
300 ft
350 ft
400 ft
100 ft (30 m) or Less
(60 m) (70 m) (90 m) (105 m) (120 m)
Weld Output
Terminals
Y
Y
Stop engine before
connectingto weld out-
put terminals.
10 − 60% 60 − 100%
Welding
Amperes
Duty
Duty
10 − 100% Duty Cycle
Cycle
Cycle
Do not use worn, dam-
aged, undersized, or
poorly spliced cables.
100
150
200
4 (20)
3 (30)
3 (30)
4 (20)
3 (30)
2 (35)
4 (20)
2 (35)
1 (50)
3 (30)
1 (50)
2 (35)
1/0 (60)
2/0 (70)
1 (50)
1/0 (60)
3/0 (95)
1/0 (60)
3/0 (95)
2/0 (70)
1/0 (60)
3/0 (95) 4/0 (120) 4/0 (120)
2 ea. 2/0 2 ea. 2/0
250
300
350
400
2 (35)
1 (50)
1 (50)
1/0 (60)
2/0 (70)
2/0 (70)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
2/0 (70)
3/0 (95) 4/0 (120)
(2x70)
(2x70)
2 ea. 2/0 2 ea. 3/0 2 ea. 3/0
(2x70) (2x95) (2x95)
3/0 (95) 4/0 (120)
2 ea. 2/0 2 ea. 3/0 2 ea. 3/0 2 ea. 4/0
(2x70) (2x95) (2x95) (2x120)
1/0 (60)
1/0 (60)
4/0 (120)
4/0 (120)
2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 2 ea. 4/0
(2x70)
(2x95)
(2x120)
(2x120)
* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
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.
5-9. Remote Receptacle Information
Engine runs at weld/power speed whenever a device connected to the remote
receptacle is running.
NOTE
Socket*
Socket Information
A
B
24 volts ac.
24 VOLTS AC
115 VOLTS AC
Contact closure to A completes 24 volt ac contac-
tor control circuit and keeps engine at Run speed
in all modes. Protected by circuit breaker CB5.
A
J
I
115 volts ac. Protected by fuse F2.
K
I
B
C
J
Contact closure to I completes 115 volts ac
contactor control circuit.
L
N
H
M
D
G
F
E
C
0 to +10 volts dc output to remote control in Stick
and TIG modes. +10 volts dc output to remote
control in Wire mode.
REMOTE
OUTPUT
CONTROL
D
E
Remote control circuit common.
0 to +10 volts dc input command signal from
remote control. Voltage is dependent on front pan-
el Voltage/Amperage control setting.
G
K
Circuit common for 24 and 115 volts ac circuits.
Chassis common.
GND
*The remaining sockets are not used.
OM-4407 Page 21
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5-10. Adjusting Wire (MIG) Weld Puddle Consistency
Y
Stop engine and let cool.
Stabilizer DC-Z is factory connected to suit
most Wire (MIG) welding applications.
To change Wire (MIG) weld puddle consis-
tency, proceed as follows:
Remove cover and right side panel.
1
2
3
Stabilizer DC-Z
Wire /CV Weld Output Terminal
Stabilizer Leads 29, 28, And 27
Lead 29 − provides stiffest weld
puddle
Lead 28 − provides wetter weld
puddle (for mild steel)
Lead 27 − provides wettest weld
puddle (for stainless steel)
Lead 29 is connected to the Wire/CV weld
output terminal at the factory.
Disconnect lead 29 from the Wire/CV weld
output terminal.
For wetter weld puddle (for mild steel):
Remove insulated sleeving from lead 28.
Connect lead 28 to Wire/CV weld output ter-
minal, reusing hardware. Insulate lead 29
with sleeving removed from lead 28. Secure
sleeving with cable ties.
For wettest weld puddle
(for stainless steel):
Remove insulated sleeving from lead 27.
Connect lead 27 to Wire/CV weld output ter-
minal, reusing hardware. Insulate lead 29
with sleeving removed from lead 27. Secure
sleeving with cable ties.
Reinstall side panel.
1
2
3
Tools Needed:
3/8, 7/16 in
803 099
OM-4407 Page 22
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SECTION 6 − OPERATING WELDING GENERATOR
6-1. Front Panel Controls
1
2
3
4
6
7
5
1
Process/Contactor Switch
With V/A Adjust Switch in Remote position,
control limits the remote amperage in Stick
and TIG modes, but has no effect in MIG
modes.
Use control to change engine air-fuel mix
when starting engine.
switch information.
2
To Start: pull out choke and turn Engine
Control switch to Start position. Release
switch and slowly push choke in when
engine starts.
Voltage/Amperage Adjust Switch And
Remote Receptacle
4
Engine Control Switch
Use switch to select front panel or remote
voltage/amperagecontrol. For remote con-
trol, place switch in Remote position and
connect remote control to Remote recep-
Use switch to start engine, select speed, and
stop engine. In Run/Idle position, engine
runs at idle speed at no load, and weld/power
speed under load. In Run position, engine
runs at weld/power speed.
. If the engine does not start, let the
engine come to a complete stop before
attempting restart.
To Stop: turn Engine Control switch to Off
position.
3
A/V Control
. Place switch in Run position for TIG
(GTAW) welding using a high frequency
device.
Use control to select weld voltage or
amperage. Control may be adjusted while
welding.
With Process/Contactor switch in any Stick
or TIG setting, use control to adjust amper-
age. With Process/Contactor switch in any
Wire position, use control to adjust voltage.
6
7
Engine Hour Meter
DC Polarity/AC Switch (AC/DC Models
Only)
.
T
h
e
u
n
i
t
w
i
l
l
n
o
t
r
e
t
u
r
n
t
o
i
d
l
e
s
p
e
e
d
Y
Do not switch under load.
when the remote contactor is on.
Use switch to select AC weld output or polar-
Ref. 206 422
5
Engine Choke Control
ity of DC weld output.
OM-4407 Page 23
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6-2. Process/Contactor Switch On CC/CV Models
1
1
Process/Contactor Switch
Y
Weld output terminals are ener-
gized when Process/Contactor
switch is in an Electrode Hot posi-
tion and the engine is running.
. The unit will not return to idle speed
when Process/Contactor switch is in
a Wire or TIG mode and the remote
contactor is on (closure between
pins A and B on remote receptacle).
Use switch to select weld process and
weld output on/off control (see table be-
Place switch in Remote positions to turn
weld output on and off with a device con-
nected to the remote receptacle.
Place switch in Electrode Hot positions
for weld output to be on whenever the en-
gine is running.
Use Stick positions for air carbon arc
(CAC-A) cutting and gouging.
When switch is in a Stick position, the dig
circuit provides additional amperage
during low voltage (short arc length con-
ditions) to prevent “sticking” electrodes.
The dig circuit is disabled when switch is
in Wire or TIG positions.
802 850
Process/Contactor Switch Settings
Switch Setting
Process
Output On/Off Control
GTAW With HF Unit, Pulsing Device, Or
Remote Control
Remote − TIG
At Remote Receptacle
Remote − Stick
Remote − Wire
Stick (SMAW) With Remote On/Off
MIG (GMAW)
At Remote Receptacle
At Remote Receptacle
Electrode Hot
Electrode Hot − Wire
MIG (GMAW)
Stick (SMAW),
Electrode Hot − Stick
Electrode Hot
Electrode Hot
Air Carbon Arc (CAC-A) Cutting And Gouging
Electrode Hot − Scratch
Scratch Start TIG (GTAW)
Start TIG
OM-4407 Page 24
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6-3. Remote Amperage/Voltage Control
1
Remote Receptacle RC4
Connect optional remote control to
2
3
Remote Hand Control (Optional)
Remote Foot Control (Optional)
. Engine runs at weld/power speed
in Wire and TIG modes whenever
a device connected to the remote
receptacle makes closure be-
tween pins A and B (exam-
ple:triggerpull on MIG gun).
1
In Example:
Process = Stick (Using Remote On/Off)
Min = 40 A CC/DC
Max = 180 A CC/DC
3
Switch
present on
AC/DC
models
only.
2
Max (180 A DC)
Min (40 A DC)
Set V/A Adjust
Select Polarity By
Set
A/V Control
Adjust Remote Control
(Stick Welding Only)
Switch
Using DC Polarity/AC
Switch (If Present) Or
By Changing Cable
Connections
802 850 / 206 422 / S-0769 / S-0774
OM-4407 Page 25
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SECTION 7 − OPERATING AUXILIARY EQUIPMENT
7-1. Generator Power Receptacles And Circuit Breakers
Y
If unit does not have GFCI re-
ceptacles, use GFCI-
protected extension cord.
.
G
e
n
e
r
a
t
o
r
p
o
w
e
r
d
e
c
r
e
a
s
e
s
a
s
weld current increases.
5
6
1
240 V 50 A AC Receptacle
RC1
RC1 supplies 60 Hz single-phase
power at weld/power speed. Maxi-
mum output is 9.5 kVA/kW.
2
120 V 20 A AC Duplex
Receptacle RC2
3
120 V 20 A AC Duplex
Receptacle RC3
1
RC2 and RC3 supply 60 Hz single-
phase power at weld/power speed.
Maximumoutput from RC2 or RC3 is
2.4 kVA/kW.
4
Circuit Breaker CB1
CB1 protects receptacles RC1, RC2,
RC3, and 115 volt ac output to Re-
mote Receptacle RC4 from over-
load. If CB1 opens, the receptacles
do not work and 115 volt ac output to
Remote Receptacle RC4 stops.
Place switch in On position to reset
breaker.
2
3
4
5
6
Circuit Breaker CB3
Circuit Breaker CB4
CB3 protects RC2 and CB4 protects
RC3 from overload. If a circuit break-
er opens, the receptacle does not
work. Press button to reset breaker.
.
I
f
c
i
r
c
u
i
t
b
r
e
a
k
e
r
c
o
n
t
i
n
u
e
s
t
o
open,
contact
Factory
Authorized Service Agent.
Combined output of all receptacles
limited to 10 kVA/kW rating of the
generator.
EXAMPLE: If 20 A is drawn from
each 120 V duplex receptacle, only
20 A is available at the 240 V
receptacle:
2 x (120 V x 20 A) + (240 V x 20 A) =
9.6 kVA/kW
Ref. 206 422
OM-4407 Page 26
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7-2. Optional Generator Power Receptacles
Y
If unit does not have GFCI re-
ceptacles, use GFCI-
protected extension cord.
1
.
G
e
n
e
r
a
t
o
r
p
o
w
e
r
d
e
c
r
e
a
s
e
s
a
s
weld current increases.
Combined output of all receptacles
limited to 8 kVA/kW rating of the
generator.
GFCI Receptacle Option
1
120 V 20 A AC GFCI Recep-
tacles GFCI-2 and GFCI-3
GFCI2 and GFCI3 supply 60 Hz
single-phasepower at weld/power
speed. Maximum output from
GFCI-2 or GFCI-3 is 2.4 kVA/kW.
Circuit breaker protection is the
same as standard receptacles.
If a ground fault is detected, the
GFCI Reset button pops out and
the circuit opens to disconnect the
faulty equipment. Check for
damaged tools, cords, plugs, etc.
connected to the receptacle. Press
button to reset receptacle and
resume operation.
. At least once a month, run
engine at weld/power speed
and press Test button to verify
GFCI is working properly.
Ref. 206 422
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-4407 Page 27
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7-3. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P)
The plug can be wired for a 240 V,
2-wire load or a 120/240V, 3-wire
load. See circuit diagram.
1
Plug Wired for 120/240 V,
3-Wire Load
7
Current Available in Amperes
When wired for 120 V loads, each
duplex receptacle shares a load
with one half of 240 V receptacle.
240 V
Receptacle*
Each 120 V Duplex
Receptacle
2
Plug Wired for 240 V, 2-Wire
Load
0
5
20
20
20
20
20
15
10
5
1
3
3
4
5
6
7
Neutral (Silver) Terminal
Load 1 (Brass)Terminal
Load 2 (Brass) Terminal
Ground (Green) Terminal
4
10
15
20
25
30
35
40
Amperes Available using
120/240 V Plug
120V
5
120V
0
240V
6
V x A = Watts
Tools Needed:
*One 240 V load or two 120 V loads.
2
3
4
240V
6
5
240 V AC
120 V AC
120 V AC
plug1 11/03 − 120 813-D
OM-4407 Page 28
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8-2. Routine Maintenance (Robin EH64-Powered Units)
Follow the storage procedure in the engine owner’s manual if the unit will not be used for an
extended period.
Note
Y
Stop engine before maintaining.
.
S
e
e
a
l
s
o
E
n
g
i
n
e
M
a
n
u
a
l
a
n
d
M
a
i
n
t
e
n
a
n
c
e
L
a
b
e
l
f
o
r
i
m
-
portant start-up, service, and storage information. Ser-
vice engine more often if used in severe conditions.
Recycle
engine
fluids.
*
To be done by Factory Authorized Service Agent.
Every 8 h
Check fluid levels.
Wipe up spills.
Every 20 h
Every 25 h
Service
air
Check and clean
spark arrestor screen.
cleaner wrapper
(foam element).
Every 50 h
Clean and
tighten weld
terminals.
Every 100 h
Change oil. See
maintenancelabel.
Clean cooling system.
See Engine Manual.
Service
cleaner element.
air
Clean
tighten battery
connections.
and
OM-4407 Page 30
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Every 200 h
Replace fuel
filter. See
Change oil filter. See
maintenancelabel.
Check
spark
plugs.
Replace
unreadable
labels.
Every 500 h
Service welding generator
brushes and slip rings. Service
more often in dirty conditions.*
Repair or
replace cracked
cables.
Check
valve
clearance.*
Every 1000 h
Blow out or
vacuum inside.
During heavy
service, clean
monthly.
OR
OM-4407 Page 31
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8-3. Servicing Air Cleaner (Robin EH64-Powered Units)
Y
Y
Stop engine.
1
2
Do not run engine without air
cleaner or with dirty element.
1
Wrapper (Foam Element)
Wash wrapper with soap and water
solution. Allow wrapper to air dry
completely.
2
Element
Replace element if dirty, oily, or
damaged.
aircleaner5 1/97 − 803 070 / Ref. 200 017 / S-0759
8-4. Servicing Optional Spark Arrestor (Robin EH64-Powered Units)
Y
Stop engine and let cool.
1
Spark Arrestor Screen
Clean and inspect screen. Replace
spark arrestor if screen wires are
broken or missing.
1
Tools Needed:
1/4 in
Ref. 803 098 / Ref. 183 175−A
OM-4407 Page 32
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8-5. Overload Protection (Robin EH64-Powered Units)
Y
Stop engine.
Tools Needed:
.
W
h
e
n
a
c
i
r
c
u
i
t
b
r
e
a
k
e
r
o
r
f
u
s
e
opens, it usually indicates a
more serious problem exists.
Contact a Factory Authorized
Service Agent.
3/8 in
1
Circuit Breaker CB5
CB5 protects the 24 volt ac output
to Remote receptacle RC4. If CB5
opens, 24 volt ac output to RC4
stops.
Press button to reset breaker.
2
3
Fuse F2 (See Parts List)
Fuse F6 (See Parts List)
2
F2 is located behind the front panel.
F2 protects the 115 volt output to
Remote Receptacle RC4. If F2
opens, 115 volt ac output to RC4
stops.
4
F6 protects the engine wiring sys-
tem from overload. If F6 opens,
engine will not crank.
Located behind front panel.
4
Fuse F1 (See Parts List)
Remove side panel.
F1 protects the exciter excitation
winding from overload. If F1 opens,
weld and generator power output
stops.
Replace any open fuses. Reinstall
cover before operating unit.
3
1
803 100 / Ref. 206 422
OM-4407 Page 33
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8-6. Changing Engine Oil, Oil Filter, and Fuel Filter (Robin EH64-Powered Units)
Y
1
Stop engine and let cool.
Oil Drain Valve
2
Oil Filter
Change engine oil and filter accord-
ing to engine owner’s manual.
Y
Close valve and valve cap
before adding oil and
running engine.
Fill crankcase with new oil to full
3
4
Fuel Filter
Fuel Line
Oil Check
Oil Fill
Replace line if cracked or worn.
Install new filter. Wipe up any spilled
fuel.
Start engine, and check for fuel
leaks.
Full
Y
Stop engine, tighten connec-
tions as necessary, and wipe
up fuel.
3
4
2
1
Tools Needed:
803 098 / S-0842
OM-4407 Page 34
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8-7. Adjusting Engine Speed (Robin EH64-Powered Units)
After tuning engine, check engine
speeds with a tachometer (see
table). If necessary, adjust speeds
as follows:
2200 100 rpm
3700 50 rpm
Start engine and run until warm.
Remove wrapper to access speed
adjustments.
Idle Speed Adjustment
Move Engine Control switch to
Run/Idle position.
1
2
3
Throttle Solenoid
Mounting Screws
Idle Speed Screw
Loosen mounting screws. Adjust
solenoid position so engine runs at
idle speed. If necessary, back out
idle speed screw so solenoid can
be moved to correct position. Tight-
en mounting screws. Be sure sole-
noid linkage works smoothly.
1
3
Turn idle speed screw for fine
adjustments.
Weld/Power Speed Adjustment
Move Engine Control switch to Run
position.
4
5
6
Jam Nut
Lock Nut
Weld/Power Speed
Adjustment Screw
Loosen jam nut and lock nut. Turn
adjustmentscrew until engine runs
at weld/power speed. Tighten jam
nut, and then tighten lock nut.
2
Y
Stop engine.
Reinstall wrapper.
4
6
5
Tools Needed:
10 mm
803 098
8 mm
OM-4407 Page 35
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SECTION 9 − MAINTENANCE (KOHLER-POWERED UNITS)
9-1. Routine Maintenance (Kohler-Powered Units)
Y
Stop engine before maintaining.
.
S
e
e
a
l
s
o
E
n
g
i
n
e
M
a
n
u
a
l
a
n
d
M
a
i
n
t
e
n
a
n
c
e
L
a
b
e
l
f
o
r
i
m
-
Recycle
engine
fluids.
portant start-up, service, and storage information. Ser-
vice engine more often if used in severe conditions.
*
To be done by Factory Authorized Service Agent.
Every 8 h
Wipe up spills.
Check fluid levels.
OIL
Full
Every 20 h
Every 25 h
Check and clean
spark arrestor screen.
Service air filter wrapper
(foam element). See
Every 50 h
Clean and tighten
weld terminals.
Every 100 h
Change oil. See
Section 9-5 and
maintenance
label.
Service air filter element.
Clean cooling system. See
engine manual.
Clean and
tighten battery
connections.
Every 200 h
Change oil filter.
and maintenance
label.
Replace fuel
filter. See
Replace
unreadable
labels.
Check spark plugs.
Every 500 h
Service welding generator
Repair or
replace cracked
cables.
brushes and slip rings.
Service more often in dirty
conditions.*
Every 1000 h
OR
Blow out or vacuum inside. During
heavy service, clean monthly.
OM-4407 Page 36
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9-3. Servicing Air Cleaner (Kohler-Powered Units)
Y
Y
Stop engine.
Do not run engine without air
cleaner or with dirty element.
1
2
1
Wrapper (Foam Element)
Wash wrapper with soap and water
solution. Allow wrapper to air dry
completely.
Spread 1 tablespoon SAE 30 oil
evenly into wrapper. Squeeze out
excess oil.
2
Element
Replace element if damaged, dirty,
or oily.
oil
aircleaner3 9/00 − 802 772 / Ref. 185 095-A / S-0759
9-4. Servicing Optional Spark Arrestor (Kohler-Powered Units)
Y
Stop engine and let cool.
1
Spark Arrestor Screen
Clean and inspect screen. Replace
spark arrestor if screen wires are
broken or missing.
1
Tools Needed:
1/4 in
802 849-A / Ref. 206 422
OM-4407 Page 38
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9-5. Changing Engine Oil, Oil Filter, And Fuel Filter (Kohler-Powered Units)
Y
1
Stop engine and let cool.
Oil Drain Valve
Oil Filter
2
Change engine oil and filter accord-
ing to engine manual.
Y
Close valve and valve cap
before adding oil and run-
ning engine.
Full
Fill crankcase with new oil to full
3
4
Fuel Filter
Fuel Line
Replace line if cracked or worn.
Install new filter. Wipe up any spilled
fuel.
Start engine, and check for fuel
leaks.
Y
Stop engine, tighten connec-
tions as necessary, and wipe
up fuel.
3
4
2
1
Tools Needed:
802 849-A / S-0842
OM-4407 Page 39
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9-6. Adjusting Engine Speed (Kohler-Powered Units)
After tuning engine, check engine
speeds with a tachometer (see
table). If necessary, adjust speeds
as follows:
Start engine and run until warm.
Turn A/V control to 10.
2200 50 rpm
3700 50 rpm
Remove top cover to access speed
adjustments.
Idle Speed Adjustment
Move Engine Control switch to
Run/Idle position.
1
1
2
3
Throttle Solenoid
Mounting Screws
Idle Speed Screw
Loosen mounting screws. Adjust
solenoid position so engine runs at
idle speed. If necessary, back out
idle speed screw so solenoid can
be moved to correct position. Tight-
en mounting screws. Be sure sole-
noid linkage works smoothly.
5
2
4
Turn idle speed screw for fine
adjustments.
Weld/Power Speed Adjustment
Move Engine Control switch to Run
position.
4
Weld/Power Speed
Adjustment Nut
5
Lock Nut
Loosen lock nut. Turn adjustment
nut until engine runs at weld/power
speed. Tighten lock nut.
3
Reinstall top cover.
Y
Stop engine.
Top View
Tools Needed:
1/4, 3/8 in
802 849-A / 801 209-A
OM-4407 Page 40
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9-7. Overload Protection (Kohler-Powered Units)
Y
Stop engine.
Tools Needed:
.
W
h
e
n
a
c
i
r
c
u
i
t
b
r
e
a
k
e
r
o
r
f
u
s
e
opens, it usually indicates a
more serious problem exists.
Contact a Factory Authorized
Service Agent.
3/8 in
1
Circuit Breaker CB5
CB5 protects the 24 volt ac output
to Remote receptacle RC4. If CB5
opens, 24 volt ac output to RC4
stops.
Press button to reset breaker.
2
3
Fuse F2 (See Parts List)
Fuse F6 (See Parts List)
4
F2 is located behind the front panel.
F2 protects the 115 volt output to
Remote Receptacle RC4. If F2
opens, 115 volt ac output to RC4
stops.
2
F6 protects the engine wiring sys-
tem from overload. If F6 opens,
engine will not crank.
Located behind front panel.
4
Fuse F1 (See Parts List)
Remove side panel.
F1 protects the exciter excitation
winding from overload. If F1 opens,
weld and generator power output
stops.
Replace any open fuses. Reinstall
cover before operating unit.
3
1
802 851-A / Ref. 206 422
OM-4407 Page 41
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SECTION 10 − TROUBLESHOOTING
10-1. Welding Troubleshooting
Trouble
No weld output.
Remedy
Check control settings.
Check weld connections.
Disconnect equipment from generator power receptacles during start-up.
Place V/A Adjust switch in Panel position, or move switch to Remote position and connect remote
Have Factory Authorized Service Agent check brushes, slip rings, integrated rectifier SR2, and circuit
boards PC1 and PC2.
Low weld output.
Check control settings.
Place V/A Adjust switch in Panel position, or move switch to Remote position and connect remote
Have Factory Authorized Service Agent check brushes, slip rings, integrated rectifier SR2, and circuit
boards PC1 and PC2.
See engine manual.
High weld output.
Check control settings.
Have Factory Authorized Service Agent check circuit boards PC1 and PC2.
Have Factory Authorized Service Agent check field current control board PC2.
Check control settings.
Weld output cannot be adjusted.
Erratic weld output.
Clean and tighten connections both inside and outside unit.
Check and secure lead connections to A/V control.
Be sure connection to work piece is clean and tight.
Remove excessive coils from weld cables.
Use dry, properly stored electrodes.
Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.
No remote fine amperage control.
No 24 volt ac power output at Remote
receptacle RC4.
No 115 volt ac power output at Remote Check fuse F2, and replace if necessary (see Section 8-5 or 9-7).
receptacle RC4.
OM-4407 Page 42
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Trouble
Remedy
Use proper size tungsten for welding amperage.
Lack of high frequency; difficulty in
establishing Gas Tungsten Arc Weld-
ing arc.
Reduce leakage of high frequency from torch or work cable (check grounding, remove excessive
coils from weld cables, use shorter weld cables, etc.).
Check cables and torch for cracked or deteriorated insulation or bad connections. Repair or replace
necessary parts.
Wandering arc − poor control of arc
direction.
Reduce gas flow rate.
Select proper size tungsten. Properly prepare tungsten.
Shield weld zone from drafts.
Tungsten electrode oxidizing and not
remaining bright after conclusion of
weld.
Increase postflow time.
Check and tighten all gas fittings.
Properly prepare tungsten.
10-2. Generator Power Troubleshooting
Trouble
Remedy
No power output.
Low power output.
Have Factory Authorized Service Agent check brushes, slip rings, integrated rectifier SR2, and circuit
boards PC1 and PC2.
Check and clean air cleaner as necessary.
See engine manual.
High power output.
Have Factory Authorized Service Agent check brushes, slip rings, and field current control board PC2.
Check receptacle wiring and connections.
Erratic power output.
Check governor according to engine manual.
10-3. Engine Troubleshooting
Trouble
Remedy
Engine will not crank.
Check battery voltage.
Check battery connections and tighten if necessary.
Check plug PLG5 and plug PLG8 connections.
Have Factory Authorized Service Agent check Engine Control switch S2.
OM-4407 Page 43
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Trouble
Remedy
Engine does not start.
Check battery and replace if necessary.
Check engine charging system according to engine manual.
Have Factory Authorized Service Agent check fuel shutoff solenoid GS1 according to engine manual
(GS1 standard on Kohler-powered units; optional on Robin-powered, LP-fueled units).
See engine manual.
Engine starts but stops when Engine
Control switch returns to Run/Idle
position.
Check oil level (see Section 5-2 or 5-3). Low oil pressure shutdown stops engine if oil pressure is too
low.
Have Factory Authorized Service Agent check low oil pressure shutdown switch S5.
Place Engine Control switch in Off position when unit is not running.
Clean top of battery with baking soda and water solution; rinse with clear water.
Periodically recharge battery (approximately every 3 months).
Replace battery.
Battery discharges between uses.
Check voltage regulator according to engine manual.
Engine stopped during normal
operation.
Check oil level (see Section 5-2 or 5-3). Low oil pressure shutdown stops engine if oil pressure is too
low.
Have Factory Authorized Service Agent check fuel shutoff solenoid GS1 according to engine manual
(GS1 standard on Kohler-powered units; optional on Robin-powered, LP-fueled units).
Have Factory Authorized Service Agent check low oil pressure shutdown switch S5.
Be sure Engine Control switch S2 is in Run/Idle position.
Remove all weld and generator power loads.
Engine does not return to idle speed.
Place Process/Contactor switch in Electrode Hot position or turn off remote contactor. The unit will not
return to idle speed when Process/Contactor switch is in a remote position and the remote contactor
is on.
Have Factory Authorized Service Agent check circuit board PC1 and current transformer CT1.
Engine does not remain at weld/power Place Engine Control switch in the Run position for small loads.
speed when power or weld load is
applied with Engine Control switch in
Run/Idle position.
OM-4407 Page 44
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Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-4407 Page 45
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209 625-C
OM-4407 Page 47
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Figure 11-2. Circuit Diagram For Welding Generator Models With DC Output Only (Kohler Only)
OM-4407 Page 48
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209 620-B
OM-4407 Page 49
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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.
NOTE
12-1. Selecting Equipment
1
Generator Power Receptacles
− Neutral Bonded To Frame
2
3-Prong Plug From Case
Grounded Equipment
3
2-Prong Plug From Double
Insulated Equipment
Y
Do not use 2-prong plug un-
less equipment is double in-
sulated.
1
2
3
Be sure equipment
has this symbol
and/or wording.
OR
gen_pwr 11/02 − Ref. ST-159 730 / ST-800 577
12-2. Grounding Generator To Truck Or Trailer Frame
Y
Always ground generator
frame to vehicle frame to pre-
vent electric shock and static
electricity hazards.
1
2
3
Equipment Grounding
Terminal (On Front Panel)
Grounding Cable (Not
Supplied)
1
Metal Vehicle Frame
Connect cable from equipment
ground terminal to metal vehicle
frame. Use #10 AWG or larger
insulated copper wire.
2
GND/PE
Y
If unit does not have GFCI re-
ceptacles, use GFCI-pro-
tected extension cord.
3
Electrically bond generator
frame to vehicle frame by
metal-to-metalcontact.
Y
Bed liners, shipping skids, and some running
gear insulate the welding generator from the ve-
hicle frame. Always connect a ground wire from
the generator equipment grounding terminal to
bare metal on the vehicle frame as shown.
S-0854
OM-4407 Page 50
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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
Y
Ground generator to system
earth ground if supplying
power to a premises (home,
shop, farm) wiring system.
Use ground device as stated
in electrical codes.
2
3
ST-800 576-B
12-4. How Much Power Does Equipment Require?
1
Resistive Load
3
A light bulb is a resistive load and
requires a constant amount of power.
VOLTS 115
AMPS 4.5
Hz 60
2
2
Non-Resistive Load
1
Equipment with a motor is a non-re-
sistive load and requires approxi-
mately six times more power while
starting the motor than when running
3
Rating Data
3
Rating shows volts and amperes, or
watts required to run equipment.
AMPERES x VOLTS = WATTS
EXAMPLE 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power
requirementin watts.
4.5 A x 115 V = 520 W
The load applied by the drill is 520 watts.
EXAMPLE 2: If three 200 watt flood lamps are used with the drill from Example 1,
add the individual loads to calculate total load.
(200 W + 200 W + 200 W) + 520 W = 1120 W
The total load applied by the three flood lamps and drill is 1120 watts.
S-0623
OM-4407 Page 51
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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-4407 Page 52
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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-4407 Page 53
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12-8. Power Required To Start Motor
1
2
3
4
Motor Start Code
Running Amperage
Motor HP
4
AC MOTOR
VOLTS 230 AMPS 2.5
Hz 60
PHASE 1
2
1
3
CODE
HP
M
1/4
Motor Voltage
To find starting amperage:
Step 1: Find code and use table to
find kVA/HP. If code is not listed,
multiplyrunning amperage by six to
find starting amperage.
Step 2: Find Motor HP and Volts.
Step 3: Determine starting amper-
age (see example).
Welding generator amperage out-
put must be at least twice the
motor’s running amperage.
Single-Phase Induction Motor Starting Requirements
Motor Start
Code
G
H
J
K
L
M
N
P
KVA/HP
6.3
7.1
8.0
9.0
10.0
11.2
12.5
14.0
kVA/HP x HP x 1000
VOLTS
= STARTING AMPERAGE
EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4
HP motor with a motor start code of M.
Volts = 230 HP = 1/4 Using Table, Code M results in kVA/HP = 11.2
11.2 x 1/4 x 1000
= 12.2 A
Starting the motor requires 12.2 amperes.
230
S-0624
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-4407 Page 54
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12-10. Typical Connections To Supply Standby Power
Y
Properly install and ground this equipment according to
its Owner’s Manual and national, state, and local codes.
1
2
3
4
Fused
Disconnect
Switch
Utility
Electrical
Service
Welding
Generator
Output
Transfer Switch
(If Required)
5
Essential
Loads
Y
Y
Have only qualified persons perform Switch transfers the electrical load from Connect generator with temporary or perma-
these connections according to all electric utility service to the generator. Trans- nent wiring suitable for the installation.
applicable codes and safety practic- fer load back to electric utility when service is
Turn off or unplug all equipment connected to
generator before starting or stopping engine.
When starting or stopping, the engine has
low speed which causes low voltage and
frequency.
es.
restored.
Properly install and ground this Install correct switch (customer-supplied).
equipment according to its Owner’s Switch rating must be same as or greater
than the branch overcurrent protection.
Manual and national, state, and local
codes.
3 Fused Disconnect Switch
5 Essential Loads
. Customer-supplied equipment is re-
quired if generator will supply standby
power during emergencies or power out-
ages.
Install correct switch (customer-supplied) if
required by electrical code.
Generatoroutput may not meet the electrical
requirements of the premises. If generator
does not produce enough output to meet all
4 Welding Generator Output
Generator output voltage and wiring must be requirements, connect only essential loads
1 Utility Electrical Service
consistent with regular (utility) system volt- (pumps, freezers, heaters, etc. − See Sec-
2 Transfer Switch (Double-Throw)
age and wiring.
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-4407 Page 55
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12-11. Selecting Extension Cord (Use Shortest Cord Possible)
Cord Lengths for 120 Volt Loads
Y
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)
Load (Watts)
4
6
8
10
12
14
5
600
350 (106)
250 (76)
175 (53)
112 (34)
87 (26)
62 (19)
50 (15)
50 (15)
37 (11)
225 (68)
150 (46)
112 (34)
75 (23)
50 (15)
37 (11)
37 (11)
137 (42)
100 (30)
62 (19)
37 (11)
30 (9)
100 (30)
62 (19)
50 (15)
30 (9)
7
840
400 (122)
275 (84)
175 (53)
137 (42)
112 (34)
87 (26)
10
15
20
25
30
35
40
45
50
1200
1800
2400
3000
3600
4200
4800
5400
6000
400 (122)
300 (91)
225 (68)
175 (53)
150 (46)
125 (38)
112 (34)
100 (30)
87 (26)
75 (23)
62 (19)
62 (19)
50 (15)
*Conductor size is based on maximum 2% voltage drop
Cord Lengths for 240 Volt Loads
Y
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)
Load (Watts)
4
6
8
10
12
14
5
1200
1680
2400
3600
4800
6000
7000
8400
9600
10,800
12,000
700 (213)
500 (152)
350 (107)
225 (69)
175 (53)
125 (38)
100 (31)
100 (31)
75 (23)
450 (137)
300 (91)
225 (69)
150 (46)
100 (31)
75 (23)
225 (84)
200 (61)
125 (38)
75 (23)
200 (61)
125 (38)
100 (31)
60 (18)
7
800 (244)
550 (168)
350 (107)
275 (84)
225 (69)
175 (53)
150 (46)
125 (38)
125 (38)
100 (31)
10
15
20
25
30
35
40
45
50
800 (244)
600 (183)
450 (137)
350 (107)
300 (91)
250 (76)
225 (69)
200 (61)
175 (53)
60 (18)
75 (23)
*Conductor size is based on maximum 2% voltage drop
OM-4407 Page 56
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Notes
OM-4407 Page 57
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Item
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. . . 1 . . . . . . . . . . . . . . 182367 . . Panel, Side Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 1 . . . . . . . . . . . . ♦185352 . . Panel, Side Rh Stainless Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . 182366 . . Panel, Side Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . ♦185353 . . Panel, Side Lh Stainless Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . +205762 . . Cover, Top (Robin EH64, Kohler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . +206758 . . Cover, Top Stainless Steel (Robin EH64, Kohler) . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦163175 . . Screw, 250−20x .75 Hex Hd−pln Stainless Steel Pln T18−8 302−305 . . . 18
. . . . . . . . . . . . . . . . . . ♦163167 . . Washer, Lock .254idx0.489odx.062t Stainless Steel Split.250 . . . . . . . . . 18
. . . . . . . . . . . . . . . . . . ♦163174 . . Washer, Flat .281idx0.625odx.050t Stainless Steel . . . . . . . . . . . . . . . . . . . 18
. . . 4 . . . . . . . . . . . . . . 205605 . . Label, Power While Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . 192042 . . Label, Use Gasoline Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . 181881 . . Grommet, Plastic Neck Filler Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . 166608 . . Cap, Tank Screw−on W/Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . 182761 . . Label, Warning General Precautionary Csa . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . 183433 . . Pipe, Exhaust Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . 183314 . . Clamp, Muffler 1.625 Dia U Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . 182365 . . Panel, Rear Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . ♦185351 . . Panel, Rear Upper Stainless Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
12 & 13 . . . . . . . . . . . Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 14 . . . . . . . . . . . . . . 205736 . . Upright, Base (Robin EH64, Kohler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 205734 . . Seal, Weather Lift Eye (Robin EH64, Kohler) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . 181789 . . Seal, Barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . 186667 . . Cover, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . 204317 . . Bracket, Mtg. Engine (Robin EH64) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . 173043 . . Bracket, Mtg Engine (Kohler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . Figure 13-3 . . Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . 215939 . . Label, Engine Maintenance (Robin EH64, Kohler) . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 202807 . . Shield, Heat Muffler (Kohler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 205713 . . Hose, Oil w/Fittings (Robin EH64, Kohler) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . 208006 . . Engine, Robin EH64 Gas Elect Start (includes) . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . 204841 . . . . Muffler, Exhaust Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 065313 . . . . Gasket, Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 198756 . . . . Pump, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . S5 . . . . . 198757 . . . . Switch, Low Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . TS1 . . . . 206573 . . . . Solenoid, Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 190827 . . . . Boot, Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 198778 . . . . Regulator, Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 215984 . . . . Filter, Fuel Inline .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . 208004 . . . . Valve, Oil Drain 3/8−18 Nptf (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 207490 . . . . . . Hose, Oil W/Fitting 9.750 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 165271 . . . . . . Valve, Oil Drain 3/8−18 Nptf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 206472 . . . . . . Ftg, Hose Brs Barbed M 1/2 Tbg X M14x1.25 . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . F6 . . . . . 021718 . . . . Fuse, Mintr Gl 30. Amp 32 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 206473 . . Washer, Seal oil copper M14 ID x M19.500 OD (Robin EH64) . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . 209023 . . Engine, Kohler CH20S-PS−64635 Gas Elec Start (includes) . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . 207458 . . . . Muffler,Exhaust Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 189477 . . . . Gasket, Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . TS1 . . . . 199530 . . . . Solenoid, Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bracket, Mtg Solenoid (See Engine Parts List) . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 215984 . . . . Filter,Fuel Inline .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . 208003 . . . . Valve,Oil Drain 3/8−18 Nptf (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 207490 . . . . . . Hose, Oil W/Fitting 9.750 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 165271 . . . . . . Valve, Oil Drain 3/8−18 Nptf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 206402 . . . . . . Ftg, Hose Brs Barbed M 1/2 Tbg X 3/8 Npt . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . F6 . . . . . 021718 . . . . Fuse,Mintr Gl 30. Amp 32 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 180096 . . Tune−up & Filter Kit, Kohler (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *067272 . . . . Air Filter Element, Kohler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *066698 . . . . Oil Filter, Kohler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *215985 . . . . Filter/Clamps, Fuel 1/4” Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *067007 . . . . Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OM-4407 Page 59
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Figure 13-1. Main Assembly (Continued)
. . . 25 . . . . . . . . . . . . . . 168385 . . Label, Warning Battery Explosion Can Blind . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . +201174 . . Door, Access Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . 182935 . . Hold Down, Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . 082319 . . Cable, Bat Neg 17.750l lg no 4 awg w/clamp & .343 rng
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Kohler, Robin EH64) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . 172 669 . . Cable, Bat Neg 11.000 lg 6ga w/.250 rng & .375 rng
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Kohler, Robin EH64) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . 173 921 . . Cable, Bat Pos 28.000 lg no 4 awg w/clamp & .312 rng
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Kohler, Robin EH64) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . 167677 . . Battery, Stor 12v 430 Crk 75 Rsv Gp 58 Maint Free . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . +201280 . . Pan, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . 197930 . . Label, Warning Do Not Weld On Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 33 . . . . . . . . . . . . . . 207864 . . Label, Engine Maintenance (Kohler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . 181057 . . Cover, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 35 . . . . DC-Z . . . . 202337 . . Stabilizer, Assy (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 202338 . . . . Plate, Rect/Stab Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . +182928 . . Bracket, Mtg Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . . 121652 . . Filter/Clamps, Fuel (Part Of Tune-Up & Filter Kits) . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . . . 173766 . . Hose, Sae .250 Id X .500 Od X 11.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . . Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 084173 . . Clamp, Hose .460 − .545 Clp Dia Slfttng . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 40 . . . . . . . . . . . . . . 182079 . . Tank, Fuel 10.0 Gal (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 124253 . . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 187502 . . . . Ftg, Stand Pipe .250 X 7.375 Lg 90 Degree . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 182922 . . . . Bushing, Tank Fuel 1.210id . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 182925 . . . . Gauge, Fuel Float Type 5.50 Float Travel . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . PC1 . . . . 212708 . . Circuit Card Assy, Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . . . 097132 . . Stand−off, No 6−32 X .375 Lg .250 Hex Brs M&f . . . . . . . . . . . . . . . . . . . . 6
. . . 43 . . . . . . . . . . . . . . 204148 . . Bracket, Mtg Pc Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . . 119148 . . Bushing, Snap−in Nyl 1.968 Id X 2.500 Mtg Hole . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . . . 200263 . . Label, Warning Electric Shock Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . . . . . . . . . . 172731 . . Holder, Fuse Mintr .250 X 1.250 Clip Anti−pivot . . . . . . . . . . . . . . . . . . . . . 1
. . . 47 . . . . . F1 . . . . . 169296 . . Fuse, Mintr Gl 25. Amp 125 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . SR2 . . . . 200759 . . Rectifier, Integ Bridge 35. Amp 600v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . . 1T . . . . . 172661 . . Block, Stud Connection 6 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 173734 . . Link, Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 50 . . . . . . . . . . . . . . 165437 . . Clip, Snap In .472 Bundle .250hole .020−.197 Thk . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . C12 . . . . 176007 . . Capacitor, Elctlt 1200 Uf 300 Vdc Can 1.37 Dia . . . . . . . . . . . . . . . . . . . . . 1
. . . 52 . . . . . C1 . . . . . 199979 . . Capacitor, Elctlt 1500 Uf 75 Vdc Can 1.40 Dia . . . . . . . . . . . . . . . . . . . . . . 1
. . . 53 . . . . . . . . . . . . . . 204166 . . Bracket, Capacitor Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 202331 . . Gasket, Capacitor Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 54 . . . . . R1 . . . . . 188067 . . Resistor, Ww Fxd 100 W 200 Ohm W/Clips (AC/DC Units Only) . . . . . . . 1
. . . 55 . . . . CT1 . . . 206 369 . . Xfmr, Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 56 . . . . . . . . . . . . . +180628 . . Panel, Front Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 57 . . . . . . . . . . Figure 13-2 . . Panel, Front w/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 58 . . . . SR1 . . . . 202222 . . Rectifier, Si 3ph 300 Amp 400 Piv 100% Duty Cycle . . . . . . . . . . . . . . . . . 1
. . . 59 . . . . . . . . . . . . . . 202339 . . Baffle, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 60 . . . . . . . . . . . . . . 196180 . . Insulator, Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . RC29, 30, PLG6 . 209831 . . Receptacles, W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 202883 . . Harness, Control Power Board Interconnecting (includes) . . . . . . . . . . . . . 1
. . . . . . . . . PLG16 . . . 115093 . . . . Conn, Rect Mini 045 6skt 2row Plug Cable Lkg (Service Kit) . . . . . . . . . 1
. . . . . . PLG12, PLG27 131054 . . . . Conn, Rect Mini 045 2skt 2row Plug Cable Lkg (Service Kit) . . . . . . . . . 2
. . . . . . . . . PLG21 . . . 115094 . . . . Conn, Rect Mini 045 4skt 2row Plug Cable Lkg (Service Kit) . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 206534 . . Harness, Wrg Interconnecting (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG25 . . . 115091 . . . . Conn, Rect Mini 045 10skt 2row Plug Cable Lkg (Service Kit) . . . . . . . . 1
. . . . . . . . . . RC9 . . . . 174823 . . . . Conn, Rect Comm 093 2p/S 1row Rcpt Cable Lkg (Service Kit) . . . . . . 1
. . . . . . . . . . RC7 . . . . 130204 . . . . Conn, Rect Univ 084 3p/S 1row Plug Cable Lkg (Service Kit) . . . . . . . . 1
. . . . . . . . . PLG18 . . . 204773 . . Plug, W/Leads (AC/DC Units Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-4407 Page 60
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 13-1. Main Assembly (Continued)
. . . . . . . . . . . . . . . . . . . . 206537 . . Harness, Wrg Ignition (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG15 . . . 115092 . . . . Conn, Rect Mini 045 8skt 2row Plug Cable Lkg (Service Kit) . . . . . . . . . 1
. . . . . . . . . . RC5 . . . . 116045 . . . . Conn, Rect Univ 084 6p/S 3row Rcpt Cable/Panel Lkg (Service Kit) . . 1
. . . . . . . . . . PLG7 . . . . 168165 . . . . Conn, Rect Comm 084 3p/S 1row Recpt Cable Lkg . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG8 . . . . 177859 . . . . Conn, Body 5 Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 202660 . . . . Conn, Push 4 Wire 12−16strnd 12−18sld 16−22tinstrnd . . . . . . . . . . . . 1
. . . . . . . . . . PLG5 . . . . 135556 . . Conn, Rect Univ 084 6p/S 3row Plug (Service Kit) . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 206123 . . Tune-Up & Filter Kit (Robin EH64) (includes) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *198755 . . . . Element, Air Cleaner w/Precleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *198754 . . . . Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *121652 . . . . Filter/Clamps, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *198777 . . . . Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 180096 . . Tune-up & Filter Kit (Kohler) (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *067272 . . . . Element, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *066698 . . . . Filter, Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 121652 . . . . Filter/Clamps, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *067007 . . . . Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . *067272 . . . . Air Filter Wrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 206122 . . Kit, Label (Robin EH64) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 205650 . . Kit, Label (Kohler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦Optional
*Recommended Spare Parts.
+
When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 206122 (Robin EH64), or 205650 (Kohler).
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-4407 Page 61
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . 1 . . . . . . . . . . . . . . 206854 . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . 115 440 . . Stand−off, No 6−32 X .625 Lg .250 Hex Al Fem . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . 203401 . . Stand−off Support, Pc Card .187 Dia W/P&l .625 . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . PC2 . . . . 212867 . . Circuit Card Assy, Control (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 206794 . . . . Bag, Protective Anti Static 5:00x12:00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . S1 . . . . . 204641 . . Switch, Changeover Assy W/Leads (AC/DC Units Only) . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . 187189 . . Bracket, Mtg Shunt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . LEM . . . . 168829 . . Transducer, Current 1000a Module Max Open Loop . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 209618 . . Harness, Remote Control 14pin (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . RC4 . . . . 143976 . . . . Conn, Circ Ms/Cpc 14skt Size 20 Rcpt Panel Pushin (Service Kit) . . . 1
. . . 9 . . . . . . . . . . . . . . 209617 . . . . Holder, Fuse w/10a Fuse (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . F2 . . . . . 085874 . . . . . . Fuse, Mintr Cer Slo-Blo 10 a 250 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG23 . . . 115093 . . . . Conn, Rect Mini 045 6skt 2row Plug Cable Lkg (Service Kit) . . . . . . . . . 1
. . . . . . . . . PLG24 . . . 131054 . . . . Conn, Rect Mini 045 2skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 202884 . . Harness, Switch Control (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG20 . . . 131204 . . . . Conn, Rect Mini 045 3skt 1row Plug Cable Lkg (Service Kit) . . . . . . . . . 1
. . . 10 . . . . . S3 . . . . . 011609 . . . . Switch, Tgl Spdt 15a 125vac On−none−on Spd Term Chr . . . . . . . . . . . 1
. . . 11 . . . . CB5 . . . . 083432 . . Circuit Breaker, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . S2 . . . . . 176606 . . Switch, Ignition 4 Position W/Out Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . RC2, RC3 . . 141432 . . Rcpt, Str Dx Grd 2p3w 20a 125v *5−20r . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 13 . GFCI2, GFCI3 ♦151981 . . Rcpt, Str Dx Grd 2p3w 20a 125v GFCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 14 . . CB3, CB4 . . 093996 . . Circuit Breaker, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . . . . . 2
. . . 15 . . . . CB1 . . . . 217858 . . Circuit Breaker, Man Reset 2p 50a 240vac Screw−90 . . . . . . . . . . . . . . . . 1
. . . 16 . . . . PC5 . . . . 148030 . . Circuit Card Assy, Filter Hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . PC3 . . . . 148021 . . Circuit Card Assy, Filter Hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 134201 . . Stand−off Support, Pc Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . . . 6
. . . 18 . . . . . . . . . . . . . . 211452 . . Control, Push/Pull Snap−in 42.000 W/1.750 Extension . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . 119014 . . Lever, Switch Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . CC, CV, WORK . 099255 . . Terminal, Pwr Output Neutral (AC/DC Units Only) . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . POS . . . . 039047 . . Terminal, Pwr Output Red (DC Units Only) . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . NEG . . . . 039046 . . Terminal, Pwr Output Black (DC Units Only) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG30 . . . 204777 . . Plug, w/ Leads (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 174824 . . . . Conn,Rect Comm 093 2p/S 1row Plug Cable Lkg (Service Kit) . . . . . . . 1
. . . . . . . . . PLG28 . . . 204664 . . Plug, w/Leads (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 130203 . . . . Conn,Rect Mini 045 12skt 2row Plug Cable Lkg (Service Kit) . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . 083030 . . Stud, Brs .250−20 X 1.750 W/Hex Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . 010915 . . Washer, Flat .257idx0.640odx.031t Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 23 . . . . . . . . . . . . . . 602207 . . Washer, Lock .255idx0.489odx.062t Stl Pld Split.250 . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . 601836 . . Nut, 250−20 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . 188039 . . Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . 203016 . . Boot, Circuit Breaker 2 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . 159921 . . Bezel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . RC1 . . . . 182954 . . Rcpt, Str 3p4w 50a 125/250v Flush Mtg *14−50 . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . 021385 . . Boot, Toggle Switch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . HM . . . . . 145247 . . Meter, Hour 12−24vdc 1.25 X 2.12 Rect . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . 207075 . . Knob, Pointer 1.625 Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . 010647 . . Pin, Spring Cs .156 X 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . . 115493 . . Handle, Switch Range (AC/DC Units Only) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . 170391 . . Conn, Circ Ms Protective Cap Size 20 Nylon . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . 207080 . . Knob, Pointer 1.125 Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . . . . . . . . . . . . Nameplate (Order By Model & Serial Number) . . . . . . . . . . . . . . . . . . . . . . 1
♦Optional
+
When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 206122 (Robin EH64), or 205650 (Kohler).
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-4407 Page 63
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Item
No.
Part
No.
Description
Quantity
. . . 1 . . . . . . . . . . . . +206 406 . . Stator, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . 182092 . . Label, Warning Moving Parts Can Caue Serious Injury . . . . . . . . . . . . . . . 2
. . . 3 . . . . . . . . . . . . . . 202346 . . Rotor, Generator (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . 181143 . . . . Bearing, Ball Rdl Sgl Row .984 X 2.047 X .591 . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . 160566 . . . . Fan, Rotor Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . 212161 . . Adapter, Engine (Kohler, Robin EH64) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . 202771 . . Baffle, Engine Adapter (Kohler, Robin EH64) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . 170861 . . Stud, Stl .375−16 X 17.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 9 . . . . . . . . . . . . . . 205725 . . Brushholder Assy, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . PLG17 . . . 203387 . . Harness, Brushholder (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 202511 . . . . Conn,Rect Univ 084 6p/S 3row Plug Cable Lkg (Service Kit) . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . 010909 . . Washer, Flat .406idx0.812odx.065t Stl Pld Ansi.375 . . . . . . . . . . . . . . . . . . 4
. . . 11 . . . . . . . . . . . . . . 010910 . . Nut, 375−16 .56hex .46h Stl Pld Elastic Stop Nut . . . . . . . . . . . . . . . . . . . . 4
. . . 12 . . . . . . . . . . . . . . 218049 . . Endbell (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . 183419 . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG10 . . . 130204 . . Connector, Rect Univ 084 3 P/S 1 Row Plug Cable Lkg (Service Kit) . . . 1
.
H
a
r
d
w
a
r
e
i
s
c
o
m
m
o
n
a
n
d
7
not available unless listed.
6
3
5
4
2
1
8
12
9
13
10
802 999
11
Figure 13-3. Generator
+
When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 206122 (Robin EH64), or 205650 (Kohler).
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-4407 Page 64
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Effective January 1, 2004
(Equipment with a serial number preface of “LE” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
*
*
*
*
*
*
*
Induction Heating Coils and Blankets
APT & SAF Model Plasma Cutting Torches
Remote Controls
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Accessory Kits
Replacement Parts (No labor)
Spoolmate Spoolguns
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.
Canvas Covers
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 date that the
equipment was delivered to the original retail purchaser, or one
year after the equipment is sent to a North American distributor
or eighteen months after the equipment is sent to an
International distributor.
2. Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
3. Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for the
equipment.
1. 5 Years Parts — 3 Years Labor
*
*
Original main power rectifiers
Inverters (input and output rectifiers only)
2. 3 Years — Parts and Labor
*
*
*
*
*
*
*
Transformer/Rectifier Power Sources
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.
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Supplies (Unless Otherwise Stated)
Intellitig
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
Maxstar 150
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
3. 1 Year — Parts and Labor Unless Specified
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
Process Controllers
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources
Water Coolant Systems
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Maxstar 85, 140
Spot Welders
Load Banks
Arc Stud Power Sources & Arc Stud Guns
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary
from state to state.
*
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may be
available, but may vary from province to province.
4. 6 Months — Batteries
5. 90 Days — Parts
*
MIG Guns/TIG Torches
miller_warr 3/04
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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
to locate a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA
2003 Miller Electric Mfg. Co. 1/03
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