diagrama miller bluestar

Blue Star 6000

Processes

Description

Stick (SMAW) Welding

Engine Driven Welding Generator

OM-499 197 850HMarch 2004

Visit our website atwww.MillerWelds.com

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local Miller distributor to receive the latest fullline catalog orindividual catalog sheets. To locate your nearestdistributor or service agency call 1-800-4-A-Miller, or visit us atwww.MillerWelds.com on the web.

Thank you and congratulations on choosing Miller. Now you can getthe job done and get it done right. We know you dont have time to doit any other way.

Thats why when Niels Miller first started building arc welders in 1929,he made sure his products offered long-lasting value and superiorquality. Like you, his customers couldnt afford anything less. Millerproducts had to be more than the best they could be. They had to be thebest you could buy.

Today, the people that build and sell Miller products continue thetradition. Theyre just as committed to providing equipment and servicethat meets the high standards of quality and value established in 1929.

This Owners Manual is designed to help you get the most out of yourMiller products. Please take time to read the Safety precautions. Theywill help you protect yourself against potential hazards on the worksite.

Weve made installation and operation quickand easy. With Miller you can count on yearsof reliable service with proper maintenance.And if for some reason the unit needs repair,theres a Troubleshooting section that willhelp you figure out what the problem is. Theparts list will then help you to decide theexact part you may need to fix the problem.Warranty and service information for yourparticular model are also provided.

Miller is the first weldingequipment manufacturer inthe U.S.A. to be registered tothe ISO 9001 Quality SystemStandard.

Working as hard as you do every power source fromMiller is backed by the mosthassle-free warranty in thebusiness.

From Miller to You

Miller offers a TechnicalManual which providesmore detailed service andparts information for yourunit. To obtain a TechnicalManual, contact your localdistributor. Your distributorcan also supply you withWelding Process Manualssuch as SMAW, GTAW,GMAW, and GMAW-P.

TABLE OF CONTENTS

SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Engine Hazards 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. Compressed Air Hazards 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. Additional Symbols For Installation, Operation, And Maintenance 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6. California Proposition 65 Warnings 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7. Principal Safety Standards 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8. EMF Information 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. Signification des symboles 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2. Dangers relatifs au soudage larc 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3. Dangers existant en relation avec le moteur 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4. Dangers lis lair comprim 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance 7 . . . . . . 2-6. Principales normes de scurit 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7. Information sur les champs lectromagntiques 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 DEFINITIONS 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 4 SPECIFICATIONS 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Weld, Power, And Engine Specifications 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Dimensions, Weights, And Operating Angles 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3. Fuel Consumption (Kohler-Powered Units) 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4. Fuel Consumption (Honda-Powered Units) 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5. Duty Cycle 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6. Generator Power Curves 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7. Volt-Ampere Curves 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 INSTALLATION 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Installing Welding Generator 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. Grounding Generator To Truck Or Trailer Frame 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3. Grounding Generator When Supplying Building Systems 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4. Engine Prestart Checks (Kohler-Powered Units) 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5. Engine Prestart Checks (Honda-Powered Units) 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6. Connecting The Battery (Electric-Start Models Only) 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7. Connecting To Weld Output Terminals 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8. Selecting Weld Cable Sizes* 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 OPERATING THE WELDING GENERATOR 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. Controls (Kohler-Powered Units) 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2. Controls (Honda-Powered Units) (See Section 6-3) 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3. Description Of Controls (Honda-Powered Units) (See Section 6-2) 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 OPERATING AUXILIARY EQUIPMENT 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Generator Power Panel 495 218 (USA) 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2. Optional Generator Power Panels 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3. Generator Power Panel Ratings 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4. Wiring Instructions For Optional 120/240 Volt Twistlock Plug (NEMA L14-30P) 24 . . . . . . . . . . . . . . . . . .

SECTION 8 MAINTENANCE 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. Maintenance Label 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2. Routine Maintenance 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3. Overload Protection (Honda-Powered Units) 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4. Adjusting Engine Speed (Kohler-Powered Units) 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5. Adjusting Engine Speed (Honda-Powered Units) 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 TROUBLESHOOTING 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 10 ELECTRICAL DIAGRAMS 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 11 GENERATOR POWER GUIDELINES 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 12 STICK WELDING (SMAW) GUIDELINES 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 13 PARTS LIST 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-499 Page 1Return To Table Of Contents

SECTION 1 SAFETY PRECAUTIONS READ BEFORE USINGrom _nd_8/03

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

1-1. Symbol UsageMeans Warning! Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoining symbols.

Marks a special safety message.

Means Note; not safety related.

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

1-2. Arc Welding Hazards The symbols shown below are used throughout this manual to

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

Only qualified persons should install, operate, maintain, and re-pair this unit.

During operation, keep everybody, especially children, away.

Touching live electrical parts can cause fatal shocks orsevere burns. The electrode and work circuit is electricallylive whenever the output is on. The input power circuit and

machine internal circuits are also live when power is on. In semiautomatic orautomatic wire welding, the wire, wire reel, drive roll housing, and all metalparts touching the welding wire are electrically live. Incorrectly installed orimproperly grounded equipment is a hazard.

ELECTRIC SHOCK can kill.

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

big enough to prevent any physical contact with the work or ground. Do not use AC output in damp areas, if movement is confined, or if there is a

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

cally hazardous conditions are present: in damp locations or while wearingwet clothing; on metal structures such as floors, gratings, or scaffolds;when in cramped positions such as sitting, kneeling, or lying; or when thereis a high risk of unavoidable or accidental contact with the workpiece orground. 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 mostsituations, use of a DC, constant voltage wire welder is recommended.And, do not work alone!

Disconnect input power or stop engine before installing or servicing thisequipment. Lockout/tagout input power according to OSHA 29 CFR1910.147 (see Safety Standards).

Properly install and ground this equipment according to its Owners Manualand national, state, and local codes.

Always verify the supply ground check and be sure that input power cordground wire is properly connected to ground terminal in disconnect box orthat cord plug is connected to a properly grounded receptacle outlet.

When making input connections, attach proper grounding conductor first double-check connections.

Frequently inspect input power cord for damage or bare wiring replacecord immediately if damaged bare wiring can kill.

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

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

er electrode from a different machine.

Use only well-maintained equipment. Repair or replace damaged parts atonce. Maintain unit according to manual.

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

table as near the weld as practical. Insulate work clamp when not connected to workpiece to prevent contact

with any metal object. Do not connect more than one electrode or work cable to any single weld

output terminal.

SIGNIFICANT DC VOLTAGE exists in inverters after stop-ping engine. Stop engine on inverter and discharge input capacitors according to

instructions in Maintenance Section before touching any parts.

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

FUMES AND GASES can be hazardous.

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

fumes and gases. If ventilation is poor, use an approved air-supplied respirator. Read the Material Safety Data Sheets (MSDSs) and the manufacturers

instructions for metals, consumables, coatings, cleaners, and degreasers. Work in a confined space only if it is well ventilated, or while wearing an air-

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

Do not weld in locations near degreasing, cleaning, or spraying operations.The heat and rays of the arc can react with vapors to form highly toxic andirritating gases.

Do not weld on coated metals, such as galvanized, lead, or cadmium platedsteel, unless the coating is removed from the weld area, the area is wellventilated, and if necessary, while wearing an air-supplied respirator. Thecoatings and any metals containing these elements can give off toxic fumesif welded.

BUILDUP OF GAS can injure or kill. Shut off shielding gas supply when not in use. Always ventilate confined spaces or use approved

air-supplied respirator.

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

ARC RAYS can burn eyes and skin.

Wear a welding helmet fitted with a proper shade of filter to protect your faceand eyes from arc rays and sparks when welding or watching (see ANSIZ49.1 and Z87.1 listed in Safety Standards).

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

warn others not to watch the arc. Wear protective clothing made from durable, flame-resistant material (wool

and leather) and foot protection.

OM-499 Page 2 Return To Table Of Contents

Welding on closed containers, such as tanks, drums, orpipes, can cause them to blow up. Sparks can fly off from thewelding arc. The flying sparks, hot workpiece, and hot

equipment can cause fires and burns. Accidental contact of electrode to metalobjects can cause sparks, explosion, overheating, or fire. Check and be surethe area is safe before doing any welding.

WELDING can cause fire or explosion.

Protect yourself and others from flying sparks and hot metal.

Do not weld where flying sparks can strike flammable material.

Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is notpossible, tightly cover them with approved covers.

Be alert that welding sparks and hot materials from welding can easily gothrough small cracks and openings to adjacent areas.

Watch for fire, and keep a fire extinguisher nearby.

Be aware that welding on a ceiling, floor, bulkhead, or partition can causefire on the hidden side.

Do not weld on closed containers such as tanks, drums, or pipes, unlessthey 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 toprevent welding current from traveling long, possibly unknown paths andcausing electric shock and fire hazards.

Do not use welder to thaw frozen pipes.

Remove stick electrode from holder or cut off welding wire at contact tipwhen not in use.

Wear oil-free protective garments such as leather gloves, heavy shirt, cuf-fless trousers, high shoes, and a cap.

Remove any combustibles, such as a butane lighter or matches, from yourperson before doing any welding.

Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hotwork and have a fire watcher and extinguisher nearby.

FLYING METAL can injure eyes. Welding, chipping, wire brushing, and grinding cause

sparks and flying metal. As welds cool, they canthrow off slag.

Wear approved safety glasses with side shields evenunder your welding helmet.

HOT PARTS can cause severe burns. Allow cooling period before maintaining. Wear protective gloves and clothing when working on

a hot engine. Do not touch hot engine parts or just-welded parts

bare-handed.

NOISE can damage hearing.

Noise from some processes or equipment can damagehearing.

Wear approved ear protection if noise level is high.

MAGNETIC FIELDS can affect pacemakers.

Pacemaker wearers keep away. Wearers should consult their doctor before going

near arc welding, gouging, or spot welding opera-tions.

Shielding gas cylinders contain gas under high pressure. Ifdamaged, a cylinder can explode. Since gas cylinders arenormally part of the welding process, be sure to treat themcarefully.

CYLINDERS can explode if damaged.

Protect compressed gas cylinders from excessive heat, mechanicalshocks, slag, open flames, sparks, and arcs.

Install cylinders in an upright position by securing to a stationary support orcylinder rack to prevent falling or tipping.

Keep cylinders away from any welding or other electrical circuits. Never drape a welding torch over a gas cylinder. Never allow a welding electrode to touch any cylinder. Never weld on a pressurized cylinder explosion will result. Use only correct shielding gas cylinders, regulators, hoses, and fittings de-

signed for the specific application; maintain them and associated parts ingood condition.

Turn face away from valve outlet when opening cylinder valve. Keep protective cap in place over valve except when cylinder is in use or

connected for use. Read and follow instructions on compressed gas cylinders, associated

equipment, and CGA publication P-1 listed in Safety Standards.

1-3. Engine Hazards

BATTERY EXPLOSION can BLIND. Always wear a face shield, rubber gloves, and protec-

tive clothing when working on a battery. Stop engine before disconnecting or connecting bat-

tery cables or servicing battery. Do not allow tools to cause sparks when working on a battery. Do not use welder to charge batteries or jump start vehicles. Observe correct polarity (+ and ) on batteries. Disconnect negative () cable first and connect it last.

FUEL can cause fire or explosion. Stop engine and let it cool off before checking or add-

ing fuel. Do not add fuel while smoking or if unit is near any

sparks or open flames. Do not overfill tank allow room for fuel to expand. Do not spill fuel. If fuel is spilled, clean up before starting engine. Dispose of rags in a fireproof container. Always keep nozzle in contact with tank when fueling.

MOVING PARTS can cause injury. Keep away from fans, belts, and rotors. Keep all doors, panels, covers, and guards closed

and securely in place.

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

and troubleshooting as necessary. To prevent accidental starting during servicing, disconnect negative ()

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

and before starting engine. Before working on generator, remove spark plugs or injectors to keep

engine from kicking back or starting. Block flywheel so that it will not turn while working on generator compo-

nents.


STEAM AND HOT COOLANT can burn. If possible, check coolant level when engine is cold to

avoid scalding. Always check coolant level at overflow tank, if pres-

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

If the engine is warm, checking is needed, and there is no overflow tank,follow the next two statements.

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

moving cap.

ENGINE EXHAUST GASES can kill. Use equipment outside in open, well-ventilated ar-

eas.

If used in a closed area, vent engine exhaust outsideand away from any building air intakes.

BATTERY ACID can BURN SKIN and EYES.

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

ENGINE HEAT can cause fire. Do not locate unit on, over, or near combustible

surfaces or flammables. Keep exhaust and exhaust pipes way from flam-

mables.

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

quired areas see applicable codes.

1-4. Compressed Air Hazards

BREATHING COMPRESSED AIR cancause serious injury or death. Do not use compressed air for breathing. Use only for cutting, gouging, and tools.

COMPRESSED AIR can cause injury. Wear approved safety goggles. Do not direct air stream toward self or others.

TRAPPED AIR PRESSURE AND WHIPPINGHOSES can cause injury. Release air pressure from tools and system before

servicing, adding or changing attachments, or open-ing compressor oil drain or oil fill cap.

HOT METAL from air arc cutting andgouging can cause fire or explosion. Do not cut or gouge near flammables. Watch for fire; keep extinguisher nearby.

HOT PARTS can cause burns and injury. Do not touch hot compressor or air system parts. Let system cool down before touching or servicing.

READ INSTRUCTIONS. Read Owners Manual before using or servicing unit. Stop engine and release air pressure before

servicing.

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

FALLING UNIT can cause injury. Use lifting eye to lift unit only, NOT running gear, gas

cylinders, trailer, or any other accessories. Use equipment of adequate capacity to lift and

support unit. If using lift forks to move unit, be sure forks are long

enough to extend beyond opposite side of unit.

OVERHEATING can damage motors. Turn off or unplug equipment before starting or stop-

ping engine. Do not let low voltage and frequency caused by low

engine speed damage electric motors. Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where

applicable.

FLYING SPARKS can cause injury. Wear a face shield to protect eyes and face. Shape tungsten electrode only on grinder with proper

guards in a safe location wearing proper face, hand,and body protection.

Sparks can cause fires keep flammables away.

OVERUSE can cause OVERHEATING. Allow cooling period; follow rated duty cycle. Reduce current or reduce duty cycle before starting

to weld again. Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards. Put on grounded wrist strap BEFORE handling

boards or parts. Use proper static-proof bags and boxes to store,

move, or ship PC boards.

TILTING OF TRAILER can cause injury. Use tongue jack or blocks to support weight. Properly install welding generator onto trailer accord-

ing to instructions supplied with trailer.


READ INSTRUCTIONS. Use only genuine MILLER/Hobart replacement

parts. Perform engine and air compressor (if applicable)

maintenance and service according to this manualand the engine/air compressor (if applicable) manu-als.

H.F. RADIATION can cause interference.

High-frequency (H.F.) can interfere with radio naviga-tion, safety services, computers, and communica-tions equipment.

Have only qualified persons familiar with electronicequipment perform this installation.

The user is responsible for having a qualified electricianpromptly correct any interference problem resulting from the installation.

If notified by the FCC about interference, stop using the equipment atonce.

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 thepossibility of interference.

ARC WELDING can cause interference.

Electromagnetic energy can interfere with sensitiveelectronic equipment such as microprocessors,computers, and computer-driven equipment such asrobots.

Be sure all equipment in the welding area is electro-magnetically compatible.

To reduce possible interference, keep weld cables as short as possible,close together, and down low, such as on the floor.

Locate welding operation 100 meters from any sensitive electronicequipment.

Be sure this welding machine is installed and grounded according to thismanual.

If interference still occurs, the user must take extra measures such asmoving the welding machine, using shielded cables, using line filters, orshielding the work area.

1-6. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which

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

Battery posts, terminals and related accessories contain leadand lead compounds, chemicals known to the State ofCalifornia to cause cancer and birth defects or otherreproductive harm. Wash hands after handling.

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

California to cause cancer, birth defects, or other reproductiveharm.

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

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

1-7. Principal Safety StandardsSafety in Welding, 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).Recommended Safe Practices for the Preparation for Welding and Cut-ting of Containers and Piping, American Welding Society StandardAWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Mi-ami, FL 33126 (phone: 305-443-9353, website: www.aws.org).National Electrical Code, NFPA Standard 70, from National Fire Protec-tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA02269-9101 (phone: 617-770-3000, website: www.nfpa.org and www.sparky.org).Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,from Compressed Gas Association, 1735 Jefferson Davis Highway,Suite 1004, Arlington, VA 22202-4102 (phone: 703-412-0900, website:www.cganet.com).Code for Safety in Welding and Cutting, CSA Standard W117.2, fromCanadian Standards Association, Standards Sales, 178 Rexdale Bou-

levard, Rexdale, Ontario, Canada M9W 1R3 (phone: 800-463-6727 orin 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, 11West 42nd Street, New York, NY 100368002 (phone: 212-642-4900,website: www.ansi.org).Standard for Fire Prevention During Welding, Cutting, and Other HotWork, NFPA Standard 51B, from National Fire Protection Association,P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (phone:617-770-3000, website: www.nfpa.org and www. sparky.org).OSHA, Occupational Safety and Health Standards for General 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 (thereare 10 Regional Officesphone for Region 5, Chicago, is312-353-2220, website: www.osha.gov).

1-8. EMF InformationConsiderations About Welding And The Effects Of Low FrequencyElectric And Magnetic Fields

Welding current, as it flows through welding cables, will cause electro-magnetic fields. There has been and still is some concern about suchfields. However, after examining more than 500 studies spanning 17years of research, a special blue ribbon committee of the NationalResearch Council concluded that: The body of evidence, in thecommittees 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 beexamined. Until the final conclusions of the research are reached, youmay wish to minimize your exposure to electromagnetic fields whenwelding or cutting.

To reduce magnetic fields in the workplace, use the followingprocedures:1. Keep cables close together by twisting or taping them.2. Arrange cables to one side and away from the operator.3. Do not coil or drape cables around your body.4. Keep welding power source and cables as far away from

operator as practical.5. Connect work clamp to workpiece as close to the weld as

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

OM-499 Page 5Revenez la table des matires

SECTION 2 CONSIGNES DE SCURIT LIRE AVANTUTILISATION

rom_fre 8/03

Avertissement: Protgez vous et les autres des blessures lisez et suivez ces prcautions.

2-1. Signification des symbolesSignifie Mise en garde ! Soyez vigilant ! Cette procdureprsente des risques de danger ! Ceux-ci sont identifis pardes symboles adjacents aux directives.

Identifie un message de scurit particulier.

Signifie NOTA ; nest pas relatif la scurit.

Ce groupe de symboles si-gnifie Mise en garde !Soyez vigilant ! Il y a desrisques de danger relis

aux CHOCS LECTRIQUES, aux PICES EN MOUVEMENT et auxPICES CHAUDES. Reportez-vous aux symboles et aux directives ci-des-sous afin de connatre les mesures prendre pour viter tout danger.

2-2. Dangers relatifs au soudage larc Les symboles prsents ci-aprs sont utiliss tout au long du

prsent manuel pour attirer votre attention et identifier les ris-ques de danger. Lorsque vous voyez un symbole, soyezvigilant et suivez les directives mentionnes afin dviter toutdanger. Les consignes de scurit prsentes ci-aprs ne fontque rsumer linformation contenue dans les normes de scu-rit numres la section 2-6 . Veuillez lire et respecter toutesces normes de scurit.

Linstallation, lutilisation, lentretien et les rparations nedoivent tre confis qu des personnes qualifies.

Au cours de lutilisation, tenir toute personne lcart et plusparticulirement les enfants.

UN CHOC LECTRIQUE peut tuer.Un simple contact avec des pices lectriques peutprovoquer une lectrocution ou des blessures graves.Llectrode et le circuit de soudage sont sous tension dsque lappareil est sur ON. Le circuit dentre et les circuitsinternes de lappareil sont galement sous tension ce

moment-l. En soudage semi-automatique ou automatique, le fil, le dvidoir, lelogement des galets dentranement et les pices mtalliques en contact avecle fil de soudage sont sous tension. Des matriels mal installs ou mal mis laterre prsentent un danger.

Ne jamais toucher les pices lectriques sous tension. Porter des gants et des vtements de protection secs ne comportant pas

de trous. Sisoler de la pice et de la terre au moyen de tapis ou dautres moyens iso-

lants suffisamment grands pour empcher le contact physique ventuelavec la pice ou la terre.

Ne pas se servir de source lectrique courant lectrique dans les zoneshumides, dans les endroits confins ou l o on risque de tomber.

Se servir dune source lectrique courant lectrique UNIQUEMENT si leprocd de soudage le demande.

Si lutilisation dune source lectrique courant lectrique savre nces-saire, se servir de la fonction de tlcommande si lappareil en est quip.

Des prcautions de scurit supplmentaires sont requises dans des envi-ronnements risque comme: les endroits humides ou lorsque lon portedes vtements mouills; sur des structures mtalliques au sol, grillages etchafaudages; dans des positions assises, genoux et allonges; ouquand il y a un risque important de contact accidentel avec la pice ou lesol. Dans ces cas utiliser les appareils suivants dans lordre de prfrence:1) un poste souder DC semiautomatique de type CV (MIG/MAG), 2) unposte souder manuel (lectrode enrobe) DC, 3) un poste souder ma-nuel AC avec tension vide rduite. Dans la plupart des cas, un postecourant continu de type CV est recommand. Et, ne pas travailler seul!

Couper lalimentation ou arrter le moteur avant de procder linstallation, la rparation ou lentretien de lappareil. Dverrouiller lalimentationselon la norme OSHA 29 CFR 1910.147 (voir normes de scurit).

Installer et mettre la terre correctement cet appareil conformment sonmanuel dutilisation et aux codes nationaux, provinciaux et municipaux.

Toujours vrifier la terre du cordon dalimentation Vrifier et sassurer quele fil de terre du cordon dalimentation est bien raccord la borne de terredu sectionneur ou que la fiche du cordon est raccorde une prisecorrectement mise la terre.

En effectuant les raccordements dentre fixer dabord le conducteur demise la terre appropri et contre-vrifier les connexions.

Vrifier frquemment le cordon dalimentation pour voir sil nest pas en-dommag ou dnud remplacer le cordon immdiatement sil estendommag un cble dnud peut provoquer une lectrocution.

Mettre lappareil hors tension quand on ne lutilise pas. Ne pas utiliser des cbles uss, endommags, de grosseur insuffisante ou

mal pisss. Ne pas enrouler les cbles autour du corps. Si la pice soude doit tre mise la terre, le faire directement avec un

cble distinct ne pas utiliser le connecteur de pice ou le cble de retour. Ne pas toucher llectrode quand on est en contact avec la pice, la terre ou

une lectrode provenant dune autre machine. Nutiliser quun matriel en bon tat. Rparer ou remplacer sur-le-champ

les pices endommages. Entretenir lappareil conformment cemanuel.

Porter un harnais de scurit quand on travaille en hauteur. Maintenir solidement en place tous les panneaux et capots. Fixer le cble de retour de faon obtenir un bon contact mtal-mtal avec

la pice souder ou la table de travail, le plus prs possible de la soudure. Isoler la pince de masse quand pas mis la pice pour viter le contact

avec tout objet mtallique.Une tension DC importante subsiste lintrieurdes onduleurs aprs avoir coup lalimentation. Couper lalimentation du poste et dcharger les condensateurs dentre

comme indiqu dans la Section Maintenance avant de toucher des compo-sants.

LES FUMES ET LES GAZ peuventtre dangereux.Le soudage gnre des fumes et des gaz. Leur inhalationpeut tre dangereux pour votre sant.

Eloigner votre tte des fumes. Ne pas respirer les fumes. linterieur, ventiler la zone et/ou utiliser un chappement au niveau de

larc pour lvacuation des fumes et des gaz de soudage. Si la ventilation est insuffisante, utiliser un respirateur alimentation dair

homologu. Lire les spcifications de scurit des matriaux (MSDSs) et les instruc-

tions du fabricant concernant les mtaux, les consommables, lesrevtements, les nettoyants et les dgraisseurs.

Travailler dans un espace ferm seulement sil est bien ventil ou en por-tant un respirateur alimentation dair. Demander toujours un surveillantdment form de se tenir proximit. Des fumes et des gaz de soudagepeuvent dplacer lair et abaisser le niveau doxygne provoquant desblessures ou des accidents mortels. Sassurer que lair de respiration neprsente aucun danger.

Ne pas souder dans des endroits situs proximit doprations de d-graissage, de nettoyage ou de pulvrisation. La chaleur et les rayons delarc peuvent ragir en prsence de vapeurs et former des gaz hautementtoxiques et irritants.

Ne pas souder des mtaux munis dun revtement, tels que lacier galvani-s, plaqu en plomb ou au cadmium moins que le revtement nait tenlev dans la zone de soudure, que lendroit soit bien ventil, et si nces-saire, en portant un respirateur alimentation dair. Les revtements ettous les mtaux renfermant ces lments peuvent dgager des fumestoxiques en cas de soudage.

OM-499 Page 6 Revenez la table des matires

LES ACCUMULATIONS DE GAZ ris-quent de provoquer des blessures oumme la mort. Fermer lalimentation du gaz protecteur en cas de

non utilisation. Veiller toujours bien arer les espaces confins ou se servir dun respi-

rateur dadduction dair homologu.

Le rayonnement de larc du procd de soudage gnredes rayons visibles et invisibles intenses (ultraviolets et

infrarouges) susceptibles de provoquer des brlures dans les yeux et sur lapeau. Des tincelles sont projetes pendant le soudage.

LES RAYONS DE LARC peuvent pro-voquer des brlures dans les yeux etsur la peau.

Porter un casque de soudage muni dun cran de filtre appropri pour pro-tger votre visage et vos yeux pendant le soudage ou pour regarder (voirANSI Z49.1 et Z87.1 numr dans les normes de scurit).

Porter des protections approuvs pour les oreilles si le niveau sondre esttrop lev.

Utiliser des crans ou des barrires pour protger des tiers de lclair et delblouissement; demander aux autres personnes de ne pas regarder larc.

Porter des vtements de protection constitu dans une matire durable, r-sistant au feu (laine ou cuir) et une protection des pieds.

Le soudage effectu sur des conteneurs ferms tels quedes rservoirs, tambours ou des conduites peut provoquerleur clatement. Des tincelles peuvent tre projetes de

larc de soudure. La projection dtincelles, des pices chaudes et desquipements chauds peut provoquer des incendies et des brlures. Le contactaccidentel de llectrode avec des objets mtalliques peut provoquer destincelles, une explosion, un surchauffement ou un incendie. Avant decommencer le soudage, vrifier et sassurer que lendroit ne prsente pas dedanger.

LE SOUDAGE peut provoquer un in-cendie ou une explosion.

Se protger et dautres personnes de la projection dtincelles et de mtalchaud.

Ne pas souder dans un endroit l o des tincelles peuvent tomber sur dessubstances inflammables.

Dplacer toutes les substances inflammables une distance de 10,7 m delarc de soudage. En cas dimpossibilit les recouvrir soigneusement avecdes protections homologus.

Des tincelles et des matriaux chauds du soudage peuvent facilementpasser dans dautres zones en traversant de petites fissures et desouvertures.

Surveiller tout dclenchement dincendie et tenir un extincteur proximit. Le soudage effectu sur un plafond, plancher, paroi ou sparation peut d-

clencher un incendie de lautre ct. Ne pas effectuer le soudage sur des conteneurs ferms tels que des rser-

voirs, tambours, ou conduites, moins quils naient t prparscorrectement conformment AWS F4.1 (voir les normes de scurit).

Brancher le cble sur la pice le plus prs possible de la zone de soudagepour viter le transport du courant sur une longue distance par des che-mins inconnus ventuels en provoquant des risques dlectrocution etdincendie.

Ne pas utiliser le poste de soudage pour dgeler des conduites geles. En cas de non utilisation, enlever la baguette dlectrode du porte-lectro-

de ou couper le fil la pointe de contact. Porter des vtements de protection dpourvus dhuile tels que des gants

en cuir, une chemise en matriau lourd, des pantalons sans revers, deschaussures hautes et un couvre chef.

Avant de souder, retirer toute substance combustible de vos poches tellesquun allumeur au butane ou des allumettes.

Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et NFPA 51Bpour les travaux chaud et avoir de la surveillance et un extincteur proxi-mit.

DES PARTICULES VOLANTESpeuvent blesser les yeux. Le soudage, lcaillement, le passage de la pice

la brosse en fil de fer, et le meulage gnrentdes tincelles et des particules mtalliques vo-

lantes. Pendant la priode de refroidissement des soudures, elles ris-quent de projeter du laitier. Porter des lunettes de scurit avec crans latraux ou un cran facial.

DES PICES CHAUDES peuventprovoquer des brlures graves. Prvoir une priode de refroidissement avant deffec-

tuer des travaux dentretien. Porter des gants et des vtements de protection pour

travailler sur un moteur chaud. Ne pas toucher mains nues les parties chaudes du moteur ni les pices

rcemment soudes.

LE BRUIT peut affecter loue.

Le bruit des processus et des quipements peut affecterloue.

Porter des protections approuvs pour les oreilles sile niveau sondre est trop lev.

LES CHAMPS MAGNTIQUES peuventaffecter les stimulateurs cardiaques.

Porteurs de stimulateur cardiaque, restez distance. Les porteurs dun stimulateur cardiaque doivent

dabord consulter leur mdecin avant de sapprocherdes oprations de soudage larc, de gougeage oude soudage par points.

Si des BOUTEILLES sont endomma-ges, elles pourront exploser.Des bouteilles de gaz protecteur contiennent du gaz soushaute pression. Si une bouteille est endommage, elle peutexploser. Du fait que les bouteilles de gaz font normale-ment partie du procd de soudage, les manipuler avecprcaution.

Protger les bouteilles de gaz comprim dune chaleur excessive, deschocs mcaniques, du laitier, des flammes ouvertes, des tincelles et desarcs.

Placer les bouteilles debout en les fixant dans un support stationnaire oudans un porte-bouteilles pour les empcher de tomber ou de se renverser.

Tenir les bouteilles loignes des circuits de soudage ou autres circuitslectriques.

Ne jamais placer une torche de soudage sur une bouteille gaz. Une lectrode de soudage ne doit jamais entrer en contact avec une bou-

teille. Ne jamais souder une bouteille pressurise risque dexplosion. Utiliser seulement des bouteilles de gaz protecteur, rgulateurs, tuyaux et

raccords convenables pour cette application spcifique; les maintenir ainsique les lments associs en bon tat.

Ne pas tenir la tte en face de la sortie en ouvrant la soupape de la bouteille. Maintenir le chapeau de protection sur la soupape, sauf en cas dutilisation

ou de branchement de la bouteille. Lire et suivre les instructions concernant les bouteilles de gaz comprim,

les quipements associs et les publication P-1 CGA numres dans lesnormes de scurit.

2-3. Dangers existant en relation avec le moteur

LES ACCUMULATIONS DE GAZ ris-quent de provoquer des blessures oumme la mort. Fermer lalimentation du gaz protecteur en cas de

non utilisation. Veiller toujours bien arer les espaces confins ou se servir dun respi-

rateur dadduction dair homologu.

LACIDE DE LA BATTERIE peut pro-voquer des brlures dans les YEUX etsur la PEAU. Ne pas renverser la batterie. Remplacer une batterie endommage. Rincer immdiatement les yeux et la peau leau.

OM-499 Page 7Revenez la table des matires

LEXPLOSION DE LA BATTERIE peutRENDRE AVEUGLE. Toujours porter une protection faciale, des gants en

caoutchouc et vtements de protection lors dune in-tervention sur la batterie.

Arrter le moteur avant de dbrancher ou de brancher les cbles debatterie.

Eviter de provoquer des tincelles avec les outils en travaillant sur labatterie.

Ne pas utiliser le poste de soudage pour charger les batteries ou des vhi-cules de dmarrage rapide.

Observer la polarit correcte (+ et ) sur les batteries. Dbrancher le cble ngatif () en premier lieu. Le rebrancher en dernier

lieu.

LE CARBURANT MOTEUR peut pro-voquer un incendie ou une explosion. Arrter le moteur avant de vrifier le niveau de carbu-

rant ou de faire le plein. Ne pas faire le plein en fumant ou proche dune sour-

ce dtincelles ou dune flamme nue. Ne pas faire le plein de carburant ras bord; prvoir de lespace pour son

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

rant renvers avant de faire dmarrer le moteur. Jeter les chiffons dans un rcipient ignifuge.

DES ORGANES MOBILES peuventprovoquer des blessures. Ne pas approcher les mains des ventilateurs, cour-

roies et autres pices en mouvement. Maintenir ferms et fixement en place les portes,

panneaux, recouvrements et dispositifs deprotection.

Arrter le moteur avant dinstaller ou brancher lappareil. Demander seulement un personnel qualifi denlever les dispositifs de

scurit ou les recouvrements pour effectuer, sil y a lieu, des travaux den-tretien et de dpannage.

Pour empcher tout dmarrage accidentel pendant les travaux dentretien,dbrancher le cble ngatif () de batterie de la borne.

Ne pas approcher les mains, cheveux, vtements lches et outils des orga-nes mobiles.

Remettre en place les panneaux ou les dipositifs de protection et fermer lesportes la fin des travaux dentretien et avant de faire dmarrer le moteur.

Avant dintervenir, dposer les bougies ou injecteurs pour viter la mise enroute accidentelle du moteur.

Bloquer le volant moteur pour viter sa rotation lors dune intervention sur legnrateur.

LA VAPEUR ET LE LIQUIDE DEREFROIDISSEMENT CHAUD peuventprovoquer des brlures. Il est prfrable de vrifier le liquide de

refroidissement une fois le moteur refroidi pour viterde se brler.

Toujours vrifier le niveau de liquide de refroidissement dans le vase dex-pansion (si prsent), et non dans le radiateur (sauf si prcis autrementdans la section maintenance du manuel du moteur).

Si le moteur est chaud et que le liquide doit tre vrifi, oprer comme sui-vant :

Mettre des lunettes de scurit et des gants, placer un torchon sur le bou-chon du radiateur.

Dvisser le bouchon lgrement et laisser la vapeur schapper avantdenlever le bouchon.

LA CHALEUR DU MOTEUR peut pro-voquer un incendie. Ne pas placer lappareil sur, au-dessus ou proximit

de surfaces inflammables. Tenir distance les produits inflammables de

lchappement.

LES TINCELLES LCHAPPEMENTpeuvent provoquer un incendie. Empcher les tincelles dchappement du moteur

de provoquer un incendie. Utiliser uniquement un pare-tincelles approuv

voir codes en vigueur.

2-4. Dangers lis lair comprim

RESPIRER LAIR COMPRIM peut pro-voquer des blessures graves ou causerla mort. Ne pas utiliser lair comprim pour respirer. Utiliser lair comprim seulement pour le coupa-

ge, gougeage et les outils pneumatiques.

LAIR COMPRIM peut provoquerdes blessures. Porter des lunettes de scurit approuves. Ne pas diriger le jet dair vers dautres ou soi

mme.

LAIR COMPRIME EMMAGASINE ET DESTUYAUX SOUS PRESSION peuvent provo-quer des blessures. Relcher la pression dair de loutillage ou du sys-

tme avant deffectuer la maintenance, avant dechanger ou de rajouter des lments ou avantdouvrir la purge ou le bouchon de remplissagedhuile.

Le METAL CHAUD lors du coupage etgougeage plasma peut provoquer un in-cendie ou une explosion. Ne pas couper ou gouger proximit de produits

inflammables. Surveillez et garder un extincteur proximit.

DES PIECES CHAUDES peuvent provo-quer des brlures et blessures.

Ne pas toucher le compresseur ou dautres l-ments du circuit air comprim chauds.

Laisser lensemble se refroidir avant de toucherou deffectuer la maintenance.

LIRE LES INSTRUCTIONS. Lisez le manuel dinstructions avant lutilisation

ou la maintenance de lappareil. Arrter le moteur et relcher la pression avant

deffectuer la maintenance.

2-5. Dangers supplmentaires en relation avec linstallation, le fonctionnement et lamaintenance

LA CHUTE DE LAPPAREIL peutblesser. Utiliser lanneau de levage uniquement pour soulever

lappareil lui-mme ; sans chariot, de bouteilles degaz, remorque, ou autres accessoires.

Utiliser un quipement de levage de capacit suffisante pour leverlappareil.

En utilisant des fourches de levage pour dplacer lunit, sassurerque les fourches sont suffisamment longues pour dpasser du ctoppos de lappareil.

OM-499 Page 8 Revenez la table des matires

LE SURCHAUFFEMENT peut endom-mager le moteur lectrique. Arrter ou dconnecter lquipement avant de d-

marrer ou darrter le moteur. Ne pas laisser tourner le moteur trop lentement sous

risque dendommager le moteur lectrique causedune tension et dune frquence trop faibles.

Ne pas brancher de moteur de 50 ou de 60 Hz la prise de 100 Hz, sil y alieu.

LES TINCELLES VOLANTES ris-quent de provoquer des blessures. Porter un cran facial pour protger le visage et les

yeux.

Affuterr llectrode au tungstne uniquement la meuleuse dote de pro-tecteurs. Cette manoeuvre est excuter dans un endroit sr lorsquelon porte lquipement homologu de protection du visage, des mains etdu corps.

Les tincelles risquent de causer un incendie loigner toute substanceinflammable.

LEMPLOI EXCESSIF peutSURCHAUFFER LQUIPEMENT. Laisser lquipement refroidir ; respecter le facteur de

marche nominal. Rduire le courant ou le facteur de marche avant de

poursuivre le soudage. Ne pas obstruer les passages dair du poste.

LES CHARGES LECTROSTATI-QUES peuvent endommager lescircuits imprims. tablir la connexion avec la barrette de terre avant de

manipuler des cartes ou des pices. Utiliser des pochettes et des botes antistatiques

pour stocker, dplacer ou expdier des cartes decircuits imprimes.

UNE REMORQUE QUI BASCULE peutentraner des blessures. Utiliser les supports de la remorque ou des blocs

pour soutenir le poids. Installer convenablement le poste sur la remorque

comme indiqu dans le manuel sy rapportant.

LIRE LES INSTRUCTIONS. Utiliser seulement les pices de rechange dorigine. Effectuer la maintenance du moteur et du compres-

seur (si applicable) suivant ce manuel et le manuel dumoteur/compresseur (si applicable).

LE RAYONNEMENT HAUTE FR-QUENCE (H.F.) risque de provoquerdes interfrences. Le rayonnement haute frquence (H.F.) peut

provoquer des interfrences avec les quipementsde radionavigation et de communication, lesservices de scurit et les ordinateurs.

Demander seulement des personnes qualifies familiarises avec desquipements lectroniques de faire fonctionner linstallation.

Lutilisateur est tenu de faire corriger rapidement par un lectricien quali-fi les interfrences rsultant de linstallation.

Si le FCC signale des interfrences, arrter immdiatement lappareil. Effectuer rgulirement le contrle et lentretien de linstallation. Maintenir soigneusement ferms les portes et les panneaux des sources

de haute frquence, maintenir les clateurs une distance correcte etutiliser une terre et et un blindage pour rduire les interfrencesventuelles.

LE SOUDAGE LARC risque deprovoquer des interfrences. Lnergie lectromagntique risque de provoquer

des interfrences pour lquipement lectroniquesensible tel que les ordinateurs et lquipement com-mand par ordinateur tel que les robots.

Veiller ce que tout lquipement de la zone de soudage soit compatiblelectromagntiquement.

Pour rduire la possibilit dinterfrence, maintenir les cbles de souda-ge aussi courts que possible, les grouper, et les poser aussi bas que pos-sible (ex. par terre).

Veiller souder une distance de 100 mtres de tout quipement lec-tronique sensible.

Veiller ce que ce poste de soudage soit pos et mis la terre conform-ment ce mode demploi.

En cas dinterfrences aprs avoir pris les mesures prcdentes, il in-combe lutilisateur de prendre des mesures supplmentaires telles quele dplacement du poste, lutilisation de cbles blinds, lutilisation de fil-tres de ligne ou la pose de protecteurs dans la zone de travail.

2-6. Principales normes de scuritSafety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, delAmerican Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (tl-phone : (305) 4439353, site Web : www.aws.org).Recommended Safe Practices for the Preparation for Welding and Cuttingof Containers and Piping, norme American Welding Society AWS F4.1, delAmerican Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (tl-phone : (305) 4439353, site Web : www.aws.org).National Electrical Code, norme NFPA 70, de la National Fire Protection As-sociation, P.O. Box 9101, 1 Battery March Park, Quincy, MA 022699101(tlphone : (617) 7703000, sites Web : www.nfpa.org et www.sparky.org).Safe Handling of Compressed Gases in Cylinders, brochure CGA P1, dela Compressed Gas Association, 1735 Jefferson Davis Highway, Suite1004, Arlington, VA 222024102 (tlphone : (703) 4120900, site Web :www.cganet.com).Code for Safety in Welding and Cutting, norme CSA W117.2, de la Cana-dian Standards Association, Standards Sales, 178 boulevard Rexdale,

Rexdale (Ontario) Canada M9W 1R3 (tlphone : (800) 4636727 ou To-ronto : (416) 7474044, site Web : www.csainternational.org).Practice For Occupational And Educational Eye And Face Protection,norme ANSI Z87.1, de lAmerican National Standards Institute, 11 West42nd Street, New York, NY 100368002 (tlphone : (212) 6424900, siteWeb : www.ansi.org).Standard for Fire Prevention During Welding, Cutting, and Other Hot Work,norme NFPA 51B, de la National Fire Protection Association, P.O. Box9101, 1 Battery March Park, Quincy, MA 022699101 (tlphone : (617)7703000, site Web : www.nfpa.org et www.sparky.org).OSHA, Occupational Safety and Health Standards for General Industry,Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, andPart 1926, Subpart J, de lU.S. Government Printing Office, Superintendentof Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10 bureauxrgionaux Tlphone pour la Rgion 5, Chicago : (312) 3532220, siteWeb : www.osha.gov).

2-7. Information sur les champs lectromagntiquesDonnes sur le soudage lectrique et les effets des champs magntiquesbasse frquence sur lorganismeEn parcourant les cbles de soudage, le courant cre des champs lectro-magntiques. Les effets potentiels de tels champs restent proccupants.Cependant, aprs avoir examin plus de 500 tudes qui ont t faites pen-dant une priode de recherche de 17 ans, un comit de spcialistes duNational Research Council a conclu : Laccumulation de preuves na pasdmontr que lexposition aux champs magntiques et aux champs lectri-ques haute frquence constitue un risque pour la sant humaine .Toutefois, les tudes et lexamen des preuves se poursuivent. En attendantles conclusions finales de la recherche, il serait souhaitable de rduire lex-position aux champs lectromagntiques pendant le soudage ou lecoupage.

Afin de rduire les champs lectromagntiques en milieu de travail, respec-ter les consignes suivantes :1. Garder les cbles ensemble en les torsadant ou en les fixant avec duruban adhsif.2. Mettre tous les cbles du ct oppos loprateur.3. Ne pas senrouler les cbles autour du corps.4. Garder le poste de soudage et les cbles le plus loin possible de soi.5. Placer la pince de masse le plus prs possible de la zone de soudage.Consignes relatives aux stimulateurs cardiaques :Les personnes qui portent un stimulateur cardiaque doivent avant toutconsulter leur mdecin. Si ce dernier les dclare aptes, il leur est recom-mand de respecter les consignes ci-dessus.


SECTION 3 DEFINITIONS3-1. Symbol Definitions

Engine Choke Read OperatorsManual A Amperes V VoltsEngine Oil Fuel Battery (Engine) Engine

Positive Negative Alternating Current(AC) Output

h Hours s Seconds Time Protective Earth(Ground)Circuit Breaker Temperature

SECTION 4 SPECIFICATIONS

This unit uses either a Kohler or a Honda engine. Differences between models arenoted throughout this manual.

NOTE

4-1. Weld, Power, And Engine Specifications

WeldingMode

Weld OutputRange

RatedWeldingOutput

MaximumOpen Circuit

VoltageGenerator Power

Rating Fuel Capacity Engine

CC/DC

40 180 A(60 Hz)

40 160 A(50 Hz)

180 A, 25 V,30% Duty

Cycle130 A, 25 V,60% Duty

Cycle100 A, 25 V,100% Duty

Cycle

80(60 Hz)

70(50 Hz)

Single-Phase,6 kVA/kW (Peak)

5.5 kVA/kW(Continuous)

50/25 A,110/220 V AC, 50 Hz120/240 V AC, 60 Hz

Kohler:1.8 gal (6.9 L) Tank

Honda:1.7 gal (6.4 L) Tank

Kohler CS12STGAir-Cooled,

One-Cylinder,Four-Cycle,

12 HP (360 CC),Gasoline Engine

ORHonda GX390

Air-Cooled,One-Cylinder,Four-Cycle,

13 HP (390 CC),Gasoline Engine


4-2. Dimensions, Weights, And Operating AnglesDimensions

Height 20-3/4 in (527 mm) DWidth 22-3/4 in (577 mm)

D

Depth 31-1/4 in (793 mm)B

Do not exceed tilt angles or engine couldbe damaged or unit could tip.

A 31-1/4 in (793 mm)B be damaged or unit could tip.

Do not move or operate unit where itB 10-1/2 in (268 mm)

Do not move or operate unit where itcould tip.

C 13-45/64 in (348 mm)AD 22-3/4 in (577 mm) A

CE 1-3/4 in (44 mm) CF 19-1/2 in (495 mm)G 13/32 in (10 mm) Dia.

1515Weight

4G

15

151515

Kohler: 265 lb (120 kg) 4HolesG

1515

Honda Electric-Start Model:278 lb (126 kg)

Honda Recoil-Start Model:253 lb (114 kg) 802 096

Holes

Engine End

FE

802 524-A

4-3. Fuel Consumption (Kohler-Powered Units)

198 575

50 HZAUX

50 HZWELD

HIGH IDLE

60 HZWELD

60 HZAUX

Fuel consumption at low idle(2000 rpm): 0.2 U.S. gal/hr.


4-4. Fuel Consumption (Honda-Powered Units)

802 122

Continuous Welding

4-5. Duty Cycle

802 093

Duty cycle is the percentage of 10minutes that unit can weld at ratedload without overheating. Exceeding duty cycle can

damage unit and voidwarranty.

100% Duty Cycle at 100 Amperes CC/DC


4-6. Generator Power Curves

198 570

The generator power curves showthe ac power available in amperesat the receptacles.

A. 60 Hz Model

B. 50 Hz Model

0

25

50

75

100

125

150

175

200

225

250

0 5 10 15 20 25 30 35

LOAD AMPS

LO

AD V

OLT

S

0

25

50

75

100

125

150

175

200

225

250

0 5 10 15 20 25 30 35LOAD AMPS

LO

AD V

OLT

S


4-7. Volt-Ampere Curves

198 570

The volt-ampere curve shows theminimum and maximum voltageand amperage output capabilities ofthe welding generator. Curves of allother settings fall between thecurves shown.

A. 60 Hz Model

B. 50 Hz Model

0

10

20

30

40

50

60

70

80

0 25 50 75 100 125 150 175 200 225 250LOAD AMPS

LO

AD V

OLT

S

MIN

MIDMAX

0

10

20

30

40

50

60

70

80

0 25 50 75 100 125 150 175 200 225 250LOAD AMPS

LO

AD V

OLT

S

MIN

MIDMAX


SECTION 5 INSTALLATION5-1. Installing Welding Generator

install1 10/00* 802 524-A / Ref. 151 556 / 158 936-A / S-0854

18 in(460 mm)

18 in(460 mm)

18 in(460 mm)

18 in(460 mm)

18 in(460 mm)

OR

Movement Airflow Clearance

Location

Always securely fasten weldinggenerator onto transport vehicleor trailer and comply with all DOTand other applicable codes.

5-2. Grounding Generator To Truck Or Trailer Frame

install1 10/00* Ref. 151 556 / S-0854

Always ground generatorframe to vehicle frame to pre-vent electric shock and staticelectricity hazards.

1 Generator Base2 Metal Vehicle Frame3 Equipment Grounding

Terminal4 Grounding CableUse #10 AWG or larger insulatedcopper wire. If unit does not have GFCI re-

ceptacles, use GFCI-protected extension cord.

1

2

Electrically bond generator frame tovehicle frame by metal-to-metal con-tact.

GND/PE

34

2

OR


5-3. Grounding Generator When Supplying Building Systems

GND/PE1 2

Use ground device asstated in electrical codes.

2 3

800 576-B

1 Equipment GroundingTerminal

2 Grounding CableUse #10 AWG or larger insulatedcopper wire.3 Ground Device Ground generator to sys-

tem earth ground if supply-ing power to a premises(home, shop, farm) wiringsystem.

5-4. Engine Prestart Checks (Kohler-Powered Units)

802 511-A

Full

Full

Gasoline

1/2 in(13 mm)

Follow run-in procedure in enginemanual.

Check all fluids daily. Engine must becold and on a level surface. Unit isshipped with 10W30 engine oil.Engine stops if oil level gets too low.

This unit has a low oil level shut-down switch. However, some con-ditions may cause engine damagebefore the engine shuts down.Check oil level often and do not usethe oil level shutdown system tomonitor oil level.

1 Fuel ValveOpen valve by turning lever to verticalposition.

Close fuel valve before moving unitor carburetor may flood and makestarting difficult.

FuelAdd fresh fuel before starting engine thefirst time (see maintenance label forspecifications). Fill fuel tank up to 1/2 in.(13 mm) from top to allow room for ex-pansion. Check fuel level on a cold en-gine before use each day.OilAfter fueling, check oil with unit on levelsurface. If oil is not up to full mark on dip-stick, add oil (see maintenance label). To improve cold weather starting:

Keep battery in good condition.Store battery in warm area.

Use correct grade oil for coldweather.

Open

1

ClosedClosed


5-5. Engine Prestart Checks (Honda-Powered Units)

802 094-A

Full

Full

Gasoline

1/2 in(13 mm)

1

Check all fluids daily. Engine mustbe cold and on a level surface. Unitis shipped with 10W30 engine oil.Engine stops if oil level gets too low.

Follow run-in procedure in en-gine manual.

1 Fuel ValveOpen valve.

Close fuel valve before movingunit or carburetor may floodand make starting difficult.

FuelAdd fresh fuel before startingengine the first time (see mainte-nance label for specifications). Fillfuel tank up to 1/2 in. (13 mm) fromtop to allow room for expansion.Check fuel level on a cold enginebefore use each day.OilAfter fueling, check oil with unit onlevel surface. If oil is not up to fullmark on dipstick, add oil (see main-tenance label). To improve cold weather

starting:

Keep battery in good condition.Store battery in warm area.

Use correct grade oil for coldweather.

Open

5-6. Connecting The Battery (Electric-Start Models Only)

802 524 / Ref. S-0756-D3/8, 1/2 in

Tools Needed:

+

Connect negative ()cable last.

Turn Engine Switch to Off(electric-start models only).


5-7. Connecting To Weld Output Terminals

196 914 / 495 178

1 Positive (+) Weld OutputTerminal

2 Negative () Weld OutputTerminal

For Direct Current Electrode Posi-tive (DCEP), connect work cable toNegative () terminal and electrodeholder to Positive (+) terminal.For Direct Current Electrode nega-tive (DCEN), reverse cable con-nections.

Tools Needed:

3/4 in

1 2

5-8. Selecting Weld Cable Sizes*Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit

Not Exceeding***

100 ft (30 m) or Less 150 ft(45 m)200 ft(60 m)

250 ft(70 m)

300 ft(90 m)

350 ft(105 m)

400 ft(120 m)

Weld OutputTerminals

Stop engine beforeconnecting to weld out-put terminals.

Do not use worn, dam-aged, undersized, orpoorly spliced cables.

WeldingAmperes

10 60%DutyCycle

60 100%DutyCycle

10 100% Duty Cycle

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

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

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

250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0(2x70)2 ea. 2/0(2x70)

* This chart is a general guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), use next size largercable.**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.( ) = mm2 for metric use S-0007-E***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.


SECTION 6 OPERATING THE WELDING GENERATOR6-1. Controls (Kohler-Powered Units)

802 511-A / 802 0511 / 495 178

6

7

60 Hz

Weld and generator power output stops ifgenerator overheats or engine speed istoo low.

1 Engine Switch

Use switch to open ignition circuit, and to stopengine.

2 Throttle Control Lever

Use lever to select engine speed. Use 50 Hzor 60 Hz position for 50 or 60 Hz generatorpower. Use 60 Hz position for maximum weldoutput.

3 Choke Control Lever

Use lever to change engine air/fuel mix. Movelever to right if starting a cold engine. Move le-ver to left if starting a warm engine.

To Start (Electric): open fuel valve (see Sec-tion 5-4), move throttle lever to Idle, set choke,and turn engine switch to Start position. Openchoke as engine warms. If engine does notcrank, use recoil starting procedure followingto start engine.

If engine does not start, let enginecome to a complete stop before at-tempting restart.

4 Starter Handle

To Start (Recoil): open fuel valve (see Sec-tion 5-4), move throttle lever to Idle, set choke,and pull starter handle. Open choke as enginewarms.

To Stop: turn engine switch to Off.

Always close fuel valve after stoppingunit. Moving unit with fuel valve open maycause carburetor flooding and makestarting difficult.

5 Engine Hour Meter6 Welding Range LabelUse label to determine correct weld amper-age based on electrode size, type, and mate-rial thickness.7 Current ControlUse control to select weld amperage. Controlmay be adjusted while welding.To Set Current Control: Use label to deter-mine correct size electrode for material thick-ness. Select electrode type and set currentcontrol to corresponding amperage range.Adjust control to obtain desired weldperformance.EXAMPLE:Material Thickness: 1/8 to 1/4 inElectrode Diameter: 1/8Electrode Type: E-6013Current Control Setting: 90 120 A

1

3

5

2

4

50 Hz


6-2. Controls (Honda-Powered Units) (See Section 6-3)

802 094-A / 802 095 / 495 187

Recoil-Start

Electric-Start

60 Hz50 Hz

1

3

6

2

1

4

5

7


6-3. Description Of Controls (Honda-Powered Units) (See Section 6-2)

Weld and generator power output stops ifgenerator overheats or engine speed istoo low.

1 Engine SwitchOn models with recoil-start, use switch toopen ignition circuit, and to stop engine.On models with electric-start, use switch toopen ignition circuit, and to start and stop en-gine.2 Throttle Control LeverUse lever to select engine speed. Use 50 Hzor 60 Hz position for generator power. Use 60Hz position for maximum weld output.3 Choke Control LeverUse lever to change engine air/fuel mix. Movelever to left if starting a cold engine. Move le-ver to right if starting a warm engine.4 Starter Handle (Recoil-Start Models

Only)

To Start (Recoil): open fuel valve, turn engineswitch to On, move throttle lever to Idle, setchoke, and pull starter handle. Open choke asengine warms.To Start (Electric): open fuel valve, movethrottle lever to Idle, set choke, and turn en-gine switch to Start position. Open choke asengine warms. If engine does not start, let engine

come to a complete stop before at-tempting restart.

To Stop: turn engine switch to Off.

Always close fuel valve after stoppingunit. Moving unit with fuel valve open maycause carburetor flooding and makestarting difficult.

5 Engine Hour Meter6 Welding Range Label

Use label to determine correct weld amper-age based on electrode size, type, and mate-rial thickness.7 Current ControlUse control to select weld amperage. Controlmay be adjusted while welding.To Set Current Control: Use label to deter-mine correct size electrode for material thick-ness. Select electrode type and set currentcontrol to corresponding amperage range onnameplate. Adjust control within selectedrange to obtain desired weld performance.EXAMPLE:Material Thickness: 1/8 to 1/4 inElectrode Diameter: 1/8Electrode Type: E-6013Current Control Setting: 90 120 A

Notes


SECTION 7 OPERATING AUXILIARY EQUIPMENT

The welding generator provides power while welding and with the Current controlin any position. However, under these conditions equipment connected to thewelding generator may be subject to larger than normal voltage fluctuations. It isrecommended that only lamps be powered under these conditions.

NOTE

7-1. Generator Power Panel 495 218 (USA)

495 218

1 2 34 5

If unit does not have GFCI recep-tacles, use GFCI-protected exten-sion cord.

Power is still present at the 240 voltreceptacle when only one circuitbreaker trips.

Unplug power cord before attempt-ing to service accessories or tools.

Generator power decreases as weldcurrent increases.

Set Amperage control at max. for fullgenerator power.

Place throttle lever in Run position (farright) for generator power.

1 120 V AC Twistlock Receptacle RC1

RC1 supplies 60 Hz single-phase power atweld/power speed. Maximum output is 3.5kVA/kW.2 120 V 20 A AC Duplex Receptacle

RC23 120 V 20 A AC Duplex Receptacle

RC3RC2 and RC3 supply 60 Hz single-phasepower at weld/power speed. Maximumoutput from RC2 or RC3 is 2.4 kVA/kW. Each receptacle of the duplex can pro-

vide 15A/1800W. Do not parallel the two 120V duplex

receptacles.4 Circuit Breaker CB1CB1 protects RC1 from overload. If CB1opens, RC1 does not work.

5 Circuit Breakers CB2 And CB3CB2 protects RC2 and CB3 protects RC3from overload. If a circuit breaker opens,the receptacle does not work.

Press button to reset circuit breaker. Ifbreaker continues to open, contactFactory Authorized Service Agent.

Combined output of all receptacles limitedto 6 kVA/kW rating of the generator (SeeSection 11 Generator Power Guide-lines).EXAMPLE: If 10 A is drawn from each 120volt duplex receptacle, only 9 A is availablefrom the 120 V twistlock receptacle.

2 x (120 V x 10 A) + (240 V x 9 A) = 3.5 kVA/KW.


7-2. Optional Generator Power Panels

Ref. ST-802 124 / H-495 290 / H-495 283 / 495 277

Generator Power Panel 495 315(USA)

Generator Power Panel 495 278(CanadaCSA)

Generator Power Panel 495 253(South Africa)

Generator Power Panel 495 289(Australia)

If unit does not have GFCI recep-tacles, use GFCI-protected exten-sion cord.

Power may still be present at a re-ceptacle when a circuit breakertrips.

Unplug power cord before attempt-ing to service accessories or tools.

Generator power decreases as weldcurrent increases.

Set Amperage control at max. for fullgenerator power.

Place throttle lever in Run position (farright) for generator power.

Circuit breakers protect the generator fromoverload.

Press button to reset circuit breaker. Ifbreaker continues to open, contactFactory Authorized Service Agent.

Generator Power Panel 495 219(USA)

Generator Power Panel 495 288(South America)

Generator Power Panel 495 290(Europe)

Generator Power Panel 495 283(S.E. Asia)


7-3. Generator Power Panel Ratings

Unless otherwise stated, the rating of duplex outlets is the combined load of allreceptacles.

NOTE

Total power from generator NOT to exceed 5500 Watts (60 Hz) or 5000 Watts (50 Hz)

Receptacle ProtectedByPanel

495 218(USA)

Panel495 315(USA)

Panel 495 219(USA)

Panel 495 278(Canada-

CSA)

Panel 495 253

(S. Africa)

Panel 495 288(South

America)

Panel 495 289

(Australia)Panel

495 290(Europe)

Panel 495 283

(S.E. Asia)

60 Hz 60 Hz 60 Hz 60 Hz 50 Hz 50 Hz 50 Hz 50 Hz 50 Hz

240 VTwist Lock CB1,2

25A/5500W

SeeNote 2

25A/5500W

SeeNote 2

240 VDuplex CB1,2

15A/3600W

SeeNote 2

15A/3600W

240 VDuplex CB3,4

15A/3600W

230 VSingle CB1

15A/3600W

15A/3600W

15A/3600W

230 VSingle CB2

15A/3600W

15A/3600W

15A/3600W

230 VSingle CB1,2

15A/3600W

230 VSingle CB3,4

15A/3600W

120 VTwist Lock CB1

30A/3500W

120 VDuplex

CB1,3/CB2,4

30A/3600W

SeeNote 1

120 VDuplex CB2

20A/2400W

120 VDuplex CB3

20A/2400W

20A/2400W

SeeNote 3

20A/2400W

SeeNote 3

120 VDuplex CB4

20A/2400W

SeeNote 3

20A/2400W

SeeNote 3

TotalPower NOTto exceed

5500W 5500W 5500W 5500W 5000W 5000W 5000W 5000W 5000W

For example, for the 495 218 Generator Power Panel,

120V, 3000W heater 3000W120V, 10A chain saw 1200W120V, 500W halogen lamp 500W

Total 4700W This loading is OK.

120V, 3000W heater 3000W120V, 10A chain saw 1200W120V, 5A router 600W120V, 1000W halogen lamp 1000W

Total 5800W This loading is not OK.It exceeds 5500W.

Notes: 1. Each receptacle of the duplex can provide 15A/1800W. Do not parallel the two 120V duplex receptacles.2. Do not parallel the two 120V circuits.3. Do not parallel the two duplex outlets.

Calculating total power provided by generator.(See Section 11 Generator Power Guidelines)Each receptacle can provide the watts or amps as shownabove. However, the total power can not exceed 5500W.

The rating plate on electrical apparatus will contain the wattsconsumed or the rated input amps. Watts may be calculated bymultiplying the rated voltage by the rated input amps.

watts = volts x amps


7-4. Wiring Instructions For Optional 120/240 Volt Twistlock Plug (NEMA L14-30P)

plug3-11/99 802 527

1 Plug Wired For 120/240 V,3-Wire Load

When wired for 120 V loads, each du-plex receptacle shares a load withone half of the 240 V receptacle.2 Neutral (Silver) Terminal3 Load 1 (Brass) Terminal4 Load 2 (Brass) Terminal5 Ground (Green) Terminal6 Cord GripStrip cord jacket back enough to sep-arate conductors.Strip conductors enough to makegood contact with plug terminals.Make plug connections and reinstallouter shell and cord grip.Tighten assembly screws onto shell.Do not overtighten.

1

3

2

4Tools Needed:

56

120 V

240 V120V

SECTION 8 MAINTENANCE

Follow the storage procedure in the engine owners manual if the unit will not beused for an extended period.

NOTE

8-1. Maintenance Label

Ref. S-175 679-A

ENGINE MAINTENANCE

8 h

1.1 l (1.2 US qt,1.94 lmp qt)

Unleaded86 + Octane6.5 l (1.7 US Gal, 11.4 lmp pt)

50 h

100 h10

W-30

F

+32

+59

+86+30

+20

+10

0

+40C

+104

-10

-10-15-20

200 h

0.7 0.8 mm(0.028 0.031 in)

SG-SF/CC-CD


8-2. Routine Maintenance

Recycleenginefluids.

Stop engine before maintaining.

See Engine Manual and Maintenance Label. Ser-vice more often if used in severe conditions.

* To be done by Factory Authorized Service Agent.

8 h 20 h

Wipe up spills.Check fluidlevels. SeeSection 5-4or 5-5

Check and cleanspark arrestor screen.See engine manual.

50 h

Clean andtighten weldterminals.

Service air cleanerelement. See enginemanual.

100 h

Change oil. Seeengine manual andmaintenance label.

Checksparkplugs.

Clean and tighten batteryconnections (Electric-Start models only).

Clean Fuelsediment cup.

200 h

Replaceunreadablelabels.

Clean fueltank andstrainer.

300 h

Check valveclearance.*

500 h

Repair orreplace crackedcables.

Service welding generatorbrushes and slip rings. Servicemore often in dirty conditions.*

1000 hBlow out orvacuum inside.During heavyservice, cleanmonthly.

OR


8-3. Overload Protection (Honda-Powered Units)1 Ignition Circuit Breaker

(Electric-Start Models Only)The circuit breaker protects the en-gine battery charging circuit. Ashort circuit or a battery connectedin reverse polarity will trip the circuitbreaker.Press button to reset breaker.

If a switch or breaker opens, itusually indicates a more seri-ous problem exists. Contact aFactory Authorized ServiceAgent.1

Ref. 802 094-A

3 12

8-4. Adjusting Engine Speed (Kohler-Powered Units)

802 511-A / Kohler Dwg.

After tuning engine, check enginespeeds. See table for proper noload speeds. If necessary, adjustspeeds as follows:Start engine and run until warm.Weld/Power SpeedAdjustment1 Throttle Control Lever2 Adjustment ScrewMove lever to Run (far right) posi-tion. To increase speed, turn screwout (counterclockwise) while lightlypushing lever to the right. To de-crease speed, turn screw in (clock-wise).Idle Speed Adjustment3 Adjustment ScrewMove lever to idle (far left) position.To increase idle speed, turn screwin (clockwise). To decrease idlespeed, turn screw out (counter-clockwise). Stop engine. Close fuel

valve.

Tools Needed:

2000 150 rpm

3720 50 rpm (60 Hz)3250 50 rpm (50 Hz)

Top View

Top View


8-5. Adjusting Engine Speed (Honda-Powered Units)

802 097-A

After tuning engine, check enginespeeds. See table for proper noload speeds. If necessary, adjustspeeds as follows:Start engine and run until warm.Weld/Power SpeedAdjustment1 Throttle Control Lever2 Adjustment ScrewMove lever to Run (60 Hz) position.Turn screw and move lever until en-gine runs at weld/power speed.Idle Speed Adjustment3 Pilot Screw4 Throttle Stop ScrewMove lever to idle position. Turn pi-lot screw until engine runs at high-est idle speed. Turn stop screw untilengine runs at rated idle speed(normally about 2-1/4 turns out.) Stop engine. Close fuel

valve.

1/4, 3/8 in

Tools Needed:

1400 150 rpm

3720 50 rpm (60 Hz)3250 50 rpm (50 Hz)

2

1

3 4


SECTION 9 TROUBLESHOOTING9-1. Troubleshooting

A. Welding

Trouble Remedy

No weld output. Check Amperage control setting.

Check weld connections.

Check engine speed, and adjust if necessary (see Section 8-4 or 8-5). Output stops if engine speed istoo low.

Be sure all equipment is disconnected from receptacles when starting unit.

Have Factory Authorized Service Agent check brushes, slip rings, capacitor C1, integrated rectifiersSR1 and SR2, resistor R3 (Kohler only), and circuit board PC1.

Low weld output. Check Amperage control and throttle lever settings.

Check engine speed, and adjust if necessary (see Section 8-4 or 8-5).Service air cleaner according to engine manual.

Check weld cable size and length.


High weld output. Check Amperage control setting.

Check engine speed, and adjust if necessary (see Section 8-4 or 8-5).Have Factory Authorized Service Agent check brushes, slip rings, capacitor C1, integrated rectifiersSR1 and SR2, suppressor VR1/R2, resistor R3 (Kohler only), and circuit board PC1.

Erratic weld output. Check Amperage control setting.

Tighten and clean connections to electrode and workpiece.

Use dry, properly-stored electrodes for Stick welding.

Remove excessive coils from weld cables.

Clean and tighten connections both inside and outside welding generator.

Check engine speed, and adjust if necessary (see Section 8-4 or 8-5).Check throttle/governor linkage for smooth, non-binding operation.


B. Generator Power

Trouble Remedy

No output at generator power ac receptacles.

Reset circuit breakers (see Sections 7-1 and 7-2).

Check receptacle wiring and connections.



High power output at generator powerac receptacles.

Check engine speed, and adjust if necessary (see Section 8-4 or 8-5).

Move throttle lever to 50 Hz position for 50 Hz equipment (see Section 6-1 or 6-2).Have Factory Authorized Service Agent check capacitor C1, resistor R3 (Kohler only), and circuitboard PC1.


Trouble Remedy

Low power output at generator power acreceptacles.

Check Amperage control setting.


Move throttle lever to 60 Hz position for 60 Hz equipment (see Section 6-1 or 6-2).Erratic power output at generatorpower ac receptacles.

Check fuel level.

Check receptacle wiring and connections.

Check throttle/governor linkage for smooth, non-binding operation.

Service air cleaner according to engine manual.


Have Factory Authorized Service Agent check brushes, slip rings, resistor R3 (Kohler only), andcircuit board PC1.

C. Engine

Trouble Remedy

Engine will not crank (electric-startmodels only).

Reset ignition circuit breaker (see Section 8-3).

Check battery voltage.

Check battery connections and tighten if necessary.

Have Factory Authorized Service Agent check engine ignition circuit.

Engine will not start. Check fuel level (see Section 5-4 or 5-5).Move choke lever to correct position (see Section 6-1 or 6-2).Open fuel valve (see Section 5-4 or 5-5). Close fuel valve before moving unit or carburetor may flood andmake starting difficult.

Check battery voltage (electric-start models only).Check battery connections and tighten if necessary (electric-start models only).Check oil level (see Section 5-4 or 5-5). Engine stops if oil level is too low. Refill crankcase with properviscosity oil for operating temperature.

Have Factory Authorized Service Agent check low oil level shutdown switch.

Engine stopped during normaloperation.

Check fuel level (see Section 5-4 or 5-5).

Open fuel valve (see Section 5-4 or 5-5). Close fuel valve before moving unit or carburetor may flood andmake starting difficult.

Check oil level (see Section 5-4 or 5-5). Engine stops if oil level is too low.Have Factory Authorized Service Agent check low oil level shutdown switch.

Check unit operating angle. Low oil level shutdown switch may stop engine if unit is tilted.

Battery discharges between uses (elec-tric-start models only).

Clean battery, terminals, and posts with baking soda and water solution; rinse with clear water.

Periodically recharge battery (approximately every 3 months).Replace battery.

Check voltage regulator and connections according to engine manual.

Unstable or sluggish engine speeds. Check engine speed, and adjust if necessary (see Section 8-4 or 8-5).Check throttle/governor linkage for smooth, non-binding operation.

Tune-up engine according to engine manual.


SECTION 10 ELECTRICAL DIAGRAMS

197 857-EFigure 10-1. Circuit Diagram For Welding Generator (1 Of 2)


197 857-E

Figure 10-2. Circuit Diagram For Welding Generator (2 Of 2)


201 026-A

Figure 10-3. Wiring Diagram For Auxiliary Power Panels (1 Of 2)


201 026-A

Figure 10-4. Wiring Diagram For Auxiliary Power Panels (2 Of 2)

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