OM-4415 209 416B

January 2005

Processes
Stick (SMAW) Welding

Description

Engine Driven Welding Generator

Blue Star 185

Blue Star 185 DX

Visit our website at

www.MillerWelds.com
 From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They Working as hard as you do
− every power source from
will help you protect yourself against potential hazards on the worksite. Miller is backed by the most
We’ve made installation and operation quick hassle-free warranty in the
business.
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard. particular model are also provided.

Miller Electric manufactures a full line

of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.

Mil_Thank 7/03
 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 SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2-4. Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . . 7
2-6. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-7. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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. Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-4. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-5. Fuel Consumption Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-6. Generator Power 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 − Standard Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-5. Engine Prestart Checks − DX Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-6. Connecting The Battery (DX 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 (Standard Models) (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6-2. Description Of Controls (Standard Models) (See Section 6-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6-3. Controls (DX Models) (See Section 6-4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6-4. Description Of Controls (DX Models) (See Section 6-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SECTION 7 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7-1. Generator Power Panel Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SECTION 8 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8-2. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8-3. Adjusting Engine Speed (Honda-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8-4. Adjusting Engine Speed (Kohler−Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SECTION 9 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SECTION 10 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SECTION 11 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SECTION 12 − STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
SECTION 13 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
WARRANTY
 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
rom _nd_10/04
 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.

 Marks a special safety message.

This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
 Means “Note”; not safety related. to avoid the hazards.

1-2. Arc Welding Hazards

 The symbols shown below are used throughout this manual to  Use only well-maintained equipment. Repair or replace damaged parts at
call attention to and identify possible hazards. When you see the once. Maintain unit according to manual.
symbol, watch out, and follow the related instructions to avoid the  Wear a safety harness if working above floor level.
hazard. The safety information given below is only a summary of
 Keep all panels and covers securely in place.
the more complete safety information found in the Safety Stan-
dards listed in Section 1-7. Read and follow all Safety Standards.  Clamp work cable with good metal-to-metal contact to workpiece or work-
table as near the weld as practical.
 Only qualified persons should install, operate, maintain, and re-  Insulate work clamp when not connected to workpiece to prevent contact
pair this unit. with any metal object.
 During operation, keep everybody, especially children, away.  Do not connect more than one electrode or work cable to any single weld
output terminal.
SIGNIFICANT DC VOLTAGE exists in inverters after stop-
ELECTRIC SHOCK can kill.
ping engine.
 Stop engine on inverter and discharge input capacitors according to
Touching live electrical parts can cause fatal shocks or
instructions in Maintenance Section before touching any parts.
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 FUMES AND GASES can be hazardous.
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. Welding produces fumes and gases. Breathing these fumes
and gases can be hazardous to your health.
 Do not touch live electrical parts.
 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
 Insulate yourself from work and ground using dry insulating mats or covers fumes and gases.
big enough to prevent any physical contact with the work or ground.
 If ventilation is poor, use an approved air-supplied respirator.
 Do not use AC output in damp areas, if movement is confined, or if there is a  Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s
danger of falling. instructions for metals, consumables, coatings, cleaners, and degreasers.
 Use AC output ONLY if required for the welding process.  Work in a confined space only if it is well ventilated, or while wearing an air-
 If AC output is required, use remote output control if present on unit. supplied respirator. Always have a trained watchperson nearby. Welding
fumes and gases can displace air and lower the oxygen level causing injury
 Additional safety precautions are required when any of the following electri- or death. Be sure the breathing air is safe.
cally hazardous conditions are present: in damp locations or while wearing
 Do not weld in locations near degreasing, cleaning, or spraying operations.
wet clothing; on metal structures such as floors, gratings, or scaffolds;
The heat and rays of the arc can react with vapors to form highly toxic and
when in cramped positions such as sitting, kneeling, or lying; or when there
irritating gases.
is a high risk of unavoidable or accidental contact with the workpiece or
ground. For these conditions, use the following equipment in order present-  Do not weld on coated metals, such as galvanized, lead, or cadmium plated
ed: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual steel, unless the coating is removed from the weld area, the area is well
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most ventilated, and if necessary, while wearing an air-supplied respirator. The
situations, use of a DC, constant voltage wire welder is recommended. coatings and any metals containing these elements can give off toxic fumes
And, do not work alone! if welded.
 Disconnect input power or stop engine before installing or servicing this
equipment. Lockout/tagout input power according to OSHA 29 CFR BUILDUP OF GAS can injure or kill.
1910.147 (see Safety Standards).
 Properly install and ground this equipment according to its Owner’s Manual  Shut off shielding gas supply when not in use.
and national, state, and local codes.  Always ventilate confined spaces or use approved
air-supplied respirator.
 Always verify the supply ground — check and be sure that input power cord
ground wire is properly connected to ground terminal in disconnect box or
that cord plug is connected to a properly grounded receptacle outlet.
ARC RAYS can burn eyes and skin.
 When making input connections, attach proper grounding conductor first −
double-check connections.
Arc rays from the welding process produce intense visible
 Frequently inspect input power cord for damage or bare wiring — replace and invisible (ultraviolet and infrared) rays that can burn eyes
cord immediately if damaged — bare wiring can kill. and skin. Sparks fly off from the weld.
 Turn off all equipment when not in use.  Wear a welding helmet fitted with a proper shade of filter to protect your face
 Do not use worn, damaged, undersized, or poorly spliced cables. and eyes from arc rays and sparks when welding or watching (see ANSI
Z49.1 and Z87.1 listed in Safety Standards).
 Do not drape cables over your body.  Wear approved safety glasses with side shields under your helmet.
 If earth grounding of the workpiece is required, ground it directly with a sep-  Use protective screens or barriers to protect others from flash and glare;
arate cable. warn others not to watch the arc.
 Do not touch electrode if you are in contact with the work, ground, or anoth-  Wear protective clothing made from durable, flame-resistant material (wool
er electrode from a different machine. and leather) and foot protection.
OM-4415 Page 1
 WELDING can cause fire or explosion. HOT PARTS can cause severe burns.

Welding on closed containers, such as tanks, drums, or  Allow cooling period before maintaining.
pipes, can cause them to blow up. Sparks can fly off from the  Wear protective gloves and clothing when working on
welding arc. The flying sparks, hot workpiece, and hot a hot engine.
equipment can cause fires and burns. Accidental contact of electrode to metal  Do not touch hot engine parts or just-welded parts
objects can cause sparks, explosion, overheating, or fire. Check and be sure bare-handed.
the area is safe before doing any welding.

 Protect yourself and others from flying sparks and hot metal. NOISE can damage hearing.
 Do not weld where flying sparks can strike flammable material.
Noise from some processes or equipment can damage
 Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not hearing.
possible, tightly cover them with approved covers.
 Wear approved ear protection if noise level is high.
 Be alert that welding sparks and hot materials from welding can easily go
through small cracks and openings to adjacent areas.

 Watch for fire, and keep a fire extinguisher nearby.

MAGNETIC FIELDS can affect pacemakers.

 Be aware that welding on a ceiling, floor, bulkhead, or partition can cause  Pacemaker wearers keep away.
fire on the hidden side.  Wearers should consult their doctor before going
near arc welding, gouging, or spot welding opera-
 Do not weld on closed containers such as tanks, drums, or pipes, unless tions.
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 CYLINDERS can explode if damaged.
causing electric shock and fire hazards.

 Do not use welder to thaw frozen pipes. Shielding gas cylinders contain gas under high pressure. If
damaged, a cylinder can explode. Since gas cylinders are
 Remove stick electrode from holder or cut off welding wire at contact tip normally part of the welding process, be sure to treat them
when not in use. carefully.

 Wear oil-free protective garments such as leather gloves, heavy shirt, cuf-  Protect compressed gas cylinders from excessive heat, mechanical
fless trousers, high shoes, and a cap. shocks, slag, open flames, sparks, and arcs.
 Install cylinders in an upright position by securing to a stationary support or
 Remove any combustibles, such as a butane lighter or matches, from your cylinder rack to prevent falling or tipping.
person before doing any welding.
 Keep cylinders away from any welding or other electrical circuits.
 Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot
 Never drape a welding torch over a gas cylinder.
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-
FLYING METAL can injure eyes. signed for the specific application; maintain them and associated parts in
good condition.
 Welding, chipping, wire brushing, and grinding cause
 Turn face away from valve outlet when opening cylinder valve.
sparks and flying metal. As welds cool, they can
throw off slag.  Keep protective cap in place over valve except when cylinder is in use or
 Wear approved safety glasses with side shields even connected for use.
under your welding helmet.  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. MOVING PARTS can cause injury.

 Always wear a face shield, rubber gloves, and protec-  Keep away from fans, belts, and rotors.
tive clothing when working on a battery.  Keep all doors, panels, covers, and guards closed
 Stop engine before disconnecting or connecting bat- and securely in place.
tery cables or servicing battery.
 Stop engine before installing or connecting unit.
 Do not allow tools to cause sparks when working on a battery.
 Have only qualified people remove guards or covers for maintenance
 Do not use welder to charge batteries or jump start vehicles. and troubleshooting as necessary.
 Observe correct polarity (+ and −) on batteries.  To prevent accidental starting during servicing, disconnect negative (−)
 Disconnect negative (−) cable first and connect it last. battery cable from battery.
 Keep hands, hair, loose clothing, and tools away from moving parts.
FUEL can cause fire or explosion.  Reinstall panels or guards and close doors when servicing is finished
and before starting engine.
 Stop engine and let it cool off before checking or add-  Before working on generator, remove spark plugs or injectors to keep
ing fuel. engine from kicking back or starting.
 Do not add fuel while smoking or if unit is near any  Block flywheel so that it will not turn while working on generator compo-
sparks or open flames. nents.
 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-4415 Page 2
 STEAM AND HOT COOLANT can burn. BATTERY ACID can BURN SKIN and EYES.

 If possible, check coolant level when engine is cold to  Do not tip battery.
avoid scalding.  Replace damaged battery.
 Always check coolant level at overflow tank, if pres-  Flush eyes and skin immediately with water.
ent on unit, instead of radiator (unless told otherwise
in maintenance section or engine manual).
 If the engine is warm, checking is needed, and there is no overflow tank,
follow the next two statements. ENGINE HEAT can cause fire.
 Wear safety glasses and gloves and put a rag over radiator cap.
 Do not locate unit on, over, or near combustible
 Turn cap slightly and let pressure escape slowly before completely re- surfaces or flammables.
moving cap.
 Keep exhaust and exhaust pipes way from flam-
mables.

ENGINE EXHAUST GASES can kill. EXHAUST SPARKS can cause fire.
 Use equipment outside in open, well-ventilated ar-
 Do not let engine exhaust sparks cause fire.
eas.
 Use approved engine exhaust spark arrestor in re-
 If used in a closed area, vent engine exhaust outside
quired areas — see applicable codes.
and away from any building air intakes.

1-4. Compressed Air Hazards

BREATHING COMPRESSED AIR can HOT METAL from air arc cutting and
cause serious injury or death. gouging can cause fire or explosion.
 Do not use compressed air for breathing.  Do not cut or gouge near flammables.
 Use only for cutting, gouging, and tools.  Watch for fire; keep extinguisher nearby.

COMPRESSED AIR can cause injury. HOT PARTS can cause burns and injury.
 Wear approved safety goggles.  Do not touch hot compressor or air system parts.
 Do not direct air stream toward self or others.  Let system cool down before touching or servicing.

TRAPPED AIR PRESSURE AND WHIPPING

READ INSTRUCTIONS.
HOSES can cause injury.
 Read Owner’s Manual before using or servicing unit.
 Release air pressure from tools and system before
servicing, adding or changing attachments, or open-  Stop engine and release air pressure before
ing compressor oil drain or oil fill cap. servicing.

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

FALLING UNIT can cause injury. OVERUSE can cause OVERHEATING.

 Use lifting eye to lift unit and properly installed acces-  Allow cooling period; follow rated duty cycle.
sories only. Do not exceed maximum lift eye weight  Reduce current or reduce duty cycle before starting
rating (see Specifications). to weld again.
 Lift and support unit only with proper equipment and  Do not block or filter airflow to unit.
correct procedures.
 If using lift forks to move unit, be sure forks are long
enough to extend beyond opposite side of unit.

OVERHEATING can damage motors. STATIC (ESD) can damage PC boards.

 Turn off or unplug equipment before starting or stop-  Put on grounded wrist strap BEFORE handling
ping engine. boards or parts.
 Do not let low voltage and frequency caused by low  Use proper static-proof bags and boxes to store,
engine speed damage electric motors. move, or ship PC boards.
 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.
 Wear a face shield to protect eyes and face.
 Shape tungsten electrode only on grinder with proper  Use tongue jack or blocks to support weight.
guards in a safe location wearing proper face, hand,  Properly install welding generator onto trailer accord-
and body protection. ing to instructions supplied with trailer.
 Sparks can cause fires — keep flammables away.

OM-4415 Page 3
 READ INSTRUCTIONS. ARC WELDING can cause interference.
 Use only genuine MILLER/Hobart replacement  Electromagnetic energy can interfere with sensitive
parts. electronic equipment such as microprocessors,
 Perform engine and air compressor (if applicable) computers, and computer-driven equipment such as
maintenance and service according to this manual robots.
and the engine/air compressor (if applicable) manu-  Be sure all equipment in the welding area is electro-
als. magnetically compatible.
 To reduce possible interference, keep weld cables as short as possible,
H.F. RADIATION can cause interference. close together, and down low, such as on the floor.
 Locate welding operation 100 meters from any sensitive electronic
 High-frequency (H.F.) can interfere with radio naviga- equipment.
tion, safety services, computers, and communica-  Be sure this welding machine is installed and grounded according to this
tions equipment. manual.
 Have only qualified persons familiar with electronic  If interference still occurs, the user must take extra measures such as
equipment perform this installation. moving the welding machine, using shielded cables, using line filters, or
 The user is responsible for having a qualified electrician shielding the work area.
promptly correct any interference problem resulting from the installation.
 If notified by the FCC about interference, stop using the equipment at
once.
 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

 Welding or cutting equipment produces fumes or gases which For Gasoline Engines:
contain chemicals known to the State of California to cause  Engine exhaust contains chemicals known to the State of
birth defects and, in some cases, cancer. (California Health & California to cause cancer, birth defects, or other reproductive
Safety Code Section 25249.5 et seq.) harm.
 Battery posts, terminals and related accessories contain lead For Diesel Engines:
and lead compounds, chemicals known to the State of  Diesel engine exhaust and some of its constituents are known
California to cause cancer and birth defects or other to the State of California to cause cancer, birth defects, and
reproductive harm. Wash hands after handling. other reproductive harm.

1-7. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, levard, Rexdale, Ontario, Canada M9W 1R3 (phone: 800-463-6727 or
from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 in Toronto 416-747-4044, website: www.csa-international.org).
(phone: 305-443-9353, website: www.aws.org).
Practice For Occupational And Educational Eye And Face Protection,
Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87.1, from American National Standards Institute, 11
ting of Containers and Piping, American Welding Society Standard West 42nd Street, New York, NY 10036–8002 (phone: 212-642-4900,
AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Mi- website: www.ansi.org).
ami, FL 33126 (phone: 305-443-9353, website: www.aws.org).
National Electrical Code, NFPA Standard 70, from National Fire Protec- Standard for Fire Prevention During Welding, Cutting, and Other Hot
tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA Work, NFPA Standard 51B, from National Fire Protection Association,
02269-9101 (phone: 617-770-3000, website: www.nfpa.org and www. P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (phone:
sparky.org). 617-770-3000, website: www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, OSHA, Occupational Safety and Health Standards for General Indus-
from Compressed Gas Association, 1735 Jefferson Davis Highway, try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
Suite 1004, Arlington, VA 22202-4102 (phone: 703-412-0900, website: and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
www.cganet.com). intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
Code for Safety in Welding and Cutting, CSA Standard W117.2, from are 10 Regional Offices—phone for Region 5, Chicago, is
Canadian Standards Association, Standards Sales, 178 Rexdale Bou- 312-353-2220, website: www.osha.gov).

1-8. EMF Information

Considerations About Welding And The Effects Of Low Frequency To reduce magnetic fields in the workplace, use the following
Electric And Magnetic Fields procedures:
1. Keep cables close together by twisting or taping them.
Welding current, as it flows through welding cables, will cause electro-
magnetic fields. There has been and still is some concern about such 2. Arrange cables to one side and away from the operator.
fields. However, after examining more than 500 studies spanning 17 3. Do not coil or drape cables around your body.
years of research, a special blue ribbon committee of the National 4. Keep welding power source and cables as far away from
Research Council concluded that: “The body of evidence, in the operator as practical.
committee’s judgment, has not demonstrated that exposure to power- 5. Connect work clamp to workpiece as close to the weld as
frequency electric and magnetic fields is a human-health hazard.”
possible.
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you About Pacemakers:
may wish to minimize your exposure to electromagnetic fields when Pacemaker wearers consult your doctor first. If cleared by your doctor,
welding or cutting. then following the above procedures is recommended.

OM-4415 Page 4
 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
rom_fre 10/04

 Avertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions.

2-1. Signification des symboles

Signifie Mise en garde ! Soyez vigilant ! Cette procédure Ce groupe de symboles si-
présente des risques de danger ! Ceux-ci sont identifiés par gnifie Mise en garde !
des symboles adjacents aux directives.
Soyez vigilant ! Il y a des
risques de danger reliés
 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-
 Signifie NOTA ; n’est pas relatif à la sécurité. sous afin de connaître les mesures à prendre pour éviter tout danger.

2-2. Dangers relatifs au soudage à l’arc

 Les symboles présentés ci-après sont utilisés tout au long du  En effectuant les raccordements d’entrée fixer d’abord le conducteur de
présent manuel pour attirer votre attention et identifier les ris- mise à la terre approprié et contre-vérifier les connexions.
ques de danger. Lorsque vous voyez un symbole, soyez  Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas en-
vigilant et suivez les directives mentionnées afin d’éviter tout dommagé ou dénudé − remplacer le cordon immédiatement s’il est
danger. Les consignes de sécurité présentées ci-après ne font endommagé − un câble dénudé peut provoquer une électrocution.
que résumer l’information contenue dans les normes de sécu-  Mettre l’appareil hors tension quand on ne l’utilise pas.
rité énumérées à la section 2-6 . Veuillez lire et respecter toutes  Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou
ces normes de sécurité. mal épissés.
 Ne pas enrouler les câbles autour du corps.
 L’installation, l’utilisation, l’entretien et les réparations ne
 Si la pièce soudée doit être mise à la terre, le faire directement avec un
doivent être confiés qu’à des personnes qualifiées.
câble distinct − ne pas utiliser le connecteur de pièce ou le câble de retour.
 Au cours de l’utilisation, tenir toute personne à l’écart et plus  Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou
particulièrement les enfants. une électrode provenant d’une autre machine.
 N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-champ
les pièces endommagées. Entretenir l’appareil conformément à ce
UN CHOC ÉLECTRIQUE peut tuer. manuel.
 Porter un harnais de sécurité quand on travaille en hauteur.
Un simple contact avec des pièces électriques peut  Maintenir solidement en place tous les panneaux et capots.
provoquer une électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension dès  Fixer le câble de retour de façon à obtenir un bon contact métal-métal avec
que l’appareil est sur ON. Le circuit d’entrée et les circuits la pièce à souder ou la table de travail, le plus près possible de la soudure.
internes de l’appareil sont également sous tension à ce
moment-là. En soudage semi-automatique ou automatique, le fil, le dévidoir, le  Isoler la pince de masse quand pas mis à la pièce pour éviter le contact
logement des galets d’entraînement et les pièces métalliques en contact avec avec tout objet métallique.
le fil de soudage sont sous tension. Des matériels mal installés ou mal mis à la Une tension DC importante subsiste à l’intérieur
terre présentent un danger.
des onduleurs après avoir coupé l’alimentation.
 Ne jamais toucher les pièces électriques sous tension.  Couper l’alimentation du poste et décharger les condensateurs d’entrée
comme indiqué dans la Section Maintenance avant de toucher des compo-
 Porter des gants et des vêtements de protection secs ne comportant pas
sants.
de trous.
 S’isoler de la pièce et de la terre au moyen de tapis ou d’autres moyens iso- LES FUMÉES ET LES GAZ peuvent
lants suffisamment grands pour empêcher le contact physique éventuel être dangereux.
avec la pièce ou la terre.
 Ne pas se servir de source électrique à courant électrique dans les zones Le soudage génère des fumées et des gaz. Leur inhalation
humides, dans les endroits confinés ou là où on risque de tomber. peut être dangereux pour votre santé.
 Se servir d’une source électrique à courant électrique UNIQUEMENT si le
procédé de soudage le demande.  Eloigner votre tête des fumées. Ne pas respirer les fumées.
 Si l’utilisation d’une source électrique à courant électrique s’avère néces-  À l’intérieur, ventiler la zone et/ou utiliser un échappement au niveau de
saire, se servir de la fonction de télécommande si l’appareil en est équipé. l’arc pour l’évacuation des fumées et des gaz de soudage.
 Des précautions de sécurité supplémentaires sont requises dans des envi-  Si la ventilation est insuffisante, utiliser un respirateur à alimentation d’air
homologué.
ronnements à risque comme: les endroits humides ou lorsque l’on porte
des vêtements mouillés; sur des structures métalliques au sol, grillages et  Lire les spécifications de sécurité des matériaux (MSDSs) et les instruc-
tions du fabricant concernant les métaux, les consommables, les
échafaudages; dans des positions assises, à genoux et allongées; ou
revêtements, les nettoyants et les dégraisseurs.
quand il y a un risque important de contact accidentel avec la pièce ou le
 Travailler dans un espace fermé seulement s’il est bien ventilé ou en por-
sol. Dans ces cas utiliser les appareils suivants dans l’ordre de préférence:
tant un respirateur à alimentation d’air. Demander toujours à un surveillant
1) un poste à souder DC semi−automatique de type CV (MIG/MAG), 2) un dûment formé de se tenir à proximité. Des fumées et des gaz de soudage
poste à souder manuel (électrode enrobée) DC, 3) un poste à souder ma- peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des
nuel AC avec tension à vide réduite. Dans la plupart des cas, un poste blessures ou des accidents mortels. S’assurer que l’air de respiration ne
courant continu de type CV est recommandé. Et, ne pas travailler seul! présente aucun danger.
 Ne pas souder dans des endroits situés à proximité d’opérations de dé-
 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 graissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de
selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité). l’arc peuvent réagir en présence de vapeurs et former des gaz hautement
toxiques et irritants.
 Installer et mettre à la terre correctement cet appareil conformément à son
 Ne pas souder des métaux munis d’un revêtement, tels que l’acier galvani-
manuel d’utilisation et aux codes nationaux, provinciaux et municipaux.
sé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été
 Toujours vérifier la terre du cordon d’alimentation − Vérifier et s’assurer que enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et si néces-
le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre saire, en portant un respirateur à alimentation d’air. Les revêtements et
du sectionneur ou que la fiche du cordon est raccordée à une prise tous les métaux renfermant ces éléments peuvent dégager des fumées
correctement mise à la terre. toxiques en cas de soudage.

OM-4415 Page 5
  Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et NFPA 51B
LES ACCUMULATIONS DE GAZ ris- pour les travaux à chaud et avoir de la surveillance et un extincteur à proxi-
quent de provoquer des blessures ou mité.
même la mort.
DES PARTICULES VOLANTES
 Fermer l’alimentation du gaz protecteur en cas de peuvent blesser les yeux.
non utilisation.
 Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi-  Le soudage, l’écaillement, le passage de la pièce
rateur d’adduction d’air homologué. à la brosse en fil de fer, et le meulage génèrent
des étincelles et des particules métalliques vo-
LES RAYONS DE L’ARC peuvent pro- lantes. Pendant la période de refroidissement des soudures, elles ris-
quent de projeter du laitier.
voquer des brûlures dans les yeux et  Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.
sur la peau.
Le rayonnement de l’arc du procédé de soudage génère DES PIÈCES CHAUDES peuvent
des rayons visibles et invisibles intenses (ultraviolets et provoquer des brûlures graves.
infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la
peau. Des étincelles sont projetées pendant le soudage.  Prévoir une période de refroidissement avant d’effec-
 Porter un casque de soudage muni d’un écran de filtre approprié pour pro- tuer des travaux d’entretien.
téger votre visage et vos yeux pendant le soudage ou pour regarder (voir  Porter des gants et des vêtements de protection pour
ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité). travailler sur un moteur chaud.
 Porter des protections approuvés pour les oreilles si le niveau sonore est  Ne pas toucher à mains nues les parties chaudes du moteur ni les pièces
trop élevé. récemment soudées.
 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-
 Porter des protections approuvés pour les oreilles si
cendie ou une explosion. le niveau sonore est trop élevé.

Le soudage effectué sur des conteneurs fermés tels que LES CHAMPS MAGNÉTIQUES peuvent
des réservoirs, tambours ou des conduites peut provoquer
leur éclatement. Des étincelles peuvent être projetées de 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  Porteurs de stimulateur cardiaque, restez à distance.
accidentel de l’électrode avec des objets métalliques peut provoquer des  Les porteurs d’un stimulateur cardiaque doivent
étincelles, une explosion, un surchauffement ou un incendie. Avant de d’abord consulter leur médecin avant de s’approcher
commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de des opérations de soudage à l’arc, de gougeage ou
danger. de soudage par points.
 Se protéger et d’autres personnes de la projection d’étincelles et de métal
chaud.
Si des BOUTEILLES sont endomma-
 Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des
gées, elles pourront exploser.
substances inflammables. Des bouteilles de gaz protecteur contiennent du gaz sous
 Déplacer toutes les substances inflammables à une distance de 10,7 m de haute pression. Si une bouteille est endommagée, elle peut
l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec exploser. Du fait que les bouteilles de gaz font normale-
des protections homologués. ment partie du procédé de soudage, les manipuler avec
précaution.
 Des étincelles et des matériaux chauds du soudage peuvent facilement
passer dans d’autres zones en traversant de petites fissures et des  Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des
ouvertures. chocs mécaniques, du laitier, des flammes ouvertes, des étincelles et des
 Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité. arcs.
 Le soudage effectué sur un plafond, plancher, paroi ou séparation peut dé-  Placer les bouteilles debout en les fixant dans un support stationnaire ou
clencher un incendie de l’autre côté. dans un porte-bouteilles pour les empêcher de tomber ou de se renverser.
 Ne pas effectuer le soudage sur des conteneurs fermés tels que des réser-  Tenir les bouteilles éloignées des circuits de soudage ou autres circuits
voirs, tambours, ou conduites, à moins qu’ils n’aient été préparés électriques.
correctement conformément à AWS F4.1 (voir les normes de sécurité).  Ne jamais placer une torche de soudage sur une bouteille à gaz.
 Brancher le câble sur la pièce le plus près possible de la zone de soudage  Une électrode de soudage ne doit jamais entrer en contact avec une bou-
pour éviter le transport du courant sur une longue distance par des che- teille.
mins inconnus éventuels en provoquant des risques d’électrocution et  Ne jamais souder une bouteille pressurisée − risque d’explosion.
d’incendie.
 Utiliser seulement des bouteilles de gaz protecteur, régulateurs, tuyaux et
 Ne pas utiliser le poste de soudage pour dégeler des conduites gelées. raccords convenables pour cette application spécifique; les maintenir ainsi
 En cas de non utilisation, enlever la baguette d’électrode du porte-électro- que les éléments associés en bon état.
de ou couper le fil à la pointe de contact.  Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la bouteille.
 Porter des vêtements de protection dépourvus d’huile tels que des gants  Maintenir le chapeau de protection sur la soupape, sauf en cas d’utilisation
en cuir, une chemise en matériau lourd, des pantalons sans revers, des ou de branchement de la bouteille.
chaussures hautes et un couvre chef.  Lire et suivre les instructions concernant les bouteilles de gaz comprimé,
 Avant de souder, retirer toute substance combustible de vos poches telles les équipements associés et les publication P-1 CGA énumérées dans les
qu’un allumeur au butane ou des allumettes. normes de sécurité.

2-3. Dangers existant en relation avec le moteur

LES ACCUMULATIONS DE GAZ ris- L’ACIDE DE LA BATTERIE peut pro-

quent de provoquer des blessures ou voquer des brûlures dans les YEUX et
même la mort. sur la PEAU.
 Fermer l’alimentation du gaz protecteur en cas de  Ne pas renverser la batterie.
non utilisation.  Remplacer une batterie endommagée.
 Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi-  Rincer immédiatement les yeux et la peau à l’eau.
rateur d’adduction d’air homologué.

OM-4415 Page 6
  Ne pas approcher les mains, cheveux, vêtements lâches et outils des orga-
L’EXPLOSION DE LA BATTERIE peut nes mobiles.
RENDRE AVEUGLE.  Remettre en place les panneaux ou les dispositifs de protection et fermer
les portes à la fin des travaux d’entretien et avant de faire démarrer le mo-
 Toujours porter une protection faciale, des gants en teur.
caoutchouc et vêtements de protection lors d’une in-  Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la mise en
tervention sur la batterie. route accidentelle du moteur.
 Arrêter le moteur avant de débrancher ou de brancher les câbles de  Bloquer le volant moteur pour éviter sa rotation lors d’une intervention sur le
batterie. générateur.
 Eviter de provoquer des étincelles avec les outils en travaillant sur la
batterie. LA VAPEUR ET LE LIQUIDE DE
 Ne pas utiliser le poste de soudage pour charger les batteries ou des véhi- REFROIDISSEMENT CHAUD peuvent
cules de démarrage rapide.
provoquer des brûlures.
 Observer la polarité correcte (+ et −) sur les batteries.
 Débrancher le câble négatif (–) en premier lieu. Le rebrancher en dernier  Il est préférable de vérifier le liquide de
lieu. refroidissement une fois le moteur refroidi pour éviter
de se brûler.
LE CARBURANT MOTEUR peut pro-
voquer un incendie ou une explosion.  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
 Arrêter le moteur avant de vérifier le niveau de carbu- dans la section maintenance du manuel du moteur).
rant ou de faire le plein.  Si le moteur est chaud et que le liquide doit être vérifié, opérer comme sui-
 Ne pas faire le plein en fumant ou proche d’une sour- vant :
ce d’étincelles ou d’une flamme nue.  Mettre des lunettes de sécurité et des gants, placer un torchon sur le bou-
 Ne pas faire le plein de carburant à ras bord; prévoir de l’espace pour son chon du radiateur.
expansion.  Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant
 Faire attention de ne pas renverser de carburant. Nettoyer tout carbu- d’enlever le bouchon.
rant renversé avant de faire démarrer le moteur.
 Jeter les chiffons dans un récipient ignifuge. LA CHALEUR DU MOTEUR peut pro-
voquer un incendie.
DES ORGANES MOBILES peuvent
provoquer des blessures.  Ne pas placer l’appareil sur, au-dessus ou à proximité
de surfaces inflammables.
 Ne pas approcher les mains des ventilateurs, cour-  Tenir à distance les produits inflammables de
roies et autres pièces en mouvement. l’échappement.
 Maintenir fermés et fixement en place les portes,
panneaux, recouvrements et dispositifs de LES ÉTINCELLES À L’ÉCHAPPEMENT
protection.
peuvent provoquer un incendie.
 Arrêter le moteur avant d’installer ou brancher l’appareil.
 Demander seulement à un personnel qualifié d’enlever les dispositifs de  Empêcher les étincelles d’échappement du moteur
sécurité ou les recouvrements pour effectuer, s’il y a lieu, des travaux d’en- de provoquer un incendie.
tretien et de dépannage.
 Utiliser uniquement un pare-étincelles approuvé −
 Pour empêcher tout démarrage accidentel pendant les travaux d’entretien, voir codes en vigueur.
débrancher le câble négatif (−) de batterie de la borne.

2-4. Dangers liés à l’air comprimé

RESPIRER L’AIR COMPRIMÉ peut pro- Le METAL CHAUD lors du coupage et
voquer des blessures graves ou causer gougeage plasma peut provoquer un in-
la mort. cendie ou une explosion.
 Ne pas utiliser l’air comprimé pour respirer.  Ne pas couper ou gouger à proximité de produits
 Utiliser l’air comprimé seulement pour le coupa- inflammables.
ge, gougeage et les outils pneumatiques.  Surveillez et garder un extincteur à proximité.
L’AIR COMPRIMÉ peut provoquer DES PIECES CHAUDES peuvent provo-
des blessures. quer des brûlures et blessures.
 Porter des lunettes de sécurité approuvées.
 Ne pas diriger le jet d’air vers d’autres ou soi−  Ne pas toucher le compresseur ou d’autres élé-
même. ments du circuit air comprimé chauds.
 Laisser l’ensemble se refroidir avant de toucher
L’AIR COMPRIME EMMAGASINE ET DES ou d’effectuer la maintenance.
TUYAUX SOUS PRESSION peuvent provo-
quer des blessures. LIRE LES INSTRUCTIONS.
 Relâcher la pression d’air de l’outillage ou du sys-
tème avant d’effectuer la maintenance, avant de  Lisez le manuel d’instructions avant l’utilisation
changer ou de rajouter des éléments ou avant ou la maintenance de l’appareil.
d’ouvrir la purge ou le bouchon de remplissage  Arrêter le moteur et relâcher la pression avant
d’huile. d’effectuer la maintenance.

2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la

maintenance
 Ne lever et ne soutenir l’appareil qu’avec de l’équipement approprié et
LA CHUTE DE L’APPAREIL peut en suivant les procédures adéquates.
blesser.  En utilisant des fourches de levage pour déplacer l’unité, s’assurer
que les fourches sont suffisamment longues pour dépasser du côté
 Utiliser un œilleton de levage pour lever l’appareil opposé de l’appareil.
et les accessoires correctement installés. Ne pas
dépasser le poids nominal maximal de l’œilleton
(voir les spécifications).
OM-4415 Page 7
 LE SURCHAUFFEMENT peut endom- LIRE LES INSTRUCTIONS.
mager le moteur électrique.
 Utiliser seulement les pièces de rechange d’origine.
 Arrêter ou déconnecter l’équipement avant de dé-  Effectuer la maintenance du moteur et du compres-
marrer ou d’arrêter le moteur. seur (si applicable) suivant ce manuel et le manuel du
moteur/compresseur (si applicable).
 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.
 Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz, s’il y a LE RAYONNEMENT HAUTE FRÉ-
lieu. QUENCE (H.F.) risque de provoquer
LES ÉTINCELLES VOLANTES ris- des interférences.
quent de provoquer des blessures.  Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipements
 Porter un écran facial pour protéger le visage et les de radio−navigation et de communication, les
yeux. services de sécurité et les ordinateurs.
 Demander seulement à des personnes qualifiées familiarisées avec des
 Affûter l’électrode au tungstène uniquement à la meuleuse dotée de pro- équipements électroniques de faire fonctionner l’installation.
tecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque
 L’utilisateur est tenu de faire corriger rapidement par un électricien quali-
l’on porte l’équipement homologué de protection du visage, des mains et
fié les interférences résultant de l’installation.
du corps.
 Si le FCC signale des interférences, arrêter immédiatement l’appareil.
 Les étincelles risquent de causer un incendie − éloigner toute substance
inflammable.  Effectuer régulièrement le contrôle et l’entretien de l’installation.
 Maintenir soigneusement fermés les portes et les panneaux des sources
L’EMPLOI EXCESSIF peut de haute fréquence, maintenir les éclateurs à une distance correcte et
utiliser une terre et un blindage pour réduire les interférences
SURCHAUFFER L’ÉQUIPEMENT. éventuelles.
 Laisser l’équipement refroidir ; respecter le facteur de
marche nominal.
 Réduire le courant ou le facteur de marche avant de LE SOUDAGE À L’ARC risque de
poursuivre le soudage.
provoquer des interférences.
 Ne pas obstruer les passages d’air du poste.
 L’énergie électromagnétique risque de provoquer
LES CHARGES ÉLECTROSTATI- des interférences pour l’équipement électronique
QUES peuvent endommager les sensible tel que les ordinateurs et l’équipement com-
circuits imprimés. mandé par ordinateur tel que les robots.
 Veiller à ce que tout l’équipement de la zone de soudage soit compatible
 Établir la connexion avec la barrette de terre avant de électromagnétiquement.
manipuler des cartes ou des pièces.  Pour réduire la possibilité d’interférence, maintenir les câbles de souda-
ge aussi courts que possible, les grouper, et les poser aussi bas que pos-
 Utiliser des pochettes et des boîtes antistatiques
sible (ex. par terre).
pour stocker, déplacer ou expédier des cartes de
circuits imprimes.  Veiller à souder à une distance de 100 mètres de tout équipement élec-
tronique sensible.
UNE REMORQUE QUI BASCULE peut  Veiller à ce que ce poste de soudage soit posé et mis à la terre conformé-
entraîner des blessures. ment à ce mode d’emploi.
 En cas d’interférences après avoir pris les mesures précédentes, il in-
 Utiliser les supports de la remorque ou des blocs combe à l’utilisateur de prendre des mesures supplémentaires telles que
pour soutenir le poids. le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de fil-
 Installer convenablement le poste sur la remorque tres de ligne ou la pose de protecteurs dans la zone de travail.
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 Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) 463−6727 ou à To-
l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (télé- ronto : (416) 747−4044, site Web : www.csa−international.org).
phone : (305) 443−9353, site Web : www.aws.org). Practice For Occupational And Educational Eye And Face Protection,
Recommended Safe Practices for the Preparation for Welding and Cutting norme ANSI Z87.1, de l’American National Standards Institute, 11 West
of Containers and Piping, norme American Welding Society AWS F4.1, de 42nd Street, New York, NY 10036−8002 (téléphone : (212) 642−4900, site
l’American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (télé- Web : www.ansi.org).
phone : (305) 443−9353, site Web : www.aws.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work,
National Electrical Code, norme NFPA 70, de la National Fire Protection As- norme NFPA 51B, de la National Fire Protection Association, P.O. Box
sociation, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 9101, 1 Battery March Park, Quincy, MA 02269−9101 (téléphone : (617)
(téléphone : (617) 770−3000, sites Web : www.nfpa.org et www.sparky.org). 770−3000, site Web : www.nfpa.org et www.sparky.org).
Safe Handling of Compressed Gases in Cylinders, brochure CGA P−1, de OSHA, Occupational Safety and Health Standards for General Industry,
la Compressed Gas Association, 1735 Jefferson Davis Highway, Suite Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and
1004, Arlington, VA 22202−4102 (téléphone : (703) 412−0900, site Web : Part 1926, Subpart J, de l’U.S. Government Printing Office, Superintendent
www.cganet.com). of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10 bureaux
Code for Safety in Welding and Cutting, norme CSA W117.2, de la Cana- régionaux − Téléphone pour la Région 5, Chicago : (312) 353−2220, site
dian Standards Association, Standards Sales, 178 boulevard Rexdale, Web : www.osha.gov).

2-7. Information sur les champs électromagnétiques

Données sur le soudage électrique et les effets des champs magnétiques Afin de réduire les champs électromagnétiques en milieu de travail, respec-
basse fréquence sur l’organisme ter les consignes suivantes :
En parcourant les câbles de soudage, le courant crée des champs électro- 1. Garder les câbles ensemble en les torsadant ou en les fixant avec du
magnétiques. Les effets potentiels de tels champs restent préoccupants. ruban adhésif.
Cependant, après avoir examiné plus de 500 études qui ont été faites pen- 2. Mettre tous les câbles du côté opposé à l’opérateur.
dant une période de recherche de 17 ans, un comité de spécialistes du 3. Ne pas s’enrouler les câbles autour du corps.
National Research Council a conclu : « L’accumulation de preuves n’a pas 4. Garder le poste de soudage et les câbles le plus loin possible de soi.
démontré que l’exposition aux champs magnétiques et aux champs électri- 5. Placer la pince de masse le plus près possible de la zone de soudage.
ques à haute fréquence constitue un risque pour la santé humaine ». Consignes relatives aux stimulateurs cardiaques :
Toutefois, les études et l’examen des preuves se poursuivent. En attendant Les personnes qui portent un stimulateur cardiaque doivent avant tout
les conclusions finales de la recherche, il serait souhaitable de réduire l’ex- consulter leur médecin. Si ce dernier les déclare aptes, il leur est recom-
position aux champs électromagnétiques pendant le soudage ou le mandé de respecter les consignes ci-dessus.
coupage.

OM-4415 Page 8
 SECTION 3 − DEFINITIONS
3-1. Symbol Definitions

Engine Choke
Read Operator’s
Manual A Amperes
V Volts

Engine Oil Fuel Battery (Engine) Engine

Alternating Current
Positive Negative Output
(AC)

s
Protective Earth

h
Hours Seconds Time
(Ground)

Circuit Breaker Temperature

SECTION 4 − SPECIFICATIONS
4-1. Weld, Power, And Engine Specifications
Weld Maximum
Welding Rated Generator Fuel
Output Open Circuit Engine
Mode Welding Output Power Rating Capacity
Range Voltage

Standard Model:
Honda GX390
Air-Cooled,
One-Cylinder,
Four-Cycle,
185 A, 25 V, Single-Phase, Standard Model: 13 HP (390 CC),
20% Duty Cycle 6 kVA/kW (Peak) 1.7 gal (6.9 L) Gasoline Engine
5.5 kVA/kW Tank (Recoil-Start)
130 A, 25 V,
CC/DC 50 − 185 A 80 (Continuous)
60% Duty Cycle DX Model: DX Model:
30/25 A,
100 A, 25 V 120/240 V AC, 5 gal (19 L) Kohler CS12
100% Duty Cycle 60 Hz Tank Air-Cooled,
One-Cylinder,
Four-Cycle,
12.75 HP (360 CC),
Gasoline Engine
(Electric-Start)

OM-4415 Page 9
4-2. Dimensions, Weights, And Operating Angles
Dimensions
Height 22-3/4 in (578 mm)
D
Width 22-3/4 in (577 mm)
Depth 31-5/8 in (803 mm)
 Do not exceed tilt angles or engine could
A 31-5/8 in (803 mm) B be damaged or unit could tip.
B 10-9/16 in (268 mm)  Do not move or operate unit where it
could tip.
tip
C 13-25/64 in (340 mm)
D 22-3/4 in (577 mm) A
E 1-9/16 in (40 mm) C
F 19-5/8 in (498 mm)
G 13/32 in (10 mm) Dia.
Weight 15° 15°
G 15°
DX Model: 315 lb (143 kg) 4 15°
Holes
H l
Standard Model: 267 lb (121 kg)
F
Optional Lifting Eye E
Weight Rating Engine End 803 403 803 597−A

430 lb (195 kg)

4-3. Duty Cycle

Duty cycle is the percentage of 10
minutes that unit can weld at rated
load without overheating.
 Exceeding duty cycle can
damage unit and void
warranty.
Continuous Welding
100% Duty Cycle at 100 Amperes CC/DC

2 Minutes Welding 8 Minutes Resting

20% Duty Cycle at 185 Amperes CC/DC

200
180
160
WELD AMPERES

140
120
100
80
60
40
20
0
0 10 20 30 40 50 60 70 80 90 100
% DUTY CYCLE 220 626−A

OM-4415 Page 10
4-4. Volt-Ampere Curves
The volt-ampere curve shows the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
other settings fall between the
curves shown.

A. Standard Model (Honda Engine)

80

70

60

50
VOLTS

40
MAX
MIN
30
MID
20

10

0
0 50 100 150 200 250 300
AMPERES

B. DX Model (Kohler Engine)

80

70

60

50
VOLTS

40
MAX
MIN
30
MID
20

10

0
0 50 100 150 200 250 300
AMPERES

220 603−A / 220 605−A

OM-4415 Page 11
4-5. Fuel Consumption Curves

A. Weld Output Standard B. Weld Output DX Model

Model (Honda Engine) (Kohler Engine)
1.00 1.00
0.80 0.80

U.S. Gal./Hr.
U.S. Gal./Hr.

0.60 0.60
0.40 0.40
0.20 0.20 Idle

0.00 0.00 0
0 25 50 75 100 125 150 175 200 25 50 75 100 125 150 175 200
DC Weld Amperes At Rated Duty Cycle DC Weld Amperes At Rated Duty Cycle

1.20
C. Auxiliary Power Standard
Model (Honda Engine)
1.00
U.S. Gal./Hr.

0.80

0.60

0.40

0.20

0.00
0 1 2 3 4 5 6 7 8
Aux Power kW At 100% Duty Cycle

1.00
D. Auxiliary Power DX Model
(Kohler Engine)
0.80
U.S. Gal./Hr.

0.60

0.40

0.20 Idle

0.00
0 1 2 3 4 5 6 7 8
Aux Power kW At 100% Duty Cycle
220 638−A / 220 639−A

OM-4415 Page 12
4-6. Generator Power Curves
The ac generator power curves
show the generator power available
A. Power Output Standard in amperes at the receptacles.
Model (Honda Engine)
300

250

200
240 VOLT
VOLTS

150

100
120 VOLT

50

0
0 10 20 30 40 50 60 70 80
AMPERES

B. Power Output DX Model

(Kohler Engine)
300

250

200
240 VOLT
VOLTS

150

100
120 VOLT

50

0
0 10 20 30 40 50 60 70 80
AMPERES 220 589−A / 220 594−A

OM-4415 Page 13
 SECTION 5 − INSTALLATION
5-1. Installing Welding Generator

Movement Airflow Clearance

18 in
(460 mm)
18 in 18 in
(460 mm) (460 mm)

18 in
(460 mm) 18 in
(460 mm)

Location  Always securely fasten welding generator

onto transport vehicle or trailer and comply
with all DOT and other applicable codes.

Shown with
OR optional
running gear.

install1 11/02 − 802 512-A / Ref. 151 556 / 158 936-A / 800 652-A / S-0854

5-2. Grounding Generator To Truck Or Trailer Frame

 Always ground generator
frame to vehicle frame to pre-
vent electric shock and static
electricity hazards.
1 Metal Vehicle Frame
2 Equipment Grounding
Terminal
3 Grounding Cable
2
Use #10 AWG or larger insulated
GND/PE
3 copper wire.
 If unit does not have GFCI
receptacles, use GFCI-
protected extension cord.

Electrically bond generator frame

to vehicle frame by metal-to-metal
contact.

 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.

install1 11/02* − Ref. 151 556 / S-0854

OM-4415 Page 14
5-3. Grounding Generator When Supplying Building Systems
1 2 1 Equipment Grounding
GND/PE Terminal
2 Grounding Cable
Use #10 AWG or larger insulated
copper wire.
3 Ground Device
 Ground generator to sys-
Use ground device as tem earth ground if supply-
stated in electrical codes. ing power to a premises
(home, shop, farm) wiring
system.

2 3

800 576-B

5-4. Engine Prestart Checks − Standard Model

Check all fluids daily. Engine must
be cold and on a level surface. Unit
is shipped with 10W30 engine oil.
1/2 in
(13 mm) 1 Fuel Valve
Full
Open valve.

 Close fuel valve before moving

unit or carburetor may flood
Gasoline and make starting difficult.
Fuel
Add fresh fuel before starting
engine the first time (see engine
manual for specifications). Fill fuel
tank up to 1/2 in. (13 mm) from top
to allow room for expansion. Check
1 fuel level on a cold engine before
use each day.
Oil
After fueling, check oil with unit on
level surface. If oil is not up to full
mark on dipstick, add oil (see en-
gine manual).
Unit stops if oil level is too low. Unit
cannot be restarted until sufficient
oil is added.

 Fuel valve is shown in the

open position. Always close
fuel valve after stopping unit.
Full
Moving unit with fuel valve
open may cause carburetor
flooding and make starting
difficult.

Ref. 803 597−A / 802 099

OM-4415 Page 15
5-5. Engine Prestart Checks − DX Model
Check all fluids daily. Engine must
be cold and on a level surface. Unit
is shipped with 10W30 engine oil.
1/2 in
(13 mm) 1 Fuel Valve
Full
Open valve.

 Close fuel valve before moving

unit or carburetor may flood
Gasoline and make starting difficult.
Fuel
Add fresh fuel before starting
1 engine the first time (see engine
manual for specifications). Fill fuel
tank up to 1/2 in. (13 mm) from top
to allow room for expansion. Check
fuel level on a cold engine before
use each day.
Oil
After fueling, check oil with unit on
level surface. If oil is not up to full
mark on dipstick, add oil (see en-
gine manual).
Unit stops if oil level is too low. Unit
cannot be restarted until sufficient
oil is added.
 To improve cold weather
starting:
 Fuel valve is shown in the
open position. Always close Keep battery in good condition.
fuel valve after stopping unit. Store battery in warm area off
Moving unit with fuel valve concrete surface.
open may cause carburetor Full
flooding and make starting Use correct grade oil for cold
difficult. weather.

803 595−A

5-6. Connecting The Battery (DX Models Only)

 Turn Engine Switch to Off
(DX models only).

 Connect negative (−)

cable last.

+
−

Tools Needed:
1/2 in
803 595−A / 803 466

OM-4415 Page 16
5-7. Connecting To Weld Output Terminals
1 Positive (+) Weld Output
Terminal
2 Negative (−) Weld Output
Terminal
For Direct Current Electrode Posi-
tive (DCEP), connect work cable to
Negative (−) terminal and electrode
holder to Positive (+) terminal.
For Direct Current Electrode nega-
tive (DCEN), reverse cable con-
nections.

2
1

Tools Needed:
3/4 in

803 596−A

5-8. Selecting Weld Cable Sizes*

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
100 ft (30 m) or Less
(45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
Weld Output
Terminals
 Turn off power before 10 − 60% 60 − 100%
connecting to weld out- Welding
Duty Duty 10 − 100% Duty Cycle
put terminals. Amperes
Cycle Cycle
 Do not use worn, dam-
aged, undersized, or
poorly spliced cables.

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)

2 ea. 2/0 2 ea. 2/0

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

2 ea. 2/0 2 ea. 3/0 2 ea. 3/0

300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x95)

* This chart is a general guideline and may not suit all applications. If cables overheat, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use S-0007-F

***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.

OM-4415 Page 17
 SECTION 6 − OPERATING THE WELDING GENERATOR
6-1. Controls (Standard Models) (See Section 6-2)
5

803 597−A / 218 611−B

OM-4415 Page 18
6-2. Description Of Controls (Standard Models) (See Section 6-1)

1 Engine Switch  Set choke. 5 Weld Output Control

Use switch to control ignition circuit. Turn  Pull starter handle. Open choke as en-
switch to On position when starting engine. gine warms.
 Set control at maximum for full generator
Turn switch to Off position to stop engine. En- power output at AC receptacles
gine cannot be started with switch in the Off  If the engine does not start, let engine
come to a complete stop before at- Use control to select weld amperage. Control
position.
tempting restart. may be adjusted while welding.
Engine stops if oil level is too low. Engine can-
not be restarted until sufficient oil is added. To Stop: To Set Weld Output Control: Use table to
determine correct size electrode for weld am-
2 Starter Handle  Turn Engine switch to Off. perage. Select electrode type and set control
3 Choke Control to corresponding amperage range on name-
 Always close fuel valve after stopping plate. Adjust control to obtain desired weld
Use control to change engine air/fuel mix. unit. Moving unit with fuel valve open may performance.
Move control to far right if starting a cold en- cause carburetor flooding and make
gine. Move control to far left if starting a warm starting difficult. EXAMPLE:
engine.
4 Welding Range Table Electrode Diameter: 1/8
To Start:
Use table to determine correct weld amper- Electrode Type: E-6013
 Open fuel valve (see Section 5-4). age based on electrode size, type, and mate-
 Turn Engine switch to On. rial thickness. Current Control Setting: 90 − 120 A

Notes

Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

OM-4415 Page 19
6-3. Controls (DX Models) (See Section 6-4)
8 7

803 596−A / 803 595−A / 218 611−B

OM-4415 Page 20
6-4. Description Of Controls (DX Models) (See Section 6-3)

1 Engine Switch To Start: 6 Run / Idle Switch

Use switch to control ignition circuit. Turn Use switch to select whether the engine stays
switch to Start position for electric start. Turn  Open fuel valve (see Section 5-5).
at run speed continuously or whether the auto
switch to On position to start engine using  Set choke. idle feature is enabled so engine speed re-
starter handle (recoil). Turn switch to Off posi- turns to idle speed after start−up or after weld
tion to stop engine.  Electric-Start: Turn Engine switch to
or generator load is removed.
Start position.
2 Low Oil Level Light 7 Weld Output Control
Recoil: Turn Engine switch to On posi-
Light goes on and engine stops if engine oil tion. Pull starter handle until engine
level is too low. starts.
 Set control at maximum for full generator
Engine cannot be restarted until sufficient oil power output at AC receptacles.
is added.  Open choke as engine warms. Use control to select weld amperage. Control
 Stop engine and add oil if light goes on  If the engine does not start, let engine may be adjusted while welding.
(see Section 5-5). come to a complete stop before at- To Set Weld Output Control: Use table to
tempting restart. determine correct size electrode for weld am-
3 Starter Handle
Use starter handle to start unit if electric start To Stop: perage. Select electrode type and set control
does not work. to corresponding amperage range on name-
 Turn Engine switch to Off. plate. Adjust control to obtain desired weld
4 Choke Control performance.
Use control to change engine air/fuel mix.  Always close fuel valve after stopping EXAMPLE:
Move control to far right if starting a cold en- unit. Moving unit with fuel valve open may
gine. Move control to far left if starting a warm cause carburetor flooding and make Electrode Diameter: 1/8
engine. starting difficult. Electrode Type: E-6013
The engine starts at weld/power speed and 5 Welding Range Table Current Control Setting: 90 − 120 A
runs at weld/power speed under weld or gen-
erator power load. The engine returns to idle Use table to determine correct weld amper- 8 Hourmeter
speed 12 seconds after start-up or after weld age based on electrode size, type, and mate- Use hourmeter to help schedule routine main-
or generator power load is removed. rial thickness. tenance.

Notes

Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

OM-4415 Page 21
 SECTION 7 − OPERATING AUXILIARY EQUIPMENT

NOTE Set Weld Output control to maximum for full generator power output at AC
receptacles.

7-1. Generator Power Panel Receptacles

5 4 1 2 3

218 611−B

 If unit does not have GFCI recep- RC2 and RC3 supply 60 Hz single-phase the receptacle does not work. Press but-
tacles, use GFCI-protected exten- power at weld/power speed. Maximum ton to reset breaker.
sion cord. output from RC2 or RC3 is 2.4 kVA/kW.
 If breaker continues to open, contact
 Generator power decreases as weld  Do not parallel the two 120V duplex Factory Authorized Service Agent.
current increases. receptacles.
1 240 V AC Receptacle RC1 Combined output of all receptacles limited
4 Circuit Breaker CB1 to 5.5 kVA/kW continuous rating of the
RC1 supplies 60 Hz single-phase power at generator (See Section 11 − Generator
weld/power speed. Maximum output is 6 CB1 protects the receptacles from over-
load. If CB1 opens, the receptacles do not Power Guidelines).
kVA/kW (peak) or 5.5 kVA/kW (continu-
ous). work. Move switch to the On position to re- EXAMPLE: If 10 A is drawn from each 120
set breaker. volt duplex receptacle, only 13 A is avail-
2 120 V 20 A AC Duplex Receptacle
RC2 5 Circuit Breakers CB2, CB3 able from the 240 V receptacle.
3 120 V 20 A AC Duplex Receptacle CB2 protects RC2 and CB3 protects RC3 2 x (120 V x 10 A) + (240 V x 13 A) = 5.5
RC3 from overload. If the circuit breaker opens, kVA/KW.

OM-4415 Page 22
 SECTION 8 − MAINTENANCE

NOTE Follow the storage procedure in the engine owner’s manual if the unit will not be
used for an extended period.

8-1. Routine Maintenance

 Stop engine before maintaining.

Recycle
 See Engine Manual for important start-up, service, and
storage information. Service more often if used in severe
engine conditions.
fluids.
* To be done by Factory Authorized Service Agent.

8h

Check fluid levels.

See Section 5-4 or Wipe up spills.
5-5.

25 h 50 h

Service precleaner Clean and

element (DX Model tighten weld
Shown) terminals.

100 h

Check
Change oil. See spark
engine manual. plug.

Service spark Clean and tighten

arrestor (optional battery connections
on DX Models) (DX models only).

Replace air Clean cooling

cleaner element. system. See
Engine Manual.

200 h 300 h

Replace Check valve

unreadable clearance.*
labels.

500 h

Service welding generator

Repair or
brushes and slip rings. Service
replace cracked
more often in dirty conditions.*
cables.

1000 h
Blow out or
vacuum inside.
During heavy OR
service, clean
monthly.

OM-4415 Page 23
 NOTE Follow the storage procedure in the engine owner’s manual if the unit will not be
used for an extended period.

8-2. Servicing Air Cleaner

 Stop engine.
 Do not run engine without air
cleaner or with dirty element.
1 Precleaner
2 Paper Element

 Do not wash paper element or

clean with compressed air.
Remove cover.
Wash precleaner with soap and wa-
ter solution. Allow precleaner to air
dry completely.
Dip precleaner in clean engine oil.
Squeeze out excess oil. The engine
will smoke if precleaner contains
1 too much oil.
Replace paper element if dirty, oily,
or damaged.

Standard Model Shown

oil

aircleaner6 9/00 − 803 404

OM-4415 Page 24
8-3. Adjusting Engine Speed (Honda-Powered Units)
After tuning engine, check engine
speeds. See table for proper no
load speeds. If necessary, adjust
speeds as follows:
1400 ± 150 rpm Start engine and run until warm.
Weld/Power Speed
3750 ± 30 rpm (62 Hz) Adjustment
1 Throttle Control Lever
2 Adjustment Screw
Move lever to Run (far left) position.
Turn screw and move lever until en-
gine runs at weld/power speed.
Idle Speed Adjustment
3 Pilot Screw
4 Throttle Stop Screw
Move lever to idle (far right) posi-
tion. Turn pilot screw until engine
runs at highest idle speed. Turn
stop screw until engine runs at
rated idle speed (normally about
2-1/4 turns out.)
2
 Stop engine. Close fuel
1 valve.

3 4

Tools Needed:

1/4, 3/8 in
803 597−A / Ref. 802 101-A

OM-4415 Page 25
8-4. Adjusting Engine Speed (Kohler−Powered Units)
After tuning engine, check engine
speed. See table for proper no load
speed. If necessary, adjust speed
as follows:
2500 ± 100 rpm (42 Hz) Start engine and run until warm.
Set Weld Output Control to Max.
3750 ± 30 rpm (62Hz) Weld/Power Speed Adjustment
1 Adjustment Screw
To increase speed, turn screw out
(counterclockwise). To decrease
speed, turn screw in (clockwise).
Idle Speed Adjustment
2 Throttle Solenoid TS1
3 Adjustment Screw
Loosen four screws on side of
throttle solenoid TS1. Adjust TS1
until idle speed is approximately
2500 rpm. Use adjustment screw
to fine tune idle speed. Be sure TS1
plunger bottoms at idle. Tighten
four screws on TS1.
 Stop engine. Close fuel
valve.

3 2

Tools Needed:

802 101-A

OM-4415 Page 26
 SECTION 9 − TROUBLESHOOTING
9-1. Troubleshooting

A. Welding

Trouble Remedy
No weld output or generator power out- Be sure all equipment is disconnected from receptacles when starting unit.
put at ac receptacles.
Have Factory Authorized Service Agent check brushes, slip rings, rotor, stator, integrated rectifier
SR2, and Weld Output control R1.
No weld output; generator power out- Check Weld Output control setting.
put okay at ac receptacles.
Check weld connections.
Have Factory Authorized Service Agent check Weld Output control R1, stator, integrated rectifier
SR2, stabilizer DC-Z, main rectifier SR1, and reactor AC-Z
Low weld output. Check Weld Output control setting.
Check engine speed, and adjust if necessary (see Section 8-3 or 8-4).
Service engine air cleaner.
Check weld cable size and length.
Have Factory Authorized Service Agent check Weld Output control R1, stator, integrated rectifier
SR2, stabilizer DC-Z, main rectifier SR1, and reactor AC-Z
High weld output. Check Weld Output control setting.
Check engine speed, and adjust if necessary (see Section 8-3 or 8-4).
Erratic weld output. Check Weld Output 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 8-3 or 8-4).
Check throttle/governor linkage for smooth, non-binding operation.

B. Generator Power

Trouble Remedy
No output at generator power ac re- Be sure all equipment is disconnected from receptacles when starting unit.
ceptacles; no weld output.
Have Factory Authorized Service Agent check brushes, slip rings, rotor, stator, integrated rectifier
SR2, and Weld Output control R1.
No output at generator power ac re- Reset and check circuit breakers (see Section 7-1).
ceptacles; weld output okay.
Check receptacle wiring and connections.
Have Factory Authorized Service Agent check stator windings and connections at terminal block 1T.
High output at generator power ac Check engine speed, and adjust if necessary (see Section 8-3 or 8-4).
receptacles.

OM-4415 Page 27
 Trouble Remedy
Low output at generator power ac Check Weld Output control setting.
receptacles.
Check engine speed, and adjust if necessary (see Section 8-3 or 8-4). Open circuit voltage is reduced
as engine speed drops.
Erratic output at generator power ac Check fuel level.
receptacles
receptacles.
Have Factory Authorized Service Agent check connections at terminal block 1T.
Check receptacle circuit breaker(s), wiring, and connections.
Check throttle linkage for smooth, non-binding operation.
Service air cleaner according to engine manual.
Check engine speed, and adjust if necessary (see Section 8-3 or 8-4).

C. Engine

Trouble Remedy

Engine will not crank (DX models only). Reset ignition circuit breaker (see engine manual).

Check and replace ignition fuse (see engine manual).

Check battery voltage.

Check battery connections and tighten if necessary.

Have Factory Authorized Service Agent check engine ignition circuit.

Engine will not start. Check fuel level (see Section 5-4 or 5-5).

Move choke control to correct position (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 and
make starting difficult.

Check battery voltage (DX models only).

Check battery connections and tighten if necessary (DX models only).

Check oil level (see Section 5-4 or 5-5). Engine stops if oil level is too low. Refill crankcase with proper
viscosity oil for operating temperature.

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

Engine stopped during normal Check fuel level (see Section 5-4 or 5-5).
operation.

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

Check oil level (see Section 5-4 or 5-5). Engine stops if oil level is too low.

Battery discharges between uses (DX Clean battery, terminals, and posts with baking soda and water solution; rinse with clear water.
models only).

Periodically recharge battery (approximately every 3 months).

Replace battery.

Check engine battery charging circuit and connections according to engine manual.

Unstable or sluggish engine speeds. Check engine speed, and adjust if necessary (see Section 8-3 or 8-4).

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

Tune-up engine according to engine manual.

OM-4415 Page 28
SECTION 10 − ELECTRICAL DIAGRAMS

218 706−B

Figure 10-1. Circuit Diagram For Welding Generator

OM-4415 Page 29
 SECTION 11 − GENERATOR POWER GUIDELINES

NOTE The views in this section are intended to be representative of all engine-driven
welding generators. Your unit may differ from those shown.

11-1. Selecting Equipment

1 Generator Power Receptacles
− Neutral Bonded To Frame
2 3-Prong Plug From Case
Grounded Equipment
3 2-Prong Plug From Double
Insulated Equipment
 Do not use 2-prong plug un-
less equipment is double in-
sulated.

Be sure equipment
OR
has this symbol
and/or wording.

gen_pwr 11/02 − Ref. ST-159 730 / ST-800 577

11-2. Grounding Generator To Truck Or Trailer Frame

 Always ground generator
frame to vehicle frame to pre-
vent electric shock and static
electricity hazards.
1 Equipment Grounding
Terminal (On Front Panel)
2 Grounding Cable (Not
Supplied)
3 Metal Vehicle Frame
Connect cable from equipment
ground terminal to metal vehicle
1 2 frame. Use #10 AWG or larger
insulated copper wire.
GND/PE  If unit does not have GFCI re-
ceptacles, use GFCI-pro-
tected extension cord.

Electrically bond generator

frame to vehicle frame by
metal-to-metal contact.

S-0854

OM-4415 Page 30
11-3. Grounding When Supplying Building Systems
1 Equipment Grounding
Terminal
1 2
2 Grounding Cable
GND/PE
Use #10 AWG or larger insulated
copper wire.
3 Ground Device
 Ground generator to system
earth ground if supplying
power to a premises (home,
shop, farm) wiring system.

Use ground device as stated

in electrical codes.
2 3

ST-800 576-B

11-4. How Much Power Does Equipment Require?

1 Resistive Load
3 A light bulb is a resistive load and
VOLTS 115 requires a constant amount of power.
2 AMPS 4.5
1 Hz 60 2 Non-Resistive Load
Equipment with a motor is a non-re-
sistive load and requires approxi-
mately six times more power while
starting the motor than when running
(see Section 11-8).
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
requirement in watts.
4.5 A x 115 V = 520 W
The load applied by the drill is 520 watts.

EXAMPLE 2: If three 200 watt flood lamps are used with the drill from 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-4415 Page 31
11-5. Approximate Power Requirements For Industrial Motors
Industrial Motors Rating Starting Watts Running Watts
Split Phase 1/8 HP 800 300
1/6 HP 1225 500
1/4 HP 1600 600
1/3 HP 2100 700
1/2 HP 3175 875
Capacitor Start-Induction Run 1/3 HP 2020 720
1/2 HP 3075 975
3/4 HP 4500 1400
1 HP 6100 1600
1-1/2 HP 8200 2200
2 HP 10550 2850
3 HP 15900 3900
5 HP 23300 6800
Capacitor Start-Capacitor Run 1-1/2 HP 8100 2000
5 HP 23300 6000
7-1/2 HP 35000 8000
10 HP 46700 10700
Fan Duty 1/8 HP 1000 400
1/6 HP 1400 550
1/4 HP 1850 650
1/3 HP 2400 800
1/2 HP 3500 1100

11-6. Approximate Power Requirements For Farm/Home Equipment

Farm/Home Equipment Rating Starting Watts Running Watts
Stock Tank De-Icer 1000 1000
Grain Cleaner 1/4 HP 1650 650
Portable Conveyor 1/2 HP 3400 1000
Grain Elevator 3/4 HP 4400 1400
Milk Cooler 2900 1100
Milker (Vacuum Pump) 2 HP 10500 2800
FARM DUTY MOTORS 1/3 HP 1720 720
Std. (e.g. Conveyors, 1/2 HP 2575 975
Feed Augers, Air 3/4 HP 4500 1400
Compressors) 1 HP 6100 1600
1-1/2 HP 8200 2200
2 HP 10550 2850
3 HP 15900 3900
5 HP 23300 6800
High Torque (e.g. Barn 1-1/2 HP 8100 2000
Cleaners, Silo Unloaders, 5 HP 23300 6000
Silo Hoists, Bunk Feeders) 7-1/2 HP 35000 8000
10 HP 46700 10700
3-1/2 cu. ft. Mixer 1/2 HP 3300 1000
High Pressure 1.8 Gal/Min 500 PSI 3150 950
Washer 2 gal/min 550 PSI 4500 1400
2 gal/min 700 PSI 6100 1600
Refrigerator or Freezer 3100 800
Shallow Well Pump 1/3 HP 2150 750
1/2 HP 3100 1000
Sump Pump 1/3 HP 2100 800
1/2 HP 3200 1050

OM-4415 Page 32
11-7. Approximate Power Requirements For Contractor Equipment
Contractor Rating Starting Watts Running Watts
Hand Drill 1/4 in 350 350
3/8 in 400 400
1/2 in 600 600
Circular Saw 6-1/2 in 500 500
7-1/4 in 900 900
8-1/4 in 1400 1400
Table Saw 9 in 4500 1500
10 in 6300 1800
Band Saw 14 in 2500 1100
Bench Grinder 6 in 1720 720
8 in 3900 1400
10 in 5200 1600
Air Compressor 1/2 HP 3000 1000
1 HP 6000 1500
1-1/2 HP 8200 2200
2 HP 10500 2800
Electric Chain Saw 1-1/2 HP, 12 in 1100 1100
2 HP, 14 in 1100 1100
Electric Trimmer Standard 9 in 350 350
Heavy Duty 12 in 500 500
Electric Cultivator 1/3 HP 2100 700
Elec. Hedge Trimmer 18 in 400 400
Flood Lights HID 125 100
Metal Halide 313 250
Mercury 1000
Sodium 1400
Vapor 1250 1000
Submersible Pump 400 gph 600 200
Centrifugal Pump 900 gph 900 500
Floor Polisher 3/4 HP, 16 in 4500 1400
1 HP, 20 in 6100 1600
High Pressure Washer 1/2 HP 3150 950
3/4 HP 4500 1400
1 HP 6100 1600
55 gal Drum Mixer 1/4 HP 1900 700
Wet & Dry Vac 1.7 HP 900 900
2-1/2 HP 1300 1300

OM-4415 Page 33
11-8. Power Required To Start Motor
4 1 Motor Start Code
AC MOTOR 2 2 Running Amperage
1 VOLTS 230 AMPS 2.5
3 Motor HP
3 CODE M Hz 60
4 Motor Voltage
HP 1/4 PHASE 1
To find starting amperage:
Step 1: Find code and use table to
find kVA/HP. If code is not listed,
multiply running 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
Single-Phase Induction Motor Starting Requirements motor’s running amperage.

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
= STARTING AMPERAGE
VOLTS
EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4
HP motor with a motor start code of M.
Volts = 230 HP = 1/4 Using Table, Code M results in kVA/HP = 11.2

11.2 x 1/4 x 1000

= 12.2 A Starting the motor requires 12.2 amperes.
230 S-0624

11-9. How Much Power Can Generator Supply?

1 Limit Load To 90% Of
Generator Output
Always start non-resistive (motor)
loads in order from largest to small-
est, and add resistive loads last.
2 5 Second Rule
1
If motor does not start within 5
seconds, turn off power to prevent
motor damage. Motor requires
more power than generator can
2 supply.

Ref. ST-800 396-A / S-0625

OM-4415 Page 34
11-10. Typical Connections To Supply Standby Power

 Properly install and ground this equipment according to

its Owner’s Manual and national, state, and local codes.

1 2 3 4
Fused
Utility Welding
Disconnect
Electrical Transfer Switch Generator
Switch
Service Output
(If Required)

Essential
Loads

 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
es. restored. Turn off or unplug all equipment connected to
generator before starting or stopping engine.
 Properly install and ground this Install correct switch (customer-supplied). When starting or stopping, the engine has
equipment according to its Owner’s Switch rating must be same as or greater low speed which causes low voltage and
Manual and national, state, and local than the branch overcurrent protection. frequency.
codes.
3 Fused Disconnect Switch
5 Essential Loads
 Customer-supplied equipment is re- Install correct switch (customer-supplied) if
quired if generator will supply standby required by electrical code. Generator output may not meet the electrical
power during emergencies or power out- requirements of the premises. If generator
4 Welding Generator Output
ages. does not produce enough output to meet all
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. tion 11-4).

Notes

Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

OM-4415 Page 35
11-11. Selecting Extension Cord (Use Shortest Cord Possible)

Cord Lengths for 120 Volt Loads

 If unit does not have GFCI receptacles, use GFCI-protected extension cord.

Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*

Current
Load (Watts) 4 6 8 10 12 14
(Amperes)

5 600 350 (106) 225 (68) 137 (42) 100 (30)

7 840 400 (122) 250 (76) 150 (46) 100 (30) 62 (19)

10 1200 400 (122) 275 (84) 175 (53) 112 (34) 62 (19) 50 (15)

15 1800 300 (91) 175 (53) 112 (34) 75 (23) 37 (11) 30 (9)

20 2400 225 (68) 137 (42) 87 (26) 50 (15) 30 (9)

25 3000 175 (53) 112 (34) 62 (19) 37 (11)

30 3600 150 (46) 87 (26) 50 (15) 37 (11)

35 4200 125 (38) 75 (23) 50 (15)

40 4800 112 (34) 62 (19) 37 (11)

45 5400 100 (30) 62 (19)

50 6000 87 (26) 50 (15)

*Conductor size is based on maximum 2% voltage drop

Cord Lengths for 240 Volt Loads

 If unit does not have GFCI receptacles, use GFCI-protected extension cord.

Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*

Current
Load (Watts) 4 6 8 10 12 14
(Amperes)

5 1200 700 (213) 450 (137) 225 (84) 200 (61)

7 1680 800 (244) 500 (152) 300 (91) 200 (61) 125 (38)

10 2400 800 (244) 550 (168) 350 (107) 225 (69) 125 (38) 100 (31)

15 3600 600 (183) 350 (107) 225 (69) 150 (46) 75 (23) 60 (18)

20 4800 450 (137) 275 (84) 175 (53) 100 (31) 60 (18)

25 6000 350 (107) 225 (69) 125 (38) 75 (23)

30 7000 300 (91) 175 (53) 100 (31) 75 (23)

35 8400 250 (76) 150 (46) 100 (31)

40 9600 225 (69) 125 (38) 75 (23)

45 10,800 200 (61) 125 (38)

50 12,000 175 (53) 100 (31)

*Conductor size is based on maximum 2% voltage drop

OM-4415 Page 36
 SECTION 12 − STICK WELDING (SMAW) GUIDELINES

12-1. Stick Welding Procedure

 Weld current starts when
electrode touches work-
piece.
 Weld current can damage
electronic parts in vehicles.
Disconnect both battery
cables before welding on a
vehicle. Place work clamp as
close to the weld as possible.
1 Workpiece
Make sure workpiece is clean be-
fore welding.
5
2 Work Clamp
4
3 Electrode
2
A small diameter electrode requires
less current than a large one. Fol-
low electrode manufacturer’s
instructions when setting weld am-
perage (see Section 12-2).
4 Insulated Electrode Holder
5 Electrode Holder Position
3 6 Arc Length
Arc length is the distance from the
6 electrode to the workpiece. A short
arc with correct amperage will give
1 7 a sharp, crackling sound.
7 Slag
Use a chipping hammer and wire
brush to remove slag. Remove slag
and check weld bead before mak-
ing another weld pass.

Tools Needed:

stick 12/96 − ST-151 593

OM-4415 Page 37
12-2. Electrode and Amperage Selection Chart

AMPERAGE
RANGE
ELECTRODE

DIAMETER

100

150

200

250

300

350

400

450

PENETRATION
50

ELECTRODE

POSITION

USAGE
3/32

DC*

AC
1/8
6010
5/32
& 3/16
6011 7/32
1/4 6010 EP ALL DEEP MIN. PREP, ROUGH
1/16 HIGH SPATTER
6011 EP ALL DEEP
5/64
3/32 6013 EP,EN ALL LOW GENERAL
1/8 SMOOTH, EASY,
6013 7014 EP,EN ALL MED FAST
5/32
3/16 LOW HYDROGEN,
7018 EP ALL LOW STRONG
7/32
1/4 FLAT
7024 EP,EN HORIZ LOW SMOOTH, EASY,
3/32 FASTER
FILLET
1/8
5/32 NI-CL EP ALL LOW CAST IRON
7014
3/16 308L EP ALL LOW STAINLESS
7/32 *EP = ELECTRODE POSITIVE (REVERSE POLARITY)
1/4 EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)
3/32
1/8
5/32
7018
3/16
7/32
1/4
3/32
1/8
5/32
7024
3/16
7/32
1/4
3/32
1/8
Ni-Cl
5/32
3/16
3/32
308L 1/8
5/32
Ref. S-087 985-A

12-3. Striking an Arc − Scratch Start Technique

1 1 Electrode
2 Workpiece
3 Arc
Drag electrode across workpiece
like striking a match; lift electrode
2 slightly after touching work. If arc
goes out electrode was lifted to
high. If electrode sticks to work-
piece, use a quick twist to free it.
3
S-0049

12-4. Striking an Arc − Tapping Technique

1 1 Electrode
2 Workpiece
3 Arc
Bring electrode straight down to
workpiece; then lift slightly to start
2 arc. If arc goes out, electrode was
lifted too high. If electrode sticks to
workpiece, use a quick twist to free it.
3

S-0050

OM-4415 Page 38
12-5. Positioning Electrode Holder
10°-30°

90° 90°

End View of Work Angle Side View of Electrode Angle

GROOVE WELDS

10°-30°
45°

45°

End View of Work Angle Side View of Electrode Angle

FILLET WELDS S-0060

12-6. Poor Weld Bead Characteristics

1 Large Spatter Deposits
2 Rough, Uneven Bead
3 Slight Crater During Welding
4 Bad Overlap
5 Poor Penetration

2 3 4

5 S-0053-A

12-7. Good Weld Bead Characteristics

1 Fine Spatter
2 Uniform Bead
3 Moderate Crater During
Welding
Weld a new bead or layer for each
1/8 in. (3.2 mm) thickness in metals
being welded.
1 4 No Overlap
5 Good Penetration into Base
Metal
2 3 4 5

S-0052-B

OM-4415 Page 39
12-8. Conditions That Affect Weld Bead Shape

NOTE Weld bead shape is affected by electrode angle, arc length, travel speed, and
thickness of base metal.

Correct Angle
Angle Too Small 10° - 30° Angle Too Large

Drag

ELECTRODE ANGLE

Spatter

Too Short Normal Too Long

ARC LENGTH

Slow Normal Fast

TRAVEL SPEED
S-0061

12-9. Electrode Movement During Welding

NOTE Normally, a single stringer bead is satisfactory for most narrow groove weld joints;
however, for wide groove weld joints or bridging across gaps, a weave bead or
multiple stringer beads work better.

1 Stringer Bead − Steady

Movement Along Seam
2 Weave Bead − Side to Side
1 2
Movement Along Seam
3 Weave Patterns
Use weave patterns to cover a wide
area in one pass of the electrode.
Do not let weave width exceed
2-1/2 times diameter of electrode.

S-0054-A

OM-4415 Page 40
12-10. Butt Joints
1 1 Tack Welds
Prevent edges of joint from drawing
2 together ahead of electrode by tack
welding the materials in position be-
fore final weld.
2 Square Groove Weld
Good for materials up to 3/16 in (5
mm) thick.
3 Single V-Groove Weld
30° Good for materials 3/16 − 3/4 in
1/16 in (5-19 mm) thick. Cut bevel with oxy-
(1.6 mm) acetylene or plasma cutting equip-
ment. Remove scale from material
after cutting. A grinder can also be
used to prepare bevels.
3 4 Create 30 degree angle of bevel on
materials in V-groove welding.
4 Double V-Groove Weld
Good for materials thicker than 3/16
in (5 mm).

S-0662

12-11. Lap Joint

30°
30° Or Less
1 Electrode
Or Less 2 Single-Layer Fillet Weld
1 1 Move electrode in circular motion.
3 Multi-Layer Fillet Weld
Weld a second layer when a heavi-
er fillet is needed. Remove slag be-
fore making another weld pass.
Weld both sides of joint for maxi-
mum strength.
2 3
Single-Layer Fillet Weld Multi-Layer Fillet Weld
S-0063 / S-0064

12-12. Tee Joint

1 Electrode
2 Fillet Weld
Keep arc short and move at definite
1 rate of speed. Hold electrode as
shown to provide fusion into the
corner. Square edge of the weld
surface.
45° For maximum strength weld both
Or Less 2 sides of upright section.
2
3 Multi-Layer Deposits
Weld a second layer when a heavi-
er fillet is needed. Use any of the
weaving patterns shown in Section
12-9. Remove slag before making
another weld pass.
1

3
S-0060 / S-0058-A / S-0061

OM-4415 Page 41
12-13. Weld Test
1 Vise
3 2 Weld Joint
3 Hammer
Strike weld joint in direction shown.
3 A good weld bends over but does
not break.
2 To 3 in
(51-76 mm)
2 To 3 in
(51-76 mm)
2 2
1/4 in
(6.4 mm) 1 1

S-0057-B

12-14. Troubleshooting − Porosity

Porosity − small cavities or holes resulting from gas

pockets in weld metal.

Possible Causes Corrective Actions

Arc length too long. Reduce arc length.

Damp electrode. Use dry electrode.

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.

12-15. Troubleshooting − Excessive Spatter

Excessive Spatter − scattering of molten metal particles

that cool to solid form near weld bead.

Possible Causes Corrective Actions

Amperage too high for electrode. Decrease amperage or select larger electrode.

Arc length too long or voltage too high. Reduce arc length or voltage.

OM-4415 Page 42
12-16. Troubleshooting − Incomplete Fusion

Incomplete Fusion − failure of weld metal to fuse completely with

base metal or a preceeding weld bead.

Possible Causes Corrective Actions

Insufficient heat input. Increase amperage. Select larger electrode and increase amperage.

Improper welding technique. Place stringer bead in proper location(s) at joint during welding.

Adjust work angle or widen groove to access bottom during welding.

Momentarily hold arc on groove side walls when using weaving technique.

Keep arc on leading edge of weld puddle.

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.

12-17. Troubleshooting − Lack Of Penetration

Lack Of Penetration − shallow fusion between weld metal and

base metal.

Lack of Penetration Good Penetration

Possible Causes Corrective Actions

Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove.

Improper weld technique. Keep arc on leading edge of weld puddle.

Insufficient heat input. Increase amperage. Select larger electrode and increase amperage.

Reduce travel speed.

12-18. Troubleshooting − Excessive Penetration

Excessive Penetration − weld metal melting through base metal and

hanging underneath weld.

Excessive Penetration Good Penetration

Possible Causes Corrective Actions

Excessive heat input. Select lower amperage. Use smaller electrode.

Increase and/or maintain steady travel speed.

OM-4415 Page 43
12-19. Troubleshooting − Burn-Through

Burn-Through − weld metal melting completely through base metal resulting

in holes where no metal remains.

Possible Causes Corrective Actions

Excessive heat input. Select lower amperage. Use smaller electrode.

Increase and/or maintain steady travel speed.

12-20. Troubleshooting − Waviness Of Bead

Waviness Of Bead − weld metal that is not parallel and does not cover
joint formed by base metal.

Possible Causes Corrective Actions

Unsteady hand. Use two hands. Practice technique.

12-21. Troubleshooting − Distortion

Distortion − contraction of weld met-

al during welding that forces base
metal to move.
Base metal moves
in the direction of
the weld bead.

Possible Causes Corrective Actions

Excessive heat input. Use restraint (clamp) to hold base metal in position.

Make tack welds along joint before starting welding operation.

Select lower amperage for electrode.

Increase travel speed.

Weld in small segments and allow cooling between welds.

OM-4415 Page 44
Notes

MATERIAL THICKNESS REFERENCE CHART

24 Gauge (.025 in)

22 Gauge (.031 in)
20 Gauge (.037 in)
18 Gauge (.050 in)
16 Gauge (.063 in)
14 Gauge (.078 in)
1/8 in (.125 in)

3/16 in (.188 in)

1/4 in (.25 in)

5/16 in (.313 in)

3/8 in (.375 in)

1/2 in (.5 in)

OM-4415 Page 45
 SECTION 13 − PARTS LIST
 Hardware is common and
not available unless listed.

7 8 11
6
5 10
9
3 4
41
1

30
31
40 32

39
33

29
28
38
12
1 34
36 35 27
37
26
25
15 13
16
17 14

18
19
20
21
22

24
23

803 599−A

Figure 13-1. Main Assembly Standard Model

OM-4415 Page 46
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 13-1. Main Assembly (Standard Model)

1 . . . . . . . . . . . . . . . . . 099255 . . Terminal, Pwr Output Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 . . . . . . . . . . . . . . . . . 217125 . . Base, Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 . . . . CB2, CB3 . . 093996 . . Circuit Breaker, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . . . . . . . 2
4 . . . . . . . CB1 . . . . . 218783 . . Circuit Breaker, Man Reset 2p 30a 250vac Frict . . . . . . . . . . . . . . . . . . . . . . . 1
5 . . . . . . . RC1 . . . . . 218772 . . Rcpt, Str 2p3w 50a 250v *6−50r Flush Mt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
6 . . . . . . . . 1T . . . . . 172661 . . Block, Stud Connection 6 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
7 . . . . . . . . . . . . . . . . . 173734 . . Link, Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
8 . . . . RC2, RC3 . . 141432 . . Rcpt, Str Dx Grd 2p3w 20a 125v *5−20r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
8 . . GFCI2, GFCI3♦151981 . . Rcpt, Str Dx Grd 2p3w 15/20a 125v *5−20r Gfi . . . . . . . . . . . . . . . . . . . . . . . 2
9 . . . . . . . . . . . . . . . . . 154408 . . Bushing, Snap−in Nyl .562 Id X .875 Mtg Hole Cent . . . . . . . . . . . . . . . . . . . 1
10 . . . . . . SR1 . . . . . 209715 . . Rectifier, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
11 . . . . . . . . . . . . . . . . 219035 . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
12 . . . . . . . . . . . . . . . . 218709 . . Engine, Gas Recoil Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 198522 . . . . Cap, Fuel Honda . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 220305 . . Tune−up & Filter Kit, Honda (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
. . . . . . . . . . . . . . . . . . . 190108 . . . . Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 220303 . . . . Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 220304 . . . . Air Filter, Pre Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
13 . . . . . . . . . . . . . . . . 214724 . . Bracket, Mtg Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
14 . . . . . . . . . . . . . . . . 211459 . . Mount, Engine Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
15 . . . . . . . . . . . . . . . . 494606 . . Adapter, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
16 . . . . . . . . . . . . . . . . 494629 . . Guard, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
17 . . . . . . . . . . . . . . . . 209010 . . Stator, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
18 . . . . . . . . . . . . . . . . 209005 . . Rotor, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
19 . . . . . . . . . . . . . . . . 495349 . . Screw, 250−20 X 12.50 Hwd Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
20 . . . . . . . . . . . . . . . . 494587 . . Endbell, Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
21 . . . . . . . . . . . . . . . . 495348 . . Screw, 312−24 X 9.25 Hwd Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
22 . . . . . . . . . . . . . . . . 494628 . . Panel, End Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
23 . . . . . . . . . . . . . . . . 216195 . . Frame, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
24 . . . . . . . . . . . . . . . . 214727 . . Mount, Generator Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
25 . . . . . . . . . . . . . . . . 211297 . . Label, Warning General Precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
26 . . . . . . . . . . . . . . . . 493509 . . Brushholder Assy, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
27 . . . . . . . . . . . . . . . . 210325 . . Tubing, Corrugated Plastic 1.500 Dia X 3.000 . . . . . . . . . . . . . . . . . . . . . . . . . 1
28 . . . . . . . . . . . . . . . . 209339 . . Duct, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
29 . . . . . . . . . . . . . . . . 209340 . . Seal, Air Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
30 . . . . . . SR2 . . . . . 035704 . . Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
31 . . . . . . . C1 . . . . . 218680 . . Capacitor, Elctlt 2000 Uf 200 Vdc Can 1.42 Dia . . . . . . . . . . . . . . . . . . . . . . . 1
32 . . . . . . . . . . . . . . . . 494915 . . Clamp, Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
33 . . . . . DC−Z . . . . 218700 . . Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
34 . . . . . . . R1 . . . . . 218565 . . Rheostat, Ww 150. W 50. Ohm Frict Term . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
35 . . . . . . . . . . . . . . . . . . . . . . . . . . Label, Nameplate (Order By Model And Serial Number) . . . . . . . . . . . . . . . . 1
36 . . . . . . . . . . . . . . . . 207077 . . Knob, Pointer 1.625 Dia. Push On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
37 . . . . . . . . . . . . . . . . 221758 . . Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
38 . . . . . . . . . . . . . . . . 209056 . . Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
39 . . . . . . . . . . . . . . . . 221273 . . Blank,Snap−in Nyl .500 X 1.100 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . 1
40 . . . . . . . . . . . . . . . . 495386 . . Cover, Meter Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
41 . . . . . AC−Z . . . . 218767 . . Reactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦ Optional
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
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-4415 Page 47
  Hardware is common and 13 14
not available unless listed.

11
10

12
15
4 16
3 5 17
2 6 18
1 7 8
60
59

50
58
43 19
57 44
45
46 42
47
56 48
41
20
55
21
40

49 39
50 23
51
54 52 22
38 24
53 25
26
27
29 28

30
31
32

35

37
36 33
34 803 598−B

Figure 13-2. Main Assembly DX Model

Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 13-2. Main Assembly (DX Model)

1 . . . . . . . CB1 . . . . . 218782 . . Circuit Breaker, Man Reset 2p 20a 250vac Frict . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . RC1 . . . . . 218772 . . Rcpt, Str 2p3w 50a 250v *6−50r Flush Mt . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 . . . . . . . . 1T . . . . . 172661 . . Block, Stud Connection 6 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4 . . . . . . . . . . . . . . . . . 173734 . . Link, Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5 . . . . RC2, RC3 . . 141432 . . Rcpt, Str Dx Grd 2p3w 20a 125v *5−20r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5 . . GFCI2, GFCI3♦151981 . . Rcpt, Str Dx Grd 2p3w 15/20a 125v *5−20r Gfi . . . . . . . . . . . . . . . . . . . . . . . 2
6 . . . . . . . CT1 . . . . . 219510 . . Xfmr, Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
7 . . . . . . . . . . . . . . . . . 154408 . . Bushing, Snap−in Nyl .562 Id X .875 Mtg Hole Cent . . . . . . . . . . . . . . . . . . . 1
8 . . . . . . . SR1 . . . . . 209715 . . Rectifier, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
9 . . . . . . . . . . . . . . . . . 209014 . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 . . . . . . . . . . . . . . . . 192042 . . Label, Use Gasoline Fuel Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
11 . . . . . . . . . . . . . . . . 087341 . . Bumper,Door 1.000 Od X .750 High Rbr 50 Duro W/O . . . . . . . . . . . . . . . . . 2
12 . . . . . . . . . . . . . . . . 221007 . . Bracket,Support Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
13 . . . . . . . . . . . . . . . . 220711 . . Cap, Tank Screw−on W/Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
14 . . . . . . . . . . . . . . . . 223079 . . Tank, Fuel 5.0 Gal (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
15 . . . . . . . . . . . . . . . . 221039 . . . . Insulation,Thermal Fuel Tank Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-4415 Page 48
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 13-2. Main Assembly (Continued)

16 . . . . . . . . . . . . . . . . 221038 . . . . Insulation,Thermal Fuel Tank Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

17 . . . . . . . . . . . . . . . . 221746 . . . . Grommet, Rbr .750 Id X 4.000 Od X .062t . . . . . . . . . . . . . . . . . . . . . . . . . . 1
18 . . . . . . . . . . . . . . . . 221750 . . Shield, Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
19 . . . . . . TS1 . . . . . 218794 . . Solenoid, 14vdc .53 Amp Pull Type Cont (included with item 20) . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 218788 . . . . Bracket, Mtg Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 602306 . . . . Pin, Spring Cs .125 X .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
20 . . . . . . . . . . . . . . . . 218786 . . Engine, Gas Elec Start (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 218411 . . . . Muffler, Exhaust Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 203959 . . . . Gasket, Muffler Kohler Cs 8.5 & 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 221584 . . Tune−up & Filter Kit, Kohler Cs 10 & 12 Electric (includes) . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 203960 . . . . Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 221582 . . . . Filter, Air Kohler Cs 10 & 12 Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 221583 . . . . Filter, Air Pre Cleaner Kohler Cs 10 & 12 Electric . . . . . . . . . . . . . . . . . . . 1
21 . . . . . . . . . . . . . . . . 214724 . . Bracket, Mtg Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
22 . . . . . . . . . . . . . . . . 211459 . . Mount, Engine Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
23 . . . . . . . . . . . . . . . . 494606 . . Adapter, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
24 . . . . . . . . . . . . . . . . 209010 . . Stator, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
25 . . . . . . . . . . . . . . . . 209005 . . Rotor, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
26 . . . . . . . . . . . . . . . . 494587 . . Endbell, Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
27 . . . . . . . . . . . . . . . . 495349 . . Screw, 250−20 X 12.50 Hwd Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
28 . . . . . . . . . . . . . . . . 494628 . . Panel, End Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
29 . . . . . . . . . . . . . . . . 495348 . . Screw, 312−24 X 9.25 Hwd Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
30 . . . . . . . . . . . . . . . . 219642 . . Cable, Bat Pos 18.000 6ga W/.312 Rng & .312 Rng . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 494039 . . Cover, Cable Btry Post . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
31 . . . . . . . . . . . . . . . . 495124 . . Battery, 12v Light Utility (Dry) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
32 . . . . . . . . . . . . . . . . 493057 . . Clamp, Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
33 . . . . . . . . . . . . . . . . 494604 . . Bolt,J Stl .250−20 X 8.000 Pld W/Nuts&washers . . . . . . . . . . . . . . . . . . . . . . 2
34 . . . . . . . . . . . . . . . . 218181 . . Tray, Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
35 . . . . . . . . . . . . . . . . 211180 . . Cable, Bat Neg 19.000 6ga W/.312 Rng & .312 Rng . . . . . . . . . . . . . . . . . . 1
36 . . . . . . . . . . . . . . . . 216195 . . Frame, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
37 . . . . . . . . . . . . . . . . 214727 . . Mount, Generator Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
38 . . . . . . . . . . . . . . . . 211297 . . Label, Warning General Precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
39 . . . . . . . . . . . . . . . . 493509 . . Brushholder Assy, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
40 . . . . . . . . . . . . . . . . 210325 . . Tubing, Corrugated Plastic 1.500 Dia X 3.000 . . . . . . . . . . . . . . . . . . . . . . . . 1
41 . . . . . . . . . . . . . . . . 209339 . . Duct, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
42 . . . . . . . . . . . . . . . . 209340 . . Seal, Air Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
43 . . . . . . . . . . . . . . . . 127854 . . Clamp, Stl Cush 1.312 Dia X .343 Mtg Hole . . . . . . . . . . . . . . . . . . . . . . . . . . 1
44 . . . . . . CR1 . . . . . 219494 . . Relay, Encl 120vac Spst 5a No/120vac 4pin Flange . . . . . . . . . . . . . . . . . . . 1
45 . . . . . . SR2 . . . . . 035704 . . Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
46 . . . . . . . C1 . . . . . 218680 . . Capacitor, Elctlt 2000 Uf 200 Vdc Can 1.42 Dia . . . . . . . . . . . . . . . . . . . . . . 1
47 . . . . . . . . . . . . . . . . 494915 . . Clamp, Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
48 . . . . . DC−Z . . . . 218700 . . Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
49 . . . . . . . R1 . . . . . 218565 . . Rheostat, Ww 150. W 50. Ohm Frict Term . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
50 . . . . . . . . . . . . . . . . 099255 . . Terminal, Pwr Output Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
51 . . . . . . . . . . . . . . . . . . . . . . . . . . Label, Nameplate (Order By Model And Serial Number) . . . . . . . . . . . . . . . 1
52 . . . . . . . . . . . . . . . . 207077 . . Knob, Pointer 1.625 Dia. Push On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
53 . . . . . . . . . . . . . . . . 221758 . . Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
54 . . . . . . . . . . . . . . . . 209056 . . Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
55 . . . . . . . S1 . . . . . 111997 . . Switch,Rocker Spst 10a 250vac On−off Visi Red Rock . . . . . . . . . . . . . . . . . 1
56 . . . . . . HM . . . . . 176365 . . Meter, Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
57 . . . . . AC−Z . . . . 218767 . . Reactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
58 . . . . . . . . . . . . . . . . 217125 . . Base, Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
59 . . . . . . PC1 . . . . . 201936 . . Module, Pull To Idle 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
60 . . . CB2, CB3 . . 093996 . . Circuit Breaker, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . . . . . . . 2
♦ Optional
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
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-4415 Page 49
 Effective January 1, 2005
(Equipment with a serial number preface of “LF” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
Warranty Questions? guarantees or warranties expressed or implied.

Call LIMITED WARRANTY − Subject to the terms and conditions * Induction Heating Coils and Blankets
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after
* APT & SAF Model Plasma Cutting Torches
for your local the effective date of this limited warranty is free of defects in * Remote Controls
material and workmanship at the time it is shipped by Miller.
Miller distributor. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
* Accessory Kits
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE * Replacement Parts (No labor)
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Spoolmate Spoolguns
Within the warranty periods listed below, Miller will repair or
Your distributor also gives replace any warranted parts or components that fail due to such
* Canvas Covers
you ... defects in material or workmanship. Miller must be notified in Miller’s True Blue Limited Warranty shall not apply to:
Service writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim 1. Consumable components; such as contact tips,
You always get the fast, procedures to be followed. cutting nozzles, contactors, brushes, slip rings,
reliable response you relays or parts that fail due to normal wear. (Exception:
need. Most replacement Miller shall honor warranty claims on warranted equipment brushes, slip rings, and relays are covered on Bobcat,
parts can be in your listed below in the event of such a failure within the warranty Trailblazer, and Legend models.)
time periods. All warranty time periods start on the date that the
hands in 24 hours. equipment was delivered to the original retail purchaser, or one 2. Items furnished by Miller, but manufactured by others,
Support year after the equipment is sent to a North American distributor such as engines or trade accessories. These items are
Need fast answers to the or eighteen months after the equipment is sent to an covered by the manufacturer’s warranty, if any.
International distributor.
tough welding questions? 3. Equipment that has been modified by any party other than
Contact your distributor. 1. 5 Years Parts — 3 Years Labor Miller, or equipment that has been improperly installed,
The expertise of the * Original main power rectifiers improperly operated or misused based upon industry
distributor and Miller is * Inverters (input and output rectifiers only)
standards, or equipment which has not had reasonable
there to help you, every and necessary maintenance, or equipment which has
step of the way. 2. 3 Years — Parts and Labor been used for operation outside of the specifications for the
equipment.
* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND
* Semi-Automatic and Automatic Wire Feeders PERSONS TRAINED AND EXPERIENCED IN THE USE AND
* Inverter Power Sources (Unless Otherwise Stated) MAINTENANCE OF WELDING EQUIPMENT.
* Water Coolant Systems (Integrated) In the event of a warranty claim covered by this warranty, the
* Intellitig exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
* Maxstar 150 replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
* Engine Driven Welding Generators replacement at an authorized Miller service station; or (4)
(NOTE: Engines are warranted separately by payment of or credit for the purchase price (less reasonable
the engine manufacturer.) depreciation based upon actual use) upon return of the goods at
3. 1 Year — Parts and Labor Unless Specified customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
* DS-2 Wire Feeder F.O.B. at a Miller authorized service facility as determined by
* Motor Driven Guns (w/exception of Spoolmate Miller. Therefore no compensation or reimbursement for
Spoolguns) transportation costs of any kind will be allowed.
* Process Controllers TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* Positioners and Controllers PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
* Automatic Motion Devices DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
* RFCS Foot Controls CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
* Induction Heating Power Sources and Coolers
ANY OTHER LEGAL THEORY.
* Water Coolant Systems (Non-Integrated)
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
* Flowgauge and Flowmeter Regulators (No Labor) ANY IMPLIED WARRANTY, GUARANTY OR
* HF Units REPRESENTATION AS TO PERFORMANCE, AND ANY
* Grids REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
* Maxstar 85, 140 PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
* Spot Welders OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING ANY IMPLIED WARRANTY OF
* Load Banks MERCHANTABILITY OR FITNESS FOR PARTICULAR
* Arc Stud Power Sources & Arc Stud Guns PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
* Racks FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
* Running Gear/Trailers
* Plasma Cutting Torches (except APT & SAF Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
Models)
special or consequential damages, so the above limitation or
* Field Options exclusion may not apply to you. This warranty provides specific
(NOTE: Field options are covered under True legal rights, and other rights may be available, but may vary
Blue for the remaining warranty period of the from state to state.
product they are installed in, or for a minimum of
one year — whichever is greater.) In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
4. 6 Months — Batteries and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
5. 90 Days — Parts Warranty provides specific legal rights, and other rights may be
* MIG Guns/TIG Torches available, but may vary from province to province.
miller_warr 1/05
 Owner’s Record
Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for: Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
Replacement Parts An Illinois Tool Works Company
1635 West Spencer Street
Training (Schools, Videos, Books) Appleton, WI 54914 USA
International Headquarters−USA
Technical Manuals (Servicing Information USA Phone: 920-735-4505 Auto-Attended
and Parts) USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Circuit Diagrams
European Headquarters −
United Kingdom
Welding Process Handbooks Phone: 44 (0) 1204-593493
To locate a Distributor or Service Agency visit FAX: 44 (0) 1204-598066
www.millerwelds.com or call 1-800-4-A-Miller www.MillerWelds.com

Contact the Delivering Carrier to: File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.

PRINTED IN USA  2005 Miller Electric Mfg. Co. 1/05