Miller Electric Welding System Blue Star 145 User Manual

OM-4417

210 403F

2007−05

Processes

Stick (SMAW) Welding

Description

Engine Driven Welding Generator

Blue Star 145

Blue Star 145 DX

File: Engine Drive

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TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

1-6. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-7. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-8. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

2-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4. Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

2-6. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-7. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2-8. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4-2. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4-3. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4-4. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4-5. Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4-6. Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

5-2. Grounding Generator When Supplying Building Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

5-3. Engine Prestart Checks − Standard Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

5-4. Engine Prestart Checks − DX Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5-5. Connecting The Battery (DX Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5-6. Connecting T o Weld Output T e rminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5-7. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

SECTION 6 − OPERATING THE WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Controls (Standard Models) (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

6-2. Description Of Controls (Standard Models) (See Section 6-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

6-3. Controls (DX Models) (See Section 6-4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

6-4. Description Of Controls (DX Models) (See Section 6-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

SECTION 7 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

8-2. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

8-3. Adjusting Engine Speed (Standard Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

8-4. Adjusting Engine Speed (DX Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

SECTION 9 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 12 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 13 − STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COMPLETE PARTS LIST - www.MillerWelds.com

WARRANTY

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SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING

rom_2007−04

Protect yourself and others from injury — read and follow these precautions.

1-1. Symbol Usage

DANGER! − Indicates a hazardous situation which, if

not avoided, will result in death or serious injury. The

possible hazards are shown in the adjoining symbols

or explained in the text.

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury. The possible

hazards are shown in the adjoining symbols or ex-

plained in the text.

This group of symbols means Warning! Watch Out! ELECTRIC

SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-

bols and related instructions below for necessary actions to avoid the

hazards.

NOTICE − Indicates statements not related to personal injury.

1-2. Arc Welding Hazards

Always verify the supply ground — check and be sure that input

power cord ground wire is properly connected to ground terminal in

disconnect box or that cord plug is connected to a properly

groundedreceptacle outlet.

When making input connections, attach proper grounding conduc-

tor first − double-check connections.

Keep cords dry, free of oil and grease, and protected from hot metal

and sparks.

Frequentlyinspect input power cord for damage or bare wiring —

replace cord immediately if damaged — bare wiring can kill.

Turn off all equipment when not in use.

Do not use worn, damaged, undersized, or poorly spliced cables.

Do not drape cables over your body.

The symbols shown below are used throughout this manual

to call attention to and identify possible hazards. When you

see the symbol, watch out, and follow the related instructions

to avoid the hazard. The safety information given below is

only a summary of the more complete safety information

found in the Safety Standards listed in Section 1-7. Read and

follow all Safety Standards.

Only qualified persons should install, operate, maintain, and

repair this unit.

During operation, keep everybody, especially children, away.

If earth grounding of the workpiece is required, ground it directly

with a separate cable.

ELECTRIC SHOCK can kill.

Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

Do not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will be

present.

Wear a safety harness if working above floor level.

Keep all panels and covers securely in place.

Touching live electrical parts can cause fatal shocks or

severe burns. The electrode and work circuit is

electrically live whenever the output is on. The input

power circuit and machine internal circuits are also live when power is

on. In semiautomatic or automatic wire welding, the wire, wire reel,

drive roll housing, and all metal parts touching the welding wire are

electrically live. Incorrectly installed or improperly grounded equip-

ment is a hazard.

Do not touch live electrical parts.

Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

Wear dry, hole-free insulating gloves and body protection.

Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work

or ground.

Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

Do not connect more than one electrode or work cable to any

single weld output terminal.

Do not use AC output in damp areas, if movement is confined, or if

there is a danger of falling.

SIGNIFICANT DC VOLTAGE exists in inverters after stop-

ping engine.

Use AC output ONLY if required for the welding process.

Stop engine on inverter and discharge input capacitors according

to instructions in Maintenance Section before touching any parts.

If AC output is required, use remote output control if present on

unit.

Additionalsafety precautions are required when any of the follow-

ing electrically hazardous conditions are present: in damp

locations or while wearing wet clothing; on metal structures such

as floors, gratings, or scaffolds; when in cramped positions such

as sitting, kneeling, or lying; or when there is a high risk of unavoid-

able or accidental contact with the workpiece or ground. For these

conditions, use the following equipment in order presented: 1) a

semiautomaticDC constant voltage (wire) welder, 2) a DC manual

(stick) welder, or 3) an AC welder with reduced open-circuit volt-

age. In most situations, use of a DC, constant voltage wire welder

is recommended. And, do not work alone!

HOT PARTS can cause severe burns.

Do not touch hot parts bare handed.

Allow cooling period before working on equip-

ment.

To handle hot parts, use proper tools and/or wear heavy, insu-

lated welding gloves and clothing to prevent burns.

FLYING METAL or DIRT can injure eyes.

Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool,

they can throw off slag.

Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according to

OSHA 29 CFR 1910.147 (see Safety Standards).

Wear approved safety glasses with side shields even under your

welding helmet.

Properly install and ground this equipment according to its

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

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Do not weld on closed containers such as tanks, drums, or pipes,

unless they are properly prepared according to AWS F4.1 (see

Safety Standards).

FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing these

fumes and gases can be hazardous to your health.

Do not weld where the atmosphere may contain flammable dust,

gas, or liquid vapors (such as gasoline).

Keep your head out of the fumes. Do not breathe the fumes.

If inside, ventilate the area and/or use local forced ventilation at the

arc to remove welding fumes and gases.

Connect work cable to the work as close to the welding area as

practical to prevent welding current from traveling long, possibly

unknown paths and causing electric shock, sparks, and fire haz-

ards.

If ventilation is poor, wear an approved air-supplied respirator.

Do not use welder to thaw frozen pipes.

Read and understand the Material Safety Data Sheets (MSDSs)

and the manufacturer’s instructions for metals, consumables,

coatings, cleaners, and degreasers.

Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

Wear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap.

Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watch-

person nearby. Welding fumes and gases can displace air and

lower the oxygen level causing injury or death. Be sure the breath-

ing air is safe.

Do not weld in locations near degreasing, cleaning, or spraying op-

erations. The heat and rays of the arc can react with vapors to form

highly toxic and irritating gases.

Do not weld on coated metals, such as galvanized, lead, or

cadmiumplated steel, unless the coating is removed from the weld

area, the area is well ventilated, and while wearing an air-supplied

respirator. The coatings and any metals containing these elements

can give off toxic fumes if welded.

Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

After completion of work, inspect area to ensure it is free of sparks,

glowing embers, and flames.

Use only correct fuses or circuit breakers. Do not oversize or by-

pass them.

Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B

for hot work and have a fire watcher and extinguisher nearby.

NOISE can damage hearing.

Noise from some processes or equipment can dam-

age hearing.

BUILDUP OF GAS can injure or kill.

Shut off shielding gas supply when not in use.

Always ventilate confined spaces or use ap-

proved air-supplied respirator.

Wear approved ear protection if noise level is

high.

MAGNETIC FIELDS can affect Implanted

Medical Devices.

ARC RAYS can burn eyes and skin.

Wearers of Pacemakers and other Implanted

Medical Devices should keep away.

Arc rays from the welding process produce intense

visible and invisible (ultraviolet and infrared) rays that

can burn eyes and skin. Sparks fly off from the weld.

ImplantedMedical Device wearers should consult their doctor

and the device manufacturer before going near arc welding, spot

welding, gouging, plasma arc cutting, or induction heating

operations.

Wear an approved welding helmet fitted with a proper shade of filter

lenses to protect your face and eyes from arc rays and sparks

when welding or watching (see ANSI Z49.1 and Z87.1 listed in

Safety Standards).

Wear approved safety glasses with side shields under your

helmet.

Use protective screens or barriers to protect others from flash,

glare, and sparks; warn others not to watch the arc.

Wear protective clothing made from durable, flame-resistant mate-

rial (leather, heavy cotton, or wool) and foot protection.

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high pres-

sure. If damaged, a cylinder can explode. Since gas

cylinders are normally part of the welding process, be

sure to treat them carefully.

Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, physical damage, slag, open flames, sparks, and arcs.

Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

WELDING can cause fire or explosion.

Keep cylinders away from any welding or other electrical circuits.

Never drape a welding torch over a gas cylinder.

Welding on closed containers, such as tanks, drums,

or pipes, can cause them to blow up. Sparks can fly off

from the welding arc. The flying sparks, hot workpiece,

Never allow a welding electrode to touch any cylinder.

Never weld on a pressurized cylinder — explosion will result.

and hot equipment can cause fires and burns. Accidental contact of

electrodeto metal objects can cause sparks, explosion, overheating,

or fire. Check and be sure the area is safe before doing any welding.

Use only correct shielding gas cylinders, regulators, hoses, and fit-

tings designed for the specific application; maintain them and

associated parts in good condition.

Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

Turn face away from valve outlet when opening cylinder valve.

Do not weld where flying sparks can strike flammable material.

Protect yourself and others from flying sparks and hot metal.

Keep protective cap in place over valve except when cylinder is in

use or connected for use.

Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

Use the right equipment, correct procedures, and sufficient num-

ber of persons to lift and move cylinders.

Watch for fire, and keep a fire extinguisher nearby.

Read and follow instructions on compressed gas cylinders,

associated equipment, and Compressed Gas Association (CGA)

publication P-1 listed in Safety Standards.

Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

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1-3. Engine Hazards

STEAM AND HOT COOLANT can burn.

BATTERY EXPLOSION can BLIND.

If possible, check coolant level when engine is

cold to avoid scalding.

Always wear a face shield, rubber gloves, and

protective clothing when working on a battery.

Always check coolant level at overflow tank, if

present on unit, instead of radiator (unless told

otherwise in maintenance section or engine

manual).

Stop engine before disconnecting or connect-

ing battery cables or servicing battery.

Do not allow tools to cause sparks when working on a battery.

Do not use welder to charge batteries or jump start vehicles.

Observe correct polarity (+ and −) on batteries.

If the engine is warm, checking is needed, and there is no over-

flow tank, follow the next two statements.

Disconnect negative (−) cable first and connect it last.

Wear safety glasses and gloves and put a rag over radiator cap.

Turn cap slightly and let pressure escape slowly before

completely removing cap.

FUEL can cause fire or explosion.

Stop engine and let it cool off before checking or

adding fuel.

Do not add fuel while smoking or if unit is near

any sparks or open flames.

Using a generator indoors CAN KILL

YOU IN MINUTES.

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.

Generator exhaust contains carbon monoxide.

This is a poison you cannot see or smell.

Always keep nozzle in contact with tank when fueling.

NEVER use inside a home or garage, EVEN IF

doors and windows are open.

Only use OUTSIDE and far away from windows, doors, and

vents.

MOVING PARTS can cause injury.

Keep away from fans, belts, and rotors.

Keep all doors, panels, covers, and guards

closed and securely in place.

BATTERY ACID can BURN SKIN and EYES.

Stop engine before installing or connecting unit.

Do not tip battery.

Replace damaged battery.

Flush eyes and skin immediately with water.

Have only qualified people remove doors, panels, covers, or

guards for maintenance and troubleshooting as necessary.

To prevent accidental starting during servicing, disconnect

negative (−) battery cable from battery.

Keep hands, hair, loose clothing, and tools away from moving

parts.

ENGINE HEAT can cause fire.

Reinstall doors, panels, covers, or guards when servicing is

finished and before starting engine.

Do not locate unit on, over, or near combustible

surfaces or flammables.

Before working on generator, remove spark plugs or injectors to

keep engine from kicking back or starting.

Keep exhaust and exhaust pipes way from

flammables.

Block flywheel so that it will not turn while working on generator

components.

HOT PARTS can cause severe burns.

Do not touch hot parts bare handed.

Allow cooling period before working on equip-

ment.

To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves and

clothing to prevent burns.

EXHAUST SPARKS can cause fire.

Do not let engine exhaust sparks cause fire.

Use approved engine exhaust spark arrestor in

required areas — see applicable codes.

1-4. Compressed Air Hazards

TRAPPED AIR PRESSURE AND WHIPPING

HOSES can cause injury.

BREATHING COMPRESSED AIR can

cause serious injury or death.

Release air pressure from tools and system be-

fore servicing, adding or changing attach-

ments, or opening compressor oil drain or oil fill

cap.

Do not use compressed air for breathing.

Use only for cutting, gouging, and tools.

COMPRESSED AIR can cause injury.

Wear approved safety goggles.

Do not direct air stream toward self or others.

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HOT METAL from air arc cutting and

gouging can cause fire or explosion.

READ INSTRUCTIONS.

Read Owner’s Manual before using or servic-

ing unit.

Stop engine and release air pressure before

servicing.

Use only genuine replacement parts from the

manufacturer.

Do not cut or gouge near flammables.

Watch for fire; keep extinguisher nearby.

HOT PARTS can cause burns and injury.

Do not touch hot compressor or air system

parts.

Let system cool down before touching or ser-

vicing.

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

FIRE OR EXPLOSION hazard.

WELDING WIRE can cause injury.

Do not install or place unit on, over, or near

combustiblesurfaces.

Do not press gun trigger until instructed to do

so.

Do not install unit near flammables.

Do not point gun toward any part of the body,

other people, or any metal when threading

welding wire.

Do not overload building wiring − be sure power supply system is

properly sized, rated, and protected to handle this unit.

FALLING UNIT can cause injury.

OVERUSE can cause OVERHEATING.

Use lifting eye to lift unit and properly installed

accessories only, NOT gas cylinders. Do not

exceed maximum lift eye weight rating (see

Specifications).

Lift and support unit only with proper equipment

and correct procedures.

Allow cooling period; follow rated duty cycle.

Reduce current or reduce duty cycle before

starting to weld again.

Do not block or filter airflow to unit.

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

extend beyond opposite side of unit.

STATIC (ESD) can damage PC boards.

Put on grounded wrist strap BEFORE handling

boards or parts.

OVERHEATING can damage motors.

Use proper static-proof bags and boxes to

store, move, or ship PC boards.

Turn off or unplug equipment before starting or

stopping engine.

Do not let low voltage and frequency caused by

low engine speed damage electric motors.

TILTING OF TRAILER can cause injury.

Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle

where applicable.

Use tongue jack or blocks to support weight.

Properly install welding generator onto trailer

according to instructions supplied with trailer.

FLYING SPARKS can cause injury.

Wear a face shield to protect eyes and face.

Shape tungsten electrode only on grinder with

proper guards in a safe location wearing proper

face, hand, and body protection.

READ INSTRUCTIONS.

Read Owner’s Manual before using or servic-

ing unit.

Use only genuine replacement parts from the

manufacturer.

Perform engine and air compressor mainte-

nance and service according to this manual

and the engine/air compressor (if applicable)

manuals.

Sparks can cause fires — keep flammables away.

MOVING PARTS can cause injury.

Keep away from moving parts.

Keep away from pinch points such as drive

rolls.

OM-4417 Page 4

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H.F. RADIATION can cause interference.

ARC WELDING can cause interference.

High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and

communicationsequipment.

Have only qualified persons familiar with

electronic equipment perform this installation.

Electromagnetic energy can interfere with

sensitive electronic equipment such as micro-

processors, computers, and computer-driven

equipmentsuch as robots.

Be sure all equipment in the welding area is

electromagneticallycompatible.

The user is responsible for having a qualified electrician

promptly correct any interference problem resulting from the

installation.

To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

If notified by the FCC about interference, stop using the

equipmentat once.

Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

Have the installation regularly checked and maintained.

Be sure this welding machine is installed and grounded

according to this manual.

Keep high-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding to

minimize the possibility of interference.

If interference still occurs, the user must take extra measures

such as moving the welding machine, using shielded cables,

using line filters, or shielding the work area.

1-6. California Proposition 65 Warnings

For Gasoline Engines:

Welding or cutting equipment produces fumes or gases

which contain chemicals known to the State of California to

cause birth defects and, in some cases, cancer. (California

Health & Safety Code Section 25249.5 et seq.)

Engine exhaust contains chemicals known to the State of

California to cause cancer, birth defects, or other reproduc-

tive harm.

For Diesel Engines:

Battery posts, terminals and related accessories contain lead

and lead compounds, chemicals known to the State of

California to cause cancer and birth defects or other

reproductiveharm. Wash hands after handling.

Diesel engine exhaust and some of its constituents are

known to the State of California to cause cancer, birth

defects, and other reproductive harm.

1-7. Principal Safety Standards

Safety inWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,

from Global Engineering Documents (phone: 1-877-413-5184, website:

www.global.ihs.com).

Ontario, Canada L4W 5NS (phone: 800-463-6727 or in Toronto

416-747-4044,website: www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protec-

tion, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036–8002 (phone:

212-642-4900,website: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work, NFPA Standard 51B, from National Fire Protection Association,

P.O. Box 9101, Quincy, MA 02269-9101 (phone: 617-770-3000, web-

site: www.nfpa.org.

Recommended Safe Practices for the Preparation for Weldingand Cut-

ting of Containers and Piping, American Welding Society Standard

AWS F4.1, from Global Engineering Documents (phone:

1-877-413-5184,website: www.global.ihs.com).

NationalElectrical Code, NFPA Standard 70, from National Fire Protec-

tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (phone:

617-770-3000,website: www.nfpa.org and www. sparky.org).

OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,

and Part 1926, Subpart J, from U.S. Government Printing Office, Super-

intendentof Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954

(phone: 1-866-512-1800) (there are 10 Regional Offices—phone for

Region 5, Chicago, is 312-353-2220, website: www.osha.gov).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

from Compressed Gas Association, 4221 Walney Road, 5th Floor,

Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, from

CanadianStandards Association, Standards Sales, 5060 Mississauga,

1-8. EMF Information

Considerations About Welding And The Effects Of Low Frequency

Electric And Magnetic Fields

1. Keep cables close together by twisting or taping them, or using a

cable cover.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep welding power source and cables as far away from

operator as practical.

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

possible.

Welding current, as it flows through welding cables, will cause electro-

magnetic fields. There has been and still is some concern about such

fields. However, after examining more than 500 studies spanning 17

years of research, a special blue ribbon committee of the National

Research Council concluded that: “The body of evidence, in the

committee’s judgment, has not demonstrated that exposure to power-

frequency electric and magnetic fields is a human-health hazard.”

However, studies are still going forth and evidence continues to be

examined.Until the final conclusions of the research are reached, you

may wish to minimize your exposure to electromagnetic fields when

welding or cutting.

About Implanted Medical Devices:

ImplantedMedical Device wearers should consult their doctor and the

device manufacturer before performing or going near arc welding, spot

welding, gouging, plasma arc cutting, or induction heating operations.

If cleared by your doctor, then following the above procedures is recom-

mended.

To reduce magnetic fields in the workplace, use the following

procedures:

OM-4417 Page 5

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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT

UTILISATION

rom_2007−04fre

Se protéger, ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud.

2-1. Signification des symboles

DANGER! − Indique une situation dangereuse qui si on

l’évite pas peut donner la mort ou des blessures graves.

Les dangers possibles sont montrés par les symboles

joints ou sont expliqués dans le texte.

Indique une situation dangereuse qui si on l’évite pas

peut donner la mort ou des blessures graves. Les dan-

gers possibles sont montrés par les symboles joints ou

sont expliqués dans le texte.

Ce groupe de symboles veut dire Avertissement! Attention! DANGER

DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES

CHAUDES. Consulter les symboles et les instructions ci-dessous y

afférant pour les actions nécessaires afin d’éviter le danger.

NOTE − Indique des déclarations pas en relation avec des blessures

personnelles.

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

souder DC semi−automatique de type CV (MIG/MAG), 2) un poste

à souder manuel (électrode enrobée) DC, 3) un poste à souder

manuelAC avec tension à vide réduite. Dans la plupart des cas, un

poste courant continu de type CV est recommandé. Et, ne pas tra-

vailler seul!

Les symboles présentés ci-après sont utilisés tout au long du

présent manuel pour attirer votre attention et identifier les ris-

ques de danger. Lorsque vous voyez un symbole, soyez

vigilant et suivez les directives mentionnées afin d’éviter tout

danger. Les consignes de sécurité présentées ci-après ne

font que résumer l’information contenue dans les normes de

sécurité énumérées à la section 2-7. Veuillez lire et respecter

toutes ces normes de sécurité.

Couper l’alimentation ou arrêter le moteur avant de procéder à

l’installation, à la réparation ou à l’entretien de l’appareil.

Déverrouiller l’alimentation selon la norme OSHA 29 CFR

1910.147(voir normes de sécurité).

Installer et mettre à la terre correctement cet appareil conformé-

ment à son manuel d’utilisation et aux codes nationaux,

provinciaux et municipaux.

L’installation, l’utilisation, l’entretien et les réparations ne

doivent être confiés qu’à des personnes qualifiées.

Toujours vérifier la terre du cordon d’alimentation − Vérifier et

s’assurer que le fil de terre du cordon d’alimentation est bien

raccordé à la borne de terre du sectionneur ou que la fiche du

cordon est raccordée à une prise correctement mise à la terre.

Au cours de l’utilisation, tenir toute personne à l’écart et plus

particulièrementles enfants.

UN CHOC ÉLECTRIQUE peut tuer.

En effectuant les raccordements d’entrée fixer d’abord le conduc-

teur de mise à la terre approprié et contre-vérifier les connexions.

Un simple contact avec des pièces électriques peut

provoquerune électrocution ou des blessures graves.

L’électrode et le circuit de soudage sont sous tension

Les câbles doivent être exempts d’humidité, d’huile et de graisse;

protégez−les contre les étincelles et les pièces métalliques chau-

des.

dès que l’appareil est sur ON. Le circuit d’entrée et les circuits

internes de l’appareil sont également sous tension à ce moment-là.

En soudage semi-automatique ou automatique, le fil, le dévidoir, le

logement des galets d’entraînement et les pièces métalliques en

contact avec le fil de soudage sont sous tension. Des matériels mal

installés ou mal mis à la terre présentent un danger.

Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est

pas endommagé ou dénudé − remplacer le cordon immédiatement

s’il est endommagé − un câble dénudé peut provoquer une électro-

cution.

Mettre l’appareil hors tension quand on ne l’utilise pas.

Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-

sante ou mal épissés.

Ne jamais toucher les pièces électriques sous tension.

Porter des gants et des vêtements de protection secs ne compor-

tant pas de trous.

Ne pas enrouler les câbles autour du corps.

Si la pièce soudée doit être mise à la terre, le faire directement

avec un câble distinct − ne pas utiliser le connecteur de pièce ou le

câble de retour.

S’isoler de la pièce et de la terre au moyen de tapis ou d’autres

moyens isolants suffisamment grands pour empêcher le contact

physique éventuel avec la pièce ou la terre.

Ne pas toucher l’électrode quand on est en contact avec la pièce,

la terre ou une électrode provenant d’une autre machine.

Ne pas se servir de source électrique à courant électrique dans les

zones humides, dans les endroits confinés ou là où on risque de

tomber.

Ne pas toucher des porte électrodes connectés à deux machines

en même temps à cause de la présence d’une tension à vide dou-

blée.

Se servir d’une source électrique à courant électrique UNIQUE-

MENT si le procédé de soudage le demande.

N’utiliser qu’un matériel en bon état. Réparer ou remplacer

sur-le-champ les pièces endommagées. Entretenir l’appareil

conformémentà ce manuel.

Si l’utilisation d’une source électrique à courant électrique s’avère

nécessaire, se servir de la fonction de télécommande si l’appareil

en est équipé.

Porter un harnais de sécurité quand on travaille en hauteur.

Maintenir solidement en place tous les panneaux et capots.

Des précautions de sécurité supplémentaires sont requises dans

des environnements à risque comme: les endroits humides ou

lorsque l’on porte des vêtements mouillés; sur des structures mé-

talliques au sol, grillages et échafaudages; dans des positions

assises, à genoux et allongées; ou quand il y a un risque important

de contact accidentel avec la pièce ou le sol. Dans ces cas utiliser

les appareils suivants dans l’ordre de préférence: 1) un poste à

Fixer le câble de retour de façon à obtenir un bon contact métal-

métal avec la pièce à souder ou la table de travail, le plus près

possible de la soudure.

Isoler la pince de masse quand pas mis à la pièce pour éviter le

contact avec tout objet métallique.

OM-4417 Page 6

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Une tension DC importante subsiste à l’intérieur

des onduleurs après avoir coupé l’alimentation.

LES RAYONS DE L’ARC peuvent pro

voquer des brûlures dans les yeux e

sur la peau.

Couper l’alimentation du poste et décharger les condensateurs

d’entrée comme indiqué dans la Section Maintenance avant de

toucher des composants.

Le rayonnement de l’arc du procédé de soudage

génère des rayons visibles et invisibles intense

(ultraviolets et infrarouges) susceptibles de provoquer des brûlure

dans les yeux et sur la peau. Des étincelles sont projetées pendant le

soudage.

DES PIÈCES CHAUDES peuvent

provoquer des brûlures graves.

Ne pas toucher à mains nues les parties chau-

des.

Prévoir une période de refroidissement avant de

travailler à l’équipement.

Porter un casque de soudage approuvé muni de verres filtrants

approprié pour protéger visage et yeux pendant le soudage

(voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).

Porter des lunettes de sécurité avec écrans latéraux même sous

votre casque.

Ne pas toucher aux pièces chaudes, utiliser les outils recomman-

dés et porter des gants de soudage et des vêtements épais pour

éviter les brûlures.

Avoir recours à des écrans protecteurs ou à des rideaux pour

protéger les autres contre les rayonnements les éblouissements

et les étincelles ; prévenir toute personne sur les lieux de ne pas

regarder l’arc.

Porter des vêtements confectionnés avec des matières résistan-

tes et ignifuges (cuir, coton lourd ou laine) et des bottes de

protection.

DES PIECES DE METAL ou DES SA-

LETES peuvent provoquer des bles-

sures dans les yeux.

LE SOUDAGE peut provoquer un in

cendie ou une explosion.

Le soudage, l’écaillement, le passage de la pièce à la brosse en

fil de fer, et le meulage génèrent des étincelles et des particules

métalliquesvolantes. Pendant la période de refroidissement des

soudures, elles risquent de projeter du laitier.

Le soudage effectué sur des conteneurs fermés tel

que des réservoirs, tambours ou des conduites peu

provoquer leur éclatement. Des étincelles peuven

être projetées de l’arc de soudure. La projection d’étincelles, des pièce

chaudes et des équipements chauds peut provoquer des incendies e

des brûlures. Le contact accidentel de l’électrode avec des objet

métalliquespeut provoquer des étincelles, une explosion, un surchauf

fement ou un incendie. Avant de commencer le soudage, vérifier e

s’assurer que l’endroit ne présente pas de danger.

Porter des lunettes de sécurité avec écrans latéraux ou un écran

facial.

LES FUMÉES ET LES GAZ peuvent être

dangereux.

Déplacer toutes les substances inflammables à une distance de

10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir

soigneusementavec des protections homologués.

Le soudage génère des fumées et des gaz. Leur

inhalationpeut être dangereux pour votre santé.

Ne pas souder dans un endroit là où des étincelles peuvent tomber

sur des substances inflammables.

Eloigner votre tête des fumées. Ne pas respirer les fumées.

À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au

niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.

Se protéger et d’autres personnes de la projection d’étincelles et

de métal chaud.

Des étincelles et des matériaux chauds du soudage peuvent

facilement passer dans d’autres zones en traversant de petites

fissures et des ouvertures.

Si la ventilation est médiocre, porter un respirateur anti-vapeurs

approuvé.

Lire et comprendre les spécifications de sécurité des matériaux

(MSDS) et les instructions du fabricant concernant les métaux, les

consommables, les revêtements, les nettoyants et les dégraisseurs.

Surveiller tout déclenchement d’incendie et tenir un extincteur à

proximité.

Le soudage effectué sur un plafond, plancher, paroi ou séparation

peut déclencher un incendie de l’autre côté.

Travailler dans un espace fermé seulement s’il est bien ventilé ou

en portant un respirateur à alimentation d’air. Demander toujours à

un surveillant dûment formé de se tenir à proximité. Des fumées et

des gaz de soudage peuvent déplacer l’air et abaisser le niveau

d’oxygène provoquant des blessures ou des accidents mortels.

S’assurer que l’air de respiration ne présente aucun danger.

Ne pas effectuer le soudage sur des conteneurs fermés tels que

des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été

préparés correctement conformément à AWS F4.1 (voir les nor-

mes de sécurité).

Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou va-

peurs inflammables (vapeur d’essence, par exemple).

Ne pas souder dans des endroits situés à proximité d’opérations

de dégraissage, de nettoyage ou de pulvérisation. La chaleur et

les rayons de l’arc peuvent réagir en présence de vapeurs et for-

mer des gaz hautement toxiques et irritants.

Brancher le câble de masse sur la pièce le plus près possible de la

zone de soudage pour éviter le transport du courant sur une

longue distance par des chemins inconnus éventuels en provo-

quant des risques d’électrocution, d’étincelles et d’incendie.

Ne pas souder des métaux munis d’un revêtement, tels que l’acier

galvanisé, plaqué en plomb ou au cadmium à moins que le revête-

ment n’ait été enlevé dans la zone de soudure, que l’endroit soit

bien ventilé, et en portant un respirateur à alimentation d’air. Les

revêtementset tous les métaux renfermant ces éléments peuvent

dégager des fumées toxiques en cas de soudage.

Ne pas utiliser le poste de soudage pour dégeler des conduites ge-

lées.

En cas de non utilisation, enlever la baguette d’électrode du porte-

électrode ou couper le fil à la pointe de contact.

Porter des vêtements de protection dépourvus d’huile tels que des

gants en cuir, une chemise en matériau lourd, des pantalons sans

revers, des chaussures hautes et un couvre chef.

LES ACCUMULATIONS DE GAZ ris

quent de provoquer des blessures ou

même la mort.

Avant de souder, retirer toute substance combustible de vos po-

ches telles qu’un allumeur au butane ou des allumettes.

Fermer l’alimentation du gaz protecteur en cas de

non utilisation.

Une fois le travail achevé, assurez−vous qu’il ne reste aucune tra-

ce d’étincelles incandescentes ni de flammes.

Veiller toujours à bien aérer les espaces confinés ou se servir d’un

respirateurd’adduction d’air homologué.

Utiliser exclusivement des fusibles ou coupe−circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

OM-4417 Page 7

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Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et

NFPA 51B pour les travaux à chaud et avoir de la surveillance et un

extincteur à proximité.

Protéger les bouteilles de gaz comprimé d’une chaleur excessive,

des chocs mécaniques, des dommages physiques, du laitier, des

flammes ouvertes, des étincelles et des arcs.

Placer les bouteilles debout en les fixant dans un support station-

naire ou dans un porte-bouteilles pour les empêcher de tomber ou

de se renverser.

LE BRUIT peut affecter l’ouïe.

Le bruit des processus et des équipements peut affec

l’ouïe.

Tenir les bouteilles éloignées des circuits de soudage ou autres

circuits électriques.

Porter des protections approuvés pour les ore

les si le niveau sonore est trop élevé.

Ne jamais placer une torche de soudage sur une bouteille à gaz.

Une électrode de soudage ne doit jamais entrer en contact avec

une bouteille.

LES CHAMPS MAGNETIQUES peuvent affec-

ter des implants médicaux.

Ne jamais souder une bouteille pressurisée − risque d’explosion.

Porteur de simulateur cardiaque ou autre im-

plants médicaux, rester à distance.

Utiliser seulement des bouteilles de gaz protecteur, régulateurs,

tuyaux et raccords convenables pour cette application spécifique;

les maintenir ainsi que les éléments associés en bon état.

Les porteurs d’implants doivent d’abord consulter leur médecin

avant de s’approcher des opérations de soudage à l’arc, de sou-

dage par points, de gougeage, du coupage plasma ou de chauf-

fage par induction.

Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la

bouteille.

Si des BOUTEILLES sont endomma

gées, elles pourront exploser.

Maintenir le chapeau de protection sur la soupape, sauf en cas

d’utilisationou de branchement de la bouteille.

Utiliser les équipements corrects, les bonnes procédures et suffi-

samment de personnes pour soulever et déplacer les bouteilles.

Des bouteilles de gaz protecteur contiennent du ga

sous haute pression. Si une bouteille est endomma

gée, elle peut exploser. Du fait que les bouteilles de gaz fon

normalement partie du procédé de soudage, les manipuler ave

précaution.

Lire et suivre les instructions sur les bouteilles de gaz comprimé,

l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas

Association) mentionné dans les principales normes de sécurité.

2-3. Dangers existant en relation avec le moteur

Seules des personnes qualifiées sont autorisées à enlever les por-

tes, panneaux, recouvrements ou dispositifs de protection pour

effectuer, s’il y a lieu, des travaux d’entretien et de dépannage.

L’EXPLOSION DE LA BATTERIE peu

RENDRE AVEUGLE.

Pour empêcher tout démarrage accidentel pendant les travaux

d’entretien,débrancher le câble négatif (−) de batterie de la borne.

Toujours porter une protection faciale, des gants

en caoutchouc et vêtements de protection lors

d’une intervention sur la batterie.

Ne pas approcher les mains, cheveux, vêtements lâches et outils

des organes mobiles.

Arrêter le moteur avant de débrancher ou de brancher les câbles

de batterie.

Remettreen place les panneaux ou les dispositifs de protection et

fermer les portes à la fin des travaux d’entretien et avant de faire

démarrer le moteur.

Eviter de provoquer des étincelles avec les outils en travaillant sur

la batterie.

Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la

mise en route accidentelle du moteur.

Ne pas utiliser le poste de soudage pour charger les batteries ou

des véhicules de démarrage rapide.

Bloquerle volant moteur pour éviter sa rotation lors d’une interven-

tion sur le générateur.

Observer la polarité correcte (+ et −) sur les batteries.

Débrancher le câble négatif (–) en premier lieu. Le rebrancher en

dernier lieu.

DES PIÈCES CHAUDES peuvent

provoquer des brûlures graves.

LE CARBURANT MOTEUR peut provo

quer un incendie ou une explosion.

Ne pas toucher à mains nues les parties chau-

des.

Prévoir une période de refroidissement avant de

travailler à l’équipement.

Arrêter le moteur avant de vérifier le niveau de

carburant ou de faire le plein.

Ne pas toucher aux pièces chaudes, utiliser les outils recomman-

dés et porter des gants de soudage et des vêtements épais pour

éviter les brûlures.

Ne pas faire le plein en fumant ou proche d’une source d’étincelles

ou d’une flamme nue.

Ne pas faire le plein de carburant à ras bord; prévoir de l’espace

pour son expansion.

LA VAPEUR ET LE LIQUIDE DE

REFROIDISSEMENT CHAUD peuvent

provoquer des brûlures.

Faire attention de ne pas renverser de carburant. Nettoyer tout

carburant renversé avant de faire démarrer le moteur.

Jeter les chiffons dans un récipient ignifuge.

Il est préférable de vérifier le liquide de refroi-

dissementune fois le moteur refroidi pour éviter

de se brûler.

Toujours garder le pistolet en contact avec le réservoir lors du

remplissage.

DES ORGANES MOBILES peuvent pro

voquer des blessures.

Toujours vérifier le niveau de liquide de refroidissement dans le

vase d’expansion (si présent), et non dans le radiateur (sauf si pré-

cisé autrement dans la section maintenance du manuel du

moteur).

Ne pas approcher les mains des ventilateurs,

courroies et autres pièces en mouvement.

Si le moteur est chaud et que le liquide doit être vérifié, opérer com-

me suivant.

Maintenirfermés et fixement en place les portes, panneaux, re-

couvrements et dispositifs de protection.

Mettre des lunettes de sécurité et des gants, placer un torchon sur

le bouchon du radiateur.

Arrêter le moteur avant d’installer ou brancher l’appareil.

OM-4417 Page 8

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Dévisser le bouchon légèrement et laisser la vapeur s’échapper

avant d’enlever le bouchon.

LA CHALEUR DU MOTEUR peut pro-

voquer un incendie.

L’utilisation d’un groupe autonome

à l’intérieur PEUT VOUS TUER EN

QUELQUES MINUTES.

Ne pas placer l’appareil sur, au-dessus ou à

proximité de surfaces inflammables.

Tenir à distance les produits inflammables de l’échappement.

Les fumées d’un groupe autonome contient du

monoxyde de carbone. C’est un poison invisi-

ble et inodore.

LES ÉTINCELLES À L’ÉCHAPPEMENT

peuvent provoquer un incendie.

JAMAIS utiliser dans une maison ou garage,

même avec les portes et fenêtres ouvertes.

Empêcher les étincelles d’échappement du

moteur de provoquer un incendie.

Uniquementutiliser à l’EXTERIEUR, loin des portes, fenêtres et

bouches aération.

Utiliser uniquement un pare-étincelles

approuvé − voir codes en vigueur.

L’ACIDE DE LA BATTERIE peut pro-

voquer des brûlures dans les YEUX et

sur la PEAU.

Ne pas renverser la batterie.

Remplacer une batterie endommagée.

Rincer immédiatement les yeux et la peau à l’eau.

2-4. Dangers liés à l’air comprimé

Le METAL CHAUD lors du coupage et

gougeage plasma peut provoquer un in-

cendie ou une explosion.

RESPIRER L’AIR COMPRIMÉ peut pro-

voquer des blessures graves ou causer

la mort.

Ne pas couper ou gouger à proximité de pro-

duits inflammables.

Surveillez et garder un extincteur à proximité.

Ne pas utiliser l’air comprimé pour respirer.

Utiliser l’air comprimé seulement pour le cou-

page, gougeage et les outils pneumatiques.

DES PIECES CHAUDES peuvent provo-

quer des brûlures et blessures.

L’AIR COMPRIMÉ peut provoquer

des blessures.

Ne pas toucher le compresseur ou d’autres

éléments du circuit air comprimé chauds.

Porter des lunettes de sécurité approuvées.

Ne pas diriger le jet d’air vers d’autres ou

soi-même.

Laisser l’ensemble se refroidir avant de toucher ou d’effectuer la

maintenance.

L’AIR COMPRIME EMMAGASINE ET DES

TUYAUX SOUS PRESSION peuvent provo-

quer des blessures.

LIRE LES INSTRUCTIONS.

Lisez le manuel d’instructions avant l’utilisation

ou la maintenance de l’appareil.

Relâcher la pression d’air de l’outillage ou du

système avant d’effectuer la maintenance,

avant de changer ou de rajouter des éléments

ou avant d’ouvrir la purge ou le bouchon de

remplissaged’huile.

Arrêter le moteur et relâcher la pression avant

d’effectuer la maintenance.

N’utiliser que les pièces de rechange recommandées par le

constructeur.

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

Risque D’INCENDIE OU D’EXPLO-

SION.

LA CHUTE DE L’APPAREIL peut blesser.

Utiliser l’anneau de levage pour lever l’appareil et

les accessoires correctement installées seuls,

PAS les bouteilles de gaz. Ne pas dépasser le

poids nominal maximal de l’œilleton (voir les spé-

cifications).

Ne pas placer l’appareil sur, au-dessus ou

à proximité de surfaces inflammables.

Ne pas installer l’appareil à proximité de pro-

duits inflammables.

Ne lever et ne soutenir l’appareil qu’avec de

l’équipement approprié et en suivant les

procédures adéquates.

Ne pas surcharger l’installation électrique − s’assurer que l’ali-

mentationest correctement dimensionnée et protégée avant de

mettre l’appareil en service.

En utilisant des fourches de levage pour déplacer l’unité, s’assurer

que les fourches sont suffisamment longues pour dépasser du

côté opposé de l’appareil.

OM-4417 Page 9

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UNE REMORQUE QUI BASCULE peut

entraîner des blessures.

LE SURCHAUFFEMENT peut endom-

mager le moteur électrique.

Utiliser les supports de la remorque ou des

blocs pour soutenir le poids.

Arrêter ou déconnecter l’équipement avant de

démarrer ou d’arrêter le moteur.

Installer convenablement le poste sur la remor-

que comme indiqué dans le manuel s’y rappor-

tant.

Ne pas laisser tourner le moteur trop lentement sous risque d’en-

dommagerle moteur électrique à cause d’une tension et d’une fré-

quence trop faibles.

Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz,

s’il y a lieu.

LIRE LES INSTRUCTIONS.

Lisez le manuel d’instructions avant l’utilisation

ou la maintenance de l’appareil.

N’utiliser que les pièces de rechange recom-

mandées par le constructeur.

LES ÉTINCELLES VOLANTES ris-

quent de provoquer des blessures.

Effectuer la maintenance et le service du moteur et du compres-

seur d’air suivant les instructions dans ce manuel ou le manuel

du moteur/compresseur (si applicable).

Porter un écran facial pour protéger le visage et

les yeux.

Affûter l’électrode au tungstène uniquement à la

meuleuse dotée de protecteurs. Cette manœuv-

re est à exécuter dans un endroit sûr lorsque l’on

porte l’équipement homologué de protection du

visage, des mains et du corps.

LE RAYONNEMENT HAUTE FRÉ-

QUENCE (H.F.) risque de provoquer

des interférences.

Le rayonnement haute fréquence (H.F.) peut

provoquer des interférences avec les équipe-

ments de radio−navigation et de communica-

tion, les services de sécurité et les ordinateurs.

Les étincelles risquent de causer un incendie − éloigner toute sub-

stance inflammable.

Demander seulement à des personnes qualifiées familiarisées

avec des équipements électroniques de faire fonctionner l’instal-

lation.

DES ORGANES MOBILES peuvent

provoquer des blessures.

Ne pas s’approcher des organes mobiles.

Ne pas s’approcher des points de coincement

tels que des rouleaux de commande.

L’utilisateurest tenu de faire corriger rapidement par un électri-

cien qualifié les interférences résultant de l’installation.

Si le FCC signale des interférences, arrêter immédiatement l’ap-

pareil.

Effectuer régulièrement le contrôle et l’entretien de l’installation.

LES FILS DE SOUDAGE peuvent

provoquer des blessures.

Maintenirsoigneusement fermés les portes et les panneaux des

sources de haute fréquence, maintenir les éclateurs à une dis-

tance correcte et utiliser une terre et un blindage pour réduire les

interférences éventuelles.

Ne pas appuyer sur la gâchette avant d’en

avoir reçu l’instruction.

Ne pas diriger le pistolet vers soi, d’autres per-

sonnes ou toute pièce mécanique en enga-

geant le fil de soudage.

LE SOUDAGE À L’ARC risque de

provoquer des interférences.

L’énergie électromagnétique risque de provo-

quer des interférences pour l’équipement élec-

tronique sensible tel que les ordinateurs et

l’équipementcommandé par ordinateur tel que

les robots.

L’EMPLOI EXCESSIF peut

SURCHAUFFER L’ÉQUIPEMENT.

Laisser l’équipement refroidir ; respecter le fac-

teur de marche nominal.

Réduire le courant ou le facteur de marche

avant de poursuivre le soudage.

Veiller à ce que tout l’équipement de la zone de soudage soit

compatibleélectromagnétiquement.

Pour réduire la possibilité d’interférence, maintenir les câbles de

soudage aussi courts que possible, les grouper, et les poser

aussi bas que possible (ex. par terre).

Ne pas obstruer les passages d’air du poste.

Veiller à souder à une distance de 100 mètres de tout équipe-

ment électronique sensible.

LES CHARGES ÉLECTROSTATI-

QUES peuvent endommager les

circuits imprimés.

Veiller à ce que ce poste de soudage soit posé et mis à la terre

conformément à ce mode d’emploi.

En cas d’interférences après avoir pris les mesures précéden-

tes, il incombe à l’utilisateur de prendre des mesures supplé-

mentairestelles que le déplacement du poste, l’utilisation de câ-

bles blindés, l’utilisation de filtres de ligne ou la pose de protec-

teurs dans la zone de travail.

Établir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pièces.

Utiliser des pochettes et des boîtes antistatiques pour stocker,

déplacer ou expédier des cartes de circuits imprimes.

OM-4417 Page 10

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2-6. Proposition californienne 65 Avertissements

Pour les moteurs à essence :

Les équipements de soudage et de coupage produisent des

fumées et des gaz qui contiennent des produits chimiques

dont l’État de Californie reconnaît qu’ils provoquent des mal-

formations congénitales et, dans certains cas, des cancers.

(Code de santé et de sécurité de Californie, chapitre 25249.5

et suivants)

Les gaz d’échappement des moteurs contiennent des pro-

duits chimiques dont l’État de Californie reconnaît qu’ils

provoquent des cancers et des malformations congénitales

ou autres problèmes de procréation.

Pour les moteurs diesel :

Les batteries, les bornes et autres accessoires contiennent

du plomb et des composés à base de plomb, produits chimi-

ques dont l’État de Californie reconnaît qu’ils provoquent des

cancers et des malformations congénitales ou autres

problèmesde procréation. Se laver les mains après manipu-

lation.

Les gaz d’échappement des moteurs diesel et certains de

leurs composants sont reconnus par l’État de Californie com-

me provoquant des cancers et des malformations

congénitalesou autres problèmes de procréation.

2-7. Principales normes de sécurité

Safety inWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,

de Global Engineering Documents (téléphone : 1-877-413-5184, site

Internet : www.global.ihs.com).

L4W 5NS (téléphone : 800-463-6727 ou à Toronto 416-747-4044, site

Internet : www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protec-

tion, ANSI Standard Z87.1, de American National Standards Institute,

11 West 43rd Street, New York, NY 10036-8002 (téléphone :

212-642-4900,site Internet : www.ansi.org).

RecommendedSafe Practices for the Preparation for Welding and Cut-

ting of Containers and Piping, American Welding Society Standard

AWS F4.1 de Global Engineering Documents (téléphone

1-877-413-5184,site Internet : www.global.ihs.com).

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work, NFPA Standard 51B, de National Fire Protection Association,

P.O. Box 9101, Quincy, MA 02269-9101 (téléphone : 617-770-3000,

site Internet : www.nfpa.org).

National Electrical Code, NFPA Standard 70, de National Fire Protec-

tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (téléphone :

617-770-3000, site Internet : www.nfpa.org).

OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,

and Part 1926, Subpart J, de U.S. Government Printing Office, Superin-

tendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954

(téléphone: 1-866-512-1800) (il y a 10 bureaux régionaux−−le télépho-

ne de la région 5, Chicago, est 312-353-2220, site Internet :

www.osha.gov).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chan-

tilly, VA 20151 (téléphone

www.cganet.com).

703-788-2700, site Internet

Code for Safety in Welding and Cutting, CSA Standard W117.2, de

CanadianStandards Association, 5060 Mississauga, Ontario, Canada

2-8. Information EMF

Considérationssur le soudage et les effets de basse fréquence et des

champs magnétiques et électriques.

1. Garder les câbles ensemble, les torsader, les scotcher, ou les

recouvrir d’une housse.

2. Disposer les câbles d’un côté et à distance de l’opérateur.

3. Ne pas courber pas et ne pas entourer pas les câbles autour de

votre corps.

Le courant de soudage, pendant son passage dans les câbles de sou-

dage, causera des champs électromagnétiques. Il y a eu et il y a encore

un certain souci à propos de tels champs. Cependant, après avoir exa-

miné plus de 500 études qui ont été faites pendant une période de

recherche de 17 ans, un comité spécial ruban bleu du National

Research Council a conclu : « L’accumulation de preuves, suivant le

jugement du comité, n’a pas démontré que l’exposition aux champs

magnétiqueset champs électriques à haute fréquence représente un

risque à la santé humaine ». Toutefois, des études sont toujours en

cours et les preuves continuent à être examinées. En attendant que les

conclusions finales de la recherche soient établies, il vous serait

souhaitablede réduire votre exposition aux champs électromagnéti-

ques pendant le soudage ou le coupage.

4. Garder le poste de soudage et les câbles le plus loin possible de

vous.

5. Connecter la pince sur la pièce aussi près que possible de la

soudure.

Des implants médicaux :

Les porteurs d’implants doivent d’abord consulter leur médecin avant

de s’approcher des opérations de soudage à l’arc, de soudage par

points, de gougeage, du coupage plasma ou de chauffage par induc-

tion. Si le médecin approuve, il est recommandé de suivre les

procédures précédentes.

Pour réduire les champs magnétiques sur le poste de travail, appliquer

les procédures suivantes :

OM-4417 Page 11

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SECTION 3 − DEFINITIONS

3-1. Symbol Definitions

Read Operator’s

Manual

Engine Choke

Amperes

Volts

Engine Oil

Positive

Fuel

Battery (Engine)

Engine

Output

Alternating Current

(AC)

Negative

Protective Earth

(Ground)

Hours

Seconds

Time

Circuit Protector

Temperature

SECTION 4 − SPECIFICATIONS

4-1. Weld, Power, And Engine Specifications

Weld

Output

Range

Maximum

Open Circuit

Voltage

Welding

Mode

Rated

Welding Output

Generator

Power Rating

Fuel

Capacity

Engine

Kohler CS10

Air-Cooled,

One-Cylinder,

Four-Cycle,

10 HP (300 CC),

Gasoline Engine

Single-Phase,

4.5 kVA/kW (Peak)

4 kVA/kW

(Continuous)

34/17 A,

120/240 V AC,

60 Hz

145 A, 25 V,

Standard Model:

1.8 gal (6.9 L)

Tank

20% Duty Cycle

100 A, 25 V,

60% Duty Cycle

CC/DC

40 − 145 A

DX Model:

5 gal (19 L)

Tank

80 A, 25 V

100% Duty Cycle

(Recoil Or Electric-

Start)

OM-4417 Page 12

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4-2. Dimensions, Weights, And Operating Angles

Dimensions

Height

22-3/4 in (578 mm)

22-3/4 in (577 mm)

31-5/8 in (803 mm)

10-9/16 in (268 mm)

13-25/64in (340 mm)

22-3/4 in (577 mm)

1-9/16 in (40 mm)

19-5/8 in (498 mm)

13/32 in (10 mm) Dia.

Weight

Width

Depth

Do not exceed tilt angles or engine could

be damaged or unit could tip.

Do not move or operate unit where it

could tip.

15°

DX Model: 309 lb (140 kg)

15°

Holes

Standard Model: 263 lb (119 kg)

Optional Lifting Eye

Weight Rating

Engine End

803 403

803 594-B

430 lb (195 kg)

4-3. 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.

MID

MAX

MIN

100

150

200

250

AMPERES

220 602

OM-4417 Page 13

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4-4. Fuel Consumption

1.00

0.80

0.60

0.40

0.20

IDLE

0.00

100

125

150

175

200

DC WELD AMPERES AT RATED DUTY CYCLE

1.00

0.80

0.60

0.40

0.20

IDLE

0.00

AUXILIARY POWER KW AT 100% DUTY CYCLE

220 637

OM-4417 Page 14

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4-5. Duty Cycle

Duty cycle is the percentage of 10

minutes that unit can weld at rated

load without overheating.

NOTICE − Exceeding duty cycle

can damage unit and void warranty.

ContinuousWelding

100% Duty Cycle at 80 Amperes CC/DC

2 Minutes Welding

8 Minutes Resting

20% Duty Cycle at 145 Amperes CC/DC

160

140

120

100

90 100

% DUTY CYCLE

220 625−A

4-6. Generator Power Curve

The ac generator power curves

show the generator power available

in amperes at the receptacles.

300

250

200

240 Volt

150

100

120 Volt

AMPERES

220 581

OM-4417 Page 15

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SECTION 5 − INSTALLATION

5-1. Installing Welding Generator

Movement

Airflow Clearance

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

Location

Do not install unit where air

flow is restricted or engine

may overheat.

Always securely fasten welding

generator onto transport vehicle

or trailer and comply with all

DOT and other applicable codes

Always ground generator frame

to vehicle frame to prevent elec-

tric shock and static electricity

hazards.

Metal Vehicle Frame

GND/PE

Equipment Grounding

Terminal

Grounding Cable

Bed liners, shipping skids, and

some running gear insulate the

welding generator from the ve-

hicle frame. Always connect a

ground wire from the generator

equipment grounding terminal

to bare metal on the vehicle

frame as shown.

Use #10 AWG or larger insulated

copper wire to make metal-to-met-

al grounding connection.

If unit does not have GFCI

receptacles,

use

GFCI-

protected extension cord.

Ref 151 556 / Ref. 800 652 / 803 597-B / S-0854

OM-4417 Page 16

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5-2. Grounding Generator When Supplying Building Systems

Ground generator to sys-

GND/PE

tem earth ground if supply-

ing power to a premises

(home, shop, farm) wiring

system.

EquipmentGrounding

Terminal

Grounding Cable

Use #10 AWG or larger insulated

copper wire.

in electrical codes.

Ground Device

800 576-B

5-3. Engine Prestart Checks − Standard Model

Check all fluids daily. Engine must

be cold and on a level surface. Unit

is shipped with 10W30 engine oil.

1/2 in

(13 mm)

Fuel Valve

Full

Open valve.

. Close fuel valve before moving

unit or carburetor may flood

and make starting difficult.

Gasoline

Fuel

Add fresh fuel before starting

engine the first time (see engine

manual for specifications). Fill fuel

tank up to 1/2 in. (13 mm) from top

to allow room for expansion. Check

fuel level on a cold engine before

use each day.

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. 803 594-B

OM-4417 Page 17

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5-4. Engine Prestart Checks − DX Model

Check all fluids daily. Engine must

be cold and on a level surface. Unit

is shipped with 10W30 engine oil.

1/2 in

(13 mm)

Fuel Valve

Full

Open valve.

. Close fuel valve before moving

unit or carburetor may flood

and make starting difficult.

Gasoline

Fuel

Add fresh fuel before starting

engine the first time (see engine

manual for specifications). Fill fuel

tank up to 1/2 in. (13 mm) from top

to allow room for expansion. Check

fuel level on a cold engine before

use each day.

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.

starting:

. Fuel valve is shown in the

open position. Always close

fuel valve after stopping unit.

Moving unit with fuel valve

Keep battery in good condition.

Store battery in warm area off

concrete surface.

Full

open may cause carburetor

flooding and make starting

difficult.

Use correct grade oil for cold

weather.

803 595-B

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

Turn Engine Switch to Off

(DX models only).

Connect negative (−)

cable last.

−

Tools Needed:

1/2 in

803 595-B / 803 466

OM-4417 Page 18

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5-6. Connecting To Weld Output Terminals

Positive (+) Weld Output

Terminal

Negative (−) Weld Output

Terminal

For Direct Current Electrode Posi-

tive (DCEP), connect work cable to

Negative (−) terminal and electrode

holder to Positive (+) terminal.

For Direct Current Electrode nega-

tive (DCEN), reverse cable con-

nections.

Failure to properly connect

weld cables may cause ex-

cessive heat and start a fire,

or damage your machine.

Weld Output Terminal

Supplied Weld Output

Terminal Nut

Weld Cable Terminal

Copper Bar

Remove supplied nut from weld

output terminal. Slide weld cable

terminal onto weld output terminal

and secure with nut so that weld

cable terminal is tight against cop-

per bar. Do not place anything be-

tween weld cable terminal and

copper bar. Make sure that the

surfaces of the weld cable termi-

nal and copper bar are clean.

Do not place

anything between

weld cable terminal

and copper bar.

Tools Needed:

3/4 in

Correct Installation

Incorrect Installation

803 596−B / 803 778-A

5-7. Selecting Weld Cable Sizes*

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit

Not Exceeding***

150 ft

(45 m)

200 ft

250 ft

300 ft

350 ft

400 ft

100 ft (30 m) or Less

(60 m) (70 m) (90 m) (105 m) (120 m)

10 −

60%

Duty

Cycle

60 − 100%

Duty

Cycle

Welding

Amperes

10 − 100% Duty Cycle

Weld Output

Terminals

100

150

200

4 (20)

3 (30)

4 (20)

3 (30)

2 (35)

4 (20)

2 (35)

1 (50)

3 (30)

1 (50)

2 (35)

1/0 (60)

2/0 (70)

1 (50)

1/0 (60)

3/0 (95)

1/0 (60)

3/0 (95)

Turn off power before

connectingto weld out-

put terminals.

2/0 (70)

1/0 (60)

3/0 (95) 4/0 (120) 4/0 (120)

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

Do not use worn, dam-

aged, undersized, or

poorly spliced cables.

250

300

2 (35)

1 (50)

1/0 (60)

2/0 (70)

3/0 (95) 4/0 (120)

(2x70)

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

(2x70)

1/0 (60)

3/0 (95) 4/0 (120)

(2x95)

* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.

**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.

( ) = mm for metric use

S-0007-F

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

OM-4417 Page 19

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SECTION 6 − OPERATING THE WELDING GENERATOR

6-1. Controls (Standard Models) (See Section 6-2)

803 956−B / 803 594−B / 218 610

OM-4417 Page 20

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6-2. Description Of Controls (Standard Models) (See Section 6-1)

Engine Switch

gine. Move control to far left if starting a warm

engine.

Welding Range Table

Use switch to control ignition circuit. Turn

switch to On position when starting engine.

Turn switch to Off position to stop engine. En-

gine cannot be started with switch in the Off

position.

Use table to determine correct weld amper-

age based on electrode size, type, and mate-

rial thickness.

To Start:

Open fuel valve (see Section 5-4).

Turn Engine switch to On.

Set choke.

Weld Output Control

Enginestops if oil level is too low. Engine can-

not be restarted until sufficient oil is added.

power output at AC receptacles

Pull starter handle. Open choke as en-

gine warms.

Use control to select weld amperage. Control

may be adjusted while welding.

Low Oil Pressure Light

Light goes on and engine stops if engine oil

level is too low.

To Set Weld Output Control: Use table to

determinecorrect size electrode for weld am-

perage. Select electrode type and set control

to corresponding amperage range on name-

plate. Adjust control to obtain desired weld

performance.

If the engine does not start, let engine

come to a complete stop before at-

tempting restart.

Engine cannot be restarted until sufficient oil

is added.

To Stop:

Stop engine and add oil if light goes on

(see Section 5-4).

Turn Engine switch to Off.

EXAMPLE:

Starter Handle

Choke Control

. Always close fuel valve after stopping

unit. Moving unit with fuel valve open may

cause carburetor flooding and make

starting difficult.

Electrode Diameter: 1/8

Electrode Type: E-6013

Current Control Setting: 90 − 120 A

Use control to change engine air/fuel mix.

Move control to far right if starting a cold en-

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at

the beginning

of this manual.

OM-4417 Page 21

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6-3. Controls (DX Models) (See Section 6-4)

803 596−A / 803 595−A / 218 610

OM-4417 Page 22

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6-4. Description Of Controls (DX Models) (See Section 6-3)

Engine Switch

To Start:

Run / Idle Switch

Use switch to control ignition circuit. Turn

switch to Start position for electric start. Turn

switch to On position to start engine using

starter handle (recoil). Turn switch to Off posi-

tion to stop engine.

Use switch to select whether the engine stays

at run speed continuously or whether the auto

idle feature is enabled so engine speed re-

turns to idle speed after start−up or after weld

or generator load is removed.

Open fuel valve (see Section 5-4).

Set choke.

Electric-Start: Turn Engine switch to

Start position.

Recoil: Turn Engine switch to On posi-

tion. Pull starter handle until engine

starts.

Low Oil Level Light

Weld Output Control

Light goes on and engine stops if engine oil

level is too low.

Engine cannot be restarted until sufficient oil

is added.

power output at AC receptacles.

Open choke as engine warms.

Use control to select weld amperage. Control

may be adjusted while welding.

If the engine does not start, let engine

come to a complete stop before at-

tempting restart.

Stop engine and add oil if light goes on

(see Section 5-4).

To Set Weld Output Control: Use table to

determinecorrect size electrode for weld am-

perage. Select electrode type and set control

to corresponding amperage range on name-

plate. Adjust control to obtain desired weld

performance.

Starter Handle

To Stop:

Use starter handle to start unit if electric start

does not work.

Turn Engine switch to Off.

Choke Control

. Always close fuel valve after stopping

unit. Moving unit with fuel valve open may

cause carburetor flooding and make

starting difficult.

Use control to change engine air/fuel mix.

Move control to far right if starting a cold en-

gine. Move control to far left if starting a warm

engine.

The engine starts at weld/power speed and

runs at weld/power speed under weld or gen-

EXAMPLE:

Electrode Diameter: 1/8

Electrode Type: E-6013

Current Control Setting: 90 − 120 A

Welding Range Table

Hourmeter

erator power load. The engine returns to idle Use table to determine correct weld amper-

speed 12 seconds after start-up or after weld age based on electrode size, type, and mate-

Use hourmeter to help schedule routine main-

tenance.

or generator power load is removed.

rial thickness.

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at

the beginning

of this manual.

OM-4417 Page 23

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SECTION 7 − OPERATING AUXILIARY EQUIPMENT

Set Current control to maximum for full generator power output at AC receptacles.

NOTE

7-1. Generator Power Panel Receptacles

218 610−B

120 V 20 A AC Duplex Receptacle

RC3

If unit does not have GFCI recep-

tacles, use GFCI-protected exten-

sion cord.

. If supplementary protector continues

to open, contact Factory Authorized

Service Agent.

RC2 and RC3 supply 60 Hz single-phase

power at weld/power speed. Maximum

output from RC2 or RC3 is 2.4 kVA/kW.

Combinedoutput of all receptacles limited

to 4 kVA/kW continuous rating of the gen-

erator (See Section 12 − Generator Power

Guidelines).

current increases.

NOTICE− Do not parallel the two 120V du-

plex receptacles.

240 V AC Receptacle RC1

RC1 supplies 60 Hz single-phase power at

weld/powerspeed. Maximum output is 4.5

kVA/kW (peak) or 4 kVA/kW (continuous).

EXAMPLE: If 10 A is drawn from each 120

volt duplex receptacle, only 6 A is available

from the 240 V receptacle.

Supplementary Protector CB1

CB1 protects the receptacles from over-

load. If CB1 opens, the receptacles do not

work. Move switch to the On position to re-

set.

120 V 20 A AC Duplex Receptacle

RC2

2 x (120 V x 10 A) + (240 V x 6 A) = 4 kVA/

KW.

OM-4417 Page 24

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SECTION 8 − MAINTENANCE

’

8-1. Routine Maintenance

Stop engine before maintaining.

. See Engine Manual and Maintenance Label

for important start-up, service, and storage

information. Service engine more often if

used in severe conditions.

Recycle engine

fluids.

Reference

* To be done by Factory Authorized Service Agent

Every

Hours

Section 5-3,

5-4

Every

Hours

Section 8-2

Every

Hours

Every

100

Hours

Engine

Manual,

Section 8-2

~ Battery Terminals (DX

Models)

(Optional on DX Models)

Every

200

Hours

Every

300

Hours

Engine

Manual

Every

500

Hours

Engine

Manual

~ Slip Rings*

Brushes*

OM-4417 Page 25

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8-2. Servicing Air Cleaner

Stop engine.

NOTICE − Do not run engine with-

out air cleaner or with dirty element.

Precleaner

Paper Element

clean with compressed air.

Remove cover.

Wash precleaner with soap and wa-

ter solution. Allow precleaner to air

dry completely.

Dip precleaner in clean engine oil.

Squeeze out excess oil. The engine

will smoke if precleaner contains

too much oil.

Replace paper element if dirty, oily,

or damaged.

Standard Model Shown

oil

aircleaner6 9/00 − 803 404

OM-4417 Page 26

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8-3. Adjusting Engine Speed (Standard Models Only)

After tuning engine, check engine

speed. See table for proper no load

speed. If necessary, adjust speed

as follows:

Start engine and run until warm.

3750 30 rpm (62 Hz)

Adjustment Screw

To increase speed, turn screw in

(clockwise). To decrease speed,

turn screw out (counterclockwise).

Stop engine. Close fuel

valve.

Tools Needed:

803 594-B

OM-4417 Page 27

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8-4. Adjusting Engine Speed (DX Models Only)

After tuning engine, check engine

speed. See table for proper no load

speed. If necessary, adjust speed

as follows:

2500 100 rpm (42 Hz)

3750 30 rpm (62 Hz)

Start engine and run until warm.

Set Weld Output Control to Max.

Weld/Power Speed Adjustment

Adjustment Screw

To increase speed, turn screw in

(clockwise). To decrease speed,

turn screw out (counterclockwise).

Idle Speed Adjustment

Throttle Solenoid TS1

Adjustment Screw

Loosen two screws on side of

throttle solenoid TS1. Adjust TS1

until idle speed is approximately

2500 rpm. Use adjustment screw

to fine tune idle speed. Be sure TS1

plunger bottoms at idle. Tighten two

screws on TS1.

Stop engine. Close fuel

valve.

Tools Needed:

803 595−B

OM-4417 Page 28

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SECTION 9 − TROUBLESHOOTING

9-1. Troubleshooting

A. Welding

Trouble

Remedy

No weld output or generator power out- Be sure all equipment is disconnected from receptacles when starting unit.

put at ac receptacles.

Have Factory Authorized Service Agent check brushes, slip rings, rotor, stator, integrated rectifier

SR2, and Weld Output control R1.

No weld output; generator power out-

put okay at ac receptacles.

Check Weld Output control setting.

Check weld connections.

Have Factory Authorized Service Agent check Weld Output control R1, stator, integrated rectifier

SR2, stabilizer DC-Z, main rectifier SR1, and reactor AC-Z

Low weld output.

Check Weld Output control setting.

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).

Check Weld Output control setting.

Erratic weld output.

Tighten and clean connections to electrode and workpiece.

Use dry, properly-stored electrodes for Stick welding.

Remove excessive coils from weld cables.

Clean and tighten connections both inside and outside welding generator.

Check 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-

ceptacles; no weld output.

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

Have Factory Authorized Service Agent check brushes, slip rings, rotor, stator, integrated rectifier

SR2, and Weld Output control R1.

No output at generator power ac re-

ceptacles; weld output okay.

Reset and check supplementary protector (see Section 7-1).

Check receptacle wiring and connections.

Have Factory Authorized Service Agent check stator windings and connections at terminal block 1T.

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

High output at generator power ac

receptacles.

OM-4417 Page 29

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Trouble

Remedy

Low output at generator power ac Check Weld Output control setting.

receptacles.

Check engine speed, and adjust if necessary (see Section 8-3 or 8-4). Open circuit voltage is reduced

as engine speed drops.

Erratic output at generator power ac Check fuel level.

receptacles.

Have Factory Authorized Service Agent check connections at terminal block 1T.

Check receptacle supplementary protector, 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). 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).

Move choke control to correct position (see Section 6-1 or 6-3).

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

starting difficult.

Check battery voltage (DX models only).

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

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

oil for operating temperature.

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

Check fuel level (see Section 5-4).

Engine stopped during normal

operation.

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

starting difficult.

Check oil level (see Section 5-4). 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-4417 Page 30

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SECTION 10 − PARTS LIST

10-1. Recommended Spare Parts

Part

No.

Description

Quantity

Recommended Spare Parts

. . . . . . . . . . . . . . . . . . . 221581 . . Tune−up & Filter Kit, Kohler CS 10 Recoil (includes) . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . 203960 . . . . Spark Plug, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . 221579 . . . . Filter, Air Kohler CS 10 Recoil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . 221580 . . . . Filter, Air Pre Cleaner Kohler CS 10 Recoil . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . 221584 . . Tune−up & Filter Kit, Kohler CS 10 & 12 Electric (includes) . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . 203960 . . . . Spark Plug, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . 221582 . . . . Filter, Air Kohler CS 10 & 12 Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . 221583 . . . . Filter, Air Pre Cleaner Kohler CS 10 & 12 Electric . . . . . . . . . . . . . . . . . . . 1

OM-4417 Page 31

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SECTION 11 − ELECTRICAL DIAGRAMS

226 737-A

Figure 11-1. Circuit Diagram For Standard Models

OM-4417 Page 32

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226 738-A

Figure 11-2. Circuit Diagram for DX Models

OM-4417 Page 33

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SECTION 12 − GENERATOR POWER GUIDELINES

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

12-1. Selecting Equipment

Generator Power Receptacles

− Neutral Bonded To Frame

3-Prong Plug From Case

Grounded Equipment

2-Prong Plug From Double

Insulated Equipment

. Be sure equipment has double

insulated symbol and/or word-

ing on it.

Do not use 2-prong plug un-

less equipment is double in-

sulated.

gen_pwr 2007−04 − Ref. ST-159 730 / ST-800 577

12-2. Grounding Generator To Truck Or Trailer Frame

Always ground generator

frame to vehicle frame to pre-

vent electric shock and static

electricity hazards.

Also see AWS Safety

Health Fact Sheet No. 29,

Grounding of Portable And

Vehicle Mounted Welding

Generators.

EquipmentGrounding

Terminal (On Front Panel)

Grounding Cable (Not

Supplied)

Metal Vehicle Frame

GND/PE

Connect cable from equipment

ground terminal to metal vehicle

frame. Use #10 AWG or larger

insulated copper wire.

. Electrically bond generator

frame to vehicle frame by met-

al-to-metal contact.

Bed liners, shipping skids,

and some running gear insu-

late the welding generator

from the vehicle frame. Al-

ways connect a ground wire

from the generator equip-

ment grounding terminal to

bare metal on the vehicle

frame as shown.

If unit does not have GFCI re-

ceptacles, use GFCI-pro-

tected extension cord.

S-0854

OM-4417 Page 34

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12-3. Grounding When Supplying Building Systems

EquipmentGrounding

Terminal

Grounding Cable

GND/PE

Use #10 AWG or larger insulated

copper wire.

Ground Device

electrical codes.

Ground generator to system

earth ground if supplying

power to a premises (home,

shop, farm) wiring system.

Also see AWS Safety

Health Fact Sheet No. 29,

Grounding of Portable And

Vehicle Mounted Welding

Generators.

ST-800 576-B

12-4. How Much Power Does Equipment Require?

Resistive Load

A light bulb is a resistive load and

requires a constant amount of power.

Non-Resistive Load

VOLTS 115

Equipment with a motor is a non-re-

sistive load and requires approxi-

mately six times more power while

starting the motor than when running

(see Section 12-8).

AMPS 4.5

Rating Data

Rating shows volts and amperes, or

watts required to run equipment.

Amperes x Volts = Watts

Example 1: If a drill uses 4.5 am-

peres at 115 volts, calculate its run-

ning power requirement in watts.

4.5 A x 115 V = 520 W

The load applied by the drill is 520

watts.

Example 2: If three 200 watt flood

lamps are used with the drill from Ex-

ample 1, add the individual loads to

calculate total load.

(3 x 200W) + 520 W = 1120 W

The total load applied by the three

flood lamps and drill is 1120 watts.

S-0623

OM-4417 Page 35

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12-5. Approximate Power Requirements For Industrial Motors

Industrial Motors

Rating

Starting Watts

Running Watts

Split Phase

1/8 HP

1/6 HP

1/4 HP

1/3 HP

1/2 HP

1/3 HP

1/2 HP

3/4 HP

1 HP

800

1225

1600

2100

3175

2020

3075

4500

6100

8200

10550

15900

23300

8100

23300

35000

46700

1000

1400

1850

2400

3500

300

500

600

700

875

Capacitor Start-Induction Run

720

975

1400

1600

2200

2850

3900

6800

2000

6000

8000

10700

400

1-1/2 HP

2 HP

3 HP

5 HP

Capacitor Start-Capacitor Run

Fan Duty

1-1/2 HP

5 HP

7-1/2 HP

10 HP

1/8 HP

1/6 HP

1/4 HP

1/3 HP

1/2 HP

550

650

800

1100

12-6. Approximate Power Requirements For Farm/Home Equipment

Farm/HomeEquipment

Stock Tank De-Icer

Rating

Starting Watts

Running Watts

1000

1650

3400

4400

2900

10500

1720

2575

4500

6100

8200

10550

15900

23300

8100

23300

35000

46700

3300

3150

4500

6100

3100

2150

3100

2100

3200

1000

650

Grain Cleaner

1/4 HP

1/2 HP

3/4 HP

Portable Conveyor

Grain Elevator

1000

1400

1100

2800

720

Milk Cooler

Milker (Vacuum Pump)

FARM DUTY MOTORS

Std. (e.g. Conveyors,

Feed Augers, Air

Compressors)

2 HP

1/3 HP

1/2 HP

3/4 HP

1 HP

975

1400

1600

2200

2850

3900

6800

2000

6000

8000

10700

1000

950

1-1/2 HP

2 HP

3 HP

5 HP

High Torque (e.g. Barn

1-1/2 HP

5 HP

Cleaners, Silo Unloaders,

Silo Hoists, Bunk Feeders)

7-1/2 HP

10 HP

1/2 HP

500 PSI

550 PSI

700 PSI

3-1/2 cu. ft. Mixer

High Pressure 1.8 Gal/Min

Washer 2 gal/min

2 gal/min

1400

1600

800

Refrigerator or Freezer

Shallow Well Pump

1/3 HP

1/2 HP

1/3 HP

1/2 HP

750

1000

800

Sump Pump

1050

OM-4417 Page 36

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12-7. Approximate Power Requirements For Contractor Equipment

Contractor

Rating

Starting Watts

Running Watts

Hand Drill

1/4 in

3/8 in

350

400

350

400

1/2 in

600

Circular Saw

Table Saw

6-1/2 in

7-1/4 in

8-1/4 in

9 in

500

900

1400

4500

6300

2500

1720

3900

5200

3000

6000

8200

10500

1100

350

1400

1500

1800

1100

720

10 in

Band Saw

14 in

Bench Grinder

6 in

8 in

1400

1600

1000

1500

2200

2800

1100

350

10 in

Air Compressor

1/2 HP

1 HP

1-1/2 HP

2 HP

Electric Chain Saw

Electric Trimmer

Electric Cultivator

1-1/2 HP, 12 in

2 HP, 14 in

Standard 9 in

Heavy Duty 12 in

1/3 HP

500

2100

400

700

Elec. Hedge Trimmer

Flood Lights

18 in

400

HID

125

100

Metal Halide

Mercury

Sodium

Vapor

313

250

1000

1400

1250

600

1000

200

Submersible Pump

Centrifugal Pump

Floor Polisher

400 gph

900 gph

3/4 HP, 16 in

1 HP, 20 in

1/2 HP

900

500

4500

6100

3150

4500

6100

1900

900

1400

1600

950

High Pressure Washer

3/4 HP

1400

1600

700

1 HP

55 gal Drum Mixer

Wet & Dry Vac

1/4 HP

1.7 HP

900

2-1/2 HP

1300

OM-4417 Page 37

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12-8. Power Required To Start Motor

Single-PhaseInduction Motor Starting Requirements

Motor Start

Code

KVA/HP

6.3

7.1

8.0

9.0

10.0

11.2

12.5

14.0

Motor Start Code

Running Amperage

Motor HP

AC MOTOR

Motor Voltage

VOLTS 230

AMPS 2.5

To find starting amperage:

CODE

Step 1: Find code and use table to

find kVA/HP. If code is not listed,

multiplyrunning amperage by six to

find starting amperage.

1/4

PHASE 1

Step 2: Find Motor HP and Volts.

Step 3: Determine starting amper-

age (see example).

Welding generator amperage out-

put must be at least twice the

motor’s running amperage.

(kVA/HP x HP x 1000) / Volts =

Starting Amperage

Example: Calculate starting amper-

age required for a 230 V, 1/4 HP mo-

tor with a motor start code of M.

Volts = 230, HP = 1/4, kVA/HP =

11.2

(11.2 x 1/4 x 1000) / 230 = 12.2A

Starting the motor requires 12.2

amperes.

S-0624

12-9. How Much Power Can Generator Supply?

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.

5 Second Rule

If motor does not start within 5

seconds, turn off power to prevent

motor damage. Motor requires

more power than generator can

supply.

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

OM-4417 Page 38

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12-10. Typical Connections To Supply Standby Power

Have only qualified persons

perform these connections

according to all applicable

codes and safety practices.

Fused

Disconnect

Switch

Properly install and ground

this equipment according to

its Owner’s Manual and na-

tional, state, and local codes.

Welding

Generator

Output

Utility

Electrical

Service

Transfer Switch

(If Required)

is required if generator will sup-

ply standby power during

emergencies or power out-

ages.

1 Utility Electrical Service

Essential

Loads

2 Transfer Switch (Double-Throw)

Switch transfers the electrical load

from electric utility service to the

generator. Transfer load back to

electric utility when service is re-

stored.

Install correct switch (customer-

supplied). Switch rating must be

same as or greater than the branch

overcurrent protection.

3 Fused Disconnect Switch

Install correct switch (customer-

supplied) if required by electrical

code.

4 Welding Generator Output

Generator output voltage and wir-

ing must be consistent with regular

(utility) system voltage and wiring.

Connect generator with temporary

or permanent wiring suitable for the

installation.

Turn off or unplug all equipment

connected to generator before

starting or stopping engine. When

starting or stopping, the engine has

low speed which causes low volt-

age and frequency.

5 Essential Loads

Generator output may not meet the

electrical requirements of the prem-

ises. If generator does not produce

enough output to meet all require-

ments, connect only essential

loads (pumps, freezers, heaters,

etc. − See Section 12-4).

OM-4417 Page 39

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12-11. Selecting Extension Cord (Use Shortest Cord Possible)

Cord Lengths for 120 Volt Loads

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

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

Current

(Amperes)

Load (Watts)

600

350 (106)

250 (76)

175 (53)

112 (34)

87 (26)

62 (19)

50 (15)

37 (11)

225 (68)

150 (46)

112 (34)

75 (23)

50 (15)

37 (11)

137 (42)

100 (30)

62 (19)

37 (11)

30 (9)

100 (30)

62 (19)

50 (15)

30 (9)

840

400 (122)

275 (84)

175 (53)

137 (42)

112 (34)

87 (26)

1200

1800

2400

3000

3600

4200

4800

5400

6000

400 (122)

300 (91)

225 (68)

175 (53)

150 (46)

125 (38)

112 (34)

100 (30)

87 (26)

75 (23)

62 (19)

50 (15)

*Conductor size is based on maximum 2% voltage drop

Cord Lengths for 240 Volt Loads

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

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

Current

(Amperes)

Load (Watts)

1200

1680

2400

3600

4800

6000

7000

8400

9600

10,800

12,000

700 (213)

500 (152)

350 (107)

225 (69)

175 (53)

125 (38)

100 (31)

75 (23)

450 (137)

300 (91)

225 (69)

150 (46)

100 (31)

75 (23)

225 (84)

200 (61)

125 (38)

75 (23)

200 (61)

125 (38)

100 (31)

60 (18)

800 (244)

550 (168)

350 (107)

275 (84)

225 (69)

175 (53)

150 (46)

125 (38)

100 (31)

800 (244)

600 (183)

450 (137)

350 (107)

300 (91)

250 (76)

225 (69)

200 (61)

175 (53)

60 (18)

75 (23)

*Conductor size is based on maximum 2% voltage drop

OM-4417 Page 40

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SECTION 13 − STICK WELDING (SMAW) GUIDELINES

13-1. Stick Welding Procedure

Weld current starts when elec-

trode touches workpiece.

Weld current can damage elec-

tronic parts in vehicles. Discon-

nect both battery cables before

welding on a vehicle. Place work

clamp as close to the weld as

possible.

Workpiece

Make sure workpiece is clean be-

fore welding.

Work Clamp

Electrode

A small diameter electrode requires

less current than a large one. Fol-

low electrode manufacturer’s

instructions when setting weld am-

perage (see Section 13-2).

Insulated Electrode Holder

Electrode Holder Position

Arc Length

Arc length is the distance from the

electrodeto the workpiece. A short

arc with correct amperage will give

a sharp, crackling sound.

Slag

Use a chipping hammer and wire

brush to remove slag. Remove slag

and check weld bead before mak-

ing another weld pass.

Tools Needed:

stick 2007−04 − ST-151 593

OM-4417 Page 41

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13-2. Electrode and Amperage Selection Chart

3/32

1/8

6010

6011

5/32

3/16

7/32

1/4

6010

6011

ALL

DEEP

LOW

MIN. PREP, ROUGH

HIGH SPATTER

1/16

5/64

3/32

6013 EP,EN

GENERAL

1/8

SMOOTH, EASY,

FAST

LOW HYDROGEN,

STRONG

6013

7014 EP,EN

ALL

MED

LOW

5/32

3/16

7/32

1/4

3/32

1/8

7018

ALL

FLAT

HORIZ LOW

FILLET

ALL

SMOOTH, EASY,

FASTER

7024 EP,EN

NI-CL

308L

LOW

CAST IRON

STAINLESS

5/32

3/16

7014

7/32

1/4

3/32

1/8

*EP = ELECTRODE POSITIVE (REVERSE POLARITY)

EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)

5/32

3/16

7/32

1/4

3/32

1/8

5/32

3/16

7/32

1/4

7018

7024

3/32

1/8

5/32

3/16

3/32

1/8

Ni-Cl

308L

5/32

Ref. S-087 985-A

13-3. Striking an Arc − Scratch Start Technique

Electrode

Workpiece

Arc

Drag electrode across workpiece

like striking a match; lift electrode

slightly after touching work. If arc

goes out electrode was lifted to

high. If electrode sticks to work-

piece, use a quick twist to free it.

S-0049

13-4. Striking an Arc − Tapping Technique

Electrode

Workpiece

Arc

Bring electrode straight down to

workpiece; then lift slightly to start

arc. If arc goes out, electrode was

lifted too high. If electrode sticks to

workpiece, use a quick twist to free it.

S-0050

OM-4417 Page 42

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13-5. Positioning Electrode Holder

10°-30°

90°

End View of Work Angle

Side View of Electrode Angle

GROOVE WELDS

10°-30°

45°

End View of Work Angle

Side View of Electrode Angle

S-0060

FILLET WELDS

13-6. Poor Weld Bead Characteristics

Large Spatter Deposits

Rough, Uneven Bead

Slight Crater During Welding

Bad Overlap

Poor Penetration

S-0053-A

13-7. Good Weld Bead Characteristics

Fine Spatter

Uniform Bead

Moderate Crater During

Welding

Weld a new bead or layer for each

1/8 in. (3.2 mm) thickness in metals

being welded.

No Overlap

Good Penetration into Base

Metal

S-0052-B

OM-4417 Page 43

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13-8. Conditions That Affect Weld Bead Shape

Correct Angle

Angle Too Large

Angle Too Small

10° - 30°

Drag

ELECTRODE ANGLE

Spatter

Normal

Too Long

Too Short

ARC LENGTH

Normal

Fast

Slow

TRAVEL SPEED

S-0061

13-9. Electrode Movement During Welding

;

a weave bead or multiple stringer beads work better.

Stringer Bead − Steady

Movement Along Seam

Weave Bead − Side to Side

Movement Along Seam

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-4417 Page 44

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13-10. Butt Joints

Tack Welds

Prevent edges of joint from drawing

together ahead of electrode by tack

welding the materials in position be-

fore final weld.

Square Groove Weld

Good for materials up to 3/16 in (5

mm) thick.

Single V-Groove Weld

Good for materials 3/16 − 3/4 in

(5-19 mm) thick. Cut bevel with oxy-

acetylene or plasma cutting equip-

ment. Remove scale from material

after cutting. A grinder can also be

used to prepare bevels.

30°

1/16 in

(1.6 mm)

Create 30 degree angle of bevel on

materials in V-groove welding.

Double V-Groove Weld

Good for materials thicker than 3/16

in (5 mm).

S-0662

13-11. Lap Joint

30°

Electrode

30°

Or Less

Single-LayerFillet Weld

Move electrode in circular motion.

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.

Single-Layer Fillet Weld

Multi-Layer Fillet Weld

S-0063 / S-0064

13-12. Tee Joint

Electrode

Fillet Weld

Keep arc short and move at definite

rate of speed. Hold electrode as

shown to provide fusion into the

corner. Square edge of the weld

surface.

45°

Or Less

For maximum strength weld both

sides of upright section.

Multi-Layer Deposits

Weld a second layer when a heavi-

er fillet is needed. Use any of the

weaving patterns shown in Section

13-9. Remove slag before making

another weld pass.

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

OM-4417 Page 45

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13-13. Weld Test

Vise

Weld Joint

Hammer

Strike weld joint in direction shown.

A good weld bends over but does

not break.

2 To 3 in

(51-76 mm)

2 To 3 in

(51-76 mm)

1/4 in

(6.4 mm)

S-0057-B

13-14. Troubleshooting − Porosity

Porosity − small cavities or holes resulting from gas

pockets in weld metal.

Possible Causes

Arc length too long.

Corrective Actions

Reduce arc length.

Use dry electrode.

Damp electrode.

Workpiece dirty.

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

welding.

13-15. Troubleshooting − Excessive Spatter

Excessive Spatter − scattering of molten metal particles

that cool to solid form near weld bead.

Possible Causes

Corrective Actions

Amperage too high for electrode.

Decrease amperage or select larger electrode.

Reduce arc length or voltage.

Arc length too long or voltage too high.

OM-4417 Page 46

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13-16. Troubleshooting − Incomplete Fusion

IncompleteFusion − failure of weld metal to fuse completely with

base metal or a preceeding weld bead.

Possible Causes

Insufficient heat input.

Corrective Actions

Increase amperage. Select larger electrode and increase amperage.

Improper welding technique.

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

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

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

Keep arc on leading edge of weld puddle.

Workpiece dirty.

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

welding.

13-17. Troubleshooting − Lack Of Penetration

Lack Of Penetration − shallow fusion between weld metal and

base metal.

Lack of Penetration

Possible Causes

Good Penetration

Corrective Actions

Improper joint preparation.

Improper weld technique.

Insufficient heat input.

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

Keep arc on leading edge of weld puddle.

Increase amperage. Select larger electrode and increase amperage.

Reduce travel speed.

13-18. Troubleshooting − Excessive Penetration

Excessive Penetration − weld metal melting through base metal and

hangingunderneath weld.

Excessive Penetration

Good Penetration

Possible Causes

Excessive heat input.

Corrective Actions

Select lower amperage. Use smaller electrode.

Increase and/or maintain steady travel speed.

OM-4417 Page 47

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13-19. Troubleshooting − Burn-Through

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

in holes where no metal remains.

Possible Causes

Excessive heat input.

Corrective Actions

Select lower amperage. Use smaller electrode.

Increase and/or maintain steady travel speed.

13-20. Troubleshooting − Waviness Of Bead

Waviness Of Bead − weld metal that is not parallel and does not cover

joint formed by base metal.

Possible Causes

Unsteady hand.

Corrective Actions

Use two hands. Practice technique.

13-21. Troubleshooting − Distortion

Distortion− contraction of weld met-

al during welding that forces base

metal to move.

Base metal moves

in the direction of

the weld bead.

Possible Causes

Corrective Actions

Excessive heat input.

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

Make tack welds along joint before starting welding operation.

Select lower amperage for electrode.

Increase travel speed.

Weld in small segments and allow cooling between welds.

OM-4417 Page 48

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Effective January 1, 2007

(Equipment with a serial number preface of “LH” or newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other

guarantees or warranties expressed or implied.

Warranty Questions?

LIMITED WARRANTY − Subject to the terms and conditions

below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to

its original retail purchaser that new Miller equipment sold after

the effective date of this limited warranty is free of defects in

material and workmanship at the time it is shipped by Miller. THIS

WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER

WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE

WARRANTIES OF MERCHANTABILITY AND FITNESS.

Induction Heating Coils and Blankets, Cables, and

Non-Electronic Controls

APT & SAF Model Plasma Cutting Torches

Remote Controls

Call

1-800-4-A-MILLER

for your local

Miller distributor.

Accessory (Kits)

Replacement Parts (No labor)

Spoolmate Spoolguns

Canvas Covers

Within the warranty periods listed below, Miller will repair or

replace any warranted parts or components that fail due to such

defects in material or workmanship. Miller must be notified in

writing within thirty (30) days of such defect or failure, at which

time Miller will provide instructions on the warranty claim

procedures to be followed.

Your distributor also gives

you ...

Miller’s True Blue® Limited Warranty shall not apply to:

Service

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, slip rings, relays

or parts that fail due to normal wear. (Exception:

brushes, slip rings, and relays are covered on Bobcat,

Trailblazer, and Legend models.)

You always get the fast,

reliable response you

need. Most replacement

parts can be in your

hands in 24 hours.

Miller shall honor warranty claims on warranted equipment listed

below in the event of such a failure within the warranty time

periods. All warranty time periods start on the delivery date of the

equipment to the original end-user purchaser, and not to exceed

one year after the equipment is shipped to a North American

distributor or eighteen months after the equipment is shipped to

an International distributor.

2. Items furnished by Miller, but manufactured by others, such

as engines or trade accessories. These items are covered

by the manufacturer’s warranty, if any.

Support

Need fast answers to the

tough welding questions?

Contact your distributor.

The expertise of the

distributor and Miller is

there to help you, every

step of the way.

3. Equipment that has been modified by any party other than

Miller, or equipment that has been improperly installed,

improperly operated or misused based upon industry

standards, or equipment which has not had reasonable and

necessary maintenance, or equipment which has been

used for operation outside of the specifications for the

equipment.

1. 5 Years Parts — 3 Years Labor

Original main power rectifiers

2. 3 Years — Parts and Labor

Transformer/Rectifier Power Sources

Plasma Arc Cutting Power Sources

Process Controllers

Semi-Automatic and Automatic Wire Feeders

Inverter Power Sources (Unless Otherwise Stated)

Water Coolant Systems (Integrated)

Intellitig

Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the

engine manufacturer.)

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND

USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS

TRAINED AND EXPERIENCED IN THE USE AND

MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the

exclusive remedies shall be, at Miller’s option: (1) repair; or (2)

replacement; or, where authorized in writing by Miller in

appropriate cases, (3) the reasonable cost of repair or

replacement at an authorized Miller service station; or (4)

payment of or credit for the purchase price (less reasonable

depreciation based upon actual use) upon return of the goods at

customer’s risk and expense. Miller’s option of repair or

replacement will be F.O.B., Factory at Appleton, Wisconsin, or

F.O.B. at a Miller authorized service facility as determined by

Miller. Therefore no compensation or reimbursement for

transportation costs of any kind will be allowed.

3. 1 Year — Parts and Labor Unless Specified

Motor Driven Guns (w/exception of Spoolmate

Spoolguns)

Positioners and Controllers

Automatic Motion Devices

RFCS Foot Controls

Induction Heating Power Sources, Coolers, and

Electronic

Controls/Recorders

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES

PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE

REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR

DIRECT,

INDIRECT,

SPECIAL,

INCIDENTAL

CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF

PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY

OTHER LEGAL THEORY.

Water Coolant Systems (Non-Integrated)

Flowgauge and Flowmeter Regulators (No Labor)

HF Units

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND

Grids

ANY

IMPLIED

WARRANTY,

GUARANTY

REPRESENTATION AS TO PERFORMANCE, AND ANY

REMEDY FOR BREACH OF CONTRACT TORT OR ANY

OTHER LEGAL THEORY WHICH, BUT FOR THIS

PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION

OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,

Spot Welders

Load Banks

Arc Stud Power Sources & Arc Stud Guns

Racks

Running Gear/Trailers

Plasma Cutting Torches (except APT & SAF

Models)

Field Options

INCLUDING

ANY

IMPLIED

WARRANTY

MERCHANTABILITY OR FITNESS FOR PARTICULAR

PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT

FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED

BY MILLER.

(NOTE: Field options are covered under True Blue®

for the remaining warranty period of the product they

are installed in, or for a minimum of one year —

whichever is greater.)

Bernard-Branded Mig Guns (No Labor)

Weldcraft-Branded TIG Torches (No Labor)

Subarc Wire Drive Assemblies

Some states in the U.S.A. do not allow limitations of how long an

implied warranty lasts, or the exclusion of incidental, indirect,

special or consequential damages, so the above limitation or

exclusion may not apply to you. This warranty provides specific

legal rights, and other rights may be available, but may vary from

state to state.

In Canada, legislation in some provinces provides for certain

additional warranties or remedies other than as stated herein,

and to the extent that they may not be waived, the limitations and

exclusions set out above may not apply. This Limited Warranty

provides specific legal rights, and other rights may be available,

4. 6 Months — Batteries

5. 90 Days — Parts

MIG Guns/TIG Torches and Subarc (SAW) Guns

but may vary from province to province.

miller_warr 2007−01

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Owner’s Record

Please complete and retain with your personal records.

Model Name

Purchase Date

Distributor

Address

Serial/Style Number

(Date which equipment was delivered to original customer.)

City

State

Zip

For Service

Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

Welding Supplies and Consumables

Options and Accessories

Personal Safety Equipment

Service and Repair

Miller Electric Mfg. Co.

An Illinois Tool Works Company

1635 West Spencer Street

Appleton, WI 54914 USA

Replacement Parts

Training (Schools, Videos, Books)

International Headquarters−USA

USA Phone: 920-735-4505 Auto-Attended

USA & Canada FAX: 920-735-4134

International FAX: 920-735-4125

Technical Manuals (Servicing Information

and Parts)

Circuit Diagrams

European Headquarters −

United Kingdom

Phone: 44 (0) 1204-593493

FAX: 44 (0) 1204-598066

Welding Process Handbooks

To locate a Distributor or Service Agency visit

www.millerwelds.com or call 1-800-4-A-Miller

www.MillerWelds.com

Contact the Delivering Carrier to:

File a claim for loss or damage during

shipment.

For assistance in filing or settling claims, contact

your distributor and/or equipment manufacturer’s

Transportation Department.

PRINTED IN USA

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