OM-4402

199101J

May 2001

Processes
MIG (GMAW) Welding
Flux Cored (FCAW)
Stick (SMAW) Welding
TIG (GTAW) Welding
Air Plasma Cutting and Gouging
with Spectrum
Unit
Air Carbon Arc (CAC-A) Cutting
and Gouging

Description

Engine Driven Welding Generator

Trailblazer 280 NT

Visit our website at

www.MillerWelds.com

From Miller to You

Thank you and congratulations on choosing Miller.
Now you can get the job done and get it done right. We
know you dont have time to do it any other way.
Thats why when Niels Miller first started building arc
welders in 1929, he made sure his products offered
long-lasting value and superior quality. Like you, his
customers couldnt afford anything less. Miller
products had to be more than the best they could be.
They had to be the best you could buy.
Today, the people that build and sell Miller products continue the
tradition. Theyre just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owners Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
Weve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
theres a Troubleshooting section that will
Miller is the first welding help you figure out what the problem is. The
equipment manufacturer in parts list will then help you to decide which
the U.S.A. to be registered to
the ISO 9001 Quality System exact part you may need to fix the problem.
Standard.
Warranty and service information for your
particular model are also provided.

Working as hard as you do

every power source from
Miller is backed by the most
hassle-free warranty in the
business.

Miller offers a Technical

Manual which provides
more detailed service and
parts information for your
unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMAW-P.

Miller Electric manufactures a full line

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

TABLE OF CONTENTS

WARNING
This product, when used
for welding or cutting,
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.)

WARNING
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 reproductive
harm. Wash hands after
handling.

WARNING
The engine exhaust from
this product contains
chemicals known to the
State of California to
cause cancer, birth
defects, or other
reproductive harm.
The following terms are
used interchangeably
throughout this manual:
MIG = GMAW, Wire Welding
TIG = GTAW
Stick = SMAW

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

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 CONSIGNES DE SCURIT LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . .
1-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Dangers relatifs au soudage larc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Dangers supplmentaires en relation avec linstallation, le fonctionnement
et la maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principales normes de scurit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. Information sur les champs lectromagntiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Dimensions, Weights, and Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Fuel Consumption (Onan-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Fuel Consumption (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Auxiliary Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Engine Prestart Checks (Onan-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Engine Prestart Checks (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Activating The Dry Charge Battery (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Selecting Weld Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Adjusting MIG Weld Puddle Consistency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 OPERATING WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Remote Amperage/Voltage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Auxiliary Power Receptacles And Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Optional Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Wiring Optional 240 Volt Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 MAINTENANCE (ONAN-POWERED UNITS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Routine Maintenance (Onan-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Maintenance Label (Onan-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Servicing Air Cleaner (Onan-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Servicing Optional Spark Arrestor (Onan-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5. Changing Engine Oil, Oil Filter, And Fuel Filter (Onan-Powered Units) . . . . . . . . . . . . . . . . .
7-6. Adjusting Engine Speed (Onan-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-7. Overload Protection (Onan-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 MAINTENANCE (KOHLER-POWERED UNITS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Routine Maintenance (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Maintenance Label (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Servicing Air Cleaner (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Servicing Optional Spark Arrestor (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5. Changing Engine Oil, Oil Filter, And Fuel Filter (Kohler-Powered Units) . . . . . . . . . . . . . . . . .
8-6. Adjusting Engine Speed (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-7. Overload Protection (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 AUXILIARY POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPTIONS AND ACCESSORIES
WARRANTY

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SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING

rom _nd_11/98

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
 Marks a special safety message.

 Means Note; not safety related.

This group of symbols means Warning! Watch Out! possible

ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.

1-2. Arc Welding Hazards

 The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
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 1-5. Read and follow all
Safety Standards.
 Only qualified persons should install, operate, maintain, and
repair this unit.
 During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
 Do not touch live electrical parts.

 Wear a safety harness if working above floor level.

 Keep all panels and covers securely in place.
 Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
 Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
 Do not connect more than one electrode or work cable to any
single weld output terminal.

SIGNIFICANT DC VOLTAGE exists after stopping

engine on inverters.
 Stop engine on inverter and discharge input capacitors according
to instructions in Maintenance Section before touching any parts.

ARC RAYS can burn eyes and skin.

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

 Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
 Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
 Use AC output ONLY if required for the welding process.
 If AC output is required, use remote output control if present on
unit.
 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).
 Properly install and ground this equipment according to its
Owners Manual and national, state, and local codes.
 Always verify the supply ground check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
 When making input connections, attach proper grounding conductor first double-check connections.
 Frequently inspect 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.
 If earth grounding of the workpiece is required, ground it directly
with a separate cable.
 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.





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.
Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes from arc rays and sparks when welding or
watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards).
Wear approved safety glasses with side shields under your
helmet.
Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection.

FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
 Keep your head out of the fumes. Do not breathe the fumes.
 If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
 If ventilation is poor, use an approved air-supplied respirator.
 Read the Material Safety Data Sheets (MSDSs) and the
manufacturers instructions for metals, consumables, coatings,
cleaners, and degreasers.
 Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
 Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
 Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
OM-4402 Page 1

WELDING can cause fire or explosion.

Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
 Protect yourself and others from flying sparks and hot metal.
 Do not weld where flying sparks can strike flammable material.
 Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
 Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
 Watch for fire, and keep a fire extinguisher nearby.
 Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
 Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
 Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
 Do not use welder to thaw frozen pipes.
 Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
 Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
 Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.

FLYING METAL can injure eyes.

 Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
 Wear approved safety glasses with side
shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

 Shut off shielding gas supply when not in use.
 Always ventilate confined spaces or use approved air-supplied respirator.

HOT PARTS can cause severe burns.

 Allow cooling period before maintaining.
 Wear protective gloves and clothing when
working on a hot engine.
 Do not touch hot engine parts or just-welded
parts bare-handed.

NOISE can damage hearing.

Noise from some processes or equipment can
damage hearing.
 Wear approved ear protection if noise level is
high.

MAGNETIC FIELDS can affect pacemakers.

 Pacemaker wearers keep away.
 Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
 Protect compressed gas cylinders from excessive heat, mechanical shocks, 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.
 Keep cylinders away from any welding or other electrical circuits.
 Never drape a welding torch over a gas cylinder.
 Never allow a welding electrode to touch any cylinder.
 Never weld on a pressurized cylinder explosion will result.
 Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
 Turn face away from valve outlet when opening cylinder valve.
 Keep protective cap in place over valve except when cylinder is in
use or connected for use.
 Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.

1-3. Engine Hazards

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.

 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.
OM-4402 Page 2

STEAM AND HOT COOLANT can burn.

 If possible, check coolant level when engine is
cold to avoid scalding.
 Always check coolant level at overflow tank, if
present on unit, instead of radiator (unless told
otherwise in maintenance section or engine
manual).
 If the engine is warm, checking is needed, and
there is no overflow tank, follow the next two
statements.
 Wear safety glasses and gloves and put a rag over radiator cap.
 Turn cap slightly and let pressure escape slowly before completely
removing cap.

MOVING PARTS can cause injury.

 Keep away from fans, belts, and rotors.
 Keep all doors, panels, covers, and guards
closed and securely in place.
 Stop engine before installing or connecting unit.
 Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary.
 To prevent accidental starting during servicing, disconnect
negative () battery cable from battery.
 Keep hands, hair, loose clothing, and tools away from moving
parts.
 Reinstall panels or guards and close doors when servicing is
finished and before starting engine.
 Before working on generator, remove spark plugs or injectors to
keep engine from kicking back or starting.
 Block flywheel so that it will not turn while working on generator
components.

BATTERY ACID can BURN SKIN and

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

ENGINE EXHAUST GASES can kill.

 Use equipment outside in open, well-ventilated
areas.
 If used in a closed area, vent engine exhaust
outside and away from any building air intakes.

ENGINE HEAT can cause fire.

BATTERY EXPLOSION can BLIND.

 Always wear a face shield, rubber gloves, and
protective clothing when working on a battery.
 Stop engine before disconnecting or connecting 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.
Disconnect negative () cable first and connect it last.

 Do not locate unit on, over, or near combustible

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

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. Additional Symbols For Installation, Operation, And Maintenance

FALLING UNIT can cause injury.

 Use lifting eye to lift unit only, NOT running
gear, gas cylinders, trailer, or any other
accessories.
 Use equipment of adequate capacity to lift and
support unit.
 If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.

OVERUSE can cause OVERHEATING.

 Allow cooling period; follow rated duty cycle.
 Reduce current or reduce duty cycle before
starting to weld again.
 Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

FLYING SPARKS can cause injury.
 Wear a face shield to protect eyes and face.
 Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
 Sparks can cause fires keep flammables away.

 Put on grounded wrist strap BEFORE handling

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

TILTING OF TRAILER can cause injury.

 Use tongue jack or blocks to support weight.
 Properly install welding generator onto trailer
according to instructions supplied with trailer.

OVERHEATING can damage motors.

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

READ INSTRUCTIONS.
 Use only genuine MILLER replacement parts.
 Perform engine maintenance and service
according to this manual and the engine
manual.
OM-4402 Page 3

H.F. RADIATION can cause interference.






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

navigation, safety services, computers, and
communications equipment.
 Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.

ARC WELDING can cause interference.






 Electromagnetic energy can interfere with

sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
 Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
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.

1-5. Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

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

from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face
Protection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

1-6. 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.

Welding current, as it flows through welding cables, will cause electromagnetic 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
committees judgment, has not demonstrated that exposure to powerfrequency 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.
To reduce magnetic fields in the workplace, use the following
procedures:

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

OM-4402 Page 4

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

4. Keep welding power source and cables as far away from
operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.

SECTION 1 CONSIGNES DE SCURIT LIRE AVANT

UTILISATION
rom _nd_fre 11/98

1-1. Signification des symboles

Signifie Mise en garde ! Soyez vigilant ! Cette procdure
prsente des risques de danger ! Ceux-ci sont identifis
par des symboles adjacents aux directives.

 Identifie un message de scurit particulier.

 Signifie NOTA ; nest pas relatif la scurit.

Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des

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

1-2. Dangers relatifs au soudage larc

 Les symboles prsents ci-aprs sont utiliss tout au long du
prsent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnes afin dviter tout
danger. Les consignes de scurit prsentes ci-aprs ne font
que rsumer linformation contenue dans les normes de scurit numres la section 1-5. Veuillez lire et respecter toutes
ces normes de scurit.
 Linstallation, lutilisation, lentretien et les rparations ne
doivent tre confis qu des personnes qualifies.
 Au cours de lutilisation, tenir toute personne lcart et plus
particulirement les enfants.







Une tension DC importante subsiste lintrieur

des onduleurs aprs avoir coup lalimentation.


Couper lalimentation du poste et dcharger les condensateurs dentre

comme indiqu dans la Section Maintenance avant de toucher des composants.

LES RAYONS DE LARC peuvent provoquer des brlures dans les yeux et
sur la peau.

UN CHOC LECTRIQUE peut tuer.

Un simple contact avec des pices lectriques peut
provoquer une lectrocution ou des blessures graves.
Llectrode et le circuit de soudage sont sous tension ds
que lappareil est sur ON. Le circuit dentre et les circuits
internes de lappareil sont galement sous tension ce
moment-l. En soudage semi-automatique ou automatique, le fil, le dvidoir, le
logement des galets dentranement et les pices mtalliques en contact avec
le fil de soudage sont sous tension. Des matriels mal installs ou mal mis la
terre prsentent un danger.

Nutiliser quun matriel en bon tat. Rparer ou remplacer sur-le-champ

les pices endommages. Entretenir lappareil conformment ce
manuel.
Porter un harnais de scurit quand on travaille en hauteur.
Maintenir solidement en place tous les panneaux et capots.
Fixer le cble de retour de faon obtenir un bon contact mtal-mtal avec
la pice souder ou la table de travail, le plus prs possible de la soudure.
Isoler la pince de masse quand pas mis la pice pour viter le contact
avec tout objet mtallique.

Le rayonnement de larc du procd de soudage gnre

des rayons visibles et invisibles intenses (ultraviolets et
infrarouges) susceptibles de provoquer des brlures dans les yeux et sur la
peau. Des tincelles sont projetes pendant le soudage.


Ne jamais toucher les pices lectriques sous tension.

Porter des gants et des vtements de protection secs ne comportant pas

de trous.

Sisoler de la pice et de la terre au moyen de tapis ou dautres moyens isolants suffisamment grands pour empcher le contact physique ventuel
avec la pice ou la terre.

Ne pas se servir de source lectrique courant lectrique dans les zones

humides, dans les endroits confins ou l o on risque de tomber.

Se servir dune source lectrique courant lectrique UNIQUEMENT si le

procd de soudage le demande.

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

Couper lalimentation ou arrter le moteur avant de procder linstallation,

la rparation ou lentretien de lappareil. Dverrouiller lalimentation
selon la norme OSHA 29 CFR 1910.147 (voir normes de scurit).




Installer et mettre la terre correctement cet appareil conformment son

manuel dutilisation et aux codes nationaux, provinciaux et municipaux.

Toujours vrifier la terre du cordon dalimentation Vrifier et sassurer que

le fil de terre du cordon dalimentation est bien raccord la borne de terre
du sectionneur ou que la fiche du cordon est raccorde une prise
correctement mise la terre.

En effectuant les raccordements dentre fixer dabord le conducteur de

mise la terre appropri et contre-vrifier les connexions.

Vrifier frquemment le cordon dalimentation pour voir sil nest pas endommag ou dnud remplacer le cordon immdiatement sil est
endommag un cble dnud peut provoquer une lectrocution.

Mettre lappareil hors tension quand on ne lutilise pas.

Ne pas utiliser des cbles uss, endommags, de grosseur insuffisante ou

mal pisss.

Ne pas enrouler les cbles autour du corps.

Si la pice soude doit tre mise la terre, le faire directement avec un

cble distinct ne pas utiliser le connecteur de pice ou le cble de retour.

Ne pas toucher llectrode quand on est en contact avec la pice, la terre ou

une lectrode provenant dune autre machine.

Porter un casque de soudage muni dun cran de filtre appropri pour protger votre visage et vos yeux pendant le soudage ou pour regarder (voir
ANSI Z49.1 et Z87.1 numr dans les normes de scurit).
Porter des protections approuvs pour les oreilles si le niveau sondre est
trop lev.
Utiliser des crans ou des barrires pour protger des tiers de lclair et de
lblouissement; demander aux autres personnes de ne pas regarder larc.
Porter des vtements de protection constitu dans une matire durable, rsistant au feu (laine ou cuir) et une protection des pieds.

LES FUMES ET LES GAZ peuvent

tre dangereux.
Le soudage gnre des fumes et des gaz. Leur inhalation
peut tre dangereux pour votre sant.

Eloigner votre tte des fumes. Ne pas respirer les fumes.

linterieur, ventiler la zone et/ou utiliser un chappement au niveau de
larc pour lvacuation des fumes et des gaz de soudage.
Si la ventilation est insuffisante, utiliser un respirateur alimentation dair
homologu.
Lire les spcifications de scurit des matriaux (MSDSs) et les instructions du fabricant concernant les mtaux, les consommables, les
revtements, les nettoyants et les dgraisseurs.
Travailler dans un espace ferm seulement sil est bien ventil ou en portant un respirateur alimentation dair. Demander toujours un surveillant
dment form de se tenir proximit. Des fumes et des gaz de soudage
peuvent dplacer lair et abaisser le niveau doxygne provoquant des
blessures ou des accidents mortels. Sassurer que lair de respiration ne
prsente aucun danger.
Ne pas souder dans des endroits situs proximit doprations de dgraissage, de nettoyage ou de pulvrisation. La chaleur et les rayons de
larc peuvent ragir en prsence de vapeurs et former des gaz hautement
toxiques et irritants.
Ne pas souder des mtaux munis dun revtement, tels que lacier galvanis, plaqu en plomb ou au cadmium moins que le revtement nait t
enlev dans la zone de soudure, que lendroit soit bien ventil, et si ncessaire, en portant un respirateur alimentation dair. Les revtements et
tous les mtaux renfermant ces lments peuvent dgager des fumes
toxiques en cas de soudage.

OM-4402 Page 5

LE SOUDAGE peut provoquer un incendie ou une explosion.

Le soudage effectu sur des conteneurs ferms tels que
des rservoirs, tambours ou des conduites peut provoquer
leur clatement. Des tincelles peuvent tre projetes de
larc de soudure. La projection dtincelles, des pices chaudes et des
quipements chauds peut provoquer des incendies et des brlures. Le contact
accidentel de llectrode avec des objets mtalliques peut provoquer des
tincelles, une explosion, un surchauffement ou un incendie. Avant de
commencer le soudage, vrifier et sassurer que lendroit ne prsente pas de
danger.














 Le soudage, lcaillement, le passage de la pice

la brosse en fil de fer, et le meulage gnrent
des tincelles et des particules mtalliques volantes. Pendant la priode de refroidissement des soudures, elles risquent de projeter du laitier.

Prvoir une priode de refroidissement avant deffectuer des travaux dentretien.

 Porter des gants et des vtements de protection pour
travailler sur un moteur chaud.
Ne pas toucher mains nues les parties chaudes du moteur ni les pices
rcemment soudes.

LE BRUIT peut affecter loue.

Le bruit des processus et des quipements peut affecter
loue.


Fermer lalimentation du gaz protecteur en cas de

non utilisation.
Veiller toujours bien arer les espaces confins ou se servir dun respirateur dadduction dair homologu.

Porter des protections approuvs pour les oreilles si

le niveau sondre est trop lev.

LES CHAMPS MAGNTIQUES peuvent

affecter les stimulateurs cardiaques.



Porteurs de stimulateur cardiaque, restez distance.

Les porteurs dun stimulateur cardiaque doivent
dabord consulter leur mdecin avant de sapprocher
des oprations de soudage larc, de gougeage ou
de soudage par points.

Si des BOUTEILLES sont endommages, elles pourront exploser.

Des bouteilles de gaz protecteur contiennent du gaz sous
haute pression. Si une bouteille est endommage, elle peut
exploser. Du fait que les bouteilles de gaz font normalement partie du procd de soudage, les manipuler avec
prcaution.


Protger les bouteilles de gaz comprim dune chaleur excessive, des

chocs mcaniques, du laitier, des flammes ouvertes, des tincelles et des
arcs.

Placer les bouteilles debout en les fixant dans un support stationnaire ou

dans un porte-bouteilles pour les empcher de tomber ou de se renverser.

Tenir les bouteilles loignes des circuits de soudage ou autres circuits

lectriques.

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

Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille.

Porter des lunettes de scurit avec crans latraux ou un cran facial.

LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou

mme la mort.

Se protger et dautres personnes de la projection dtincelles et de mtal

chaud.
Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des
substances inflammables.
Dplacer toutes les substances inflammables une distance de 10,7 m de
larc de soudage. En cas dimpossibilit les recouvrir soigneusement avec
des protections homologus.
Des tincelles et des matriaux chauds du soudage peuvent facilement
passer dans dautres zones en traversant de petites fissures et des
ouvertures.
Surveiller tout dclenchement dincendie et tenir un extincteur proximit.
Le soudage effectu sur un plafond, plancher, paroi ou sparation peut dclencher un incendie de lautre ct.
Ne pas effectuer le soudage sur des conteneurs ferms tels que des rservoirs, tambours, ou conduites, moins quils naient t prpars
correctement conformment AWS F4.1 (voir les normes de scurit).
Brancher le cble sur la pice le plus prs possible de la zone de soudage
pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provoquant des risques dlectrocution et
dincendie.
Ne pas utiliser le poste de soudage pour dgeler des conduites geles.
En cas de non utilisation, enlever la baguette dlectrode du porte-lectrode ou couper le fil la pointe de contact.
Porter des vtements de protection dpourvus dhuile tels que des gants
en cuir, une chemise en matriau lourd, des pantalons sans revers, des
chaussures hautes et un couvre chef.
Avant de souder, retirer toute substance combustible de vos poches telles
quun allumeur au butane ou des allumettes.

DES PARTICULES VOLANTES

peuvent blesser les yeux.

DES PICES CHAUDES peuvent

provoquer des brlures graves.

Ne jamais souder une bouteille pressurise risque dexplosion.

Utiliser seulement des bouteilles de gaz protecteur, rgulateurs, tuyaux et

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

Ne pas tenir la tte en face de la sortie en ouvrant la soupape de la bouteille.

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

ou de branchement de la bouteille.

Lire et suivre les instructions concernant les bouteilles de gaz comprim,

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

1-3. Dangers existant en relation avec le moteur

LE CARBURANT MOTEUR peut provoquer un incendie ou une explosion.

LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT CHAUD peuvent
provoquer des brlures.





Arrter le moteur avant de vrifier le niveau de carburant ou de faire le plein.

 Ne pas faire le plein en fumant ou proche dune source dtincelles ou dune flamme nue.
Ne pas faire le plein de carburant ras bord; prvoir de lespace pour son
expansion.
Faire attention de ne pas renverser de carburant. Nettoyer tout carburant renvers avant de faire dmarrer le moteur.
Jeter les chiffons dans un rcipient ignifuge.






OM-4402 Page 6

Il est prfrable de vrifier le liquide de

refroidissement une fois le moteur refroidi pour viter
de se brler.
Toujours vrifier le niveau de liquide de refroidissement dans le vase
dexpansion (si prsent), et non dans le radiateur (sauf si prcis autrement dans la section maintenance du manuel du moteur).
Si le moteur est chaud et que le liquide doit tre vrifi, oprer comme
suivant :
Mettre des lunettes de scurit et des gants, placer un torchon sur le
bouchon du radiateur.
Dvisser le bouchon lgrement et laisser la vapeur schapper avant
denlever le bouchon.

DES ORGANES MOBILES peuvent

provoquer des blessures.

LACIDE DE LA BATTERIE peut provoquer des brlures dans les YEUX et

sur la PEAU.









Ne pas approcher les mains des ventilateurs, courroies et autres pices en mouvement.
 Maintenir ferms et fixement en place les portes,
panneaux, recouvrements et dispositifs de
protection.
Arrter le moteur avant dinstaller ou brancher lappareil.
Demander seulement un personnel qualifi denlever les dispositifs de
scurit ou les recouvrements pour effectuer, sil y a lieu, des travaux
dentretien et de dpannage.
Pour empcher tout dmarrage accidentel pendant les travaux dentretien, dbrancher le cble ngatif () de batterie de la borne.
Ne pas approcher les mains, cheveux, vtements lches et outils des organes mobiles.
Remettre en place les panneaux ou les dipositifs de protection et fermer
les portes la fin des travaux dentretien et avant de faire dmarrer le
moteur.
Avant dintervenir, dposer les bougies ou injecteurs pour viter la mise
en route accidentelle du moteur.
Bloquer le volant moteur pour viter sa rotation lors dune intervention
sur le gnrateur.

LEXPLOSION DE LA BATTERIE peut

RENDRE AVEUGLE.








Toujours porter une protection faciale, des gants en

caoutchouc et vtements de protection lors dune intervention sur la batterie.
Arrter le moteur avant de dbrancher ou de brancher les cbles de
batterie.
Eviter de provoquer des tincelles avec les outils en travaillant sur la
batterie.
Ne pas utiliser le poste de soudage pour charger les batteries ou des vhicules de dmarrage rapide.
Observer la polarit correcte (+ et ) sur les batteries.
Dbrancher le cble ngatif () en premier lieu. Le rebrancher en dernier
lieu.





Ne pas renverser la batterie.

Remplacer une batterie endommage.
Rincer immdiatement les yeux et la peau leau.

LES GAZ DCHAPPEMENT DU

MOTEUR peuvent provoquer des
accidents mortels.


Utiliser lquipement lextrieur dans des zones ouvertes et bien ventiles.

En cas dutilisation dans un endroit ferm vacuer les gaz dchappement du moteur vers lextrieur distance des entres dair dans les btiments.

LA CHALEUR DU MOTEUR peut provoquer un incendie.




Ne pas placer lappareil sur, au-dessus ou proximit

de surfaces inflammables.
Tenir distance les produits inflammables de
lchappement.

LES TINCELLES LCHAPPEMENT

peuvent provoquer un incendie.



Empcher les tincelles dchappement du moteur

de provoquer un incendie.
Utiliser uniquement un pare-tincelles approuv
voir codes en vigueur.

1-4. Dangers supplmentaires en relation avec linstallation, le fonctionnement

et la maintenance
LA CHUTE DE LAPPAREIL peut
blesser.




Utiliser lanneau de levage uniquement pour soulever

lappareil lui-mme ; sans chariot, de bouteilles de
gaz, remorque, ou autres accessoires.
Utiliser un quipement de levage de capacit suffisante pour lever lappareil.

En utilisant des fourches de levage pour dplacer lunit, sassurer

que les fourches sont suffisamment longues pour dpasser du ct
oppos de lappareil.

LES TINCELLES VOLANTES risquent de provoquer des blessures.




Porter un cran facial pour protger le visage et les

yeux.

Affuterr llectrode au tungstne uniquement la meuleuse dote de protecteurs. Cette manoeuvre est excuter dans un endroit sr lorsque
lon porte lquipement homologu de protection du visage, des mains et
du corps.
Les tincelles risquent de causer un incendie loigner toute substance
inflammable.

LEMPLOI EXCESSIF peut

SURCHAUFFER LQUIPEMENT.




LES
CHARGES
LECTROSTATIQUES
peuvent
endommager les circuits imprims.



tablir la connexion avec la barrette de terre avant de

manipuler des cartes ou des pices.
Utiliser des pochettes et des botes antistatiques
pour stocker, dplacer ou expdier des cartes de
circuits imprimes.

UNE REMORQUE QUI BASCULE peut

entraner des blessures.


LE SURCHAUFFEMENT peut endommager le moteur lectrique.

Laisser lquipement refroidir ; respecter le facteur de

marche nominal.
Rduire le courant ou le facteur de marche avant de
poursuivre le soudage.
Ne pas obstruer les passages dair du poste.

Utiliser les supports de la remorque ou des blocs

pour soutenir le poids.
Installer convenablement le poste sur la remorque
comme indiqu dans le manuel sy rapportant.

Arrter ou dconnecter lquipement avant de dmarrer ou darrter le moteur.

 Ne pas laisser tourner le moteur trop lentement sous
risque dendommager le moteur lectrique cause
dune tension et dune frquence trop faibles.
Ne pas brancher de moteur de 50 ou de 60 Hz la prise de 100 Hz, sil y a
lieu.

LIRE LES INSTRUCTIONS.




Utiliser seulement les pices de rechange dorigine.

Effecteur la maintenance et la mise en service
daprs le manuel et celui du moteur.

OM-4402 Page 7

LE RAYONNEMENT HAUTE FRQUENCE (H.F.) risque de provoquer

des interfrences.

LE SOUDAGE LARC risque de

provoquer des interfrences.








Le rayonnement haute frquence (H.F.) peut

provoquer des interfrences avec les quipements
de radionavigation et de communication, les
services de scurit et les ordinateurs.
Demander seulement des personnes qualifies familiarises avec des
quipements lectroniques de faire fonctionner linstallation.
Lutilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interfrences rsultant de linstallation.
Si le FCC signale des interfrences, arrter immdiatement lappareil.
Effectuer rgulirement le contrle et lentretien de linstallation.
Maintenir soigneusement ferms les portes et les panneaux des sources
de haute frquence, maintenir les clateurs une distance correcte et
utiliser une terre et et un blindage pour rduire les interfrences
ventuelles.







Lnergie lectromagntique risque de provoquer

des interfrences pour lquipement lectronique
sensible tel que les ordinateurs et lquipement command par ordinateur tel que les robots.
Veiller ce que tout lquipement de la zone de soudage soit compatible
lectromagntiquement.
Pour rduire la possibilit dinterfrence, maintenir les cbles de soudage aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre).
Veiller souder une distance de 100 mtres de tout quipement lectronique sensible.
Veiller ce que ce poste de soudage soit pos et mis la terre conformment ce mode demploi.
En cas dinterfrences aprs avoir pris les mesures prcdentes, il incombe lutilisateur de prendre des mesures supplmentaires telles que
le dplacement du poste, lutilisation de cbles blinds, lutilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.

1-5. Principales normes de scurit

Safety in Welding and Cutting, norme ANSI Z49.1, de lAmerican Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126
Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme AWS
F4.1, de lAmerican Welding Society, 550 N.W. Lejeune Rd, Miami FL
33126
National Electrical Code, NFPA Standard 70, de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

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

de la Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Rgles de scurit en soudage, coupage et procds connexes, norme
CSA W117.2, de lAssociation canadienne de normalisation, vente de
normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face Protection, norme ANSI Z87.1, de lAmerican National Standards Institute,
1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, norme NFPA 51B, de la National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.

1-6. Information sur les champs lectromagntiques

Donnes sur le soudage lectrique et sur les effets, pour lorganisme,
des champs magntiques basse frquence

Afin de rduire les champs lectromagntiques dans lenvironnement

de travail, respecter les consignes suivantes :
1

Le courant de soudage, pendant son passage dans les cbles de soudage, causera des champs lectromagntiques. Il y a eu et il y a encore
un certain souci propos de tels champs. Cependant, aprs avoir examin plus de 500 tudes qui ont t faites pendant une priode de
recherche de 17 ans, un comit spcial ruban bleu du National Research Council a conclu: Laccumulation de preuves, suivant le
jugement du comit, na pas dmontr que lexposition aux champs
magntiques et champs lectriques haute frquence reprsente un
risque la sant humaine. Toutefois, des tudes sont toujours en cours
et les preuves continuent tre examines. En attendant que les conclusions finales de la recherche soient tablies, il vous serait
souhaitable de rduire votre exposition aux champs lectromagntiques pendant le soudage ou le coupage.

OM-4402 Page 8

2
3
4
5

Garder les cbles ensembles en les torsadant ou en les

attachant avec du ruban adhsif.
Mettre tous les cbles du ct oppos de loprateur.
Ne pas courber pas et ne pas entourer pas les cbles autour de
votre corps.
Garder le poste de soudage et les cbles le plus loin possible de
vous.
Relier la pince de masse le plus prs possible de la zone de
soudure.

Consignes relatives aux stimulateurs cardiaques :

Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur docteur. Si vous tes dclar apte par votre docteur, il est
alors recommand de respecter les consignes cidessus.

SECTION 2 DEFINITIONS
2-1. Symbol Definitions
Stop Engine

Fast
(Run, Weld/Power)

Fast/Slow
(Run/Idle)

Slow (Idle)

Start Engine

Panel/Local

Temperature

Fuel

Engine Oil

On

Check Valve
Clearance

Battery (Engine)

Engine

Read Operators
Manual

MIG (GMAW),
Wire

Stick (SMAW)

TIG (GTAW)

Circuit Breaker

Positive

Negative

Alternating Current
(AC)

Output

Time

Hours

Seconds

Protective Earth
(Ground)

Remote 14
Receptacle

Work Connection

Engine Choke

Electrode
Positive

Electrode Negative

Do not switch while

welding

14

Wire Feed

Amperes

Volts

SECTION 3 SPECIFICATIONS
3-1. Weld, Power, And Engine Specifications
Welding
Mode

CC/DC

Rated
Welding
Output
280 A, 25 V,
100% Duty
Cycle
(Onan & Kohler)

Maximum
Open-Circuit
Voltage

80

300 A, 25 V,
40% Duty Cycle
(Kohler)

Amperage
Range In
CC Mode

Voltage
Range In
CV Mode

Auxiliary
Power Rating

Fuel
Capacity

Onan P220
Air-Cooled,
Two-Cylinder,
Four-Cycle,
20 HP Gasoline
Engine

20 280 A
(Onan)
20 300 A
(Kohler)
10 33 V

CV/DC

280 A, 25 V,
100% Duty
Cycle

50

CC/AC

200 A, 25 V,
60% Duty Cycle

75

40 200 A

Continuous: 8 kVA/kW,
66.6/33.3 A,
120/240 V AC, 60 Hz,
Single-Phase,
Peak: 9 kVA/kW
(w/Weld Contactor Off)

Engine

10 gal (38 L)
Tank

or
Kohler CH-20
Air-Cooled,
Two-Cylinder,
Four-Cycle,
20 HP Gasoline
Engine

OM-4402 Page 9

3-2. Dimensions, Weights, and Operating Angles

Dimensions

A
B

Height

33 in (838 mm)

Width

18-3/4 in (476 mm)

Depth

45-1/2 in (1156 mm)

18 in (457 mm)

16-1/2 in (419 mm)

3/4 in (19 mm)

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

D
G
4 Holes

 Do not move or operate unit where it could

tip.

E
F

3-1/8 in (79 mm)

32-3/4 in (832 mm)

45-1/2 in (1156 mm)

25

13/32 in (10 mm) Dia.

25

25
25

Weight
Onan: 591 lb (268 kg)
Kohler: 567 lb (257 kg)

Engine End

800 426

LITERS/HR.

US GAL/HR.

3-3. Fuel Consumption While Welding

7.57

2.00

6.62

1.75

5.68

1.50

4.73

1.25

3.79

1.00

2.84

0.75

1.89

0.50

0.95

0.25

0.00

0.00

DC WELD ONAN
DC WELD KOHLER

IDLE ONAN
IDLE KOHLER

50

100

150

200

250

300

350

400

DC WELD AMPERES AT 100% DUTY CYCLE

201 526

OM-4402 Page 10

LITERS/HR.

US GAL/HR.

3-4. Fuel Consumption While Using Auxiliary Power

7.57

2.00

6.62

1.75

5.68

1.50

4.73

1.25

3.79

1.00

2.84

0.75

1.89

0.50

0.95

0.25

0.00

0.00

AUX POWER ONAN

AUX POWER KOHLER

IDLE ONAN
IDLE KOHLER

OUTPUT AT 100% DUTY CYCLE (KW)

201 527

3-5. Auxiliary Power Curve

AC POWER VOLTS

The ac auxiliary power curve

shows the auxiliary power available
in amperes at the receptacles.

280

140

240

120

200

100

160

80

120

60

80

40

40

20

0
0

20

40

60

80

100

120

140

160

60

70

80

AC POWER AMPERES AT 120V

0

10

20

30

40

50

AC POWER AMPERES AT 240V

189 268

OM-4402 Page 11

3-6. Volt-Ampere Curves

The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of
other settings fall between the
curves shown.

A. CC/DC Mode
80
70
60
DC VOLTS

50
MAX
40
30

MIN

20
10
0
0

50

100

150

200

250

300

350

400

DC AMPERES

B. CV/DC Mode
50

40

DC VOLTS

Max
30
50%
20

10

Min

0
0

100

200

300

400

500

600

DC AMPERES

C. CC/AC Mode
80
70

AC VOLTS

60
50
40

MAX

30

MIN

20
10
0
0

50

100

150

200

AC AMPERES
OM-4402 Page 12

250

300

350
189 280 / 189 282-A / 189 265

3-7. Duty Cycle

Duty cycle is the percentage of 10
minutes that unit can weld at rated
load without overheating.

100% Duty Cycle at 280 Amperes DC

 Exceeding duty cycle can

damage unit and void
warranty.

Continuous Welding

350
DC WELD KOHLER

WELDING AMPERES

300

DC WELD ONAN

250
200
AC WELD

150
100
0

10

20

30

40

50

60

70

80

90

100

% DUTY CYCLE
199 467-A

SECTION 4 INSTALLATION
4-1. Installing Welding Generator

Movement

 Do not weld on base. Welding on base can cause fuel

tank fire or explosion. Bolt
unit down using holes provided in base.

Airflow Clearance
18 in
(460 mm)

 Do not lift unit from end.

18 in
(460 mm)

18 in
(460 mm)

 Always ground generator

frame to vehicle frame to prevent electric shock and static
electricity hazards.

OR

18 in
(460 mm)

18 in
(460 mm)

Grounding

Location

 Always securely fasten

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

1
2
3
4

1
GND/PE

Generator Base
Metal Vehicle Frame
Equipment Grounding
Terminal
Grounding Cable

Use #10 AWG or larger insulated

copper wire.

 If unit does not have GFCI receptacles,

use
GFCIprotected extension cord.

OR
OR

Electrically bond generator frame to vehicle frame

by metal-to-metal contact.

2
install1 10/00 Ref. 800 652 / Ref. 800 477-A / 158 936-A / S-0854

OM-4402 Page 13

4-2. Engine Prestart Checks (Onan-Powered Units)

Check all fluids daily. Engine must be
cold and on a level surface. Unit is
shipped with 10W30 engine oil.

 Follow run-in procedure in engine

manual.

 This unit has a low oil pressure shut-

down switch. However, some conditions may cause engine damage before the engine shuts down. Check
oil level often and do not use the oil
pressure shutdown system to monitor oil level.

Fuel
Add fresh fuel before starting engine the
first time (see maintenance label for
specifications). 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 maintenance label).

 To improve cold weather starting:

Full

Keep battery in good condition.

Store battery in warm area off concrete surface.
Use correct grade oil
weather.

1/2 in
(13 mm)

for cold

Full

Gasoline

Ref. 151 983 / 801 942-C / Ref. 800 395

OM-4402 Page 14

4-3. Engine Prestart Checks (Kohler-Powered Units)

Check all fluids daily. Engine must be
cold and on a level surface. Unit is
shipped with 10W30 engine oil.

 Follow run-in procedure in engine

manual.

 This unit has a low oil pressure

shutdown switch. However, some

conditions may cause engine
damage before the engine shuts
down. Check oil level often and do
not use the oil pressure shutdown
system to monitor oil level.

Fuel
Add fresh fuel before starting engine
the first time (see maintenance label for
specifications). 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 maintenance label).

 To improve cold weather starting:

Keep battery in good condition.
Store battery in warm area off concrete surface.
Full

1/2 in
(13 mm)

Use correct grade oil

weather.

for cold

Full

Gasoline

801 221 / 802 692

OM-4402 Page 15

4-4. Activating The Dry Charge Battery (If Applicable)

Remove battery from unit.
1

4
1

2
3
4
5

Eye Protection Safety

Glasses Or Face Shield
Rubber Gloves
Vent Caps
Sulfuric Acid Electrolyte
(1.265 Specific Gravity)
Well

Fill each cell with electrolyte to

bottom of well (maximum).

 Do not overfill battery cells.

Wait ten minutes and check electrolyte level. If necessary, add electrolyte to raise to proper level. Reinstall vent caps.
6

Battery Charger

 Read and follow all instructions supplied with battery

charger.

Charge battery for 12 minutes at 30

amperes or 30 minutes at 5 amperes. Disconnect charging cables
and install battery.

 When electrolyte

is low, add
only distilled water to cells to
maintain proper level.

5 A For 30 Minutes

Tools Needed:

OR

rubbergloves

30 A For 12 Minutes

glasses
drybatt1 1/98 S-0886

OM-4402 Page 16

4-5. Connecting The Battery

 Connect negative ()
cable last.

Tools Needed:
3/8, 1/2 in

Ref. 800 394-C / Ref. 203 073 / Ref. S-0756-D

4-6. Installing Exhaust Pipe

 Engine backfire can cause severe burns or other injuries.
Do not point exhaust pipe toward control panel. Keep
away from exhaust outlet.

 Point exhaust pipe in desired di-

rection but always away from

front panel and direction of travel.

Tools Needed:
1/2 in

801 681 / Ref. 203 073

4-7. Connecting To Weld Output Terminals

 Do not connect to CC and CV
terminals at the same time.
1
2
3

Work Weld Output Terminal

Stick/TIG (CC) Weld Output
Terminal
Wire (CV) Weld Output
Terminal

For MIG welding, connect work

cable to Work terminal and wire
feeder cable to Wire (CV) terminal.
For Stick/TIG welding, connect
work cable to Work terminal and
electrode holder cable to Stick/TIG
(CC) terminal.
1

801 943-B / Ref. 203 073

OM-4402 Page 17

4-8. Selecting Weld Cable Sizes*

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
100 ft (30 m) or Less

150 ft
(45 m)

200 ft
(60 m)

250 ft
(70 m)

300 ft
(90 m)

350 ft
400 ft
(105 m) (120 m)

Weld Output
Terminals
 Stop engine before
connecting to weld output terminals.

Welding
Amperes

10 60%
Duty
Cycle

60 100%
Duty
Cycle

100

4 (20)

4 (20)

4 (20)

3 (30)

2 (35)

1 (50)

1/0 (60)

1/0 (60)

150

3 (30)

3 (30)

2 (35)

1 (50)

1/0 (60)

2/0 (70)

3/0 (95)

3/0 (95)

200

3 (30)

2 (35)

1 (50)

1/0 (60)

2/0 (70)

3/0 (95)

4/0 (120)

4/0 (120)

250

2 (35)

1 (50)

1/0 (60)

2/0 (70)

3/0 (95)

4/0 (120)

2 ea. 2/0
(2x70)

2 ea. 2/0
(2x70)

300

1 (50)

1/0 (60)

2/0 (70)

3/0 (95)

4/0 (120)

2 ea. 2/0
(2x70)

2 ea. 3/0
(2x95)

2 ea. 3/0
(2x95)

350

1/0 (60)

2/0 (70)

3/0 (95)

4/0 (120)

2 ea. 2/0
(2x70)

2 ea. 3/0
(2x95)

2 ea. 3/0
(2x95)

2 ea. 4/0
(2x120)

 Do not use worn, damaged, undersized, or

poorly spliced cables.

10 100% Duty Cycle

* This

chart is a general guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), use next size larger
cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use

S-0007-E

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

4-9. Remote 14 Receptacle Information

NOTE

Engine runs at weld/power speed whenever a device connected to the remote 14

receptacle is running.

Socket*

Socket Information

24 volts ac.

Contact closure to A completes 24 volt ac contactor control circuit. Protected by circuit breaker
CB5.

115 volts ac.

Contact closure to I completes 115 volt ac contactor control circuit. Protected by circuit breaker
CB6.

0 to +10 volts dc output to remote control.

Remote control circuit common.

0 to +10 volts dc input command signal from

remote control.

Circuit common for 24 and 115 volt ac circuits.

Chassis common.

24 VOLTS AC
A
B

J
I

H
C L N
D M
G
E F

115 VOLTS AC

A/V
AMPERAGE
VOLTAGE

GND
801 943-B

*The remaining sockets are not used.

OM-4402 Page 18

4-10. Adjusting MIG Weld Puddle Consistency

 Stop engine.
Stabilizer
DC-Z
is
factory
connected to suit most MIG (Wire
Welding) applications.
To change MIG weld puddle consistency, proceed as follows:
Remove lower front panel and side
panel.
Starting from center of DC-Z, the
three leads 79 will be referred to as
inner, middle, and outer.
1

Stabilizer DC-Z

Inner Lead 79

3
4
5

Middle Lead 79
Outer Lead 79
Wire (CV) Weld Output
Terminal

Middle lead 79 is connected to Wire

(CV) weld terminal at the factory.
Disconnect middle lead 79 from
terminal.
To wet out weld puddle:
Remove insulation sleeve from inner lead 79. Connect inner lead 79
to Wire (CV) terminal, reusing
hardware.
To stiffen weld puddle:
Remove insulation sleeve from outer lead 79. Connect outer lead 79 to
Wire (CV) terminal, reusing
hardware.
Slide sleeves over unused leads 79,
and secure with cable ties. Reinstall
panels.

4
5
2

End View

Tools Needed:

3/8, 7/16 in
801 944-C / Ref. 203 073

OM-4402 Page 19

SECTION 5 OPERATING WELDING GENERATOR

5-1. Front Panel Controls

7
Ref. 203 073

 Do not switch under load.

runs at idle speed at no load, and weld/power

speed under load. In Run position, engine
runs at weld/power speed.

Use switch to select AC weld output or polarity of DC weld output.

 Place switch in Run position to operate

DC Polarity/AC Switch

Process Select Switch

Use switch to select output for weld process.

3

A/V Control

most GMAW equipment.

Engine Choke Control

Use control to change engine air-fuel mix.

To Stop: turn Engine Control switch to Off

position.
6

Engine Hour Meter

Output (Contactor) Switch

Use switch to control remote contactor if

connected to remote 14 receptacle RC1
(see Section 5-2).

Use control to select weld voltage or

amperage. Control may be adjusted while
welding.

To Start: pull out choke and turn Engine

Control switch to Start position. Release
switch and slowly push choke in when
engine starts.

 Weld output terminals are energized

when Output (Contactor) switch is
On and engine is running.

 If

Engine Control Switch

Use switch to start engine, select speed, and

stop engine. In Run/Idle position, engine
OM-4402 Page 20

the engine does not start, let the

engine come to a complete stop before
attempting restart.

Remote Amperage/Voltage Switch

Use switch to select front panel or remote

amperage/voltage control (see Section 5-2).

5-2. Remote Amperage/Voltage Control

1

Remote 14 Receptacle RC1

Connect optional remote control to

RC1 (see Section 4-9).
2
3

Remote Hand Control

(Optional)
Remote Foot Control
(Optional)

 Engine

runs at weld/power
speed whenever a device connected to the remote 14 receptacle is running.

In Example:
Process = Stick (SMAW)
Min = 40 A CC/DC
Max = 180 A CC/DC
3

Max (180 A DC)

Min (40 A DC)

Set Remote
Control Switches

Set Polarity Switch

Set Process and

A/V Control

Adjust Remote Control

(Stick Welding Only)

801 943-B / 203 073 / S-0769 / S-0774

OM-4402 Page 21

SECTION 6 OPERATING AUXILIARY EQUIPMENT

6-1. Auxiliary Power Receptacles And Circuit Breakers
 If unit does not have GFCI receptacles,
use
GFCIprotected extension cord.
5

 Auxiliary

power decreases as
weld current increases.

240 V 50 A AC Receptacle
RC1

RC1 supplies 60 Hz single-phase

power at weld/power speed. Maximum output is 8 kVA/kW.

120 V 20 A AC Duplex
Receptacle RC2

120 V 20 A AC Duplex
Receptacle RC3

RC2 and RC3 supply 60 Hz singlephase power at weld/power speed.

Maximum output from RC2 or RC3 is
2.4 kVA/kW.
4

Circuit Breaker CB1

CB1 protects all the receptacles from

overload. If CB1 opens, the receptacles do not work.

 Place switch in On position to reset circuit breaker. If breaker

continues to open, contact Factory Authorized Service Agent.

Circuit Breaker CB3

Circuit Breaker CB4

CB3 protects RC2 and CB4 protects

RC3 from overload. If a circuit breaker opens, the receptacle does not
work.

 Press

button to reset circuit

breaker. If breaker continues to
open,
contact
Factory
Authorized Service Agent.

Simultaneous Welding And Auxiliary Power Output

Weld Current
In Amperes
300
250
200
150
100
0

Total
Power In
Watts
1600
3500
5140
6700
8000
8000

120 V
240 V
Receptacle Receptacle
Amperes
Amperes
7
14
15
31
23
46
30
60
33
66
33
66

Combined output of all receptacles

limited to 8 kVA/kW rating of the generator.
EXAMPLE: If 20 A is drawn from
each 120 V duplex receptacle, only
13 A is available at the 240 V
receptacle:
2 x (120 V x 20 A) + (240 V x 13 A) =
8 kVA/kW

Ref. 203 073

OM-4402 Page 22

6-2. Optional Auxiliary Power Receptacles

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

 Auxiliary power decreases as

weld current increases.

Combined output of all receptacles

limited to 8 kVA/kW rating of the
generator.
GFCI Receptacle Option
1

120 V 15 A AC GFCI Receptacles GFCI2 and GFCI3

GFCI2 and GFCI3 supply 60 Hz

single-phase power at weld/power
speed. Maximum output from
GFCI2 or GFCI3 is 2.4 kVA/kW. Circuit breaker protection is the same
as standard receptacles.
If a ground fault is detected, the
GFCI Reset button pops out and
the circuit opens to disconnect the
faulty equipment. Check for
damaged tools, cords, plugs, etc.
connected to the receptacle. Press
button to reset receptacle and
resume operation.

Simultaneous Welding And Auxiliary Power Output

Weld Current
In Amperes

Total
Power In
Watts

300
250
200
150
100
0

1600
3500
5140
6700
8000
8000

 At

120 V
240 V
Receptacle Receptacle
Amperes
Amperes
7
14
15
31
23
46
30
60
33
66
33
66

least once a month, run

engine at weld/power speed
and press Test button to verify
GFCI is working properly.

Ref. 203 073

6-3. Wiring Optional 240 Volt Plug

The plug can be wired for a 240 V,
2-wire load or a 120/240V, 3-wire
load. See circuit diagram.

3
4

7
Current Available in Amperes

240 V
Each 120 V Duplex
Receptacle*
Receptacle
20
15
10
5
0

0
5
10
15
20
V x A = Watts

120V
120V

240V

When wired for 120 V loads, each

duplex receptacle shares a load
with one half of 240 V receptacle.
2

Plug Wired for 240 V, 2-Wire

Load

Neutral (Silver) Terminal

Load 1 (Brass)Terminal

Load 2 (Brass) Terminal

6
2
3
4

*One 240 V load or two 120 V loads.

Plug Wired for 120/240 V,

3-Wire Load

Ground (Green) Terminal

Amperes Available using

120/240 V Plug

240V
Tools Needed:
6

ST-120 813-D

OM-4402 Page 23

SECTION 7 MAINTENANCE (ONAN-POWERED UNITS)

7-1. Routine Maintenance (Onan-Powered Units)
 Stop engine before maintaining.
Recycle
engine
fluids.

 See Engine Manual and Maintenance Label. Service more often if used in severe conditions.

To be done by Factory Authorized Service Agent.

8h
Wipe up spills.

Check fluid levels.

See Section 4-2.

OIL
Full

20 h

25 h

Check and clean

spark arrestor screen.
See Section 7-4.

Service air filter wrapper

(foam element). See
Section 7-3.

50 h
Clean and
tighten weld
terminals.

Clean cooling system. See

engine manual.

100 h
Change oil. See
Section 7-5 and
maintenance
label.

Change oil filter.

See Section 7-5
and maintenance
label.

Service air filter element.

See Section 7-3.

Clean and
tighten battery
connections.

200 h
Check valve
clearance.*

Replace fuel
filter. See
Section 7-5.

Replace
unreadable
labels.

Check spark plugs.

500 h
Service welding generator
brushes and slip rings.
Service more often in dirty
conditions.*

Repair or
replace cracked
cables.

1000 h
Remove cylinder
head deposits.*

OM-4402 Page 24

Clean crankcase
breather valve.

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

OR

7-2. Maintenance Label (Onan-Powered Units)

NOTE

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

OM-4402 Page 25

7-3. Servicing Air Cleaner (Onan-Powered Units)

 Stop engine.
 Do not run engine without air
cleaner or with dirty element.
1

Wash wrapper with soap and water

solution. Allow wrapper to air dry
completely.

Wrapper (Foam Element)

Spread 1 tablespoon SAE 30 oil

evenly into wrapper. Squeeze out
excess oil.
2

Element

Replace element if damaged, dirty,

or oily.

oil

aircleaner3 1/97 156 852 / Ref. 185 095-A / S-0759

7-4. Servicing Optional Spark Arrestor (Onan-Powered Units)

 Stop engine and let cool.
1

Spark Arrestor Screen

Clean and inspect screen. Replace

spark arrestor if screen wires are
broken or missing.

Tools Needed:
1/4 in

801 942-C / Ref. 801 695-A / Ref. 203 073

OM-4402 Page 26

7-5. Changing Engine Oil, Oil Filter, And Fuel Filter (Onan-Powered Units)
 Stop engine and let cool.
1

Oil Drain Valve

1/2 ID x 12 in Hose

Oil Filter

Change engine oil and filter according to engine manual.

 Close valve and valve cap
before adding oil and running engine.
Fill crankcase with new oil to full
mark on dipstick (see Section 7-2).

Full

Fuel Filter

Fuel Line

Replace line if cracked or worn.

Install new filter. Wipe up any spilled
fuel.
Start engine, and check for fuel
leaks.
 Stop engine, tighten connections as necessary, and wipe
up fuel.

Tools Needed:

Ref. 801 942-C / 800 395-B / Ref. 203 073 / S-0842

OM-4402 Page 27

7-6. Adjusting Engine Speed (Onan-Powered Units)

After tuning engine, check engine
speeds with a tachometer (see
table). If necessary, adjust speeds
as follows:
2200 100 rpm
3700 50 rpm

Start engine and run until warm.

Turn A/V control to max.
Idle Speed Adjustment
1

Throttle Solenoid

Mounting Screw

Loosen two mounting screws.

Governor Arm

Carburetor

Idle Speed Screw

Pull governor arm away from

carburetor and hold while making
the following adjustment:
Turn idle speed screw until engine
runs at idle speed (see table).

Left Side

Release governor arm. Place

Engine Control switch in Run/Idle
position.
6

Carburetor Stop

With solenoid energized, slide solenoid until idle speed screw just
touches carburetor stop. Tighten
solenoid mounting screws.
7

4
10

Check for smooth operation, and

readjust solenoid position if
necessary.

2
9

Governor Arm Extension

11
3
2

Weld/Power Speed Adjustment

Place Engine Control switch in Run
position.
8

Weld/Power Speed Rod

Locking Nut

Loosen nut.
10 Adjustment Nut

Top View

Turn adjustment nut until engine

runs at weld/power speed. Tighten
locking nut.
 Stop engine.
11 Sensitivity Spring
See engine manual for governor
sensitivity adjustment.

Tools Needed:

1/4, 3/8 in
Ref. 801 942-C / 800 397-A

OM-4402 Page 28

7-7. Overload Protection (Onan-Powered Units)

 Stop engine.

Tools Needed:

 When a circuit breaker or fuse

opens, it usually indicates a
more serious problem exists.
Contact a Factory Authorized
Service Agent.

3/8 in

1 Circuit Breaker CB5

CB5 protects the 24 volt ac output
to Remote 14 receptacle RC1. If
CB5 opens, 24 volt ac output to
RC1 stops.
2 Circuit Breaker CB6
CB6 protects the 115 volt ac output
to Remote 14 receptacle RC1. If
CB6 opens, 115 volt ac output to
RC1 stops.
Press button to reset breaker.
3 Fuse F6 (See Parts List)

F6 protects the engine wiring system from overload. If F6 opens,

engine will not crank.

Fuse F1 (See Parts List)

Fuse F2 (See Parts List)

Remove side panel.

F1 protects the exciter excitation

winding from overload. If F1 opens,
weld and auxiliary power output
stops.
F2 protects the stator winding from
overload. If F2 opens, weld output
stops. Auxiliary power will still be
available.
Replace any open fuses. Reinstall
cover before operating unit.

2 1

2
801 945-C / Ref. 203 073

OM-4402 Page 29

SECTION 8 MAINTENANCE (KOHLER-POWERED UNITS)

8-1. Routine Maintenance (Kohler-Powered Units)
 Stop engine before maintaining.

 See Engine Manual and Maintenance Label. Ser-

Recycle
engine
fluids.

vice more often if used in severe conditions.

To be done by Factory Authorized Service Agent.

8h
Wipe up spills.

Check fluid levels.

See Section 4-3.

OIL

20 h
Check and clean
spark arrestor screen.
See Section 8-4.

25 h
Service air filter wrapper
(foam element). See
Section 8-3.

50 h
Clean and tighten
weld terminals.

100 h
Change oil. See
Section 8-5 and
maintenance
label.

Service air filter element.

See Section 8-3.

Clean cooling system. See

engine manual.

Clean and
tighten battery
connections.

200 h
Change oil filter.
See Section 8-5
and maintenance
label.

Replace fuel
filter. See
Section 8-5.

Check spark plugs.

Replace
unreadable
labels.

500 h
Service welding generator
brushes and slip rings.
Service more often in dirty
conditions.*

Repair or
replace cracked
cables.

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

OM-4402 Page 30

OR

8-2. Maintenance Label (Kohler-Powered Units)

NOTE

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

OM-4402 Page 31

8-3. Servicing Air Cleaner (Kohler-Powered Units)

 Stop engine.
 Do not run engine without air
cleaner or with dirty element.

Wrapper (Foam Element)

Wash wrapper with soap and water

solution. Allow wrapper to air dry
completely.

Spread 1 tablespoon SAE 30 oil

evenly into wrapper. Squeeze out
excess oil.
2

Element

Replace element if damaged, dirty,

or oily.

oil

aircleaner3 9/00 802 772 / Ref. 185 095-A / S-0759

8-4. Servicing Optional Spark Arrestor (Kohler-Powered Units)

 Stop engine and let cool.
1

Spark Arrestor Screen

Clean and inspect screen. Replace

spark arrestor if screen wires are
broken or missing.

Tools Needed:
1/4 in

802 692 / Ref. 203 073

OM-4402 Page 32

8-5. Changing Engine Oil, Oil Filter, And Fuel Filter (Kohler-Powered Units)
 Stop engine and let cool.
1

Oil Drain Valve

1/2 ID x 12 in Hose

Oil Filter

Change engine oil and filter according to engine manual.

 Close valve and valve cap
before adding oil and running engine.

Full

Fill crankcase with new oil to full

mark on dipstick (see Section 8-2).
4

Fuel Filter

Fuel Line

Replace line if cracked or worn.

Install new filter. Wipe up any spilled
fuel.
Start engine, and check for fuel
leaks.
 Stop engine, tighten connections as necessary, and wipe
up fuel.

Tools Needed:

802 692 / S-0842

OM-4402 Page 33

8-6. Adjusting Engine Speed (Kohler-Powered Units)

After tuning engine, check engine
speeds with a tachometer (see
table). If necessary, adjust speeds
as follows:
2200 50 rpm
3700 50 rpm

Start engine and run until warm.

Turn A/V control to 10.
Remove top cover to access speed
adjustments.
Idle Speed Adjustment
Move Engine Control switch to
Run/Idle position.

5
2

Throttle Solenoid

Mounting Screws

Idle Speed Screw

Loosen mounting screws. Adjust

solenoid position so engine runs at
idle speed. If necessary, back out
idle speed screw so solenoid can
be moved to correct position. Tighten mounting screws. Be sure solenoid linkage works smoothly.
Turn idle speed screw for fine
adjustments.
Weld/Power Speed Adjustment
Move Engine Control switch to Run
position.
4

Weld/Power Speed
Adjustment Nut

Lock Nut

Loosen lock nut. Turn adjustment

nut until engine runs at weld/power
speed. Tighten lock nut.

Reinstall top cover.

 Stop engine.

Top View

Tools Needed:
1/4, 3/8 in
OM-4402 Page 34

802 692 / ST-801 209-A

8-7. Overload Protection (Kohler-Powered Units)

 Stop engine.

Tools Needed:

 When a circuit breaker or fuse

opens, it usually indicates a
more serious problem exists.
Contact a Factory Authorized
Service Agent.

3/8 in

1 Circuit Breaker CB5

CB5 protects the 24 volt ac output
to Remote 14 receptacle RC1. If
CB5 opens, 24 volt ac output to
RC1 stops.
2 Circuit Breaker CB6
CB6 protects the 115 volt ac output
to Remote 14 receptacle RC1. If
CB6 opens, 115 volt ac output to
RC1 stops.
Press button to reset breaker.
3 Fuse F6 (See Parts List)

F6 protects the engine wiring system from overload. If F6 opens,

engine will not crank.
4

Fuse F1 (See Parts List)

Fuse F2 (See Parts List)

Remove side panel.

F1 protects the exciter excitation
winding from overload. If F1 opens,
weld and auxiliary power output
stops.
F2 protects the stator winding from
overload. If F2 opens, weld output
stops. Auxiliary power will still be
available.
3

Replace any open fuses. Reinstall

cover before operating unit.

2 1

802 694 / Ref. 203 073

OM-4402 Page 35

SECTION 9 TROUBLESHOOTING
9-1. Welding Troubleshooting

Trouble
No weld output.

Remedy
Check control settings.
Check weld connections.
Disconnect equipment from auxiliary power receptacles during start-up.
Place Output (Contactor) switch in On position, or move switch to Remote 14 position and connect
remote contactor to Remote 14 receptacle RC1 (see Sections 4-9 and 5-1).
Check fuses F1 and F2, and replace if necessary (see Section 7-7 or 8-7).
Have Factory Authorized Service Agent check brushes, slip rings, and field current control board PC2.

Low weld output.

Check control settings.

Place Remote Amperage/Voltage switch in Panel position, or move switch to Remote 14 position and
connect remote amperage/voltage control to Remote 14 receptacle RC1.
Check and clean air cleaner as necessary (see Section 7-3 or 8-3).
Check and adjust engine speed (see Section 7-6 or 8-6).
Have Factory Authorized Service Agent check brushes, slip rings, and field current control board PC2.
See engine manual.

High weld output.

Check control settings.

Check and adjust engine speed (see Section 7-6 or 8-6).
Check for obstructed movement of solenoid linkage (see Section 7-6 or 8-6).
Have Factory Authorized Service Agent check field current control board PC2.

Weld output cannot be adjusted.

Check position of Remote Amperage/Voltage switch (see Section 5-1).

Have Factory Authorized Service Agent check field current control board PC2.

Erratic weld output.

Check control settings.

Clean and tighten connections both inside and outside unit.
Check and secure lead connections to A/V control.
Be sure connection to work piece is clean and tight.
Remove excessive coils from weld cables.
Use dry, properly stored electrodes.
Check and adjust engine speed (see Section 7-6 or 8-6).
Have Factory Authorized Service Agent check brushes, slip rings, and field current control board PC2.

Remote contactor control does not

activate contactor.

Place Output (Contactor) switch in Remote 14 position (see Section 5-1).

Check and tighten connections to Remote 14 receptacle RC1 (see Section 4-9).

No power output at Remote 14

receptacle RC1.

OM-4402 Page 36

Reset circuit breaker CB1 and/or CB2 (see Section 7-7 or 8-7).

Trouble
Lack of high frequency; difficulty in
establishing Gas Tungsten Arc Welding arc.

Remedy
Use proper size tungsten for welding amperage.

Reduce leakage of high frequency from torch or work cable (check grounding, remove excessive
coils from weld cables, use shorter weld cables, etc.).
Check cables and torch for cracked or deteriorated insulation or bad connections. Repair or replace
necessary parts.
Wandering arc poor control of arc
direction.

Reduce gas flow rate.

Select proper size tungsten. Properly prepare tungsten.

Tungsten electrode oxidizing and not

remaining bright after conclusion of
weld.

Shield weld zone from drafts.

Increase postflow time.

Check and tighten all gas fittings.
Properly prepare tungsten.

9-2. Auxiliary Power Troubleshooting

Trouble
No power output.

Remedy
Reset circuit breakers (see Section 6-1).
Check fuse F1, and replace if necessary (see Section 7-7 or 8-7).
Have Factory Authorized Service Agent check brushes, slip rings, and field current control board PC2.

Low power output.

Check and clean air cleaner as necessary.

Check and adjust engine speed (see Section 7-6 or 8-6).
See engine manual.

High power output.

Check and adjust engine speed (see Section 7-6 or 8-6).

Erratic power output.

Have Factory Authorized Service Agent check brushes, slip rings, and field current control board PC2.
Check receptacle wiring and connections.
Check governor according to engine manual.

9-3. Engine Troubleshooting

Trouble
Engine will not crank.

Remedy
Check fuse F6, and replace if open (see Section 7-7 or 8-7).
Check battery voltage.
Check battery connections and tighten if necessary.
Check plug PLG5 and plug PLG8 connections.
Have Factory Authorized Service Agent check Engine Control switch S5.

OM-4402 Page 37

Trouble
Engine does not start.

Remedy
Check fuel level (see Section 4-2 or 4-3).
Check battery and replace if necessary.
Check engine charging system according to engine manual.
Have Factory Authorized Service Agent check fuel shutoff solenoid GS1 according to engine manual
(GS1 standard on Kohler-powered units; optional on Onan-powered, LP-fueled units).
See engine manual.

Engine starts but stops when Engine

Control switch returns to Run position.

Check oil level (see Section 4-2 or 4-3).

Check and refill crankcase with proper viscosity oil for operating temperature, if necessary (see Section 7-2 or 8-2).
Have Factory Authorized Service Agent check low oil pressure shutdown switch S5.

Battery discharges between uses.

Clean top of battery with baking soda and water solution; rinse with clear water.
Periodically recharge battery (approximately every 3 months).
Replace battery.
Check voltage regulator according to engine manual.

Engine stopped during normal

operation.

Check fuel level (see Section 4-2 or 4-3).

Check oil level (see Section 4-2 or 4-3).
Have Factory Authorized Service Agent check fuel shutoff solenoid GS1 according to engine manual
(GS1 standard on Kohler-powered units; optional on Onan-powered, LP-fueled units).
Have Factory Authorized Service Agent check low oil pressure shutdown switch S5.

Engine does not return to idle speed.

Be sure Engine Control switch S2 is in Run/Idle position.

Remove all weld and auxiliary power loads.
Turn off remote device connected to Remote 14 receptacle RC1 (see Section 4-9).
Check for obstructed movement of solenoid linkage (see Section 7-6 or 8-6).
Have Factory Authorized Service Agent check idle module PC1 and current transformer CT1.

Engine does not remain at weld/power

speed when power or weld load is
applied with Engine Control switch in
Run/Idle position.

OM-4402 Page 38

Place Engine Control switch in the Run position for small loads.

Notes

OM-4402 Page 39

SECTION 10 ELECTRICAL DIAGRAM

Figure 8-1. Circuit Diagram For Welding Generator

OM-4402 Page 40

203 082

OM-4402 Page 41

SECTION 11 AUXILIARY POWER GUIDELINES

11-1. Selecting Equipment
1
2
3

Auxiliary Power Receptacles

Neutral Bonded To Frame
3-Prong Plug From Case
Grounded Equipment
2-Prong Plug From Double
Insulated Equipment

3
Be sure equipment
has this symbol
and/or wording.

OR

aux_pwr 4/01 Ref. ST-159 730 / ST-800 577

11-2. Grounding Generator To Truck Or Trailer Frame

1
2
3
4

Generator Base
Metal Vehicle Frame
Equipment Grounding
Terminal
Grounding Cable

Use #10 AWG or larger insulated

copper wire.
 If unit does not have GFCI receptacles, use GFCI-protected extension cord.
3

GND/PE

OR

Electrically bond generator

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

S-0854

OM-4402 Page 42

11-3. Grounding When Supplying Building Systems

1
1

GND/PE

Equipment Grounding
Terminal
Grounding Cable

Use #10 AWG or larger insulated

copper wire.
3

Ground Device

 Ground generator to system

earth ground if supplying
power to a premises (home,
shop, farm) wiring system.

Use ground device as stated

in electrical codes.
2

ST-800 576-B

11-4. How Much Power Does Equipment Require?

1
3
2
1

VOLTS 115
AMPS 4.5
Hz
60

Resistive Load

A light bulb is a resistive load and

requires a constant amount of power.
2

Non-Resistive Load

Equipment with a motor is a non-resistive load and requires approximately six times more power while
starting the motor than when running (see Section 11-8).
3

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 amperes at 115 volts, calculate its running power
requirement in watts.
4.5 A x 115 V = 520 W
The load applied by the drill is 520 watts.

EXAMPLE 2: If three 200 watt flood lamps are used with the drill from Example 1,
add the individual loads to calculate total load.
(200 W + 200 W + 200 W) + 520 W = 1120 W
The total load applied by the three flood lamps and drill is 1120 watts.
S-0623

OM-4402 Page 43

11-5. Approximate Power Requirements For Industrial Motors

Industrial Motors
Split Phase

Capacitor Start-Induction Run

Capacitor Start-Capacitor Run

Fan Duty

Rating

Starting Watts

Running Watts

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
1-1/2 HP
2 HP
3 HP
5 HP
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

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
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
400
550
650
800
1100

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

Farm/Home Equipment
Stock Tank De-Icer
Grain Cleaner
Portable Conveyor
Grain Elevator
Milk Cooler
Milker (Vacuum Pump)
FARM DUTY MOTORS
Std. (e.g. Conveyors,
Feed Augers, Air
Compressors)

High Torque (e.g. Barn

Cleaners, Silo Unloaders,
Silo Hoists, Bunk Feeders)
3-1/2 cu. ft. Mixer
High Pressure 1.8 Gal/Min
Washer 2 gal/min
2 gal/min
Refrigerator or Freezer
Shallow Well Pump
Sump Pump

OM-4402 Page 44

Rating

1/4 HP
1/2 HP
3/4 HP
2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/2 HP
500 PSI
550 PSI
700 PSI
1/3 HP
1/2 HP
1/3 HP
1/2 HP

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
1000
1400
1100
2800
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
1000
950
1400
1600
800
750
1000
800
1050

11-7. Approximate Power Requirements For Contractor Equipment

Contractor
Hand Drill

Circular Saw

Table Saw
Band Saw
Bench Grinder

Air Compressor

Electric Chain Saw

Electric Trimmer
Electric Cultivator
Elec. Hedge Trimmer
Flood Lights

Submersible Pump
Centrifugal Pump
Floor Polisher
High Pressure Washer

55 gal Drum Mixer

Wet & Dry Vac

Rating

Starting Watts

Running Watts

1/4 in
3/8 in
1/2 in
6-1/2 in
7-1/4 in
8-1/4 in
9 in
10 in
14 in
6 in
8 in
10 in
1/2 HP
1 HP
1-1/2 HP
2 HP
1-1/2 HP, 12 in
2 HP, 14 in
Standard 9 in
Heavy Duty 12 in
1/3 HP
18 in
HID
Metal Halide
Mercury
Sodium
Vapor
400 gph
900 gph
3/4 HP, 16 in
1 HP, 20 in
1/2 HP
3/4 HP
1 HP
1/4 HP
1.7 HP
2-1/2 HP

350
400
600
500
900
1400
4500
6300
2500
1720
3900
5200
3000
6000
8200
10500
1100
1100
350
500
2100
400
125
313
1000
1400
1250
600
900
4500
6100
3150
4500
6100
1900
900
1300

350
400
600
500
900
1400
1500
1800
1100
720
1400
1600
1000
1500
2200
2800
1100
1100
350
500
700
400
100
250

1000
200
500
1400
1600
950
1400
1600
700
900
1300

OM-4402 Page 45

11-8. Power Required To Start Motor

4
1
3

AC MOTOR
VOLTS 230
AMPS 2.5
CODE M
Hz
60
HP
1/4
PHASE 1

1
2
3
4

Motor Start Code

Running Amperage
Motor HP
Motor Voltage

To find starting amperage:

Step 1: Find code and use table to
find kVA/HP. If code is not listed,
multiply running amperage by six to
find starting amperage.
Step 2: Find Motor HP and Volts.
Step 3: Determine starting amperage (see example).
Welding generator amperage output must be at least twice the
motors running amperage.

Single-Phase Induction Motor Starting Requirements

Motor Start
Code

KVA/HP

6.3

7.1

8.0

9.0

10.0

11.2

12.5

14.0

kVA/HP x HP x 1000
VOLTS

= STARTING AMPERAGE

EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4

HP motor with a motor start code of M.
Volts = 230

HP = 1/4

Using Table, Code M results in kVA/HP = 11.2

11.2 x 1/4 x 1000

= 12.2 A Starting the motor requires 12.2 amperes.
230

S-0624

11-9. How Much Power Can Generator Supply?

1

Limit Load To 90% Of

Generator Output

Always start non-resistive (motor)

loads in order from largest to smallest, and add resistive loads last.
2

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-4402 Page 46

11-10. Typical Connections To Supply Standby Power

 Have only qualified persons
perform these connections
according to all applicable
codes and safety practices.
1
2

 Customer-supplied equipment is required if

generator is to supply standby power during

emergencies or power outages.

Obtain and install correct switch.

Switch rating must be same as or
greater than the branch overcurrent
protection.

1
240 V

120/240 Volt
60 Hz
Three-Wire
Service

120 V

Neutral

Circuit Breakers or Fused

Disconnect Switch

Obtain and install correct circuit

breakers or switch.

120 V

Extension Cord

Select as shown in Section 11-11.

3

Generator Connections

Connect terminals or plug of adequate amperage capacity to cord.

Follow all applicable codes and
safety practices.

240 V

120 V
Load

Power Company Service

Meter
Main and Branch Overcurrent
Protection
Double-Pole, Double-Throw
Transfer Switch

120 V

4
7

Turn off or unplug all equipment

connected to generator before
starting or stopping engine. When
starting or stopping, the engine has
low speed which causes low voltage and frequency.
7

Load Connections

CB
or

Item 4 is not necessary if circuit

protection is already present in
welding generator auxiliary
power output circuit.

F1

6
240 V
120/240 Volt
Single-Phase
Three-Wire
Generator Output
Connection

120 V
120 V
Ground

S-0405-A

OM-4402 Page 47

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

Cord Lengths for 120 Volt Loads

 If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)

Load (Watts)

600

840

10

1200

15

10

12

14

350 (106)

225 (68)

137 (42)

100 (30)

400 (122)

250 (76)

150 (46)

100 (30)

62 (19)

400 (122)

275 (84)

175 (53)

112 (34)

62 (19)

50 (15)

1800

300 (91)

175 (53)

112 (34)

75 (23)

37 (11)

30 (9)

20

2400

225 (68)

137 (42)

87 (26)

50 (15)

30 (9)

25

3000

175 (53)

112 (34)

62 (19)

37 (11)

30

3600

150 (46)

87 (26)

50 (15)

37 (11)

35

4200

125 (38)

75 (23)

50 (15)

40

4800

112 (34)

62 (19)

37 (11)

45

5400

100 (30)

62 (19)

50

6000

87 (26)

50 (15)

*Conductor size is based on maximum 2% voltage drop

Cord Lengths for 240 Volt Loads

 If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)

Load (Watts)

1200

1680

10

2400

15

10

12

14

700 (213)

450 (137)

225 (84)

200 (61)

800 (244)

500 (152)

300 (91)

200 (61)

125 (38)

800 (244)

550 (168)

350 (107)

225 (69)

125 (38)

100 (31)

3600

600 (183)

350 (107)

225 (69)

150 (46)

75 (23)

60 (18)

20

4800

450 (137)

275 (84)

175 (53)

100 (31)

60 (18)

25

6000

350 (107)

225 (69)

125 (38)

75 (23)

30

7000

300 (91)

175 (53)

100 (31)

75 (23)

35

8400

250 (76)

150 (46)

100 (31)

40

9600

225 (69)

125 (38)

75 (23)

45

10,800

200 (61)

125 (38)

50

12,000

175 (53)

100 (31)

*Conductor size is based on maximum 2% voltage drop

OM-4402 Page 48

Notes

OM-4402 Page 49

28

SECTION 12 PARTS LIST

29

 Hardware is common and

27

55
32

34

45

43

49

47

50

45

44
41

Figure 12-1. Main Assembly (Onan Engine Shown)

OM-4402 Page 50

53

54 Fig. 12-2

51

40

48

47

46

39

42

10

52

44

11

12

38

33

13

37

14

35

15

36

16

17

19

25

31

26

24Fig 12-3

20

18

22
21

30

23

not available unless listed.

ST-802 048-D

Item
No.

Dia.
Mkgs.

Part
No.

Description

Quantity

Figure 12-1. Main Assembly

. . . 1 . . . . . . . . . . . . . 182 367 . . PANEL, right side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 1 . . . . . . . . . . . . 185 352 . . PANEL, right side stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . . 182 366 . . PANEL, left side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . 185 353 . . PANEL, left side stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . . . +183 221 . . COVER, top (Onan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . . . +183 222 . . COVER, top (Kohler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . . +185 354 . . COVER, top stainless (Onan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . . +185 355 . . COVER, top stainless (Kohler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . . . . . . . . . 182 761 . . LABEL, general precautionary engine drive . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . . . . . . . . . 192 042 . . LABEL, warning engine fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . . . . . . . . . 181 881 . . GROMMET, neck filler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . . . . . . . . . . 147 601 . . CAP, tank screw-on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . . . . . . . . . . . 108 487 . . LABEL, warning falling equipment etc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . . . . . . . . . . 183 433 . . PIPE, exhaust elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 10 . . . . . . . . . . . . . 183 314 . . CLAMP, muffler 1.625 dia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . . . . . . . . . . 182 365 . . PANEL, rear upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . . . . . . . . . 185 351 . . PANEL, rear upper stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . . . . . . . . . . . 183 626 . . BAFFLE, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 185 323 . . SEAL, baffle engine air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 010 493 . . BUSHING, snap-in nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . . . 186 670 . . UPRIGHT, base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 14 . . . . . . . . . . . . . 181 789 . . SEAL, barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 15 . . . . . . . . . . . . . 186 667 . . PANEL, rear lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . . . . 165 271 . . VALVE, oil drain 3/8-18NPTF (included with engine) . . . . . . . . . . . . . . . . . .
. . . 17 . . . . . . . . . . . . . 165 623 . . LABEL, engine maintenance (Onan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . . . . . . . . . . . 173 088 . . LABEL, engine maintenance (Kohler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 18 . . . . . . . . . . . . . 187 126 . . ENGINE, (Onan) gas elec P220gi/11592h (consisting of) . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . . 183 434 . . . . MUFFLER, exhaust engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . . 065 313 . . . . GASKET, muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 21 . . . . . . . . . . . . . 059 926 . . . . PIN, spring CS .093 x 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 22 . . . . TS1 . . . 165 810 . . . . SOLENOID, 14VDC .53A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 23 . . . . . . . . . . . . . 165 522 . . . . BRACKET, mtg solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . *066 113 . . . . FILTER, fuel in-line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 192 868 . . . . INDICATOR/CAP ASSEMBLY (Dipstick) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . F6 . . . . *021 718 . . . . FUSE, mintr gl 30A 32V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 18 . . . . . . . . . . . . . 200 762 . . ENGINE, (Kohler) gas elec CH20sps64653 (consisting of) . . . . . . . . .
. . . 19 . . . . . . . . . . . . . 183 435 . . . . MUFFLER, exhaust engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . . 189 477 . . . . GASKET, muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . *066 113 . . . . FILTER, fuel in-line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . F6 . . . . *021 718 . . . . FUSE, mintr gl 30 A 32V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 200 761 . . SHIELD, heat muffler (Kohler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 192 093 . . PUMP, electric fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . PLG5 . . . . . . . . . . . . . . CONNECTOR, (Part of engine harness) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . RC5 . . . . 116 045 . . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . PLG7, RC7 . . . . . . . . . . . CONNECTOR, (Part of engine harness) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . PLG10 . . 174 823 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . RC10 . . . 174 824 . . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 24 . . . . . . . . . . Figure 12-3 . . GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 25 . . . . . . . . . . . . . 167 730 . . CABLE, bat neg 29.00 lg no 4 awg w/clamp & .406 rng (Onan) . . . . . . .
. . . . . . . . . . . . . . . . . . . 165 600 . . CABLE, bat neg 18.500 lg 6ga w/.250 rng & .375 rng (Onan) . . . . . . . . .
. . . 25 . . . . . . . . . . . . . 082 319 . . CABLE, cable,bat neg 17.750 lg no 4 awg w/clamp & .343 rng (Kohler)
. . . . . . . . . . . . . . . . . . . 172 669 . . CABLE, bat neg 11.000 lg 6ga w/.250 rng & .375 rng (Kohler) . . . . . . . .
. . . 26 . . . . . . . . . . . . . 182 935 . . HOLD DOWN, battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 27 . . . . . . . . . . . . +201 174 . . DOOR, access bat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 28 . . . . . . . . . . . . . 168 385 . . LABEL, warning battery explosion can blind . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 29 . . . . . . . . . . . . . 167 731 . . CABLE, bat pos 19.500 lg (Onan) (included w/engine) . . . . . . . . . . . . . . .
. . . 29 . . . . . . . . . . . . . 173 921 . . CABLE, bat pos 28.000 lg no 4 awg w/clamp & .312 rng (Kohler) . . . . . .
. . . 30 . . . . . Batt . . . 167 677 . . BATTERY, stor 12V 450crk 75rsv GP58 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 31 . . . . . . . . . . . . +201 280 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 32 . . . . . . . . . . . . . 181 057 . . COVER, base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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OM-4402 Page 51

Item
No.

Dia.
Mkgs.

Part
No.

Description

Quantity

Figure 12-1. Main Assembly (Continued)

. . . 33 . . . . DC-Z . . . 187 018
. . . . . . . . . . . . . . . . . . . 187 020
. . . . . . . . . . . . . . . . . . . 180 625
. . . . . . . . . . . . . . . . . . . 164 920
. . . 34 . . . . SR1 . . . 202 222
. . . 35 . . . . . . . . . . . . . 182 928
. . . 36 . . . . . . . . . . . . . 159 905
. . . 36 . . . . . . . . . . . . . 173 043
. . . 37 . . . . . . . . . . . . . 121 652
. . . 38 . . . . . . . . . . . . . 174 001
. . . 39 . . . . . . . . . . . . . 182 079
. . . . . . . . . . . . . . . . . . . 124 253
. . . . . . . . . . . . . . . . . . . 187 502
. . . . . . . . . . . . . . . . . . . 182 922
. . . . . . . . . . . . . . . . . . . 182 925
. . . 40 . . . . . . . . . . . . . 181 587
. . . 41 . . . . PC2 . . . 198 359
. . . . . . . . . . RC1 . . . 174 824
. . . . . . . . . . PLG1 . . . 174 823
. . . . . . . . . . PLG3 . . . 135 275
. . . . . . . . . . PLG6 . . . 174 823
. . . . . . . . . . RC6 . . . 174 824
. . . . . . . . . . PLG9 . . . 168 071
. . . 42 . . . . C52 . . . 176 007
. . . 43 . . . . . . . . . . . . . 176 199
. . . 44 . . . . . 1T . . . . 172 661
. . . . . . . . . . . . . . . . . . . 173 734
. . . 45 . . . . . . . . . . . . . 172 731
. . . 46 . . . F1, F2 . . *169 296
. . . 47 . . . . SR2,3 . . 035 704
. . . 48 . . . . . D2 . . . . 135 184
. . . 49 . . . . . C1 . . . . 176 719
. . . 50 . . . . . . . . . . . . . 177 136
. . . 51 . . . . CT1 . . . 187 144
. . . 52 . . . . R4,5 . . . 139 812
. . . 53 . . . . . . . . . . . . . 180 628
. . . 54 . . . . . . . . . . Figure 12-2
. . . 55 . . . . . . . . . . . . . 197 930
. . . . . . . . . . . . . . . . . . . 137 046
. . . . . . . . . . . . . . . . . . . *064 617
. . . . . . . . . . . . . . . . . . . *065 251
. . . . . . . . . . . . . . . . . . . *121 652
. . . . . . . . . . . . . . . . . . . *065 709
. . . . . . . . . . . . . . . . . . . 180 096
. . . . . . . . . . . . . . . . . . . *067 272
. . . . . . . . . . . . . . . . . . . *066 698
. . . . . . . . . . . . . . . . . . . 121 652
. . . . . . . . . . . . . . . . . . . *067 007
. . . . . . . . . . . . . . . . . . . *067 272

. . STABILIZER ASSEMBLY, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BRACKET, mtg rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BRACKET, mtg stab/reactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RECTIFIER,si 3ph 300 amp 400 piv 100% duty cycle . . . . . . . . . . . . . . . .
. . BRACKET, mtg generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, mtg engine (Onan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, mtg engine (Kohler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FILTER KIT, fuel w/clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SEAL, fuel hose fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TANK, fuel 10 gal (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BUSHING, tank fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . FITTING, stand pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BUSHING, fuel tank 1.210 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . GAUGE, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRAY, pc board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD ASSEMBLY. field current controller . . . . . . . . . . . . . . . . . .
. . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR, slectl 1200uf 300VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BLOCK, stud connection 6posn (consisting of) . . . . . . . . . . . . . . . . . . . . . .
. . . . JUMPER LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOLDER, fuse mintr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FUSE, mintr gls 25A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . DIODE, board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR, electl 1000uf 75VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSFORMER, current sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RESISTOR, WW fxd 30W 5K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, lower front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning do not weld on base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TUNE-UP & FILTER KIT (Onan) (consisting of) . . . . . . . . . . . . . . . . . . . . .
. . . . ELEMENT, air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . FILTER/CLAMPS, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TUNE-UP & FILTER KIT (Kohler) (consisting of) . . . . . . . . . . . . . . . . . . . .
. . . . ELEMENT, air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . FILTER, oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . FILTER/CLAMPS, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . AIR FILTER WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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2
1
1
1
1
2
1
1
1
1
2
1

Optional
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-4402 Page 52

 Hardware is common and

not available unless listed.

5
4
3
9
1

10
11

12
6

36
35

14
13
15

34

16

33

17
32
31
18

30

19

29

20
23
25

21

24

26
27

22

28

ST-802 049-B

Figure 12-2. Panel, Front w/Components

OM-4402 Page 53

Item
No.

Dia.
Mkgs.

Part
No.

Description

Quantity

Figure 12-2. Panel, Front w/Components (Figure 12-1 Item 54)

. . . 1 . . . . . . . . . . . . . 187 593 . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . S1 . . . . 187 190 . . SWITCH, changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . 187 189 . . BRACKET, shunt mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . 030 080 . . SHUNT, meter 50MV 400A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . R1 . . . . 072 623 . . POTENTIOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . S6 . . . . 088 409 . . SWITCH, toggle DPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . PC1 . . . 202 124 . . MODULE, pull to idle 4 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . PC4 . . . 147 554 . . CIRCUIT CARD ASSEMBLY, connector/receptacle . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . S4 . . . . . 011 609 . . SWITCH, tgl SPDT 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . S3 . . . . . 011 611 . . SWITCH, tgl DPDT 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . CB5,6 . . 083 432 . . CIRCUIT BREAKER, man reset 1P 10A 250V . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 13 . . . . . S2 . . . . 176 606 . . SWITCH, ign 4posn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG8 . . . 177 859 . . CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . RC2,3 . . 141 432 . . RECEPTACLE, str dx grd 2P3W 20A 125VAC . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . GFCI2,3 147 939 . . RECEPTACLE, str dx grd 2P3W 15A 125VAC GFCI . . . . . . . . . . . . . . . . . 2
. . . 15 . . . . PC3 . . . 148 021 . . CIRCUIT CARD, filter HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . CB1 . . . 202 683 . . CIRCUIT BREAKER, man reset 2p 40a 240vac screw90 . . . . . . . . . . . . 1
. . . 17 . . . . CB3,4 . . 093 996 . . CIRCUIT BREAKER, man reset 1P 20A 250V . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 18 . . . . PC5 . . . 148 030 . . CIRCUIT CARD, filter HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . 073 756 . . STAND OFF, 6-32 x .625 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 20 . . . . . . . . . . . . . 199 031 . . CONTROL, push pull . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . 119 014 . . LEVER, switch black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . 099 255 . . TERMINAL, pwr output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 23 . . . . . . . . . . . . . 083 030 . . STUD, brs .250-20 x 1.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . 010 915 . . WASHER, flat brs .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 25 . . . . . . . . . . . . . 601 836 . . NUT, brs hex jam .250-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 26 . . . . . . . . . . . . . 188 039 . . COVER, receptacle with gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . 203 016 . . BOOT, circuit breaker 2-pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . 159 921 . . BEZEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . RC1 . . . 182 954 . . RECEPTACLE, str 3P4W 50A 125/250VAC . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 119 172 . . PLUG, st 50A 125/250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . 170 391 . . CAP, dust connector 9760-20 protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . HM . . . . 145 247 . . METER, hour 10-32VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . 021 385 . . BOOT, toggle switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 33 . . . . . . . . . . . . . 097 924 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . 072 590 . . LOCK, shaft .375-32 x .250dia shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . 115 493 . . HANDLE, range switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . . . 1
Optional
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-4402 Page 54

Item
No.

Part
No.

Description

Quantity

Figure 12-3. Generator (Figure 12-1 Item 24)

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

1
2
3
4
5
6
7
7
8
9
10
11
12
13
14
15

. . . . . . . . . . . . +186 238
. . . . . . . . . . . . . 013 367
. . . . . . . . . . . . . 201 516
. . . . . . . . . . . . . 181 143
. . . . . . . . . . . . . 107 417
. . . . . . . . . . . . . 134 981
. . . . . . . . . . . . . 160 567
. . . . . . . . . . . . . 172 683
. . . . . . . . . . . . . 187 151
. . . . . . . . . . . . . 047 878
. . . . . . . . . . . . . 161 306
. . . . . . . . . . . . . *126 984
. . . . . . . . . . . . . 005 614
. . . . . . . . . . . . . 187 183
. . . . . . . . . . . . . 187 536
. . . . . . . . . . . . . 183 419

. . STATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning moving parts can cause serious injury . . . . . . . . . . . . . . .
. . ROTOR ASSEMBLY, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BEARING, ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . FAN, rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ADAPTER, fan rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ADAPTER, engine (Onan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ADAPTER, engine (Kohler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STUD, stl .375 -16 x 23.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BAR, retaining brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAP, brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRUSH, w/spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOLDER, brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, mtg brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ENDBELL, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . O-RING, 1.984 ID x .139CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1
1
1
1
1
1
1
1
4
1
3
3
3
1
1
1

 Hardware is common and

not available unless listed.

6

5
7

8
2
1
14
15

13

12

11

10 9

ST-802 050

Figure 12-3. Generator

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-4402 Page 55

Notes

OM-4402 Page 56

Effective January 1, 2000

(Equipment with a serial number preface of LA or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.

Warranty Questions?

Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
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.

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.
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.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that
the equipment was delivered to the original retail purchaser, or
one year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to an
International distributor.
1.

5 Years Parts 3 Years Labor

*
*
2.

3 Years Parts and Labor

*
*
*
*
*
*

3.

Original main power rectifiers

Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Supplies
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)

1 Year Parts and Labor

*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*

DS-2 Wire Feeder

Motor Driven Guns (w/exception of Spoolmate
185 & Spoolmate 250)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources
Water Coolant Systems
HF Units
Grids
Maxstar 140
Spot Welders
Load Banks
Miller Cyclomatic Equipment
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue for the remaining warranty period of the
product they are installed in, or for a minimum of
one year whichever is greater.)

4.

6 Months Batteries

5.

90 Days Parts

*
*

MIG Guns/TIG Torches

Induction Heating Coils and Blankets

*
*
*
*
*

APT, ZIPCUT & PLAZCUT Model Plasma Cutting

Torches
Remote Controls
Accessory Kits
Replacement Parts (No labor)
Spoolmate 185 & Spoolmate 250
Canvas Covers

Millers True Blue Limited Warranty shall not apply to:

1.

Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.

2.

Items furnished by Miller, but manufactured by others,

such as engines or trade accessories. These items are
covered by the manufacturers warranty, if any.

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.

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 Millers 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 customers risk and expense. Millers 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.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
DISCLAIMED BY MILLER.
Some states in the U.S.A. do not allow limitations of how long
an implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty
provides specific legal rights, and other rights may be
available, but may vary from state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may
be available, but may vary from province to province.
miller_warr 7/00

Owners Record
Please complete and retain with your personal records.
Model Name

Serial/Style Number

Purchase Date

(Date which equipment was delivered to original customer.)

Distributor
Address
City
State

Zip

For Service
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

Welding Supplies and Consumables

Options and Accessories
Personal Safety Equipment
Service and Repair

Miller Electric Mfg. Co.

An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA

Replacement Parts
Training (Schools, Videos, Books)

International HeadquartersUSA
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

www.MillerWelds.com

Contact the Delivering Carrier for:

File a claim for loss or damage during

shipment.

For assistance in filing or settling claims,

contact your distributor and/or equipment
manufacturers Transportation Department.

PRINTED IN USA

2001 Miller Electric Mfg. Co.

1/01