Onan 200 Portaweld CCK User manual

MC6RAUHDIS0IU
Operators
Manual
200 Portaweld®
Welder
• Gasoline Driven Welder
• Two Cylinder Air Cooled
927-0155
SPEC T
1-82

Important Safety Precautions
Read and observe these safety precautions when using
or working on electric generators, engines and related
equipment. Also read and follow the literature provided
with the equipment.
Proper operation and maintenance are critical to perfor¬
mance and safety. Electricity, fuel, exhaust, moving parts
and batteries present hazards that can cause severe
personal injury or death.
FUEL, ENGINE OIL, AND FUMES ARE
FLAMMABLE AND TOXIC
Fire, explosion, and personal injury can result from im¬
proper practices.
• Used engine oil, and benzene and lead, found in
some gasoline, have been identified by government
agencies as causing cancer or reproductive toxicity.
When checking, draining or adding fuel or oil, do not
ingest, breathe the fumes, or contact gasoline or
used oil.
• Do not fill tanks with engine running. Do not smoke
around the area. Wipe up oil or fuel spills. Do not
leave rags in engine compartment or on equipment.
Keep this and surrounding area clean.
• Inspect fuel system before each operation and peri¬
odically while running.
• Equip fuel supply with a positive fuel shutoff.
• Do not store or transport equipment with fuel in tank.
• Keep an ABC-rated fire extinguisher available near
equipment and adjacent areas for use on all types of
fires except alcohol.
• Unless provided with equipment or noted otherwise
in installation manual, fuel lines must be copper or
steel, secured, free of leaks and separated or
shielded from electrical wiring.
• Use approved, non-conductive flexible fuel hose for
fuel connections. Do not use copper tubing as a flex¬
ible connection. It will work-harden and break.
EXHAUST GAS IS DEADLY
• Engine exhaust contains carbon monoxide (CO),
an odorless, invisible, poisonous gas. Learn the
symptoms of CO poisoning.
• Never sleep in a vessel, vehicle, or room with a gen-
set or engine running unless the area is equipped
with an operating CO detector with an audible
alarm.
• Each time the engine or genset is started, or at least
every day, thoroughly inspect the exhaust system.
Shut down the unit and repair leaks immediately;
• Warning: Engine exhaust is known to the State of
California to cause cancer, birth defects and other
reproductive harm.
Make sure exhaust is properly ventilated.
• Vessel bilge must have an operating power
exhaust.
• Vehicle exhaust system must extend beyond ve¬
hicle perimeter and not near windows, doors or
vents.
• Do not use engine or genset cooling air to heat an
area.
• Do not operate engine/genset in enclosed area
without ample fresh air ventilation.
• Expel exhaust away from enclosed, sheltered, or
occupied areas.
• Make sure exhaust system components are se¬
curely fastened and not warped.
MOVING PARTS CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH
• Do not remove any guards or covers with the equip¬
ment running.
• Keep hands, clothing, hair, and jewelry away from
moving parts.
• Before performing any maintenance, disconnect
battery (negative [-] cable first) to prevent acciden¬
tal starting.
• Make sure fasteners and joints are secure. Tighten
supports and clamps, keep guards in position over
fans, drive belts, etc.
• If adjustments must be made while equipment is
running, use extreme caution around hot manifolds
and moving parts, etc. Wear safety glasses and pro¬
tective clothing.
BATTERY GAS IS EXPLOSIVE
• Wear safety glasses and do not smoke while servic¬
ing batteries.
• Always disconnect battery negative (-) lead first
and reconnect it last. Make sure you connect battery
correctly. A direct short across battery terminals can
cause an explosion. Do not smoke while servicing
batteries. Hydrogen gas given off during charging is
explosive.
• Do not disconnect or connect battery cables if fuel
vapors are present. Ventilate the area thoroughly.
GSP-i
1 of 2

DO NOT OPERATE IN FLAMMABLE AND
EXPLOSIVE ENVIRONMENTS
Flammable vapor can be ignited by equipment operation
or cause a diesel engine to overspeed and become diffi¬
cult to stop, resulting in possible fire, explosion, severe
personal injury and death. Do not operate diesel equip¬
ment where a flammable vapor environment can be
created by fuel spill, leak, etc., unless equipped with
an automatic safety device to block the air intake and
stop the engine.
HOT COOLANT CAN CAUSE SEVERE
PERSONAL INJURY
• Hot coolant is under pressure. Do not loosen the
coolant pressure cap while the engine is hot. Let the
engine cool before opening the pressure cap.
ELECTRICAL SHOCK CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH
• Do not service control panel or engine with unit run¬
ning. High voltages are present. Work that must be
done while unit is running should be done only by
qualified service personnel.
• Do not connect the generator set to the public utility
or to any other electrical power system. Electrocu¬
tion can occur at a remote site where line or equip¬
ment repairs are being made. An approved transfer
switch must be used if more than one power source
is connected.
• Disconnect starting battery (negative [-] cable first)
before removing protective shields or touching elec¬
trical equipment. Use insulative mats placed on dry
wood platforms. Do not wear jewelry, damp clothing
or allow skin surface to be damp when handling
electrical equipment.
• Use insulated tools. Do not tamper with interlocks.
• Follow all applicable state and local electrical
codes. Have all electrical installations performed by
a qualified licensed electrician. Tag open switches
to avoid accidental closure.
• With transfer switches, keep cabinet closed and
locked. Only authorized personnel should have
cabinet or operational keys. Due to serious shock
hazard from high voltages within cabinet, all service
and adjustments must be performed by an electri¬
cian or authorized service representative.
If the cabinet must be opened for any reason:
1. Move genset operation switch or Stop/Auto/
Handcrank switch (whichever applies) to Stop.
2. Disconnect genset batteries (negative [-] lead
first).
3. Remove AC power to automatic transfer
switch. If instructions require otherwise, use
extreme caution due to shock hazard.
MEDIUM VOLTAGE GENERATOR SETS
(601V TO 15kV)
• Medium voltage acts differently than low voltage.
Special equipment and training are required to work
on or around medium voltage equipment. Operation
and maintenance must be done only by persons
trained and qualified to work on such devices. Im¬
proper use or procedures will result in severe per¬
sonal injury or death.
• Do not work on energized equipment. Unauthorized
personnel must not be permitted near energized
equipment. Induced voltage remains even after
equipment is disconnected from the power source.
Plan maintenance with authorized personnel so
equipment can be de-energized and safely
grounded.
GENERAL SAFETY PRECAUTIONS
• Do not work on equipment when mentally or physi¬
cally fatigued or after consuming alcohol or drugs.
• Carefully follow all applicable local, state and feder¬
al codes.
• Never step on equipment (as when entering or leav¬
ing the engine compartment). It can stress and
break unit components, possibly resulting in dan¬
gerous operating conditions from leaking fuel, leak¬
ing exhaust fumes, etc.
• Keep equipment and area clean. Oil, grease, dirt, or
stowed gear can cause fire or damage equipment
by restricting airflow.
• Equipment owners and operators are solely re¬
sponsible for operating equipment safely. Contact
your authorized Onan/Cummins dealer or distribu¬
tor for more information.
KEEP THIS DOCUMENT NEAR EQUIPMENT FOR
EASY REFERENCE.
GSP-1
2 of 2

Safety Precautions
ALWAYS USE PRECAUTIONARY MEASURES DUR¬
ING ARC WELDING OPERATIONS TO ENSURE
MAXIMUM PERSONAL SAFETY AND THE SAFETY
OF NEARBY PERSONNEL.
[ WARNING | This symbol is used through¬
out this manual to warn of
possible serious personal injury.
This symbol refers to possible
l— e quipment damage.
• Operate and Maintain The Machine And Its
Equipment Properly.
Do not overload the cables. Do not use worn or
poorly connecting cables. Do not allow the
welding cables to contact hot metal, water, oil or
grease. Prevent cables from becoming a stum¬
bling hazard by keeping them in order and out of
the way.
Use electrode holders that are completely in¬
sulated. Do not use holders with defective jaws.
Do not use the welder without grounding the
frame or the case. Do not ground to pipelines
carrying gases of flammable liquids. Be sure the
conductors can safely carry the grounding
current.
Keep all connections clean and tight.
Do not use an electric welder on an engine unless
both the engine’s battery cables and alternator
wires are disconnected.
• Take Precautions Against Electric Shock.
NEVER work in a damp area without suitable
insulation against shock.
NEVER stand in water or on a wet floor or use wet „
gloves when welding.
ALWAYS dry out the work pieces or bench if there
is any evidence of moisture.
OPEN power circuits before inspecting
machines.
ALWAYS turn off the machine when leaving the
work.
• Do Not Weld Near Flammable Materials.
NEVER weld in or near EXPLOSIVE AT¬
MOSPHERES.
Clean any container that has heid combustible or
flammable materials by approved or prescribed
methods. A very small amount of residual gas cr
liquid can cause a serious explosion. When the
contacts of the container is unknown, use an
explosimeter.
Use carbon dioxide or nitrogen to ventilate a
container. NEVER USE OXYGEN.
When the container has held a gas or liquid that
readily dissolves in water, perform the following:
1. Flush the container several times with water
and a wetting agent (e.g., a low powered
detergent). Then, fill with as much wateras the
work permits.
2. Provide a vent or opening in the container to
allow the release of air pressure.
When the container has held a gas or liquid that
does not readily dissolve in water, proceed as
follows:
1. Clean the container with steam or a cleaning
agent and purge all air with a gas such as
carbon dioxide or nitrogen.
2. Use steam to clean out light material.
3. To clean out heavy grease or oil, use a strong
caustic soda solution.
4. Before welding on the container, PURGE ALL
AIR with a gas such as carbon dioxide or
nitrogen.
Wear goggles and gloves when cleaning with
steam or caustic soda.
Always clean the container in a well ventilated
area, away from,any open flame.
When scraping or hammering heavy sludge or
scale, use a WET, spark resistant tool.
Always keep head and arms as far awav from the
work as possible.

Never Weld On Hollow (Cored) Castings That
Have Not Been Properly Vented.
Never Pick Up Hot Metal With Bare Hands.
Do Not Weld In Confined Areas Without Ade¬
quate Ventilation.
Never Wear Frayed, Flammable Or Otherwise
Inadequate Clothing When Welding. Keep
Clothing Dry.
Avoid wearing light colored or open shirts that
allow arc rays to penetrate and expose parts of the
body to ultra-violet rays. Do not wear flammable
cotton fabrics when arc welding. Wear heavy
shoes, tightly laced.
To prevent severe burns from splatter and molten
metal, wear leather or asbestos gloves at all times
protecting the hand and wrists. When welding in
vertical and overhead positions, wear ear shields
under helmet and leather sleevelets, apron, and
leggings.
• Use Eye Protection At All Times.
ALWAYS wear safety goggles under the welding
helmet. Keep the helmet, hand shields, and face
shield in good condition. Replace defective
equipment.
All arc welding produces intense ultra-violet and
infra-red radiation. When welding in open areas,
provide portable nonreflecting screens to protect
nearby personnel from arc rays.
• Do Not Work On This Equipment When Mentally
Or Physically Fatigued.
• If the unit is mounted with wheels and is portable,
chock the wheels before use to prevent move¬
ment from vibration.
| WARNING I
ENGINE EXHAUST GAS (CARBON MONOXIDE) IS DEADLY!
Carbon monoxide is an odorless, colorless gas formed by incomplete
combustion of hydrocarbon fuels. Carbon monoxide is a dangerous gas that
can cause unconsciousness and is potentially lethal. Some of the symptoms or
signs of carbon monoxide inhalation are:
• Dizziness • Vomiting
• Intense Headache • Muscular Twitching
• Weakness and Sleepiness • Throbbing in Temples
If you experience any of the above symptoms, get out into fresh air immediately.
The best protection against carbon monoxide inhalation is proper installation
and regular, frequent inspections of the complete exhaust system. If you notice
a change in the sound or appearance of exhaust system, shut the unit down
immediately and have it inspected and repaired by a competent mechanic.

Table of Contents
TITLE
PAGE
SAFETY PRECAUTIONS
TABLE OF CONTENTS .
GENERAL INFORMATION ...
About This Manual .
When Service Is Needed ....
SPECIFICATIONS .
INSTALLATION .
General .
Ventilation .
Exhaust .
Mobile Mounting .
Battery Connections .
OPERATION ..
Initial Start .
Starting .
Stopping .
Welder Operation .
AC Operation .
Battery Charger Operation ..
Operating Recommendations
Micro Switch Troubleshooting
MAINTENANCE .
Periodic Maintenance Table .
Lubrication System .
Fuel Recommendations .
Battery .
Safe Operation Inspection ..
Air Cleaner .
Crankcase Breather .
Governor Linkage .
Spark Plugs .
ADJUSTMENTS ..
Carburator Adjustments ....
Governor Adjustments .
Breaker Point Adjustment ...
Ignition Timing Adjustment .
Troubleshooting __
INSIDE FRONT COVER
. 1
.. 2
. 2
. 2
. 3
. 4
. 4
. 4
. 4
. 4
. 4
. 5
. 5
. 5
. 6
. 6
. 9
. 9
. 9
... 10
. 11
. 11
. 12
. 12
. 12
. 13
. 13
. 13
. 14
. 14
. 15
. 15
.. 15
. 17
. 17
. 18
1

General Information
ABOUT THIS MANUAL
This manual provides complete information for oper¬
ating, maintaining, and making adjustments to your
Onan welder. Study this manual carefully and
observe all warnings and cautions. Using your welder
properly and following a regular maintenance pro¬
gram can result in longer unit life, better perfor¬
mance, and safer operation.
WHEN SERVICE IS NEEDED
When your welder requires servicing, contact your
Onan dealer or distributorforassistance. Onan’sfac-
tory trained Parts and Service representatives are
located throughout the United States and Canada
and are ready to handle all your service needs.
When contacting your Onan Dealer or Distributor,
always supply the complete Model and Spec No. and
Serial No. as shown on the set nameplate. This infor¬
mation is necessary to identify the welder from
among the many types of sets manufactured by
Onan. Electrical characteristics are shown on the
lower portion of the nameplate.
Qnoft§(fi)®Welder
Model and Spec No.
Serial No.
Important: Always give above numbers
when ordering parts
DC Welder Rating
200 Amp at 28 Volts
Range 50-200 Amps, 2700 RPM
50% Duty Cycle at 200 Amps
100% Duty Cycle at 140 Amps
AC Rating
Onan Corp MinneapoVs Mn 55432 USA
Made in USA 99-1587
j^WARNING^
ONAN RECOMMENDS THAT ALL SERVICE INCLUDING INSTALLATION OF REPLACEMENT
PARTS ONLY BE DONE BY PERSONS QUALIFIED TO PERFORM ELECTRICAL AND/OR
MECHANICAL SERVICE. TO PREVENT POSSIBLE INJURY AND/OR EQUIPMENT DAMAGE IT IS
IMPERATIVE THAT THE SERVICE PERSON BE QUALIFIED.
2

Specifications
GENERAL
Height .
Width .
Length .
Weight .
ENGINE DETAILS
Number of Cylinders (horizontal opposed)
Displacement .
Compression Ratio .
Engine Speed
Welder Operation .
AC Operation (60 Hz) .
GENERATOR DETAILS
Welding Range at 28 Volts .
AC Output
50 Hertz .
60 Hertz .
CAPACITIES AND REQUIREMENTS
Fuel .
Fuel Tank Capacity .
Oil Capacity .
Starting System Voltage .
Battery Requirements
BCI Group Size .
Cranking Perf. at 0° F .
Amp Hour Cap (20 hour rate) .
Battery Voltage .
Quantity Required .
TUNE-UP SPECIFICATIONS
Spark Plug Gap ...
Ignition Timing .
Breaker Point Gap .
CCK 200 PORTA WELD
. 27.25 inches (692 mm)
. 29.00 inches (737 mm)
. 36.00 inches (914 mm)
. 430 pounds (195 Kg.)
. 2
. 49.8 in 3 (816 cm 3 )
. 7 to 1
. 2600 r/min
. 1800 r/min
. 50-200 Amperes
. 2.5 kW
. 3.5 kW
Regular or Unleaded Gasoline
. 7.3 gallons (27.8 litre)
. 4 quarts (3.8 litre)
. 12
. U1
. 220 Amperes
. 32
. 12
. 1
.025 inches (0.64 mm)
. 20° BTC
.020 inches (0.51 mm)
3

Installation
GENERAL
The Onan 200 Portaweld welder is primarily designed
for outdoor applications where the exhaust gases
and engine waste heat can be discharged directly
into the open air. Do not operate the welder near an
open window, door, air intake, or any other place
where exhaust gases may enter the interior of a build¬
ing. If it is necessary to install the welder in an enclo¬
sure or a mobile application, refer to the following
sections for general installation recommendations.
Proper installation increases welder life, decreases
operating costs, and reduces the frequency of neces¬
sary repairs. Plan installations carefully to ensure
best welder performance and safety.
VENTILATION
Welders generate considerable heat during opera¬
tion. If operating welder in any small enclosure, pro¬
vide separate, unobstructed air inlet and outlet open¬
ings (minimum area of 3-1/2 square feet [3252 cm 2 ]
each). Locate the inlet opening as close to the front of
the engine as possible and provide an outlet opening
toward the generator end somewhat higher than the
inlet opening.
EXHAUST
Pipe all exhaust gases to the outside if installing the
generator in an enclosure. When mounting an exten¬
sion exhaust pipe to the engine, use a piece of flexible
tubing between the extension and the engine. Fit the
muffler to the outer end of the exhaust pipe.
WARNING \ Check exhaust system frequently
for leaks. Be sure poisonous
exhaust gases are piped to outside. Inhalation of
exhaust gases can result in serious personal injury or
death.
Never operate the welder inside a building or con¬
fined area without piping exhaust gases outside the
enclosure.
MOBILE MOUNTING
When the welder is mobile mounted, extra vehicle
floor support may be necessary to prevent the welder
mounting bolts from disengaging because of rough
roads, turning sharp corners, etc. Use pipe clamps or
U-bolts to secure the welder frame to the floor. For
servicing convenience (especially when draining the
oil), elevate the welder above the vehicle floor. Maxi¬
mum operation angle of the unit is 15 degrees side¬
ways, 30 degrees front-to-rear.
BATTERY CONNECTIONS (Optional)
Connect battery cable marked POS. to the battery
positive (+) terminal. Connect unmarked cable to the
battery negative (-) terminal. Always keep cable con¬
nections tight and clean.
4

Operation
INITIAL START STARTING
Fill the engine crankcase with oil and the fuel tank
with fuel before attempting to operate the welder.
Refer to the MAINTENANCE section for the lubricat¬
ing oil and fuel recommendations. In addition, inspect
new units for loose, missing, or damaged parts and
correct as required.
| WARNING k To P rev ent hazardous gasoline spil-
lage, never fill the tank when the
engine is running and leave some fuel expansion
space. Observe safety precautions when handling
gasoline to prevent an explosion which may result in
personal injury.
After filling the fuel tank, prime the fuel system on
manual start models as follows:
1. Remove the engine and control cover.
2. Operate the fuel pump primer rod (Figure 1)
approximately 15 complete strokes to fill the car¬
buretor. Primer rod is not furnished on electric
start models.
If the camshaft pump lobe is up, crank the engine one revolu¬
tion to permit hand priming.
3. Return the priming rod to the downward position
after priming and replace the engine and control
cover.
The fuel system may also have to be primed if the
welder has been idle long enough for the gasoline to
evaporate from the carburetor.
The CCK 200 Portaweld welder is equipped with
either a Readi-Pull manual starter or with an electric
starter. Electric start models can be started manually
with a pull rope when necessary.
If the first attempt at starting the engine fails, the
inhibitor oil used at the factory may have fouled the
spark plugs—remove the plugs, clean in solvent, dry
thoroughly and reinstall. When the engine is first
started, heavy exhaust smoke is normal and is caused
by the inhibitor oil.
Manual Start
Refer to Figure 2 for the location of the choke control
and ignition switch. No loads should be connected
during starting.
1. Pull the choke control knob fully out if starting in
cold temperatures. Partially choke the engine if
the ambient temperature is high or if the engine is
warm from previous operation.
2. Place the ignition switch in the ON position on
electric start models and wind the starting rope
on the flywheel sheave. Wind in a clockwise direc¬
tion and leave about 6 inches (152 mm) of the
rope end free for pulling.
FIGURE 1. PRIMING FUEL PUMP
FIGURE 2. STARTING/STOPPING
5

3. Crank the unit with a rapid pull on the starting
rope. DO NOT JERK the rope. If the unit does not
start immediately, change the choke setting.
Avoid over-choking as this can cause oil dilution
that can result in excessive wear of the internal
engine parts.
4. Adjust the choke control to the best running posi¬
tion as soon as the engine starts. Gradually push
the choke all the way in as the engine warms up.
Setting the throttle control lever in the POWER position (1800
rpm) aids starting, especially in cold weather.
Electric Start
On initial start (or if the unit has run out of fuel), it will
be necessary to pump fuel to the carburetor. It usu¬
ally takes about 30 revolutions to properly fill the
carburetor.
Refer to Figure 2 for the location of the choke control,
ignition switch, and Start switch.
1. Move ignition switch located on control panel to
ON position. (The battery must be connected.)
2. Pull the choke control knob fully out if starting in
cold temperatures. Partially choke the engine if
the ambient temperature is high or if the engine is
warm from previous operation.
3. Push START switch firmly. If unit does not start
within a few seconds, release START switch and
wait a few seconds before re-attempting. If unit
does not start after second attempt, open choke
and repeat starting sequence.
4. After unit starts, adjust choke to best running
position. Gradually push choke control in as unit
warms up.
Oil Pressure
Check the engine oil pressure following start-up.
Normal operating oil pressure is 20-35 psi (138-242
kPa). Pressure is higher until the engine warms up.
STOPPING
Before stopping the engine, place the speed control
lever in the POWER position and allow the engine to
run at the lower speed for at least 30 seconds. If the
engine speed control lever remains in the WELD posi¬
tion when the engine is stopped, restarting the engine
may be difficult.
To stop a MANUAL START unit, press firmly on the
STOP button (located on the engine blower housing)
until the engine has come to a complete stop. If the
STOP button is released too soon, the engine picks
up speed again and continues to run. . _ .
To stop an ELECTRIC START unit, move the ignition
switch (located on the control panel) to OFF.
WELDER OPERATION
The following sections cover operation of the welder.
The operator must be familiar with standard welding
practices and procedures before attempting to use
the welder.
Duty Cycle
If the welder is operated at current levels greater than
140 amperes, it must be run at no-load for short peri¬
ods of time to allow for cooling. The amount of no-
load time required is dependent on the current being
used. Figure 3 shows the percentage of no-load time
required for each 10 minutes of operation at various
current levels.
At 200 amperes rated load, the no-welding time must
be at least one-half (50%) of each 10-minute operat¬
ing period. As the welding load is reduced, longer
welding time is permissible because less no-welding
load time is required for the welder to cool. Any
extreme ambient temperatures must also be taken
into consideration. Continuous welding is permissi¬
ble at 140 amperes or less.
Duty cycle equals one 10 minute period.
FIGURE 3. DUTY CYCLE CHART
Welding Cable Connections
Insert welding cables into the main current amperage
jack receptacles (Figure 4) according to the welding
requirements. Some welding jobs may require fre¬
quent polarity changing to permit using various types
of welding rod.
Straight Polarity Welding: Connect the electrode
cable to the negative (NEG.) jack receptacle. Con¬
nect the ground cable to the desired amperage jack
receptacle.
Reverse Polarity Welding: Connect the ground cable
to the negative (NEG.) jack receptacle. Connect the
electrode cable to the desired amperage jack
receptacle.
6

~cPX
■ o ; o
FOR STRAIGHT POLAR t T Y
Use as electrode cable
Use as ground cable —
F O R REVERSE POLARITY
Use as electrode cable
Use as ground cable
FIGURE 4. MAIN CURRENT WELDING JACK RECEPTACLES
Electrodes
All 1/16-inch through 5/32-inch electrodes can
be used. Positive and negative 3/16-inch elec¬
trodes which do not exceed the welder capacity
can also be used.
Welders In Parallel
Two welders can be connected in parallel if the weld¬
ing amperage requirements are greater than those
provided by one welder (see Figure 5).
1. Start both engines before connecting the cables
to parallel the welders.
a. Adjust engines to same no-load speed. Use a
tachometer or voltmeter for this adjustment.
If the welders are not
adjusted to the same speed,
the output will not double the current jack
rating.
b. After engines are operating at the same speed,
connect the paralleling cables to the proper
jacks.
2. Determine welding current requirements. Select
IDENTICAL current jack receptacles on each
welder which total the ampere requirement.
EXAMPLE: If 300 amperes are required, select the
160 ampere receptacle on each welder. It may be
necessary to select currents which total slightly
higher than the welding requirements to obtain
proper welding characteristics. This is due to volt¬
age and current differences which occur when
welders are connected in parallel and not running
at the same speed.
Proper current can be obtained using the fine
current control adjustment. Adjust to approxi¬
mately the same setting on both welders.
FIGURE 5. CONNECTIONS FOR WELDING IN PARALLEL
7

3. Large welding cables must be used because of
the higher current. Consult your dealer, if in
doubt, as to the welding cable size required.
a. Connect a cable between the preselected
IDENTICAL current jack receptacles of the
welders. This cable (Figure 5) must have
some means of attaching a second cable by
splicing, clamping, etc., which will ensure a
tight connection.
b. Connect another cable (equal size and length)
to the Negative jack receptacle of only one
welder. DO NOT complete connection to NEG
jack receptacle of second welder until both
welders are running.
T~^Jt«on^1 Do not attempt to parallel the
_ w elder’s AC output. Serious
control and welder damage will result.
Welding Current Adjustment
Welders have an engine speed control lever and a fine
current adjustment control (Figure 6).
When the engine speed control lever is in the WELD
position, AC output is cut off and only welding cur¬
rent is available. When the lever is in the POWER
position, welding current is by-passed and only AC
output is available.
The jack receptacle type main current control con¬
nects various resistance units into the welding cir¬
cuit, limiting the amount of current at each jack
receptacle. The fine current control provides for
further adjustment between the jack receptacles of
the main control.
✓ - MAIN CURRENT -*
NEGATIVE AMPERAGE
[ CAUTION ] NEVER WELD WITH ENGINE AND
CONTROL COVER REMOVED!
Considerable heat is generated by the resistance
units inside the welder control box. Always keep the
engine and control cover installed on the unit to
properly direct cooling air to the control box.
1. Plug cables into proper jack receptacles to obtain
the amperage recommended for the electrode
used.
2. Set fine current control at its approximate center
position (midway between minimum and maxi¬
mum). Try the welding characteristics, making
fine current adjustments as necessary.
Fine current control range is greater than the current spread
of the main current control jack receptacles. If perfect arc
conditions are not obtained by normal procedure, try the next
higher or lower jack receptacle connections and re-adjust the
fine current control to compensate.
3. W h e n operating welders in parallel (see
WELDERS IN PARALLEL), always have both
ends of the connection cables plugged into iden¬
tical jack receptacles on each welder. If an
amperage connection change is made on one
welder, immediately connect the other end of the
connecting cable to the same jack receptacle on
the second welder.
If welding current cannot be adjusted satisfactorily, check for
poor electrical contact of cable connections at welder,
ground clamp, or electrode clamp.
FIGURE 6. WELDER CONTROL
8

AC OPERATION
Move the speed control lever to the POWER position
(1800 rpm on 60 hertz models or 1500 rpm on 50 hertz
models). This bypasses welding current control and
supplies 120 (or 240) volts to the output receptacles.
Limit AC loads to not more than 3500 watts, 60 hertz,
or 2500 watts, 50 hertz.
Grounding
For AC operation, the Onan 200 Portaweld welder
has all non-current carrying metal parts electrically
bonded and solidly connected to the generator neu¬
tral to meet National Electric Code require¬
ments for AC generator sets. Local officials
enforcing codes may require that the welder frame be
electrically connected to a grounding electrode
(water pipe, earth-driven grounding rod, etc.) during
AC operation. Onan has provided a lug (Figure 6) for
connecting the welder to a grounding electrode con¬
ductor if required.
warning I A potentially lethal electric shock
hazard exists if faulty electrical
equipment is connected to the generator set. Check
all electrical equipment for frayed cords or breaks in
the insulation before using.
Properly maintain all AC equipment used with the
Onan welder. As a minimum measure of protection,
use only 3-wire or double insulated equipment. All
3-wire equipment must be used only with properly
maintained 3-wire extension cords. Additional
backup protection (in case of a faulty equipment
grounding wireorflawed insulation) can be provided
by Ground Fault Circuit Interrupters (GFCI’s). Onan
recommends that where moisture or faulty cord-and-
plug equipment may represent a hazard, GFCI’s be
used in addition to (but not instead of) the protection
provided by 3-wire equipment or double insulation.
BATTERY CHARGER OPERATION
When the welder is used infrequently, keep the Hi-Lo
toggle switch in the Hi position to provide approxi¬
mately a 2 ampere charge rate. Under normal opera¬
tion, keep the switch in the Lo position—this provides
a 1.5 ampere charge.
OPERATING RECOMMENDATIONS
The following sections provide guidelines for break-
in, severe environment operation, and extended
storage.
Break-In
A disciplined break-in procedure using the properoil
and employing a routine maintenance schedule
helps to ensure satisfactory welder service.
Initial welder operation should be as follows:
1. One-half hour at 1/2 load (100 amps).
2. One-half hour at 3/4 load (150 amps).
3. Change crankcase oil after the first 50 hours of
operation.
Following the recommended break-in procedure
helps seat piston rings and brings oil consumption to
normal in the shortest time. Refer to Duty Cycle sec¬
tion for loading intervals. Drain the oil while the
engine is still hot after the first 50 hours of operation
and replace with the recommended oil.
The welder is designed to operate with a load applied.
When possible, avoid running the welder for ex¬
tended periods of time without a load, especially dur¬
ing the first 50 hours of operation.
The valve lash should be adjusted after the first 50
hours of operation on new engines. Contact an auth¬
orized service center for assistance.
Exercise Periods
Infrequent use results in hard starting. Operate
welder for at least a half hour each week. Run longer if
battery needs charging.
High/Low Operating
Temperatures
The welder has been designed to operate satisfactor¬
ily in both high (above 100°F/38 o C ) and low (below
0° F/-18°C) temperatures. Use the oil recommended
in the MAINTENANCE section for the expected
temperature conditions.
High Temperatures:
1. See that nothing obstructs air flow to and from
the set.
2. Keep cooling fins clean. Cylinder air housings
should be properly installed and undamaged.
Low Temperatures:
1. Use correct oil for temperature conditions.
Change oil only when engine is warm. If an unex¬
pected temperature drop causes an emergency,
move the welder to a warm location or apply
flameless heat externally until oil flows freely.
2. Use fresh, regular grade (not premium) gasoline.
Protect against moisture condensation. Below
0° F, adjust the carburetor main jet for slightly
richer fuel mixture.
3. Keep ignition system clean, properly adjusted,
and batteries well-charged.
9

Dusty or Dirty Conditions
1. Keep welder clean. Keep cooling fins free of dirt,
etc.
2. Service air cleaner as frequently as necessary.
3. Change crankcase oil every 50 operating hours or
less.
4. Keep oil and fuel in approved dust-tight
containers.
5. Keep governor linkage clean.
High Altitude Operation
When operating the welder at altitudes of 2500 feet
(775 m) above sea level, slightly closing the carbure¬
tor main adjustment maintains proper air-to-fuel ratio
(refer to the ADJUSTMENTS section). Maximum
power reduces about 4 percent for each 1000 feet
(310 m) above sea level after the first 1000 feet. Thus,
at an altitude of 5000 feet (1550 m), the welder deliv¬
ers about 160 amperes with proper carburetor adjust¬
ment.
Out-Of-Service Protection
Protect a welder that will be out-of-service for more
than 30 days as follows:
1. Run until thoroughly warm and then shut down.
2. Disconnect battery and follow standard battery
storage procedure.
3. Drain oil from oil base while still warm. Refill and
attach a tag stating oil viscosity used.
4. Remove each spark plug. Pour one ounce (two
tablespoons) of rust inhibitor (or SAE #30 oil)
into each cylinder. Crank engine slowly (by hand)
several times. Install spark plugs.
5. Service air cleaner. See MAINTENANCE section.
6. Clean governor linkage and protect by wrapping
with a clean cloth.
7. Plug exhaust outlet to prevent entrance of mois¬
ture, dirt, bugs, etc.
8. Remove access panels and clean all cooling
surfaces.
9. Wipe entire unit. Coat rustable parts with a light
film of grease or oil.
10. P r ovide a suitable cover for the entire unit.
Returning Unit to Service:
1. Remove cover from unit and all protective wrapping.
2. Check tag on oil base and verify that oil viscosity
is still correct for existing ambient temperatures.
3. Clean and check battery. Measure specific grav¬
ity (1.260 at 77° F [25° C] and verify level to be at
split ring. If specific gravity is low. charge until
correct value is obtained. If the level is low, add
distilled water and charge until specific gravity is
correct. DO NOT OVERCHARGE.
j warning | Do not smoke while servicing
batteries. Explosive gases are
emitted from batteries in operation. Ignition of
gases can cause severe personal injury.
4. Check that fuel filter and fuel lines are secure,
with no leaks.
5. Connect battery. Connect ground lead last.
6. Be sure no load is connected to the welder.
7. Start engine.
MICRO SWITCH TROUBLESHOOTING
The engine speed control lever governs micro switch
operation. If the micro switch becomes stuck or
otherwise inoperative, welder operation is vitally
affected. If the welder develops any of the following
problems, the micro switch is probably defective and
should be replaced. Contact an Onan Dealer or Dis¬
tributor for service.
1. If the micro switch DC contacts remain closed
when the speed control lever is in the WELD posi¬
tion, welder voltage at no-load increases from a
normal 60 volts (approximate) to 80 volts. At
heavy welding load, speed drops excessively and
appears to lack power.
2. If the micro switch DC contacts remain open
when the speed control lever is in the POWER
position, AC voltage is low, with similar low
power performance.
3. If the micro switch AC contacts fail to close with
the speed control lever in the POWER position,
no AC output is available.
4. If the micro switch AC contacts remain closed
with the speed control lever in the WELD position,
AC output voltage is excessively high, and any
AC load connected is damaged.
n

Regularly scheduled maintenance is the key to lower operating costs and longer service life for the welder. The
time intervals shown in the Periodic Maintenance Schedule should be used as a guide for regular maintenance
However, actual operating conditons should be the determining factor in establishing a maintenance schedule
When operating in very dusty or dirty conditions or hot and cold temperature extremes, the maintenance time
intervals must be reduced.
PERIODIC MAINTENANCE SCHEDULE
warning 1 Always allow welder to cool oft be-
Working on a hot unit could cause severe burns.
SERVICE THESE ITEMS
SERVICE TIME
8
Hours
50
Hours
100
Hours
200
Hours
500
Hours
1000
Hours
Inspect Welder
X’
Check Fuel Level
X
Check Oil Level
X
Service Air Cleaner
X 2
Clean Governor Linkage
X 2
Service Spark Plugs
X
Change Crankcase Oil
X 2
Check Battery Water Level
X
Clean Crankcase Breather
X
Clean Fuel Sediment Bowl
X
Inspect Breaker Points
X
Remove Carbon From Cylinder Heads
!---
X 3
Check Valve Lash
X 3
Clean Welder
X
1. See Safe Operation Inspection section for procedure.
2. Perform more often in extremely dusty conditions.
3. This service should be performed by an Onan Dealer or Distributor.

LUBRICATION SYSTEM
The following sections cover crankcase oil recom¬
mendations, checking the oil level, and changing the
oil.
Crankcase Oil
Use an oil with the API (American Petroleum Insti¬
tute) classification SE, SE/CB, or SE/CC. Oil should
be labeled as having passed MS Sequence Tests
(also known as having passed ASTMG-IV Sequence
Tests). Refer to oil chart below for recommended
viscosity according to temperature.
Oil consumption may be higher with a multigrade oil
than with a single-grade oil if both oils have compar¬
able viscosities at 210°F (99° C). Therefore, single
grade oils are generally more desirable unless antici¬
pating a wide range of temperatures.
When adding oil between oil changes, it is preferable
to use the same brand as various brands of oil may
not be compatible together. Refer to the Periodic
Maintenance Schedule for recommended oil change
intervals.
Oil Level Check
Check the oil level indicator after every 8 hours of
operation and maintain the oil level at the full mark
(Figure 7). Refer to the SPECIFICATIONS section for
crankcase capacity.
! warning k 0° not remove the dipstick while the
engine is running. Oil may blow out
the oil fill tube causing injury.
CAP AND OIL
LEVEL INDICATOR
KEEP OIL
AT THIS LEVEL
DO NOT
OVERFILL
NEVER OPERATE
ENGINE WITH OIL
BELOW THIS LEVEI_
ALWAYS REPLACE
CAP TIGHTLY. OR
OIL LEAKAGE MAY
OCCUR.
FIGURE 7. CHECKING OIL LEVEL
Oil Change
Stop the engine and drain the crankcase oil while the
engine is still hot. Place a pan under the drain outlet
and remove the oil drain plug or open the oil drain
valve. After the oil is completely drained, replace the
drain plug or close the drain valve. Refill with oil of the
correct API designation and the appropriate SAE vis¬
cosity grade for the temperature conditions.
FUEL RECOMMENDATIONS
Use clean, fresh, regular grade, automotive gasoline.
Do not use highly leaded premium types. For new
engines, most satisfactory results can be obtained by
using unleaded gasoline. Forolderenginesthathave
previously used leaded gasoline, the heads must be
taken off and all lead deposits removed from the
engine before switching to unleaded gasoline.
T caijtTon^ - ^ M * eac * deposits are not removed
—__ f rom engine before switching from
leaded to unleaded gasoline, pre-ignition could occur
causing severe damage to the engine.
warning I To prevent hazardous gasoline spil-
l —— l age, never fill the tank when the
engine is running and leave some fuel expansion
space. Observe safety precautions when handling
gasoline to prevent an explosion which may result in
personal injury.
BATTERY (Electric Start Model)
Check the condition of the starting battery at speci¬
fied intervals. See that connections are clean and
tight. A light coating of non-conductive grease will
retard corrosion at terminals. Keep the electrolyte at
the proper level above the plates by adding distilled
water.
12

SAFE OPERATION INSPECTION
Be alert for mechanical problems that could create
unsafe or hazardous conditions. The following sec¬
tions cover several areas that should be frequently
inspected to insure continued safe operation.
Exhaust System: With the welder operating, inspect
the entire exhaust system including the exhaust
manifold and muffler. Check for leaks at all connec¬
tions, welds, gaskets, and joints and also make sure
that exhaust pipes are not heating surrounding areas
excessively. If any leaks are detected, have them cor¬
rected immediately.
warning } Check exhaust system frequently
*' ■ . " ■ for leaks. Be sure poisonous exhaust
gases are piped to outside. Inhalation of exhaust
gases can result in serious personal injury.
Fuel System: With the welder operating, inspect the
fuel supply lines and fittings for leaks. Check any
flexible sections for cuts, cracks and abrasions and
make sure they are not rubbing against anything that
could cause breakage. If any leaks are detected, have
them corrected immediately.
DC Electrical System: Check the terminals on the
battery for clean and tight connections. Loose or
corroded connections create resistance which can
hinder starting. Clean and reconnect the battery
cables if loose. Always connect the negative battery
cable last to reduce the possibility of arcing.
! warning I Batteries emit hydrogen, a highly
l I explosive gas. Do not smoke or
create electrical sparks while servicing a battery to
prevent a possible explosion.
Mechanical: With the welder stopped, check for loose
fittings, leaking gaskets, or any signs of mechanical
damage. If any problems are found, have them cor¬
rected immediately. With the set running, listen for
any unusual noises that may indicate mechanical
problems and check the oil pressure frequently.
Investigate anything that indicates possible mechan¬
ical problems.
AIR CLEANER
The CCK welder engine has a replaceable air cleaner
cartridge. Remove the cartridge and shake out every
50 hours. After 200 hours of operation, remove the air
cleaner cartridge element and replace with a new one
(Figure 8).
FIGURE 8. AIR CLEANER
CRANKCASE BREATHER
Lift off the rubber breather cap and carefully pry valve
from cap (Figure 9). Wash and rinse the whole valve
in a suitable solvent. Dry the valve and re-insert. Be
sure the valve flapper is toward the engine.
FIGURE 9. CRANKCASE BREATHER
13

GOVERNOR LINKAGE
The linkage must be able to move freely through its
entire travel. Every 50 hours of operation, clean the
joints and lubricate as shown in Figure 10. Also
inspect the linkage for binding, excessive slack and
wear.
LUBRICATED
FIGURE 10. GOVERNOR LINKAGE
SPARK PLUGS
Check, clean and reset spark plugs every 100 hours of
operation. See Figure 11. Replace spark plugs that
show signs of fouling or electrode erosion. Spark
plug gap is 0.025 inch (0.64 mm). Replace plugs at
least every 200 hours of operation. The use of
unleaded gasoline will extend spark plug life.
FIGURE 11. SPARK PLUG SERVICE
14

Adjustments
CARBURETOR ADJUSTMENTS
Before adjusting the carburetor, be sure the ignition
system is working properly and the governor is
adjusted. Allow the engine to warm up before starting
carburetor adjustments.
If carburetor is completely out of adjustment so the engine will not
start, open both adjustment screws counterclockwise 1 to 1-1/2
turns off their seats to permit starting. Do not force the needles
against their seats. This can bend the needle.
Adjusting the carburetor means obtaining the correct
fuel-to-air mixture for smooth, efficient operation.
Always adjust in two steps, first the load adjustment
and then the idle adjustment.
Load Adjustment
1. Apply a full load to the welder.
2. Loosen packing nut as shown in Figure 12. Turn
the main adjustment screw in (clockwise) until
engine speed drops and then out (counterclock¬
wise) until engine speed returns to normal.
Loosen the packing nut before
making main fuel adjustment
and then tighten the nut to a snug fit after
adjustment has been made. This procedure pre¬
vents fuel leaks around the packing nut. Fuel
leaks cause hard starting because the float level
becomes lower than normal.
3. Check the main mixture adjustment by removing
and adding a heavy load. The engine should
operate smoothly and without hesitation. If it
does not, turn the main adjustment screw out in
1/8 turn increments until the engine operates
smooth ly but do not turn it out more than 1 /2 turn
beyond the original setting.
4. Remove load from welder and tighten the packing
nut.
T Forcing the mixture adjustment
screws tight will damage the
needle and seat. Turn in only until light tension
can be felt.
FIGURE 12. CARBURETOR ADJUSTMENTS
Throttle Stop Screw Adjustment
Set the throttle stop/screw (on the throttle shaft
lever)to clear the manifold surface by 1/32 inch when
the engine is operating at 1800 rpm with no electrical
load connected (see Figure 13).
STARTING POSITION
IDLING POSITION
THROTTLE
STOP SCREW
THROTTLE
PLATE
' ■ i - 1
SET THIS DISTANCE AT
1/32" (0.79 min) WHEN
GENERATOR SET IS RUNNING
AT NO LOAD
Idle Adjustment
1. Remove alt loads from the welder.
2. Turn the idle adjustment screw in (clockwise)
until engine speed drops and then out (counter¬
clockwise) until engine speed returns to normal
and engine runs smoothly.
FIGURE 13. THROTTLE STOP SCREW ADJUSTMENTS
GOVERNOR ADJUSTMENTS
The governor keeps engine speed nearly constant,
regardless of the load. Nominal welding speed is 2500
rpm. When the engine speed control lever is in the
POWER position for AC output, engine speed is
about 1800 (60 hertz) or 1500 rpm (50 hertz) depend¬
ing on the particular unit.
15