Valsi ROBIN 92493 User manual

240 AMP WELDER AND 5000240 AMP WELDER AND 5000
240 AMP WELDER AND 5000240 AMP WELDER AND 5000
240 AMP WELDER AND 5000
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ATT GENERATT GENERA
TT GENERATT GENERA
TT GENERATOR WITHTOR WITH
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13.5 HP ROBIN13.5 HP ROBIN
13.5 HP ROBIN13.5 HP ROBIN
13.5 HP ROBIN®®
®®
®ENGINEENGINE
ENGINEENGINE
ENGINE
ASSEMBLY AND OPERATING INSTRUCTIONS
3491 MISSION OAKS BLVD., CAMARILLO, CA 93011
VISIT OUR WEB SITE AT HTTP://WWW.HARBORFREIGHT.COM
Copyright©2005 by Harbor FreightTools®. Allrights reserved.Noportion ofthis
manual or any artwork contained herein may be reproduced in any shape or
form without the express written consent of Harbor FreightTools.
For technical questions and replacement parts,please call 1-800-444-3353
92493
Revised Cover Page Logo 03/05

Page 2SKU 92493 For technical questions, please call 1-800-444-3353.
SPECIFICATIONS
IMPORTANT PRECAUTIONS BEFORE STARTING ENGINE
ADD OIL. This generator / welder requires oil and fuel to be added before starting. At-
tempting to start the engine without oil will ruin the engine and void the warranty.
This generator / welder is not intended to power sensitive electronic equipment without
the addition of an appropriate line conditioner (sold separately).
Before using the Welder/Generator, read and understand the Robin Subaru®Engine
Operation, Maintenance, and Parts Manual. Also read the safety precautions in this
manual which should always be followed to reduce the risk of personal injury and dam-
age to equipment.
SAVE THIS MANUAL
You will need the manual for the safety warnings and precautions, assembly instructions,
operating and maintenance procedures, parts list and diagram. Keep your invoice with this
manual. Write the invoice number on the inside of the front cover. Keep the manual and
invoice in a safe and dry place for future reference.
WARNING!
READ AND UNDERSTAND ALL INSTRUCTIONS. Failure to follow all instruc-
tions listed below may result in electric shock, fire, and/or serious injury.
SAVE THESE INSTRUCTIONS
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Page 3SKU 92493 For technical questions, please call 1-800-444-3353.
GENERAL SAFETY RULES
Read all instructions before installing or using this generator / welder!
1. Ensure installation meets all applicable safety, and local and national electrical codes.
Have installation performed by a qualified, licensed electrician and building contractor.
2. Do not operate the generator or welder with protective covers, access covers, or
terminal box covers removed.
3. Disable engine-starting circuits before carrying out maintenance.
4. Disable closing circuits and place warning notices on any circuit breakers normally
used for connection to the mains or other generators to avoid accidental closure.
5. Do not alter or adjust any part of the generator assembled and supplied by the
manufacturer.
6. Always follow and complete scheduled engine and generator maintenance.
7. Do not attempt to operate the generator / welder when conditions are unsafe. Disable
the generator until the unsafe condition is corrected.
8. Before performing any internal generator maintenance, remove the wire to the spark
plug.
9. Operate the generator only when in full compliance with relevant local and national
electrical codes and standards.
Handling and Installation Precautions
1. All electrical work, including earth-ground connection, should be completed by a
licensed electrician.
2. Any separate fuel storage generator supply facility, must be built or installed in full
compliance with relevant local, state, and federal regulations.
3. If the generator/welder is installed indoors, exhaust fumes must be piped out of the
building using leak-free, heat-resistant piping. Pipes and silencer should not use any
flammable materials, nor should they be installed near the same. Generator exhaust
fumes should be within legal limits.
4. If the generator / welder is installed outdoors, it must be weatherproofed and can be
soundproofed. It should not be run outdoors without weather protection to the
generator and wiring conduit.
5. Never lift the generator using the engine or alternator lifting lugs. Connect lifting
equipment to the Hoist Bar (12) at the top of the unit.
6. Before lifting the generator, ensure the lift rigging and supporting structure are in good
condition, and are rated to lift such a load.
7. Keep all personnel away from the suspended generator during relocation.

Page 4SKU 92493 For technical questions, please call 1-800-444-3353.
8. The supporting floor should be level, and strong enough to safely hold the weight of
the generator / welder.If the floor is not level, strong cross members should be placed
under the full length of the generator steel frame at its low side.
9. Install sound and weather proofing only when it is not raining or snowing to avoid
trapping moisture within the generator.
Fire and Explosion Precautions
1. Engine fuel and fumes are flammable, and potentially explosive. Use proper fuel
storage and handling procedures. Always have multiple ABC class fire extinguishers
nearby.
2. The generator/welder room must be adequately ventilated. Exhaust fumes must be
piped to the outdoors.
3. Keep the generator / welder, surrounding floors, and room clean at all times.
4. When spills of fuel or oil occur, they must be cleaned up immediately. Dispose of
fluids and cleaning materials as per any local, state, or federal codes and regulations.
Store oil rags in a covered metal container.
5. Never store fuel or other flammable materials near the generator / welder.
6. Do not smoke, or allow sparks, flames or other sources of ignition around the engine,
fuel tanks, or batteries. Fuel vapors are explosive.
7. Keep grounded conductive objects, such as tools, away from exposed, live electrical
parts and connections to avoid sparking or arcing.These events could ignite fumes or
vapors.
8. Do not refill the generator/welder fuel tank on the bed frame while the engine is
running.
9. Do not operate the generator/welder with known leaks in the fuel system.
10. Use only engine manufacturer recommended fuel and oil fluids.
Mechanical Precautions
1. The generator is designed with guards for protection from moving parts.In any case,
care must still be taken to protect personnel and equipment from other mechanical
hazards when working around the generator.
2. Do not operate the generator/welder with safety guards removed.While the generator
is running, do not attempt to reach around the safety guards for maintenance or any
other reason.
3. Keep hands, arms, long hair, loose clothing, and jewelry away from pulleys, belts, and
other moving parts. Be aware that when engine parts are moving fast they cannot be
seen clearly.
4. When working in and around the generator/welder always wear protective clothing
including gloves, ANSI approved safety glasses, and welding helmet with appropriate
shaded lens.

Page 5SKU 92493 For technical questions, please call 1-800-444-3353.
Noise Precautions
The generator can produce high noise levels. Prolonged exposure to noise levels above 85
dBA is hazardous to hearing. Always wear ear protection when operating or working
around the generator when it is running.
Electrical Precautions
1. All connections and conduit from the generator to the load must only be installed by
trained and licensed electricians, and in compliance with all relevant local, state, and
federal electrical codes and standards, and other regulations where applicable.
2. The generator / welder must be earth-grounded in accordance with all relevant
electrical codes and standards before operation.
3. Before performing any maintenance or connecting or disconnecting any electrical load
connections, the engine must be disabled.
4. Do not attempt to connect or disconnect load connections while standing in water, or
on wet or soggy ground.
5. Do not touch electrically energized parts of the generator / welder and interconnecting
cables or conductors with any part of the body, or with any non-insulated conductive
object.
6. Connect the generator only to a load or electrical system that is compatible with the
electrical characteristics and rated capacity of the generator.
7. Before servicing equipment powered by the generator, disconnect the equipment from
its power input.
8. Keep all electrical equipment clean and dry. Replace any wiring where the insulation
is cracked, cut, abraded or otherwise degraded. Replace terminals that are worn,
discolored, or corroded. Keep terminals clean and tight.
9. Insulate all connections and disconnected wires.
10. Use only Class BC or Class ABC fire extinguishers on electrical fires.
General Precautions
1. Check for damaged parts. Before using the generator/welder, any part that appears
damaged should be carefully checked to determine that it will operate properly and
perform its intended function. Check for alignment and binding of moving parts; any
broken parts; and any other condition that may affect proper operation. Any part that
is damaged should be properly repaired or replaced by a qualified technician.
2. People with pacemakers should consult their physician(s) before using this product.
Electromagnetic fields in close proximity to a heart pacemaker could cause
interference to, or failure of the pacemaker. In addition, people with pacemakers
should adhere to the following:
Caution is necessary when near the coil, spark plug cables, or distributor of a running
engine.The engine should always be off if adjustments are to be made.

Page 6SKU 92493 For technical questions, please call 1-800-444-3353.
3. Guard against electric shock. Prevent body contact with grounded surfaces such as
pipes, radiators, ranges, and refrigerator enclosures.
4. Replacement parts and accessories. When servicing, use only identical replacement
parts. Use of any other parts will void the warranty. Only use accessories intended for
use with this tool. Approved accessories are available from Harbor Freight Tools.
5. Do not operate generator / welder if under the influence of alcohol or drugs. Read
warning labels on prescriptions to determine if your judgment or reflexes are impaired
while taking drugs. If there is any doubt, do not operate the generator/welder.
6. Maintenance. For your safety, service and maintenance should be performed
regularly by a qualified technician. Never work alone on the generator/welder.
GENERATOR SAFETY PRECAUTIONS AND WARNINGS
Warning: This engine-run generator must never be used indoors,in a house,or any
other sealed structure. Carbon monoxide is produced during operation and is deadly in
a closed environment. Early signs of carbon Monoxide poisoning resemble the flu,with
headaches,dizziness,or nausea.If you have any of these signs get fresh air immediately.
1. The generator produces electrical current. Improper use can result in electrocution,
injury or death. Only a qualified technician should service or repair this generator.
2. The generator was designed to be used in a dry area. Do not expose to rain, snow,
sleet, or damp conditions. Damage to the generator could occur. Moisture can carry
electrical current and could cause electrocution.
3. If the generator is connected to a building, home, business, or any other electrical
circuit normally fed by utility power, steps must be taken to ensure that the Generator
output and the utility power are positively isolated. Failure to isolate the systems will
result in generator damage.It could also result in personal injury or death to those
working around these circuits. Any connection in this regard must only be done by a
licensed electrician.
4. Avoid damaging the generator by not exceeding its rated capacity.The total electrical
loads at each outlet must be added to determine the total electrical load. If the
electrical appliance does not list the wattage rating, you can calculate it by multiplying
amps times voltage (amps x voltage = watts).
5. Do not tamper with the engine-governed speed.The generator operates at a nominal
speed of 3600 RPM. Increases in speed could damage rotating parts of the generator.
Slower speeds could damage the generator or appliances connected to the generator
due to low voltage.
6. Always follow national and local safety codes.
7. Do not start the generator with appliances connected and turned on.
8. Give the generator at least two feet of space to dissipate heat.
9. Never handle electrically charged extension cords while standing in water.

Page 7SKU 92493 For technical questions, please call 1-800-444-3353.
10. Properly ground the generator.The National Electrical Code requires that the
generator frame be properly grounded to earth.This should be done by a licensed
electrician. (Refer to the section on Grounding.)
11. Only use 3-prong (120 VAC), or 4-prong (240 VAC), twist-lock grounded extension
cords.
WELDER SAFETY PRECAUTIONS AND WARNINGS
1. Maintain labels and nameplates on the welder / generator. These carry important
information. If unreadable or missing, contact Harbor Freight Tools for a replacement.
2. Maintain a safe working environment. Keep the work area well lit. Make sure there is
adequate surrounding workspace. Always keep the work area free of obstructions,
grease, oil, trash, and other debris. Do not use the welder in areas near flammable
chemicals, dusts, and vapors. Do not use this product in a damp or wet location.
3. Avoid unintentional starting. Make sure you are prepared to begin work before turning
on the Welder.
4. Disable engine before performing maintenance. Always disable the engine by pulling
off the spark plug wire before performing any inspection, maintenance, or cleaning
procedures.
5. Never leave the Welder unattended while energized.Turn power off if you have to
leave the Welder.
6. Prevent eye injury and burns. Wearing and using ANSI approved personal safety
clothing and safety devices reduce the risk for injury.
• Wear ANSI approved safety impact eye goggles with a welding helmet
featuring at least a number 10 shade lens rating.
• Leather leggings, fire resistant work shoes or boots should be worn when using this
product. Do not wear pants with cuffs, shirts with open pockets, or any clothing that
can catch and hold molten metal or sparks.
• Keep clothing free of grease, oil, solvents, or any flammable substances. Wear dry,
insulating gloves and protective clothing.
• Wear an approved head covering to protect the head and neck.Use aprons, cape,
sleeves, shoulder covers, and bibs designed and approved for welding and cutting
procedures.
• When welding or cutting overhead or in confined spaces, wear flame resistant ear
plugs or ear muffs to keep sparks out of ears.
7. Prevent accidental fires. Remove any combustible material from the work area.
• When possible, move the work to a location well away from combustible materials.
If relocation is not possible, protect the combustibles with a cover made of fire
resistantmaterial.

Page 8SKU 92493 For technical questions, please call 1-800-444-3353.
•Remove or make safe all combustible materials for a radius of 35 feet (10 meters)
around the work area. Use a fire resistant material to cover or block all open
doorways, windows, cracks, and other openings.
•Enclose the work area with portable fire resistant screens. Protect combustible walls,
ceilings, floors, etc., from sparks and heat with fire resistant covers.
•If working on a metal wall, ceiling, etc., prevent ignition of combustibles on the other
side by moving the combustibles to a safe location. If relocation of combustibles is
not possible, designate someone to serve as a fire watch, equipped with a fire
extinguisher, during the welding process and for at least one half hour after the
welding is completed.
•Do not weld or cut on materials having a combustible coating or combustible internal
structure, as in walls or ceilings, without an approved method for eliminating the
hazard.
•Do not dispose of hot slag in containers holding combustible materials. Keep a fire
extinguisher nearby and know how to use it.
•After welding or cutting, make a thorough examination for evidence of fire. Be aware
that easily visible smoke or flame may not be present for some time after the fire has
started. Do not weld or cut in atmospheres containing dangerously reactive or
flammable gases, vapors, liquids, and dust. Provide adequate ventilation in work
areas to prevent accumulation of flammable gases, vapors, and dust. Do not apply
heat to a container that has held an unknown substance or a combustible material
whose contents, when heated, can produce flammable or explosive vapors. Clean
and purge containers before applying heat. Vent closed containers, including
castings, before preheating, welding, or cutting.
8. Avoid overexposure to fumes and gases. Always keep your head out of the fumes.
Do not breathe the fumes. Use enough ventilation or exhaust, or both, to keep fumes
and gases from your breathing zone and general area.
•Where ventilation is questionable, have a qualified technician take an air sampling to
determine the need for corrective measures. Use mechanical ventilation to improve
air quality. If engineering controls are not feasible, use an approved respirator.
•Work in a confined area only if it is well ventilated, or while wearing an air-supplied
respirator.
•Follow OSHA guidelines for Permissible Exposure Limits (PEL’s) for various fumes
andgases.
•Follow the American Conference of Governmental Industrial Hygienists
recommendations forThreshold LimitValues (TLV’s) for fumes and gases.
•Have a recognized specialist in Industrial Hygiene or Environmental Services check
the operation and air quality and make recommendations for the specific welding or
cutting situation.
•Take special care when welding galvanized materials.

Page 9SKU 92493 For technical questions, please call 1-800-444-3353.
9. Always keep the Welding Cables away from welding spot. Examine the Welding
Cables for cuts, burns, or worn areas before each use. If any damaged areas are
found, replace the Welding Cables immediately.
10. Read and understand all instructions and safety precautions as outlined in the
manufacturer’s manual for the material you will weld.
WARNING! This product,when used for welding and similar applications,contains
or produces a chemical known to the State of California to cause cancer and birth
defects (or other reproductive harm). (California Health & Safety Code 25249.5 et seq.)
WARNING! The brass components of this product contain lead,a chemical known
to the State of California to cause birth defects (or other reproductive harm). (Califor-
nia Health & Safety Code 25249.5 et seq.)
WARNING! Pacemaker safety warning. People with pacemakers should consult
their physician(s) before using this product. Electromagnetic fields in close proximity
to a heart pacemaker could cause interference to, or failure of the pacemaker.
WARNING! The warnings, cautions, and instructions discussed in this instruction
manual cannot cover all possible conditions and situations that may occur. It must be
understood by the operator that common sense and caution are factors which cannot
be built into this product, but must be supplied by the operator.
FIRST AID FOR ELECTRIC SHOCK
1. Do not touch the victim’s skin with bare hands until the source of the electricity has
been turned off. Note:If the generator is the source of electricity, shutting down the
generator will stop the electrical connection.
2. Turn the engine switch to the Off position.
(1)

Page 10SKU 92493 For technical questions, please call 1-800-444-3353.
3. Pull the plug or hot cable away from the victim using an insulated material.
4. Stand on dry insulating material and pull the victim clear of the conductor, preferably
using insulated material such as dry wood or an insulated hook.
5. Once the victim is free of the electric current, check for breathing. If not breathing,
perform CPR and keep the victim warm. Have someone call the paramedics.
GROUNDING
WARNING: This generator / welder must be grounded to earth ground
before using.
Improperly connecting the grounding wire (or not using one) can result in the risk of
electric shock. Check with a qualified electrician if you are in doubt as to whether the
generator is properly grounded. Do not modify tool power cords or extension cords
that will be connected to the generator. Do not remove their grounding prong. Do not
connect to the generator, or use any tool when the line cord or plug is damaged. If the
plug will not fit the outlet, have a proper plug installed by a qualified electrician.
GroundedTools with Three Prong Plugs
1. Tools marked with “Grounding Required” have a three wire cord and three prong
grounding plug. The plug must be connected to a properly grounded outlet.If the tool
should electrically malfunction or break down, grounding provides a low resistance
path to carry electricity away from the user, reducing the risk of electric shock. (See
Figure A.)
2. The grounding prong in the plug is connected through the green wire inside the cord to
the grounding system in the tool.The green wire in the cord must be the only wire
connected to the tool’s grounding system and must never be attached to an electrically
“live” terminal. (See Figure A.)
3. Your tool must be plugged into an appropriate outlet, properly installed and grounded
in accordance with all codes and ordinances. The plug and outlet should look like
those in the following illustration. (See Figure A.)
Generator /Welder GroundTerminal
Connect a # 6 AWG solid
copperwire(not included)from
the Generator /Welder ground
terminal to an earth grounding
point.

Page 11SKU 92493 For technical questions, please call 1-800-444-3353.
Double Insulated Tools with Two Prong Plugs
4. Tools marked “Double Insulated” do not require grounding.They have a special double
insulation system which satisfies OSHA requirements and complies with the
applicable standards of Underwriters Laboratories, Inc., the Canadian Standard
Association, and the National Electrical Code. (See Figure B above.)
5. Double insulated tools may be used in either of the 120 volt outlets shown in the
following illustration. (See Figure B above.)
EXTENSION CORDS
1. Grounded tools require a three wire extension cord. Double Insulated tools can use
either a two or three wire extension cord.
2. As the distance from the supply outlet increases, you must use a heavier gauge
extension cord. Using extension cords with inadequately sized wire causes a serious
drop in voltage, resulting in loss of power and possible tool damage. (See Table A.)
3. The smaller the gauge number of the wire, the greater the capacity of the cord. For
example, a 14 gauge cord can carry a higher current than a 16 gauge cord.
4. When using more than one extension cord to make up the total length, make sure
each cord contains at least the minimum wire size required. (See Table A.)
5. If you are using one extension cord for more than one tool, add the nameplate
amperes and use the sum to determine the required minimum cord size. (See Table
A.)
6. If you are using an extension cord outdoors, make sure it is marked with the suffix “W-
A” (“W” in Canada) to indicate it is acceptable for outdoor use.
7. Make sure your extension cord is properly wired and in good electrical condition.
Always replace a damaged extension cord or have it repaired by a qualified
electrician before using it.
8. Protect your extension cords from sharp objects, excessive heat, and damp or wet
areas.
9. Extension cords used on the 240 VAC outlet must be sufficient size to carry the
wattage load of the appliance being powered.
Figure A Figure B

Page 12SKU 92493 For technical questions, please call 1-800-444-3353.
Table A
RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS*
(120 VOLT)
NAMEPLATE
AMPERES
(At Full Load) EXTENSION CORD LENGTH
25
Feet 50 Feet 75 Feet 100 Feet 150 Feet
0 – 2.0 (amps) 18 18 18 18 16
2.1 – 3.4 18 18 18 16 14
3.5 – 5.0 18 18 16 14 12
5.1 – 7.0 18 16 14 12 12
7.1 – 12.0 18 14 12 10 -
12.1 – 16.0 14 12 10 - -
16.1 – 20.0 12 10 - - -
* Based on limiting the line voltage drop to five volts at 150% of the rated amperes.
SYMBOLOGY
Table B
UNPACKING
When unpacking, check to make sure that all the parts are included.Refer to the Assembly
section, and the Assembly Drawing and Parts List at the end of this manual. If any parts are
missing or broken, please call Harbor Freight Tools at the number on the cover of this
manual as soon as possible.

Page 13SKU 92493 For technical questions, please call 1-800-444-3353.
ASSEMBLY INSTRUCTIONS
Before operating the generator/welder, the following items have to be installed: Handle
Bars, Wheel kit, and Front Support Bracket.
Handle Bar Installation
1. Unpack and review all parts for defects or missing items.
2. Find two Brackets (21) and four Bolts, Washers, and Nuts. See photo below showing
completed assembly of Handle Bars.
3. Attach each Bracket to the Frame using two Bolts, Washers, and Nuts.Securely
tighten. (Handle Bar holes in Brackets must face inward.)
4. Find two Handle Bars (17) and push on the rubber Grips (6) onto the Handle Bar
ends (opposite the end with the key tabs).
5. Insert the Handle Bars (17) through the holes in the Brackets (21). Note that the
Handle Bars have a key tab on the end and can only fit through the holes one way.
6. Once inserted, turn the Handle Bars one half turn so they cannot slide out.
Wheel Installation
1. Find twoWheels (19), two Axles (18), and two Cotter Keys.
2. Loosen the Set Screws on each Axle Sleeve using a Hex Wrench (not supplied), and
slide in the thick part of the Axle (18). Securely tighten each Set Screw. See photo on
the next page.
3. With the help of another strong person, lift the unit by its Handle Bars (17) and front roll
cage, high enough to insert two, six inch blocks under each side of the Frame.
Brackets (21)
Handle Bars (17)
Grips (6)

Page 14SKU 92493 For technical questions, please call 1-800-444-3353.
4. Before mounting the Wheels (19), ensure that they are inflated to a pressure between
15 and 20 PSI. Pressures over 24 PSI could cause the tire to burst.
5. Slide the Wheel over each Axle and lock in place by placing the Cotter Key into the
end of the Axle.Bend the Cotter Key to keep it from falling out. See photo below, right.
6. Using the Handle Bars (17), lift the unit high enough to remove the two blocks.
Caution: While assembling the wheels,keep hands and feet clear of the area below the
Frame.
Front Support Bracket Installation
1. Using the Handle Bars (17), lift the front of the unit high enough to place the two six
inch blocks under the front Frame (3) at the cross bar. See illustration below.
2. If not already installed, mount the #3 Bracket (15) (with Rubber Foot) into the front
support bracket on the Frame (3) using two Hex Bolts and two Hex Nuts. Securely
tighten.
3. Using the Handle Bars (17), lift the unit high enough to remove the two blocks.
Axle Sleeve
Set Screw
Wheel Axle (18)
Cotter Key
AirValve
#3 Bracket (15)
Rubber Foot (16)

Page 15SKU 92493 For technical questions, please call 1-800-444-3353.
OPERATING INSTRUCTIONS
Engine Setup and Generator Cable Connections
1. Place the generator / welder outdoors where it will be used. Ground this product as
required (see page 10).
This should be on a flat surface able to support the weight of the unit, and away from
flammable materials. Do not allow the generator / welder to get wet. If used indoors,
the area must be well ventilated to allow dissipation of exhaust fumes. Push Handle
Bars (17) in to enable easy access to the Control Panel.
2. Fill the Gas Tank (outdoors) with up to 1.85 gallons of unleaded gasoline, leaving
some room at top of tank for expansion. Do not top-off tank.
3. Add 40.5 oz. of oil to the Engine by removing the Dip Stick and adding through its hole.
If the area temperature is above freezing, use F-SAE 30 weight oil. If below freezing,
use F-SAE 5W-30 weight oil.Use a siphon to avoid spilling the oil. Check the oil level
with the Dip Stick.It should be up to the “Full” mark. Carefully screw the plastic Dip
Stick back into the metal Engine crankcase to avoid stripping the plastic threads on
the Dip Stick.
4. Plug in the extension cords or appliances, making sure that the appliance (loads) are
turned off.
Refer to the section on Extension Cords on page 11. Do not overload the generator.
Calculate the total wattage of the appliances.The generator has a maximum power
output is 5,000 watts (total from all outlets being used).
5. Set the Function Switch to the GEN (generator) position (picture showing light bulb).
Warning: If the generator will be used to replace facility power in times of outages, the
facility power input must be isolated. Refer to the Generator Safety Precautions on
page 6.These connections must only be made by a licensed electrician.
Engine Controls
ON / OFF Switch Choke Lever Starter Rope
Oil Dip Stick

Page 16SKU 92493 For technical questions, please call 1-800-444-3353.
Generator / Welder Controls and Outlets
Starting the Generator
1. Check oil level by unscrewing the Oil Dip Stick.Add oil if necessary. Never run with
low or no oil. Running unit with no,or low oil will void the warranty.
2. Open the GasValve (under the gas tank) by turning it counterclockwise until it stops.
3. Turn the On/Off Switch to the On position.
4. Verify all connected appliances are turned off.
5. If the Engine is cold, push the Choke Lever all the way to the left. For warm or hot
engines, move the Choke Lever midway between the choke and run positions.
6. Pull the Starter Rope with a brisk, smooth motion.The engine should start.
7. After running for a few minutes without a load, push in the Choke Lever all the way to
the right, run position.
8. Begin to turn on the connected appliances.
The engine governor will regulate the throttle automatically depending on the
electrical load applied to the generator. If electricity to one of the outlets stops, it could
be that the circuit was overloaded. Check the appliance(s) wattage, then push in on
the corresponding Circuit Breaker Reset Button to resume power. Disconnect load, if
it exceeds the capacity of the circuit.
9. When you are finished using the Generator:
- Turn off, then unplug all appliances.
- Stop the engine by turning the engine On/Off Switch to the Off position.
-Turn the Gas Valve (under the gas tank) clockwise and close it completely.
240VAC
Circuit Breaker
Reset Button
120VAC
Circuit Breaker
Reset Button
240VAC Outlet
4-Prong Locking
NEMA # L4-30
120VAC Outlet
3-Prong Standard
Function Switch
Generator / Welder
Welder
Current
Range
Welder
Current
Selection
Welder PositiveTorch
Cable Connector Welder Ground
Cable Connector

Page 17SKU 92493 For technical questions, please call 1-800-444-3353.
Welding Operation
Warning:Before arc welding,read,understand,and follow all safety precautions and
warnings, especially those listed on pages 7 through 9.
1. On an arc welding work bench, secure the pieces of metal to be welded so they
cannot move.
2. ConnectappropriatelysizedTorch and Ground Cables(not
supplied) to the provided Dins Connections. The cable
must be of appropriate gauge for the cable length used -
see chart to the right.
3. Properly connect the Torch Cable to an appropriate Arc
Welding Torch and the Ground Cable to an appropriate
GroundClamp(neither one included), if thecablesare not
pre-attached to suitable ones.
4. Connect theTorch Cable connector to the welder positive electrode connector on the
Control Panel. See the illustration at the upper left of the previous page.
5. Connect the Ground Cable connector to the welder ground cable connector on the
Control Panel.
6. Securely clamp the Ground Cable Clamp as close as possible to the metal object to
be welded, or to the metal work bench where the object is mounted and electrically
connected.
7. Start the generator / welder engine as described in steps 1 through 7 on the previous
page.
8. Set theWelding Current Range Switch to I.MAX (140 to 240 amps) or I.MIN (40 to 135
amps) on the Control Panel.
9. For I.MAX range, set theWelder Current Selection Switch to the desired current as
read on the red numbers. For I.MIN range, set the switch to the desired current as read
on the black numbers.
10. Place the desired welding electrode rod securely into the jaws of the Torch Cable
Clamp.Generally, the higher the amperage, the thicker the welding rod.
11. While holding the Torch Cable Clamp with electrode clearly out of the way of any
grounded objects, turn the GEN / WELD Function Switch from the GEN position to the
WELD position.
12. Orient yourself on the area to be welded, then lower the face shield over your eyes.
Warning: Never look at the ignited arc without ANSI approved impact glasses under arc
shaded, eye protection in a full face shield. Permanent eye damage or blindness can
occur. Skin burns can occur. Never breath arc fumes.
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Page 18SKU 92493 For technical questions, please call 1-800-444-3353.
Welder Duty Cycle And Overheating
1. IMPORTANT! Welding longer than the rated duty cycle for thisWelding equipment
can damage the product and void its warranty.
2. Duty cycle is a percentage of 10 minutes that the unit can weld at a specific load without
overheating.
3. If the unit should overheat, the thermostat opens, output stops, and the cooling fans
continuetorun. Waitfifteenminutesfortheunitto cool. Reduce amperageorvoltage,or
duty cycle, before welding.
4. This Welder, at its 180 Amp, 70% duty cycle, can run continuously under load for 7
minutes out of each 10 minute period.
5. NOTE: Higher duty cycles can be used at lower currents.
13. Stroke the area to be welded with the electrode to ignite the arc.
Never tap the electrode into the welding surface to ignite the arc.This damages its
external coating on the electrode which prevents oxygen in the air from coming into
contact with the molten metal, causing it to oxidize.
14. Once the arc is ignited, tilt the electrode forward at an angle of approximately 30° and
hold it at a distance from the welding object equal to the diameter of the electrode.
Note: If too much current is drawn from the arc welder, the thermal overload protector will
activate, and the welder will turn off until it cools down.
15. When welding is complete, lift the electrode clearly away from any grounded object
and lift the face shield up.Turn toward the welder and turn the Function Switch to the
GEN position.The Torch Cable is now free from current.
16. Remove the electrode from theTorch Cable Clamp after it cools.
17. Unplug the Torch Cable and Ground Cable from the connectors on the Control Panel.
18. Keep the engine running for at least five minutes to allow for generator cool down.

Page 19SKU 92493 For technical questions, please call 1-800-444-3353.
INSPECTION, MAINTENANCE, AND CLEANING
WARNING! Disconnect the wire to the spark plug of the engine, and allow the en-
gine to cool completely, before performing any inspection, maintenance, or cleaning
procedures. Any repairs must be done by a qualified electrician or mechanic.
1. Before each use, inspect the general condition of the generator / welder. Check for
loose screws, misalignment or binding of moving parts, cracked or broken parts,
damaged electrical wiring, and any other condition that may affect its safe operation. If
abnormal noise or vibration occurs, have the problem corrected before further use.Do
not use damaged equipment.
2. Periodically tighten all cable connection screws on the cable clamps.
3. Periodically clean both cable clamps of all grease, dirt, welding slag, and carbon
deposits. Check for damaged or cut cables.
4. Store the generator / welder and welding cable clamps in a clean and dry location,
free from airborne impurities and contaminants which can breakdown insulation.
5. Periodically blow out dust from within the unit.
6. If the generator / welder fails to operate after troubleshooting it, do not attempt to open
and repair it yourself.Take it to a qualified technician.
7. For engine maintenance and troubleshooting, refer to the Robin Subaru Engine
Operator’s Manual. Engine adjustments and repairs should be done by a qualified
engine mechanic.
8. After the Engine has cooled down, siphon the remaining gasoline into a gasoline
container before storing the unit.
9. After the first five hours of use, drain and replace the engine oil. After that, replace the
oil after every 25 hours of use.
Adding or Replacing Oil
1. Pull out the Oil Level Dip Stick and check the level of oil in the engine. See the photo
at the bottom-left of page 15.
2. If oil is needed, unscrew the Oil Level Dip Stick and add only enough oil to bring the
oil level to the full mark as read on the Oil Level Dip Stick.
3. To replace all the oil, first remove the Oil Drain Plug from the side of the engine, and
empty the oil into a bucket. Dispose of the oil according to local regulations. Replace
the Oil Drain Plug. Add oil as described in step 2.
4. Wipe up any spilled oil from the engine.
5. Replace the Oil Level Dip Stick.

Page 20SKU 92493 For technical questions, please call 1-800-444-3353.
TROUBLESHOOTING
Symptom Possible Cause Remedy
Generator
No voltage output from
generator. 1. Circuit breakers tripped.
2. Extension cord defective.
3. Function Switch not set to GEN.
4. Generator component defective.
1. Reset unit circuit breakers.
2. Replace extension cord (to b e
done only by a qualified
electrician).
3. Turn Function Switch to GEN.
4. Have generator checked by a
qualified technician.
Low generator output
voltages. 1. Engine speed abnormally slow.
2. Overload of generator.
1. Have engine checked by a
qualified technician.
2. Remove some of the load.
High generator output
voltages. Engine speed too fast Have engine checked by a qualified technician.
Engine
Engine will not start 1. On / Off switch set to Off.
2. Gas tank empty.
3. Engine cold and choke is off.
4. Low or no oil.
5. Engine needs repairs.
1. Turn switch to the On position.
2. Add unleaded gasoline.
3. Turn choke on and try starting.
4. Add or replace oil.
5. Have engine checked by a
qualified technician. See Robin
EH 41 Service Manual.
Welder
Welding bead is thin or
thick 1. Travel speed incorrect.
2. Current setting incorrect.
3. Incorrect electrode.
1. Use proper welding techniques.
2. Raise or reduce current setting.
3. Replace electrode with correct
size (to b e done only by a
qualified technician).
Welding bead does not
penetrate base metal 1. Travel speed incorrect.
2. Current setting too low.
3. Electrode diameter too large.
1. Use proper welding techniques.
2. Raise current output.
3. Replace electrode with correct
size (to b e done only by a
qualified technician).
Electrode sticks to metal. 1. Arc length too short.
2. Current setting too low.
3. Incorrect electrode type.
1. Lift electrode to correct arc
length as soon as arc is struck.
2. Increase current setting or
change to a smaller diameter
electrode.
3. Verify correct electrode type for
metal being welded.