Miller BIG 40G User manual

Miller BIG 40G User manual
OM-477 116 508T
July 1899
Miller ==
e Stick (SMAW) Welding
The Ё ower of Blue. Ч Air Carbon Arc (CAC-A
4 Cutting and Gouging
With Optional Equipment:
a TIG (GTAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Engine Driven Weiding Generator
Big 40G
Thank you and congratulations on choosing Miller. Now|
you can get the job done and get it done right. We know
you don’t have time to do 1t any other way.
That’s why when Niels Miller first started building arc
welders in 1929, he made sure his products offered
long-lasting value and superior quality. Like you, his
customers couldn’t afford anything less. Miller products
had to be more than the best they could be. They had to
be the best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They will
help you protect yourself against potential hazards on the worksite. We've
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, there’s a
Troubleshooting section that will help you
Miller is the first welding figure out what the problem is. The parts list
A 10 bo rsaicioro q o will then help you to decide which exact part
the ISO 9001 Quality System you may need to fix the problem. Warranty and
Standard. service information for your particular model
are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor
to receive the latest full line catalog or
individual catalog sheets. To locate your nearest
distributor call 1-800-4-A-Miller.
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.)
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:
Stick = SMAW
1-1. Symbol Usage, RR 1
1-2. Arc Welding Hazards.........040 0144444 aa 44 ee A4 eee 4 de 4 ee ee 4 ee 4 a de a a a ae 0 1
1-3. Engine HazardS 4 4 44 4 44 A ee ee 44 ee ee A ee ee a ee a a da ae 0 2
1-4. Additional Symbols For installation, Operation, And Maintenance ................... 3
1-5. Principal Safety Standards. ........... eae 2 0 4
1-6. EMF Information.........._—.eeonorrvcador ii eri ere ir arranco reereA erore ne. 4
1-1. Signification des symboles............o ee RR 5
1-2. Dangers relatifs au soudage a lar... .. Lee 0 5
1-3. Dangers existant en relation avec le moteur ..........._ 4 AAA 6
1-4. Dangers supplémentaires en relation avec l'installation, le fonctionnement
et la maintenance........200 424444 ea ee 68 4 6 8 4 4 0 4 4 66 4 4 8 A A8 4 4 4 4 4 4 4 A RAA 4e 0 7
1-5. Principales normes de sécurité. ...............r... Le La ae a aa La LL aa aa ae 8
1-6. Information sur les champs électromagnétiques...........2020120 04010 1 11110 ee 8
SECTION 2 - DEFINITIONS ...22441 0410011 ee eee eee eee a eee eee eee ee ee se ea eee a see ace num = 9
2-1. Symbols And Definitions . LL... 0000220444 4 4e Ada 4 4 ee ea 44 ee ea a ee aa a ee 440 9
SECTION 3 - SPECIFICATIONS. . ..eeccrrovacirenoerarnoorenaoonanmearvnnnmanonaneramnacen. 9
3-1. Weld, Power, And Engine Specifications ...........__re.r.rerreesreaaararerea e cea 9
3-2. Dimensions, Weights, And Operating Angles . i iii, 10
3-3. Fuel Consum pion. «ee ae 10
3-4. Duty Cycle And Overheating. 1000000004 444 4444 ed 4 4 4 ea ee A 4 4 4 Aa a a a A aa ee 6 11
3-5. ACC Auxiliary Power, RR ee ee a 11
36. Optional AC Power Plant CUMVeS, ir i i sie ee ea 12
3-7. VoOl-AMpPEre CUNZVES. oo ee 13
SECTION 4 - INSTALLATION. .......ereeneroorornoenvecacnrrianenarnacnerreamerrenen» De 14
4-1, Installing Welding Generator. .......... e... enrdnecacoaaaaconen aa 14
4-2. Connecting The Battery. ................ 2... LL AL LL LL A a La 14
4-3, Installing Muffler. . Lo 4 4444 4e 44 A da LR A La aa A A A ae 0 14
4-4, Engine Prestart Checks. oe 15
4-5. Connecting To Weld Output Terminals ...................... 2... A a a a ea ae 16
4-6. Selecting Weld Cable SizeS . 4 4 4 4 4 4 4 4 4 A AA A A aa 0 16
4-7. Remote 14 Receptacle RC3 Information (Optional, See Section 4-8). ................ 17
4-8. Terminal Strip 3T Connections (Optional). ......... iii iin. 17
SECTION 5 - OPERATING WELDING GENERATOR .......eenrrearrernnoraranoornanannenaa 18
5-1. Front Panel Controls (See Section 5-2) 1... 120000002444 a a ae a 4 4 4 ea a 4 da 400 18
5-2. Description Of Front Panel Controls (See Section 5-1)... ............ iit. 19
5-3. Remote Control (Optional). . . o.oo ee b 20
SECTION 6 - OPERATING AUXILIAR Y EQUIPMENT. .........—..—_—e-——erenernorscareneeere. 21
6-1. 120 Volt Duplex And Optional GFCI Receptacies. ............. eee... 21
6-2. 240 Volt Duplex Receptacie (Optional). ............... aa ae ea a A 22
6-3. Connecting Optional Auxiliary Power Plant ............ecerreresrrerrerrrresr rea 23
SECTION 7 - MAINTENANCE AND TROUBLESHOOTING. ......e.e-onasernnnanorenecanacoo 24
7-1. Routine Maintenance..............—.—_— >. 009:r0erirrerarerienrreerirrerrerecooo 24
7-2. Maintenance Label. RR 4 4 aa 0 0 25
7-3. Servicing Air Cleaner. i i ee a 26
7-4. Overload Protection... oe 26
7-5. Changing Engine Oil And Filter... ir ie eee eee aa 27
7-6. Changing Fuel Filter. . .. oe 28
7-7. Inspecting And Cleaning Optional Spark Arrestor Muffier.............. 28
7-8. Adjusting Engine Weld/Power Speed _ _ 0er. ermrmeerareresasraraa 0 29
7-9. Adjusting Engine Idle Speed. . .. LL eee aa 0 30
7-10. Adjusting Governor Sensitivity... 0.0. a La a LL LL Le 30
7-11. Adjusting Optional High Altitude Carburetor............ 2... 31
7-12. Troubleshooting . «oe eae aa 31
SECTION 8 - ELECTRICAL DIAGRAMS .............--.oersnaerornvvconmenavnnecareccoo. 35
SECTION 9 - AUXILIARY POWER GUIDELINES. .......eeanreanvoenacsonmedaroraaernnedme ea 38
SECTION 10 - PARTS LIST ........e.esxnuaaracenoeormn. PS 46
rom _nd 11/98
Means Warning! Watch Cut! There are possible
hazards with this procedure! The possible hazards are
shown in the adjoining symbols.
A Marks a special safety message.
IF Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
Consult symbols and related instructions below for necessary
actions to avoid the hazards.
A 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.
A Only qualified persons should install, operate, maintain, and
repair this unit.
A During operation, keep everybody, especially children, away.
Touching live electrical paris 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 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.
e Donotuse AC outputindampareas, ifmovementis confined, orif
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
e 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).
e Properly install and ground this equipment according to its
Owner's Manual and national, state, and local codes.
e 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.
e When making input connections, attach proper grounding
conductor first - double-check connections.
e Frequently inspect input power cord for damage or bare wiring -
replace cord immediately if damaged - bare wiring can kill.
e Turn off all equipment when not in use.
¢ Donotuse worn, damaged, undersized, or poorly spliced cables.
e [Do not drape cables over your body.
H earth grounding of the workpiece is required, ground it directly
with a separate cable.
¢ Doncttouch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
e Useonly well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
® Wear a safety harness if working above floor level.
Keep all panels and covers securely in piace.
e Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
e [nsulate work clamp when not connected to workpiece to prevent
contact with any metal object.
e 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.
e Stop engine oninverter and discharge input capacitors according
to instructions in Maintenance Section before touching any parts.
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
e Wear awelding 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).
e Wear approved safety glasses with side shields under your
® Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the are.
® Wear protective clothing made from durable, flame-resistant
material {wool and leather) and foot protection.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
e Keep your head out of the fumes, Do not breathe the fumes.
e jf inside, ventilaie the area and/or use exhaust at the arc to
remove welding fumes and gases.
¢ |f ventilation is poor, use an approved air-supplied respirator.
e Read the Material Safety Data Sheets (MSDSs) and the
manufacturers instructions for metals, consumabies, coatings,
cleaners, and degreasers.
e Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watch-
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the
breathing air is safe.
e 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.
e 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-suppiied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
OM-477 Page 1
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 surethe
area is safe before doing any welding.
e Protect yourself and others from flying sparks and hot metal.
e Do not weld where flying sparks can strike flammable material.
e Remove all flammables within 35 ft (10.7 m} of the welding arc. If
this is not possible, tightly cover them with approved covers,
e 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.
e 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).
e 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.
e Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
e 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.
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
e Wear approved safety glasses with side
shields even under your welding helmet.
Shut off shielding gas suppiy when not in use.
e Always ventilate confined spaces or use ap-
proved air-suppiied respirator.
Stop engine and let it cool off before checking
or adding fuel.
e Do not add fuel while smoking or if unit is near
any sparks or open flames.
e Do not overfill tank - allow room for fuel to expand.
e Do not spill fuel. If fuel is spilled, clean up before starting engine.
¢ Dispose of rags in a fireproof container.
OM-477 Page 2
e Aiow cooling period before maintaining.
e Wear protective gloves and clothing when
working on a hot engine.
® Do not touch hot engine parts or just-welded
parts bare-handed.
Noise from some processes or equipment can
damage hearing.
e Wear approved ear protection if noise level is
Pacemaker wearers keep away.
e Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
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.
e Protect compressed gas cylinders from excessive heat,
mechanical shocks, slag, open flames, sparks, and arcs.
e [nstall 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 aliow 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.
e Keep protective cap in piace over valve except when cylinderisin
use or connected for use.
e Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
H possible, check coolant level when engine is
cold to avoid scaiding.
e Always check coolant level at overflow tank, if
present on unit, instead of radiator (unless told
otherwise in maintenance section or engine
e |fine engine is warm, checkingis needed, and
there is no overflow tank, follow the next two
e Wear safety glasses and gloves and put a rag over radiator cap.
e Turn cap slightly and let pressure escape slowly before
completely removing cap.
e Keep aw
<= ¢ Keep all doors, panels, covers, and guards
closed and securely in place.
e Stop engine before installing or connecting unit.
Have only qualified people remove guards or covers for maint-
enance and troubleshooting as necessary.
e To prevent accidental starting during servicing, disconnect
negative (-) battery cable from battery.
e Keep hands, hair, loose clothing, and tools away from moving
e Reinstall panels or guards and close doors when servicing is
finished and before starting engine.
e Before working on generator, remove spark plugs or injectorsto
Keep engine from kicking hack or starting.
e Block flywheel so that it will not turn while working on generator
e Always wear aface shield, rubber gloves, and
protective clothing when working on a battery.
e Stop engine before disconnecting or connect-
ing battery cables or servicing battery.
® Do not allow tools to cause sparks when working on a battery.
® Do not use welder to charge batteries or jump start vehicles.
e Observe correct polarity (+ and -) on batteries.
e Disconnect negative (-) cable first and connect it last.
e Use lifting eve to lift unit only, NOT running
gear, gas cylinders, trailer, or any other
® Use equipment of adequate capacity to lift and
support unit.
e [f using lift forks tc move unit, be sure forks are long enough to
extend beyond opposite side of unit.
® Wear a face shield to protect eyes and face.
6 Shape tungsten electrode only on grinder with
proper guards in a safe location wearing prop-
er face, hand, and body protection.
e Sparks can cause fires — keep flammables away.
¢ 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.
e Donot connect 50 or 60 Hertz motors to the 100 Hertz recep-
tacle where appiicabie.
Do not tip battery.
Replace damaged battery.
e Flush eyes and skin immediately with water.
Use equipment outside in open, well-
ventilated areas.
e |fused in a closed area, vent engine exhaust
outside and away from any building air in-
# Do not locate unit on, over, or near
combustible surfaces or flammables.
e Keep exhaust and exhaust pipes way from
Do not let engine exhaust sparks cause fire.
Use approved engine exhaust spark arrestor
in required areas - see applicable codes.
Allow cooling period; follow rated duty cycle.
e Reduce current or reduce duty cycle before
starting to weid again.
® Do not block or filter airflow to unit,
handling boards or parts.
e Use proper static-proof bags and boxes to
store, move, or ship PC boards.
Use tongue jack or blocks to support weight.
Properly install welding generator onto trailer
according to instructions supplied with trailer,
Use only genuine MILLER replacement parts.
Perform engine maintenance and service
according to this manual and the engine
OM-477 Page 3
e High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
e Have only qualified persons familiar with
electronic equipment perform this installation.
e The user is responsible for having a qualified electrician
promptly correct any interference problem resulting from the
e 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.
e Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
e Be sure all equipment in the welding area is
electromagnetically compatible.
e To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the fioor.
e Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
e Be sure this welding machine is installed and grounded
according to this manual.
e [f 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.
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 Superinten-
dent 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 MSW 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 Nationa!
Fire Protection Association, Batterymarch Park, Quincy, MÁ 02269.
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electro-
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee's judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-heaith hazard.”
However, studies are still going forth and évidence 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
OM-477 Page 4
1. Keep cabies close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from
operator as practical.
5. Connect work clamp to workpiece as close to the weld as
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
rom _nd_fre 11/98
Signifie Mise en garde ! Soyez vigilant! Cette procédure
présente des risques de danger ! Ceux-ci sont identifiés
par des symboles adjacents aux directives.
À ldentifie un message de sécurité particulier.
[7 Signifie NOTA ; rest pas relatif a la sécurité.
ang! tifs au soudage
A Lessymboles présentés ci-après sontutiliséstoutaulong du
présent manuel pour attirer votre attention et identifier les
risques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnées afin d’évitertout
danger. Les consignes de sécurité présentées ci-après ne
font que résumer l’information contenue dans les normes de
sécurité énumérées à la section 1-5. Veuillez fire et respecter
toutes ces normes de sécurité.
À L'installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées.
Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrement les enfants.
Un simple contact avec des pièces électriques peut
provoquer une électrocution ou des blessures graves.
L'électrode et le circuit de soudage sont sous tension dès
que l'appareil est sur ON. Le circuit d'entrée et ies circuits
internes de l'appareil sont également sous tension à ce
moment-là. En soudage semi-automatique ou automatique, le fil, le dévidoir, le
logement des galets d'entraînement et les pièces métalliques en contact avec
le fil de soudage sont sous tension. Des matériels mal installés ou mai mis à la
terre présentent un danger.
Ne jamais toucher les pièces électriques sous tension.
Porter des gants et des vêtements de protection secs ne comportant pas
de trous.
e S'isoler de la pièce et de là terre au moyen de tapis ou d'autres moyens
isolants suffisamment grands pour empêcher je contact physique éventuel
avec la pièce ou la terre.
e Ne pas se servir de source électrique âcourant électrique dans les zones
humides, dans les endroits confinés ou là où on risque de tomber.
e Se servir d'une source électrique acourant électrique UNIQUEMENT si le
procédé de soudage le demande.
e Si l'utilisation d'une source électrique acourant électrique s'avère néces-
saire, se servir de la fonction de télécommande si l'appareil en est équipé.
e Couper l'alimentation ou arrêter le moteur avant de procéder à
l'installation, à la réparation ou à l'entretien de l'appareil. Déverrouiller
l'alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de
® Installer et mettre á la terre correctement cet appareil conformément à son
manuel d'utilisation et aux codes nationaux, provinciaux et municipaux.
e Toujours verifier laterre du cordon d'alimentation - Vérifier et s'assurer que
le fil de terre du cordon d'alimentation est bien raccordé á la borne de terre
du sectionneur ou que la fiche du cordon est raccordée à une prise
correctement mise à la terre.
e Er effectuant les raccordements d'entrée fixer d'abord le conducteur de
mise à |a terre approprié et contre-vérifier les connexions.
e Vérifier fréquemment le cordon d'alimentation pour voir s'il n'est pas en-
dommagé ou dénudé - remplacer le cordon immédiatement s’il est
endommagé - un câble dénudé peut provoquer une électrocution.
Mettre l'appareil hors tension quand on ne l'utilise pas.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou
mal épisses.
Ne pas enrouler les cables autour du corps.
Si là pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct - ne pas utiliser le connecteur de pièce ou le cable de retour.
e Nepastoucher l’électrode quand onesten contact avec la pièce, la terre ou
une électrode provenant d'une autre machine.
No wf
Ce groupe de symboles signifie Mise en garde ! Soyez vigilant! liy a des
risques de danger relies aux CHOCS ELECTRIQUES, aux PIECES EN
MOUVEMENT etaux PIECES CHAUDES. Reportez-vous aux symboles
etaux directives ci-dessous afin de connaître les mesures à prendre pour
éviter tout danger.
+ N'utiliser qu'un matériel en bon état. Réparer ou remplacer sur-le-champ
les pièces endommagées. Entretenir l'appareil conformément à ce
e Porter un harnais de sécurité quand on travaille en hauteur.
Maintenir solidement en place tous les panneaux et capots.
Fixer le câbie de retour de façon à obtenir un bon contact métal-métal avec
la piece à souder ou la table de travail, le plus près possible de la soudure.
* |[soler la pince de masse quand pas mis à la pièce pour éviter le contact
avec tout objet métallique.
Une tension DC importante subsiste à l’intérieur
des onduleurs après avoir coupé l’alimentation.
# Couper l'alimentation du poste et décharger les condensateurs d'entrée
comme indiqué dans la Section Maintenance avant de toucher des compo-
a. Le rayonnement de l'arc du procédé de soudage génère
] des rayons visibles et invisibles intenses (ultraviolets et
infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la
peau. Des étincelles sont projetées pendant ie soudage.
e Porter un casque de soudage muni d'un écran de filtre approprié pour pro-
téger votre visage et vos yeux pendant le soudage ou pour regarder (voir
ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
e Porter des protections approuvés pour les oreilles si le niveau sondre est
trop élevé,
e Utiliser des écrans ou des barrières pour protéger des tiers de l'éclair et de
l'éblouissement; demander aux autres personnes de ne pas regarder l'arc.
e Porter des vêtements de protection constitué dans une matière durable, ré-
sistant au feu (laine ou cuir) et une protection des pieds.
Le soudage génère des fumées et des gaz. Leur inhalation
peut être dangereux pour votre santé.
e Eloigner votre tête des fumées. Ne pas respirer les fumées,
e À l'interieur, ventiler la zone et/ou utiliser un échappement au niveau de
l’arc pour l'évacuation des fumées et des gaz de soudage.
® Sila ventilation est insuffisante, utiliser un respirateur à alimentation d'air
e Lire les spécifications de sécurité des matériaux (MSDSs) et les instruc-
tions du fabricant concernant les métaux, les consommables, les
revêtements, les nettoyants et les dégraisseurs.
e Travailler dans un espace fermé seulement s'il est bien ventilé ou en por-
tant un respirateur à alimentation d'air. Demander toujours à un surveillant
dûment formé de se tenir à proximité. Des fumées et des gaz de soudage
peuvent dépiacer l'air et abaisser le niveau d'oxygène provoquant des
blessures où des accidents mortels. S'assurer que l'air de respiration ne
présente aucun danger.
e Ne pas souder dans des endroits situés à proximité d'opérations de dé-
graissage, de nettoyage ou de pulvérisation, La chaleur et les rayons de
l'arc peuvent réagir en présence de vapeurs et former des gaz hautement
toxiques et irritants.
e Ne pas souder des métaux munis d'un revêtement, tels que l'acier galvani-
sé, plaqué en plomb ou au cadmium à moins que le revêtement n'ait été
enlevé dans la zone de soudure, que l'endroit soit bien ventilé, et si néces-
saire, en portant un respirateur à alimentation d'air. Les revêtements et
tous les métaux renfermant ces éléments peuvent dégager des fumées
toxiques en cas de soudage.
OM-477 Page 5
Le soudage effectué sur des conteneurs fermés tels que
des réservoirs, tambours ou des conduites peut provoquer
leur éclaternent. Des étincelies peuvent être projetées de
l'arc de soudure. La projection d'étincelles, des pièces chaudes et des
équipements chauds peut provoquer des incendies et des brûlures. Le contact
accidentel de l’électrode avec des objets métalliques peut provoquer des
étincelles, une explosion, un surchauffement cu un incendie. Avant de
commencer le soudage, vérifier et s'assurer que l'endroit ne présente pas de
Se protéger et d'autres personnes de la projection d’étincelles et de métal
Ne pas souder dans un endroit !à où des étincelles peuvent tomber sur des
substances inflammables.
Déplacer toutes les substances inflammables à une distance de 10,7 mde
l'arc de soudage. En cas d'impossibilité les recouvrir soigneusement avec
des protections homologués.
Des étincelles et des matériaux chauds du soudage peuvent facilement
passer dans d'autres zones en traversant de petites fissures et des
Surveiller tout déclenchement d'incendie et tenir un extincteur à proximité.
Le soudage effectué sur un plafond, plancher, paroi ou Séparation peut dé-
clencher un incendie de l'autre côté.
Ne pas effectuer le soudage sur des conteneurs fermés tels que des réser-
voirs, tambours, ou conduites, à moins qu'ils n'aient été préparés
correctement conformément à AWS F4.1 (voir les normes de sécurité).
Brancher le câble sur la pièce !e plus près possible de la zone de soudage
pour éviter le transport du courant sur une longue distance par des che-
mins inconnus éventuels en provoquant des risques d'électrocution et
Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
En cas de non utilisation, enlever la baguette d’électrode du porte-électrode
ou couper le fil à la pointe de contact.
Porter des vêtements de protection dépourvus d'huile tels que des gants
en cuir, une chemise en matériau lourd, des pantalons sans revers, des
chaussures hautes et un couvre chef,
Avant de souder, retirer toute substance combustible de vos poches telles
qu'un allumeur au butane où des allumettes.
e Lesoudage, récaillement, le passage de la piece
à la brosse en fil de fer, et le meulage générent
desétincellesetdes particules métailiques volan-
tes. Pendant la période de refroidissement des soudures, elles risquent
de projeter du laitier.
e Porter des \unettes de sécurité avec écrans latéraux ou un écran facial.
e Fermer l'alimentation du gaz protecteur en cas de
non utilisation.
e Veillertoujours à bien aérer les espaces confinés ou se servir d'un respi-
rateur d'adduction d'air homologué.
e Arrêter ie moteur avant de vérifier le niveau de carbu-
rant ou de faire le plein.
e Ne pas faire le plein en fumant ou proche d'une sour-
ce d'étincelles ou d'une flamme nue.
Ne pes faire le plein de carburant à ras bord; prévoir de l'espace pour son
Faire attention de ne pas renverser de carburant. Nettoyer tout carbu-
rant renversé avant de faire démarrer |e moteur.
Jeter les chiffons dans un récipient ignifuge.
OM-477 Page 6
s Prévoirune période de refroidissement avant d'effec-
tuer des travaux d'entretien.
e Porter des gants et des vêtements de protection pour
travailler sur un moteur chaud.
e Ne pas toucher à mains nues les parties chaudes du moteur ni les pièces
récemment soudées.
Le bruit des processus et des équipements peut affecter
e Porter des protections approuvés pour les oreilles si
le niveau sondre est trop élevé.
Porteurs de stimulateur cardiaque, restez à distance.
Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter teur médecin avant de s'approcher
des opérations de soudage à l'arc, de gougeage ou
de soudage par points.
Des bouteilles de gaz protecteur contiennent du gaz sous
haute pression. Si une bouteille est endommagée, elle
peut exploser. Du fait que les bouteilles de gaz font
normalement partie du procédé de soudage, les manipuier
avec précaution.
Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des
chocs mécaniques, du laitier, des flammes ouvertes, des étincelles et des
e Placer les bouteilles debout en les fixant dans un support stationnaire ou
dans un porte-bouteilles pour les empêcher de tomber ou de se renverser.
Tenir ies bouteilles éloignées des circuits de soudage ou autres circuits
Ne jamais placer une torche de soudage sur une bouteille à gâz.
e Une électrode de soudage ne doit jamais entrer en contact avec ung bou-
e Ne jamais souder une bouteille pressurisée - risque d'expiosion.
e Utiliser seulement des bouteilles de gaz protecteur, régulateurs, tuyaux et
raccords convenables pour cette application spécifique; les maintenir ainsi
que les éléments associés en bon état.
e Nepastenirlatête enface dela sortie en ouvrant la soupape de ia bouteille.
e Maintenir le chapeau de protection sur la soupape, sauf en cas d'utilisation
ou de branchement de la bouteille.
® Lire et suivre les instructions concernant les bouteilles de gaz comprimé,
les équipements associés et les publication P-1 CGA enumérées dans les
normes de sécurité.
ll est préférable de vérifier le liquide de
refroidissement une fois le moteur refroidi pour éviter
de se brûler.
e Toujours vérifier le niveau de liquide de refroidissement dans ie vase
d'expansion (si présent), et non dans le radiateur (sauf si précisé autre-
ment dans la section maintenance du manuel du moteur).
e Sile moteur est chaud et que le liquide doit être vérifié, opérer comme
suivant :
e Mettre des lunettes de sécurité et des gants, placer un torchon sur le
bouchon du radiateur.
e Dévisser le bouchon légèrement et laisser |a vapeur s'échapper avant
d'enlever le bouchon.
Ne pas approcher les mains des ventilateurs, cour-
roles et autres pièces en mouvement.
e Maintenir fermés et fixement en place les portes,
panneaux, recouvrements et dispositifs de protection.
Arrêter le moteur avant d'installer ou brancher l'appareil.
Demander seulement à un personnel qualifié d'eniever ies dispositifs de
sécurité ou les recouvrements pour effectuer, s'il y a lieu, des travaux
d'entretien et de dépannage.
Pour empêcher tout démarrage accidentel! pendant les travaux d'entre-
tien, débrancher le câbie négatif (-) de batterie de la borne.
Ne pas approcher les mains, cheveux, vêtements laches et outils des or-
ganes mobiles.
Remettre en place !es panneaux ou les dipositifs de protection et fermer
les portes à la fin des travaux d'entretien et avant de faire démarrer le
Avant d'intervenir, déposer les bougies ou injecteurs pour éviter la mise
en route accidentelle du moteur.
Bloquer le volant moteur pour éviter sa rotation lors d’une intervention
sur le générateur.
¢ Toujours porter une protection faciale, des gants en
caoutchout et vêtements de protection lors d'une in-
tervention sur la batterie.
e Arrêter le moteur avant de débrancher ou de brancher les cables de
Eviter de provoquer des étincelles avec les outils en travaillant sur la
Ne pas utiliser le poste de soudage pour charger les batteries ou des vé-
hicules de démarrage rapide.
Observer la polarité correcte (+ et -) sur les batteries.
Débrancher le câble négatif —) en premier lieu. Le rebrancher en dernier
e Ne pas renverser la batterie.
e Remplacer une batterie endommagée.
e Rincer immédiatement les yeux et la peau à l'eau.
® Utiliser l'équipement à l'extérieur dans des zones ou-
vertes et bien ventilées.
e En cas d'utilisation dans un endroit fermé évacuer les gaz d'échappe-
ment du moteur vers l'extérieur à distance des entrées d'air dans les bâti-
e Ne pas placer l'appareil sur, au-dessus où à proximi-
té de surfaces inflammables.
e Tenir à distance les produits inflammables de
e Empécher les étincelles d'échappement du moteur
de provoquer un incendie.
e Utiliser uniquement un pare-étincelles approuvé -
voir codes er vigueur.
e Utiliser l'anneau de levage uniquement pour
soulever l'appareil lui-même ; sans chariot, de
bouteilles de gaz, remorque, ou autres accessoires.
e Utiliser un équipernent de levage de capacité suffi-
sante pour lever l'appareil.
e Enutilisant des fourches de levage pour déplacer l’unité, s'assurer
que les fourches sont suffisamment longues pour dépasser du côté
opposé de l'appareil.
= e Porter un écran facial pour protéger le visage et les
® Affuterr l'électrode au tungstène uniquement à la meuleuse dotée de
protecteurs. Cette manoeuvre est à exécuter dans un endroit sûr lorsque
l'on porte l'équipement homologué de protection du visage, des mains et
du corps.
Les étincelles risquent de causer un incendie - éloigner toute substance
e Arrêter ou déconnecter l'équipement avant de dé-
marrer ou d'arrêter ie moteur,
e Ne pas laisser tourner le moteur trop lentement sous
risque d'endommager le moteur électrique à cause
d'une tension et d’une fréquence trop faibles.
e Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz, s'il y a
De и e Laisser l'équipement refroidir ; respecter ie facteur de
marche nominal.
e Réduire le courant ou le facteur de marche avant de
poursuivre le soudage.
® Ne pas obstruer les passages d'air du poste.
> s Etablir la connexion avec la barrette de terre avant de
manipuler des cartes ou des pièces.
e Utiliser des pochettes et des boîtes antistatiques
pour stocker, déplacer ou expédier des cartes de
circuits imprimes.
e Utiliser les supports de la remorque ou des blocs
pour soutenir le poids.
e Installer convenablement ie poste sur la remorque
comme indiqué dans le manuel s’y rapportant.
e Utiliser seulement les pièces de rechange d'origine.
e Efecteur la maintenance et la mise en service
d'après le manuel et celui du moteur.
OM-477 Page 7
# Le rayonnement haute fréquence (H.F) peut
provoquer des interférences avec les équipements
de radio-navigation et de communication, les
services de sécurité et les ordinateurs.
e Demander seulement à des personnes qualifiées familiarisées avec des
équipements électroniques de faire fonctionner l'installation.
e L'utilisateur esttenu de faire corriger rapidement par un électricien quali-
fié les interférences résultant de l'installation.
Si le FCC signale des interférences, arrêter immédiatement l'appareil.
Effectuer régulièrement le contrôle et l'entretien de l'installation.
e Maintenir soigneusement fermés les portes etes panneaux des sources
de haute fréquence, maintenir les éclateurs à une distance correcie et
utiliser une terre et et un blindage pour réduire les interférences
Safety in Welding and Cutting, norme ANSI Z49.1, de l'American
Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126
Safety and Health Sandards, OSHA 29 CFR 1810, du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
Recommended Safe Practice for the Preparation for Welding and Cut-
ting of Containers That Have Held Hazardous Substances, nome
AWS F4.1, de "' American Welding Society, 550 N.W. Lejeune Rd, Mi-
ami FL 33126
National Electrical Code, NFPA Standard 70, de la National Fire
Protection Association, Batterymarch Park, Quincy, MÁ 02269.
Données sur te soudage électrique et sur les effets, pour l'organisme,
des champs magnétiques basse fréquence
Le courant de soudage, pendant son passage dans les câbles de sou-
dage, causera des champs électromagnétiques. I! y a eu et il y a
encore un certain souci à propos de tels champs. Cependant, après
avoir examiné plus de 500 études qui ont été faites pendant une pé-
riode de recherche de 17 ans, un comité spécial ruban bieu du
National Research Council a conclu: “L’accumulation de preuves, sui-
vant le jugement du comité, n’a pas démontré que l'exposition aux
champs magnétiques et champs électriques à haute fréquence repré-
sente un risque à la santé humaine”. Toutefois, des études sont
toujours en cours et les preuves continuent à être examinées. En at-
tendant que les conclusions finales de la recherche soient établies, il
vous serait souhaitable de réduire votre exposition aux champs elec-
tromagnétiques pendant le soudage ou le coupage.
OM-477 Page 8
e L'énergie électromagnétique risque de provoquer
des interférences pour l'équipement électronique
sensible tel que les ordinateurs et l'équipement com-
mandé par ordinateur tel que les robots.
e Veiller à ce que tout l'équipement de ia zone de soudage soit compatible
e Pour réduire la possibilité d'interférence, maintenir les câbles de souda-
ge aussi courts que possible, les grouper, et les poser aussi bas que pos-
sible (ex. par terre).
e Veiller á souder á une distance de 100 métres de tout equipement élec-
tronique sensible,
e Veiller à ce que ce poste de soudage soit posé et mis & la terre conformé-
ment à ce mode d'emploi.
e En cas d'interférences après avoir pris les mesures précédentes, il in-
combe à l'utilisateur de prendre des mesures supplémentaires telles que
\е déplacement du poste, l’utilisation de câbles blindés, l’utilisation de fil-
tres de ligne ou la pose de protecteurs dans la zone de travail.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-1, de la Compressed Gas Association, 1235 Jefferson Davis High-
way, Suite 501, Arlington, VA 22202.
Regles de sécurité en soudage, coupage et procédes connexes,
norme CSA W117.2, de l'Association canadienne de normalisation,
vente de normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada
MaW 1R3.
Safe Practices For Occupation And Educational Eye And Face Protec-
tion, norme ANSI Z87.1, de ' American National Standards institute,
1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, norme NFPA 51B, dela National Fire
Protection Association, Batterymarch Park, Quincy, MA 02268.
Afin de réduire les champs électromagnétiques dans l’environnement
de travail, respecter les consignes suivantes :
1 Garder les câbles ensembles en les torsadant ou en les
attachant avec du ruban adhésif.
2 Mettre tous les câbles du côté opposé de l’opérateur.
3 Ne pas courber pas et ne pas entourer pas les câbles autour de
votre corps.
4 Garder le poste de soudage et les câbles le plus loin possible
de vous.
5 Relier la pince de masse le plus près possible de la zone de
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur docteur. Si vous êtes déclaré apte par votre docteur, il
est alors recommandé de respecter les consignes ci-dessus,
2-1. Symbols And Definitions
. Fast (Run, Weld/ ,
© Stop Engine CG Power) - > Slow (Idle) E) Start Engine
© / <? oid Battery (Engine) (>> Output IA Engine Oil
—— ai Check Valve Protective Earth
o © Circuit Breaker Clearance В Fuel © (Ground)
ca — E Certified/Trained /
+ Positive Negative ov Mechanic 7. Welding Arc
A Amperes \/ Volts © Panel/Local [7] 14 Remote 14
Read Operators , Engine Coolant
yA Manual Ne Engine | Temperature ~ Ё + Temperature
Ny Alternating ©) Time Hours Seconds
Current h S
Yam Stick Welding Constant Current о MIG Welding I Constant Voltage
e (SMAW) (CC) 2e (GMAW) (CV)
Do Not Switch ,Ç
® el While Welding 1 A Single Phase 3 Ny Three Phase
3-1. Weld, Power, And Engine Specifications
. . Maximum |
Welding | Weld Output Rated Welding Cire Auxiliary Power : -
Mode Range Output OP Rating Engine Fuel Capacity
375 A, 35 Volts DC,
50% Duty Cycle .
CC/DC 50 - 440 À 95 Single-Phase, TM-20 Water-Cooled,
300 A, 32 Volts DC 3 KVA/KW, 26 A, Three-Cylinder, 16 gal (60.6 L)
100% Duty Cycle 120 V AC, 60 Hz 38 HP Gasoline
CV/DC 14-38 y | 800 A, 32 Volts DC, 40 Engine
(Optional) 100% Duty Cycle
OM-477 Page 9
3-2. Dimensions, Weights, And Operating Angles
48-3/4 in (1238 mm)
24-5/8 in (625 mm)
64-1/2 (1638 mm)
62 in (1575 mm)
59-1/8 in (1502 mm)
46-1/4 in (1175 mm)
34-3/4 in (883 mm)
26-15/16 in (684) mm)
9-1/2 in (241 mm)
2.7/8 in (73 mm)
7/8 in (22 mm)
23-1/4 in (591 mm)
Ale | О ПЕН | |
24-5/8 in (625 mm)
21/32 IN
(16.7 mm) Dia.
12 Holes
1390 Ib (631 kg)
L Engine End
т tip.
Г ——
51-154 859
A Do not exceed tilt angles or engine could
be damaged or unit could tip.
À Donotmoveoroperate unitwhereitcould
angies_1 8/99
3-3. Fuel Consumption
The curve shows typical fuel use
under weld or power loads.
= x =
I > вх
< — —
en <C <
Y 3 CO
br .
= Q Un
— = =
757 1.67 2.00
5.81 1.59 180 р
6.05 1.33 1.50 1850 Mm
5.30 1.17 1.40
4.54 1.00 1.20
3.73 0.83 1.00
3.03 0.67 080 Г
227 0.50 089 FDLE 1250 RPM
1.51 0.33 040 г
0.76 0.17 0.20 Г
0.00 0.00 0.00 ` : ` ` |
O 50 100 150 200 250 300 350 400 430 500
$B-114 553-A
OM-477 Page 10
3-4. Duty Cycle And Overheating
a Duty Cycle is percentage of 10
À minutes that unit can weld at rated
load without overheating.
A Exceeding duty cycle can
damage unit and void
10 15 20 25 30 40 50 60 80 150
60% Duty Cycle At 350 Amperes 100% Duty Cycle At 300 Amperes
6 Minutes Welding 4 Minutes Resting Continuous Welding rdutyl 5/05 - SB-111 076-A
3-5. AC Auxiliary Power
The ac power curve shows the
150 300 auxiliary power in amperes avail-
able at the 120 and 240 volt
Г receptacles.
125 250
(7 100 200
H _
> 75 150 +
с _
< 50 100 +
25 50 |
O 0 ] | ] |
О > 10 15 20 25
O 103 20 30 40 20
rsb3.1 2/92 - ST-109 365-C
OM-477 Page 11
3-6. Optional AC Power Plant Curves
The ac power curves show the
auxiliary power in amperes avail-
A. 8.5 KVA/KW Single-Phase Auxiliary Power Plant able at the single-phase 120/240
voit or three-phase 240 volt
(No Weld Load) terminals.
260 -
200 -
180 T T T T T T T 1 т т T F T T T T T
B. 12.5 KVA/KW Three-Phase Auxiliary Power Plant
(No Weld Load)
a A A Na e NANA do; (—_— |
1 80 I 1 I I I } i I + 1 1 Ï I
30 40 50 60 70
rsb13,1 12/94 - ST-111 118-D / ST-112 449-B
OM-477 Page 12
3-7. Volt-Ampere Curves
A. CC/DC (Standard) The volt-ampere curve shows the
minimum and maximum voltage
100 and amperage output capabilities
of the welding generator, Curves of
= . all other settings fall between the
Ranges: 199 Max curves shown.
80 A 85-210
© AN Min-65
= 3 A:
S e 4 \
oO o
2 НО:
20 Foi)
= Ë \ 3 N =.
20 LE 11% 3 ``
O i | | | | | 1 \ ] | | | | |
О 100 200 300 400 500 600 700
DC Amperes
B. CC/AC (Models with Optional Polarity/AC Selector Switch)
80 E
& 60
< 40
0 L L 1 | | L
O 100 200 300 400 500 600 700
AC Amperes
C. CV/DC (Models with Optional CV-3 Module)
80 +
£ 60 +
m =
© 40 МАХ
20 MIN
O 1 1 L | 1 I 1 1 | } L | L
O 100 200 300 400 500 600 700
DC Amperes
rsb13.1 12/94 - ST-184 477-A/ST-184 475-A ST-184 480-A
OM-477 Page 13
Installing Welding Generator
A Do Not Lift Unit From End
Airflow Clearance
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
Grounding 1 3 4
i OR
— — dd
Electrically bond generator frame to CA
vehicle frame by metal-to-metal
2 contact. 2
install 12/99 -
A Always ground generator frame to ve-
hicie frame to prevent electric shock
and static electricity hazards.
Generator Base
Metal Vehicle Frame
Equipment Grounding Terminai
Grounding Cable
Use #10 AWG or larger insulated copper wire.
À 'funitdoes not have GFCl receptacles,
use GFCl-protected extension cord.
Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / 5-0854
4-2. Connecting The Battery
A Connect
Negative (-)
Cable Last
Y ad AUN
Tools Needed:
I———e 1/2in
Ref. ST-138 751-B / Ref. ST-191 896 / Ref. 5-0756-C
4-3. Installing Muffler
IR Gun
Tools Needed:
aT 12in
A Stop engine and let cool.
A Do not blow exhaust toward
air cleaner or air intake.
muff 4/96 - ST-154 088-B / Ref, ST-191 898
OM-477 Page 14
4-4. Engine Prestart Checks
Check all fluids daily. Engine must
be cold and on a level surface.
[= This unit has alow oil pressure
shutdown switch. However,
some conditions may cause
engine damage before the en-
gine shuts down. Check oillev-
el often and do not use the ОЙ
pressure shutdown system to
monitor oil level.
1 Carburetor Heat Selector
2 Manifold
Turn pipe toward manifold in cold
weather and away from manifold in
warm weather.
3 Fuel
Add fresh fuel before starting
engine the first time {see mainte-
nance label for specifications). Fill
fuel tank up to 1/2 in. (13 mm) from
top to allow room for expansion.
Open fuel shut-off valve. Check
fuel level on a cold engine before
use each day.
4 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).
сн НЙ
9 at (8.5 L)
5 Coolant
Add coolant iflevelis below bottom
of radiator filler neck.
Engine coolant is a mixture of
water and ethylene glycol base
antifreeze. Add anti-freeze to mix-
ture if using unit in temperatures
below 0° F (-18° C).
Keep radiator, air intake, and cool-
ing fins clean and free of dirt.
A Incorrect engine tempera-
ture can damage engine. Do
not run engine without a
properly working 180°F
(80°C) thermostat and a 7 psi
(48 kPa) radiator cap.
[7 To improve cold weather
Top View Keep battery in good condi-
tion. Store battery in warm
area off concrete surface.
Use correct grade oil for cold
40°F (4°C)
Tools Needed:
C0 546in
ST-801 026-A / Ref. ST-159 727-C / Ref. ST-159 728-A
OM-477 Page 15
4-5. Connecting To Weld Output Terminals
Open left side door.
1 Bracket
Route cables through bracket.
2 Positive (+) Weld Output
3 Negative {-} Weld Output
For Stick welding Direct Current
Electrode Positive (DCEP), con-
nect work cable to (-) terminal and
electrode holder cable to (+)
к Г г,
For Direct Current Electrode Neg-
ative (DCEN), reverse cable
Left Side
If equipped with optional polarity
switch, connect electrode holder
cable to Electrode (-) terminal and
work cable to Work (+) terminal.
For MIG and FCAW welding with
CV option, connect work cable to
(-) terminal and wire feeder cable
to (+) terminal
Close door.
Tools Needed:
ST-800 162-A
4-6. Selecting Weld Cable Sizes
Total Cable (Copper) Length In Weld Circuit Not Exceeding
150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
Welding 100 ft (30 m) Or Less
Amperes (45 m) (60 Mm) (70 m) (90 m) (105 т) {120 т)
10 - 60% 60 - 100% Duty o
Duty Cycle Cycle 10 - 100% Duty Cycle
100 4 4 4 3 2 1 1/0 1/0
150 3 3 2 1 1/0 2/0 3/0 3/0
200 3 2 1 1/0 2/0 3/0 4/0 4/0
250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0
300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0
350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0
400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0
500 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-3/0
“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. Contact your
distributor for the mm? equivalent weld cable sizes. S-0007-E
OM-477 Page 16
4-7. Remote 14 Receptacle RC3 Information (Optional, See Section 4-8)
ET] ch «3 «3
Am ©
Ref. ST-159 730-A
[77] немоте 44 Socket” Socket Information
A 24 volts ac. Protected by circuit
(> breaker CB4.
B Contact closure to A completes 24
volts ac contactor control circuit.
115 volts ac. Protected by circuit
breaker CB3.
J Contact closure to | completes 115
volts ac contactor control circuit.
G Circuit common for 24 and 115 volts
ac circuits.
С О 10 +10 volts de output to remote
AN D Remote control circuit common.
E 0 to +10 volts de input command
signal from remote control.
K Chassis common.
*The remaining sockets are not used.
4-8. Terminal Strip 3T Connections (Optional)
24 VAC \ | |
| |
| 24 vAC
1Kf |
Ref. ST-139 670-6 / ST-185 316 / Ref. ST-191 898
A Stop engine.
Hremote control plug does not fitin
receptacie RC3, wire cord directly
to terminal strip 3T.
A Do not connect to Remote
14 receptacie RC3 and ter-
minal strip 3T at the same
time, Use only one remote
control method.
Open right side door.
1 Cover
2 Terminal Strip 31
Connectleads to 3T using terminal
information shown in Section 4-7.
Reinstall cover. Close door.
Tools Needed:
== В
OM-477 Page 17
5-1. Front Panel Controls (See Section 5-2)
120V 15A
17 60Hz
e 6
ee Ie == DC
bea dina ELECTRODE
A Y» —
11 EA,
Ref. ST-159 730-A / Ref. ST-191 898
OM-477 Page 18
5-2. Description Of Front Panel Controls (See Section 5-1)
| _8
[7 This unit has a max OCV control circuit
that resets Amperage/Vvoltage Adjust
Control! R1 to maximum when the arc
breaks. When an arc is struck, weld out-
put controf returns to the R1 front panel or
combination front panelremote control
setting. The Amperage/Voltage Adjust
control adjusts amperage only when
constant current (CC) welding and does
not adjust open-circuit voltage. The тах
OCV control circuit does not function
when constant voltage (CV) welding
1 Ampere Range Switch
À Do not switch under load.
Use switch to select weld amperage range.
For most welding applications, use lowest
amperage range possible to help prevent arc
outages. When using MIG (CV) mode (op-
tional}, place switch in maximum position.
2 Amperage/Voltage Adjust Control
Control adjusts amperage within range se-
lected by Ampere Range switch. Weld output
would be 148 A DC with controls set as
shown (50% of 85 to 210 A).
3 Amperage/Voltage Adjust Switch
Use switchto select front panel or remote am-
perage control (see Section 5-3).
For front panel control, place switch in Panel
position. For remote control, place switch in
Remote position and connect remote control
to Remote 14 receptacle RC3 or terminal
strip 3T.
4 Quiput (Electrode) Control Switch
Use switch to control remote contactor con-
nected to receptacle RC3 or terminal strip 3T
(see Sections 4-7 and 4-8).
A Weld output terminals are energized
when Output (Electrode) switch is On
(Hot) and engine is running.
For weld output, place switch in the On (Hot)
position. Open-circuit voltage is present at
the weld output terminals whenever engine is
For remote output control, place switch in Re-
mote position, Open-circuit voltage is present
at the weld output terminals when remote
contactor switch is closed.
3 Process Switch (Optional)
Use switch to select Stick or MIG (CV) weld
output. Use Stick for Stick (SMAW) welding.
Use MIG (CV) for wire feed processes (MIG,
FCAW). If using MIG (CV), place Ampere
Range switch in maximum position. To en-
sure wire feeder reliability and improve
arc starting, unit does not run at idle
speed when operated in MIG (CV) mode.
[5 Place Process switch in Stick position
when using optional auxiliary power
6 DC Voltmeter (Optional)
7 DC Ammeter (Optional)
8 Magnetic Shutdown Switch
Use switch during start-up to bypass engine
shutdown system. System stops engine if oil
pressure is too low or coolant temperature is
too high.
9 Choke Control
Use choke to change engine air-fuel mix.
10 Engine Control Switch
Use switch to start engine, select engine
speed, and stop engine.
In Run position, engine runs at weld/power
speed. In Run/ldle position, engine runs at
idle speed at no load and weld speed with
load applied. Turn to run position if using op-
tional auxiliary power plant.
To Start: Pull choke out. Turn Engine Control
switch to Start while pressing Shutdown
switch. Release Engine Control switch when
engine starts, then release Shutdown switch
and push choke in.
[5 If the engine does not start, let engine
come to a complete stop before attempt-
ing restart.
To Stop: turn Engine Control switch to Off
11 Engine Hour Meter
12 Polarity And AC Selector Switch
A Do not switch under load.
13 Battery Charging Warning Light
Light goes on if battery is not charging.
14 Low Oil Pressure/High Engine Temper-
ature Waming Light
Light goes on if oil pressure is low or coolant
temperature is high.
A Stop engine and fix trouble if either
warning light goes on.
15 Fuel Gauge
16 Engine Temperature Gauge (Optional)
Normal temperature is 180 - 200° F (81 - 93°
C). Stop engine if temperature exceeds 240°
Е (116° С).
17 Engine Oil Pressure Gauge (Optional)
Normal pressure is 40 psi (276 kPa). Stop en-
gine tf pressure is below 8 psi (55 kPa).
OM-477 Page 19
5-3. Remote Control (Optional)
EN A Weld output terminals are
energized when Output
7 N (Electrode) switch is On
(Hot) and engine is running.
1 Remote 14 Receptacle RC3
Connect optional remote control to
RC3 (see Section 4-7).
En 393
b= =3 |
Example: Combination remote amperage controi
in Example:
Range = 85 to 210 ADC
Min = 85 A DC
Percentage of Range = 50%
Max = 148 A DC (50% of 85 to 210)
8 7
RE LA] {
Ce A oR
STE LT Max (148 A DC) a
Min (85 A DC)
Set switches — Set range — Set percentage — Adjust optional remote control
5-0774 / Ref, ST-159 730-A / Ref. ST-191 895
OM-477 Page 20
6-1. 120 Volt Duplex And Optional GFCI Receptacles
120V 15A
17\, 60Hz
| [ | Ù
11 1 Î
120V 15A
17 60Hz
nn; | añ
car U
A If unit does not have GFCI
receptacles, use GFCl-pro-
tected extension cord.
1 120V 15 A AC Receptacle
2 120V 15 A AC Receptacle
3 120V 15 A AC GFCI Recep-
tacles GFCI1 And GFCI2
Receptacles supply 60 Hz single-
phase power at weld/power speed.
4 Circuit Breaker CB1
5 Circuit Breaker CB2
CB1 protects RC1/GFCI1 and CB2
protects RC2/GFCI2 from over-
toad. IT CB1 or CB2 opens, the re-
ceptacle does not work. Press but-
ton to reset circuit breaker.
[7 fa circuit breaker continues to
open, contact a Factory
Authorized Service Agent.
If a ground fault is detected, the
GFCI Reset button pops out and
the circuit opens to disconnect the
faulty equipment. Check for dam-
aged tools, cords, plugs, etc. con-
nected to the receptacle. Press
button to reset receptacle and re-
sume operation.
IF Atleast once a month, run en-
gine at weld/power speed and
press Test button to verify
GFCl is working properly.
Maximum output from each duplex
receptacle is 1.8 kVA/kW, and 3
KVA/KW from all receptacies.
Auxiliary power is not affected by
weld output,
EXAMPLE: If 15 A is drawn from
RC1, only 10 À is available at RC2:
(120 V x 15 A) + (120 V x 10 A) =
3.0 KVA/KW
Ref. ST-191 898
OM-477 Page 21
6-2. 240 Volt Duplex Receptacle (Optional)
13A 120V. — 15A
| Ü
a 0
240V vv AC
= |= | 11
a a
13A 15A
©| ©
в ng)
A If unit does not have GFCI
receptacles, use GFCl-pro-
tected extension cord.
1 240 V 15 À ÀC Receptacle
Receptacle supplies 60 Hz single-
phase power at weld/power speed.
Maximum output is 3 KVA/KW.
2 Circuit Breaker CB1
3 Circuit Breaker CB2
CB1 and CB2 protect the recep-
tactes from overload. If CB1 or CB2
opens, the 240 V receptacle and
half of the 120 V receptacle does
not work. 120 volts may stili be
present at the 240 V receptacle.
Press button to reset circuit
K7 If a circuit breaker continues to
open, contact a Factory
Authorized Service Agent.
Combined output of all receptacles
is 3 KVA/KW. Auxiliary power is not
affected by weld output.
EXAMPLE: If 10 A is drawn from
the 240 V receptacle, only 5 À is
available at the 120 V receptacle:
(240 V x 10 A) + (120Vx5A)=3.0
Ref, ST-181 711-A / Ref, ST-174 408
OM-477 Page 22
6-3. Connecting Optional Auxiliary Power Plant
tl t+ — 4
3 WN
AC A Single Three
Output phase Phase
Volts 120/240 240
Amps 35 30
KVA/KW 8.5 12.5
Frequency 60 Hz
Engine Speed 1850 RPM
Max. Fuse Size 45 Amperes
front of unit,
Lead 42 connects to GROUND stud on
Jumper 42 is connected to 90 at factory.
Tools Needed:
—% ==
À Stop engine.
A Power and weld outputs are
live atthe same time. Discon-
nect or insulate unused
[7 Have qualified person install
according to circuit diagram
and Auxiliary Power Guidelines
Booklet (M176 712).
7 Place optional Process switch
in Stick position when using op-
tional auxiliany power plant.
Remove junction box cover.
Lead 93
Lead 92
Lead 91
Lead 90 (Neutral)
Isolated Neutral Termina!
Jumper Lead 42
Grounding Terminal
Lead 42 (Circuit Grounding
Jumper 42 is connected to lead 20
at factory. Jumper 42 may be dis-
connected from neutral to meet ap-
plicable electrical codes.
O 40 N A o N —
Lead 42 connects to front panel
Ground stud.
9 User-Supplied Leads
10 Load Terminals
Connect leads to terminals.
11 Fuses F1, F2, And F3
F1, F2, and F3 protect each load
line from overload.
[7 Set Engine Control switch to
Run when using auxiliary
Ref. 5-185 Q0D-A
OM-477 Page 23
Follow the storage procedure in the engine owner's manual if the unit will not be
used for an extended period.
7-1. Routine Maintenance
A Stop engine before maintaining.
27) ll
Recycle (= See also Engine Manual and Maintenance
engine Label. Service engine more often if used in
fluids. severe conditions.
* Tobe done by Factory Authorized Service
@ sh
Wipe up spills.
Check fluid levels.
See Section 4-4,
@ soh
Clean air filter.
See Section 7-3.
Clean and tighten
weld terminals.
€) 100h
Change oil. See
Section 7-5.
Change oil filter.
See Section 7-5.
Replace fuel filter.
See Section 7-6.
Clean and tighten battery
O 250h
Check and ciean
spark arrestor.
See Section 7-7. x
Check spark
O sooh
Check valve clearance.*
Repaír or replace
cracked cables.
Blow out or
vacuum inside,
During heavy æ
service, clean
Service welding generator
Check brushes and slip rings.
belt Service more often in
tension, dirty conditions.*
OM-477 Page 24
7-2. Maintenance Label
See Engine Manual for complete engine care,
Give Engine Specification and Serial Number when ordering parts.
Multiviscosity Qils
Single Viscosity Oils
Recommended Vil... API Service Classification SE/CD, SF/CD
Stant 5330 180
Radiator Cap 7 Ib .... Gates 31327
Protect to lowest expected temperature with ethylene glycoi based anti-
freeze. Protect to at least -35°F (-37°C) for year-round lubrication and
antirust protection.
IA Oil Change € Filter .. dirty conditions .......... 50 hours or less
normal conditions ....... 100-150 hours
Check ON Filter ............ MILLER 114 559, Fram PH43
UY. ON Capacity 5 at (4.7 L) or 5.5 at (5.25 L) with filter change
Fuel Capacity ....... 16 gal (60 L)
Fuel Grade ......... Regular or Unleaded, 85 Octane min,
. Fuel Filter .......... MILLER 047 420, Fram G1, Hastings GF1
Air Filter Service... 50 hours or less - see Owner's Manual
Air Filter Element .... MILLER 017 309, Donaldson P181050,
Fram CAK 256
Coolant Capacity .... 9gt (8.5L)
СТО Thermostat ......... 180°F (80°C), TOM TM27K00402, Gates 33008,
a Valve Clearance - Но!
== 4 intake... 0.014 in (0.36 mm)
<= Exhaust . 0.018 in (0.46 mm)
Battery ...... BCI Group 24
Cranking Performance at
OF (-18%C) .. 415 Amps
Engine RPM - No Load
(о) Fan Belt . .. Gates 9500
(o) X-27019-500
Weld............ 1850
Idle ............. 1250
Spark Plug Gap ...................... 0.032 in (.8 mm)
Spark Plug .......... 7... .emereees Champion RN12YC
Firing Order ................... . 1-3-2
Ignition Timing ....................... 18° BTDC at 1800 RPM
Coil EEE Continental TM27M00227
Resistor (Coil). ....................... Continental TM27M228
Distributor ........................... Continental TMD20M-503
Cap кулак лв лаков елееноо Continental TM20M00203
Rotor EEE Continental TM27M00224
Use only resistor spark plugs and wires.
Spark Arrestor Inspection And Service .......... 250 operating hours -
see Owner's Manual
S-114 793-H
OM-477 Page 25
7-3. Servicing Air Cleaner
À Stop engine.
A Do notrun engine withoutair
cleaner or with dirty element.
Clean or replace element if dirty or
damaged. Replace element yearly
or after six cleanings.
1 Dust Cap
2 Baffle
3 Element
4 Plastic Fins
5 Housing
To Clean air filter:
Wipe off cap and housing. Remove
cap and dump out dust. Wipe dust
from inside cap and housing with
damp cloth. Remove element and
reinstall cap.
A Donotclean housing with air
Clean etement with compressed air
only. Keep nozzle at least 1 in (25
mm) from inside of element. Max.
air pressure: 100 psi (690 kPa). Do
not remove plastic fins. Replace
element if it has holes or damaged
Reinstall element and cap (cap
arrows pointing up).
aircleaner1 6/96 - ST-153 929-B/ 87-153 585 / Ref. ST-191 898 / Ref. 5-0696-B
7-4. Overload Protection
À of =
A Stop engine.
[7 if any fuse or circuit breaker
Tools Needed:
N continues to open, contact Fac-
tory Authorized Service Agent.
1 Magnetic Shutdown
M Switch MS1
2 Fuse F (See Parts List)
>| Fuse F protects magnetic shui-
== down switch MS1.!ffuse F opens,
the engine stops.
ole O J р
ad Check fuse and replace if open.
3 Circuit Breaker CB3 (Optional)
4 Circuit Breaker CB4 {Optional}
CB3 protects the 115 volt ac output
and CB4 protects the 24 volt ac out-
put to optional Remote 14 recep-
tacle RC3 and terminal strip 3T. if a
circuit breaker opens, 24 or 115
volts ac output stops.
Press button to reset breaker.
Ref. ST-159 730-A / Ref. 57-191 698
OM-477 Page 26
7-5. Changing Engine Oil And Filter
Stop engine and let cool.
Standard Qil Filter
Optional Remote Oil Filter
W@W Ny
Optional Remote Oil Filter
Hoses And Adapter
4 Oi Drain Plug
5 Oil Fill Cap
Change filter according to engine
Install optional remote oil filter if lo-
cation makes it difficult to change
standard filter.
[7 The remote oil filter requires
extra oil to fill the hoses. Keep
oil up to full mark on dipstick.
Tools Needed:
Ref. ST-159 727-B / Ref, ST-159 728-A / Ref. ST-191 898
OM-477 Page 27
7-6. Changing Fuel Filter
An A Stop engine and let cool.
Mi 1 Fuel Shutoff Valve
— 2 Fuel Line
3 Fuel Filter
Toreplacefilter, close valve and re-
move clamps and filter. Install new
filter and clamps. Inspect line and
replaceif cracked or worn. Wipe up
any spilled fuel. Open valve.
Start engine and check for leaks.
A Stop engine, tighten con-
nections as necessary, and
wipe up spilled fuel.
Close door.
Tools Needed:
Ref. 51-191 898 / Ref. ST-159 727-C
7-7. Inspecting And Cleaning Optional Spark Arrestor Muffler
A Stop engine and let cool.
1 Spark Arrestor Muffier
2 Cleanout Plug
= Wf
Remove plug and remove any dirt
covering cleanout hole.
3 Exhaust Pipe
Start engine and run at idle speed
to blow out cleanout hole. If nothing
blows out of hole, briefly cover end
of exhaust pipe with fireproof
A Stop engine and let cool.
Reinstall cleanout plug.
Tools Needed:
4€ 3/8in
ST-B00 722 / Ref. ST-191 898
OM-477 Page 28
7-8. Adjusting Engine Weld/Power Speed
В и Ñ IF Governor sensitivity may re-
À quire adjusiment if engine
AL i speed is adjusted (see Section
E 1850 rpm If linkage binds, loosen socket
(max) nuts and turn sockets until link-
age works smoothly. Tighten
After tuning engine, check engine
no load speed with a tachometer
(see table for no load speeds). If
necessary, adjust speed as
1 Socket Nut
2 Governor Linkage Rod
3 Lock Nut
4 Socket
5 Governor Arm
Rod length should be 3-1/4 in (83
mm) between lock nuts. To adjust,
remove socket from arm and loos-
en lock nut. Turn socket to adjust
length. Tighten nut and reattach
socket to arm.
6 Carburetor
7 Throttle Stop Plate
8 Throttle Stop
Clearance between plate and stop
should be 1/16 in (1.6 mm). To ad-
just clearance, proceed as follows:
9 Linkage Pivot Arm
10 Linkage Socket
11 Lock Nut
Remove socket at arm and loosen
lock nut. Turn socket to adjust
clearance. Reattach socket and
tighten nut.
Start engine and run until warm.
Turn Engine Control switch to Run
12 Governor Speed Screw
13 Lock Nut
Loosen nut. Turn screw until en-
gine runs at weld/power speed.
A Stop engine.
Close door.
Tools Needed:
© 3/8, 7/16 In
| Ref. ST-801 179 / Ref. ST-800 159-C / Ref. ST-800 161
OM-477 Page 29
7-9. Adjusting Engine Idle Speed
SA Start engine. Place Engine Control
E Switch in Run/tdle position.
1 Solenoid Bracket Screws
2 5 © 2 Throttle Arm
<> 1250 rpm 3 Idle Speed Screw
4 Throttle Stop
© O Loosen bracket screws and move
arm so screw touches stop. Do not
release arm. Turnidie speed screw
to obtain 550 rpm.
5 Idle Mixture Screw
Turn mixture screw counterclock-
wise until engine falters, then turn
screw clockwise until engine runs
Turn idle speed screw to obtain
1250 rpm.
6 Solenoid
7 Plunger
Slide sciencid inside bracket so
plunger bottoms in solenoid. If nec-
essary, shim solenoid/bracket to
prevent linkage from binding. Do
not readiustidle speed screw when
Right Side adjusting soienoid.
Tighten bracket screws. Release
throttie arm. Recheck idle speed
and readjust if necessary.
Tools Needed: A Stop engine.
ЕЕ В Close door.
I———£ 1/4 in
Ref. ST-115 155-A
[7 Governor sensitivity may re-
quire readjusiment if weld
speedis adjusted. Weld speed
must be readjusted if sensitiv-
ity is adjusted.
Be sure carburetor and fink-
ages are adjusted properly be-
fore adjusting sensitivity.
Start engine. Apply and remove
1 Locking Nuts
2 Sensitivity Adjustment Screw
3 Governor Spring
If engine is slow to pick up load or
rpm drops under load, adjust
spring tension as follows:
Loosen top nut and tighten bottom
nut to move screw down. Tighten
If engine hunts with or without load,
adjust spring tension as follows:
Loosen bottom nut and tighten top
nut to move screw up. Tighten
A Stop engine.
Close door.
Tools Needed:
uF 1/2 in
Ref, ST-115 155-A / Ref, ST-159 728-A
OM-477 Page 30
7-11. Adjusting Optional High Altitude Carburetor
= у A A too lean air-fuel mixture
N 7 can damage valves. Do not
adjust main adjustment
screw so alr-fuel mixture is
too lean.
Carburetor can be equinped with
an adjustable main jet for operation
above 4000 ft (1219 m). Adjust car-
buretor as follows:
Start engine and apply nearly full
load to welding generator.
1 Main Adjustment Screw
2 Lock Nut
Loosen nut, Turn screw in until en-
gine falters (lean air-fuel mixture).
Turn screw out until engine runs
smoothly, then turn screw out an
additional 1/4 turn. Tighten nut.
A Stop engine.
Close door.
Tools Needed:
© 1/2in
Ref. ST-159 727-B / Ref. ST-115 155-A
7-12. Troubleshooting
A. Welding
Trouble Remedy
No weld output. Check control settings.
Place optionat Qutput (Electrode) Control switch in On (Hot) position, or move switch to Remote
position and connect remote contactor to Remote 14 receptacle RC3 or terminal strip 3T (see Sec-
tions 4-7, 4-6, and 5-1).
Check and secure connections to optional Remote 14 receptacle RC3 or terminal strip 3T (see Sec-
tions 4-7 and 4-8).
Disconnect equipment from 120 voit ac receptacles during start-up.
Have Factory Authorized Service Agent check brushes and slip rings, and field current regulator board
Erratic weld output. Check and tighten connections inside and outside unit.
Use dry, properly-stored electrodes,
Remove excessive coils from weld cables.
Be sure connection to work piece is clean and tight.
Have Factory Authorized Service Agent check brushes and slip rings.
OM-477 Page 31
Low or high weld output.
Check contro) settings.
Place optional Process switch in correct position (see Section 5-1).
Check engine weld/power speed, and adjust if necessary (see Section 7-8).
Have Factory Authorized Service Agent check field current regulator board PCH.
Low apen-circuit voltage.
Place gptional Process switch in correct position.
Check engine weld/power speed, and adjust if necessary (see Section 7-8).
Have Factory Authorized Service Agent check field current regulator board PC1 and optional CV-3
regulator board PC2.
Maximurn weld output only in each
ampere range.
Have Factory Authorized Service Agent check Amperage/Voltage Adjust control R1, capacitor C8,
diode 09, integrated rectifier SR4, control relay CR3, field current regulator board PCT, and optional
CV-3 regulator board PC2.
No CV weld output {units with remote
control or CV-3 option only).
Check connections to Remote 14 receptacle RC3 and terminal strip 3T (see Sections 4-7 and 4-8).
Repair or replace remote control device.
Have Factory Authorized Service Agent check connector board PCS and connections.
Wire feeder does not work (models with
CV-3 option).
Reset circuit breaker CB3 and/or CB4 (see Section 7-4).
Check connections to Remote 14 receptacle RC3 and terminal strip 37 (see Sections 4-7 and 4-8).
Repair or replace wire feeder.
No amperage control (or voltage control
on models with CV-3 option).
Place Amperage/Voltage Adjust switch in correct position.
Check connections to Remote 14 receptacle RC3 and terminal strip 3T (see Sections 4-7 and 4-8).
Repair or replace remote control device.
Have Factory Authorized Service Agent check optional CV-3 regulator board PC2.
Low CV weld output (models with CV-3
Set Ampere Range switch to highest range.
Min or max CV weld output only {models
with CV-3 option).
Check position of Amperage/Voltage Adjust control and Amperage/Voltage Adjust switch.
Repair or replace remote control device.
Have Factory Authorized Service Agent check optional CV-3 regulator board PC2.
B. Auxiliary Power
No output at auxiliary power ac
Reset circuit breaker CB1 and/or CB2 (see Section 6-1).
Disconnect equipment from receptacles during start-up.
Have Factory Authorized Service Agent check brushes and slip rings.
No or low output at optional auxiliary
power plant.
Place optional Output (Electrode) Control switch in On (Hot) position, or move switch to Remote
position and connect remote contactor to Remote 14 receptacle RC3 or terminal strip 31 (see Sec-
tions 4-7, 4-8, and 5-1).
Place optional Amperage/Voitage Adjust switch in Panel position, or move to Remote position and
connect remote amperage control to Remote 14 receptacle RC3 or terminal strip 3T (see Sections
4-7, 4-8, and 5-1)
Place optional remote amperage control in maximum position {see Section 5-3).
Place optional Process switch in Stick position (see Section 5-1).
Check fuses F1, F2, and F3 and repiace as necessary (see Section 6-3).
Check engine weld/power speed, and adjust if necessary (see Section 7-8).
Have Factory Authorized Service Agent check brushes and slip rings, and field current regulator board
OM-477 Page 32
High or ow voltage at auxiliary power
ac receptacles.
Check engine weld/power speed, and adjust if necessary (see Section 7-8).
Have Factory Authorized Service Agent check field current resistor R3.
High output at optional auxiliary power
Check engine weld/power speed, and adjust if necessary (see Section 7-8).
Have Factory Authorized Service Agent check field current regulator board PCH.
C. Engine
Engine does not start.
Check fuel level. Open fuel shutoff valve (see Section 4-4).
Check battery and replace if necessary (see Section 4-2).
Check oil and water levels. Automatic shutdown system stops engine if oil pressure gets too low or
coolant temperature gets too high (see Section 4-4).
Check Engine Control switch, and replace if necessary.
Check Magnetic Shutdown switch MS1 fuse F and replace if open (see Section 7-4).
See engine manual.
Have Factory Authorized Service Agent check engine charging system.
Battery discharges between uses.
Clean battery, terminals, and posts with baking soda and water solution; rinse with clear water.
Periodically recharge battery (approximately every 3 months).
Replace battery (see Section 4-2).
Have Factory Authorized Service Agent check engine charging system.
Engine idles, but does not come up to
weld speed.
Check Engine Control switch, and replace if necessary.
Have Factory Authorized Service Agent check idle module and current transformer CT1.
Engine does not run at idie speed.
Move Optional Process switch to Stick position (see Section 5-1). Unit does not run at idle speed
when operated in MIG (CV) mode.
Engine slowly stopped and cannot be
Check fuel level. Open fuel shutoff valve (see Section 4-4).
Check oil and water levels. Automatic shutdown system stops engine if oil pressure gets too low or
coolant temperature gets too high (see Section 4-4).
See engine manual.
OM-477 Page 33
OM-477 Page 34
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OM-477 Page 35
Figure 8-1. Circuit Diagram For Welding Generator For Standard Models
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Figure 8-2. Circuit Diagram For Welding Generator With Welders And Deluxe Package Options
OM-477 Page 36
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OM-477 Page 37
9-1. Selecting Equipment
“TN 1 Auxiliary Power Receptacles
7 - Neutral Bonded To Frame
| 2 3-Prong Plug From Case
Grounded Equipment
3 2-Prong Plug From Double
insulated Equipment
Be sure equipment
has this symbol
and/or wording.
aux_pwr 2/99 - Ref. 51-159 730 / ST-800 577
9-2. Grounding Generator To Truck Or Trailer Frame
2 Metal Vehicle Frame
3 Equipment Grounding
4 Grounding Cable
Use #10 AWG or larger insulated
copper wire.
À I unit does not have GFCI
receptacles, use GFCl-pro-
tected extension cord.
> 1 Generator Base
— — |
2 Electrically bond generator
2 frame to vehicle frame by
metal-to-metal contact.
OM-477 Page 38
9-3. Grounding When Supplying Building Systems
1 Equipment Grounding
2 Grounding Cable
Use #10 AWG or larger insulated
copper wire.
3 Ground Device
A 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.
51-200 576-B
9-4. How Much Power Does Equipment Require?
e AMPS 4.5
1 Hz 60
EXAMPLE 1: Hadrill uses 4.5 amperes at 115 volts, calculate its running power
requirement in watts.
4.5AX115V=520 W
The load applied by the drill is 520 watts.
EXAMPLE 2: Ifthree 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 drilt is 1120 watts.
1 Resistive Load
À light bulb is a resistive load and
requires a constant amount of
2 Non-Resistive Load
Equipment with a motor is a non-
resistive load and requires approx-
imately sixtimes more power while
starting the motor than when run-
ning (see Section 2-8).
3 Rating Data
Rating shows volts and amperes,
or watts required to run equipment,
OM-477 Page 39
9-5. Approximate Power Requirements For Industrial Motors
Industrial Motors Rating Starting Watts Running Watts
Split Phase 1/8 HP 800 300
1/6 HP 1225 500
1/4 HP 1600 600
1/3 HP 2100 700
1/2 HP 3175 875
Capacitor Start-Induction Run 1/3 HP 2020 720
1/2 HP 3075 975
3/4 HP 4500 1400
1 HP 6100 1600
1-1/2 HP 8200 2200
2 HP 10550 2850
3 HP 15900 3900
5 HP 23300 6800
Capacitor Start-Capacitor Run 1-1/2 HP 8100 2000
5 HP 23300 6000
7-1/2 HP 35000 8000
10 HP 46700 10700
Fan Duty 1/8 HP 1000 400
1/6 HP 1400 550
1/4 HP 1850 650
1/3 HP 2400 800
1/2 HP 3500 1100
9-6. Approximate Power Requirements For Farm/Home Equipment
Farm/Home Equipment Rating Starting Watts Running Watts
Stock Tank De-Icer 1000 1000
Grain Cleaner 1/4 HP 1650 650
Portable Conveyor 1/2 HP 3400 1000
Grain Elevator 3/4 HP 4400 1400
Milk Cocier 2900 1100
Mitker (Vacuum Pump) 2 HP 10500 2800
FARM DUTY MOTORS 1/3 HP 1720 720
Std. (e.g. Conveyors, 1/2 HP 2575 975
Feed Augers, Air 3/4 HP 4500 1400
Compressors) 1 HP 6100 1600
1-1/2 HP 8200 2200
2 HP 10550 2850
3 HP 15900 3900
5 HP 23300 6800
High Torque {e.g. Barn 1-1/2 HP 8100 2000
Cleaners, Sile Unloaders, 5 HP 23300 6000
Silo Hoists, Bunk Feeders) 7-1/2 HP 35000 8000
10 HP 46700 10700
3-1/2 cu. ft. Mixer 1/2 HP 3300 1000
High Pressure 1.8 Gal/Min 500 PSI 3150 950
Washer 2 gal/min 550 PSI 4500 1400
2 gal/min 700 PSI 6100 1600
Refrigerator or Freezer 3100 800
Shallow Well Pump 1/3 HP 2150 750
1/2 HP 3100 1000
Sump Pump 1/3 HP 2100 800
1/2 HP 3200 1050
OM-477 Page 40
9-7. Approximate Power Requirements For Contractor Equipment
Contractor Rating Starting Watts Running Watts
Hand Drill 1/4 in 350 350
3/8 in 400 400
1/2 in 600 600
Circular Saw 6-1/2 in 500 500
7-1/4 in 800 900
8-1/4 in 1400 1400
Table Saw 9 in 4500 1500
10 in 6300 1800
Band Saw 14 in 2500 1100
Bench Grinder 6 in 1720 720
8 in 3900 1400
10 in 5200 1600
Air Compressor 12 HP 3000 1000
1 HP 5000 1500
1-1/2 HP 8200 2200
2 HP 10500 2800
Electric Chain Saw 1-1/2 HP, 12 in 1100 1100
2 HP, 14 in 1100 1100
Electric Trimmer Standard 9 in 320 350
Heavy Duty 12 in 500 500
Electric Cultivator 1/3 HP 2100 700
Elec. Hedge Trimmer 18 in 400 400
Flood Lights RID 125 100
Metal Halide 313 250
Mercury 1000
Sodium 1400
Vapor 1250 1000
Submersible Pump 400 gph 600 200
Centrifugal Pump 900 gph 900 500
Ficor Polisher 3/4 HP, 16 in 4500 1400
1 HP, 20 in 6100 1600
High Pressure Washer 1/2 HP 3150 950
3/4 HP 4500 1400
1 HP 6100 1600
55 gal Drum Mixer 1/4 HP 1900 700
Wet & Dry Vac 1.7 HP 900 900
2-1/2 HP 1300 1300
OM-477 Page 41
9-8. Power Required To Start Motor
4 AC MOTOR 1 Motor Start Code
1 NN VOLTS 230 AMPS 252” 2 2 Running Amperage
> 3 Motor HP
3 ay CODE M Hz SO 4 Motor Voltage
«HP 1/4 | PHASE 1 J
To find starting amperage:
Step 1: Find code and use table to
find KVA/HP. If code is not listed,
multiply running amperage by six
to find starting amperage.
Step 2: Find Motor HP and Volts.
Step 3: Determine starting amper-
age (see example).
Welding generator amperage out-
put must be at least twice the
Single-Phase Induction Motor Starting Requirements motor’s running amperage.
Motor Start
Code G | H J K LI MIN | P
KVA/HP 63 | 74 | 80 | 90 | 100 | 11.2 | 125 | 140
EXAMPLE: Calculate the starting amperage required for a 230 Y, 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
230 = 12.2 A Starting the motor requires 12.2 amperes.
9-9. 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
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
Ref. ST-800 396-A / 5-0625
OM-477 Page 42
9-10. Typical Connections To Supply Standby Power
[7 Customer-supplied equipment is required if
generator is to supply standby power during
emergencies or power outages.
| 240 V
120/240 Volt À
60 Hz ООО y 120V
Three-Wire co 120 V A
Service Y
— A
2 3
\ =
240 V
- Ÿ
* y 120v ALA
Load— “— X
1 y 120V
= J OO
- MF]
\ 240 V Де
— Y
120/240 Volt y 120V
Single-Phase x
Three-Wire — Ÿ 120 V
Generator Output x
Connection Ground
1 Power Company Service
2 Main and Branch Overcurrent
3 Double-Pole, Double-Throw
Transfer Switch
Obtain and install correct switch.
Switch rating must be same as or
greater than the branch overcur-
rent protection.
4 Circuit Breakers or Fused
Disconnect Switch
Obtain and install correct circuit
breakers or switch.
5 Extension Cord
Select as shown in Section 9-11.
6 Generator Connections
Connect terminals or plug of ade-
quate amperage capacity to cord,
3 Follow all applicable codes and
safety practices.
Turn off or unplug all equipment
connected to generator before
starting or stopping engine. When
starting or stopping, the engine has
low speed which causes low volt-
age and frequency.
7 Load Connections
y Item 4 is not necessary if circuit
protection is already present in
welding generator auxiliary
power output circuit.
OM-477 Page 43
9-11. Selecting Extension Cord (Use Shortest Cord Possible)
Cord Lengths for 120 Volt Loads
A lfunit does not have GFCI receptacies, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current Load (Watts) 4 6 8 10 12 14
5 600 350 (106) 225 (68) 137 (42) 100 (30)
7 840 400 (122) 250 (76) 150 (46) 100 (30) 62 (19)
10 1200 400 (122) 275 (84) 175 (53) 112 (34) 62 (19) 50 (15)
15 1800 300 (91) 175 (53) 112 (34) 75 (23) 37 (11) 30 (9)
20 2400 225 (68) 137 (42) 87 (26) 50 (15) 30 (9)
25 3000 175 (53) 112 (34) 62 (19) 37 (11)
30 3600 150 (46) 87 (26) 50 (15) 37 (11)
35 4200 125 (38) 75 (23) 50 (15)
40 4800 112 (34) 62 (19) 37 (11)
45 5400 100 (30) 62 (19)
50 6000 87 (26) 50 (15)
*Conductor size is based on maximum 2% voltage drop
Cord Lengths for 240 Volt Loads
A [If unit does not have GFCI receptacles, use GFCl-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current Load (Watts) 4 6 8 10 12 14
5 1200 700 (213) 450 (137) 225 (84) 200 (61)
7 1680 800 (244) 500 (152) 300 (91) 200 (61) 125 (38)
10 2400 800 (244) 550 (168) 350 (107) 225 (69) 125 (38) 100 (31)
15 3600 600 (183) 350 (107) 225 (69) 150 (46) 75 (23) 60 (18)
20 4800 450 (137) 275 (84) 175 (53) 100 (31) 60 (18)
25 6000 350 (107) 225 (69) 125 (38) 75 (23)
30 7000 300 (81) 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-477 Page 44
OM-477 Page 45
17 Hardware is common and
not available unless listed.
Figure 10-1. Main Assembly
OM-477 Page 46
Creed и К у
ST-115 004-P
OM-477 Page 47
lem Dia. Part
No. Mkgs No. Description Quantity
Figure 10-1. Main Assembly
Cd LL Lea ee aa eee 134 771... PLUG, protective .6408Q ........10220020 414424 e as Le a ea aa ea a 2
1 D Less ea ae a aa ace an» 184 677 .. . TANK, fuel (consisting of) ......... i iii. 1
C3 AA 182 022.... CAP, fuel large ........ La aa ee La ae a eee nee 0 1
SP оо 146 357... SENDER, fuel gauge ......... coi aa ea ane 6 1
ree 020108... FLANGE, fuelgauge . ..... cocoon À
RE RAA AAA 602 938... FITTING, pipe galv plug sqhd 125NPT .......... o.oo ih. 1
Beer n ee 097507... STRIP, rbradh back 125 x1... coi aa aa aan ne» 2
CT Lane 010314... VALVE, shut-off fuel 1.112201 0 01 a 4e ee a a ae a a a a ea ane 1
LB O 173 818... FITTING, hose brs barbed eibow M 1/4tbg x 1/4NPT ............. 1
CO 11111 aa 1111006 084 173... CLAMP hose .460-.545 1111111114 4 4 4 4 4 04 ee a a ae ee ee na a ae» 4
‚10 .........к.ккк... 107 816... HOSE, SAE .250 1D x .500 OD (order by ft) ...............—.«—.—.. 2ft
E e LL LR 047 420... FILTER, fuel in line .250 w/hose & clamps ...................... 1
12 ..............5... 017 479... SEAL, weather lifteye ........ iii a ee a» 1
C18 L LL LL ae 188 235... UPRIGHT, base center ..........12200 440004000444 ae REA 1
RE AS 072 848... TUBING, nprn .875 OD x 2.500 OD x 2.000 ...........—........e. 4
C0 1 a 41100006 071 730... ТОВМС, 5! .875 ОР х 12да х 2.375 .................... 0..0... 4
‚16 .................. 071890... RETAINER, mounteng/gen ......... coins 4
17 LL 10211 ea aa aa 240 071 731... WASHER, flat sti .656 ID x 2.250 OD .............. iin. 4
| PO 601 945... SCREW, .625-18 x 4.000 hexhd stl ................. к.кв. 4
C18 eee 018 765... AIR CLEANER, intake carb (consistingof) ..................... 1
10 018859 .... CAP, air cleaner intake .......... ci. 1
C21 11112 008698 .... BAFFLE, dustcap ..... ci i ee 1
‚22 1111111 a LL a ana ee 021 117 .... NUT, stlwing .437-20 w/washer ........... iii... 1
C23 *017309.... ELEMENT, aircleanercarb ............. iii iii, 1
‚ 24 .................. 000272 .... CLAMP air cleaner ..........._.eeeeereduarieodaedaarerecee. 1
‚ 25 2..2... ккклвкукк., 031 868... BRACKET, mtg air cleaner .........0022 0200040 eee es aa 1
y PU 010875... CLAMP, muffler 2.000dia ............. cc iii . 1
C27 aa a+ 0 105 740... MUFFLER, exhaustengine .......... cc iii, 1
‚28 AAA 52...55... 035 968 ... WASHER, flat rbr 3.625 ID x 5.875 OD ......................... 1
PS 195869 ... CABLE TIE, 0-17.500 weatherresistant ........................ 1
E 108 487... LABEL, warning falling equipment ............eo..e.eeereresro 2
e BO en niaaaaaronan aa +105 631... COVER, top ........... ee eee 1
een 057 359 ... BLANK, snap-in nyl .375mtghole .............................. 4
C31 ae 028 089... DOOR, access radiator ...... oc. 100044 a ea aa a aa» 1
Ce 191 865... ВЫМРЕВ, даоог ассез$ га @Ююг ............................... 2
BO eee 089 343... RIVET, nyl .250diax1.0001g ........... iit. 6
e BB aan au 0 0 004 130... BRACKET, support door ............eeerevre0reseereereen e 2
NA nando. +089 510... DOOR, side ............. re revesrerresara a rene ereaennodo na 2
eee aaa 114793... LABEL, enginemaintenance ................ oo iii 7
2.35 2к..кккккквкеко о. 158 610... LABEL, electric shock and moving parts ........................ 2
C36 087 336... LATCH oi i eee ea 2
ee LV a Aa ae a a 1 a 0400 087 341... BUMPER, door 1.000 CD x .750 high .......................... 4
BT 22e a ee eee 089 947 ... RADIATOR, w/shroud (consistingof) ............. o.oo. 1
REC = PR 605 982 .... CAP, radiator pressure 71b ........ cc iii 1
BI aaron nenana 006 015.... FITTING, pipe brs drain cock 1/4NPT ........................ 1
‚. 40 ue 163 197... GUARD, fan upper ..........exr.ceexerrarerea, rara e ea AD 1
1 109 792... ENCLOSURE, radiator ............__...eeceeenernvrererorecec,.. 1
‚ 42 .................. 147 923... LABEL, warning fan .........._oemeeresnmarrerere rare e. 2
43 LL LL Lana ee +153 866 ... GUARD, fan RH ee ARE 1
AA 5....... 5.2... 5.5... 010862... CLAMP, hose 1.312 -2250c¢clpdia........... cc iit. 6
M5 LL ea a ana 113 676 ... HOSE, radiator lower ..........20100024 00444 ee ea ae a a a see a 06 1
‚ 46 ..............,... 084 979... HOSE, radiator ............ o ees_eeseerrecoo0errerecar eterna 1
47 eucrocrarer ar +163 195 ... GUARD, fan LH .. 1.211412 00004 a 4e a 0e eee eee ae a ea Se ea 0 i
48 e... .eo.. 176 364... ENGINE, gas elec start (consisting of) ..............._ em... 1
4911112 Lee ae eee 089 515.... ANGLE, mig engine ...........oeeeeresesceredexre rev eere 1
BO urea 1156857 .... BRACKET, mtg solenoid ¡dle ................ 2.020... .... 1
51 ..... TS1........ 005 373 .... SOLENOID, 14VDC .84A .. 2... 20000000 0 1
BZ iaa 010 837.... PIN, spring CS .093 x 625 ....10.020200 0002400 e 04e ea ae a nan e ee 1
OM-477 Page 48
No. Mkgs. No. Description Quantity
Figure 10-1. Main Assembly (Continued)
DB anna. 113658..,. LINKAGE, throttie .............—.—.—.... retraracererercere, 1
2.5.54 ..... Р®1 .................... CARBURETOR, (see engine partslist) ....................... 1
LBs 602 887 .... FITTING, pipe brs plughexhd 1/4NPT ........................ 1
..56...... 37 os... 025473 .... SWITCH, pressure oil ......... iii iii einen, 1
DT лана анваонеь. 010289 .... FITTING, brs fird invt conn M 1/4tbg x 1/8NPT ................. 1
e DB aan 111 851.... LINE, fuel RR LL 11 1
andrade riarereneerenea 087 318.... CLAMP, sil cush 1.000dia x .208mtghole ..................... 1
Ce ee 172725 .... BOOT, starter eyeletterminalred ............................ 1
e DI nnuanananraaa Fig 10-2... GENERATOR ..... a a aa 4 a ea a ea a aa ea a a aa eee 0 1
...80.... Shunt ..... ¢030 084 ... SHUNT, meter 5SO0MV 800A ......... ia, 1
Bt 188 629... HOSE, elbow air cleaner ............ i 1
e B2 nana 173 034... TUBING, heatstove ............. i, 1
E 010863... CLAMP, hose 1.125-3.000clpdia ..............eeee.es0r0reco. 2
Lu B4 к...... 173036... HOSE, elbaircleaner ......... ieee 1
E -- .................. 134 779... HOLD DOWN, bat ............... e esracaceae cen ene. 1
зн. 66 ................., 182 276 ... САВГЕ, БаНегу роз w/clamp (included w/engine) ................ 1
AT AS 047 812... CABLE, battery neg (included w/engine) ........................ 1
не. 68 .................. 108 081... TERMINAL PROTECTOR, batpost ............................ 2
.. 69... BAT ........ 071678... BATTERY, stor 12V 415crk .... ees 1
TO екекелеку к... 134 782 ... BATTERY BOX ee da ane 1
aT 0 082672... BOLT, Lstl 312-18 Xx 6.375 . .... i aa aa ins, 1
ea 604 433 ... NUT, stl siflkg hex hvy .312-18 .............. iin 1
2. TB LL LL a naar 163 666 ... BASE ...uiiirererrerrarreneaneercecer 4 ea A4 a a a a a aa ana ae 1
ce TB aunar +186 008 ... INSULATION, terminal strip .. .. . cc... co 0. 000000. 1
Annan 3T ...... * 038 601... BLOCK, term S0A 9P ......... a anaaa aa 1
CTD ¢155 731... BRACKET, migterminal strip ............ iii... 1
ге. 76 .........,..... +134 902... COVER, fuse box ........,.,........... 2.2.5... A a a aa La a ae 1
PO aan * 185 000... LABEL, warning auxiliary power ..............__ ere... 1
LTB, +026 947 ... STAND-OFF, insulated 2.50-20 x 1.000 lg ...................... 1
e TI aaa +134 003... FUSE, boX .... en e arenennonara nao 1
Le80 +149 541 ... HOLDER, fuse ertg 60A 250V 3 fUSES 1
81... F1-3 ..... ¢*012625 ... FUSE, crig 45A 250V . RR ea aa 3
TT 113 932... GUARD, panel rept (consisting of) ....................2 2... 1
83 eee 113730 .... LABEL, warning stop enginebeforeetc ....................... 1
...84..... SR4........ 035 704 ... RECTIFIER, integ 40A 800 V ....... iii iii 1
L885 aa e ee 173982... PANEL, mtgcomponents ............... cirri 1
...86.. PLG9,RCS..... 168 071... CONNECTOR & SOCKETS ....... iii о. 2
e BTs DS ........ 182 307... KIT, diode W/Washers ..... ct eee iia, 1
=> ...... C8 ........ 170674... CAPACITOR BOARD RR 1
..89...... RE ........ 030 844... RESISTOR, WW xd 25W250hm ................. cco... 1
ea 605 741... CLIP, mtg resistor ........ iii iii iii La La aa 2
.. MO... CR3 ....... 044 588... RELAY, enci 12VDC 3PDT 10A/120VAC ............ e..." 1
.. Me... PC5..... . 9150415... CIRCUIT CARD, connecior ............... erecciones 1
TE PLG6-8 .... #141450... CONNECTOR, rect 10skt plug Amp 207396-1 ................... 3
L092 ¢097 132... STAND-OFF, NO. 6-32X.37519 ... oii iii 5
...93..... PC6...... ¢152966 ... CIRCUIT CARD, filter HF .. ..... a es ea ea aa 1
94.111111 Lean +181 841 ... PANEL, trontiower 1121011011 LL LL La ne na ana 1
1 +134 792... LABEL, warning general precautionary ......................... 1
e BO aaa 6111 785... HANDLE, switch .............. 2.2.2. 00iraranaoeanaco 1
LOT AS 6112 003... SWITCH, plrt RER уу ееоее 1
Ce $133 725... LABEL, AC/DC polarity switch ........................ 1
..98..... CT1........ 105370... TRANSFORMER, current ............. iii... 1
..99...... Li 1... 084 814... REACTOR .LL.LLLL11 111212 A AA A Aa 4 Va dd da ea aan 1
.. 100 .... Neg........ 039 046... TERMINAL, pwr output black .............. co... 1
. 101 .... Pos...... . 039047... TERMINAL, pwroutputred ........... cc. iin... 1
.…. 102 122212201000 0 Fig 10-3... PANEL, frontw/components ............. cc iii... 1
.. 108 ................. 108 127... BRACKET, mtgtermpwroutput .............. i... 1
. 104 .... PC4........ 148 608 ... CIRCUIT CARD, filter HF ......... ee 1
ce 097132... STAND-OFF, N0.6-32x.3751g ........oi 2
‚ 105 ................. 188 237... UPRIGHT, base front ........ ууу ви ве виа неее вввавь, 1
ОМ-477 Раде 49
Item Dia. Part |
No. Mkgs. No. Description Quantity
Figure 10-1. Main Assembly (Continued)
. 106 ................, 085 551... FRAME, mtgreactorffueltank ................ i. 1
. 107 ..... R3 ........ 128 862... RESISTOR, WW adj 375W 50 ohm w/migbkt ....... ........... 1
108 ................. 085656... STRIP, mtg resistor ............ KK 1
e 109 ................. 605 288... FITTING, pipe galv plug sghd .250NPT ............. ........... 1
2. 110 .....112211 1100000 070910... BOLT, Jstl .250-20 X 2.312 ..........ex0r00ríerere erre reee. 2
Lot 6 010143... CLAMP, nyl 375 clampdia ............ ci, 1
2. 112 er не к век... 138 027 ... EDGE TRIM ......... 22. .000000rveaderri ervecerrerecve—. 2
…. 113 ares, 081 499... BRACKET, mtg strip terminal ............ oo iit, 1
,. 114 .... TE4........ 038 621 ... BLOCK, term 30A 4P ee 1
AR 038620... LINK, jumperterm blk 30A .......... oi a, @
2. 116 0 1000 053 967 ... INSULATION, rectifier eK 1
2. 116 ................. 089517... STRAP, fuel tank .................0e00m00000rear rea, nec. 2
La eee de ae ea see 010021... CLAMP, stlcush .562dia ......... ccc iii. 2
eee 136 310... KIT, label ............. 1
*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 Manufacturer's Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
(7 Hardware is common and
not available unless listed.
Figure 10-2. Generator
OM-477 Page 50
item Dia. Part
No. Mkgs. No. Description Quantity
Figure 10-2. Generator (Fig 10-1 Hem 59)
CU кеккекк о. 106 426 .. INSULATOR «eee ee eee 4
I 1 Lee 4e 106 440 .. BUS BAR, rectifier .... LA AAA Aa a a a a a aa a aan 2
..…. 3 ... SR3.... 106427 .. DIODE ASSEMBLY, reverse polarity (consistingof) .................... 1
не. 4 rer 048420 .... CAPACITOR, rectifier ......... iii ii iii iii a aa 0 2
eee 106 641 .... CAPACITOR ..... eee cece À
Bose 037 957 .... DIODE, rect 275A 300V RP .... iii ice 0 3
16 ............ 106 425 .... INSULATOR RR века кк екв навек нен нак. 2
CT 2411. 173 066 .. BRACKET, mtgbrushholder.......... i 0 1
2 8 DS 018 614 .. BRUSH SET, (consisting of) ........10200000 000400 ea aa ea aa ea ae 3
a9 2e 51299 .... BRUSH, contact oii 4 4 AA A A 1
2. 10 ............ 600 270 .... HOLDER, brush ..... 2.2... 2... 00srereerearereaeererarere. 1
E к... 152 044 .... CAP, brushholder .............. 2.2.2... eaaacenanonena 2 1
1 12 O 013 367 .. LABEL, warning moving parts can cause serious injury ................ 2
2. 13 rss 110371 .. GUARD, starter ............ 2... aaa de e noonrenacaraa» 1
A canoa +128 730 .. STATOR, gen (consisting of) ....... i iii, 1
oo14 +4132 222 .. STATOR, gen (consisting of) .......... i. 1
RE 039207 .... BAFFLE, air gen .................00000 0 A A. 1
…. 16 ............ 105 668 .. ROTOR, gen (consisting of)... iii ei ea 1
1 17 112124110004 024 617 .... RING, retainingexternal ............ iii. 1
L188 053390 .... BEARING, ball ....... i ea 1
DI: nn. 089 737 .... FAN, rotor ............0. 0. 000arieeriarerocrrecendereecerenmero, 1
Ca 035776 .... KEY, 375 X.375X 2.000 ...... cei a a 0 a a aa aa ana Y
1 ............ 044 374 .. STATOR, excitor .............eresrere0r e recooereareneaneneaeeem. 1
QA ueno 173 068 .. ENDBELL, gen (consisting of) ....................... 00.0... 000erec.. 1
7D 143220 .... O-RING, 2.859 1D x .1396S ........ i Í
2. 23 aaa 106 424 .. BARREL, rectifier. ........112100 00044 44 a Aa 44 4 en 4 4 4 0 4 a 4 a aa ea 1
Ce 163271 .. EDGE TRIM eee Y
.. 24... SR3.... 106430 .. DIODE ASSEMBLY, straight polarity (consistingof) .................... 1
e 2D 2........... 048 420 .... CAPACITOR, rectifier .............. ee. .e00eeareaeracenearecena 2
Ce 106 641 .... CAPACITOR .... icici cca À
… 26........... 106 425 .... INSULATOR eK 1
2 aaa 037956 .... DIODE, rect 275A 300V SP... iii aa ea aa 4 a ea as ea a a aa 3
. 28. VR1,H4 .. 046819 .... SUPPRESSOR .... 2011100 La AR A4 a A ee a ee a ane 1
*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 Manufacturer's Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-477 Page 51
No. Mkgs. No. - Description Quantity
Figure 10-3. Panel, Front w/Components (Fig 10-1 item 102)
E 00 010 647 .. . PIN, spring CS .156 x 1.250 ..........ees0ererererererari e. 1
Ce 2 c Lena a nee 044 328... HANDLE, switch range .............ee_.—.eeerírevereresr rea. 1
Banned ea oonacar ena PLATE, ident control rating (order by model and serial number) .... 1
не. 4 a NAMEPLATE, (order by model and serial number) ............... 1
105... SE 172070... SWITCH, ign Sposn w/out handle ,............—__—reeesreresene 1
addon aaron radrrrararer,. ¢ ... LO OIL & HI TEMP SHUTDOWN, (consistingof) ................ 1
Ce eee 0 110958 .... SWITCH, automatic shutdown (consistingof) .................. 1
6... MST ....... 011 072...... SWITCH, magnetic (consisting of) ................ee22. 200000 1
Tona Foot. *048 317 ........ FUSE, mintr gl 14A 32V ............000000errerer are een 1
Cee D8 ........087970...... DIODE .............0s0000rererrerenrerecarerececare ee À
зн. В AS 131 999... PANEL, front upper ............_.emvereege ere rescerenAen A ED 1
ee 9 LLe eee Lacs 086 706... SPACER, range Switch .......202 02044444 a ane ae aa aan a as een 1
e O. S3 ........ 119850... SWITCH, range/changeover ......... ini eine 1
e | 086 991... BRACKET, support switch range ..........eeoeeexerreecer a. 1
{7 Hardware is common ang
not available uniess listed.
ltem 20
ST-115 005-C
Figure 10-3. Panel, Front w/Components
OM-477 Page 52
No. Mkgs. No. | Description Quantity
Figure 10-3. Panel, Front w/Components (Fig 10-1 Item 102)
E PO Fig 10-4... CONTROL BOX w/COMPONENTS .................0 0. rea 1
…..13.... CBi2....... 139 206... CIRCUIT BREAKER, man reset 1P 15A 250VAC ................ 2
...14.... RC12....... 170 901... RECEPTACLE, str dx grd 2P3W 15A 125V ..................... 2
e. 14... GFCI,2.... 6168068... RECEPTACLE, strdx grd 2P3W 15A125V ..................... 2
SA 073 690 ... PLUG, str grd armd 2P3W 15A 125V P & S 5266DF
ee 4042 655... RECEPTACLE KIT, 240V (consistingof) ........................ 1
‚..13.... CB12...... . 139 266 .... CIRCUIT BREAKER, man reset 1P 15A 250VAC .............. 2
e A. RC1 ...... . 8604103 .... RECEPTACLE, str dx grd 2PBW 15A250V .................... 1
e TA... RC2 ....... 039864 .... RECEPTACLE, strdxgrd 2P3W 15A125V .................... 1
….15..... RC3 ..... +143 976... CONNECTOR w/SOCKETS 11.102011 04 4 ea aa da a a aa ae ae 1
eee 134 734... CONNECTOR, circ 14 pin plug Amp 213571-2
ea 134 731... CONNECTOR, circ pin push-in 14-18ga Amp 213603-1
eee 079 739... CONNECTOR, circ clamp str rif .703 max cable OD
Amp 206322-2 (or)
eee 143 922... CONNECTOR, circ clamp str rlf .453 max cable OD
Amp 206070-3
‚..16.... CB34..... +083 432... CIRCUIT BREAKER, manreset 1P 10A250V ................... 2
L170 S45 ..... *011 609... SWITCH, tgl SPDT 15A 125VAC ....... 2... as 2
[E 011 611... SWITCH, tgl DPDT 15A 125V 1.111120 4 aa ea ea ea a a aa ane 1
e 1... RT ....... . 072 462... POTENTIOMETER, w/shatft lock (consisting of) ................. 1
1 .................. 072 590 .... LOCK, shaft pot .375-32 x .250diashaft ...................... 1
Br Lan ane 022289... TUBING, stl 3120D x 187 IDX 437 ...... iri. 2
не. 22 nana aarrena 097926... KNOB, pointer ..... e nereaeedearenrev. 1
2 aaa *021 385... BOOT, tgl switch lever ........... iii, 2
2 2... .ккк в.в... 170 663... HINGE, panel front ......... ii, 1
RE AS 083 030... STUD, brs grd .250-20 x 1.750 ............ 000080000 1
E canne 601 836... NUT, brs hex .250-20 ...............0000000r0deder eco e. 3
7 2... A? ...... +046 652... МЕТЕН, атр дс БОМ\У 0-600 зса!е ............................ 1
2... 28 ...... Vea. 046654... METER, voltdc 0-100scale .......... ii... 1
E: € 170391... CONNECTOR, circ protective cap Amphenol 9760-20 ............ 1
a ea $... ENGINE METER KIT, (consisting of) ........................... 1
e BO e кий... 047 842 .... GAUGE, pressure 5-100 bs ............002. een, 1
EC LLLL 11e aan ee 047 841 .... GAUGE, temperature mechanical 100/250deg ................. i
Cee eet ees 128826 .... KIT, 0il line 44.000 in 1/8NPT x 10mm ........................ 1
eee 602946 .... FITTING, pipestiteeB1/8NPT ........................... À
Ce ee 175465.... FITTING, pipebrsadapter ................ 7
ee 162 380.... FITTING, pipe sil adapter 3/8 ............................... 1
REC ananaa, 133 814... CONTROL, push/pult ....10 0114000010 La aa a aa a a a a a Aa na ae 1
Ce 33 ее. 119014... LEVER, switch black . . ........ ioe ee is 1
e BA naa, HM ........ 145247... METER, hour 12-24VDC ...... ein 1
Ce eae, 604 784 ... SCREW, 6-32 x .500rdh-slot brs .............e.eÑexee ae a. 2
Ce eee 601829... NUT, brshex 6-32 ......... 2
a3 cea. 082 788... HOLDER, lightind . ....... ee 2
E] aan 082 789... LENS, light ind red ................. 222.000 aanooe 2
Be PLAZ e... *048 155... BULB, incand fig base 12V .......... 2... aaa 2
‚ 38...... FG ....... . 118 066... GAUGE, fuel elec 12V ....... ananeeo 1
*Recommended Spare Parts.
Jo maintain the factory original performance of your equipment, use only Manufacturer's Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-477 Page 53
Item Dia. Part
No. Mkas. No. Description Quantity
Figure 10-4. Control Box w/Components (Fig 10-3 Item 12)
A CRT ....... 044 588... RELAY, encl 12VDC 3PDT .... KK 1
2... R2 ...... ¢130515... RESISTOR, board. ........ ci ieee 1
831... D1 ........ 189701... DIODE/CAPACITOR BOARD .......... ii iii, 1
UY: 2T ere. 116005... BLOCK, term 10A 7P e... RN Là 1
… 5... TE e. 129 939... BLOCK, term 10A 19P .......... 0... 0.00 00earererec en a 1
OB ................., 130 608... MOUNTING BOX, components ........... citrine... 1
A 603 107... HOSE, nprn slit back .156 ID x .343 OD (order byt) ............. 1ft
E E 134 201... STAND-OFF SUPPORT, PC card ............ ii iit, 8
‚.. 9 ..... PC1...... +166 205 ... CIRCUIT CARD, field currentregulator ......................... 1
Cee PLG1 ....... 135275... CONNECTOR PLUG & SOCKETS ......... civ. À
e. TO... РС2........ 114 832... CIRCUIT CARD, voltage regulator .............. 202... 1
41... CR99 ....... 090 104... RELAY, encl 12VDC SPST L...010111 014 ae La a ae La ane 1
A Y SR2........ 097 353... DIODE/SCR, bridge integ2scr3 diodes .............. cocoon... 1
.. 13... SR1........ 035 704... RECTIFIER, nteg40A800V ........ iii ее 1
... 14... IdeMod...... 189 742 ... MODULE, pull to ide 5 pin ........... _e..eeerrre ee en an» 1
I Hardware is common and
rot available unless fisted.
ST-109 773-C
Figure 10-4. Controi Box w/Components
To maintain the factory original performance of your equipment, use only Manufacturer's Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-477 Page 54
Big 40G
index No. ED/8.1
Issued March 1999
Engine Driven Welding Generator
12 [3
Ц =
2 DE Stick (DC SMAW)
4 Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
With Optional Packages:
rE Flux Cored (FCAW)
Bid Weiding
ll) Welding
Ra AC/DC Stick (SMAW)
Aa Welding
Miller Electric Mfg. Co.
An lilinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters-USA
Phone: 920-735-4505 (Auto-Afiended)
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX: 920-735-4125
The Power of Blue.
Take on tough welding jobs
now and keep your options
open. The Big 40%G's solid-
state circuitry and alternator
deliver smooth welding overits entire range. Even
Options enable Flux Cored, MIG, AC Stick and
non-critical AC TIG. While welding, the Big 40G
provides 3 kW at 120 VAC. For more auxiliary
output alone, the Deluxe Package option offers
12 kW of three-phase power when not welding.
under heavy loads in demanding locations, this
machine furnishes reliable productivity.
3-phase, 4-pole revoiving field
Provides efficient welding current with less horsepower than DC generator technology
— less horsepower per welding amp saves fuel — as much as 20 to 30 percent. Easily
connects in paraliel with no special kits for heavy gouging or stud welding applications.
Five welding ranges
Provides overlapping ranges and fine current control in each range for easy set-up
and control of welding amperage.
Wiscon Continental gasoline
Continental engines have been used for decades in Miller's industrial engine-driven
weiders. Engine runs at 1800 rpm for long service life.
Automatic idle
Saves fuel and prolongs engine life. Reduces noise.
Automatic engine shutdown
Recently added as a standard feature. It protects the engine from failure due to tow
oil pressure or high coolant temperature.
Improved fuel tank design
New, fieavier gauge, aluminized steel tank is more resistant to corrosion —
17-1/2 gal (66 L} runs ai! shift before refueling.
New fuel gauge and hour meter
Helps operator monitor fuel [evel and maintenance schedule. Conveniently mounted
on front panel.
Solid-state circuitry
Provides field current regulation to minimize any decrease in output as the machine
heats up— even at rated loads. It also permits factory or field installed CV-3 or
14-pin remote control options to be added.
3 KWAYA auxiliary power while
Auxiliary power available from two 120 VAC duplex receptacles that are circuit
breaker protected. Optional 240 VAC and GFC| receptacles available.
Optional Welder’s Package
Order one package to get all the factory-installed options needed to weld AC Stick and
AC TIG. Includes weld meters, polarity/AC selector switch, and remote control facilities.
Optional Welder's Package with CV
Adds constant voltage CV-3 module to Welder's Package options.
Optional Deluxe Package
Includes all factory options required for MIG and Hux Cored welding: Constant voltage
CV-3 module, weld meters and 12 kW auxiliary power.
Miller's True Blue® Warranty
Parts and labor warranted far three years. Wiscon warrants the engine for three
Specifications (subject to change without notice.) Industrial CC DC
Max. Onen-Circuit
Rated Output DC Amperage Range | Voltage DC (Nominal) | Auxiliary Power Dimensions Weight
375Aat |300Aat | 50-440 95 (90) 3 kKVA, 120/240 VAC | H: 48-3/4 in (1238 mm)* | Net: 1390 Ib
35 VD6, | 32 VDC, 26/13 À, 60 Hz W: 24-5/8 in (625 mm) | (631 ka}
50% Duty | 100% Duty while welding D: 64-1/2 in (1638 mm) Ship: 1430 Ib
Cycle Cycle (649 kg)
* To top of muffler.
Engine Specifications and Capacities
Engine Brand | Horsepower (HP) | Type Weld Speed | Idle Speed | Fuel Dil Coolant
Continental 38 at 1800 RPM Three-cylinder, industrial, | 1800 RPM 1200 RPM | 16 gal 5 qt 9 gt
TM-20 liquid-cooled, gasoline (60 L} 4.7L) | (851)
Ordering Information
Big 40°G 120 Volts, 60 Hz #903 043
with Welder's Package* #903 043-01-32
with Welder's Package with CV* #903 043-01-34
with Deluxe Package* #903 043-01-33
"See package details in Options and Accessories section.
Performance Data
en i
= 400 || =
= : |
Е Hs
= 300
= |
| .
200 | o |
20 25 30 40 5 & 70 80 90 100
Control Panel
GC Volts
Ranges: 190-Max
509 600 700
HR. à
& 3
100 180 200 2% 300 350 400
Í I | | I |
1.0 2.5 4.0 6.0 90 12.0
9 50
U.S. GAL. { HR.
1. Ampere Range Switch
2. Engine Oil Pressure Gauge"
3. Engine Temperature Gauge”
4, engine Indicator Lights
5. Fuel Gauge
6, Engine Contre! Switch
(Start, Run, Automatic Idle, Off)
7. Running Hour Meter
8. Remote/Panel Switches "Optional
9. Amperage/Voltage Adjustment Control
10. Process (CC/CV) Switch* 1
11. DC Voltmeter”
12. DC Ammeter*
13. Automatic Shutdown Switch
14. Remote 14 Receptacie*
15. 120 VAG Duplex Receptacles
and Circuit Breakers
do N 4 с
Options and Accessories
+ & 9
Factory Option Packages
Big 40%G with Welder's Package
#903 043-01-32
Factory-installed options include: weld ammeter
and voltmeter, polarity/AC selector switch, and
remote control facilities. (See descriptions below.)
Big 40°G with Welder's Package with CV
#903 043-01-34
Adds CV-3 constant voltage module to
welders package.
Big 40°G with Deluxe Package
#903 043-01-33
Factory-installed options include: CV-3 constant
voltage module, engine temperature and oil
pressure gauges, welder’s package and 12.5 kW,
three-phase auxiliary power while not welding.
The 12.5 KW power option is easily reconnectable
to 8 kW, single-phase, 1.0 power factor, 60 Hz,
120/240 VAC.
Weld Ammeter and Voltmeter #041569 Field
Monitors weld output. Installs on welder
control panel.
Polarity/AC Selector Switch #042 421 Field
Extend the versatility of this product by adding
AC weld output and polarity reversing functions.
AC weld output is 80% of the DC rating,
Remote Control Facilities #042381 Field
Consists of 14-pin receptacle and two switches
for full remote control and contactor control.
(Included with CV-3 option.)
CV-3 Constant Voltage Module #042405 Field
Converts welding output from constant current
(CC) DC to constant voltage (CV) DC for use
in GMAW/FCAW welding. Module consists of
circuit board, 14-pin remote contro} receptacle
and two switches, Field kit (same as factory
installed CV-3) is simple and easy-to-install.
Engine Gauge Kit #041 606 Field
Mechanical gauges for oil pressure/water
temperature in addition to standard
indicator lights.
Remote Oil Filter Kit #041 776 Field
Permits oil filter to be mounted on injection
side of engine if one-side servicing is required.
Automatic Shutdown Kit #041 960 Field
For units prior to Serial No. KG195828, Shuts
down engine if it senses low oil pressure or
high coolant temperature,
Coolant System Heater #040878 Field only
Starting aid for severe cold weather. Allows
easy infernal mounting, thermostat controlied,
operates on 115 VAC,
7) Miller.
Spark Arrestor (Muffler) Kit
#041 953 Field only
Mandatory when operating on California
grasslands, brush, or forest-covered land, and
all National Forests, For other areas, check
your state and local laws.
FA-1 Lockable Flame Arrestor Fuel Cap
#041 056 Field only
120 Volt GFCI Receptacle Kit
#043 259 Factory
#043 097 Field
120 Y duplex receptacle is ground fault
240 Volt Auxiliary Power Receptacle Kit
#042 594 Field
240 VAC duplex receptacle is convenient and
easy to install (replaces one of the standard
120 Y duplex receptacles}. Capable of 3 kVA at
240 VAC while welding.
CC-9 Canvas Cover #042595
Attractive, heavy-duty, blue waterproof and
mildew-resistant cover protects the finish of
your welder,
No. 4WA Stick Welding Accessory Kit
#040 045
35 ft (10.7 m) No. 2/0 electrode cable with
electrode holder and lug, 30 ft {9 m) No. 2/0
work cable with lugs attached, welding helmet,
and wire scratch brush.
Options and Accessories (Continued)
Remote Controls and Switches
RFCS-14 Foot Control #043554
Foot current and contactor control, 20 it (6 m)
cord and 14-pin plug.
RHC-14 Hand Control #129 340
Miniature hand control for remote current and
contactor control. Dimensions: 4 in (102 mm) x
4 in (102 mm) x 3-1/4 in (82 mm). Includes
20 ft (6 m) cord and 14-pin plug.
RMIS-14 Switch 7129337
For contactor control. Push switch forward
for maintained contact and back for momen-
tary contact. Includes 20 ft (6 m) cord and
14-pin plug.
RCC-14 Remote Contactor and Current
Control #151086
Rotary-motion fingertip control. Fastens to TIG
torch using two Velcro strips. Allows complete
current and contactor control at operator's
fingertips. Includes 28 ft (8.5 m) cord and plug.
Extension Cords for 14-Pin Remote Controls
#122 973 25 ft (7.6 m)
#122974 50 ft (15.2 m)
F122 975 75 ft (22.9 т)
Trailers and Hitches
HWY-224 Trailer #043805
A 2650 1b (1202 kg) capacity highway trailer.
Welded steel tubing frame, heavy-duty axle
with roller bearing hubs and leaf-spring
suspension. The HWY-224 comes with jack
stand, 2 in (50 mm) ball hitch, fenders and Lights.
OFR-224 Trailer #043 802
A 26501b (1202 kg) capacity off road trailer.
Welded steel tubing frame, heavy-duty axle
with roller bearing hubs and leaf spring
suspension. The OFR-224 comes with jack
stand and 2 in {50 mm) ball hitch.
Lunette Eye 2-1/2in (64 mm) #043 824
For use with both 224 trailers.
Clevis (not for highway use) #043 825
For use with both 224 trailers.
Cable Tree #043 826
Provides an area to conveniently wrap weld
cables and extension cords. Works on on all
224 and 430 trailers.
HWY-430 Tandem Axle Trailer #043 806
Smooth riding with 3750 1b (1701 kg) capacity.
Includes: adjustable hitch for level operation, a
hand operated parking brake, a self-actuating
hydraulic brake system and a break-away
device to lock brakes if the trailer comes loose.
It also includes jack stand, fenders and lights.
(Hitch must be ordered separately.)
Trailer Specifications (Subject to change without notice.)
Ball Hitch 2 in (50 mm) #043 864
For use with the 430 trailer,
Lunette Eye 3 in (76 mm) #043 863
For use with the 430 trailer.
Clevis (not for highway use) #043 823
For use with the 430 trailer.
Cable Tree #043826
Provides an area to conveniently wrap weld
cables and extension cords. Works on on all
224 and 430 trailers.
4 West Four-Wheel Steerable Off-Road Trailer
#042 801
A heavy-duty 3000 Ib {1361 kg) capacity trailer
designed for use in mines, quarries, and other
rough terrain. Has narrow 22 ft (6.7 m) turning
radius. Includes 3 in lunette eye, universal
hitch and safety chains.
Note: Trailers are shipped unassembled.
Gross Axle Gross Vehicle Road Track (Center to | Standard Tires (Standard Net
Model Weight Rating | Weight Rating | Net Payload | Height of Bed | Clearance | center of tires} | rating or P-size rating) Dimensions Weight
HWY-224 3500 Ib 2960 Ib 2650 16 18-1/2 in 7-1/2 in 52 in B-78-13C Length; 122-1/2 in (3.1 m) 355 Ib
OFR-224 (1588 ka) (1343 kg) (1202 kg) (470 mm) (191 mm) | (1.32 m) Width: HWY— 61 in (1.54 m)* | (161 kg)
OFR—58-1/2 in (1.51 m)
HWY-430 2200 Ib/axle 4280 Ib 3750 Ib 19-1/4 in 8-1/2 in 52 in B78-13B Length: 156-1/2 in (4 m) 530 Ib
(998 kg/axle) | {1941 kg} (1701 kg) (489 mm) (216 mm) | (1.32 m) Width: 61 in (1.54 m)* (240 kg)
4 West 2000 !b/axie 3000 Ib 2570 Ib 21-1/4 in gin 55-1/4 in B78-13 Length: 91 in (2311 mm)** 430 Ib
(907 kg/axle) | (1361 kg) (1166 kg) (540 mm) (203 mm) | (1.4 m) Width: 61-1/4 in (1556 mm) (1950 kg)
* Width at outside of fenders. ** Does not include tongue.
(J) mier. :
System Checklist and Quotation Sheet
Litho in USA
The Power of Blue.
Equipment and Factory Options Stock No. Description Qty. Price
Big 40%G #903 043 60 Hz
#903 043-01-32 | with Welders Package
#903 043-01-34 | with Welder's Package w/CV
#903 043-01-33 | with Deluxe Package
Weld Ammeter and Voltmeter #041 569 Field
Polarity/AC Selector Switch #042 421 Field
Remote Control Facilities #043 381 Field
CV-3 Constant Voltage Module #042 405 Field
Engine Gauge Kit #041 606 Field
Remate Oil Filter Kit #041 776 Fieid
Automatic Shutdown Kit #041 960 Field
Coolant System Heater #040 878 Field
Spark Arrestor (Muffier) Kit #041 953 Field
FA-1 Lockable Flame Arrestor Fuel Cap #041 056 Field
120 Volt GFCI Receptacle Kit #043 259 Factory
#043 097 Field
240 Volt Auxiliary Power Receptacle Kit #042 594 Field
CC-9 Canvas Cover #042 595
No. 4WA Stick Welding Accessory Kit #040 045
Remote Controls and Switches
RFCS-14 #043 554 Foot control
RHC-14 #129 340 Hand control
RMLS-14 #129 337 Momentary- and maintained-contact switch
RGC-14 #151 086 Fingertip control
Extension Cord #122 973 25 ft (7.6 m)
#122 974 50 ft (15.2 m)
#122 975 75 ft (22.9 m)
Trailers and Hitches
HWY-224 Trailer #043 805
QFR-224 Trailer #043 802
Lunette Eye 2-1/2 in (64 mm) #043 824 Far use with both 224 trailers
Clevis (not for highway use) #043 825 For use with both 224 trailers
HWY-430 Tandem Axle Trailer #043 806
| Ball Hitch 2 in (50 mm) #043 864 For use with the 430 trailer
Lunette Eye 3 in (76 mm) #043 863 For use with the 430 trailer
Clevis (not for highway use) #043 823 For use with the 430 trailer
_ Cable Tree #043 826 Works on al! 224 and 430 trailers
4 West Trailer : #043 801
Date: Total Quoted Price:
Distributed by:
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.
LIMITED WARRANTY - Subject to the terms and conditions
below, Miller Electric Mig. 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 Milier.
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
fatlure, 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. © Years Parts - 3 Years Labor
* Original main power rectifiers
* Inverters (input and output rectifiers only)
2, 3 Years — Parts and Labor
* 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.)
3. 1 Year — Parts and Labor
* Motor Driven Guns (w/exception of Spoolmate
* Process Controllers
* Positioners and Controllers
* Automatic Motion Devices
* Robots
* RFCS Foot Controls
* Induction Heating Power Sources
* Water Coolant Systems
* HF Units
* Grids
* Maxstar 140
* Spot Welders
* Load Banks
* SDX Transformers
* Miller Cyclomatic Equipment
* Running Gear/Trailers
* Plasma Cutting Torches (except APT, ZIPCUT &
* 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. 890 Days — Parts
* MIG Guns/TIG Torches
* Induction Heating Coils and Blankets
* APT, ZIPCUT & PLAZCUT Model Plasma Cutting
* Remote Controls
* Accessory Kits
* Replacement Parts (No labor)
* Spoolmate 185
Miller's True Blue® Limited Warranty shall not apply to:
1. Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer's warranty, if any.
2. Consumable components; such as contact tips, cutting
nozzles, contactors, brushes, slip rings, relays or parts
that fail due to normal wear.
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.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller's option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods
at customer's risk and expense. Miller's option of repair or
replacement will be F.O.B,, Factory at Appleton, Wisconsin, or
F.O.B. at a Milier authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed,
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 1/00
P= Owner's Record
Please complete and retain with your personal records.
Model Name Serial/Style Number
Purchase Date (Date which equipment was delivered to original customer.)
State Zip
esources Available
Always provide Model Name and Serial/Style Number.
Contact your Distributor for: Welding Supplies and Consumables
To locate a distributor or service agency Options and Accessories
near you, cali 1-800-4-A-Miller or visit our
website at Personal Safety Equipment
Service and Repair
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts
Circuit Diagrams
Welding Process Handbooks
Contact the Delivering Carrier for: File a claim for loss or damage during
For assistance in filing or settling claims,
contact your distributor and/or equipment
manufacturer's Transportation Department.
PRINTED IN USA © 2000 Miller Electric Mfg. Co. 1/00
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