Miller MILLER LEGEND 301 G Owner’s Manual

OM-4411
207 283C
September 2003
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
MIG (GMAW) Welding &
Flux Cored (FCAW) WeldingWith Voltage Sensing Feeder
Description
Engine Driven Welding Generator
Miller Legend 301 G
Visit our website at
www.MillerWelds.com
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it 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 figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard.
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 or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 7/03
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-7. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-8. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . .
2-6. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Dimensions, Weights, and Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Fuel Consumption While Welding And Using Generator Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Stick And MIG Mode Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. DC TIG Mode Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Activating The Dry Charge Battery (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Remote Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9. Adjusting Wire (MIG) Weld Puddle Consistency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − OPERATING WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Description Of Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Process Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Remote Amperage/Voltage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. 60 Hz Generator Power Receptacles And Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Variable Frequency (Hz) Generator Power Receptacle RC3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Wiring Optional 240 Volt Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
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4
5
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8
8
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10
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19
20
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23
24
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TABLE OF CONTENTS
SECTION 8 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Servicing Optional Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5. Changing Engine Oil, Oil Filter, And Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-7. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPTIONS AND ACCESSORIES
WARRANTY
28
28
29
29
30
31
32
33
36
38
45
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
rom _nd_10/02
Warning: Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
Marks a special safety message.
Means “Note”; not safety related.
1-2. Arc Welding Hazards
Use only 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 place.
Only qualified persons should install, operate, maintain, and repair this unit.
Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical.
During operation, keep everybody, especially children, away.
Insulate work clamp when not connected to workpiece to prevent contact
with any metal object.
Do not connect more than one electrode or work cable to any single weld
output terminal.
The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see the
symbol, watch out, and follow the related instructions to avoid the
hazard. The safety information given below is only a summary of
the more complete safety information found in the Safety Standards listed in Section 1-7. Read and follow all Safety Standards.
SIGNIFICANT DC VOLTAGE exists in inverters after stopping engine.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks or
severe burns. The electrode and work circuit is electrically
live whenever the output is on. The input power circuit and
machine internal circuits are also live when power is on. In semiautomatic or
automatic wire welding, the wire, wire reel, drive roll housing, and all metal
parts touching the welding wire are electrically live. Incorrectly installed or
improperly grounded equipment is a hazard.
Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats or covers
big enough to prevent any physical contact with the work or ground.
Do not use AC output in damp areas, if movement is confined, or if there is a
danger of falling.
Use AC output ONLY if required for the welding process.
If AC output is required, use remote output control if present on unit.
Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp locations or while wearing
wet clothing; on metal structures such as floors, gratings, or scaffolds;
when in cramped positions such as sitting, kneeling, or lying; or when there
is a high risk of unavoidable or accidental contact with the workpiece or
ground. For these conditions, use the following equipment in order presented: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most
situations, use of a DC, constant voltage wire welder is recommended.
And, do not work alone!
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing these fumes
and gases can be hazardous to your health.
Disconnect input power or stop engine before installing or servicing this
equipment. Lockout/tagout input power according to OSHA 29 CFR
1910.147 (see Safety Standards).
Properly install and ground this equipment according to its Owner’s Manual
and national, state, and local codes.
Always verify the supply ground — check and be sure that input power cord
ground wire is properly connected to ground terminal in disconnect box or
that cord plug is connected to a properly grounded receptacle outlet.
When making input connections, attach proper grounding conductor first −
double-check connections.
Frequently inspect input power cord for damage or bare wiring — replace
cord immediately if damaged — bare wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly with a separate cable.
Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine.
Stop engine on inverter and discharge input capacitors according to
instructions in Maintenance Section before touching any parts.
Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use exhaust at the arc to remove welding
fumes and gases.
If ventilation is poor, use an approved air-supplied respirator.
Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s
instructions for metals, consumables, coatings, cleaners, and degreasers.
Work in a confined space only if it is well ventilated, or while wearing an airsupplied respirator. Always have a trained watchperson nearby. Welding
fumes and gases can displace air and lower the oxygen level causing injury
or death. Be sure the breathing air is safe.
Do not weld in locations near degreasing, cleaning, or spraying operations.
The heat and rays of the arc can react with vapors to form highly toxic and
irritating gases.
Do not weld on coated metals, such as galvanized, lead, or cadmium plated
steel, unless the coating is removed from the weld area, the area is well
ventilated, and if necessary, while wearing an air-supplied respirator. The
coatings and any metals containing these elements can give off toxic fumes
if welded.
BUILDUP OF GAS can injure or kill.
Shut off shielding gas supply when not in use.
Always ventilate confined spaces or use approved
air-supplied respirator.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense visible
and invisible (ultraviolet and infrared) rays that can burn eyes
and skin. Sparks fly off from the weld.
Wear a welding helmet fitted with a proper shade of filter to protect your face
and eyes from arc rays and sparks when welding or watching (see ANSI
Z49.1 and Z87.1 listed in Safety Standards).
Wear approved safety glasses with side shields under your helmet.
Use protective screens or barriers to protect others from flash and glare;
warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant material (wool
and leather) and foot protection.
Return To Table Of Contents
OM-4411 Page 1
WELDING can cause fire or explosion.
HOT PARTS can cause severe burns.
Welding on closed containers, such as tanks, drums, or
pipes, can cause them to blow up. Sparks can fly off from the
welding arc. The flying sparks, hot workpiece, and hot
equipment can cause fires and burns. Accidental contact of electrode to metal
objects can cause sparks, explosion, overheating, or fire. Check and be sure
the area is safe before doing any welding.
NOISE can damage hearing.
Protect yourself and others from flying sparks and hot metal.
Do not weld where flying sparks can strike flammable material.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not
possible, tightly cover them with approved covers.
Be alert that welding sparks and hot materials from welding can easily go
through small cracks and openings to adjacent areas.
Watch for fire, and keep a fire extinguisher nearby.
Be aware that welding on a ceiling, floor, bulkhead, or partition can cause
fire on the hidden side.
Do not weld on closed containers such as tanks, drums, or pipes, unless
they are properly prepared according to AWS F4.1 (see Safety Standards).
Connect work cable to the work as close to the welding area as practical to
prevent welding current from traveling long, possibly unknown paths and
causing electric shock and fire hazards.
Do not use welder to thaw frozen pipes.
Remove stick electrode from holder or cut off welding wire at contact tip
when not in use.
Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.
Remove any combustibles, such as a butane lighter or matches, from your
person before doing any welding.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot
work and have a fire watcher and extinguisher nearby.
Noise from some processes or equipment can damage
hearing.
Wear approved ear protection if noise level is high.
MAGNETIC FIELDS can affect pacemakers.
FLYING METAL can injure eyes.
Allow cooling period before maintaining.
Wear protective gloves and clothing when working on
a hot engine.
Do not touch hot engine parts or just-welded parts
bare-handed.
Welding, chipping, wire brushing, and grinding cause
sparks and flying metal. As welds cool, they can
throw off slag.
Wear approved safety glasses with side shields even
under your welding helmet.
Pacemaker wearers keep away.
Wearers should consult their doctor before going
near arc welding, gouging, or spot welding operations.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high pressure. If
damaged, a cylinder can explode. Since gas cylinders are
normally part of the welding process, be sure to treat them
carefully.
Protect compressed gas cylinders from excessive heat, mechanical
shocks, slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary support or
cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder — explosion will result.
Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in
good condition.
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is in use or
connected for use.
Read and follow instructions on compressed gas cylinders, associated
equipment, and CGA publication P-1 listed in Safety Standards.
1-3. Engine Hazards
MOVING PARTS can cause injury.
BATTERY EXPLOSION can BLIND.
Always wear a face shield, rubber gloves, and protective clothing when working on a battery.
Stop engine before disconnecting or connecting battery cables or servicing battery.
Do not allow tools to cause sparks when working on a battery.
Do not use welder to charge batteries or jump start vehicles.
Observe correct polarity (+ and −) on batteries.
Disconnect negative (−) cable first and connect it last.
FUEL can cause fire or explosion.
Stop engine and let it cool off before checking or adding fuel.
Do not add fuel while smoking or if unit is near any
sparks or open flames.
Do not overfill tank — allow room for fuel to expand.
Do not spill fuel. If fuel is spilled, clean up before starting engine.
Dispose of rags in a fireproof container.
Always keep nozzle in contact with tank when fueling.
OM-4411 Page 2
Keep away from fans, belts, and rotors.
Keep all doors, panels, covers, and guards closed
and securely in place.
Stop engine before installing or connecting unit.
Have only qualified people remove guards or covers for maintenance
and troubleshooting as necessary.
To prevent accidental starting during servicing, disconnect negative (−)
battery cable from battery.
Keep hands, hair, loose clothing, and tools away from moving parts.
Reinstall panels or guards and close doors when servicing is finished
and before starting engine.
Before working on generator, remove spark plugs or injectors to keep
engine from kicking back or starting.
Block flywheel so that it will not turn while working on generator components.
Return To Table Of Contents
STEAM AND HOT COOLANT can burn.
If possible, check coolant level when engine is cold to
avoid scalding.
Always check coolant level at overflow tank, if present on unit, instead of radiator (unless told otherwise
in maintenance section or engine manual).
If the engine is warm, checking is needed, and there is no overflow tank,
follow the next two statements.
Wear safety glasses and gloves and put a rag over radiator cap.
Turn cap slightly and let pressure escape slowly before completely removing cap.
ENGINE EXHAUST GASES can kill.
Use equipment outside in open, well-ventilated areas.
If used in a closed area, vent engine exhaust outside
and away from any building air intakes.
BATTERY ACID can BURN SKIN and EYES.
Do not tip battery.
Replace damaged battery.
Flush eyes and skin immediately with water.
ENGINE HEAT can cause fire.
Do not locate unit on, over, or near combustible
surfaces or flammables.
Keep exhaust and exhaust pipes way from flammables.
EXHAUST SPARKS can cause fire.
Do not let engine exhaust sparks cause fire.
Use approved engine exhaust spark arrestor in required areas — see applicable codes.
1-4. Compressed Air Hazards
BREATHING COMPRESSED AIR can
cause serious injury or death.
Do not use compressed air for breathing.
Use only for cutting, gouging, and tools.
COMPRESSED AIR can cause injury.
Wear approved safety goggles.
Do not direct air stream toward self or others.
TRAPPED AIR PRESSURE AND WHIPPING
HOSES can cause injury.
HOT METAL from air arc cutting and
gouging can cause fire or explosion.
Release air pressure from tools and system before
servicing, adding or changing attachments, or opening compressor oil drain or oil fill cap.
Do not cut or gouge near flammables.
Watch for fire; keep extinguisher nearby.
HOT PARTS can cause burns and injury.
Do not touch hot compressor or air system parts.
Let system cool down before touching or servicing.
READ INSTRUCTIONS.
Read Owner’s Manual before using or servicing unit.
Stop engine and release air pressure before
servicing.
1-5. Additional Symbols For Installation, Operation, And Maintenance
FALLING UNIT can cause injury.
Use lifting eye to lift unit only, NOT running gear, gas
cylinders, trailer, or any other accessories.
Use equipment of adequate capacity to lift and
support unit.
If using lift forks to move unit, be sure forks are long
enough to extend beyond opposite side of unit.
OVERHEATING can damage motors.
Turn off or unplug equipment before starting or stopping engine.
Do not let low voltage and frequency caused by low
engine speed damage electric motors.
OVERUSE can cause OVERHEATING.
Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before starting
to weld again.
Do not block or filter airflow to unit.
STATIC (ESD) can damage PC boards.
Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where
applicable.
Put on grounded wrist strap BEFORE handling
boards or parts.
Use proper static-proof bags and boxes to store,
move, or ship PC boards.
FLYING SPARKS can cause injury.
TILTING OF TRAILER can cause injury.
Wear a face shield to protect eyes and face.
Shape tungsten electrode only on grinder with proper
guards in a safe location wearing proper face, hand,
and body protection.
Use tongue jack or blocks to support weight.
Properly install welding generator onto trailer according to instructions supplied with trailer.
Sparks can cause fires — keep flammables away.
Return To Table Of Contents
OM-4411 Page 3
READ INSTRUCTIONS.
ARC WELDING can cause interference.
Use only genuine MILLER/Hobart replacement
parts.
Perform engine and air compressor (if applicable)
maintenance and service according to this manual
and the engine/air compressor (if applicable) manuals.
To reduce possible interference, keep weld cables as short as possible,
close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic
equipment.
Be sure this welding machine is installed and grounded according to this
manual.
If interference still occurs, the user must take extra measures such as
moving the welding machine, using shielded cables, using line filters, or
shielding the work area.
H.F. RADIATION can cause interference.
High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment.
Have only qualified persons familiar with electronic
equipment perform this installation.
The user is responsible for having a qualified electrician
promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the equipment at
once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep spark
gaps at correct setting, and use grounding and shielding to minimize the
possibility of interference.
Electromagnetic energy can interfere with sensitive
electronic equipment such as microprocessors,
computers, and computer-driven equipment such as
robots.
Be sure all equipment in the welding area is electromagnetically compatible.
1-6. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases which
contain chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)
For Gasoline Engines:
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
For Diesel Engines:
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
1-7. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(phone: 305-443-9353, website: www.aws.org).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard
AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (phone: 305-443-9353, website: www.aws.org).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269-9101 (phone: 617-770-3000, website: www.nfpa.org and www.
sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202-4102 (phone: 703-412-0900, website:
www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale Bou-
levard, Rexdale, Ontario, Canada M9W 1R3 (phone: 800-463-6727 or
in Toronto 416-747-4044, website: www.csa-international.org).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036–8002 (phone: 212-642-4900,
website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (phone:
617-770-3000, website: www.nfpa.org and www. sparky.org).
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Offices—phone for Region 5, Chicago, is
312-353-2220, website: www.osha.gov).
1-8. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
OM-4411 Page 4
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables 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
possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
Return To Table Of Contents
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
rom_fre 8/03
Avertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions.
2-1. Signification des symboles
Signifie Mise en garde ! Soyez vigilant ! Cette procédure
présente des risques de danger ! Ceux-ci sont identifiés par
des symboles adjacents aux directives.
Identifie un message de sécurité particulier.
Signifie NOTA ; n’est pas relatif à la sécurité.
Ce groupe de symboles signifie Mise en garde !
Soyez vigilant ! Il y a des
risques de danger reliés
aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux
PIÈCES CHAUDES. Reportez-vous aux symboles et aux directives ci-dessous afin de connaître les mesures à prendre pour éviter tout danger.
2-2. Dangers relatifs au soudage à l’arc
Les symboles présentés ci-après sont utilisés tout au long 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’éviter tout
danger. Les consignes de sécurité présentées ci-après ne font
que résumer l’information contenue dans les normes de sécurité énumérées à la section 2-6 . Veuillez lire et respecter toutes
ces normes de sécurité.
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.
En effectuant les raccordements d’entrée fixer d’abord le conducteur de
mise à la terre approprié et contre-vérifier les connexions.
Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas endommagé ou dénudé − remplacer le cordon immédiatement s’il est
endommagé − un câble dénudé peut provoquer une électrocution.
Mettre l’appareil hors tension quand on ne l’utilise pas.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou
mal épissés.
Ne pas enrouler les câbles autour du corps.
Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct − ne pas utiliser le connecteur de pièce ou le câble de retour.
Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou
une électrode provenant d’une autre machine.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-champ
les pièces endommagées. Entretenir l’appareil conformément à ce
manuel.
Porter un harnais de sécurité quand on travaille en hauteur.
Maintenir solidement en place tous les panneaux et capots.
Fixer le câble de retour de façon à obtenir un bon contact métal-métal avec
la pièce à souder ou la table de travail, le plus près possible de la soudure.
Isoler la pince de masse quand pas mis à la pièce pour éviter le contact
avec tout objet métallique.
UN CHOC ÉLECTRIQUE peut tuer.
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 les circuits
internes de l’appareil sont également sous tension à ce
moment-là. En soudage semi-automatique ou automatique, le fil, le dévidoir, le
logement des galets d’entraînement et les pièces métalliques en contact avec
le fil de soudage sont sous tension. Des matériels mal installés ou mal mis à la
terre présentent un danger.
Une tension DC importante subsiste à l’intérieur
des onduleurs après avoir coupé l’alimentation.
Ne jamais toucher les pièces électriques sous tension.
Porter des gants et des vêtements de protection secs ne comportant pas
de trous.
S’isoler de la pièce et de la terre au moyen de tapis ou d’autres moyens isolants suffisamment grands pour empêcher le contact physique éventuel
avec la pièce ou la terre.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Ne pas se servir de source électrique àcourant électrique dans les zones
humides, dans les endroits confinés ou là où on risque de tomber.
Le soudage génère des fumées et des gaz. Leur inhalation
peut être dangereux pour votre santé.
Se servir d’une source électrique àcourant électrique UNIQUEMENT si le
procédé de soudage le demande.
Eloigner votre tête des fumées. Ne pas respirer les fumées.
Si l’utilisation d’une source électrique àcourant électrique s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé.
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.
Des précautions de sécurité supplémentaires sont requises dans des envi-
Si la ventilation est insuffisante, utiliser un respirateur à alimentation d’air
homologué.
Lire les spécifications de sécurité des matériaux (MSDSs) et les instructions du fabricant concernant les métaux, les consommables, les
revêtements, les nettoyants et les dégraisseurs.
Travailler dans un espace fermé seulement s’il est bien ventilé ou en portant un respirateur à alimentation d’air. Demander toujours à un surveillant
dûment formé de se tenir à proximité. Des fumées et des gaz de soudage
peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des
blessures ou des accidents mortels. S’assurer que l’air de respiration ne
présente aucun danger.
Ne pas souder dans des endroits situés à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de
l’arc peuvent réagir en présence de vapeurs et former des gaz hautement
toxiques et irritants.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier galvanisé, 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 nécessaire, 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.
ronnements à risque comme: les endroits humides ou lorsque l’on porte
des vêtements mouillés; sur des structures métalliques au sol, grillages et
échafaudages; dans des positions assises, à genoux et allongées; ou
quand il y a un risque important de contact accidentel avec la pièce ou le
sol. Dans ces cas utiliser les appareils suivants dans l’ordre de préférence:
1) un poste à souder DC semi−automatique de type CV (MIG/MAG), 2) un
poste à souder manuel (électrode enrobée) DC, 3) un poste à souder manuel AC avec tension à vide réduite. Dans la plupart des cas, un poste
courant continu de type CV est recommandé. Et, ne pas travailler seul!
Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation,
à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation
selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).
Installer et mettre à la terre correctement cet appareil conformément à son
manuel d’utilisation et aux codes nationaux, provinciaux et municipaux.
Toujours vérifier la terre du cordon d’alimentation − Vérifier et s’assurer que
le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre
du sectionneur ou que la fiche du cordon est raccordée à une prise
correctement mise à la terre.
Couper l’alimentation du poste et décharger les condensateurs d’entrée
comme indiqué dans la Section Maintenance avant de toucher des composants.
Revenez à la table des matières
OM-4411 Page 5
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou
même la mort.
Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et NFPA 51B
pour les travaux à chaud et avoir de la surveillance et un extincteur à proximité.
DES PARTICULES VOLANTES
peuvent blesser les yeux.
Fermer l’alimentation du gaz protecteur en cas de
non utilisation.
Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué.
LES RAYONS DE L’ARC peuvent provoquer des brûlures dans les yeux et
sur la peau.
Le soudage, l’écaillement, le passage de la pièce
à la brosse en fil de fer, et le meulage génèrent
des étincelles et des particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier.
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
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 le soudage.
Porter un casque de soudage muni d’un écran de filtre approprié pour protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir
ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
Porter des protections approuvés pour les oreilles si le niveau sondre est
trop élevé.
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.
Porter des vêtements de protection constitué dans une matière durable, résistant au feu (laine ou cuir) et une protection des pieds.
Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.
Prévoir une période de refroidissement avant d’effectuer des travaux d’entretien.
Porter des gants et des vêtements de protection pour
travailler sur un moteur chaud.
Ne pas toucher à mains nues les parties chaudes du moteur ni les pièces
récemment soudées.
LE BRUIT peut affecter l’ouïe.
Le bruit des processus et des équipements peut affecter
l’ouïe.
LE SOUDAGE peut provoquer un incendie ou une explosion.
Porter des protections approuvés pour les oreilles si
le niveau sondre est trop élevé.
Le soudage effectué sur des conteneurs fermés tels que
des réservoirs, tambours ou des conduites peut provoquer
leur éclatement. Des étincelles 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 ou un incendie. Avant de
commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de
danger.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
Se protéger et d’autres personnes de la projection d’étincelles et de métal
chaud.
Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des
substances inflammables.
Si des BOUTEILLES sont endommagées, elles pourront exploser.
Déplacer toutes les substances inflammables à une distance de 10,7 m de
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
ouvertures.
Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.
Le soudage effectué sur un plafond, plancher, paroi ou séparation peut déclencher un incendie de l’autre côté.
Ne pas effectuer le soudage sur des conteneurs fermés tels que des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été préparés
correctement conformément à AWS F4.1 (voir les normes de sécurité).
Brancher le câble sur la pièce le plus près possible de la zone de soudage
pour éviter le transport du courant sur une longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution et
d’incendie.
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 ou des allumettes.
Porteurs de stimulateur cardiaque, restez à distance.
Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur 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 manipuler avec
précaution.
Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des
chocs mécaniques, du laitier, des flammes ouvertes, des étincelles et des
arcs.
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 les bouteilles éloignées des circuits de soudage ou autres circuits
électriques.
Ne jamais placer une torche de soudage sur une bouteille à gaz.
Une électrode de soudage ne doit jamais entrer en contact avec une bouteille.
Ne jamais souder une bouteille pressurisée − risque d’explosion.
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.
Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la bouteille.
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 énumérées dans les
normes de sécurité.
2-3. Dangers existant en relation avec le moteur
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou
même la mort.
Fermer l’alimentation du gaz protecteur en cas de
non utilisation.
Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué.
OM-4411 Page 6
Revenez à la table des matières
L’ACIDE DE LA BATTERIE peut provoquer des brûlures dans les YEUX et
sur la PEAU.
Ne pas renverser la batterie.
Remplacer une batterie endommagée.
Rincer immédiatement les yeux et la peau à l’eau.
L’EXPLOSION DE LA BATTERIE peut
RENDRE AVEUGLE.
Toujours porter une protection faciale, des gants en
caoutchouc et vêtements de protection lors d’une intervention sur la batterie.
Arrêter le moteur avant de débrancher ou de brancher les câbles de
batterie.
Eviter de provoquer des étincelles avec les outils en travaillant sur la
batterie.
Ne pas utiliser le poste de soudage pour charger les batteries ou des véhicules de démarrage rapide.
Observer la polarité correcte (+ et −) sur les batteries.
Débrancher le câble négatif (–) en premier lieu. Le rebrancher en dernier
lieu.
LE CARBURANT MOTEUR peut provoquer un incendie ou une explosion.
Arrêter le moteur avant de vérifier le niveau de carburant ou de faire le plein.
Ne pas faire le plein en fumant ou proche d’une source d’étincelles ou d’une flamme nue.
Ne pas faire le plein de carburant à ras bord; prévoir de l’espace pour son
expansion.
Faire attention de ne pas renverser de carburant. Nettoyer tout carburant renversé avant de faire démarrer le moteur.
Jeter les chiffons dans un récipient ignifuge.
Pour empêcher tout démarrage accidentel pendant les travaux d’entretien,
débrancher le câble négatif (−) de batterie de la borne.
Ne pas approcher les mains, cheveux, vêtements lâches et outils des organes mobiles.
Remettre en place les panneaux ou les dipositifs de protection et fermer les
portes à la fin des travaux d’entretien et avant de faire démarrer le moteur.
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.
LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT CHAUD peuvent
provoquer des brûlures.
Toujours vérifier le niveau de liquide de refroidissement dans le vase d’expansion (si présent), et non dans le radiateur (sauf si précisé autrement
dans la section maintenance du manuel du moteur).
Si le moteur est chaud et que le liquide doit être vérifié, opérer comme suivant :
Mettre des lunettes de sécurité et des gants, placer un torchon sur le bouchon du radiateur.
Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant
d’enlever le bouchon.
LA CHALEUR DU MOTEUR peut provoquer un incendie.
DES ORGANES MOBILES peuvent
provoquer des blessures.
Ne pas approcher les mains des ventilateurs, courroies et autres pièces en mouvement.
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’enlever les dispositifs de
sécurité ou les recouvrements pour effectuer, s’il y a lieu, des travaux d’entretien et de dépannage.
Ne pas placer l’appareil sur, au-dessus ou à proximité
de surfaces inflammables.
Tenir à distance les produits inflammables de
l’échappement.
LES ÉTINCELLES À L’ÉCHAPPEMENT
peuvent provoquer un incendie.
Il est préférable de vérifier le liquide de
refroidissement une fois le moteur refroidi pour éviter
de se brûler.
Empêcher les étincelles d’échappement du moteur
de provoquer un incendie.
Utiliser uniquement un pare-étincelles approuvé −
voir codes en vigueur.
2-4. Dangers liés à l’air comprimé
RESPIRER L’AIR COMPRIMÉ peut provoquer des blessures graves ou causer
la mort.
Le METAL CHAUD lors du coupage et
gougeage plasma peut provoquer un incendie ou une explosion.
Ne pas utiliser l’air comprimé pour respirer.
Utiliser l’air comprimé seulement pour le coupage, gougeage et les outils pneumatiques.
Ne pas couper ou gouger à proximité de produits
inflammables.
Surveillez et garder un extincteur à proximité.
L’AIR COMPRIMÉ peut provoquer
des blessures.
DES PIECES CHAUDES peuvent provoquer des brûlures et blessures.
Porter des lunettes de sécurité approuvées.
Ne pas diriger le jet d’air vers d’autres ou soi−
même.
Ne pas toucher le compresseur ou d’autres éléments du circuit air comprimé chauds.
Laisser l’ensemble se refroidir avant de toucher
ou d’effectuer la maintenance.
L’AIR COMPRIME EMMAGASINE ET DES
TUYAUX SOUS PRESSION peuvent provoquer des blessures.
LIRE LES INSTRUCTIONS.
Relâcher la pression d’air de l’outillage ou du système avant d’effectuer la maintenance, avant de
changer ou de rajouter des éléments ou avant
d’ouvrir la purge ou le bouchon de remplissage
d’huile.
Lisez le manuel d’instructions avant l’utilisation
ou la maintenance de l’appareil.
Arrêter le moteur et relâcher la pression avant
d’effectuer la maintenance.
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la
maintenance
LA CHUTE DE L’APPAREIL peut
blesser.
Utiliser l’anneau de levage uniquement pour soulever
l’appareil lui-même ; sans chariot, de bouteilles de
gaz, remorque, ou autres accessoires.
Utiliser un équipement de levage de capacité suffisante pour lever
l’appareil.
En utilisant des fourches de levage pour déplacer l’unité, s’assurer
que les fourches sont suffisamment longues pour dépasser du côté
opposé de l’appareil.
Revenez à la table des matières
OM-4411 Page 7
LE SURCHAUFFEMENT peut endommager le moteur électrique.
LIRE LES INSTRUCTIONS.
Arrêter ou déconnecter l’équipement avant de démarrer ou d’arrêter le moteur.
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.
Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz, s’il y a
lieu.
LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer
des interférences.
LES ÉTINCELLES VOLANTES risquent de provoquer des blessures.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
Établir la connexion avec la barrette de terre avant de
manipuler des cartes ou des pièces.
Utiliser des pochettes et des boîtes antistatiques
pour stocker, déplacer ou expédier des cartes de
circuits imprimes.
UNE REMORQUE QUI BASCULE peut
entraîner des blessures.
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.
Demander seulement à des personnes qualifiées familiarisées avec des
équipements électroniques de faire fonctionner l’installation.
L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié 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.
Maintenir soigneusement fermés les portes et les panneaux des sources
de haute fréquence, maintenir les éclateurs à une distance correcte et
utiliser une terre et et un blindage pour réduire les interférences
éventuelles.
Laisser l’équipement refroidir ; respecter le facteur de
marche nominal.
Réduire le courant ou le facteur de marche avant de
poursuivre le soudage.
Ne pas obstruer les passages d’air du poste.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les
circuits imprimés.
Porter un écran facial pour protéger le visage et les
yeux.
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
inflammable.
Utiliser les supports de la remorque ou des blocs
pour soutenir le poids.
Installer convenablement le poste sur la remorque
comme indiqué dans le manuel s’y rapportant.
Utiliser seulement les pièces de rechange d’origine.
Effectuer la maintenance du moteur et du compresseur (si applicable) suivant ce manuel et le manuel du
moteur/compresseur (si applicable).
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
L’énergie électromagnétique risque de provoquer
des interférences pour l’équipement électronique
sensible tel que les ordinateurs et l’équipement commandé par ordinateur tel que les robots.
Veiller à ce que tout l’équipement de la zone de soudage soit compatible
électromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de soudage aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que
le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.
2-6. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, de
l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (téléphone : (305) 443−9353, site Web : www.aws.org).
Recommended Safe Practices for the Preparation for Welding and Cutting
of Containers and Piping, norme American Welding Society AWS F4.1, de
l’American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (téléphone : (305) 443−9353, site Web : www.aws.org).
National Electrical Code, norme NFPA 70, de la National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101
(téléphone : (617) 770−3000, sites Web : www.nfpa.org et www.sparky.org).
Safe Handling of Compressed Gases in Cylinders, brochure CGA P−1, de
la Compressed Gas Association, 1735 Jefferson Davis Highway, Suite
1004, Arlington, VA 22202−4102 (téléphone : (703) 412−0900, site Web :
www.cganet.com).
Code for Safety in Welding and Cutting, norme CSA W117.2, de la Canadian Standards Association, Standards Sales, 178 boulevard Rexdale,
Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) 463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−international.org).
Practice For Occupational And Educational Eye And Face Protection,
norme ANSI Z87.1, de l’American National Standards Institute, 11 West
42nd Street, New York, NY 10036−8002 (téléphone : (212) 642−4900, site
Web : www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot Work,
norme NFPA 51B, de la National Fire Protection Association, P.O. Box
9101, 1 Battery March Park, Quincy, MA 02269−9101 (téléphone : (617)
770−3000, site Web : www.nfpa.org et www.sparky.org).
OSHA, Occupational Safety and Health Standards for General Industry,
Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and
Part 1926, Subpart J, de l’U.S. Government Printing Office, Superintendent
of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10 bureaux
régionaux − Téléphone pour la Région 5, Chicago : (312) 353−2220, site
Web : www.osha.gov).
2-7. Information sur les champs électromagnétiques
Données sur le soudage électrique et les effets des champs magnétiques
basse fréquence sur l’organisme
En parcourant les câbles de soudage, le courant crée des champs électromagnétiques. Les effets potentiels de tels champs restent préoccupants.
Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de recherche de 17 ans, un comité de spécialistes du
National Research Council a conclu : « L’accumulation de preuves n’a pas
démontré que l’exposition aux champs magnétiques et aux champs électriques à haute fréquence constitue un risque pour la santé humaine ».
Toutefois, les études et l’examen des preuves se poursuivent. En attendant
les conclusions finales de la recherche, il serait souhaitable de réduire l’exposition aux champs électromagnétiques pendant le soudage ou le
coupage.
OM-4411 Page 8
Afin de réduire les champs électromagnétiques en milieu de travail, respecter les consignes suivantes :
1. Garder les câbles ensemble en les torsadant ou en les fixant avec du
ruban adhésif.
2. Mettre tous les câbles du côté opposé à l’opérateur.
3. Ne pas s’enrouler les câbles autour du corps.
4. Garder le poste de soudage et les câbles le plus loin possible de soi.
5. Placer la pince de masse le plus près possible de la zone de soudage.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur médecin. Si ce dernier les déclare aptes, il leur est recommandé de respecter les consignes ci-dessus.
Revenez à la table des matières
SECTION 3 − DEFINITIONS
3-1. Symbol Definitions
Stop Engine
Fast
(Run, Weld/Power)
Fast/Slow
(Run/Idle)
Slow (Idle)
Start Engine
Panel/Local
Temperature
Fuel
Engine Oil
Engine Choke
Check Valve
Clearance
Battery (Engine)
Engine
Read Operator’s
Manual
MIG (GMAW),
Wire
Stick (SMAW)
TIG (GTAW)
Circuit Breaker
Positive
Negative
Alternating Current
(AC)
Output
Time
Hours
Seconds
Protective Earth
(Ground)
h
A
s
V
Amperes
Volts
Do not switch while
welding
Remote
Receptacle
Work Connection
CC
Constant
Current
Wire Feed
Electrode
Positive
Electrode Negative
CV
Constant
Voltage
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
Return To Table Of Contents
OM-4411 Page 9
SECTION 4 − SPECIFICATIONS
4-1. Description
This multiprocess engine-driven welder and AC generator provides low speed generator AC power and DC weld output for quiet, fuel-efficient operation. At 1800 rpm, this unit produces 5 kW/kVA 60 Hz 120/240 Volt AC generator
power. Achieve high quality Stick and TIG welding results at either 3000 or 3600 rpm. A special variable frequency
(60-120 Hz) receptacle provides 2.4 kW/kVA 120 Volt AC generator power continuously.
4-2. Weld, Power, And Engine Specifications
Rated
Welding
Output
Welding
Mode
CC/DC
Maximum
Open-Circuit
Voltage
280 A, 25 V, 100%
Duty Cycle
Amperage
Range In
CC Mode
72
Voltage
Range In
CV Mode
20 − 300 A
10 − 33 V
Generator
Power Rating
5.5 kVA/kW (Peak)
5 kVA/kW (Continuous)
42/21 A,
120/240 V AC,
60 Hz,
Single-Phase at
1800 rpm
And
CV/DC
300 A, 25 V, 100%
Duty Cycle
50
2.4 kVA/kW, 20 A,
120 V AC,
60-120 Hz,
Single-Phase
At All Speeds
−−
Fuel
Capacity
Engine
10 gal
(38 L)
Tank
Kohler CH-20
Air-Cooled,
Two-Cylinder,
Four-Cycle,
20 HP Gasoline/LP
Engine
w/Electronic
Governor
4-3. Dimensions, Weights, and Operating Angles
Dimensions
Height
33 in (838 mm)
Width
18-3/4 in (476 mm)
Depth
45-1/2 in (1156 mm)
A
18 in (457 mm)
B
16-1/2 in (419 mm)
C
3/4 in (19 mm)
D
3-1/8 in (79 mm)
E
32-3/4 in (832 mm)
F
45-1/2 in (1156 mm)
G
13/32 in (10 mm) Dia.
A
B
C
Do not exceed tilt angles or engine could
be damaged or unit could tip.
D
G
4 Holes
Do not move or operate unit where it could
tip.
E
F
25°
25°
25°
25°
Engine End
Weight
590 lb (267 kg)
OM-4411 Page 10
800 426
Return To Table Of Contents
803 129
LITERS/HR.
U.S. GAL./HR.
4-4. Fuel Consumption While Welding And Using Generator Power
7.57
2.00
6.62
1.75
5.67
1.50
4.73
1.25
3.78
1.00
2.84
0.75
1.98
0.50
0.95
0.25
0.00
0.00
3600 RPM Weld
3000 RPM Weld
Idle (At 1800 RPM)
Generator
at 2 kW
Generator
at 1 kW
0
100
Generator
at 3 kW
150
200
Generator
at 5 kW
Generator
at 4 kW
250
300
DC WELD AMPERES AT 100% DUTY CYCLE
207 967
4-5. Generator Power Curve
The ac generator power curve
shows the generator power available in amperes at the receptacles.
300
250
AC VOLTS
200
150
100
50
0
0
5
10
15
20
25
30
AC AMPERES
207 969
Return To Table Of Contents
OM-4411 Page 11
4-6. Duty Cycle
Duty cycle is the percentage of 10
minutes that unit can weld at rated
load without overheating.
100% Duty Cycle at 280 Amperes DC/CC
Exceeding duty cycle can
damage unit and void
warranty.
Continuous Welding
325
DC/CV
300
275
DC/CC
WELD AMPERES
250
225
200
175
150
0
10
20
30
40
50
60
70
% DUTY CYCLE
80
90
100
Ref. 207 925
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-4411 Page 12
Return To Table Of Contents
4-7. Stick And MIG Mode Volt-Ampere Curves
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of
other settings fall between the
curves shown.
A. CC/DC Stick Mode
90
80
DC VOLTS
70
60
50
3000 RPM
3600 RPM
40
30
20
10
0
0
50
100
150
200
250
300
350
400
450
DC AMPERES
B. CV/DC MIG Mode
50
45
40
3600 RPM
DC VOLTS
35
30
3000 RPM
25
20
15
10
5
0
0
100
200
300
400
500
600
DC AMPERES
207 970 / 207 971
Return To Table Of Contents
OM-4411 Page 13
4-8. DC TIG Mode Volt-Ampere Curves
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of
other settings fall between the
curves shown.
50
45
DC VOLTS
40
35
30
25
20
15
10
5
0
0
50
100
150
200
250
DC AMPERES
300
350
204 930
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-4411 Page 14
Return To Table Of Contents
SECTION 5 − INSTALLATION
5-1. Installing Welding Generator
Do not weld on base. Welding
on base can cause fuel tank fire
or explosion. Bolt unit down
using holes provided in base.
Movement
Always securely fasten welding generator onto transport
vehicle or trailer and comply
with all DOT and other applicable codes.
Do not lift unit from end.
OR
Do not mount unit by supporting the base only at the four
mounting holes. Use crosssupports to adequately support unit and prevent damage
to base.
Location
Always ground generator
frame to vehicle frame to prevent electric shock and static
electricity hazards.
OR
If unit does not have GFCI receptacles, use GFCI-protected
extension cord.
OR
Mounting:
1
Mounting
Cross-Supports
Mount unit on flat surface or use
cross-supports to support base.
Grounding:
2
3
4
Equipment Grounding Terminal
(On Front Panel)
Grounding Cable (Not Supplied)
Metal Vehicle Frame
Connect cable from equipment
ground terminal to metal vehicle
frame. Use #10 AWG or larger insulated copper wire.
OR
Inadequate support.
Do not use flexible mounts.
1
2
Grounding
3
GND/PE
Electrically bond generator frame to
vehicle frame by metal-to-metal contact.
4
Airflow Clearance
Bed liners, shipping skids, and some running
gears insulate the welding generator from the
vehicle frame. Always connect a ground wire
from the generator equipment grounding terminal to bare metal on the vehicle frame as shown.
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
install2 5/03 − Ref. 800 652 / Ref. 800 477-A / 803 274
Return To Table Of Contents
OM-4411 Page 15
5-2. Engine Prestart Checks
Check all fluids daily. Engine must be
cold and on a level surface. Unit is
shipped with 10W30 engine oil.
Follow run-in procedure in engine
manual.
This unit has a low oil pressure
shutdown switch. However, some
conditions may cause engine
damage before the engine shuts
down. Check oil level often and do
not use the oil pressure shutdown
system to monitor oil level.
Fuel
Add fresh fuel before starting engine
the first time (see maintenance label for
specifications). Always leave filler
neck empty to allow room for expansion. Check fuel level on a cold engine
before use each day.
Oil
Check oil with unit on level surface. If
oil is not up to full mark on dipstick, add
oil (see maintenance label).
To improve cold weather starting:
Keep battery in good condition.
Store battery in warm area.
Use correct grade oil for cold
weather.
Full
Full
Gasoline
803 129
OM-4411 Page 16
Return To Table Of Contents
5-3. Activating The Dry Charge Battery (If Applicable)
Remove battery from unit.
1
5
4
1
2
3
4
5
Eye Protection − Safety
Glasses Or Face Shield
Rubber Gloves
Vent Caps
Sulfuric Acid Electrolyte
(1.265 Specific Gravity)
Well
Fill each cell with electrolyte to
bottom of well (maximum).
3
Do not overfill battery cells.
Wait ten minutes and check electrolyte level. If necessary, add electrolyte to raise to proper level. Reinstall vent caps.
6
Battery Charger
Read and follow all instructions supplied with battery
charger.
2
Charge battery for 12 minutes at 30
amperes or 30 minutes at 5 amperes. Disconnect charging cables
and install battery.
When electrolyte
is low, add
only distilled water to cells to
maintain proper level.
6
5 A For 30 Minutes
Tools Needed:
OR
+
−
rubbergloves
30 A For 12 Minutes
glasses
drybatt1 1/98 − S-0886
Return To Table Of Contents
OM-4411 Page 17
5-4. Connecting The Battery
Connect negative (−)
cable last.
+
−
Tools Needed:
3/8, 1/2 in
Ref. 800 394-C / Ref. 211 909 / Ref. S-0756-D
5-5. Installing Exhaust Pipe
Stop engine and let cool.
Engine backfire can cause severe burns or other injuries.
Do not point exhaust pipe toward control panel. Keep away
from exhaust outlet.
Point exhaust pipe in desired di-
rection but always away from
front panel and direction of travel.
Tools Needed:
1/2 in
OM-4411 Page 18
801 681 / Ref. 211 909
Return To Table Of Contents
5-6. Connecting To Weld Output Terminals
Stop engine.
Do not connect to CC and CV
terminals at the same time.
1
2
3
Negative (−) Weld Output
Terminal
Stick/TIG (CC) Weld Output
Terminal
Wire /CV Weld Output Terminal
For MIG welding, connect work cable
to Negative (−) terminal and wire
feeder cable to Wire (CV) terminal.
For Stick/TIG welding, connect work
cable to Negative (−) terminal and
electrode holder cable to Stick/TIG
(CC) terminal.
1
2
3
803 128 / Ref. 211 909
5-7. Selecting Weld Cable Sizes*
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
100 ft (30 m) or Less
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
400 ft
(105 m) (120 m)
Weld Output
Terminals
Stop engine before
connecting to weld output terminals.
Welding
Amperes
10 − 60%
Duty
Cycle
60 − 100%
Duty
Cycle
100
4 (20)
4 (20)
4 (20)
3 (30)
2 (35)
1 (50)
1/0 (60)
1/0 (60)
150
3 (30)
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
200
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
4/0 (120)
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 2/0
(2x70)
300
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
350
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
400
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
2 ea. 4/0
(2x120)
Do not use worn, damaged, undersized, or
poorly spliced cables.
10 − 100% Duty Cycle
* This
chart is a general guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), use next size larger
cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
S-0007-E
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.
Return To Table Of Contents
OM-4411 Page 19
5-8. Remote Receptacle Information
NOTE
Engine runs at weld speed (3000 or 3600 rpm) whenever a device connected to
the remote receptacle is running.
Socket*
24 VOLTS AC
A
B
K
J
I
H
C L N
D M
G
E F
115 VOLTS AC
Socket Information
A
24 volts ac. Protected by circuit breaker CB5.
B
Not used.
I
115 volts ac. Protected by fuse F2
J
Not used.
C
Output to remote control: 0 to +10 volts dc output
to remote control in Stick and TIG modes. +10
volts dc output to remote control in Wire mode.
D
Remote control circuit common.
E
DC input command signal: 0 to +10 volts dc from
min. to max of remote control with front panel V/A
control at max.
G
Circuit common for 24 volt ac circuits.
K
Chassis common.
A/V
AMPERAGE
VOLTAGE
GND
*The remaining sockets are not used.
Notes
OM-4411 Page 20
Return To Table Of Contents
5-9. Adjusting Wire (MIG) Weld Puddle Consistency
Stop engine and let cool.
Stabilizer DC-Z is factory connected to
suit most Wire (MIG) welding applications.
To change Wire (MIG) weld puddle consistency, proceed as follows:
Remove cover and right side panel.
1
Stabilizer DC-Z
2
Wire /CV Weld Output Terminal
3
Stabilizer Leads 29, 28, And 27
Lead 29 − provides stiffest weld
puddle
Lead 28 − provides wetter weld
puddle (for mild steel)
Lead 27 − provides wettest weld
puddle (for stainless steel)
Lead 29 is connected to the Wire/CV
weld output terminal at the factory.
Disconnect lead 29 from the Wire/CV
weld output terminal.
For wetter weld puddle (for mild
steel):
Remove insulated sleeving from lead
28. Connect lead 28 to Wire/CV weld
output terminal, reusing hardware. Insulate lead 29 with sleeving removed from
lead 28. Secure sleeving with cable ties.
For wettest weld puddle
(for stainless steel):
Remove insulated sleeving from lead
27. Connect lead 27 to Wire/CV weld
output terminal, reusing hardware. Insulate lead 29 with sleeving removed from
lead 27. Secure sleeving with cable ties.
Reinstall side panel.
1
3
2
Tools Needed:
3/8, 7/16 in
Ref. 803 100
Return To Table Of Contents
OM-4411 Page 21
SECTION 6 − OPERATING WELDING GENERATOR
6-1. Front Panel Controls
1
2
3
4
7
6
5
Ref. 211 909
OM-4411 Page 22
Return To Table Of Contents
6-2. Description Of Front Panel Controls
1 Process Switch
See Section 6-3 for Process switch information.
Use hour meter to help schedule routine
maintenance (see Section 8-1).
2
Use control to change engine air-fuel mix
when starting engine. Pull control out when
starting a cold engine. Push control in when
engine starts.
Voltage/Amperage Adjust Switch And
Remote Receptacle
Use switch to select front panel or remote
voltage/amperage control. For remote control, place switch in Remote position and
connect remote control to Remote receptacle RC4 (see Sections 5-8 and 6-4).
3 V/A Control
Use control to select weld voltage or
amperage. Control may be adjusted while
welding.
For maximum weld output (above 220
Amps), run unit at 3600 rpm. For weld
output below 220 Amps, operate unit at
3000 or 3600 rpm.
With Process/Contactor switch in Stick or
TIG setting, use control to adjust amperage.
With Process/Contactor switch in Wire position, use control to adjust voltage. With V/A
Adjust Switch in Remote position, control
limits the remote amperage in Stick and TIG
modes, but has no effect in MIG modes.
4 Engine Hour Meter
5
Engine Choke Control
Do not run engine with Choke control
partially on or spark plugs will foul.
6
engine speed increases in response to
weld load and generator power output
stops at receptacles RC1 and RC2.
Generator power load does not affect
engine speed.
Engine Control Switch
Use switch to start engine, stop engine, and
select engine speed. (Use switch in combination with Speed Control switch to select
engine speed.) In Run/Idle 3600/2400 RPM
position, engine runs at 2400 rpm at no weld
load, and 3600 rpm under weld load. In Run/
Idle 3000/1800 RPM position, engine runs at
1800 rpm at no weld load, and 3000 rpm
under weld load. In either position, engine
speed is determined by weld load and position of Speed Control switch (see item 7 and
table below).
Generator power is available at recep-
tacles RC1 and RC2 only at 1800 rpm.
If generator is not locked at 1800 rpm,
7
Speed Control Switch
Use switch to control engine auto idle function. Place switch in Generator Lock position
when not welding to lock engine speed at
1800 rpm for generator power at 60 Hz ac receptacles RC1 and RC2. (Generator power
is always available at 60-120 Hz receptacle
RC3.)
Place switch in Weld position to allow engine
speeds to be determined by position of Engine Control switch. The Speed Control
switch is not needed at start-up.
To Start: pull out choke and turn Engine
Control switch to Start position. Release
switch and slowly push choke in when
engine starts.
If
the engine does not start, let the
engine come to a complete stop before
attempting restart.
To Stop: turn Engine Control switch to Off
position.
Controlling Engine Speed And Weld/Generator Power Output
Engine Controls
Engine Speed
Generator Power
Output
1800 rpm (Power Speed)
Continuous
Weld Output
Welding Not
Recommended
5 kW/kVA Total From
All AC Receptacles
Speed Control Switch In Generator
Lock. Engine Control Switch in either
Run/Idle position.
No Load: 2400 rpm (Idle Speed)
Load: 3600 rpm (Weld Speed)
Speed Control Switch In Weld.
Engine Control Switch in 3600/2400 RPM.
No Load: 1800 rpm (Idle Speed)
Load: 3000 rpm (Weld Speed)
2.4 kW/kVA at 60-120 Hz
From AC Receptacle
RC3 Only
5 kW/kVA Total From
All AC Receptacles At 1800 rpm.
3600 rpm:
20 − 300 A
3000 rpm:
20 − 220 A
At 3000 rpm, Output Available
Only At 2.4 kW/kVA 60-120 Hz
AC Receptacle RC3
Speed Control Switch In Weld.
Engine Control Switch in 3000/1800 RPM.
Return To Table Of Contents
OM-4411 Page 23
6-3. Process Switch
1
1
Process Switch
Weld output terminals are energized whenever the engine is running.
The unit will not return to idle speed
when the remote contactor is on (closure between pins A and B on remote
receptacle).
Use switch to select weld process (see
table below and Section 5-8).
Use Stick position for air carbon arc
(CAC-A) cutting and gouging.
When switch is in a Stick position, the dig
circuit provides additional amperage during low voltage (short arc length conditions) to prevent “sticking” electrodes.
The dig circuit is disabled when switch is in
Wire or TIG position.
803 128
Process Switch Settings
Switch Setting
Process
Output On/Off Control
Electrode Hot − Wire
MIG (GMAW)
Electrode Hot
Electrode Hot − Stick
Stick (SMAW),
Air Carbon Arc (CAC-A) Cutting And Gouging
Electrode Hot
Electrode Hot − Scratch
Start TIG
Scratch Start TIG (GTAW)
Electrode Hot
OM-4411 Page 24
Return To Table Of Contents
6-4. Remote Amperage/Voltage Control
1
Remote Receptacle RC4
Connect optional remote control to
RC4 (see Section 5-8).
2
3
Remote Hand Control (Optional)
Remote Foot Control (Optional)
Engine runs at weld speed when
1
a device connected to the remote
receptacle makes closure between pins A and B (example:
trigger pull on MIG gun).
Example: Combination Remote Amperage Control (Stick)
Set V/A Adjust
Switch
Set Process
In Example:
Process = Stick (Using Remote On/Off)
Min = 40 A CC/DC
Max = 180 A CC/DC
Set
V/A Control
3
2
Max (180 A DC)
Min (40 A DC)
Adjust Remote Control
(Stick Welding Only)
This unit does not have remote
contactor control. Output is always on.
803 128 / 211 909 / S-0769 / S-0774
Return To Table Of Contents
OM-4411 Page 25
SECTION 7 − OPERATING AUXILIARY EQUIPMENT
7-1. 60 Hz Generator Power Receptacles And Circuit Breakers
If unit does not have GFCI receptacles, use GFCI-protected
extension cord.
2
Weld output and 60 Hz generator
4
power output at receptacles RC1
and RC2 are not available at the
same time. When welding, generator power is available from AC
receptacle RC3 only (see Section 7-2).
1
See Section
7-2 for RC3
information.
Generator power is available at
receptacles RC1 and RC2 only at
1800 rpm. If generator is not
locked at 1800 rpm, engine
speed increases in response to
weld load and generator power
output stops at receptacles RC1
and RC2. Generator power load
does not affect engine speed.
1
240 V 50 A AC Receptacle RC1
RC1 supplies 60 Hz single-phase
power at 1800 rpm. Maximum output
is 5 kVA/kW(20 A at 240 volts ac). For
60 Hz generator power at RC1, set
controls as shown in table.
2
RC2 supplies 60 Hz single-phase
power at 1800 rpm. Maximum output
from RC2 is 2.4 kVA/kW (20 A at 120
volts ac).
3
3
Controlling Engine Speed And Weld/Generator Power Output
Generator Power
Output
Engine Controls
Weld Output
Engine Speed
1800 rpm
(Power Speed)
Continuous
Welding Not
Recommended
5 kW/kVA Total From
All AC Receptacles
No Load: 2400 rpm
(Idle Speed)
Load: 3600 rpm
(Weld Speed)
No Load: 1800 rpm
(Idle Speed)
Load: 3000 rpm
(Weld Speed)
3600 rpm:
20 − 300 A
2.4 kW/kVA at 60-120
Hz From AC
Receptacle RC3 Only
5 kW/kVA Total From
All AC Receptacles
At 1800 rpm.
Circuit Breaker CB1
CB1 protects receptacles RC1 and
RC2 from overload. If CB1 opens, the
receptacles do not work. Place switch
in On position to reset breaker.
4
Either
Run/Idle
position.
120 V 20 A AC Duplex
Receptacle RC2
Circuit Breaker CB3
CB3 protects RC2 from overload. If
CB3 opens, the receptacle does not
work. Press button to reset breaker.
If
circuit breaker continues to
open,
contact
Factory
Authorized Service Agent.
Combined output of all receptacles
limited to 5 kVA/kW continuous rating
of the generator.
EXAMPLE: If 10 A is drawn from 120
V duplex receptacle RC2, only 16 A is
available at 240 V receptacle RC1.
(120 V x 10 A) + (240 V x 16 A) = 5
kVA/kW
3000 rpm:
20 − 220 A
At 3000 rpm, Output
Available Only At 2.4
kW/kVA 60-120 Hz AC
Receptacle RC3
Ref. 211 909
OM-4411 Page 26
Return To Table Of Contents
7-2. Variable Frequency (Hz) Generator Power Receptacle RC3
Do not operate equipment requiring a constant frequency
from variable frequency receptacle RC3.
2
1
120 V 20 A Variable Frequency
AC Receptacle RC3
Receptacle supplies single-phase
power continuously. Frequency (Hz)
of generator power output changes
with engine speed. Total output available is 2.4 kVA/kW.
1
2
Circuit Breaker CB4
CB4 protects the receptacle from
overload. If CB4 opens, the receptacle does not work.
Press
button to reset circuit
breaker. If breaker continues to
open, contact a Factory Authorized Service Agent.
Ref. 203 096
7-3. Wiring Optional 240 Volt Plug
The plug can be wired for a 240 V,
2-wire load or a 120/240V, 3-wire
load. See circuit diagram.
1
7
Current Available in Amperes
240 V
Each 120 V Duplex
Receptacle*
Receptacle
20
15
10
5
0
0
5
10
15
20
V x A = Watts
*One 240 V load or two 120 V loads.
When wired for 120 V loads, each
duplex receptacle shares a load
with one half of 240 V receptacle.
1
3
4
120V
120V
5
240V
Plug Wired for 120/240 V,
3-Wire Load
6
2
Plug Wired for 240 V, 2-Wire
Load
3
Neutral (Silver) Terminal
4
Load 1 (Brass)Terminal
5
Load 2 (Brass) Terminal
6
Ground (Green) Terminal
7
Amperes Available using
120/240 V Plug
2
3
4
Tools Needed:
240V
6
5
120 813-D
Return To Table Of Contents
OM-4411 Page 27
SECTION 8 − MAINTENANCE & TROUBLESHOOTING
8-1. Routine Maintenance
Stop engine before maintaining.
See Engine Manual and Maintenance Label. Ser-
Recycle
engine
fluids.
vice more often if used in severe conditions.
*
To be done by Factory Authorized Service Agent.
Every 8 h
Wipe up spills.
Check fluid levels.
See Section 5-2.
OIL
Full
20 h
25 h
Check and clean
spark arrestor screen.
See Section 8-3.
Service air filter wrapper
(foam element). See
Section 8-4.
Every 50 h
Clean and tighten
weld terminals.
Every 100 h
Change oil. See
Section 8-5 and
maintenance
label.
Service air filter element.
See Section 8-4.
Clean cooling system. See
engine manual.
Clean and
tighten battery
connections.
Every 200 h
Change oil filter. See Section
8-5 and maintenance label.
Replace fuel
filter. See
Section 8-5.
Check spark plugs, and
replace if fouled. Operation
at low speed (1800 rpm)
may increase fouling.
Replace
unreadable
labels.
Every 500 h
Service welding generator
brushes and slip rings.
Service more often in dirty
conditions.*
Repair or
replace cracked
cables.
Every 1000 h
Blow out or vacuum inside. During
heavy service, clean monthly.
OM-4411 Page 28
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OR
8-2. Maintenance Label
Follow the storage procedure in the engine owner’s manual if the unit will not be
used for an extended period.
NOTE
8-3. Servicing Optional Spark Arrestor
Stop engine and let cool.
1
Spark Arrestor Screen
Clean and inspect screen. Replace
spark arrestor if screen wires are
broken or missing.
1
Tools Needed:
1/4 in
803 127 / Ref. 211 909
Return To Table Of Contents
OM-4411 Page 29
8-4. Servicing Air Cleaner
Stop engine.
Do not run engine without air
cleaner or with dirty element.
1
Wrapper (Foam Element)
Wash wrapper with soap and water
solution. Allow wrapper to air dry
completely.
1
Spread 1 tablespoon SAE 30 oil
evenly into wrapper. Squeeze out
excess oil.
2
2
Element
Replace element if damaged, dirty,
or oily.
oil
aircleaner3 9/00 − 802 772 / Ref. 185 095-A / S-0759
OM-4411 Page 30
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8-5. Changing Engine Oil, Oil Filter, And Fuel Filter
Stop engine and let cool.
1
Oil Drain Valve
2
Oil Filter
Change engine oil and filter according to engine manual.
Close valve and valve cap
before adding oil and running engine.
Full
Fill crankcase with new oil to full
mark on dipstick (see Section 8-2).
3
Fuel Filter
4
Fuel Line
Replace line if cracked or worn.
Install new filter. Wipe up any spilled
fuel.
Start engine, and check for fuel
leaks.
Stop engine, tighten connections as necessary, and wipe
up fuel.
3
4
2
1
Tools Needed:
803 127 / S-0842
Return To Table Of Contents
OM-4411 Page 31
8-6. Overload Protection
Stop engine.
Tools Needed:
When a circuit breaker or fuse
opens, it usually indicates a more
serious problem exists. Contact
a Factory Authorized Service
Agent.
3/8 in
1
2
Circuit Breaker CB5
CB5 protects the 24 volt ac output to
Remote receptacle RC4. If CB5
opens, 24 volt ac output to RC4 stops.
2 Fuse F1 (See Parts List)
3
Fuse F2 (See Parts List)
Remove cover.
3
Fuse F1 is located on power board
PC7. F1 protects the exciter stator
from overload. If F1 opens, weld and
generator power output stops.
Fuse F2 is located behind front panel.
F2 protects the 115 volt ac output to
Remote receptacle RC4. If F2 opens,
115 volt ac output to RC4 stops.
Replace fuse(s) if open. Reinstall
cover before operating unit.
Located behind front panel.
4
Fuse F6 (See Parts List)
F6 protects the engine wiring system
from overload. If F6 opens, the engine
will not crank. Replace fuse if open.
1
4
802 851-A / Ref. 211 909
OM-4411 Page 32
Return To Table Of Contents
8-7. Troubleshooting
A. Welding
Trouble
No weld output.
Remedy
Check control settings.
Check weld connections.
Disconnect equipment from generator power receptacles during start-up.
Place V/A Adjust switch in Panel position, or move switch to Remote position and connect remote
control to Remote receptacle RC4 (see Sections 5-8 and 6-1).
Check and secure connections to Remote receptacle RC4 (see Sections 5-8).
Check fuse F1 on circuit board PC7, and replace if necessary (see Section 8-6).
Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.
Low weld output.
Check weld control settings.
Change position of Engine Control switch and Speed Control switch to achieve desired engine speed.
Place V/A Adjust switch in Panel position, or move switch to Remote position and connect remote
control to Remote receptacle RC4 (see Sections 5-8 and 6-1).
Check and clean air cleaner as necessary (see Section 8-4).
Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.
See engine manual.
High weld output.
Check control settings.
Check for obstructed movement of solenoid linkage.
Have Factory Authorized Service Agent check circuit boards PC1, PC2, and PC7.
Weld output cannot be adjusted.
Check position of V/A Adjust switch (see Section 6-1).
Have Factory Authorized Service Agent check field current control board PC2.
Erratic weld output.
Check control settings.
Clean and tighten connections both inside and outside unit.
Be sure connection to work piece is clean and tight.
Remove excessive coils from weld cables.
Use dry, properly stored electrodes.
Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.
No remote fine amperage control.
Place V/A Adjust switch in Remote position (see Section 6-1).
Check and tighten connections to Remote receptacle RC4 (see Section 5-8).
No 24 volt ac output at Remote
receptacle RC4.
Reset circuit breaker CB5 (see Section 8-6).
No 115 volt ac output at Remote
receptacle RC4.
Check fuse F2, and replace if open (see Section 8-6).
Return To Table Of Contents
OM-4411 Page 33
Trouble
Lack of high frequency; difficulty in
establishing Gas Tungsten Arc Welding arc.
Remedy
Use proper size tungsten for welding amperage.
Reduce leakage of high frequency from torch or work cable (check grounding, remove excessive
coils from weld cables, use shorter weld cables, etc.).
Check cables and torch for cracked or deteriorated insulation or bad connections. Repair or replace
necessary parts.
Wandering arc − poor control of arc
direction.
Reduce gas flow rate.
Select proper size tungsten. Properly prepare tungsten.
Tungsten electrode oxidizing and not
remaining bright after conclusion of
weld.
Shield weld zone from drafts.
Increase postflow time.
Check and tighten all gas fittings.
Properly prepare tungsten.
B. 60 Hz Generator Power Receptacles RC1 And RC2
Trouble
No power output at 60 Hz ac receptacles RC1 or RC2.
Remedy
Reset circuit breakers CB1 and/or CB3 (see Section 7-1).
Stop welding, or place Speed Control switch in Generator Lock position to run engine at 1800 rpm. 60
Hz receptacles RC1 and RC2 work only at 1800 rpm.
Check receptacle wiring and connections.
Check fuse F1 on circuit board PC7, and replace if necessary (see Section 8-6).
Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1, PC2, and
PC7.
Low power output at 60 Hz ac receptacles RC1 or RC2.
Check and clean air cleaner as necessary.
Check engine electronic governor system. See engine manual.
High power output at 60 Hz ac receptacles RC1 or RC2.
Check engine electronic governor system. See engine manual.
Erratic power output at 60 Hz ac
receptacles RC1 or RC2.
Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1, PC2, and
PC7.
Check receptacle wiring and connections.
Check governor according to engine manual.
C. Variable Frequency Generator Power Receptacle RC3
Trouble
No generator power output at ac receptacle RC3.
Remedy
Reset circuit breaker CB4 (see Section 7-2).
Check receptacle RC3 for continuity and proper connections. Replace receptacle if necessary.
Check fuse F1 on circuit board PC7 and replace if necessary (see Section 8-6).
Have Factory Authorized Service Agent check brushes and slip rings, and circuit boards PC1, PC2, and
PC7.
Low generator power output at ac receptacle RC3.
Check fuse F1 on circuit board PC7 and replace if necessary (see Section 8-6).
Turn Engine Control switch to Run/Idle 3600/2400 RPM position.
OM-4411 Page 34
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D. Engine
Trouble
Engine will not crank.
Remedy
Check fuse F6, and replace if open (see Section 8-6).
Check battery voltage.
Check battery connections and tighten if necessary.
Check plug PLG5 and plug PLG8 connections.
Have Factory Authorized Service Agent check Engine Control switch S2.
Engine does not start.
Check fuel level (see Section 5-2).
Check battery and replace if necessary.
Check engine charging system according to engine manual.
See engine manual.
Engine starts but stops when Engine
Control switch returns to either Run/
Idle position.
Check oil level (see Section 5-2). Low oil pressure shutdown stops engine if oil pressure is too low.
Use correct grade oil for operating temperature. (see Section 8-2).
Have Factory Authorized Service Agent check low oil pressure shutdown switch S5.
Battery discharges between uses.
Place Engine Control switch in Off position when unit is not running.
Clean top of battery with baking soda and water solution; rinse with clear water.
Periodically recharge battery (approximately every 3 months).
Replace battery.
Check voltage regulator according to engine manual.
Engine stopped during normal
operation.
Check fuel level (see Section 5-2).
Check oil level (see Section 5-2). Low oil pressure shutdown stops engine if oil pressure is too low.
Have Factory Authorized Service Agent check low oil pressure shutdown switch S5.
Engine does not return to idle speed.
Place Engine Control switch S2 in either Run/Idle position.
Remove all weld and generator power loads.
Turn off remote contactor. The unit will not return to idle speed when the remote contactor is on.
Turn off remote device connected to Remote receptacle RC4 (see Section 5-8).
Check for obstructed movement of solenoid linkage.
Have Factory Authorized Service Agent check circuit board PC2 and current transformer CT1.
Engine does not go to weld speed.
Place Speed Control switch in Weld position.
Return To Table Of Contents
OM-4411 Page 35
SECTION 9 − ELECTRICAL DIAGRAM
Figure 9-1. Circuit Diagram For Welding Generator
OM-4411 Page 36
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211 395-A
Return To Table Of Contents
OM-4411 Page 37
SECTION 10 − GENERATOR POWER GUIDELINES
NOTE
The views in this section are intended to be representative of all engine-driven
welding generators. Your unit may differ from those shown.
10-1. Selecting Equipment
1
2
3
Generator Power Receptacles
− Neutral Bonded To Frame
3-Prong Plug From Case
Grounded Equipment
2-Prong Plug From Double
Insulated Equipment
Do not use 2-prong plug unless equipment is double insulated.
1
2
3
Be sure equipment
has this symbol
and/or wording.
OR
gen_pwr 11/02 − Ref. ST-159 730 / ST-800 577
10-2. Grounding Generator To Truck Or Trailer Frame
Always ground generator
frame to vehicle frame to prevent electric shock and static
electricity hazards.
1
2
1
GND/PE
3
Equipment Grounding
Terminal (On Front Panel)
Grounding Cable (Not
Supplied)
Metal Vehicle Frame
Connect cable from equipment
ground terminal to metal vehicle
frame. Use #10 AWG or larger
insulated copper wire.
2
3
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Electrically bond generator
frame to vehicle frame by
metal-to-metal contact.
Bed liners, shipping skids, and some running
gear insulate the welding generator from the vehicle frame. Always connect a ground wire from
the generator equipment grounding terminal to
bare metal on the vehicle frame as shown.
OM-4411 Page 38
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S-0854
10-3. Grounding When Supplying Building Systems
1
1
2
Equipment Grounding
Terminal
Grounding Cable
2
GND/PE
Use #10 AWG or larger insulated
copper wire.
3
Ground Device
Ground generator to system
earth ground if supplying
power to a premises (home,
shop, farm) wiring system.
Use ground device as stated
in electrical codes.
2
3
ST-800 576-B
10-4. How Much Power Does Equipment Require?
1
3
2
1
VOLTS 115
AMPS 4.5
Hz
60
Resistive Load
A light bulb is a resistive load and
requires a constant amount of power.
2
Non-Resistive Load
Equipment with a motor is a non-resistive load and requires approximately six times more power while
starting the motor than when running
(see Section 10-8).
3
3
Rating Data
Rating shows volts and amperes, or
watts required to run equipment.
AMPERES x VOLTS = WATTS
EXAMPLE 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power
requirement in watts.
4.5 A x 115 V = 520 W
The load applied by the drill is 520 watts.
EXAMPLE 2: If three 200 watt flood lamps are used with the drill from Example 1,
add the individual loads to calculate total load.
(200 W + 200 W + 200 W) + 520 W = 1120 W
The total load applied by the three flood lamps and drill is 1120 watts.
S-0623
Return To Table Of Contents
OM-4411 Page 39
10-5. Approximate Power Requirements For Industrial Motors
Industrial Motors
Split Phase
Capacitor Start-Induction Run
Capacitor Start-Capacitor Run
Fan Duty
Rating
Starting Watts
Running Watts
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
800
1225
1600
2100
3175
2020
3075
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
1000
1400
1850
2400
3500
300
500
600
700
875
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
400
550
650
800
1100
10-6. Approximate Power Requirements For Farm/Home Equipment
Farm/Home Equipment
Stock Tank De-Icer
Grain Cleaner
Portable Conveyor
Grain Elevator
Milk Cooler
Milker (Vacuum Pump)
FARM DUTY MOTORS
Std. (e.g. Conveyors,
Feed Augers, Air
Compressors)
High Torque (e.g. Barn
Cleaners, Silo Unloaders,
Silo Hoists, Bunk Feeders)
3-1/2 cu. ft. Mixer
High Pressure 1.8 Gal/Min
Washer 2 gal/min
2 gal/min
Refrigerator or Freezer
Shallow Well Pump
Sump Pump
OM-4411 Page 40
Rating
1/4 HP
1/2 HP
3/4 HP
2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/2 HP
500 PSI
550 PSI
700 PSI
1/3 HP
1/2 HP
1/3 HP
1/2 HP
Return To Table Of Contents
Starting Watts
Running Watts
1000
1650
3400
4400
2900
10500
1720
2575
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
3300
3150
4500
6100
3100
2150
3100
2100
3200
1000
650
1000
1400
1100
2800
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
1000
950
1400
1600
800
750
1000
800
1050
10-7. Approximate Power Requirements For Contractor Equipment
Contractor
Hand Drill
Circular Saw
Table Saw
Band Saw
Bench Grinder
Air Compressor
Electric Chain Saw
Electric Trimmer
Electric Cultivator
Elec. Hedge Trimmer
Flood Lights
Submersible Pump
Centrifugal Pump
Floor Polisher
High Pressure Washer
55 gal Drum Mixer
Wet & Dry Vac
Rating
Starting Watts
Running Watts
1/4 in
3/8 in
1/2 in
6-1/2 in
7-1/4 in
8-1/4 in
9 in
10 in
14 in
6 in
8 in
10 in
1/2 HP
1 HP
1-1/2 HP
2 HP
1-1/2 HP, 12 in
2 HP, 14 in
Standard 9 in
Heavy Duty 12 in
1/3 HP
18 in
HID
Metal Halide
Mercury
Sodium
Vapor
400 gph
900 gph
3/4 HP, 16 in
1 HP, 20 in
1/2 HP
3/4 HP
1 HP
1/4 HP
1.7 HP
2-1/2 HP
350
400
600
500
900
1400
4500
6300
2500
1720
3900
5200
3000
6000
8200
10500
1100
1100
350
500
2100
400
125
313
1000
1400
1250
600
900
4500
6100
3150
4500
6100
1900
900
1300
350
400
600
500
900
1400
1500
1800
1100
720
1400
1600
1000
1500
2200
2800
1100
1100
350
500
700
400
100
250
Return To Table Of Contents
1000
200
500
1400
1600
950
1400
1600
700
900
1300
OM-4411 Page 41
10-8. Power Required To Start Motor
4
1
3
AC MOTOR
VOLTS 230
AMPS 2.5
CODE M
Hz
60
HP
1/4
PHASE 1
1
2
3
4
2
Motor Start Code
Running Amperage
Motor HP
Motor Voltage
To find starting amperage:
Step 1: Find code and use table to
find kVA/HP. If code is not listed,
multiply running amperage by six to
find starting amperage.
Step 2: Find Motor HP and Volts.
Step 3: Determine starting amperage (see example).
Welding generator amperage output must be at least twice the
motor’s running amperage.
Single-Phase Induction Motor Starting Requirements
Motor Start
Code
G
H
J
K
L
M
N
P
KVA/HP
6.3
7.1
8.0
9.0
10.0
11.2
12.5
14.0
kVA/HP x HP x 1000
VOLTS
= STARTING AMPERAGE
EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4
HP motor with a motor start code of M.
Volts = 230
HP = 1/4
Using Table, Code M results in kVA/HP = 11.2
11.2 x 1/4 x 1000
= 12.2 A Starting the motor requires 12.2 amperes.
230
S-0624
10-9. How Much Power Can Generator Supply?
1
Limit Load To 90% Of
Generator Output
Always start non-resistive (motor)
loads in order from largest to smallest, and add resistive loads last.
2
1
2
5 Second Rule
If motor does not start within 5
seconds, turn off power to prevent
motor damage. Motor requires
more power than generator can
supply.
Ref. ST-800 396-A / S-0625
OM-4411 Page 42
Return To Table Of Contents
10-10. Typical Connections To Supply Standby Power
Properly install and ground this equipment according to
its Owner’s Manual and national, state, and local codes.
1
2
Utility
Electrical
Service
3
Transfer Switch
4
Fused
Disconnect
Switch
(If Required)
Welding
Generator
Output
5
Essential
Loads
Have only qualified persons perform
these connections according to all
applicable codes and safety practices.
Switch transfers the electrical load from
electric utility service to the generator. Transfer load back to electric utility when service is
restored.
Properly install and ground this
equipment according to its Owner’s
Manual and national, state, and local
codes.
Install correct switch (customer-supplied).
Switch rating must be same as or greater
than the branch overcurrent protection.
Customer-supplied
equipment is required if generator will supply standby
power during emergencies or power outages.
1 Utility Electrical Service
2 Transfer Switch (Double-Throw)
3 Fused Disconnect Switch
Install correct switch (customer-supplied) if
required by electrical code.
4 Welding Generator Output
Generator output voltage and wiring must be
consistent with regular (utility) system voltage and wiring.
Connect generator with temporary or permanent wiring suitable for the installation.
Turn off or unplug all equipment connected to
generator before starting or stopping engine.
When starting or stopping, the engine has
low speed which causes low voltage and
frequency.
5 Essential Loads
Generator output may not meet the electrical
requirements of the premises. If generator
does not produce enough output to meet all
requirements, connect only essential loads
(pumps, freezers, heaters, etc. − See Section 10-4).
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
Return To Table Of Contents
OM-4411 Page 43
10-11. Selecting Extension Cord (Use Shortest Cord Possible)
Cord Lengths for 120 Volt Loads
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)
Load (Watts)
5
600
7
840
10
1200
15
4
6
8
10
12
14
350 (106)
225 (68)
137 (42)
100 (30)
400 (122)
250 (76)
150 (46)
100 (30)
62 (19)
400 (122)
275 (84)
175 (53)
112 (34)
62 (19)
50 (15)
1800
300 (91)
175 (53)
112 (34)
75 (23)
37 (11)
30 (9)
20
2400
225 (68)
137 (42)
87 (26)
50 (15)
30 (9)
25
3000
175 (53)
112 (34)
62 (19)
37 (11)
30
3600
150 (46)
87 (26)
50 (15)
37 (11)
35
4200
125 (38)
75 (23)
50 (15)
40
4800
112 (34)
62 (19)
37 (11)
45
5400
100 (30)
62 (19)
50
6000
87 (26)
50 (15)
*Conductor size is based on maximum 2% voltage drop
Cord Lengths for 240 Volt Loads
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)
Load (Watts)
5
1200
7
1680
10
2400
15
4
6
8
10
12
14
700 (213)
450 (137)
225 (84)
200 (61)
800 (244)
500 (152)
300 (91)
200 (61)
125 (38)
800 (244)
550 (168)
350 (107)
225 (69)
125 (38)
100 (31)
3600
600 (183)
350 (107)
225 (69)
150 (46)
75 (23)
60 (18)
20
4800
450 (137)
275 (84)
175 (53)
100 (31)
60 (18)
25
6000
350 (107)
225 (69)
125 (38)
75 (23)
30
7000
300 (91)
175 (53)
100 (31)
75 (23)
35
8400
250 (76)
150 (46)
100 (31)
40
9600
225 (69)
125 (38)
75 (23)
45
10,800
200 (61)
125 (38)
50
12,000
175 (53)
100 (31)
*Conductor size is based on maximum 2% voltage drop
OM-4411 Page 44
Return To Table Of Contents
Fig.11-2 − 35
38
40
1
37
2
36
3
4
Return To Table Of Contents
34
32
31
5
17
6
7
7
33
30
9
8−Fig.11-3
18
16
10
29
19
11
28
12
27
41−Fig.11-4
14
26
20
25
21
13
24
22
23
15
SECTION 11 − PARTS LIST
803 340
Figure 11-1. Main Assembly
OM-4411 Page 45
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-1. Main Assembly
. . . 1 . . . . . . . . . . . . . . 181881 . . Grommet, Plastic Neck Filler Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . . . 147601 . . Cap, Tank Screw−on W/Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . . . . . 182761 . . Label, Warning General Precautionary Csa . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . . . . . . . . . . 183433 . . Pipe, Exhaust Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . . . . . . . . . . 183314 . . Clamp, Muffler 1.625 Dia U Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . . . . . . . . . +205762 . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . . . . . . . ♦+206758 . . Cover, Top Stainless Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . ♦163175 . . Screw, .250−20 x .75 Hex Hd−pln Stainless Steel Pln . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . ♦163167 . . Washer, Lock .254 id x 0.489 odx x .062t Stainless Steel Split.250 . . . .
. . . . . . . . . . . . . . . . . . ♦163174 . . Washer, Flat .281 id x 0.625 od x 0.50t Stainless Steel . . . . . . . . . . . . . .
. . . 7 . . . . . . . . . . . . . . 182365 . . Panel, Rear Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . . . . . . . . . ♦185351 . . Panel, Rear Upper Stainless Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . . . . . . . . . Figure 11-3 . . Bracket w/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . . . . . . . . . . . 205736 . . Upright, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 10 . . . . . . . . . . . . . . 205734 . . Seal, Weather Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . . . . . . . . . . 181789 . . Seal, Barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . . . . . . . . . . . . 186667 . . Cover, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . . . . 208463 . . Engine, Koh Gas Elec Ch20s−ps−64663 (Includes) . . . . . . . . . . . . . . . . . .
. . . 14 . . . . . . . . . . . . . . 207458 . . . . Muffler, Exhaust Engine W/Heat Shield . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 189477 . . . . Muffler Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 15 . . . . . . . . . . . . . . 208003 . . . . Hose, Oil W/Fittings And Valve (Includes) . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 207490 . . . . . . Hose, Oil W/Fitting 11.750 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 165271 . . . . . . Valve, Oil Drain 3/8−18 Nptf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 206402 . . . . . . Ftg, Hose Brs Barbed M 1/2 Tbg X 3/8 Npt . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 023562 . . . . . . Clamp, Hose .312 − .875 Clp Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . . . . *215984 . . . . Filter, Fuel In−line .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 135556 . . . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . F6 . . . . . 021718 . . . . Fuse, Mintr Gl 30. Amp 32 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 180096 . . Tune−up & Filter Kit, Kohler (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . *067272 . . . . Air Filter Element, Kohler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . *066698 . . . . Oil Filter, Kohler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . *215985 . . . . Filter/Clamps, Fuel, 1/4” Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . *067007 . . . . Spark Plug, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . *067273 . . . . Air Filter Wrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . . . . . . . . . . . . 182079 . . Tank, Fuel 10.0 Gal (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 124253 . . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 187502 . . . . Ftg, Stand Pipe .250 X 7.375 Lg 90 Degree . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 182922 . . . . Bushing, Tank Fuel 1.210id . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 182925 . . . . Gauge, Fuel Float Type 5.50 Float Travel . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 161860 . . Hose, Sae .250 Id X .500 Od X 8.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 18 . . . . . . . . . . . . . . 182928 . . Bracket, Mtg Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . . . 173043 . . Bracket, Mtg Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . . . 082319 . . Cable, Bat Neg 17.750 No 4 Awg W/Clamp & .343 Rng . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 172669 . . Cable, Bat Neg 11.000 6ga W/.250 Rng & .375 Rng . . . . . . . . . . . . . . . . .
. . . 21 . . . . . . . . . . . . . . 182935 . . Hold Down, Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 22 . . . . . . . . . . . . . . 168385 . . Label, Warning Battery Explosion Can Blind . . . . . . . . . . . . . . . . . . . . . . . .
. . . 23 . . . . . . . . . . . . . +201174 . . Door, Access Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 24 . . . . . . . . . . . . . . 173921 . . Cable, Bat Pos 28.000 No 4 Awg W/Clamp & .312 Rng . . . . . . . . . . . . . .
. . . 25 . . . . BATT . . . . 168037 . . Battery, Stor 12v 430 Crk 75 Rsv Gp 58 Dry . . . . . . . . . . . . . . . . . . . . . . . .
. . . 26 . . . . . . . . . . . . . . 192362 . . Bracket, Mtg Nyl 1/2 Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 27 . . . . . . . . . . . . . +201280 . . Pan, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 28 . . . . . . . . . . . . . . 197930 . . Label, Warning Do Not Weld On Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 29 . . . . . . . . . . . . . . 215939 . . Label, Engine Maintenance Kohler Ch20/Ch23 . . . . . . . . . . . . . . . . . . . . . .
. . . 30 . . . . . . . . . . . . . . 181057 . . Cover, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 31 . . . . DCZ . . . . 202337 . . Stabilizer, Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 32 . . . . SR1 . . . . 202222 . . Rectifier, Si 3ph 300 Amp 400 Piv 100% Duty Cycle . . . . . . . . . . . . . . . . .
. . . . . . . . . R3/VR1 . . . . . . . . . . . . . Kit, Suppressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 33 . . . . . . . . . . . . . . 202339 . . Baffle, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 34 . . . . . . . . . . . . . . 180628 . . Panel, Front Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 35 . . . . . . . . . . . Figure 11-2 . . Panel, Front w/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 36 . . . . CT1 . . . . 207812 . . Xfmr, Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-4411 Page 46
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1
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1
1
1
1
1
1
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-1. Main Assembly (Continued)
. . . 37 . . . . . . . . . . . . . . 182367
. . . 37 . . . . . . . . . . . . ♦185352
. . . 38 . . . . . . . . . . . . . . 182366
. . . 38 . . . . . . . . . . . . ♦185353
. . . 39 . . . . . . . . . . . . . . deleted
. . . 40 . . . . . . . . . . . . . . 192042
. . . 41 . . . . GEN . Figure 11-4
. . . . . . . . . . . . . . . . . . . . 209831
. . . . . . . . . PLG29 . . . 113751
. . . . . . . . . . . . . . . . . . . . 204640
. . . . . . . . . . RC30 . . . . 136924
. . . . . . . . . . . . . . . . . . . . 204664
. . . . . . . . . PLG28 . . . 116513
. . . . . . . . . . . . . . . . . . . . 202883
. . . . . . . . . PLG16 . . . 114655
. . . . . . PLG12,PLG27 117037
. . . . . . . . . PLG21 . . . 113750
. . . . . . . . . . . . . . . . . . . . 206534
. . . . . . . . . . RC9 . . . . 136924
. . . . . . . . . PLG25 . . . 113752
. . . . . . . . . . RC7 . . . . 092670
. . . . . . . . . . . . . . . . . . . . 211421
. . . . . . . . . PLG31 . . . 135134
. . . . . . . . . PLG22 . . . 136925
. . . . . . . . . PLG19 . . . 113752
. . Panel, Side Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Panel, Side Rh Stainless Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Panel, Side Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Panel, Side Lh Stainless Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
....................................................................
. . Label, Use Gasoline Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Generator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Connectors, W/Leads (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Conn, Rect Mini 045 8skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . 1
. . . . Cable, LEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Conn, Rect Comm 093 2p/S 1row Rcpt Cable Lkg . . . . . . . . . . . . . . . . . 1
. . Plug, W/Leads (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Conn, Rect Mini 045 12skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1
. . Harness, Control Power Board Interconnecting (Includes) . . . . . . . . . . . . . 1
. . . . Conn, Rect Mini 045 6skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . 1
. . . . Conn, Rect Mini 045 2skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . 2
. . . . Conn, Rect Mini 045 4skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . 1
. . Harness, Wrg Interconnecting (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Conn, Rect Comm 093 2p/S 1row Rcpt Cable Lkg . . . . . . . . . . . . . . . . . 1
. . . . Conn, Rect Mini 045 10skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1
. . . . Conn, Rect Univ 084 3p/S 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1
. . Harness, Wrg Interconnecting (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Conn, Rect Univ 084 9p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 2
. . . . Conn, Rect Comm 093 2p/S 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . 1
. . . . Conn, Rect Mini 045 10skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1
♦
Optional
*
Recommended Spare Parts.
+
When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 207 019.
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.
Notes
Start Your Professional
Welding Career Now!
400 Trade Square East, Troy, Ohio 45373
1-800-332-9448 www.welding.org
Return To Table Of Contents
Over 80,000 trained
since 1930!
OM-4411 Page 47
4
Hardware is common and
not available unless listed.
38
3
5
2
1
7
37
9
6
10
12
8
11
13
36
35
14
15
34
16
17
33
18
32
20
19
23
21
25
24
26
28
30
29
27
22
803 341
31
Figure 11-2. Panel, Front w/Components
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-2. Panel, Front w/Components (Figure 11-1 Item 35)
. . . 1 . . . . . . . . . . . . . . . . . . . . . . . . Nameplate (Order By Model And Serial Number) . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . . . 206854 . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . . . . . 203401 . . Stand−off Support, Pc Card .187 Dia W/P&l .625 . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . PC2 . . . . 211273 . . Circuit Card Assy, Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 206794 . . Shield, Pcb Protective Anti Static 4.813x12.750 . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 209618 . . Harness, Remote Control 14pin (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . . . . . . . . . . 209617 . . . . Holder, Fuse W/10A Fuse (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . F2 . . . . . 085874 . . . . . . Fuse, Mintr Cer Slo−blo 10. Amp 250 Volt . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . RC4 . . . . 143976 . . . . Conn, Circ Ms/Cpc 14skt Size 20 Rcpt Panel Pushin (Service Kit) . . . .
. . . . . . . . . PLG23 . . . 115093 . . . . Conn, Rect Mini 045 6skt 2row Plug Cable Lkg (Service Kit) . . . . . . . . .
. . . . . . . . . PLG24 . . . 131054 . . . . Conn, Rect Mini 045 2skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 202884 . . Harness, Switch Control (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . PLG20 . . . 131198 . . . . Conn, Rect Mini 045 3skt 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . . S3 . . . . . 011609 . . . . Switch, Tgl Spdt 15a 125vac On−none−on Spd Term Chr . . . . . . . . . . .
. . . 8 . . . . . S2 . . . . . 176606 . . Switch, Ignition 4 Position W/Out Handle . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-4411 Page 48
Return To Table Of Contents
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-2. Panel, Front w/Components (Continued)
....................
. . . 9 . . . . . S4 . . . . .
. . . . . . . . . PLG15 . . .
. . . . . . . . . . RC5 . . . .
. . . . . . . . . . PLG7 . . . .
. . . . . . . . . . PLG8 . . . .
....................
....................
. . . 10 . . . . RC2 . . . .
. . . 11 . . . . CB3 . . . .
....................
. . . 12 . . . . RC3 . . . .
. . . 13 . . . . CB4 . . . .
. . . 14 . . . . CB1 . . . .
. . . 15 . . . . PC5 . . . .
. . . 16 . . . . PC3 . . . .
. . . 17 . . . . . . . . . . . . . .
. . . 18 . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . . .
. . . 20 . . . . . HM . . . . .
. . . 21 . . . . . . . . . . . . . .
. . . 22 . . . CC/CV . . .
. . . . . . . . . . GRD . . . .
. . . 23 . . . . . . . . . . . . . .
. . . 24 . . . . . . . . . . . . . .
. . . 25 . . . . . . . . . . . . . .
. . . 26 . . . . . . . . . . . . . .
. . . 27 . . . WORK . . .
....................
. . . 28 . . . . RC1 . . . .
. . . 29 . . . . . . . . . . . . . .
. . . 30 . . . . . . . . . . . . . .
. . . 31 . . . . . . . . . . . . . .
. . . 32 . . . . . . . . . . . . . .
. . . 33 . . . . . . . . . . . . . .
. . . 34 . . . . . . . . . . . . . .
. . . 35 . . . . . . . . . . . . . .
. . . 36 . . . . LEM . . . .
....................
. . . . . . . . . PLG30 . . .
. . . 37 . . . . CB5 . . . .
. . . 38 . . . . . . . . . . . . . .
♦Optional
+
206886
011609
113751
113634
166380
177859
202660
211429
141432
093996
211431
211224
093996
203095
148030
148021
129524
211452
119014
145247
134201
039047
197203
083030
010915
602207
601836
039046
211425
182954
188039
203016
159921
021385
170391
097924
097922
168829
204777
136925
083432
073756
. . Harness, Wrg Ignition (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Switch, Tgl Spdt 15a 125vac On−none−on Spd Term Chr . . . . . . . . . . .
. . . . Conn, Rect Mini 045 8skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Univ 084 6p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . .
. . . . Conn, Rect Univ 084 3p/S 1row Rcpt Cable/Panel Lkg . . . . . . . . . . . . .
. . . . Conn, Body 5 Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Push 4 Wire 12−16strnd 12−18sld 16−22tinstrnd . . . . . . . . . . . .
. . Receptacle/Circuit Breaker, W/Leads (Includes) . . . . . . . . . . . . . . . . . . . . .
. . . . Rcpt, Str Dx Grd 2p3w 20a 125v *5−20r . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Circuit Breaker, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . . .
. . Receptacle/Circuit Breaker, W/Leads (Ivory) (Includes) . . . . . . . . . . . . . . .
. . . . Rcpt, Str Dx Grd 2p3w 20a 125v *5−20r Ivory . . . . . . . . . . . . . . . . . . . . .
. . . . Circuit Breaker, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . . .
. . Circuit Breaker, Man Reset 2p 25a 240vac Screw−90 . . . . . . . . . . . . . . . .
. . Circuit Card Assy, Filter Hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Circuit Card Assy, Filter Hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Term, Frict 250x032 Uninsul Male .130 Stud Mtg 3pr . . . . . . . . . . . . . . . . .
. . Control, Push/Pull Snap−in 42.000 W/1.750 Extension . . . . . . . . . . . . . . .
. . Lever, Switch Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Meter, Hour 12−24vdc 1.25 X 2.12 Rect . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Stand−off Support, Pc Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . . .
. . Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Grounding Stud Assy, Brass (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Stud, Brs .250−20 X 1.750 W/Hex Collar . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Washer, Flat .257idx0.640odx.031t Brs . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Washer, Lock .255idx0.489odx.062t Stl Pld Split.250 . . . . . . . . . . . . . . .
. . . . Nut, 250−20 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Receptacle, W/Leads (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Rcpt, Str 3p4w 50a 125/250v Flush Mtg *14−50 . . . . . . . . . . . . . . . . . . .
. . Cover, Receptacle w/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Boot, Circuit Breaker 2 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bezel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Boot, Toggle Switch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Conn, Circ Ms Protective Cap Size 20 Nylon . . . . . . . . . . . . . . . . . . . . . . .
. . Knob, Pointer 1.625 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . .
. . Knob, Pointer .875 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . . .
. . Transducer, Current 1000a Module Max Open Loop . . . . . . . . . . . . . . . . .
. . Plug, W/Leads (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Comm 093 2p/S 1row Plug Cable Lkg . . . . . . . . . . . . . . . . .
. . Circuit Breaker, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . . . . .
. . Stand−off, No 6−32 X .625 Lg .250 Hex Al Fem . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
6
2
1
1
2
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 207 019.
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.
Return To Table Of Contents
OM-4411 Page 49
2
3
Hardware is common and
1
not available unless listed.
4
5
7
6
4
8
17
9
10
16
11
12
13
14
15
803 343
Figure 11-3. Bracket w/Components
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-2. Bracket w/Components (Figure 11-1 Item 8)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
. . . . PC1 . . . . 211276
. . . . PC7 . . . . 203130
. . . . . F1 . . . . . 027660
. . . . . . . . . . . . . . 115440
. . . . . . . . . . . . . . 004214
. . . . . . . . . . . . . . 200263
. . . . . . . . . . . . . . 206901
. . . . CR2 . . . . 113247
. . . . . . . . . . . . . . 204769
. . . . . . . . . . . . . . 196180
. . . . . 1T . . . . . 172661
. . . . . . . . . . . . . . 173734
. . . . C25 . . . . 176007
. . . . . . . . . . . . . . 202331
. . . . . . . . . . . . . . 204166
. . . . . . . . . . . . . +204148
. . . . . . . . . . . . . . 165437
OM-4411 Page 50
. . Circuit Card Assy, Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Circuit Card Assy, Gen Power (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Fuse, Mintr Cer 20. Amp 250 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Stand-off, No 6−32 X .687 Lg .250 Hex Al Fem . . . . . . . . . . . . . . . . . . . . .
. . Bushing, Snap−in Nyl 1.625 Id X 2.000 Mtg Hole . . . . . . . . . . . . . . . . . . . .
. . Label, Warning Electric Shock Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bracket, Mtg Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Relay, Encl 12vdc Dpdt 20a/120vac 8pin Flange Mtg . . . . . . . . . . . . . . . .
. . Label, Term Mkg Stator Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Insulator, Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Block, Stud Connection 6 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Link, Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Capacitor, Elctlt 1200 Uf 300 Vdc Can 1.37 Dia . . . . . . . . . . . . . . . . . . . . .
. . Gasket, Capacitor Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bracket, Capacitor Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bracket, Mtg Pc Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Clip, Snap In .472 Bundle .250hole .020−.197 Thk . . . . . . . . . . . . . . . . . .
Return To Table Of Contents
1
1
1
10
1
2
1
1
1
1
1
2
1
1
1
1
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-4. Generator (Figure 11-1 Item 41)
. . . 1 . . STATOR +206890 . . Stator, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . 182092 . . Label, Warning Moving Parts Can Cause Serious Etc . . . . . . . . . . . . . . . . 3
. . . 3 . . . ROTOR . . . 207126 . . Rotor, Generator (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . 181143 . . . . Bearing,Ball Rdl Sgl Row .984 X 2.047 X .591 . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . 160566 . . . . Fan, Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . 212161 . . Adapter, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . 202771 . . Baffle, Engine Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . 170861 . . Stud, Stl .375−16 X 17.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 9 . . . . . . . . . . . . . . 205725 . . Brushholder Assy, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 206894 . . Harness, Wrg Brushholder (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG17 . . . 066104 . . . . Conn, Rect Univ 084 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC22 . . . . 136924 . . . . Conn, Rect Comm 093 2p/S 1row Rcpt Cable Lkg . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . 010910 . . Washer, Flat .406idx0.812odx.065t Stl Pld Ansi.375 . . . . . . . . . . . . . . . . . . 4
. . . 11 . . . . . . . . . . . . . . 010909 . . Nut, .375−16 .56hex .46h Stl Pld Elastic Stop Nut . . . . . . . . . . . . . . . . . . . 4
. . . 12 . . . . . . . . . . . . . . 210438 . . Endbell (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . 183419 . . . . O−ring, 1.984 Id X .139 Cs 70 Duro Viton . . . . . . . . . . . . . . . . . . . . . . . . 1
+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 207 019.
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.
Hardware is common and
not available unless listed.
7
6
3
5
4
2
1
8
12
9
13
10
11
803 342
Figure 11-4. Generator
Return To Table Of Contents
OM-4411 Page 51
Notes
MATERIAL THICKNESS REFERENCE CHART
24 Gauge (.025 in)
22 Gauge (.031 in)
20 Gauge (.037 in)
18 Gauge (.050 in)
16 Gauge (.063 in)
14 Gauge (.078 in)
1/8 in (.125 in)
3/16 in (.188 in)
1/4 in (.25 in)
5/16 in (.313 in)
3/8 in (.375 in)
1/2 in (.5 in)
TM-188 304 Page 52
Invision 354MP
Effective January 1, 2003
(Equipment with a serial number preface of “LC” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants
to its original retail purchaser that new Miller equipment sold
after the effective date of this limited warranty is free of defects
in material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Your distributor also gives
you ...
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such defects in material or workmanship. Miller must be
notified in writing within thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that
the equipment was delivered to the original retail purchaser, or
one year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to an
International distributor.
1.
5 Years Parts — 3 Years Labor
*
*
2.
3 Years — Parts and Labor
*
*
*
*
*
*
*
3.
Original main power rectifiers
Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Supplies
Intellitig
Maxstar 150
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources
Water Coolant Systems
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Maxstar 85, 140
Spot Welders
Load Banks
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
4.
6 Months — Batteries
5.
90 Days — Parts
*
MIG Guns/TIG Torches
*
*
*
*
*
*
*
Induction Heating Coils and Blankets
APT & SAF Model Plasma Cutting Torches
Remote Controls
Accessory Kits
Replacement Parts (No labor)
Spoolmate Spoolguns
Canvas Covers
Miller’s True Blue Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.
(Exception: brushes, slip rings, and relays are
covered on Bobcat, Trailblazer, and Legend models.)
2.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE
AND MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods
at customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
DISCLAIMED BY MILLER.
Some states in the U.S.A. do not allow limitations of how long
an implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty
provides specific legal rights, and other rights may be
available, but may vary from state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may
be available, but may vary from province to province.
miller_warr 8/03
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.)
Distributor
Address
City
State
Zip
For Service
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
www.MillerWelds.com
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA
 2003 Miller Electric Mfg. Co.
1/03