Miller | LF279651 | Owner Manual | Miller MILLER LEGEND 302 User manual

Miller MILLER LEGEND 302 User manual
OM-4430
217 243J
2005−10
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
MIG (GMAW) Welding &
Flux Cored (FCAW) Welding
With Voltage Sensing Feeder
Description
Engine Driven Welding Generator
Miller Legend 302
File: Engine Drive
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 specification 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 4/05
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. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-8. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. TIG Mode Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Stick And MIG Mode Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Connecting Or Replacing The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Remote Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Adjusting Wire (MIG) Weld Puddle Consistency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − OPERATING WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Description Of Engine Controls (See Section 6-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Controlling Engine Speed And Weld/Generator Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Process Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Stick Start Procedure − Scratch Start Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. TIG Lift-ArcE Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. Remote Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. 60 Hz Generator Power Receptacles And Supplementary Protectors . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Variable Frequency (Hz) Generator Power Receptacle RC3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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7-3. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P) . . . . . . . . . . . . . . . . . . . 28
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 DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
rom _nd_3/05
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.
Marks a special safety message.
Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see the
symbol, watch out, and follow the related instructions to avoid the
hazard. The safety information given below is only a summary of
the more complete safety information found in the Safety Standards listed in Section 1-7. Read and follow all Safety Standards.
Do not touch electrode holders connected to two welding machines at
the same time since double open-circuit voltage will be present.
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.
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!
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.
Use only well-maintained equipment. Repair or replace damaged parts at
once. Maintain unit according to manual.
SIGNIFICANT DC VOLTAGE exists in inverters after stopping engine.
Stop engine on inverter and discharge input capacitors according to
instructions in Maintenance Section before touching any parts.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing these fumes
and gases can be hazardous to your health.
Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use local forced ventilation at the arc to
remove welding fumes and gases.
If ventilation is poor, wear an approved air-supplied respirator.
Read and understand 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 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 an approved welding helmet fitted with a proper shade of filter lenses
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, glare, and
sparks; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant material
(leather, heavy cotton, or wool) and foot protection.
OM-4430 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.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not
possible, tightly cover them with approved covers.
Do not weld where flying sparks can strike flammable material.
Protect yourself and others from flying sparks and hot metal.
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, sparks, 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.
Do not touch hot parts bare handed.
Allow cooling period before working on equipment.
To handle hot parts, use proper tools and/or wear
heavy, insulated welding gloves and clothing to prevent burns.
NOISE can damage hearing.
Noise from some processes or equipment can damage
hearing.
Wear approved ear protection if noise level is high.
MAGNETIC FIELDS can affect pacemakers.
Pacemaker wearers keep away.
Wearers should consult their doctor before going
near arc welding, gouging, or spot welding operations.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high pressure. If
damaged, a cylinder can explode. Since gas cylinders are
normally part of the welding process, be sure to treat them
carefully.
Protect compressed gas cylinders from excessive heat, mechanical
shocks, physical damage, 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.
Remove any combustibles, such as a butane lighter or matches, from your
person before doing any welding.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot
work and have a fire watcher and extinguisher nearby.
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.
FLYING METAL can injure eyes.
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.
Use the right equipment, correct procedures, and sufficient number of persons to llift and move cylinders.
Read and follow instructions on compressed gas cylinders, associated
equipment, and Compressed Gas Association (CGA) publication P-1 listed
in Safety Standards.
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.
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-4430 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 doors, panels, covers, or guards 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 doors, panels, covers, or guards 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.
HOT PARTS can cause severe burns.
Do not touch hot engine parts.
Allow cooling period before maintaining.
Wear protective gloves and clothing when working on
a hot engine.
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.
Release air pressure from tools and system before
servicing, adding or changing attachments, or opening compressor oil drain or oil fill cap.
HOT METAL from air arc cutting and
gouging can cause fire or explosion.
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.
Use only genuine Miller/Hobart replacement parts.
1-5. Additional Symbols For Installation, Operation, And Maintenance
FALLING UNIT can cause injury.
Use lifting eye to lift unit and properly installed accessories only. Do not exceed maximum lift eye weight
rating (see Specifications).
Lift and support unit only with proper equipment and
correct procedures.
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.
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.
Put on grounded wrist strap BEFORE handling
boards or parts.
Use proper static-proof bags and boxes to store,
move, or ship PC boards.
Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where
applicable.
FLYING SPARKS can cause injury.
OVERUSE can cause OVERHEATING.
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.
TILTING OF TRAILER can cause injury.
Use tongue jack or blocks to support weight.
Properly install welding generator onto trailer according to instructions supplied with trailer.
Sparks can cause fires — keep flammables away.
OM-4430 Page 3
READ INSTRUCTIONS.
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.
H.F. RADIATION can cause interference.
ARC WELDING 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.
To reduce possible interference, keep weld cables as short as possible,
close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic
equipment.
Be sure this welding machine is installed and grounded according to this
manual.
If interference still occurs, the user must take extra measures such as
moving the welding machine, using shielded cables, using line filters, or
shielding the work area.
1-6. 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 Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard
AWS F4.1, from Global Engineering Documents (phone:
1-877-413-5184, website: www.global.ihs.com).
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.
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-4430 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 before welding or going near
welding operations. If cleared by your doctor, then following the above
procedures is recommended.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
rom_fre 3/05
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 2-7 . 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.
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.
Une tension DC importante subsiste à l’intérieur des
onduleurs après avoir coupé l’alimentation.
Couper l’alimentation du poste et décharger les condensateurs d’entrée comme indiqué dans la Section Maintenance avant de toucher des composants.
LES FUMÉES ET LES GAZ peuvent être
dangereux.
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.
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.
Ne pas se servir de source électrique à courant électrique dans les zones humides, dans les endroits confinés ou là où on risque de tomber.
Se servir d’une source électrique à courant électrique UNIQUEMENT si le
procédé de soudage le demande.
Si l’utilisation d’une source électrique à courant électrique s’avère nécessaire,
se servir de la fonction de télécommande si l’appareil en est équipé.
Des précautions de sécurité supplémentaires sont requises dans des environnements 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.
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.
Ne pas toucher des porte électrodes connectés à deux machines en même
temps à cause de la présence d’une tension à vide doublée.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-champ les
pièces endommagées. Entretenir l’appareil conformément à ce manuel.
Le soudage génère des fumées et des gaz. Leur inhalation
peut être dangereux pour votre santé.
Eloigner votre tête des fumées. Ne pas respirer les fumées.
À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au niveau de
l’arc pour l’évacuation des fumées et des gaz de soudage.
Si la ventilation est médiocre, porter un respirateur anti-vapeurs approuvé.
Lire et comprendre les spécifications de sécurité des matériaux (MSDS) 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 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.
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.
LES RAYONS DE L’ARC peuvent provoquer des brûlures dans les yeux et
sur la peau.
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 approuvé muni de verres filtrants approprié
pour protéger visage et yeux pendant le soudage (voir ANSI Z49.1 et Z87.1
énuméré dans les normes de sécurité).
Porter des lunettes de sécurité avec écrans latéraux même sous votre casque.
Avoir recours à des écrans protecteurs ou à des rideaux pour protéger les autres contre les rayonnements les éblouissements et les étincelles ; prévenir
toute personne sur les lieux de ne pas regarder l’arc.
Porter des vêtements confectionnés avec des matières résistantes et ignifuges (cuir, coton lourd ou laine) et des bottes de protection.
OM-4430 Page 5
LE SOUDAGE peut provoquer un incendie ou une explosion.
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.
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.
Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des
substances inflammables.
Se protéger et d’autres personnes de la projection d’étincelles et de métal
chaud.
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.
Brancher le câble de masse 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,
d’étincelles 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.
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.
Le soudage, l’écaillement, le passage de la pièce à la bros-
se 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.
Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
Ne pas toucher à mains nues les parties chaudes.
Prévoir une période de refroidissement avant de travailler à
l’équipement.
Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour éviter les brûlures.
LE BRUIT peut affecter l’ouïe.
Le bruit des processus et des équipements peut affecter
l’ouïe.
Porter des protections approuvés pour les oreilles si le niveau sonore est trop élevé.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
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.
Si des BOUTEILLES sont endommagées, elles pourront exploser.
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, des dommages physiques, 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.
Utiliser les équipements corrects, les bonnes procédures et suffisamment de
personnes pour soulever et déplacer les bouteilles.
Lire et suivre les instructions sur les bouteilles de gaz comprimé, l’équipement
connexe et le dépliant P-1 de la CGA (Compressed Gas Association) mentionné dans les principales normes de sécurité.
2-3. Dangers existant en relation avec le moteur
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.
Arrêter le moteur avant d’installer ou brancher l’appareil.
Seules des personnes qualifiées sont autorisées à enlever les portes, panneaux, recouvrements ou dispositifs de protection pour effectuer, s’il y a lieu,
des travaux d’entretien et de dépannage.
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 dispositifs 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.
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.
DES PIECES CHAUDES peuvent provoquer des brûlures et blessures.
OM-4430 Page 6
Porter des gants et des vêtements de protection pour travailler sur un
moteur chaud.
LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT CHAUD peuvent
provoquer des brûlures.
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.
Ne pas toucher les parties chaudes du moteur.
Laisser l’ensemble se refroidir avant d’effectuer la
maintenance.
Il est préférable de vérifier le liquide de refroidissement
une fois le moteur refroidi pour éviter de se brûler.
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.
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou
même la mort.
LA CHALEUR DU MOTEUR peut provoquer un incendie.
LES ÉTINCELLES À L’ÉCHAPPEMENT
peuvent provoquer un incendie.
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.
Ne pas placer l’appareil sur, au-dessus ou à proximité de
surfaces inflammables.
Tenir à distance les produits inflammables de l’échappement.
L’ACIDE DE LA BATTERIE peut provoquer des brûlures dans les YEUX et
sur la PEAU.
Empêcher les étincelles d’échappement du moteur de
provoquer un incendie.
Utiliser uniquement un pare-étincelles approuvé − voir
codes en vigueur.
Ne pas renverser la batterie.
Remplacer une batterie endommagée.
Rincer immédiatement les yeux et la peau à l’eau.
2-4. Dangers liés à l’air comprimé
Le METAL CHAUD lors du coupage et
gougeage plasma peut provoquer un incendie ou une explosion.
RESPIRER L’AIR COMPRIMÉ peut provoquer des blessures graves ou causer
la mort.
Ne pas couper ou gouger à proximité de produits inflammables.
Surveillez et garder un extincteur à proximité.
Ne pas utiliser l’air comprimé pour respirer.
Utiliser l’air comprimé seulement pour le coupage, gougeage et les outils pneumatiques.
DES PIECES CHAUDES peuvent provoquer des brûlures et blessures.
L’AIR COMPRIMÉ peut provoquer
des blessures.
Porter des lunettes de sécurité approuvées.
Ne pas diriger le jet d’air vers d’autres ou soi-même.
L’AIR COMPRIME EMMAGASINE ET DES
TUYAUX SOUS PRESSION peuvent provoquer des blessures.
2-5.
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.
Laisser l’ensemble se refroidir avant de toucher ou d’effectuer la maintenance.
LIRE LES INSTRUCTIONS.
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.
Utiliser uniquement des pièces de rechange Miller/Hobart.
Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
LA CHUTE DE L’APPAREIL peut blesser.
Utiliser un œilleton de levage pour lever l’appareil et les
accessoires correctement installés. Ne pas dépasser
le poids nominal maximal de l’œilleton (voir les
spécifications).
Ne lever et ne soutenir l’appareil qu’avec de l’équipement
approprié et en suivant les procédures adéquates.
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.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les
circuits imprimés.
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.
LES ÉTINCELLES VOLANTES risquent
de provoquer des blessures.
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.
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.
LE SURCHAUFFEMENT peut endommager le moteur électrique.
Ne pas toucher le compresseur ou d’autres éléments
du circuit air comprimé chauds.
UNE REMORQUE QUI BASCULE peut
entraîner des blessures.
Porter un écran facial pour protéger le visage et les yeux.
Affûter l’électrode au tungstène uniquement à la meuleuse dotée de protecteurs. Cette manœuvre 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.
OM-4430 Page 7
LIRE LES INSTRUCTIONS.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
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 RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer
des interférences.
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 un blindage pour réduire les interférences
éventuelles.
2-6.
Proposition californienne 65 Avertissements
Les équipements de soudage et de coupage produisent des fumées et
des gaz qui contiennent des produits chimiques dont l’État de Californie
reconnaît qu’ils provoquent des malformations congénitales et, dans
certains cas, des cancers. (Code de santé et de sécurité de Californie,
chapitre 25249.5 et suivants)
Les batteries, les bornes et autres accessoires contiennent du plomb et
des composés à base de plomb, produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des cancers et des malformations
congénitales ou autres problèmes de procréation. Se laver les mains
après manipulation.
2-7.
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.
Pour les moteurs à essence :
Les gaz d’échappement des moteurs contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des cancers
et des malformations congénitales ou autres problèmes de procréation.
Pour les moteurs diesel :
Les gaz d’échappement des moteurs diesel et certains de leurs composants sont reconnus par l’État de Californie comme provoquant des
cancers et des malformations congénitales ou autres problèmes de procréation.
Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone :
de Global Engineering Documents (téléphone : 1-877-413-5184, site In- 800-463-6727 ou à Toronto 416-747-4044, site Internet :
ternet : www.global.ihs.com).
www.csa-international.org).
Recommended Safe Practices for the Preparation for Welding and Cutting
of Containers and Piping, American Welding Society Standard AWS F4.1
de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, de American National Standards Institute, 11 West
42nd Street, New York, NY 10036-8002 (téléphone : 212-642-4900, site
Internet : www.ansi.org).
National Electrical Code, NFPA Standard 70, de National Fire Protection Standard for Fire Prevention During Welding, Cutting, and Other Hot
Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA Work, NFPA Standard 51B, de National Fire Protection Association, P.O.
Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (téléphone :
02269-9101 (téléphone : 617-770-3000, site Internet : www.nfpa.org).
617-770-3000, site Internet : www.nfpa.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, de
Compressed Gas Association, 1735 Jefferson Davis Highway, Suite OSHA, Occupational Safety and Health Standards for General Industry,
1004, Arlington, VA 22202-4102 (téléphone : 703-412-0900, site Internet Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and
Part 1926, Subpart J, de U.S. Government Printing Office, Superintendent
: www.cganet.com).
of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10 bureaux
Code for Safety in Welding and Cutting, CSA Standard W117.2, de régionaux−−le téléphone de la région 5, Chicago, est 312-353-2220, site
Canadian Standards Association, Standards Sales, 178 Rexdale Internet : www.osha.gov).
2-8.
Information EMF
Considérations sur le soudage et les effets de basse fréquence et des
champs magnétiques et électriques.
Le courant de soudage, pendant son passage dans les câbles de soudage, causera des champs électromagnétiques. Il y a eu et il y a encore un
certain souci à propos de tels champs. Cependant, après avoir examiné
plus de 500 études qui ont été faites pendant une période de recherche
de 17 ans, un comité spécial ruban bleu du National Research Council a
conclu : « L’accumulation de preuves, suivant le jugement du comité, n’a
pas démontré que l’exposition aux champs magnétiques et champs électriques à haute fréquence représente un risque à la santé humaine ».
Toutefois, des études sont toujours en cours et les preuves continuent à
être examinées. En attendant que les conclusions finales de la recherche
soient établies, il vous serait souhaitable de réduire votre exposition aux
champs électromagnétiques pendant le soudage ou le coupage.
Pour réduire les champs magnétiques sur le poste de travail, appliquer les
OM-4430 Page 8
procédures suivantes :
1. Maintenir les câbles ensemble en les tordant ou en les enveloppant.
2. Disposer les câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber pas et ne pas entourer pas les câbles autour de
votre corps.
4. Garder le poste de soudage et les câbles le plus loin possible de
vous.
5. Connecter la pince sur la pièce aussi près que possible de la soudure.
En ce qui concerne les stimulateurs cardiaques
Les porteurs de stimulateur cardiaque doivent consulter leur médecin
avant de souder ou d’approcher des opérations de soudage. Si le médecin
approuve, il est recommandé de suivre les procédures précédentes.
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 Protector
Positive
Negative
Alternating Current
(AC)
Output
Seconds
Protective Earth
(Ground)
Time
h
Hours
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.
OM-4430 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
50
Voltage
Range In
CV Mode
20 − 300 A
13 − 35 V
CV/DC
300 A, 25 V, 100%
Duty Cycle
35
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
2.4 kVA/kW, 20 A,
120 V AC,
60-120 Hz,
Single-Phase
At All Speeds
−−
Fuel
Capacity
Engine
12 gal
(45 L)
Tank
Kohler CH-20
Air-Cooled,
Two-Cylinder,
Four-Cycle,
Four Cycle,
20 HP Gasoline/LP
Engine
w/Electronic
Governor
4-3. Dimensions, Weights, and Operating Angles
Dimensions
Height
34 in (864 mm)
Width
20−1/2 in (521 mm)
Depth
45-1/2 in (1156 mm)
A
20 in (508 mm)
B
16-1/2 in (419 mm)
C
1−3/4 in (44 mm)
A
B
C
Do not exceed tilt angles or engine could
be damaged or unit could tip.
D
D
5 in (127 mm)
E
32-3/4 in (832 mm)
F
44-1/4 in (1124 mm)
G
13/32 in (10 mm) Dia.
G
4 Holes
F
E
2 °
25
25°
25°
25°
Weight
590 lb (267 kg)
Do not move or operate unit where it could
tip.
Engine End
Lifting Eye Weight Rating
800 426
1280 lb (580 kg)
OM-4430 Page 10
803 983−A
983 A
4-4. Fuel Consumption While Welding And Using Generator Power
LITERS/HR.
U.S. GAL./HR.
On a typical job using 1/8 in 7018
electrodes (125 amps, 20% duty
cycle), expect over 20 hours of operation.
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
Welding at 150 amps at 40% duty
cycle uses approximately 3/4 gallon per hour, or about 16 hours of
operation.
A 2kW generator load at 50% duty
cycle uses less than 1/2 gallon per
hour providing over 24 hours of operation.
3600 RPM Weld
3000 RPM Weld
Idle (At
1800 RPM)
Generator
at 1 kW
0
100
Generator
at 2 kW
150
Generator
at 5 kW
Generator
at 4 kW
Generator
at 3 kW
200
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
AC VOLTS
250
200
150
100
50
0
0
5
10
15
AC AMPERES
20
25
30
222 553
OM-4430 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
MIG/FCAW
300
275
STICK
WELD AMPERES
250
225
200
175
150
0
10
20
30
40
50
70
60
80
90
% DUTY CYCLE
100
Ref. 207 925
4-7. 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
40
3600RPM Max
DC VOLTS
35
3000RPM Max
30
25
20
Min
15
10
5
0
0
100
200
300
400
DC AMPERES
222 558
OM-4430 Page 12
4-8. 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
100
DC VOLTS
80
60
3600RPM Max
3000RPM Max
40
Min
20
0
0
200
DC AMPERES
400
600
400
600
B. CV/DC MIG Mode
40
3600RPM Max
35
DC VOLTS
30
3000RPM Max
25
20V Preset
20
15
Min
10
5
0
0
200
DC AMPERES
222 555 / 222 556 / 222 557
OM-4430 Page 13
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 / Airflow Clearance
Always ground generator
frame to vehicle frame to prevent electric shock and static
electricity hazards.
If unit does not have GFCI receptacles, use GFCI-protected
extension cord.
OR
Mounting:
1
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
Grounding:
2
3
4
18 in
(460 mm)
18 in
(460 mm)
Mounting
Cross-Supports
Mount unit on flat surface or use
cross-supports to support base.
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.
Grounding
2
3
GND/PE
1
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.
Electrically bond generator frame to
vehicle frame by metal-to-metal contact.
4
OM-4430 Page 14
install2 11/04 − Ref. 800 652 / Ref. 800 477-A / 803 274
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.
Full
Fuel
Empty
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.
To check fuel level, turn Engine Control
switch to either Run/Idle position.
LED’s indicate fuel level in tank.
Oil
Do not
exceed the ”Full” mark on
the oil level dipstick. The fuel
pump may operate erratically if
crankcase is overfilled.
Check oil with unit on level surface. If
oil is not up to full mark on dipstick, add
oil (see maintenance label).
Full
Use front panel meters to determine
hours until next recommended oil
change (see Section 6-2).
To improve cold weather starting:
Keep battery in good condition.
Store battery in warm area.
Full
Use correct grade oil for cold
weather.
Gasoline
803 983−A / Ref 216 172−B
OM-4430 Page 15
5-3. Connecting Or Replacing The Battery
Connect negative (−)
cable last.
−
+
Replacing The Battery
Remove end panel to replace battery.
Connect negative (−)
cable last.
−
+
+
−
Tools Needed:
3/8, 1/2 in
803 847 / 803 849 / Ref. S-0756-D Ref 216 172−B / Ref 803 983−A
OM-4430 Page 16
5-4. 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
Ref 216 172−B / 803 891
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-4430 Page 17
5-5. 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 welding, connect work
cable to Negative (−) terminal and
electrode holder cable to Stick/TIG
(CC) terminal.
For TIG welding, connect work cable
to Stick/TIG (CC) terminal and electrode holder to Negative (−) terminal.
2
1
3
Failure to properly connect
weld cables may cause excessive heat and start a fire, or
damage your machine.
4
5
6
7
Weld Output Terminal
Supplied Weld Output Terminal
Nut
Weld Cable Terminal
Copper Bar
Remove supplied nut from weld output terminal. Slide weld cable terminal onto weld output terminal and secure with nut so that weld cable terminal is tight against copper bar. Do not
place anything between weld
cable terminal and copper bar.
Make sure that the surfaces of the
weld cable terminal and copper
bar are clean.
4
7
Do not place
anything between
weld cable terminal
and copper bar.
5
6
Correct Installation
Incorrect Installation
Tools Needed:
3/4 in
216 172−B / 803 984−A / 803 778-A
OM-4430 Page 18
5-6. 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.
* This
10 − 100% Duty Cycle
chart is a general guideline and may not suit all applications. If cable overheats, 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-F
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.
5-7. Remote Receptacle Information
NOTE
A
B
K
Engine runs at weld speed (3000 or 3600 rpm) whenever a device connected to
the remote receptacle is running.
J
I
H
C L N
M
D
G
E F
24 VOLTS AC
115 VOLTS AC
A/V
AMPERAGE
VOLTAGE
GND
Socket*
Socket Information
A
24 volts ac. Protected by supplementary protector
CB4.
B
Not used.
I
115 volts ac. Protected by supplementary protector CB3.
J
Not used.
C
+10 volts dc output to remote control.
D
Remote control circuit common.
E
0 to +10 volts dc input command signal from
remote control.
G
Circuit common for 24 and 115 volts ac circuits.
K
Chassis common.
*The remaining sockets are not used.
OM-4430 Page 19
5-8. 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 right side panels.
1
Stabilizer DC-Z
2
Stabilizer Tabs 1, 2, and 3
Tab 3 − provides stiffest weld puddle
(for aluminum and mild steel)
Tab 2 − provides wetter weld puddle
(for mild steel)
Tab 1 − provides wettest weld puddle
(for stainless steel)
Lead 28 is connected between the Wire/CV
weld output terminal and Tab 3 at the
factory.
For wetter weld puddle (for mild steel):
Remove insulated sleeving from Tab 2. Disconnect Lead 28 from Tab 3. Connect lead
28 to Tab 2, reusing hardware. Insulate Tab
3 with sleeving removed from Tab 2. Secure
sleeving with cable ties.
For wettest weld puddle
(for stainless steel):
Remove insulated sleeving from Tab 1. Disconnect Lead 28 from Tab 3. Connect lead
28 to Tab 1, reusing hardware. Insulate Tab
3 with sleeving removed from Tab 1. Secure
sleeving with cable ties.
Reinstall side panel.
1
2
Tools Needed:
3/8, 7/16 in
Ref 216 172−B / 803 985−A
OM-4430 Page 20
SECTION 6 − OPERATING WELDING GENERATOR
6-1. Front Panel Controls
2
1
3
4
5
6
9
8
7
1 Process Switch
See Section 6-4 for Process switch information.
2 Remote Receptacle
Use receptacle to connect remote control.
When a remote voltage/amperage control is
connected to the Remote receptacle, the
Auto Sense Remote feature automatically
switches voltage/amperage control to the remote control (see Sections 5-7 and 6-7).
With remote voltage/amperage control connected, weld output in CC mode is determined by a combination of front panel and remote control voltage/amperage settings.
If no remote voltage/amperage control is
connected to the Remote receptacle, the
front panel Voltage/Amperage control adjusts voltage and amperage.
3 And 4 Displays
Displays can show weld process information
(voltage and amperage) or maintenance information (hourmeter or oil change countdown).
Meter Weld Functions: In Wire mode, Volt-
meter displays preset weld voltage when not
welding. Meters display actual voltage and
amperage when welding and for five seconds after welding has stopped.
In Stick and TIG modes, Voltmeter reads ON
and Ammeter displays preset amperage
when not welding. Meters display actual voltage and amperage when welding and for five
seconds after welding has stopped.
Meter Engine Maintenance Functions:
Meters display engine hours when Engine
Control switch is in the Run/Idle 3600/2400
position but engine is not running.
Meter Oil Change Countdown: With engine off, place Engine Control switch in Run/
Idle 3000/1800 position to see hours before
next recommended oil change. Oil change
hours start at 100 (fresh oil) and count down
to 0 (oil change due). The meters display
negative (−) hours if 100 hours is exceeded.
After changing oil, reset counter by cycling
Engine Control switch between Run/Idle
positions three times.
Place Engine Control switch in Off position
after reading meters.
5 Fuel Level Indicator
With Engine running or Engine Control
switch in either Run/Idle position, LED’s indicate fuel left in tank.
6 Voltage/Amperage 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 switch in any Stick or TIG setting, use control to adjust amperage. With
Process switch in Wire position, use control
to adjust voltage. When a remote voltage/
amperage control is connected to Remote
receptacle RC4, control sets the maximum
amperage in Stick and TIG modes, but has
no effect in MIG mode.
7 Engine Control Switch (see Section 6-2)
8 Engine Choke Control (see Section 6-2)
9 Engine Speed Control Switch (see Section 6-2)
Ref 216 172−B
OM-4430 Page 21
6-2. Description Of Engine Controls (See Section 6-1)
Engine Control Switch
Use switch to start engine, select speed, and
stop engine. Use switch in combination with
Engine Speed Control switch to select engine speed.
In Run/Idle 3600/2400 RPM position, engine
runs at 2400 rpm no weld load and 3600 rpm
under weld load.
In Run/Idle 3000/1800 RPM position, engine
runs at 1800 rpm no weld load and 3000 rpm
under weld load.
In either position, engine speed is determined by weld load and position of Engine
Speed Control switch.
Generator power is available at recep-
tacles 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.
Engine Choke Control
Use control to change engine air-fuel mix
when starting engine.
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.
Engine 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. See Section 7-2.)
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.
6-3. Controlling Engine Speed And Weld/Generator Output
Set engine controls as shown
to obtain the corresponding
weld and generator power output.
Disconnect
Engine Controls
Engine Speed
Either
Run/Idle
position.
1800 rpm
(Power Speed)
Continuous
Generator Power
Output
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)
Weld Output
equipment from
auxiliary power receptacles
during start-up and shutdown.
Some equipment can be damaged by changes in frequency
as engine rpms change during
start-up and shutdown.
Welding Not
Recommended
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.
3000 rpm:
20 − 220 A
At 3000 rpm, Output
Available Only At 2.4
kW/kVA 60-120 Hz AC
Receptacle RC3
Ref 216 172−B
OM-4430 Page 22
6-4. Process Switch
1
1
Process Switch
Weld output terminals are energized
when Process switch is in an Electrode Hot position and the engine is
running.
The unit will not return to idle speed
when Process switch is in a Wire or TIG
position and 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 5-7).
Wire Position:
Use Wire position for MIG welding using a
voltage sensing wire feeder.
Stick Positions:
Use Stick positions for stick (SMAW) and
air carbon arc (CAC-A) cutting and
gouging.
When switch is in a Stick mode, select one
of four dig settings to provide additional amperage during short arc length conditions
and help prevent electrodes from “sticking”.
See Stick position descriptions following
(reading L to R):
Soft Arc (E 7018) (Position 1) - This setting
provides a low dig/arc force setting for
smooth weld performance. A stable weld
puddle with little arc “snap” gives excellent
weld bead appearance with minimal
spatter.
Medium Soft Arc (Position 2) - This setting
provides a low to medium dig/arc force that
gives a slightly more fluid weld puddle,
more arc “snap”, and reduces the potential
for electrode sticking at shorter arc lengths.
Medium Stiff Arc (Position 3) - This setting
provides medium dig/arc force for open root
vertical up joints or joints that do not require
additional current for fit up inconsistencies.
Stiff Arc (E6010) (Position 4) - This setting
provides a high dig/arc force for open root
vertical down joints where additional
current is needed to compensate for tight
joint fit up without the need to increase
overall welding current. This setting is recommended for those who prefer a very stiff
arc with 6010 electrodes.
The dig circuit is disabled when switch is in
Wire or TIG positions.
TIG Position:
Electrode Hot − Lift-Arc™/Scratch Start TIG
(Provides great DC starts with either starting method) - With switch in this position,
normal open-circuit voltage is not present
between the electrode and workpiece. A
solid-state contactor energizes after the
electrode touches
the
workpiece,
preventing overheating, sticking, or contamination of the electrode (see Sections
6-5 and 6-6).
Ref 216 172−B / 803 984
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-4430 Page 23
6-5.
Stick Start Procedure − Scratch Start Technique
With Stick selected, start arc as
follows:
1
2
3
Electrode
Workpiece
Arc
Drag electrode across workpiece like
striking a match; lift electrode slightly
after touching work. If arc goes out
electrode was lifted to high. If
electrode sticks to workpiece, use a
quick twist to free it.
1
2
3
6-6. TIG Lift-Arc™ Start Procedure
Select Lift-Arc/Scratch Start TIG at
Process switch to achieve great arc
starts with either procedure. Perform
Lift-Arc starting method as follows:
Lift-Arc TIG
Lift-Arc Start Method
1
“Touch”
1
Second
2
1
TIG Electrode
2
Workpiece
Turn gas on. Touch tungsten
electrode to workpiece at weld start
point. Hold electrode to workpiece
for 1 second, and slowly lift electrode.
Arc is started when electrode is lifted.
Normal open-circuit voltage is not
present before tungsten electrode
touches workpiece; only a low sensing
voltage is present between electrode
and workpiece. The solid-state output
contactor does not energize until after
electrode is touching workpiece. This
allows electrode to touch workpiece
without overheating, sticking, or
getting contaminated.
Application:
Lift-Arc is used for the DCEN GTAW
process when HF Start method is not
permitted.
Do NOT Strike Like A Match!
OM-4430 Page 24
6-7. Remote Amperage Control
1
Remote Receptacle RC4
Connect optional remote voltage/
amperage (V/A) control to RC4 (see
Section 5-7).
With remote control connected, weld
output in a CC mode (Stick, TIG) is
determined by a combination of front
panel and remote control voltage/
amperage settings. In CV mode
(Wire), weld output is controlled
through remote control only.
1
2
3
Remote Hand Control
(Optional)
Remote Foot Control (Optional)
Engine
runs at weld/power
speed in Wire and TIG mode
whenever a device connected to
the remote receptacle makes
closure between pins A and B.
This unit does not have remote
contactor control. Output is always on.
In Example:
Process = Stick (Using Remote On/Off)
Min = 20 A CC/DC
Max = 160 A CC/DC
3
2
Max (160 A DC)
Min (20 A DC)
Connect Remote
V/A Control To
Remote
Receptacle RC4
Set Process
Set V/A Control
(Mid-Range: About 160 A)
Adjust Remote V/A Control
(Stick Welding Only)
803 984−A / 216 172−B / S-0769 / S-0774
OM-4430 Page 25
SECTION 7 − OPERATING AUXILIARY EQUIPMENT
7-1. 60 Hz Generator Power Receptacles And Supplementary Protectors
If unit does not have GFCI receptacles, use GFCI-protected
extension cord.
4
1
Disconnect equipment from aux-
iliary power receptacles during
start−up and shutdown.Some
equipment can be damaged by
changes in frequency as engine
rpms change during start-up and
shutdown.
2
Weld output and 60 Hz generator
See Section
7-2 for RC3
information.
power output at receptacles RC1
and RC2 are not always available
at the same time. When welding,
generator power is available from
AC receptacle RC3 only (see
Section 7-2).
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
3
Controlling Engine Speed And Weld/Generator Power Output
Engine Controls
Engine Speed
Either
Run/Idle
position.
1800 rpm
(Power Speed)
Continuous
Generator Power
Output
2
Weld Output
Welding Not
Recommended
Load: 3600 rpm
(Weld Speed)
3600 rpm:
20 − 300 A
2.4 kW/kVA at 60-120
Hz From AC
Receptacle RC3 Only
Supplementary Protector CB1
CB1 protects receptacles RC1 and
RC2 from overload. If CB1 opens, the
receptacles do not work. Place switch
in On position to reset.
4
No Load: 2400 rpm
(Idle Speed)
120 V 20 A AC Duplex
Receptacle RC2
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
5 kW/kVA Total From
All AC Receptacles
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.
Supplementary Protector CB2
CB2 protects RC2 from overload. If
CB2 opens, the receptacle does not
work. Press button to reset.
If supplementary protector continues to open, contact Factory
Authorized Service Agent.
Combined output of all receptacles
limited to 5 kVA/kW continuous rating
of the generator.
No Load: 1800 rpm
(Idle Speed)
Load: 3000 rpm
(Weld Speed)
5 kW/kVA Total From
All AC Receptacles
At 1800 rpm.
At 3000 rpm, Output
Available Only At 2.4
kW/kVA 60-120 Hz AC
Receptacle RC3
3000 rpm:
20 − 220 A
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
Ref. 211 909
OM-4430 Page 26
7-2. Variable Frequency (Hz) Generator Power Receptacle RC3
2
1
Do not operate equipment requiring a constant frequency
from variable frequency receptacle RC3.
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.
2
Supplementary Protector CB3
CB3 protects receptacle RC3 and
115 volt ac output to Remote Receptacle RC4 from overload. If CB3
opens, the receptacle does not work
and 115 volt ac output at RC4 stops.
Press button to reset. If supple-
mentary protector continues to
open, contact a Factory Authorized Service Agent.
Ref. 216 172−B
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-4430 Page 27
7-3. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P)
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
When wired for 120 V loads, each
duplex receptacle shares a load
with one half of 240 V receptacle.
240 V
Each 120 V Duplex
Receptacle*
Receptacle
20
15
10
5
0
Plug Wired for 120/240 V,
3-Wire Load
0
5
10
15
20
V x A = Watts
1
3
4
*One 240 V load or two 120 V loads.
120V
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
5
120V
240V
6
Tools Needed:
2
3
4
240V
6
5
240 V AC
120 V AC
120 V AC
plug1 11/03 − 120 813-D
OM-4430 Page 28
SECTION 8 − MAINTENANCE & TROUBLESHOOTING
8-1. Routine Maintenance
Note
Follow the storage procedure in the engine owner’s manual if the unit will not be used for an
extended period.
Stop engine before maintaining.
See Engine Manual and Maintenance Label
Recycle engine
for important start-up, service, and storage
fluids.
information. Service engine more often if
used in severe conditions.
= Check
= Change
= Clean
* To be done by Factory Authorized Service Agent
= Replace
Reference
Every
8
Hours
Section 5-2
Fuel Level
Oil Level
Oil, Fuel Spills
Every
25
Hours
Section 8-3,
8-4
Spark Arrestor Screen
Air Cleaner Wrapper
Every
50
Hours
Weld Terminals
Every
100
Hours
Engine
Manual,
Section 8-4,
8-5
Battery Terminals
Cooling System
Oil
Air Cleaner Element
Every
200
Hours
Engine
Manual,
Section 8-5
Unreadable Labels
Spark Plug Gap
Oil Filter
Fuel Filter
Every
500
Hours
Every
1000
Hours
Weld Cables
Slip Rings*
Brushes*
OR
Inside Unit
OM-4430 Page 29
8-2. Maintenance Label
NOTE
OM-4430 Page 30
Follow the storage procedure in the engine owner’s manual if the unit will not be
used for an extended period.
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
803 983−A / Ref 216 172−B
8-4. Servicing Air Cleaner
Stop engine.
Do not run engine without air
cleaner or with dirty element.
1
Precleaner
Wash precleaner with soap and water solution. Allow precleaner to air
dry completely.
1
Spread 1 tablespoon SAE 30 oil
evenly into precleaner. Squeeze
out excess oil.
2
2
Element
Replace element if damaged, dirty,
or oily.
oil
aircleaner3 11/04 − 802 772 / S-0759
OM-4430 Page 31
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
2
4
1
Tools Needed:
803 983−A / Ref 216 172−B / S-0842
OM-4430 Page 32
8-6. Overload Protection
Stop engine.
Open left side door.
When a supplementary protec-
tor or fuse opens, it usually indicates a more serious problem
exists. Contact a Factory Authorized Service Agent.
1
Supplementary Protector CB4
CB4 protects the stator winding
supplying 24 volt ac output to Remote receptacle RC4. If CB4
opens, 24 volt ac output to RC4
stops.
Supplementary Protector CB3
protect the stator winding supplying 115 volt ac output to Remote Receptacle RC4 (see
Section 7-1).
Press button to reset.
2
Fuse F6 (See Parts List)
F6 protects the engine wiring system from overload. If F6 opens,
engine will not crank.
Replace fuse if open.
Close left side door.
1
2
803 773−A / Ref. 216 172−B
OM-4430 Page 33
8-7. Troubleshooting
A. Welding
Trouble
No weld output.
Remedy
Check weld control settings.
Check weld connections.
Disconnect equipment from generator power receptacles during start-up.
Increase front panel and/or remote control voltage/amperage control setting (see Sections 6-2 and
6-7).
Check and secure connections to Remote receptacle RC4 (see Sections 5-7).
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.
Increase front panel and/or remote control voltage/amperage control setting (see Sections 6-2 and
6-7).
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 and PC2.
Weld output cannot be adjusted.
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.
Check and tighten connections to Remote receptacle RC4 (see Section 5-7).
No front panel voltage/amperage control.
Disconnect remote control from Remote Receptacle RC4 if not needed for weld process (see Section
6-7).
No 24 volt ac output at Remote
receptacle RC4.
Reset supplementary protector CB4 (see Section 8-6).
No 115 volt ac output at Remote
receptacle RC4.
Reset supplementary protector CB3 (see Section 7-2).
OM-4430 Page 34
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 supplementary protectors CB1 and/or CB2 (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.
Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.
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 supplementary protector CB4 (see Section 7-2).
Check receptacle RC3 for continuity and proper connections. Replace receptacle if necessary.
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.
Turn Engine Control switch to Run/Idle 3600/2400 RPM position.
OM-4430 Page 35
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.
Have Factory Authorized Service Agent check fuel shutoff solenoid FS1 according to engine manual.
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.
Engine also stops if oil level is too high.
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.
Engine also stops if oil level is too high.
Have Factory Authorized Service Agent check low oil pressure shutdown switch S5.
Have Factory Authorized Service Agent check fuel shutoff solenoid FS1 according to engine manual.
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 5-7.
Check for obstructed movement of solenoid linkage.
Have Factory Authorized Service Agent check circuit board PC2.
Engine does not go to weld speed.
Place Speed Control switch in Weld position.
Check for obstructed movement of solenoid linkage.
OM-4430 Page 36
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)
OM-4430 Page 37
SECTION 9 − ELECTRICAL DIAGRAMS
Figure 10-1. Circuit Diagram For Welding Generator Models
OM-4430 Page 38
222 088-A
OM-4430 Page 39
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)
OM-4430 Page 40
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.
S-0854
OM-4430 Page 41
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.
2
Use ground device as stated
in electrical codes.
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
OM-4430 Page 42
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
Rating
1/4 HP
1/2 HP
3/4 HP
2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/2 HP
500 PSI
550 PSI
700 PSI
1/3 HP
1/2 HP
1/3 HP
1/2 HP
Starting Watts
Running Watts
1000
1650
3400
4400
2900
10500
1720
2575
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
3300
3150
4500
6100
3100
2150
3100
2100
3200
1000
650
1000
1400
1100
2800
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
1000
950
1400
1600
800
750
1000
800
1050
OM-4430 Page 43
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
OM-4430 Page 44
Rating
Starting Watts
Running Watts
1/4 in
3/8 in
1/2 in
6-1/2 in
7-1/4 in
8-1/4 in
9 in
10 in
14 in
6 in
8 in
10 in
1/2 HP
1 HP
1-1/2 HP
2 HP
1-1/2 HP, 12 in
2 HP, 14 in
Standard 9 in
Heavy Duty 12 in
1/3 HP
18 in
HID
Metal Halide
Mercury
Sodium
Vapor
400 gph
900 gph
3/4 HP, 16 in
1 HP, 20 in
1/2 HP
3/4 HP
1 HP
1/4 HP
1.7 HP
2-1/2 HP
350
400
600
500
900
1400
4500
6300
2500
1720
3900
5200
3000
6000
8200
10500
1100
1100
350
500
2100
400
125
313
1000
1400
1250
600
900
4500
6100
3150
4500
6100
1900
900
1300
350
400
600
500
900
1400
1500
1800
1100
720
1400
1600
1000
1500
2200
2800
1100
1100
350
500
700
400
100
250
1000
200
500
1400
1600
950
1400
1600
700
900
1300
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-4430 Page 45
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.
OM-4430 Page 46
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-4430 Page 47
SECTION 11 − PARTS LIST
Hardware is common and
not available unless listed.
8
9
10
13
11 12
7
14
28
16
5
4
30
27
15
6
29
22
17 21
18
19
20
26 Fig.11-3
23
31
25
24
32
3
2
33
59
1
57
58
55
54
56
54
31
34
35
53
51 Fig.11-2
42
39
40
41
52
44
46
43
36
38
37
45
47
48
50
49
803 987−B
Figure 11-1. Main Assembly
OM-4430 Page 48
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-1. Main Assembly
. . . 1 . . . . . . . . . . . . . . 215873
. . . 2 . . . . . . . . . . . . . . 211366
. . . 3 . . . . . . . . . . . . . . 219329
. . . 4 . . . . . . . . . . . . . . 222324
. . . 5 . . . . . . . . . . . . . . 211367
. . . 6 . . . . . . . . . . . . . . 211365
. . . 7 . . . . . . . . . . . . . . 217395
. . . 8 . . . . . . . . . . . . . . 211370
. . . 9 . . . . . . . . . . . . . . 211368
. . . 10 . . . . . . . . . . . . . . 211398
. . . 11 . . . . . . . . . . . . . . 220711
. . . 12 . . . . . . . . . . . . . . 211527
. . . 13 . . . . . . . . . . . . . . 211369
. . . 14 . . . . . . . . . . . . . . 220407
. . . 15 . . . . . . . . . . . . . . 211368
. . . 16 . . . . . . . . . . . . . . 215799
. . . 17 . . . . PC1 . . . . 217869
. . . 18 . . . . . . . . . . . . . . 215797
. . . 19 . . . . C39 . . . . 176007
. . . 20 . . . . . . . . . . . . . . 215800
. . . 21 . . . . . . . . . . . . . . 211360
. . . 22 . . . . . . . . . . . . . . 205734
. . . 23 . . . . CB4 . . . . 083432
. . . 24 . . . . . . . . . . . . . . 211209
. . . 25 . . . . . . . . . . . . . . 179276
. . . 26 . . . . . . . . . . . Figure 11-2
. . . 27 . . . . . . . . . . . . . . 211402
. . . 28 . . . . . . . . . . . . . . 209057
. . . 29 . . . . . . . . . . . . . . 189477
. . . 30 . . . . . . . . . . . . . . 217223
. . . . . . . . . . . F6 . . . . *021718
. . . . . . . . VOLT REG . *190249
. . . . . . . . . . . . . . . . . . . . 180096
. . . . . . . . . . . . . . . . . . . *067272
. . . . . . . . . . . . . . . . . . . *066698
. . . . . . . . . . . . . . . . . . . *215985
. . . . . . . . . . . . . . . . . . . *067007
. . . . . . . . . . . . . . . . . . . *067273
. . . 31 . . . . . . . . . . . . . . 167788
. . . 32 . . . . . . . . . . . . . . 208003
. . . 33 . . . . . . . . . . . . . . 211364
. . . 34 . . . . . . . . . . . . . . 217848
. . . 35 . . . . . . . . . . . . . . 219811
. . . 36 . . . . . . . . . . . . . . 182935
. . . 37 . . . . . . . . . . . . . . 167677
. . . 38 . . . . . . . . . . . . . . 211394
. . . 39 . . . . . . . . . . . . . . 216641
. . . 40 . . . . . . . . . . . . . . 215984
. . . 41 . . . . . . . . . . . . . . 215035
. . . . . . . . . . . . . . . . . . . . 124253
. . . . . . . . . . . . . . . . . . . . 226600
. . . . . . . . . . . . . . . . . . . . 216308
. . . 42 . . . . . . . . . . . . . . 219654
. . . 43 . . . . . . . . . . . . . . 211356
. . . 44 . . . . . . . . . . . . . . 217015
. . . 45 . . . . . . . . . . . . . . 211355
. . Shroud, Air Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Panel, Side RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Label, Use Gasoline Fuel Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Label, Warning General Precautionary Csa . . . . . . . . . . . . . . . . . . . . . . . . .
. . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Panel, Side LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bumper, Rubber Press−in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Latch, Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Door, Access Engine Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Grommet, Plastic Neck Filler Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Cap, Tank Screw−on W/Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Pipe, Exhaust Elbow Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Door Assy, Access Engine Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Label, Engine Maintenance Robin & Kohler . . . . . . . . . . . . . . . . . . . . . . . . .
. . Door, Access Engine Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Cover, PC Board Bkt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Circuit Card Assy, Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bracket, Mtg Pc Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Capacitor, Elctlt 1200 Uf 300 Vdc Can 1.37 Dia . . . . . . . . . . . . . . . . . . . . . .
. . Gasket, Capacitor Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Upright, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Seal, Weather Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Supplementary Pro, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . .
. . Cover, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bushing, Snap−in Nyl 1.000 Id X 1.375 Mtg Hole Cent . . . . . . . . . . . . . . . .
. . Generator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Muffler, Exhaust Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Clamp, Muffler 1.625 Dia U Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Muffler Gasket, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Engine, Gas Elec Start (Kohler) (includes) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Fuse, Mintr Gl 30, Amp 32 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Regulator, Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Tune−up & Filter Kit (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Air Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Filter/Clamps, Fuel 1/4 in Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Air Filter Wrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Nut, 375−16 .56hex .34h Stl Pld Sem Cone Wshr.88d . . . . . . . . . . . . . . .
. . Hose, Oil W/Fittings And Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Cable, Bat Neg 15.000 No 4 Awg W/Clamp & .343 Rng . . . . . . . . . . . . . .
. . Cable, Bat Pos 25.000 No 4 Awg W/Clamp & .312 Rng . . . . . . . . . . . . . .
. . Hold Down, Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Battery, Stor 12v 430 Crk 75 Rsv Gp 58 Maint Free . . . . . . . . . . . . . . . . .
. . Baffle, Engine Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Seal, Engine Air Baffle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Tank, Fuel 12.0 Gal W/Sender (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Ftg, Stand Pipe .250 X 6.10 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Sender, Fuel Gauge 7.875 Deep Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Label, Warning Battery Explosion Can Blind . . . . . . . . . . . . . . . . . . . . . . . .
. . Pan, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Label, Warning Do Not Weld On Base/Fuel Level . . . . . . . . . . . . . . . . . . .
. . Cover, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
10
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
2
1
3
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
2
2
OM-4430 Page 49
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-1. Main Assembly (Continued)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
46
47
48
49
50
51
52
53
54
55
56
57
58
59
. . . . DC−Z . . . . 214824
. . . . . . . . . . . . . . 214814
. . . . . . . . . . . . . . 211091
. . . . SR1 . . . . 202222
. . . . . . . . . . . . . . 211092
. . . . . . . . . . . Figure 11-3
. . . . CR2 . . . . 113247
. . . . . . . . . . . . . . 211358
. . . . . . . . . . . . . . 010954
. . . . . . . . . . . . . . 214556
. . . . . . . . . . . . . . 127595
. . . . . . . . . . . . . . 211210
. . . . . . . . . . . . . . 215798
. . . . C41 . . . . 217632
. . Stabilizer Assy, (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Plate, Mtg Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Mtg Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Rectifier, Si 3ph 300 Amp 400 Piv 100% Duty Cycle . . . . . . . . . . . . . . . . . 1
. . Baffle, Stab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Panel, Front w/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Relay ,Encl 12vdc Dpdt 20a/120vac 8pin Flange Mtg . . . . . . . . . . . . . . . . . 1
. . Bracket, Mtg Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Washer, Flat .406idx1.250odx.125t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . Mount, Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . Screw, 375−16x2.50 Hex Hd−pln Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Bracket, Mtg Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Capacitor Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Capacitor, Elctlt 1200 Uf 300 Vdc Can 2.00 Dia . . . . . . . . . . . . . . . . . . . . . 1
*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 217247.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-4430 Page 50
Item
No.
Part
No.
Description
Quantity
Figure 11-2. Generator (Figure 11-1 Item 26)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
. . . . . . . . . . . . . +218746
. . . . . . . . . . . . . . 182092
. . . . . . . . . . . . . . 217225
. . . . . . . . . . . . . . 181143
. . . . . . . . . . . . . . 215344
. . . . . . . . . . . . . . 212161
. . . . . . . . . . . . . . 202771
. . . . . . . . . . . . . . 142156
. . . . . . . . . . . . . . 170861
. . . . . . . . . . . . . . 205725
. . . . . . . . . . . . . . 010910
. . . . . . . . . . . . . . 010909
. . . . . . . . . . . . . . 136343
. . . . . . . . . . . . . . 217046
. . . . . . . . . . . . . . 216532
. . . . . . . . . . . . . . 214017
. . . . . 1T . . . . . 172661
. . . . . . . . . . . . . . 173734
. . Stator, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Warning Moving Parts Can Cause Serious Etc . . . . . . . . . . . . . . . . 1
. . Rotor, Generator (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Bearing, Ball Rdl Sgl Row .984 X 2.047 X .591 . . . . . . . . . . . . . . . . . . . . 1
. . . . Fan, Rotor Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Adapter, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Baffle, Engine Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Screw, 375−16x1.75 Hexwhd.81d Gr8 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . Stud, Stl .375−16 X 17.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . Brushholder Assy, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Washer, Flat .406idx0.812odx.065t Stl Pld Ansi.375 . . . . . . . . . . . . . . . . . . 4
. . Nut, 375−16 .56hex .46h Stl Pld Elastic Stop Nut . . . . . . . . . . . . . . . . . . . . 4
. . Screw, K50x 20 Pan Hd−phl Stl Pld Pt Thread Forming . . . . . . . . . . . . . . . 4
. . Endbell (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Tolerance Ring, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Terminal Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Block, Stud Connection 6 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Link, Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hardware is common and
not available unless listed.
7
6
3
18
5
2
4
17
1
8
16
14
9
15
10
11
13
12
803 887-B
Figure 11-2. Generator
+
When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 217247.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-4430 Page 51
Hardware is common and
not available unless listed.
3
2
6
5
4
1
7
31
8
9
10
11
29
28
27
26
30
12
13
14
16
25
15
18
17
24
23
22
19
21
20
803 989−B
Figure 11-3. Panel, Front w/Components
OM-4430 Page 52
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-3. Panel, Front w/Components (Figure 11-1 Item 51)
. . . 1 . . . . . . . . . . . . . . . . . . . . . . . . Nameplate (Order By Model & Serial Number) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . 190512 . . Stand−off, No 6−32 X .640 Lg .250 Hex Al Fem . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . PC2 . . . . 221757 . . Circuit Card Assy, Control (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 221479 . . . . Shield, PCB Protective Anti Static 4.813x12.750 . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . RC4 . . . . 134735 . . Conn, Circ Ms/Cpc 14skt Size 20 Rcpt Panel Pushin . . . . . . . . . . . . . . . . .
. . . 5 . . . . NEG . . . . 039046 . . Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . LEM . . . . 168829 . . Transducer, Current 1000a Module Max Open Loop . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . CB1 . . . . 217813 . . Supplementary Protector, Man Reset 2p 25a 240vac . . . . . . . . . . . . . . . . 1
. . . 8 . . . . RC2 . . . . 222091 . . Rcpt, Str Dx W/Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . GFCI2 . ♦222093 . . Rcpt, Str Dx Grd Gfci W/Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . CB2, CB3 . 093996 . . Supplementary Pro, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . RC3 . . . . 222092 . . Rcpt, Str Dx Ivory W/Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . GFCI3 . ♦222094 . . Rcpt, Str Dx Gfci Ivory W/Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . POS . . . . 039047 . . Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . . . S2 . . . . . 217680 . . Switch, Ignition 4 Position W/Out Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . S4 . . . . . 011609 . . Switch, Tgl Spdt 15a 125vac On−none−on Spd Term Chr . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . 021385 . . Boot, Toggle Switch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 221516 . . Control,Push/Pull Snap−in 36.000 W/1.750 Extension . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . 207073 . . Lever, Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . 212977 . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . RC1 . . . . 182954 . . Rcpt, Str 3p4w 50a 125/250v Flush Mtg *14−50 . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . 211416 . . Bezel, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . 216775 . . Cover, Output Stud Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . 213914 . . Cover, Output Stud Stick/Tig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . 216773 . . Cover, Receptacle Duplex 120v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . 216774 . . Cover, Receptacle Full Kva 120/240v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . 216771 . . Cover, Output Stud Negative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . 211405 . . Pin, Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . 170391 . . Conn, Circ Ms Protective Cap Size 20 Nylon . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . 197203 . . Grounding Stud Assy, Brass (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 083030 . . . . Stud, Brs .250−20 X 1.750 W/Hex Collar . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 010915 . . . . Washer, Flat .257idx0.640odx.031t Brs . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 163167 . . . . Washer, Lock .254idx0.489odx.062t Sst Split.250 . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 601836 . . . . Nut, 250−20 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . 207075 . . Knob, Pointer 1.625 Dia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . 207080 . . Knob, Pointer 1.125 Dia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . C49 . . . . 222064 . . Capacitor, Polye Met Film .1 Uf 500 Vdc 10% . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . C48 . . . . 222065 . . Capacitor Module, Polye Met Film .1 Uf 500 Vdc 10% . . . . . . . . . . . . . . . . 1
♦OPTIONAL
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-4430 Page 53
Note
Item
No.
Some wiring harness components (switches, relays, circuit breakers) are also referenced
elsewhere in this parts list. Purchase components separately or as part of the associated
wiring harness.
Dia.
Mkgs.
Part
No.
Description
Quantity
Wiring Harnesses
....................
. . . . . . . . . PLG 12 . . .
. . . . . . . . . PLG 15 . . .
. . . . . . . . . . RC 5 . . . .
. . . . . . . . . PLG 24 . . .
. . . . . . . . . PLG 8 . . .
....................
. . . . . PLG 27, PLG30
. . . . . . . . . PLG 25 . . .
. . . . . . . . . PLG 31 . . .
. . . . . . . . . PLG 26 . . .
. . . . . . . . . PLG 17 . . .
. . . . . . . . . PLG 23 . . .
. . . . . . . . . PLG 21 . . .
. . . . . . . . . PLG 16 . . .
. . . . . . . . . . RC30 . . . .
218735
130693
113752
113634
117865
177859
202660
176121
114063
114063
066104
117037
117037
113752
116513
206808
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
Harness, Wrg Unit (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conn,Rect Mini 045 5skt 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . .
Conn, Rect Mini 045 10skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . .
Conn, Rect Univ 084 6p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . . .
Conn, Rect Mini 045 14skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . .
Conn, Body 5 Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conn, Push 4 Wire 12−16strnd 12−18sld 16−22tinstrnd . . . . . . . . . . . . . .
Conn, Rect Univ 084 2p/S 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . .
Conn, Rect Univ 084 4p/S 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . .
Conn, Rect Univ 084 4p/S 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . .
Conn, Rect Univ 084 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . .
Conn, Rect Mini 045 2skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . .
Conn, Rect Mini 045 2skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . .
Conn, Rect Mini 045 10skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . .
Conn, Rect Mini 045 12skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . .
Conn, Rect Univ 084 2p/S 1row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
....................
. . . . . . . . . . RC 4 . . . .
. . . . . . . . . PLG 14 . . .
. . . . . . . . . . CB 4 . . . .
218733
134735
113751
083432
..
..
..
..
Harness, Remote Control 14Pin (includes) . . . . . . . . . . . . . . . . . . . . . . .
Conn, Circ Ms/Cpc 14skt Size 20 Rcpt Panel Pushin . . . . . . . . . . . . . . . .
Conn, Rect Mini 045 8skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . .
Supplementary Pro, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . .
1
1
1
1
. . . . . . . . . . . . . . . . . . . . 217747 . . Plugs, w/Leads (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG 6 . . . 113750 . . Conn, Rect Mini 045 4skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG13 . . . 113750 . . Conn, Rect Mini 045 4skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG5 . . . . 135556 . . Plug, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-4430 Page 54
Effective January 1, 2005
(Equipment with a serial number preface of “LF” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
*
Induction Heating Coils and Blankets
*
APT & SAF Model Plasma Cutting Torches
*
Remote Controls
*
Accessory Kits
*
Replacement Parts (No labor)
*
Spoolmate Spoolguns
*
Canvas Covers
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.
Miller’s True Blue® Limited Warranty shall not apply to:
1.
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.
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.
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 Sources (Unless Otherwise Stated)
*
Water Coolant Systems (Integrated)
*
*
*
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 and Coolers
Water Coolant Systems (Non-Integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Maxstar 85, 140
Spot Welders
Load Banks
Arc Stud Power Sources & Arc Stud Guns
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
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 1/05
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
Contact 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.
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
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
© 2005 Miller Electric Mfg. Co. 10/05
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
www.MillerWelds.com
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