Miller | LH140791Q | Owner Manual | Miller TRAILBLAZER 302 GAS User manual

Miller TRAILBLAZER 302 GAS User manual
OM-4426
215 348X
2007−11
Processes
MIG (GMAW) Welding
Flux Cored (FCAW)
Stick (SMAW) Welding
TIG (GTAW) Welding
Air Plasma Cutting and Gouging
with Spectrum Unit
Air Carbon Arc (CAC-A) Cutting
and Gouging
Description
Engine Driven Welding Generator
(AC Available On AC/DC Models Only)
Trailblazer 302
Trailblazer 275 DC
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. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Dimensions, Weights, and Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Dimensions For Units With Optional Running Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Fuel Consumption Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Stick And MIG Mode Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. TIG Mode Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Engine Prestart Checks (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Engine Prestart Checks (Robin-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Connecting Or Replacing The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9. Remote Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − OPERATING WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Front Panel Controls (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Description Of Front Panel Controls (See Section 6-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Cold Weather Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Process/Contactor Switch On AC/DC Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Stick Start Procedure − Scratch Start Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Lift-Arc TIG With Auto-Crater And Auto-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. Remote Voltage/Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Generator Power Receptacles And Supplementary Protectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Optional GFCI Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Simultaneous Weld And Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P) . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS
SECTION 8 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Servicing Optional Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5. Changing Engine Oil, Oil Filter, And Fuel Filter (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . .
8-6. Changing Engine Oil, Oil Filter, and Fuel Filter (Robin-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . .
8-7. Adjusting Engine Speed (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-8. Adjusting Engine Speed (Robin-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-9. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-10. Welding Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-11. Generator Power Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-12. Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPLETE PARTS LIST - www.MillerWelds.com
OPTIONS AND ACCESSORIES
WARRANTY
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SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
rom_2007−04
Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
Indicates special instructions.
This group of symbols means Warning! Watch Out! 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.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
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.
Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
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.
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.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
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.
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.
HOT PARTS can cause severe burns.
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.
FLYING METAL or DIRT can injure eyes.
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.
OM-4426 Page 1
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 air-supplied 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.
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).
Do not weld where the atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
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.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
Use only correct fuses or circuit breakers. Do not oversize or bypass them.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
NOISE can damage hearing.
BUILDUP OF GAS can injure or kill.
Noise from some processes or equipment can damage hearing.
Shut off shielding gas supply when not in use.
Always ventilate confined spaces or use approved air-supplied respirator.
Wear approved ear protection if noise level is
high.
MAGNETIC FIELDS can affect Implanted
Medical Devices.
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.
WELDING can cause fire or explosion.
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.
OM-4426 Page 2
Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
Implanted Medical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
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.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder — explosion will result.
Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
Use the right equipment, correct procedures, and sufficient number of persons to lift 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.
1-3. Engine Hazards
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.
MOVING PARTS can cause injury.
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.
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.
Using a generator indoors CAN KILL
YOU IN MINUTES.
Generator exhaust contains carbon monoxide.
This is a poison you cannot see or smell.
NEVER use inside a home or garage, EVEN IF
doors and windows are open.
Only use OUTSIDE and far away from windows, doors, and
vents.
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.
HOT PARTS can cause severe burns.
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.
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.
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.
COMPRESSED AIR can cause injury.
Wear approved safety goggles.
Do not direct air stream toward self or others.
OM-4426 Page 3
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.
READ INSTRUCTIONS.
Read Owner’s Manual before using or servicing unit.
Stop engine and release air pressure before
servicing.
Use only genuine replacement parts from the
manufacturer.
Do not touch hot compressor or air system
parts.
Let system cool down before touching or servicing.
1-5. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
Do not install or place unit on, over, or near
combustible surfaces.
Do not install unit near flammables.
Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING UNIT can cause injury.
Use lifting eye to lift unit and properly installed
accessories only, NOT gas cylinders. 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.
Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle
where applicable.
FLYING SPARKS can cause injury.
Wear a face shield to protect eyes and face.
Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
Sparks can cause fires — keep flammables away.
MOVING PARTS can cause injury.
Keep away from moving parts.
Keep away from pinch points such as drive
rolls.
OM-4426 Page 4
WELDING WIRE can cause injury.
Do not press gun trigger until instructed to do
so.
Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
OVERUSE can cause OVERHEATING.
Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
starting to weld again.
Do not block or filter airflow to unit.
STATIC (ESD) can damage PC boards.
Put on grounded wrist strap BEFORE handling
boards or parts.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
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.
READ INSTRUCTIONS.
Read Owner’s Manual before using or servicing unit.
Use only genuine replacement parts from the
manufacturer.
Perform engine and air compressor maintenance and service according to this manual
and the engine/air compressor (if applicable)
manuals.
H.F. RADIATION can cause interference.
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician
promptly correct any interference problem resulting from the
installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
ARC WELDING can cause 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.)
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 Gasoline Engines:
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive harm.
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, 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, 4221 Walney Road, 5th Floor,
Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 5060 Mississauga,
Ontario, Canada L4W 5NS (phone: 800-463-6727 or in Toronto
416-747-4044, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd 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, 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 15250-7954
(phone: 1-866-512-1800) (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.
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
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 Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
OM-4426 Page 5
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
rom_2007−04fre
Se protéger, ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud.
2-1. Signification des symboles
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
NOTE − Indique des déclarations pas en relation avec des blessures
personnelles.
Indique des instructions spécifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le 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.
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).
L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées.
Installer et mettre à la terre correctement cet appareil conformément à son manuel d’utilisation et aux codes nationaux,
provinciaux et municipaux.
Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrement les enfants.
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.
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
OM-4426 Page 6
En effectuant les raccordements d’entrée fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.
Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques chaudes.
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.
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 métalmétal 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.
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.
DES PIECES DE METAL ou DES SALETES peuvent provoquer des blessures dans les yeux.
Le soudage, l’écaillement, le passage de la pièce à la brosse en
fil de fer, et le meulage génèrent des étincelles et des particules
métalliques volantes. Pendant la période de refroidissement des
soudures, elles risquent de projeter du laitier.
Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
LES FUMÉES ET LES GAZ peuvent être
dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
LES RAYONS DE L’ARC peuvent pro
voquer des brûlures dans les yeux e
sur la peau.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intense
(ultraviolets et infrarouges) susceptibles de provoquer des brûlure
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.
LE SOUDAGE peut provoquer un in
cendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tel
que des réservoirs, tambours ou des conduites peu
provoquer leur éclatement. Des étincelles peuven
être projetées de l’arc de soudure. La projection d’étincelles, des pièce
chaudes et des équipements chauds peut provoquer des incendies e
des brûlures. Le contact accidentel de l’électrode avec des objet
métalliques peut provoquer des étincelles, une explosion, un surchauf
fement ou un incendie. Avant de commencer le soudage, vérifier e
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.
Eloigner votre tête des fumées. Ne pas respirer les fumées.
Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
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.
Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
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 ris
quent 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.
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).
Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou vapeurs inflammables (vapeur d’essence, par exemple).
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 porteélectrode 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.
Une fois le travail achevé, assurez−vous qu’il ne reste aucune trace d’étincelles incandescentes ni de flammes.
Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
OM-4426 Page 7
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.
LE BRUIT peut affecter l’ouïe.
Le bruit des processus et des équipements peut affec
l’ouïe.
Porter des protections approuvés pour les ore
les si le niveau sonore est trop élevé.
LES CHAMPS MAGNETIQUES peuvent affecter des implants médicaux.
Porteur de simulateur cardiaque ou autre implants médicaux, rester à distance.
Les porteurs d’implants doivent d’abord consulter leur médecin
avant de s’approcher des opérations de soudage à l’arc, de soudage par points, de gougeage, du coupage plasma ou de chauffage par induction.
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.
Si des BOUTEILLES sont endomma
gées, elles pourront exploser.
Maintenir le chapeau de protection sur la soupape, sauf en cas
d’utilisation ou de branchement de la bouteille.
Des bouteilles de gaz protecteur contiennent du ga
sous haute pression. Si une bouteille est endomma
gée, elle peut exploser. Du fait que les bouteilles de gaz fon
normalement partie du procédé de soudage, les manipuler ave
précaution.
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 peu
RENDRE AVEUGLE.
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.
Toujours porter une protection faciale, des gants
en caoutchouc et vêtements de protection lors
d’une intervention sur la batterie.
Pour empêcher tout démarrage accidentel pendant les travaux
d’entretien, débrancher le câble négatif (−) de batterie de la borne.
Arrêter le moteur avant de débrancher ou de brancher les câbles
de batterie.
Eviter de provoquer des étincelles avec les outils en travaillant sur
la batterie.
Ne pas utiliser le poste de soudage pour charger les batteries ou
des véhicules de démarrage rapide.
Observer la polarité correcte (+ et −) sur les batteries.
Débrancher le câble négatif (–) en premier lieu. Le rebrancher en
dernier lieu.
LE CARBURANT MOTEUR peut provo
quer 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.
Toujours garder le pistolet en contact avec le réservoir lors du
remplissage.
DES ORGANES MOBILES peuvent pro
voquer des blessures.
Ne pas approcher les mains des ventilateurs,
courroies et autres pièces en mouvement.
Maintenir fermés et fixement en place les portes, panneaux, recouvrements et dispositifs de protection.
Arrêter le moteur avant d’installer ou brancher l’appareil.
OM-4426 Page 8
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.
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.
LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT CHAUD peuvent
provoquer des brûlures.
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.
L’utilisation d’un groupe autonome
à l’intérieur PEUT VOUS TUER EN
QUELQUES MINUTES.
Les fumées d’un groupe autonome contient du
monoxyde de carbone. C’est un poison invisible et inodore.
JAMAIS utiliser dans une maison ou garage,
même avec les portes et fenêtres ouvertes.
Uniquement utiliser à l’EXTERIEUR, loin des portes, fenêtres et
bouches aération.
L’ACIDE DE LA BATTERIE peut provoquer des brûlures dans les YEUX et
sur la PEAU.
LA CHALEUR DU MOTEUR peut provoquer un incendie.
Ne pas placer l’appareil sur, au-dessus ou à
proximité de surfaces inflammables.
Tenir à distance les produits inflammables de l’échappement.
LES ÉTINCELLES À L’ÉCHAPPEMENT
peuvent provoquer un incendie.
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
RESPIRER L’AIR COMPRIMÉ peut provoquer des blessures graves ou causer
la mort.
Le METAL CHAUD lors du coupage et
gougeage plasma peut provoquer un incendie ou une explosion.
Ne pas utiliser l’air comprimé pour respirer.
Utiliser l’air comprimé seulement pour le coupage, gougeage et les outils pneumatiques.
Ne pas couper ou gouger à proximité de produits inflammables.
Surveillez et garder un extincteur à proximité.
L’AIR COMPRIMÉ peut provoquer
des blessures.
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.
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.
DES PIECES CHAUDES peuvent provoquer des brûlures et blessures.
Ne pas toucher le compresseur ou d’autres
éléments du circuit air comprimé chauds.
Laisser l’ensemble se refroidir avant de toucher ou d’effectuer la
maintenance.
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.
N’utiliser que les pièces de rechange recommandées par le
constructeur.
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU D’EXPLOSION.
Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
Ne pas installer l’appareil à proximité de produits inflammables.
Ne pas surcharger l’installation électrique − s’assurer que l’alimentation est correctement dimensionnée et protégée avant de
mettre l’appareil en service.
LA CHUTE DE L’APPAREIL peut blesser.
Utiliser l’anneau de levage pour lever l’appareil et
les accessoires correctement installées seuls,
PAS les bouteilles de gaz. 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.
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.
OM-4426 Page 9
UNE REMORQUE QUI BASCULE peut
entraîner des blessures.
LE SURCHAUFFEMENT peut endommager le moteur électrique.
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.
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 ÉTINCELLES VOLANTES risquent de provoquer 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.
LIRE LES INSTRUCTIONS.
Lisez le manuel d’instructions avant l’utilisation
ou la maintenance de l’appareil.
N’utiliser que les pièces de rechange recommandées par le constructeur.
Effectuer la maintenance et le service du moteur et du compresseur d’air suivant les instructions dans ce manuel ou le manuel
du moteur/compresseur (si applicable).
LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer
des interférences.
DES ORGANES MOBILES peuvent
provoquer des blessures.
Ne pas s’approcher des organes mobiles.
Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil de soudage.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
Laisser l’équipement refroidir ; respecter le facteur de marche nominal.
Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
Ne pas obstruer les passages d’air du poste.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les
circuits imprimés.
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.
OM-4426 Page 10
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.
L’énergie électromagnétique risque de provoquer des interférences pour l’équipement électronique sensible tel que les ordinateurs et
l’équipement commandé par ordinateur tel que
les robots.
Veiller à ce que tout l’équipement de la zone de soudage soit
compatible électromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser
aussi bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.
2-6. 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.
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.
2-7. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
de Global Engineering Documents (téléphone : 1-877-413-5184, site
Internet : 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 de Global Engineering Documents (téléphone :
1-877-413-5184, site Internet : www.global.ihs.com).
National Electrical Code, NFPA Standard 70, de National Fire Protection Association, P.O. Box 9101, Quincy, MA 02269-9101 (téléphone :
617-770-3000, site Internet : www.nfpa.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chantilly, VA 20151 (téléphone : 703-788-2700, site Internet :
www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, de
Canadian Standards Association, 5060 Mississauga, Ontario, Canada
L4W 5NS (téléphone : 800-463-6727 ou à Toronto 416-747-4044, site
Internet : www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, de American National Standards Institute,
11 West 43rd Street, New York, NY 10036-8002 (téléphone :
212-642-4900, site Internet : www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, de National Fire Protection Association,
P.O. Box 9101, Quincy, MA 02269-9101 (téléphone : 617-770-3000,
site Internet : 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, de U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(téléphone : 1-866-512-1800) (il y a 10 bureaux régionaux−−le téléphone de la région 5, Chicago, est 312-353-2220, site 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 procédures suivantes :
1. Garder les câbles ensemble, les torsader, les scotcher, ou les
recouvrir d’une housse.
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 implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.
OM-4426 Page 11
A complete Parts List is available at www.MillerWelds.com
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)
Lift Arc TIG
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
Circuit Protector
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-4426 Page 12
A complete Parts List is available at www.MillerWelds.com
SECTION 4 − SPECIFICATIONS
4-1. Weld, Power, And Engine Specifications
Welding
Mode
Rated
Welding
Output
CC/DC
280 A, 25 V, 100%
Duty Cycle
50
20 − 300 A
CV/DC
300 A, 25 V, 100%
Duty Cycle
35
13 − 35 V
CC/AC*
200 A, 25 V, 60%
Duty Cycle
Maximum
Open-Circuit
Voltage
Weld
Output
Range
60
Generator
Power Rating
Fuel
Capacity
Robin EH65 Engine:
Continuous: 9.5 kVA/
kW,
Peak: 10.5 kVA/kW
(w/Weld Contactor Off)
80/40 A, 120/240 V AC,
60 Hz, Single-Phase
12 gal
(45 L)
Tank
Kohler CH−23
Continuous: 9.5 kVA/
kW
kW,
Peak: 11 kVA/kW
(w/Weld Contactor Off)
80/40 A, 120/240 V AC,
60 Hz, Single-Phase
35 − 225 A
Engine
Robin EH65
Air-Cooled,
Two-Cylinder, FourCycle,
22 HP
Gasoline Engine
or
Kohler CH-23
CH 23
Air-Cooled,
Two-Cylinder,
Four-Cycle,
23 HP Gasoline Engine
AC/DC Models Only.
*
4-2. Dimensions, Weights, and Operating Angles
Dimensions
Height
33−1/2 in (851 mm)
(To Top Of Exhaust)
Width
20 in (508 mm)
Depth
45-3/8 in (1153 mm)
A
20 in (508 mm)
B
16-1/2 in (419 mm)
C
1-3/4 in (44 mm)
D
6−1/16 in (154 mm)
E
32-3/4 in (832 mm)
F
45−3/8 in (1153 mm)
G
13/32 in (10 mm) Dia.
A
B
C
D
G
4 Holes
F
!
Do not exceed tilt angles or engine could
be damaged or unit could tip.
!
Do not move or operate unit where it could
tip
tip.
E
20°
20°
20°
20°
Weight
Robin: 580 lb (263 kg)
Kohler: 580 lb (263 kg)
Lifting Eye Weight Rating
1280 lb (580 kg)
E i End
Engine
E d
800 426
803 572−A
572 A
OM-4426 Page 13
A complete Parts List is available at www.MillerWelds.com
4-3. Dimensions For Units With Optional Running Gear
Dimensions
Height
All Running Gear Options:
42-1/2 in (1079 mm)
(To Top Of Handle
Assembly)
C
A
Protective Cage Width:
26 in (660 mm)
B
Running Gear Width:
32 in (813 mm)
C
Protective Cage Length:
48 in (1219 mm)
D
D
A
B
B
Running Gear Length:
45−1/2 in (1156 mm)
4-4. Fuel Consumption Curves
On a typical job using 1/8 in 7018
electrodes (125 amps, 20% duty
cycle), expect about 20 hours of operation.
6.62
DC Weld
US GAL/HR.
1.50
5.68
1.25
4.73
1.00
3.79
Generator
Power
0.75
2.84
1.89
0.50
Idle
0.25
0.00
Welding at 150 amps at 40% duty
cycle uses approximately 3/4 gallon per hour, or about 16 hours of
operation.
LITERS/HR.
1.75
0
0.95
0.00
50
100
150
200
250
300
DC WELD AMPERES AT 100% DUTY CYCLE
0
2
4
6
8
10
KW AT 100% DUTY CYCLE
206 135 / 206 136
OM-4426 Page 14
A complete Parts List is available at www.MillerWelds.com
4-5. Generator Power Curve
The ac generator power curve
shows the generator power available in amperes at the receptacles.
Tools and motors are designed to
operate within 10% of 120/240
VAC.
300 150
264 132
+/− 10%
VOLTS
250 125
216 108
200 100
150
75
100
50
50
25
0
0
0
20
40
60
80
100 120 140
AC AMPERES At 120 V
160
180
200
0
10
20
30
40
50
60
70
AC AMPERES AT 240 V
80
90
100
Ref. 220 807−A
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
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
AC output is not available on all
models.
Continuous Welding
350
MIG/FCAW
WELDING AMPERES
300
STICK
250
200
AC WELD
150
100
0
10
20
30
40
50
60
70
80
90
100
% DUTY CYCLE
OM-4426 Page 15
A complete Parts List is available at www.MillerWelds.com
4-7. Stick And MIG Mode Volt-Ampere Curves
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of
other settings fall between the
curves shown.
A. CC/DC Stick Mode
100
90
DC VOLTS
80
70
60
MAX
50
40
30
MIN
20
10
0
MAX DIG
MIN DIG
0
50
100
150
200 250 300
DC AMPERES
350
400
450
500
B. CV/DC MIG Mode
40
35
MAX
DC VOLTS
30
25
MID
20
15
MIN
10
5
0
0
200
400
DC AMPERES
600
800
C. CC/AC STICK Mode
AC output is not available on all models.
80
70
AC VOLTS
60
50
MAX
40
30
MIN
20
MIN DIG
10
0
MAX DIG
0
50
100
150
200
AC AMPERES
OM-4426 Page 16
250
300
350
228 632 / 220 313−A / 228 631
A complete Parts List is available at www.MillerWelds.com
4-8. 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.
A. CC/AC TIG Mode
80
AC output is not available on all
models.
AC VOLTS
70
60
50
MAX
40
MIN
30
20
10
0
0
50
100
150
AC AMPERES
200
250
B. CC/DC TIG Mode
45
40
MAX
DC VOLTS
35
30
MIN
25
20
15
10
5
0
0
50
100
150
200
250
300
DC AMPERES
220 312−A / 220 311−A
OM-4426 Page 17
A complete Parts List is available at www.MillerWelds.com
SECTION 5 − INSTALLATION
5-1. Installing Welding Generator
Do not lift unit from end.
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.
OR
Do not mount unit by supporting the base only at the four
mounting holes. Do not use
flexible mounts. Use crosssupports to adequately support unit and prevent damage
to base.
Location / Airflow Clearance
OR
OR
18 in
(460 mm)
If unit does not have GFCI receptacles, use GFCI-protected
extension cord.
Do not install unit where air
flow is restricted or engine
may overheat.
18 in
(460 mm)
18 in
(460 mm)
Always ground generator
frame to vehicle frame to prevent electric shock and static
electricity hazards.
Mounting:
1
Cross-Supports
Mount unit on flat surface or use
cross-supports to support base.
Grounding:
2
18 in
(460 mm)
18 in
(460 mm)
3
4
Mounting
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.
Electrically bond generator frame
to vehicle frame by metal-to-metal
contact.
1
2
Grounding
3
GND/PE
4
OM-4426 Page 18
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.
install2 2007−10 − Ref. 800 652 / Ref. 800 477-A / 803 274-A / 804 712
A complete Parts List is available at www.MillerWelds.com
5-2. Engine Prestart Checks (Kohler-Powered Units)
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.
Open top service door
Full
Empty
Oil Check/Fill
Fuel
Add fresh fuel before starting engine
the first time (see maintenance label
for specifications). Always leave filler
neck empty to allow room for expansion. Check fuel level on a cold engine before use each day.
To check fuel level, turn Engine Control switch to Run/Idle position.
LED’s indicate fuel level in tank.
Full
Oil Fill
Oil
Do not
exceed the ”Full” mark on
the oil level dipstick. The fuel
pump may operate erratically if
crankcase is overfilled.
After fueling, check oil with unit on
level surface. If oil is not up to full
mark on dipstick, add oil (see maintenance label).
Use front panel meters to determine
hours until next recommended oil
change (see Section 6-1).
To
improve
starting:
cold
weather
Keep battery in good condition.
Store battery in warm area.
Use correct grade oil for cold
weather.
Close top service door
Full
Gasoline
Ref. 803 571−A / Ref. 803 573−A
OM-4426 Page 19
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5-3. Engine Prestart Checks (Robin-Powered Units)
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.
Open top service door.
Full
Empty
Oil Check
Oil Fill
Fuel
Add fresh fuel before starting engine
the first time (see maintenance label
for specifications). Always leave filler
neck empty to allow room for expansion. Check fuel level on a cold engine before use each day.
To check fuel level, turn Engine Control switch to Run/Idle position.
LED’s indicate fuel level in tank.
Full
Oil
Do not
exceed the ”Full” mark on
the oil level dipstick. The fuel
pump may operate erratically if
crankcase is overfilled.
After fueling, check oil with unit on
level surface. If oil is not up to full
mark on dipstick, add oil (see maintenance label).
Use front panel meters to determine
hours until next recommended oil
change (see Section 6-1).
To
improve
starting:
cold
weather
Keep battery in good condition.
Store battery in warm area.
Use correct grade oil for cold
weather.
Close top service door.
Full
Gasoline
Ref. 803 571−A / Ref. 803 572−A
OM-4426 Page 20
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5-4. Connecting Or Replacing The Battery
!
Connect negative (−) battery
cable last
To connect battery, open right side
engine access door.
1
Battery Holddown
To change battery, remove rear panel with baffle and battery holddown.
Tools Needed:
1/2 in
Be sure battery cables are not
pinched when installing battery.
+
−
1
Ref. 803−573−A / Ref. 803 752-C / Ref. 202 069-A / Ref. S-0756-D
OM-4426 Page 21
A complete Parts List is available at www.MillerWelds.com
5-5. Installing Exhaust Pipe
!
Stop engine and let cool.
!
Engine backfire can cause severe burns or other injuries.
Do not point exhaust pipe toward control panel. Keep away
from exhaust outlet.
!
Do not point exhaust pipe toward LP fuel tank (if equipped).
Do not point exhaust pipe towards shielding gas tank (if
equipped).
!
Point exhaust pipe in desired
direction but always away
from front panel and direction
of travel.
Tools Needed:
1/2 in
803 891/ Ref. 216 170
Notes
WELD POSITION: FLAT
WELD JOINT
TYPES
HORIZONTAL
BUTT
1G
VERTICAL
BUTT
2G
FILLET
Ref. AWS/ANSI D1.1
OM-4426 Page 22
T−JOINT
1F
BUTT
4G
BUTT
3G
T−JOINT
2F
GROOVE
OVERHEAD
T−JOINT
4F
T−JOINT
3F
Ref. 804 248-A
A complete Parts List is available at www.MillerWelds.com
5-6. Weld Output Terminals
!
Stop engine.
!
Do not connect to CC and CV
terminals at the same time.
AC/DC Models:
1
2
3
Work Weld Output Terminal
Stick/TIG (CC) Weld Output
Terminal
Wire /CV Weld Output Terminal
For MIG welding, connect work cable
to Work terminal and wire feeder
cable to Wire (CV) terminal.
For Stick/TIG welding, connect work
cable to Work terminal and electrode
holder/TIG torch cable to Stick/TIG
(CC) terminal.
DC Models:
4
5
6
Negative (−) Weld Output
Terminal
Stick/TIG (+) Weld Output
Terminal
Wire (+) Weld Output Terminal
For MIG welding, connect work cable
to Negative (−) terminal and wire
feeder cable to CV (Wire) terminal.
1
2
For Stick welding, connect work
cable to Negative (−) terminal and
electrode holder cable to CC (Stick/
TIG) terminal.
3
For TIG welding, connect work cable
to CC (Stick/TIG) terminal and electrode holder cable to Negative (−)
terminal.
Weld output terminals on
units with AC/DC output.
4
5
6
Weld output terminals on
units with DC output only.
803 571 / Ref. 216 170 / 204 353 / Ref. 216 169-A
OM-4426 Page 23
A complete Parts List is available at www.MillerWelds.com
5-7. Connecting To Weld Output Terminals
!
Stop engine.
!
Failure to properly connect
weld cables may cause excessive heat and start a fire,
or damage your machine.
1
2
Weld Output Terminal
Supplied Weld Output
Terminal Nut
Weld Cable Terminal
Copper Bar
3
4
1
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
Do not place
anything between
weld cable terminal
and copper bar.
2
Tools Needed:
3
3/4 in
Correct Installation
Incorrect Installation
803 778-A
5-8. Selecting Weld Cable Sizes*
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
100 ft (30 m) or Less
Weld
W
ld Output
O t t
Terminals
!
Stop engine before
connecting to weld
output terminals.
!
Do not use worn,
damaged,
undersized,,
or
p
poorly
y
spliced cables.
cables
* This chart
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
400 ft
(105 m) (120 m)
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)
10 − 100% Duty Cycle
is a general guideline and may not suit all applications. If cables overheat, 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
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.
OM-4426 Page 24
S-0007-F
A complete Parts List is available at www.MillerWelds.com
5-9. Remote Receptacle Information
Engine runs at weld/power speed whenever a device connected to the remote
receptacle is running.
Socket*
Socket Information
A
24 volts ac. Protected by supplementary protector
CB4.
B
Contact closure to A completes 24 volt ac contactor control circuit and keeps engine at Run speed
in all Wire modes.
I
115 volts ac. Protected by supplementary protector CB3.
J
Contact closure to I completes 115 volts ac
contactor control circuit.
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.
F
Current feedback: 1 volt per 100 amperes.
H
Voltage feedback: 1 volt per 10 arc volts.
G
Circuit common for 24 and 115 volts ac circuits.
K
Chassis common.
24 VOLTS AC
A
B
K
C L N
D M
E
J
I
H
F
115 VOLTS AC
G
REMOTE
OUTPUT
CONTROL
803 571
GND
*The remaining sockets are not used.
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-4426 Page 25
A complete Parts List is available at www.MillerWelds.com
SECTION 6 − OPERATING WELDING GENERATOR
6-1. Front Panel Controls (See Section 6-2)
1
2
3
4
5
6
9
7
8
Ref. 216 170 / Ref. 227 723-A
OM-4426 Page 26
A complete Parts List is available at www.MillerWelds.com
6-2. Description Of Front Panel Controls (See Section 6-1)
1
Process/Contactor Switch
See Section 6-4 for Process/Contactor
switch information.
2
Remote Receptacle
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.
Use receptacle to connect remote control or
wire feeder.
Meter Engine Maintenance Functions:
See inset from maintenance label.
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 5-9 and 6-7).
5
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. In
CV mode, weld output is controlled through
remote control only.
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, oil change countdown, or rpm).
Meter Weld Functions: In Wire modes,
Voltmeter displays preset weld voltage
when not welding. Meters display actual voltage and amperage when welding and for five
seconds after welding has stopped.
Fuel Level Indicator
With Engine running or Engine Control
switch in Run or 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.
next recommended oil change (see items 3
and 4 earlier in this section).
The unit
will not return to idle speed
when the remote contactor is on and
Process/Contactor switch is in any Wire
position. The unit will return to idle speed
in all other modes.
8
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.
With Process/Contactor switch in any Stick
or TIG setting, use control to adjust amperage. With Process/Contactor switch in any
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 modes.
If
7
To Stop: turn Engine Control switch to Off
position.
Engine Control Switch
Use switch to start engine, select speed, and
stop engine. In Run/Idle position, engine
runs at idle speed at no load, and weld/power
speed under load. In Run position, engine
runs at weld/power speed.
Use switch in combination with meters to determine total engine hours and hours until
the engine does not start, let the
engine come to a complete stop before
attempting restart.
During cold weather some gasoline en-
gines encounter difficulties that are easily remedied. See Section 6-3 and 8-12.
9 DC Polarity/AC Switch (AC/DC Models
Only)
!
Do not switch under load.
Use switch to select AC weld output or polarity of DC weld output.
6-3. Cold Weather Engine Operation
1
Engine Control Switch
Carburetor Icing
1
Infrequently
Loaded
Carburetor icing causes the unit to drop below the normal idle speed and then
stall. This condition occurs when the temperature is near freezing and the relative humidity is high. Ice forms on the throttle plate and inner bore of the carburetor. The engine typically restarts without problems but soon stalls again.
Treat gasoline with a fuel de−icer product (isopropyl alcohol).
Place the Engine Control switch in the Run position.
Run engine only when expecting to frequently load it.
Breather Icing
Frequently
Loaded
Oil breather/pulse line icing occurs in severe cold (continuously below 0F).
Moisture accumulates in the oil from piston ring blow−by if the engine is extensively idled. This may cause vacuum line freezing, oil breather tube freezing
or ice in the carburetor. All of these cause operating problems. Due to ice in
the lines, the engine may not restart until it is warmed to above freezing.
Load engine and reduce idle times to prevent engine shutdowns.
Use an electric fuel pump to avoid pulse line freezing.
Install engine cold−weather kit.
Both Kohler (1-800-544-2444) and Robin (1-800-277-6246) offer kits for cold
weather operation. The user can install these kits. Both kits pull heated air from
the muffler surface into the carburetor and shut the cold air off. This increases
engine temperature during operation in both idle and high speed.
When the ambient temperatures become warmer (above 45_F) the air
flow will have to be returned to normal.
Ref. 216 170
OM-4426 Page 27
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6-4. Process/Contactor Switch On AC/DC Models
1
803 571−A / 216 170−A
1
Process/Contactor Switch
Stick Positions:
!
Weld output terminals are energized
when Process/Contactor switch is
in an Electrode Hot position and the
engine is running.
Use Stick positions for stick (SMAW) and
air carbon arc (CAC-A) cutting and
gouging.
The unit will not return to idle speed
when Process/Contactor switch is in a
Wire position and the remote contactor
is on (closure between pins A and B on
remote receptacle).
Use switch to select weld process and weld
output on/off control (see table below and
Section 5-9).
Place switch in Remote positions to turn
weld output on and off with a device connected to the remote receptacle.
Place switch in Electrode Hot positions for
weld output to be on whenever the engine
is running.
Wire Positions:
Use Wire positions for MIG welding using a
voltage sensing wire feeder (Electrode Hot)
or wire feeder using remote control.
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 Positions :
TIG − Remote On/Off − Use this position for
AC or DC TIG welding using remote on/off
control.
Electrode Hot − Lift-Arc™ w/Auto Crater™
TIG (DC only) - 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 Section
6-6).
End the arc using either the Auto-Crater or
Auto-Stop feature (see Section 6-6).
Process/Contactor Switch Settings
Switch Setting
Process
Output On/Off Control
Electrode Hot − Wire
MIG (GMAW)
Electrode Hot
Electrode Hot − Stick
Stick (SMAW)
Select Preferred Dig
Electrode Hot
Electrode Hot − Stick
Air Carbon Arc (CAC-A) Cutting And Gouging
Select Any Dig
Electrode Hot
Electrode Hot − Lift Arc w/
Auto-Crater
TIG (GTAW) Lift Arc w/Auto-Crater (GTAW) (DC Only)
Electrode Hot
TIG − Remote On/Off
GTAW With HF Unit, Pulsing Device, Or
Remote Control (AC or DC)
At Remote Receptacle
Stick − Remote On/Off
Stick (SMAW) With Remote On/Off
At Remote Receptacle
Wire − Wire Feeder (CV)
Using Remote
MIG (GMAW)
At Remote Receptacle
OM-4426 Page 28
A complete Parts List is available at www.MillerWelds.com
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
OM-4426 Page 29
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6-6. Lift-Arct TIG With Auto-Cratert And Auto-Stopt
Arc Start With Lift-Arc TIG
Lift-Arc is used for the DCEN
GTAW process when HF Start
method is not permitted.
Select Lift-Arc at Process/Contactor switch.
Arc Start With Lift-Arc
1
Turn gas on.
1
2
2
Touch or scratch.
Lift at any angle.
Touch tungsten electrode to
workpiece at weld start point.
Slowly lift electrode. Arc is started
when electrode is lifted.
Maintain shielding gas coverage
and eliminate tungsten and workpiece contamination by using
Auto-Crater or Auto-Stop to end
the arc.
Arc End With Auto-Crater:
Remote control is not needed
when using Auto-Crater.
1
2
Arc End With Auto-Crater
1
2
3
4
3
4
While welding.
Lift torch slightly to start
Auto-Crater end (current is
reduced).
Lower torch. Weld current
ramps down.
Shielding gas continues until
shut off.
Arc End With Auto-Stop:
1
2
3
OR
While welding.
Lift torch to start Auto-Stop.
(Lift higher than that needed
to start Auto-Crater.) Arc
stops.
Move torch back down to
maintain gas coverage and
prevent contamination.
Arc End With Auto-Stop
1
2
3
WM Marketing
OM-4426 Page 30
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6-7. Remote Voltage/Amperage Control
1
Remote Receptacle RC4
Connect optional remote voltage/
amperage (V/A) control to RC4
(see Section 5-9).
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 mode whenever
a device connected to the remote receptacle makes closure between pins A and B. In
all other modes, the engine
runs at idle speed until a load is
applied.
In Example:
Process = Stick (Using Remote On/Off)
Min = 25 A CC/DC
Max = 160 A CC/DC
3
Switch
present on
AC/DC
models
only.
2
Max (160 A DC)
Min (25 A DC)
Connect Remote
V/A Control To
Remote
Receptacle RC4
Select Polarity By
Using DC Polarity/AC
Switch (If Present) Or
By Changing Cable
Connections
Set V/A Control
(Mid-Range: About 160 A)
Adjust Remote V/A Control
(Stick Welding Only)
803 571−A / 216 170−A / S-0769 / S-0774
OM-4426 Page 31
A complete Parts List is available at www.MillerWelds.com
SECTION 7 − OPERATING AUXILIARY EQUIPMENT
7-1. Generator Power Receptacles And Supplementary Protectors
5
1
6
3
4
2
!
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Generator power decreases as weld
current increases.
1
240 V 50 A AC Receptacle RC1
RC1 supplies 60 Hz single-phase power at
weld/power speed. Maximum output idepends on engine (10.5 kVA/kW for Robin,
11 kVA/kW for Kohler).
2
3
120 V 20 A AC Duplex Receptacle
RC2
120 V 20 A AC Duplex Receptacle
RC3
RC2 and RC3 supply 60 Hz single-phase
power at weld/power speed. Maximum out-
Ref. 216 170
put from RC2 or RC3 is 2.4 kVA/kW (20 A
x 120 V).
ac output to RC4 stops. Press button to reset.
4
If supplementary protector
Supplementary Protector CB1
CB1 protects receptacles RC1, RC2, RC3,
and 115 volt ac output to Remote Receptacle RC4 from overload. If CB1 opens, the
receptacles do not work and 115 volt ac output to Remote Receptacle RC4 stops.
Place switch in On position to reset.
5
Supplementary Protector CB2
6
Supplementary Protector CB3
CB2 protects RC2 from overload. CB3 protects RC3 and the 115 volt ac output to Remote Receptacle RC4 from overload. If
CB2 opens, RC2 does not work. If CB3
opens, RC3 does not work and the 115 volt
continues to
open, contact Factory Authorized Service Agent.
Combined output of all receptacles limited
to peak rating of the generator.
Robin Engine Example: If 20 A is drawn
from each 120 V duplex receptacle, only 23
A is available at the 240 V receptacle:
2 x (120 V x 20 A) + (240 V x 23 A) = 10.5
kVA/kW
Kohler Engine Example: If 20 A is drawn
from each 120 V duplex receptacle, only 25
A is available at the 240 V receptacle:
2 x (120 V x 20 A) + (240 V x 25 A) = 11 kVA/
kW
7-2. Optional GFCI Receptacles
!
1
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Generator power decreases as weld
current increases.
Combined output of all receptacles limited
to peak rating of the generator (10.5 kVA/
kW Robin Engine or 11 kVA/kW Kohler Engine).
GFCI Receptacle Option
1
120 V 20 A AC GFCI Receptacles
GFCI-2 and GFCI-3
GFCI2 and GFCI3 supply 60 Hz singlephase power at weld/power speed. Maximum output from GFCI-2 or GFCI-3 is 2.4
kVA/kW. Circuit protection is the same as
standard receptacles.
If a ground fault is detected, the GFCI Reset button pops out and the circuit opens to
disconnect the faulty equipment. Check for
damaged tools, cords, plugs, etc. connected to the receptacle. Press button to
reset receptacle and resume operation.
At least once a month, run engine at
Ref. 216 170
OM-4426 Page 32
weld/power speed and press Test button to verify GFCI is working properly.
A complete Parts List is available at www.MillerWelds.com
7-3. Simultaneous Weld And Power
Weld Current in Amperes
Total Power in Watts
120 V Receptacle Amperes
240 V Receptacle Amperes
300
1000
10
5
250
3500
31
15
200
5200
46
23
150
6700
60
30
100
8000
70
35
0
10,500 (Robin), 11,000 (Kohler)
88
44
7-4. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P)
1
3
The plug can be wired for a 240 V,
2-wire load or a 120/240V, 3-wire
load. See circuit diagram.
4
1
120V
5
120V
240V
6
2
3
4
Plug Wired for 120/240 V,
3-Wire Load
When wired for 120 V loads, each
duplex receptacle shares a load
with one half of 240 V receptacle.
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
240V
6
5
7
Current Available in Amperes
240 V
Each 120 V Duplex
Receptacle*
Receptacle
0
5
10
15
20
25
30
35
40
20
20
20
20
20
15
10
5
0
V x A = Watts
240 V AC
Tools Needed:
120 V AC
120 V AC
*One 240 V load or two 120 V loads.
plug1 11/03 − 120 813-D
OM-4426 Page 33
A complete Parts List is available at www.MillerWelds.com
SECTION 8 − MAINTENANCE & TROUBLESHOOTING
8-1. Maintenance Label
OM-4426 Page 34
A complete Parts List is available at www.MillerWelds.com
8-2. Routine Maintenance
Also see Voltmeter/Ammeter displays to assist in scheduling maintenance (see Section 6-1). The Voltmeter and Ammeter display total engine
operating hours at start-up.
Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended
period.
!
Recycle engine
fluids.
= Check
= Change
= Clean
* To be done by Factory Authorized Service Agent
Stop engine before maintaining.
See
Engine Manual and Maintenance Label
for important start-up, service, and storage
information. Service engine more often if
used in severe conditions.
= Replace
Reference
Every
8
Hours
Section 5-2,
5-3, 6-2
Fuel Level
Oil Level
Meters for next oil
change interval
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, 8-6
Battery Terminals
Cooling System
Oil
Air Cleaner Element
Every
200
Hours
Engine
Manual,
Section 8-5,
8-6
Unreadable Labels
Spark Plug Gap
Oil Filter
Every
500
Hours
Fuel Filter
Engine
Manual
Weld Cables
Slip Rings*
Brushes*
Valve Clearance*
OM-4426 Page 35
A complete Parts List is available at www.MillerWelds.com
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
Ref. 803 572−A / Ref. 183 175−A
8-4. Servicing Air Cleaner
Robin−Powered
!
Kohler−Powered
Stop engine.
NOTICE − 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
1
Spread 1 tablespoon SAE 30 oil
evenly into precleaner. Squeeze
out excess oil.
2
2
2
Element
Replace element if damaged, dirty,
or oily.
oil
aircleaner3 11/04 − 802 772 / 803 070 / S-0759
OM-4426 Page 36
A complete Parts List is available at www.MillerWelds.com
8-5. Changing Engine Oil, Oil Filter, And Fuel Filter (Kohler-Powered Units)
!
Stop engine and let cool.
1
Oil Drain Valve
2
Oil Filter
Change engine oil and filter according to engine manual.
NOTICE − Close valve and valve
cap before adding oil and running
engine.
Full
Fill crankcase with new oil to full
mark on dipstick (see Section 5-2).
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.
Reset oil maintenance countdown
by flipping Engine Control switch
from Run/Idle to Run three times.
3
2
4
1
Tools Needed:
Ref. 803 573−A / S-0842
OM-4426 Page 37
A complete Parts List is available at www.MillerWelds.com
8-6. Changing Engine Oil, Oil Filter, and Fuel Filter (Robin-Powered Units)
!
Stop engine and let cool.
1
Oil Drain Valve
2
Oil Filter
Change engine oil and filter according to engine owner’s manual.
Oil Fill
NOTICE − Close valve and valve
cap before adding oil and running
engine.
Oil Check
Fill crankcase with new oil to full
mark on dipstick (see Section 5-3).
3
Fuel Filter
4
Fuel Line
Replace line if cracked or worn.
Install new filter. Wipe up any spilled
fuel.
Full
Start engine, and check for fuel
leaks.
!
2
Stop engine, tighten connections as necessary, and wipe
up fuel.
Reset oil maintenance countdown
by flipping Engine Control switch
from Run/Idle to Run three times.
3
4
Tools Needed:
1
803 572 / S-0842
OM-4426 Page 38
A complete Parts List is available at www.MillerWelds.com
8-7. Adjusting Engine Speed (Kohler-Powered Units)
2200 − 2300 rpm
(36.6 − 38.3 Hz)
3675 − 3750 rpm
(61.3 − 62.5 Hz)
After tuning engine, check engine
speeds with a tachometer (see
table). If necessary, adjust speeds
as follows:
Start engine and run until warm.
Turn A/V control to 10.
Open top cover access panel to access speed adjustments.
Idle Speed Adjustment
1
Move Engine Control switch to
Run/Idle position.
5
2
4
1
Throttle Solenoid
2
Mounting Screws
3
Idle Speed Screw
Loosen mounting screws. Adjust
solenoid position so engine runs at
idle speed. If necessary, back out
idle speed screw so solenoid can
be moved to correct position. Tighten mounting screws. Be sure solenoid linkage works smoothly.
Turn idle speed screw for fine
adjustments.
Weld/Power Speed Adjustment
Move Engine Control switch to Run
position.
3
4
Weld/Power Speed
Adjustment Nut
5
Lock Nut
Loosen lock nut. Turn adjustment
nut until engine runs at weld/power
speed. Tighten lock nut.
Close and secure top cover access
panel.
!
Stop engine.
Tools Needed:
1/4, 3/8 in
803 573 / 801 209-A
OM-4426 Page 39
A complete Parts List is available at www.MillerWelds.com
8-8. Adjusting Engine Speed (Robin-Powered Units)
After tuning engine, check engine
speeds with a tachometer (see
table). If necessary, adjust speeds
as follows:
Start engine and run until warm.
Open top cover access panel to access speed adjustments.
Idle Speed Adjustment
2
1
Move Engine Control switch to
Run/Idle position.
1
Throttle Solenoid
2
Mounting Screws
3
Idle Speed Screw
Loosen mounting screws. Adjust
solenoid position so engine runs at
idle speed. If necessary, back out
idle speed screw so solenoid can
be moved to correct position. Tighten mounting screws. Be sure solenoid linkage works smoothly.
4
Turn idle speed screw for fine
adjustments.
6
Weld/Power Speed Adjustment
Move Engine Control switch to Run
position.
5
3
4
Jam Nut
5
Lock Nut
6
Weld/Power Speed
Adjustment Screw
Loosen jam nut and lock nut. Turn
adjustment screw until engine runs
at weld/power speed. Tighten jam
nut, and then tighten lock nut.
!
Stop engine.
Close and secure top cover access
panel.
2200 − 2300 rpm
(36.6 − 38.3 Hz)
3675 − 3750 rpm
(61.3 − 62.5 Hz)
Tools Needed:
10 mm
8 mm
OM-4426 Page 40
803 572−A
A complete Parts List is available at www.MillerWelds.com
8-9. 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
protectors
CB1 and 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. 216 170
OM-4426 Page 41
A complete Parts List is available at www.MillerWelds.com
8-10. Welding Troubleshooting
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 voltage/amperage control settings (see Sections 5-9 and 6-1).
Check and secure connections to Remote receptacle RC4 (see Sections 5-9).
Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.
Low weld output.
Check control settings.
Increase front panel and/or remote voltage/amperage control settings (see Sections 5-9 and 6-1).
Check and clean air cleaner as necessary (see Section 8-4).
Check engine speed, and adjust if necessary (see Section 8-7 or 8-8).
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 and adjust engine speed (see Section 8-8 or 8-7).
Check for obstructed movement of solenoid linkage (see Section 8-7 or 8-8).
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.
Check and secure lead connections to remote control.
Be sure connection to work piece is clean and tight.
Remove excessive coils from weld cables.
Use dry, properly stored electrodes.
Check and adjust engine speed (see Section 8-7 or 8-8).
Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.
Check shielding gas, ensure proper shielding gas coverage while welding.
No remote voltage/amperage control.
Check and tighten connections to Remote receptacle RC4 (see Section 5-9). Check and secure lead
connections to remote control.
No front panel voltage/amperage
control.
Disconnect remote control from Remote receptacle RC4 if not needed for weld process (see Section
5-9).
No 24 volt ac power output at Remote
receptacle RC4.
Reset supplementary protector CB4 (see Section 8-9).
No 115 volt ac power output at Remote
receptacle RC4.
Reset supplementary protector(s) CB1 and/or CB3 (see Section 7-1).
Lack of high frequency; difficulty in
establishing Gas Tungsten Arc Welding arc.
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.
OM-4426 Page 42
A complete Parts List is available at www.MillerWelds.com
Trouble
Wandering arc − poor control of arc
direction.
Remedy
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.
8-11. Generator Power Troubleshooting
Trouble
No power output.
Remedy
Reset supplementary protectors CB1, CB2 and/or CB3 (see Section 7-1).
Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.
Low power output.
Check and clean air cleaner as necessary.
Check engine speed, and adjust if necessary (see Section 8-7 or 8-8).
See engine manual.
High power output.
Check engine speed, and adjust if necessary (see Section 8-7 or 8-8).
Erratic power output.
Have Factory Authorized Service Agent check brushes, slip rings, and field current control board PC2.
Check receptacle wiring and connections.
Check governor according to engine manual.
8-12. Engine Troubleshooting
Trouble
Engine will not crank.
Remedy
Check fuse F6, and replace if open (see Section 8-9).
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 or 5-3).
Check battery and replace if necessary.
Check engine charging system according to engine manual.
Have Factory Authorized Service Agent check fuel shutoff solenoid FS1 according to engine manual.
See engine manual.
Engine starts but stops when Engine
Control switch returns to Run/Idle
position.
Check oil level (see Section 5-2 or 5-3). Low oil pressure shutdown stops engine if oil pressure is too
low.
Use correct grade oil for operating temperature. (see Section 8-1).
Have Factory Authorized Service Agent check low oil pressure shutdown switch S5.
OM-4426 Page 43
A complete Parts List is available at www.MillerWelds.com
Trouble
Battery discharges between uses.
Remedy
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 or 5-3).
Check oil level (see Section 5-2 or 5-3). Low oil pressure shutdown stops engine if oil pressure is too
low. Oil level too high reduces capacity of the fuel pump.
Have Factory Authorized Service Agent check fuel shutoff solenoid FS1 according to engine manual.
Have Factory Authorized Service Agent check low oil pressure shutdown switch S5.
Engine does not return to idle speed.
Be sure Engine Control switch S2 is in Run/Idle position.
Remove all weld and generator power loads.
Place Process/Contactor switch in Electrode Hot position or turn off remote contactor. The unit will not
return to idle speed when Process/Contactor switch is in a remote position and the remote contactor
is on.
Turn off remote device connected to Remote receptacle RC4 (see Section 5-9).
Check for obstructed movement of solenoid linkage (see Section 8-7 or 8-8).
Have Factory Authorized Service Agent check circuit board PC1 and current transformer CT1.
Engine does not remain at weld/power
speed when power or weld load is
applied with Engine Control switch in
Run/Idle position.
Place Engine Control switch in the Run position for small loads.
Check for obstructed movement of solenoid linkage (see Section 8-7 or 8-8).
During operation in near freezing temperatures, engine starts and goes to
idle but stalls after a few minutes.
Treat fuel with isopropyl alcohol de-icer product.
Place Engine Control switch in the Run position until unit has been in operation and loaded for a period of time.
During operation in severe cold weather, engine starts and goes to idle but
stalls after a few minutes.
OM-4426 Page 44
Install engine manufacturer’s kit for cold-weather operation.
A complete Parts List is available at www.MillerWelds.com
SECTION 9 − PARTS LIST
A complete Parts List is available on-line at www.MillerWelds.com.
9-1. Recommended Spare Parts
Dia.
Mkgs.
Part
No.
Description
Quantity
Recommended Spare Parts
. . . . . . . . . . . F6 . . . . .
....................
....................
....................
....................
....................
....................
....................
....................
....................
....................
....................
021718
230015
230016
066698
215985
067007
230017
199062
198755
198754
215985
198777
. . Fuse, Mintr Gl 30. Amp 32 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Tune−up & Filter Kit, Kohler (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Air Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Filter, Fuel w/Clamps & 1/4 in Fuel Line . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Air Filter Wrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Tune−up & Filter Kit (Robin) (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Element, Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Filter/Clamps, Fuel 1/4 in Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
2
1
1
1
1
1
2
Notes
OM-4426 Page 45
SECTION 10 − ELECTRICAL DIAGRAMS
Figure 10-1. Circuit Diagram For Welding Generator Models With AC/DC Output
OM-4426 Page 46
232 959-B
OM-4426 Page 47
Figure 10-2. Circuit Diagram For Welding Generator Models With DC Output Only
OM-4426 Page 48
232 960-B
OM-4426 Page 49
SECTION 11 − GENERATOR POWER GUIDELINES
The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown.
11-1. 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
Be sure equipment has double
insulated symbol and/or wording on it.
1
2
!
Do not use 2-prong plug unless equipment is double insulated.
3
OR
gen_pwr 2007−04 − Ref. ST-159 730 / ST-800 577
11-2. Grounding Generator To Truck Or Trailer Frame
!
Always ground generator
frame to vehicle frame to prevent electric shock and static
electricity hazards.
!
Also see AWS Safety &
Health Fact Sheet No. 29,
Grounding of Portable And
Vehicle Mounted Welding
Generators.
1
Equipment Grounding
Terminal (On Front Panel)
Grounding Cable (Not
Supplied)
Metal Vehicle Frame
2
1
GND/PE
3
2
Connect cable from equipment
ground terminal to metal vehicle
frame. Use #10 AWG or larger
insulated copper wire.
3
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.
!
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
S-0854
OM-4426 Page 50
11-3. Grounding When Supplying Building Systems
1
1
2
2
GND/PE
Equipment Grounding
Terminal
Grounding Cable
Use #10 AWG or larger insulated
copper wire.
3
Ground Device
Use ground device as stated in
electrical codes.
2
3
!
Ground generator to system
earth ground if supplying
power to a premises (home,
shop, farm) wiring system.
!
Also see AWS Safety &
Health Fact Sheet No. 29,
Grounding of Portable And
Vehicle Mounted Welding
Generators.
ST-800 576-B
11-4. How Much Power Does Equipment Require?
1
Resistive Load
A light bulb is a resistive load and
requires a constant amount of power.
3
2
1
VOLTS 115
AMPS 4.5
Hz
60
2
3
3
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 11-8).
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.
(3 x 200W) + 520 W = 1120 W
The total load applied by the three
flood lamps and drill is 1120 watts.
S-0623
OM-4426 Page 51
11-5. 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
11-6. Approximate Power Requirements For Farm/Home Equipment
Farm/Home Equipment
Stock Tank De-Icer
Grain Cleaner
Portable Conveyor
Grain Elevator
Milk Cooler
Milker (Vacuum Pump)
FARM DUTY MOTORS
Std. (e.g. Conveyors,
Feed Augers, Air
Compressors)
High Torque (e.g. Barn
Cleaners, Silo Unloaders,
Silo Hoists, Bunk Feeders)
3-1/2 cu. ft. Mixer
High Pressure 1.8 Gal/Min
Washer 2 gal/min
2 gal/min
Refrigerator or Freezer
Shallow Well Pump
Sump Pump
OM-4426 Page 52
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
11-7. Approximate Power Requirements For Contractor Equipment
Contractor
Hand Drill
Circular Saw
Table Saw
Band Saw
Bench Grinder
Air Compressor
Electric Chain Saw
Electric Trimmer
Electric Cultivator
Elec. Hedge Trimmer
Flood Lights
Submersible Pump
Centrifugal Pump
Floor Polisher
High Pressure Washer
55 gal Drum Mixer
Wet & Dry Vac
Rating
Starting Watts
Running Watts
1/4 in
3/8 in
1/2 in
6-1/2 in
7-1/4 in
8-1/4 in
9 in
10 in
14 in
6 in
8 in
10 in
1/2 HP
1 HP
1-1/2 HP
2 HP
1-1/2 HP, 12 in
2 HP, 14 in
Standard 9 in
Heavy Duty 12 in
1/3 HP
18 in
HID
Metal Halide
Mercury
Sodium
Vapor
400 gph
900 gph
3/4 HP, 16 in
1 HP, 20 in
1/2 HP
3/4 HP
1 HP
1/4 HP
1.7 HP
2-1/2 HP
350
400
600
500
900
1400
4500
6300
2500
1720
3900
5200
3000
6000
8200
10500
1100
1100
350
500
2100
400
125
313
1000
1400
1250
600
900
4500
6100
3150
4500
6100
1900
900
1300
350
400
600
500
900
1400
1500
1800
1100
720
1400
1600
1000
1500
2200
2800
1100
1100
350
500
700
400
100
250
1000
200
500
1400
1600
950
1400
1600
700
900
1300
OM-4426 Page 53
11-8. Power Required To Start Motor
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
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.
(kVA/HP x HP x 1000) / Volts =
Starting Amperage
Example: Calculate starting amperage required for a 230 V, 1/4 HP motor with a motor start code of M.
Volts = 230, HP = 1/4, kVA/HP =
11.2
(11.2 x 1/4 x 1000) / 230 = 12.2A
Starting the motor requires 12.2
amperes.
S-0624
11-9. 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-4426 Page 54
11-10. Typical Connections To Supply Standby Power
1
2
Utility
Electrical
Service
Have only qualified persons
perform these connections
according to all applicable
codes and safety practices.
!
Properly install and ground
this equipment according to
its Owner’s Manual and national, state, and local codes.
4
3
Transfer Switch
!
Fused
Disconnect
Switch
(If Required)
Welding
Generator
Output
Customer-supplied equipment
is required if generator will supply standby power during
emergencies or power outages.
5
Essential
Loads
1 Utility Electrical Service
2 Transfer Switch (Double-Throw)
Switch transfers the electrical load
from electric utility service to the
generator. Transfer load back to
electric utility when service is restored.
Install correct switch (customersupplied). Switch rating must be
same as or greater than the branch
overcurrent protection.
3 Fused Disconnect Switch
Install correct switch (customersupplied) 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 11-4).
OM-4426 Page 55
11-11. 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
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-4426 Page 56
6
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-4426 Page 57
Notes
Welding Symbols
Ref. AWS/ANSI A2.4
OM-4426 Page 58
Effective January 1, 2007
(Equipment with a serial number preface of “LH” or newer)
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.
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions
* Induction Heating Coils and Blankets, Cables, and
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
Non-Electronic Controls
its original retail purchaser that new Miller equipment sold after
* APT & SAF Model Plasma Cutting Torches
the effective date of this limited warranty is free of defects in
* Remote Controls
material and workmanship at the time it is shipped by Miller. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
* Accessory (Kits)
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
* Replacement Parts (No labor)
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Spoolmate Spoolguns
Within the warranty periods listed below, Miller will repair or
* Canvas Covers
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 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 delivery date of the
equipment to the original end-user purchaser, and not to exceed
one year after the equipment is shipped to a North American
distributor or eighteen months after the equipment is shipped to
an International distributor.
1.
5 Years Parts — 3 Years Labor
2.
3 Years — Parts and Labor
*
*
*
*
*
*
*
*
*
3.
Original main power rectifiers
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Process Controllers
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (Unless Otherwise Stated)
Water Coolant Systems (Integrated)
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources, Coolers, and
Electronic
Controls/Recorders
Water Coolant Systems (Non-Integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
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.)
Bernard-Branded Mig Guns (No Labor)
Weldcraft-Branded TIG Torches (No Labor)
Subarc Wire Drive Assemblies
4.
6 Months — Batteries
5.
90 Days — Parts
*
MIG Guns/TIG Torches and Subarc (SAW) Guns
Miller’s True Blue® Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings, relays
or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)
2.
Items furnished by Miller, but manufactured by others, such
as engines or trade accessories. These items are covered
by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable and
necessary maintenance, or equipment which has been
used for operation outside of the specifications for the
equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available,
but may vary from province to province.
miller_warr 2007−01
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
© 2007 Miller Electric Mfg. Co. 2007−01
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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