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Miller DU-OP

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1. cc SS 94 Snck nc up POSITIVE ELECTRODE I CH Kees O GI c21 Ly g Y X f cB c9 PLG24Yi Y2 LES SCR TN SCR A SCR 91 140 95 1 2 3 mm 4 c22 cv POSITIVE ale 8 L d Lo 12 SR3 2 s9 FIRST 1 T 13 POLARITY T ex bd SWITCH t M M RES AN Kisha RO RIS 12 T lel 10 UA BGS Ne M e c12 L REV SGR pe SCR m SCR Gr 228 as ip NT it A S sg 6 i SA A 4 o 256 237196 224232 baii RC21 RC22 CR 1 T8 5 Ple2t pos AAAA AAAA ARAR RA A A RATOS zaa A to ro nt MM 29 7 1 Tier sm N 2226 2222 2225 32 28g EE pi PCB 2 MET Sra 4 8 45 235 AMP VOLT E LEZ wc ue RCA 7 2425 RCI 1 5 podes PE 1 T9 5 Y 268 PCs RC4 5 2212 RC11 2 BOARD lt lt p SX RC3 17 Ge BOARD RC4 8 gt H lt lt RC11 8 RC10 PLG25 262 nc3 15 RC1 PLG2 RC4 6 gt H py RC11 9 RC11 PLG26 sis 2 5 32v Ree LES RC4 9 2217 SS RC11 6 RC5 PLG12 RC6 6 le Rc11 10 4 8 43 RC6 PLG27 RCE 11 gt on me Gd au A 1 T10 5 Y RC6 7 gt gt zo o sad l sS RC6 12 gt 2 SS S 2 1997 z 7 8 to m ax Y Y Y Yy yvy ya 3388 55 8 88 4 d A A 4 Yadda 1250 i o O O 5 2 i aZ S ERE ge 2 E RS Y 2 ze PES a V V V V NA NA Y NNN NA NN B Y 251 253 Y 257 s tze 259 oa 274 247 d T8 ON e 241 mt 4
2. Tools Needed IZ 3 4 in Stop engine NOTICE Do not exceed machine duty cycle IE Welder A left weld output terminals are disabled in Single Operator mode Connect only to Welder B right termi nals for Single Operator mode opera tion x Use Single Operator mode for CC weld ing only Welder A and Welder B CV weld output terminals are disabled in Single Operator mode see Section 5 10 See Section 5 17 for proper cable size See Section 5 17 for proper cable size 1 Strain Relief Route cables through strain reliefs 2 Electrode Holder Cable 3 Work Cable For Stick TIG welding Direct Current Elec trode Positive DCEP connect work cable Welder B Right Side Ref 225 543 802 292 A to Negative terminal and electrode hold er cable to CC terminal For Stick TIG Direct Current Electrode Neg ative DCEN connect work cable to CC terminal and electrode holder cable to Neg ative receptacle If unit has the Polarity switch option con nect work cable to Work terminal and elec trode holder cable to Electrode receptacle F Be sure Process Selector switch is set correctly See Section 6 3 OM 225 590 Page 33 5 17 Selecting Weld Cable Sizes NOTICE The Total Cable Length in Weld Circuit see table below is the combined length of both weld cables For example if the power source is
3. 17 4 4 Fuel Consumption i manie yews Obes maniere son eee ee dents E RUE EP ed 18 4 5 AC Generator Power 18 4 6 Duty Cycle And Overheating 19 4 7 Volt Ampere Curves 444444444 paad Aa PEEN rne 20 SECTION 5 INSTALLATION i oer c ns diate il 21 5 1 Serial Number And Rating Label Location 21 5 2 Installing Welding Generator 21 5 3 Grounding Generator To Truck Or Trailer Frame 22 5 4 Activating The Dry Charge Battery If Applicable 23 5 5 Connecting The Bailen iiis axe NEEN NENNEN NEEN dk wh ERR ER 23 5 6 Installing Exhaust Pipe cipere Rr RR RETE le die ERIS 0e PREX GRIP eer 24 5 7 Engine Prestart Checksum WEE re Rt Rr EPIS d EEN dee d CE amer e 24 5 8 Safety Information For Connecting To Weld Output Terminals 25 5 9 Weld Output Terminals 26 5 10 Making Dual Operator CC Weld Connections wl Separate Work Cables 27 5 11 Making Dual Operator Mode CC Weld Connections wl Common Work Cable 28 5 12 Making Dual Operator CV Weld Connections w Separate Work Cables 29 5 13 Making Dual Operator CV
4. Note position of Process Selector switches He I Note position Note position of optional of optional 4 Polarity switch Polarity switch p 2 2 3 WA A Stop engine NOTICE Do not exceed machine duty cycle EF For common work connection work cable must be able to carry combined weld output of both CC weld output ter minals see Section 5 17 for proper cable size x Use Dual Operator mode for CC and CV welding see Section 6 1 1 Strain Relief Route cables through strain reliefs 2 Wire Feeder Cables 3 Work Jumper Cable 4 Common Work Cable For MIG and FCAW welding Direct Current Electrode Positive DCEP connect com mon work cable and work jumper cable to Welder B right Negative terminal Connect other end of work jumper cable to Welder A left Negative terminal Connect wire feeder cables to CV termi nals For MIG and FCAW Direct Current Elec trode Negative DCEN connect common work cable and work jumper cable to Weld er B right CV terminal Connect other end of work jumper cable to Welder A left CV terminal Ref 225 543 802 292 A Connect wire feeder cables to Negative terminals If unit has the Polarity switch option con nect common work cable and work jumper cable to Welder B ri
5. 1 2 in 13 mm Minimum Length tee 1 1 8 in 28 6 mm New Length Replace Damaged Brushes 1 Ref 225 543 S 0233 A OM 225 590 Page 47 8 10 Circuit Protection E A Stop engine EF When a supplementary protector or fuse opens it usually indicates a more serious problem exists Contact Facto ry Authorized Service Agent Fuse F1 Fuse F2 Fuse F3 Fuse F4 Open front panel A ND Fuse F1 protects the exciter excitation winding If F1 opens there is no weld or generator power output on both sides Fuse F2 protects the exciter main field ex citation winding If F2 opens there is no weld output on both sides Fuse F3 protects Welder A left control board PC1 If F3 opens Welder A left weld output stops Fuse F4 protects Welder B right control board PC1 If F4 opens Welder B right weld output stops 5 Supplementary Protector CB5 6 Supplementary Protector CB6 7 Supplementary Protector CB7 8 Supplementary Protector CB8 Supplementary Protector CB5 protects the 24 volt and 115 volt AC output to Welder A left remote receptacle RC9 If CB5 opens Welder A left RC9 24 and 115 volt AC out put stops Supplementary Protector CB6 protects the 24 volt and 115 volt AC ou
6. 4 se D ora dtc ERR 206 795 BOOT circuit breaker 4 sx M easque ree a ds PLATE ident control rating order by model and serial number 1 UE PENDET 190 375 NAMEPLATE node a EEN E 1 sxU0 agen tein odes 216270 PANEL aux power 1 7 GFCI1 2 246865 RECEPTACLE str dx grd 2P3W 20A 125V GFCI 2 8 CB1 4 093996 SUPPLEMENTARY PRO man reset 1p 20a 250vac frict 4 9 RCI RC2 193257 RECEPTACLE str dx grd 2P3W 15 20A 250V 2 10 R10 189699 RESISTOR WW tap 375W 1 send xxr 038 620 LINK jumper term blk 30A 2 12 TE1 2 038621 BLOCK term 30A 4 pole 2 18 T5 10 210636 TRANSFORMER control 6VA 120VCT 6 14 PC4 191255 CIRCUIT CARD ASSEMBLY field current regulator 1 phe Ee eat eas 083 147 GROMMET SCR NO 8 10 panel 4 O n CE ses 192 332 PANEL LAYOUT mtg component 1 17 CB7 8 189266 SUPPLEMENTARY PROTECTOR man reset 1p 15a 250vac 2 ROTEN ES 206 795 BOOT circuit breaker clear hex nut 2 18 1T 2T 190210 BLOCK term 5
7. 2 M NOR EM 162817 BUS BAR capacitor 2 EE C15 C20 163535 CAPACITOR elctit 6 ERR R4 R6 140002 RESISTOR WW fxd 10W 1 T 162 799 BRACKET mtg capacitors 2 OM 225 590 Page 67 Item Dia Part No Mkgs No Description Quantity Figure 12 1 Main Assembly Continued 102 men 233 088 LABEL danger using a generator indoors can kill you in minutes unit 1 Loved tut i RU 193 501 KIT label includes safety and informational labels 1 When ordering a component originally displaying a precautionary label the label should also be ordered Order label individually or as part of Label Kit 193 501 Recommended Spare Parts OPTIONAL To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor Hardware is common and not available unless listed 804 290 A Figure 12 2 Front Panel OM 225 590 Page 68 Item Dia Part Recommended Spare Parts OPTIONAL No Mkgs No Description Quantity Figure 12 2 Front Panel Figure 12 1 Item 94 ES arm 225550 PANEL front control 1 dise eed is 209 056 COVER receptacle w gasket
8. A Have only qualified persons perform these connections according to all applicable codes and safety practices A Properly install and ground this equipment according to its Owner s Manual and na tional state and local codes E Customer supplied equipment is required if generator will sup ply standby power during emergencies or power out ages 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 re stored Install correct switch customer supplied Switch rating must be same as or greater than the branch overcurrent protection 3 Fused Disconnect Switch Install correct switch customer supplied if required by electrical code 4 Welding Generator Output Generator output voltage and wir ing 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 volt age and frequency 5 Essential Loads Generator output may not meet the electrical requirements of the prem ises If generator does not produce enough output to meet all require ments connect only essential loads pumps freezers
9. 43 8 4 Servicing Fuel And Lubrication Systems 44 8 5 Adjusting Engine Speed 45 8 6 Servicing Optional Ether Starting Aid 45 8 7 Priming Euel System s ECCE RR AE AEN NEE ENN a he E Aas RA 46 8 8 Inspecting And Cleaning Optional Spark Arrestor Muffler 47 8 9 Checking Generator Brushes 47 8 10 Circuit Protection ug de EE mean ee A e DNE hop SE 48 8 11 Troubleshooting x2 e RES AAA AEN oe eU ee E EIE OR IR e an 49 SECTION 9 ELECTRICAL DIAGRAMS 52 SECTION 10 RUN IN PROCEDURE 0 cece eee eee eee ne nn e nen nnn 54 1051 E Le Le GEET 54 10 2 Run In Procedure Using Load Bank 55 10 3 Run In Procedure Using Resistance Grid 56 SECTION 11 GENERATOR POWER GUIDELINES ooccococcocccccnr ke eee eee eee eens 57 SECTION 12 PARTS LIST RI SEE a RT NIE 64 OPTIONS AND ACCESSORIES WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING rom 2010 03 A Protect yourself and others from injury read follow and save these important safety precautions and operating instructions 1 A A 1 Symbol Usage DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury The possible hazards are sho
10. 8 Under Left Side Of Fuel Tank Behind Control Panel Tools Needed 3 3 8 7 16 3 4 in MOST Oil Filter Oil Drain Valve And Hose Oil Fill Cap Primary Fuel Filter Fuel Water Separator A Stop engine and let cool 4 2 3 4 Petcock Secondary Fuel Filter Fuel Shutoff Valve Lever oN OW Sludge Drain Plug To change oil and filter See engine manual To drain water from fuel system Open primary fuel filter petcock and drain water into metal container Close petcock when water free fuel flows To replace primary fuel filter Close shutoff valve and turn filter counterclockwise Remove filter Apply thin coat of fuel to gasket on new filter Install new filter and turn clockwise Open shutoff valve Use primer pump to prime injector sys tem see Section 8 7 Inspect fuel line and replace if cracked or worn To replace secondary fuel filter See engine manual To drain sludge from fuel tank gt This procedure should only be done by a Factory Authorized Service Agent Remove Welder A left control panelto access sludge drain plug Put metal container under drain and remove plug Reinstall plug when sludge has drained Reinstall control panel A After servicing start engine and check for fuel leaks A Stop engine
11. 12 si LO Gu gt 4 Generator Power Receptacles Neutral Bonded To Frame 3 Prong Plug From Case Grounded Equipment 2 Prong Plug From Double Insulated Equipment 7 Be sure equipment has double A insulated symbol and or word ing on it Do not use 2 prong plug un less equipment is double in sulated gen pwr 2010 04 ST 800 577 1 GND PE ox 1 2 3 Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards Also see AWS Safety amp Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Generators Equipment Grounding Terminal On Front Panel Grounding Cable Not Supplied Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 8 AWG or larger insu lated copper wire gt Electrically bond generator A frame to vehicle frame by met al to metal contact Bed liners shipping skids and some running gear insu late the welding generator from the vehicle frame Al ways connect a ground wire from the generator equip ment grounding terminal to bare metal on the vehicle frame as shown If unit does not have GFCI re ceptacles use GFCI pro tected extension cord 800 652 D OM 225 590 Page 57 11 3 Grounding When Supplying Building Systems ES 1 Equipment Grounding
12. 1 2 Terminal GND PE yA 2 Grounding Cable Use 8 AWG or larger insulated copper wire 3 Ground Device EF Use ground device as stated in electrical codes A Ground generator to system earth ground if supplying power to a premises home shop farm wiring system A Also see AWS Safety amp 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 ES 1 Resistive Load A light bulb is a resistive load and requires a constant amount of power 2 Non Resistive Load Equipment with a motor is a non re 3 sistive load and requires approxi 2 ABC s mately six times more power while H dd starting the motor than when running 1 Z see Section 11 8 Ne SON 3 Rating Data 0 Rating shows volts and amperes or watts required to run equipment Amperes x Volts Watts 3 Example 1 If a drill uses 4 5 am 7 q peres at 115 volts calculate its run ning 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 Ex ample 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 225 590 Page 58 11 5 Approximate Power Requirements For Industr
13. 4 e Release air pressure from tools and system be fore servicing adding or changing attach ments or opening compressor oil drain or oil fill cap 1 6 Additional Symbols For Installation Operation And Maintenance CA ALI FIRE OR EKPLOSION hazard OVERHEATING can damage motors e Turn off or unplug equipment before starting or stopping engine e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not let low voltage and frequency caused by e Do not overload building wiring be sure power supply system is low engine speed damage electric motors properly sized rated and protected to handle this unit e Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable MIKO FALLING EQUIPMENT can injure Use lifting eye to lift unit and properly installed Ab FLYING SPARKS can injure accessories only NOT gas cylinders Do not exceed maximum lift eye weight rating see cz e Wear a face shield to protect eyes and face Specifications YA e Shape tungsten electrode only on grinder with e Use equipment of adequate capacity to lift and proper guards in a safe location wearing proper support unit face hand and body protection e If using lift forks to move unit be sure forks are long enough to e Sparks can cause fires keep flammables away extend beyond opposite side of unit e Keep equipment cables and cords away fro
14. EF After installing cylinder wait at least 10 minutes before using to let ether particles settle and prevent atomizer plugging Put cap on fitting when cylinder is removed ether1 7 96 153 382 A 225 543 804 289 A 5 19 Remote 14 Receptacle Information Place Welder Selector switch in Welder A Welder B position dual operator mode for both remote receptacles to work Welder A left remote receptacle output contactor and control is disabled when switch is in Welder B position 7 senor 14 Socket Socket Information 24 VOLTS AC A 24 volts AC Protected by supplementary protectors CB5 and CB6 OUTPUT CONTACTOR B Contact closure to A completes 24 volts AC contactor control circuit C Output to remote control 10 volts DC in CV O to 10 volts DC in CC REMOTE OUTPUT D Remote control circuit common CONTROL E 0 to 10 volts DC input command signal from remote control AN F Current feedback O to 10 volts dc 1 volt per 100 amperes AMPERAGE H Voltage f k 1 volts D 1 Its VOLTAGE oltage feedback 41 volts DC per 10 arc volts 115 VOLTS AC 115 volts 15 amperes 60 Hz ac Protected by supplementary protectors CB5 and CB6 OUTPUT CONTACTOR a Contact closure to completes 115 volts AC contactor control circuit K Chassis common GND G Circuit common for 24 and 115 volts AC circuits The remaining sockets are not used OM 225 590 Page 35 5 20 Remo
15. OM 225 590H 2011 04 m Miller e i E Stick SMAW Welding MIG GMAW Welding Flux Cored FCAW Welding TIG GTAW Welding e Air Carbon Arc CAC A id Cutting and Gouging Description DES LZ Dual Operator Engine Driven Welding Generator Miller DU OP OWNER S MANUAL File Engine Drive FA 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 n U 3 Bl E PEENI 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 Working as hard as you do A every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most hassle free warranty in the We ve made
16. gt e A e Y Y gt gt Sar A Welding Trouble Remedy No weld output on either side generator power output okay at AC receptacles Place Output Contactor switches in On Hot position or place switches in Remote position and connect remote contactors to remote receptacles RC8 and RC9 see Section 6 3 Unit overheated High Temp Shutdown light goes on wait several minutes for thermostat s TP3 and TP4 to reset see Section 8 10 Check position of Process Selector switches and Welder Selector switch All weld output stops if either Process Selector switch is placed in CV position when Welder Selector switch is in Welder B position see Sections 6 1 and 6 3 Check fuse F2 and replace if open see Section 8 10 Have Factory Authorized Service Agent check field current regulator board PC4 Have Factory Authorized Service Agent check field current regulator board PC4 and Welder Selector switch S2 No weld output on either side and no generator power output at AC recept acles Disconnect equipment from generator power receptacles during start up Check fuse F1 and replace if open see Section 8 10 Reset supplementary protectors CB7 and or CB8 see Section 8 10 Have Factory Authorized Service Agent check brushes and slip rings field excitation circuit rotor stator and field current regulator board PCA No Welder A left weld output Welder B right weld output okay Check f
17. 5 1 7 California Proposition 65 Warnings 2 6 1 8 Principal Safety Standards wi i e eni ae a GOE E E E E E D E EE a a 7 119 EMF Information e seri terr eer eerte ue E a an RR Re KO RECEN ROS be tb RR 7 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 8 2 1 Signification des symboles b ENEE A NEE AT ER SURE AX AREE E 8 2 2 Dangers relatifs au soudage l arc 8 2 3 Dangers existant en relation avec le moteur 10 2 4 Dangersliesalhydrauligue 11 2 5 Dangers li s Fair comprim 12 2 6 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 13 2 7 Proposition californienne 65 Avertissements 14 2 8 Principales normes de s curit 15 2 9 Informations relatives aux CEM 15 SECTION 3 DEFINITIONS oo IRR te eme x E ENEE eg 16 3 1 Symbols And Definitions 2 32 nib RI PR Re a a rac RR DERART PEERS REA 16 SECTION 4 SPECIFICATIONS NENNEN ENEE BEEN ee a 17 441 RE ENT MER 17 4 2 Weld Power And Engine Specifications 17 4 3 Dimensions Weights And Operating Angles
18. A CC DC Single Mode The volt ampere curve shows the minimum medium and maximum 100 voltage and amperage output capa bilities of the welding generator Curves of all other settings fall be tween the curves shown DC VOLTS 0 100 200 300 400 500 600 700 800 900 1000 DC AMPERES B CC DC Dual Mode 100 80 DC VOLTS 0 0 50 100 150 200 250 300 350 400 450 500 DC AMPERES C CV DC Mode 100 80 72 H 60 O gt O o 40 MAX 20 MED MIN 0 O 100 200 300 400 500 600 700 800 900 1000 DC AMPERES 194 397 194 398 194 399 OM 225 590 Page 20 SECTION 5 INSTALLATION EF When facing the front panel the Welder B controls and weld terminals are on the right and the Welder A controls and weld terminals are on the left 5 1 Serial Number And Rating Label Location The serial number and rating information for this product is located on the front Use rating label to determine input power requirements and or rated output For future reference write serial number in space provided on back cover of this manual 5 2 Installing Welding Generator EZ P G 4 AN y i A Do not move or operate unit Wi RE where it could tip A Do not lift unit from end Movement A Always securely Tasten welding generator onto transport vehicle or trailer and comply with all DOT and other applicable codes NOTICE Do not install unit where air flow is restricted or engine may over heat
19. Protective Earth IN Pump Clearance Fuel Ground Positive Negative M Ei Welding Arc Amperes Volts Panel Local Va Remote On Temperature Output Contactor ING po das SET eae an WEN VU Tee Phase Time Hours Seconds Single Phase HI Read Operator s Manual OM 225 590 Page 16 SECTION 4 SPECIFICATIONS 4 1 Description This unit has two CC CV modules with separate weld controls for applications where two welding arcs are needed A Welder Selector switch controls whether one or both sets of weld output terminals are active see Section 6 2 When the unit is operated in the dual operator mode each welder has CC and CV weld output available for Stick TIG and MIG welding When in the single operator mode CC weld output is available to the welder on the Welder B right side only CV not active in single operator mode 4 2 Weld Power And Engine Specifications Max Weld Weld Rated IE IE 3E ME E RM Available Range Voltage Output 1 550 Aat 30 Single Phase Deut S o A eutz Single Right Side CC DC 30 600A 85 Hm ea 4 KVAJKW 34 17 A DAOS Kee Ko Air Cooled 22 3 gal 50 60 Hz Three Cylinder 84 4 L CC DC 15 300A 85 275 A at 31 Ee Dual s Volts DC 40 4 KVA KW Shared By d Both Sides C
20. gers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte NOTE Indique des d clarations pas en relation avec des blessures personnelles 2 2 Dangers relatifs au soudage l arc A Les symboles pr sent s ci apr s sont utilis s tout au long du pr sent manuel pour attirer votre attention et identifier les ris ques de danger Lorsque vous voyez un symbole soyez vigilant et suivez les directives mentionn es afin d viter tout danger Les consignes de s curit pr sent es ci apr s ne font que r sumer l information contenue dans les normes de s curit num r es la section 1 8 Veuillez lire et respecter toutes ces normes de s curit L installation l utilisation l entretien et les r parations ne doivent tre confi s qu des personnes qualifi es A Au cours de l utilisation tenir toute personne a l cart et plus particuli rementles enfants UN CHOC LECTRIQUE peut tuer Un simple contact avec des pi ces lectriques peut provoquer une lectrocution ou des blessures gra ves L lectrode et le circuit de soudage sont sous tension d s que l appareil est sur ON Le circuit d entr e et les circuits internes de l appareil sont galementsous tension ce moment l En soudage semi automatique ou automatique le fil le d vidoir le logement des galets d entrainement et les pi ces m talliques en contact avec le fil de soudage sont sous tension Des mat riels mal insta
21. un surchauffement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger e D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneusement avec des protections homologu s e Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables e Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud e Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures e Surveiller tout d clenchement d incendie et tenir un extincteur proximit e Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t e Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient t pr par s correctement conform ment AWS F4 1 voir les nor mes de s curit e Ne soudez pas si l air ambiant est charg de particules gaz ou va peurs inflammables vapeur d essence par exemple e Brancherle cable de masse sur la piece le plus pr s possible de la zone de soudage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provo quant des risques d lectrocution d tincelles et d incend
22. 22 SR2 e si STR 18 DE I m POLARITY e 1 a Dru Pa SWITCH 96 t BU Maho eds 17 T El we A NE E C10 c11 c12 L OH I REV 16004 gt rmi m CRZ CR2 o A SgR ZA SgR Sg SgR Gr EZ A A A A Ed gt G A tE ONR 37 24 20 32 3004 gt RC6 36 1 05 REIS AW AW E A du o do 70MM nb 21 1 T5 SPEI E AAAA ARK ARAA A R R R A an A 9 oo TETS uen TITO oe eet RC4 1 gt gt HL Ru 0 2255 2222 2225 nop 23 8 RC4 2 gt lt RC10 4 Om Wp ae ee 32V 5 222 2225 98 999 4 SER E g ee RC4 4 FE mes E omm i 22 4 8 43 CARE RC4 7 25457 lt lt RC11 5 bL zai v E RC4 5 DS RC11 2 Pc2 I D BS e e Bos RC3 17 pei Ros gt H g lt ROM 8 AMPLVOLT I I 2 2 sie CONTROL BOARD RCA 6 25177 RC11 9 WI SD 2 s I 32V RO3 PLG3 RC4 9 gt gt TE lt lt RC11 6 RC10 PLG10 a REL PB EES lt lt RC11 10 R TI PLOT 4 8 43 de Ss 18 T RC6 PLG18 RC6 11 gt gt 757 7 RP Py T7 e EN 27 1 77 5 Y RC6 7 gt gt y S roe 4 lt RC6 12 gt 2 ggg 8 a 1977 3g 7317 7 zb YA VEN das Vo 8883 8 8 8 88 8 8 8 8 5 2 z s d as ERES 2 E E 82 Y 2 gg ns eu Le V V V V NA Y Y Y Y Y M MN D V 51 Le sz s 5 59 50 771 47 A oi T see 7 TE2 184 4 sl X AT r 120V a V 8 Dd o 2 A ene e 142 TE2 13 eE p ce I v 4 9 RMT Er bo 10 A s3 4 79 s Mes M PANEL RCB 15 ai 485 I p 4 PANEL REMOTE o OC RED Y cw DER 1y WU ER TE2 A R2 AN ADJUST PLG19 76 zz Le Us 120V 24
23. 342 hex nyl 6 MC CR eine eae 059 773 HANDLE switch 2 sx SAT See 010 647 PIN Spring i use se is 2 Data mr os ue 091 067 SWITCH polarity 2 EE sat 199 123 LABEL component identification master polarity 1 DUE 199 124 LABEL component identification slave polarity 1 35 PL2 PL3 159522 LED yellow 2 1v 20 ma 45 0 mcd panel mtg 250 hole 2 DOU EEEE 159 036 LENS led clear panel mtg 2 When ordering a component originally displaying a precautionary label the label should also be ordered Order label individually or as part of Label Kit 193 501 OPTIONAL To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 225 590 Page 71 Hardware is common and not available unless listed 2 3 1 d Sy 12 13 15 14 Ref 048 456 E Figure 12 4 Generator Item Dia Part No Mkgs No Description Quantity Figure 12 4 Generator Figure 12 1 Item 76 OR NEED 151 299 BRUSH contact elect clrg 875 x 750 3 TED EN 188 387 BRUSHHOLDER BRACKET ASSEMBLY includes 1 iud
24. Connect electrode holder cable to either CC terminal Connect wire feeder cable to CV terminal on other side EF Be sure Process Selector switches are set correctly See Section 6 3 For Direct Current Electrode Negative DCEN connect common work cable and work jumper cable to Welder B right CC terminal Connect other end of work jumper cable to Welder A left CV terminal Ref 225 543 802 292 A Connect electrode holder cable to either Negative terminal and wire feeder cable to remaining Negative terminal If unit has the Polarity switch option con nect common work cable and work jumper cable to Welder B right Work receptacle Connect other end of work jumper cable to Welder A left Work receptacle Connect electrode holder cable to either Electrode receptacle Connect wire feeder cable to CV recep tacle on other side Place optional Polarity switch in Re verse position when using CV weld re ceptacle There is no CV weld output when switch is in Straight position Be sure Process Selector and Polarity switches are set correctly See Section 6 3 OM 225 590 Page 32 5 16 Making Single Operator CC Weld Connections Welder A left Terminals Inactive In Single Operator Mode Direct Current Electrode Positive DCEP connections are shown Note position of Process Selector Switch
25. ceptacle s circuit opens to disconnect the faulty equipment and the GFCI Reset but ton pops out Check for damaged tools cords plugs etc connected to the recep tacle Press button to reset receptacle and resume operation x At least once a month run engine at weld power speed and press Test but ton to verify GFCI is working properly 5 Supplementary Protectors CB1 And CB2 6 Supplementary Protectors CB3 And CB4 CB1 and CB2 protect RC1 and GFCI 1 from overload If CB1 or CB2 opens RC1 does not work 120 volts may still be present at RC1 If CB2 opens GFCI 1 does not work Press button to reset CB3 and CB4 protect RC2 and GFCI 2 from overload If CB3 or CB4 opens RC2 does 190 376 not work 120 volts may still be present at RC2 If CB4 opens GFCI 2 does not work Press button to reset FF If a supplementary protector continues to open contact Factory Authorized Service Agent Maximum output from each 120 volt GFCI receptacle is 2 4 KVA KW Maximum output from each 240 volt duplex receptacle half is 4 0 KVA KW Total combined output from all receptacles is 4 kVA kW EXAMPLE If 12 A is drawn from RC1 only 9 A is available at GFCI 1 240 V x 12 A 120 V x 9 A 4 0 KVA KW Generator power is not affected by weld output OM 225 590 Page 40 SECTION 8 MAINTENANCE amp TROUBLESHOOTING 8 1 Routine Maintenance fluids for important start up s
26. consommables les rev tements les nettoyants et les d graisseurs e Travailler dans un espace ferm seulement s il est bien ventil ou en portant un respirateur alimentation d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent d placer l air et abaisser le niveau d oxyg ne provoquant des blessures ou des accidents mortels S assurer que l air de respiration ne pr sente aucun danger e Ne pas souder dans des endroits situ s proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et for mer des gaz hautement toxiques et irritants e Ne pas souder des m taux munis d un rev tement tels que l acier galvanis plaqu en plomb ou au cadmium moins que le rev te ment n ait t enlev dans la zone de soudure que l endroit soit bien ventil et en portant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confin s ou se servir d un respirateur d adduction d air homologu LES RAYONS DE L ARC peuvent provoquer des br lures dans les yeux et sur la pea
27. dicaux comme des stimulateurs cardiaques Des mesures de protection pour les porteurs d implants m dicaux doivent tre prises par exemple des restrictions d acc s pour les passants ou une valuation individuelle des risques pour les soudeurs Tous les soudeurs doivent appliquer les proc dures suivantes pour minimiser l exposition aux CEM provenant du circuit de soudage 1 Rassembler les c bles en les torsadant ou en les attachant avec du ruban adh sif ou avec une housse 2 Ne passe tenir au milieu des c bles de soudage Disposer les c bles d un c t et distance de l op rateur 3 Ne pas courber et ne pas entourer les c bles autour de votre corps 25 West 43rd Street New York NY 10036 phone 212 642 4900 web site www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org For Standards about hydraulic systems contact the National Fluid Power Association Publications Department 3333 North Mayfair Road Suite 211 Milwaukee WI 53222 3219 phone 414 778 3344 website www nfpa com OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 p
28. tiqueter l appareil d tendre la pression et s assurer que le circuit hydraulique ne peut tre remis sous pression par inadvertance e Demander seulement un personnel qualifi d enlever les dispositifs de s curit ou les recouvrements pour effectuer S il y a lieu des travaux d entretien et de d pannage e Remettre en place les portes panneaux recouvrements ou dispositifs de protection la fin des travaux d entretien et avant de mettre le moteur en marche 2 5 Dangers li s l air comprim Un QUIPEMENT PNEUMATIQUE risque de provoquer des blessures ou m me la mort e Uneinstallation ou une utilisation incorrecte de cet appareil pourrait conduire des d g ts mat riels ou corporels Seul un personnel qualifi est autoris installer utiliser et entretenir cet appareil conform ment son manuel d utilisation aux normes industrielles et aux codes nationaux d tat ou locaux Ne pas d passer le d bit nominal ou la capacit du compresseur ou de tout quipement du circuit d air comprim Concevoir le circuit d air comprim de telle sorte que la d faillance d un composant ne risque pas de provoquer un accident mat riel ou corporel e Avant d intervenir sur le circuit d air comprim couper l alimentation lectrique verrouiller et tiqueter l appareil d tendre la pression et s assurer que le circuit d air ne peut tre mis sous pression par inadvertance e Ne pas intervenir sur le circ
29. 225 590 Page 73 Item Dia Part No Mkgs No Description Quantity Wiring Harnesses xpi ed uta a 192 208 HARNESS wiring control box welder A left includes 1 ER CR2 000770 RELAY encl 24VDC 3PDT 10A 120VAC 11 pin 1 E GRD 185011 STUD primary board brs 10 32 x 1 592 1 IUE S3 6 7 011 609 SWITCH tgl SPDT 15A 125VAC on none on 3 Muret R1 8 035897 POTENTIOMETER cp std slot 1t 2w 1k linear 2 T LS1 2 089645 SWITCH lim 11A 125V 2 iba aida PLG18 131056 CONNECTOR housing plug pins and sockets 1 EE 187 651 SEAL wire univ 9P S 3 row 1 EE PLG19 168071 CONNECTOR housing plug pins and sockets 1 PLG4 11 148 439 CONNECTOR housing plug pins and sockets 2 DEE PLG5 152249 CONNECTOR housing plug pins and sockets 1 Spain PLG10 153 501 CONNECTOR housing plug pins and sockets 1 Mae dv RC6 168 845 CONNECTOR housing plug pins and sockets 1 SSL A Les at RC7 168846 CONNECTOR housing plug pins and sockets 1 duds PLG3 169240 CONNECTOR housing plug pins and sockets 1 EE 192 336 HARNES
30. 2T 120V EL PL av 14 og V 242 o 213 205 A RMT I ig bo 255 J B AT 1 510 RC9 I pys PANEL ot Lh T4 zA 279 mE BLK RED 4T d 278 11 dd For Y SV ces Ein PANEL REMOTE oz WHT BLUE 2 V TP4 cw evy 14 E t T 42 RS e A9 A V ADJUST Y d RECT sg 276 Las La Las GIK A I C18 c19 PC7 1 gt RC9 PES 2500 pn AR lt GRD 2 2 3 ait 215 AT rH rH rh rH M vL c V A Lid D E C F H P RC9 RI RI ELIS 12 PCT SIDE A Rc19 Rc20 PCS SIDE B SI eS Ede RC6 PLG18 peia D RC6 PLG27 WITH THE POLARITY SWITCH OPTION RC6 14 gt lt 1 amp RC6 14 LEADS 20 amp 27 ON SIDE AND LEADS 94 amp 96 ON SIDE B GO TO RCB 8 aaa RC6 10 E 745 aces THE POLARITY SWITCH RATHER THAN ae rU d THE OUTPUT STUDS THE OUTPUT RC6 9 m S S RC6 9 STUDS ARE LABELED ELECTRODE AND RC6 1 ee Rc6 1 WORK VIEWED FROM REAR OF SWITCH SIDE A TT SIDE B WE 96 20 26 iT o 7r S2 43 43 43 43 YEL 43 43 43 YEL42 d o o o 3T 43 43434343 AT 43 43 43 4343 4 WARNING Do not touch live electrical parts Disconnect input power or stop N engine before servicing Do not operate with covers removed ELECTRIC Have only qualified persons install SHOCK HAZARD use or service this unit 225 565 C OM 225 590 Page 53 SECTION 10 RUN IN PROCEDURE run in3 2007 05 10 1 Wetstacking A Do not perform run in procedure at less than 20 volts weld output and do not
31. Bee E VS 600 270 HOLDER brush 3 ERE grote EUM dedo 152 044 CAP holder brush 3 n D d eir rare ee 173066 BRACKET mtg brushholder 1 se WEE Mars 205 600 STATOR generator includes 1 Du d visu eukbrha 039 207 BAFFLE air generator 1 ni Bua eee 192 286 ROTOR generator includes 1 DEEP 024 617 RING retaining external 1 os TO ssim 053 390 BEARING bell p ER REGEM ee din iR RR EA 1 saan A HEEN ISE re TC REES FAN TOE EE 1 E KEE 225 120 LABEL warning moving parts can cause injury 2 tic TD whe een aaa 195 704 STATOR exciter aux pwr 120 240 1 wt NA an te aes 173 068 ENDBELL generator includes 1 Mii 143220 O RING 2 858ID x 189CS 1 When ordering a component originally displaying a precautionary label the label should also be ordered Order label individually or as part of Label Kit 193 501 Recommended Spare Parts To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when o
32. L CHAPPEMENT peuvent provoquer un incendie e Emp cher les tincelles d chappement du moteur de provoquer un incendie e Utiliser uniquement un pare tincelles approuv voir codes en vigueur LES PI CES CHAUDES peuvent provoquer des br lures e Ne pas toucher des parties chaudes mains nues e Pr voir une p riode de refroidissement avant de travailler l quipement Ne pas toucher aux pi ces chaudes utiliser les outils recomman d s et porter des gants de soudage et des v tements pais pour viter les br lures LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT CHAUD peuvent provoquer des br lures e est pr f rable de v rifier le liquide de refroi dissement une fois le moteur refroidi pour viter de se br ler e Toujours v rifier le niveau de liquide de refroidissement dans le vase d expansion si pr sent et non dans le radiateur sauf si pr cis autrement dans la section maintenance du manuel du moteur e Sile moteur est chaud et que le liquide doit tre v rifi op rer com me suivant 2 4 Dangers li s l hydraulique Les QUIPEMENTS HYDRAULIQUES peuvent provoquer des blessures ou m me la mort e Une installation ou une utilisation incorrecte de cet appareil pourrait conduire des d g ts mat riels ou corporels Seul un personnel qualifi est autoris installer faire fonctionner et r parer cet appareil conform ment son manuel d utilisatio
33. No Labor 6 Months Parts Batteries Bernard Guns No Labor Tregaskiss Guns No Labor A A x F HF F 6 90 Days Parts Accessory Kits Canvas Covers Induction Heating Coils and Blankets Cables and Non Electronic Controls M Guns MIG Guns and Subarc SAW Guns Remote Controls and RFCS RJ45 Replacement Parts No labor Roughneck Guns Spoolmate Spoolguns Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes relays work station table tops and welding curtains or parts that fail due to normal wear Exception brushes and relays are covered on all engine driven products 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 w
34. OSI SZ 4 pue G 9POD OLVN d 2 d 1 88 S26 d WLSV eV pue Ly 698c Sd 06S N3 NIG 1e6 9 v2 1 Leg 7138310 COLvd UE 4261 81 zn q 9096b3 HATIIN c VGV Ld We Z8S0SSd uospeuoq vel pt HIYTIIW I 68v9v XIM 89 cc8d uospeuoq 826 2614 YATIIN 269Hd Wey L002 8LL zineq S096 c H3 TTIIN INdH 0884 40 08L v 089 S vz 198 AGE pes be 1se V 40 30 QO ldv O6t9t XIM 69 2284 uospreuoq 686 261 H3TIIIN Ruondo 0894 s99 9ScG occ Ze LS 990 HATIIN A A o PIS y 067 Se 3NI9N3 135314 1601714694 ZLNAG OM 225 590 Page 42 8 3 Servicing Air Cleaner EO sop y y 79 ie Optional A AY Keep nozzle 2 in 51 mm from element ON 299 RAN ON GO ya AV i WV M XN SN M do d lo M d d A Blow vi 3 XS Wee AS amp d LR Inspect SA d d C d x OQ di ANA WA XS AM XXX d L i d d di nj A vi di SN 0 M d W d Q A WW f R AW A Stop engine NOTICE Do not run engine without air cleaner or with dirty element Engine damage caused by using a damaged ele ment is not covered by the warranty EF The air cleaner primary element can be cleaned but the dirt holding capac ity of the filter is reduced with each cleaning The chance of dirt reaching the clean sid
35. PLG3 152249 HOUSING plug pins and sockets 1 Ae unes PLG13 185556 HOUSING plug pins and sockets 1 AM LL M FERE 188 512 SEAL wire univ 6P S 3 row 1 RAH cT eed ent Edd 225 595 HARNESS engine du op includes 1 Sri PB1 046433 SWITCH pb mc no spst 35a 12vdc w black cap 1 Gel S14 199691 SWITCH tgl spdt 6a 125vac on none mc spd term 1 SR4 5 035704 RECTIFIER integ bridge 40 amp 800v 2 aa pee eu iba aed 192 334 HARNESS aux power panel includes 1 E GFCI1 2 151981 RCPT str dx grd 2p3w 15 20a 125v 5 20r gfi 2 FEDE Ede RC1 2 193257 RCPT str dx grd 2p3w 15 20a 250v 6 20r 2 Ee CB1 2 3 4 093 996 SUPPLEMENTARY PRO man reset 1p 20a 250vac frict 4 OM 225 590 Page 74 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 Q Mini
36. Parts 3 Years Labor Original main power rectifiers only to include SCRs diodes and discrete rectifier modules 2 3 Years Parts and Labor Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer Inverter Power Sources Unless Otherwise Stated Plasma Arc Cutting Power Sources Process Controllers Semi Automatic and Automatic Wire Feeders Smith 30 Series Flowgauge and Flowmeter Regulators No Labor Transformer Rectifier Power Sources Water Coolant Systems Integrated 3 2 Years Parts Auto Darkening Helmet Lenses No Labor 4 1 Year Parts and Labor Unless Specified Automatic Motion Devices CoolBelt and CoolBand Blower Unit No Labor External Monitoring Equipment and Sensors Field Options NOTE Field options are covered for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater Flowgauge and Flowmeter Regulators No Labor RFCS Foot Controls Except RFCS RJ45 Fume Extractors HF Units ICE Plasma Cutting Torches No Labor Induction Heating Power Sources Coolers and Electronic Controls Recorders Load Banks Motor Driven Guns w exception of Spoolmate Spoolguns PAPR Blower Unit No Labor Positioners and Controllers Racks Running Gear Trailers Spot Welders Subarc Wire Drive Assemblies Water Coolant Systems Non Integrated Weldcraft Branded TIG Torches No Labor Work Stations Weld Tables
37. Reliefs V 1 3 Ref 225 543 802 292 A Route cables through strain reliefs CC terminals and electrode holder cables 2 Electrode Holder Cables to Negative terminals 3 Work Cables If unit has the Polarity switch option con For Stick TIG welding Direct Current Elec nect work cables to Work receptacles and trode Positive DCEP connect work electrode holder cables to Electrode recep cables to Negative terminals and elec tacles trode holder cables to CC terminals For Stick TIG Direct Current Electrode CS Be sure Process Selector switches are set correctly See Section 6 3 Negative DCEN connect work cables to OM 225 590 Page 27 5 11 Making Dual Operator Mode CC Weld Connections w Common Work Cable m 5 17 for proper cable size Welder A Left Side Direct Current Electrode Positive DCEP connections are shown ZL Tools Needed LT 3 4 in A INADEQUATE CABLE CONNECTIONS can cause serious damage to welding generator and create a hazardous condition e When making weld connections with a common work cable connect a weld cable of adequate size between the Negative weld terminals and connect a single weld cable of adequate size from the Welder B right Negative terminal to the workpiece e When using these connections as a common work terminal all connections must be of the sam
38. SHOCK MOVING PARTS and HOT PARTS hazards Consult sym bols and related instructions below for necessary actions to avoid the hazards 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 conduc tor 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 ma chines at the same time since double open circuit voltage will be present e 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
39. See Section 4 3 for lifting eye rating install1 1 08 Ref ST 800 652 Ref ST 800 477 A ST 158 936 A 804 712 OM 225 590 Page 21 5 3 Grounding Generator To Truck Or Trailer Frame A Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards Also see AWS Safety amp Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Generators Bed liners shipping skids and some running gear insu late the welding generator from the vehicle frame Al ways connect a ground wire from the generator equip 1 2 ment grounding terminal to bare metal on the vehicle frame as shown GND PE Or A If unit does not have GFCI re ceptacles use GFCI pro tected extension cord 1 Equipment Grounding a Terminal On Front Panel 3 cD 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insulated copper wire gt Electrically bond generator frame to vehicle frame by met al to metal contact rot grnd 2008 01 800 652 D OM 225 590 Page 22 5 4 Activating The Dry Charge Battery If Applicable A Always wear a face shield rubber gloves and protective clothing when working on a battery Remove battery from unit 1 Vent Caps 2 Sulfuric Acid E
40. allow tools to cause sparks when working on a battery e Do not use welder to charge batteries or jump start vehicles un less the unit has a battery charging feature designed for this pur pose Observe correct polarity and on batteries Disconnect negative cable first and connect it last Keep sparks flames cigarettes and other ignition sources away from batteries Batteries produce explosive gases during normal operation and when being charged e Follow battery manufacturer s instructions when working on or near a battery BATTERY CHARGING OUTPUT can injure Battery charging feature not present on all models e Have only qualified persons do battery charging work e Charge lead acid batteries only Do not use battery charger to supply power to an extra low voltage electrical system or to charge dry cell batteries Do not charge a frozen battery Do not use damaged charging cables Do not charge a battery that has loose terminals or one showing damage such as a cracked case or cover e Before charging battery select correct charger voltage to match battery voltage e Set battery charging controls to the Off position before connect ing to battery Do not allow battery charging clips to touch each other Keep charging cables away from vehicle hood door or moving parts ho FUEL can cause fire or explosion d e Stop engine and let it cool off before checking or adding fuel e Do not add fuel w
41. bid iba RC19 PLG20 168 071 HOUSING plugs and pins 1 Dee pate SER EGN 192 218 HARNESS wiring control box welder B right includes 1 Dee CR3 000770 RELAY end 24VDC 3PDT 10A 120VAC 11 pin 1 AMNES GRD 185011 STUD primary board brs 10 32 x 1 592 1 D ROME S8 10 11 011 609 SWITCH tgl SPDT 15A 125VAC on none on 8 eR TA R7 8 035 897 POTENTIOMETER cp std slot 1t 2w 1k linear 2 re LS3 4 089 645 SWITCH lim 11A 125V 2 LS mere d PLG27 131 056 CONNECTOR housing plug pins and sockets 1 MuR NEUE Mati AU 187 651 SEAL wire univ 9P S 3 row 1 E PLG20 168071 CONNECTOR housing plug pins and sockets 1 TIE PLG9 26 148439 CONNECTOR housing plug pins and sockets 2 E PLG12 152249 CONNECTOR housing plug pins and sockets 1 Igea PLG10 153501 CONNECTOR housing plug pins and sockets 1 Lig deeds RC22 168845 CONNECTOR housing plug pins and sockets 1 TE RC23 168846 CONNECTOR housing plug pins and sockets 1 TET PLG8 169240 CONNECTOR housing plug pins and sockets 1 OM
42. doors panels covers and guards closed and securely in place e Keep hands hair loose clothing and tools away from moving parts e Before working on hydraulic system turn off and lockout tagout unit release pressure and be sure hydraulic pressure cannot be accidentally applied e Have only qualified people remove guards or covers for maint enance and troubleshooting as necessary e Reinstall doors panels covers or guards when servicing is finished and before starting engine HOT PARTS AND FLUID can burn e Do not touch hot parts bare handed or allow hot fluid to contact skin e Allow cooling period before working on equip ment e To handle hot parts use proper tools and or wear heavy insu lated welding gloves and clothing to prevent burns READ INSTRUCTIONS e Read and follow all labels and the Owner s Manual carefully before installing operating or servicing unit Read the safety information at the beginning of the manual and in each section e Use only genuine replacement parts from the manufacturer e Perform maintenance and service according to the Owner s Manuals industry standards and national state and local codes e Do not work on compressed air system with unit running unless you are a qualified person and following the manufacturer s in structions e Do not modify or alter compressor or manufacturer supplied equipment Do not disconnect disable or override a
43. e N utiliser que les pi ces de rechange recommand es par le constructeur e Effectuer l entretien en respectant les manuels d utilisation les normes industrielles et les codes nationaux d tat et locaux LIRE LES INSTRUCTIONS e Lire et appliquer les instructions sur les tiquettes et le Mode d emploi avant l installation l utilisation ou l entretien de l appareil Lire les informations de s curit au d but du manuel et dans chaque section L AIR COMPRIM risque de provoquer des blessures ou m me la mort e Avant d intervenir sur le circuit d air comprim couper l alimentation lectrique verrouiller et tiqueter l appareil d tendre la pression et s assurer que le circuit d air ne peut tre mis Sous pression par inadvertance e D tendre la pression avant de d brancher ou de brancher des canalisations d air e Avant d utiliser l appareil contr ler les composants du circuit d air comprim les branchements et les flexibles en recherchant tout signe de d t rioration de fuite et d usure Ne pas diriger un jet d air vers soi m me ou vers autrui e Pour intervenir sur un circuit d air comprim porter un quipement de protection tel que des lunettes de s curit des gants de cuir une chemise et un pantalon en tissu r sistant des chaussures montantes et une coiffe e Pour rechercher des fuites utiliser de l eau savonneuse ou un d tecteur ultrasons jamais les
44. exceed duty cycle or equip ment damage may occur 1 Welding Generator Run diesel engines near rated volt age and current during run in period to properly seat piston rings and prevent wetstacking See name plate rating label or specifications section in this manual to find rated voltage and current Do not idle engine longer than necessary Piston rings seat faster if engine runs at weld power rpm and the welding generator is kept loaded during run in 2 Engine Exhaust Pipe Wetstacking is unburned fuel and oil in the exhaust pipe and occurs during run in if the engine is run too long at light load or idle rpm If exhaust pipe is coated with a wet black tar like substance dry the engine using one of the following run in procedures See the engine manual for addition al engine run in information OM 225 590 Page 54 10 2 Run In Procedure Using Load Bank Lay Ct A Stop engine lt ar t3 A Do not touch hot exhaust pipe engine parts or load bank grid A Keep exhaust and pipe away from flammables A Do not perform run in procedure at less than 20 volts weld output and do not exceed duty cycle or equip ment damage may occur 1 Load Bank Turn all load bank switches Off If needed connect load bank to 115 volts ac wall receptacle or genera tor auxiliary power receptacle 2 Welding Generator Place Welder Selector switch in Welder B positi
45. heaters etc See Section 11 4 OM 225 590 Page 62 11 11 Selecting Extension Cord Use Shortest Cord Possible Cord Lengths for 120 Volt Loads e If unit does not have GFCI receptacles use GFCI protected extension cord Maximum Allowable Cord Length in ft m for Conductor Size AWG Current Load Watts 4 6 8 10 12 14 Amperes 5 600 350 106 225 68 137 42 100 30 7 840 400 122 250 76 150 46 100 30 62 19 10 1200 400 122 275 84 175 53 112 34 62 19 50 15 15 1800 300 91 175 53 112 34 75 23 37 11 30 9 20 2400 225 68 137 42 87 26 50 15 30 9 25 3000 175 53 112 34 62 19 37 11 30 3600 150 46 87 26 50 15 37 11 35 4200 125 38 75 23 50 15 40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 296 voltage drop Cord Lengths for 240 Volt Loads e A If unit does not have GFCI receptacles use GFCI protected extension cord Maximum Allowable Cord Length in ft m for Conductor Size AWG Current Load Watts 4 6 8 10 12 14 Amperes 5 1200 700 213 450 137 225 84 200 61 7 1680 800 244 500 152 300 91 200 61 125 38 10 2400 800 244 550 168 350 107 225 69 125 38 100 31 15 3600 600 183 350 107 225 69 150 46 75 23 60
46. installation and operation quick business and easy With Miller you can count on years NII 0001 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 AR Eels d S exact part you may need to fix the problem the ISO 9001 Quality System Warranty and service information for your Standard particular model are also provided REGISTERED QUALITY SYSTEM 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 Mili mer Mil_Thank 2009 09 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 TTo Symbol Usage 3 9 oer A QURE UBER WAAGE dan RANA EATER 1 1 2 Arc Welding Hazards oce Seba A SE ee 1 1 3 Engine Hazards ud er ettet at ute md e na e EA A A 3 1 4 Hydraulic Hazards led dE rs ha RENTES REA Ma oe AES 4 1 5 Compressed Air Hazards usi Rx a EE REEL REA Ske BEY MEA 4 1 6 Additional Symbols For Installation Operation And Maintenance
47. le cordon imm diatement s il est endommag un c ble d nud peut provoquer une lectro cution e Mettre l appareil hors tension quand on ne l utilise pas e Ne pas utiliser des c bles us s endommag s de grosseur insuffi sante ou mal piss s e Ne pas enrouler les c bles autour du corps e Si la pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct ne pas utiliser le connecteur de pi ce ou le c ble de retour Ne pas toucher l lectrode quand on est en contact avec la piece la terre ou une lectrode provenant d une autre machine Ne pas toucher des porte lectrodes connect s deux machines en m me temps cause de la pr sence d une tension vide dou bl e e N utiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment ce manuel e Porter un harnais de s curit quand on travaille en hauteur e Maintenir solidement en place tous les panneaux et capots e Fixer le c ble de retour de facon obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s pos sible de la soudure e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique Il reste une TENSION DC NON N GLIGEABLE dans les sources de soudage onduleur UNE FOIS le moteur coup e Couper l alimentation du poste et d charger les condensa
48. 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 zt 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 2010 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 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 Car
49. ph cada 124941 CABLE bat pos 4 1 SN PO ee e 208 353 HOLD DOWN battery 1 AY viui ee ee 032453 CABLE bat neg AHAAA WANAWA 1 NA WEE 190 896 BATTERY stor 12v 660 crk 110 rsv gp 24 low 1 Ree iiec es 010 460 STUD stl 812 18 x 10 000 1 90 SR2 SR3Figure 12 5 RECTIFIER ASSEMBLY 2 1 Ll grs das mel 013 466 LABEL fuel Shut off 1 Tc 145 282 FITTING hose brs barbed elbow M 5 16tbg x 1 4NPT 2 GUB due be ur AS 202242 BASE fuel filter assy 1 scd visui 192 744 FILTER fuel spin on 1 xDD assessed 135 205 NUT 625 11 94 hex 76H stl pld 4 E A 116 707 SUPPORT front engine 1 EE EE 119 849 SCREW 625 11 x 4 00 hexhd pln gr 5 pld 4 Tuc e EE 071 731 WASHER flat stl 656 ID x 2 250 OD x 187thk 4 sm 39 uiis pope 071 890 RETAINER mount eng gen 4 40 071 730 TUBING stl 875 OD x 12ga wall x 2 500 4 iA NEE 072 848 MOUNT eng gen nprn 875 ID x 2 500 OD x 2 000 50 dur 2 n 010
50. 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 inverter power sources AFTER stopping engine Stop engine on inverter and discharge input capacitors according to instructions in Maintenance Section before touching any parts HOT PARTS can burn e Do not touch hot parts bare handed e Allow cooling period before working on equip ment e To handle hot parts use proper tools and or wear heavy insu SSC lated welding gloves and clothing to prevent burns FLYING METAL or DIRT can injure eyes e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet OM 225 590 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
51. standards and na tional state and local codes Do not exceed the rated output or capacity of the hydraulic pump or any equipment in the hydraulic system Design hydraulic sys tem so failure of any hydraulic component will not put people or property at risk Before working on hydraulic system turn off and lockout tagout unit release pressure and be sure hydraulic pressure cannot be accidentally applied Do not work on hydraulic system with unit running unless you are a qualified person and following the manufacturer s instructions Do not modify or alter hydraulic pump or manufacturer supplied equipment Do not disconnect disable or override any safety equipmentin the hydraulic system Use only components accessories approved by the manufac turer Keep away from potential pinch points or crush points created by equipment connected to the hydraulic system Do not work under or around any equipment that is supported only by hydraulic pressure Properly support equipment by mechanical means HYDRAULIC FLUID can injure or kill e Before working on hydraulic system turn off and lockout tagoutunit release pressure and be sure hydraulic pressure cannot be accidentally applied e Relieve pressure before disconnecting or con necting hydraulic lines e Check hydraulic system components and all con nections and hoses for damage leaks and wear before operating unit e Wear protective equipment such as safety glas
52. welding 5 Amperage Voltage Control When Process Selector switch is in the Stick TIG position turn control clockwise to in crease amperage Read amperage from outer scale of control The Amperage Voltage con trol adjusts amperage only when constant cur rent CC welding and does not adjust open circuit voltage When Process Selector switch is in the MIG position turn control clockwise to increase voltage Voltmeter value changes as control knob is turned Control can be adjusted while welding When Welder Selector switch is in Welder B position single operator mode weld amperage is two times the value selected by the Amperage Voltage control For ex ample if Amperage Voltage control is set to 250 A weld output is actually 500A 6 Weld Meters With Process Selector switch in the Stick Tig position meters read O zero with contactor off Meters display actual output voltage and amperage with contactor on With Process Selector switch in the MIG posi tion voltmeter displays preset voltage with contactor off Voltmeter and ammeter display actual output voltage and amperage with con tactor on 7 High Temperature Shutdown Light Light goes on and weld output stops if weld rectifier gets too warm Let unit cool before welding 8 Remote Amperage Voltage Control Switch For front panel control place switch in Panel position For remote control place switch in Remote position and connect remote device s
53. 100 800 1 2 HP 3200 1050 OM 225 590 Page 59 11 7 Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1 4 in 350 350 3 8 in 400 400 1 2 in 600 600 Circular Saw 6 1 2 in 500 500 7 1 4 in 900 900 8 1 4 in 1400 1400 Table Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in 2500 1100 Bench Grinder 6 in 1720 720 8 in 3900 1400 10 in 5200 1600 Air Compressor 1 2 HP 3000 1000 1HP 6000 1500 1 1 2 HP 8200 2200 2HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1 3 HP 2100 700 Elec Hedge Trimmer 18 in 400 400 Flood Lights HID 125 100 Metal Halide 313 250 Mercury 1000 Sodium 1400 Vapor 1250 1000 Submersible Pump 400 gph 600 200 Centrifugal Pump 900 gph 900 500 Floor Polisher 3 4 HP 16 in 4500 1400 1HP 20 in 6100 1600 High Pressure Washer 1 2 HP 3150 950 3 4 HP 4500 1400 1HP 6100 1600 55 gal Drum Mixer 1 4 HP 1900 700 Wet amp Dry Vac 1 7 HP 900 900 2 1 2 HP 1300 1300 OM 225 590 Page 60 11 8 Power Required To Start Motor Single Phase Induction Motor Starting Requirements CODE M Hz 60 x gy xN HP 1 4 PHASE 1 NU Motor Start G H J K L M N P Code KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0
54. 100 ft 30 m from the workpiece the total cable length in the weld circuit is 200 ft 2 cables x 100 ft Use the 200 ft 60 m column to determine cable size Weld Cable Size and Total Cable Copper Length in Weld Circuit RS Not Exceeding e EX 150ft 200ft 250ft 300ft 350ft 400ft 100ft 30m orLess 45m 60m 70m 90m 105 m 120m Weld Output Terminals A Turn off power before Weldi 10 60 60 100 connecting s weld zini Eid Duty Duty 10 100 Duty Cycle output terminals D Cycle Cycle Do not use worn dam aged undersized or poorly spliced cables 100 4 20 4 20 4 20 3 30 2 85 1 50 1 0 60 1 0 60 150 3 30 3 30 2 85 1 50 1 0 60 2 0 70 3 0 95 3 0 95 200 3 30 2 85 1 50 1 0 60 2 0 70 3 0 95 4 O 120 4 O 120 2 ea 2 0 2 ea 2 0 250 2 85 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2x70 2x70 2 ea 2 0 2 ea 3 0 2 ea 3 0 300 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2x70 2x95 2x95 2 ea 2 0 2ea 3 0 2ea 3 0 2 ea 4 0 350 1 0 60 2 0 70 3 0 95 4 0 120 5470 2x95 2x05 2x120 2 ea 2 0 2ea 3 0 2ea 4 0 2 ea 4 0 400 1 0 60 2 0 70 3 0 95 4 0 120 ax 2k95 2x120 2x120 2 ea 2 0 2 ea 3 0 2ea 4 0 3 ea 3 0 3 ea 3 0 500 2 0 70 3 0 95 4 0 120 2x70 2x95 2x120 3x95 3x
55. 18 4 6 Duty Cycle And Overheating a j P e Dual Operator Mode 40 Duty Cycle At 275 Amperes From Each Side Single Operator Mode 40 Duty Cycle At 550 Amperes From Welder B side Right WELD AMPERES 1000 800 600 500 400 500 250 200 150 100 amo O 4 Minutes Welding 6 Minutes Resting 10 15 20 25 30 40 50 60 80 100 DUTY CYCLE Nam pou P gt s Overheating E High Temp Shutdown Minutes Aor V pa Y gt I2 on Reduce Duty Cycle Duty Cycle is percentage of 10 min utes that unit can weld at rated load without overheating NOTICE Exceeding duty cycle can damage unit and void warranty If a weld module overheats the High Temperature light goes on and the thermostat opens to stop weld output to that module Wait fifteen minutes for module to cool Reduce amperage voltage or duty cycle before welding This unit has separate duty cycle ratings for each operating mode If the unit is operated in the dual oper ator mode the unit is rated at 4096 duty cycle This means each side of the unit can be operated at 275 am peres at 4096 duty cycle When the unit is operated in the single operator mode the Welder B side right is rated at 4096 duty cycle 550 A at 40 duty cycle gt Ref rduty1 5 95 194 313 A OM 225 590 Page 19 4 7 Volt Ampere Curves
56. 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 296 voltage drop OM 225 590 Page 63 SECTION 12 PARTS LIST 5 Hardware is common and not available unless listed 30 See Fig 12 4 See Fig 12 2 94 Figure 12 1 Main Assembly OM 225 590 Page 64 102 j 45 See Fig 128 30 p 804 287 A OM 225 590 Page 65 Item Dia Part No Mkgs No Description Quantity Figure 12 1 Main Assembly e KEE 605 288 FITTING pipe galv plug sqhd 250NPT 1 ou cinia NM es 070010 BOLT J stl 250 20 x 2 750 pld 2 DEC MERE 088 696 STRAP hold down fuel tank 2 cR 134 771 PLUG protective 640sq 2 D EE 184 675 TANK fuel 22 3gal includes 1 EE EU 192 022 5 CAP EES 1 ud oe erts 020 185 FITTING pipe brs elbow st 1 8NPT 1 O as dea 053 525 FITTING hose brs barbed M 5 16tbg x 1 8NPT 1 un utu riens 172071 CLAMP hose 520 605clp dia
57. 3 3 2 E ia 083 030 STUD brs 250 20 x 1 1 UN DRE T 010381 CONNECTOR rectifier 1 21 T1 T8 192367 TRANSFORMER control 2 Mg 184 649 HOLDER fuse mintr 250 4 28 F3 4 012 643 FUSE mintr gl slo blo 1A 250V 2 24 F1 2 125 847 FUSE mintr cer slo blo 12A 250V 2 LO ste Parsons 129 351 SCREW 008 32x 50 hexwhd 34d stl pld slffmg tap rw 2 426 vias Rp 177 136 CLAMP capacitor 1 375dia 1 Ter Cl 087 110 CAPACITOR elctit 240 1 28 SR1 035704 RECTIFIER integ bridge 1 29 82 192292 SWITCH paralleling 1 90 84 021 467 SWITCH tgl spst 3a 250v off none on spd term 1 Mere EE utes 021 385 BOOT toggle switch lever 91 PB1 046433 SWITCH pb mc no spst 35a 1 92 S14 199 691 SWITCH tgl spdt 6a 125vac on none mc spd term 1 199 prob Reiluma
58. 875 CLAMP muffler 2 000 dia 1 UA aa 105 734 PIPE muffler extension elbow 1 Zp0ODn co 1 44 176232 BAFFLE air muffler exhaust 1 BEE Vetro Figure 12 3 SIDE CONTROL PANELS 2 22 46 0222 DIM es 41059092 COVER TOD AI Lee RE atu AREE 1d 1 x s LT Vert gs 192041 LABEL use diesel fuel only 1 AO lr 035 968 WASHER flat rbr 3 625 ID x 5 875 OD x O bk 1 AG ea 158 610 LABEL warning electricshock 2 2 507 een 168 385 LABEL warning battery explosion 1 Db S oec ns 3192 313 DOOR side LH EE 1 ID sd eive 222 513 LABEL warning falling equipment can cause serious 2 UD uie teet a 117 257 PANEL end engine 1 Lee cc ar arx 4192314 DOOR Side BH vu co ERE Re be A gebe E LA etie i e een 1 OO a a 225589 LABEL diesel engine maintenance f 31914 1 EE 004 130 BRACKET support door 2 OM 225 590 Page 66 Item Dia Part No Mkgs No Description Quantity Figure 12 1 Main Assembly Continued EE 087 341 BUMPER door 1 000 OD x 750 high 4 DB uic eee ia 087 336 x LATE EDD gue Ru RI ERN HM dee UE Sae
59. 95 2ea 2 0 2ea 3 0 2ea 4 0 3 ea 3 0 3 ea 4 0 3 ea 4 0 600 3 0 95 4 0 120 2x70 2x95 2x120 3x95 3x120 3x120 2 ea 2 0 2ea 3 0 2ea 4 0 3ea 3 0 3 ea 4 0 3 ea 4 0 4 ea 4 0 700 4 0 120 2x70 2x95 2x120 3x95 3x120 3x120 4x120 2 ea 2 0 2ea 3 0 2ea 4 0 3ea 4 0 3 ea 4 0 4 ea 4 0 4 ea 4 0 800 4 0 120 2x70 2x95 2x120 3x120 3x120 4x120 4x120 This chart is a general guideline and may not suit all applications If cable overheats use next size larger cable Weld cable size AWG is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere mm for metric use For distances longer than those shown in this guide call a factory applications rep at 920 735 4505 Miller or 1 800 332 3281 Hobart Ref S 0007 G 2009 08 OM 225 590 Page 34 5 18 Installing Ether Cylinder Optional Ether Starting Aid A Stop engine A Improper handling or expo sure to ether can harm your health Follow manufactur er s safety instructions on cylinder A Do not use Ether Starting Aid while engine is running Open right side door 1 Ether Cylinder 2 Nozzle Remove cover and clean cylinder nozzle 3 Clamp 4 Fitting 5 Cap 6 Valve Remove cap and clean fitting Install cylinder on fitting Tighten clamp
60. ANGER DE CHOC ELECTRIQUE PIECES EN MOUVEMENT et PIECES CHAUDES Consulter les symboles et les instructions ci dessous y aff rant pour les actions n cessaires afin d viter le danger souder manuel lectrode enrob e DC 3 un poste souder manuel AC avec tension vide r duite Dans la plupart des cas un poste courant continu de type CV est recommand Et ne pas tra vailler seul e Couper l alimentation ou arr ter le moteur avant de proc der l installation la r paration ou l entretien de l appareil D verrouiller l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de s curit e Installer et mettre la terre correctement cet appareil conform ment son manuel d utilisation et aux codes nationaux provinciaux et municipaux e Toujours v rifier la terre du cordon d alimentation V rifier et s assurer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre e En effectuant les raccordements d entr e fixer d abord le conduc teur de mise la terre appropri et contre v rifier les connexions e Les c bles doivent tre exempts d humidit d huile et de graisse prot gez les contre les tincelles et les pi ces m talliques chau des e V rifier fr quemment le cordon d alimentation pour voir s il n est pas endommag ou d nud remplacer
61. BASCULE peut provoquer des blessures e Utiliser les supports de la remorque ou des blocs pour soutenir le poids e Installer convenablement le poste sur la remor que comme indiqu dans le manuel s y rappor tant LIRE LES INSTRUCTIONS e Lire et appliquer les instructions sur les tiquettes et le Mode d emploi avant l installation l utilisation ou l entretien de l appareil Lire les informations de s curit au d but du manuel et dans chaque section e N utiliser que les pi ces de rechange recommand es par le constructeur e Effectuer l entretien en respectant les manuels d utilisation les normes industrielles et les codes nationaux d tat et locaux LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences OK e Le rayonnement haute fr quence H F peut provoquer des interf rences avec les quipe ments de radio navigation et de communica tion les services de s curit et les ordinateurs Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation Si le FCC signale des interf rences arr ter imm diatement l ap pareil Effectuer r guli rement le contr le et l entretien de l installation Maintenir soigneusement ferm s l
62. INT 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 4 Motor Voltage AC MOTOR 2 To find starting amperage 1 VOLTS 230 AMPS 2541 gamperag Step 1 Find code and use table to find kVA HP If code is not listed multiply running amperage by six to find starting amperage Step 2 Find Motor HP and Volts Step 3 Determine starting amper age see example Welding generator amperage out put must be at least twice the motors running amperage KVA HP x HP x 1000 Volts Starting Amperage Example Calculate starting amper age required for a 230 V 1 4 HP mo tor 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 small est and add resistive loads last 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 225 590 Page 61 11 10 Typical Connections To Supply Standby Power EZ Utility Electrical Service Transfer Switch Essential Loads Fused Disconnect Switch If Required Welding Generator Output
63. R EN QUELQUES MINUTES Lesfum es d un groupe autonome contient du monoxyde de carbone C est un poison invisi ble et inodore e JAMAIS utiliser dans une maison ou garage m me avec les portes et fen tres ouvertes e Uniquementutiliser PEXTERIEUR loin des portes fen tres et bouches a ration L ACIDE DE LA BATTERIE peut pro voquer des br lures dans les YEUX et sur la PEAU e Ne pas renverser la batterie e Remplacer une batterie endommag e e Rincer imm diatement les yeux et la peau l eau 7 4 LA CHALEUR DU MOTEUR peut pro d voquer un incendie e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Tenir distance les produits inflammables de l chappement e Ne pas intervenir sous ou autour d un quipement qui n est soutenu que par la pression hydraulique Soutenir l quipement de facon appropri e par un moyen m canique Le LIQUIDE HYDRAULIQUE risque de provoquer des blessures ou m me la mort e Avant d intervenir sur le circuit hydraulique couper l alimentation lectrique verrouiller et tiqueter l appareil d tendre la pression et s assurer que le circuit hydraulique ne peut tre remis sous pression par inadvertance e D tendre la pression avant de d brancher ou de brancher des canalisations hydrauliques e Avant d utiliser l appareil contr ler les composants du circuit hydraulique les branchements et les flexibles en recherchant tout signe d
64. S wiring unit welder B right includes 1 ETE 4T 190210 BLOCK term 5 3 3 EET CB6 139266 SUPPLEMENTARY PROTECTOR man reset 1p 15a 250vac 1 uui EE RC9 134735 CONNECTOR circ MS CPC 14skt 1 WA EE PC7 181261 CIRCUIT CARD ASSEMBLY filter 1 Ade ima PLG24 115094 HOUSING plug and sockets 1 SEE Da PLG22 168847 HOUSING plug pins and sockets 1 Nu veh ia PLG23 152249 HOUSING plug pins and sockets 1 HERE PLG21 185556 HOUSING plug pins and sockets 1 EE 188 512 SEAL wire univ 6P S 3 row 1 erha tiled wee 192 337 HARNESS wiring unit welder A left includes 1 shad bes ak d OT 190 210 BEOCK term 5 3 9 sas ira EE CB5 139266 SUPPLEMENTARY PROTECTOR man reset 1p 15a 250vac 1 UE RC8 134735 CONNECTOR circ MS CPC 14skt onn dew PC3 181261 CIRCUIT CARD ASSEMBLY filter 1 ouibus PLG14 115 094 HOUSING plug and sockets 1 RS E PLG6 168 847 HOUSING plug pins and sockets 1 sons
65. V DC 10232V 49 Duty Cycle All Receptacles ngine 4 3 Dimensions Weights And Operating Angles Dimensions Em Height 47 5 8 in 1210 mm Width 31 1 4 in 794 mm L Depth 60 1 2 in 1537 mm Engine End Do not exceed tilt angles or engine could A 59 1 8 in 1502 mm be damaged or unit could tip A Do not move or operate unit where it B 47 1 4 in 1200 mm could tip C 43 1 4 in 1099 mm D 32 3 4 in 832 mm E 24 15 16 in 633 mm F 10 1 2 in 267 mm G 6 1 2 in 165 mm H 2 7 8 in 73 mm J 29 7 8 in 759 mm K 11 16 in 24 mm L 21 32 in 17 mm Dia 16 Holes Weight angles 1 8 99 2115 Ib 959 kg E Lifting Eye Weight Rating 2161 Ib 980 kg Maximum OM 225 590 Page 17 4 4 Fuel Consumption The curve shows typical fuel use un der the combined weld loads of both sides Welder A and Welder B 7 57 1 70 2 00 6 62 1 46 1 75 5 67 1 25 1 50 4 73 1 04 1 25 3 78 0 83 1 00 2 84 0 62 0 75 CV 1 98 0 40 0 50 0 95 0 21 0 25 0 50 100 150 200 250 300 350 400 450 500 550 600 DC WELD AMPERES AT 40 DUTY CYCLE LITERS HR IMP GAL HR U S GAL HR 195 711 4 5 AC Generator Power The AC power curve shows the generator power in amperes avail able at the 120 and 240 volt receptacles 150 300 125 250 100 200 75 150 AC VOLTS O1 o 100 25 50 0 5 10 15 20 25 30 AC AMPERES IN 240V MODE 0 10 20 30 40 50 60 AC AMPERES IN 120V MODE 193 018 OM 225 590 Page
66. V RC19 c13 c14 44 5y PLG7 YN 1Y ya cy C6 o WHT BLUE y T RC7 Y np 4 gt aN A Ae y T 1 22 o v mi m dn m 20 RECT am Le 4 PCS 122 ele a 1 S a D E C F H XGRD 222 yg RCB 60 3004 V7 RCB 32 1 i 751 749 708 cB7 La m A A A 5 eS X32 5 108 12 CR5 CB8 1522 o 312 o 1 90 Lei 707 lt 4 gt XT 1 CC i A t IN 1 RUNNING I 703 P HOUR 7 METER lt FIELD CURRENT gt gt 101 REGULATOR T yas o lt lt gt La start N PB ie e lt gt RC1 Lamm o NO CHARGE lt PIG 17 1397 WARNING gt 5 H E z ON FS1 lt e gt SR1 3 8 HS DZ qf EI yy z h B D4 PAAS 42 za B 7 LT TH kazi 5 5 71 137 p A 138 104 do F2 mus A B C D n TE2 h2 voir sa 7 3 e STARTER A D TET Hd es 8 RC1 240V 12V 120V CB car BATTERY ES1 en 2 GR E y 70 a w He H2 H 102 ES ES 3 IN 42 ng NS S E enoj g ETHER START Se 2 bm 42 OPTIONAL 120V d 42 GFCI 2 OM 225 590 Page 52 Figure 9 1 Circuit Diagram For Welding Generator SIDE B
67. Weld Connections wi Common Work Cable 30 5 14 Making Dual Operator CC And CV Weld Connections w Separate Work Cables 31 5 15 Making Dual Operator CC And CV Weld Connections w Common Work Cable 32 5 16 Making Single Operator CC Weld Connections 33 5 17 Selecting Weld Cable Sizes e sse eek a 34 5 18 Installing Ether Cylinder Optional Ether Starting Aid 35 5 19 Remote 14 Receptacle Information 35 5 20 Remote 14 Receptacle Connections 36 TABLE OF CONTENTS SECTION 6 OPERATING THE WELDING GENERATOR 37 6 1 Engine Control tir rre te rte PIPER ec e es ete rer 37 6 2 Weld Controls See Section 6 3 38 6 3 Weld Control Descriptions See Gechong2 eee 39 SECTION 7 OPERATING AUXILIARY EQUIPMENT eseeeee IRI nnn 40 7 1 120 Volt And 240 Volt Duplex Receptacles 40 SECTION 8 MAINTENANCE A TROUBLESHOOTING 41 81 Routine Maintenance vs oue reno hen state Ma fare ends reden RE Se de o Ra ROCA RECEN GR Ue n 41 8 2 Maintenance Label Zo AN nete tre ERN EUER ER ERA dag de den Gos dla NEN DE 42 8 3 Servicing Air Cleaner
68. arranty 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 WARRANT Y 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
69. charge e Respecter les consignes du fabricant de la batterie pour travailler sur une batterie ou proximit Le COURANT DE CHARGE DE BATTERIE peut provoquer des blessures la fonctionnalit de charge de batterie n est pas disponible sur tous les mod les e Les op rations de charge de batterie ne doivent tre effectu es que par des personnes qualifi es e Ne charger que des batteries plomb acide Ne pas utiliser le chargeur de batterie pour alimenter un autre circuit lectrique basse tension ou pour charger des batteries s ches e Ne pas charger une batterie gel e e Ne pas utiliser de c bles de charge endommag s Ne pas charger une batterie dont les bornes sont desserr es ou pr sentant une d t rioration comme par exemple un bo tier ou un couvercle fissur e Avant de charger une batterie s lectionner la tension de charge correspondant la tension de la batterie e R glerles commandes de charge de batterie sur la position d arr t avant de brancher la batterie Veiller ce que les pinces de charge ne se touchent pas OM 225 590 Page 10 e Ranger les c bles de charge distance du capot des portes et des pi ces mobiles du v hicule LE CARBURANT MOTEUR peut pro voquer un incendie ou une explosion Arr ter le moteur avant de v rifier le niveau de carburant ou de faire le plein Ne pas faire le plein en fumant ou proche d une source d tincel les ou d une flamme nue Ne pas fai
70. cran facial pour prot ger le visage et proximit de surfaces inflammables les yeux e Ne pas installer l appareil proximit de pro e Aff ter l lectrode au tungst ne uniquement duits inflammables la meuleuse dot e de protecteurs Cette ma e Ne pas surcharger l installation lectrique s assurer que l ali noeuvre est ex cuter dans un endroit s r lors mentation est correctement dimensionn e et prot g e avant de que l on porte l quipement homologu de pro mettre l appareil en service tection du visage des mains et du corps e Les tincelles risquent de causer un incendie loigner toute LA CHUTE DE L EQUIPEMENT substance inflammable peut provoquer des blessures e Utiliser l anneau de levage pour lever l appareil et les accessoires correctement install es Les PI CES MOBILES peuvent seuls PAS les bouteilles de gaz Ne pas d causer des blessures passer le poids nominal maximal de l illeton voir les sp cifications e Ne pas s approcher des organes mobiles e Utiliser un quipement de levage de capacit suffisante pour e Ne pas s approcher des points de coincement lever l appareil tels que des rouleaux de commande e Enutilisant des fourches de levage pour d placer l unit s assu rer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil e Tenir l quipement c bles et cordons distance des v hicules mobiles lors de toute op
71. ctions and hoses for damage leaks and wear before operating unit Do not direct air stream toward self or others e Wear protective equipment such as safety glasses hearing pro tection leather gloves heavy shirt and trousers high shoes and a cap when working on compressed air system e Use soapy water or an ultrasonic detector to search for HOT PARTS can burn e Do not touch hot compressor or air system leak bare hands Do not i t if leak paris Eun M SHEEP O PES SETUP EES e Allow cooling period before working on equip ment e Reinstall doors panels covers or guards when servicing is finished and before starting unit If ANY air is injected into the skin or body seek medical help im mediately e To handle hot parts use proper tools and or wear heavy insu lated welding gloves and clothing to prevent burns BREATHING COMPRESSED AIR can in jure or kill READ INSTRUCTIONS e Read and follow all labels and the Owner s Manual carefully before installing operating or servicing unit Read the safety information at the beginning of the manual and in each TRAPPED AIR PRESSURE AND WHIPPING section HOSES can injure e Use only genuine replacement parts from the manufacturer e Perform maintenance and service according to the Owner s Manuals industry standards and national state and local codes e Do not use compressed air for breathing e Use only for cutting gouging and tools
72. d Controls See Section 6 3 x AMPS 300 AMPS WELDER A Welder B 600 AMPS Welder B D DO NOT SWITCH UNDER LOAD OR WITH OUTPUT ON RH JE Z Y PROCESS OUT sur AIV am AMPS High Temp Shutdown A V ADJUST EN ea en NI o Ref 225 543 191 848 804 289 A OM 225 590 Page 38 6 3 Weld Control Descriptions See Section 6 2 HA os Sar 1 Welder Selector Switch Use switch to select Dual Operator or Single Operator welding mode Place switch in Welder A Welder B dual oper ator position for CC and CV output from Weld er A left and Welder B right weld output ter minals Control the weld output from the termi nals on each side using the weld controls on that same side Place switch in Welder B single operator position for CC weld output from Welder B right weld output terminals only CV weld out put terminals on both sides do not work when unit is in Single Operator mode Welder A left weld output terminals are disabled in Single Operator mode Con nect only to Welder B right terminals for Single Operator operation When in single Operator mode only CC weld output is available Welder A left and Welder B right side CV weld output terminals are disabled in Single Operator mode see Section 5 10 2 Process Selector Switch Use sw
73. ding gloves and clothing to prevent burns STEAM AND HOT COOLANT can burn e If possible check coolant level when engine is cold to avoid scalding e Always check coolant level at overflow tank if present on unit instead of radiator unless told otherwise in maintenance section or engine manual e fthe engine is warm checking is needed and there is no over flow tank follow the next two statements e Wear safety glasses and gloves and put a rag over radiator cap e Turn cap slightly and let pressure escape slowly before completely removing cap Using a generator indoors CAN KILL YOU IN MINUTES e Generator exhaust contains carbon monoxide This is a poison you cannot see or smell e NEVER use inside a home or garage EVEN IF doors and windows are open e Only use OUTSIDE and far away from windows doors and vents BATTERY ACID can BURN SKIN and EYES e Do nottip battery e Replace damaged battery e Flush eyes and skin immediately with water ENGINE HEAT can cause fire e Do not locate unit on over or near combustible surfaces or flammables e Keep exhaust and exhaust pipes way from flammables OM 225 590 Page 3 1 4 Hydraulic Hazards HYDRAULIC EQUIPMENT can injure or kill e Incorrect installation or operation of this unit could result in equipment failure and personal injury Only qualified persons should install op erate and service this unit according to its Owner s Manual industry
74. e EOM ol 2 A800 sine ute iu 048 213 BAFFLE air Intake 1 Ee ae pua 194 467 WASHER flat for baffle 6 25 ID x 11 50 OD x 62 T buna 1 VEG MEE 023 313 CLAMP hose 3 250 3 000 clp dia slftg 3 XO abuses 225643 TUBE air intake ha 1 E win esas 225 642 HOSE air cleaner 1 OO EE 189 764 AIR CLEANER intake 1 wi O4 nie dus 165 785 HOSE air cleaner 2 500 id 1 EE 192 938 FILTER air element primary l SUAM Piu INDE e192 939 FILTER air element safety OD a esos atio qct 203 460 BRACKET mig air cleaner 1 24 905 ne o ge 237 006 ENGINE Deutz dsl elec D914L03i includes 1 nad der e TER 249605 FOER Oil eats ot EL Run auae neering dela uA 249606 FILTER fuel secondary 1 A saint eed gees 1066271 eins VSBELT sise mt neue men Kiel eee gaer d glgsduT gp Mead 246989 KIT Filter Includes Fuel Oil And Air Filters 1 eire edet 199 507 HOSE ASSY oil drain 20 000 lg includes 1 OA astas 165271 VALVE oil drain 3 8 18 nptf 1 eg D EN 176529 FTG
75. e Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe e Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases e Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded BUILDUP OF GAS can injure or kill e Shutoff shielding gas supply when not in use e Always ventilate confined spaces or use ap proved air supplied respirator ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld e 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 e Wear approved safety glasses with side shields under your helmet e Use protective screens or barriers to protect others from fla
76. e d t rioration de fuite et d usure e Pour intervenir sur un circuit hydraulique porter un quipement de protection tel que des lunettes de s curit des gants de cuir une chemise et un pantalon en tissu r sistant des chaussures montantes et une coiffe e Pour rechercher des fuites utiliser un morceau de papier ou de carton jamais les mains nues En cas de d tection de fuite ne pas utiliser l quipement e Le LIQUIDE HYDRAULIQUE est INFLAMMABLE Ne pas intervenir sur des composants hydrauliques proximit d tincelles ou de flammes ne pas fumer proximit de liquide hydraulique e Remettre les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de mettre en marche l appareil e Encas de p n tration d un QUELCONQUE liquide dans la peau celui ci doit tre retir chirurgicalement sous quelques heures par OM 225 590 Page 11 un m decin familiaris avec ce type de blessure faute de quoi la gangr ne pourrait appara tre A Les PIECES MOBILES peuvent causer des blessures a e S abstenir de toucher des parties mobiles telles que des ventilateurs courroies et rotors e Maintenir ferm s et verrouill s les portes panneaux recouvrements et dispositifs de protection e Ne pas approcher les mains cheveux v tements laches et outils des organes mobiles e Avant d intervenir sur le circuit hydraulique couper l alimentation lectrique verrouiller et
77. e of the filler while clean ing and the possibility of filter damage makes cleaning a risk Consider the risk of unwarrantable equipment damage when determining whether to clean or replace the primary ele ment If you decide to clean the primary ele ment we strongly recommend instal ling an optional safety element to pro vide additional engine protection Never clean a safety element Re place the safety element after servic ing the primary element three times Clean or replace primary element if dirty see note above before cleaning Re place primary element if damaged Re place primary element yearly or after six cleanings 1 Housing 2 Safety Element Optional 3 Primary Element 4 Dust Cap 5 Dust Ejector To clean air filter Wipe off cap and housing Remove cap and dump out dust Remove element s Wipe dust from inside cap and housing with damp cloth Reinstall safety element if present Reinstall cap NOTICE Do not clean housing with air hose Clean primary element with compressed air only Air pressure must not exceed 100 psi 690 kPa Use 1 8 in 3 mm nozzle and keep nozzle at least 2 in 51 mm from inside of element Replace primary ele ment if it has holes or damaged gaskets Reinstall primary element and cap dust ejector down aircleaner1 2 01 ST 153 929 B ST 153 585 Ref S 0698 B OM 225 590 Page 43 8 4 Servicing Fuel And Lubrication Systems w
78. e polarity For a common work cable connection the work cable must be able to carry the combined weld output of both modules see Section Welder B Right Side Note position of Process Selector 7 switches ee A Stop engine NOTICE Do not exceed machine duty cycle IE For common work connection work cable must be able to carry combined weld output of both CC weld output ter minals see Section 5 17 for proper cable size x Use Dual Operator mode for CC and CV welding see Section 6 1 1 Strain Relief Route cables through strain reliefs 2 Electrode Holder Cables 3 Work Jumper Cable 4 Common Work Cable For Stick TIG welding Direct Current Elec trode Positive DCEP connect common work cable and work jumper cable to Weld er B right Negative terminal Connect other end of work jumper cable to Welder A left Negative terminal Connect electrode holder cables to CC ter minals For Stick TIG Direct Current Electrode Negative DCEN connect common work cable and work jumper cable to Welder B right CC terminal Connect other end of Ref 225 543 802 292 A work jumper cable to Welder A left CC ter minal Connect electrode holder cables to Nega tive termina
79. eaker CB12 may have tripped CB12 automatically resets when fault is corrected Have Factory Authorized Service Agent check wiring harness and components Engine cranks but does not start Check fuel level see Section 5 7 Open fuel valve see Section 5 7 Check battery voltage and replace battery if necessary Check engine charging system according to en gine manual Have Factory Authorized Service Agent check time delay relay TD1 control relay CR5 fuel pump and fuel solenoid FS1 Air in fuel system Use primer pump to prime fuel system see Section 8 7 See engine manual Engine suddenly stops Check oil level see Section 5 7 Automatic shutdown system stops engine if oil pressure is too low or oil temperature is too high Automatic shutdown system is inhibited for 30 seconds after start up See engine manual Engine slowly stopped and cannot be re started Check fuel level see Section 5 7 Check engine air and fuel filters see Sections 8 3 and 8 4 Engine hard to start in cold weather Use starting aid switch see Section 6 1 Keep battery in good condition Store battery in warm area off cold surface Use fuel formulated for cold weather diesel fuel can gel in cold weather Contact local fuel supplier for fuel information Use correct grade oil for cold weather see Section 8 2 Battery discharges between uses Clean battery terminals and po
80. ee Section 5 19 9 Output Contactor Switch For front panel control of output place switch in On Hot position For remote control of out put place switch in Remote position and con nect remote device see Section 5 19 Weld output terminals are energized when Output Contactor switch is On and engine is running 10 Polarity Switch Optional NOTICE Do not switch under load Use switch to change polarity of weld output see Sections 5 9 thru 5 16 gt Place optional Polarity switch in Reverse position when using CV weld receptacle There is no CV weld output when switch is in Straight position OM 225 590 Page 39 SECTION 7 OPERATING AUXILIARY EQUIPMENT 7 1 120 Volt And 240 Volt Duplex Receptacles Iw 3 2 5 1 120 V 20A 240 V 20A 120 V 20A 1 60Hz 240 V 20A CB1 L mw e D E D T eS 4 N LE M elt A Be sure equipment connected to the 240 V receptacles is GFCI pro tected CS Generator power is not affected by position of Welder Selector switch CS 4 kVA kW generator power output is shared by all receptacles 1 240 V 20 A AC Receptacle RC1 2 120 V 20A AC GFCI Receptacle GFCI 1 3 240 V 20A AC Receptacle RC2 4 120 V 20A AC GFCI Receptacle GFCI 2 Receptacles supply 60 Hz single phase power at weld power speed If a ground fault is detected the GFCI re
81. elding output of different polarities to the same structure See ANSI Z49 1 and OSHA Title 29 Chapter XVII Part 1910 Subpart Q addresses at beginning of manual When welding on the same workpiece all connections to the workpiece must be of the same polarity Do not handle or come in contact with two live electrodes at the same time ELECTRIC SHOCK can kill TWO TIMES NORMAL OPEN CIRCUIT VOLTS can exist between electrode holders of opposite polarity Do not touch electrode holders of opposite polarity at the same time Separate electrode holders of opposite polarity to prevent contact Consult ANSI 249 1 for common grounding safe practices OM 225 590 Page 25 5 9 Weld Output Terminals E er Welder A Left Side Welder B Right Side A Stop engine A Failure to properly connect weld cables may cause excessive heat and start a fire or damage your ma chine 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 1 Correct Weld Cable Connection 2 Incorrect Weld Cable Connection Weld Output Terminal Supplied Weld Outpu
82. enerator Place Welder Selector switch in Welder B position 600 Amps AN control in minimum position and both Process Selector switches in Stick TIG position 3 Weld Cables Connect grid to generator Welder B right weld output terminals using proper size weld cables with cor rect connectors polarity is not im portant 4 Voltmeter P Clamp On Ammeter Connect voltmeter and ammeter as shown if not provided on generator Start engine and run for several minutes Set grid switches and then adjust generator A V control so load equals 350 Amps at 40 volts Check generator and meters after first five minutes then every fifteen minutes to be sure generator is loaded properly Check oil level frequently dur ing run in add oil if needed It is recommended to run the weld ing generator for two hours mini mum and up to four hours under load Place A V control in minimum position then shut down grid to remove load Run engine several minutes at no load A Stop engine and let cool 6 Engine Exhaust Pipe Repeat procedure if wetstacking is present S 0684 OM 225 590 Page 56 SECTION 11 GENERATOR POWER GUIDELINES x 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 ES VAN VAN 9 Q
83. er Effective January 1 2010 Equipment with a serial number preface of MA or newer This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Miller must be notified in writing within thirty 30 days of such defect or failure at which time Miller will provide instructions on the warranty claim procedures to be followed Miller 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
84. er CB5 or Welder B right circuit breaker CB6 see Section 8 10 Check position of Process Selector switches and Welder Selector switch All weld output stops if either Process Selector switch is placed in CV position when Welder Selector switch is in Welder B position see Sections 6 1 and 6 3 Check connections to Remote 14 receptacle RC8 see Section 5 19 Place optional Polarity switches in Reverse position There is no CV weld output when Polarity switch is in Straight position Have Factory Authorized Service Agent check brushes and slip rings and field excitation circuit Repair or replace wire feeder OM 225 590 Page 50 B Generator Power Trouble Remedy No output at generator power AC re ceptacles Reset receptacle supplementary protectors see Section 7 1 Press GFCI reset button on 120 volt GFCI receptacles see Section 7 1 Check fuse F1 and replace if open see Section 8 10 Check receptacle s for continuity and proper connections Replace receptacle s if necessary Have Factory Authorized Service Agent check brushes and slip rings High or low output at generator power AC receptacles Check engine speed and adjust if necessary see Section 8 5 C Engine Trouble Remedy Engine will not crank Check battery voltage and replace battery if necessary Check battery connections and tighten if necessary Circuit br
85. ers are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal 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 fit tings 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 num ber 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 injure e Always wear a face shield rubber gloves and protective clothing when working on a battery e Stop engine before disconnecting or connect ing battery cables battery charging cables if applicable or servicing battery e Do not
86. ervice and storage information Service engine more often if used in severe conditions WEE d hidi we e Stop engine before maintaining 2 j 4 g EX ES Recycle engine See Engine Manual and Maintenance Label y Check Change Q Clean Replace Reference To be done by Factory Authorized Service Agent Every Section 5 7 FUEL 8 WATER m ex 8 4 Hours Fuel Water Separator Fuel Level Oil Level Q Oil Fuel Spills Every Section 8 3 50 A oA Hours al J Q Weld Terminals Every 100 Hours Q Battery Terminals 1 Air Cleaner Hoses Every L PEE Engine 250 4 d gt Manual Hours E d Section 8 8 Unreadable Labels QSpark Arrestor Y Alternator Belt Tension Every NOTICE Change engine 500 oil and filter after initial 50 to Hours S 75 hours of use e R a Fx Weld Cables Oil Oil Filter Every gu r Section 8 4 1000 8 9 and En Hours SLUDGE gine Manual Q Inside Unit Fuel Filter Q Drain Sludge C Slip Rings X Brushes OM 225 590 Page 41 Maintenance Label 8 2 ut 90070 ww SL O Xe ut 90070 ww GU0 ul 4 022 I 02 oneuu s 0 MS gt e 0Z MOZ rei FT 0 MOL Hp et 9 MSI HH et 9v M0L te 6869 c II 431114 9 gt S VING 4138 OSI KING 4138
87. ervice according to the Owner s Manuals industry standards and national state and local codes Er 1 7 California Proposition 65 Warnings A 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 amp Safety Code Section 25249 5 et seq gt 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 gt This product contains chemicals including lead known to the state of California to cause cancer birth defects or other reproductive harm Wash hands after use OM 225 590 Page 6 H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation e The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation e f notified by the FCC about interference stop using the equipmentat 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 shieldin
88. es portes et les panneaux des sources de haute fr quence maintenir les clateurs une distan ce correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique risque de provo quer des interf rences pour l quipement lec tronique sensible tel que les ordinateurs et l quipementcommand par ordinateur tel que les robots Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement Pour r duire la possibilit d interf rence maintenir les c bles de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre Veiller souder une distance de 100 m tres de tout quipe ment lectronique sensible Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi En cas d interf rences apr s avoir pris les mesures pr c den tes il incombe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de c bles blind s l utilisation de filtres de ligne ou la pose de protec teurs dans la zone de travail 2 7 Proposition californienne 65 Avertissements A Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l tat de Californie reconnait qu ils provoquent de
89. ess ment for welders All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 1 Keep cables close together by twisting or taping them or using a cable cover 2 Do not place your body between welding cables Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 25 West 43rd Street New York NY 10036 phone 212 642 4900 web site www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org For Standards about hydraulic systems contact the National Fluid Power Association Publications Department 3333 North Mayfair Road Suite 211 Milwaukee WI 53222 3219 phone 414 778 3344 website www nfpa com OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there are 10 OSHA Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov U S Consumer Product Safety Commission CPSC 4330 East West Highway Bethesda MD 20814 phone 301 504 7923 website WWW CpSC gov Applications Manual for the R
90. evised NIOSH Lifting Equation The Na tional Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 phone 1 800 232 4636 website www cdc gov NIOSH 4 Keep head and trunk as far away from the equipment in the welding circuit as possible 5 Connect work clamp to workpiece as close to the weld as possible 6 Do not work next to sit or lean on the welding power source 7 Donot weld whilst carrying the welding power source or wire feeder 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 recom mended OM 225 590 Page 7 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION fre rom 2010 03 A Pour carter les risques de blessure pour vous m me et pour autrui lire appliquer et ranger en lieu s r ces consignes relatives aux pr cautions de s curit et au mode op ratoire 2 1 Signification des symboles DANGER Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dangers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dan
91. g to minimize the possibility of interference ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as micro processors computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagnetically compatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e f interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area For Gasoline Engines A Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive harm For Diesel Engines A 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 8 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 ins com Safe Practices for the Preparation of Containers and Piping for Welding and Cutting American Welding Society Standard AWS F4 1 from Glob a
92. ge engine Add diesel fuel before starting engine the first time see mainte nance label for specifications Fill fuel tank up to 1 2 in 13 mm from top to allow room for expansion Open fuel shut off valve Diesel Do not run out of fuel or air enters fuel system and causes starting problems Use primer pump to prime injector system see Section 8 7 Cil After fueling check oil with unit on level surface If oil is not up to full mark on dipstick add oil see main tenance label gt Engine stops if oil pressure is too low CS To improve cold weather starting Keep battery in good condition Store battery in warm area Use fuel formulated for cold weather diesel fuel can gel in cold weather Contact local fuel supplier for fuel in formation Use correct grade oil for cold weather Ref 804 285 013 466 OM 225 590 Page 24 5 8 Tr ENKE EE Safety Information For Connecting To Weld Output Terminals gt UNEXPECTED WELD OUTPUT can cause injury or fire Both weld outputs can be live ON when Welder Selector switch is in Welder A Welder B position and engine is running Disconnect or insulate any unused cables Know where cables are located BEFORE starting engine ELECTRIC SHOCK can kill ARCING can burn skin or damage electrical connections Stop engine before making any weld output connections Do not connect w
93. ght Work receptacle Connect other end of work jumper cable to Welder A left Work receptacle Connect wire feeder cables to CV recep tacles 7 Place optional Polarity switches in Re verse position when using CV weld re ceptacles There is no CV weld output when switch is in Straight position Be sure Process Selector and Polarity switches are set correctly See Sec tion 6 3 OM 225 590 Page 30 5 14 Making Dual Operator CC And CV Weld Connections w Separate Work Cables mU Tad Welder A Left Side Direct Current Electrode Positive DCEP connections are shown Tools Needed LT 3 4 in Welder B Right Side Note position of optional Polarity switch A Stop engine NOTICE Do not exceed machine duty cycle Use Dual Operator mode for CC and CV welding see Section 6 1 See Section 5 17 for proper cable size 1 Strain Reliefs Route cables through strain reliefs 2 Electrode Holder Cable 3 Wire Feeder Cable 4 Work Cables For Stick TIG welding Direct Current Elec trode Positive DCEP connect work Note position of Process Selector switches IE 1 r DE 1 4 cable to Negative terminal and elec trode holder cable to CC terminal For Stick TIG Direct Current Electrode Negative DCEN connect wo
94. hile 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 Le MOVING PARTS can injure e Keep away from moving parts such as fans ty belts and rotors e Keep all doors panels covers and guards closed and securely in place Stop engine before installing or connecting unit Have only qualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary e 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 e 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 EXHAUST SPARKS can cause fire e Do not let engine exhaust sparks cause fire e Use approved engine exhaust spark arrestor in required areas see applicable codes HOT PARTS can burn e Do not touch hot parts bare handed e Allow cooling period before working on equip ment e To handle hot parts use proper tools and or wear heavy insulated wel
95. hone 1 866 512 1800 there are 10 OSHA Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov U S Consumer Product Safety Commission CPSC 4330 East West Highway Bethesda MD 20814 phone 301 504 7923 website WWW CpSC gov Applications Manual for the Revised NIOSH Lifting Equation The Na tional Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 phone 1 800 232 4636 website www cdc gov NIOSH 4 Maintenir la t te et le torse aussi loin que possible du mat riel du circuit de soudage 5 Connecter la pince sur la pi ce aussi pr s que possible de la soudure 6 Ne pas travailler proximit d une source de soudage ni s asseoir ou se pencher dessus 7 Ne pas souder tout en portant la source de soudage ou le d vidoir En ce qui concerne les implants m dicaux Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de soudage par points de gougeage du coupage plasma ou de chauffage par induc tion Si le m decin approuve il est recommand de suivre les proc dures pr c dentes OM 225 590 Page 15 Symbols And Definitions SECTION 3 DEFINITIONS 16 Stop Engine Start Engine Ether Starting Aid Engine Do Not Switch While Welding Or Under Load Battery Engine Circuit Protector Engine Oil Check Injectors Check Valve
96. hose brs barbed fem 1 2 tbg x 3 8 npt 1 OO ria 113854 HOSE sae 500 id x 780 od xcoil 1 66ft Lan ec uud a 023 562 CLAMP hose 312 875clpdia 1 MO e ees 176 528 FTG hose brs barbed elbow m 1 2 tbg x 1 2 npt 1 ET A NEE 206 906 ADAPTER oil drain fitting 1 AM GTR ES 047 235 WASHER seal oil copper 879id x 1 059od 111 8737 1 eX d xac rakusas 195 745 SWITCH pressure oil 1 5 bar nc Cont 1 xA Gran Eech 195 746 SENDER coolant temp amp 130c switch 1 vx D auta das 083 476 MOUNT eng gen nprn 875 ID x 2 500 OD x 2 000 60 dur 2 WALO acest Figure 12 4 GENERATOR 1 TET Ur 225 120 LABEL warning moving parts can cause injury 2 LO Bees date 176 236 BAFFLE air outlet 1 oe PO oid ense rat gent CLAMP muffler included with engine 1 A cs 105 733 PIPE muffler extension elbow 1 875 OD 1 ox OT greta net va 165739 BASE EE 1 UNOS M ied ios 191 446 EXTRUSION rubber w adhesive 1 000 x 1 000 D order by ft 2 1ft ABS PEE 173352 EXTRUSION rubber clamp bulb order by ft 2 4ft CO eda fe des 192305025 DRA Da
97. ial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1 8 HP 800 300 1 6 HP 1225 500 1 4 HP 1600 600 1 3 HP 2100 700 1 2 HP 3175 875 Capacitor Start Induction Run 1 3 HP 2020 720 1 2 HP 3075 975 3 4 HP 4500 1400 1HP 6100 1600 1 1 2 HP 8200 2200 2HP 10550 2850 3 HP 15900 3900 5HP 23300 6800 Capacitor Start Capacitor Run 1 1 2 HP 8100 2000 5HP 23300 6000 7 1 2 HP 35000 8000 10 HP 46700 10700 Fan Duty 1 8 HP 1000 400 1 6 HP 1400 550 1 4 HP 1850 650 1 3 HP 2400 800 1 2 HP 3500 1100 11 6 Approximate Power Requ irements For Farm Home Equipment Farm Home Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 Milker Vacuum Pump 2HP 10500 2800 FARM DUTY MOTORS 1 3 HP 1720 720 Std e g Conveyors 1 2 HP 2575 975 Feed Augers Air 3 4 HP 4500 1400 Compressors 1HP 6100 1600 1 1 2 HP 8200 2200 2HP 10550 2850 3 HP 15900 3900 5 HP 23300 6800 High Torque e g Barn 1 1 2 HP 8100 2000 Cleaners Silo Unloaders 5HP 23300 6000 Silo Hoists Bunk Feeders 7 1 2 HP 35000 8000 10 HP 46700 10700 3 1 2 cu ft Mixer 1 2 HP 3300 1000 High Pressure 1 8 Gal Min 500 PSI 3150 950 Washer 2 gal min 550 PSI 4500 1400 2 gal min 700 PSI 6100 1600 Refrigerator or Freezer 3100 800 Shallow Well Pump 1 8 HP 2150 750 1 2 HP 3100 1000 Sump Pump 1 3 HP 2
98. ide output LH 1 See sie oit 027 434 LABEL welder will not start by applying power to terminals 2 EXON 010 828 HANDLES eu pict Via dese tite A peu a Ms hi IAN 2 VE QM RF Mat teat 086 074 TUBING cop 540 ID x 123 wall x 562 welder A left side only 1 5 81 S9 204903 SWITCH mode single w dust cover includes 2 Visa KUU d E 163557 SWITCH mode single d FEE ES 202881 COVER EE EEN iB acc ctn 159 863 ELECTRONICS BOX 2 7 PCS 204832 CIRCUIT CARD ASSEMBLY welder B right side control 1 she PC1 204835 CIRCUIT CARD ASSEMBLY welder A left side control 1 89 CR2 CR3 000770 RELAY encl 24VDC 3PDT 10A 120VAC Ipin 2 9 GRD 185011 STUD primary board brs 10 32 x 1 592 2 1083 6 7 8 10 11 011 609 SWITCH tgl SPDT 15A 125VAC on none on 6 11 R1 2 7 8 035 897 POTENTIOMETER cp std slot 1t 2w 1k linear 4 12 LS1 2 3 4 089645 SWITCH lim 11A 125V anann 4 18 PC2 PC6 231 149 CIRCUIT CARD ASSEMBLY display w program 2 un dA WEEN 165 316 STAND OFF No 6 32 x 875 lg 342 hex nyl 8 e scii AG 097 924 KNOB pointer 1 625dia
99. ie e Ne pas utiliser le poste de soudage pour d geler des conduites ge l es e En cas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact e Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans revers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos po ches telles qu un allumeur au butane ou des allumettes e Une fois le travail achev assurez vous qu il ne reste aucune tra ce d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Suivre les recommandations dans OSHA 1910 252 a 2 iv et NFPA 51B pour les travaux chaud et avoir de la surveillance et un extincteur proximit LE BRUIT peut affecter l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv s pour les oreilles si le niveau sonore est trop lev OM 225 590 Page 9 Les CHAMPS LECTROMAGN TIQUES CEM peuvent affecter les implants m dicaux e Les porteurs de stimulateurs cardiaques et autres implants m dicaux doivent rester distance e Les porteurs d implants m dicaux doivent consulter leur m decin et le fabricant du dispositif avant de s approcher de la zone ou se d roule du s
100. is not plugged and valve fitting is clean Replace cylinder according to Section 5 18 ether2 7 96 153 382 A Ref 225 543 S 0692 OM 225 590 Page 45 8 7 Priming Fuel System A Stop engine Open right hand side door 1 Primer Pump After running out of fuel or changing fuel filters use pump to prime fuel system Push primer pump approximately 12times to pump fuel into the injec tor system Use Engine Control Switch to start engine Die 225 543 804 286 A OM 225 590 Page 46 8 8 Inspecting And Cleaning Optional Spark Arrestor Muffler E ar A Stop engine and let cool t3 1 Spark Arrestor Muffler 2 Cleanout Plug E V 3 we Remove plug and remove any dirt Q covering cleanout hole 3 Exhaust Pipe Start engine and run several min utes to blow out cleanout hole If nothing blows out of hole briefly cover end of exhaust pipe with fire proof material A Stop engine and let cool Reinstall cleanout plug Tools Needed IZ 3 8 in Ref 800 633 B Ref 225 543 8 9 Checking Generator Brushes ABS A Stop engine and let cool 1 Generator Brush With Spring Mark and disconnect leads at brush hold er cap Remove brushes Replace brushes if damaged or if brush material is at or near minimum length
101. itch to select output for weld process If switch is in Stick Tig position place Welder Selector switch in Welder A Welder B or Weld er B Position If switch is in MIG position place Welder Selector switch in Welder A Welder B position only CV weld output for MIG is only available when Welder Selector switch is in Welder A Welder B position All weld output stops if either Process Selector switch is placed in MIG position when Welder Selector switch is in Welder B position 7 Place optional Polarity switch in Reverse position when using CV weld output There is no CV weld output when Polarity switch is in Straight position NOTICE Do not switch under load or with output on 3 Arc Force Dig Control Use control to automatically increase amper age as arc length is decreased to assist in arc starts and reduce the chance of the electrode sticking in the puddle Turn clockwise to in crease short circuit amperage Set at mini mum for TIG welding 4 Hot Start Switch Use switch to disable hot start circuit Turn switch On for Stick SMAW and Submerged Arc SAW Welding and Air Carbon Arc Cut ting and Gouging CAC A Turn switch Off for TIG GTAW welding When switch is in On position higher short cir cuit amperage helps arc starting After arc starts the front panel or remote Amperage Voltage control setting determines weld am perage The hot start circuit does not function when constant voltage CV
102. just if necessary see Section 8 5 Have Factory Authorized Service Agent check field current regulator board PC4 Low open circuit voltage on either side Increase Amperage Voltage control setting Welder A left side check fuses F21 F22 and F23 and replace if open If fuse s are open have Factory Authorized Service Agent check main rectifier SR2 Welder B right side check fuses F11 F12 and F13 and replace if open If fuse s are open have Factory Authorized Service Agent check main rectifier SR3 Have Factory Authorized Service Agent check main rectifiers SR2 and SR3 synchronization trans formers T5 thru T10 and control board PC1 or PC5 No control of weld output on either side Place A V Control switch in Panel position or place switch in Remote position and connect remote control to remote receptacle RC8 or RC9 see Sections 5 19 and 6 3 Have Factory Authorized Service Agent check control board PC1 or PC5 No voltage control on either side open circuit voltage present Repair or replace remote device Place A V Control switch in Panel position or place switch in Remote position and connect remote control to remote receptacle RC8 or RC9 see Sections 5 19 and 6 3 Check connections to Remote receptacle RC8 and RC9 Have Factory Authorized Service Agent check control board PC1 or PC5 Wire feeder does not work either side Reset Welder A left circuit break
103. l Engineering Documents phone 1 877 413 5184 website www global ins com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Quincy MA 02269 phone 1 800 344 3555 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 Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Ontario Canada L4W 5NS phone 800 463 6727 website www csa international org Battery Chargers CSA Standard C22 2 NO 107 2 01 from Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Ontario Canada L4W 5NS phone 800 463 6727 website www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 1 9 EMF Information Electric current flowing through any conductor causes localized electric and magnetic fields EMF Welding current creates an EMF field around the welding circuit and welding equipment EMF fields may inter fere with some medical implants e g pacemakers Protective measures for persons wearing medical implants have to be taken For example access restrictions for passers by or individual risk ass
104. lectrolyte 1 265 Specific Gravity 3 Well Fill each cell with electrolyte to bottom of well maximum A Do not overfill battery cells Wait ten minutes and check electro lyte level If necessary add electro lyte to raise to proper level Reins tall vent caps 4 Battery Charger A Read and follow all instruc tions supplied with battery charger 5 5 Amperes For 30 Minutes Charge Time 6 30 Amperes For 12 Minutes Charge Time Charge battery Disconnect charg ing cables and install battery EF When electrolyte is low add only distilled water to cells to maintain proper level Tools Needed drybatt 12008 01 S 0886 5 5 Connecting The Battery De A Connect Cable Last Tools Needed X 1 2in Ref 225 543 153 654 C OM 225 590 Page 23 5 6 Installing Exhaust Pipe Lay Fr A Stop engine and let cool ta A Do not blow exhaust toward air cleaner or air intake Es O I Top View Tools Needed SF 1 2 in ech pipe2 4 96 154 089 A 154 611 190 377 5 7 Engine Prestart Checks Ct Check all fluids daily Engine must y Eon be cold and on a level surface Follow run in procedure in engine manual If unburned fuel and oil col lect in exhaust pipe during run in see Section 10 1 2in 13 mm Full Fuel 4 B 2 NOTICE Do not use gasoline LE B Gasoline will dama
105. ll s ou mal mis la terre pr sentent un danger Ne jamais toucher les pieces lectriques sous tension Porter des gants et des v tements de protection secs ne compor tant pas de trous e S isoler de la pi ce et de la terre au moyen de tapis ou d autres moyens isolants suffisamment grands pour emp cher le contact physique ventuel avec la pi ce ou la terre Ne passe servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou l o on risque de tomber e Se servir d une source lectrique courant lectrique UNIQUE MENT si le proc d de soudage le demande e Sil tilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip e Des pr cautions de s curit suppl mentaires sont requises dans des environnements risque comme les endroits humides ou lorsque l on porte des v tements mouill s sur des structures m talliques au sol grillages et chafaudages dans des positions assises genoux et allong es ou quand il y a un risque important de contact accidentel avec la pi ce ou le sol Dans ces cas utiliser les appareils suivants dans l ordre de pr f rence 1 un poste souder DC semi automatique de type CV MIG MAG 2 un poste OM 225 590 Page 8 EF Indique des instructions sp cifiques AEN Ce groupe de symboles veut dire Avertissement Attention D
106. ls If unit has the Polarity switch option con nect common work cable and work jumper cable to Welder B right Work receptacle Connect other end of work jumper cable to Welder A left Work receptacle Connect electrode holder cables to Elec trode receptacles x Be sure Process Selector switches and optional Polarity switches are set correctly See Section 6 3 OM 225 590 Page 28 5 12 Making Dual Operator CV Weld Connections w Separate Work Cables pe Bi You Welder A Left Side 3 a dem Direct Current Electrode Positive DCEP connections are shown Tools Needed LT 3 4 in Welder B Right Side Note position of Process Selector switches i Note position of optional 2 Polarity switch A Stop engine NOTICE Do not exceed machine duty cycle IEC Use Dual Operator mode for CC and CV welding see Section 6 1 See Section 5 17 for proper cable size 1 Strain Reliefs Route cables through strain reliefs 2 Wire Feeder Cables 3 Work Cables For MIG and FCAW welding Direct Current Electrode Positive DCEP connect work cables to Negative terminals and wire feeder cables to CV terminals For MIG and FCAW Direct Current Elec trode Negative DCEN connect work cables to CV terminals and wire feeder cable
107. ls and connect a single weld cable of adequate size from the Welder B right Negative terminal to the work piece e Whenusing these connections as a common work terminal all connections must be of the same polarity e Fora common work cable connection the work cable must be able to carry the combined weld output of both modules see Section 5 17 for proper cable size Welder A Left Side Direct Current Electrode Positive DCEP connections are shown Welder B Right Side M Note position of Process Selector switches 1E I Note position of optional Polarity switch 3 E EX A Stop engine NOTICE Do not exceed machine duty cycle IE For common work connection work cable must be able to carry combined weld output of both CC weld output ter minals see Section 5 17 for proper cable size x Use Dual Operator mode for CC and CV welding see Section 6 1 1 Strain Reliefs Route cables through strain reliefs 2 Electrode Holder Cable 3 Wire Feeder Cable 4 Work Jumper Cable 5 Common Work Cable For Direct Current Electrode Positive DCEP connect common work cable and work jumper cable to Welder B right Neg ative terminal Connect other end of work jumper cable to Welder A left Nega tive terminal
108. m moving vehicles when working from an aerial location e Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation Publication No 94 110 when manu ally lifting heavy parts or equipment MOVING PARTS can injure e Keep away from moving parts e Keep away from pinch points such as drive rolls 3 OM 225 590 Page 5 WELDING WIRE can injure e Do not press gun trigger until instructed to do so e Do not point gun toward any part of the body other people or any metal when threading welding wire pots f OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle e Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit s N STATIC ESD can damage PC boards y e Puton grounded wrist strap BEFORE handling SS boards or parts Eo e Use proper static proof bags and boxes to store move or ship PC boards ya TILTING OF TRAILER can injure gd e Use tongue jack or blocks to support weight e Properly install welding generator onto trailer according to instructions supplied with trailer READ INSTRUCTIONS e Read and follow all labels and the Owner s Manual carefully before installing operating or servicing unit Read the safety information at the beginning of the manual and in each section Use only genuine replacement parts from the manufacturer Perform maintenance and s
109. mains nues En cas de d tection de fuite ne pas utiliser l quipement e Remettre les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de mettre en marche l appareil e En cas d injection d air dans la peau ou le corps demander imm diatementune assistance m dicale L INHALATION D AIR COMPRIM risque de provoquer des blessures ou m me la mort e Ne pas inhaler d air comprim e Utiliser Pair comprim uniquement pour d couper ou gouger ainsi que pour l outillage pneumatique e Remettre en place les portes panneaux recouvrements ou dispositifs de protection la fin des travaux d entretien et avant de mettre le moteur en marche Une PRESSION D AIR R SIDUELLE 1 ETDES FLEXIBLES QUI FOUETTENT risquent de provoquer des blessures AY e D tendrela pression pneumatique des outils et circuits avant d entretenir ajouter ou changer des accessoires et avant d ouvrir le bouchon de vidange ou de remplissage d huile du compresseur DES PI CES CHAUDES peuvent provoquer des br lures graves e Ne pas toucher de pi ces chaudes du compresseur ou du circuit d air e Pr voir une p riode de refroidissement avant d intervenir sur l quipement Les PIECES MOBILES peuvent causer ES Ed e Ne pas toucher aux pi ces chaudes utiliser les outils des blessures recommand s et porter des gants de soudage et des v tements pais pour viter les br lures a e S ab
110. n aux normes industrielles et aux codes nationaux d tat ou locaux e Ne pas d passer le d bit nominal ou la capacit de la pompe hydraulique ou de tout quipement du circuit hydraulique Concevoir le circuit hydraulique de telle sorte que la d faillance d un composant hydraulique ne risque pas de provoquer un accident mat riel ou corporel e Avant d intervenir sur le circuit hydraulique couper l alimentation lectrique verrouiller et tiqueter l appareil d tendre la pression et s assurer que le circuit hydraulique ne peut tre remis sous pression par inadvertance e Ne pas intervenir sur le circuit hydraulique lorsque l appareil fonctionne Seul un personnel qualifi et appliquant les consignes du fabricant est autoris le faire e Ne pas modifier ou alt rer la pompe hydraulique ou les quipements fournis par le fabricant Ne pas d brancher d sactiver ou neutraliser les quipements de s curit du circuit hydraulique e Utiliser uniquement des composants et accessoires homologu s par le fabricant e Setenir l cart de tout point pr sentant un danger de pincement ou d crasement cr par l quipement raccord au circuit hydraulique e Mettre des lunettes de s curit et des gants placer un torchon sur le bouchon du radiateur e D visser le bouchon l g rement et laisser la vapeur s chapper avant d enlever le bouchon L utilisation d un groupe autonome l int rieur PEUT VOUS TUE
111. ny safety equipmentin the compressed air system e Use only components and accessories approved by the manufac turer e Keep away from potential pinch points or crush points created by equipment connected to the compressed air system e Do not work under or around any equipment that is supported only by air pressure Properly support equipment by mechanical means y HOT METAL from air arc cutting and MOVING PARTS can injure h 4 gouging can cause fire or explosion e Keep away from moving parts such as fans e Do not cut or gouge near flammables a belts and rotors e Watch for fire keep extinguisher nearby e Keep all doors panels covers and guards closed and securely in place mn 9 e Keep hands hair loose clothing and tools away from movin COMPRESSED AIR can injure or kill Ges 3 T i e Before working on compressed air system turn off and lockout tagout unit release pressure and be sure air pressure cannot be accidentally applied Have only qualified people remove guards or covers for maint enance and troubleshooting as necessary Reinstall doors panels covers or guards when servicing is finished and before starting engine e Before working on compressed air system turn off and lockout tagout unit release pres sure and be sure air pressure cannot be acci dentally applied e Relieve pressure before disconnecting or con necting air lines e Check compressed air system components and all conne
112. o the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire haz ards 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 by pass them Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby n NOISE can damage hearing Noise from some processes or equipment can dam age hearing e Wear approved ear protection if noise level is high ELECTRIC AND MAGNETIC FIELDS EMF can affect Implanted Medical Devices e 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 pres sure If damaged a cylinder can explode Since gas cylind
113. on 600 Amps A V control in minimum position and both Process Selector switches in Stick TIG position 3 Weld Cables Connect load bank to generator Welder B right weld output termi nals using proper size weld cables with correct connectors Observe correct polarity Start engine and run for several minutes Set load bank switches and then adjust generator A V control so load equals 350 Amps at 40 volts Check generator and load bank meters after first five minutes then every fifteen minutes to be sure generator is loaded properly Check oil level frequently dur ing run in add oil if needed It is recommended to run the weld ing generator for two hours mini mum and up to four hours under load Place AV control in minimum position then turn off load bank to remove load Run engine several minutes at no load A Stop engine and let cool 4 Engine Exhaust Pipe Repeat procedure if wetstacking is present S 0683 OM 225 590 Page 55 10 3 Run In Procedure Using Resistance Grid e Lay gt gt Lis 4 ar A Stop engine Ca A Do not touch hot exhaust pipe engine parts or load bank grid A Keep exhaust and pipe away from flammables A Do not perform run in procedure at less than 20 volts weld output and do not exceed duty cycle or equip ment damage may occur 1 Resistance Grid Use grid sized for generator rated output Turn Off grid 2 Welding G
114. oudage l arc du soudage par points du gougeage de la d coupe plasma ou une op ration de chauffage par induction Si des BOUTEILLES sont endomma g es elles pourront exploser Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endomma g e elle peut exploser Du fait que les bouteilles de gaz font normalement partie du proc d de soudage les manipuler avec pr caution e Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques des dommages physiques du laitier des flammes ouvertes des tincelles et des arcs Placer les bouteilles debout en les fixant dans un support station naire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser Tenir les bouteilles loign es des circuits de soudage ou autres circuits lectriques Ne jamais placer une torche de soudage sur une bouteille gaz Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille Ne jamais souder une bouteille pressuris e risque d explosion Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat Ne pas tenir la t te en face de la sortie en ouvrant la soupape de la bouteille Maintenir le chapeau de protection sur la soupape sauf en cas d utilisation ou de branchement de la bou
115. ourself 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 follow ing 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 unavoid able 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 volt age 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 EF Indicates special instructions AEN This group of symbols means Warning Watch Out ELECTRIC
116. r the Preparation of Containers and Piping for Welding and Cutting American Welding Society Standard AWS F4 1 from Glob al Engineering Documents phone 1 877 413 5184 website www global ins com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Quincy MA 02269 phone 1 800 344 3555 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 Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Ontario Canada L4W 5NS phone 800 463 6727 website www csa international org Battery Chargers CSA Standard C22 2 NO 107 2 01 from Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Ontario Canada L4W 5NS phone 800 463 6727 website www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 2 9 Informations relatives aux CEM Le courant lectrique qui traverse tout conducteur g n re des champs lectromagn tiques CEM a certains endroits Le courant de soudage cr e un CEM autour du circuit et du mat riel de soudage Les CEM peuvent cr er des interf rences avec certains implants m
117. ration en hauteur e Suivreles consignes du Manuel des applications pour l quation de levage NIOSH r vis e Publication N294 110 lors du levage manuelle de pi ces ou quipements lourds LES FILS DE SOUDAGE peuvent provoquer des blessures e Ne pas appuyer sur la g chette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi d autres per sonnes ou toute pi ce m canique en enga geant le fil de soudage LE SURCHAUFFEMENT peut endommager le moteur lectrique T I L EMPLOI EXCESSIF peut e Arr ter ou d connecter l quipement avant de SURCHAUFFER L QUIPEMENT arr ter teur ee d ameter le moten P e Laisser l quipement refroidir respecter le fac e Ne pas laisser tourner le moteur trop lentement sous risque d en teur de marche nominal dommager le moteur lectrique cause d une tension et d une fr e R duire le courant ou le facteur de marche avant de poursuivre le soudage e Ne pas obstruer les passages d air du poste quence trop faibles e Ne pas brancher de moteur de 50 ou de 60 Hz la prise de 100 Hz S il y a lieu OM 225 590 Page 13 LES CHARGES LECTROSTATI QUES peuvent endommager les circuits imprim s e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antistatiques pour stocker d placer ou exp dier des cartes de circuits imprimes UNE REMORQUE QUI
118. rdering parts from your local distributor OM 225 590 Page 72 Hardware is common and not available unless listed 802 319 Figure 12 5 Rectifier Assembly Item Dia Part No Mkgs No Description Quantity Figure 12 5 Rectifier Figure 12 1 Item 30 DE EE 205 613 RECTIFIER ASSEMBLY 1 sug dt PT LA ptus 203 001 RECTIFIER Si Diode One Side Service kit W Varnish Coating 1 Dx PLG1 PLG2 158 720 CONNECTOR amp SOCKETS 1 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor L Some wiring harness components switches relays supplementary protectors are also referenced elsewhere in this parts list Purchase components separately or as part of the associated wiring harness Item Dia Part No Mkgs No Description Quantity Wiring Harnesses pate lado quie 195 702 HARNESS wiring component panel includes 1 he MR BAR Gare 188 512 SEAL wire univ 6P S 3 row 8 rper 187 651 SEAL wire univ 9P S 3 row 8 RC13 21 116 045 HOUSING plugs and pins 2 Tm PLG17 135 275 HOUSING plugs and pins 1
119. re le plein de carburant ras bord pr voir de l espace pour son expansion Faire attention de ne pas renverser de carburant Nettoyer tout carburant renvers avant de faire d marrer le moteur Jeter les chiffons dans un r cipient ignifuge Toujours garder le pistolet en contact avec le r servoir lors du remplissage m Les PIECES MOBILES peuvent causer des blessures v e S abstenir de toucher des parties mobiles telles que des ventilateurs courroies et rotors Maintenir ferm s et verrouill s les portes panneaux recouvrements et dispositifs de protection Arr ter le moteur avant d installer ou brancher l appareil Lorsque cela est n cessaire pour des travaux d lentretien et de d pannage faire retirer les portes panneaux recouvrements ou dispositifs de protection uniquement par du personnel qualifi Pour emp cher tout d marrage accidentel pendant les travaux d entretien d brancher le c ble n gatif de batterie de la borne Ne pas approcher les mains cheveux v tements l ches et outils des organes mobiles Remettre en place les portes panneaux recouvrements ou dispositifs de protection la fin des travaux d entretien et avant de mettre le moteur en marche Avant d intervenir d poser les bougies ou injecteurs pour viter la mise en route accidentelle du moteur Bloquer le volant moteur pour viter sa rotation lors d une intervention sur le g n rateur LES TINCELLES
120. rier 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 ORIGINAL INSTRUCTIONS PRINTED IN USA 2010 Miller Electric Mfg Co 2010 01 Miller Electric Mfg Co An Illinois Tool Works Company 1635 West Spencer Street Appleton WI 54914 USA International Headquarters USA USA Phone 920 735 4505 Auto Attended USA amp Canada FAX 920 735 4134 International FAX 920 735 4125 For International Locations Visit www MillerWelds com 72 Miller
121. rk cable to CC terminal and electrode holder cable to Negative terminal x Be sure Process Selector switches are set correctly See Section 6 3 For MIG and FCAW welding Direct Current Electrode Positive DCEP connect work cable to Negative terminal and wire feeder cable to CV terminal For MIG and FCAW Direct Current Elec trode Negative DCEN connect work cable to CV terminal and wire feeder cable to Negative terminal Ref 225 543 802 292 A For Stick TIG welding on units with Polarity switch option connect work cable to Work receptacle and electrode cable to Elec trode receptacle For MIG FCAW welding on units with Po larity switch option connect work cable to Work receptacle and wire feeder cable to CV receptacle 7 Place optional Polarity switches in Re verse position when using CV weld re ceptacles There is no CV weld output when switch is in Straight position Be sure Process Selector and Polarity switches are set correctly See Sec tion 6 3 OM 225 590 Page 31 5 15 Making Dual Operator CC And CV Weld Connections w Common Work Cable STOP Tools Needed LT 3 4 in INADEQUATE CABLE CONNECTIONS can cause serious damage to welding generator and create a hazardous condition e When making weld connections with a common work cable connect a weld cable of adequate size between the Negative weld termina
122. s are open have Factory Authorized Service Agent check main rectifier SR3 Have Factory Authorized Service Agent check main rectifier SR3 synchronization transformers T8 T9 and T10 and control board PC5 OM 225 590 Page 49 Trouble Remedy Low weld output on both sides Check engine speed and adjust if necessary see Section 8 5 Check position of Process Selector switch s see Section 6 3 Increase Amperage Voltage controls settings Have Factory Authorized Service Agent check field current regulator board PC4 High weld output on both sides Have Factory Authorized Service Agent check field current regulator board PC4 Erratic weld output on either side Check and tighten connections inside and outside unit Be sure connection to work piece is clean and tight Use dry properly stored electrodes Remove excessive coils from weld cables Check Process Selector switch s connections and contacts Welder A left side check fuses F21 F22 and F23 and replace if open If fuse s are open have Factory Authorized Service Agent check main rectifier SR2 Welder B right side check fuses F11 F12 and F13 and replace if open If fuse s are open have Factory Authorized Service Agent check main rectifier SR3 Have Factory Authorized Service Agent check Welder Selector switch S2 Low open circuit voltage on both sides Check engine speed and ad
123. s 083 030 STUD 24 ciuili EE Ah a eae ea nel a ERR Ee 1 34 HM 210 424 METER hour 12 24VDC 1 S3 do uere 021 385 BOOT toggle switch lever 1 S90 2s Pl 188 266 LIGHT ind red lens 13V includes 1 OL erre 082 788 HOLDER light ind only 1 DT anten euet ted 048 155 BULB incand min 444 4 I In 1 D BEE 082 789 LENS light ind red 1 AQ owing EE 010647 PIN spring CS 156 x 1 250 1 SAM oum 111 785 HANDLE switch 1 EE PLATE ident control rating order by model and serial number 1 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 225 590 Page 69 Hardware is common and not available unless listed 802 320 A Figure 12 3 Side Control Panels Welder B Right Side Shown OM 225 590 Page 70 Item Dia Part No Mkgs No Description Quantity Figure 12 3 Side Control Panels Figure 12 1 Item 45 s NU PEL DE 192 330 PANEL side output RH 1 wow titm 192 325 PANEL s
124. s mal formations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants A Les batteries les bornes et autres accessoires contiennent du plomb et des compos s a base de plomb produits chimi ques dont l tat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apr s manipu lation A Ce produit contient des l ments chimiques dont le plomb reconnus par l Etat de Californie pour leur caract re OM 225 590 Page 14 canc rog ne ainsi que provoquant des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apr s toute manipulation Pour les moteurs essence A Les gaz d chappement des moteurs contiennent des pro duits chimiques dont l tat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Pour les moteurs diesel A Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l Etat de Californie com me provoquant des cancers et des malformations cong nitales ou autres probl mes de procr ation 2 8 Principales normes de s curit Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 from Global Engineering Documents phone 1 877 413 5184 website www global ins com Safe Practices fo
125. s to Negative terminals Note position of optional Po larity switch Ref 225 543 802 292 A If unit has the Polarity switch option con nect work cables to Work receptacles and wire feeder cables to CV receptacles 7 Place optional Polarity switches in Re verse position when using CV weld re ceptacles There is no CV weld output when switch is in Straight position x Be sure Process Selector and Polarity switches are set correctly See Section 6 3 OM 225 590 Page 29 5 13 Making Dual Operator CV Weld Connections w Common Work Cable mU Td Tools Needed LT 3 4 in A INADEQUATE CABLE CONNECTIONS can cause serious damage to welding generator and create a hazardous condition e When making weld connections with a common work cable connect a weld cable of adequate size between the Negative weld terminals and connect a single weld cable of adequate size from the Welder B right Negative terminal to the work piece e When using these connections as a common work terminal all connections must be of the same polarity e Fora common work cable connection the work cable must be able to carry the combined weld output of both modules see Section 5 17 for proper cable size Direct Current Electrode Positive Welder A Left Side DCEP connections are shown Welder B Right Side L
126. se A hace ec oot ora ace ins SARI Ah Ch ee Eger Mal hh ee 1 ws BO ouan lun 176 167 NUT 250 20 acorn nylon 6 m BG share has 192 303 ANGLE mtg stabilizer nh 4 e ZN 7192 296 STABILIZER Rete EE ea en HE ee dee Pa EN 2 E p 205 791 BRACKET mtg fuse assembly includes 1 499 sta etaed Re 204 965 STRIP insulation 6 o EE 026947 STAND OFF insul 2p0 20x10 eee 12 91 F11 13 F21 23 027 267 FUSE link 300 A 250 volt 6 Mu 192 304 PANEL front lower 1 E tes Pate 233 953 LABEL warning general precautionary CSA 1 iuga sis sus Figure 12 2 FRONT PANEL tee a oo ade debeat cette 1 gb eure ce ia 175256 INSULATOR side RH 1 sn 06 gh diva oa 192 300 SHROUD generator LH 1 97 T2 T4 192371 TRANSFORMER 115V pri 24VCT 8A w leads 2 0908 a rela 192 301 SHROUD generator RH 1 299 iuro tee 168 829 TRANSDUCER current 1000A module max open loop 2 20100 sue ra 192 299 SHROUD generator center 1 e EM seus 194 021 CAPACITOR ASSEMBLY includes
127. ses leather gloves heavy shirt and trousers high shoes and a cap when working on hydraulic system e Use a piece of paper or cardboard to search for leaks never use bare hands Do not use equipment if leaks are found 1 5 Compressed Air Hazards COMPRESSED AIR EQUIPMENT can injure or kill e Incorrect installation or operation of this unit could result in equipment failure and personal injury Only qualified persons should install op erate and service this unit according to its Owner s Manual industry standards and na tional state and local codes e Do not exceed the rated output or capacity of the compressor or any equipment in the compressed air system Design compressed air system so failure of any component will not put people or prop erty at risk Before working on compressed air system turn off and lockout tagout unit release pressure and be sure air pressure cannot be accidentally applied OM 225 590 Page 4 e HYDRAULIC FLUID is FLAMMABLE do not work on hydraulics near sparks or flames do not smoke near hydraulic fluid e Reinstall doors panels covers or guards when servicing is finished and before starting unit e f ANY fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury or gan grene may result e MOVING PARTS can injure e Keep away from moving parts such as fans a belts and rotors e Keep all
128. sh glare and sparks warn others not to watch the arc e Wear protective clothing made from durable flame resistant mate rial leather heavy cotton or wool and foot protection AA 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 e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers 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 e 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 225 590 Page 2 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 t
129. slfng 6 zx WEE 134835 HOSE SAE 312 ID x 560 OD order by ft 9ft con e FER 097 507 STRIP rbr adh back 125 x 1 000 x 20 500 60 duro 2 c2 gee ast eet oe 010314 VALVE shut off fuel 1 te Mere eget ots 039 599 FITTING brs barbed M 5 16 tbg x 1 4 NPT 3 NS TAs u oo De 048 227 UPRIGHT base front 1 SUD uiuere cedes 170 689 FRAME mtg reactor and fuel tank 1 TG se see arate 170 617 UPRIGHT base center 1 sb ur rade AA 017 479 SEAL weather lift eye 1 18 R8 R5 097 459 RESISTOR WW fxd 375W 20 ohm 2 FER KS PRAES OR ES 216 565 BRACKET mounting components 1 20 TD1 214928 TIMER delay on make break open 30 sec 12vdc 1 21 SR4 SR5 035 704 RECTIFIER Integ bridge 40 amp 800v 2 22 CRS 090104 RELAY end 12vdc spst 30a 15vdc 5pin flange mtg 1 28 CB12 205927 CIRCUIT BREAKER auto reset 12vdc 12amp 1 RL RE COE ees 108 081 TERMINAL PROTECTOR battery post mtg 2 sr OD
130. stenirde toucher des parties mobiles telles que des ventilateurs courroies et rotors e Maintenir ferm s et verrouill s les portes panneaux recouvrements et dispositifs de protection LIRE LES INSTRUCTIONS e Lire et appliquer les instructions sur les tiquettes et le Mode d emploi avant l installation l utilisation ou l entretien de l appareil Lire les informations de s curit au e Ne pas approcher les mains cheveux v tements laches et outils des organes mobiles E e Avant d intervenir sur le circuit d air comprim couper l alimentation lectrique verrouiller et tiqueter l appareil d but du manuel et dans chaque section d tendre la pression et s assurer que le circuit d air ne peut tre mis sous pression par inadvertance e N utiliser que les pieces de rechange recommand es par le e Demander seulement un personnel qualifi d enlever constructeur les dispositifs de s curit ou les recouvrements pour effectuer e Effectuer l entretien en respectant les manuels d utilisation s il y a lieu des travaux d entretien et de d pannage les normes industrielles et les codes nationaux d tat et locaux 2 6 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance LES TINCELLES PROJET ES peuvent provoquer des blessures S Risque D INCENDIE OU h d D EXPLOSION e Ne pas placer l appareil sur au dessus ou A Ska e Porter un
131. sts with baking soda and water solution rinse with clear water Periodically recharge battery approximately every 3 months Replace battery Check voltage regulator and connections according to engine manual Engine uses oil during run in period wetstacking occurs Dry engine see Section 10 OM 225 590 Page 51 SECTION 9 ELECTRICAL DIAGRAMS SI 1 zi si s2 26 zc CN 3 te ol T oF 27 STICK TIG Le v 16 3004 gt T POSITIVE NEAR si C21 8 ELECTRODE E zx E CL K scr ps sg Ka E 25 p 17 Q KO T o 22 POSITIVE t OLD gt a MEP SUE
132. t Terminal Nut Weld Cable Terminal Copper Bar Remove supplied nut from weld output ter minal Slide weld cable terminal onto weld output terminal and secure with nut so that weld cable terminal is tight against copper bar 7 Negative Weld Output Terminal 8 CV Weld Output Terminal out Ww Tools Needed I 3 4 in Ref 225 543 802 292 A 803 788 B 9 CC Weld Output Terminal See Sections 5 10 thru 5 15 for dual opera tor output connections for CC and CV weld ing See Section 5 16 for single operator output connections CC only If unit has the Polarity switch option the Negative weld output terminals are la beled Work receptacles and the CC weld output terminals are labeled Electrode re ceptacles OM 225 590 Page 26 5 10 Making Dual Operator CC Weld Connections w Separate Work Cables mU Tad Welder A Left Side 2 3 4 in Q y CH Direct Current Electrode Positive DCEP connections are shown Welder B Right Side Tools Needed Note position of Process Selector switches I nie N A Stop engine NOTICE Do not exceed machine duty cycle Use Dual Operator mode for CC and CV welding see Section 6 1 See Section 5 17 for proper cable size 1 Strain
133. te 14 Receptacle Connections Dual Operator Operation Single Operator Operation 804 289 A Ref 225 543 OM 225 590 Page 36 SECTION 6 OPERATING THE WELDING GENERATOR EF When facing the front panel the Welder B controls and weld terminals are on the right and the Welder A side controls and weld terminals are on the left 6 1 Engine Controls 2999 x E d WELDER A K ex DO NOT SWITCH UNDER LOAD 300 AMPS 300 AMPS WELDER B 600 AMPS WELDER B Notes WELDER A B MUST BE IN STICK MODE AMPERAGE ADJUST IS 2X DIAL VALUE GND PF See Section 6 3 for weld control descriptions 1 Engine Start Button 2 Stop Switch 3 Ether Starting Aid Switch Optional Push switch up and release while cranking engine to release ether To Start Press button and use Ether switch if necessary Release button when engine starts gt If the engine does not start let engine come to a complete stop before attempt ing restart 225 543 804 289 A To Stop Push switch down and hold Re lease when engine stops 4 Battery Charging Warning Light Light goes on when battery is not charging NOTICE If light goes on stop engine and check alternator and engine belt 5 Engine Hour Meter OM 225 590 Page 37 6 2 Wel
134. teille Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s cu rit 2 3 Dangers existant en relation avec le moteur L EXPLOSION DE LA BATTERIE peut provoquer des blessures e Toujours porter une protection faciale des gants en caoutchouc et v tements de protec tion lors d une intervention sur la batterie Arr ter le moteur avant de d brancher ou de brancher des c bles de batterie des c bles de chargeur de batterie le cas ch ant ou de batterie d entretien e Eviter de provoquer des tincelles avec les outils en travaillant sur la batterie e Ne pas utiliser l appareil de soudage pour charger des batteries ou faire d marrer des v hicules l aide de c bles de d marrage sauf si l appareil dispose d une fonctionnalit de charge de batterie destin e cet usage e Observer la polarit correcte et sur les batteries e D brancher le c ble n gatif en premier lieu Le rebrancher en dernier lieu e Les sources d tincelles flammes nues cigarettes et autres sources d inflammation doivent tre maintenues l cart des batteries Ces derni res produisent des gaz explosifs en fonctionnementnormal et en cours de
135. teurs d entr e comme indiqu dans la Section Maintenance avant de toucher des composants LES PI CES CHAUDES peuvent provoquer des br lures e Ne pas toucher mains nues les parties chau des e Pr voir une p riode de refroidissement avant de travailler l quipement e Ne pas toucher aux pi ces chaudes utiliser les outils recomman d s et porter des gants de soudage et des v tements pais pour viter les br lures DES PIECES DE METAL ou DES aor SALETES peuvent provoquer des blessures dans les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la p riode de refroidissement des soudures elles risquent de projeter du laitier Porter des lunettes de s curit avec crans lat raux ou un cran facial LES FUM ES ET LES GAZ peu vent tre dangereux Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereux pour votre sant e Eloigner votre t te des fum es Ne pas respirer les fum es e l int rieur ventiler la zone et ou utiliser une ventilation forc e au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Sila ventilation est m diocre porter un respirateur anti vapeurs approuv e Lire et comprendre les sp cifications de s curit des mat riaux MSDS et les instructions du fabricant concernant les m taux les
136. tighten connec tions as necessary and wipe up Spilled fuel Close doors 225 543 804 285 A 013 466 OM 225 590 Page 44 8 5 Adjusting Engine Speed A Engine speed is factory set and Ar should not require adjustment Af e Engine Speed ter tuning engine check engine No Load RPM HZ speed with tachometer See table for proper no load speed If neces sary adjust speed as follows Weld Power 1850 61 6 1 Adjustment Rod 2 Thumbwheels Start engine and turn thumbwheels to increase or decrease engine no load speed 3 Speed Control Lever gt Rotating lever clockwise increases engine speed A Stop engine Close side door Tools Needed IX 3 8 in 804 285 A 8 6 Servicing Optional Ether Starting Aid A Stop engine A Improper handling or expo sure to ether can harm your health Follow manufactur er s safety instructions on cylinder awe If engine does not start in cold weather check ether cylinder as follows Remove cylinder from valve 1 Ether Cylinder 2 Valve 3 Scale Weigh cylinder to see if it is empty Be sure atomizer
137. tput to Welder B right remote receptacle RC8 If CB6 opens Welder B right RC8 24 and 115 volt AC output stops Supplementary Protector CB7 protects field current regulator board PC4 If CB7 opens weld and generator power output on both sides stops Supplementary Protector CB8 protects the generator field flashing circuit If CB8 Tools Needed EA Ref 802 300 Ref 802 292 A opens weld and generator power output may continue if generator maintains excita tion Weld and generator power output stops if generator requires field flashing cir cuit to restore excitation Press button to reset supplementary pro tector 9 Fuses F11 F12 F13 F21 F22 F23 These fuses protect the weld stator wind ings If fuse F11 F12 or F13 opens Welder B right side output is erratic or low If fuse F21 F22 or F23 opens Welder A left side output is erratic or low 10 Thermostats TP3 And TP4 Internal Not Shown Thermostat TP3 protects Welder A left SR2 rectifier and TP4 protects Welder B right SR3 rectifier from overheating If TP3 or TP4 opens Welder A left or Welder B right weld output stops and the High Temp Shutdown light goes on Wait fifteen minutes for module to cool and thermostat to automatically reset Reduce amperage voltage or duty cycle before welding OM 225 590 Page 48 8 11 Troubleshooting
138. u Le rayonnement de l arc du proc d de soudage g n re des rayons visibles et invisibles intenses ultraviolets et infrarouges susceptibles de provoquer des br lures dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage e Porter un casque de soudage approuv muni de verres filtrants appropri pour prot ger visage et yeux pour prot ger votre visage et vos yeux pendant le soudage ou pour regarder voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit Porter des lunettes de s curit avec crans lat raux m me sous votre casque Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les blouissements et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc e Porter des v tements confectionn s avec des mati res r sistan tes et ignifuges cuir coton lourd ou laine et des bottes de protection L LE SOUDAGE peut provoquer un PRESS incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincelles des pi ces chaudes et des quipements chauds peut provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion
139. uit d air comprim lorsque l appareil fonctionne Seul un personnel qualifi est autoris et appliquant les consignes du fabricant e Ne pas modifier ou alt rer le compresseur ou les quipements fournis par le fabricant Ne pas d brancher d sactiver ou neutraliser les quipements de s curit du circuit d air comprim e Utiliser uniquement des composants et accessoires homologu s par le fabricant e Se tenir l cart de tout point pr sentant un danger de pincement ou d crasement cr par l quipement raccord au circuit d air comprim e Ne pas intervenir sous ou autour d un quipement qui n est soutenu que par la pression pneumatique Soutenir l quipement de facon appropri e par un moyen m canique M TAL CHAUD provenant du d cou page ou du gougeage l arc risque de provoquer un incendie ou une explo sion Ne pas d couper ou gouger proximit de produits inflammables e Attention aux risques d incendie tenir un extincteur proximit OM 225 590 Page 12 LES PI CES ET LIQUIDES CHAUDS peuvent provoquer des br lures e Ne pas toucher les pi ces chaudes main nue ni laisser des liquides chauds entrer en contact avec la peau e Pr voir une p riode de refroidissement avant d intervenir sur l quipement e Ne pas toucher aux pi ces chaudes utiliser les outils recommand s et porter des gants de soudage et des v tements pais pour viter les br lures LL
140. use F3 and replace if open see Section 8 10 Check position of Welder Selector switch Welder A left weld output stops when Welder Selector Switch is placed in Welder B position see Section 6 1 Unit overheated High Temp Shutdown light goes on wait several minutes for thermostat s TP3 to reset see Section 8 10 Have Factory Authorized Service Agent check Welder A left contactor circuit No Welder B right weld output Welder A left weld output okay Check fuse F4 and replace if open see Section 8 10 Unit overheated High Temp Shutdown light goes on wait several minutes for thermostat s TP4 to reset see Section 8 10 Have Factory Authorized Service Agent check Welder B right contactor circuit Low Welder A left weld output Weld er B right output okay Check position of Process Selector switch see Section 6 3 Increase Amperage Voltage control setting Check fuses F21 F22 and F23 and replace if open If fuse s are open have Factory Authorized Service Agent check main rectifier SR2 Have Factory Authorized Service Agent check main rectifier SR2 synchronization transformers T5 T6 and T7 and control board PC1 Low Welder B right weld output Welder A left weld output okay Check position of Process Selector switch see Section 6 3 Increase Amperage Voltage control setting Check fuses F11 F12 and F13 and replace if open If fuse
141. wn 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 ex plained in the text NOTICE Indicates statements not related to personal injury 1 2 Arc Welding Hazards A A A The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 8 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 equipmentis a hazard Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Insulate y
142. x 250 ID 2 2816 021 385 BOOT toggle switch lever 6 RP TREE 097 922 KNOB pointer 875dia x 250 ID 2 TO iss n 148 956 HANDLE switch 2 TEL TET NAMEPLATE order by model and serial number 2 usd Lied tens 162815 PANEL Tront uppet ovest DEEP EPDRIPRed ba ee DILE e 2 A ATI uou 161 297 CAM switch selector 2posn 2 EE E 170391 CONNECTOR circ protective cap 2 EE E 241432 TERMINAL pwr output red 4 vw ed oeste ads 241 433 TERMINAL pwroutputblack 2 E EENEG 192 494 BUS BAR connecting en 2 iP a etais 192 493 STAND OFF bus bar 6 27 C2 4 5 21 22 23 136 736 CAPACITOR cer disc 1uf 500VDC 6 28 SL AT 190210 BLOCK term 5 3 3 2 29 CB5 CB6 139266 SUPPLEMENTARY PROTECTOR man reset 1p 15a 250vac 2 30 RC8 RC9 134 735 CONNECTOR circ MS CPC 14skt 2 91 PC3 PC7 181261 CIRCUIT CARD ASSEMBLY filler 2 EA a 165 316 STAND OFF No 6 32 x 875 lg

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