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Miller Electric OM-4409 User's Manual

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1. 2 rS Evan 186621 Boot Generic Output Stud 2 OM 4409 Page 89 Dia Part No Mkgs No Description Quantity Figure 19 3 Panel Front w Components Continued MITT 059773 Switch Handle Polarity AC Switch 1 010647 Pin Polarity AC Switch 1 059773 Handle Switch Battery Charging 1 010647 Pin Spring Cs 156 X 1 250 Battery Charging 1 081499 Bracket Mtg Strip Terminal Battery Charging 1 9012 61 039047 Terminal Pwr Output Red 1 PAE ig awa 021385 Boot Toggle Switch Lever 1 UA cen auc ENT 190323 Boot Circuit Breaker Clear Hex Nut 4 AO cereis 170391 Conn Circ Ms Protective Cap Size 20 Nylon 1 47 1 210424 Meter Hour 12 24vdc Snap in 1 48 FUEL 192265 Gauge Fuel Elec Switch W O Switchgage Sensor 1 49 BAT 193228 Meter Volt DC 8 18 Scale 2 250 In Black Face 1 206599 Gauge Pressure 0 200 Psi Electric Switch
2. 1 Di xd eus eive ie 201077 Control 1 MOMENT 201078 Control Box Rh 1 7 HM2 145247 Meter Hour Air Compressor 1 8 CR3 CR6 090104 Relay Encl 12vdc Spst 30a 15vdc 5pin Flange 2 9 CR8 197325 Relay Encl 12vdc Spst 70a Flange 1 10 CB15 083432 Supplementary Protector Man Reset 1p 10a 250vac Frict 1 11 CB8 139266 Supplementary Protector Man Reset 1p 15a 250vac Frict Air Dryer 1 12 C8 D8 C10 D10 189701 Diode Capacitor Board 2 13 CR1 214876 Relay Encl 6vdc Spst 35a 14vdc 5 Pin 1 14 CB14 205927 Circuit Breaker Auto Reset 12vdc 12 Amp 1 15 CB10 190374 Circuit Breaker Auto Reset 12vdc 40 Amp 1 16 CR5 223710 Relay EncH2vdc Dpst no 25a 6pin 1 17 14 090104 Relay Encl 12vdc Spst 30a 15vdc 5pin Flange Mtg Air Dryer 1 18 SR1 035704 Rectifier Integ Bridge 40 Amp 800v 1 19 PC7 195706 Module Pull To Idle Two Output 7 Pin 1
3. 1 218003 Bracket Mtg Fuel Filter Solenoid 1 RE o 232968 Base Fuel Filter ASSy 1 tr vata us 192744 Filter Fuel Spin on 1 ode 199383 Hose Sae 312 Id X 560 Od X 8 000 Fuel Filter To Fuel Pump 1 DOPO 191819 Hose Sae 312 Id X 560 Od X 14 000 Fuel Tank To Fuel Filter 1 Lcd us DR 190992 Keeper Latch Engine Access Door 1 206604 Channel Stiffener Engine Access 1 EEE S A 209093 Bracket Safety Latch 1 ne 209092 Bracket Mtg Saftey Latch 1 ge a dires trans 174064 Idle Solenoid Assy includes 1 E doce sce 196036 Bracket Arm Throttle 1 Jn reset My ars e 125663 Ball Joint 250 28 Sp Lh 1 etg aer A SS 175936 Rod Throttle 5 250 1 PE 127994 Ball Joint 250 28 Spf Female Rod End 1 E MERECE RS 127648 Clevis Throttle 1 124974
4. 1 1T 189549 Block Term Assy Standard W Clamp includes 1 038621 Block Term 30 4 Pole Frict Term Str Both Side 1 081499 Bracket Mtg Strip Terminal 1 138027 Edge Trim Style TI750 b2x1 16 Black W Clips 3 750 2 020225 Clamp 875 Clamp Dia X 500 Wide 203 Mtg Hole 1 10 SR4 585 035704 Rectifier Integ Bridge 40 Amp 800 V 2 11 045061 Circuit Breaker Auto Reset 24vdc 7 Amp 1 PARENT 206352 Brace Front To Center Upright 2 13 TA uus 205636 Transformer W Brkt Environmental 1 oe 201697 Pan Reactor And Rectifier 1 tes 173352 Extrusion Rubber order by ft 1 189708 Firewall 1 1 T EAS 194485 Hose Air Cleaner 1 ARR ET 189764 Air Cleaner Intake Engine includes 1 192938 Filter Air Element Primary 1 teeta 192939 Filter Air Element
5. 3 46 esses 205712 Spark Arrestor 2 1 1 CAT eu ua 205748 Pipe Exhaust Elbow 1 OM 4409 Page 82 Dia Part No Mkgs No Description Quantity Figure 19 1 Main Assembly Continued 224265 Label Warning Hot Exhaust Parts Do Not Touch 1 baa AO Leurs 213895 Manifold Exhaust Muffler B Am2011 Deutz 1 ark west tres teh 202633 Support Cover E coat 1 Cg Od aces eee Figure 19 6 Air Compressor Assembly 1 dates rea ee 191577 Guard Starter Deutz 1 iud 191809 Bracket Mtg Engine LH 1 nap DERS 209632 Hose Tubing Oil Assyw Fittings 22 380lg 1 iae DO LEO aud eR RUE 218619 Engine Deutz Dsl Elec Bf4m2011 includes 1 T 193256 Adapter Engine Deutz 1011 1 qM DM 195748 Flywheel Deutz 1 nj ar bya cA aa UE Cw d 195746 Sender Coolant Temp 4 130c Switch 1 iei en AR 195745 Switch Pressure Oil 1 5 Bar Nc Cont
6. 2 37 7 3 Optional Generator Power Receptacles 38 SECTION 8 OPERATING OPTIONAL BATTERY CHARGER 39 8 1 Battery Charge Controls 39 8 2 Determining Battery Charging Current 39 8 3 Battery Charge Cable Connections 40 8 4 Battery Charging Procedure 41 8 5 Jump Starting Procedure 42 SECTION 9 ENGINE GENERATOR 43 9 1 Engine Maintenance 1 43 9 2 Routine Engine Generator Maintenance 44 9 3 Checking Generator Brushes 45 9 4 Servicing Engine Air 46 9 5 Inspecting Cleaning Optional Spark Arrestor Muffler 47 9 6 Adjusting Engine 48 9 7 Servicing Engine Fuel And Lubrication Systems
7. 1 067265 Oll Filter 1 pubs taka eae 066217 Secondary Fuel Filter 1 sdb 208041 Spacer Stl 323 Id 625 Od X 141 Thk Alternator 1 193230 Sender Pressure 0 100 Psi 1 194403 Adaptor Oil Pressure Sender 1 GLOW PLUG 190059 Glow 7 1 Bis anni ou den 207203 Fan Engine Cooling 18 000 Suction 1 REUS 208042 Spacer Stl 800id X 1 18804 X 090 Thk Fan Hub Bolt 1 207808 Belt 375 45 125 Lg 1 209675 Extension Hydraulic 37 Deg Flare 1 E m 209633 Hose Tubing Oil Assyw Fittings 27 040lg 1 cce ict 209621 Stl Adapter 3 4 Sae 3 4 1 ss Od s Runner 207269 Guard Fan LH meas eae 1 MP 206749 Shroud Fan Air Ranked 4 e E wea 1 LES 69 ec iue 206558 Cooler Oil Engine Compressor 1 fat 209623 Brs Adapter Long 3 4
8. 803 228 Add recommended oil until oil level indicator shows system is full see compressor mainte nance label for oil specifications Reinstall oil fill cap Tighten cap with wrench To replace air oil separator Loosen nut securing tube on separator base Lift oil scavenge tube from separator Turn fil ter counterclockwise Remove filter Apply thin coat of oil to gasket on new filter Install filter and turn clockwise Reinstall oil scavenge tube Start engine run air compressor and check for oil leaks A Stop engine OM 4409 Page 55 10 6 Adjusting Compressor Air Pressure leas DE Tools Needed 3 5 16 3 8 in Check compressor air pressure using air pressure gauge known to be accu rate necessary adjust air pressure as follows 1 Screw Loosen jam nut securing screw Turn screw clockwise increase pressure or counterclockwise decrease until pressure is 125 psi 862 kPa Maximum weld output is reduced if compressor air pressure is set above 125 psi 862 kPa Tighten nut 2 Pressure Relief Valve Pressure relief valve opens and re leases pressure at 150 psi 1034 kPa The pressure relief valve is not adjustable 803 228 OM 4409 Page 56 SECTION 11 TROUBLESHOOTING 11 1 Troubleshooting Tables Rh 4 Welding Trouble Remedy No weld output generato
9. V TITI Remove rod Move torch to front of pool Repeat process ST 162 002 B OM 4409 Page 78 18 3 Positioning Torch Tungsten For Various Weld Joints 90 Butt Weld And Stringer Bead IN 702 Jj 20 20 T Joint 70 a 20 10 40 Lap Joint 70 20 30 Corner Joint 90 162 003 5 0792 4409 79 SECTION 19 PARTS LIST 07 Hardware is common and not available unless listed 146 Figure 19 5 42 1 144 Figure 19 3 Figure 19 1 Main Assembly OM 4409 Page 80 150 803 324 4409 81 Dia Part No Mkgs No Description Quantity Figure 19 1 Main Assembly bie Eae ey 189824 Panel Gen LH 1 EN 189828 Panel Engine Sida e cie aa DI CITATI TR ae 1 DUO SE 206601 Panel Engine Extension LH 1 4 208277 Reactor AC Environmental 1 5 CR7 188636 Relay Control Battery Charging 1 GO ohn sa nares ss 081499 Bracket Mtg Strip Terminal Battery Charging 1 038620 Link Jumper Term 30 Amp
10. Use switch to select weld battery charge output Output automatically decreases but does not stop when terminal voltage is 15 to 25 percent above required battery voltage EF Before connecting charging cables place Output Selector switch in position match ing voltage of battery being charged 12 VOLT 4 DO NOT SWITCH UNDER LOAD CHARGE When done charging stop engine or set Pro cess Contactor switch to any Remote On Off Switch Required position Move Output Selec tor switch to AC Weld or DC Weld position 24VOLT CHARGE MATCH VOLTAGE amp POLARITY TO BATTERY BEFORE CHARGING CHARGE IN LOWEST AMPERAGE RANGE TO EXTEND BATTERY LIFE 803 231 A 210 149 B 8 2 Determining Battery Charging Current 1 1 Battery Charging Current i Chart 400 Find battery cold crank amp CCA Q rating on battery Use CCA rating 350 chart to find charge current set ting for battery Z EXAMPLE If battery CCA rating is 300 ff 500 charging current from chart is tc 100 amperes 2 250 Do not exceed charging current 9 found on chart For longer battery 2 200 life use lowest charge rate Z possible lt 150 I 2 100 f E 50 S 0 0 500 1000 1500 2000 BATTERY COLD CRANK AMP RATING CCA 142 975 OM 4409 Page 39 8 3 Battery Charge Cable Connections gt gt
11. 49 9 8 Engine Generator Overload Protection ss 50 SECTION 10 AIR COMPRESSOR MAINTENANCE 51 10 1 Air Compressor Maintenance Label 51 10 2 Routine Air Compressor Maintenance 52 10 3 Servicing Compressor Air Cleaner 4 53 10 4 Compressor Overload Protection 54 10 5 Servicing Air Compressor 55 10 6 Adjusting Compressor Air Pressure 56 SECTION 11 TROUBLESHOOTING 57 1121 Troubleshooting Tables 22 Sas LEWIS RENE ESL NUR AA 57 SECTION 12 AIR COMPRESSOR DIAGRAM 61 SECTION 13 CIRCUIT DIAGRAM 62 SECTION 14 RUN IN PROCEDURE 64 14 1 Wetstacking onte zd yadda phy gona 64 14 2 Procedure Using Load 65 14 3 Run In Procedure Using Resistance Grid 66 SECTION 15 AIR COMPRESSOR
12. Ree Foun X ond RE AURA RA 1 5 Additional Symbols For Installation Operation And Maintenance 1 6 California Proposition 65 Warnings 1 7 Principal Safety Standards 1 8 EMFE Informatior trees EP Pa E Pee te E eaae er Dont TORRE ERR SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 2 1 Signification des symboles ois eis mee hb ee a hh ey Yer 2 2 Dangers relatifs au soudage l arc 2 3 Dangers existant en relation avec le moteur 2 4 Dangers li s lair comprim 2 5 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 2 6 Proposition californienne 65 Avertissements 2 7 Principales normes de s curit 2 8 Information EMF 2 keeper BRI OPCION RPM NE PS SECTIONS DEFINITIONS 5 20 EXE Deni eee eee ee 3 1 Symbols And Definitions 4 SECTION 4 SPECIFICATIONS ve eve Ex mE Rma oen qx 4 1 Weld Power And Engine Speci
13. TL ate Engine Starting Controls 1 Starting Aid Switch Use switch to energize starting aid for cold weather starting Push switch up for 60 seconds to operate the starting aid intake air heater before cranking engine see starting instructions following 2 Engine Control Switch Use switch to start engine select engine speed and stop engine In Run position engine runs at weld power speed In Run ldle position engine runs at idle speed with no generator power or weld load and weld power speed with load ap plied The air compressor load does not affect en gine speed Run engine at weld power speed for maximum air compressor output To Start gt If engine does not start let engine come to a complete stop before attempting re start Above 32 F 0 C turn Engine Control switch to Start Release Engine Control switch when engine starts Below 32 F 0 C using starting aid Switch Turn Engine Control switch to Run ldle posi tion Push Starting Aid switch up for 60 sec onds While still holding Starting Aid switch turn Engine Control switch to Start Release Engine Control switch and Starting Aid switch when engine starts To Stop turn Engine Control switch to Off position Engine Compressor Gauges 3 Engine Hour Meter Use gauge to monitor engine running time for scheduling maintenance 4 Fuel Gauge Use gauge to check fuel level Engine stops if fuel level is l
14. 4409 206 941V 2007 05 Miller Stick SMAW Welding MIG GMAW Welding Flux Cored FCAW Welding TIG GTAW Welding Pm Air Carbon Arc CAC A ld Cutting and Gouging With Optional Equipment Battery Charging Description E a4 Engine Driven Welding Generator And Air Compressor Big Blue Air Pak OWNER S MANUAL File Engine Drive Visit our website at www MillerWelds com From Miller to You Thank you and congratulations on choosing Miller Now you can get the job done and get it done right We know you don t have time to do it any other way That s why when Niels Miller first started building arc welders in 1929 he made sure his products offered long lasting value and superior quality Like you his customers couldn t afford anything less Miller products had to be more than the best they could be They had to be the best you could buy Today the people that build and sell Miller products continue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 n U 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 hard as you do every power source from will help you protect yourself against potential hazards on the worksite Miller
15. 2 p De 084999 Pipe Brs Elbow St 45 1 4 Npt 1 dass 117826 Pipe Brs Nipple Close 1 4 Npt 2 RE 210053 Valve Pressure Regulator 1 D ICT RM 071270 Pipe Brs Tee St 1 4 Npt 071 269 1 pug cet 209854 Ftg Pipe Adapter M 1 4 Npt X 1 4 Line 4 zd Eres 218602 Hose Nylon Blue 44 000lg 1 ed santa Beate 210040 120 2 151662 Pipe Brs Plug Hex 125 1 218601 Hose Nylon Red 36 0001g 1 T4 210054 Valve Automatic Blowdown 1 206746 Switch Pressure 20psi 1 602965 Pipe Brs Tee 1 8 Npt 1 ne ie 209635 Hose Assy w Fittings 42 3609 1 209621 Stl Adapter 3 4 Sae 3 4 Jic 1 TO 210051 Valve Check Minimum Pressure 1 ES 209767 Pipe Stl Conne
16. Grounding Electrically bond generator frame to vehicle frame by metal to metal contact A Bed liners shipping skids and some running gears insulate the welding generator from the vehicle frame Always connect a ground wire from the generator equipment grounding termi nal to bare metal on the vehicle frame as shown installa 8 06 Ref 800 652 Ref 800 477 803 274 804 712 OM 4409 Page 22 5 2 Mounting Welding Generator Supporting The Unit A Do not weld on base Weld ing on base can cause fuel tank fire or explosion Weld only on the four mounting brackets or bolt unit down A Do not mount unit by sup porting the base only at the four mounting brackets Use cross supports to ade quately support unit and pre vent damage to base Mounting Surface 1 Cross Supports 2 Mounting Brackets Supplied Mount unit on flat surface or use cross supports to support base Secure unit with mounting brack ets 3 1 2 in Bolt And Washer Minimum Not Supplied 4 3 8 16 x 1 in Screws Supplied To Bolt Unit In Place 1 Remove hardware securing the four mounting brackets to the base Reverse brackets and reattach to base with original hardware Using Mounting Brackets Mount unit to truck or trailer with 1 2 in 12 mm or larger hardware not supplied To Weld Unit In Place Weld unit to truck or trailer only at the four mounting brackets
17. PLG10 150316 Conn Rect Univ 039 6p S 3row Plug Cable Lkg 1 s s CB5 139266 Supplementary Protector Man Reset 1 15a 250vac Frict 1 Ue Matte CB6 139266 Supplementary Protector Man Reset 15 250vac Frict 1 uw 202209 Spacer Nylon 221 2 9 PC6 192995 Circuit Card Assy Connector Receptacle 1 2105250 51 212436 Switch Ignition 4 Position W Handle 1 SAV 10 206624 Switch Tgl Sptt 6a 125vac Spd Term Included In Engine Hata aca Wiring Harness See Figure Figure 19 2 1 125 2 S2 021467 Switch Spst 250v Off none On Spd Term Included In Engine D Wiring Harness See Figure Figure 19 2 1 13 CB1 201083 Supplementary Protector Man Reset 2p 20a 250 1 pps uu tM ons 201553 Clip Retaining Circuit Breaker 1 TOIT 201109 Harness Receptacle Auxillary Power includes 1 14 CB2 093996 Supplementary Protector Man Reset 1p 20a 250vac Frict 1 15 GFCH 151981 Rept Str Dx Grd 2p3w 15 20a 125v 5 20r 1 16 147632 Rept Tw Lk Grd 2p3w 30a 250
18. Welding Unit In Place Bolting Unit In Place Tools Needed 3 9 16in install3 8 06 803 274 200 864 A 803 602 4409 23 5 3 Installing Optional Spark Arrestor Muffler Stop engine and let cool Spark Arrestor Muffler Double Flanged Elbow Nut Flat Washer Mount Bracket Screw Single Flanged Elbow Rain Cap 10 Clamp Loosely assemble components as shown os ous on Mount the muffler with the clean out plug to the outside After assembly final tighten all clamps and hardware Lx Be sure to tighten rain mounting screw Tools Needed 7 16 1 2 in 803 230 OM 4409 Page 24 5 4 Activating The Dry Charge Battery If Applicable 5 A For 30 Minutes OR 30 12 Minutes Tools Needed 8 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 Electrolyte 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
19. CE Section 250 GS Ce 10 3 5 Unreadable Labels Belt Tension Cooling System Air Filter Element Worn or Damaged Air Oil Hoses Every Section 500 10 5 Hours Oil O Oil Filter Every Section 1000 10 5 Hours Air Oil Separator OM 4409 Page 52 10 3 Servicing Compressor Air Cleaner Keep nozzle 2 in 51 from element M QU 55906 ANNA AN WO 7 9 p KX amp Ke TS XR 99500 ROK 555 A x XX 2 ON x X NA P Inspect A Stop engine NOTICE Do not run air compressor without air cleaner or with dirty element Compressor damage caused by using a damaged element is not covered by the warranty 1 Compressor Air Cleaner Remove engine air cleaner cover and element to access compressor air cleaner see Section 9 4 5 The air cleaner primary element be cleaned but the dirt holding capac ity of the filter is reduced with each cleaning The chance of dirt reaching the clean side of the filter 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
20. Stop engine Do not touch hot exhaust pipe engine parts or load bank grid gt Keep exhaust and pipe away from flammables NOTICE Do not perform run in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur 1 Resistance Grid Use grid sized for generator rated output Turn Off grid 2 Welding Generator Place A V range switch in maxi mum position A V control in mini mum position and Output Selector switch if present in either DC position 3 Weld Cables Connect grid to generator weld output terminals using proper size weld cables with correct connec tors polarity is not important 4 Voltmeter 5 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 ad just generator A V control so load equals rated voltage and current of the generator see nameplate rating label or the specifications section in this manual Check generator and meters after first five minutes then every fifteen minutes to be sure generator is loaded properly NOTICE Check oil level frequent ly during 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
21. gt ne Stop engine Do not charge or jump start a battery which has loose terminals or one showing damage such as a cracked case or cover Have only qualified persons do bat tery charging work Keep cables away from moving parts Do not use damaged cables Be sure charger output voltage matches battery voltage A Read BCI Battery Service Manual before charging or jump starting Before connecting to battery place Output Selector switch in position matching voltage of battery being charged 1 Battery 2 Battery Charging Cables For battery charging use less than 20 feet 6 1 m of AWG 1 or larger cable For jump starting use less than 20 feet 6 1 m of AWG 2 0 or larger cable 3 Terminal Lug 803 231 A 210 156 Ref S 0714 Ref S 0756 Use lugs of proper amperage capacity and hole size for connecting to charge output terminals Install suitable connectors on remaining ends of battery cables 4 Battery Charge Positive Output Terminal 5 Battery Charge Negative Output Terminal x Connect charging cables to battery charge output terminals before con necting to battery terminals Connect Battery Charge Positive cable to battery positive terminal and battery Charge Negative cable to battery nega tive terminal OM 4409 Page 40 8 4 Battery Charging Procedure wc Stop Engine Determine Charge C
22. 3 4 1 201749 Upright Rear Radiator 1 Dos vertu cen 201006 Bolt J 51 312 18 X 7 750 Pld 2 67 BATT 190897 Battery Stor 12v 650 Crk 110 Rsv Gp 24 Free 1 ia OG six ege 108081 Terminal Protector Battery Post Mtg 2 190206 Cable Bat Neg 42 In Lg 2 Awg W Clamp 4 375 Rng 1 bx TO ns 190207 Cable Bat Pos 45 In Lg No 1 Awg W Clamp amp 406 Rng 1 xd d PR 203430 Bracket Battery Holddown 1 201183 Cover Battery Access 1 ees CO sigas na d 168385 Label Warning Battery Explosion Can Blind 1 bat TA M 225120 Label Warning Moving Parts Can Cause Injury 7 dE tas 206602 Panel Engine Extension 1 207270 Guard Farm RH voee e CA Re i GC de a ae 1 via d oer ta 210229 Label Compressor Oil Fill 1 Figure 19 6 Air Compressor Assembly 1 rds 208024 Pulley Fan Assy W Bearings 1 206613 Bracket Fan Altern
23. 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 sistive load and requires approxi mately six times more power while starting the motor than when running see Section 16 8 3 Rating Data Rating shows volts and amperes or watts required to run equipment Amperes x Volts Watts Example 1 If a drill uses 4 5 am peres at 115 volts calculate its run ning power requirement in watts 4 5Ax115V 2 520W 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 4409 Page 70 16 5 Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1 8 HP 800 300 1 6 HP 1225 500 1 4 HP 1600 600 1 3 HP 2100 700 1 2 HP 3175 875 Capacitor Start Induction Run 1 3 HP 2020 720 1 2 HP 3075 975 3 4 HP 4500 1400 1 6100 1600 1 1 2 HP 8200 2200 2 10550 2850 3 HP 15900 3900 5 HP 23300 6800 Capacitor Start Capacitor Run 1 1 2 HP 8100 2000 5 HP 23300 6000 7 1 2 HP 35000 8000 10 HP 46700 10700 Fan Duty 1 8 HP 1000 400 1 6 HP 1400 550 1 4 HP 1850 650 1 3 HP 2400 800 1 2 HP 3500 1100 16 6 Appr
24. Closed Position A Air pressure is present at air shutoff valve whenever Air Pressure Gauge on front panel indicates air pressure 1 3 4 Air Pressure Fitting 2 Air Shutoff Valve Connect air hose with 3 4 in NPT fitting not supplied to air shutoff valve Be sure valve is in open position when us ing air compressor The compressor runs and air pressure is available whenever the engine is running and the front panel Compressor switch is moved to the On position see Section 6 1 Run engine at weld power speed for maxi mum air compressor output Compressor output is reduced when engine is running at idle speed A Stop engine and release air pres sure before servicing compressor 803 231 The air compressor will not start if still under pressure If air compressor is turned off wait for air pressure to bleed off about 20 seconds before turning air compressor on again EF Using the air compressor does not sig nificantly affect weld or generator pow er output OM 4409 Page 31 SECTION 6 OPERATING THE WELDING GENERATOR 6 1 Controls See Section 6 2 15 010100012 Pd 5 8 x 3 30 GE o A E 5 B SQ 803 229 217 356 A OM 4409 Page 32 6 2 Description Of Controls See Section 6 1
25. OM 4409 Page 41 8 5 Jump Starting Procedure REMOTE ON OFF SWITCH REQUIRED Stop Engine Set Process Contactor Switch To Any Remote On Off Switch Required Position SJ ves Set Ampere Range Switch To 300 Max Position NOTICE Do not switch under load Connect Cables Observe Correct Polarity When Equipment Starts Stop Welding Generator And Disconnect Cables Charge battery for 10 minutes before jump starting battery VOLTAQE amp POLARITY TO BATTERY BEFORE CHARINA CHARGE IN LOWEBT AMPERAGE RANGE TO EXTEND BATTERY LIFE Set Output Selector Switch To Voltage Of Battery Being Charged 12 Or 24 Volt NOTICE Do not switch under load gt A Connect Remote Control Device TON Momentary On go Sk Switch Press close switch only while cranking engine of equipment being started ALT Lg OFF START OFF START gt Start Engine Press Close Remote Momentary On Stop Engine Switch While Cranking Engine Of Equip Disconnect ment Being Jump Started Release Switch Cables OM 4409 Page 42 ENGINE GENERATOR MAINTENANCE tenance Label SECTION 9 Engine Main 9 1 0200 90 ut 2100 eo 4 20 0 02 GSb 0GGd uospleuoq 969t ZLI zineq 412 990 HATIIN c 2850964 uospjeuog 261 amp ds
26. Receptacle GFCI1 2 240V 16A AC European Receptacle RC1 3 240V 15 A AC Australian Receptacle RC1 4 240V 15A AC South African Receptacle RC1 Receptacles supply 60 Hz single phase power at weld power speed If a ground fault is detected the GFCI Reset button pops out and the receptacle does not work Check for faulty tools plugged in receptacle Press button to reset GFCH EF At least once a month run en gine at weld power speed and press test button to verify GFCI is working properly 5 Supplementary Protector CB2 6 Supplementary Protector CB3 CB2 protects from overload If CB2 opens GFCI1 does not work Place button to reset breaker CB3 protects RC1 from overload If opens RC1 does not work Press button to reset breaker 5 If a supplementary protector continues to open contact Factory Authorized Service Agent x Generator power is not af fected by weld output Maximum output is 2 4 kVA kW from GFCI1 and 4 kVA kW from RC1 Maximum output from all re ceptacles is 4 kVA kW EXAMPLE If 13 A is drawn from RC1 only 7 Ais available at 240 V x 13 A 120 V x 7 A 4 0 191 624 OM 4409 Page 38 SECTION 8 OPERATING OPTIONAL BATTERY CHARGER 8 1 a Mii d Controls 1 Output Selector Switch NOTICE Do not switch under load Stop en gine or set Process Contactor switch to any Remote position before switching P373
27. 5 67 15 1 Flow Of Free Air CFM Through Orifices Of Various Diameters 67 15 2 Approximate Air Consumption Cubic Feet To Operate Pneumatic Equipment At 70 90 P S I G 68 SECTION 16 GENERATOR POWER GUIDELINES 69 SECTION 17 SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING 76 17 1 Selecting Tungsten Electrode Wear Clean gloves To Prevent Contamination Of Tungsten 76 17 2 Preparing Tungsten Electrode For Welding With Phase Control Machines 76 SECTION 18 GUIDELINES FOR TIG WELDING GTAW 77 18 1 Positioning The ue entem ERU e Rea 77 18 2 Torch Movement During Welding 78 18 3 Positioning Torch Tungsten For Various Weld Joints 79 SECTION 19 PARTS LIST isso pie x eie x RD RC RUE 80 WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 2007 04 Protect yourself and others from injury read and follow these precautions 1 1 Symbol Usage DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury The possible hazards are shown in the adjoining symbols or
28. Place switch in Remote On Off Switch Required positions to turn weld output on and off with a device connected to the remote 14 receptacle Place switch in Weld Terminals Always On positions for weld output to be on whenever the engine is running Use Stick position for air carbon arc CAC A cutting and gouging When switch is in a Stick position the arc drive dig circuit provides addition al amperage during low voltage short arc length conditions to prevent stick ing electrodes The arc drive dig circuit is disabled when switch is in MIG or TIG positions gt The engine auto idle option does not work in the Remote On Off Switch Required TIG mode 217 356 A Process Contactor Switch Settings Switch Setting Process Output On Off Control Engine Auto Idle Optional Remote On Off Switch Re quired TIG HF Required ee UM At Remote 14 Receptacle Not Active Or Scratch Start TIG Stick SMAW With Remote On Off At Remote 14 Receptacle Active Remote On Off Switch Required CV Feeder MIG GMAW At Remote 14 Receptacle Active Using Remote wee ona MIG GMAW Electrode Hot Active Stick SMAW Weld ways On Air Carbon Arc Cutting Electrode Hot Active And Gouging 22 p TIG Scratch Start GTAW Electrode Hot Active OM 4409 Page 34 6 4 Using Remote Voltage Amperage Control Fa 1 Remote 14 Receptacle RC14
29. des tincelles peuvent tomber sur des substances inflammables Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures Surveiller tout d clenchement d incendie et tenir un extincteur proximit Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t 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 Ne soudez pas si l air ambiant est charg de particules gaz ou va peurs inflammables vapeur d essence par exemple Brancher le cable de masse sur la pi ce 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 incendie Ne pas utiliser le poste de soudage pour d geler des conduites ge l es En cas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact 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 h
30. HOIH a Hari 209 059 Na T HOlVHVd3S o 110 AHVHNIHd A WO9 Nd 39lIHO H3ETIJ 3ATVA MO3HO 39N3AVOS HO1LVH VAS a4nsSS2Hd xIaWassy AAWA 13 uaria Figure 12 1 Circuit Diagram For Air Compressor OM 4409 Page 61 SECTION 13 CIRCUIT DIAGRAM PLG1 RC1 9 100 100 RAN 100 5100 STANDARD 72 25 RECEPTACLE al 5 3 3 9 22 7 707 101 PACKAGE fer gt 703 51 2 D gt 4 22 OCA 55 OFF RUN RUN IDLE START 2 9 R lt 406 5 gt 106 124 6 gt 704 gt Ey g lE gt 9 gt 3 E EM ij Jo Sh T T GFCI1 120V Bec ar 120V E 8 8 L_4 8 E 4 PLG3 RC3 X CLOSED TO oH ME 1B TERMINAL AUX 2 n 2 i gt STATOR I 2 85 4 GND 4 225 542 l A 5 A 3 722 45 102 52 703 6 703 108s 7 106 gt 405 8 105 70 108 240V 102 gt gt 9 gt RECEPTACLE 1 RS 0 PA
31. wel PIS 0001 9vHd Weg anaq 992 290 H3TIIIN mt 02 MOc O MS Gb 11 1701 t 19 39 09 SvVZ 1X 99 808 206 YATIIN 2 1 i PIS 066 68797 892228 856 261 YATIIN 06797 69 cc8d 656 261 HATIIN 9 gt 8 2 4 4 9008 4 AA 2 18 926 WLSV ZY LY 698 58 il 40 981 v 099 109 LS NIG lt 2 1 2 26 tz 108 BE AGE 7Tasaia 0981 gt Secr lt E EE lt INVA zinaa 4409 43 9 2 Routine Engine Generator Maintenance See Section 10 air compressor maintenance information gt g Gh w s Recycle engine A Stop engine before maintaining See Engine Manual and Maintenance Label for important start up service and storage fluids information Service engine more often if used in se
32. 198560 Clip Spring hee ad WY PATER NER caret 3 Ou simon 189142 Brushholder Assy Generator 1 602242 Washer Flat 375idx0 8750dx 083t Stl 2 BO cs e aeu 602211 Washer Lock 318idx0 5860dx 078t Stl Pld Spli 312 2 SO rage 604534 Screw 312 18x1 25 Hex Gr5 2 When ordering a component originally displaying a precautionary label the label should also be ordered 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 OM 4409 Page 92 Hardware is common and not available unless listed 802 279 A Figure 19 5 Main Rectifier Assembly Item Dia Part No Mkgs No Description Quantity Figure 19 5 Main Rectifier Assembly Figure 19 1 Item 146 583 215910 Rectifier environmental includes 1 Em MT 188137 Connection Board Rectifier Ac 1 E 1 188517 Bus Bar Conn 3 188135 Enclosure Rectifier 2 Ser 134201 Stand off Suppor
33. 5 Have qualified person install ac cording to circuit diagram and Generator Power Guidelines see Section 16 Remove power panel screws Tilt panel forward Lead 93 Lead 92 Lead 91 Lead 42 Circuit Grounding Lead Lead 90 Neutral Isolated Neutral Terminal mounting N Da 9 10 Grounding Terminal Jumper Lead 42 Jumper 42 is connected to lead 90 at factory Jumper 42 may be discon nected from neutral to meet applicable electrical codes Lead 42 connects to front panel Ground stud 11 12 Supplementary Protector CB7 User Terminals User Supplied Leads Connect user supplied leads to termi nals on CB7 and to the isolated neutral terminal and grounding terminal as necessary Supplementary protector pro tects single phase receptacle RC5 and the load wires from overload If CB7 opens all ac power plant output stops and the receptacle does not work Reinstall power panel OM 4409 Page 37 7 3 Optional Generator Power Receptacles European Receptacle 120 20 1 60 Hz 240 V 15A Australian Receptacle 120 V 20A 1 60 Hz 240 15 3 d 7 120 V 20A 1 60Hz 240V 15A South African Receptacle 5 1 4 1 120V 20 A AC
34. AMPERES 240V MODE 0 10 20 30 40 50 60 AC AMPERES IN 120V MODE 193 018 Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual OM 4409 Page 18 4 10 Optional 3 Phase Generator Power Curves AC VOLTS The ac power curves show the gen erator power available in amperes at the single phase 120 240 volt re ceptacle or three phase 240 volt A 12 kVA kW Single Phase AC Output No Weld Load terminals 140 135 130 125 120 115 110 105 100 95 90 280 270 260 250 240 230 220 210 200 190 180 20 40 60 80 100 AC AMPERES 20 kVA kW Three Phase AC Output No Weld Load AC VOLTS 280 260 240 220 200 180 10 20 30 40 50 60 70 AC AMPERES 197 472 197 473 4409 19 4 11 Air Compressor Output Curve The air output curve shows the vol ume and pressure of air available from the air compressor 140 1204 100 Idle POUNDS PER SQUARE INCH PSI m 0 10 20 30 40 50 60 70 80 90 100 CUBIC FEET PER MINUTE 208 955 4 12 Optional Battery Charging Output Curve The battery charging curves show the charging amperage and voltage output of the welding generator As battery voltage
35. Connect optional remote control to RC14 see Section 5 10 803 231 In Example Process Stick Using Remote On Off Example Combination Remote Amperage Control Stick Range 125 to 400 ADC Min 125 ADC Max 400 A DC 12 PANEL 57 P Max 400 A DC gt REMOTE REMOTE ON OFF SWITCH REQUIRED En Min 125 A DC Set Set Remote 4 t Opt IR t trol m d Process gt Set Range i sacs OW OT gt dj st Optional emote Contro SES Switch Required Stick Mode In Example Process TIG Using Remote On Off Range 40 to 330 A DC Percentage Of Range 5096 Min 40 A DC Max About 185 A DC 50 of 40 to 330 Example Combination Remote Amperage Control TIG 1251400 185 7 9 Min 40 A DC Set Set Remote gt Set Range Set Control Panel Remote Process Switch 0774 Ref 217 356 A 803 231 Adjust Optional Remote Control OM 4409 Page 35 SECTION 7 OPERATING AUXILIARY EQUIPMENT 7 1 120 Volt And i Volt Receptacles AE i K 2 A E A 7 120 V 20A 17 60 Hz 240 V 20A 1 120V 20 A AC Receptacle GFCI1 2 240V 30A AC Twistlock Receptacle RC1 Receptacles supply 60 Hz single phase power at weld power speed If a ground fa
36. lt 90 mm 42 Ce TS o 85 E NEGATIVE WORK CB7 27 AUX POWER OPTION A e e 42 Ts BATTERY CHARGE GND gt OPTION 24 PC5 4 9 29 71 o eh 5 AN 15 gt POSITIVE 4 eg I O ZOCHARGE 1 i RECTIFIER 9 sis PROTECTION POS T t 0 12 Y WELD METERS DCO O CHARGE OPTIONAL on eb L NEGATIVE 02 AX 04 06 SR3 oe L3 2 32 BATTERY CHARGE se a EN WITH THE BATTERY CHARGE OPTION LEADS 19 amp 30 GO TO THE BATTERY CHARGE SWITCH RATHER THAN THE OUTPUT STUDS 47 37 77 132 i JO 7 130 PC7 pei 1 IDLE 5 E MODULE 6 53 EI I TIT TIE HTH FE 13 78 9 17 1 B 5 19 737 42 BATTERY N gt 133 m 4 re e L 4 D 6 1 6 1 6 1 6 1 6 1 Bog ie fe fe fe 42 4 3 4 3 4 3 4 3 ee 4 3 omm HOUR METER HEATER 7 m OPTION O OIL COOLANT ee evel AR mE PRESSURE wa SENDER SENDER SENDER MEAN 42 42 42 42 2 42 2 MACHINE WIRE NUMBERS p 72 2 10 39 WELD SECONDARY 40 79 ENGINE CONTROLS E
37. 1 51 TEMP 217084 Gauge Engine Temperature 1 OIL 217083 Gauge Engine Oil Pressure 1 JD es A1 164873 Meter Amp AC DC 0 500 0 600 Dc Scale 2 5 In 1 54 209274 Xfmr Current Meters 1 DD V1 164874 Meter Volt AC DC 0 100 Scale2 5 In 1 06 cese nrbes 097922 Knob Pointer 875 Dia X 250 Id W Set Screwsplstc 1 AD eoe DS Sree eee 189161 Handle Switch Range 1 OG 010647 Pin Spring 156 1 250 1 errant 097924 Knob Pointer 1 625 Dia X 250 Id W Set Screwsplstc 1 I IE 072590 Lock Shaft Pot 375 32 X 250 Dia Shaft 1 aset I RU ep as 215207 Harness Unit Weld Control CV includes 1 PEE PLG6 114063 Conn Rect Univ 084 5 1row Plug Cable Lkg 1 bac PLG8 amp 193184 Conn Rect Cinch 30 Pin 1 147992 Conn Rect Univ 039 10 5 2row Plug Cable Lkg 1 PLG13 158465 Conn Rect Univ 084 12p S 3row Plug Cable Lkg 1 Pie bd EE od ei 088731 Bushing Snap in 375 Id X 500 Mtg Hol
38. 2 A Y 1 DE ES GLOW 9 PLUG AUX TD1 12 VOLT BATTERY gt gt 25 19 START eje 42 42 2 42 cnet ap START AD Figure 13 1 Circuit Diagram For Welding Generator OM 4409 Page 62 7752 pu BATTERY CHARGE RECEPTACLE PACKAGE a OPTION OPTIONS WITH THE BATTERY 22 CHARGE OPTION LEAD 98 GOES CR7 AND LEAD 97 GOES TO CB4 __ 1 MU CB4 n a RCS 120 240v POLARITY SWITCH OPTIONAL WITH THE POLARITY SWITCH OPTION LEADS 19 amp 30 GO TO THE POLARITY SWITCH RATHER THAN THE OUTPUT STUDS THE OUTPUT STUDS ARE LABELED ELECTRODE AND WORK LEADS 17 amp 37 ARE HOOKED DIRECT FROM THE RECTIFIER TO THE POLARITY SWITCH POSITIVE ELECTRODE po 1
39. 40 Volts DC At 500 Amps 44 Volts DC At 600 Amps Air Compressor On 96 6 Lwa sound power 71 7 dBa at 23 ft 7 m 77 2 dBA 3 3 ft 1 m from front panel 102 8 Lwa sound power 77 9 dBa at 23 ft 7 m 83 0 dBA 3 3 ft 1 m from front panel 103 9 Lwa sound power 79 0 dBa at 23 ft 7 m 89 8 dBA 3 3 ft 1 m from front panel 106 0 Lwa sound power 81 1 dBa at 23 ft 7 m 93 3 dBA 3 3 ft 1 m from front panel 104 5 Lwa sound power Air Compressor Off 94 6 Lwa sound power 69 7 dBa at 23 ft 7 m 74 5 dBA 3 3 ft 1 m from front panel 100 6 Lwa sound power 75 7dBa at 23 ft 7 m 78 8 dBA 3 3 ft 1 m from front panel 103 0 Lwa sound power 78 1dBa at 23 ft 7 m 86 0 dBA 3 3 ft 1 m from front panel 79 6 dBa at 23 ft 7 m 91 8 dBA 3 3 ft 1 m from front panel OM 4409 Page 13 4 4 Dimensions Weights And Operating Angles SF Front Panel End Dimensions 54 1 2 in 1384 mm Height to top of muffler 28 1 2 in 724 mm mtg brackets turned in Width 30 3 4 in 781 mm mtg brackets turned out Depth 69 1 2 in 1765 mm A 69 1 2 in 1765 mm B 55 7 8 in 1419 mm 46 3 8 in 1178 D 11 in 279 mm E 27 1 2 699 mm F 1 in 25 mm G 29 13 16 in 757 mm H 9 16 in 14 mm Dia 4 Holes With mounting brackets in center position Dimen
40. call 1 800 4 A Miller File a claim for loss or damage during shipment Contact the Delivering Carrier to For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA 2007 Miller Electric Mfg Co 2007 01 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 European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 www MillerWelds com 2 Miller
41. o lt lt lt Ig lt m m S 6 gt 78 OT UTI PLG13 4 gt 127 CONTACTOR 2 S lt lt lt G2 122 723 72 20 19 27 42 42 1395 A gt 27 mc 56 gt 2 i m B ELECTRODE REMOTE o gt 56 c1 gt 4 SWITCH LEAD STICK o D1 4 5 NUMBERS NUMBERS 215 TIG STICK MIG HT 1 2 119 120 x 14257 2 3 120 121 TIG RMT o 6 5 OL ALL HOT CR5 STICK RMT MIG RMT x S 5 6 122 123 6 7 123 124 x x t CB13 9 10 48 68 X X X X 11 12 84 98 X X CONTACT CLOSED PLG14 gt 22 di CBB DRYER Bh neater ROC 56 x OC gt 51 NS w o gt o CR1 OPTION _ e zd a Hn 4 1 67 RTE Tp imd 1 14 zsa pes 9 9 764 le zr 7 LES 6 D CR14 CR15 D sl le UT 47 CRO m D Woe 777 772 775 amp 2258 12 VOLT cB15 9 52 57 46 BATTERY DISCONNECT 9140 STARTER TM DS en c 50 23 gt FS1
42. 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 10 AWG or larger insulated 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 ceptacles use GFCI pro tected extension cord S 0854 OM 4409 Page 69 16 3 Grounding When Supplying Building Systems 1 Equipment Grounding Terminal 2 Grounding Cable Use 10 AWG or larger insulated copper wire 3 Ground Device EF Use ground device as stated in electrical codes 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 16 4 How Much Power Does Equipment Require VOLTS 115 2 AMPS 4 5 1 Hz 60
43. Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 Keep welding power source and cables as far away from operator as practical 5 Connect work clamp to workpiece as close to the weld as possible About Implanted Medical Devices Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding spot welding gouging plasma arc cutting or induction heating operations If cleared by your doctor then following the above procedures is recom mended OM 4409 Page 5 SECTION 2 CONSIGNES DE SECURITE LIRE AVANT UTILISATION rom_2007 04fre A Se prot ger ainsi que toute autre personne travaillant sur les lieux contre les tincelles et le m tal chaud 2 1 Signification des symboles 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 DANGER Indique une situation dangereuse qui si on peut donner la mort ou des blessures graves Les dan gers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte A Indique une situation dangereuse qui si on l vite pas NOTE Indique des d clarations pas en relation avec des blessures personnelles 2 2 Dangers relatifs au soudage l arc Les symboles pr sent s ci apr s sont tout au long du pr sent manuel p
44. Trouble Remedy Engine will not crank Check battery and replace if necessary Check battery connections and tighten if necessary Circuit breaker CB10 may be open CB10 automatically resets when fault is corrected see Section 9 8 Have Factory Authorized Service Agent check engine wiring harness and components Check engine wiring harness plug connections Turn optional battery disconnect switch to On position see Section 5 6 Have Factory Authorized Service Agent check Engine Control switch S1 control relay CR1 and diode capacitor board D8 C8 Engine cranks but does not start Check fuel level Optional low fuel shutdown stops engine if fuel level is low Reset supplementary protector CB13 see Section 10 4 Have Factory Authorized Service Agent check engine wiring harness and components Check battery and replace if necessary Check engine charging system according to engine manual Have Factory Authorized Service Agent check time delay relay TD1 control relay CR5 fuel pump and fuel solenoid FS1 Air in fuel system See engine manual Engine starts but stops when Engine Control switch is released Check oil level Automatic shutdown system stops engine if oil pressure is too low or engine temperature is too high see Section 5 7 Have Factory Authorized Service Agent check time delay relay TD1 and control relay CR5 Engine hard to start in cold weather
45. and HOT PARTS hazards Consult sym bols and related instructions below for necessary actions to avoid the hazards e Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet e When making input connections attach proper grounding conduc tor first double check connections Keep cords dry free of oil and grease and protected from hot metal and sparks e 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 e Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable a
46. 20 C1 D1 189701 Diode Capacitor Board 1 21 9 087110 Capacitor Elctlt 240 Uf 200 1 39 Di 1 22 en ee 177136 Clamp Capacitor 1 375 Dia 1 OM 4409 Page 86 Dia Part No Mkgs No Description Quantity Figure 19 2 Control Box Assembly Continued ach EN 217823 Label Layout Control Box 1 201079 Cover Control BOX 1 25 CR4 CR10 113247 Relay Encl 12vdc Dpdt 20a 120vac Flange 2 26 214928 Timer Delay On Make Break Open 30 Sec 12vdc 1 27 CB11 CB12 CB13 139266 Supplementary Protector Man Reset 1p 15 250vac Frict 3 Mu uos ANAL 217815 Harness Engine Deutz Bf4m2011 includes 1 156734 Nut 010 32 31hex 13h Stl Pld Sem Cone Wshr 38d 4 Pour A eati aM decide 148850 Socket Relay 5 Pin 5 S2 021467 Switch Tgl Spst 250v Off none On Spd Term Located On Front Panel See Figure 19 3 1 211292 Conn Body 5 Terminal For Ignition Switch S1 1
47. 60 70 90 105 120 aged undersized or poorly spliced cables 10 6096 60 100 Welding Duty Duty 10 100 Duty Cycle Amperes Cycle Cycle 100 4 20 4 20 4 20 3 30 2 85 160 10060 1 0 60 150 3 30 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 3 0 95 200 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 4 0 120 250 2 85 1 60 1 0 60 2 0 70 3 0 95 4 0 120 25 2ea 2 0 2ea 2 ea 300 1 50 1 0 60 2 0 70 3 0 95 4 0 120 on 2 aS 2 2 0 2ea 2 2 4 0 350 1 0 60 200 70 3 0 95 40 120 aa a et 2 2ea 2 0 2 2 ea 4 0 2 ea 4 0 400 1 0 60 2 0 70 3 0 95 4 0 120 a ea 2 on x 2 ea 2 0 2 ea 3 0 2 ea 4 0 3 3 0 3 ea 3 0 500 2 0 70 3 0 95 4 0 120 2x70 2x95 2x120 3x95 3x95 2 ea 2 0 2ea 3 0 2 ea 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 2 ea 3 0 2ea 4 0 3 ea 3 0 3 ea 4 0 3 ea 4 0 4 ea 4 0 199 4 0 120 2x70 2x95 2x120 3x95 3 120 3 120 4x120 2 ea 2 0 2 3 0 2 4 0 3ea 4 0 3 ea 4 0 4 ea 4 0 4 ea 4 0 890 4 0 120 2x70 2x95 2x120 3x120 3x120 4x120 4x120 This chart is a general guideline and may not suit all applications If cable overh
48. AND DISCLAIMED BY MILLER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province miller warr 2007 01 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair 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
49. AR RE PS 217356 Plate Screened Ident Control Rating 1 D cs Esa 215014 Panel Engine Weld Control 1 ade 53 208278 Switch Range Changeover 1 Bab ha ted E try ace din 192558 Harness Range Switch includes 1 DRE edid RC6 148389 Conn Rect Univ 084 4p S 1row Rcpt Cable Panel Lkg 1 4 R1 193118 Pot Flat 112 W 1k Ohm Linear 1 OM 4409 Page 88 Dia Part No Mkgs No Description Quantity Figure 19 3 Panel Front w Components Continued T 206809 Harness Weld Control includes 1 eus S6 193234 Switch Rotary 6 Position Gold Contacts 1 197257 Guard Circuit Breaker 56 Not Included w Harness 1 55 011609 Switch Spdt 15a 125vac Spd Term Chr 1 T PLG9 193183 Conn Rect Cinch 18 Pin 1 196603 Seal Switch 6 Position Rotary 250 Shaft 1 PLG14 141450 Conn Rect Metrmate 10skt 1row Plug Cable Lkg 1 164617 Clip Wiring Straight 2 T
50. Access Rh W Om Pocket 1 ee 209240 Door Access Lh 1 Tm 209236 Nab LOCKOUt een ea RI UE PRO NE NERA 209241 gt Mount eerie eae Ra eee 209242 Mount Access Lh 1 189975 Hinge Door Access 180 Deg 4 TO 155146 Sponge Nprn 060 1 000 Wide 4 000 Sce 41 Close When ordering a component originally displaying a precautionary label the label should also be ordered 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 OM 4409 Page 85 1 Tw 803 325 D Figure 19 2 Control Box Assembly Item Dia Part No Mkgs No Description Quantity Figure 19 2 Control Box Assembly Figure 19 1 Item 131 1 F1 F2 085874 Fuse Mintr Cer Slo blo 10 Amp 250 Volt 2 2 2 uu Ei 046432 Holder Fuse Mintr 250 X 1 250 Panel 2 een 134201 Stand off Support Pc Card 312 375w Post amp lock 43 3 4 PC9 192224 Circuit Card Assy Display
51. 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 18 400 400 Flood Lights HID 125 100 Metal Halide 313 250 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 4409 Page 72 16 8 Power Required To Start Motor Single Phase Induction Motor Starting Requirements Motor Start G H J K L M N Code KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0 1 Motor Start Code 2 Running Amperage 3 Motor HP x AC MOTOR 2 4 Motor Voltage fivouts_2s0 AMPS 254 ag CODE Hz 60 To find starting amperage N HP 1 4 PHASE 1 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
52. Safety 1 T 206556 Pipe Air Cleaner Intake Deutz Turbo Hose To Air Cleaner Hose 1 e esce 189763 Bracket Mtg Air Cleaner 1 dO Lisci 206351 Upright Center Assy 1 PT ares 189464 Seal Weather Lift Eye 1 197613 Air Cleaner Intake 5 250 In Compressor includes 1 23 L 197675 Dust Ejector Air Cleaner 1 197676 El ment AIF Gleaner seres e exer 1 197677 Cover Assy Air Cleaner 1 197678 Body Air Cleaner 1 eM en 197679 Element Air Cleaner Safety 1 gt iG van ia RAS 197829 Bracket Mtg Air Cleaner 1 206696 Hose Elbow Cleaner Compressor 1 198457 Tube Air Intake Perkins 104 1 ond osos 206697 Hose Elbow Air Cleaner Compressor 180 Degree 1 28 gus 207268 Hose Flexaust 2 000 Id X 22 000 1 seg erba 219140 Bracket Mtg Air
53. Tools Needed 9 i 3 8 in 803 228 803 230 OM 4409 Page 47 9 6 Adjusting Engine Speed Tools Needed 3 3 8 7 16 in A Stop engine and let cool Engine speed is factory set and should not require adjustment Af ter tuning engine check engine no load speed with a tachometer or fre quency meter see table for no load speeds If necessary adjust speed as follows Start engine and run until warm Turn Process Contactor switch to Weld Terminals Always On Stick position 1 Throttle Rod 2 Locknut Loosen locknuts Place engine control switch in Run Idle position Wait 15 seconds for throttle sole noid to energize and lower engine speed to idle rpm Turn throttle rod to adjust idle speed Tighten locknuts 3 Engine Speed Adjustment Screw 4 Locknut Place engine control switch in Run position Loosen locknut Turn screw to ad just weld power speed Tighten locknut Do not set engine speed higher than specified A Stop engine Close door c 3 1850 61 6 Hz gt 1235 41 1 2 803 228 802 313 4409 48 9 7 Servicing Engine Fuel And Lubrication Systems A 7 4 t3 Ab APES Tools Needed Stop engine and let cool After servicin
54. Use starting aid switch see Section 6 1 If Starting Aid switch does not work have Factory Authorized Service Agent check Engine Control switch S2 and control relay CR8 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 9 1 Engine suddenly stops Check fuel level Optional low fuel shutdown stops engine if fuel level is low Check oil level Automatic shutdown system stops engine if oil pressure is too low or engine temperature is too high see Section 5 7 Have Factory Authorized Service Agent check time delay relay TD1 control relay CR5 fuel pump and fuel solenoid FS1 See engine manual Engine slowly stopped and cannot be restarted Check fuel level Check engine air and fuel filters see Sections 9 4 and 9 7 See engine manual Battery discharges between uses Turn Engine Control switch S1 off when unit is not running Clean top of battery with baking soda and water solution rinse with clear water Recharge or replace battery if necessary Periodically recharge battery approximately every 3 months Engine idles but does not come up to weld speed Have Factory Authorized Service Agent check idle module PC7 Check for obstructed throttle s
55. 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 C Miller Effective January 1 2007 Equipment with a serial number preface of LH 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 S 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 eve
56. bare handed e Allow cooling period before working on equip ment To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns 1 4 Compressed Air Hazards BREATHING COMPRESSED AIR can cause serious injury or death e Do use compressed air for breathing e Use only for cutting gouging and tools COMPRESSED AIR can cause injury e Wear approved safety goggles e Do not direct air stream toward self or others STEAM AND HOT COOLANT can burn e f 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 Ifthe engine is warm checking is needed and there is 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 not tip battery e Replace damaged battery e Flush eyes and skin immediately with water ENG
57. circuits imprimes OM 4409 Page 10 entrainer 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 Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil e N utiliser que les pi ces de rechange recom mand es par le constructeur e Effectuer la maintenance et le service du moteur et du compres seur d air suivant les instructions dans ce manuel ou le manuel du moteur compresseur si applicable El UNE REMORQUE QUI BASCULE peut LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences 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 e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l instal lation e L utilisateur est tenu de faire corriger rapidement par un lectri cien qualifi les interf rences r sultant de l installation e Sile 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 e Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir
58. compressor on and off Air pressure is present at the compressor air shutoff valve whenever the compressor is running The compressor shuts off when the engine stops To use air the compressor must be turned on each time the engine is started The air compressor will not start if still under pressure If air compressor is turned off wait for air pressure to bleed off about 20 sec onds before turning air compressor on again E To extend clutch bearing life cycle air compressor off and on once every two hours during periods of extended use 18 Air Shutoff Valve A Air pressure is present at valve when ever Air Pressure Gauge item 5 indi cates air pressure Close valve to stop air flow when connecting or changing tools or air hoses see Section 5 11 OM 4409 Page 33 6 3 Process Contactor Switch WIRE Voltage Sensing Feeder CV 2 y CV Feeder s Using Remote REMOTE ON OFF SWITCH REQUIRED 1 Process Contactor Switch A Weld output terminals are ener gized when Process Contactor switch is in Weld Terminals Al ways On position and the en gine is running A DC voltage is still present at the HF Required Or Scratch Start weld terminals when Process Contactor switch is in the Re mote On Off Switch Required Stick position and the engine is running Use switch to select weld process and weld output on off control see table be low and Section 6 4
59. comprim d une chaleur excessive des chocs m caniques des dommages physiques du laitier des flammes ouvertes des tincelles et des arcs 2 3 Dangers existant en relation avec le L EXPLOSION DE LA BATTERIE peu RENDRE AVEUGLE e Toujours porter une protection faciale des gants en caoutchouc et v tements de protection lors d une intervention sur la batterie Arr ter le moteur avant de d brancher ou de brancher les c bles de batterie e Eviter de provoquer des tincelles avec les outils en travaillant sur la batterie Ne pas utiliser le poste de soudage pour charger les batteries ou des v hicules de d marrage rapide Observer la polarit correcte et sur les batteries e D brancher le c ble n gatif en premier lieu Le rebrancher en dernier lieu LE CARBURANT MOTEUR peut provo quer un incendie ou une explosion e 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 tincelles ou d une flamme nue Ne pas faire le plein de carburant ras bord pr voir de l espace pour son expansion e Faire attention de ne pas renverser de carburant Nettoyer toul 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 DES ORGANES MOBILES peuvent pro voquer des bless
60. de la soudure 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 4409 Page 11 SECTION 3 DEFINITIONS 3 1 Symbols And Definitions 5 Fast Run Weld c Stop Engine EON gt Slow Idle 2 Start Engine Check engine belt Check Air Cleaner Starting Aid Cy Engine Jump start Battery Battery Engine Charge Battery Charge Jump Start OPT Do Not Switch Read Operator s Certified Trained of Under Load b 9v Mechanic T A Engine Oil Check Injectors Check Valve Fuel 3 Engine Coolant Pump Clearance Temperature PPS IN Hourmeter HM Q Air Pressure Temperature Air Compressor Positive Negative olo Wire Feed n Welding Arc A Amperes V Volts Panel Local Remote Output Direct Current Alternating L Gas Tungsten Arc sipu DC Current AC DE Welding TIG 7 Stick GMAW Constant Current G MIG GMAW Constant Voltage Welding CC Welding CV Air Carbon Arc Protective Earth 3 7 Three Phase 1 7 Single Phase GE Cutting Ground DC Electrode DC
61. duite Dans la plupart des cas un poste courant continu de type CV est recommand Et ne pas tra vailler seul 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 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 Ne pas enrouler les cables autour du
62. 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 The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 7 Read and follow all Safety Standards A Only qualified persons should install operate maintain and repair this unit A During operation keep everybody especially children away FA e ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks 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 equip 5 a hazard e Do not touch live electrical parts Wear dry hole free insulating gloves and body protection e Insulate yourself from work
63. if used in dirty humid conditions 10 1 Air Compressor Maintenance Label Ingersoll Rand approved oil amp filters INGERSOLL RAND S must be used to maintain 3 yr warranty AIR COMPRESSOR e y 125 F to 10 F 125 F to 40 F PRO TEC 36899698 Synthetic ATF MILSPEC MILSPEC MIL PRF 2104G SAE 10W MIL L 46167 CH 52 C to 23 C 52 C to 40 C Ingersoll Rand Mobil 1 3 81 4 qt MILLER 206 745 Ingersoll Rand 39329602 MILLER 197 679 Donaldson P822858 1000 h 1 yr std WIX 42985 7 e 5 MILLER 197 676 aia Donaldson P821575 MILLER 218 609 WIX 46438 Gates K060578 Air Oil Separator MILLER 206 747 Ingersoll Rand 89259337 OM 4409 Page 51 10 2 Routine Air Compressor Maintenance See Section 9 for engine generator maintenance information KY A Stop engine before maintaining 7 ee C3 Recvcle air See Compressor Maintenance Label for im ine ebp portant start up service and storage infor fluids mation Service air compressor more often if used severe conditions Check Change Clean Replace Reference To be done by Factory Authorized Service Agent Every Section 5 7 8 Hours Spills Oil Level Every 100 Hours Air Cleaner Hoses Every
64. 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 heaters etc See Section 16 4 OM 4409 Page 74 16 11 Selecting Extension Cord Use Shortest Cord Possible gt Cord Lengths for 120 Volt Loads 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 5 600 350 106 225 68 137 42 100 30 7 840 400 122 250 76 150 46 100 30 62 19 10 1200 40
65. 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 Si le moteur est chaud et que le liquide doit tre v rifi op rer com me suivant Mettre des lunettes de s curit et des gants placer un torchon sur le bouchon du radiateur 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 TUER EN QUELQUES MINUTES Lesfum es d un groupe autonome contient du monoxyde de carbone C est un poison invisi ble et inodore JAMAIS utiliser dans une maison ou garage m me avec les portes et fen tres ouvertes e Uniquementutiliser EXTERIEUR 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 Ne pas renverser la batterie e Remplacer une batterie endommag e e Rincer imm diatement les yeux et la peau l eau 2 4 Dangers li s l air comprim RESPIRER L AIR COMPRIM peut pro voquer des blessures graves ou causer la mort e Ne pas utiliser l air comprim pour respirer e Utiliser l air comprim seulement pour le cou page gougeage et les outils pneumatiques L AIR COMPRIM peut provoquer des blessures e Porter des lunettes de s curit approuv es Ne pas diriger le jet d air vers d autres ou soi m me L AI
66. les clateurs une dis tance 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 e 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 cables de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre e Veiller souder une distance de 100 m tres de tout quipe ment lectronique sensible e Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi e 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 6 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 des mal formations cong nitales et dans cert
67. protect others from flash 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 WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding Remove all flammables within 35 ft 10 7 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 4409 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 c
68. we strongly recommend instal ling an optional safety element to pro vide additional air compressor protection Never clean a safety ele ment Replace the safety element af ter servicing 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 2 Housing 3 Safety Element 4 Primary Element 5 Cover 6 Dust Ejector To clean air filter Wipe off cover and housing Remove cover and dump out dust Remove ele ment s Wipe dust from inside cover and housing with damp cloth Reinstall safety element if present Reinstall cover 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 cover dust ejector down aircleaner1 9 02 803 228 153 929 B 153 585 Ref 0698 OM 4409 Page 53 10 4 Compressor Overload Protection A Stop engine ee When a circuit breaker or fuse opens it usually indicates a more serious problem exists Contact Factory Authorized Service Agent See Section 9 8 for engine genera tor overload protection 1 Circuit Breaker CB15 Circuit breaker CB1
69. 0 122 275 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 maximum 2 voltage drop Cord Lengths for 240 Volt Loads 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 18 20 4800 450 137 275 84 175 53 100 31 60 18 25 6000 350 107 225 69 125 38 75 23 30 7000 300 91 175 53 100 31 75 23 35 8400 250 76 150 46 100 31 40 9600 225 69 125 38 75 23 45 10 800 200 61 125 38 50 12 000 175 53 100 31 Conductor size is based on maximum 2 voltage drop OM 4409 Page 75 SECTION 17 SELECTING AND PREPARING TUNGSTEN FOR DC OR AC WELDING gtaw_Phase_2007 04 Whenever possible and practical use DC weld output instead of weld output 17 1 Selecting Tungsten Electrod
70. 1 5 4 Activating The Dry Charge Battery If Applicable 5 5 Connecting The Battery 1 5 6 Using The Optional Battery Disconnect 2 5 7 Engine Compressor Prestart Checks 5 8 Connecting To Weld Output Terminals 5 9 Selecting Weld Cable Sizes 225 eer err er ex ET POE Ea Yu x 5 10 Connecting To Remote 14 Receptacle RC14 5 11 Connecting To The Air Compressor SECTION 6 OPERATING THE WELDING GENERATOR 6 1 Controls See Section 6 2 6 2 Description Of Controls See Section 6 1 6 3 Process Contactor Switch 6 4 Using Remote Voltage Amperage Control TABLE OF CONTENTS SECTION 7 OPERATING AUXILIARY EQUIPMENT 36 7 1 120 Volt And 240 Volt Receptacles 36 7 2 Connecting To Optional AC Power Plant
71. 1 Le 084999 Pipe Brs Elbow St 45 1 4 1 aT cure ERAS 176518 Pipe Brs Elbow St 1 4 Npt 1 MT beate Deleted aba e vea S MIA V ta pti aa eet OM 4409 Page 95 Dia Part No Mkgs No Description Quantity Figure 19 5 Air Compressor Assembly Continued DS 206698 Plate Mtg Compressor To Bracket 1 218305 Valve Inlet Unloader 9099 1 uncut ea i 210016 Gasket Unloader Valve 1 55 CLUTCH 210055 Clutch Electro Magnetic 12vdc W 5 75 Dia Pulley 1 56 218609 Belt Micro V 21mm X 1485mm 1 bel os sta un 206800 Pulley Crankshaft 1 DS 210001 Airend Gear driven W Tapered Input Shaft 1 9 ce save es 209853 Pipe Stl Adapter M M16 1 5 X 1 2 1 tiens 209634 Hose Tubing Assyw Fittings 15 860lg 1 esce 206558 Cooler Engine Compressor 1 262 s 209851 Pipe Stl Tube End Cap 3 4 Orfs 1 OSs aR Soh 209825 Stl Adapte
72. 211293 Conn Pack Terminal Position Assurance Lock 1 EDEN 150316 Conn Rect Univ 039 6p S 3row Plug Cable 5 510 206624 Switch 125vac On on On Spd Term Ya E Located On Front Panel See Figure 19 3 1 ee ee Grue eee 164617 Clip Wiring Straight 2 m 219873 Harness Control Box Weld Control LH includes 1 itus ui 158466 Conn Rect Univ 084 12p S 3row Rept Cable Panel Lkg 1 M RC1 185133 Conn Rect Univ 084 9p S 3row Rept Cable Panel Lkg 1 EE 204737 Cable Tie Mount Winged Push 3 Sead AE CR15 172015 Time Delay Relay Air Dryer 1 Optional 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 ordering parts from your local distributor OM 4409 Page 87 OQ 5 Hardware is common and 54 ARRAN 3 AS D NES Ne oP A i 4 not available unless listed 803 326 A Figure 19 3 Panel Front w Components Item Dia Part No Mkgs No Description Quantity Figure 19 3 Panel Front w Components Figure 19 1 Item 144 PE
73. 5 protects the air compressor clutch If CB15 opens the compressor does not run and air output stops Press button to reset breaker amp gt 803 228 803 229 OM 4409 Page 54 10 5 Servicing Air Compressor 4 Ab Tools Needed 3 7 8 15 16 in Right Side A Stop engine and let cool Wait 20 sec onds for system pressure to drop be fore changing oil 1 Air Compressor Oil Filter 2 Air Compressor Air Oil Separator 3 Air Compressor Oil Drain Hose w Removable Cap 4 Air Compressor Oil Fill Cap 5 Air Compressor Oil Level Indicator On Tank 6 Oil Scavenge Tube To change compressor oil and filter EF The engine oil drain and compressor oil drain hoses are located together in the base Be sure to select the correct hose when draining compressor oil EF Be sure o rings at oil drain and oil fill fit tings are in place before reinstalling caps Drain compressor oil while compressor is still warm Route compressor oil drain hose through hole in base Remove compressor oil fill cap Re move cap from oil drain hose and drain oil into a suitable container Reinstall oil drain hose cap Tighten cap with wrench Remove filter by turning filter counterclock wise Remove filter Apply thin coat of oil to gasket on new filter Install new filter and turn clockwise until tight
74. CKAGE MOVE LEAD 84 1 CONNECTION TO 707 TERMINAL B W 240V RECEPTACLE OPTION 100 737 gt t 9 LED BOARD gt gt USFS 95 L3 PLG4 RC4 737 1 737 7325 2 gt 732 445 3 gt 133 730 gt 4 gt 130 5 CB6 AUX SR1 STATOR LS IM 136 129 727 T gt PANEL REMOTE cw 55 128 c2 D2 BS 01 707 E gt 425 gt 725 RECEPTACLE POSITION 226 126 3 2 10 NAN RRA A2 727 67 A PLGG RCG STANDARD 240V 1 136 1 gt gt gt C3 02 03 K2 F3 42 BS jS 772 2 RC2 PLG14 104 36 2 3246 gt 133 H1 gt Al 1 2 gt AUX 4 14 POR A FILTER BOARD gt 42 107 737 116 Bi FIELD CURRENT REGULATOR 130 PLG10 RC10 m IMS S 154 4 8 gt gt less 87 117 A1 PLGB 30 PIN gt B2 3 PLce 18 PIN F2 F2 LES gt 7 gt gt 1267 136 a HE 190s 3 5156 e gt RC2 PLG14 67 126 gt 4 gt ele 4 p gt 5 725 o o F1 IN 8 gt gt 5
75. Charge battery for 12 minutes at 30 amperes or 30 minutes at 5 am peres Disconnect charging cables and install battery When electrolyte is low add only distilled water to cells to maintain proper level drybatt1 6 05 S 0886 5 5 Connecting The Battery Tools Needed 1 2 gt Reinstall cover after connecting battery 802 168 E Ref 202 705 802 313 S 0756 C OM 4409 Page 25 5 6 Using The Optional Battery Disconnect Switch e A Stop engine t3 1 Battery Disconnect Switch The battery disconnect switch dis connects battery voltage from the circuit When the switch is turned Off the front panel controls do not work To run unit turn switch to On posi tion To prevent unit from running turn switch to Off position The switch may be locked using a customer supplied padlock 803 228 Ref 803 324 HOBART INSTITUT _ OF WELDING TECHNOLOGY _ Start Your Professional Square East Troy Ohio 45373 Over 80 000 trained Welding Career Now 1 800 332 9448 www welding org since 1930 OM 4409 Page 26 5 7 Engine Compressor Prestart Checks Diesel Check all engine compressor fluids daily Engine must be cold and on a level surface Unit is shipped with 20W break in oil The automatic shutdown system stops engine if oil pre
76. Cleaner 1 210151 Label Air Cleaner Location 1 sal imeem 209612 Lever Switch Lockout Disconnect Battery 1 sale ate rien 209597 Bracket Mtg Battery Disconnect Switch 1 CC UE EAD MEE 209611 Switch Disc Battery 2P 6 36 Volts 1 196220 Bracket Holddown Fuel Tank Rear 1 192362 Bracket Mtg 1 2 Conduit 1 3206609 Cover ek Le STE Gn RUD SM 1 Edna 189052 Grommet Plastic Neck Filler Fuel 1 190198 Cap Tank Screw on 3 500 In W Vent W Lanyard 8 1 192041 Label Use Diesel Fuel Only 1 DA rte 222513 Label Warning Falling Equipment Can Cause Serious 1 cervi eeu 143915 Mount Sgl Stud 1 5 Dia X 1 000 Lg 312 18 Stud 1 240 anes 205702 Bracket Mtg Spark Arrestor 1 pag os icon 205749 Pipe Exhaust Elbow 1 cci 603767 Cap Weather Exhaust 1 5 AD lees 010875 Clamp Muffler 2 000 Dia U Pld
77. ELLES VOLANTES ris quent de provoquer des blessures N e Porter un cran facial pour prot ger le visage et les yeux e Aff ter l lectrode au tungst ne uniquement la meuleuse dot e de protecteurs Cette manceuv re est ex cuter dans un endroit s r lorsque l on porte l quipement homologu de protection du visage des mains et du corps e Les tincelles risquent de causer un incendie loigner toute sub stance inflammable DES ORGANES MOBILES peuvent provoquer des blessures Ne pas s approcher des organes mobiles Ne pas s approcher des points de coincement tels que des rouleaux de commande LES FILS SOUDAGE peuvent provoquer des blessures e Ne pas appuyer sur la gachette avant d en avoir recu l instruction Ne pas diriger le pistolet vers soi d autres per sonnes ou toute pi ce m canique en enga geant le fil de soudage Tm i L EMPLOI EXCESSIF peut SURCHAUFFER L QUIPEMENT Laisser l quipement refroidir respecter le fac teur de marche nominal 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 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
78. ES The volt ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator Curves of all other settings fall between the curves shown 208 136 208 957 OM 4409 Page 16 4 7 Fuel Consumption US Gal Hr 3 00 2 75 2 50 2 25 2 00 1 75 1 50 1 25 1 00 0 75 0 50 0 25 0 00 w Air Output IDLE 0 50 100 150 200 250 300 350 400 450 500 550 600 DC WELD AMPERES AT 100 DUTY CYCLE The curve shows typical fuel use under weld or generator power loads 208 211 4 8 Duty Cycle And Overheating pan 5 WELD AMPERES 1000 800 600 500 400 300 250 200 150 100 3 100 Duty Cycle At 500 Amperes Continuous Welding 40 Duty Cycle At 600 Amperes 4 Minutes Welding 6 Minutes Resting 10 15 20 25 30 40 50 60 80 100 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 202 356 OM 4409 Page 17 4 9 Generator Power Curve The ac power curve shows the gen erator power in amperes available at the 120 and 240 volt receptacles 150 300 E 250 E 200 N 150 VOLTS 100 50 0 5 10 15 20 25 30
79. Electrode Electrode Positive Negative Da Work Connection FAS Connection es Circuit Protector e Time h Hours S Seconds Off OM 4409 Page 12 SECTION 4 SPECIFICATIONS 4 1 Weld Power And Engine Specifications Weld Rated Maximum Engine Welding Output Weldin Open Circuit Generator Power Enaine ET Fuel Tank Mode Parr Out a Voltage Rating 9 Capacit Capacity g utput Nominal PARIN 500 A CC DC 20 750 40 Volts 95 DC 100 Duty Standard CV DC 14 40v 56 DEUTZ 600 A 120 240 V AC 50 60 Hz Deutz BF4M2011 CC AC Oil Cooled 11 at 2 Optional 20 575 40 Duty 64 2 rator Four Cylinder 04 1 Gat Cycle Single Phase Three Phase Turbo Charged 12 20 kVA kW 50 48A 63 4 HP Diesel Engine 12 Volt 120 240 VAC 60 Hz eu i Jump Start In Addition To Standard 12 24 V 14 28 4 KVA KW Generator Power Jump 750 A Start 24 Volt Jump Start 4 2 Air Compressor Specifications Compressor Model And Type Air Output At Effective Working Pressure Factory Pressure Setting Safety Relief Valve Rating Air Compressor Capacity Ingersoll Rand CE55 G Rotary Screw 60 scfm 1 7 m3 min 100 psi 690 kPa 100 Duty Cycle 125 psi 862 kPa 150 psi 1034 kPa 4 qt 3 8 L 4 3 Sound Level Table Idle Speed 1235 rpm Weld Power Speed 1850 rpm
80. INE HEAT can cause fire e Do not locate unit on over or near combustible surfaces or flammables Keep exhaust and exhaust pipes way from flammables EXHAUST SPARKS can cause fire e Do not let engine exhaust sparks cause fire e Use approved engine exhaust spark arrestor in required areas see applicable codes TRAPPED AIR PRESSURE AND WHIPPING RY HOSES can cause injury 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 OM 4409 Page 3 HOT METAL from air arc cutting and gouging can cause fire or explosion 2 6 Do not cut or gouge near flammables e Watch for fire keep extinguisher nearby HOT PARTS can cause burns and injury e Do not touch hot compressor or air system parts Let system cool down before touching or ser vicing READ INSTRUCTIONS e Read Owner s Manual before using or servic ing unit Stop engine and release air pressure before servicing Use only genuine replacement parts from the manufacturer 1 5 Additional Symbols For Installation Operation And Maintenance FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING UNIT can cause inj
81. MENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Miller s option 1 repair or 2 replacement or where authorized in writing by Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Miller authorized service facility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED
82. MSDS for safety infor or yttria instead of thoria Grinding dust from A Preparing Tungsten For DC Electrode Negative DCEN Welding 2 1 2 Times Electrode Diameter Radial Grinding Causes Wandering Arc Ideal Tungsten Preparation Stable Arc 1 Grinding Wheel Grind end of tungsten on fine grit hard abrasive wheel before welding Do not use wheel for other jobs or tungsten can become contaminated causing lower weld quality 2 Tungsten Electrode A 296 ceriated tungsten is recommended 3 Flat Diameter of this flat determines amperage capacity 4 Straight Ground Grind lengthwise not radial B Preparing Tungsten For AC Welding 2 1 1 1 1 2 Times W Electrode Diameter 2 1 A pure tungsten is recommended 2 Balled End Ball end of tungsten by applying AC amper age recommended for a given electrode diameter see Section 17 1 Let ball on end of the tungsten take its own shape Tungsten Electrode OM 4409 Page 76 SECTION 18 GUIDELINES FOR TIG WELDING GTAW gtaw 7 2006 18 1 Positioning The Torch A Grinding the tungsten elec trode produces dust and fly ing sparks which can cause injury and start fires Use lo cal exhaust forced ventila tion at the grinder or wear an approved respirator Read MSDS for safety information Consider using cerium or lanthanum based tungsten instead of thoriated Tho rium dust contains low level r
83. R COMPRIME EMMAGASINE ET DES TUYAUX SOUS PRESSION peuvent provo quer des blessures e Rel cher la pression d air de l outillage ou du syst me avant d effectuer la maintenance avant de changer ou de rajouter des l ments ou avant d ouvrir la purge ou le bouchon de remplissage d huile LA CHALEUR DU MOTEUR peut pro voquer un incendie Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Tenir distance les produits inflammables de l chappement LES TINCELLES 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 Le METAL CHAUD lors du coupage et gougeage plasma peut provoquer un in cendie ou une explosion Ne pas couper ou gouger proximit de pro duits inflammables e Surveillez et garder un extincteur proximit DES PIECES CHAUDES peuvent provo quer des br lures et blessures Ne pas toucher le compresseur ou d autres l ments du circuit air comprim chauds Laisser l ensemble se refroidir avant de toucher ou d effectuer la maintenance LIRE LES INSTRUCTIONS Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil Arr ter le moteur et rel cher la pression avant d effectuer la maintenance e N utiliser que les pi ces de rechange re
84. Solenoid 12vdc Pull Hold Type 1 Stroke 1 TEE 601868 Nut 250 28 44hex 26h Stl Pld 2 126388 Nut 250 28 44hex 27h Stl Pld Lh 1 sided M e C 089800 Nut 250 20 44hex 22h Stl Pld 58d Flange Defor 1 108941 Screw 250 20 1 00 Hexwhd 61d Gr5 Pld 1 d dag satt en iis 156733 Nut 250 28 44hex 13h Stl Pld Sem Cone Wshr 51d 1 eo 209090 Bracket Stiffener Panel EE tis E 2 108 sa 209089 Panel Engine Access Lift Off 1 es 206464 Label Maintenance Big Blue Air Pak Deutz Ce 1 Sie 199592 Latch Paddle Series 20 Black 1 55106 Eee 210681 Handle Pocket Pull Door Access 1 Ju 107 dz ga 209091 Panel Rocker Short 1 2e 108 191626 Bumper Door Engine Access 4 10954 Leni 189827 Panel Gen Rh 1 x bl t 207448 Label Maintenance Compressor 1 gene 209059 Label Schematic Air System 1 TELE Figure 19 4 Gene
85. XCEPT 42 CHASSIS 80 99 AUX SECONDARY 100 149 EXCITER CONTROL 160 180 AIR COMPRESSOR CONTROL 221 915 4409 63 SECTION 14 RUN IN PROCEDURE 14 1 Wetstacking run_in1 2007 04 NOTICE Do not perform run in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment 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 NOTICE 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 4409 Page 64 14 2 Run In Procedure Using Load Bank CL p A Stop engine A Do not touch hot exhaust pipe engine parts or load bank grid A Keep exhaust and pipe away from flammables NOTICE Do not perform run in proce
86. able to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire 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 Wear approved ear protection if noise level is high MAGNETIC FIELDS can affect Implanted Medical Devices 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
87. adioactive material Proper ly dispose of grinder dust in an environmentally safe way Wear proper face hand and body protection Keep flam mables away 1 Workpiece Make sure workpiece is clean before welding 2 Work Clamp Place as close to the weld as possible 3 Torch 4 Filler Rod If Applicable 5 Gas Cup 6 Tungsten Electrode Select and prepare tungsten according to Section 17 Guidelines The inside diameter of the gas cup should be at least three times the tungsten diameter to provide ade quate shielding gas coverage For example if tungsten is 1 16 in diameter gas cup should be a minimum of 3 16 in diameter Tungsten extension is the distance the tungsten extends out gas cup of torch 1 16 in The tungsten extension should be no greater than the inside diameter of the gas cup Bottom View Of Gas Cup Arc length is the distance from the tungsten to the workpiece Ref ST 161 892 OM 4409 Page 77 18 2 Torch Movement During Welding Tungsten Without Filler Rod Welding direction 1 7 gt 75 9 gt 1 Z 727 277 2 ZZZ 2 Z LA Form pool Tilt torch Move torch to front of pool Repeat process Tungsten With Filler Rod 75 Welding direction gt 15 TL lt lt y gt 1 Zz TELLE Zz 2 Form pool Tilt torch Add filler metal I
88. ains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants 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 2 7 Principales normes de s curit Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com National Electrical Code NFPA Standard 70 de National Fire Protec tion Association Box 9101 Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet 1 de Compressed Gas Association 4221 Walney Road 5th Floor Chan tilly VA 20151 t l phone 703 788 2700 site Internet www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 de Canadian Standards Association 5060 Mississauga Ontario Canada 2 8 Information EMF Consid rations sur le soudage et les effets de ba
89. and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground e 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 e If AC output is required use remote output control if present on unit e Additionalsafety 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 e Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards Properly install and ground this equipment according to its Owner s Manual and national state and local codes EF Indicates special instructions APA This group of symbols means Warning Watch Out ELECTRIC SHOCK MOVING PARTS
90. arge Battery Charge 1 et wee 207096 Cover Box Front Upright 1 WA 209683 Label Warning Safety Air System 1 144 Figure 19 3 Panel Front w components 1 145 202130 Xfmr Current Sensing Auto Idle 1 22 VAG vs Figure 19 5 Main Rectifier Assembly 1 oos 193453 Bracket Mtg Box Fer 1 148 PC1 207397 Module Field Current Regulator 1 085963 Spring Ext 375 Od X 041 Wire X 2 000 ForSafety Latch 1 TOOL 105734 Pipe Muffler Extension Elbow 1 750 1 VOW at 233088 Label Danger Using A Generator Indoors Can Kill You In Minutes 1 TEE 049525 Nut 312 18 U nut Multi thread 4 T 049525 Nut 312 18 U nut Multi thread 4 T 206468 Kit Label Includes Safety And Informational Labels 1 195118 Kit Lock Out Vandalism 5 1 4209238 Door
91. ator 1 199849 Screw 625 11 4 00 Hex Gr5 Pld 4 BP i 071731 Washer Flat 656idx2 2500dx 187t Stl Pld 4 OO hea pee 191812 Bracket Mtg Engine 1 wh 071890 Retainer Mount Eng Gen 4 ai E 071730 Tubing Stl 875 Od X12ga Wall 2 500 4 TE EIEEE TEDE 083476 Mount Eng Gen Nprn 875id X 2 50004 X 2 000 60 Dur 4 VOU orte aaa E dat 135205 Nut 625 11 94hex 77h 51 Pld Elastic Stop Nut 4 OM 4409 Page 83 Dia Part No Mkgs No Description Quantity Figure 19 1 Main Assembly Continued 199505 Hose Assy Oil Drain 32 000 Lg includes 1 Lis aai ora 165271 Valve Oil Drain 3 8 18 Nptf 1 quU 176529 Hose Brs Barbed Fem 1 2 Tbg X 3 8 Npt 1 EET ETT 113854 Hose Sae 500 Id X 780 Od Xcoil 2 666 Et ot 176528 Hose Brs Barbed Elbow M 1 2 X 1 2 Npt 1 d vasa 173336 Adapter Oil Drain 1 niii rnt ERES 066298 Ring Oil Drain
92. attery 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 see Section 9 1 OM 4409 Page 27 5 8 Connecting To Weld Output Terminals 3 4 5 6 Stop engine Positive Weld Output Terminal Negative Weld Output Terminal Failure to properly connect weld cables may cause excessive heat and start a fire or damage your machine Weld Output Terminal Supplied Weld Output Terminal Nut Weld Cable Terminal Copper Bar Remove supplied nut from weld output termi nal Slide weld cable terminal onto weld output terminal and secure with nut so that weld cable terminal is tight against copper bar Do not place anything between weld cable termi nal and copper bar Make sure that the sur faces of the weld cable terminal and cop per bar are clean Tools Needed 3 4 in Correct Installation Do not place anything between weld cable terminal Stick And TIG Welding For Stick welding Direct Current Electrode Positive DCEP connect electrode hold er cable to Positive terminal on left and work cable to Negative terminal on right For Stick and TIG Direct Current Elec trode Negative DCEN connect elec trode holder cable to Nega
93. autes et un couvre chef Avant de souder retirer toute substance combustible de vos po ches telles qu un allumeur au butane ou des allumettes Une fois le travail achev assurez vous qu il ne reste aucune tra ce d tincelles incandescentes ni de flammes Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter Suivre les recommandations dans 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 affec l ouie e Porter des protections approuv s pour les ore les si le niveau sonore est trop lev OM 4409 Page 7 LES CHAMPS MAGNETIQUES peuv ent affecter des implants m dicaux Porteur de simulateur cardiaque ou autre im plants m dicaux rester a distance e Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de sou dage par points de gougeage du coupage plasma ou de chauf fage par induction Si des BOUTEILLES sont endomma g es elles pourront exploser Des bouteilles de gaz protecteur contiennent du ga sous haute pression Si une bouteille est endomme g e elle peut exploser Du fait que les bouteiles de gaz for normalement partie du proc d de soudage les manipuler ave pr caution e Prot ger les bouteilles de gaz
94. circuit High output at generator power Check engine weld power speed and adjust if necessary see Section 9 6 receptacles Have Factory Authorized Service Agent adjust field current resistor R3 Low output at generator power Check engine weld power speed and adjust if necessary see Section 9 6 receptacles Check fuse F1 and replace if open see Section 9 8 Have Factory Authorized Service Agent check inte grated rectifier SR1 resistor R3 and capacitor C9 C Optional AC Power Plant Trouble Remedy No or low output at optional ac power plant receptacle RC5 Place Process Contactor switch in Weld Terminals Always On Stick position see Section 6 3 Reset supplementary protector CB7 see Section 7 2 Reset supplementary protector CB5 see Section 9 8 Check engine weld power speed and adjust if necessary see Section 9 6 Have Factory Authorized Service Agent check brushes and slip rings and field current regulator board High output at optional ac power plant receptacle RC5 Check engine weld power speed and adjust if necessary see Section 9 6 Have Factory Authorized Service Agent check field current regulator board PC1 Erratic output at optional ac power plant receptacle RC5 Have Factory Authorized Service Agent check brushes and slip rings and field current regulator board PC1 OM 4409 Page 58 D Engine
95. command es par le constructeur 2 5 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance SION Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Ne pas installer l appareil proximit de pro duits inflammables e Ne pas surcharger l installation lectrique s assurer que l ali mentation est correctement dimensionn e et prot g e avant de mettre l appareil en service Risque D INCENDIE OU D EXPLO NEN LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage pour lever l appareil et les accessoires correctement install es seuls PAS les bouteilles de gaz Ne pas d passer le poids nominal maximal de l ceilleton voir les sp cifications Ne lever et ne soutenir l appareil qu avec de l quipement appropri et en suivant les proc dures ad quates En utilisant des fourches de levage pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil OM 4409 Page 9 LE SURCHAUFFEMENT peut endom mager le moteur lectrique Arr ter ou d connecter l quipement avant de d marrer ou d arr ter le moteur Ne pas laisser tourner le moteur trop lentement sous risque d en dommager le moteur lectrique cause d une tension et d une fr quence trop faibles Ne pas brancher de moteur de 50 ou de 60 Hz la prise de 100 Hz LES ETINC
96. corps e Sila pi ce soud e doit tre mise la terre le faire directement avec un cable 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 pi ce 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 Porter un harnais de s curit quand on travaille en hauteur e Maintenir solidement en place tous les panneaux et capots e Fixer le cable 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 possible de la soudure e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique Une tension DC importante subsiste l int rieur des onduleurs apr s avoir coup l alimentation Couper l alimentation du poste et d charger les condensateurs d entr e comme indiqu dans la Section Maintenance avant de toucher des composants DES PIECES CHAUDES peuvent provoquer des br lures graves Ne pas toucher a mains nues les parties chau des Pr voir une p riode de refroidissement avant travailler l quipement Ne
97. ctor M 3 4 Sae npt Adapter 1 cue ona nci i M 206615 Sender Pressure 0 200 Psi 1 NPD ay ea hate tnr ais 073655 Pipe Brs Nipple 1 8 Npt 1 2S este 206937 Manifold Air 1 UE 206743 Valve Safety Relief 150psi 1 AO 209754 Pipe Stl Elbow 4599 3 4 X Npt jic 4599 1 E ED 214685 Hose Assy Air W Fittings 3 4 X 21 750 Lg 1 209787 Ftg Pipe Stl Nipple Close 3 4 Npt 2 pi 209621 Fitting Stl Adapter 3 4 SAE 3 4 1 29 210058 Gauge Oil Level Assembly 1 Deleted o pad 209766 Pipe Stl Tee Street 3 4 Npt M f f 1 va 209457 Ftg Pipe Stl Elbow St 3 4 2 209638 Hose Oil W Fittings 25 670 Lg 1 UE TERREA 209639 Hose Oil W Fittings 26 320 Lg 1 210254 Bracket Mtg ide de 1 T EE 210251 Stl Swivel Strai
98. degreasers 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 injure or kill Shut off 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 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 749 1 and 287 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet e Use protective screens or barriers to
99. dure at less than 20 volts weld output and do not exceed duty cycle or equipment 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 A V range switch in maxi mum position A V control in mini mum position and Output Selector switch if present in either DC position 3 Weld Cables Connect load bank to generator weld output terminals 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 rated voltage and current of generator see name plate rating label or the specifi cations section in this manual Check generator and load bank meters after first five minutes then every fifteen minutes to be sure generator is loaded properly NOTICE Check oil level frequent ly during 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 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 5 0683 4409 65 14 3 Run In Procedure Using Resistance Grid Ct 4
100. e 1 135873 Clip Conduit Convoluted 1 2 In 6 35mm Mtg Hole 187654 Seal Wire Univ 12p S 3row 1 iate cris 196602 Plug Cavity 18 30 Position Cinch Connector 7 059712 Clip Component 437 Dia Mtg Adh Back 1 das 024103 Blank Nyl 750 Mtg Hole Black 1 iiA 120304 Blank 250 Mtg Hole Black P DUET 025234 Plug Str Grd 2p3w 15a 250v 6 15p 1 Optional T To maintain the factory original performance of your equipment When ordering a component originally displaying a precautionary label the label should also be ordered use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 4409 Page 90 Figure 19 4 Generator Description Figure 19 4 Generator Figure 19 1 Item 112 6 STATOR STATOR 209220 Screw 375 16 1 50 Hex Gr5 Pld Washer Cone 380idx 8600dx 109t Stl Pld 4000105 Endbell Gen includes O Ring 2 859 ID X 139 Cs 70 Duro Viton Stator Exciter Aux Power Stator Weld Assy Complete Stator Weld Assy Complete 3 Phase Generator Option Label Warning Moving Parts Can Cause Serious Guard Generator Wire Me
101. e Air Motor 1 Horsepower Air Motor 2 Horsepower Air Motor 3 Horsepower Paint Spray Gun Production Scaling Hammer Chipping Hammer Riveting Hammer Light Riveting Hammer Heavy SAWS Circular 8 Circular 12 Chain Lightweight Chain Heavy Duty Always check with tool manufacturers for actual air consumption of tools being used The above is based on averages and should not be considered accurate for any particular make of tool Above tools are rated based upon typical on load performance characteristics For other values adjust the C F air consumption on a proportional basis The cubic feet C F air consumption for 1 minute may also be expressed as air consumption in cubic feet per minute C F M OM 4409 Page 68 SECTION 16 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 16 1 Selecting Equipment Generator Power Receptacles Neutral Bonded To Frame 3 Prong Plug From Case Grounded Equipment 2 Prong Plug From Double Insulated Equipment EF 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 2007 04 Ref ST 159 730 ST 800 577 A A 1 2 3 Always ground generator frame to vehicle frame to pre
102. e Wear Clean gloves To Prevent Contamination Of Tungsten Amperage Range Gas Polarity Electrode Diameter DCEN Argon Direct Current Electrode Negative For Use With Mild Or Stainless Steel AC Argon Balance Control 65 Electrode Negative For Use With Aluminum 2 Ceria Orange Band 1 5 Lanthanum Gray Band Or 2 Thoriu m Red Band Alloy Tungstens 040 1 mm 25 85 20 80 1 16 1 6 mm 50 160 50 150 3 32 2 4 mm 135 235 130 250 1 8 3 2 mm 250 400 225 360 Pure Tungsten Green Band 040 1 mm Pure Tungsten Not Recommended 10 60 1 16 1 6 mm For DCEN Argon 50 100 3 32 2 4 mm 100 160 1 8 3 2 mm 150 210 Typical argon shielding gas flow rates are 11 to 35 cfh cubic feet per hour Figures listed are a guide and are a composite of recommendations from American Welding Society AWS and electrode manufacturers 17 2 Preparing Tungsten Electrode For Welding With Phase Control Machines Nye mation Consider using tungsten containing ceria lanthana thoriated electrodes contains low level radioactive material Properly dispose of grinder dust in an environ mentally safe way Wear proper face hand and body protection Keep flammables away A Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires Use local exhaust forced ventilation at the grinder or wear an approved respirator Read
103. e primary element if damaged Re place primary element yearly or after six cleanings ON 2 Housin 9 C RAM 3 Safety Element Optional 5599 4 Primary Element 5 Dust Cap 6 Dust Ejector 6 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 Q ivi lt K x ON 2 x X VV x 5 KAP LR Waters AX Inspect aircleaner1 9 00 803 228 153 929 B 153 585 Ref S 0698 B OM 4409 Page 46 9 5 Inspecting Cleaning Optional Spark Arrestor Muffler E we Ap Stop engine and let cool NC eo 1 Spark Arrestor Muffler 2 Cleanout Plug c Remove plug and remove any dirt covering cleanout hole Start engine and run at idle speed to blow out cleanout hole If nothing blows out of hole briefly cover end of exhaust pipe with fireproof material A Stop engine and let cool Reinstall cleanout plug
104. e unit Be sure connection to work piece is clean and tight Use dry properly stored electrodes Remove excessive coils from weld cables High weld output Check position of Ampere Range switch and Voltage Amperage Adjust control Check engine weld power speed and adjust if necessary see Section 9 6 Have Factory Authorized Service Agent check field current regulator board PC1 Voltage Amperage control does not work when welding in Stick mode Place Ampere Range switch in lower range Voltage Amperage control does not work with Ampere Range switch in highest range Low weld output Check engine weld power speed and adjust if necessary see Section 9 6 Check fuses F1 and F2 and replace if open see Section 9 8 Have Factory Authorized Service Agent check integrated rectifier SR1 capacitor C9 field current regulator board PC1 and the rotor Electrode sticks to the workpiece more frequently during low voltage short arc length conditions Circuit breaker CB4 may be open CB4 automatically resets when the fault is corrected see Section 9 8 Have Factory Authorized Service Agent check transformer T1 and integrated rectifiers SR4 and SR5 Have Factory Authorized Service Agent check optional battery charging relay CR7 Low open circuit voltage Check engine weld power speed and adjust if necessary No remote fine amperage or voltage control Place Panel Remote Sw
105. eats use next size larger cable Weld cable size AWG is based on either 4 volts or less drop or a current density of at least 300 circular mils per ampere mm for metric use 5 0007 For distances longer than those shown in this guide call a factory applications representative at 920 735 4505 Notes OM 4409 Page 29 5 10 Connecting To Remote 14 Receptacle RC14 803 231 14 Socket Socket Information A 24 volts ac Protected by sup plementary protector CB5 24 VOLTS AC OUTPUT B Contact closure to A completes CONTACTOR 24 volt ac contactor control circuit C Output to remote control 10 volts dc in MIG or Stick mode 0 to 10 volts dc in TIG mode REMOTE D Remote control circuit common OUTPUT CONTROL E DC input command signal 0 to 10 volts from min to max of remote control with Voltage Amperage Adjust control at max 115 volts 10 amperes 60 Hz ac Protected by supplementary 115 VOLTS AC protector CB6 OUTPUT CONTACTOR Contact closure to completes J 115 volt ac contactor control circuit GND K Chassis common NEUTRAL G Circuit common for 24 and 115 volt ac circuit The remaining sockets are not used Notes OM 4409 Page 30 5 11 Connecting To The Air Compressor Open Position
106. engine several minutes at no load Stop engine and let cool 6 Engine Exhaust Pipe Repeat procedure if wetstacking is present S 0684 OM 4409 Page 66 SECTION 15 AIR COMPRESSOR TABLES 15 1 Flow Of Free Air CFM Through Orifices Of Various Diameters Orifice Diameter in And Free Air Flow CFM Gauge Pressure psi OM 4409 Page 67 15 2 Approximate Air Consumption Cubic Feet To Operate Pneumatic Equipment At 70 90 P S I G Percent Use Factor And Compressed Air Consumption CF 3 75 6 25 8 75 25 MISCELLANEOUS PORTABLE TOOLS Drill 1 18 to 3 8 Drill 3 8 to 5 16 Screwdriver 2 to 6 Screw Screwdriver 6 to 5 16 Screw Tapper to 3 8 Nutsetters to 3 8 Nutsetters to 3 4 Impact Wrench 1 4 Impact Wrench 3 8 Impact Wrench 5 8 Impact Wrench 3 4 Impact Wrench 1 Impact Wrench 1 1 4 Die Grinder Small Die Grinder Medium Horizontal Grinder 2 Horizontal Grinder 4 Horizontal Grinder 6 Horizontal Grinder 8 Vertical Grinders and Sanders 5 Pad Vertical Grinders and Sanders 7 Pad Vertical Grinders and Sanders 9 Pad Burring Toll Small MISCELLANEOUS PORTABLE TOOLS Percent Use Factor And Compressed Air Consumption CF Burring Tool Large 3 6 6 0 8 4 24 Rammers Small Rammers Medium Rammers Large Backfill Tamper Compression Riveter 0 2 cu ft per cycl
107. es de s curit moteur Seules des personnes qualifi es sont autoris es enlever les por tes panneaux recouvrements ou dispositifs de protection pour effectuer s il y a lieu des travaux d entretien et de d pannage 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 panneaux ou les dispositifs de protection et fermer les portes la fin des travaux d entretien et avant de faire d marrer le moteur 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 interven tion sur le g n rateur DES PI CES CHAUDES peuvent provoquer des br lures graves Ne pas toucher mains nues les parties chau des 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 1 est pr f rable de v rifier le liquide de refroi dissement une fois le moteur refroidi pour viter de se br ler Toujours v rifier le niveau de liquide de refroidissement dans
108. es 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 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 ris quent de provoquer des blessures oi m me la mort 4 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 pro voquer des br lures dans les yeux e sur la peau Le rayonnement de l arc du proc d de soudag g n re des rayons visibles et invisibles intense ultraviolets et infrarouges susceptibles de provoquer des br lure dans les yeux et sur la peau Des tincelles sont projet es pendant 1 soudage Porter un cas
109. fications 4 2 Air Compressor Specifications 429 Sound Level Table uc cr atn EE PE ER SN WR ER ER UE ER diede 4 4 Dimensions Weights And Operating Angles 4 5 Stick And MIG Volt Ampere Curves 4 6 TIG Volt Ampere Curves 4 7 iF el Gonsuimplion SD p ex E d 4 8 Duty Cycle And Overheating 2 4 9 Generator AC Power 4 10 Optional 3 Phase Generator Power Curves 4 11 Air Compressor Output 4 12 Optional Battery Charging Output Curve 4 13 Manufacturing Rating 4 5 INSTALLATION ened eet deed Beene Ree te lta 5 1 Installing Welding Generator 5 2 Mounting Welding Generator 5 3 Installing Optional Spark Arrestor
110. g start engine and check for fuel leaks Stop engine tighten connections as necessary and wipe up spilled fuel Oil Filter Oil Drain Hose And Valve Oil Fill Cap Primary Fuel Filter Fuel Water Separator 5 Petcock 6 Secondary Fuel Filter 7 Fuel Tank Sludge Drain Valve To change oil and filter D gt The engine oil drain and compressor oil drain hoses are located together in the base Be sure to select the correct hose when draining engine oil Route engine oil drain hose through hole in base See engine manual and engine main tenance label for oil specifications 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 Turn filter counterclockwise Remove filter Apply thin coat of fuel to gasket on new filter Fill filter with fuel Install filter and turn clock wise until tight Bleed air from fuel system according to engine manual Inspect fuel lines and replace if cracked or worn Right Side 03 228 8 To replace secondary fuel filter See engine manual Close doors To drain sludge from fuel tank A Beware of fire Do not smoke and keep sparks and flames away from drained fuel Dispose of drained fuel in an environmentally safe manner Do not leave unit unattended while draining fuel tank A Properl
111. gas cylinders 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 BLIND e Always wear a face shield rubber gloves and protective clothing when working on a battery Stop engine before disconnecting or connect ing battery cables or servicing battery Do not allow tools to cause sparks when
112. gh Clean debris from radiator Automatic shutdown stops compressor if compressor temperature is too high Low air pressure Check for leaks in air lines and hoses Adjust compressor air pressure see Section 10 6 Check air compressor air cleaner see Section 10 3 Have Factory Authorized Service Agent check compressor for rated output High air pressure Adjust compressor air pressure see Section 10 6 Be sure control line is connected at regulator valve and inlet valve Pneumatic tools freeze up because of moisture in compressed air Install optional air dryer filter kit Part No 195 117 Oil in air from compressor Check compressor oil level see Section 5 7 If oil level is too high system becomes saturated with oil Change compressor air oil separator see Section 10 5 Check connections of control lines see air compressor circuit diagram in Section 12 Have Factory Authorized Service Agent check for blocked separator scavenge check valve filter orifice Oil in compressor air cleaner Have Factory Authorized Service Agent verify compressor inlet valve is operating properly F Optional Battery Charging Trouble Remedy No battery charge output weld output okay Place Output Selector switch in 12 Volt Charge or 24 Volt Charge position Check and tighten battery connections if necessary Turn on remote control device or turn Proce
113. ght Thread Conn 3 4 O ring 1 rp 210252 Stl Bulkhead Branch Tee 3 4 Flare Tube End 1 E 210250 Hose Assy W Fittings 3 4 X 15 500 Lg 1 209765 Pipe Stl Elbow Adapter 9099 3 4 Sae jic 1 208040 Tensioner Belt 1 208428 Idler Pulley eet ee 1 Ee 225038 Bracket Mtg Compressor 1 AS Lees 4 206742 Switch High Air Temperature 248 Nc 1 210022 O ring High Air Temp Switch 1 ui ee 211904 Manifold 1 218558 Screw 8 1 2 50 Hex 8 8 Pld Manifold Mtg Screws 4 AD 209641 Hose Nylon White 32 000lg 1 209855 Pipe Stl Adapter 1 8 Npt X 1 4 Line 2 TA ide 015732 Pipe Brs Elbow St 45 1 8 Not 1 48 9 209852 Pipe Stl Adapter M M10 X 1 8 Npt F 1 49 225005 Brace Compressor
114. in 16 Gauge 063 in 14 Gauge 078 in 1 8 in 125 in 3 16 in 188 in 1 4 in 25 in 5 16 in 313 in 3 8 in 375 in 1 2 in 5 in OM 4409 Page 45 9 4 Servicing Engine Air Cleaner ES 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 1 Engine Air Cleaner EF air cleaner primary element be cleaned but the dirt holding capac ity of the filter is reduced with each cleaning The chance of dirt reaching the clean side 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 OX Optional Keep nozzle 2 in 51 from element M 7 7 RIN MA XX X X x x g Kx Clean or replace primary element if dirty see note above before cleaning Re 4 5 5 plac
115. is backed by the most hassle free warranty in the We ve made installation and operation quick business and easy With Miller you can count on years 90 00012000 of reliable service with proper maintenance And if for some reason the unit needs repair QUALITY SYSTEM there s a Troubleshooting section that will help you figure out what the problem is The Miller is the first welding parts list will then help you to decide the equipment manufacturer the U S A ta be registered to exact part you may need to fix the problem the ISO 9001 2000 Quality Warranty and service information for your System Standard particular model are also provided Miller Electric manufactures a full line of welders and welding related equipment For information on other quality Miller products contact your local Miller distributor to receive the latest full line catalog or individual specification sheets To locate your nearest distributor or service agency call 1 800 4 A Miller or visit us at www MillerWelds com on the web Mill mer Mil_Thank 4 05 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING Symbol RA ORE AA RU CD ees 1 2 Are Welding Hazards 06 ee oe Lt ede ee ea ee oa ie aA 1 9 Engine Hazards x uere eR ven dad hele ue equ IN EO eed RE Mes 1 4 Compressed Air Hazards Ve ee een sug
116. itch in Remote position Check and secure connections to Remote 14 receptacle RC14 see Section 5 10 Repair or replace remote control device OM 4409 Page 57 Trouble Remedy Constant speed wire feeder does not work Reset supplementary protector s CB5 and CB13 see Section 9 8 Check and secure connections to Remote 14 receptacle RC14 see Section 5 10 Repair or replace wire feeder Low CV weld output Set Ampere Range switch to highest range Min or max CV weld output only Check position of Voltage Amperage Adjust control and Panel Remote Switch Repair or replace remote control device Have Factory Authorized Service Agent check field current regulator board PC1 B Standard Generator Power Trouble Remedy No generator power output at ac recep tacles weld output okay Reset receptacle supplementary protectors No generator power or weld output Disconnect equipment from generator power receptacles during start up Check fuses F1 and F2 and replace if open see Section 9 8 Have Factory Authorized Service Agent check integrated rectifier SR1 capacitor C9 diode capacitor board D1 C1 and the rotor Reset supplementary protector CB12 Have Factory Authorized Service Agent check field current regula tor board PC1 see Section 10 4 Have Factory Authorized Service Agent check brushes and slip rings and field excitation
117. machine using shielded cables using line filters or shielding the work area For Gasoline Engines 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 Ontario Canada L4W 5NS phone 800 463 6727 or in Toronto 416 747 4044 website www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard 287 1 from American National Standards Institute 25 West 43 Street New York NY 10036 8002 phone 212 642 4900 website www ansi org Standardfor Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 web site www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart 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 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 Keep cables close together by twisting or taping them or using a cable cover 2
118. mo tor with a motor start code of M Volts 230 HP 1 4 11 2 11 2 1 4 x 1000 230 12 2A Starting the motor requires 12 2 amperes S 0624 16 9 How Much Power Can Generator Supply 1 Limit Load 90 Of Generator Output Always start non resistive motor loads in order from largest to small est and add resistive loads last 2 5Second 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 4409 Page 73 16 10 Typical Connections To Supply Standby Power Utility Electrical Service Transfer Switch Essential Loads Fused Disconnect Switch If Required Welding Generator Output 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 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
119. n Base 2 sas ML sue 206463 Label Manufacturing Rating 1 oL 233953 Label Warning General Precautionary CSA 2 OM 4409 Page 84 Dia Part No Mkgs No Description Quantity Figure 19 1 Main Assembly 225129 c 189699 Resistor WW 375 W 10 Ohm W Mtg Bkt 1 a e O tered 218086 Bracket Holddown Fuel Tank 1 pe ASD Fig re 19525 Control BOX aie ea wees Lye eka S eA RD ER ake ke e a 1 cu pt 189731 Firewall Bottom 1 1332 203260 Label Caution Do Not Ether 1 seu regu 191448 Cover Top Front Upright 1 L 206609 Upright Front aces ees PA abe nr as 1 130 206606 Box Valve Ball 1 eee eee 209682 Label Air Power Ingersoll Rand 1 LB 039047 Terminal Pwr Output Red 1 139 207095 Box Battery Charge 1 140 039046 Terminal Pwr Output Black 1 io 210156 Label Battery Ch
120. n any Stick or TIG setting use control to adjust amperage within range selected by Ampere Range switch With Process Contactor switch in any MIG position use control to adjust voltage With Panel Remote Switch in Remote posi tion control limits the remote amperage in TIG mode but has no effect in Stick and MIG modes Weld output would be about 263 A DC with controls set as shown 5096 of 125 to 400 A The numbers around the Voltage Amper age Adjust control are for reference only and do not represent an actual percent age value 18 Panel Remote Switch And Remote 14 Receptacle Use switch to select front panel or remote voltage amperage control For remote con trol place switch in Remote position and con nect remote control to Remote 14 receptacle RC14 see Sections 5 10 and 6 4 14 Polarity AC Selector Switch Optional Or Output Selector Switch Optional NOTICE Do not switch under load Use Polarity AC selector switch to select AC or DC weld output and DC weld output po larity Use Output Selector switch to select AC Weld DC Weld or battery charge output see Section 8 1 Weld Meters 15 AC DC Voltmeter Optional Voltmeter displays voltage at the weld output terminals but not necessarily the welding arc due to resistance of cable and connections 16 AC DC Ammeter Optional Ammeter displays amperage output of the unit Air Compressor Controls 17 Air Compressor Switch Use switch to turn air
121. ncers et des malformations cong nitales ou autres probl mes de procr ation LAW 5NS t l phone 800 463 6727 ou Toronto 416 747 4044 site Internet www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 de American National Standards Institute 11 West 43rd Street New York NY 10036 8002 t l phone 212 642 4900 site Internet www ansi org Standardfor Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart and Part 1926 Subpart J de U S Government Printing Office Superin tendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 t l phone 1 866 512 1800 il y a 10 bureaux r gionaux le t l pho ne de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 1 Garder les c bles ensemble les torsader les scotcher ou les recouvrir d une housse 2 Disposer les c bles d un c t et distance de l op rateur 3 Ne pas courber pas et ne pas entourer pas les c bles autour de votre corps 4 Garder le poste de soudage et les cables le plus loin possible de vous 5 Connecter la pince sur la pi ce aussi pr s que possible
122. nd Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures ARC WELDING can cause interference Electromagnetic energy can interfere with sensitive electronic equipment such as micro processors computers and computer driven equipmentsuch as robots Be sure all equipment in the welding area 15 electromagnetically compatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor Locate welding operation 100 meters from any sensitive elec tronic equipment 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
123. nears the charg ing voltage charging current de creases DC VOLTS 0 100 200 300 400 500 600 700 800 900 1000 DC AMPERES 210 269 OM 4409 Page 20 4 13 Manufacturing Rating Label FREE em 10 w aw w av M w aw x Le ao SS x om 100 e azsa uM Up 64V WENT Up 34V 10A 14V 750A 28V x ae w ew 120 240V 20 17A 1 60Hz 120 240V Optional OM 4409 Page 21 SECTION 5 INSTALLATION 5 1 Installing Welding Generator A Always securely fasten weld ing generator onto transport vehicle or trailer and comply with all DOT and other applica ble codes A Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards A If unit does not have GFCI re ceptacles use GFCI protected extension cord NOTICE Do not install unit where air flow is restricted or engine may overheat OR See Section 4 4 for lifting eye rat ing See Section 5 2 for mounting in formation Grounding 1 Equipment Grounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insu lated copper wire
124. nections are made to power plant KVA KW 12 20 Frequency 60 Hz Engine Speed 1850 RPM Lead 42 connects to GROUND stud on front of unit Jumper 42 is connected to 90 at factory 93 91 90 92 2 12 A Close panel opening if no are made to power plant connections 1 Phase Ref 197 399 802 332 240V Tools Needed IL 3 Phase SS gt gt Do not weld while using optional ac power plant Place Process Contactor switch in Weld Terminals Always On Stick position when using optional ac power plant see Section 6 3 Single Phase Generator Power 1 120 240 V 50 A Receptacle RC5 RC5 is connected to the optional ac power plant and supplies 60 Hz single phase power at weld power speed Maximum output from RC5 is 12 kW Power available at RC5 is reduced when welding 2 Supplementary Protector Supplementary protector CB7 protects single phase receptacle RC5 and the load wires from overload If CB7 opens all generator ac output stops and the receptacle does not work Three Phase Generator Power Stop engine Power and weld outputs are live at the same time Disconnect or insulate unused cables
125. nt of such a failure within the warranty time periods All warranty time periods start on the delivery date of the equipmentto the original end user purchaser and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers 2 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Process Controllers Semi Automatic and Automatic Wire Feeders Inverter Power Sources Unless Otherwise Stated Water Coolant Systems Integrated Intellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified Motor Driven Guns w exception of Spoolmate Spoolguns Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Coolers and Electronic Controls Recorders Water Coolant Systems Non Integrated Flowgauge and Flowmeter Regulators No Labor HFUnits Grids Spot Welders Load Banks Arc Stud Power Sources amp Arc Stud Guns Racks Running Gear Trailers Plasma Cutting Torches except APT amp SAF Models Field Options NOTE Field options are covered under True Blue for the remaining warranty period of the product they are installed in
126. olenoid OM 4409 Page 59 Trouble Remedy Engine does not run at idle speed Turn Process Contactor switch to any position but Remote On Off Switch Required TIG Check for obstructed throttle solenoid Allow circuit breaker CB14 to reset Have Factory Authorized Service Agent check throttle solenoid TS1 and linkage see Section 9 8 Have Factory Authorized Service Agent check idle module control relays and CR6 and current transformer CT1 Engine uses oil during run in period wetstacking occurs Dry engine see Section 14 E Air Compressor Trouble Remedy Air compressor does not operate no air pressure at air shutoff valve Place Air Compressor switch in On position The air compressor will not start if still under pressure If compressor is turned off wait for air pressure to bleed off about 20 seconds before turning compressor on again Reset supplementary protector CB15 see Section 10 4 Check compressor belt tension Be sure correct belt is used and is properly installed Have Factory Authorized Service Agent check Air Compressor switch S10 control relay CR10 air pres sure switch S11 temperature switch S12 compressor control circuit and air compressor clutch Air compressor stops after short period of operation Check compressor oil level see Section 5 7 Automatic shutdown stops compressor if compressor tem perature is too hi
127. or for a minimum of one year whichever is greater Bernard Branded Mig Guns No Labor Weldcraft Branded TIG Torches No Labor Subarc Wire Drive Assemblies 6 Months Batteries 90 Days Parts MIG Guns TIG Torches and Subarc SAW Guns Induction Heating Coils and Blankets Cables and Non Electronic Controls APT amp SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Millers True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Bobcat Trailblazer and Legend models 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIP
128. our 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 2 7 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 Au cours de l utilisation tenir toute personne 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 graves 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 galement sous 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 install s ou mal mis la terre pr sentent un danger e Ne jamais toucher les pi ces lectriques sous tension e 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 g
129. ow on units with low fuel shut down option To check fuel level when engine is not run ning turn Engine Control switch to Run Idle position 5 Air Pressure Gauge Use gauge to check compressor air pressure 6 Engine Oil Pressure Gauge Normal pressure is 30 60 psi 206 414 kPa Engine stops if pressure is below 20 psi 138 kPa 7 Engine Temperature Gauge Normal temperature is 212 239 F 100 115 C Engine stops if temperature exceeds 270 F 132 C 8 Battery Voltmeter Use gauge to check battery voltage and moni tor the engine charging system The meter should read about 14 volts dc when the en gine is running and about 12 volts dc when the engine is stopped 9 Air Compressor Hour Meter Optional Use gauge to monitor compressor running time for scheduling maintenance Weld Controls 10 Process Contactor Switch See Section 6 3 for Process Contactor Switch information 11 Ampere Range Switch NOTICE Do not switch under load Use switch to select weld amperage range Use all five ranges for Stick welding and the lowest four ranges for TIG welding Read the upper set of numbers at each range for Stick welding and the lower set at each range for TIG welding Use the highest range for MIG welding and for cutting and gouging CAC A For most welding applications use lowest amperagerange possible to help prevent arc outages 12 Voltage AmperageAdjust Control With Process Contactor switch i
130. oximate 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 2 HP 10500 2800 FARM DUTY MOTORS 1 3 HP 1720 720 Std e g Conveyors 1 2 HP 2575 975 Feed Augers Air 3 4 HP 4500 1400 Compressors 1HP 6100 1600 1 1 2 HP 8200 2200 2HP 10550 2850 3 HP 15900 3900 5 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 2100 800 1 2 HP 3200 1050 OM 4409 Page 71 16 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 4500 1500 10 in 6300 1800 Band Saw 14 in 2500 1100 Bench Grinder 6in 1720 720 8in 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
131. 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 SA E LETES peuvent provoquer des bles sures dans les yeux 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 inhalation peut tre dangereux pour votre sant LES FUMEES ET LES GAZ peuvent dangereux E Le soudage g n re des fum es et des gaz Leur 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 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 d
132. que de soudage approuv muni de verres filtrants appropri pour prot ger visage et yeux pendant le soudage 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 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 LE SOUDAGE peut provoquer un in ITER cendie ou une explosion Le soudage effectu sur des conteneurs ferm s tel que des r servoirs tambours ou des conduites pet provoquer leur clatement Des tincelles peuver tre projet es de de soudure La projection d tincelles des pi ce chaudes et des quipements chauds peut provoquer des incendies des br lures Le contact accidentel de l lectrode avec des objet m talliques peut provoquer des tincelles une explosion un surchaut fement ou un incendie Avant de commencer le soudage v rifier s assurer que l endroit ne pr sente pas de danger D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneusementavec des protections homologu s Ne pas souder dans un endroit l
133. quipment produces fumes 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 A 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 1 7 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard 249 1 from Global Engineering Documents phone 1 877 413 5184 website www global ins com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 4221 Walney Road 5th Floor Chantilly VA 20151 phone 703 788 2700 website www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Mississauga 1 8 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric A
134. r Swivel 12m X Jic 12F 1 209764 Pipe Stl Tee Branch Sae 12 X Jic 12 1 1652 209828 Stl Swivel Union Jic 12 1 Keno 209621 Stl Adapter 3 4 Sae 3 4 1 OL 210052 Valve Oil Temperature Control 1 E 206744 Thermostat 1707 w gasket 1 69 sees aera 206745 Filter pin 1 AO Soo ree UR 209756 Pipe Stl Elbow M 90994 1 2 Jic X 3 4 Sae 1 TIG DR EE 214686 Pipe Stl Elbow 90dg 3 4bspt M X 3 4 Jic M 1 TA n s epe ees 210023 Filter Separator Assembly includes 1 ah 206747 Separator Filter 1 re S 208029 Bracket Mtg Filter Base 1 POS eure nee 209646 Tubing Ssstl 312 Od X 028 W Ftgs 1 209856 Stl Adapter Tube End Reducer 041 X 05m 1 dees eas 210027 Valve Check Scavenge Orifice Screen 1 209755 Pipe Stl Swivel F 1 4 X 1 4 F dic 1 T HEP PE 210056 Oil Compre
135. r airflow to unit gt STATIC ESD can damage PC boards e Puton grounded wrist strap BEFORE handling 52 boards parts Use proper static proof bags and boxes to store move or ship PC boards Use tongue jack or blocks to support weight Properly install welding generator onto trailer y E TILTING OF TRAILER can cause injury e according to instructions supplied with trailer READ INSTRUCTIONS Read Owner s Manual before using or servic ing unit Use only genuine replacement parts from the manufacturer Perform engine and air compressor mainte nance and service according to this manual and the engine air compressor if applicable manuals RADIATION can cause interference High frequency H F can interfere with radio navigation safety services computers and communications equipment Have only qualified persons familiar with electronic equipment perform this installation 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 shielding to minimize the possibility of interference 1 6 California Proposition 65 Warnings Welding or cutting e
136. r power output okay at ac receptacles Place Process Contactor switch in a Weld Terminals Always On position or place switch in a Remote On Off Switch Required position and connect remote contactor to Remote 14 receptacle RC14 see Sec tions 5 10 and 6 1 Check position of Ampere Range switch Check position of optional Output Selector switch see Section 8 1 Reset supplementary protector 11 see Section 9 8 Reset supplementary protector CB5 see Section 9 8 Check for faulty remote device connected to RC14 Check and secure connections to Remote 14 receptacle RC14 see Section 5 10 Have Factory Authorized Service Agent check connector board PC6 and connections Check fuse F2 and replace if open see Section 9 8 Have Factory Authorized Service Agent check brushes and slip rings field excitation circuit field current regulator board PC1 and the rotor No weld output or generator power output Disconnect equipment from generator power receptacles during start up Check fuses F1 and F2 and replace if open see Section 9 8 Have Factory Authorized Service Agent check integrated rectifier SR1 capacitor C9 field current regulator board PC1 and the rotor Reset supplementary protector CB12 see Section 9 8 Have Factory Authorized Service Agent check brushes and slip rings and field excitation circuit Erratic weld output Check and tighten connections inside and outsid
137. rands 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 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 souder manuel lectrode enrob e DC 3 un poste souder OM 4409 Page 6 Indique des instructions sp cifiques APA Ce groupe de symboles veut dire Avertissement Attention DANGER DE CHOC ELECTRIQUE PIECES EN MOUVEMENT et PIECES CHAUDES Consulter les symboles et les instructions ci dessous y aff rant pour les actions n cessaires afin d viter le danger manuel AC avec tension vide r
138. rator Assembly 1 Bt IAS este dea 218087 Tank Fuel 1 ss 114 coke eo cee 124253 Bushing Tank Fuel 4 LS ME 189912 Stl Barbed Elbow W 047in Orifice Zinc Pld 1 da TG iere 189909 Stand Pipe Hose 250 X 9 26519 90 Deg Zinc 1 WAIL esteri cs 189913 Stl Barbed Elbow Zinc Pld 1 ca d48 rein 190142 Sender Fuel Gauge 9 750 Deep Tank 1 ie uestes ue 189910 Stand Pipe Hose 3125 X 9 260lg 90 Deg Zinc 1 zs 222 Ies 189908 Valve Drain Fuel 180 Deg Zinc Pld 1 o2 28 ee Fad 181572 Bushing Tank Fuel 1 TE CR TR TUE 196219 Hose Sae 250 Id X 500 Od X 26 000 Fuel Return Line 1 22 ET 191446 Extrusion Rubber w Adhesive 1 000 x 1 000 order by ft 6ft SE RE ET 209094 Bracket Mtg Hose 1 242106 Lovina aaah 212224 eta OV ee ERU NI aby een 1 gt LOU eee 191897 Bracket Mtg Unit 4 lt gt set nga 224266 Label Do Not Weld O
139. s near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists in inverters after stop ping engine e Stop engine on inverter and discharge input capacitors according to instructions in Maintenance Section before touching any parts HOT PARTS can cause severe burns 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 lated welding gloves and clothing to prevent burns cause sparks and flying metal As welds cool they can throw off slag Wear approved safety glasses with side shields even under your welding helmet FLYING METAL or DIRT can injure eyes e Welding chipping wire brushing and grinding OM 4409 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
140. sh Spring Ext 240 Od X 041 Wire X 3 500 Pid uror ree reu Rotor Generator Includes Ring Rtng Ext 1 375 Shaft X 050 Thk Bearing Ball Rdl Sgl Row 1 370 X 2 830 X 6 Fan Rotor Assy Generator Segmented includes Hub Drive Not Sold Separately DTE Plate Flex Hubmount Fan Rotor Segmented Assy Gen Screw 10 1 5 25 Hex 8 8 Pin Washer Lock 402idx0 7090dx 087t Stl Spliti Omm Screw 312 18 1 00 Hexwhd 66d Stl Pld Siffmg Tap rw Washer Lock 402idx0 7090dx 087t Stl Spliti Omm Screw 10 1 5 25 Hex 8 8 Pin Cover Starter EX DRY BER Washer Lock 402idx0 7090dx 087t Stl Spliti Omm OM 4409 Page 91 Dia Part No Mkgs No Description Quantity Figure 19 4 Generator Continued 172555 Screw M10 1 5x 50 Hex Hd pln 8 8 Pld 6 Ae etes 602159 Screw 312 18x 75 Hexwhd 66d Stl Pld Slffmg Tap rw 6 604950 Screw 312 18x2 00 Hex Hd pln Gr5 Pld 4 26 enel 602211 Washer Lock 318idx0 5860dx 078t Stl Pld Split 812 4 DT Lagann 1389341 Washer Exciter gt vce aw ale poa ee ma 4 28 190823 Brush Contact Elect 250 500 X 1 250 Grd 3 2
141. sions vary with loca tion of mounting brackets Weight No fuel 2010 Ib 907 kg w fuel 2185 Ib 993 kg Lifting Eye Weight Rating 2185 Ib 993 kg Maximum 802 161 A Do not exceed tilt angles or engine could be damaged or unit could tip A Do not move or operate unit where it could tip 803 231 Notes OM 4409 Page 14 Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual 4 5 Stick And MIG Volt Ampere Curves A DC Stick Mode The volt ampere curve shows the minimum and maximum voltage 100 and amperage output capabilities of the welding generator Curves of all other settings fall between the curves shown 80 60 40 DC VOLTS 20 0 100 200 300 400 500 600 700 800 900 1000 DC AMPERES B AC Stick Mode Optional 100 80 E 40 VOLTS 20 300 400 500 600 AMPERES MIG Mode 100 80 DC VOLTS 0 100 200 300 400 500 600 700 800 900 1000 DC AMPERES 208 135 203 415 208 956 OM 4409 Page 15 4 6 TIG Volt Ampere Curves A DC TIG Mode 100 Ranges 60 450 80 40 330 30 220 20 110 60 DC VOLTS 40 20 0 0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 DC AMPERES B AC TIG Mode Optional 100 80 AC VOLTS 300 400 500 600 AC AMPER
142. ss Contactor switch to any Weld Terminals Always On position see Section 6 3 No battery charge or weld output Disconnect equipment from generator power receptacles during start up Check fuses F1 and F2 and replace if open see Section 9 8 Have Factory Authorized Service Agent check integrated rectifier SR1 capacitor C9 field current regulator board PC1 and the rotor Reset supplementary protector CB12 see Section 9 8 Have Factory Authorized Service Agent check brushes and slip rings field current regulator board PC1 and field excitation circuit OM 4409 Page 60 SECTION 12 AIR COMPRESSOR DIAGRAM Do not touch live electrical parts Disconnect input power or stop engine before servicing Do not operate with covers removed Have only qualified persons install use or service this unit WARNING 7 ELECTRIC SHOCK HAZARD ONidid NIVHQ 10 XIN ONildid aonvo QN3931 ONldid 13431710 HOLVHVdaS 025 GIOAINVN AATVA 440 1NHS AATVA 5 SS3Hd WNWININ HOLVINSAY yc gonvodunssaug HOLMS 2HNSS2Hd 31009 110 E IOHLNOO OLLVLSOWHAHL HOLIMS SHNIWHAdWAL
143. sse fr quence et des champs magn tiques et lectriques Le courant de soudage pendant son passage dans les c bles de sou causera des champs lectromagn tiques Il y a eu et il y a encore un certain souci propos de tels champs Cependant apr s avoir exa min plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban bleu du National Research Council a conclu L accumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lectriques haute fr quence repr sente un risque la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent tre examin es En attendant que les conclusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn ti ques pendant le soudage ou le coupage Pour r duire les champs magn tiques sur le poste de travail appliquer les proc dures suivantes Pour les moteurs essence Les gaz d chappement des moteurs contiennent des 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 Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l Etat de Californie com me provoquant des ca
144. ssor 1gal 1 MO us 044772 Screw 12 1 7 30 Hex 8 8 Pin 6 602216 Washer Lock 502idx0 8790dx 151t Stl Pld Split 500 6 lE 198447 Screw M10 1 5x 20 Hex Hd pln 8 8 Pin 1 tps 602243 Washer Flat 438idx1 0000dx 083t Stl Pld 1 o e s 208425 Screw 10 1 5 60 Hex Hd pln 8 8 Pld Din 931 1 cha fatten 198631 Nut M10 Hex Lock Nut Stl Pld 1 gt cio 208426 Screw M12 1 75x 40 Hex Hd 12pt Flange Screw 12 9 2 ix 602216 Washer Lock 502idx0 8790dx 151t Stl Pld Split 500 2 08 214687 Pipe Stl 3 4bspp X 3 4 Jic 1 BOO 214920 Seal Ring Bonded Rbr Stl 950 Id X 1 380 Od X 100 1 9 dean ecb ta 218423 O RING ete esa Sak aX E RE AN UEM an Eee 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 4409 Page 96 Warranty Questions Call 1 800 4 A MILLER for your local Miller distributor
145. ssure is too low or coolant tempera ture is too high x This unit has a low oil pressure shut down switch However some condi tions may cause engine damage before the engine shuts down Check oil level often and do not use the oil pressure shutdown system to monitor oil level Follow run in procedure in engine manual If unburned fuel and oil collect in exhaust pipe during run in see Section 14 Fuel NOTICE Do not use gasoline Gasoline will damage engine Engine Oil Add fresh diesel fuel before starting to pre vent air from entering the fuel system see engine maintenance label for fuel specifica tions Leave filler neck empty to allow room for expansion Engine stops if fuel level is low on units with low fuel shutdown option Do not run out of fuel or air may enter fuel system and cause starting problems See engine manual to bleed air from fuel system Engine Oil After fueling check oil with unit on level sur face If oil is not up to full mark on dipstick add oil see maintenance label for engine oil specifications Compressor 1 Compressor Oil Level Indicator On Tank Check oil with unit on level surface Add oil Compressor 803 228 if oil is not up to full mark on indicator see maintenance label for oil specifications Cold Weather Starting To improve cold weather starting Use Starting Aid switch see Section 6 1 Keep battery in good condition Store b
146. st Split 250 2 28 GRD 083030 Stud Brs 250 20 X 1 750 W Hex Collar 1 s eO cater gears 209056 Cover Receptacle W Gasket 1 d soe eas 190861 Label Warning Electric Shock And Moving Parts Etc 1 uS Ade a Ne 197399 Label Warning Ph Generator Power 1 UST Luca PV eee 209056 Cover Receptacle 2 250 Dia Lexan 2 210149 Label Battery Charge Switch Position 1 Label Polarity AC Switch Position wae 12 220491 Switch Polarity AC 1 tyes 13 210217 Switch Battery Charge Assy 1 201125 Panel Mtg Terminal Power Output 1 35 4 PC5 189744 Circuit Card Assembly 2 ia dO ce SUR 210206 Bracket Support Switch 1 Ner OE EOD EN 039046 Terminal Pwr Output Black 1 180735 Washer Output Stud 2 134201 Stand off Support Pc Card 312 375w Post amp lock 43 8 03 181169 Spacer Output Stud
147. t Pc Card 312 375w Post amp lock 43 3 5 215755 Circuit Card Assy Protection 1 188136 Insulator Heatsink 8 NA 188493 Heat Sink Rectifier Al 2 8 03 05 07 208334 Diode Rect 275 300v 3 9 D2 D4 D6 208335 Diode Rect 275 300v 3 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 4409 Page 93 Hardware is common and not available unless listed Nea 803 328 G Figure 19 6 Air Compressor Assembly OM 4409 Page 94 Dia Part No Mkgs No Description Quantity Figure 19 6 Air Compressor Assembly Figure 19 1 78 200607 Valve Ball 2i eee ter 1 210523 Flrd Stl Tube End Female Pipe End 3 4 1 dre DR 206939 Tank Separator 1 AP 210248 Hose Assy Air W Fittings 3 4 X 35 250 Lg
148. tive terminal on right and work cable to Positive ter minal on left If equipped with optional Polarity AC Se lector switch connect electrode holder cable to Electrode terminal on left and work cable to Work terminal on right Incorrect Installation MIG And FCAW Welding For MIG welding Direct Current Electrode Positive DCEP connect wire feeder cable to Positive terminal on left and work cable to Negative terminal on right Use Process Contactor switch to select type of weld output see Section 6 3 For MIG and FCAW Direct Current Elec trode Negative DCEN connect wire feeder cable to Negative terminal on right and work cable to Positive termi nal on left Use Process Contactor switch to select type of weld output see Section 6 3 If equipped with optional Polarity AC Se lector switch connect wire feeder cable to Electrode terminal on left and work cable to Work terminal on right OM 4409 Page 28 803 231 803 778 5 9 Selecting Weld Cable Sizes Weld Cable Size and Total Cable Copper Length in Weld Circuit Not Exceeding Weld Output Terminals A Turn off power before connecting to weld output terminals 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 100 ft 30 m or Less A Do not use worn dam 80 45
149. ult is detected GFCI Reset button pops out and receptacle does not work Check for faulty tools plugged in receptacle Press button to reset GFCH gt At least once a month run en gine at weld power speed and press test button to verify GFCI is working properly 3 Supplementary Protector CB1 4 Supplementary Protector CB2 CB1 protects RC1 and the genera tor winding from overload If CB1 opens RC1 and GFCl1 do not work Place switch in On position to reset CB2 protects from overload If CB2 opens GFCI1 does not work Press button to reset x If a supplementary protector continues to open contact Factory Authorized Service Agent Generator power is not af fected by weld output Maximum output is 2 4 kVA kW from GFCI1 and 4 kVA kW from RC1 Maximum output from all re ceptacles is 4 kVA kW EXAMPLE If 13 A is drawn from RC1 only 7 A is available at GFCI1 240 V x 13 A 120 V x 7 A 4 0 191 624 OM 4409 Page 36 7 2 Connecting To Optional AC Power Plant i gt ERE AP AS b s plug before inserting leads Reinstall bushing 91 92 Rear Of Panel 29 3 Single Phase Power Connection 1 2 J Three Phase Power Connection 4622 Sin gle Th res Output 1 ase Volts 120 240 240 A vee Amps 50 48 if no con
150. ures Ne pas approcher les mains des ventilateurs courroies et autres pi ces en mouvement e Maintenir ferm s et fixement en place les portes panneaux re couvrements et dispositifs de protection e Arr ter le moteur avant d installer ou brancher l appareil OM 4409 Page 8 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 bouteille 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 norm
151. urrent From Battery CCA Rating And Chart See Section 8 2 Start Engine REMOTE ON OFF SWITCH REQUIRED Set Process Contactor Switch To Any Remote On Off Switch Required Position 425 400 40 P 4 Set Ampere Range Switch To Lowest Range That Exceeds Charge Current NOTICE Do not switch under load G O REMOTE ON OFF SWITCH REQUIRED Set Process Contactor Switch To Any Weld Terminals Always On Position To Begin Charging To control battery charging output using remote device connected to the Remote 14 receptacle keep Process Contactor switch in Remote On Off Switch Required position and use remote device to turn charging output on and off In Example Battery Voltage 12 Volts Battery CCA Rating 500 Charge Current 100 A See Section 8 2 Ampere Range Setting 55 to 125A V A Control Setting Any Position This battery charging procedure uses the front panel controls to turn charging output on and off CHARGE MATCH VOLTAGE POLARITY TO BATTERY BEFORE CHARGING CHARGE IN LOWEST AMPERAGE RANGE EXTEND BATTERY LFE Set Output Selector Switch To Voltage Of Battery Being Charged 12 Or 24 Volt NOTICE Do not switch under load 2 J amp gt gt Connect Cables Observe Correct Polarity 124 2 Charge 10 minutes Check Battery Voltage Continue Charging If Necessary
152. ury Use lifting eye to lift unit and properly installed accessories only NOT gas cylinders Do not exceed maximum lift eye weight rating see Specifications e Liftand support unit only with proper equipment and correct procedures e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit OVERHEATING can damage motors e Turn off or unplug equipment before starting or stopping engine e Do not let low voltage and frequency caused by low engine speed damage electric motors Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable FLYING SPARKS can cause injury Wear a face shield to protect eyes and face Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face hand and body protection Sparks can cause fires keep flammables away N MOVING PARTS can cause injury e Keep away from moving parts Keep away from pinch points such as drive rolls 3 OM 4409 Page 4 WELDING WIRE can cause injury 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 OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again Do not block or filte
153. ut to field current regulator board PC1 If CB5 opens weld output and 24 volt outputto RC14 stops On units with op tional power plant power at receptacle 5 also stops if CB5 opens CB6 protects the 115 volt ac output to remote receptacle RC14 If CB6 opens 115 volt output to RC14 stops CB10 protects the engine battery cir cuit If CB10 opens the engine will not crank CB10 automatically resets when the fault is corrected CB11 protects the engine wiring har ness IfCB11 opens weld output stops generator power is still available CB12 protects the field flashing circuit If CB12 opens the generator may not excite at start up and weld and genera tor power output may not be available CB13 protects the engine shutdown cir cuit If CB13 opens the engine cranks but does not start Press button to reset CB14 protects the throttle solenoid If CB14 opens the engine will not run at idle speed CB14 automatically resets when the fault is corrected 803 229 OM 4409 Page 50 SECTION 10 AIR COMPRESSOR MAINTENANCE EF Use only genuine Ingersoll Rand compressor and filters to maintain 3 year warranty on air compressor The air compressor warranty will be reduced to 2 years if non Ingersoll Rand oil and filters are used The air compressor normally requires service at the intervals listed in the maintenance schedule if used in a clean dry environment The compres sor will require service more often
154. v L6 30r 1 edge Na tee sa eM 010146 Clamp Nyl 625 Clamp Dia X 500 Wide 203 Mtg Hole 2 17 RC5 182954 Rept Str 3p4w 50 125 250 1 TO eL bb 025248 Stand off Insul 250 20 1 2 1 604102 Connector Clamp Cable 1 000 1 197527 Guard Circuit Breaker 1 oa ee tare se des 197363 Terminal Ring Tng Screw Clamp 3 22 CB7 214926 Supplementary Protector Man Reset 50 250vac 1 215347 deed er Ax Den ear ERA 1 opu ead agate 215363 Panel Generator Power Full Option 1 S So cuts Rhea CT2 197433 Transformer Current Sensing 1 sed siii 4214927 Boot Circuit Breaker 1 Pole 1 2 ss 197508 Plug Protective 1 205 077440 Bushing Conduit 11 1 601836 Nut 250 20 50hex 19h Brs 3 DIERUM 010915 Washer Flat 257idx0 6400dx 031t Brs 4 163167 Washer Lock 254idx0 4890dx 062t S
155. vere conditions Check Change Clean Replace Reference To be done by Factory Authorized Service Agent Every Section 5 7 8 FUEL 9 6 WATER Hours Fuel Water Separator Fuel Level Oil Level Oil Fuel Spills Every 50 p Hours M 2 Weld Terminals Every Section 9 4 100 Hours of C Battery Terminals Air Cleaner Hoses Air Cleaner Element Every un Engine 250 N o Manual Hours 5 Section 9 5 Unreadable Labels Fan Belt Tension Cooling System QSpark Arrestor Every Sf 8 Hours gt lt lt Weld Cables Oil Oil Filter Every Section 9 6 1000 9 3 and Hours Engine Manual Fuel Filter Inside Unit Valve Clearance Drain Sludge 3 Slip Rings Brushes Every 3000 Hours amp Q Injectors Every 6000 Hours or 5 Years Engine Timing Belt OM 4409 Page 44 9 3 Checking Generator Brushes 1 Generator Brush AN i ler A Stop engine and let cool Remove brushes from brush holder Replace brushes if damaged or if brush material is at or near minimum length Minimum Length 5 8 in 16 mm EL New Length 1 1 4 in 32 mm Replace Damaged Brushes 1 Ref 206 467 Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge 025 in 22 Gauge 031 in 20 Gauge 037 in 18 Gauge 050
156. working on a battery Do not use welder to charge batteries or jump start vehicles Observe correct polarity and on batteries Disconnect negative cable first and connect it last FUEL can cause fire or explosion e Stop engine and let it cool off before checking or adding fuel Do not add fuel while smoking or if unit is near any sparks or open flames Do not overfill tank allow room for fuel to expand Do not spill fuel If fuel is spilled clean up before starting engine Dispose of rags in a fireproof container Always keep nozzle in contact with tank when fueling MOVING PARTS can cause injury Keep away from fans belts and rotors v e Keep all doors panels covers and guards closed and securely in place Stop engine before installing or connecting unit Have only qualified people remove doors panels covers or guards for maintenance and troubleshooting as necessary To prevent accidental starting during servicing disconnect negative battery cable from battery Keep hands hair loose clothing and tools away from moving parts Reinstall doors panels covers or guards when servicing is finished and before starting engine 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 HOT PARTS can cause severe burns Do not touch hot parts
157. y lift unit and secure in a level position Use adequate blocks or stands to support unit while drain ing fuel tank Attach 1 2 ID hose to drain valve Put metal container under drain and use screwdriver to open sludge drain valve Close valve when sludge has drained Remove hose OM 4409 Page 49 9 8 Engine Generator Overload Protection A Stop engine gt When a supplementary protector circuit breaker or fuse opens it usually indicates a more serious problem exists Contact Factory Authorized Service Agent See Section 10 4 for air compres sor overload protection 1 Fuse F1 2 Fuse F2 F1 and F2 protect the stator exciter winding from overload If F1 opens weld and generator power is low or stops entirely If F2 opens weld output is low or stops entirely 4 KVA KW gen erator power is still available 3 Circuit Breaker Not Shown 4 Supplementary Protector CB5 5 Supplementary Protector 6 6 Circuit Breaker CB10 Not Shown Supplementary Protector CB11 N Supplementary Protector CB12 Supplementary Protector CB13 10 Circuit Breaker CB14 Not Shown CB4 protects the welding arc drive dig circuit If CB4 opens electrode may stick to the workpiece more frequently during low voltage short arc length conditions CB4 automatically resets when the fault is corrected CB5 protects the 24 volt ac output to re mote receptacle RC14 and 24 volt out p

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