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Miller Electric Big Blue 300 User's Manual

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1. RE Pnau sens l EITHER ONE OR BOTH RECEPTACLES MAY REPLACE GFCIS RCS RC6 120v NU m G X ig Y l ze Ys li E pa um L RECEPTACLE CONFIGURATIONS eren d Ce 21 uH MX nal EN lev z NS end 42 T D TH 120 240V a Z CB5 AC I tl 8 t t 8 97 KN TE zn 94 E E el E A D LX S x 120VAC 67 dm NL EZ T t 788 189 120VAC m Les A A A A A A A A m m x c1 01 En EZ 2 Le PORN Da OOAD V 97 RC11 GFCI2 CBA a RC1 5 gt es HO uH M OG 113 2 E ew g RC1 3 NS GND 7 L RC1 gt lt F3 e m rn RC2 PLG10 RC1 1 BM K E2 22 PC3 RC1 sp 02 lt RC2 2 VOLTAGE RC1 os REGULATOR 700 RCI 10 gt C3 lt RC2 5 RC1 2 120 21 e RC1 gt Kis H 107 Fi lt lt Rc2 8 5 CA F2 k c1 M RCI PLGB m YY Y PE Izo 791 190 81 24VAC ao TE 42 pow me 1 m pre 42 pc2 2227 METER DISPLAY CB3 GR1 mi rN 45 TL ag u CX Bi HX RC1 PLOS pl mem amp
2. 1 7 PC1 231705 Module Main Control Scr Gating 1 8 PC3 214770 Module Voltage Regulator 1 Lab loger kang han 215522 Bracket Vault corse AEN MAER Ee aaa 1 AY OEA Zl ane 21992972 StabIllZer Leed Vi esos NG eere acr LG HANG E 1 A eut ge Nate Ed 192303 Angle Mtg Stabilizer 2 11 TE1 172661 Block Stud Connection 6 Position 1 naka Eer 179734 Link Jumper orai ee a an rhin es A tr ho e KEE 213500 Brkt Beam Support 1 Seal E E ETE ica aes 213602 Gasket Exhaust Outlet Cat 3013 1 wae ld Yoda Pad 214753 Bracket Holddown Fuel Tank 1 pis WERNER 213493 Upright Center Assy 1 SEEN A RENNES 189464 Seal Weather Lift Eye 1 AP E EE 213501 Bracket Fuel Pump Filter 1 sana NG eer ee NA KEN KANE KAEN SN Bracket Fuel Filter Mtg Order Thru Engine Manufacturer 1 eu 217687 Filtet Fuel SDIFE ODI ihe reete e ee eh d iron 1 SAONE dant een 207721 Pump F el ee e ALADIN KAN Tan ense deg dem 1 xad EE 213858 Filter Fuel In line 5 16x5 16 M
3. 15 4 3 Vot Amp re C S r sco eer ret gov de ect da sos dad ng erm Pb RUE RE eos ARE ARR ie 16 4 4 F el Gonsumplion vereri rrt tme aie ee a C e POP RR Y oe XR RUSO ER CR D AR C PCS 17 4 5 Duty Cycle And Overheating 17 4 6 AC Generator Power Curve esses n 18 SECTION 5 INSTALLATION 22 023 NGA GAPANG ia 19 5 1 Installing Welding Generator 19 5 2 Mounting Welding Generator 20 5 3 Installing Exhaust Pipe ii ce eene iure tras 21 5 4 Activating The Dry Charge Battery If Applicable 22 5 5 Connecting The Battery 25er eee e se Fir da mei etae RO peg d e ls 22 5 6 Engine Prestart Checks 2n a ER ae nn E REX nx AD ER REA ne ea 23 5 7 Connecting To Weld Output Terminals 24 5 8 Selecting Weld Cable Sizes 25 5 9 Connecting To Remote 14 Receptacle RC14 26 SECTION 6 OPERATING WELDING GENERATOR LLLLLL RII n nnn 28 6 1 Front Panel Controls See Section 6 2 28 6 2 Description Of Front Panel Controls See Section 6 1 29 6 3 Process Contactor Switch
4. 1 ppp Ol eege 212611 Hose Fuel Stand Pipe W 3 16 In Ftg Return 1 paa BB eae na 212610 Hose Fuel Stand Pipe W 5 16 In Ftg Supply 1 89 SENDER 213265 Sender Fuel Gauge 1 OM 4433 Page 63 Item Dia Part No Mkgs No Description Quantity Figure 12 1 Main Assembly Continued Vn ety ie ars 172071 Clamp Hose 520 605 Clp Dia Slittng Black 8 os his AANE mer Rte 211961 Hose Sae 312 Id X 560 Od X 16 000 2 Sa HS sah te ER 213804 Hose Sae 312 Id X 560 Od X 2 500 1 Miam toi awa eL 191819 Hose Sae 312 Id X 560 Od X 15 000 1 aperi EU IA 145054 Hose Sae 187 Id X 410 Od X 26 000 1 Iss d cc una 213465 Bolt J Stl 312 18 X 7 250 Pld 2 sug APO ae 213466 Bracket Battery Holddown 1 92 BATT 146237 Battery Stor 12v 585 Crk 95 Rsv Gp 55 Maint Free 1 Ec 190207 Cable Bat Pos 45 In Lg No 1 Awg W Clamp amp 406 Rng 1 xcd ves M EPI 213668 Bracket Mtg Unit 4 Ses sot cUm dod ee 2194585 BAS out de ane pts RELIER aa 1 pix 9065 sees RES 213483 Support Engine Rh Ca
5. 2 Oia 010381 Connector Rectifier 3 19 C13 14 15 128750 Capacitor Cer Disc 1 Uf 500 Vdc W Terms 3 DOG ve V Ran 209056 Cover Receptacle W Gasket 4 21 RC11 182954 Ropt Str 3p4w 50a 125 250v Flush Mtg 14 50 1 ANA RE Nameplate Generator Power Order By Model amp Serial No 1 PA suos At catis 213509 Panel Power 1 24 RC5 6 214918 Rept Str Dx Grd 2p3w 20a 125v 5 20r Order By Model 8 Serial No 24 GFCI1 2 151981 Ropt Str Dx Grd 2p3w 15 20a 125v 5 20r Gfi Order By Model 8 Serial No 25 C11 C12 217054 Capacitor Cer Disc 0047 Uf 3000 Vdc W Terms 2 26 CB4 CB6 093996 Supplementary Pro Man Reset 1p 20a 250vac Frict 2 27 CB5 203026 Supplementary Protector Man Reset 2p 50a 240vac 1 28 GRD 083030 Stud Brs 250 20 X 1 750 W Hex Collar 1 OD ia ostendi ess 010915 Washer Flat 257idx0 6400dx 031t BIS 4 col 601836 Nut 250 20 50hex 19h Brs 3 iu Ol ass echa e Re ac brit Nameplate Weld Terminal Order By Model amp Serial No 1 181169 Spacer Output Stud 3 O uu revera 186621 Boo
6. 30 6 4 Lift Arc Start Procedure 31 6 5 Remote Voltage Amperage Control 32 SECTION 7 OPERATING AUXILIARY EQUIPMENT 33 7 1 Generator Power Receptacles eee a RU Ra Oa rx E e P a ed 33 SECTION 8 MAINTENANCE amp TROUBLESHOOTING LLLLLL Inn 34 8 1 Routine Maintenance nosies ia maa eek nk RANA LAAN ERE Ra y EE YER ERE EE Rae 34 8 2 Maintenance kabila E eee Sea oe LPS E Ad 35 8 3 Servicing Ait Cleaner EE C Rp EA UL Ad 36 8 4 Inspecting And Cleaning Optional Spark Arrestor Muffler 37 TABLE OF CONTENTS 8 5 Servicing Engine Cooling System 37 8 6 Adjusting Engine Speed On Standard Models 38 8 7 Adjusting Engine Speed On Models With Automatic Idle Optional 39 8 8 Servicing Fuel And Lubrication Systems 40 8 9 Overload Protection eos wating ia RR REGE RA CRN AAA ENS 41 8 10 Checking Generator Brushes 42 8 11 Voltmeter Ammeter Help Displays 43 8 12 Troubleshooting 2 224 rot NG Ge aussie no
7. 2 tc estne seen 126984 Brush w Spring 2 sux E WEE 005614 EEN Holder Brush 4 aa EE 2 iw Ke WEE 125548 Holder Brush Elect 1 na O ciat LAS 158832 Screw 010 32x 50 Hex Hd slt Stl Pld Sq Cone Sems 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 4433 Page 68 E Hardware is common and not available unless listed Wirng harnesses are listed at the end of parts section 4 Z 10 HENRY 2 3 Ran ty a pe Pa ES po ni p 2 Z o PA NS pia e AN o ue By Pd y 5 4 9 803 685 A Figure 12 5 Rectifier Assembly Item Dia Part No Mkgs No Description Quantity Figure 12 5 Rectifier Assembly Figure 12 1 Item 4 TET 217081 Rectifier Assembly Includes 1 Pan ere 211984 Heat Sink 22 1 2 MOD1 2 3 218296 Kit Module SCR 3 3 MOD4 5 6 218292 Kit Module SCR
8. Front Panel End o Weight No fuel 1100 Ib 499 kg w fuel 1199 lb 544 kg Lifting Eye Weight Rating 1500 Ib 680 Kg Maximum Do not exceed tilt angles or engine could be damaged or unit could tip Do not move or operate unit where it could tip OM 4433 Page 15 4 3 Volt Ampere Curves A Stick Mode The volt ampere curves show the minimum and maximum voltage and amperage output capabilities of 100 the welding generator Curves of all other settings fall between the 90 L curves shown DC VOLTS u O MAX 200 300 400 500 DC AMPERES 0 100 B MIG Mode 100 o co o o T T DC VOLTS A O N o T T 0 1 1 1 1 1 1 1 1 1 0 100 200 300 400 500 DC AMPERES C TIG Mode 100 80 60 40 DC VOLTS 20 MAX 0 100 200 300 400 500 DC AMPERES 217 517 217 516 217 518 OM 4433 Page 16 4 4 Fuel Consumption U S GAL HR 2 00 1 75 1 50t 1 25 1 00 f 0 75f 0 50 f 0 251 0 00 The curve shows typical fuel use under weld or power loads 50 100 150 200 250 300 350 400 DC WELD AMPERES AT 100 DUTY CYCLE 217 509 4 5 Duty Cycle And Overheating D 1 10096 Duty Cycle EX 1 Duty Cycle is percentage of 10 min 9 utes that
9. 2 Ala reu 225120 Label Warning Moving Parts Can Cause Injury 3 Sanat ada a A eps 189975 Hinge Door Access 180 Deg 2 DADO Ad cux figu 087341 Bumper Door 1 000 Od X 750 High Rbr 50 Duro W O 2 E EE 2193486 Panel ROCKER ci Re ERES n e eR ia tar ate et DEUDA 1 PAIS NEP AE 217698 Label Help Codes 1 saa DO upra eR 168385 Label Warning Battery Explosion Can Blind 1 ann f sa evade RE 203260 Label Caution Do Not Use Ether 1 i DOG evo entes 225120 Label Warning Moving Parts Can Cause Injury 1 230637 Idle Solenoid Assy consisting of 1 D vit LV 6230828 Bracket Mtg Solenoid Idle 1 60 TS1 6230634 Solenoid Throttle W 4 8 4 Lb Spring 1 ADEM 198109 Screw Shld Stl Sch 250 20 X 437 X 500 Shld 1 sin Ole dnos atus 198018 Linkage Throttle Solenoid 1 Pun ENG A E tend NR 230830 Arm Throttle 1 ma EE 213266 Mount Engine Generator Flange Mtg 2 xig Dee 197506 Screw M14 1 5x 30 Hex Hd pln 8 8 PIN 6 E
10. Be sure connection to work piece is clean and tight Use dry properly stored electrodes Remove excessive coils from weld cables Have Factory Authorized Service Agent check brushes and slip rings High weld output Have Factory Authorized Service Agent check main control module PC1 and hall device HD1 Low weld output Check engine speed and adjust if necessary Check fuse F1 and replace if open see Section 8 9 If F1 is open have Factory Authorized Service Agent check the rotor Low open circuit voltage Check engine speed and adjust if necessary Have Factory Authorized Service Agent check main control module PC1 voltage regulator module PC3 and main rectifier No remote fine amperage control Repair or replace remote control device Check and secure connections to Remote Amperage Adjust receptacle RC14 see Section 5 9 No 24 volt or 115 volt ac output at Re mote receptacle RC14 Reset supplementary protector CB7 24 volt or CB8 115 volt see Section 8 9 OM 4433 Page 44 B Generator Power Trouble Remedy No generator power output at ac recep tacles weld output okay Reset receptacle supplementary protector s see Section 7 1 No generator power or weld output Disconnect equipment from generator power receptacles during start up Check fuse F1 and replace if open see Section 8 9 Have Factory Authorized
11. 2 EE CB1 190374 Circuit Breaker Auto Reset 12vdc 40 Amp 1 uses CB2 CB3 083432 Supplementary Pro Man Reset 1p 10a 250vac Frict 2 sans CR3 197325 Relay Encl 12vdc Spst 70a 4pin Flange Mig 1 EN CR2 244876 Relay Encl 6vdc Spst 35a 14vdc 5 Pin 1 dex ea Rid R4 4 217335 Resistor Board sas same a ado RR Ge kaaa V Vac AIME AY ax 148850 Socket Relay 5 Pin 1 Ce 212116 Conn Deutsch 2p 1row Female Plug 8 m T ee a 212117 Conn Deutsch Wedge Lock 2 Position 3 UE PLG1 214932 Conn Rect Univ 039 8p S 2row Plug Cable Lkg Seal 1 acid OR TA 214933 Seal Wire Univ O39 7 mng Ee Ge Baa 214934 Seal Plug Univ 039 1 CAMP p For 81 211292 Conn Pack 4p 1row Female 1 EET For S1 211293 Conn Pack Terminal Position Assurance Lock 1 Eten d AEE 129524 Term Frict 250x032 Uninsul Male 130 Stud Mtg 3pr 2 Den 217002 Harness Weld Control Includes 1 EN PLG2 150316 Conn Rect Univ 039 6p S 3row Plug Cable Lkg 1 PANA PLG9 214951 Conn
12. OM 4433 218 314P 2007 11 m Miller e Stick SMAW Welding Ka TIG GTAW Welding MIG GMAW Welding re Flux Cored FCAW Welding FC Air Carbon Arc CAC A WAS Cutting and Gouging Description CSS Engine Driven Welding Generator Big Blue 300 P OWNER S MANUAL File Engine Drive a Visit our website at www MillerWelds com From Miller to You Thank you and congratulations on choosing Miller Now you can get the job done and get it done right We know you don t have time to do it any other way That s why when Niels Miller first started building arc welders in 1929 he made sure his products offered long lasting value and superior quality Like you his customers couldn t afford anything less Miller products had to be more than the best they could be They had to be the best you could buy Today the people that build and sell Miller products continue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 n U 3 BL E PEENI This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They Working as hard as you do every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most hassle free warranty in the We ve made installation and operation quick
13. Hose Radiator Upper Cat 3013 1 pul A GE 216811 Clip Nut Retaining 2 sara O edle ge 197613 Air Cleaner Intake 5 250 In Includes 1 Lacu deum gel LANNE NAME 197675 Dust Ejector Air Cleaner 1 gd ado 197676 Element Air Cleaner 1 Vac AD RIS TANE 197677 Cover Assy Air Cleaner 1 d cr Fe Pa d 197678 Body Air Cleaner 1 AAN Aaa 197679 Element Air Cleaner Safety 1 Ee 197829 Bracket Mtg Air Cleaner 1 KUA rm 212617 Hose Air Intake Cat 3013 1 pa IO Figure 12 4 Generator Assembly 1 dh agn e EA 213461 Bracket Mtg Generator 1 NEUE 213266 Mount Engine Generator Flange Mtg 1 CE KA PERO AN 212623 Tank Fuel Includes Fuel Cap And Items Below 1 bo BA usw dus 189908 Valve Drain Fuel 180 Deg Zinc Pld 1 ns OD se ated sedo un 181572 Bushing Tank Fuel 1 EE pep 124253 Bushing Tank Fuel
14. Le METAL CHAUD lors du coupage et gougeage plasma peut provoquer un in cendie ou une explosion e 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 e 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 e 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 recommand es par le constructeur 2 5 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance SION e 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 cific
15. Z REMOTE Connect Remote To Desired Maximum Control To Remote ni a Adjust Optional Remote Wel i R R G O REMOTE ON OFF SWITCH REQ eld Output Using Weld eceptacle RC14 Se Control to 100 ee g Set TIG or STICK Process Max 205 A DC 0 Min 20 A DC m gt Set V A Control amp HF Required Or Scratch Adjust Optional Remote Control to desired weld output WIRE Voitago Sensing O Feeder CV ZX D O Weld meters will always show the combined main and remote control setting and machine welds at nominal output setting of the meter REMOTE CV Feeder Using Remote Adjust Optional Remote Control to desired weld output Connect Remote Control To Remote Receptacle RC14 Weld meters show preset output when not welding Set WIRE Process 0774 Ref 217 357 B 803 562 OM 4433 Page 32 SECTION 7 OPERATING AUXILIARY EQUIPMENT 7 1 Generator Power Receptacles Cs aw n KJ E C LJ n Co co 1 120 V 20 A AC shown Receptacle RC5 and or GFCI1 2 120 V 20A AC GFCI shown Receptacle RC6 and or GFCI2 3 240V50AAC Receptacle RC11 RC5 6 and GFCI1 2 supply 60 Hz single phase power at weld power speed Recep tacle configuration var
16. 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 e Ne pas faire le plein en fumant ou proche d une source d tincelles ou d une flamme nue e 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 blessures e 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 Arr ter le moteur avant d installer ou brancher l appareil OM 4433 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 pressuri
17. 08190ZSb1 SUMIOA Te1souueu 19114 SUTT U PIS Y 00S vOL60LO90 sud 989 Z Lc HJTIIN El q y Ng von Ng vr8cHd Weg 0 L9 SOV sued 668 Z6L HATIIN 19 sib ce 49 39 Q00 Idv S SLc8d uospreuog 929 261 H3TIIIN NG 7 8958228d uospieuoq 629 261 H3TIIIN 0 81 4 0 v 989 SG 194 NEL El gt S 3 40 140 V 40 008 AN a z G L 18 526 a WLSV ev LV 6982 SA Ki k09 LS NIG Ci S er eb ei 138310 va MM INdH 0881 E Ruondo MWdH 0SzL O n AP EID EB E EE I Te dH Z LZ S1 D 0b SNIMHId OM 4433 Page 35 8 3 Servicing Air Cleaner A Stop engine NOTICE Do not run engine without air 1 2 3 4 cleaner or with dirty element Engine damage caused by using a damaged ele ment is not covered by the warranty EF The air cleaner primary element can VER be cleaned but the dirt holding capac KOKAK KAO H H j j C Ke ity of the filter is reduced with each DANO cleaning The chance of dirt reaching 6 the clean side of the filter while clean K L DANA NNN ORO ing and the possibility of filter damage makes cleaning a risk Consider the risk of unwarrantable equipment 5 damage
18. 4 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 A 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 4 Les symboles pr sent s ci apr s sont utilis s tout au long du pr sent manuel pour attirer votre attention et identifier les ris ques de danger Lorsque vous voyez un symbole soyez vigilant et suivez les directives mentionn es afin d viter tout danger Les consignes de s curit pr sent es ci apr s ne font que r sumer l information contenue dans les normes de s curit num r es la section 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 4 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
19. lated welding gloves and clothing to prevent burns cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet FLYING METAL or DIRT can injure eyes e Welding chipping wire brushing and grinding OM 4433 Page 1 FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instructions for metals consumables coatings cleaners and degreasers e Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe e Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases e Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventil
20. 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 grands pour emp cher le contact physique ventuel avec la pi ce ou la terre Ne passe servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou l o on risque de tomber e Se servir d une source lectrique courant lectrique UNIQUE MENT si le proc d de soudage le demande e Sil tilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip e Des pr cautions de s curit suppl mentaires sont requises dans des environnements risque comme les endroits humides ou lorsque l on porte des v tements mouill s sur des str
21. 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 e 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 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 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 e JAMAIS utiliser dans une maison ou garage m me avec les portes et fen tres ouvertes e Uniquemen
22. Front Access 1 su NOB aaa Figure 12 2 Front Panel Assembly 1 man MOD md saccis A05370 XMr GUrtent zoe secet AA e CET e ROC date TI dd 1 zi TO SE Figure 12 3 Control Panel 1 xa do ios as 213504 Tray Reactor amp Rectifier 1 Lah KGG eh 213491 Insulator Capacitor Bank Applies To Reactor Redtifier Tray 1 EM TETTE 215328 Kit Label Includes Safety And Informational Labels 1 When ordering a component ER 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 4433 Page 64 E Hardware is common and not available unless listed Wirng harnesses are listed at the end of parts section 34 32 33 803 684 B Figure 12 2 Panel Front w Components Item Dia Part No Mkgs No Description Quantity Figure 12 2 Panel Front w Components Figure 12 1 Item 108 Dan PE A RE AR es 097926 Knob Pointer 2 375 Dia X 250 Id W Set Screwsplstc 1 uM ER 072590 Lock Shaft Pot 375 32 X 250 Dia Shaft Tall 1 s deest e
23. See table for proper no load speed If necessary adjust speed as follows Start engine and run until warm Turn Process Contactor switch to Weld Terminals Always On Stick position 1 Lock Nut 2 Adjustment Screw Loosen nut Turn screw until engine runs at weld power speed Tighten nut EF Do not set engine speed higher than specified Tampering with adjustments other than shown may affect engine warranty 3 Engine Stop Lever A Stop engine Close door SAURENTS Ep rrr Ej LUSELIDEESIB mo Tools Needed JA 803 563 E OM 4433 Page 38 8 7 Adjusting Engine Speed On Models With Automatic Idle Optional Engine Speed Adjustment Ee y Engine Speed After tuning engine check en No Load gine speed with tachometer or 1880 rpm max frequency meter See table for S 62 6 Hz proper no load speed If neces sary adjust speed as follows 1500 rpm 50 Hz Start engine and run until warm Turn Process Contactor switch to Stick Weld Terminals Al ways On position 1 Throttle Rod Plunger 2 Lock Nut 3 Rubber Boot 4 Adjustment Screw Adjustment screw is not used to adjust engine speed when auto matic idle option is installed However it must be at least 1 8 in 3 mm away from the throttle arm when engine is running at idle rpm Unhook rubber boot from the so lenoid h
24. 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 e Properly install and ground this equipment according to its Owner s Manual and national state and local codes 5 Indicates special instructions AEN This group of symbols means Warning Watch Out ELECTRIC SHOCK MOVING PARTS 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 e 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
25. business and easy With Miller you can count on years ISO 9001 2000 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 in the U S A to 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 1 131 Symbol Usage itoni ceded te A re ER e HDD e a 1 1 2 Are Welding Hazards d geed eae ENN D Ue p DM NEED ee A Sepa 1 1 93 Engine Hazards ias mrmi ans A pig ol ene bee ee ety 3 1 4 Compressed Air Hazards as Konrat tex EU pb da ee EE las 3 1 5 Additional Symbols For Installation Operation And Maintenance 4 1 6 California Proposition 65
26. e Keep away from fans belts and rotors v e Keep all doors panels covers and guards closed and securely in place e Stop engine before installing or connecting unit e Have only qualified people remove doors panels covers or guards for maintenance and troubleshooting as necessary e To prevent accidental starting during servicing disconnect negative battery cable from battery e Keep hands hair loose clothing and tools away from moving parts e 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 e Block flywheel so that it will not turn while working on generator components HOT PARTS can cause severe burns Do not touch hot parts bare handed e Allow cooling period before working on equip ment e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns 1 4 Compressed Air Hazards BREATHING COMPRESSED AIR can cause serious injury or death e Do not 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 If possible check coolant level when engine is cold to avoid scalding e Always check coo
27. min 1 DLE SPEED nj 1500 RPM min 1 Optiona 00 A or 10kW 1 10 GPH 4 16 LPH 99 GPH 3 75 LPH 69 GPH 2 61 LPH 43 GPH 1 63 LPH 35 GPH 1 32 LPH 25 GPH 95 LPH Optiona 73dB 9 23 ft 98Lwa 73dB 23 ft 98Lwa 69dB 9 23 ft 94LwaOptiona 1 A 60Hz Diesel Engine ni Fuel Economy 00 A or 5 6kW 00 A or 2 4kW e E o gt U 120 240 CERTIFICATIONS NEMA EW1 LR5071 ISO 9001 ho EVIDENCE OF LABEL TAMPERING VOIDS WARRANTY 228417 B E US 228 417 B 803 562 F OM 4433 Page 13 3 3 Symbols And Definitions Some symbols are found only on CE products 2e Read Operator s Circuit Protector eN Do Not Switch KI Stop Engine Fes Eun gt Slow Idle D Start Engine Starting Aid Engine Oil Check Injectors Check Valve Fuel Protective Earth Pump Clearance Ground NN i i o Certified Trained Positive Negative q Mechanic PS Welding Arc A Amperes V Volts Panel Local Remote Air Temperature Or Q lt Engine Engine gt gt Output Ny g Temperature y Stick SMAW Constant Current G MIG GMAW n KYA Welding ES CC SA Welding DY TIG GTAW Time h Hours Seconds 1 NU Single Phase Three Phase Manual o o s While Welding A Engine Driven Electrode Three Phase H H Connection A Work Connection eS HI Alternator With Z Hertz
28. 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 e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e 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 e Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as 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
29. 120m 10 60 60 100 Duty Duty 10 100 Duty Cycle Amperes Cycle Cycle 100 4 20 4 20 4 20 360 2 35 1 50 1 0 60 1 0 60 150 3 30 3 30 2 85 1 50 1 0 60 2 0 70 3 0 95 3 0 95 200 3 30 2 85 160 1 0 60 2 0 70 3 O 95 4 O 120 4 0 120 250 2 85 1 50 1 0 60 2 0 70 3 0 95 4 0 120 SCH 2 a 2ea 2 0 2 ea 3 0 2 ea 300 1 50 1 0 60 2 0 70 3 0 95 4 0 120 e e Ca 2 ea 2 0 2 ea 3 0 2ea 3 0 2ea 4 350 1 0 60 2 0 70 3 0 95 4 0 120 Gao gt oo xd 20 2 ea 2 0 2 ea 3 0 2ea 4 0 262 4 400 1 0 60 2 0 70 3 0 95 4 0 120 on oe Pa o ixi 2 2 ea 2 0 2ea 3 0 2 ea 4 0 3 ea 3 0 3ea 3 0 500 2 0 70 3 0 95 4 0 120 2x70 2x95 2x120 3x95 3x95 mm for metric use This chart is a general guideline and may not suit all applications If cables overheat use next size larger cable Weld cable size AWG is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere For distances longer than those shown in this guide call a factory applications representative at 920 735 4505 S 0007 F Notes OM 4433 Page 25 5 9 Connecting To Remote 14 Receptacle RC14 OY LDR 14 long distance remote includes 12
30. 3 dui a 212602 Bus Bar Rectifier 1 c E EET 212639 e BUS Bar Rectifier ee free ERU wan ewe staat E aU ER VR 3 Diete AN ee 212601 Insulator Rectifier 1 7 TH1 213930 Thermistor Ntc 30k Ohm 25 Deg C 8 5in Lead 1 8 C1 6 215611 Capacitor Assy 3 9 C7 8 9 048420 Capacitor Cer Disc 01 Uf 1000 Vdc W Terms 3 m mE 217085 Bus Bar Rectifier v sens ela EINEN EN a 1 Da NU d Register eed 181853 Insulator Screw For Mounting Rectifier 4 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 4433 Page 69 Some wiring harness components switches relays supplementary protectors are also referenced elsewhere in this parts list Purchase compo nents separately or as part of the associated wiring harness Item Dia Part No Mkgs No Description Quantity Wiring Harnesses A SE HUE E 231122 Harness Engine Includes 1 kah aqu S4 021467 Switch Tgl Spst 3a 250v Off none On Spd Term 1 AIDE SR1 SR2 035704 Rectifier Integ Bridge 40 Amp 800v
31. Fillet Size of Weld A Field Weld Symbol Depth of Bevel R Weld All Around Reference Line Symbol e J Groove L P Tail A Line Weld Symbol Length of Weld Pitch Center to Center Spacing S E Both Sides Arrow Side Other Side gt V Groove U Groove O Ref AWS ANSI A2 4 T Square Groove OM 4433 Page 27 SECTION 6 OPERATING WELDING GENERATOR Front Panel Controls See Section 6 2 6 1 aC to B KO gt 8 SSSWER NN TNA NA ER 217 357 B 803 563 OM 4433 Page 28 6 2 Description Of Front Panel Controls See Section 6 1 ESTIS SUN A ak Engine Starting Controls 1 Preheat Switch Use switch to energize starting aid for cold weather starting see starting instructions fol lowing 2 Engine Control Switch Use switch to start engine select engine speed if unit has auto idle option and stop engine In Run position engine runs at weld power speed In Auto position optional engine runs at idle speed at no load and weld speed with load applied 3 Engine Stop Lever Use lever to stop engine if Engine Control switch does not work The Engine Stop lever shuts off the fuel sup
32. G e 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 e 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 injury e 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 e Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable L3 FLYING
33. Generator Item Dia Par No Mkgs No Description Quantity Figure 12 4 Generator Figure 12 1 Item 80 1 ROTOR 212474 Rotor Generator 4 Pole Includes 1 EEN 053390 Bearing Ball Rdl Gol Row 1 370 X 2 830 X 6 1 WE EE M TC 192600 Fan Generator 1 E ase ee s 159978 Bale Fans corso ains nee SM Pe EE 1 oe D aa aga e e 212126 Adapter Engine Machined 1 EON ata dete sack ya eeeey 602211 Washer Lock 318idx0 5860dx 078t Stl Pld Split312 6 p 192686 Screw M 8 1 25x 25 Hex Hd pln 8 8 Pld Din933 6 Ba a 602211 Washer Lock 318idx0 5860dx 078t Stl Pld Split 312 6 TEE METRE 192686 Screw M 8 1 25x 25 Hex Hd pln 8 8 Pld Din933 6 nup GE 212641 Stud Stl 375 16 1 625x 19 000 4 11 STATOR 212470 Stator Generator 4 Pole 1 n pU 1160943 JEndbell 2s tes sa pena wr Na alak da aed dela eh aes re ey alee 1 neu d M ANICA 167788 Nut 375 16 56hex 34h Stl Pld Sem Cone Wshr 88d 4 ur cp 218552 Brush Assembly 2 Pole Includes 1 seas VEER 047879 Bar Retaining Brushholder 2 Brushes 1 A MAL 161306 Cap Brushholder
34. 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 soudage Porter un casque 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 N 7 LE SOUDAGE peut provoquer un in PR cendie ou une explosion Le soudage effec
35. REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province miller warr 2007 01 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Nu
36. 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 engine several minutes at no load A Stop engine and let cool 6 Engine Exhaust Pipe Repeat procedure if wetstacking is present S 0684 OM 4433 Page 52 SECTION 11 GENERATOR POWER GUIDELINES x The views in this section are intended to be representative of all engine driven welding generators Your unit may differ from th
37. Use only correct fuses or circuit breakers Do not oversize or by pass them Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby n NOISE can damage hearing Noise from some processes or equipment can dam age hearing e Wear approved ear protection if noise level is high MAGNETIC FIELDS can affect Implanted Medical Devices e Wearers of Pacemakers and other Implanted Medical Devices should keep away Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding spot welding gouging plasma arc cutting or induction heating operations CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pres sure If damaged a cylinder can explode Since gas 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 ho
38. Warnings 5 1 7 Principal Safety Standards 2 5 1 8 EMF Information na sce t aaa 5 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 6 2 1 Signification des symboles 6 2 2 Dangers relatifs au soudage l arc 6 2 3 Dangers existant en relation avec le moteur 8 2 4 Dangers li s l air comprim 9 2 5 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 9 2 6 Proposition californienne 65 Avertissements 11 2 7 Principales normes de s curit 11 2 8 Information EME te EE ABIRE a LUE ERES ei DE UNE HE 11 SECTION S DEFINITIONS t mic e eM S Dan Ree eee RT NM Ne LR Era RR 12 3 1 Warning Label Definitions 12 3 2 Manufacturers Rating Label 13 3 3 Symbols And Definitioris iia NEE ha ee e ja ue le oe mn Ne 14 SECTION 4 SPECIFICATIONS ski z a xe Ee Y ER 15 4 1 Weld Power And Engine Specifications 15 4 2 Dimensions Weights And Operating Angles
39. Watts Split Phase 1 8 HP 800 300 1 6 HP 1225 500 1 4 HP 1600 600 1 3 HP 2100 700 1 2 HP 3175 875 Capacitor Start Induction Run 1 3 HP 2020 720 1 2 HP 3075 975 3 4 HP 4500 1400 1HP 6100 1600 1 1 2 HP 8200 2200 2HP 10550 2850 3 HP 15900 3900 5HP 23300 6800 Capacitor Start Capacitor Run 1 1 2 HP 8100 2000 5HP 23300 6000 7 1 2 HP 35000 8000 10 HP 46700 10700 Fan Duty 1 8 HP 1000 400 1 6 HP 1400 550 1 4 HP 1850 650 1 3 HP 2400 800 1 2 HP 3500 1100 11 6 Approximate Power Requ irements For Farm Home Equipment Farm Home Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 Milker Vacuum Pump 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 1 HP 6100 1600 1 1 2 HP 8200 2200 2 HP 10550 2850 3 HP 15900 3900 5 HP 23300 6800 High Torgue e g Barn 1 1 2 HP 8100 2000 Cleaners Silo Unloaders 5 HP 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 4433 Page 55 11 7 Approx
40. air flow is restricted or engine may overheat See Section 4 2 for lifting eye rating IF See Section 5 2 for mounting information Grounding 1 Equipment Grounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame gt Electrically bond generator frame to vehicle frame by met al to metal contact Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insu lated copper wire A Bed liners shipping skids and some running gears insu late the welding generator from the vehicle frame Al ways connect a ground wire from the generator equipment grounding terminal to bare metal on the vehicle frame as shown Grounding install3 2007 04 Ref 800 652 Ref 800 477 A 803 274 804 712 OM 4433 Page 19 5 2 Mounting Welding Generator 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 NOTICE Do not mount unit by supporting the base only at the four mounting brackets Use cross supports to adequately support unit and prevent damage to base Mi Supporting The Unit 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 2in Bolt And Washer Minimum Not Supplied 4 3 8 16
41. and use table to find KVA HP If code is not listed multiply running amperage by six to find starting amperage Step 2 Find Motor HP and Volts Step 3 Determine starting amper age see example Welding generator amperage out put must be at least twice the motors running amperage KVA HP x HP x 1000 Volts Starting Amperage Example Calculate starting amper age required for a 230 V 1 4 HP mo tor with a motor start code of M Volts 230 HP 1 4 KVA HP 11 2 11 2 x 1 4 x 1000 230 12 2A Starting the motor requires 12 2 amperes S 0624 11 9 How Much Power Can Generator Supply 1 Limit Load To 90 Of Generator Output Always start non resistive motor loads in order from largest to small est and add resistive loads last 2 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 4433 Page 57 11 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 pract
42. device filter board PC6 and main control module PC1 803 562 217 357 A OM 4433 Page 43 8 12 Troubleshooting P 4 t A Welding 3 Also see Voltmeter Ammeter help displays to assist in troubleshooting weld problems see Section 8 11 Trouble Remedy No weld output generator 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 turn remote contactor on see Section 5 9 Reset supplementary protector CB7 or CB8 see Section 8 9 Check for faulty remote device connected to RC14 Check and secure connections to Remote Control receptacle RC14 see Section 5 9 Check Voltmeter Ammeter help displays see Section 8 11 No weld output or generator power out put at ac receptacles Disconnect equipment from generator power receptacles during start up Reset supplementary protector CB3 see Section 8 9 Check fuse F1 and replace if open see Section 8 9 If F1 is open have Factory Authorized Service Agent check the voltage regulator module PC3 Check Voltmeter Ammeter help displays see Section 8 11 Have Factory Authorized Service Agent check brushes and slip rings voltage regulator module PC3 and field excitation circuit Erratic weld output Check and tighten connections inside and outside unit
43. in see Section 10 Fuel NOTICE Do not use gasoline Gasoline will damage engine The unit is shipped with enough fuel to pre vent air from entering fuel system Add fresh diesel fuel before starting see engine main tenance label for fuel specifications Leave filler neck empty to allow room for expansion Check radiator coolant level when fluid is low in recovery tank Capacity 6 qt 5 7 L Coolant Recovery Tank se Hot Full se Cold Full Do nat run out of fuel or air will enter fuel sys tem and cause starting problems See en gine manual to bleed air from fuel system 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 Coolant Check coolant level in radiator before start ing unit the first time If necessary add cool ant to radiator until coolant level is at bottom of filler neck Check coolant level in recovery tank daily If necessary add coolant to recovery tank until coolant level is between Cold Full and Hot Full levels If recovery tank coolant level was low also check coolant level in radiator Add coolant if level is below bottom of radia tor filler neck Unit is shipped with an engine coolant mix ture of water and ethylen
44. switches voltage am perage control to the remote control see Sec tion 5 9 With remote control connected weld output is determined by a combination of front panel and remote control voltage amperage set tings If no remote control is connected to the Re mote receptacle the front panel Voltage Am perage control adjusts voltage and amper age E If a remote device connected to Remote Receptacle RC14 is faulty or is discon nected the meters display Help 25 see Section8 11 Clear fault by stopping and restarting the unit or by turning Process Contactor switch to another position 7 Process Contactor Switch See Section 6 3 for Process Contactor Switch information 8 Voltage Amperage Control With Process Contactor switch in any Stick or TIG setting use control to adjust amperage With Process Contactor switch in any Wire MIG position use control to adjust voltage With Voltage Amperage Adjust Switch in Re mote position control limits the remote am perage in Stick or TIG mode but has no effect in Wire MIG modes Weld Meters EF Weld meters also work in combination to display troubleshooting help codes see Section 8 11 9 DC Voltmeter Voltmeter displays preset voltage MIG weld ing with contactor off and actual output volt age with the contactor on Voltmeter displays voltage at the weld output terminals but not necessarily the welding arc due to resistance of cable and connections To se
45. unit can weld at rated load without overheating EF This unit is rated for welding at 250 amperes continuously NOTICE Exceeding duty cycle can damage unit and void warranty 1000 800 a 600 LL s 500 a 400 z pa 300 T 250 200 150 1 Ss 25 30 40 50 60 DUTY CYCLE 217 515 OM 4433 Page 17 4 6 AC Generator Power Curve The ac power curve shows the gen erator power in amperes available atthe 120 and 240 volt receptacles 150 300 125 250 100 200 2 L a 75 1504 gt L Q 50 1007 25 507 Oo OO SSS SSS 0 20 40 60 80 AC AMPERES IN 240 V MODE 0 40 80 120 160 AC AMPERES IN 120 V MODE 217 519 Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge 025 in 22 Gauge 031 in 20 Gauge 037 in 18 Gauge 050 in 16 Gauge 063 in 14 Gauge 078 in 1 8 in 125 in 3 16 in 188 in 1 4 in 25 in 5 16 in 313 in 3 8 in 375 in 1 2 in 5 in OM 4433 Page 18 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
46. z 8 k S1 S 2 215 cB2 Ss OPTIONAL 1 rd A ZA NG 18 ach fue o0 A MASAS B x x x B ga S y c x 5 67 D x 8 1 CLOSED TO A TERMINAL 43 S 54 m PRE HEAT Piki 50 EE 2 4 7 SRI S4 r I NER ENS Apu e 6 a E AUTO IDLE 49 OPTIONAL 2 3 5 ER CR2 t GLOW PLUG 47 5 e z l FUEL LEVEL e SENDER SS o je Je P 12 VOLT Ln BATTERY sal s3 CR 3 42 42 42 42 42 2 le m m m m m m m OM 4433 Page 48 Figure 9 1 Circuit Diagram For Welding Generator 4 WARNING e Do not touch live electrical parts 2 e Disconnect input power or stop engine before servicing Do not operate with covers removed ELECTRIC Have only qualified persons install SHOCK HAZARD use or service this unit E j CC CV MODEL ONLY ee al UNE ATE PA T cc cv Mover pi o CC CV MODEL ONLY CC CV MODEL ONLY C C MODEL 5 C15 Le l Le je i H 909 l Lom ta LA vt SAS 190 cc riu rz ha Ar Je Jon ca lH gt Iei co L I gt lesi TRL LT T IT E Er A ScR2 IT end T i E EE R3 HI 1 A 1 la la
47. 0 Ref 801 434 OM 4433 Page 40 8 9 Overload Protection A Stop engine EF When a circuit breaker supple mentary protector or fuse opens it usually indicates a more serious problem exists Contact Factory Authorized Service Agent 1 FuseF1 F1 protects the stator exciter wind ing from overload If F1 opens weld and generator power is low or stops entirely 2 Circuit Breaker CB1 Not Shown Supplementary Protector CB2 Supplementary Protector CB3 Supplementary Protector CB7 o0 BR o Supplementary Protector CB8 7 Circuit Breaker CB9 CB1 protects the engine battery cir cuit If CB1 opens the engine will not crank CB1 automatically resets when the fault is corrected CB2 protects the engine wiring har ness If CB2 opens the engine will not crank CB3 protects part of the weld control wiring harness If CB3 opens weld and generator power output stops CB7 protects the 115 volt ac output to remote receptacle RC14 If CB7 opens 115 volt output to RC14 stops CB8 protects the 24 volt ac output to remote receptacle RC14 If CB8 opens 24 volt output to RC14 stops Press button to reset supplementary protector CB9 protects the throttle solenoid against overload If CB9 opens the engine does not automatically idle down Check the linkage and sole noid CB9 automatically resets 803 562 803 566 OM 4433 Page 41 8 10
48. 0 V receptacle 803 562 Lal REMOTE 14 Socket Socket Information A 24 volts ac Protected by sup lementary protector CB8 24 VOLTS AC p xP OUTPUT B Contact closure to A completes CONTACTOR 24 volt ac contactor control circuit C Output to remote control 10 volts dc in MIG mode 0 to 10 volts dc in Stick or TIG mode REMOTE D Remote control circuit common OUTPUT CONTROL E DC input command signal O 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 CB7 OUTPUT Contact cl tol letes ontact closure to complete CONTACTOR J 115 volt ac contactor control circuit F Current feedback 1 volt per 100 amperes AMPERAGE A V VOLTAGE H Voltage feedback 1 volt per 10 arc volts GND K Chassis common NEUTRAL G Circuit common for 24 and 115 volt ac circuit The remaining sockets are not used Notes OM 4433 Page 26 Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual Notes Welding Symbols Finish Symbol Groove Angle Included Angle of A Countersink for Plug Weld Contour Sy eeh F Root Opening Depth of Filling L Groove Weld Size fer Plug Welds
49. 223710 Relay Encl 12vdc Dpst no 25a 6pin Flange 1 Otero ale aestus 046432 Holder Fuse Mintr 250 X 1 250 Panel Mtg 1 Dior F1 085874 Fuse Mintr Cer Slo blo 10 Amp 250 Volt 1 8 us R4 21 335 Resistor Boar meri as 1 9 CR4 090104 Relay Encl 12vdc Spst 30a 15vdc 5pin Flange Mtg 1 10 CR3 197325 Relay Encl 12vdc Spst 70a 4pin Flange Mtg 1 11 SR3 035704 Rectifier Integ Bridge 40 Amp 800v 1 12 SR1 SR2 035704 Rectifier Integ Bridge 40 Amp 800v 2 13 PC5 e214761 Module Pull To ldle 1 14 CB2 CB3 083432 Supplementary Pro Man Reset 1p 10a 250vac Frict 2 15 CB9 230635 Circuit Breaker Auto Reset 12vdc 8 Amp 1 Optional When ordering a component originally displaying a precautionary label the label should also be ordered 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 4433 Page 67 E Hardware is common and not available unless listed Wirng harnesses are listed at the end of parts section 803 686 B Figure 12 4
50. 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 4433 Page 59 SECTION 12 PARTS LIST 5 Hardware is common and not available unless listed Wirng harnesses are listed at the end of parts section 4 Fig 12 5 110 Fig 12 3 108 Fig 12 2 Figure 12 1 Main Assembly OM 4433 Page 60 803 683 F OM 4433 Page 61 Item Dia Part No Mkgs No Description Quantity Figure 12 1 Main Assembly 1 HD1 168829 Transducer Current 1000a Module Max Open Loop 1 TE R3 213027 Resistor WW Tap 300 W 40 Ohm 1 ssh Ot Tr 217070 Bracket Rectifier 1 pape As are im irs Figure 12 5 Rectifier Assembly 1 sapi EE 181853 Insulator Screw For Rectifier Mtg 2 ad OY IR IE aise 214742 Capacitor Assy Includes 1 Mp eU ILE Gadel 213489 Bus Bar Capacitor Bank Negative 1 EE APA EE 213490 Bus Bar Capacitor Bank Positive 1 ep b s imas C10 163535 Capacitor Elctlt 16000 Uf 60 Vdc Can 1 75 Dia 6 Or ted 4213488 Panel Engine Side
51. 7718 Conn Faston Mini Polarized 2 Skt G2k2 3 Sette ve dyes EEN TR 217010 Harness Receptacle Auxiliary Power Includes 1 Pune CB4 CB6 093996 Supplementary Pro Man Reset 1p 20a 250vac Fric 2 OM 4433 Page 70 Warranty Questions Call 1 800 4 A MILLER for your local Miller distributor Your distributor also gives you Service You always get the fast reliable response you need Most replacement parts can be in your hands in 24 hours Support Need fast answers to the tough welding questions Contact your distributor The expertise of the distributor and Miller is there to help you every step of the way 7 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
52. Checking Generator Brushes k er A Stop engine and let cool pe e Y A j EP EX 1 Generator Brush With Spring S Sko RUN AUTO OFF A START Mark and disconnect leads at brush hold er cap Remove brushes Replace brushes if damaged or if brush material is at or near minimum length 5 16 in 8 mm Minimum Length EN gt 9 16 in 14 3 mm NM ni Replace Damaged Brushes 1 Ref 2114 778 D S 0233 A Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge 025 in 22 Gauge 031 in 20 Gauge 037 in 18 Gauge 050 in 16 Gauge 063 in 14 Gauge 078 in 1 8 in 125 in 3 16 in 188 in 1 4 in 25 in 5 16 in 313 in 3 8 in 375 in 1 2 in 5 in OM 4433 Page 42 8 11 Voltmeter Ammeter Help Displays EN NOLTAGE pMPERAGE HLP 20 HL P 21 HLP 22 ES NOLTAGE HL Se N D Use the Voltmeter Ammeter help displays to diagnose and correct fault conditions EF When a help code is displayed normally weld output has stopped but generator power output may be okay To reset help displays stop unit and then restart See item 6 below to reset Help 25 dis play 1 Help 20 Display Indicates a failure of meter display module PC2 or the wiring between PC2 and main control module
53. Flowgauge and Flowmeter Regulators No Labor HFUnits Grids Spot Welders Load Banks Arc Stud Power Sources 8 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 amp for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater Bernard Branded Mig Guns No Labor Weldcraft Branded TIG Torches No Labor Subarc Wire Drive Assemblies 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 8 SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Bobcat Trailblazer and Legend models 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Miller or equipment that has been improperly installed improperly opera
54. I T T wops rT T TT none rT a EET LAS k2 A EIc Ec 4d FO NE ENS H 2 Je Joe Le S TI A scrs Ni A scre l L3 _Mob2 L3 MODS HD1 Do A A A A WORK We Tew E a gt a ke D be a ke D ke a we S GER z 3 2 2 AAAAX T N INL 1 3 2 4 AK R A A A AA R A A A OO AG O 85 OO AO AO SHIELD Sr RED SI BLACK AZ S HATE PCI gt MRE MAIN CONTROL SCR GATING c2 bg A K3 PLG6 30 PIN ay A1 F3 PLG7 18 PIN psa l AD EZ PLGI1 18 PIN oyee Do EEN 6120 4 TA LEADS 42 amp 180 NOT 7 WE LT ammo Fon Eer BS F1 F3 ps H2 r2 G2 B1 Al K1 C2 B2 A2 JU VV N v M VV f PLG4 RC4 750 1F6 140 143 737 747 135 760 761 162 165 166 167 gag D zre TI TY Ill ere 1895 5180 87 Ex R2 MACHINE WIRE NUMBERS KS KS L ee 132 PCS PROCESS V A ADJUST 10 39 WELD SECONDARY 165 5165 FILTER BOARD 166 166 40 79 ENGINE CONTROLS mum pa EXCEPT 42 CHASSIS 32 e 80 99 AUX SECONDARY PLG3 RC3 1603 RED ux 1133 135 136 737 140 141 187 144 142 54T Hi I I I I po 100 249 EXCITER CONTROL LOTS 5 MT A B C D E F G H J K 1623 5 LY RC14 PLGB RC2 e 7 3150 zes no ua o gt 592 LPS q AZ C 1353 135 219 228 E OM 4433 Page 49 SECTION 10 RUN IN PROCEDURE 10 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 eguipment damage
55. MS SANGA hae AN 213480 Bracket Mtg Engine 2 E 54 PS epus 083883 Washer Lock 402idx0 7090dx 087t Stl Splitt10mm 2 na EE 049026 Screw M10 1 5x 25 Hex Hd pln 8 8 PIn 2 ASG Near petite su dus Washer Oil Drain Order Thru Engine Manufacturer 1 nn ceps aie ase 212612 Ftg Adapter Oil Drain Cat 3013 1 a 199505 Hose Assy Oil Drain 32 000 Lg Includes 1 DEE CC DEE 165271 Valve Oil Drain 3 8 18 Nptf 1 da POS 176529 Ftg Hose Brs Barbed Fem 1 2 Tbg X 3 8 Npt 1 REA ERE ERE 113854 Hose Sae 500 Id X 780 Od Xcoil 2 6 Ft ER AS AE a 197448 Ftg Hose Brs Barbed Elbow M 1 2 Tbg X 3 8 Npt 1 A aa tare al s e 212614 Hose Radiator Lower Cat 3013 1 beoe cu even EE Wn 217686 Belt Alternatot ix oorpore ciam ex IN res RUD ex o NC ens 1 lau Dos eae 217651 Engine Perkins Includes 1 da eae 212600 Ehwbteel derer ciate reset a 1 A 4202166 Filter OIL ci EIE Ee ev bee en d Sih Sas DE EAR acr 217695 Switch Coolant Temp N c 110c 1 Vu Ee EE 217696 Switch Lubricating Oil Pressure N O 1 su Ost bte 4 212613
56. PC1 If this display is shown have Facto ry Authorized Service Agent check PC1 PC2 and the wiring between PC1 and PC2 2 Help 21 Display Indicates thermistor TH1 on the main rectifier heat sink has failed If this display is shown have Facto ry Authorized Service Agent check TH1 and the wiring between TH1 and PC1 3 Help 22 Display Indicates the rectifier heat sink has overheated If this display is shown check generator cooling system and or reduce duty cycle Keep en gine access door closed when run ning to maintain proper cooling air flow past rectifier Allow unit to cool before restarting If problem contin ues have Factory Authorized Ser vice Agent check unit 4 Help 23 Display Indicates one of the rectifier output SCR s has failed If this display is shown have Factory Authorized Service Agent check the rectifier SCR s 5 Help 24 Display Indicates weld open circuit voltage OCV is too high above 41 volts do If this display is shown have Factory Authorized Service Agent check main control module PC1 6 Help 25 Display Indicates a remote device con nected to Remote Receptacle RC14 may be faulty Help 25 is also displayed whenever a remote de vice has been connected to RC14 and then disconnected Clear fault by stopping and restarting the unit or by turning Process Contactor switch to another position If prob lem continues have Factory Autho rized Service Agent check the re mote
57. Rect Univ 039 6p S 3row Plug Cable Lkg Seal 1 AN Vere gana da 214933 Seal Wire Univ O39 3 sceptra erige 214934 Seal Plug Univ 039 3 TER PLG8 147992 Conn Rect Univ 039 10p S 2row Plug Cable Lkg 1 d die O ba PLG6 193184 Conn Rect Cinch 30 Pin 1 Uus vete cd PLG7 193183 Conn Rect Cinch 18 Pin 1 nn PLG9 215261 Conn Deutsch 12p 2row Female Plug 1 Mines PLG10 215262 Conn Deutsch 12p 2row Female Plug 1 EE EE PENE MENE SENA 215265 Conn Deutsch Wedge Lock 12 Position 2 a T ad 215343 Seal Plug Deutsch 12 16 Size 7 a ds PLG5 113750 Conn Rect Mini 045 4skt 2row Plug Cable Lkg 1 TE 247000 GA tada al EEEE 215340 Conn Rect Univ 039 2p S 1row Rcpt Cable Pnl LkgS 1 a ddr 214933 Seal Wire Univ 039 2 Saha GA nee ph he 214984 Harness Rectifier Cc Cv Includes 1 EEN PLG11 193183 Conn Rect Cinch 18 Pin 1 DUE ba cas ed ae 207716 Conn Faston Mini Polarized 2 Skt G1k1 7 6 Ae 20
58. Rectifier X Duty Cycle U Rated No Load U Conventional Rated Load y vy O Voltage Average 2 Load Voltage n Speed n Rated Idle n Rated No Load atat Rated Welding 1 Speed 0 Speed 2 Current Contactor On Dn Arc Force Dig H Lift Arc TIG OM 4433 Page 14 SECTION 4 SPECIFICATIONS 4 1 Weld Power And Engine Specifications Maximum Welding Weld Output Rated Welding Open Generator Power Fuel Mode Range Output Circuit Rating Capacity Voltage 400 A 23 Volts DC 4096 Duty Cycle 20 410A 300 A 32 Volts DC CCIDC CC Models 60 Duty Cycle 23 Perkins 250 A 30 Volts DC Single Phase 100 Duty cycle e 10 KVAYKW 84 42 A Perkins 403C 15 11 5 gal 400 A 23 Volts DC 120 240 V AC Water Cooled 43 5 L 30 Duty Cvcle 60 Hz Three Cylinder CV DC y Sy 21 7 HP Diesel Engine CC CV 14 40 V 300 A 29 Volts DC Models 6096 Duty Cycle Only 250 A 26 5 Volts DC 100 Duty cycle 4 2 Dimensions Weights And Operating Angles Dimensions Height 32 in 813 mm 35 3 4 in 908 mm to top of lift eye Width 26 1 4 in 667 mm Dr 1 mtg brackets turned in 28 3 4 in 730 mm mtg brackets turned out Depth 56 in 1422 mm 56 in 1422 mm 54 in 1372 mm A 52 in in 1321 mm 2in 51 mm 26 in 660 mm 7 8 in 22 mm Om O OJO 27 3 4 in 705 mm 9 16 in 14 mm Dia 4 Holes H
59. SPARKS can cause injury e Wear a face shield to protect eyes and face e Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face hand and body protection e Sparks can cause fires keep flammables away N MOVING PARTS can cause injury e Keep away from moving parts e Keep away from pinch points such as drive rolls 3 OM 4433 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 pun EVA N 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 filter airflow to unit P STATIC ESD can damage PC boards e Put on grounded wrist strap BEFORE handling So e boards or 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
60. Service Agent check vol tage regulator module PC3 Reset supplementary protector CB3 see Section 8 9 Check Voltmeter Ammeter help displays see Section 8 11 Have Factory Authorized Service Agent check brushes and slip rings and field excitation circuit High output at generator power ac re ceptacles Have Factory Authorized Service Agent check voltage regulator module PC3 Low output at generator power ac recep tacles Check engine speed and adjust if necessary Check fuse F1 and replace if open see Section 8 9 If F1 is open have Factory Authorized Service Agent check the rotor C Engine Trouble Remedy Engine will not crank Check battery and replace if necessary Check battery connections and tighten if necessary Circuit breaker CB1 may be open CB1 automatically resets when fault is corrected see Section 8 9 Have Factory Authorized Service Agent check engine wiring harness and components Reset supplementary protector CB2 see Section 8 9 Check engine wiring harness plug connections Have Factory Authorized Service Agent check Engine Control switch S1 and control relay CR2 Engine cranks but does not start Check fuel level Check battery and replace if necessary Check engine charging system according to engine manual Have Factory Authorized Service Agent check control relay CR1 fuel solenoid FS1 and the fuel pump A
61. Subpart Q 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 regionaux 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 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 4433 Page 11 SECTION 3 DEFINITIONS 3 1 Warning Label Definitions 8 177 571 Sa Rem a b ES API CD MIL L 2104D CD SE CD SF Remove unit from shipping crate Remove Owner s Manual from unit Follow instructions to install muffler Read Owner s Manual Read labels on unit Use Diesel Fuel only and fill fuel tank Leave room for expansion Warning Wat
62. able Use 10 AWG or larger insulated copper wire 3 Ground Device EF Use ground device as stated in electrical codes A Ground generator to system earth ground if supplying power to a premises home shop farm wiring system A Also see AWS Safety amp Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Generators ST 800 576 B 11 4 How Much Power Does Equipment Require VOLTS 115 2 AMPS 4 5 1 Hz 60 60W 1 Resistive Load A light bulb is a resistive load and requires a constant amount of power 2 Non Resistive Load Eguipment with a motor is a non re sistive load and reguires approxi mately six times more power while starting the motor than when running see Section 11 8 3 Rating Data Rating shows volts and amperes or watts reguired to run eguipment 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 4433 Page 54 11 5 Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running
63. ap Primary Canister Fuel Filter a A OWN Secondary In Line Fuel Filter 6 Fuel Tank Sludge Drain Valve To change oil and filter Route oil drain hose and valve through hole in base See engine manual and engine maintenance label for oil fiter change in formation To replace primary canister fuel filter Turn filter counterclockwise Re move filter Fill new filter with fresh fuel Apply thin coat of fuel to gasket on new fil ter Install new filter and turn clock wise Inspect fuel lines and replace if cracked or worn To drain water from fuel system See engine manual To replace secondary in line fuel filter Note direction of fuel flow as indi cated by arrow on side of filter Re move fuel line clamps and discon nect fuel lines from fuel filter Re place filter reconnect fuel lines and reinstall clamps To drain sludge from fuel tank A Beware of fire Do not smoke and keep sparks and flames away from drained fuel Dis pose of drained fuel in an en vironmentally safe manner Do not leave unit unattended while draining fuel tank A Properly lift unit and secure in a level position Use ade quate blocks or stands to support unit while draining 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 Close door Tools Needed E gt C se 802 49
64. applicable manuals H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation e The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation e f notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference 1 6 California Proposition 65 Warnings 4 Welding or cutting eguipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq 4 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 Z49 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com Recommended Safe Practices for the Preparation for Weldin
65. ated and while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded BUILDUP OF GAS can injure or kill e Shutoff shielding gas supply when not in use e Always ventilate confined spaces or use ap proved air supplied respirator ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld e Wearan approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet e Use protective screens or barriers to protect others from 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 FM WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding e Re
66. ations e 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 4433 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 e 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 e Ne pas brancher de moteur de 50 ou de 60 Hz la prise de 100 Hz n LES TINCELLES 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 e Ne pas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande LES FILS DE SOUDAGE peuvent provoquer des blessures e Ne pas appuyer sur la g chette avant d en avoir recu l ins
67. ch Out There are possible hazards as shown by the symbols Read Owner s Manual Follow instructions to activate battery Check oil level Add oil if necessary During the first 50 hours of operation keep welding load above 200 amperes Do not weld below 200 amperes of output After the first 50 hours of operation change the oil and oil filter 3 96 Notes OM 4433 Page 12 Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual 3 2 Manufacturer s Rating Label C Miller MILLER ELECTRIC MFG CO APPLETON WI USA Model BIG BLUE 300P CC CV Stock Number 907242 Serial Number SERIAL Dimensions 32 H x 26 W x 56 D 813 H x 660 W x 1422 D mm Weight with Fuel 1200 Ibs 544 kg SEE onum RATED VOLTAGE U2 E sovvcj ZEZ DC 6owc o 14 40V 20 400A MM DUTY CYCLE X 30 60 ma RATED CURRENT 2 400 300 RATED VOLTAGE U 23 3 ____ udov 1 ulavcj oO MODEL PERKINS 403C 15 TIER 2 ENGINE SPEC HL 70567U RATED OUTPUT DISPLACEMENT CYLINDERS 21 7 HP 1800 RPM 91 Cu In 1 496 L E o z ziais elalelz z a o o 9 O gt S rir gt Cinir ojo o olojo PIS A ir gv o a Ko ko ol o vpr r c X VIDIO m z mioa olas m m O 3 a m ON 11 5 gal 43 5L 1800 RPM min 1 no 1880 RPM
68. che 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 e Ne pas enrouler les c bles autour du corps e Si la pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct ne pas utiliser le connecteur de pi ce ou le c ble de retour e 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 Nutiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment ce manuel e Porter un harnais de s curit quand on travaille en hauteur e Maintenir solidement en place t
69. d PARE hu dos Bakes KE aa ale eee Ra n Rt EUM A 44 SECTION 9 ELECTRICAL DIAGRAMS L eee n nnn nn nnn 48 SECTION 10 RUN IN PROCEDURE LLLLLL nnn n n hh n n nnn 50 10 1 EE D EEN 50 10 2 Run In Procedure Using Load Bank 22 51 10 3 Run In Procedure Using Resistance Grid 52 SECTION 11 GENERATOR POWER GUIDELINES 422 A ee eee AA 53 SECTION 12 PARTS LIST isis d ENNEN aa pai aaia XS EE 60 WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING rom 2007 04 4 Protect yourself and others from injury read and follow these precautions 1 1 Symbol Usage DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury The possible hazards are shown in the adjoining symbols or explained in the text Indicates a hazardous situation which if not avoided could result in death or serious injury The possible hazards are shown in the adjoining symbols or ex plained in the text NOTICE Indicates statements not related to personal injury 1 2 Arc Welding Hazards 4 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 t
70. da 170391 Conn Circ Ms Protective Cap Size 20 Nylon 1 iM La e Ca 190323 Boot Circuit Breaker Clear Hex Nut 2 D EE 097922 Knob Pointer 875 Dia X 250 Id W Set Screwsplstc 1 TE MCI Nameplate Control Order By Model Serial No 1 7 PC6 229949 Circuit Card Assy Connector Receptacle 1 8 CB7 CB8 083432 Supplementary Pro Man Reset 1p 10a 250vac Frict 2 vus ace cogent raso is 213655 Panel Front Engine Weld Control 1 OM 4433 Page 65 Item Dia Part No Mkgs No Description Quantity Figure 12 2 Panel Front w Components Continued rM 214543 Enclosure Circuit Card ASSY 1 5 WE 2 Sie cease mens 134201 Stand off Support Pc Card 312 375w Post amp lock 43 4 12 PC2 214660 Circuit Card Assy Display W Program 1 AS cus R1 214760 Switch Rotary 12 Posn 1p 200ma 28vdc W Resistors 1 14 R2 193118 Pot Cp Flat 1t 2 W 1k Ohm Linear 1 15 4 S4 021467 Switch Tgl Spst Ja 250v Off none On Spd Term 1 16 S1 212436 Switch Ignition 4 Position Includes Knob 1 T re saec 039047 Terminal Pwr Output Red
71. e glycol base anti freeze rated to 34 F 37 C Add anti 803 563 freeze to mixture if using the unit in tempera tures below 34 F 37 C Keep radiator and air intake clean and free of dirt NOTICE Incorrect engine temperature can damage engine Do not run engine with out a properly working thermostat and ra diator cap To improve cold weather starting Use Preheat switch see Section 6 1 Keep battery in good condition Store battery in warm area Use fuel formulated for cold weather diesel fuel can gel in cold weather Contact local fuel supplier for fuel in formation Use correct grade oil for cold weather see Section 8 2 OM 4433 Page 23 5 7 Connecting To Weld Output Terminals Jf 4 ear Stick and TIG Welding 5 E For Stick and TIG welding Direct Current Elec trode Positive DCEP connect electrode holder cable to CC Stick TIG terminal on right and work cable to Work Negative ter minal on left For Direct Current Electrode Negative DCEN reverse cable connections Use Process Contactor switch to select type of weld output see Section 6 3 Stop engine Work Negative Weld Output Terminal CV wire Weld Output Terminal CC Stick TIG Weld Output Terminal Po 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 We
72. e 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 c ble 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 hautes 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 OSHA 1910 252 a 2 iv et NFPA 51B pour les travaux chaud et avoir de la surveillance et un extincteur proximit LE BRUIT peut affecter l ouie Le bruit des processus et des quipements peut affec l ouie e Porter des protections approuv s pour les ore les si le niveau sonore est
73. ef 217 357 A OM 4433 Page 36 8 4 Inspecting And Cleaning Optional Spark Arrestor Muffler IZ 3 8 in 1 Spark Arrestor Muffler 2 Cleanout Plug ear Tools Needed A Stop engine and let cool Remove plug and remove any dirt covering cleanout hole 3 Exhaust Pipe 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 803 582 Ref 214 778 B 8 5 Servicing Engine Cooling System ap A Stop engine and let cool 1 Radiator Draincock 2 Radiator Cap Cover Change coolant according to engine manual Add coolant according to Sec tion 5 6 Run engine until engine reaches normal operating temperature Check coolant level in recovery tank Add coolant if nec essary After engine cools check coolant level again and add coolant if necessary 803 563 OM 4433 Page 37 8 6 Adjusting Engine Speed On Standard Models A ESP D Engine Speed No Load y RPM Hz Weld Power 1880 61 7 Maximum Le VA 7I Bad A Stop engine and let cool Engine speed is factory set and should not require adjustment Af ter tuning engine check engine speed with tachometer or frequen cy meter
74. es 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 4 Les gaz d chappement des moteurs contiennent des pro duits chimiques dont l tat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Pour les moteurs diesel 4 Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l Etat de Californie com me provoquant des cancers et des malformations cong nitales ou autres probl mes de procr ation 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
75. 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 des gaz de soudage peuvent d placer l air et abaisser le niveau d oxyg ne provoquant des blessures ou des accidents mortels S assurer que l air de respiration ne pr sente aucun danger e Ne pas souder dans des endroits situ s proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et for mer des gaz hautement toxiques et irritants e Ne pas souder des m taux munis d un rev tement tels que l acier galvanis plaqu en plomb ou au cadmium moins que le rev te ment n ait t enlev dans la zone de soudure que l endroit soit bien ventil et en portant un respirateur alimentation d air
76. g 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 And 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 electromag
77. he Safety Standards listed in Section 1 7 Read and follow all Safety Standards 4 Only gualified persons should install operate maintain and repair this unit 4 During operation keep everybody especially children away FA e ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equip ment is a hazard e Do not touch live electrical parts e Wear dry hole free insulating gloves and body protection e Insulate yourself from work 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 e 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
78. ic 125 175 1 kak Da d Dou A Der te 212621 Pipe Exhaust Flexible Inlet Cat 3013 1 HER CE EDO ERE 183314 Clamp Muffler 1 625 Dia U Pld 3 ma OA ccm e es 212604 Baffle Air Lower Radiator 1 it xa qe PT 201528 Muffler Exhaust Engine 1 truc es aun 212605 Pipe Exhaust Blue Fuel 1 Laure ac su asa ne 233088 Label Danger Using A Generator Indoors Can Kill You In Minutes 1 TIE EM 213470 Cover TOP aaa an ELA rad x a ea ea RR RR RAS dan a 1 aa Ad ue Eins 049525 Nut 312 18 U nut Multi thread 15 ns EE 189052 Grommet Plastic Neck Filler Fuel 1 pir EE been 190198 Cap Tank Screw on 3 500 In W Vent W Lanyard 8 1 bend cement EE EA 222513 Label Warning Falling Equipment Can Cause Serious 1 BIAG urge ode ia 201851 Cover Radiator Access 1 E KC AA aoe ys Bets 214604 Pipe Exhaust Elbow 1 viae AA 224265 Label Warning Hot Exhaust Parts Do Not Touch 1 maman CR TR TANANG 192041 Label Use Diesel Fuel Only 1 S gO NR ds 213472 Keeper Latch Engine Acce
79. ices A Properly install and ground this equipment according to its Owner s Manual and na tional state and local codes 5 Customer supplied equipment is required if generator will sup ply standby power during emergencies or power out ages 1 Utility Electrical Service 2 Transfer Switch Double Throw Switch transfers the electrical load from electric utility service to the generator Transfer load back to electric utility when service is re stored Install correct switch customer supplied Switch rating must be same as or greater than the branch overcurrent protection 3 Fused Disconnect Switch Install correct switch customer supplied if required by electrical code 4 Welding Generator Output Generator output voltage and wir ing must be consistent with regular utility system voltage and wiring Connect generator with temporary or permanent wiring suitable for the installation Turn off or unplug all equipment connected to generator before starting or stopping engine When starting or stopping the engine has low speed which causes low volt age and frequency 5 Essential Loads Generator output may not meet the electrical requirements of the prem ises If generator does not produce enough output to meet all require ments connect only essential loads pumps freezers heaters etc See Section 11 4 OM 4433 Page 58 11 11 Selecting Extension Cord Use Shortest Cord Possib
80. ies depending on machine model and serial number Maximum output from these receptacles is 2 4 kVA kW If a ground fault is detected GFCI Reset button pops out and receptacle does not work Check for faulty equipment plugged in receptacle Press button to reset GFCI receptacle EF At least once a month run engine at weld power speed and press test but ton to verify GFCI is working properly RC11 supplies 60 Hz single phase power at weld power speed Maximum output from RC11 is 10 kVA kW 4 Supplementary Protector CB4 5 Supplementary Protector CB6 6 Supplementary Protector CB5 CB4 protects RC6 GFCI2 and CB6 pro tects RC5 GFCI1 from overload If a sup plementary protector opens the receptacle does not work Press button to reset Supplementary protector CB5 protects re ceptacles and the generator winding from 217 357 A overload If CB5 opens the receptacles do not work Place CB5 switch in On position to reset circuit breaker CS If a supplementary protector continues to open contact Factory Authorized Service Agent Generator power decreases as weld output increases Combined output of all receptacles is limit ed to the 10 kVA kw rating of the generator EXAMPLE If 15 A is drawn from each 120 V receptacle only 26 A is available at the 240 V receptacle 2x 120 V x 15 A 240 V x 26 A 10 0 KVA KW OM 4433 Page 33 SECTION 8 MAINTENANCE amp TROUBLESHOOTING D Rout
81. imate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1 4 in 350 350 3 8 in 400 400 1 2 in 600 600 Circular Saw 6 1 2 in 500 500 7 1 4 in 900 900 8 1 4 in 1400 1400 Table Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in 2500 1100 Bench Grinder 6 in 1720 720 8 in 3900 1400 10 in 5200 1600 Air Compressor 1 2 HP 3000 1000 1HP 6000 1500 1 1 2 HP 8200 2200 2HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1 3 HP 2100 700 Elec Hedge Trimmer 18 in 400 400 Flood Lights HID 125 100 Metal Halide 313 250 Mercury 1000 Sodium 1400 Vapor 1250 1000 Submersible Pump 400 gph 600 200 Centrifugal Pump 900 gph 900 500 Floor Polisher 3 4 HP 16 in 4500 1400 1 HP 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 4433 Page 56 11 8 Power Required To Start Motor Single Phase Induction Motor Starting Requirements Motor Start G H J K L M N P Code KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0 1 Motor Start Code 2 Running Amperage 3 Motor HP x AC MOTOR 2 4 Motor Voltage o VOLTS 230 AMPS 25477 mag CODE M Hz 60 To find starting amperage N HP 1 4 PHASE 1 Step 1 Find code
82. ine Maintenance XA hi ws A CX td Recycle engine A Stop engine before maintaining See Engine Manual and Maintenance Label for important start up service and storage fluids f information Service engine more often if used in severe conditions 17 Check Change Q Clean x Replace Reference To be done by Factory Authorized Service Agent Every Section 5 6 8 Le 8 8 Hours a Coolant Level Fuel Level Y Oil Level Q Oil Fuel Spills Every 50 Hours Aa 2 Q Weld Terminals Every Section 8 3 100 Hours Q Battery Terminals Y Air Cleaner Hoses w Air Cleaner Element Every o WARN A Engine 250 4d EE E Manual Hours E BE Section 8 4 d Unreadable Labels Fan Belt Tension Oil Oil Filter LO Spark Arrestor Every gt 500 yo TIT Hours PR PETI wk Weld Cables Inline Fuel Filter w Radiator Thermostat Every Section 5 6 1000 8 10 8 8 Hours and Engine Manual Radiator Fluid Level Q Inside Unit Valve Clearance Q Drain Sludge ER JO Slip Rings x Brushes Every 2000 Hours NR Q Injectors OM 4433 Page 34 Maintenance Label 8 2 g 0 816 09690 LEL Sul4184 O 02 4 22 ww Z 0 ut 8200 0 ISNEUXJ ER IE g ww z o ui 8Z00 0 eet 06 L90 0 SUMISd 266 261 YITIIN e 898 E12 HITIM L 19 sib 9
83. ir in fuel system See engine manual Engine hard to start in cold weather Use Preheat switch see Section 6 1 Keep battery in good condition Store battery in warm area off cold surface Use fuel formulated for cold weather diesel fuel can gel in cold weather Contact local fuel supplier for fuel information Use correct grade oil for cold weather see Section 8 2 Have Factory Authorized Service Agent check Preheat switch S4 control relay CR3 and the glow plug Engine suddenly stops Check oil and coolant levels Automatic shutdown system stops engine if oil pressure is too low or coolant temperatureis too high see Section 5 6 Circuit breaker CB1 may be open CB1 automatically resets when fault is corrected see Section 8 9 Reset supplementary protector CB2 see Section 8 9 Have Factory Authorized Service Agent check engine alternator engine harness throttle solenoid TS1 fuel solenoid FS1 and the fuel pump Have Factory Authorized Service Agent check Engine Control switch S1 control relay CR1 inte grated rectifier SR2 fuel solenoid FS1 and the fuel pump See engine manual OM 4433 Page 45 Trouble Remedy Engine slowly stopped and cannot be restarted Check fuel level Check engine air and fuel filters see Sections 8 3 and 8 8 See engine manual Battery discharges between uses Turn Engine Control switch off when unit is no
84. lant 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 no over flow tank follow the next two statements e Wear safety glasses and gloves and put a rag over radiator cap e Turn cap slightly and let pressure escape slowly before completely removing cap Using a generator indoors CAN KILL YOU IN MINUTES e Generator exhaust contains carbon monoxide This is a poison you cannot see or smell e NEVER use inside a home or garage EVEN IF doors and windows are open e Only use OUTSIDE and far away from windows doors and vents BATTERY ACID can BURN SKIN and EYES e Do not tip battery e Replace damaged battery e Flush eyes and skin immediately with water ENGINE HEAT can cause fire e Do not locate unit on over or near combustible surfaces or flammables e Keep exhaust and exhaust pipes way from flammables 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 a TRAPPED AIR PRESSURE AND WHIPPING DV 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 4433 Page 3 HOT METAL from air arc cutting and gouging can cause fire or explosion
85. ld 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 NOG E Tools Needed I 3 4 in Do not place anything between weld cable terminal and copper bar Correct Installation MIG and FCAW Welding For MIG and FCAW welding Direct Current Electrode Positive DCEP connect wire feed er cable to CV Wire terminal on right and work cable to Work Negative terminal on left Use Process Contactor switch to select type of weld output see Section 6 3 For Direct Current Electrode Negative DCEN reverse cable connections Incorrect Installation 803 562 803 778 A OM 4433 Page 24 5 8 Selecting Weld Cable Sizes T Weld Output Terminals A Stop engine before connecting to weld output terminals A Do not use worn dam aged undersized or poorly spliced cables Welding Weld Cable Size and Total Cable Copper Length in Weld Circuit Not Exceeding 150ft 200ft 250ft 300ft 350ft 400ft 100ft 30m orLess 45m 60m 70m 90m 105 m
86. le ZA 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 400 122 275 84 175 53 112 34 62 19 50 15 15 1800 300 91 175 53 112 34 75 23 37 11 30 9 20 2400 225 68 137 42 87 26 50 15 30 9 25 3000 175 53 112 34 62 19 37 11 30 3600 150 46 87 26 50 15 37 11 35 4200 125 38 75 23 50 15 40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 296 voltage drop Cord Lengths for 240 Volt Loads 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
87. lobal 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 P O 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 P 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 basse fr quence et des champs magn tiques et lectriques Le courant de soudage pendant son passage dans les c bles de sou dage 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 final
88. 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 4433 Page 50 10 2 Run In Procedure Using Load Bank ra A A Stop engine y WE CI 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 procedure 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
89. mber Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks To locate a Distributor or Service Agency visit www millerwelds com or call 1 800 4 A Miller 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 7 Miller
90. move all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Do not weld where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas e Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side OM 4433 Page 2 Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline Connect work cable to the work as close 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
91. netic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as micro processors computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagnetically compatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e If interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area For Gasoline Engines 4 Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive harm For Diesel Engines 4 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 Z87 1 from American National Standards Institute 25 West 43rd Stree
92. ose shown 11 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 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 GFCI re ceptacles use GFCI pro tected extension cord S 0854 OM 4433 Page 53 11 3 Grounding When Supplying Building Systems 1 Equipment Grounding Terminal 2 Grounding C
93. ous les panneaux et capots e Fixer le c ble de retour de facon obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s 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 e 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 PI CES CHAUDES peuvent provoquer des br lures graves e Ne pas toucher a 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 DES PIECES DE METAL ou DES SA E LETES peuvent provoquer des bles sures dans les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la p riode de refroidissement des soudures elles risquent de projeter du laitier Porter des lunettes de s curit avec crans lat raux ou un cran facial inhalation peut tre dangereux pour votre sant LES FUM ES ET LES GAZ peuvent tre dangereux E Le soudage
94. ousing but leave con nected to plunger Loosen lock nut Place Engine Control Switch in Auto position Turn throttle rod and plunger un til engine runs at idle speed Tighten lock nut Hook rubber boot back onto so lenoid housing 5 Be sure solenoid plunger pulls all the way in bot toms when energized Weld Power Speed Adjustment Weld power speed adjust ment must be done by the engine manufacturer s fac tory authorized service agent Tampering with adjustments other than shown may affect engine warranty A Stop engine 4 To prevent solenoid damage be sure a 1 8 in 3 mm gap exists be tween the engine low speed screw and throttle lever when the solenoid is held in the energized position 803 563 G OM 4433 Page 39 8 8 Servicing Fuel And Lubrication Systems Mi eo Id HN LD n POL Brei A Stop engine and let cool A After servicing start engine and check for fuel leaks Stop engine tighten connec tions as necessary and wipe up spilled fuel Oil Filter Oil Drain Valve And Hose Oil Fill C
95. ply However the Engine Stop lever will not stop the engine if the engine can draw fuel rich air from the surrounding atmosphere oil refineries To Start NOTICE Do not use ether E 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 turn engine control switch to Auto position Push Preheat switch up for 60 seconds Turn Engine Control switch to Start Release Engine Control switch and Preheat switch when engine starts To Stop turn Engine Control switch to Off position Engine Gauges Meters And Lights 4 Fuel Gauge Hourmeter Use gauge to check fuel level or total engine operating hours To check fuel level or engine hours when en gine is not running turn Engine Control switch to Run or Auto optional position 5 Engine Indicator Light Light goes on and engine stops if engine tem perature exceeds 230 F 110 C or engine oil pressure is below 10 psi 69 kPa E Normal engine temperature is 180 203 F 82 95 C Normal oil pressure is 30 60 psi 207 414 kPa NOTICE Do not run engine until trouble is fixed Weld Controls 6 Remote Control Receptacle Use receptacle to connect remote controls wire feeders and tools When a remote control is connected to the Remote receptacle the Auto Sense Remote feature automatically
96. r 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 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 e 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 sen
97. rode to workpiece at weld start point Hold electrode to workpiece for 1 2 seconds and slowly lift electrode Arc is formed when electrode is lifted Normal open circuit voltage is not present before tungsten electrode touches workpiece only a low sensing voltage is present between electrode and workpiece The solid state output contactor does not energize until after electrode is touching workpiece This allows electrode to touch workpiece without overheating sticking or be ing contaminated Application Lift Arc is used for the DCEN GTAW process when HF Start method is not permitted or to replace the scratch method Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual OM 4433 Page 31 6 5 Remote Voltage Amperage Control E 1 Remote 14 Receptacle RC14 Connect optional remote control to RC14 see Section 5 9 E When a remote control is connected to the Remote receptacle the Auto Sense Re mote feature automatically switches volt age amperage control to the remote con trol When a device is connected to the Re mote receptacle remote voltage amper age control is always available regardless of the position of the Process Contactor switch In Example Min 20 A DC Max 205 A DC WELD TERMINALS ALWAYS ON Lift Arc
98. s 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 normes 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
99. ses 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 e Stop engine before disconnecting or connect ing battery cables or servicing battery Do not allow tools to cause sparks when working on a battery Do not use welder to charge batteries or jump start vehicles Observe correct polarity and on batteries Disconnect negative cable first and connect it last FUEL can cause fire or explosion e Stop engine and let it cool off before checking or adding fuel e 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
100. sible e Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi e En cas d interf rences apr s avoir pris les mesures pr c den tes il incombe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de c bles blind s l utilisation de filtres de ligne ou la pose de protec teurs dans la zone de travail 2 6 Proposition californienne 65 Avertissements 4 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 certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants A Les batteries les bornes et autres accessoires contiennent du plomb et des compos s a base de plomb produits chimi ques dont l tat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apr s manipu lation 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 G
101. ss 1 Vang Ae ined wis 213471 Bracket Cover Top 2 ma BB nbn eM e 217387 Balle Fan siemens eos NIAN E SUIS IRIS eor a e IE oa 1 MCI 213503 Q ard Fahr isi Nan so ier tiep anta ts reus c 1 Li PE 4212607 Shroud Radiator 1 pod os NG ere 233256 Radiator W 14 Cap 3 Row Core 1 25 In Inlet Outlet Includes 1 EN 187120 Cap Radiator Pressure 141b 1 na PAD NG a Banda 212603 Baffle Air Upper Radiator ees 1 ture suere zano 225400 Upright Rear NEEN oed ten kb RR Ra Reda 1 Tr E ia 225412 Cover Radiator Access 1 EE dca a nt 220295 Bracket Stiffenier erp see xara CR ac NANANG ar raa a 1 iA aa 190190 Tank Coolant Recovery 1 sud Gia D DA iua 213502 Guard Fam isis ra da vesti Gad Un thn a UD REA 1 i 4B EE 215268 Label Diesel Engine Maintenance Cat 3013c 1 OM 4433 Page 62 Item Dia Part No Mkgs No Description Quantity Figure 12 1 Main Assembly Continued Na vci v VS 199592 Latch Paddle Series 20 Black 1 Tn 4213487 Door Engine Access 1 PET 191626 Bumper Door Engine Access
102. 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 S 0683 OM 4433 Page 51 10 3 Run In Procedure Using Resistance Grid pA 4 t NU C 1 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 procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur 1 Resistance Grid
103. switch is in Stick mode select one of four arc drive dig settings to provide additional amperage during low voltage short arc length conditions and prevent sticking electrodes Turn control from A to D to increase arc drive dig from min to max Use the Lift Arc TIG mode for TIG GTAW welding using the Lift Arc TIG starting procedure see Section 6 4 803 562 217 357 Process Contactor Switch Settings Switch Setting Process Output On Off Control Engine Auto Idle Optional Remote On Off Switch Re i h GTAW With HF Unit Pulsing quired SC deeg Or Device Or Remote Control At Remote 14 Receptacle Active ceu cai Stick SMAW With Remote On Off At Remote 14 Receptacle Active Remote On Off Switch MIG GMAW e w Constant Speed Feeder At Remote 14 Receptacle Active Weld Terminals Always On MIG GMAW Wire w Voltage Sensing Feeder Flectrode Hot BREME E Stick SMAW Weld E ways On Air Carbon Arc CAC A Cutting Electrode Hot Active And Gouging Wed MAU Bie TIG Lift Arc GTAW Electrode Hot Active OM 4433 Page 30 6 4 Lift Arc Start Procedure NW A ws E ous Lift Arc Start Method 2 o o L 9 o o o o o o 5 1 2 Touch Seconds Do NOT Strike Like A Match p 1 2 Lift Arc TIG With Lift Arc TIG selected start arc as follows 1 TIG Electrode 2 Workpiece Turn gas on Touch tungsten elect
104. t 1 zu ij 190206 Cable Bat Neg 42 In Lg 2 Awg W Clamp amp 375 Rng 1 AAO Acer ARCO 224266 Label Warning Do Not Weld On Base 2 E EE 213462 Pad Mtg Generator 1 Pado eee NONA 213670 Screw 500 13x2 25 Hex Flange hd Gr8 PIn Chem Phys 2 Et SP ANS EE 071731 Washer Flat 656idx2 2500dx 187t Stl PId 2 n 0 rien 213463 Spacer Snubber Generator Mtg 1 nu AOA mobs 213485 Support Engine Lh 1 as 102 c smit 213459 Crossmember Engine 1 ODA ds 213460 Crossmember Generator 1 Ro CPI ERES 213600 Screw 500 13x3 00 Hex Flange hd Gr8 Pin 1 PEE 071731 Washer Flat 656idx2 2500dx 187t Stl PId 2 ad e A EE edd v 213464 Bracket Battery Locator In Base Not Shown 1 e ep Eeer cris 213506 Bracket Hold Down Fuel Tank Not Shown 1 en AOA uices 226104 Upright Front aaa e M panne m eee 1 zs NOD isl 233953 Label Warning General Precautionary CSA 1 d MOG stich des 216347 Label Rating Card Code 133 Provide Serial No When Ordering 1 Pe MOT tud o 220955 Panel
105. t Generic Output Stud 3 EE 180735 Washer Output Stud 3 a TEN 039046 Terminal Pwr Output Black 1 36 FUEL HM 214768 Gauge Fuel Elec Hour Meter 1 Ol dubie Va awe et 021385 Boot Toggle Switch Lever 1 Optional When ordering a component originally displaying a precautionary label the label should also be ordered 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 4433 Page 66 2 5 Hardware is common and not 5 available unless listed ni 4 Wirng harnesses are listed at the end of parts section to amp Pom W 9 803 689 D Figure 12 3 Control Panel Item Dia Part No Mkgs No Description Quantity Figure 12 3 Control Panel Figure 12 1 Item 110 T eset Reged 220981 Bracket Mtg Components 1 P re TAS 129524 Term Frict 250x032 Uninsul Male 130 Stud Mtg 3pr 2 3 CR2 214876 Relay Encl 6vdc Spst 35a 14vdc 5 Pin 1 4 CB1 190374 Circuit Breaker Auto Reset 12vdc 40 Amp 1 5 CR1
106. t 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 Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there are 10 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 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 4433 Page 5 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION rom 2007 04fre
107. t 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 units with idle option only Have Factory Authorized Service Agent check idle module PC5 and current transformer CT1 Check for obstructed throttle solenoid Engine does not run at idle speed units with idle option only Check for obstructed throttle solenoid Circuit breaker CB9 may be open CB9 automatically resets when fault is corrected see Section 8 9 Have Factory Authorized Service Agent check idle module PC5 and control relay CR4 Engine uses oil during run in period wetstacking occurs Dry engine according to run in procedure see Section 10 Notes OM 4433 Page 46 Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge 025 in 22 Gauge 031 in 20 Gauge 037 in 18 Gauge 050 in 16 Gauge 063 in 14 Gauge 078 in 1 8 in 125 in 3 16 in 188 in 1 4 in 25 in 5 16 in 313 in 3 8 in 375 in 1 2 in 5 in OM 4433 Page 47 SECTION 9 ELECTRICAL DIAGRAMS 92 97 90 S 50 42 o o A B Cc D E F TE1
108. t voltage turn contactor off and turn Pro cess Contactor switch to Wire position Turn V A control until desired voltage is displayed on Voltmeter When welding is finished volt meter displays weld voltage and then defaults to preset voltage 10 DC Ammeter Ammeter displays preset amperage Stick and TIG only when not welding and actual output amperage when welding To set amperage turn Process Contactor Switch to Stick or TIG position Turn V A con trol until desired amperage is displayed on Ammeter When welding is finished ammeter displays weld amperage and then defaults to preset amperage OM 4433 Page 29 6 3 Process Contactor Switch gt WELD TERMINALS ALWAYS ON Voltage Sensing Feeder CV CV Feeder Using Remote HF Required Or Scratch Start 1 Process Contactor Switch Weld output terminals are ener gized when Process Contactor switch is in a Weld Terminals Al ways On position and the engine is running Use switch to select weld process and weld output on off control see table be low 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 mode for air carbon arc CAC A cutting and gouging When
109. ted or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Miller s option 1 repair or 2 replacement or where authorized in writing by Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Miller authorized service facility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR
110. tery cells Wait ten minutes and check electro lyte level If necessary add electro lyte to raise to proper level Reins tall vent caps 8 Battery Charger A Read and follow all instruc tions supplied with battery charger 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 5 A For 30 Minutes 30 A For 12 Minutes Tools Needed drybatt1 6 05 S 0886 5 5 Connecting The Battery Close door after connecting battery A Connect Negative Cable Last Tools Needed 3 e 1 2 in 803 563 Ref 217 357 A S 0756 C OM 4433 Page 22 5 6 Engine Prestart Checks 4 d Diesel Full Check all engine fluids daily Engine must be cold and on a level surface Unit is shipped with 20W break in oil Automatic shutdown system stops engine if oil pressure is too low or coolant tempera ture is too high E 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
111. trop lev OM 4433 Page 7 LES CHAMPS MAGNETIQUES peuv ent affecter des implants m dicaux Porteur de simulateur cardiaque ou autre im plants m dicaux rester 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 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 e Ne pas utiliser le poste de soudage pour charger les batteries ou des v hicules de d marrage rapide e Observer la polarit correcte et sur les batteries
112. truction e Ne pas diriger le pistolet vers soi d autres per sonnes ou toute pi ce m canique en enga geant le fil de soudage Tm i L EMPLOI EXCESSIF peut SURCHAUFFER L QUIPEMENT e 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 Pa 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 antistatigues pour stocker d placer ou exp dier des cartes de circuits imprimes OM 4433 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 Nutiliser 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 y El UNE REMORQUE QUI BASCULE peut LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Le rayonnement haute f
113. tu 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 l arc 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 e 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 o 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 d
114. tutiliser 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 e 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 e Ne pas diriger le jet d air vers d autres ou soi m me L AIR 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 e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Tenir distance les produits inflammables de l chappement LES TINCELLES L CHAPPEMENT peuvent provoquer un incendie e Emp cher les tincelles d chappement du moteur de provoquer un incendie e Utiliser uniquement un pare tincelles approuv voir codes en vigueur
115. uctures 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 4433 Page 6 F Indique des instructions sp cifiques AEN 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 duite Dans la plupart des cas un poste courant continu de type CV est recommand Et ne pas tra vailler seul e Couper l alimentation ou arr ter le moteur avant de proc der l installation la r paration ou l entretien de l appareil D verrouiller l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de s curit e Installer et mettre la terre correctement cet appareil conform ment son manuel d utilisation et aux codes nationaux provinciaux et municipaux e Toujours v rifier la terre du cordon d alimentation V rifier et s assurer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fi
116. when determining whether to clean or replace the primary ele ment Optional If you decide to clean the primary ele ment we strongly recommend instal ling an optional safety element to pro vide additional engine protection Never clean a safety element Re place the safety element after servic ing the primary element three times Clean or replace primary element if dirty see note above before cleaning Re place primary element if damaged Re place primary element yearly or after six cleanings 1 Housin Keep nozzle CA H 2 in 51 mm f 2 Safety Element Optional from element CS ND 3 Primary Element DS DS 4 Dust Cap RES mp EA _ COSS OS gt 99999994 yet H p 282833 KIT 5 Dust Ejector SOS LEO PEO k22 2T 53333383 2252222 To clean air filter KS KIS d LE 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 Blow Inspect if present Reinstall cap NOTICE Do not clean housing with air hose Clean primary element with compressed air only Air pressure must not exceed 100 psi 690 kPa Use 1 8 in 3 mm nozzle and keep nozzle at least 2 in 51 mm from inside of element Replace primary ele ment if it has holes or damaged gaskets Reinstall primary element and cap dust ejector down aircleaner1 2 01 ST 153 929 B ST 153 585 Ref S 0698 B R
117. will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Miller must be notified in writing within thirty 30 days of such defect or failure at which time Miller will provide instructions on the warranty claim procedures to be followed Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the delivery date of the 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 3 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
118. x 1 in Screws Supplied To Bolt Unit In Place Remove hardware securing the four mounting brackets to the base Reverse brackets and reattach to base with original hardware Inadequate support A Do not use flexible mounts Mount unit to truck or trailer with 1 2 Using Mounting Brackets 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 Welding Unit In Place Bolting Unit In Place Tools Needed 3 9 9 16 in installa 2007 04 803 274 200 864 A 803 562 OM 4433 Page 20 5 3 Installing Exhaust Pipe PY ar A Stop engine and let cool F Point exhaust pipe in desired di rection but always away from front panel and direction of travel Tools Needed SF 1 2 in 803 582 Ref 217 357 A Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual OM 4433 Page 21 5 4 Activating The Dry Charge Battery If Applicable A Always wear a face shield rubber gloves and protective clothing when working on a battery Remove battery from unit 5 Vent Caps 6 Sulfuric Acid Electrolyte 1 265 Specific Gravity 7 Well Fill each cell with electrolyte to bottom of well maximum A Do not overfill bat

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