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Miller Electric 301 G User's Manual

1. mm 802 851 A Ref 211 909 OM 4411 Page 33 8 7 Troubleshooting A Welding Trouble Remedy No weld output Check control settings Check weld connections Disconnect equipment from generator power receptacles during start up Place V A Adjust switch in Panel position or move switch to Remote position and connect remote control to Remote receptacle RC4 see Sections 5 8 and 6 1 Check and secure connections to Remote receptacle RC4 see Sections 5 8 Check fuse F1 on circuit board PC7 and replace if necessary see Section 8 6 Have Factory Authorized Service Agent check brushes slip rings and circuit boards PC1 and PC2 Low weld output Check weld control settings Change position of Engine Control switch and Speed Control switch to achieve desired engine speed Place V A Adjust switch in Panel position or move switch to Remote position and connect remote control to Remote receptacle RC4 see Sections 5 8 and 6 1 Check and clean air cleaner as necessary see Section 8 4 Have Factory Authorized Service Agent check brushes slip rings and circuit boards PC1 and PC2 See engine manual High weld output Check control settings Check for obstructed movement of solenoid linkage Have Factory Authorized Service Agent check circuit boards PC1 PC2 an
2. Single Phase Induction Motor Starting Requirements motors running amperage Motor Start Code G H J K L M N P KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0 kVA HP x HP x 1000 VOLTS EXAMPLE Calculate the starting amperage required for a 230 V 1 4 HP motor with a motor start code of M Volts 280 HP 1 4 Using Table Code M results in KVA HP 11 2 STARTING AMPERAGE 11 2 x 1 4 x 1000 A Starting ih t ires 12 2 12 2 amperes 230 arting the motor requires amperes S 0624 10 9 How Much Power Can Generator Supply 1 Limit Load To 90 Of Generator Output Always start non resistive motor loads in order from largest to small est and add resistive loads last 2 5 Second Rule If motor does not start within 5 seconds turn off power to prevent motor damage Motor requires more power than generator can supply Ref ST 800 396 A S 0625 OM 4411 Page 44 10 10 Typical Connections To Supply Standby Power Properly install and ground this equipment according to its Owner s Manual and national state and local codes 1 2 3 4 Utility D Fused Welding S isconnect Electrical v gt Transfer Switch Switch a Generator Service If Required Output 5 Essential Loads Have only qualified person
3. 803 128 Ref 211 909 5 7 Selecting Weld Cable Sizes Weld Cable Size and Total Cable Copper Length in Weld Circuit Not Exceeding 150ft 200ft 250ft 300ft 350ft 400 ft 100 ft 30 m or LESS 45m 60m 70m 90m 105 m 120 m Weld Output Terminals A Stop engine before 10 60 60 100 connectingto weld out Welding Duty Duty 10 100 Duty Cycle put terminals Amperes Cycle Cycle Do not use worn dam aged undersized or poorly spliced cables 100 4 20 4 20 4 20 3 30 2 35 1 50 1 0 60 1 0 60 150 3 30 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 3 0 95 200 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 4 0 120 250 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 zo UU 2 ea 2 0 2ea 3 0 2ea 300 1 50 1 0 60 2 0 70 3 0 95 4 0 120 on ket ker 2 ea 2 0 2 ea 3 0 2 ea 3 0 2 ea 4 350 4 0 60 2 0 70 3 0 95 4 0 120 oan ee ken exi 2 2 ea 2 0 2ea 3 0 2ea 4 0 2 ea 4 400 1 0 60 2 0 70 3 0 95 4 0 120 Ger eg Ge si 20 This chart is a general guideline and may not suit all applications If cable overheats use next size larger cable Weld cable size AWG is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere mm for met
4. Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual OM 4411 Page 45 10 11 Selecting Extension Cord Use Shortest Cord Possible F Cord Lengths for 120 Volt Loads A lf 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 2 voltage drop Cord Lengths for 240 Volt Loads A lf 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 10
5. 1 EE PLG30 136925 Conn Rect Comm 093 2p S 1row Plug Cable Lkg 37 CBS 083432 Circuit Breaker Man Reset 1p 10a 250vac Frict 1 DEE EEN 115440 Stand ofi No 6 32 X 687 Lg 250 Hex AlFem 1 Optional When ordering a component originally displaying a precautionary label the label should also be ordered Order label individually or as part of Label Kit 207 019 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 4411 Page 52 F Hardware is common and not available unless listed 8 803 343 Figure 11 3 Bracket w Components Item Dia Par No Mkgs No Description Quantity Figure 11 2 Bracket w Components Figure 11 1 Item 8 1 1 PC1 212705 Circuit Card Assy Power 1 2 PCT 208130 Circuit Card Assy Gen Power Includes 1 EMO aarti 027660 Fuse Mintr Cer 20 Amp 250 Volt 1 OE 115440 Stand off No 6 32 X 687 Lg 250 Hex Al Fem 10 ID 004214 Bushing Snap in Nyl 1 625 Id X 2 000 Mtg Hole 1 sea KO id eat rares 200263 Label Warning Electric Shock Haza
6. 2 4 1 8 EM Information SE 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 Signification des symboles sa bra seere EN 5 2 2 Dangers relatifs au soudage l arc 5 2 3 Dangers existant en relation avec le moteur 6 2 4 Dangers li s Pair comprim 7 2 5 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 7 2 6 Principales normes de s curit 8 2 7 Information sur les champs lectromagn tiques 8 SECTION 3 DEFINITIONS spir SRR S ee 9 3 1 Symbol Definitions olsa busi s tb ua ds RI e e e eR dees en Cede een 9 SECTION 4 SPECIFICATIONS Lu 10 41 DeSGIDUOOSNESSSE eom SUR SE edn ele erbe eg ex prar iet ated 10 4 2 Weld Power And Engine Specifications 10 4 3 Dimensions Weights and Operating Angles 10 4 4 Fuel Consumption While Welding And Using Generator Power 11 4 5 Generator Power Curve 4444444 11 4 6 Duty Cycles secs Gah de ee RE REY R KO Re LEE EE nM EE Lise
7. OFF AUN IDLE 3600 2400 RPM RUN IDLE 3000 1800 RPM 120 VAC 60 120 HZ OFF CC CV DC Welder 5 500 Watt Generator 25A I Yon MAIN BREAKER 120 240 VAC MADE IN une mn APPLETON W M RA Ref 211 909 OM 4411 Page 22 6 2 Description Of Front Panel Controls MM er ABEE 1 Process Switch See Section 6 3 for Process switch informa tion 2 Voltage AmperageAdjust Switch And Remote Receptacle Use switch to select front panel or remote voltage amperagecontrol For remote con trol place switch in Remote position and connect remote control to Remote recep tacle RC4 see Sections 5 8 and 6 4 3 V A Control Use control to select weld voltage or amperage Control may be adjusted while welding F For maximum weld output above 220 Amps run unit at 3600 rom For weld output below 220 Amps operate unit at 3000 or 3600 rom With Process Contactor switch in Stick or TIG setting use control to adjust amperage With Process Contactor switch in Wire posi tion use control to adjust voltage With V A Adjust Switch in Remote position control limits the remote amperage in Stick and TIG modes but has no effect in MIG modes 4 Engine Hour Meter Use hour meter to help schedule routine maintenance see Section 8 1 5 Engine Choke Control Use control to change engine air fuel mix when star
8. HOBART INSTITUT OF WELDING TECHNOLOGY Start Your Professional A Trade Square East Troy Ohio 45373 Over 80 000 trained Welding Career Now 1 800 332 9448 www welding org Since 1930 OM 4411 Page 37 SECTION 9 ELECTRICAL DIAGRAM 4 WARNING e Do not touch live electrical parts 20 e Disconnect input power or stop engine before servicing e Do not operate with covers removed ELECTRIC SHOCK HAZARD e Have only qualified persons install use or service this unit 43 S2 POSIMON MODE S2 PLG8 ss PC7 2 5 1 RUN DLE GEN POWER PCB 3600 2400 RPM F ze o E RC31 1 2 X RUN IDLE ti 148 3000 1800 RPM lt lt RC31 6 3 START g Leen 747 KROS 5 AR dE 1 ECT ies A i 46 45 Wi 41 42 52 52 5 SB s ACRES 4 RS RCS ARCS A RCS KRC15 3 1 2 ol A PL65 PLG5 AER APLGS A Pros Ames ag f lt RC15 7 yo av RED YL BK RED YEL lt lt RC15 8 RED Di HOUR i p 1 ELECTRONICI METER m GOVERNOR M LOW OIL ae DA PRESSURE PC1 gt seh D I WELD POWER PCB 12 VOLT 1
9. Time e h Hours S Seconds Ground Do not switch while Remote Constant welding E Receptacle Work Connection C C Current olo Wire Feed EM A Electrode Negative CV Constant Positive K Voltage Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual OM 4411 Page 9 SECTION 4 SPECIFICATIONS 4 1 Description This multiprocess engine driven welder and AC generator provides low speed generator AC power and DC weld out put for quiet fuel efficient operation At 1800 rpm this unit produces 5 kW kVA 60 Hz 120 240 Volt AC generator power Achieve high quality Stick and TIG welding results at either 3000 or 3600 rpm A special variable frequency 60 120 Hz receptacle provides 2 4 kW kVA 120 Volt AC generator power continuously 4 2 Weld Power And Engine Specifications z Rated Maximum Amperage Voltage peer Welding Open Circuit Range In Range In slet der Engine Output Voltage CC Mode CV Mode 9 pacity 5 5 kVA kW Peak 5 kVA kW Continuous o 42 21 A CC DC 280A 25 V 100 72 20 300 A 120 240 V AC Kohler CH 20 Duty Cycle i 60 Hz Air Cooled Single Phase at 10 gal Two Cylinder 1800 rpm Four Cycle 10 33 V And n 20 HP Gasoline LP Engine 2 4 KVA KW 20 A w Electronic CV DC 300 A 25 V 100 50 lje 120 VAC Governor Duty Cycle 60 120 Hz Single Pha
10. ER SEE RUN IDLE 2600 2400 RPM RUN IDLE 3000 1800 RPM START Tools Needed JF 1 2 in Stop engine and let cool Engine backfire can cause se vere burns or other injuries Do not point exhaust pipe to ward control panel Keep away from exhaust outlet F Point exhaust pipe in desired di rection but always away from front panel and direction of travel 801 681 Ref 211 909 OM 4411 Page 18 5 6 Connecting To Weld Output Terminals n7 s RUN IDLE 3600 2400 RPM RUN IDWE 3000 1800 RPM START Stop engine Do not connect to CC and CV terminals at the same time 1 Negative Weld Output Terminal 2 Stick TIG CC Weld Output Terminal 3 Wire CV Weld Output Terminal For MIG welding connect work cable to Negative terminal and wire feeder cable to Wire CV terminal For Stick TIG welding connect work cable to Negative terminal and electrode holder cable to Stick TIG CC terminal gt gt ELECTRIC SHOCK CAN KILL ARCING CAN BE HAZARI Do not connect to both CC and CV weld output terminals at the same time Both the GC and CV output terminals are electrically hot energized whenever the engine is running AE DOUS O cc GND PE GE STICK TIG e LO
11. 1 ON ere 160566 4 Fans Rotor sv ss data Inv ea OU atre eh hike en 1 EE Rs te bet 2121061 Adapter Engine LSE 1 Sex dU EE 202771 Baffle Engine Adapter 1 fis OF he Pea ees 170861 Stud Stl 375 16 X 17 375 4 e AE IE 205725 Brushholder Assy Generator 2 OMEN 206894 Harness Wrg Brushholder Includes 1 EN PLG17 066104 Conn Rect Univ 084 6p S 3row Plug Cable Lkg 1 DD RC22 136924 Conn Rect Comm 093 2p S 1row Rept Cable Lkg 1 states VOM se Mad teur 010910 Washer Flat 406idx0 8120dx 065t Stl Pld Ansi 375 4 Eh arate ar run 010909 Nut 375 16 56hex 46h Stl Pld Elastic Stop Nut 4 Se S rh Dg KDA 218049 Endbell Includes 1 Suc 183419 O ring 1 984 Id X 139 Cs 70 Duro Viton 1 When ordering a component originally displaying a precautionary label the label should also be ordered Order label individually or as part of Label Kit 207 019 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 F Hardware is common and not available unless listed 803 34
12. OM 4411 207 283E May 2004 a Si Miller Stick SMAW Welding TIG GTAW Welding p MIG GMAW Welding amp KN Flux Cored FCAW Welding With Voltage Sensing Feeder Description DS Engine Driven Welding Generator Miller Legend 301 G DL OWNER S MANUAL 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 BU 3 A ea 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 2 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 business a
13. 202222 Rectifier Si 3ph 300 Amp 400 Piv 100 Duty Cycle 1 Paletni RIMA eus eue Kit SUPPIESSOF SS SS AAE 202339 Battle Air oe Rx ete aia ts 1 ale WOO a uii ce iE 180628 Panel Front Lower 1 idu OO aa eae ts Figure 11 2 Panel Front w Components 1 36 CT1 207812 Xfmr Current Sensing 1 OM 4411 Page 49 Item Dia Part No Mkgs No Description Quantity Figure 11 1 Main Assembly Continued RA OE era dee SA 182367 Panel Side Rh 1 S A s d 4185352 Panel Side Rh Stainless Steel 1 DX PE ay anaes 1823601 Panel Side Eh i oec Ope pei ME cam is hr ais 1 OG ivit 185353 Panel Side Lh Stainless Steel 1 v OO aaa i cmn deleted vi eot te t e TRU c e te na era a LAO sara t 192042 Label Use Gasoline Only 1 41 GEN Figure 11 4 Generator Assembly 1 OE RO etre 209831 Connectors W Leads Includes DET PLG29 113751 Conn Rect Mini 045 8skt 2row Plug Cable Lkg 1 pido aat LE 204640 Cable LEM spittin be RC30 136924 Conn Re
14. 197203 Grounding Stud Assy Brass Includes 1 e do nate eA 083030 Stud Brs 250 20 X 1 750 W Hex Collar 1 RO AN O 010915 Washer Flat 257idx0 6400dx 031t BrS 2 un 2D ati death VE Pen 602207 Washer Lock 255idx0 4890dx 062t Stl Pld Split 250 1 A A 601836 Nut 250 20 50hex 19h BIS 1 27 WORK 039046 Terminal Pwr Output Black 1 ee eeh eg 211425 Receptacle W Leads Includes 28 RC1 182954 Rept Str 3p4w 50a 125 250v Flush Mtg 14 50 1 Sih Obs ce cr is 188039 Cover Receptacle w Gasket 1 Mascot P 203016 Boot Circuit Breaker 2 Pole 1 ico lo cuota Prey za 159921 Bezel sai a e SANE EN 1 EN ts 021385 Boot Toggle Switch Lever 2 ES 170391 Conn Circ Ms Protective Cap Size 20 Nylon 1 sea de wie Ia 207075 Knob Pointer 1 625 Dia 1 LIA OO Du mI DRIN IDE 207080 Knob Pointer 875 Dia 1 36 LEM 168829 Transducer Current 1000a Module Max Open Loop 1 EE 204777 Plug W Leads Includes
15. 26 7 1 60 Hz Generator Power Receptacles And Circuit Breakers 26 7 2 Variable Frequency Hz Generator Power Receptacle RC3 27 7 3 Wiring Instructions For Optional 240 Volt Single Phase Plug NEMA 14 50P 28 TABLE OF CONTENTS SECTION 8 MAINTENANCE amp TROUBLESHOOTING 29 BL Routine Maintenance ote vehi ince nes Ge Ee RR wq eq quae e pee tas 29 8 2 Maintenance Label sacre oa RAGE LAE PNT NW e Y du pr CORTE Y eere 30 8 3 Servicing Optional Spark Arrestor 30 8 4 Servicing AIF Cleaner s err RE REPE OL SG eR OS 31 8 5 Changing Engine Oil Oil Filter And Fuel Filter 32 8 6 Overload Protection ai ssi Sege ee EM fat are AF EORR MEE Br elses oa Ebert 33 8 7 iTroubleshooting dr st mor hes toed E ers der d ee dhe edhe ls ale eck dna ath oleae La dad 34 SECTION 9 ELECTRICAL DIAGRAM o x rr RR MEER ges E Me Eee 38 SECTION 10 GENERATOR POWER GUIDELINES 40 SECTION 11 PARTS LIST dil se 48 OPTIONS AND ACCESSORIES WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING rom nd 10 02 Warning Protect yourself and others from injury read and follow these precautions 1 1 Symbol Usage with this procedure The possible h
16. NOTE F The views in this section are intended to be representative of all engine driven welding generators Your unit may differ from those shown 10 1 Selecting Equipment Generator Power Receptacles Neutral Bonded To Frame 3 Prong Plug From Case Grounded Equipment 2 Prong Plug From Double Insulated Equipment Do not use 2 prong plug un less equipment is double in sulated Be sure equipment has this symbol and or wording gen pwr 11 02 Ref ST 159 730 ST 800 577 F Electrically bond generator v frame to vehicle frame by metal to metalcontact Bed liners shipping skids and some running gear insulate the welding generator from the ve hicle frame Always connect a ground wire from the generator equipment grounding terminal to bare metal on the vehicle frame as shown A Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards 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 lf unit does not have GFCI re ceptacles use GFCI pro tected extension cord S 0854 OM 4411 Page 40 10 3 Grounding When Supplying Building Systems 1 Equipment Grounding Terminal 1 z 2 Grounding Cable GND PE E p U
17. F To improve cold weather starting Keep battery in good condition Store battery in warm area Use correct grade oil for cold weather Gasoline 803 129 OM 4411 Page 16 5 3 Activating The Dry Charge Battery If Applicable GO Remove battery from unit 1 Eye Protection Safety Glasses Or Face Shield 2 Rubber Gloves 3 Vent Caps 4 Sulfuric Acid Electrolyte 1 265 Specific Gravity 5 Well Fill each cell with electrolyte to bottom of well maximum Do not overfill battery cells Wait ten minutes and check electro lyte level If necessary add electro lyte to raise to proper level Reins tall vent caps 6 Battery Charger 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 F When electrolyte is low add only distilled water to cells to maintain proper level 5 A For 30 Minutes Tools Needed px pou rubbergloves p glasses OR TN 30 A For 12 Minutes drybatt1 1 98 S 0886 OM 4411 Page 17 Connecting The Battery WI 27 RUN IDLE 3600 2400 RPM RUN IDLE 3000 1800 RPM Tools Needed I 3 1 2 in Connect negative cable last Ref 800 394 C Ref 211 909 Ref S 0756 D Installing Exhaust Pipe 5 5
18. FL 33126 phone 305 443 9353 website www aws org National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 phone 703 412 0900 website www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Bou 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 electromagnetic fields when welding or cutting OM 4411 Page 4 ARC WELDING can
19. and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky 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 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 Keep welding power source and cables as far away from operator as practical 5 Connect work clamp to workpiece as close to the weld as possible About Pacemakers Pacemaker wearers consult your doctor first If cleared by your doctor then following the above procedures is recommended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION rom_fre 8 03 A Avertissement Prot gez vous et les autres des blessures lisez et suivez ces pr cautions Le Ce groupe de symboles si gnifie Mise en garde lt Soyez vigilant Il y a des 2 1 Signification des symboles Signifie Mise en garde Soyez vigilant
20. 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 3 04 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 Call 1 800 4 A Miller or see our website at www MillerWelds com to locate a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering Carrier to File a claim for loss or d
21. 707 115VAC CONTACTOR f 115VAC SOURCE 1 CHASSIS COMMON ail A 4 RC4 Rca i 706 K RC23 3 UU RO24 2 PC2 CONTROL PCB SI F2 Figure 9 1 Circuit Diagram For Welding Generator PLG22 2 RC22 2 RC22 1 RC33 7 gt RC17 4 E PLG22 1 x WEA RC17 3 gt gt RC10 1 92 RC10 3 gt Z RC33 9 gt La RC33 6 ess y 7 lt RC12 1 lt RC12 2 93 000000000000000000 EXCITER REVOLVING FIELD 000000000000000000 60 67 60 90 217 116 RC27 1 gt RC27 2 gt 174 135 RC25 5 gt RC25 2 gt CR2 CR2 81 42 60 81 80 S 82 EXCITER FIELD COMMON MAIN FIELD UP COLLECTOR RINGS PLG9 1 PLG9 2 RC9 1 RC9 2 RC20 1 p RC20 3 gt 108 RC20 2 gt _ PANEL A V ADJUST 530 SWITCH REMOTE IZ RC30 1 87 A lt PLG30 1 VR1 37 R3 JO RC30 2 PLG30 2 141 lt lt PLGB 142 143 lt lt N m Ku 144 2 Q N o 1 YY 42 V V lt a DC Z OM 4411 Page 39 211 395 C SECTION 10 GENERATOR POWER GUIDELINES
22. Exhaust Elbow 1 MR IEEE 183314 Clamp Muffler 1 625 Dia U Pld 1 DR ON atch ae 205762 COVER MODY SAND 1 ad EE 4206758 Cover Top Stainless Steel 1 EE 163175 Screw 250 20 x 75 Hex Hd pln Stainless Steel Pin 18 NU E EU 163167 Washer Lock 254 id x 0 489 odx x 062t Stainless Steel Split 250 18 UE rn NE 163174 Washer Flat 281 id x 0 625 od x 0 50t Stainless Steel 18 ETE NE 182365 Panel Rear Upper 1 SET EE 185351 Panel Rear Upper Stainless Steel 1 O Late Figure 11 3 Bracket w Components 1 EE 205736 Upright Base eee laa eid ke base Wate od a ne R R d 1 Dd aus 205734 Seal Weather Lift Eye 1 ONT sei ni 181789 4 3 Seal Barrel apr ata land ana PUR tu a a ea 1 KEE 186667 Cover Tank Fuel 1 Tu at eae eis 208463 Engine Koh Gas Elec Ch20s ps 64663 Includes 1 ST 207458 Muffler Exhaust Engine W Heat Shield 1 a bigs rad a eu dur en 189477 Muffler Gasket 15 emis 208003 Hose Oil W
23. Fittings And Valve Includes 1 ET lanis 207490 Hose Oil W Fitting 9 750 Lg 1 LAT a EA ASIN 165271 Valve Oil Drain 3 8 18 Nptf dado REM UD DNE 206402 Ftg Hose Brs Barbed M 1 2 Tbg X 3 8 Npt 1 ads RE duis 023562 Clamp Hose 312 875 Clp Dia 1 TO slbi uro 215984 Filter Fuel In line 250 1 DO a a 135556 Housing Plug Skts Service Kit Save ena F6 021718 Fuse Mintr GI 30 Amp 32 Volt 1 EE DI 180096 Tune up 8 Filter Kit Kohler Includes 1 an 067272 Air Filter Element Kohler EE 066698 Oil Filter Kohler 1 anga as P 215985 Filter Clamps Fuel 1 4 Line 1 EE ENE Debate 067007 4 e Ell PlUG LESLESSO Date ode suste EEN EEE an teed 067273 Air Filter Wrapper ENEE EEN id ana ila zava lad dane NE 182079 Tank Fuel 10 0 Gal Includes 1 iata ure att ea 124253 Bushing Tank Fuel ee Se E 187502 Ftg Stand Pipe 250 X 7 375 Lg 90 Degree 1 EEN 182
24. Stick Using Remote On Off Min 40 A CC DC Max 180 A CC DC gt ELECTRODE HOT a PANEL 3 M OUTPUT Wipe sary ADJUST A OTE Set V A Adjust Set Process Set Switch V A Control 3 ne 2 3 Max 180 A DC Min 40 A DC Adjust Remote Control Stick Welding Only F This unit does not have remote con tactor control Output is always on 803 128 211 909 S 0769 S 0774 OM 4411 Page 25 SECTION 7 OPERATING AUXILIARY EQUIPMENT 7 1 60 Hz Generator Power Receptacles And Circuit Breakers WW TOTAL LOADS 5 500 WATTS NEUTRAL BONDED TO FRAME NEUTRE RACCORDE AU BATI 120 240 VAC AT 1800 RPM ONLY 4 zi POR ZA v Ne AY 120 VAC 60 120 HZ q l O d 0 om opm u zi oh Ai 2H of om ab Klo Sky og da lt H OFF 25A 2 MAIN BREAKER 120 240 VAC ER 3 See Section 7 2 for RC3 information Controlling Engine Speed And Weld Generator Power Output Engine Controls ES Bal Weld Output Engine Speed Either B Run ldle Oy coo position 1800 rpm Ts Power Speed Welding Not Ls Continuous Recommended 5 KW KVA Total From All AC Receptacles No Load 2400 rpm Idle Speed pic as Pope
25. avec tension vide r duite Dans la plupart des cas un poste courant continu de type CV est recommand Et ne pas travailler seul e Couper l alimentation ou arr ter le moteur avant de proc der l installation la r paration ou l entretien de l appareil D verrouiller l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de s curit e Installer et mettre la terre correctement cet appareil conform ment son manuel d utilisation et aux codes nationaux provinciaux et municipaux e Toujours v rifier la terre du cordon d alimentation V rifier et s assurer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre risques de danger reli s aux CHOCS LECTRIQUES aux PIECES EN MOUVEMENT et aux PIECES CHAUDES Reportez vous aux symboles et aux directives ci des sous afin de conna tre les mesures prendre pour viter tout danger En effectuant les raccordements d entr e fixer d abord le conducteur de mise la terre appropri et contre v rifier les connexions V rifier fr quemment le cordon d alimentation pour voir s il n est pas en dommag ou d nud remplacer le cordon imm diatement s il est endommag un cable d nud peut provoquer une lectrocution Mettre l appareil hors tension quand on ne l utilise pas Ne pas utiliser des c bles us
26. chappement au niveau de l arc pour l vacuation des fum es et des gaz de soudage Sila ventilation est insuffisante utiliser un respirateur alimentation d air homologu Lire les sp cifications de s curit des mat riaux MSDSs et les instruc tions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d graisseurs Travailler dans un espace ferm seulement s il est bien ventil ou en por tant 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 oxygene provoquant des blessures ou des accidents mortels S assurer que l air de respiration ne pr sente aucun danger Ne pas souder dans des endroits situ s proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et former des gaz hautement toxiques et irritants Ne pas souder des m taux munis d un rev tement tels que l acier galvani S plaqu en plomb ou au cadmium moins que le rev tement n ait t enlev dans la zone de soudure que l endroit soit bien ventil et si n ces saire en portant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage OM 4411 Page 5 LES ACCUMULATIONS
27. dela 2 4 KW KVA at 60 120 peed Hz From AC Receptacle RC3 Only Q No TR LA 5 kW kVA Total From T All AC Receptacles 3000 rpm a X Load 3000 rpm At 1800 rpm 20 220A Weld Speed At 3000 rpm Output Available Only At 2 4 kW kVA 60 120 Hz AC Receptacle RC3 A lf unit does not have GFCI re ceptacles use GFCI protected extension cord F Weld output and 60 Hz generator power output at receptacles RC1 and RC2 are not available at the same time When welding gen erator power is available from AC receptacle RC3 only see Sec tion 7 2 F Generator power is available at receptacles RC1 and RC2 only at 1800 rpm If generator is not locked at 1800 rpm engine speed increases in response to weld load and generator power output stops at receptacles RC1 and RC2 Generator power load does not affect engine speed 1 240 V 50A AC Receptacle RC1 RC1 supplies 60 Hz single phase power at 1800 rom Maximum output is 5 kKVA kW 20 A at 240 volts ac For 60 Hz generator power at RC1 set controls as shown in table 2 120 V 20A AC Duplex Receptacle RC2 RC2 supplies 60 Hz single phase power at 1800 rpm Maximum output from RC2 is 2 4 KVA KW 20 A at 120 volts ac 3 Circuit Breaker CB1 CB1 protects receptacles RC1 and RC2 from overload If CB1 opens the receptacles do not work Place switch in On position to reset breaker 4 Circuit Breaker CB3 CB3 protects RC2 from overload If CB3 opens the recepta
28. des che mins inconnus ventuels en provoquant des risques d lectrocution et d incendie Ne pas utiliser le poste de soudage pour d geler des conduites gel es En cas de non utilisation enlever la baguette d lectrode du porte lectro de ou couper le fil la pointe de contact e Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans revers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes Suivre les recommandations dans OSHA 1910 252 a 2 iv et NFPA 51B pour les travaux chaud et avoir de la surveillance et un extincteur proxi mit DES PARTICULES VOLANTES PR peuvent blesser 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 vo lantes Pendant la p riode de refroidissement des soudures elles ris quent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial DES PI CES CHAUDES peuvent provoquer des br lures graves e Pr voir une p riode de refroidissement avant d effec tuer des travaux d entretien e Porter des gants et des v tements de protection pour travailler sur un moteur chaud e Ne pas toucher mains nues les parties chaudes du m
29. det SVO kne mase Ms 12 4 7 Stick And MIG Mode Volt Ampere Curves 18 4 8 DC TIG Mode Volt Ampere Curves 14 SECTION 5 INSTALLATION mix NEE E EE Dee Ree eee Rae RITU 15 5 1 Installing Welding Generator 15 5 2 Engine Prestart Checks Dai don ma nu Ex awa same SER das 16 5 3 Activating The Dry Charge Battery If Applicable 17 5 4 Connecting The Battery ume Bland shoe neta Ge ER ek Mesa ae haha 18 5 5 Installing Exhaust Pipe ssi a mala ated Al Kas far NIE i Lente PNR haw state 18 5 6 Connecting To Weld Output Terminals 19 5 7 Selecting Weld Cable Sizes 19 5 8 Remote Receptacle Information 20 5 9 Adjusting Wire MIG Weld Puddle Consistency 21 SECTION 6 OPERATING WELDING GENERATOR 000 cee eee cece cece cece eee nn nnn 22 6 1 Front Panel Controls 2c oat i a oblate net En DEOR EAR GA Ge 22 6 2 Description Of Front Panel Controls 23 6 3 Process WI iii di Obs SNE avg weed Ee RR de adhe 24 6 4 Remote Amperage Voltage Control 25 SECTION 7 OPERATING AUXILIARY EQUIPMENT
30. does not have GFCI re ceptacles use GFCI protected extension cord Mounting 1 Cross Supports Mount unit on flat surface or use cross supports to support base Grounding 2 Equipment Grounding Terminal On Front Panel 3 Grounding Cable Not Supplied 4 Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insu lated copper wire install2 5 03 Ref 800 652 Ref 800 477 A 803 274 OM 4411 Page 15 5 2 Engine Prestart Checks Y Check all fluids daily Engine must b y Engine must be y Ep cold and on a level surface Unit is shipped with 10W30 engine oil IF Follow run in procedure in engine manual mcm 7 This unit has a low oil pressure shutdown switch However some conditions may cause engine damage before the engine shuts down Check oil level often and do not use the oil pressure shutdown system to monitor oil level Fuel Add fresh fuel before starting engine the first time see maintenance label for specifications Always leave filler neck empty to allow room for expan sion Check fuel level on a cold engine before use each day Cil Check oil with unit on level surface If oil is not up to full mark on dipstick add oil see maintenance label MONON
31. f STARTER 1 A EROR ce i ELECTRIC i VOLT REG I L PUMP RECT BLACK DU m m m im o m AAA A a 5 LEON Lj lt RC15 1 ggg Y GAS KOHLER ENGINE rF PRVE en es iat sai hannes peu eege Pre SEU A A A A A 6 5 3 1 4 2 A PLG5 A PLGS PLGS PLG5 A PLGS A PLCS Wo lav HL EL env NO FUEL PLG7 2 RC7 2 55 o LOCK OFF PLG7 1 REI ES 1 kel oy K SOLENOID PLG7 3 RA 68 RIR S 2 fo gt ELECTRONIC lt lt 1 II GOVERNOR 64 AAA AR AA ao dete o nO xo MAT i I POWER WELD 2 9 Q RER 12 VOLT 7 NAN NANA A 3 STARTER D lt RC25 8 gee ELLE EL a 45 K RO25 6 amp 14 PIN REMOTE RC4 G CIRCUIT COMMON I Ed lt lt Rc24 1 RC4 A 700 m m m m ZAVAC SOURCE lt lt RC23 6 24VAC CONTACTOR DH lt RC23 5 RC4 E REMOTE COMMAND gt T KRC23 1 keen _ 1 circu COMMON RED 70 X RC23 4 1 OM 4411 Page 38 1 1 1 i ae SIJ 1 o 0 Y Y Y i e H t m GFCI 3 1 CB4 rodi ami I Leer R N 2 42 GND N l a i m H GFCI 2 1 84 A 85 NIS 1 Hc l CB3 20 5 42 GND N 1 P wo mh or Z CB1 I ES 89 h 54 i D rh I LINE LOAD AAA ROI i YWXG 240V 1 GFCI 1 RECEPTACLE 1 OPTION EE EE Te 1 COMMAND REF gt RC4 C1 707 RC4 J
32. of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechanical shocks slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fittings de signed 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 Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards 4 MOVING PARTS can cause injury e Keep away from fans belts and rotors Y e Keep all doors panels covers and guards closed and securely in place Stop engine before installing or connecting unit Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary To prevent accidental starting during servicing disconnect negative battery cable from battery Keep hands hair loose clothing and tools away from mov
33. side panel icis 1 Stabilizer DC Z P um 2 Wire CV Weld Output Terminal 3 Stabilizer Leads 29 28 And 27 Lead 29 provides stiffest weld puddle Lead 28 provides wetter weld puddle for mild steel Lead 27 provides wettest weld puddle for stainless steel Lead 29 is connected to the Wire CV weld output terminal at the factory Disconnect lead 29 from the Wire CV weld output terminal For wetter weld puddle for mild steel Remove insulated sleeving from lead 28 Connect lead 28 to Wire CV weld output terminal reusing hardware Insu late lead 29 with sleeving removed from lead 28 Secure sleeving with cable ties For wettest weld puddle for stainless steel Remove insulated sleeving from lead 27 Connect lead 27 to Wire CV weld output terminal reusing hardware Insu late lead 29 with sleeving removed from lead 27 Secure sleeving with cable ties Reinstall side panel Tools Needed gt gt IZ 3 8 7 16in Ref 803 100 OM 4411 Page 21 SECTION 6 OPERATING WELDING GENERATOR 6 1 Front Panel Controls ELECTRODE HOT WE STICK IRE Sensing der CV EL f REMOTE A REMOTE VOLTAGE AMPERAGE 300 OUTPUT ADJUST 120 240 VAC AT 1800 RPM ONLY TOTAL LOADS 5 500 WATTS NEUTRAL BONDED TO FRAME NEUTRE RAGGORD AU BATI
34. supplied respirator ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld e Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes from arc rays and sparks when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards Wear approved safety glasses with side shields under your helmet Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc e Wear protective clothing made from durable flame resistant material wool and leather and foot protection OM 4411 Page 1 AWE 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 Protect yourself and others from flying sparks and hot metal e Do not weld where flying sparks can strike flammable material e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers e Be alert that welding sparks and hot materials from welding can
35. up service and storage information Service fluids more often if used in severe conditions To be done by Factory Authorized Service Agent e Every 8h Check fluid levels L ck Wipe up spills See Section 5 2 OIL 20h Check and clean spark arrestor screen See Section 8 3 ny Service air filter wrapper foam element See Section 8 4 O Every 50 h Clean and tighten weld terminals O Every 100 h Change oil See Section 8 5 and maintenance label Clean cooling system See engine manual Service air filter element See Section 8 4 Clean and tighten battery connections O Every 200 h may increase fouling I Change oil filter See Section Replace fuel T an 8 5 and maintenance label filter See 522 Section 8 5 B Check spark plugs and Replace replace if fouled Operation unreadable at low speed 1800 rpm labels O Every 500 h 2 Repair or O 7 replace cracked cables y TS Service welding generator brushes and slip rings Service more often in dirty conditions O Every 1000 h Blow out or vacuum inside During heavy service clean monthly OM 4411 Page 29 8 2 Maintenance Label N OTE Follow the storage procedure in the engine owner s manual if the unit will not be gt used for an extended period KOHLER CH20 ROBIN E
36. 0 31 15 3600 600 183 350 107 225 69 150 46 75 23 60 18 20 4800 450 137 275 84 175 53 100 31 60 18 25 6000 350 107 225 69 125 38 75 23 30 7000 300 91 175 53 100 31 75 23 35 8400 250 76 150 46 100 31 40 9600 225 69 125 38 75 23 45 10 800 200 61 125 38 50 12 000 175 53 100 31 Conductor size is based on maximum 2 voltage drop OM 4411 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 4411 Page 47 SECTION 11 PARTS LIST 15 A 22 3 MU ii SCH NQ SS N i e ANI Y SI A Jur Te y Fig 11 2 e 803 340 Figure 11 1 Main Assembly OM 4411 Page 48 Item Dia Part No Mkgs No Description Quantity Figure 11 1 Main Assembly A re 181881 Grommet Plastic Neck Filler Fuel 1 Se 166608 Cap Tank Screw on W Vent 1 cu 182761 Label Warning General Precautionary Csa 1 2A wea Imus 183433 Pipe
37. 2 Figure 11 4 Generator OM 4411 Page 54 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 Miller Effective January 1 2004 Equipment with a serial number preface of LE or newer This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Miller must be notified in writing within thirty 80 days of such defect or failure at which time Miller will provide instruct
38. 922 Bushing Tank Fuel 1 210id PE A AO A A ae 182925 Gauge Fuel Float Type 5 50 Float Travel 1 TE 161860 Hose Sae 250 Id X 500 Od X 8 000 1 T8 Sedes 182928 Bracket Mtg Generator 1 OM 173043 Bracket Mtg Engine 1 20 ae presses 082319 Cable Bat Neg 17 750 No 4 Awg W Clamp amp 343 Rng 1 MN UD Hea 172669 Cable Bat Neg 11 000 6ga W 250 Rng 8 375 Rng 1 WE toe be equ dt 182935 Hold Down Battery 1 EE 168385 Label Warning Battery Explosion Can Blind 1 LOA ta 4201174 Door Access Battery 1 E EEE 173921 Cable Bat Pos 28 000 No 4 Awg W Clamp 8 312 Rng 1 25 BATT 168037 Battery Stor 12v 430 Crk 75 Rsv Gp 58 Dry 1 HB Hd Skinn 192362 Bracket Mtg Nyl 1 2 Conduit 1 sh Prin a na uus 201280 Pan Base SS 1 4 NA a 197930 Label Warning Do Not Weld On Base 2 SG PEER 215939 Label Engine Maintenance Kohler Ch20 Ch23 1 mec BRP E E 181057 1 1 Cover Base vu ce Dea A areas Id d eh eater DE 2 Les Glisse DCZ 202337 Stabilizer ASSY iis es ak e e ba a Va CR EAR ec ER 1 82 SR1
39. Cette proc dure pr sente des risques de danger Ceux ci sont identifi s par des symboles adjacents aux directives ldentifie un message de s curit particulier F Signifie NOTA n est pas relatif la s curit 2 2 Dangers relatifs au soudage l arc 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 cu rit num r es la section 2 6 Veuillez lire et respecter toutes ces normes de s curit A L installation l utilisation l entretien et les r parations ne doivent tre confi s qu des personnes qualifi es Au cours de l utilisation tenir toute personne l cart et plus particuli rement les enfants x UN CHOC LECTRIQUE peut tuer Un simple contact avec des pi ces lectriques peut provoquer une lectrocution ou des blessures graves L lectrode et le circuit de soudage sont sous tension d s que l appareil est sur ON Le circuit d entr e et les circuits internes de l appareil sont galement sous tension ce moment l En soudage semi automatique ou automatique le fil le d vidoir le logement des galets d entrainement et les pi ces m talliques en conta
40. DE GAZ ris quent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confin s ou se servir d un respi rateur d adduction d air homologu LES RAYONS DE LARC peuvent pro Voduer des br lures dans les yeux et sur la peau Le rayonnement de l arc du proc d de soudage g n re des rayons visibles et invisibles intenses ultraviolets et infrarouges susceptibles de provoquer des br lures dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage e Porter un casque de soudage muni d un cran de filtre appropri pour pro t ger votre visage et vos yeux pendant le soudage ou pour regarder voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit e Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev e Utiliser des crans ou des barri res pour prot ger des tiers de l clair et de l blouissement demander aux autres personnes de ne pas regarder l arc e Porter des v tements de protection constitu dans une mati re durable r sistant au feu laine ou cuir et une protection des pieds FRA LE SOUDAGE peut provoquer un in cendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer leur clatement Des tincelles peuvent tre projet es de l arc de s
41. Generator Power Receptacle RC3 Trouble Remedy No generator power output at ac re ceptacle RC3 Reset circuit breaker CB4 see Section 7 2 Check receptacle RC3 for continuity and proper connections Replace receptacle if necessary Check fuse F1 on circuit board PC7 and replace if necessary see Section 8 6 Have Factory Authorized Service Agent check brushes and slip rings and circuit boards PC1 PC2 and PC7 Low generator power output at ac re ceptacle RC3 Check fuse F1 on circuit board PC7 and replace if necessary see Section 8 6 Turn Engine Control switch to Run Idle 3600 2400 RPM position OM 4411 Page 35 D Engine Trouble Remedy Engine will not crank Check fuse F6 and replace if open see Section 8 6 Check battery voltage Check battery connections and tighten if necessary Check plug PLG5 and plug PLG8 connections Have Factory Authorized Service Agent check Engine Control switch S2 Engine does not start Check fuel level see Section 5 2 Check battery and replace if necessary Check engine charging system according to engine manual See engine manual Engine starts but stops when Engine Control switch returns to either Run Idle position Check oil level see Section 5 2 Low oil pressure shutdown stops engine if oil pressure is too low Use correct grade oil for operating temperature see S
42. H64 EH65 GAS ENGINES See Engine Manual for complete engine care Give Engine Specification and Serlal Number when ordering parts To Drain Oil Push And Tum CCW FR Check Daily Recommended Oil API Service Classification SG or higher If using LP fuel use synthetic oll Oil Change 100 hours Oll Filter Change 200 hours KOHLER MILLER 066 698 Kohler 1205001 ROBIN MILLER 198 754 Robin 248 65801 00 Oil Capacity w filter change Approximately 1 5 quarts DO NOT OVERFILL KOHLER Keep oil level between L amp F marks on dipstick ROBIN Keep oil level between 2 holes on dipstick Fuel Grade Unleaded 87 Octane min Fuel Filter KOHLER MILLER 215 984 Kohler 2505008 ROBIN MILLER 215 984 Robin 263 65012 A3 Gasoline Alr Filter Service 100 hours see Owner s Manual Air Filter KOHLER MILLER 067 272 Kohler 4708303 Air Filter Wrapper KOHLER MILLER 067 273 Kohler 2408302 Air Filter ROBIN MILLER 198 755 Robin 263 32610 A1 includes Air Filter Wrapper 12 Volt Battery ES BCI Group 58 Cranking Performance at 430 Amps min Engine Speed High Speed 3675 3750 RPM No Load Idle 2200 2300 RPM Miller Legend See Owner s Manual Spark Plug KOHLER MILLER 067 007 Kohler 1213202 Gap 0 030 In Champion RC 12YC ROBIN MILLER 198 777 Robin X65 01407 30 NGK BPR4EY Use only resistor spark plugs and wires Tune up and Filter Kit Includes Air Oil and Fuel Filters and 2 Spark Plugs KO
43. HLER MILLER 180 096 ROBIN MILLER 199 062 215 939 6 8 3 Servicing Optional Spark Arrestor Stop engine and let cool KP 1 Spark Arrestor Screen Clean and inspect screen Replace spark arrestor if screen wires are broken or missing RUN IDLE 3600 2400 RPM RUN IDLE 3000 1800 RPM START Tools Needed JE 1 4 in Hun 803 127 Ref 211 909 OM 4411 Page 30 8 4 Servicing Air Cleaner KE RUN IDLE 3600 2400 RPM RUN IDLE 3000 1800 RPM START A Stop engine Do not run engine without air cleaner or with dirty element 1 Wrapper Foam Element Wash wrapper with soap and water solution Allow wrapper to air dry completely Spread 1 tablespoon SAE 30 oil evenly into wrapper Squeeze out excess oil 2 Element Replace element if damaged dirty or oily aircleaner3 9 00 802 772 Ref 185 095 A S 0759 OM 4411 Page 31 8 5 Changing Engine Oil Oil Filter And Fuel Filter 4 CL ws EE G Tools Needed Te RUN IDLE 3600 2400 RPM RUN IDLE 3000 1800 RPM START Stop engine and let cool 1 Oil Drain Valve 2 Oil Filter Change engine oil and filter accord ing to engine manual Close valve and valve cap before adding oil and run ning engine Fill crank
44. amage during shipment For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA 2003 Miller Electric Mfg Co 1 03 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 Miller
45. arranty the exclusive remedies shall be at Miller s option 1 repair or 2 replacement or where authorized in writing by Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Miller authorized service facility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER Some states in the U S A
46. as utiliser l air comprim pour respirer e Utiliser l air comprim seulement pour le coupa ge 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 sys t 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 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 laches et outils des orga nes mobiles Remettre en place les panneaux ou les dipositifs de protection et fermer les portes la fin des travaux d entretien et avant de faire d marrer le moteur Avant d intervenir d poser les bougies ou injecteurs pour viter la mise en route accidentelle du moteur Bloquer le volant moteur pour viter sa rotation lors d une intervention sur le g n rateur LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT CHAUD peuvent provoquer des br lures e est pr f rable de v rifier le liquide de refroidissement une fois le moteur refroidi pour viter de se br ler Toujours v rifier le niveau de liquide de refroi
47. azards are shown in Means Warning Watch Out There are possible hazards A the adjoining symbols Marks a special safety message F Means Note not safety related 1 A A A 2 Arc Welding Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Stan dards listed in Section 1 7 Read and follow all Safety Standards Only qualified persons should install operate maintain and re pair this unit During operation keep everybody especially children away I 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 equipment is a hazard Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contac
48. case with new oil to full mark on dipstick see Section 8 2 3 Fuel Filter 4 Fuel Line Replace line if cracked or worn Install new filter Wipe up any spilled fuel Start engine and check for fuel leaks Stop engine tighten connec tions as necessary and wipe up fuel 803 127 S 0842 OM 4411 Page 32 8 6 Overload Protection pum 7 4 K E Tools Needed JF 3 8 in RUN IDLE 3600 2400 RPM RUN IDLE 3000 1800 RPM START Located behind front panel Stop engine F When a circuit breaker or fuse opens it usually indicates a more serious problem exists Contact a Factory Authorized Service Agent 1 Circuit Breaker CB5 CB5 protects the 24 volt ac output to Remote receptacle RC4 If CB5 opens 24 volt ac output to RC4 stops 2 Fuse F1 See Parts List 3 Fuse F2 See Parts List Remove cover Fuse F1 is located on power board PC7 F1 protects the exciter stator from overload If F1 opens weld and generator power output stops Fuse F2 is located behind front panel F2 protects the 115 volt ac output to Remote receptacle RC4 If F2 opens 115 volt ac output to RC4 stops Replace fuse s if open Reinstall cover before operating unit 4 Fuse F6 See Parts List F6 protects the engine wiring system from overload If F6 opens the engine will not crank Replace fuse if open
49. cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as microprocessors computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electro magnetically 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 electronic equipment e Be sure this welding machine is installed and grounded according to this manual e lf 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 Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm For Diesel Engines Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm levard Rexdale Ontario Canada M9W 1R3 phone 800 463 6727 or in Toronto 416 747 4044 website www csa international org Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 11 West 42nd Street New York NY 10036 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting
50. cle does not work Press button to reset breaker EP If circuit breaker continues to open contact Factory Authorized Service Agent Combined output of all receptacles limited to 5 KVA KW continuous rating ofthe generator EXAMPLE If 10 A is drawn from 120 V duplex receptacle RC2 only 16 A is available at 240 V receptacle RC1 120 V x 10 A 240 V x 16 A 5 KVA KW Ref 211 909 OM 4411 Page 26 7 2 Variable Frequency Hz Generator Power Receptacle RC3 D TOTAL LOADS 5 500 WATTS NEUTRAL BONDED TO FRAME NEUTRE RACCORDE AU BATI 120 240 VAC AT 1800 RPM ONLY d O 120 VAC O 120 VAC 60 120 HZ V o s m EJ D amp a o Q J ES o Z lt D uy u A 7 E E s n F4 6 p I S 8 zl a o q l O d OFF 25A ON MAIN BREAKER 120 240 VAC Do not operate equipment re quiring a constant frequency from variable frequency re ceptacle RC3 1 120 V 20 A Variable Frequency AC Receptacle RC3 Receptacle supplies single phase power continuously Frequency Hz of generator power output changes with engine speed Total output avail able is 2 4 kVA kW 2 Circuit Breaker CB4 CB4 protects the receptacle from overload If CB4 opens the recep tacle does not work F Press button to reset circuit b
51. ct Comm 093 2p S 1row Rept Cable Lkg 1 kein UN ak oleae Akay 204664 Plug W Leads Includes 1 mE PLG28 116513 Conn Rect Mini 045 12skt 2row Plug Cable Lkg 1 POTERE 202883 Harness Control Power Board Interconnecting Includes 1 bebes PLG16 114655 Conn Rect Mini 045 6skt 2row Plug Cable Lkg 1 Page PLG12 PLG27 117037 Conn Rect Mini 045 2skt 2row Plug Cable Lkg 2 S isme PLG21 113750 Conn Rect Mini 045 4skt 2row Plug Cable Lkg 1 PESE au 206534 Harness Wrg Interconnecting Includes 1 cheba ies RC9 136924 Conn Rect Comm 093 2p S 1row Rept Cable Lkg 1 Mg PLG25 113752 Conn Rect Mini 045 10skt 2row Plug Cable Lkg 1 beds RC7 092670 Conn Rect Univ 084 3p S 1row Plug Cable Lkg 1 Vader dic kre Manet 211421 Harness Wrg Interconnecting Includes 1 E PLG31 135134 Conn Rect Univ 084 9p S 3row Plug Cable Lkg 2 baba PLG22 136925 Conn Rect Comm 093 2p S 1row Plug Cable Lkg 1 dudes PLG19 113752 Conn Rect Mini 045 10skt 2row Plug Cable Lkg 1 Optional Recommended Spare Parts When ordering a component originally displaying a precauti
52. ct avec le fil de soudage sont sous tension Des mat riels mal install s ou mal mis la terre pr sentent un danger Ne jamais toucher les pi ces lectriques sous tension Porter des gants et des v tements de protection secs ne comportant pas de trous e S isoler de la pi ce et de la terre au moyen de tapis ou d autres moyens iso lants suffisamment grands pour emp cher le contact physique ventuel avec la pi ce ou la terre e Ne pas se servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou l o on risque de tomber e Seservir d une source lectrique courant lectrique UNIQUEMENT si le proc d de soudage le demande e Sil utilisation d une source lectrique courant lectrique s av re n ces saire se servir de la fonction de t l commande si l appareil en est quip Des pr cautions de s curit suppl mentaires sont requises dans des envi ronnements risque comme les endroits humides ou lorsque l on porte des v tements mouill s sur des structures m talliques au sol grillages et chafaudages dans des positions assises genoux et allong es ou quand il y a un risque important de contact accidentel avec la pi ce ou le sol Dans ces cas utiliser les appareils suivants dans l ordre de pr f rence 1 un poste souder DC semi automatique de type CV MIG MAG 2 un poste souder manuel lectrode enrob e DC 3 un poste souder ma nuel AC
53. d 16 22tinstrnd 1 EE 211429 Receptacle Circuit Breaker W Leads Includes 1 10 RC2 141432 Rept Str Dx Grd 2p3w 20a 125v 5 20r 1 11 CB3 093996 Circuit Breaker Man Reset 1p 20a 250vac Frict 1 Hat BEE rau Pg iar 211431 Receptacle Circuit Breaker W Leads Ivory Includes 1 12 RC3 211224 Rept Str Dx Grd 2p3w 20a 125v 5 20r Ivory 1 13 CB4 093996 Circuit Breaker Man Reset 1p 20a 250vac Frict 1 14 CB1 203095 Circuit Breaker Man Reset 2p 25a 240vac Screw 90 1 15 PC5 148030 Circuit Card Assy Filter Hf 1 16 PC3 148021 Circuit Card Assy Filter Hf 1 sede F oes re Pirates 129524 Term Frict 250x032 Uninsul Male 130 Stud Mtg 3pr 1 O er 211452 Control Push Pull Snap in 42 000 W 1 750 Extension 1 E eg dat 119014 Lever Switch Black 1 PO ass HM 145247 Meter Hour 12 24vdc 1 25 X 2 12 Rect 1 Er ita CE 134201 Stand off Support Pc Card 312 375w Post amp lock 43 6 22 CC CV 039047 Terminal Pwr Output Red 2 PARAS GRD
54. d PC7 Weld output cannot be adjusted Check position of V A Adjust switch see Section 6 1 Have Factory Authorized Service Agent check field current control board PC2 Erratic weld output Check control settings Clean and tighten connections both inside and outside unit Be sure connection to work piece is clean and tight Remove excessive coils from weld cables Use dry properly stored electrodes Have Factory Authorized Service Agent check brushes slip rings and circuit boards PC1 and PC2 No remote fine amperage control Place V A Adjust switch in Remote position see Section 6 1 Check and tighten connections to Remote receptacle RC4 see Section 5 8 No 24 volt ac output at Remote receptacle RC4 Reset circuit breaker CB5 see Section 8 6 No 115 volt ac output at Remote receptacle RC4 Check fuse F2 and replace if open see Section 8 6 OM 4411 Page 34 Trouble Remedy Lack of high frequency difficulty in establishing Gas Tungsten Arc Weld ing arc Use proper size tungsten for welding amperage Reduce leakage of high frequency from torch or work cable check grounding remove excessive coils from weld cables use shorter weld cables etc Check cables and torch for cracked or deteriorated insulation or bad connections Repair or replace necessary parts Wandering arc poor control of arc direction Reduce gas
55. 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 e Lire et suivre les instructions concernant les bouteilles de gaz comprim les quipements associ s et les publication P 1 CGA num r es dans les normes de s curit 2 3 Dangers existant en relation avec le moteur LES ACCUMULATIONS DE GAZ ris quent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confin s ou se servir d un respi rateur d adduction d air homologu OM 4411 Page 6 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 L EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE e Toujours porter une protection faciale des gants en caoutchouc et v tements de protection lors d une in tervention sur la batterie e Arr ter le moteur avant de d brancher ou de brancher les cables de batterie e Eviter de provoquer des tincelles avec l
56. dissement dans le vase d ex pansion 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 comme sui vant Mettre des lunettes de s curit et des gants placer un torchon sur le bou chon du radiateur D visser le bouchon l g rement et laisser la vapeur s chapper avant d enlever le bouchon 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 A 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 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 produits 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 e 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 e Arr te
57. e starting or stop ping 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 FLYING SPARKS can cause injury e Wear a face shield to protect eyes and face z e Shapetungsten 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 T OVERUSE can cause OVERHEATING Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit STATIC ESD can damage PC boards e Put on grounded wrist strap BEFORE handling boards or parts Use proper static proof bags and boxes to store move or ship PC boards TILTING OF TRAILER can cause injury e Use tongue jack or blocks to support weight e Properly install welding generator onto trailer accord ing to instructions supplied with trailer OM 4411 Page 3 READ INSTRUCTIONS e Use only genuine MILLER Hobart replacement parts e Perform engine and air compressor if applicable maintenance and service according to this manual and the engine air compressor if applicable manu als H F RADIATION can cause interference e High frequency H F can interfere with radio naviga tion safety services computers and communica tion
58. easily go through small cracks and openings to adjacent areas e Watch for fire and keep a fire extinguisher nearby e Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side e 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 e 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 and fire hazards e Do not use welder to thaw frozen pipes e Remove stick electrode from holder or cut off welding wire at contact tip when not in use e Wear oil free protective garments such as leather gloves heavy shirt cuf fless trousers high shoes and a cap e Remove any combustibles such as a butane lighter or matches from your person before doing any welding e Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby FLYING METAL can injure eyes ES e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet 1 3 Engine Hazards BATTERY EXPLOSION can BLIND e Always wear a face shield rubber gloves and protec tive clothing when working on a battery e Stop engi
59. ection 8 2 Have Factory Authorized Service Agent check low oil pressure shutdown switch S5 Battery discharges between uses Place Engine Control switch in Off position when unit is not running Clean top of battery with baking soda and water solution rinse with clear water Periodically recharge battery approximately every 3 months Replace battery Check voltage regulator according to engine manual Engine stopped during normal operation Check fuel level see Section 5 2 Check oil level see Section 5 2 Low oil pressure shutdown stops engine if oil pressure is too low Have Factory Authorized Service Agent check low oil pressure shutdown switch S5 Engine does not return to idle speed Place Engine Control switch S2 in either Run Idle position Remove all weld and generator power loads Turn off remote contactor The unit will not return to idle speed when the remote contactor is on Turn off remote device connected to Remote receptacle RC4 see Section 5 8 Check for obstructed movement of solenoid linkage Have Factory Authorized Service Agent check circuit board PC2 and current transformer CT1 Engine does not go to weld speed Place Speed Control switch in Weld position OM 4411 Page 36 Notes NG JH
60. es outils en travaillant sur la batterie e Ne pas utiliser le poste de soudage pour charger les batteries ou des v hi cules de d marrage rapide e Observer la polarit correcte et sur les batteries D brancher le cable n gatif en premier lieu Le rebrancher en dernier lieu LE CARBURANT MOTEUR peut pro voquer un incendie ou une explosion e Arr ter le moteur avant de v rifier le niveau de carbu rant ou de faire le plein e Ne pas faire le plein en fumant ou proche d une sour ce 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 tout carbu rant renvers avant de faire d marrer le moteur e Jeter les chiffons dans un r cipient ignifuge a DES ORGANES MOBILES peuvent provoquer des blessures a e Ne pas approcher les mains des ventilateurs cour roies et autres pieces en mouvement e Maintenir ferm s et fixement en place les portes panneaux recouvrements et dispositifs de protection Arr ter le moteur avant d installer ou brancher l appareil e Demander seulement un personnel qualifi d enlever les dispositifs de S curit ou les recouvrements pour effectuer s il y a lieu des travaux d en tretien et de d pannage 2 4 Dangers li s l air comprim RESPIRER L AIR COMPRIM peut pro voquer des blessures graves ou causer la mort e Ne p
61. flow rate Select proper size tungsten Properly prepare tungsten Tungsten electrode oxidizing and not remaining bright after conclusion of weld Shield weld zone from drafts Increase postflow time Check and tighten all gas fittings Properly prepare tungsten B 60 Hz Generator Power Receptacles RC1 And RC2 Trouble Remedy No power output at 60 Hz ac recep tacles RC1 or RC2 Reset circuit breakers CB1 and or CB3 see Section 7 1 Stop welding or place Speed Control switch in Generator Lock position to run engine at 1800 rpm 60 Hz receptacles RC1 and RC2 work only at 1800 rpm Check receptacle wiring and connections Check fuse F1 on circuit board PC7 and replace if necessary see Section 8 6 Have Factory Authorized Service Agent check brushes slip rings and circuit boards PC1 PC2 and PC7 Low power output at 60 Hz ac recep tacles RC1 or RC2 Check and clean air cleaner as necessary Check engine electronic governor system See engine manual High power output at 60 Hz ac recep tacles RC1 or RC2 Check engine electronic governor system See engine manual Erratic power output at 60 Hz ac receptacles RC1 or RC2 Have Factory Authorized Service Agent check brushes slip rings and circuit boards PC1 PC2 and PC7 Check receptacle wiring and connections Check governor according to engine manual C Variable Frequency
62. gner toute substance ali e Ey 3 3 D o D L EMPLOI EXCESSIF peut SURCHAUFFER L QUIPEMENT Laisser l quipement refroidir respecter le facteur de marche nominal R duire le courant ou le facteur de marche avant de poursuivre le soudage e Ne pas obstruer les passages d air du poste LES CHARGES LECTROSTATI QUES peuvent endommager les circuits imprim s 7 i HA j IN ASS so e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antistatiques pour stocker d placer ou exp dier des cartes de circuits imprimes UNE REMORQUE QUI BASCULE peut entrainer des blessures e Ultiliser les supports de la remorque ou des blocs pour soutenir le poids e Installer convenablement le poste sur la remorque comme indiqu dans le manuel s y rapportant Bes 2 6 Principales normes de s curit Safety in Welding Cutting and Allied Processes norme ANSI 749 1 de American Welding Society 550 N W LeJeune Rd Miami FL 33126 t l phone 305 443 9353 site Web www aws org Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping norme American Welding Society AWS F4 1 de American Welding Society 550 N W LeJeune Rd Miami FL 33126 t l phone 305 443 9353 site Web www aws org National Electrical Code norme NFPA 70 de la National Fire Protection A
63. ield options are covered under True Blue for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater 4 6 Months Batteries 5 90 Days Parts MIG Guns TIG Torches Induction Heating Coils and Blankets APT amp SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Millers True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Bobcat Trailblazer and Legend models 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this w
64. ing adding or changing attachments or open ing compressor oil drain or oil fill cap 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 flam mables EXHAUST SPARKS can cause fire e Do not let engine exhaust sparks cause fire e Use approved engine exhaust spark arrestor in re quired areas see applicable codes HOT METAL from air arc cutting and gouging can cause fire or explosion 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 servicing READ INSTRUCTIONS e Read Owner s Manual before using or servicing unit e Stop engine and release air pressure before servicing 1 5 Additional Symbols For Installation Operation And Maintenance FALLING UNIT can cause injury Use lifting eye to lift unit only NOT running gear gas cylinders trailer or any other accessories Use equipment of adequate capacity to lift and support unit If using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit A OVERHEATING can damage motors e Turn off or unplug equipment befor
65. ing parts Reinstall panels or guards and close doors when servicing is finished and before starting engine Before working on generator remove spark plugs or injectors to keep engine from kicking back or starting Block flywheel so that it will not turn while working on generator compo nents STEAM AND HOT COOLANT can burn e If possible check coolant level when engine is cold to avoid scalding e Always check coolant level at overflow tank if pres ent 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 overflow tank follow the next two statements Wear safety glasses and gloves and put a rag over radiator cap Turn cap slightly and let pressure escape slowly before completely re moving cap ENGINE EXHAUST GASES can kill e Use equipment outside in open well ventilated ar eas e If used in a closed area vent engine exhaust outside and away from any building air intakes 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 TRAPPED AIR PRESSURE AND WHIPPING HOSES can cause injury A 4 e Release air pressure from tools and system before servic
66. ions 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 date that the equipment was delivered to the original retail purchaser or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers Inverters input and output rectifiers only 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Semi Automatic and Automatic Wire Feeders Inverter Power Supplies Unless Otherwise Stated Intellitig Maxstar 150 Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified DS 2 Wire Feeder Motor Driven Guns w exception of Spoolmate Spoolguns Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Water Coolant Systems Flowgauge and Flowmeter Regulators No Labor HF Units Grids Maxstar 85 140 Spot Welders Load Banks Arc Stud Power Sources amp Arc Stud Guns Racks Running Gear Trailers Plasma Cutting Torches except APT amp SAF Models Field Options NOTE F
67. isque pour la sant humaine Toutefois les tudes et l examen des preuves se poursuivent En attendant les conclusions finales de la recherche il serait souhaitable de r duire l ex position aux champs lectromagn tiques pendant le soudage ou le coupage OM 4411 Page 8 Afin de r duire les champs lectromagn tiques en milieu de travail respec ter les consignes suivantes 1 Garder les c bles ensemble en les torsadant ou en les fixant avec du ruban adh sif 2 Mettre tous les c bles du c t oppos l op rateur 3 Ne pas s enrouler les c bles autour du corps 4 Garder le poste de soudage et les c bles le plus loin possible de soi 5 Placer la pince de masse le plus pr s possible de la zone de soudage Consignes relatives aux stimulateurs cardiaques Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur m decin Si ce dernier les d clare aptes il leur est recom mand de respecter les consignes ci dessus SECTION 3 DEFINITIONS 3 1 Symbol Definitions e Fast Fast Slow Stop Engine Run Weld Power IG Run ldle Slow ldle D Start Engine O Panel Local Temperature E Fuel Engine Oil x Engine Choke su Battery Engine O lt Engine A bs s A Amperes V Volts MIG mi T m Stick SMAW TIG GTAW NN Circuit Breaker Positive Output Negative AM oe Protective Earth GY
68. ke and turn Engine Control switch to Start position Release switch and slowly push choke in when engine starts F If the engine does not start let the engine come to a complete stop before attempting restart To Stop turn Engine Control switch to Off position Controlling Engine Speed And Weld Generator Power Output Generator Power Weld Output Engine Controls Engine Speed Output e Qui 1800 rpm Power Speed Welding Not TT Continuous Recommended 5 KW KVA Total From Speed Control Switch In Generator ATAG Receptacles Lock Engine Control Switch in either Run ldle position No Load 2400 rpm Idle Speed 3600 rpm pm Load 3600 rpm Weld Speed prn Weld Speed 2 4 KW KVA at 60 120 Hz 20 300 A From AC Receptacle Speed Control Switch In Weld RC3 Only Engine Control Switch in 3600 2400 RPM 9 No Load 1800 rpm Idle Speed E GE K Load 3000 rpm Weld Speed 5 kW KVA Total From BT All AC Receptacles At 1800 rpm At 3000 rpm Output Available Speed Control Switch In Weld Only At 2 4 kW kVA 60 120 Hz Engine Control Switch in 3000 1800 RPM AC Receptacle RC3 OM 4411 Page 23 6 3 Process Switch ELECTRODE HOT SCRATCH START TIG WIRE Voltage Sensing Wire Feeder CV a Process Switch A Weld output terminals a
69. king input connections attach proper grounding conductor first double check connections Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a sep arate cable Do not touch electrode if you are in contact with the work ground or anoth er electrode from a different machine AEN This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazards e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual 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 work table 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 inst
70. nd easy With Miller you can count on years NII 00012000 of reliable service with proper maintenance And e 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 gt mets A ta cetecietered fo 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 catalog 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 7 03 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 151 Symbol Usage bsf sanere RANA 1 12 5 Arc Welding Hazards EE 1 1 37 Engine ee EE 2 1 4 CoimpresSsediAiEiHaZafdSEa ETL E Gu Y UE 3 1 5 Additional Symbols For Installation Operation And Maintenance 3 1 6 California Proposition 65 Warnings 4 1 7 Principal Safety Standards
71. ne before disconnecting or connecting bat tery 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 Stopengine and let it cool off before checking or add ing 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 OM 4411 Page 2 HOT PARTS can cause severe burns Allow cooling period before maintaining Wear protective gloves and clothing when working on a hot engine bare handed NOISE can damage hearing Noise from some processes or equipment can damage hearing e e e Do not touch hot engine parts or just welded parts e Wear approved ear protection if noise level is high MAGNETIC FIELDS can affect pacemakers Pacemaker wearers keep away Wearers should consult their doctor before going near arc welding gouging or spot welding opera tions CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part
72. ning 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 10in 6300 1800 Band Saw 14 in 2500 1100 Bench Grinder 6in 1720 720 8in 3900 1400 10in 5200 1600 Air Compressor 1 2 HP 3000 1000 1 HP 6000 1500 1 1 2 HP 8200 2200 2 HP 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 1 HP 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 4411 Page 43 10 8 Power Required To Start Motor A MOTOR 1 Motor Start Code 2 2 Running Amperage Ls AMES Dee o SE 3 Motor HP 3 CODE M Hz 60 4 Motor Voltage X HP 1 4 PHASE 1 To find starting amperage Step 1 Find code and use table to find kVA HP If code is not listed multiply running amperage by six to find starting amperage Step 2 Find Motor HP and Volts Step 3 Determine starting amper age see example Welding generator amperage out put must be at least twice the
73. on norme ANSI Z87 1 de l American National Standards Institute 11 West 42nd Street New York NY 10036 8002 t l phone 212 642 4900 site Web www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work norme NFPA 51B de la National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 site Web www nfpa org et www sparky org OSHA Occupational Safety and Health Standards for General Industry Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de l U S Government Printing Office Superintendent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux r gionaux T l phone pour la R gion 5 Chicago 312 353 2220 site Web www osha gov 2 7 Information sur les champs lectromagn tiques Donn es sur le soudage lectrique et les effets des champs magn tiques basse fr quence sur l organisme En parcourant les cables de soudage le courant cr e des champs lectro magn tiques Les effets potentiels de tels champs restent pr occupants Cependant apr s avoir examin plus de 500 tudes qui ont t faites pen dant une p riode de recherche de 17 ans un comit de sp cialistes du National Research Council a conclu L accumulation de preuves n a pas d montr que l exposition aux champs magn tiques et aux champs lectri ques haute fr quence constitue un r
74. onary label the label should also be ordered Order label individually or as part of Label Kit 207 019 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 Notes HOBART INSTITUT OF WELDING TECHNOLOGY 400 Trade Square East Troy Ohio 45373 1 800 332 9448 www welding org Over 80 000 trained since 1930 Start Your Professional Welding Career Now OM 4411 Page 50 F Hardware is common and not available unless listed 22 YY 808 341 31 Figure 11 2 Panel Front w Components Item Dia Part No Mkgs No Description Quantity Figure 11 2 Panel Front w Components Figure 11 1 Item 35 E NEE Nameplate Order By Model And Serial Number 1 du AD re dee e 206854 Panel Front LLS 1 c une 203401 Stand off Support Pc Card 187 Dia W P amp l 625 2 4 PC2 211273 Circuit Card Assy Control 1 EE 206794 Shield Pcb Protective Anti Static 4 813x12 750 1 SA 209618 Harness Remote Control 14pin Includes 1 bids OF tomates 209617 Holder Fuse W 10A Fuse Includes 1 OT EM F2 085874 F
75. or Start Induction Run 1 3 HP 2020 720 1 2 HP 3075 975 3 4 HP 4500 1400 1 HP 6100 1600 1 1 2 HP 8200 2200 2 HP 10550 2850 3 HP 15900 3900 5 HP 23300 6800 Capacitor Start Capacitor Run 1 1 2 HP 8100 2000 5 HP 23300 6000 7 1 2 HP 35000 8000 10 HP 46700 10700 Fan Duty 1 8 HP 1000 400 1 6 HP 1400 550 1 4 HP 1850 650 1 3 HP 2400 800 1 2 HP 3500 1100 10 6 Approximate Power Regu irements For Farm Home Eguipment Farm Home Eguipment 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 3 HP 2150 750 1 2 HP 3100 1000 Sump Pump 1 3 HP 2100 800 1 2 HP 3200 1050 OM 4411 Page 42 10 7 Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Run
76. oteur ni les pi ces r cemment soud es LE BRUIT peut affecter l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques Porteurs de stimulateur cardiaque restez distance Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de gougeage ou de soudage par points Si des BOUTEILLES sont endomma g es elles pourront exploser Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endommag e elle peut exploser Du fait que les bouteilles de gaz font normale ment partie du proc d de soudage les manipuler avec pr caution e Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques du laitier des flammes ouvertes des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e 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 bou teille Ne jamais souder une bouteille pressuris e risque
77. oudure La projection d tincelles des pi ces chaudes et des quipements chauds peut provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un surchauffement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger e Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud e Ne pas souder dans un endroit l ou des tincelles peuvent tomber sur des substances inflammables e D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneusement avec des protections homologu s e 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 e Ne pas effectuer le soudage sur des conteneurs ferm s tels que des reser voirs tambours ou conduites moins qu ils n aient t pr par s correctement conform ment AWS F4 1 voir les normes de s curit e Brancher le c ble 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
78. r le moteur et rel cher la pression avant d effectuer la maintenance 2 5 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage uniquement pour soulever l appareil lui m me sans chariot de bouteilles de gaz remorque ou autres accessoires Utiliser un quipement de levage de capacit suffisante pour lever l appareil 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 4411 Page 7 LE SURCHAUFFEMENT peut endom mager le moteur lectrique e 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 endommager 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 s il ya lieu liz LES ETINCELLES VOLANTES ris quent de provoquer des blessures N y e Porter un cran facial pour prot ger le visage et les yeux e Affuterr l lectrode au tungst ne uniquement la meuleuse dot e de pro tecteurs Cette manoeuvre est ex cuter dans un endroit s r lorsque l on porte l quipement homologu de protection du visage des mains et du corps Les tincelles risquent de causer un incendie loi
79. rd 2 te Cr 206901 Bracket Mtg Relay 1 8 CR2 113247 Relay Encl 12vdc Dpdt 20a 120vac 8pin Flange Mtg 1 KTS Cae eet 204769 Label Term Mkg Stator Connections 1 pr OS meses 196180 Insulator Terminal Block 1 Eh DEE 1T uu 172661 Block Stud Connection 6 Position 1 um 173734 Link Jumper 2 13 C25 176007 Capacitor Elctlt 1200 Uf 300 Vdc Can 1 37 Dia 1 oua sor mus 202331 Gasket Capacitor Support 1 ec ND vate Seres estudia 204166 Bracket Capacitor Support 1 OG iot rte 4204148 Bracket Mtg Pc Board 1 Morc en ee 165437 Clip Snap In 472 Bundle 250hole 020 197 Thk 1 OM 4411 Page 53 Item Dia Part No Mkgs No Description Quantity Figure 11 4 Generator Figure 11 1 Item 41 1 STATOR 206890 Stator Generator 1 ee 182092 Label Warning Moving Parts Can Cause Serious Etc 3 3 ROTOR 207126 Rotor Generator Includes 1 San Whaat pe 181143 Bearing Ball Rdl Gol Row 984 X 2 047 X 591
80. re ener gized whenever the engine is run ning F The unit will not return to idle speed when the remote contactor is on clo sure between pins A and B on remote receptacle Use switch to select weld process see table below and Section 5 8 Use Stick position for air carbon arc CAC A cutting and gouging When switch is in a Stick position the dig circuit provides additional amperage dur ing low voltage short arc length condi tions to prevent sticking electrodes The dig circuit is disabled when switch is in Wire or TIG position 803 128 Process Switch Settings Switch Setting Process Output On Off Control Electrode Hot Wire MIG GMAW Electrode Hot Electrode Hot Stick Stick SMAW Air Carbon Arc CAC A Cutting And Gouging Electrode Hot Electrode Hot Scratch Start TIG Scratch Start TIG GTAW Electrode Hot OM 4411 Page 24 6 4 Remote Amperage Voltage Control O 1 Remote Receptacle RC4 y N Veg Connect optional remote control to RC4 see Section 5 8 d 2 Remote Hand Control Optional 0 3 Remote Foot Control Optional e lt 9 o O F Engine runs at weld speed when a device connected to the remote receptacle makes closure be tween pins A and B example trigger pull on MIG gun Example Combination Remote Amperage Control Stick In Example Process
81. reaker If breaker continues to open contact a Factory Autho rized Service Agent Ref 203 096 Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual OM 4411 Page 27 7 3 Wiring Instructions For Optional 240 Volt Single Phase Plug NEMA 14 50P F R Current Available in Amperes 240 V Each 120 V Duplex Receptacle Receptacle 20 0 15 5 10 10 5 15 0 20 V x A Watts One 240 V load or two 120 V loads 240 V AC KREM The plug can be wired for a 240 V 2 wire load or a 120 240V 3 wire load See circuit diagram 1 Plug Wired for 120 240 V 3 Wire Load When wired for 120 V loads each duplex receptacle shares a load with one half of 240 V receptacle 2 Plug Wired for 240 V 2 Wire Load Neutral Silver Terminal Load 1 Brass Terminal Load 2 Brass Terminal Ground Green Terminal Amperes Available using 120 240 V Plug No P Co Tools Needed plug1 11 03 120 813 D OM 4411 Page 28 SECTION 8 MAINTENANCE amp TROUBLESHOOTING 8 1 Routine Maintenance 4 ey ub ws AE AO Stop engine before maintaining F See Engine Manual and Maintenance Label for impor Full UR i tant start
82. res DC CC Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating A Exceeding duty cycle can damage unit and void warranty Continuous Welding 325 DC CV ii TT 275 DC CC M 250 U gt S 22 m JU m 200 175 150 0 10 20 30 40 50 60 70 80 90 100 DUTY CYCLE Ref 207 925 Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual OM 4411 Page 12 4 7 Stick And MIG Mode Volt Ampere Curves A CC DC Stick Mode 90 The volt ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator Curves of other settings fall between the curves shown 80 70 Eed 60 50 3000 RP 3600 RPM 40 DC VOLTS 30 20 10 50 100 150 200 250 DC AMPERES 300 350 B CV DC MIG Mode 50 400 450 45 40 35 3600 RPM 30 25 20 DC VOLTS 15 10 100 200 300 400 500 DC AMPERES 600 207 970 207 971 OM 4411 Page 13 4 8 DC TIG Mode Volt Ampere Curves The volt ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator Curves of other set
83. ric use S 0007 F For distances longer than those shown in this guide call a factory applications representative at 920 735 4505 OM 4411 Page 19 5 8 Remote Receptacle Information NOTE F Engine runs at weld speed 3000 or 3600 rom whenever a device connected to the remote receptacle is running 7 senor 14 Socket Socket Information 24 VOLTS AC A 24 volts ac Protected by circuit breaker CB5 OUTPUT CONTACTOR B Not used 115 VOLTS AC 115 volts ac Protected by fuse F2 OUTPUT CONTACTOR J Not used C Output to remote control 0 to 10 volts dc output to remote control in Stick and TIG modes 10 volts dc output to remote control in Wire mode AMPERAGE D Remote control circuit common VOLTAGE E DC input command signal 0 to 10 volts de from min to max of remote control with front panel V A control at max G Circuit common for 24 volt ac circuits GND K Chassis common The remaining sockets are not used OM 4411 Page 20 5 9 Adjusting Wire MIG Weld Puddle Consistency I Y Stop engine and let cool po Stabilizer DC Z is factory connected to e suit most Wire MIG welding applica tions To change Wire MIG weld puddle con sistency proceed as follows RUN IDLE 3600 2400 RPM Remove cover and right
84. ructions in Maintenance Section before touching any parts FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator Read 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 watchperson nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breathing air is safe e Do not weld in locations near degreasing cleaning or spraying operations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases e Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and if necessary 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 Shut off shielding gas supply when not in use e Always ventilate confined spaces or use approved air
85. s sociation P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 sites Web www nfpa org et www sparky org Safe Handling of Compressed Gases in Cylinders brochure CGA P 1 de la Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 t l phone 703 412 0900 site Web www cganet com Code for Safety in Welding and Cutting norme CSA W117 2 de la Cana dian Standards Association Standards Sales 178 boulevard Rexdale EH LIRE LES INSTRUCTIONS e Utiliser seulement les pi ces de rechange d origine Effectuer la maintenance du moteur et du compres seur si applicable suivant ce manuel et le manuel du moteur compresseur si applicable LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Le rayonnement haute fr quence H F peut provoquer des interf rences avec les quipements de radio navigation et de communication 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 installation e L utilisateur est tenu de faire corriger rapidement par un lectricien quali fi les interf rences r sultant de l installation e Sile FCC signale des interf rences arr ter imm diatement l appareil e Effectuer r guli rement le contr le et l entretien de l installation e Maintenir soigne
86. s endommag s de grosseur insuffisante ou mal piss s Ne pas enrouler les c bles autour du corps Si la pi ce soud e doit tre mise la terre le faire directement avec un cable distinct ne pas utiliser le connecteur de pi ce ou le cable de retour Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine N utiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment ce manuel Porter un harnais de s curit quand on travaille en hauteur Maintenir solidement en place tous les panneaux et capots Fixer le c ble de retour de fa on 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 Isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique Une tension DC importante subsiste l int rieur des onduleurs apr s avoir coup l alimentation Couper l alimentation du poste et d charger les condensateurs d entr e comme indiqu dans la Section Maintenance avant de toucher des compo sants LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereux pour votre sant Eloigner votre t te des fum es Ne pas respirer les fum es l interieur ventiler la zone et ou utiliser un
87. s 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 If notified by the FCC about interference stop using the equipment at once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference 1 6 California Proposition 65 Warnings A Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq A Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling 1 7 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 phone 305 443 9353 website www aws org Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Mi ami
88. s perform these connections according to all applicable codes and safety practic es A Properly install and ground this equipment according to its Owner s Manual and national state and local codes F Customersupplied equipment is re quired if generator will supply 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 Trans fer load back to electric utility when service is restored 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 wiring must be consistent with regular utility system volt age and wiring Connect generator with temporary or perma nent wiring suitable for the installation Turn off or unplug all equipment connected to generator before starting or stopping engine When starting or stopping the engine has low speed which causes low voltage and frequency 5 Essential Loads Generator output may not meet the electrical requirements of the premises If generator does not produce enough output to meet all requirements connect only essential loads pumps freezers heaters etc See Sec tion 10 4 Notes
89. se 10 AWG or larger insulated copper wire 3 Ground Device Ground generator to system earth ground if supplying power to a premises home shop farm wiring system Use ground device as stated in electrical codes ST 800 576 B 10 4 How Much Power Does Equipment Require 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 10 8 3 Rating Data Rating shows volts and amperes or watts reguired to run eguipment VOLTS 115 AMPS 4 5 Hz 60 60W AMPERES x VOLTS WATTS EXAMPLE 1 If a drill uses 4 5 amperes at 115 volts calculate its running power requirementin watts 4 5 Ax 115 V 520 W The load applied by the drill is 520 watts EXAMPLE 2 If three 200 watt flood lamps are used with the drill from Example 1 add the individual loads to calculate total load 200 W 200 W 200 W 520 W 1120 W The total load applied by the three flood lamps and drill is 1120 watts S 0623 OM 4411 Page 41 10 5 Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1 8 HP 800 300 1 6 HP 1225 500 1 4 HP 1600 600 1 3 HP 2100 700 1 2 HP 3175 875 Capacit
90. se At All Speeds 4 3 Dimensions Weights and Operating Angles Dimensions m Height 33 in 838 mm B Width 18 3 4 in 476 mm Do not exceed tilt angles or engine could be damaged or unit could tip Depth 45 1 2 in 1156 mm D Do not move or operate unit where it could G tip A 18 in 457 mm 4 Holes B 16 1 2 in 419 mm E C 3 4 in 19 mm F D 3 1 8 in 79 mm E 32 3 4 in 832 mm F 45 1 2 in 1156 mm G 13 32 in 10 mm Dia Engine End Weight 590 Ib 267 kg 800 426 803 129 OM 4411 Page 10 4 4 Fuel Consumption While Welding And Using Generator Power or oc z 5 a E a D 7 57 2 00 6 62 1 75 5 67 1 50 4 73 1 25 3600 RPM Weld 3 78 1 00 3000 RPM Weld esee Generator 2 84 0 75 Eege at 5 kW L at 4 kW 1 98 0 50 7 Idle At 1800 RPM Generator Generator at 3 kW Generator at2kW 0 95 0 25 ati kW 0 00 0 00 0 100 150 200 250 300 DC WELD AMPERES AT 100 DUTY CYCLE 207 967 4 5 Generator Power Curve AC VOLTS 300 250 200 150 100 50 15 AC AMPERES 20 25 30 The ac generator power curve shows the generator power avail able in amperes at the receptacles 207 969 OM 4411 Page 11 4 6 Duty Cycle 100 Duty Cycle at 280 Ampe
91. t with the work or ground Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit Additional safety precautions are required when any of the following electri cally hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoidable or accidental contact with the workpiece or ground For these conditions use the following equipment in order present ed 1 a semiautomatic DC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit voltage In most situations use of a DC constant voltage wire welder is recommended And do not work alone Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards Properly install and ground this equipment according to its Owner s Manual and national state and local codes Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet When ma
92. ting engine Pull control out when starting a cold engine Push control in when engine starts F Do not run engine with Choke control partially on or spark plugs will foul 6 Engine Control Switch Use switch to start engine stop engine and select engine speed Use switch in com bination with Speed Control switch to select engine speed In Run Idle 3600 2400 RPM position engine runs at 2400 rpm at no weld load and 3600 rpm under weld load In Run Idle 3000 1800 RPM position engine runs at 1800 rpm at no weld load and 3000 rpm under weld load In either position engine speed is determined by weld load and posi tion of Speed Control switch see item 7 and table below F Generator power is available at recep tacles RC1 and RC2 only at 1800 rom If generator is not locked at 1800 rpm engine speed increases in response to weld load and generator power output stops at receptacles RC1 and RC2 Generator power load does not affect engine speed 7 Speed Control Switch Use switch to control engine auto idle func tion Place switch in Generator Lock position when not welding to lock engine speed at 1800 rpm for generator power at 60 Hz ac re ceptacles RC1 and RC2 Generator power is always available at 60 120 Hz receptacle RC3 Place switch in Weld position to allow engine speeds to be determined by position of En gine Control switch The Speed Control switch is not needed at start up To Start pull out cho
93. tings fall between the curves shown 50 45 40 35 30 25 20 15 10 DC VOLTS 0 50 100 150 200 250 300 350 DC AMPERES mom Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual OM 4411 Page 14 SECTION 5 INSTALLATION 5 1 Installing Welding Generator Mounting Grounding Electrically bond generator frame to vehicle frame by metal to metal contact A Bed liners shipping skids and some running gears insulate the welding generator from the vehicle frame Always connect a ground wire from the generator equipment grounding termi nal to bare metal on the vehicle frame as shown Airflow Clearance Do not weld on base Welding on base can cause fuel tank fire or explosion Bolt unit down using holes provided in base A Always securely fasten weld ing generator onto transport vehicle or trailer and comply with all DOT and other applica ble codes Do not mount unit by support ing the base only at the four mounting holes Use cross supports to adequately sup port unit and prevent damage to base A Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards A lf unit
94. use Mintr Cer Slo blo 10 Amp 250 Volt 1 6 RC4 143976 Conn Circ Ms Cpc 14skt Size 20 Rept Panel Pushin Service Kit 1 E PLG23 115093 Conn Rect Mini 045 6skt 2row Plug Cable Lkg Service Kit 1 EE PLG24 131054 Conn Rect Mini 045 2skt 2row Plug Cable Lkg 1 raet r 202884 Harness Switch Control Includes 1 Ate Ee PLG20 131198 Conn Rect Mini 045 3skt 1row Plug Cable Lkg 1 TRE lad tole S9 011609 Switch Tgl Spdt 15a 125vac On none on Spd Term Chr 1 D WEE S2 176606 Switch Ignition 4 Position W Out Handle 1 OM 4411 Page 51 Item Dia Part No Mkgs No Description Quantity Figure 11 2 Panel Front w Components Continued m 206886 Harness Wrg Ignition Includes URE anne S4 011609 Switch Tgl Spdt 15a 125vac On none on Spd Term Chr 1 bee PLG15 113751 Conn Rect Mini 045 8skt 2row Plug Cable Lkg 1 T RC5 113634 Conn Rect Univ 084 6p S 3row Rept Cable Panel Lkg 1 TOR PLG7 166380 Conn Rect Univ 084 3p S 1row Rept Cable Panel Lkg 1 rests PLG8 177859 Conn Body 5 Terminal Sabie O tet eke 202660 Conn Push 4 Wire 12 16strnd 12 18sl
95. usement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distance correcte et utiliser une terre et 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 provoquer des interf rences pour l quipement lectronique sensible tel que les ordinateurs et l quipement com mand 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 dinterference maintenir les cables de souda ge aussi courts que possible les grouper et les poser aussi bas que pos sible ex par terre e Veiller souder une distance de 100 m tres de tout quipement lec tronique sensible 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 dentes il in combe 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 fil tres de ligne ou la pose de protecteurs dans la zone de travail Rexdale Ontario Canada M9W 1R3 t l phone 800 463 6727 ou To ronto 416 747 4044 site Web www csa international org Practice For Occupational And Educational Eye And Face Protecti

Miller Electric 301 G User's Manual

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