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Miller Electric PRO 300 Welding System User Manual

1. 25 5 9 Connecting To Remote 14 Receptacle RC14 26 SECTION 6 OPERATING WELDING GENERATOR 28 6 1 Front Panel Controls See Section 6 2 28 6 2 Description Of Front Panel Controls See Section 6 1 29 6 3 Process Contactor Switch On CC CV Models 30 6 4 Lift Arc Start Procedure css LU ine Gc Ae SERE SI WE nee LIRE EIER 31 6 5 Remote Voltage Amperage Control 32 SECTION 7 OPERATING AUXILIARY EQUIPMENT 33 7 1 120 Volt And 240 Volt Receptacles 33 SECTION 8 MAINTENANCE amp TROUBLESHOOTING 34 8 1 Maintenance Label sinsi cava ea cee aeree Ida y E E ERE RETE te 34 8 2 Routine Maintenance silos 8 ema RE Ne pad LUE eee ites 35 8 3 Caterpillar Customer 36 8 4 Checking Generator Brushes 36 TABLE OF CONTENTS 8 5 Servicing Cleaner N WEER EED ED CS Y E Ya 37 8 6 Inspecting And C
2. 2 NON ER 197506 Screw M14 1 5x 30 Hex Hd pln 8 8 PIN 6 xiu OF tote ERA 213480 Bracket Mtg Engine 2 AGB ee 083883 Washer Lock 402idx0 7090dx 087t Stl 10 2 LS 049026 Screw 10 1 5 25 Hd pln 8 8 PIN 2 OF xL ME E ex des Washer Oil Drain Order Thru Engine Manufacturer 1 EE cx ees 212612 Adapter Oil Drain Cat 3013 1 RE E 199505 Hose Assy Drain 32 000 Lg Includes 1 69 Is 165271 Valve Drain 3 8 18 Nptf 1 px TOE Satake bad 176529 Hose Brs Barbed Fem 1 2 X 3 8 Npt 1 EO A PET NE 113854 Hose Sae 500 Id X 780 Od Xcoil 2 6 Ft RE d bte 197448 Hose Brs Barbed Elbow 1 2 Tbg X 3 8 Npt 1 Sect Ko ee ener RUE 212614 Hose Radiator Lower Cat 3013 1 o serta AE N 217686 Belt Alternator us ease RICE eee Re ed a E ds 1 TO pH 210792 Engine Cat Dsl Elec 3013c 1800 Series Includes 1 gai nar ves ee EE 212600 Flywheel Cat 3013c 1 EE DE paier cios 202166 Fi
3. 1 QUOS 212623 Tank Fuel Includes Fuel Cap And Items Below 1 578 6 Lis us dir eed eM 189908 Valve Drain Fuel 180 Deg Zinc Pld 1 OD PM REN 181572 Bushing Tank Fuel 1 AE SO dies 124253 Bushing Tank Fuel 1 p EE 212611 Hose Fuel Stand Pipe W 3 16 In Return 1 1 0188 Peet ees 212610 Hose Fuel Stand Pipe W 5 16 Supply 1 89 SENDER 213265 Sender Fuel Gauge 1 OM 4422 Page 63 Item Dia Part No Mkgs No Description Quantity Figure 12 1 Main Assembly Continued Whig e NEU 172071 Clamp Hose 520 605 Dia Black 8 ee Peto Deeds 211961 Hose Sae 312 Id X 560 Od X 16 000 2 Tn 213804 Hose Sae 312 Id 560 Od X 2 500 1 EE ELE 191819 Hose Sae 312 Id X 560 Od X 15 000 1 Ma N 145054 Hose Sae 187 Id X 410 Od X 26 000 1 ssa ER Ad 213465 Bolt J Stl 312 18 X 7 250 Pld 2 3 AO emori asa sn 213466 Bracket Battery Holddown 1 92 BATT 146237 Battery Sto
4. 2 1 20 820070 1sneuxa 0 84000 ayeyu 898 212 YITNA N 16114 wel 0 13 061 IVO 991 202 HATIIN 19 sib t 49 39 09 9291 8 uospjeuoq 949 261 858 8 Uospleuod 6 9 261 H3TIIN PIS 001 989 221 1 9 e 9 gt 8 4 V AA 2008 2 1 18 5 6 IN1SV LV 6982 58 gt 109 LS IEB 798910 v ME gt E 0881 9 81 4 0 v 589 gt 99 199 jeuondo 0921 gt E ETT ERRETETTO 2 12 92102 4422 34 8 2 Routine Maintenance gt 7 Gh v LAY d Recycle engine A Stop engine before maintaining See Engine Manual and Maintenance Label for important start up service and storage fluids information Service engine more often if used in severe conditions Check Change Clean Replace Reference To be done by Fa
5. OM 4422 Page 12 Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual 3 2 Manufacturer s Rating Label 2 MILLER ELECTRIC MFG CO APPLETON WI USA Model PRO 300 CC CV Stock Number 907144 Serial Number SERIAL Dimensions 32 H x 26 W x 56 D 813 H x 660 W x 1422 D mm Weight with Fuel 1200 Ibs 544 kg AA LE EEN DUTY CYCLE 30 60 100 LI NENNEN RATED CURRENT 400 250 DC 60 VDC ________ RATED CURRENT 400 300 250 OCV NENEMDUTYCYCLE 30 60 maar RATED CURRENT 400 RATED VOLTAGE U 23 29 DC COLA ai vel _ MODEL NGINE SPEC CATERPILLAR 3013C tier 2 HL 230 9551 21 7 HP 1800 RPM 91 Cu In 1 496 L gym 2 m c 79 c m o 2l elle 8 o CIS A i mio a x m z 3 o a m OIN FUEL CAPACITY RATED LOAD SPEED n NO LOAD SPEED DLE SPEED nj 00 A or 10kW 11 5 gal 43 5L 1800 RPM min 1 1880 RPM min 1 1500 RPM min 1 1 10 GPH 4 16 LPH 99 GPH 3 75 LPH 69 GPH 2 61 LPH 43 GPH 1 63 LPH 35 GPH 1 32 LPH Diesel Engine 00 or 5 6kW 100 A or 2 4kW NO LOAD RUN NO LOAD IDLE 25 GPH 95 LPH FULL LOAD 73 dB 23 ft NO LOAD RUN 73 dB 23 ft 69 dB 23 ft Optiona 1 A
6. 1 oi ui det TEE 215522 Bracket Vault Ba a bad ERR CEDE An 1 ssp is 82 218929 5 rig cei RE EE ESAME IRR Ge WE EA Ee De des 1 hilfe eiie EI 192303 Angle Mtg Stabilizer 2 11 TE1 172661 Block Stud Connection 6 Position 1 POT VIE C 1737434 Link Jumper ccce edie pada eb e RONDE ER RA E 213500 Brkt Beam Support 1 Oc teg de Len 213602 Gasket Exhaust Outlet Cat 3013 1 sea d esed RR 214753 Bracket Holddown Fuel Tank 1 AA EE EE 213493 Upright Center Assy 1 DEE 189464 Seal Weather Lift Eye 1 iac AA ree MA 213501 Bracket Fuel Pump Filter 1 LET Bracket Fuel Filter Mtg Order Thru Engine Manufacturer 1 ted 217687 Filter Fuel Spin on 1 seg RTE sant 207721 2 EN D REI eI RE 1 be PT D 213858 Filter Fuel In line 5 16x5 16 Mic 125 175 1 Eum 212621 Pipe Exhaust Flexible Inlet Cat 3013
7. 1 13 3 3 Symbols And Definitioris 4 ES WE EE a EER baled REOR ue le oe RR UN Re 14 SECTION 4 SPECIFIGATIONS 2 donnee RE ee 15 4 1 Weld Power And Engine Specifications 15 4 2 Dimensions Weights And Operating Angles 15 423 Vot Amp re C EE OR HE OE CIEGO 16 4 4 OR AE N TOR ER PCS 17 4 5 Duty Cycle And Overheating 4 17 4 6 AC Generator Power 18 SECTION 5 INSTALLATION 22 023 ah ee dar Re nei Ee Ge fe ig 19 5 1 Installing Welding Generator 19 5 2 Mounting Welding Generator 4 20 5 3 Installing Exhaust Pipe se etc ce eene iure do Rd ENE Re RE ote a nt e ares 21 5 4 Activating The Dry Charge Battery If Applicable 22 5 5 Connecting The Battery 25er da mei etae RO peg tepore e ls 22 5 6 Engine Prestart Checks iis ER GER EER ee nn REX nx ER REA ne ea 23 5 7 Connecting To Weld Output Terminals 24 5 8 Selecting Weld Cable Sizes
8. CB6 093996 Supplementary Pro Man Reset 1p 20a 250vac Frict 2 27 CB5 203026 Supplementary Protector Man Reset 2p 50a 240vac 1 28 GRD 083030 Stud Brs 250 20 X 1 750 W Hex Collar 1 Sam osos tius 010915 Washer Flat 257idx0 6400dx 031t Brs 4 eco 601836 Nut 250 20 50hex 19h Brs 3 ODN Nameplate Weld Terminal Order By Model amp Serial No 1 c 181169 Spacer Output Stud 3 vius a qa HEL 186621 Boot Generic Output Stud 3 spud AA 180735 Washer Output Stud 3 Au rc 039046 Terminal Pwr Output Black 1 36 FUEL HM 214768 Gauge Fuel Elec Hour Meter 1 ra RIS 021385 Boot Toggle Switch Lever 1 Optional When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 4422 Page 66 2 H
9. 5 MODs z 8 58 518 s B s AAA amp fa sel B2 FED D2 gt BACK PC1 Ad MAIN CONTROL SCR GATING 2 gt PLG6 30 PIN mU A1 F3 PLc7 18 PIN 83 59 2 PLG11 18 PIN gt 180 DE Les 42 nor HD L JUMPERED FOR CC CV B3 F1 F3 r2 c2 B1 Al gt e nns EM V V y 0 72 150 136 740 148 137 141 160 767 162 2 ee gt m Vs d R2 MACHINE WIRE NUMBERS PLG2 RC2 CB8 LS ME mi PROCESS V A ADJUST 10 39 WELD SECONDARY 18148 40 79 ENGINE CONTROLS mu 80 EXCEPT 42 CHASSIS 42 80 99 AUX SECONDARY PLG3 RC3 A F 260 AA A A A A A 100 249 EXCITER CONTROL 25501 H OJ K 6 gt RC14 PLG8 RC2 190 5 150 P 140 03722 re 9547 4 e 219 228 E OM 4422 Page 49 SECTION 10 RUN IN PROCEDURE 10 1 Wetstacking run 2007 04 NOTICE Do not perform run in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur 1 Welding Generator Run diesel engines near rated volt age and current during run in period to properly seat piston rings and prevent wetstacking See name plate rating label or specifications section in this manual to find rated
10. OM 4422 215 177Q 2007 11 Miller Stick SMAW Welding TIG GTAW Welding MIG GMAW Welding Flux Cored FCAW Welding Air Carbon Arc CAC A Cutting and Gouging NAN Description 124 Engine Driven Welding Generator PRO 300 CAT Powered OWNER S MANUAL File Engine Drive Visit our website at www MillerWelds com From Miller to You Thank you and congratulations on choosing Miller Now you can get the job done and get it done right We know you don t have time to do it any other way That s why when Niels Miller first started building arc welders in 1929 he made sure his products offered long lasting value and superior quality Like you his customers couldn t afford anything less Miller products had to be more than the best they could be They had to be the best you could buy Today the people that build and sell Miller products continue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 n U Bl PEENI This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They Working as hard as you do every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most hassle free warranty in the We ve made installation and operat
11. WELD POSITION FLAT HORIZONTAL VERTICAL OVERHEAD BUTT BUTT ie ra i 2G FY 3 T JOINT GROOVE 2F FILLET Ref AWS ANSI D1 1 Ref 804 248 A OM 4422 Page 27 SECTION 6 OPERATING WELDING GENERATOR Front Panel Controls See Section 6 2 6 1 aC NS qm Ti JU 214 778 D 803 563 OM 4422 Page 28 6 2 Description Of Front Panel Controls See Section 6 1 21 5 Engine Starting Controls 1 Preheat Switch Use switch to energize starting aid for cold weather starting see starting instructions fol lowing 2 Engine Control Switch Use switch to start engine select engine speed if unit has auto idle option and stop engine In Run position engine runs at weld power speed In Auto position optional engine runs at idle speed at no load and weld speed with load applied 3 Engine Stop Lever Use lever to stop engine if Engine Control switch does not work The Engine Stop lever shuts off the fuel supply However the Engine Stop lever will not stop the engine if the engine can draw fuel rich air from the surrounding atmosphere oil refineries To Start NOTIC
12. rh Ate el Me 44 59 AUTO IDLE 8 OPTIONAL 2 3 5 4 f epe i T z EMEN GLOW PCS PLUG z T 2 4 B De 71 IT MODULE FUEL LEVEL SENDER 42 X sR2 STARTER gt 56 57 FUEL PUMP p 9 12 VOLT iei n BATTERY 52 bos 42 42 42 42 42 42 42 2 m WARNING e Do not touch live electrical parts 78 Disconnect input power or stop engine before servicing 7 Do not operate with covers removed ELECTRIC Have only qualified persons install SHOCK HAZARD use or service this unit CC CV MODEL ONLY MEE REEL HEN EE EE eee ee CC CV MODEL ONLY CC CN MODEL ONLY d MODEL 1 En n 71 1 Ly 16 0 72 0o zi TT Boc l roa cto c14 Ki K1 2 Ee Bb BERE T mg gt md gt TD MES gt HE SCRB SCR scRe SCRS R 14 la 1 T 1 T TT 7 LM s 1 L 1928 Le 477 des e FI P Les SCRE L3
13. s assurer que l endroit ne pr sente pas de danger D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneusement avec des protections homologu s Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures Surveiller tout d clenchement d incendie et tenir un extincteur proximit Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient t pr par s correctement conform ment AWS F4 1 voir les nor mes de s curit Ne soudez pas si l air ambiant est charg de particules gaz ou va peurs inflammables vapeur d essence par exemple Brancher le c ble de masse sur la pi ce le plus pr s possible de la zone de soudage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provo quant des risques d lectrocution d tincelles et d incendie Ne pas utiliser le poste de soudage pour d geler des conduites ge l es En cas de
14. Check fuse F1 and replace if open see Section 8 11 If F1 is open have Factory Authorized Service Agent check the rotor Low open circuit voltage Check engine speed and adjust if necessary Have Factory Authorized Service Agent check main control module PC1 voltage regulator module PC3 and main rectifier No remote fine amperage control Repair or replace remote control device Check and secure connections to Remote Amperage Adjust receptacle RC14 see Section 5 9 No 24 volt or 115 volt ac output at Re mote receptacle RC14 Reset supplementary protector CB7 24 volt or CB8 115 volt see Section 8 11 OM 4422 Page 44 B Standard Generator Power Trouble Remedy No generator power output at ac recep tacles weld output okay Reset receptacle supplementary protector s see Section 7 1 No generator power or weld output Disconnect equipment from generator power receptacles during start up Check fuse F1 and replace if open see Section 8 11 Have Factory Authorized Service Agent check voltage regulator module PC3 Reset supplementary protector CB3 see Section 8 11 Check Voltmeter Ammeter help displays see Section 8 12 Have Factory Authorized Service Agent check brushes and slip rings and field excitation circuit High output at generator power ac re ceptacles Have Factory Authorized Service Agent check voltage regulator mod
15. See Section 4 2 for lifting eye rating See Section 5 2 for mounting information Grounding 1 Equipment Grounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame gt Electrically bond generator frame to vehicle frame by met al to metal contact Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insu lated copper wire A Bed liners shipping skids and some running gears insu late the welding generator from the vehicle frame Al ways connect a ground wire from the generator equipment grounding terminal to bare metal on the vehicle frame as shown 18 460 mm Grounding install3 2007 04 Ref 800 652 Ref 800 477 803 274 804 712 OM 4422 Page 19 5 2 Mounting Welding Generator Supporting The Unit Inadequate support A Do not use flexible mounts Using Mounting Brackets A Do not weld on base Weld ing on base can cause fuel tank fire or explosion Weld only on the four mounting brackets or bolt unit down NOTICE Do not mount unit by supporting the base only at the four mounting brackets Use cross supports to adequately support unit and prevent damage to base Mounting Surface 1 Cross Supports 2 Mounting Brackets Supplied Mount unit on flat surface or use cross supports to support base Secure unit with mounting brack ets 3 1 2 Bo
16. ing and the possibility of filter damage makes cleaning a risk Consider the risk of unwarrantable equipment 5 damage when determining whether to clean or replace the primary ele ment Optional If you decide to clean the primary ele ment we strongly recommend instal ling an optional safety element to pro vide additional engine protection Never clean a safety element place the safety element after servic ing the primary element three times Clean or replace primary element if dirty see note above before cleaning Re place primary element if damaged Re place primary element yearly or after six cleanings 1 Keep nozzle lt lt 9 2 in 61 mm 2 2 Safety Element Optional from element CS ND 3 Primary Element DS DS 4 Dust Cap EA _ lt 2524242 lt 2525242 gedek p 5555525 5999999 5 Dust Ejector lt 2 lt 2 lt 2 lt 2 gt lt gt 2 lt 26252 2 lt 2 lt 2 lt 2 lt gt gt lt 2 lt 62 lt 1 555555 5522552 To clean air filter 55252527 5542527 d 2202 Wipe off and housing Remove cap and dump out dust Remove element s Wipe dust from inside cap and housing with damp cloth Reinstall safety element Blow Inspect if present Reinstall cap NOTICE Do not clean housing with air hose Clean primary element with compressed air only Air pressure must not exceed 100 psi 690 kPa Use 1 8 in 3 mm nozzle and keep nozzle
17. Le rayonnement de l arc du proc d de soudag g n re des rayons visibles et invisibles intense ultraviolets et infrarouges susceptibles de provoquer des br lure dans les yeux et sur la peau Des tincelles sont projet es pendant 1 soudage Porter un casque de soudage approuv muni de verres filtrants appropri pour prot ger visage et yeux pendant le soudage voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit Porter des lunettes de s curit avec crans lat raux m me sous votre casque Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les blouissements et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc Porter des v tements confectionn s avec des mati res r sistan tes et ignifuges cuir coton lourd ou laine et des bottes de protection TE LE SOUDAGE peut provoquer un in ITER cendie ou une explosion Le soudage effectu sur des conteneurs ferm s tel que des r servoirs tambours ou des conduites pet provoquer leur clatement Des tincelles peuver tre projet es de l arc de soudure La projection d tincelles des pi ce chaudes et des quipements chauds peut provoquer des incendies des br lures Le contact accidentel de l lectrode avec des objet m talliques peut provoquer des tincelles une explosion un surchau fement ou un incendie Avant de commencer le soudage v rifier
18. insulated symbol and or word ing on it Do not use 2 prong plug un less equipment is double in sulated gen pwr 2007 04 Ref ST 159 730 ST 800 577 A A 1 2 3 Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards Also see AWS Safety amp Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Generators Equipment Grounding Terminal On Front Panel Grounding Cable Not Supplied Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insulated copper wire gt Electrically bond generator A frame to vehicle frame by met al to metal contact Bed liners shipping skids and some running gear insu late the welding generator from the vehicle frame Al ways connect a ground wire from the generator equip ment grounding terminal to bare metal on the vehicle frame as shown If unit does not have GFCI re ceptacles use GFCI pro tected extension cord S 0854 OM 4422 Page 53 11 3 Grounding When Supplying Building Systems 1 Equipment Grounding Terminal 2 Grounding Cable Use 10 AWG or larger insulated copper wire 3 Ground Device Use ground device as stated in electrical codes A Ground generator to system earth ground if supplying power to a premises home shop farm wiring syste
19. rom 2007 04 A Protect yourself and others from injury read and follow these precautions 1 1 Symbol Usage DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury The possible hazards are shown in the adjoining symbols or explained in the text Indicates a hazardous situation which if not avoided could result in death or serious injury The possible hazards are shown in the adjoining symbols or ex plained in the text NOTICE Indicates statements not related to personal injury 1 2 Arc Welding Hazards A The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 7 Read and follow all Safety Standards A Only qualified persons should install operate maintain and repair this unit A During operation keep everybody especially children away FA e ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks 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 h
20. Bracket Cover Top 2 55 DO a reta 217387 Baffle vc est v s in b ERE EET ACE RA RE 1 ssa Jg Luo Eire 213503 Guard Fan unie idee eee bee oe hee 1 Lia s o eer 212607 Shroud Radiator 1 ei 233256 Radiator W 14 Cap 3 Row Core 1 25 In Inlet Outlet Includes 1 V Aera eM 187120 Cap Radiator Pressure 141b 1 Li P ute 212603 Baffle Air Upper Radiator 1 Pus e ueste wait es 1225400 Upright Rear isc sis as RE lene aie aie repa ee DE e eate 1 Er MM 225412 Cover Radiator Access 1 xiu ADR 220295 Bracket 1 coe 190190 Tank Coolant Recovery 1 Jun ET auris a 219502 Guard Fan sra s DE d air 1 ca NE N 215268 Label Diesel Engine Maintenance Cat 3013c 1 OM 4422 Page 62 Item Dia Part No Mkgs No Description Quantity Figure 12 1 Main Assembly Continued TE ota 199592 Latch Paddle Series 20 Black 1 nas EE EE 213487 Door Engine Access
21. ON OFF SWITCH REQUIRE Receptacle RC14 Control to 100 Meters Set TIG or STICK Process Max 205 DC gt Min 20 A DC Adjust Optional Remote Control to desired weld output 0 gt Weld meters will always show the combined main and remote control setting and machine welds at nominal output setting of Adjust Optional Remote the meter Control to desired weld output REMOTE gt Connect Remote Control To Remote Receptacle RC14 Weld meters show preset output when not welding Set WIRE Process 0774 Ref 214 778 D 803 562 OM 4422 Page 32 SECTION 7 OPERATING AUXILIARY EQUIPMENT 7 1 120 Volt And 240 Volt Receptacles 120V 20A n 120V 20A n co 120 240 V 50A NEUTRAL BONDED TO FRAME NEUTRE RACCORD AU 1 120V 20 A AC shown Receptacle RC5 and or 2 120V 20A AC shown Receptacle RC6 and or GFCI2 240V50AAC Receptacle RC11 RC5 6 and GFCI1 2 supply 60 Hz single phase power at weld power speed Recep tacle configuration varies depending on machine model and serial number Maximum output from these receptacles is 2 4 kVA kW If a ground fault is detected GFCI Reset button pops out and receptacle does not work
22. 193183 Conn Rect Cinch 18 Pin 1 Pede Sol PLG9 215261 Conn Deutsch 12 2row Female Plug 1 PLG10 215262 Conn Deutsch 12 2row Female Plug 1 RE etr EE 215265 Conn Deutsch Wedge Lock 12 Position 2 cp exce bala EK 215343 Seal Plug Deutsch 12 16 Size 7 jig sii PLG5 113750 Conn Rect Mini 045 4skt 2row Plug Cable 1 AD E 27000 52 Gable Lem d rap dE au a EE YN TRU 215340 Conn Rect Univ 039 2p S 1row Rept Cable Pnl Lkg S 1 Sch ri anual EO 214933 Seal Wire Univ 039 2 POE 214984 Harness Rectifier Cc Cv Includes 1 dad So VAS PLG11 193183 Conn Rect Cinch 18 Pin 1 TL EE 207716 Conn Faston Mini Polarized 2 Skt G1k1 6 N EE 207718 Conn Mini Polarized 2 Skt G2K2 3 217010 Harness Receptacle Auxiliary Power Includes 1 CT CB4 CB6 093996 Supplementary Pro Man Reset 1p 20a 250vac Frict 2 OM 4422 Page 70 Warranty Questions Call 1 800 4 A MILLER f
23. Check for obstructed throttle solenoid Engine does not run at idle speed units with idle option only Check for obstructed throttle solenoid Circuit breaker CB9 may be open CB9 automatically resets when fault is corrected see Section 8 11 Have Factory Authorized Service Agent check idle module PC5 and control relay CR4 Engine uses oil during run in period wetstacking occurs Dry engine according to run in procedure see Section 10 OM 4422 Page 46 Notes Start Your Professional H EE Over 80 000 Welding Career Now 400 Trade Square East Troy 08104575 trained since 1930 1 800 332 9448 www welding org OM 4422 Page 47 SECTION 9 ELECTRICAL DIAGRAMS 2 397 90 92 40 42 B D E F TE1 Fi
24. age see example Welding generator amperage out put must be at least twice the motors running amperage KVA HP x HP x 1000 Volts Starting Amperage Example Calculate starting amper age required for a 230 V 1 4 HP mo tor with a motor start code of M Volts 230 HP 1 4 KVA HP 11 2 11 2 x 1 4 x 1000 230 12 2A Starting the motor requires 12 2 amperes S 0624 11 9 How Much Power Can Generator Supply 1 Limit Load To 90 Of Generator Output Always start non resistive motor loads in order from largest to small est and add resistive loads last 2 5Second Rule If motor does not start within 5 seconds turn off power to prevent motor damage Motor requires more power than generator can supply Ref ST 800 396 A S 0625 OM 4422 Page 57 11 10 Typical Connections To Supply Standby Power 7 Utility Electrical Service Transfer Switch Essential Loads Fused Disconnect Switch If Required Welding Generator Output A Have only qualified persons perform these connections according to all applicable codes and safety practices A Properly install and ground this equipment according to its Owner s Manual and na tional state and local codes Customer supplied equipment is required if generator will sup ply standby power during emergenci
25. damaged undei 45 m 60m 70m 90m 105 m 120 m sized or poorly spliced cables 10 60 60 100 Duty Duty 10 100 Duty Cycle Cycle Cycle 100 4 20 4 20 4 20 3 2 85 1 50 1 0 60 1 0 60 150 3 3 30 2 85 1 50 1 0 60 2 0 70 3 0 95 3 0 95 200 3 2 85 1 50 1 0 60 2 0 70 3 0 95 4 O 120 4 0 120 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 RUE 2 5 300 1 50 1 0 60 2 0 70 3 0 95 4 O 120 UU ps 2 2 ea 2 0 2ea 3 0 2 ea 3 0 2 ea 4 0 350 1 0 60 2 0 3 0 95 4 0 120 Co 5 ed 20 2 ea 2 0 2ea 3 0 2ea 4 0 2ea 4 0 400 1 0 60 2 0 70 3 0 95 4 0 120 eu Et ex ex 20 2 ea 2 0 2ea 3 0 2ea 4 0 3 ea 3 0 3 ea 3 0 500 2 0 70 3 0 95 4 0 120 2x70 2x95 2x120 3x95 3x95 This chart is a general guideline and may not suit all applications If cables overheat use next size larger cable Weld cable size AWG is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere mm for metric use S 0007 F For distances longer than those shown in this guide call a factory applications representative at 920 735 4505 Notes Start Your Professional Welding Career Now H OBART INSTITUT OF WELDING TECHNOLOGY 400 Trade Square East Troy Ohio 45373 1 800
26. e Utiliser l air comprim seulement pour le cou page gougeage et les outils pneumatiques L AIR COMPRIM peut provoquer des blessures e Porter des lunettes de s curit approuv es Ne pas diriger le jet d air vers d autres ou soi m me L AIR COMPRIME EMMAGASINE ET DES TUYAUX SOUS PRESSION peuvent provo quer des blessures e Rel cher la pression d air de l outillage ou du syst me avant d effectuer la maintenance avant de changer ou de rajouter des l ments ou avant d ouvrir la purge ou le bouchon de remplissage d huile LA CHALEUR DU MOTEUR peut pro voquer un incendie Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e distance les produits inflammables de l chappement LES TINCELLES peuvent provoquer un incendie e Emp cher les tincelles d chappement du moteur de provoquer un incendie e Utiliser uniquement un pare tincelles approuv voir codes en vigueur Le METAL CHAUD lors du coupage et gougeage plasma peut provoquer un in cendie ou une explosion Ne pas couper ou gouger proximit de pro duits inflammables e Surveillez et garder un extincteur proximit DES PIECES CHAUDES peuvent provo quer des br lures et blessures Ne pas toucher le compresseur ou d autres l ments du circuit air comprim chauds Laisser l ensemble se refroidir avant de toucher ou d effectu
27. 1 Have Factory Authorized Service Agent check Preheat switch S4 control relay CR3 and the glow plug Engine suddenly stops Check oil and coolant levels Automatic shutdown system stops engine if oil pressure is too low or coolant temperatureis too high see Section 5 6 Circuit breaker CB1 may be open CB1 automatically resets when fault is corrected see Section 8 11 Reset supplementary protector CB2 see Section 8 11 Have Factory Authorized Service Agent check engine alternator engine harness throttle solenoid TS1 fuel solenoid FS1 and the fuel pump Have Factory Authorized Service Agent check Engine Control switch S1 control relay CR1 inte grated rectifier SR2 fuel solenoid FS1 and the fuel pump See engine manual OM 4422 Page 45 Trouble Remedy Engine slowly stopped and cannot be restarted Check fuel level Check engine air and fuel filters see Sections 8 5 and 8 10 See engine manual Battery discharges between uses Turn Engine Control switch off when unit is not running Clean top of battery with baking soda and water solution rinse with clear water Recharge or replace battery if necessary Periodically recharge battery approximately every 3 months Engine idles but does not come up to weld speed units with idle option only Have Factory Authorized Service Agent check idle module PC5 and current transformer CT1
28. 1 ER 191626 Bumper Door Engine Access 2 Dae eet EN 225120 Label Warning Moving Parts Can Cause Injury 3 hr DLE eis 189975 Hinge Door Access 180 Deg 2 087341 Bumper Door 1 000 Od X 750 High Rbr 50 Duro W O 2 AE AE OE ET 213486 Panel Rocker 1 MOE LE sed Res ni 217698 Label Help Codes 1 TEC mS 168385 Label Warning Battery Explosion Can Blind 1 RAIDT vaa IRIS DR 203260 Label Caution Do Not Use Ether 1 CUu DO ext d ee 225120 Label Warning Moving Parts Can Cause Injury 1 RA 230637 Idle Solenoid Assy consisting of 1 DO d vata 230828 Bracket Mtg Solenoid Idle 1 60 TS1 230634 Solenoid Throttle W 4 8 4 Lb Spring 1 EEN 198109 Screw Shld Stl Sch 250 20 X 437 X 500 Shid 1 ci Ea 198018 Linkage Throttle Solenoid 1 Tr OE EE 230830 Arm 1 EE EES 213266 Mount Engine Generator Flange Mtg
29. 332 9448 www welding org Over 80 000 trained since 1930 OM 4422 Page 25 5 9 Connecting To Remote 14 Receptacle RC14 LDR 14 long distance remote includes 120 V receptacle 803 562 REMOTE 14 Socket Socket Information A 24 volts ac Protected by sup tect B8 24 VOLTS AC plementary protector CB8 OUTPUT B Contact closure to A completes CONTACTOR 24 volt ac contactor control circuit C Output to remote control 10 volts dc in MIG mode 0 to 10 volts dc in Stick or TIG mode REMOTE D Remote control circuit common OUTPUT CONTROL E DC input command signal 0 to 10 volts from min to max of remote control with Voltage Amperage Adjust control at max 115 volts 10 amperes 60 Hz ac Protected by supplementary 115 VOLTS AC protector CB7 OUTPUT CONTACTOR Contact closure to completes J 115 volt ac contactor control circuit F Current feedback 1 volt per 100 amperes AMPERAGE A N VOLTAGE H Voltage feedback 1 volt per 10 arc volts GND K Chassis common NEUTRAL G Circuit common for 24 and 115 volt ac circuit The remaining sockets are not used Notes OM 4422 Page 26 Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual Notes
30. 60Hz 120 240 CURRENT 83 42 SIMULTANEOUS WELDING AND POWER TABLE 120V 240V WELD TOTAL POWER Receptacle Receptacle AMPERES AVAILBLE IN WATTS Amperes Amperes 225 o 0 LR5071 CERTIFICATIONS NEMA EW1 ISO 9001 EVIDENCE OF LABEL TAMPERING VOIDS WARRANTY _ 2261568 US 226 156 803 562 F OM 4422 Page 13 3 3 Symbols And Definitions Some symbols are found only CE products 2e Read Operator s Circuit Protector eN Do Not Switch Stop Engine Fes Eun ee gt Slow Idle 2 Start Engine Starting Aid Engine Oil Check Injectors Check Valve Fuel Protective Earth Pump Clearance Ground i i 4 Certified Trained 5 Positive Negative d Mechanic PS Welding Arc A Amperes V Volts Panel Local Remote Air Temperature Or 2 4 Engine Engine gt Output 7 g Temperature me Stick SMAW Constant Current G MIG GMAW n oe Welding SA Welding DY TIG GTAW Time h Hours Seconds 1 7 Single Phase Three Phase Manual gt While Welding Engine Driven Electrode Three Phase H Connection Work Connection CE Al Alternator With Z Hertz Rectifier X Duty Cycle U Rated No Load U Conventional Rated Load Voltage Average 2 Load Voltage n Speed n Rated Idl
31. Contactor switch to select type of weld output see Section 6 3 Remove supplied nut from weld output termi nal Slide weld cable terminal onto weld output terminal and secure with nut so that weld cable terminal is tight against copper bar Do not place anything between weld cable termi nal and copper bar Make sure that the sur faces of the weld cable terminal and cop per bar are clean Tools Needed SP Do not place anything between weld cable terminal and copper bar Correct Installation MIG and FCAW Welding For MIG and FCAW welding Direct Current Electrode Positive DCEP connect wire feed er cable to CV Wire terminal on right and work cable to Work Negative terminal on left Use Process Contactor switch to select type of weld output see Section 6 3 For Direct Current Electrode Negative DCEN reverse cable connections Incorrect Installation 803 562 803 778 A OM 4422 Page 24 5 8 Selecting Weld Cable Sizes 7 Weld Output Terminals A Stop engine before connecting to weld output terminals Weld Cable Size and Total Cable Copper Length in Weld Circuit Not Exceeding 150 ft 200 ft 250ft 300ft 350ft 400ft A Do not use worn 100 ft 30 m or Less
32. Engine Hazards BATTERY EXPLOSION can BLIND e Always wear a face shield rubber gloves and protective clothing when working on a battery Stop engine before disconnecting or connect ing battery cables or servicing battery Do not allow tools to cause sparks when working on a battery Do not use welder to charge batteries or jump start vehicles Observe correct polarity and on batteries Disconnect negative cable first and connect it last FUEL can cause fire or explosion Stop engine and let it cool off before checking or adding fuel Do not add fuel while smoking or if unit is near any sparks or open flames Do not overfill tank allow room for fuel to expand Do not spill fuel If fuel is spilled clean up before starting engine Dispose of rags in a fireproof container Always keep nozzle in contact with tank when fueling MOVING PARTS can cause injury Keep away from fans belts and rotors v e Keep all doors panels covers and guards closed and securely in place e Stop engine before installing or connecting unit e Have only qualified people remove doors panels covers or guards for maintenance and troubleshooting as necessary To prevent accidental starting during servicing disconnect negative battery cable from battery Keep hands hair loose clothing and tools away from moving parts e Reinstall doors panels covers or guards when servicing is
33. In Base Not Shown 1 Sistah eagle Roe E RE 213506 Bracket Hold Down Fuel Tank Not Shown 1 4 dan 226104 Upright 1 o5 DE 233953 Label Warning General Precautionary CSA 1 106 iid 216347 Label Rating Card Code 133 Provide Serial No When Ordering 1 uc Aue fcm Ie 220955 Panel Front ACCESS RE tros EE mese aen LC 1 108 Figure 12 2 Front Panel Assembly 1 TOO ass 105370 E EY ant eda ke e 1 sx MO ics Figure 12 3 Control Panel 1 SHE 213504 Tray Reactor amp Rectifier 1 EE EE E 213491 Insulator Capacitor Bank Applies To Reactor Redtifier Tray 1 TER be eu riis 215328 Kit Label Includes Safety And Informational Labels 1 When ordering a component originally displaying a precautionary label the label should also be ordered Recommended Spare Parts Optional To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 4422
34. PARTS LIST Hardware is common and not available unless listed Wirng harnesses are listed at the end of parts section 4 Fig 12 5 110 Fig 12 3 108 Fig 12 2 Figure 12 1 Main Assembly OM 4422 Page 60 803 683 F OM 4422 Page 61 Item Dia Part No Mkgs No Description Quantity Figure 12 1 Main Assembly 1 HD1 168829 Transducer Current 1000a Module Max Open Loop 1 dudes ed 213027 Resistor WW Tap 300 W 40 Ohm 1 mc 217070 Bracket Rectifier 1 n Figure 12 5 Rectifier Assembly 1 EE teens 181853 Insulator Screw For Rectifier Mtg 2 D pars OE EN 214742 Capacitor Assy Includes 1 AE HT e d NAE 213489 Bus Bar Capacitor Bank Negative 1 uo M 444 M 2342 213490 Bus Bar Capacitor Bank Positive 1 da exe C10 163535 Capacitor Elctlt 16000 Uf 60 Can 1 75 Dia 6 Bre ce 213488 Panel Engine Side 1 7 PC1 231705 Module Main Control Scr Gating 1 8 214770 Module Voltage Regulator
35. Page 64 Hardware is common and not available unless listed Wirng harnesses are listed at the end of parts section 34 32 33 803 684 A Figure 12 2 Panel Front w Components Item Dia Part No Mkgs No Description Quantity Figure 12 2 Panel Front w Components Figure 12 1 Item 108 ob 097926 Knob Pointer 2 375 Dia X 250 Id W Set Screwsplstc 1 EE ES 072590 Lock Shaft Pot 375 32 X 250 Dia Shaft Tall 1 ET N 170391 Conn Circ Ms Protective Cap Size 20 Nylon 1 AA aA TAA 190323 Boot Circuit Breaker Clear Hex Nut 2 UD aldea 097922 Knob Pointer 875 Dia X 250 Id W Set Screwsplstc 1 ALIS Beet EE Nameplate Control Order By Model amp Serial No 1 7 PC6 229949 Circuit Card Assy Connector Receptacle 1 8 CB7 CB8 083432 Supplementary Pro Man Reset 1p 10a 250vac Frict 2 ue Dg osea incen 213655 Panel Front Engine Weld Control 1 OM 4422 Page 65 Item Dia Part No Mkgs No Description Quantity Figure 12 2 Panel Front w Components Continued ERN 214543 Enclosure Circuit Card Assy 1 erp 134201 Stand off Support Pc Card 312 375w Post amp lock 43 4 12
36. Set load bank switches and then adjust generator A V control so load equals rated voltage and current of generator see name plate rating label or the specifi cations section in this manual Check generator and load bank meters after first five minutes then every fifteen minutes to be sure generator is loaded properly NOTICE Check oil level frequent ly during run in add oil if needed It is recommended to run the weld ing generator for two hours mini mum and up to four hours under load Place A V control in minimum position then turn off load bank to remove load Run engine several minutes at no load A Stop engine and let cool 4 Engine Exhaust Pipe Repeat procedure if wetstacking is present S 0683 OM 4422 Page 51 10 3 Run In Procedure Using Resistance Grid gt CL NU C 1 Stop engine A Do not touch hot exhaust pipe engine parts or load bank grid A Keep exhaust and pipe away from flammables NOTICE Do not perform run in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur 1 Resistance Grid Use grid sized for generator rated output Turn Off grid 2 Welding Generator Place A V range switch in maxi mum position A V control in mini mum position and Output Selector switch if present in either DC position 3 Wel
37. a quate blocks or stands to Ie im LL support unit while draining LT EE fuel tank ed ie Attach 1 2 ID hose to drain valve San 2 2 OX b gt Put metal container under drain 9 mE and use screwdriver to open o sludge drain valve Close valve when sludge has drained Remove o 5 hose 5 Close door Tools Needed EE QQu p 1 C e 802 490 Ref 801 434 803 563 OM 4422 Page 41 8 11 Overload Protection A Stop engine When a circuit breaker supple mentary protector or fuse opens it usually indicates a more serious problem exists Contact Factory Authorized Service Agent 1 Fuse F1 F1 protects the stator exciter wind ing from overload If F1 opens weld and generator power is low or stops entirely 2 Circuit Breaker CB1 Not Shown Supplementary Protector CB2 Supplementary Protector CB3 Supplementary Protector Supplementary Protector CB8 7 Circuit Breaker CB9 CB1 protects the engine battery cir cuit If CB1 opens the engine will not crank CB1 automatically resets when the fault is corrected CB2 protects the engine wiring har ness If CB2 opens the engine will not crank protects part of the weld control wiring harness If CB3 opens weld and generator power output stops CB7 protects the 115 volt a
38. as on the floor Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e f interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area For Gasoline Engines A Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive harm For Diesel Engines A Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Ontario Canada L4W 5NS phone 800 463 6727 or in Toronto 416 747 4044 website www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 25 West 43 Street New York NY 10036 8002 phone 212 642 4900 website www ansi org Standardfor Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 web site www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart and Part 1926 Subpart J from U S Government Printing Office Super i
39. at least 2 in 51 mm from inside of element Replace primary ele ment if it has holes or damaged gaskets Reinstall primary element and cap dust ejector down aircleaner1 2 01 ST 153 929 B ST 153 585 Ref S 0698 B Ref 214 778 B OM 4422 Page 37 8 6 Inspecting And Cleaning Optional Spark Arrestor Muffler SR 38in 1 Spark Arrestor Muffler 2 Cleanout Plug covering cleanout hole 3 Exhaust Pipe material Reinstall cleanout plug Tools Needed A Stop engine and let cool Remove plug and remove any dirt Start engine and run at idle speed to blow out cleanout hole If nothing blows out of hole briefly cover end of exhaust pipe with fireproof A Stop engine and let cool 803 582 Ref 214 778 B 8 7 Servicing Engine Cooling System A Stop engine and let cool 1 Radiator Draincock 2 Radiator Cap Cover Ab tion 5 6 essary Change coolant according to engine manual Add coolant according to Sec Run engine until engine reaches normal operating temperature Check coolant level in recovery tank Add coolant if nec After engine cools check coolant level again and add coolant if necessary 803 563 OM 4422 Page 38 8 8 Adjusting Engine Speed On Standard Models RS Engine Speed No Load RPM Hz Weld Power
40. d un c t et distance de l op rateur 3 Ne pas courber pas et ne pas entourer pas les c bles autour de votre corps 4 Garder le poste de soudage et les c bles le plus loin possible de vous 5 Connecter la pince sur la pi ce aussi pr s que possible de la soudure En ce qui concerne les implants m dicaux Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de soudage par points de gougeage du coupage plasma ou de chauffage par induc tion Si le m decin approuve il est recommand de suivre les proc dures pr c dentes OM 4422 Page 11 SECTION 3 DEFINITIONS 3 1 Warning Label Definitions 8 177 571 A n ES API CD MIL L 2104D CD SE CD SF Remove unit from shipping crate Remove Owner s Manual from unit Follow instructions to install muffler Read Owner s Manual Read labels on unit Use Diesel Fuel only and fill fuel tank Leave room for expansion Warning Watch Out There are possible hazards as shown by the symbols Read Owner s Manual Follow instructions to activate battery Check oil level Add oil if necessary During the first 50 hours of operation keep welding load above 200 amperes Do not weld below 200 amperes of output After the first 50 hours of operation change the oil and oil filter 3 96 Notes
41. damage unit and void warranty 1000 800 600 500 400 300 250 200 WELD AMPERES 150 100 10 15 20 25 30 40 50 60 80 100 DUTY CYCLE 217 515 OM 4422 Page 17 4 6 Generator Power Curve The ac power curve shows the gen erator power in amperes available atthe 120 and 240 volt receptacles 150 300 125 250 100 200 2 L d 75 1504 gt L Q 50 1007 25 507 Oo OO SSS EIE 0 20 40 60 80 AC AMPERES IN 240 V MODE 0 40 80 120 160 AC AMPERES IN 120 V MODE 217 519 Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge 025 in 22 Gauge 031 in 20 Gauge 037 in 18 Gauge 050 in 16 Gauge 063 in 14 Gauge 078 in 1 8 in 125 in 3 16 in 188 in 1 4 in 25 in 5 16 in 313 in 3 8 in 375 in 1 2 in 5 in OM 4422 Page 18 SECTION 5 INSTALLATION 5 1 Installing Welding Generator A Always securely fasten weld ing generator onto transport vehicle or trailer and comply with all DOT and other applica ble codes A Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards A If unit does not have GFCI re ceptacles use GFCI protected extension cord NOTICE Do not install unit where air flow is restricted or engine may overheat
42. non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans revers des chaussures hautes et un couvre chef Avant de souder retirer toute substance combustible de vos po ches telles qu un allumeur au butane ou des allumettes Une fois le travail achev assurez vous qu il ne reste aucune tra ce d tincelles incandescentes ni de flammes Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter Suivre les recommandations dans OSHA 1910 252 a 2 iv et NFPA 51B pour les travaux chaud et avoir de la surveillance et un extincteur proximit LE BRUIT peut affecter l ouie Le bruit des processus et des quipements peut affec l ouie e Porter des protections approuv s pour les ore les si le niveau sonore est trop lev OM 4422 Page 7 LES CHAMPS MAGNETIQUES peuv ent affecter des implants m dicaux Porteur de simulateur cardiaque ou autre im plants m dicaux rester distance e Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de sou dage par points de gougeage du coupage plasma ou de chauf fage par induction Si des BOUTEILLES sont endomma g es elles pourront exploser Des boute
43. proc dures et suffi samment de personnes pour soulever et d placer les bouteilles Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s curit moteur Seules des personnes qualifi es sont autoris es enlever les por tes panneaux recouvrements ou dispositifs de protection pour effectuer s il y a lieu des travaux d entretien et de d pannage Pour emp cher tout d marrage accidentel pendant les travaux d entretien d brancher le c ble n gatif de batterie de la borne Ne pas approcher les mains cheveux v tements l ches et outils des organes mobiles Remettre en place les panneaux ou les dispositifs de protection et fermer les portes la fin des travaux d entretien et avant de faire d marrer le moteur Avant d intervenir d poser les bougies ou injecteurs pour viter la mise en route accidentelle du moteur Bloquer le volant moteur pour viter sa rotation lors d une interven tion sur le g n rateur DES PI CES CHAUDES peuvent provoquer des br lures graves Ne pas toucher mains nues les parties chau des e Pr voir une p riode de refroidissement avant de travailler l quipement Ne pas toucher aux pi ces chaudes utiliser les outils recomman d s et porter des gants de soudage et des v tements pais pour viter les br lures LA VAPEU
44. smell e NEVER use inside a home or garage EVEN IF doors and windows are open e Only use OUTSIDE and far away from windows doors and vents BATTERY ACID can BURN SKIN and EYES Do not tip battery e Replace damaged battery e Flush eyes and skin immediately with water ENGINE HEAT can cause fire Do not locate unit on over or near combustible surfaces or flammables Keep exhaust and exhaust pipes way from flammables EXHAUST SPARKS can cause fire Do not let engine exhaust sparks cause fire e Use approved engine exhaust spark arrestor in required areas see applicable codes TRAPPED AIR PRESSURE AND WHIPPING RY HOSES can cause injury e Release air pressure from tools and system be fore servicing adding or changing attach ments or opening compressor oil drain or oil fill cap OM 4422 Page 3 HOT METAL from air arc cutting and gouging can cause fire or explosion Lh Do not cut or gouge near flammables Watch for fire keep extinguisher nearby HOT PARTS can cause burns and injury e Do not touch hot compressor or air system parts Let system cool down before touching or ser vicing READ INSTRUCTIONS Read Owner s Manual before using or servic ing unit Stop engine and release air pressure before servicing Use only genuine replacement parts from the manufacturer 1 5 Additional Symbols For Installation Operation And Maintenance FIRE O
45. 00 Table Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in 2500 1100 Bench Grinder 6in 1720 720 8in 3900 1400 10 in 5200 1600 Air Compressor 1 2 HP 3000 1000 1HP 6000 1500 1 1 2 HP 8200 2200 2HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1 3 HP 2100 700 Elec Hedge Trimmer 18 400 400 Flood Lights HID 125 100 Metal Halide 313 250 1000 Sodium 1400 Vapor 1250 1000 Submersible Pump 400 gph 600 200 Centrifugal Pump 900 gph 900 500 Floor Polisher 3 4 HP 16 in 4500 1400 1HP 20 in 6100 1600 High Pressure Washer 1 2 HP 3150 950 3 4 HP 4500 1400 1HP 6100 1600 55 gal Drum Mixer 1 4 HP 1900 700 Wet amp Dry Vac 1 7 HP 900 900 2 1 2 HP 1300 1300 OM 4422 Page 56 11 8 Power Required To Start Motor Single Phase Induction Motor Starting Requirements Motor Start G H J K L M N P Code KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0 1 Motor Start Code 2 Running Amperage 3 Motor HP x AC MOTOR 2 4 Motor Voltage fivouts_2s0 AMPS 254 Sd CODE M Hz 60 To find starting amperage N HP 1 4 PHASE 1 Step 1 Find code and use table to find KVA HP If code is not listed multiply running amperage by six to find starting amperage Step 2 Find Motor HP and Volts Step 3 Determine starting amper
46. 1 ise dus mp 183314 Clamp Muffler 1 625 Dia U Pld 3 IA 212604 Baffle Air Lower Radiator 1 201528 Muffler Exhaust Engine 1 SPONS M 212605 Pipe Exhaust Blue Fuel 1 233088 Label Danger Using A Generator Indoors Can Kill You In Minutes 1 vau vp bera N 1213470 Cover 222225254 4 kk EER X EXACTES X CA RU ca 1 049525 Nut 312 18 U nut Multi thread 15 e uno is 189052 Grommet Plastic Neck Filler Fuel 1 iade iis 190198 Cap Tank Screw on 3 500 In W Vent W Lanyard 8 1 id cases SR ER 222513 Label Warning Falling Equipment Can Cause Serious 1 nri e ra A 201851 Cover Radiator Access 1 Xu BOE etui ares 214604 Pipe Exhaust 1 1 Isl d 224265 Label Warning Hot Exhaust Parts Do Not Touch 1 bah AR acd xA 192041 Label Use Diesel Fuel Only 1 DO EE EE eae tom 213472 Keeper Latch Engine Access 1 AA 213471
47. 1199 Ib 544 kg Lifting Eye Weight Rating 1500 Ib 680 kg Maximum Do not exceed tilt angles or engine could be damaged or unit could tip Do not move or operate unit where it could tip OM 4422 Page 15 4 3 Volt Ampere Curves A Stick Mode The volt ampere curves show the minimum and maximum voltage and amperage output capabilities of 100 the welding generator Curves of all other settings fall between the 90 L curves shown DC VOLTS 200 300 400 500 AMPERES 0 100 MIG Mode 100 T DC VOLTS A N T 0 1 1 1 1 1 1 1 1 1 0 100 200 300 400 500 DC AMPERES C TIG Mode 100 80 60 40 DC VOLTS 20 MAX 0 100 200 300 400 500 DC AMPERES 217 517 217 516 217 518 OM 4422 Page 16 4 4 Fuel Consumption The curve shows typical fuel use under weld or power loads 2 00 1 75 1 50 1 25 1 00 0 75 0 50 0 25 0 00 U S GAL HR 0 50 100 150 200 250 300 350 400 DC WELD AMPERES AT 10096 DUTY CYCLE 217 509 4 5 Duty Cycle And Overheating n ul 100 Duty Cycle At 250 Amperes gt Y Continuous Welding 5 N Duty Cycle is percentage of 10 min utes that unit can weld at rated load without overheating NOTICE Exceeding duty cycle can
48. 1850 61 7 Maximum EI El El EI D A Stop engine and let cool Engine speed is factory set and should not require adjustment Af ter tuning engine check engine speed with tachometer or frequen cy meter See table for proper no load speed If necessary adjust speed as follows Start engine and run until warm Turn Process Contactor switch to Weld Terminals Always On Stick position 1 Lock Nut 2 Adjustment Screw Loosen nut Turn screw until engine runs at weld power speed Tighten nut Do not set engine speed higher than specified Tampering with adjustments other than shown may affect engine warranty 3 Engine Stop Lever A Stop engine Close door Tools Needed DEP 803 563 E OM 4422 Page 39 8 9 Adjusting Engine Speed On Models With Automatic Idle Optional ce Engine Speed No Load 1880 rpm max 62 6 Hz lt gt 1500 rpm 50 Hz mag 4 Lx To prevent solenoid damage be sure a 1 8 in 3 mm gap exists be tween the engine low speed screw and throttle lever when the solenoid is held in the 2 energized position Engine Speed Adjustment After tuning engine check engine speed with tachometer or frequen cy meter See table for proper no load speed If necessary adjust s
49. 2 6 Proposition californienne 65 Avertissements A Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l tat de Californie reconnait qu ils provoquent des mal formations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants A Les batteries les bornes et autres accessoires contiennent du plomb et des compos s a base de plomb produits chimi ques dont l tat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apr s manipu lation 2 7 Principales normes de s curit Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com National Electrical Code NFPA Standard 70 de National Fire Protec tion Association Box 9101 Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de Compressed Gas Association 4221 Walney Road 5th Floor Chan VA 201
50. 20151 phone 703 788 2700 website www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Mississauga 1 8 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures ARC WELDING can cause interference Electromagnetic energy can interfere with sensitive electronic equipment such as micro processors computers and computer driven equipmentsuch as robots e Be sure all equipment in the welding area is electromagnetically compatible e To reduce possible interference keep weld cables as short as possible close together and down low such
51. 5 Hex Hd pln 8 8 Pld 933 6 602211 Washer Lock 318idx0 5860dx 078t Stl Pld Split 312 6 NOE RE CO 192686 Screw M 8 1 25 25 Hex 8 8 Pld 933 6 sov OL 212641 Stud Stl 375 16 1 625x 19 000 4 11 STATOR 212470 Stator Generator 4 Pole 1 EET EE EE 160943 Endbell 6t eens WANG RENT mare va dares 1 d CE 167788 Nut 375 16 56hex 34h Stl Pld Sem Cone Wshr 88d 4 ex Ree 218552 Brush Assembly 2 Pole Includes 1 LS It este S 047879 Bar Retaining Brushholder 2 Brushes 1 oa EE EE 161306 Cap Brushholder 2 EE ER EG 126984 Brush w Spring 2 TEA o EE 005614 Holder Brush tse sce bv REOR Red ea AA 2 EE un 125548 Holder Brush Elect 1 xa oe cerea 158832 Screw 010 32 50 Hex Hd slt Stl Pld Sq Cone Sems 2 When ordering a component originally displaying a precautionary label the label should also be ordered Recommended Spare Parts Optional To maintain the factory original performance of your equipment use only Manufacturer s Suggested
52. 51 t l phone 703 788 2700 site Internet www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 de Canadian Standards Association 5060 Mississauga Ontario Canada 2 8 Information EMF Consid rations sur le soudage et les effets de basse fr quence et des champs magn tiques et lectriques Le courant de soudage pendant son passage dans les c bles de sou causera des champs lectromagn tiques Il y a eu et il y a encore un certain souci propos de tels champs Cependant apr s avoir exa min plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban bleu du National Research Council a conclu L accumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lectriques haute fr quence repr sente un risque la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent tre examin es En attendant que les conclusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn ti ques pendant le soudage ou le coupage Pour r duire les champs magn tiques sur le poste de travail appliquer les proc dures suivantes Pour les moteurs essence A Les gaz d chappement des moteurs contiennent des pro duits chimiques dont l tat de Californie reconnait qu ils provo
53. 61 Module Pull To Idle 1 14 CB2 083432 Supplementary Pro Man Reset 1p 10a 250vac Frict 2 15 CB9 230635 Circuit Breaker Auto Reset 12vdc 8 Amp 1 Optional When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 4422 Page 67 Hardware is common and not available unless listed Wirng harnesses are listed at the end of parts section 803 686 B Figure 12 4 Generator Item Dia Par No Mkgs No Description Quantity Figure 12 4 Generator Figure 12 1 Item 80 1 ROTOR 212474 Rotor Generator 4 Pole Includes 1 Lada E Ir e RE EEE 053390 Bearing Ball Sgl Row 1 370 X 2 830 X 6 1 RTE OU EE 192600 Fan Generat t ia ie nt oraret e RC RR RD ERR ladda sg 1 Ur P Tr 159918 Baffle Fat iis cpu VEG EP RA ERE VES 1 es D arre MEN 212126 Adapter Engine Machined Cat 3013c 1 TELE 602211 Washer Lock 318idx0 5860dx 078t Stl Pld Split 312 6 E 192686 Screw M 8 1 25 2
54. A 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 5 Indicates special instructions APA This group of symbols means Warning Watch Out ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult sym bols and related instructions below for necessary actions to avoid the hazards e Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet e When making input connections attach proper grounding conduc tor first double check connections Keep cords dry free of oil and grease and protected from hot metal and sparks e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable Do not touch electrode if you are in contact with the work ground or another electrode from a different machine Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual e Do not touch electrode holders conne
55. Agency visit www millerwelds com or call 1 800 4 A Miller File a claim for loss or damage during shipment Contact the Delivering Carrier to For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA 2007 Miller Electric Mfg Co 2007 01 Miller Electric Mfg Co An Illinois Tool Works Company 1635 West Spencer Street Appleton WI 54914 USA International Headquarters USA USA Phone 920 735 4505 Auto Attended USA amp Canada FAX 920 735 4134 International FAX 920 735 4125 European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 www MillerWelds com 2 Miller
56. Check for faulty equipment plugged in receptacle Press button to reset GFCI receptacle EF At least once month run engine at weld power speed and press test but ton to verify GFCI is working properly RC11 supplies 60 Hz single phase power at weld power speed Maximum output from RC11 is 10 KVA KW 4 Supplementary Protector CB4 5 Supplementary Protector CB6 6 Supplementary Protector CB5 CB4 protects RC6 GFCI2 and CB6 pro tects RC5 GFCI1 from overload If a sup plementary protector opens the receptacle does not work Press button to reset Supplementary protector CB5 protects re ceptacles and the generator winding from 214 778 D overload If CB5 opens the receptacles do not work Place CB5 switch in On position to reset If a supplementary protector continues to open contact Factory Authorized Service Agent Generator power decreases as weld output increases Combined output of all receptacles is limit ed to the 10 kVA kw rating of the generator EXAMPLE If 15 A is drawn from each 120 V receptacle only 26 A is available at the 240 V receptacle 2x 120 V x 15 A 240 V x 26 A 10 0 KVA KW OM 4422 Page 33 SECTION 8 MAINTENANCE amp TROUBLESHOOTING Maintenance Label 8 1 2 892 912 LVO 2 02 4 22 N ON evLv 0SL IVO sib9 489 212 H3TIIIN C 928L vSL IVO sowy 89 2 29 1V9 989 112 H3TIIIN 1
57. E Do not use ether If engine does not start let engine come to a complete stop before attempting re start Above 32 F 0 C turn Engine Control switch to Start Release Engine Control switch when engine starts Below 32 F 0 C turn engine control switch to Auto position Push Preheat switch up for 60 seconds Turn Engine Control switch to Start Release Engine Control switch and Preheat switch when engine starts To Stop turn Engine Control switch to Off position Engine Gauges Meters And Lights 4 Fuel Gauge Hourmeter Use gauge to check fuel level or total engine operating hours To check fuel level or engine hours when en gine is not running turn Engine Control switch to Run or Auto optional position 5 Engine Indicator Light Light goes on and engine stops if engine tem perature exceeds 230 F 110 C or engine oil pressure is below 10 psi 69 kPa Normal engine temperature is 180 203 F 82 95 C Normal oil pressure is 30 60 psi 207 414 kPa NOTICE Do not run engine until trouble is fixed Weld Controls 6 Remote Control Receptacle Use receptacle to connect remote controls wire feeders and tools When a remote control is connected to the Remote receptacle the Auto Sense Remote feature automatically switches voltage am perage control to the remote control see Sec tion 5 9 With remote control connected weld output is determined by a combination of front p
58. E USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Miller s option 1 repair or 2 replacement or where authorized in writing by Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Millers 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 EQUI
59. O Ld Ser 217085 Bus Bar Rectifier 1 Bas Ria Seal LI ME 181853 Insulator Screw For Mounting Rectifier 4 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 4422 Page 69 Some wiring harness components switches relays supplementary protectors are also referenced elsewhere in this parts list Purchase compo nents separately or as part of the associated wiring harness Item Dia Part No Mkgs No Description Quantity Wiring Harnesses EE SG 231122 Harness Engine Cat 3013c Includes 1 em S4 021467 Switch Tgl Spst 3a 250v Off none On Spd Term 1 EER SR1 SR2 035704 Rectifier Integ Bridge 40 Amp 800v 2 CB1 190374 Circuit Breaker Auto Reset 12vdc 40 Amp 1 idera CB2 083432 Supplementary Pro Man Reset 1p 10a 250vac Frict 2 197325 Relay Encl 12vdc Spst 70a Flange Mig 1 Duos m CR2 214876 Relay Encl 6vdc Spst 35a 14vdc 5 Pin 1 Lo nes R4 217335 Resistor Board 1 a AS D ad AR aca 148850 Socke
60. P 15900 3900 5HP 23300 6800 Capacitor Start Capacitor Run 1 1 2 HP 8100 2000 5HP 23300 6000 7 1 2 HP 35000 8000 10 HP 46700 10700 Fan Duty 1 8 HP 1000 400 1 6 HP 1400 550 1 4 HP 1850 650 1 3 HP 2400 800 1 2 HP 3500 1100 11 6 Approximate Power Requ irements For Farm Home Equipment Farm Home Equipment Rating Starting Watts Running Watts Stock Tank De lcer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 Milker Vacuum Pump 2HP 10500 2800 FARM DUTY MOTORS 1 3 HP 1720 720 Std e g Conveyors 1 2 HP 2575 975 Feed Augers Air 3 4 HP 4500 1400 Compressors 1HP 6100 1600 1 1 2 HP 8200 2200 2HP 10550 2850 3 HP 15900 3900 5 HP 23300 6800 High Torque e g Barn 1 1 2 HP 8100 2000 Cleaners Silo Unloaders 5HP 23300 6000 Silo Hoists Bunk Feeders 7 1 2 HP 35000 8000 10 HP 46700 10700 3 1 2 cu ft Mixer 1 2 HP 3300 1000 High Pressure 1 8 Gal Min 500 PSI 3150 950 Washer 2 gal min 550 PSI 4500 1400 2 gal min 700 PSI 6100 1600 Refrigerator or Freezer 3100 800 Shallow Well Pump 1 8 HP 2150 750 1 2 HP 3100 1000 Sump Pump 1 3 HP 2100 800 1 2 HP 3200 1050 OM 4422 Page 55 11 7 Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1 4 in 350 350 3 8 in 400 400 1 2 in 600 600 Circular Saw 6 1 2 in 500 500 7 1 4 in 900 900 8 1 4 in 1400 14
61. PC2 214660 Circuit Card Assy Display W Program 1 gal e R1 214760 Switch Rotary 12 Posn 1p 200ma 28vdc W Resistors 1 14 2 5 5 193118 Pot Flat 1t 2 W 1k Ohm Linear 1 LOTO Lud S4 021467 Switch Spst 250v Off none On Spd Term 1 bod ST iss 212436 Switch Ignition 4 Position Includes Knob 1 novitas ba Be 039047 Terminal Pwr Output Red 2 MEE EE ar 010381 Connector Rectifier 3 19 C13 14 15 128750 Capacitor Cer Disc 1 Uf 500 W Terms 3 Me 209056 Cover Receptacle W Gasket 4 21 RC11 182954 Rept Str 3p4w 50a 125 250v Flush Mtg 14 50 1 RE EE E AE E Nameplate Generator Power Order By Model amp Serial No 1 DS DEER 213509 Panel POW t e x Ra Pee x OE RET RA 1 24 RC5 6 214918 Rept Str Grd 2p3w 20a 125v 5 20r Order Model amp Serial No 24 GFCI1 2 151981 Ropt Str Dx 2p3w 15 20a 125v 5 20r Gfi Order By Model amp Serial No 25 C11 C12 217054 Capacitor Cer Disc 0047 Uf 3000 W Terms 2 26
62. PMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province miller warr 2007 01 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks To locate a Distributor or Service
63. R ET LE LIQUIDE DE REFROIDISSEMENT CHAUD peuvent provoquer des br lures e 1 est pr f rable de v rifier le liquide de refroi dissement une fois le moteur refroidi pour viter de se br ler Toujours v rifier le niveau de liquide de refroidissement dans le vase d expansion si pr sent et non dans le radiateur sauf si pr cis autrement dans la section maintenance du manuel du moteur Si le moteur est chaud et que le liquide doit tre v rifi op rer com me suivant Mettre des lunettes de s curit et des gants placer un torchon sur le bouchon du radiateur D visser le bouchon l g rement et laisser la vapeur s chapper avant d enlever le bouchon L utilisation d un groupe autonome l int rieur PEUT VOUS TUER EN QUELQUES MINUTES Lesfum es d un groupe autonome contient du monoxyde de carbone C est un poison invisi ble et inodore JAMAIS utiliser dans une maison ou garage m me avec les portes et fen tres ouvertes e Uniquementutiliser EXTERIEUR loin des portes fen tres et bouches a ration L ACIDE DE LA BATTERIE peut pro voquer des br lures dans les YEUX et sur la PEAU Ne pas renverser la batterie e Remplacer une batterie endommag e e Rincer imm diatement les yeux et la peau l eau 2 4 Dangers li s l air comprim RESPIRER L AIR COMPRIM peut pro voquer des blessures graves ou causer la mort e Ne pas utiliser l air comprim pour respirer
64. R EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING UNIT can cause injury Use lifting eye to lift unit and properly installed accessories only NOT gas cylinders Do not exceed maximum lift eye weight rating see Specifications e Liftand support unit only with proper equipment and correct procedures e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit OVERHEATING can damage motors e Turn off or unplug equipment before starting or stopping engine Do not let low voltage and frequency caused by low engine speed damage electric motors Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable L3 FLYING SPARKS can cause injury Wear a face shield to protect eyes and face e Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face hand and body protection e Sparks can cause fires keep flammables away N MOVING PARTS can cause injury Keep away from moving parts Keep away from pinch points such as drive rolls 3 OM 4422 Page 4 WELDING WIRE can cause injury Do not press gun trigger until instructed to do so e Do not
65. Replacement Parts Model and serial number required when ordering parts from your local distributor OM 4422 Page 68 Hardware is common and not available unless listed Wirng harnesses are listed at the end of parts section 4 7 10 LENS 2 4 ty a ie Pa ES 22 E p 2 a 7 Sy IN d 1 g N OA By y 5 4 9 803 685 A Figure 12 5 Rectifier Assembly Item Dia Part No Mkgs No Description Quantity Figure 12 5 Rectifier Assembly Figure 12 1 Item 4 TT 217081 Rectifier Assembly Includes 1 eere 2411984 Heat SINK aeri ct ee Tree Per esta aca GE de nes ae 1 2 MOD1 2 3 218296 Kit Module SCR 3 3 MOD4 5 6 218292 Kit Module 5 3 RE EE 212602 Bus Bar Rectifief E ak xe EAD AR ee dan 1 sd Dr n de 212639 Bus Bar Rectifier 3 OR 212601 Insulator Rectifier 1 7 TH1 213930 Thermistor Ntc 30k Ohm 25 Deg C 8 5in Lead 1 8 C1 6 215611 Capacitor Assy 3 9 C7 8 9 048420 Capacitor Cer Disc 01 Uf 1000 W Terms 3 CA
66. Symbols For Installation Operation And Maintenance 4 1 6 California Proposition 65 Warnings 5 1 7 Principal Safety Standards 5 1 8 EMF Iriformation oci dt alle Rd ES 5 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 6 2 1 Signification des symboles 6 2 2 Dangers relatifs au soudage l arc 6 2 3 Dangers existant en relation avec le moteur 8 2 4 Dangers li s l air comprim 9 2 5 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 9 2 6 Proposition californienne 65 Avertissements 11 2 7 Principales normes de s curit 11 258 intormation EMF sU te EE ABIRE RISE LUE ERES ei DE UNE HE 11 SECTION S DEFINITIONS t tee ER RR RT NM Ne LR Era RR 12 3 1 Warning Label Definitions 1 12 3 2 Manufacturers Rating Label
67. TI QUES peuvent endommager les circuits imprim s e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces Utiliser des pochettes et des bo tes antistatiques pour stocker d placer ou exp dier des cartes de circuits imprimes OM 4422 Page 10 entrainer des blessures e Utiliser les supports de la remorque ou des blocs pour soutenir le poids e Installer convenablement le poste sur la remor que comme indiqu dans le manuel s y rappor tant LIRE LES INSTRUCTIONS Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil e N utiliser que les pi ces de rechange recom mand es par le constructeur Effectuer la maintenance et le service du moteur et du compres seur d air suivant les instructions dans ce manuel ou le manuel du moteur compresseur si applicable El UNE REMORQUE QUI BASCULE peut LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences Le rayonnement haute fr quence H F peut provoquer des interf rences avec les quipe ments de radio navigation et de communica tion les services de s curit et les ordinateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l instal lation e L utilisateur est tenu de faire corriger rapidement par un lectri cien qualifi les interf rences r sultant de l instal
68. Wait ten minutes and check electro lyte level If necessary add electro lyte to raise to proper level Reins tall vent caps 8 Battery Charger Read and follow all instruc tions supplied with battery charger Charge battery for 12 minutes at 30 amperes or 30 minutes at 5 am peres Disconnect charging cables and install battery When electrolyte is low add only distilled water to cells to maintain proper level For 30 Minutes OR Tools Needed 30 A For 12 Minutes gt drybatt1 6 05 S 0886 5 5 Connecting The Battery wit Close door after connecting battery A Connect Negative Cable Last Tools Needed SEP 1 2 803 563 Ref 214 778 B S 0756 C OM 4422 Page 22 5 6 Engine Prestart Checks af Check radiator coolant level when fluid is low in recovery tank Capacity 6 qt 5 7 L Coolant Recovery Tank 4e Hot Full Cold Full SS SS OONDE Full Check all engine fluids daily Engine must be cold and on a level surface Unit is shipped with 20W break in oil Automatic shutdown system stops engine if oil pressure is too low or coolant tempera ture is too high x This unit has a low oil pressure shut down switch H
69. al forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instructions for metals consumables coatings cleaners and degreasers Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded BUILDUP OF GAS injure or kill e Shutoff shielding gas supply when not in use Always ventilate confined spaces or use proved air supplied respirator ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld e Wearan approved welding helmet fitted
70. anel and remote control voltage amperage set tings If no remote control is connected to the Re mote receptacle the front panel Voltage Am perage control adjusts voltage and amper age 5 If a remote device connected to Remote Receptacle RC14 is faulty or is discon nected the meters display Help 25 see Section 8 12 Clear fault by stopping and restarting the unit or by turning Pro cess Contactor switch to another posi tion 7 Process Contactor Switch See Section 6 3 for Process Contactor Switch information 8 Voltage Amperage Control With Process Contactor switch in any Stick or TIG setting use control to adjust amperage With Process Contactor switch in any Wire MIG position use control to adjust voltage With Voltage Amperage Adjust Switch in Re mote position control limits the remote am perage in Stick or TIG mode but has no effect in Wire MIG modes Weld Meters Weld meters also work in combination to display troubleshooting help codes see Section 8 12 9 DC Voltmeter Voltmeter displays preset voltage MIG weld ing with contactor off and actual output volt age with the contactor on Voltmeter displays voltage at the weld output terminals but not necessarily the welding arc due to resistance of cable and connections To set voltage turn contactor off and turn Pro cess Contactor switch to Wire position Turn V A control until desired voltage is displayed on Voltmeter When weldi
71. ardware is common and not 5 available unless listed 4 Wirng harnesses are listed at the end of parts section Pom W 9 803 689 D Figure 12 3 Control Panel Item Dia Part No Mkgs No Description Quantity Figure 12 3 Control Panel Figure 12 1 Item 110 jp cu 220981 Bracket Mtg Components 1 PENSE IE 129524 Term Frict 250x032 Uninsul Male 130 Stud Mtg 3pr 2 3 CR2 214876 Relay Encl Spst 35a 14vdc 5 Pin 1 4 CB1 190374 Circuit Breaker Auto Reset 12vdc 40 Amp 1 5 CR1 223710 Relay Encl 12vdc Dpst no 25a 6pin Flange 1 210 care buen ed 046432 Holder Fuse Mintr 250 X 1 250 Panel Mtg 1 T iem El sa 085874 Fuse Cer Slo blo 10 Amp 250 Volt 1 R4 217335 gt Resistor Board er SER Ra edu DE tad 1 9 090104 Relay Encl 12vdc Spst 30a 15vdc 5pin Flange 1 10 197325 Relay Encl 12vdc Spst 70a Flange Mtg 1 11 SR3 035704 Rectifier Integ Bridge 40 Amp 800v 1 12 SR1 582 035704 Rectifier Bridge 40 Amp 800v 2 19 PC5 2147
72. c output to remote receptacle RC14 If CB7 opens 115 volt output to RC14 stops protects the 24 volt ac output to remote receptacle RC14 If CB8 opens 24 volt output to RC14 stops Press button to reset supplementary protector CB9 protects the throttle solenoid against overload If CB9 opens the engine does not automatically idle down Check the linkage and sole noid CB9 automatically resets 803 562 Ref 803 566 F OM 4422 Page 42 8 12 Voltmeter Ammeter Help Displays pMPERAGE HLP 75 HLP 21 HLP 22 NOLTAGE HL U NO B Use the Voltmeter Ammeter help displays to diagnose and correct fault conditions When a help code is displayed normally weld output has stopped but generator power output may be okay To reset help displays stop unit and then restart See item 6 below to reset Help 25 dis play 1 Help 20 Display Indicates a failure of meter display module PC2 or the wiring between PC2 and main control module PC1 If this display is shown have Facto ry Authorized Service Agent check PC1 PC2 and the wiring between PC1 and PC2 2 Help 21 Display Indicates thermistor TH1 on the main rectifier heat sink has failed If this display is shown have Facto ry Authorized Service Agent check TH1 and the wiring between TH1 and PC1 3 Help 22 Display Indicates the rectifier heat sink has overheated If this
73. cted to two welding ma chines at the same time since double open circuit voltage will be present Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists in inverters after stop ping engine Stop engine on inverter and discharge input capacitors according to instructions in Maintenance Section before touching any parts HOT PARTS can cause severe burns Do not touch hot parts bare handed Allow cooling period before working on equip ment e To handle hot parts use proper tools and or wear heavy insu lated welding gloves and clothing to prevent burns cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet FLYING METAL or DIRT can injure eyes e Welding chipping wire brushing and grinding OM 4422 Page 1 FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use loc
74. ctory Authorized Service Agent Every Section 5 6 8 10 Hours Coolant Level Fuel Level Oil Level Oil Fuel Spills Every 50 p A Hours M 2 Q Weld Terminals Every Section 8 5 100 7 Hours Fi C Q Battery Terminals Air Cleaner Hoses Air Cleaner Element Every analy WEER Engine 250 4d Manual Hours 5 gt Section 8 6 Unreadable Labels Fan Belt Tension Oil Oil Filter QSpark Arrestor Every gt 500 vA Hours Weld Cables Inline Fuel Filter Radiator Thermostat Every Section 5 6 1000 8 4 8 10 Hours and Engine Manual Radiator Fluid Level Q Inside Unit Valve Clearance Q Drain Sludge O C Slip Rings x Brushes Every 2000 Hours gt Q Injectors OM 4422 Page 35 8 3 Caterpillar Customer Assistance Service When a problem arises concerning the op eration or service of the engine the prob lem will normally be managed by the dealer in your area Your satisfaction is a primary concern to Caterpillar and to Caterpillar dealers If you have a problem that has not been handled to your complete satisfaction follow these steps 1 Discuss your problem with a manager from the dealership Diesel Power 2 If your problem cannot be resolved at the dealer level without additional assistance call a Field Service Coordinator at 1 800 447 4986 3 If your needs still have not been met submit
75. d Cables Connect grid to generator weld output terminals using proper size weld cables with correct connec tors polarity is not important 4 Voltmeter 5 Clamp On Ammeter Connect voltmeter and ammeter as shown if not provided on generator Start engine and run for several minutes Set grid switches and then ad just generator A V control so load equals rated voltage and current of the generator see nameplate rating label or the specifications section in this manual Check generator and meters after first five minutes then every fifteen minutes to be sure generator is loaded properly NOTICE Check oil level frequent ly during run in add oil if needed It is recommended to run the weld ing generator for two hours mini mum and up to four hours under load Place A V control in minimum position then shut down grid to remove load Run engine several minutes at no load A Stop engine and let cool 6 Engine Exhaust Pipe Repeat procedure if wetstacking is present S 0684 OM 4422 Page 52 SECTION 11 GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine driven welding generators Your unit may differ from those shown 11 1 Selecting Equipment Generator Power Receptacles Neutral Bonded To Frame 3 Prong Plug From Case Grounded Equipment 2 Prong Plug From Double Insulated Equipment Be sure equipment has double A
76. diqu dans la Section Maintenance avant de toucher des composants DES PI CES CHAUDES peuvent provoquer des br lures graves Ne pas toucher a mains nues les parties chau des e Pr voir une p riode de refroidissement avant de travailler l quipement Ne pas toucher aux pi ces chaudes utiliser les outils recomman d s et porter des gants de soudage et des v tements pais pour viter les br lures DES PIECES DE METAL ou DES SA E LETES peuvent provoquer des bles sures dans les yeux Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la p riode de refroidissement des soudures elles risquent de projeter du laitier Porter des lunettes de s curit avec crans lat raux ou un cran facial inhalation peut tre dangereux pour votre sant LES FUM ES ET LES GAZ peuvent tre dangereux E Le soudage g n re des fum es et des gaz Leur e Eloigner votre t te des fum es Ne pas respirer les fum es e l int rieur ventiler la zone et ou utiliser une ventilation forc e au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Sila ventilation est m diocre porter un respirateur anti vapeurs approuv e Lire et comprendre les sp cifications de s curit des mat riaux MSDS et les instructions du fabricant concernant les m taux les consommab
77. display is shown check generator cooling system and or reduce duty cycle Keep en gine access door closed when run ning to maintain proper cooling air flow past rectifier Allow unit to cool before restarting If problem contin ues have Factory Authorized Ser vice Agent check unit 4 Help 23 Display Indicates one of the rectifier output SCR s has failed If this display is shown have Factory Authorized Service Agent check the rectifier SCR s 5 Help 24 Display Indicates weld open circuit voltage OCV is too high above 41 volts do If this display is shown have Factory Authorized Service Agent check main control module PC1 6 Help 25 Display Indicates a remote device con nected to Remote Receptacle RC14 may be faulty Help 25 is also displayed whenever a remote de vice has been connected to RC14 and then disconnected Clear fault by stopping and restarting the unit or by turning Process Contactor switch to another position If prob lem continues have Factory Autho rized Service Agent check the re mote device filter board PC6 and main control module PC1 803 562 214 778 B OM 4422 Page 43 8 13 Troubleshooting gt CL A Welding Also see Voltmeter Ammeter help displays to assist in troubleshooting weld problems see Section 8 12 Trouble Remedy No weld output generator power output okay at ac receptacles Place P
78. e A Indique une situation dangereuse qui si on l vite pas NOTE Indique des d clarations pas en relation avec des blessures personnelles 2 2 Dangers relatifs au soudage l arc A Les symboles pr sent s ci apr s sont utilis s tout au long du pr sent manuel pour attirer votre attention et identifier les ris ques de danger Lorsque vous voyez un symbole soyez vigilant et suivez les directives mentionn es afin d viter tout danger Les consignes de s curit pr sent es ci apr s ne font que r sumer l information contenue dans les normes de s curit num r es la section 2 7 Veuillez lire et respecter toutes ces normes de s curit L installation l utilisation l entretien et les r parations ne doivent tre confi s qu des personnes qualifi es A Au cours de l utilisation tenir toute personne a l cart et plus particuli rementles enfants UN CHOC LECTRIQUE peut tuer Un simple contact avec des pi ces lectriques peut provoquer une lectrocution ou des blessures graves L lectrode et le circuit de soudage sont sous tension d s que l appareil est sur ON Le circuit d entr e et les circuits internes de l appareil sont galement sous tension ce moment l En soudage semi automatique ou automatique le fil le d vidoir le logement des galets d entrainement et les pi ces m talliques en contact avec le fil de soudage sont sous tension Des mat riels mal install s ou mal mis la terr
79. e n Rated No Load Rated Welding 1 Speed 0 Speed 2 Current Contactor On AN Arc Force Dig Lift Arc TIG OM 4422 Page 14 SECTION 4 SPECIFICATIONS 4 1 Weld Power And Engine Specifications Welding Mode Weld Output Range Rated Welding Output Maximum Open Circuit Voltage Generator Power Rating Fuel Engine Capacity CC DC 20 410A 400 A 23 Volts DC 4096 Duty Cycle 300 A 32 Volts DC 6096 Duty Cycle 250 A 30 Volts DC 100 Duty cycle CV DC 14 40V 400 A 23 Volts DC 3096 Duty Cycle 300 A 29 Volts DC 6096 Duty Cycle 250 A 26 5 Volts DC 10096 Duty cycle 65 Single Phase 10 kVA kW 84 42 A 120 240 V AC 60 Hz 11 5 gal Caterpillar 3013C 43 51 Water Cooled Three Cylinder 21 7 HP Diesel Engine 4 2 Dimensions Weights And Operating Angles Dimensions Height 32 in 813 mm 35 3 4 in 908 mm to top of lift eye Width 26 1 4 in 667 mm Dr 1 mtg brackets turned in 28 3 4 in 730 mm mtg brackets turned out Depth 56 in 1422 mm 56 in 1422 mm 54 in 1372 mm A 52 in in 1321 mm 2in 51 mm 26 in 660 mm 7 8 in 22 mm 27 3 4 in 705 mm 9 16 in 14 mm Dia 4 Holes H Front Panel End gt gt Weight No fuel 1100 Ib 499 kg w fuel
80. e pr sentent un danger Ne jamais toucher les pi ces lectriques sous tension e Porter des gants et des v tements de protection secs ne compor tant pas de trous e S isoler de la pi ce et de la terre au moyen de tapis ou d autres moyens isolants suffisamment grands pour emp cher le contact physique ventuel avec la pi ce ou la terre Ne passe servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou l on risque de tomber e Se servir d une source lectrique courant lectrique UNIQUE MENT si le proc d de soudage le demande e Sil tilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip Des pr cautions de s curit suppl mentaires sont requises dans des environnements risque comme les endroits humides ou lorsque l on porte des v tements mouill s sur des structures m talliques au sol grillages et chafaudages dans des positions assises genoux et allong es ou quand il y a un risque important de contact accidentel avec la pi ce ou le sol Dans ces cas utiliser les appareils suivants dans l ordre de pr f rence 1 un poste souder DC semi automatique de type CV MIG MAG 2 un poste souder manuel lectrode enrob e DC 3 un poste souder OM 4422 Page 6 Indique des instructions sp cifiques APA Ce groupe de symbo
81. ease arc drive dig from min to max Use the Lift Arc TIG mode for TIG GTAW welding using the Lift Arc TIG starting procedure see Section 6 4 803 562 214 778 Process Contactor Switch Settings Switch Setting Process Output On Off Control Engine Auto Idle Optional Remote On Off Switch Re GTAW With HF Unit Pulsing quired PE ds Or Device Or Remote Control At Remote 14 Receptacle Active Stick SMAW With Remote On Off At Remote 14 Receptacle Active Remote On Off Switch MIG GMAW 22 w Constant Speed Feeder At Remote 14 Receptacle Active Weld Terminals Always On MIG GMAW l Wire w Voltage Sensing Feeder Flectrode Hot Active _ Stick SMAW Weld e ways On Air Carbon Arc CAC A Cutting Electrode Hot Active And Gouging Weld MEAT On TIG Lift Arc GTAW Electrode Hot Active OM 4422 Page 30 6 4 Lift Arc Start Procedure 9X A ws E ous Lift Arc Start Method 57 o 9 e 9 5 1 2 Touch Seconds Do NOT Strike Like A Match 5 1 2 Lift Arc TIG With Lift Arc TIG selected start arc as follows 1 TIG Electrode 2 Workpiece Turn gas on Touch tungsten electrode to workpiece at weld start point Hold electrode to workpiece for 1 2 seconds and slowly lift electrode Arc is formed when electrode is lifted Normal open circuit voltage is not present before tungs
82. er la maintenance LIRE LES INSTRUCTIONS Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil Arr ter le moteur et rel cher la pression avant d effectuer la maintenance e N utiliser que les pi ces de rechange recommand es par le constructeur 2 5 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance SION Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables Ne pas installer l appareil proximit de pro duits inflammables Ne pas surcharger l installation lectrique s assurer que mentation est correctement dimensionn e et prot g e avant de mettre l appareil en service Risque D INCENDIE OU D EXPLO NEN LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage pour lever l appareil et les accessoires correctement install es seuls PAS les bouteilles de gaz Ne pas d passer le poids nominal maximal de l ceilleton voir les sp cifications Ne lever et ne soutenir l appareil qu avec de l quipement appropri et en suivant les proc dures ad quates En utilisant des fourches de levage pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil OM 4422 Page 9 LE SURCHAUFFEMENT peut endom mager le moteur lectrique Arr ter ou d connecter l quipement avant de d marrer ou d arr t
83. er le moteur Ne pas laisser tourner le moteur trop lentement sous risque d en dommager le moteur lectrique cause d une tension et d une fr quence trop faibles Ne pas brancher de moteur de 50 ou de 60 Hz la prise de 100 Hz LES TINCELLES VOLANTES ris quent de provoquer des blessures N Porter un cran facial pour prot ger le visage les yeux e Aff ter l lectrode au tungst ne uniquement la meuleuse dot e de protecteurs Cette manceuv re est ex cuter dans un endroit s r lorsque l on porte l quipement homologu de protection du visage des mains et du corps e Les tincelles risquent de causer un incendie loigner toute sub stance inflammable DES ORGANES MOBILES peuvent provoquer des blessures Ne pas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande 4 LES FILS DE SOUDAGE peuvent provoquer des blessures e Ne pas appuyer sur la g chette avant d en avoir recu l instruction Ne pas diriger le pistolet vers soi d autres per sonnes ou toute pi ce m canique en enga geant le fil de soudage Tm i L EMPLOI EXCESSIF peut SURCHAUFFER L QUIPEMENT Laisser l quipement refroidir respecter le fac teur de marche nominal e R duire le courant ou le facteur de marche avant de poursuivre le soudage e Ne pas obstruer les passages d air du poste LES CHARGES LECTROSTA
84. es or power out ages 1 Utility Electrical Service 2 Transfer Switch Double Throw Switch transfers the electrical load from electric utility service to the generator Transfer load back to electric utility when service is re stored Install correct switch customer supplied Switch rating must be same as or greater than the branch overcurrent protection 3 Fused Disconnect Switch Install correct switch customer supplied if required by electrical code 4 Welding Generator Output Generator output voltage and wir ing must be consistent with regular utility system voltage and wiring Connect generator with temporary or permanent wiring suitable for the installation Turn off or unplug all equipment connected to generator before starting or stopping engine When starting or stopping the engine has low speed which causes low volt age and frequency 5 Essential Loads Generator output may not meet the electrical requirements of the prem ises If generator does not produce enough output to meet all require ments connect only essential loads pumps freezers heaters etc See Section 11 4 OM 4422 Page 58 11 11 Selecting Extension Cord Use Shortest Cord Possible gt Cord Lengths for 120 Volt Loads A If unit does not have GFCI receptacles use GFCI protected extensi
85. finished and before starting engine e Before working on generator remove spark plugs or injectors to keep engine from kicking back or starting e Block flywheel so that it will not turn while working on generator components HOT PARTS can cause severe burns Do not touch hot parts bare handed Allow cooling period before working on equip ment To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns 1 4 Compressed Air Hazards BREATHING COMPRESSED AIR can cause serious injury or death e Do not use compressed air for breathing Use only for cutting gouging and tools COMPRESSED AIR can cause injury e Wear approved safety goggles Do not direct air stream toward self or others STEAM AND HOT COOLANT can burn f possible check coolant level when engine is cold to avoid scalding Always check coolant level at overflow tank if present on unit instead of radiator unless told otherwise in maintenance section or engine manual e Ifthe engine is warm checking is needed and there is over flow tank follow the next two statements e Wear safety glasses and gloves and put a rag over radiator cap e Turn cap slightly and let pressure escape slowly before completely removing cap Using a generator indoors CAN KILL YOU IN MINUTES Generator exhaust contains carbon monoxide This is a poison you cannot see or
86. ge 2 Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire haz ards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap Remove any combustibles such as a butane lighter or matches from your person before doing any welding After completion of work inspect area to ensure it is free of sparks glowing embers and flames Use only correct fuses or circuit breakers Do not oversize or by pass them Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby n NOISE can damage hearing Noise from some processes or equipment can dam age hearing e Wear approved ear protection if noise level is high MAGNETIC FIELDS can affect Implanted Medical Devices Wearers of Pacemakers and other Implanted Medical Devices should keep away Implanted Medical Device wearers should consult their doct
87. gure 9 1 Circuit Diagram For Welding Generator OM 4422 Page 48 rx AE p mcr WEE EITHER ONE OR BOTH RECEPTACLES MAY REPLACE GFCIS RC5 RC6 120V 120V G XW G XW 84 as 90 90 m RECEPTACLE CONFIGURATIONS Ip RER A M GFCH CB6 uH 4 5 5 he NS GND 42 m 120 240V 8 E LA 58 o EZA TX 94 LX REV I z 120VAC 2 57 90 T 788 189 120VAC MI ACA 2 OO APE wey 1 Ee V 97 705 108 RC11 gt GFCI2 T GF cB4 oN 109 ama 4 CIE DK ES EN 1 g E Rois GND 42 RC1 622 7 amp F3 RC2 PLG10 RC1 11 gt 772 TH 707 X 22 RC1 955 X 02 lt RC2 2 onm VOLTAGE RC1 85 amp REGULATOR 721 100 RC1 1020 9 K 03 lt RC2 5 170 2 lt E 72 gt 29 1 42 107 74 lt Rc2 8 RC1 3 gt gt F2 k A Gi RC1 PLG9 VY 72 797 190 ot 24 go 42 KEND Ci iR 1 h 42 2 2 gt mE METER DISPLAY h y n gt n RC1 PLG5 SERRA 1 5 568 OPTIONAL 5 2 S1 L 4 2 4 45 Xx DL 0 8 _ ETES B 2 57 c x D 62 1 X CLOSED TO A TERMINAL 4 PRE HEAT PLG1 CR EN 50 cem __ 8 4 7 m IND SRI 54 DES 4 4 4
88. illes de gaz protecteur contiennent du ga sous haute pression Si une bouteille est endomme elle peut exploser Du fait que les bouteiles de gaz for normalement partie du proc d de soudage les manipuler ave pr caution e Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques des dommages physiques du laitier des flammes ouvertes des tincelles et des arcs 2 3 Dangers existant en relation avec le L EXPLOSION DE LA BATTERIE peu RENDRE AVEUGLE Toujours porter une protection faciale des gants en caoutchouc et v tements de protection lors d une intervention sur la batterie Arr ter le moteur avant de d brancher ou de brancher les c bles de batterie Eviter de provoquer des tincelles avec les outils en travaillant sur la batterie e Ne pas utiliser le poste de soudage pour charger les batteries ou des v hicules de d marrage rapide Observer la polarit correcte et sur les batteries e D brancher le c ble n gatif en premier lieu Le rebrancher en dernier lieu LE CARBURANT MOTEUR peut provo quer un incendie ou une explosion Arr ter le moteur avant de v rifier le niveau de carburant ou de faire le plein Ne pas faire le plein en fumant ou proche d une source d tincelles ou d une flamme nue Ne pas faire le plein de carburant ras bord pr voir de l espace pour son expansion e Faire attention de ne pas renver
89. ion quick business and easy With Miller you can count on years 90 00012000 of reliable service with proper maintenance And if for some reason the unit needs repair QUALITY SYSTEM there s a Troubleshooting section that will help you figure out what the problem is The Miller is the first welding parts list will then help you to decide the equipment manufacturer in the U S A ta be registered to exact part you may need to fix the problem the ISO 9001 2000 Quality Warranty and service information for your System Standard particular model are also provided Miller Electric manufactures a full line of welders and welding related equipment For information on other quality Miller products contact your local Miller distributor to receive the latest full line catalog or individual specification sheets To locate your nearest distributor or service agency call 1 800 4 A Miller or visit us at www MillerWelds com on the web Mill mer Mil_Thank 4 05 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 131 Symbol BE A re ER e HDD e els 1 1 2 Are Welding Hazards booed eae teed Ue p DM NEED ee A Sepa 1 1 3 Engine Hazards ias he gfe pig mi ene bee 3 1 4 Compressed Air tex pb ini EUN E NR EDE REN 3 1 5 Additional
90. lation e Sile FCC signale des interf rences arr ter imm diatement l ap pareil Effectuer r guli rement le contr le et l entretien de l installation e Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une dis tance correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences L nergie lectromagn tique risque de provo quer des interf rences pour l quipement lec tronique sensible tel que les ordinateurs et l quipementcommand par ordinateur tel que les robots e Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement Pour r duire la possibilit d interf rence maintenir les c bles de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre e Veiller souder une distance de 100 m tres de tout quipe ment lectronique sensible e Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi d interf rences apr s avoir pris les mesures pr c den tes il incombe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de c bles blind s l utilisation de filtres de ligne ou la pose de protec teurs dans la zone de travail
91. leaning Optional Spark Arrestor Muffler 38 8 7 Servicing Engine Cooling 38 8 8 Adjusting Engine Speed On Standard Models 39 8 9 Adjusting Engine Speed On Models With Automatic Idle Optional 40 8 10 Servicing Fuel And Lubrication Systems 41 8 11 Overload Protection e be rq eR S 42 8 12 Voltmeter Ammeter Help Displays 43 8 13 Troubleshooting si os eh wee ie gee CIERRE Ra re bae s ee 44 SECTION 9 ELECTRICAL DIAGRAMS 48 SECTION 10 RUN IN PROCEDURE 50 10 1 2 ER he rr eR ce danse es dre Oia e RR RE EE 50 10 2 Run In Procedure Using Load 51 10 3 Run In Procedure Using Resistance Grid 52 SECTION 11 GENERATOR POWER GUIDELINES 53 SECTION 12 PARTS LIST DE SEE DERE DER Ee NEER be 60 WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING
92. les les rev tements les nettoyants et les d graisseurs e Travailler dans un espace ferm seulement s il est bien ventil ou en portant un respirateur alimentation d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent d placer l air et abaisser le niveau d oxyg ne provoquant des blessures ou des accidents mortels S assurer que l air de respiration ne pr sente aucun danger Ne pas souder dans des endroits situ s proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et for mer des gaz hautement toxiques et irritants Ne pas souder des m taux munis d un rev tement tels que l acier galvanis plaqu en plomb ou au cadmium moins que le rev te ment n ait t enlev dans la zone de soudure que l endroit soit bien ventil et en portant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage LES ACCUMULATIONS DE GAZ ris quent de provoquer des blessures oi m me la mort 4 e Fermer l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confin s ou se servir d un respirateur d adduction d air homologu LES RAYONS DE L ARC peuvent pro voquer des br lures dans les yeux e sur la peau
93. les veut dire Avertissement Attention DANGER DE CHOC ELECTRIQUE PIECES EN MOUVEMENT et PIECES CHAUDES Consulter les symboles et les instructions ci dessous y aff rant pour les actions n cessaires afin d viter le danger manuel AC avec tension vide r duite Dans la plupart des cas un poste courant continu de type CV est recommand Et ne pas tra vailler seul 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 Toujours v rifier la terre du cordon d alimentation V rifier et s assurer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre e En effectuant les raccordements d entr e fixer d abord le conduc teur de mise la terre appropri et contre v rifier les connexions Les c bles doivent tre exempts d humidit d huile et de graisse prot gez les contre les tincelles et les pi ces m talliques chau des e V rifier fr quemment le cordon d alimentation pour voir s il n est pas endommag ou d nud remplacer le cordon imm diatemen
94. llation 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 Global Engineering Documents phone 1 877 413 5184 website www global ins com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 4221 Walney Road 5th Floor Chantilly VA
95. lt And Washer Minimum Not Supplied 4 3 8 16 x 1 in Screws Supplied To Bolt Unit In Place Remove hardware securing the four mounting brackets to the base Reverse brackets and reattach to base with original hardware Mount unit to truck or trailer with 1 2 in 12 mm or larger hardware not supplied To Weld Unit In Place Weld unit to truck or trailer only at the four mounting brackets Welding Unit In Place Bolting Unit In Place Tools Needed SEP 9 16in insi tall3 2007 04 803 274 200 864 A 803 562 OM 4422 Page 20 5 3 Installing Exhaust Pipe Stop engine and let cool gt Point exhaust pipe in desired di rection but always away from front panel and direction of travel Tools Needed SP 1 2 803 582 Ref 214 778 B Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual OM 4422 Page 21 5 4 Activating The Dry Charge Battery If Applicable A Always wear a face shield rubber gloves and protective clothing when working on a battery Remove battery from unit 5 Vent Caps 6 Sulfuric Acid Electrolyte 1 265 Specific Gravity 7 Well Fill each cell with electrolyte to bottom of well maximum A Do not overfill battery cells
96. lter Oil Cat 150 4140 1 Ci esa EA EA 217695 Switch Coolant Temp 110c 1 My 217696 Switch Lubricating Oil Pressure N O 1 pied O s tive EE 212613 Hose Radiator Upper Cat 3013 1 216811 Clip Nut Retaining 2 M B VR a EE 197613 Air Cleaner Intake 5 250 In Includes 1 RE A 197675 Dust Ejector Air Cleaner 1 ad Rs e EE ach 197676 Element Air Cleaner 1 S aa ac AT 197677 Cover Assy Air Cleaner 1 AE ER EE 197678 Body Air Cleaner 1 TOT TREES 197679 Element Air Cleaner Safety 1 197829 Bracket Air Cleaner 1 saree LD 212617 Hose Air Intake Cat 3013 1 eis Figure 12 4 Generator Assembly 1 RE EEN 213461 Bracket Mtg Generator 1 213266 Mount Engine Generator Flange Mtg
97. m A Also see AWS Safety amp Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Generators ST 800 576 B 11 4 How Much Power Does Equipment Require VOLTS 115 2 AMPS 4 5 1 Hz 60 1 Resistive Load A light bulb is a resistive load and requires a constant amount of power 2 Non Resistive Load Equipment with a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when running see Section 11 8 3 Rating Data Rating shows volts and amperes or watts required to run equipment Amperes x Volts Watts Example 1 If a drill uses 4 5 am peres at 115 volts calculate its run ning power requirement in watts 4 5Ax115V 2 520W The load applied by the drill is 520 watts Example 2 If three 200 watt flood lamps are used with the drill from Ex ample 1 add the individual loads to calculate total load 3 x 200W 520 W 1120 W The total load applied by the three flood lamps and drill is 1120 watts S 0623 OM 4422 Page 54 11 5 Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1 8 HP 800 300 1 6 HP 1225 500 1 4 HP 1600 600 1 3 HP 2100 700 1 2 HP 3175 875 Capacitor Start Induction Run 1 3 HP 2020 720 1 2 HP 3075 975 3 4 HP 4500 1400 1HP 6100 1600 1 1 2 HP 8200 2200 2HP 10550 2850 3 H
98. mix ture of water and ethylene glycol base anti freeze rated to 34 F 37 C Add anti 803 563 freeze to mixture if using the unit in tempera tures below 34 F 37 C Keep radiator and air intake clean and free of dirt NOTICE Incorrect engine temperature can damage engine Do not run engine with out a properly working thermostat and ra diator cap 5 To improve cold weather starting Use Preheat switch see Section 6 1 Keep battery in good condition Store battery in warm area Use fuel formulated for cold weather diesel fuel can gel in cold weather Contact local fuel supplier for fuel in formation Use correct grade oil for cold weather see Section 8 1 OM 4422 Page 23 5 7 Connecting To Weld Output Terminals PAL Stop engine Work Negative Weld Output Terminal 1 2 wire Weld Output Terminal 3 CC Stick TIG Weld Output Terminal Failure to properly connect weld cables may cause excessive heat and start a fire or damage your machine Weld Output Terminal Supplied Weld Output Terminal Nut Weld Cable Terminal Copper Bar N OO BR Stick and TIG Welding For Stick and TIG welding Direct Current Elec trode Positive DCEP connect electrode holder cable to CC Stick TIG terminal on right and work cable to Work Negative ter minal on left For Direct Current Electrode Negative DCEN reverse cable connections Use Process
99. ng is finished volt meter displays weld voltage and then defaults to preset voltage 10 DC Ammeter Ammeter displays preset amperage Stick and TIG only when not welding and actual output amperage when welding To set amperage turn Process Contactor switch to Stick or TIG position Turn V A con trol until desired amperage is displayed on Ammeter When welding is finished ammeter displays weld amperage and then defaults to preset amperage OM 4422 Page 29 6 3 Process Contactor Switch On CC CV Models WELD TERMINALS ALWAYS ON STICK c en 1 1 Process Contactor Switch A Weld output terminals are ener gized when Process Contactor switch is in a Weld Terminals Al ways On position and the engine is running Use switch to select weld process and weld output on off control see table be low Place switch in Remote On Off Switch Required positions to turn weld output on and off with a device connected to the Remote 14 receptacle Place switch in Weld Terminals Always On positions for weld output to be on whenever the engine is running Use Stick mode for air carbon arc CAC A cutting and gouging When switch is in Stick mode select one of four arc drive dig settings to provide additional amperage during low voltage short arc length conditions and prevent sticking electrodes Turn control from A to D to incr
100. nk Sludge Drain Valve To change oil and filter Route oil drain hose and valve through hole in base See engine manual and engine maintenance label for oil filter change in formation To replace primary canister fuel filter Turn filter counterclockwise Re move filter Fill new filter with fresh fuel Apply thin coat of fuel to gasket on new fil ter Install new filter and turn clock wise Inspect fuel lines and replace if cracked or worn To drain water from fuel system See engine manual To replace secondary in line fuel filter Note direction of fuel flow as indi cated by arrow on side of filter Re move fuel line clamps and discon nect fuel lines from fuel filter Re place filter reconnect fuel lines and reinstall clamps To drain sludge from fuel tank A Beware of fire Do not smoke and keep sparks and flames away from drained fuel Dis pose of drained fuel in an en 9 9 vironmentally safe manner Do not leave unit unattended 1 m E while draining fuel tank Seti gt A Properly lift unit and secure anse perly 8 m SS in a level position Use ade 3
101. nted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the delivery date of the equipmentto the original end user purchaser and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers 2 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Process Controllers Semi Automatic and Automatic Wire Feeders Inverter Power Sources Unless Otherwise Stated Water Coolant Systems Integrated Intellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified Motor Driven Guns w exception of Spoolmate Spoolguns Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Coolers and Electronic Controls Recorders Water Coolant Systems Non Integrated Flowgauge and Flowmeter Regulators No Labor HFUnits Grids Spot Welders Load Banks Arc Stud Power Sources amp Arc Stud Guns Racks Running Gear Trailers Plasma Cutting Torches except APT amp SAF Models Field Options NOTE Field options are covered under True Blue for the remaining warranty period
102. ntendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 Keep cables close together by twisting or taping them or using a cable cover 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 Keep welding power source and cables as far away from operator as practical 5 Connect work clamp to workpiece as close to the weld as possible About Implanted Medical Devices Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding spot welding gouging plasma arc cutting or induction heating operations If cleared by your doctor then following the above procedures is recom mended OM 4422 Page 5 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION rom 2007 04fre A Se prot ger ainsi que toute autre personne travaillant sur les lieux contre les tincelles et le m tal chaud 2 1 Signification des symboles l vite pas peut donner la mort ou des blessures graves Les dangers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte A DANGER Indique une situation dangereuse qui si on peut donner la mort ou des blessures graves Les dan gers possibles sont montr s par les symboles joints ou sont expliqu s dans le text
103. of the product they are installed in or for a minimum of one year whichever is greater Bernard Branded Mig Guns No Labor Weldcraft Branded TIG Torches No Labor Subarc Wire Drive Assemblies 6 Months Batteries 90 Days Parts MIG Guns TIG Torches and Subarc SAW Guns Induction Heating Coils and Blankets Cables and Non Electronic Controls APT 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 TH
104. on cord Maximum Allowable Cord Length in ft m for Conductor Size AWG Current Load Watts 4 6 8 10 12 14 Amperes 5 600 350 106 225 68 137 42 100 30 7 840 400 122 250 76 150 46 100 30 62 19 10 1200 400 122 275 84 175 53 112 34 62 19 50 15 15 1800 300 91 175 53 112 34 75 23 37 11 30 9 20 2400 225 68 137 42 87 26 50 15 30 9 25 3000 175 53 112 34 62 19 37 11 30 3600 150 46 87 26 50 15 37 11 35 4200 125 38 75 23 50 15 40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 296 voltage drop Cord Lengths for 240 Volt Loads A If unit does not have GFCI receptacles use GFCI protected extension cord Maximum Allowable Cord Length in ft m for Conductor Size AWG Current Load Watts 4 6 8 10 12 14 Amperes 5 1200 700 213 450 137 225 84 200 61 7 1680 800 244 500 152 300 91 200 61 125 38 10 2400 800 244 550 168 350 107 225 69 125 38 100 31 15 3600 600 183 350 107 225 69 150 46 75 23 60 18 20 4800 450 137 275 84 175 53 100 31 60 18 25 6000 350 107 225 69 125 38 75 23 30 7000 300 91 175 53 100 31 75 23 35 8400 250 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 4422 Page 59 SECTION 12
105. or and the device manufacturer before going near arc welding spot welding gouging plasma arc cutting or induction heating operations CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pres sure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks physical damage slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Use the right equipment correct procedures and sufficient num ber of persons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3
106. or 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 2 Miller Effective January 1 2007 Equipment with a serial number preface of LH or newer This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller THIS WARRANTY S EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Miller must be notified in writing within thirty 30 days of such defect or failure at which time Miller will provide instructions on the warranty claim procedures to be followed Miller shall honor warranty claims on warra
107. ousing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equip ment is a hazard Do not touch live electrical parts Wear dry hole free insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground 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 e Additionalsafety precautions are required when any of the follow ing electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomatic DC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSH
108. owever some condi tions may cause engine damage before the engine shuts down Check oil level often and do not use the oil pressure shutdown system to monitor oil level Follow run in procedure in engine manual If unburned fuel and oil collect in exhaust pipe during run in see Section 10 Fuel NOTICE Do not use gasoline Gasoline will damage engine The unit is shipped with enough fuel to pre vent air from entering fuel system Add fresh diesel fuel before starting see engine main tenance label for fuel specifications Leave filler neck empty to allow room for expansion Do not run out of fuel or air will enter fuel sys tem and cause starting problems See en gine manual to bleed air from fuel system Oil After fueling check oil with unit on level sur face If oil is not up to full mark on dipstick add oil see maintenance label Coolant Check coolant level in radiator before start ing unit the first time If necessary add cool ant to radiator until coolant level is at bottom of filler neck Check coolant level in recovery tank daily If necessary add coolant to recovery tank until coolant level is between Cold Full and Hot Full levels If recovery tank coolant level was low also check coolant level in radiator Add coolant if level is below bottom of radia tor filler neck Unit is shipped with an engine coolant
109. peed as follows Start engine and run until warm Turn Process Contactor switch to Stick Weld Terminals Always On position 1 Throttle Rod Plunger 2 Lock Nut 3 Rubber Boot 4 Adjustment Screw Adjustment screw is not used to ad just engine speed when automatic idle option is installed However it must be at least 1 8 in 8 mm away from the throttle arm when engine is running at idle rpm Unhook rubber boot from the sole noid housing but leave connected to plunger Loosen lock nut Place Engine Control Switch in Auto position Turn throttle rod and plunger until engine runs at idle speed Tighten lock nut Hook rubber boot back onto sole noid housing Be sure solenoid plunger pulls all the way in bottoms when energized Weld Power Speed Adjustment Weld power speed adjustment must be done by the engine manufacturers factory autho rized service agent Tampering with adjustments other than shown may affect engine warranty A Stop engine 803 563 G OM 4422 Page 40 8 10 Servicing Fuel And Lubrication Systems A Stop engine and let cool ES AN After servicing start engine and check for fuel leaks Stop engine tighten connec tions as necessary and wipe up spilled fuel Oil Filter Oil Drain Valve And Hose Oil Fill Cap Primary Canister Fuel Filter a BOND Secondary In Line Fuel Filter 6 Fuel Ta
110. point gun toward any part of the body N other people or any metal when threading welding wire OVERUSE can cause OVERHEATING Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again Do not block or filter airflow to unit gt STATIC ESD can damage PC boards Puton grounded wrist strap BEFORE handling 52 boards or parts Use proper static proof bags and boxes to store move or ship PC boards Use tongue jack or blocks to support weight Properly install welding generator onto trailer E TILTING OF TRAILER can cause injury according to instructions supplied with trailer READ INSTRUCTIONS Read Owner s Manual before using or servic ing unit Use only genuine replacement parts from the manufacturer Perform engine and air compressor mainte nance and service according to this manual and the engine air compressor if applicable manuals H F RADIATION can cause interference High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation e The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation e f notified by the FCC about interference stop using the equipmentat once Have the insta
111. quent des cancers et des malformations cong nitales ou autres probl mes de procr ation Pour les moteurs diesel A Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l Etat de Californie com me provoquant des cancers et des malformations cong nitales ou autres probl mes de procr ation LAW 5NS t l phone 800 463 6727 ou Toronto 416 747 4044 site Internet www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 de American National Standards Institute 11 West 43rd Street New York NY 10036 8002 t l phone 212 642 4900 site Internet www ansi org Standardfor Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart and Part 1926 Subpart J de U S Government Printing Office Superin tendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 t l phone 1 866 512 1800 il y a 10 bureaux r gionaux le t l pho ne de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 1 Garder les c bles ensemble les torsader les scotcher ou les recouvrir d une housse 2 Disposer les c bles
112. r 12v 585 Crk 95 Rsv Gp 55 Maint Free 1 DOREM 190207 Cable Bat Pos 45 In Lg No 1 Awg W Clamp amp 406 Rng 1 iss RE sobres 213668 Bracket Mtg Unit 4 ter 213458 gt cuore Sheds SO ANN eeu paetos see sn es 1 Gerets 213483 Support Engine Rh Cat 1 ban OF SEER ESE uns 190206 Cable Bat Neg 42 In Lg 2 Awg W Clamp 8 375 Rng 1 REC ash EET 224266 Label Warning Do Not Weld On Base 2 RAN EE 213462 Pad Mtg Generator 1 UE Lee Kk 213670 Screw 500 13x2 25 Hex Flange hd Gr8 Chem Phys 2 AT AE e 071731 Washer Flat 656idx2 2500dx 187t Stl Pld 2 2 MOO 213463 Spacer Snubber Generator Mtg 1 at 213485 Support Engine Lh 1 se 102 i Rs 213459 Crossmember Engine 1 S 213460 Crossmember Generator 1 Me ERA HE 213600 Screw 500 13x3 00 Hex Flange hd Gr8 PIN 1 EE EIE MA 071731 Washer Flat 656idx2 2500dx 187t Stl Pld 2 EE aii 213464 Bracket Battery Locator
113. rocess Contactor switch in a Weld Terminals Always On position or place switch in a Remote On Off Switch Required position and turn remote contactor on see Section 5 9 Reset supplementary protector CB7 or CB8 see Section 8 11 Check for faulty remote device con nected to RC14 Check and secure connections to Remote Control receptacle RC14 see Section 5 9 Check Voltmeter Ammeter help displays see Section 8 12 No weld output or generator power out put at ac receptacles Disconnect equipment from generator power receptacles during start up Reset supplementary protector CB3 see Section 8 11 Check fuse F1 and replace if open see Section 8 11 If F1 is open have Factory Authorized Service Agent check the voltage regulator module PC3 Check Voltmeter Ammeter help displays see Section 8 12 Have Factory Authorized Service Agent check brushes and slip rings voltage regulator module PC3 and field excitation circuit Erratic weld output Check and tighten connections inside and outside unit Be sure connection to work piece is clean and tight Use dry properly stored electrodes Remove excessive coils from weld cables Have Factory Authorized Service Agent check brushes and slip rings High weld output Have Factory Authorized Service Agent check main control module PC1 and hall device HD1 Low weld output Check engine speed and adjust if necessary
114. ser de carburant Nettoyer toul carburant renvers avant de faire d marrer le moteur Jeter les chiffons dans un r cipient ignifuge Toujours garder le pistolet en contact avec le r servoir lors du remplissage DES ORGANES MOBILES peuvent pro voquer des blessures Ne pas approcher les mains des ventilateurs courroies et autres pi ces en mouvement e Maintenir ferm s et fixement en place les portes panneaux re couvrements et dispositifs de protection Arr ter le moteur avant d installer ou brancher l appareil OM 4422 Page 8 Placer les bouteilles debout en les fixant dans un support station naire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser Tenir les bouteilles loign es des circuits de soudage ou autres circuits lectriques Ne jamais placer une torche de soudage sur une bouteille gaz Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille Ne jamais souder une bouteille pressuris e risque d explosion Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat Ne pas tenir la t te en face de la sortie en ouvrant la soupape de la bouteille Maintenir le chapeau de protection sur la soupape sauf en cas d utilisation ou de branchement de la bouteille Utiliser les quipements corrects les bonnes
115. t Relay 5 Pin 1 Supe Rus eda NE 212116 Conn Deutsch 2p 1row Female Plug 3 SEE ER 212117 Conn Deutsch Wedge Lock 2 Position 3 IT PLG1 214932 Conn Rect Univ 039 8p S 2row Plug Cable Lkg Seal 1 te a 214933 Seal Wire Univ O39 7 ELE A need 214934 Seal Plug Univ 039 1 Jaca doses For 81 211292 Conn Pack 4p 1row Female 1 rie For 51 211293 Conn Pack Terminal Position Assurance Lock 1 ES RE De el 129524 Term Frict 250x032 Uninsul Male 130 Stud Mtg 3pr 2 Sa biden oo AE RU ON TR 217002 Harness Weld Control Includes 1 Dun vs PLG2 150316 Conn Rect Univ 039 6p S 3row Plug Cable Lkg 1 Digi PLG9 214951 Conn Rect Univ 039 6p S 3row Plug Cable Lkg Seal 1 TE 214933 Seal Wire Univ O39 3 Va kg FAN a Ea 214934 Seal Plug Univ 039 3 TEE PLG8 147992 Conn Rect Univ 039 10p S 2row Plug Cable 1 VIE Sud PLG6 193184 Conn Rect Cinch 30 Pin 1 AE PLG7
116. t s il est endommag un c ble d nud peut provoquer une lectro cution e Mettre l appareil hors tension quand on ne l utilise pas e Ne pas utiliser des c bles us s endommag s de grosseur insuffi sante ou mal piss s Ne pas enrouler les c bles autour du corps e Si la pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct ne pas utiliser le connecteur de pi ce ou le c ble de retour Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine Ne pas toucher des porte lectrodes connect s deux machines en m me temps cause de la pr sence d une tension vide dou bl e e N utiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment ce manuel Porter un harnais de s curit quand on travaille en hauteur e Maintenir solidement en place tous les panneaux et capots e Fixer le c ble de retour de facon obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s possible de la soudure e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique Une tension DC importante subsiste l int rieur des onduleurs apr s avoir coup l alimentation Couper l alimentation du poste et d charger les condensateurs d entr e comme in
117. ten electrode touches workpiece only a low sensing voltage is present between electrode and workpiece The solid state output contactor does not energize until after electrode is touching workpiece This allows electrode to touch workpiece without overheating sticking or be ing contaminated Application Lift Arc is used for the DCEN GTAW process when HF Start method is not permitted or to replace the scratch method Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual OM 4422 Page 31 6 5 Remote Voltage Amperage Control pe 1 Remote 14 Receptacle RC14 Connect optional remote control to RC14 see Section 5 9 gt When a remote control is connected to the Remote receptacle the Auto Sense Re mote feature automatically switches volt age amperage control to the remote con trol When a device is connected to the Re mote receptacle remote voltage amper age control is always available regardless of the position of the Process Contactor switch In Example Min 20 A DC Max 205 A DC 3 WELD TERMINALS ALWAYS ON STICK 9 1 2 REMOTE gt 2 gt oi gt OER DI ru 53 Set V A Control Connect Remote Control To Remote A Adjust Optional Remote 2 Wold
118. the matter in writing to Caterpillar Inc Manager Customer Service Engine Division Mossville Bldg A P O Box 600 Peoria IL 61552 0600 Please follow the above steps in sequence if a problem arises Website Address www caterpillarcom Altitude Contact the Caterpillar applications depart ment for information on the effect of ambient conditions on Caterpillar 3024 engines 8 4 Checking Generator Brushes AF ws 5 16 in 8 mm Minimum Length TAER New Length Replace Damaged Brushes A Stop engine and let cool 1 Generator Brush With Spring Mark and disconnect leads at brush hold er cap Remove brushes Replace brushes if damaged or if brush material is at or near minimum length 9 16 in 14 3 mm Ref 2114 778 D S 0233 A OM 4422 Page 36 8 5 Servicing Air Cleaner A Stop engine NOTICE Do not run engine without air 1 2 3 4 cleaner or with dirty element Engine damage caused by using a damaged ele ment is not covered by the warranty The air cleaner primary element VER be cleaned but the dirt holding capac ji H j C REAR ity of the filter is reduced with each cleaning The chance of dirt reaching 4 the clean side of the filler while clean
119. ule PC3 Low output at generator power ac recep tacles Check engine speed and adjust if necessary Check fuse F1 and replace if open see Section 8 11 If F1 is open have Factory Authorized Service Agent check the rotor C Engine Trouble Remedy Engine will not crank Check battery and replace if necessary Check battery connections and tighten if necessary Circuit breaker CB1 may be open CB1 automatically resets when fault is corrected see Section 8 11 Have Factory Authorized Service Agent check engine wiring harness and components Reset supplementary protector CB2 see Section 8 11 Check engine wiring harness plug connections Have Factory Authorized Service Agent check Engine Control switch S1 and control relay CR2 Engine cranks but does not start Check fuel level Check battery and replace if necessary Check engine charging system according to engine manual Have Factory Authorized Service Agent check control relay CR1 fuel solenoid FS1 and the fuel pump Air in fuel system See engine manual Engine hard to start in cold weather Use Preheat switch see Section 6 1 Keep battery in good condition Store battery in warm area off cold surface Use fuel formulated for cold weather diesel fuel can gel in cold weather Contact local fuel supplier for fuel information Use correct grade oil for cold weather see Section 8
120. voltage and current NOTICE Do not idle engine longer than necessary Piston rings seat faster if engine runs at weld power rpm and the welding generator is kept loaded during run in 2 Engine Exhaust Pipe Wetstacking is unburned fuel and oil in the exhaust pipe and occurs during run in if the engine is run too long at light load or idle rpm If exhaust pipe is coated with a wet black tar like substance dry the engine using one of the following run in procedures See the engine manual for addition al engine run in information OM 4422 Page 50 10 2 Run In Procedure Using Load Bank 6 A Stop engine 2 We Do touch hot exhaust pipe engine parts or load bank grid A Keep exhaust and pipe away from flammables NOTICE Do not perform run in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur 1 Load Bank Turn all load bank switches Off If needed connect load bank to 115 volts ac wall receptacle or genera tor auxiliary power receptacle 2 Welding Generator Place A V range switch in maxi mum position A V control in mini mum position and Output Selector switch if present in either DC position 3 Weld Cables Connect load bank to generator weld output terminals using proper size weld cables with correct connectors Observe correct polarity Start engine and run for several minutes
121. with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet e Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc Wear protective clothing made from durable flame resistant mate rial leather heavy cotton or wool and foot protection WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Do not weld where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas e Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side OM 4422 Pa

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