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Miller Electric Big Blue 251D Welding System User Manual

1. O O SED Naga NN D S 9 8 7 6 AC NV Single Three Output Phase Phase 93 1 3 M Volts 120 240 240 91 Amps 31 24 KVA KW 7 5 10 Frequency 60 Hz S Engine Speed 1850 RPM Max Fuse Size 35 Amperes ba Lead 42 connects to GROUND stud on front of pM 42 is connected to 90 at factory A Stop engine A Power and weld outputs are live at the same time Disconnect or insulate unused cables Lx Have qualified person install according to circuit diagram and Generator Power Guide lines Section 11 Remove junction box cover 1 Lead 93 2 Lead 92 3 Lead 91 4 Lead 90 Neutral 5 Lead 42 Circuit Grounding Lead Lead 42 connects to front panel Ground stud 6 Grounding Terminal 7 Jumper Lead 42 8 Isolated Neutral Terminal Jumper 42 is connected to lead 90 at factory Jumper 42 may be dis connected from neutral to meet applicable electrical codes 9 Lead 80 10 Receptacle RC9 leads 11 Lead 42 12 Lead 81 13 Lead 82 14 Load Terminals Connect leads to terminals 15 Fuses F1 F2 And F3 F1 F2 and F3 protect each load line from overload Set Engine Control switch to Run when using generator power Tools Needed ES em Ref S 179 637 B OM 480 Page 22 7 4 120 240 Volt Twistlock Receptacle Optional
2. 1 BO LA quan bius 4197 676 ELEMENT air cleaner 1 e 1 lt cr 197 679 ELEMENT air cleaner safety 1 OL na es 197 829 BRACKET mtg air cleaner 2 OB Be ex it eam 197 678 BODY air clearer AE Seed ame e Ce ant ae ROTE IE dl 1 SO ur ioa NN LA Me Deleted ti a AAP WES det dO reisen 010863 CLAMP hose 2 062 3 000clp dia 1 p 124985 HOSE air cleaner to engine 1 ag AD re compos 010862 CLAMP 1 812 2 500clp dia 1 DAS Vet is 010 089 FITTING pipe brs coupling 1 8NPT 1 44 046 545 RESTRICTION INDICATOR 1 E sng OP PAA 158610 LABEL warning electric shock and moving parts 2 246 4 a dinate 087 3362 PAT GH sated coated eL pa odds BADA 2 AE alg Run ans 173 908 BAFFLE alt assi A GNG ED up Pa Ga nee Tees 1 I ou petiere cd E Y 010 736 TUBING stl 625 OD x 12ga wall x 625 1 48 cote Ies 173910 WEATHERSTRIPPING e nn 1 A eun 173943 ENGINE Deutz dsl elec 0 0 I 1 MAER PLG5 173916 CONN RECT HOUSING 10 CIRCUIT 1 Aka AG BAM aden Ja atau aah a 173935 TERMINAL Receptacle Mini Spring 4 OM 480
3. 2 18 PL1 2 048155 BULB incand flg base 12V 2 vu 195m mex 082 788 HOLDER lightind III 2 20 HM 145247 METER hour 4 40VDC 1 mu PETER 019 602 KNOB PIME ma et ee om eld e Ro RU NAAL ka CRDI a 1 td PP accu SR 2 019 754 HANDLE switch range mI 1 O debian bad LK ented NAMEPLATE order by model and serial number 1 man Ja uus Sd esses 176 606 SWITCH ignition 4posn 1 a APA PA e 127 618 PANEL front upper sfc 7 dame den ER a Dapa etait ay 1 ei CR D then hs 189 404 SPACER nylon e 1 E Hardware is common and not available unless listed ST 130 264 G 11 Figure 12 2 Panel Front w Components OPTIONAL Recommended Spare Parts To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 480 Page 49 Hardware is common and not available unless listed PA LE S W Figure 12 3 Generator La ST 110 922 F OM 480 Page 50 Item Dia Part No Mkgs No Description Quantity Figure 12 3 Generator Fig 12 1 Item 65 refermer 22 106 426 INSULATOR RLE Rd eese mme 4 E feas adits
4. 1 LAM 032 897 RECEPTACLE twlk grd 2P3W 15A 125V 1 6 CB1 2 139 266 CIRCUIT BREAKER man reset 1P 15A 250VAC 2 7 RC1 2 170 901 RECEPTACLE str dx grd 2P3W 15A 125V 2 7 GFCI1 2 151981 RECEPTACLE str dx grd 2P3W 15 20A GFCI 2 C LR dd 073 690 PLUG str grd 2P3W 15A 125V Arrow Hart 5965V SOs PET 601 836 NUT brs hex 250 20 jam hvy 3 ME AAP dete 083 030 STUD brs grd 250 20 x 1 750 1 SO A SRE d sco eL PLATE ident control rating order by model and serial number 1 DI Ib ELE 046 652 METER amp DC 50MV 0 600 1 Di ANS 046 654 METER volt DC 0 100 1 OM 480 Page 48 No Mkgs No Description Quantity Figure 12 2 Panel Front w Components Fig 12 1 Item 111 Cont d Adan 021 385 BOOT toggle switch ever 2 Ee AR PERA 129 860 GAUGE oil pressure 2 n 1 a us Probe tante ba 128 829 KIT oil line 44 000 in 1 8NPT x 10mm 1 A S ARN A COR e128 633 FITTING pipe brs adapter 1 8NPT x 12mm 1 na EE 129 837 GAUGE engine temperature esses 1 a CA 119014 LEVER switch black 22022 00 Rn 1 Ke e RS tang 082 789 LENS light ind red
5. 2 1 108 R6 030844 RESISTOR WW fxd 25W 25 ohm 1 anG d ee rade docs 605 741 CLIP mtg resistor 2 109 CR2 044 588 RELAY end 12VDC 3PDT 1 TIO x sites 1173317 PANEL front lower 1 TIO uk 4175 368 PANEL front lower 1 TEL ists s fer Fig 11 2 PANEL front w components 1 112 CT1 105370 TRANSFORMER Current 1 TTB are Ll sss 204 797 REACTOR eher KAPA AD na N ANAL 1 114 Neg 039 046 TERMINAL pwr output black 1 115 Pos 039 047 TERMINAL pwr output red aaa 1 Mica 174008 BRACKET mtg switch and output terminals 1 117 R2 3 189699 RESISTOR WW tap 375W 10 ohm w mounting bracket 2 WG RR 174010 SWITCH polarity III 1 T TER 059 773 HANDLE switch 1 VID ss tasses des 085 656 STRIP mtg resistor 1 AD ren 188237 UPRIGHT base front n 1 121 gave Lara 108 163 FRAME mtg reactor amp fuel tank 1 122 4 ave NANG 110069 FITTING brs flrd elbow M 1 4tbg x 1 4NPT 2 TEEN 010314 VA
6. 4 M UC nati EE 072848 TUBING nprn 875 ID x 2 500 OD x 2 000 4 I NA 173929 BRACKET mtg solenoid 1 Fig 12 3 GENERATOR eere BG mer ee RR be dee Se ae See 1 uo vie etes eda 030 084 SHUNT meter 50MV 600A 1 naa Of sius gs 188239 BRACKET mtg engine LH re 1 DO sale i tae eds 109591 CLAMP muffler 1 750dia 1 EN Libet fui etta 124 866 PIPE muffler extension elb 1 ete rang eas Cea E 087 341 BUMPER door 1 000 OD x 750 high 4 van 200 788 BASE filter fuel standard models includes items 72 thru 77 1 EE 208 858 BASE filter fuel models w 7 5 10 KVA opt incl items 72 thru 77 1 Maya ice et 110069 FITTING flrd brs elbow M 1 4 1 icone nn i tf iS 106 394 FITTING flrd brs conn M HD 1 4 tbg x 1 4 NPT 7 5 10 KVA option 1 E d i oa eS 080389 SCREW 312 18 x 1 000 cap hexhd 2 nA ilg niit us 124 607 STRIP mtg separator fuel 0 eee 1 ri EE 172684 NUT 312 18 x 50 hex 2 One dri 200787 BASE filter w adapter and vent 1 PAT dr RENDERE E 145282 FITTING hose brs barbed elb M 5 16tbg x 1 ANPT 1 O sh 134835
7. LES RAYONS DE L ARC peuvent pro voquer des br lures dans les yeux et sur la peau Le rayonnement de l arc du proc d de soudage g n re des rayons visibles et invisibles intenses ultraviolets et infrarouges susceptibles de provoquer des br lures dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage e Porter un casque de soudage muni d un cran de filtre appropri pour pro t ger votre visage et vos yeux pendant le soudage ou pour regarder voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit e Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev e Utiliser des crans ou des barri res pour prot ger des tiers de l clair et de l blouissement demander aux autres personnes de ne pas regarder l arc e Porter des v tements de protection constitu dans une mati re durable r sistant au feu laine ou cuir et une protection des pieds NG LE SOUDAGE peut provoquer un in 5 cendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer leur clatement Des tincelles peuvent tre projet es de Parc de soudure La projection d tincelles des pieces chaudes et des quipements chauds peut provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un surchauf
8. Mi i 1 120 240 V 50 A Twistlock Re ceptacle RC9 RC9 is connected to the optional ac power plant and supplies 60 Hz single phase power at weld power speed Maximum output from re ceptacle is 7 5 kVA kW Power available at RC9 is reduced when welding Fuses F1 and F2 protect RC9 from overload see Section 7 3 If a fuse opens the receptacle does not work 120 volts may still be present at RC9 801 057 A OM 480 Page 23 SECTION 8 MAINTENANCE AND TROUBLESHOOTING 8 1 Routine Maintenance ES A A t3 NY Recycle engine V i A Stop engine before maintaining See Engine Manual and Maintenance Label for impor tant start up service and storage information Service engine more often if used in severe conditions fluids To be done by Factory Authorized Service Agent O Every 8 h Check Fluid FUEL Ee KIK Y Levels See WATER ss Section 5 4 Section 8 4 e Every 50h Clean And Clean Air Filter A i Tighten Weld See Section 8 3 ail ec Terminals O Every 100 h Check air cleaner hoses for cracks and loose clamps O Every 200 h Clean Clean And t Cooling Tighten System Battery Connections WARNIN yi NG Replace zs Check And LE Unreadable Tu Clean Spark Labels e Arrestor See Section 8 8 O Every 500 h Change Oil d
9. OM 480 128 576AC January 2005 Miel Miller d Stick SMAW Welding Va Air Carbon Arc CAC A VA Cutting And Gouging With Optional Equipment pu Flux Cored FCAW With N Voltage Sensing Wire Feeder Description D ES Engine Driven Welding Generator Big Blue 251D C EE OWNER S MANUAL 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 E Bl E Kia 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 f every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most hassle free warranty in the We ve made installation and operation quick busi
10. BEARING ball is r da eR ANT A 1 ss WO ees 089 737 gai FAN TOOT sss LEUR Dane e D DONEC Vu ADR DE Sawa c und 1 ES 035 776 a KEY 375 X 975 X 2 000 a ss sons noble rs d pes 20 ob ERIS 204 695 STATOR exciter endbell consisting of 1 x22 E 204 714 STATOR exciter aux power 1 NA HERES E 173 068 ENDBELL gen consisting of 1 iin 28 BE eae 143 220 O RING 2 859 ID x 189CS 1 se A sie faste etes 173323 BARREL rectifier 1 25 SR3 106 430 DIODE ASSEMBLY consisting of 1 2064 anna 048 420 CAPACITOR rectifier 2 panied A ees T ares 106 641 zn CAPACITOR corista dead a ae eta dew re eu d iat Pf pis 106 425 INSULATOR sssssssse esse nme 1 e lt ines 037 956 DIODE rect 275A 300V SP 3 29 VR1 R4 046819 SUPPRESSOR 2 4 1 OPTIONAL Recommended Spare Parts 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
11. HOSE SAE 312 ID x 560 OD order by ft 2ft im UA B n iiie erbe dM 010 323 CLAMP hose 250 625clp dia 2 Na BOS iM duit a ur 192744 FILTER fuel spin on BI 1 iO deas Re Yd 145283 HOSE fuel 10 000 1 4 swivel both ends 1 ho Ba ang aanak Rab 188 250 ka BASE a ties teret prr be erbe Pub eM eese La 1 E est beers 020225 CLAMP Nyl 875 Clamp Dia X 500 Wide 1 pa OF a TR ean 123 794 EDGE TRIM order by ft 1ft nam 9D aisa TE 038 621 BLOCK term 30A 4P 1 K 038 620 LINK jumper term blk 30A 2 ee be PLG7 135556 CONNECTOR 8 SOCKETS 1 86 CR98 CR99 090 104 RELAY end 12VDC SPST 2 87 Idle mod 189 742 MODULE pull to idle bon 1 sen OO totas 176775 BRACKET mtg comp panel auto idle 1 89 F4 073 429 FUSE mintr gl slo blo 15A 32V 1 set OO ace ARINA AGA 046 432 HOLDER fuse mintr 250 x 1 250 panel mtg 1 caa A sine shit avt 053 967 INSULATION rectifier 1 A ias cc ees 081 499 BRACKET mtg strip terminal 0 00 c cece eee eee
12. 7l REMOTE CONTROL x REMOTE CONTROL FACILITIES PIN ACCESSORY Zu o 120V 240V z1 Jee 17 s3 AA mot E KC o e 120V 240V d 2 TE1 E E 3 PHASE 21 FIELD PTION S s WA PHASE 2 E 23 RC2 CB2 CB RCI my 24 3 120v 240V 1 E V y 701 7 102 RG Le En ES 104 m bs PL68 8 E A o IT GR W GR E mO SR 39 Co By Ag GFCI FACTORY OPTION ol cle sly al LA na JE TE4 q Y y C8 TE1 p a ime a Q M E lt lt Sek o cii o Pe si PLG8 5 Ze 2 GFCI1 J D2 D3 28 120V pz 120v 120V G C RCI D ng N 101 102 B 200 120V pe pee w w c2 c3 H z z H 101 102 2 EN NS 2 Y 3 3 A B C D no IN y 42 D4 D5 10000 GND GND 27 7 n Pra E f 1633 5 43 45 103 GR W W GR ETSTZTE S1 PLG1 yt SR3 Ni SERRE WHEN MS1 OPTION IS USED RUNNING D6 D7 gt a 3 gt 60 REMOVE LEAD 49 ON mi THAT COMES pos A PL67 3 i e ZE Pr 5 B SAO PLG8 4 N FROM PLZ amp INSTALL ON LOOSE LEAD 49 S 5 27 IN HARNESS INSTALL LOOSE LEAD 44 IN 3 Cp C7 TIKTIK pim PE HARNESS TO HM Ng H g VRI gt gt 1 T e 9 os 2 x 3 x ay Ye o HOLD IN I E d r d SHUNT IS CONNECTED IN K 0 4 PLO PLZ F LIO START B G SERIES WITH LINE 19 X CLOSED TO B NPL67 2 LE B S CI OPTIONAL IDLE R4 e TERMINAL 60 PLG7 1 MODULE cs 09 LI P O Ho ETHER START Pa SHUNT ST OPTIONAL 45 P EURE c E e 9 o ES ka Ee L PLE5 2 Y PLG5 6 Y 85 v SB 60 61 D4 yo i m 9 GS 9 a H bo ai CC Da T 8 da JN wep METERS N a t o
13. Block flywheel so that it will not turn while working on generator compo nents STEAM AND HOT COOLANT can burn e f possible check coolant level when engine is cold to avoid scalding e Always check coolant level at overflow tank if pres ent on unit instead of radiator unless told otherwise in maintenance section or engine manual e Ifthe engine is warm checking is needed and there is no overflow tank follow the next two statements Wear safety glasses and gloves and put a rag over radiator cap Turn cap slightly and let pressure escape slowly before completely re moving cap ENGINE EXHAUST GASES can kill Use equipment outside in open well ventilated ar eas e fused in a closed area vent engine exhaust outside and away from any building air intakes 1 4 Compressed Air Hazards BREATHING COMPRESSED AIR can cause serious injury or death e Donotuse compressed air for breathing e Use only for cutting gouging and tools COMPRESSED AIR can cause injury e Wear approved safety goggles e Do not direct air stream toward self or others TRAPPED AIR PRESSURE AND WHIPPING HOSES can cause injury A L 4 e Release air pressure from tools and system before servicing adding or changing attachments or open ing compressor oil drain or oil fill cap BATTERY ACID can BURN SKIN and EYES e Do not Hp battery e Replace damaged battery e Flush eyes and skin immediately wit
14. e Ne pas obstruer les passages d air du poste LES CHARGES LECTROSTATI QUES peuvent endommager les circuits imprim s 2 Vi VA ie 4 IN ASS e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antistatiques pour stocker d placer ou exp dier des cartes de circuits imprimes UNE REMORQUE QUI BASCULE peut entrainer des blessures e Ultiliser les supports de la remorque ou des blocs pour soutenir le poids e Installer convenablement le poste sur la remorque comme indiqu dans le manuel s y rapportant Bes 2 6 Principales normes de securite Safety in Welding Cutting and Allied Processes norme ANSI Z49 1 de l American Welding Society 550 N W LeJeune Rd Miami FL 33126 t l phone 305 443 9353 site Web www aws org Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping norme American Welding Society AWS F4 1 de American Welding Society 550 N W LeJeune Rd Miami FL 33126 t l phone 305 443 9353 site Web www aws org National Electrical Code norme NFPA 70 de la National Fire Protection As sociation P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 sites Web www nfpa org et www sparky org Safe Handling of Compressed Gases in Cylinders brochure CGA P 1 de la Compressed Gas Association 1735 Jefferson Davi
15. OM 480 Page 51 Item Part ol No No Description Quantity 114193 Figure 12 4 Switch Range Fig 12 2 Item 1 T t 114 285 BRACKET mtg switch consisting of 1 iau 2 010671 SPRING ext x 312 OD x 042 wire x 1 875pld 1 ee E 8 017 428 LOCATOR quadrant 1 4 004 998 CONTACT BOARD ASSEMBLY switch range consisting of 1 MT 5 011 980 CONTACT BOARD movable switch 2 EES 6 011 645 CONTACT ASSEMBLY movable consisting of 3 PRE Tots uhh rd WEE EINEN SANG Bian 0719598 so oa CONTACT EE E 9 011074 SPRING pressure 1 eee 10 011 644 CONTACT stationary 15 lue 11 004999 CONTACT BOARD stationary 2 SOM 12 011 012 SHIM guide contact board 8 dad 13 100623 GUIDE contact board movable 8 E Hardware is common and not available unless listed 6 SB 011 273 Includes 8 9 Item 7 SB 011 100 Figure 12 4 Switch Range To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering pa
16. TIQUES peuvent affecter les stimulateurs cardiaques Porteurs de stimulateur cardiaque restez distance Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de gougeage ou de soudage par points Si des BOUTEILLES sont endomma g es elles pourront exploser Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endommag e elle peut exploser Du fait que les bouteilles de gaz font normale ment partie du proc d de soudage les manipuler avec pr caution e Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques du laitier des flammes ouvertes des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e Tenir les bouteilles loign es des circuits de soudage ou autres circuits lectriques Ne jamais placer une torche de soudage sur une bouteille gaz Une lectrode de soudage ne doit jamais entrer en contact avec une bou teille Ne jamais souder une bouteille pressuris e risque 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 e
17. ae ot Y PLes 7 e 7e OPTIONAL Hd PRESSURE s2 76 a AE ad KAA STR POLARITY SWITCH Np167 4 ri Fst y Prev OPTIONAL ES I 12 VOLT OIL PLG7 6 Y A WITH THE POLARITY SWITCH STARTER PRESSURE OPTION LEADS 19230 CO TO 181 THE POLARITY SWITCH RATHER AUTOMATIC 12 VOLT v ii 3 OUTPUT STUDS ARE LABELED IDLE CONTROL BATTERY ASE P7 AUTOMATIC kapi AY ELECTRODE AND WORK IDLE CONTROL OPTIONAL 42 42 42 42 42 42 n OPTIONAL NEGATIVE POSITIVE T1 TI T1 T1 11 TI ELECTRODE WORK For Welding Generator ircuit Diagram Figure 9 1 C OM 480 Page 32 SECTION 10 RUN IN PROCEDURE 10 1 Wetstacking run in1 8 01 A Do not perform run in procedure at less than 20 volts weld output and do not exceed duty cycle or equip ment damage may occur 1 Welding Generator Run diesel engines near rated volt age and current during run in period to properly seat piston rings and prevent wetstacking See name plate rating label or specifications section in this manual to find rated voltage and current Do not idle engine longer than necessary Piston rings seat faster if engine runs at weld power rpm and the welding generator is kept loaded during run in 2 Engine Exhaust Pipe Wetstacking is unburned fuel and oil in the exhaust pipe and occurs during run in if the engine is run too long at light load or idle rpm If exhaust pipe is coa
18. ing restart In Run position engine runs at weld power speed In Run Idle position optional engine runs at idle speed at no load and weld power speed with load applied To Stop turn switch to Off position 8 Battery Charging Warning Light Light goes on when battery is not charging 9 Oil Pressure Warning Light Light goes on if oil pressure is too low If unit has automatic shutdown option light also goes on if oil temperature is too high A Stop engine and fix trouble if either light goes on 10 Ether Starting Aid Switch Optional Push switch up and release while cranking engine to release ether A Do not use Ether if engine is running 11 Engine Hour Meter 12 Oil Temperature Gauge Switch Optional 13 Oil Pressure Gauge Switch Optional 14 Polarity Switch Optional Place switch in Straight position for electrode negative or Reverse position for electrode positive 15 Manual Shutoff Lever Use lever to stop engine if engine control switch does not work 6 3 Remote A V Control lt A N 1 AN Control Switch Use switch to select front panel or remote amperage control 2 Remote A V Receptacle RC3 Connect optional remote control to RC3 Example Combination Remote Amperage Control 95 200 160 330 200 MAX O y Set Switch m 65 120 ag AIN In Example Range 95 to 200 A Percentage Of Range 50 Max 148 A DC 50 o
19. rences e L nergie lectromagn tique risque de provoquer des interf rences pour l quipement lectronique sensible tel que les ordinateurs et l quipement com mand par ordinateur tel que les robots e Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement e Pour r duire la possibilit d interf rence maintenir les c bles de souda ge aussi courts que possible les grouper et les poser aussi bas que pos sible ex par terre e Veiller souder une distance de 100 m tres de tout quipement lec tronique sensible e Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi e En cas dinterferences apr s avoir pris les mesures pr c dentes il in combe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de c bles blind s l utilisation de fil tres de ligne ou la pose de protecteurs dans la zone de travail Rexdale Ontario Canada M9W 1R3 t l phone 800 463 6727 ou To ronto 416 747 4044 site Web www csa international org Practice For Occupational And Educational Eye And Face Protection norme ANSI Z87 1 de l American National Standards Institute 11 West 42nd Street New York NY 10036 8002 t l phone 212 642 4900 site Web www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work norme NFPA 51B de la N
20. temperature gets too high See engine manual Have Factory Authorized Service Agent check engine charging system Engine suddenly stops Check oil level Optional automatic shutdown system stops engine if oil pressure gets too low or oil temperature gets too high Check optional Magnetic Shutdown switch fuse F and replace if open see Section 8 6 Engine slowly stopped unable to restart engine Check fuel level Open fuel valve see Section 5 4 Engine does not stop when Engine Con trol switch is placed in Off position Use manual shutoff lever to stop engine see Section 6 1 Check connections to Engine Control switch Have Factory Authorized Service Agent check engine fuel solenoid Engine remains at idle speed when Engine Control switch is placed in Run Idle position and an arc is struck models with automatic idle option only Have Factory Authorized Service Agent check Engine Control switch and idle module Engine will not run at idle speed models with automatic idle option only Check throttle solenoid fuse F4 and replace if open see Section 8 6 Have Factory Authorized Service Agent check Engine Control switch and idle module Battery discharges between uses Make sure Engine Control switch is in Off position when unit is shut down Clean battery terminals and posts with baking soda and water solution rinse with clear water Periodically recharge battery
21. 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 2 voltage drop Cord Lengths for 240 Volt Loads A If unit does not have GFCI receptacles use GFCI protected extension cord Maximum Allowable Cord Length in ft m for Conductor Size AWG HET 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 480 Page 42 Notes OM 480 Page 43 SECTION 12 PARTS LIST Hardware is common and not available unless listed 71 Includes 72 77 Figure 12 1 Main Assembly OM 480 Page 44 65 Fig 12 3 ST 129 956 U OM 480 Page 45 Item Dia Part No Mkgs No Description Quantity Figure 12 1 Main Assembly ar 134771 PLUG protective 640sq 2 e Cors AA ee 184 676 TANK fuel consisting of 1 N
22. Change Oil See Filter See cracked Section 8 4 Section 8 4 Cables 000 h Blow Out Or Service Welding Vacuum Inside Change Fuel Generator Brushes During Heavy Filters See And Slip Rings Service Section 8 4 Service More Often Clean Monthly In Dirty Conditions Drain Sludge Check From Fuel Check Belt Tank See Valve Tension Section 8 4 Clearance Clean Set Injectors OM 480 Page 24 N OTE Follow the storage procedure in the engine owner s manual if the unit will not be IER used for an extended period 8 2 Maintenance Label DEUTZ F3L1011F DIESEL ENGINE T See Engine Manual for complete engine care Give Engine Specification and Serial Number when ordering parts 1 Only with engine oil preheating Recommended Oil API Service Classification CC SE CC SF CD SE CD SF or better or better Oil Change amp Filter dirty conditions 250 hours 375 hours normal conditioi 500 hours 750 hours Oil Filter MILLER 067 265 Deutz 116 4626 Fram PH46 Oil Capacity 5 8 qt 5 5 L or 6 2 qt 5 9 L with filter change Fuel Capacity 11 3 gal 42 8 L Fuel Grade 1 Dor 2 D Cetane No 45 min Primary Fuel Filter Water Seperator MILLER 192744 Donaldson P550587 Fram P1145A Secondary Fuel Filter MILLER 066 217 Deutz 117 4696 Fill filter with clean fuel before installing read instructions on filter Air Filter Service 50 hours or less see Owner s Ma
23. Required To Start Motor E KG MOTOR 1 Motor Start Code 2 2 Running Amperage STB BT SPD t Er nal 3 Motor HP 3 CODE M Hz 60 4 Motor Voltage x HP 1 4 PHASE 1 To find starting amperage Step 1 Find code and use table to find kVA HP If code is not listed multiply running amperage by six to find starting amperage Step 2 Find Motor HP and Volts Step 3 Determine starting amper age see example Welding generator amperage out put must be at least twice the Single Phase Induction Motor Starting Requirements motors running amperage Motor Start Code G H J K L M N P KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0 KVA HP x HP x 1000 VOLTS EXAMPLE Calculate the starting amperage required for a 230 V 1 4 HP motor with a motor start code of M Volts 230 HP 1 4 Using Table Code M results in KVA HP 11 2 STARTING AMPERAGE 11 2 x 1 4 x 1000 A Starting ih t ires 12 2 _ 12 2 amperes 230 arting the motor requires amperes S 0624 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
24. SPARKS can cause injury e Wear a face shield to protect eyes and face z e Shapetungsten electrode only on grinder with proper guards in a safe location wearing proper face hand and body protection e Sparks can cause fires keep flammables away T OVERUSE can cause OVERHEATING Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit STATIC ESD can damage PC boards e Put on grounded wrist strap BEFORE handling boards or parts Use proper static proof bags and boxes to store move or ship PC boards TILTING OF TRAILER can cause injury Use tongue jack or blocks to support weight e Properly install welding generator onto trailer accord ing to instructions supplied with trailer OM 480 Page 3 READ INSTRUCTIONS e Use only genuine MILLER Hobart replacement parts e Perform engine and air compressor if applicable maintenance and service according to this manual and the engine air compressor if applicable manu als H F RADIATION can cause interference e High frequency H E can interfere with radio naviga tion safety services computers and communica tions 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 f
25. 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 S 0623 OM 480 Page 37 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 1 HP 6100 1600 1 1 2 HP 8200 2200 2 HP 10550 2850 3 HP 15900 3900 5 HP 23300 6800 Capacitor Start Capacitor Run 1 1 2 HP 8100 2000 5 HP 23300 6000 7 1 2 HP 35000 8000 10 HP 46700 10700 Fan Duty 1 8 HP 1000 400 1 6 HP 1400 550 1 4 HP 1850 650 1 3 HP 2400 800 1 2 HP 3500 1100 11 6 Approximate Power Requ irements For Farm Home Equipment Farm Home Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 Milker Vacuum Pump 2 HP 10500 2800 FARM DUTY MOTORS 1 3 HP 1720 720 Std e g Conveyors 1 2 HP 2575 975 Feed Augers Air 3 4 HP 4500 1400 Compressors 1 HP 6100 1600 1 1 2 HP 8200 2200 2 HP 10550 2850 3 HP 15900 3900 5 HP 23300 6800 High Torque e g Barn 1 1 2 HP 8100 2000 Cleaners Silo Unloaders 5 HP
26. approximately every three months Replace battery Engine uses oil during run in period wetstacking occurs Dry engine see Section 10 See engine manual OM 480 Page 31 SECTION 9 ELECTRICAL DIAGRAM 4 WARNING e Do not touch live electrical parts e Disconnect input power or stop SS BEN engine before servicing g Do not operate with covers removed S M a ELECTRIC Have only qualified persons install o SHOCKHAZARD use or service this unit OPTIONAL OPTIONAL D 5 RC9 El RC3 Xx 103 Wh SS 1 1 2 STD 8 42 PLGB 9 Ks 2 us RMTA so 5 sg Sw GR CRZ 7 OND R AK x y 18 tow PLG8 7
27. entretien de l appareil D verrouiller l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de s curit e Installer et mettre la terre correctement cet appareil conform ment son manuel d utilisation et aux codes nationaux provinciaux et municipaux e Toujours v rifier la terre du cordon d alimentation V rifier et s assurer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre risques de danger reli s aux CHOCS LECTRIQUES aux PIECES EN MOUVEMENT et aux PIECES CHAUDES Reportez vous aux symboles et aux directives ci des sous afin de conna tre les mesures prendre pour viter tout danger En effectuant les raccordements d entr e fixer d abord le conducteur de mise la terre appropri et contre v rifier les connexions V rifier fr quemment le cordon d alimentation pour voir s il n est pas en dommag ou d nud remplacer le cordon imm diatement s il est endommag un cable d nud peut provoquer une lectrocution Mettre l appareil hors tension quand on ne l utilise pas Ne pas utiliser des c bles us s endommag s de grosseur insuffisante ou mal piss s Ne pas enrouler les c bles autour du corps Si la pi ce soud e doit tre mise la terre le faire directement avec un cable distinct ne pas utiliser le connecteur de pi ce ou le
28. nas Naw tirer ee ORO ie 1 AE be e 134 792 LABEL warning general precautionary 1 sse Ni bagang clagtesiee 107 990 LABEL use diesel fuel only 1 22 lida itus 035 968 WASHER flat rbr 3 625 ID x 5 875 OD x 062thk 1 a An Gaba sa 195 869 CABLE TIE 0 17 500 weather resistant 1 PI AA 108487 LABEL warning falling equipment can cause serious injury 2 NOT ST 004 130 BRACKET support door 2 TU MP TIPP 173847 LABEL diesel engine maintenance cee eee eee 1 20 pea 124 687 DOOR side RH ooooccccccccccc nenna annen 1 TURN 124 685 DOOR side LH 1 UE 168385 LABEL warning battery explosion can blind 1 r enin ele Paced CRUS 089 343 RIVET nyl 250dia x 1 000 Ig KaRa cete paaa igaya O O keer lag Naya KUA 1787693 PANEL TEA a aaah a aaa E 1 28 419956 is 4162 741 t GUARD belt c r le RM e MUERE 1 NOR PANA 146 994 LABEL warning moving parts can cause serious injury 1 sie tO eue AO ah ras 107343 GROMMET rbr neck 2 2 2 RR RR ee 1 D A E 197 614 a AIR BOX ot A n E C Rare beni BG 1 Mmm 197 613 AIR CLEANER intake consisting of 1 A ae 197675 DUST EJECTOR air cleaner 1 ee SES 197 677 COVER ASSY air cleaner
29. of the fumes Do not breathe the fumes If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator Read the Material Safety Data Sheets MSDSs and the manufacturer s instructions for metals consumables coatings cleaners and degreasers e Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watchperson nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breathing air is safe e Do not weld in locations near degreasing cleaning or spraying operations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases e Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and if necessary while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded BUILDUP OF GAS can injure or kill e Shut off shielding gas supply when not in use e Always ventilate confined spaces or use approved air 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 we
30. pas de trous e S isoler de la pi ce et de la terre au moyen de tapis ou d autres moyens iso lants suffisamment grands pour emp cher le contact physique ventuel avec la pi ce ou la terre e Ne pas se servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou l ou on risque de tomber e Se servir d une source lectrique courant lectrique UNIQUEMENT si le proc d de soudage le demande e Sil utilisation d une source lectrique courant lectrique s av re n ces saire se servir de la fonction de t l commande si l appareil en est quip Des pr cautions de s curit suppl mentaires sont requises dans des envi ronnements risque comme les endroits humides ou lorsque l on porte des v tements mouill s sur des structures m talliques au sol grillages et chafaudages dans des positions assises genoux et allong es ou quand il y a un risque important de contact accidentel avec la pi ce ou le sol Dans ces cas utiliser les appareils suivants dans l ordre de pr f rence 1 un poste souder DC semi automatique de type CV MIG MAG 2 un poste souder manuel lectrode enrob e DC 3 un poste souder ma nuel AC avec tension vide r duite Dans la plupart des cas un poste courant continu de type CV est recommand Et ne pas travailler seul e Couper l alimentation ou arr ter le moteur avant de proc der l installation la r paration ou l
31. 0 50 060 Fr 1 51 0 33 0 40 0 76 0 17 0 20 Fr 0 00 0 00 0 00 L L L L L L L L L O 50 100 150 200 250 300 350 400 450 500 IC WELD AMPERES AT 100 DUTY CYCLE SB 137 487 A 4 4 Duty Cycle And Overheating Ru j Es Duty Cycle is percentage of 10 min 10096 Duty Cycle At 250 Amperes utes that unit can weld at rated load IN a without overheating U A Exceeding duty cycle can damage unit and void warranty Continuous Welding 1000 800 T 600 Lj 500 Li 400 E eee lt 300 ty 250 CC Eaa 200 s 150 100 10 15 20 25 50 40 50 60 80 100 7 DUTY CYCLE rduty1 5 95 SB 070 999 B OM 480 Page 11 4 5 AC Generator Power The ac power curve shows the gen erator power in amperes available at the 120 and 240 volt receptacles 150 300 125 2501 100 200 o sl O 75 1501 gt O lt 50 1004 25 50 1 o 0 0 5 10 15 20 25 30 AC AMPERES IN 240V MODE 0 10 20 30 40 50 60 AC AMPERES IN 120V MODE rsb3 1 2 92 206 031 4 6 Volt Ampere Curves The volt ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator Curves of all other settings fall between the 100 RANGES curves shown 80 60 VOLTS 40 20 0 100 200 300 400 500 600 700 AMPERES 206 033 OM 480 P
32. 1 E tena ares E ET 179637 LABEL warning auxiliary power 1 uud PAG PUP Nik 113 730 LABEL warning stop engine 1 Vm LEE 16173410 COVER fuse box 1 na 9 lt tuii Aa 026947 STAND OFF insulator 1 co OF entra an 134 908 F SE BOX magaan Ng wee ins ne Miam mener IRR 1 iaa DO ur vest ac be es 6149541 HOLDER fuse crtg 60A 250V 1 SEE E 44089585 FUSE og 35A 250V 3 100 SR1 2 4 035704 RECTIFIER integ 40A 800V 3 OM 480 Page 47 Item Dia Part No Mkgs No Description Quantity Figure 12 1 Main Assembly TO A LTO 173982 PANEL mtg components eene 1 102 RC9 168071 CONNECTOR amp SOCKETS 1 TOS erret 6173423 RECEPTACLE 3P 50A 125 250V 1 unde EA iS 123 794 EDGE TRIM order by ft 1f 104 ito tii 173408 BRACKET mtg receptacle sese 1 105 D8 192 307 KIT diode w washers 1 106 D1 C1 D9 C9 189701 DIODE CAPACITOR BOARD 2 107 C8 170674 CAPACITOR BOARD
33. 20 4 20 3 30 2 85 1 50 1 0 60 1 0 60 150 3 30 3 30 2 85 1 50 1 0 60 2 0 70 3 0 95 3 0 95 200 3 30 2 85 1 50 1 0 60 2 0 70 3 0 95 4 0 120 4 0 120 2 ea 2 0 2 ea 2 0 250 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2x70 2x70 2 ea 2 0 2 ea 3 0 2 ea 3 0 300 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2x70 2x95 2x95 2 ea 2 0 2 ea 3 0 2 ea 3 0 2 ea 4 0 350 1 0 60 2 0 70 3 0 95 4 0 120 ax 2x25 2x05 2x120 2 ea 2 0 2 ea 3 0 2 ea 4 0 2 ea 4 0 400 1 0 60 2 0 70 3 0 95 4 0 120 oro 2x25 2x120 2x120 2 ea 2 0 2 ea 3 0 2 ea 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 cable overheating occurs normally you can smell it 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 E For distances longer than those shown in this guide call a factory applications representative at 920 735 4505 OM 480 Page 17 SECTION 6 OPERATING THE WELDING GENERATOR 6 1 Controls See Section 6 2 95 160 330 ga 200
34. 23300 6000 Silo Hoists Bunk Feeders 7 1 2 HP 35000 8000 10 HP 46700 10700 3 1 2 cu ft Mixer 1 2 HP 3300 1000 High Pressure 1 8 Gal Min 500 PSI 3150 950 Washer 2 gal min 550 PSI 4500 1400 2 gal min 700 PSI 6100 1600 Refrigerator or Freezer 3100 800 Shallow Well Pump 1 3 HP 2150 750 1 2 HP 3100 1000 Sump Pump 1 3 HP 2100 800 1 2 HP 3200 1050 OM 480 Page 38 11 7 Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1 4 in 350 350 3 8 in 400 400 1 2 in 600 600 Circular Saw 6 1 2 in 500 500 7 1 4 in 900 900 8 1 4 in 1400 1400 Table Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in 2500 1100 Bench Grinder 6 in 1720 720 8 in 3900 1400 10in 5200 1600 Air Compressor 1 2 HP 3000 1000 1 HP 6000 1500 1 1 2 HP 8200 2200 2 HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1 3 HP 2100 700 Elec Hedge Trimmer 18 in 400 400 Flood Lights HID 125 100 Metal Halide 313 250 Mercury 1000 Sodium 1400 Vapor 1250 1000 Submersible Pump 400 gph 600 200 Centrifugal Pump 900 gph 900 500 Floor Polisher 3 4 HP 16 in 4500 1400 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 480 Page 39 11 8 Power
35. 480 Page 8 Afin de r duire les champs lectromagn tiques en milieu de travail respec ter les consignes suivantes 1 Garder les c bles ensemble en les torsadant ou en les fixant avec du ruban adh sif 2 Mettre tous les c bles du c t oppos l op rateur 3 Ne pas s enrouler les c bles autour du corps 4 Garder le poste de soudage et les c bles le plus loin possible de soi 5 Placer la pince de masse le plus pr s possible de la zone de soudage Consignes relatives aux stimulateurs cardiaques Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur m decin Si ce dernier les d clare aptes il leur est recom mand de respecter les consignes ci dessus SECTION 3 DEFINITIONS 3 1 Symbols And Definitions Fast Run Weld KI Stop Engine ee Slow Idle Start Engine i lt gt eres Battery Engine Circuit Breaker Engine Oil Check Injectors Check Valve Fuel Protective Earth Pump Clearance ue Ground NN Positive Negative E ee i Welding Arc A Amperes Volts Panel Local Remote A EE g Engine Temperature Output Ni no Time Hours Seconds Do Not Switch e SA While Welding Single Phase 3 Three Phase Ether Starting Aid E Engine Coolant naa Temperature OM 480 Page 9 SECTION 4 SPECIFICATIONS 4 1 Weld Power And Engine Specifications Maximum Open Circuit Rated Welding Ampera
36. 6 199 B 801 320 B 8 7 Servicing Optional Ether Starting Aid w E A Stop engine A Improper handling or expo sure to ether can harm your health Follow manufactur er s safety instructions on cylinder If engine does not start in cold weather check ether cylinder as follows Remove cylinder from valve 1 Ether Cylinder 2 Valve 3 Scale Weigh cylinder to see if it is empty Be sure atomizer is not plugged and valve fitting is clean Replace cylinder according to Section 5 5 ether2 7 96 153 382 A S 0692 OM 480 Page 29 8 8 Inspecting And Cleaning Optional Spark Arrestor A Stop engine and let cool 1 Spark Arrestor Tools Needed IZ 3 8in 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole 3 Exhaust Pipe Start engine and run at idle speed to blow out cleanout hole If nothing blows out of hole briefly cover end of exhaust pipe with fireproof material A Stop engine and let cool Reinstall cleanout plug 800 523 Ref 206 029 8 9 Troubleshooting PN M Wer A Welding Trouble Remedy No weld output Check position of Ampere Range switch Check position of optional Polarity switch Place A V control switch in Pan
37. E AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Miller s option 1 repair or 2 replacement or where authorized in writing by Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Miller authorized service facility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR 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 EQUIPME
38. G WEE 182 022 6 4 CAP TUS esa a aces basta aaa ata 1 EE 605 288 FITTING pipe galv plug sqhd 250NPT 1 AA RE AR 020 185 FITTING pipe brs elbow st 1 8NPT 1 Du Gg eso Eg 073 432 FITTING brs barbed M 3 16tbg x 1 8NPT 1 O aces Deleted eres a LU stb DAANG ANG 125687 HOSE nprn SAE 125 ID x 343 OD order by ft 1ft Bara 192757 FITTING hose brs splice 3 16 tbg x 3 16 tbg 1 lt iom duos 097 507 STRIP rbr adh back 1 125 x 1 000 x 20 500 2 MO scere 188235 UPRIGHT base center 1 zu aene ex 017 479 SEAL weather lift eye 1 7 a e eem 111 352 BATTERY stor 12V 380crk 80rsv 1 TO iron eres 108081 TERMINAL PROTECTOR battery post mtg 2 TA uses stor a 124941 CABLE bat pos relau reana ehh 1 E EIE EE 089914 BOLT L stl 312 18 x 10 000 1 TO a Rea 124 668 HOLD DOWN battery n 1 TE dex ead a 010460 STUD stl 312 18x 10 000 1 TB ra c os 032453 CABLE bat neg 1 Dre te GT NA rie 049 026 SCREW M10 1 5 x 25mm hexhd 1 NI oies 4124 7066 COVER TOD cc exo Er e da aan el
39. Kun Renee NG 12 4 6 Volt Ampere CUIVesS vase en uer ER a CE YE RU NEED B gite quae Haale nies 12 4 7 Optional AC Power Plant Curves 2 e as 18 SECTION 5 INSTAELATION a Ra epe 14 5 1 Installing Welding Generator 14 5 2 Connecting The Battery cani ma phase ANERE ERR E bg EUR aaa 14 5 3 Installing Muffler Pipe EE NEIEN RR bee ERR pede eee eee eee tb 15 5 4 Enginie Prestart Checks s 3 tee daa EEN NEE a pb Enel wh Mle Lene DARAGA 15 5 5 Installing Ether Cylinder Optional Ether Starting Aid 16 5 6 Connecting To Weld Output Terminals ess 16 5 7 Selecting Weld Cable Gizeen ahh 17 SECTION 6 OPERATING THE WELDING GENERATOR 222222202522220 2222220 nnn 18 6 1 Controls See Section 6 2 aas 18 6 2 Description Of Front Panel Controls See Section 6 1 19 GH Remote A V Control ect ri epe PERI de OLAS Aden ada aes 19 SECTION 7 OPERATING AUXILIARY EQUIPMENT K x x K x K K cece cece eee AK Hh 20 7 1 120 Volt Duplex And Optional GFCI Receptacles 20 7 2 240 Volt Duplex Receptacle Optional es s 21 7 3 Connecting Optional AC Power Plant sehn 22 7 4 120 240 Volt Twistlock Receptacle Optional 23 TABLE OF CONTENTS SECTION 8 MAINTENANCE AND TROUBLESHOOTING 24 8 1 Routine Maintenance 4 er A ADAN TAN ne PY Ga 24 8 2 M
40. LVE shut off fuel 1 Za 070010 BOLT J stl 250 20 x 2 750 4 125 EE 089 517 e STRAE T el tank 2 vue detinent rece ele Detox val b e a Des 2 O et AH 175465 FITTING pipe brs adapter extender 1 8 x 1 8 120 1 Ee NAAN epus 179919 x KIT label unm m ri nicis unius A pauci eme pt Et 168 071 CONNECTOR A SOCKETS 2 E rd BONI 165 669 CONNECTOR A SOCKETS 1 TEE PN 116045 CONNECTOR 8 SOCKETS 1 OPTIONAL When ordering a component originally displaying a precautionary label the label should also be ordered Recommended Spare Parts To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor Item Dia Part No Mkgs No Description Quantity Figure 12 2 Panel Front w Components Fig 12 1 Item 111 p Ec 114193 SWITCH range Fig 11 4 o oocccoccccccccccnnc eee 1 mit cn as UR arate 605 960 RHEOSTAT WW 300W 34 ohm 1 pang MS1 011072 SWITCH magnetic consisting of 1 E F 048317 FUSE mintr gl 14A 32V a c Ana NT NT UE 011 609 SWITCH tgl SPDT 15A 125V
41. MAX 200 Be 65 120 MIN 80 Ref 206 029 800 162 A 800 159 D OM 480 Page 18 6 2 Description Of Front Panel Controls See Section 6 1 This unit has a max OCV control circuit that resets the Amperage Voltage Con trol to maximum when the arc breaks When an arc is struck weld output control returns to the front panel or remote con trol setting The Amperage voltage Con trol adjusts amperage only when welding and does not adjust open circuit voltage 1 Ampere Range Switch Use switch to select weld amperage range For most welding applications use lowest amperage range possible to prevent arc out ages A Do not switch under load 2 Amperage Voltage Control Control adjusts amperage within range selected by Ampere Range switch Weld out put would be 148 A DC with controls set as shown 5096 of 95 to 200 A 3 DC Voltmeter Optional 4 DC Ammeter Optional 5 Remote A V Switch And Receptacle See Section 6 3 6 Magnetic Shutdown Switch Optional Use switch during start up to bypass optional engine shutdown system System stops en gine if oil pressure is too low or oil temperature is too high 7 Engine Control Switch To Start turn switch to Start while pressing Shutdown switch Release switches when engine starts If the engine does not start let engine come to a complete stop before attempt
42. NT 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 1 05 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 n n aw 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 o
43. Ne ae 106 440 BUS BAR rectifier 2 8 SR3 106 427 DIODE ASSEMBLY reverse polarity consisting of 1 naaa An Baan Metre ba 048 420 CAPACITOR rectifier RII 2 Palaka Se OU pa diet 106 641 27 CAPACITOR D ne soc eu ALAM su Even HD Ate 037 957 DIODE rect 275A 300V RP 3 x ep 106 425 occ INSULATOR ueber Ru ex IRE mel pP b ped eb EE Ree 2 TO EDI 188 387 BRUSHHOLDER BRACKET ASSEMBLY consisting of 3 EXEC 173 066 BRACKET mtg brushholder 1 VO EE 600 270 HOLDER bet uvas Wa de t drag dur Ie EDUC eat s Ee 1 sha 9 aa 152 044 0 CAP brushholden reu aaa an ati dat 1 NO ree oes 151 299 BRUSH Contacts dunes seed egre Aa kA dare RR Y NAGA 1 um AT A rhe Deleted iii a AA AA AA se ARA AaS 013 367 LABEL warning moving parts can cause serious injury 2 Vaf e baga dd oni ds 124 855 GUARD Starter usse tam e acre Ce E eR ATE TD 1 dC erbe 204 693 STATOR gen consisting of 1 ss d eios 204 742 STATOR gen consisting of 1 Le LoT 039 207 BAFEEE alt geli rice etes ep Rb er UR BER A 1 i TO s ook a ast ots 204 682 ROTOR gen consisting of 1 za Vus aai onus 024 617 RING retaining external ees 1 LUCUS tnu 053 390
44. Oil Drain Plug 3 Oil Fill Cap 4 Primary Fuel Filter Fuel Water Separator Petcock Secondary Fuel Filter Fuel Shutoff Valve Fuel Line O o N Oo 0 Sludge Drain Plug To change oil and filter See engine manual 9 To drain water from fuel system Open primary fuel filter petcock and drain water into metal container Close petcock when water free fuel flows To replace primary fuel filter Close shutoff valve and turn filter counterclockwise Remove filter Apply thin coat of fuel to gasket on new filter Install new filter and turn clockwise Open shutoff valve Bleed air from fuel system accord ing to engine manual Inspect fuel line and replace if cracked or worn To replace secondary fuel filter See engine manual To drain sludge from fuel tank Put metal container under drain and remove sludge drain plug Re install plug when done A After servicing start engine and check for fuel leaks A Stop engine tighten connec tions as necessary and wipe up spilled fuel Close doors Valve Open 7 8 Tools Needed IZ 7 16 11 16 in Ref 800 159 E Ref 206 029 OM 480 Page 27 8 5 Adjusting Engine Speed CH EX CI 1850 rpm 61 6 Hz 1250 rpm 41 5 Hz De Standard Models Tools Needed LT 3 8 7 16 in After tuning engine check engine no l
45. Page 46 Item Dia Part No Mkgs No Description Quantity Figure 12 1 Main Assembly a EE 128287 STUD adjusting throttle d DN ICE 127 648 CLEVIS throttle 1 md DT Daghan EEE 6127 994 BALL JOINT 250 28 1 E GA TA 175936 ROD throttle oca rura a A acra Dea 1 PEDO EE 6126388 NUT 250 28 LH 1 E EE 194 036 BRACKET arm throttle 1 PEE 010021 CLAMP stl cush 562dia x 343mtg hole 1 dee Se 072 082 BUSHING stl 265 ID x 499 OD x 593 lg 2 pM 118679 SCREW M 6 1 0 x 30 2 r BB aida 125663 BALL JOINT 250 28 LH ees 1 an bingi TS1 6124974 SOLENOID 12VDC 2 e enn 1 ubl vu baklad 175937 BRACKET support solenoid 1 DD uni dee nets 188246 BRACKET mtg engine RH 1 223159 s osos pep 601 945 SCREW cap stl hexhd 625 18 x 4 000 4 qp 071 731 WASHER flat stl 656 ID x 2 250 OD x 187thk 4 AN A tae amy 071890 RETAINER mount eng gen 4 van OS ritui 071 730 TUBING stl 875 OD x 12ga wall x 2 375
46. ST 800 396 A S 0625 OM 480 Page 40 11 10 Typical Connections To Supply Standby Power T Properly install and ground this equipment according to its Owner s Manual and national state and local codes Essential Loads A Have only qualified persons perform these connections according to all applicable codes and safety practic es A Properly install and ground this equipment according to its Owner s Manual and national state and local codes Fx Customer supplied equipment is re quired if generator will supply standby power during emergencies or power out ages 1 Utility Electrical Service 2 Transfer Switch Double Throw Switch transfers the electrical load from electric utility service to the generator Trans fer load back to electric utility when service is restored Install correct switch customer supplied Switch rating must be same as or greater than the branch overcurrent protection 3 Fused Disconnect Switch Install correct switch customer supplied if required by electrical code 4 Welding Generator Output Generator output voltage and wiring must be consistent with regular utility system volt age and wiring 1 2 3 4 Utility D Fused Welding H S isconnect Electrical Transfer Switch dn Switch a Generator Service If Required Output 5 Connect generator with temporary or perma nent wiring suitable fo
47. age 12 4 7 Optional AC Power Plant Curves AC VOLTS A 7 5 KVA KW Single Phase AC Power Plant No Weld Load 150 125 100 75 50 25 AC VOLTS 300 250 200 150 100 50 280 260 240 220 200 180 0 0 PF The ac power curves show the gen erator power in amperes available at the single phase 120 240 volt or three phase 240 volt terminals O 10 20 30 40 50 AC AMPERES IN 240V MODE el 20 40 60 80 100 AC AMPERES IN 120V MODE COMBINED LOADS 31 AMPERES PER LINE MAXIMUM 10 KVA KW Three Phase AC Power Plant No Weld Load 0 10 20 30 40 50 60 70 AC AMPERES rsb13 1 12 94 134 636 A 206 032 OM 480 Page 13 SECTION 5 INSTALLATION 5 1 Installing Welding Generator d A NR Mass Movement Airflow Clearance A Do Not Lift Unit From End Location Grounding Electrically bond generator frame to 3 za vehicle frame by metal to metal T contact A Bed liners shipping skids and some running gears insulate the welding generator from the vehicle frame Always connect a ground wire from the generator equipment grounding termi nal to bare metal on the vehicle frame as shown A Always securely fasten welding generator onto transport vehicle or trailer and comply with all DOT
48. aintenance Label ssl RTI AN tn 25 8 3 Servicing Ait Cleaner ere WADA NAG as 26 8 4 Servicing Fuel And Lubrication Systems ee 27 8 5 Adjusting Engine Speed 28 8 6 Overload Protection os be tod pea E ee MR Re th sees Late kA ig Ber Rs 29 8 7 Servicing Optional Ether Starting Aid se 29 8 8 Inspecting And Cleaning Optional Spark Arrestor sse 30 8 9 Troubleshooting 2 de o ame da ne E CRI eid eats RE RU Rea kr ex Pa p ER e Ede M 30 SECTION 9 ELECTRICAL DIAGRAM E 32 SECTION 10 RUN IN PROCEDURE x K x K K K e cece eee eee nnn nnne nenne 33 10 1 Wetstackilig sr Lea One ER eae wes a A He A eee as 33 10 2 Run In Procedure Using Load Bank 34 10 3 Run In Procedure Using Resistance Grid annen r arenen neee 35 SECTION 11 GENERATOR POWER GUIDELINES xx x x x x x K x K K ERE SER KKK AN n 36 SECTION 12 PARTS LIST vul A ANEN sc bebe A sents eke E era 44 OPTIONS AND ACCESSORIES WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING rom nd 8 03 A Warning Protect yourself and others from injury read and follow these precautions 1 1 Symbol Usage with this procedure The possible hazards are shown in Means Warning Watch Out There are possible hazards A the adjoining symbols Marks a special safety message EF Means Note not safety related 1 A A A 2 Arc Weld
49. and other applicable codes A Always ground generator frame to vehicle frame to prevent elec tric shock and static electricity hazards A If unit does not have GFCI recep tacles use GFCI protected ex tension cord 1 Equipment Grounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insulated copper wire install 11 02 Ref ST 800 652 Ref ST 800 477 A ST 158 936 A S 0854 5 2 Connecting The Battery Tools Needed N a 1 2in A Connect Negative Cable Last 156 011 A Ref 206 029 S 0756 OM 480 Page 14 5 3 Installing Muffler Pipe A Stop engine and let cool A Do not blow exhaust toward air cleaner or air intake ce ol Top View Tools Needed IX 1 2in exh_pipe2 12 96 154 089 A 154 611 Ref 206 029 5 4 Engine Prestart Checks Check all fluids daily Engine must be cold and on a level surface Follow run in procedure in engine manual If unburned fuel and oil col lect in exhaust pipe during run in see Section 10 Fuel A Do not use gasoline Gasoline will damage engine Add fresh diesel fuel before starting engine the first time see mainte nance label for specifications Fill fuel tank up to 1 2 in 13 mm from top to allow room for expansion Open fuel shut off valve Di
50. ational Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 site Web www nfpa org et www sparky org OSHA Occupational Safety and Health Standards for General Industry Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de U S Government Printing Office Superintendent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux r gionaux T l phone pour la R gion 5 Chicago 312 353 2220 site Web www osha gov 2 7 Information sur les champs lectromagn tiques Donn es sur le soudage lectrique et les effets des champs magn tiques basse fr quence sur l organisme En parcourant les cables de soudage le courant cr e des champs lectro magn tiques Les effets potentiels de tels champs restent pr occupants Cependant apr s avoir examin plus de 500 tudes qui ont t faites pen dant une p riode de recherche de 17 ans un comit de sp cialistes du National Research Council a conclu L accumulation de preuves n a pas d montr que l exposition aux champs magn tiques et aux champs lectri ques haute fr quence constitue un risque pour la sant humaine Toutefois les tudes et l examen des preuves se poursuivent En attendant les conclusions finales de la recherche il serait souhaitable de r duire l ex position aux champs lectromagn tiques pendant le soudage ou le coupage OM
51. c ble de retour Ne pas toucher l lectrode quand on est en contact avec la piece la terre ou une lectrode provenant d une autre machine N utiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment ce manuel Porter un harnais de s curit quand on travaille en hauteur Maintenir solidement en place tous les panneaux et capots Fixer le c ble de retour de fa on obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s possible de la soudure Isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique Une tension DC importante subsiste l int rieur des onduleurs apr s avoir coup l alimentation Couper l alimentation du poste et d charger les condensateurs d entr e comme indiqu dans la Section Maintenance avant de toucher des compo sants LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage genere des fum es et des gaz Leur inhalation peut tre dangereux pour votre sant Eloigner votre t te des fum es Ne pas respirer les fum es l interieur ventiler la zone et ou utiliser un chappement au niveau de l arc pour l vacuation des fum es et des gaz de soudage Sila ventilation est insuffisante utiliser un respirateur alimentation d air homologu Lire les sp cifications de s curit des mat riaux MSDSs et les
52. eceptacles Gen erator power is not affected by weld output EXAMPLE If 15 A is drawn from RC1 only 10 A is available at RC2 120 V x 15 A 120 Vx 10A 3 0 kVA KW Ref 206 029 OM 480 Page 20 7 2 240 Volt Duplex Receptacle Optional A If unit does not have GFCI re ceptacles use GFCI pro tected extension cord 1 240 V 15 A AC Receptacle RC1 Receptacle supplies 60 Hz single phase power at weld power speed Maximum output is 3 KVA kW 2 Circuit Breakers CB1 And CB2 CB1 and CB2 protect the 240V AC receptacles from overload If CB1 or CB2 opens the 240 V receptacle and half of the 120 V receptacle does not work 120 volts may still be present at the 240 V receptacle EF If a circuit breaker continues to open contact Factory Autho rized Service Agent 43A TOTAL 26A TOTAL Combined output of all receptacles is 3 kVA kW Generator power is not affected by weld output EXAMPLE If 10 Ais drawn from the 240 V receptacle only 5 A is avail able at the 120 V receptacle 240 V x 10 A 120V x54 3 0 KVA KW Ref 206 029 174 408 OM 480 Page 21 7 3 Connecting Optional AC Power Plant PANNE
53. el position or place switch in Remote position and connect Remote Am perage control to Remote A V receptacle RC3 see Section 6 3 Check and secure connections to Remote A V receptacle RC3 Disconnect equipment from generator power receptacles during start up Have Factory Authorized Service Agent check brushes and slip rings and field excitation circuit Erratic weld output Use dry properly stored electrode Be sure connection to work piece is clean and tight Remove excessive coils from weld cables Check and tighten connections both inside and outside unit Have Factory Authorized Service Agent check brushes and slip rings and field excitation circuit Low or high weld output Check control settings Check engine speed and adjust if necessary see Section 8 5 Low open circuit voltage Check engine speed and adjust if necessary see Section 8 5 Have Factory Authorized Service Agent check integrated rectifier SR2 Amperage Voltage control R1 and resistor R2 Maximum weld output only in each am pere range Have Factory Authorized Service Agent check Amperage Voltage control R1 capacitor C8 diode D8 integrated rectifier SR4 and control relay CR2 OM 480 Page 30 B Generator Power Trouble Remedy No output at receptacles generator power Reset circuit breaker CB1 and or CB2 see Section 7 1 or 7 2 Disconnect equ
54. elatifs au soudage l arc A Les symboles pr sent s ci apres 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 apres ne font que r sumer l information contenue dans les normes de s cu rit num r es la section 2 6 Veuillez lire et respecter toutes ces normes de s curit A L installation l utilisation l entretien et les r parations ne doivent tre confi s qu des personnes qualifi es Au cours de l utilisation tenir toute personne l cart et plus particulierement les enfants ra x UN CHOC LECTRIQUE peut tuer Un simple contact avec des pi ces lectriques peut provoquer une lectrocution ou des blessures graves L lectrode et le circuit de soudage sont sous tension d s que l appareil est sur ON Le circuit d entr e et les circuits internes de l appareil sont galement sous tension ce moment l En soudage semi automatique ou automatique le fil le d vidoir le logement des galets d entrainement et les pi ces m talliques en contact avec le fil de soudage sont sous tension Des mat riels mal install s ou mal mis la terre pr sentent un danger Ne jamais toucher les pi ces lectriques sous tension Porter des gants et des v tements de protection secs ne comportant
55. er lieu Le rebrancher en dernier lieu LE CARBURANT MOTEUR peut pro voquer un incendie ou une explosion e Arr ter le moteur avant de v rifier le niveau de carbu rant ou de faire le plein e Ne pas faire le plein en fumant ou proche d une sour ce d tincelles ou d une flamme nue e Ne pas faire le plein de carburant ras bord pr voir de l espace pour son expansion e Faire attention de ne pas renverser de carburant Nettoyer tout carbu rant renvers avant de faire d marrer le moteur e Jeter les chiffons dans un r cipient ignifuge a DES ORGANES MOBILES peuvent provoquer des blessures Ng e Ne pas approcher les mains des ventilateurs cour roies et autres pi ces en mouvement e Maintenir ferm s et fixement en place les portes panneaux recouvrements et dispositifs de protection Arr ter le moteur avant d installer ou brancher l appareil e Demander seulement un personnel qualifi d enlever les dispositifs de S curit ou les recouvrements pour effectuer s il y a lieu des travaux d en tretien et de d pannage 2 4 Dangers li s l air comprim RESPIRER L AIR COMPRIM peut pro voquer des blessures graves ou causer la mort e Ne pas utiliser l air comprim pour respirer e Utiliser l air comprim seulement pour le coupa ge gougeage et les outils pneumatiques L AIR COMPRIM peut provoquer des blessures e Porter des lunettes de s curit approuv es e Ne pas dirige
56. ers Plasma Cutting Torches except APT amp SAF Models Field Options NOTE Field options are covered under True Blue for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater 4 6 Months Batteries 5 90 Days Parts MIG Guns TIG Torches Induction Heating Coils and Blankets APT amp SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Millers True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Bobcat Trailblazer and Legend models 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipmentthat has been modified by any party other than Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE US
57. esel Do not run out of fuel or air enters fuel system and causes starting prob lems See engine manual to bleed air from fuel system Oil After fueling check oil with unit on lev el surface If oil is not up to full mark on dipstick add oil see maintenance la bel Your unit may have the optional low oil pressure shutdown switch However some condi tions may cause engine damage before the engine shuts down Check oil level often and do not use the oil pressure shutdown system to monitor oil level Valve Open To improve cold weather starting Keep battery in good condition Store battery in warm area Full 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 Ref 800 159 D OM 480 Page 15 5 5 Installing Ether Cylinder Optional Ether Starting Aid 7 A Stop engine g y y El A Improper handling or expo L lt sure to ether can harm your health Follow manufactur Pa er s safety instructions on cylinder A Do not use Ether Starting Aid while engine is running Open side door s 1 Ether Cylinder 2 Nozzle Remove cover and clean cylinder nozzle 3 Clamp 4 Fitting 5 Cap 6 Valve Remove cap and clean fitting Install cylinder on fitting Tighten clamp x After installing cylinder wait at
58. f 95 to 200 Max 148 DC Min 70A DC Set Range Set Percentage Adjust Optional Remote Control S 0774 OM 480 Page 19 SECTION 7 OPERATING AUXILIARY EQUIPMENT 7 1 120 Volt Duplex And Optional GFCI Receptacles ay NE Wy Mi i 1 2 RM 120V 15A 17V 60Hz 3 3 3 3 120V Np A If unit does not have GFCI re ceptacles use GFCI pro tected extension cord 1 120 V 15A AC Receptacle RC1 2 120 V 15A AC Receptacle RC2 3 120 V 20 A AC GFCI Receptacles GFCI1 And GFCI2 Optional Receptacles supply 60 Hz single phase power at weld power speed 4 Circuit Breakers CB1 And CB2 CB1 protects RC1 GFCI1 and CB2 protects RC2 GFCI2 from over load If CB1 or CB2 opens the receptacle does not work EF If a circuit breaker continues to open contact Factory Autho rized Service Agent If a ground fault is detected GFCI Reset button pops out and receptacle does not work Check for faulty tools plugged in receptacle Press button to reset x At least once a month run en gine at weld power speed and press test button to verify GFCI is working properly Maximum output from each duplex receptacle is 1 8 kVA kW and 3 kVA kW from all r
59. fement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger e Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud e Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables e D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneusement avec des protections homologu s e Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures Surveiller tout d clenchement d incendie et tenir un extincteur proximit Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t e Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r ser voirs tambours ou conduites moins qu ils n aient t pr par s correctement conform ment AWS F4 1 voir les normes de s curit e Brancher le c ble sur la pi ce le plus pr s possible de la zone de soudage pour viter le transport du courant sur une longue distance par des che mins inconnus ventuels en provoquant des risques d lectrocution et d incendie Ne pas utiliser le poste de soudage pour d geler des conduites gel es En cas de non utilisation enlever la baguette d lectrode du porte lectro de o
60. ge Voltage DC Generator Power Engine Fuel Capacity Output Range Nominal Rating 250A Single Phase AE edet 40 Volts DC 40 400 95 90 3 KVA KW 26A Three Cylin dat 11 3 gal 42 8 L O d 100 Duty Cycle 120 V AC 60 Hz 29 HP Diesel Engine 4 2 Dimensions Weights And Operating Angles Dimensions Height 40 1 2in 1029 mm EN Width 24 5 8 in 625 mm i N Depth 56 in 1422 mm Ng S sean A Do not exceed tilt angles or engine B 24 5 8 in 625 mm M SI could be damaged or unit could tip ek AM 1 A Do not move or operate unit where it C 11 16in 17 mm L could tip D 2 7 8 in 73 mm 7 a 1 K E 4 1 2 in 114 mm B i H J F 22 9 16 in 573 mm B P G 27i M F in 686 mm Si 5 H 30 3 8 in 772 mm It a le fepe Pal J 41 1 4 in 1048 mm A ES a K 51 1 8in 1299 mm BT RS angles 4 96 ef 110 850 54 in 1372 mm M 21 32 in 16 7 mm Dia 4 Holes N 1 2 in 12 7 mm Dia 10 Holes Weight 1475 Ib 670 kg OM 480 Page 10 4 3 Fuel Consumption The curve shows typical fuel use ag oe o under weld or power loads Z 3 S D 5 5 E a un 2 D 7 57 1 67 2 00 6 81 1 50 180 F 6 06 133 160 F 5 30 1 17 140 F 4 54 1 00 1 20 fF 3 79 0 83 100 F 3 03 0 67 0 80 f 2 27
61. h water ENGINE HEAT can cause fire e Do not locate unit on over or near combustible surfaces or flammables e Keep exhaust and exhaust pipes way from flam mables EXHAUST SPARKS can cause fire e Donotlet engine exhaust sparks cause fire Use approved engine exhaust spark arrestor in re quired areas see applicable codes HOT METAL from air arc cutting and gouging can cause fire or explosion e Do not cut or gouge near flammables e Watch for fire keep extinguisher nearby HOT PARTS can cause burns and injury e Do not touch hot compressor or air system parts e Let system cool down before touching or servicing READ INSTRUCTIONS e Read Owner s Manual before using or servicing unit e Stop engine and release air pressure before servicing 1 5 Additional Symbols For Installation Operation And Maintenance FALLING UNIT can cause injury Use lifting eye to lift unit only NOT running gear gas cylinders trailer or any other accessories Use equipment of adequate capacity to lift and support unit If using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit E OVERHEATING can damage motors e Turn off or unplug equipment before starting or stop ping engine e Do not let low voltage and frequency caused by low engine speed damage electric motors e Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable FLYING
62. ill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a sep arate cable Do not touch electrode if you are in contact with the work ground or anoth er electrode from a different machine AEN This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazards e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual e Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or work table as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists in inverters after stop ping engine e Stop engine on inverter and discharge input capacitors according to instructions in Maintenance Section before touching any parts FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out
63. ing Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Stan dards listed in Section 1 7 Read and follow all Safety Standards Only qualified persons should install operate maintain and re pair this unit During operation keep everybody especially children away FA e ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical 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 re
64. instruc tions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d graisseurs Travailler dans un espace ferm seulement s il est bien ventil ou en por tant un respirateur alimentation d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent d placer l air et abaisser le niveau d 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 former des gaz hautement toxiques et irritants Ne pas souder des m taux munis d un rev tement tels que l acier galvani S plaqu en plomb ou au cadmium moins que le rev tement n ait t enlev dans la zone de soudure que l endroit soit bien ventil et si n ces saire en portant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage OM 480 Page 5 LES ACCUMULATIONS DE GAZ ris quent de provoquer des blessures ou meme la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confin s ou se servir d un respi rateur d adduction d air homologu
65. ipment from generator power receptacles during start up Have Factory Authorized Service Agent check brushes and slip rings and field excitation circuit Low or high output at generator power receptacles Check engine speed and adjust if necessary see Section 8 5 Low output at optional ac power plant junction box or receptacle RC9 Check engine speed and adjust if necessary see Section 8 5 If optional remote device is being used set A V Control switch in Remote position and remote device at maximum see Section 6 3 If optional remote device not being used set A V Control switch in Panel position see Section 6 3 Check and replace fuses F1 F2 and or F3 if necessary see Section 7 3 Have Factory Authorized Service Agent check brushes and slip rings No output from optional ac power plant weld output and standard generator power receptacle output okay Check connections to ac power plant see Section 7 3 Check fuses F1 F2 and F3 and replace if necessary see Section 7 3 C Engine Trouble Remedy Engine does not start Check fuel level Open fuel valve see Section 5 4 Check optional Magnetic Shutdown switch fuse F and replace if open see Section 8 6 Check battery and replace if necessary Check connections to Engine Control switch Check oil level Optional automatic shutdown system stops engine if oil pressure gets too low or oil
66. ite www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 phone 703 412 0900 website www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Bou 1 8 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting OM 480 Page 4 ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as microprocessors computers and computer driven equipment such as robots e Be sure all equipment in the welding area is elec
67. ld e Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes from arc rays and sparks when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards Wear approved safety glasses with side shields under your helmet Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc e Wear protective clothing made from durable flame resistant material wool and leather and foot protection OM 480 Page 1 AWE WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding e Protect yourself and others from flying sparks and hot metal e Do not weld where flying sparks can strike flammable material e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers e Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas e Watch for fire and keep a fire extinguisher nearby e Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden
68. least 10 minutes before using to let ether particles settle and prevent atomizer plugging Put cap on fitting when cylinder is removed ether1 12 96 153 382 A Ref 206 029 E e EA Open left side door EX El E 1 Bracket Route cables through bracket 2 Positive Weld Output Terminal 3 Negative Weld Output Ter minal For Stick welding Direct Current Electrode Positive DCEP con nect work cable to terminal and electrode holder cable to terminal For Direct Current Electrode Nega tive DCEN reverse cable connections If equipped with optional polarity switch connect electrode holder cable to Electrode terminal and work cable to Work terminal For FCAW welding connect work cable to terminal and wire feeder cable to 4 terminal Close door Tools Needed LT 3 4in Ref 800 162 A OM 480 Page 16 5 7 Selecting Weld Cable Sizes Weld Cable Size and Total Cable Copper Length in Weld Circuit Not Exceeding 150 ft 200ft 250ft 300ft 350ft 400ft 100 ft 30m orLess 45m 60m 70m 90m 105 m 120 m Weld Output Terminals A Turn off power before 2 10 6095 60 10096 connectingto weld out Welding Duty Duty 10 100 Duty Cycle put terminals Amperes Cycle Cycle A Do not use worn dam aged undersized or poorly spliced cables 100 4 20 4
69. ment pour soulever l appareil lui m me sans chariot de bouteilles de gaz remorque ou autres accessoires Utiliser un quipement de levage de capacit suffisante pour lever l appareil En utilisant des fourches de levage pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil OM 480 Page 7 LE SURCHAUFFEMENT peut endom mager le moteur lectrique e Arr ter ou d connecter l quipement avant de d marrer ou d arr ter le moteur e Ne pas laisser tourner le moteur trop lentement sous risque d endommager le moteur lectrique cause d une tension et d une fr quence trop faibles e Ne pas brancher de moteur de 50 ou de 60 Hz la prise de 100 Hz s il ya lieu ca LES TINCELLES VOLANTES ris quent de provoquer des blessures N y e Porter un cran facial pour prot ger le visage et les yeux e Affuterr l lectrode au tungst ne uniquement la meuleuse dot e de pro tecteurs Cette manoeuvre est ex cuter dans un endroit s r lorsque l on porte l quipement homologu de protection du visage des mains et du corps Les tincelles risquent de causer un incendie loigner toute substance Jan e Ey 3 3 D o L EMPLOI EXCESSIF peut SURCHAUFFER L EQUIPEMENT Laisser l quipement refroidir respecter le facteur de marche nominal R duire le courant ou le facteur de marche avant de poursuivre le soudage
70. mote output control if present on unit Additional safety precautions are required when any of the following electri cally hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoidable or accidental contact with the workpiece or ground For these conditions use the following equipment in order present ed 1 a semiautomatic DC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit voltage In most situations use of a DC constant voltage wire welder is recommended And do not work alone Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards Properly install and ground this equipment according to its Owner s Manual and national state and local codes Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet When making input connections attach proper grounding conductor first double check connections Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can k
71. n ouvrant la soupape de la bouteille Maintenir le chapeau de protection sur la soupape sauf en cas d utilisation ou de branchement de la bouteille e Lire et suivre les instructions concernant les bouteilles de gaz comprim les quipements associ s et les publication P 1 CGA num r es dans les normes de s curit 2 3 Dangers existant en relation avec le moteur LES ACCUMULATIONS DE GAZ ris quent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confin s ou se servir d un respi rateur d adduction d air homologu OM 480 Page 6 L ACIDE DE LA BATTERIE peut pro voquer des br lures dans les YEUX et sur la PEAU e Ne pas renverser la batterie e Remplacer une batterie endommag e e Rincer imm diatement les yeux et la peau l eau L EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE e Toujours porter une protection faciale des gants en caoutchouc et v tements de protection lors d une in tervention sur la batterie Arr ter le moteur avant de d brancher ou de brancher les cables de batterie e Eviter de provoquer des tincelles avec les outils en travaillant sur la batterie e Ne pas utiliser le poste de soudage pour charger les batteries ou des v hi cules de d marrage rapide e Observer la polarit correcte et sur les batteries D brancher le cable n gatif en premi
72. ness and easy With Miller you can count on years NII 00012000 of reliable service with proper maintenance And N for some reason the unit needs repair QUALITY SYSTEM there s a Troubleshooting section that will help you figure out what the problem is The Miller is the first welding parts list will then help you to decide the equipment manufacturer in gt mets Ata boiedlatoled fo exact part you may need to fix the problem the ISO 9001 2000 Quality Warranty and service information for your System Standard particular model are also provided Miller Electric manufactures a full line of welders and welding related equipment For information on other quality Miller products contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets To locate your nearest distributor or service agency call 1 800 4 A Miller or visit us at www MillerWelds com on the web Mill mer Mil_Thank 7 03 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 fb Symbol Usa nsaan nine enr E Le CPC e aaa TRE E pA 1 1 27 Are Welding Hazards 4 ertet esM PROF m iR Ever e pr e ECPISUG PSU 1 1 37 Engine Hazard ip e RR PST nn miris were tn UnpY pun Pe 2 1 4 Compressed Air Flazards set teer er ame ER REY PAG EC EINEN Gu Y UE Y 3 1 5 Additional Symbols For Installation Operation And Maintenance 3 1 6 California P
73. nual Air Filter Element MILLER 197676 Donaldson P821575 WIX 46438 Air Filter Element Safety Opt MILLER 197679 Donaldson P822858 Ly Blower Belt Gates 7435 Deutz 117 9565 Avoid recirculation of air from hot air exit to blower intake Battery BCI Group 55 Cranking Performance at 0 F 18 C 500 Amps Engine RPM No Load Valve Clearance Cold Weld 1850 8 Intake 0 012 in 0 3 mm Exhaust 0 020 in 0 5 mm Have only trained technician maintain injection pump and injectors AIR WATER or GASOLINE will harm the injection system Injectors should be checked annually Spark Arrestor Inspection and Service 250 operating hours See Owners Manual 173 847 E OM 480 Page 25 8 3 Servicing Air Cleaner A Stop engine A Do not run engine without air cleaner or with dirty element En gine damage caused by using a damaged element is not covered by the warranty The air cleaner primary element can be cleaned but the dirt holding ca pacity of the filter is reduced with each cleaning The chance of dirt reaching the clean side of the filter while cleaning and the possibility of filter damage makes cleaning a risk Consider the risk of unwarrantable equipmentdamage when determin ing whether to clean or replace the primary element If you decide to clean the primary element we strongly recommend installing an optional safety element to provide additi
74. oad speed with a tachometer see table for no load speeds If necessary adjust speed as follows Start engine and run until warm Turn Amperage Voltage Control to 100 Standard Models 1 Engine Speed Adjustment Screw 2 Locking Nut Loosen nut Turn screw until engine runs at 1850 rpm Tighten nut Models With Automatic Idle Optional 3 Throttle Rod 4 Locknut Loosen locknuts Place engine control switch in Run Idle position Turn throttle rod until engine runs at idle speed Tighten locknuts 5 Engine Speed Adjustment Screw 6 Locknut Place engine control switch in Run position Loosen locknut Turn screw until engine runs at weld power speed Tighten locknut A Stop engine Ref 801 179 Ref 800 159 D Ref 800 161 OM 480 Page 28 8 6 Overload Protection CH EX w GI Ni A Stop engine EF When a fuse opens it usually indicates a more serious prob lem exists Contact a Factory Authorized Service Agent 1 Magnetic Shutdown Switch MS1 Optional 2 FuseF See Parts List Fuse F protects magnetic shut down switch MS1 If fuse F opens the engine stops 3 Throttle Solenoid Fuse F4 Optional Fuse F4 protects the throttle sole noid from overload on models with automatic idle option If fuse F4 opens the engine does not run at idle speed Check fuses and replace if open Tools Needed maa COLA Ref 15
75. onal engine protec tion Never clean a safety element Replace the safety element after servicing the primary element three times Air Cleaner Service Indicator Optional Window 4 Reset Button Service air cleaner element if red band appears in window A green band means air cleaner is okay Press button to reset indicator G N 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 5 Housing 6 Safety Element Optional 7 Primary Element 8 Cover 9 Dust Ejector To clean air filter Wipe off cover and housing Remove cover and dump out dust Remove element s Wipe dust from inside cover and housing with damp cloth Reinstall safety element if present Reinstall cover Keep nozzle 2in 51 mm from element A Do not clean housing with air hose Clean primary element with compressed air only Air pressure must not exceed 100 psi Blow Inspect 690 kPa Use 1 8 in 3 mm nozzle and keep nozzle at least 2 in 51 mm from inside of element Replace primary ele ment if it has holes or damaged gaskets Reinstall primary element and cover dust ejector down aircleaner4 9 02 802 495 Ref S 0698 B OM 480 Page 26 8 4 Servicing Fuel And Lubrication Systems gt i d Ng ar LEY A Stop engine and let cool e EY 1 Oil Filter 2
76. polarity and on batteries Disconnect negative cable first and connect it last FUEL can cause fire or explosion e Stopengine and let it cool off before checking or add ing fuel e Do not add fuel while smoking or if unit is near any Sparks or open flames Do not overfill tank allow room for fuel to expand Do not spill fuel If fuel is spilled clean up before starting engine Dispose of rags in a fireproof container Always keep nozzle in contact with tank when fueling OM 480 Page 2 HOT PARTS can cause severe burns Allow cooling period before maintaining Wear protective gloves and clothing when working on a hot engine bare handed NOISE can damage hearing Noise from some processes or equipment can damage hearing e e e Do not touch hot engine parts or just welded parts e Wear approved ear protection if noise level is high MAGNETIC FIELDS can affect pacemakers Pacemaker wearers keep away Wearers should consult their doctor before going near arc welding gouging or spot welding opera tions CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechanical shocks slag open flames sparks and arcs Install cylinders in an upright position by secu
77. r Service Agency visit www millerwelds com or call 1 800 4 A Miller File a claim for loss or damage during shipment Contact the Delivering Carrier to For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA 2005 Miller Electric Mfg Co 1 05 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 C Miller
78. r le jet d air vers d autres ou soi m me L AIR COMPRIME EMMAGASINE ET DES TUYAUX SOUS PRESSION peuvent provo quer des blessures e Rel cher la pression d air de l outillage ou du sys t me avant d effectuer la maintenance avant de changer ou de rajouter des l ments ou avant d ouvrir la purge ou le bouchon de remplissage d huile Pour emp cher tout d marrage accidentel pendant les travaux d entretien d brancher le c ble n gatif de batterie de la borne Ne pas approcher les mains cheveux v tements l ches et outils des orga nes mobiles Remettre en place les panneaux ou les dipositifs de protection et fermer les portes la fin des travaux d entretien et avant de faire d marrer le moteur Avant d intervenir d poser les bougies ou injecteurs pour viter la mise en route accidentelle du moteur Bloquer le volant moteur pour viter sa rotation lors d une intervention sur le g n rateur LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT CHAUD peuvent provoquer des br lures e est pr f rable de v rifier le liquide de refroidissement une fois le moteur refroidi pour viter de se br ler Toujours v rifier le niveau de liquide de refroidissement dans le vase d ex pansion si pr sent et non dans le radiateur sauf si pr cis autrement dans la section maintenance du manuel du moteur Si le moteur est chaud et que le liquide doit tre v rifi op rer comme sui vant Mett
79. r the installation Turn off or unplug all equipment connected to generator before starting or stopping engine When starting or stopping the engine has low speed which causes low voltage and frequency 5 Essential Loads Generator output may not meet the electrical requirements of the premises If generator does not produce enough output to meet all requirements connect only essential loads pumps freezers heaters etc See Sec tion 11 4 Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual OM 480 Page 41 11 11 Selecting Extension Cord Use Shortest Cord Possible P Cord Lengths for 120 Volt Loads A If unit does not have GFCI receptacles use GFCI protected extension cord Maximum Allowable Cord Length in ft m for Conductor Size AWG current Load Watts 4 6 8 10 12 14 Amperes 5 600 350 106 225 68 137 42 100 30 7 840 400 122 250 76 150 46 100 30 62 19 10 1200 400 122 275 84 175 53 112 34 62 19 50 15 15 1800 300 91 175 53 112 34 75 23 37 11 30 9 20 2400 225 68 137 42 87 26 50 15 30 9 25 3000 175 53 112 34 62 19 37 11 30 3600 150 46 87 26 50 15 37 11 35 4200 125 38 75 23 50 15 40 4800 112 34 62 19 37 11 45
80. re vent electric shock and static electricity hazards Equipment Grounding Terminal On Front Panel Grounding Cable Not Supplied Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insulated copper wire A If unit does not have GFCI re ceptacles use GFCI pro tected extension cord S 0854 OM 480 Page 36 11 3 Grounding When Supplying Building Systems Use ground device as stated in electrical codes 1 Equipment Grounding Terminal 2 Grounding Cable Use 10 AWG or larger insulated copper wire 3 Ground Device A Ground generator to system earth ground if supplying power to a premises home shop farm wiring system ST 800 576 B 11 4 How Much Power Does Equipment Require VOLTS 115 AMPS 4 5 Hz 60 60W AMPERES x VOLTS WATTS EXAMPLE 1 If a drill uses 4 5 amperes at 115 volts calculate its running power requirementin watts 4 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 Example 1 add the individual loads to calculate total load 200 W 200 W 200 W 520 W 1120 W The total load applied by the three flood lamps and drill is 1120 watts 1 Resistive Load A light bulb is a resistive load and requires a constant amount of power 2 Non Resistive Load Equipment with
81. re des lunettes de s curit et des gants placer un torchon sur le bou chon du radiateur D visser le bouchon l g rement et laisser la vapeur s chapper avant d enlever le bouchon LA CHALEUR DU MOTEUR peut pro voquer un incendie e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Tenir distance les produits inflammables de l chappement LES TINCELLES L CHAPPEMENT peuvent provoquer un incendie e Emp cher les tincelles d chappement du moteur de provoquer un incendie e Utiliser uniquement un pare tincelles approuv voir codes en vigueur Le METAL CHAUD lors du coupage et gougeage plasma peut provoquer un in cendie ou une explosion e Ne pas couper ou gouger proximit de produits inflammables e Surveillez et garder un extincteur proximit DES PIECES CHAUDES peuvent provo quer des br lures et blessures e Ne pas toucher le compresseur ou d autres l ments du circuit air comprim chauds e Laisser l ensemble se refroidir avant de toucher ou d effectuer la maintenance LIRE LES INSTRUCTIONS e Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil e Arr ter le moteur et rel cher la pression avant d effectuer la maintenance 2 5 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage unique
82. ring to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fittings de signed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards CA MOVING PARTS can cause injury e Keep away from fans belts and rotors Y e Keep all doors panels covers and guards closed and securely in place Stop engine before installing or connecting unit Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary To prevent accidental starting during servicing disconnect negative battery cable from battery Keep hands hair loose clothing and tools away from moving parts Reinstall panels or guards and close doors when servicing is finished and before starting engine Before working on generator remove spark plugs or injectors to keep engine from kicking back or starting
83. rom the installation e If notified by the FCC about interference stop using the equipment at once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference 1 6 California Proposition 65 Warnings A Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq A Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling 1 7 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 phone 305 443 9353 website www aws org Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Mi ami FL 33126 phone 305 443 9353 website www aws org National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 webs
84. roposition 65 Warnings 000 cece nett teen eee 4 1 7 Principal Safety Standards 0 0 ete e nee eens 4 TIR EME Information iet ue Serre ee manele Na GG gia tua AA Rcs bu alesis ERO S TE RU PU 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 Signification des symboles i b HY a EK ENEE NEE EE E 5 2 2 Dangers relatifs au soudage l arc 5 2 3 Dangers existant en relation avec le moteur 6 2 4 Dangers li s Pair comprim 7 2 5 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 7 2 6 Principales normes de S curit 6 eee eee eee e eee e eee ees 8 2 7 Information sur les champs lectromagn tiques 8 SECTION S DEFINITIONS ssi dY N incarne fonda EEN eee etek e SEN ey 9 3 1 Symbols And Definitions essees seenen nenene 9 SECTION 4 SPECIFICATIONS EEN 10 4 1 Weld Power And Engine Specifications 10 4 2 Dimensions Weights And Operating Angles 10 4 3 Fiel Consumption venue ee EY E RT E ne YEN YR UC Oe OPERE DUCERE I s 11 4 4 Duty Cycle And Overheating ea hs 11 4 5 AG Generator POWer ln Daw TE Sd RR rs LEURS Rex
85. rts from your local distributor OM 480 Page 52 Warranty Questions Call 1 800 4 A MILLER for your local Miller distributor Your distributor also gives yOu Service You always get the fast reliable response you need Most replacement parts can be in your hands in 24 hours Support Need fast answers to the tough welding questions Contact your distributor The expertise of the distributor and Miller is there to help you every step of the way 7 Miller Effective January 1 2005 Equipment with a serial number preface of LF or newer This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Miller must be notified in writing within thirty 30 days of such defect or failure at which time Miller will provide instr
86. s Highway Suite 1004 Arlington VA 22202 4102 t l phone 703 412 0900 site Web www cganet com Code for Safety in Welding and Cutting norme CSA W117 2 de la Cana dian Standards Association Standards Sales 178 boulevard Rexdale EH LIRE LES INSTRUCTIONS e Utiliser seulement les pi ces de rechange d origine Effectuer la maintenance du moteur et du compres seur si applicable suivant ce manuel et le manuel du moteur compresseur si applicable LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Le rayonnement haute fr quence H E peut provoquer des interf rences avec les quipements de radio navigation et de communication les Services de s curit et les ordinateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installation e L utilisateur est tenu de faire corriger rapidement par un lectricien quali fi les interf rences r sultant de l installation e Sile FCC signale des interf rences arr ter imm diatement l appareil e Effectuer r guli rement le contr le et l entretien de l installation e Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distance correcte et utiliser une terre et et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf
87. side e Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards e Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock and fire hazards e Do not use welder to thaw frozen pipes e Remove stick electrode from holder or cut off welding wire at contact tip when not in use e Wear oil free protective garments such as leather gloves heavy shirt cuf fless trousers high shoes and a cap e Remove any combustibles such as a butane lighter or matches from your person before doing any welding e Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby FLYING METAL can injure eyes ES e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet 1 3 Engine Hazards BATTERY EXPLOSION can BLIND e Always wear a face shield rubber gloves and protec tive clothing when working on a battery e Stop engine before disconnecting or connecting bat tery cables or servicing battery Do not allow tools to cause sparks when working on a battery Do not use welder to charge batteries or jump start vehicles Observe correct
88. ted 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 480 Page 33 10 2 Run In Procedure Using Load Bank A t 8 p Stop engine Do not touch hot exhaust pipe engine parts or load bank grid A Keep exhaust and pipe away from flammables A Do not perform run in procedure at less than 20 volts weld output and do not exceed duty cycle or equip ment damage may occur 1 Load Bank Turn all load bank switches Off If needed connect load bank to 115 volts ac wall receptacle or genera tor auxiliary power receptacle 2 Welding Generator Place A V range switch in maxi mum position A V control in mini mum position and Output Selector switch if present in either DC position 3 Weld Cables Connect load bank to generator weld output terminals using proper size weld cables with correct connectors Observe correct polarity Start engine and run for several minutes Set load bank switches and then adjust generator A V control so load equals rated voltage and current of generator see nameplate rating label or the specifications 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 gt gt Check oil level frequently dur ing r
89. this manual Check generator and meters after first five minutes then every fifteen minutes to be sure generator is loaded properly Check oil level frequently dur ing run in add oil if needed After one hour minimum 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 480 Page 35 SECTION 11 GENERATOR POWER GUIDELINES NOTE gt 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 A Do not use 2 prong plug un less equipment is double in sulated Be sure equipment has this symbol and or wording gen pwr 11 02 Ref ST 159 730 ST 800 577 P Electrically bond generator v frame to vehicle frame by metal to metalcontact Bed liners shipping skids and some running gear insulate the welding generator from the ve hicle frame Always connect a ground wire from the generator equipment grounding terminal to bare metal on the vehicle frame as shown A Always ground generator frame to vehicle frame to p
90. tro magnetically compatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor Locate welding operation 100 meters from any sensitive electronic 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 reproductive 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 levard Rexdale Ontario Canada M9W 1R3 phone 800 463 6727 or in Toronto 416 747 4044 website www csa international org Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 11 West 42nd Street New York NY 10036 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org OSHA Occupational Safe
91. ty and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov To reduce magnetic fields in the workplace use the following procedures 1 Keepcables close together by twisting or taping them 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 Keep welding power source and cables as far away from operator as practical 5 Connect work clamp to workpiece as close to the weld as possible About Pacemakers Pacemaker wearers consult your doctor first If cleared by your doctor then following the above procedures is recommended SECTION 2 CONSIGNES DE SECURITE LIRE AVANT UTILISATION rom fre 8 03 A Avertissement Protegez vous et les autres des blessures lisez et suivez ces precautions Le Ce groupe de symboles si gnifie Mise en garde e Soyez vigilant Il y a des 2 1 Signification des symboles Signifie Mise en garde Soyez vigilant Cette proc dure pr sente des risques de danger Ceux ci sont identifi s par des symboles adjacents aux directives A ldentifie un message de s curit particulier Signifie NOTA n est pas relatif la s curit 2 2 Dangers r
92. u couper le fil la pointe de contact e Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans revers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes e Suivre les recommandations dans OSHA 1910 252 a 2 iv et NFPA 51B pour les travaux chaud et avoir de la surveillance et un extincteur proxi mit DES PARTICULES VOLANTES Fa f peuvent blesser les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques vo lantes Pendant la p riode de refroidissement des soudures elles ris quent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial DES PI CES CHAUDES peuvent provoquer des br lures graves e Pr voir une p riode de refroidissement avant d effec tuer des travaux d entretien e Porter des gants et des v tements de protection pour travailler sur un moteur chaud e Ne pas toucher mains nues les parties chaudes du moteur ni les pi ces r cemment soud es LE BRUIT peut affecter l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev LES CHAMPS MAGN
93. uctions on the warranty claim procedures to be followed Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the date that the equipment was delivered to the original retail purchaser or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers Inverters input and output rectifiers only 2 8 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Semi Automatic and Automatic Wire Feeders Inverter Power Sources Unless Otherwise Stated Water Coolant Systems Integrated Intellitig Maxstar 150 Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified DS 2Wire Feeder Motor Driven Guns w exception of Spoolmate Spoolguns Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources and Coolers Water Coolant Systems Non Integrated Flowgauge and Flowmeter Regulators No Labor HFUnits Grids Maxstar 85 140 Spot Welders Load Banks Arc Stud Power Sources amp Arc Stud Guns Racks Running Gear Trail
94. un in add oil if needed After one hour minimum 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 480 Page 34 10 3 Run In Procedure Using Resistance Grid pA A t GI 1 Stop engine Do not touch hot exhaust pipe engine parts or load bank grid A Keep exhaust and pipe away from flammables gt gt A Do not perform run in procedure at less than 20 volts weld output and do not exceed duty cycle or equip ment damage may occur 1 Resistance Grid Use grid sized for generator rated output Turn Off grid 2 Welding Generator Place A V range switch in maxi mum position A V control in mini mum position and Output Selector switch if present in either DC position 3 Weld Cables Connect grid to generator weld output terminals using proper size weld cables with correct connec tors polarity is not important 4 Voltmeter 5 Clamp On Ammeter Connect voltmeter and ammeter as shown if not provided on generator Start engine and run for several minutes Set grid switches and then adjust generator A V control so load equals rated voltage and current of the generator see nameplate rat ing label or the specifications sec tion in

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