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Miller Electric 250 Welder User Manual

1. Running Gear Length 45 1 2 in 1156 mm OM 217 455 Page 13 IS A complete Parts List is available at www MillerWelds com SECTION 5 INSTALLATION 5 1 Installing Welding Generator 460 mm Mounting Inadequate support A Do not use flexible mounts 1 A Always Grounding 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 Electrically bond generator frame to vehicle frame by metal to metal contact A Do not weld on base Welding on base can cause fuel tank fire or explosion Bolt unit down using holes provided in base A Always securely fasten weld ing generator onto transport vehicle or trailer and comply with all DOT and other applica ble codes A Do not mount unit by support ing the base only at the four mounting holes Use cross supports to adequately sup port unit and prevent damage to base ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards A If unit does not have GFCI re ceptacles use GFCI protected extension cord NOTICE Do not install u
2. 5 5 Connecting to Weld Output Terminals ee 5 6 Selecting Weld Cable Sizes 422 SECTION 6 OPERATING THE WELDING GENERATOR 6 1 Engine Control SWItChes sss cet tci reete pe etuer Ba Age er EE o Ub das og roe ant ag 6 2 Weld Output Controls rrr tee ere a a Ek 6 3 Typical Stick Welding Connections And Control Settings 6 4 Typical MIG Welding Connections And Settings ii 6 5 Typical MIG Connections And Settings Using Weld Control And Spoolgun SECTION 7 OPERATING AUXILIARY EQUIPMENT 7 1 Generator Power Receptacles 7 2 Simultaneous Weld And Power ss 7 3 Wiring Instructions For Optional 240 Volt Single Phase Plug NEMA 14 50P SECTION 8 OPERATING OPTIONAL BATTERY CHARGER 8 1 Battery Charge Controls SE 8 2 Determining Battery Charging Current ee 8 3 Battery Charge Cable Connections 8 4 Battery Charging Procedure SECTION 9 MAINTENANCE AND TROUBLESHOOTING 9 1 Routine Maintenance dre RR ke Re rh maa ek ner a RE IEEE Edda 9 2 Maintenance Label And Engine Maintenance Activities 9 8 Servicing Air Cleaner eR K 0 R K R R sa v e
3. Remove all grease oil moisture rust paint coatings slag and dirt from work surface before welding 15 15 Troubleshooting Excessive Spatter Excessive Spatter scattering of molten metal particles that cool to solid form near weld bead Possible Causes Corrective Actions Amperage too high for electrode Decrease amperage or select larger electrode Arc length too long or voltage too high Reduce arc length or voltage OM 217 455 Page 63 15 16 Troubleshooting Incomplete Fusion Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead AN Possible Causes Corrective Actions Insufficient heat input Increase amperage Select larger electrode and increase amperage Improper welding technique Place stringer bead in proper location s at joint during welding Adjust work angle or widen groove to access bottom during welding Momentarily hold arc on groove side walls when using weaving technique Keep arc on leading edge of weld puddle Workpiece dirty Remove all grease oil moisture rust paint coatings slag and dirt from work surface before welding 15 17 Troubleshooting Lack Of Penetration Lack Of Penetration shallow fusion between weld metal and base metal Lack of Penetration Good Penetration Possible Causes Corrective Actions
4. The volt ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator Curves of other settings fall between the curves shown 45 40 35 30 PO 25 DC Volts 20 15 10 0 100 200 300 400 500 600 700 800 DC Amps 226 794 A OM 217 455 Page 50 SECTION 14 GENERATOR POWER GUIDELINES x The views in this section are intended to be representative of all engine driven welding generators Your unit may differ from those shown 14 1 Selecting Equipment Generator Power Receptacles Neutral Bonded To Frame 3 Prong Plug From Case Grounded Equipment 2 Prong Plug From Double Insulated Equipment IS Be sure equipment has double A insulated symbol and or word ing on it Do not use 2 prong plug un less equipment is double in sulated gen_pwr 2007 04 Ref ST 159 730 ST 800 577 A A 1 2 3 Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards Also see AWS Safety amp Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Generators Equipment Grounding Terminal On Front Panel Grounding Cable Not Supplied Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insulated copper wire gt Electrically bond generator A frame to v
5. Wier S CB3 co D 120 240V J a CBI 50 A MAIN BREAKER LN WORK CHARGE ON OFF N lt MAIN BREAKER hs dn L 120V ELECTRODE A A EE E E Stop engine Do not charge a battery which has loose terminals or one showing damage such as a cracked case or cover Have only qualified persons do bat tery charging work Keep cables away from moving parts Do not use damaged cables Be sure charger output voltage matches battery voltage 99 N A Read BCI Battery Service Manual before charging x Before connecting to battery place Charge Voltage switch in position matching voltage of battery being charged 1 Battery 2 Battery Charging Cables Use less than 20 feet 6 1 m of AWG 1 or larger cable 3 Terminal Lug Use lugs of proper amperage capacity and hole size for connecting to charge output terminals Ref 228 649 A Ref 804 397 A S 0714 Install suitable connectors on remaining ends of battery cables 4 Battery Charge Positive Output Terminal 5 Battery Charge Negative Output Terminal x Connect charging cables to battery charge output terminals before con necting to battery terminals Connect Battery Charge Positive cable to battery positive terminal
6. oN o Dust Ejector To clean air filter Wipe off cover and housing Remove cover and dump out dust Remove ele ment s Wipe dust from inside cover and housing with damp cloth Reinstall safety element if present Reinstall cover Keep nozzle 2 in 61 mm from element NOTICE Do not clean housing with air hose A Es ss Clean primary element with compressed RSS alr only es L BSS RSA P c 53383333 E Air pressure must not exceed 100 psi E E 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 k x i 4 d G 0 Q SS Reinstall primary element and cover Blow Inspect dust ejector down aircleaner1 9 02 ST 153 929 B ST 153 585 Ref S 0698 B OM 217 455 Page 34 IS A complete Parts List is available at www MillerWelds com 9 4 Adjusting Engine Speed F If the engine does not start and stop properly verify the fuel solenoid is installed properly before adjusting engine speed see Section A following If the engine does not stay at idle speed verify the throttle solenoid is installed and adjusted properly before adjusting engine speed see Section B following If the engine runs properly but the speeds are incorrect do not adju
7. Miler OM 217 455H 2007 05 21 Processes Stick SMAW Welding Fana VIG GMAW Welding N Flux Cored FCAW Welding 4 Non Critical TIG GTAW A Welding Description L1 B4 E Engine Driven Welding Generator Bobcat 250 Diesel Visit our website at www MillerWelds com OWNER S MANUAL File Engine Drive pa From Miller to You Thank you and congratulations on choosing Miller Now you can get the job done and get it done right We know you don t have time to do it any other way That s why when Niels Miller first started building arc welders in 1929 he made sure his products offered long lasting value and superior quality Like you his customers couldn t afford anything less Miller products had to be more than the best they could be They had to be the best you could buy Today the people that build and sell Miller products continue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 n U 3 BI E PEENI This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They Working as hard as you do every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most hassle free warranty in the We ve made installation and operation q
8. 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 217 455 Page 54 14 8 Power Required To Start Motor Single Phase Induction Motor Starting Requirements Motor Start G H J K L M N P Code KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0 1 Motor Start Code 2 Running Amperage 3 Motor HP x AC MOTOR 2 4 Motor Voltage VoLTS 230 AMPS 25477 XN CODE M Hz 60 To find starting amperade N HP 1 4 PHASE 1 Step 1 Find code and use table to find KVA HP If code is not listed multiply running amperage by six to find starting amperage Step 2 Find Motor HP and Volts Step 3 Determine starting amper age see example Welding generator amperage out put must be at least twice the motors running amperage KVA HP x HP x 1000 Volts Starting Amperage Example Calculate starting amper age required for a 230 V 1 4 HP mo tor with a motor start code of M Volts 230 HP 1 4 KVA HP 11 2 11 2 x 1 4 x 1000 230 12 2A Starting the motor requires 12 2 amperes S 0624 14 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
9. and battery Charge Negative cable to battery nega tive terminal OM 217 455 Page 28 A complete Parts List is available at www MillerWelds com 8 4 Battery Charging Procedure La 2 In Example CT Battery Voltage 12 Volts t3 Battery CCA Rating 500 Charge Current 100 A See Section 8 2 Coarse Range Setting 60 to 140 A V A Control Setting 5096 CHARGE 36V BATTERY ON Q D 24V BATTERY Ol po WER ur Our ge Stop Engine gt Turn Off Battery Charging Set Weld Process Switch To Switch Charge Position Set Charge Voltage Switch To Voltage Of Battery Being Charged 12 24 Or 36 Volt NOTICE Do not switch under load 12V BATTERY RUN STAR 5 DO NOT USE FOR JUMP STARTING 4 OA P E SR i Determine Charge Current From Set Coarse Range Switch And Connect Cables Observe Battery CCA Rating And Chart Fine Control To Obtain Correct Correct Polarity See Section 8 2 Charging Current NOTICE Do not switch under load OFF Oh RUN IDLE oN 36V BATTERY B 124 e q RON T 24V BATTERY START OFF 12V BATTERY R POWER a JUMP STARTING Start Engine Turn On Battery Charge 10 Stop Engine Charge 10 minutes Charging Switch Minutes Check Battery Voltage Continue Charging If Necessary OM 217 455 Page 29 EF A complete Parts List
10. o 30 Or Less Or Less RA 2 3 Single Layer Fillet Weld Multi Layer Fillet Weld 1 Electrode 2 Single Layer Fillet Weld Move electrode in circular motion 3 Multi Layer Fillet Weld Weld a second layer when a heavi er fillet is needed Remove slag be fore making another weld pass Weld both sides of joint for maxi mum strength S 0063 S 0064 15 12 Tee Joint 1 Electrode 2 Fillet Weld Keep arc short and move at definite rate of speed Hold electrode as shown to provide fusion into the corner Square edge of the weld surface For maximum strength weld both sides of upright section 3 Multi Layer Deposits Weld a second layer when a heavi er fillet is needed Use any of the weaving patterns shown in Section 15 9 Remove slag before making another weld pass S 0060 S 0058 A S 0061 OM 217 455 Page 62 15 13 Weld Test 1 Vise 3 2 Weld Joint 3 Hammer A Strike weld joint in direction shown een lle mm Bd NE 1 4 in b 2 6 4 mm 1 RU a UNS 2To3 in T 51 76 mm ww A good weld bends over but does not break S 0057 B 15 14 Troubleshooting Porosity Porosity small cavities or holes resulting from gas pockets in weld metal Possible Causes Corrective Actions Arc length too long Reduce arc length Damp electrode Use dry electrode Workpiece dirty
11. 0049 15 4 Striking an Arc Tapping Technique L 1 eer 1 Electrode 2 Workpiece 3 Arc Bring electrode straight down to workpiece then lift slightly to start arc If arc goes out electrode was lifted too high If electrode sticks to workpiece use a quick twist to free it S 0050 OM 217 455 Page 59 15 5 Positioning Electrode Holder 10 30 EAT 907 90 a T 8 t End View of Work Angle Side View of Electrode Angle GROOVE WELDS o o 10 30 V ga End View of Work Angle Side View of Electrode Angle FILLET WELDS S 0060 15 6 Poor Weld Bead Characteristics Large Spatter Deposits Rough Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration Qn E GM S 0053 A 15 7 Good Weld Bead Characteristics 1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During Welding Weld a new bead or layer for each 1 8 in 3 2 mm thickness in metals being welded 4 NoOverlap 5 Good Penetration into Base Metal S 0052 B OM 217 455 Page 60 15 8 Conditions That Affect Weld Bead Shape LS Weld bead shape is affected by electrode angle arc length travel speed and thickness of base metal Correct Angle Angle Too Small b 4 10 30 Angle Too Large a aaa nen 8 3 prag ELECTRODE ANGLE
12. 1 16 in from stop Screw check for clearance between jam nut and fuel solenoid If there is clearance between jam nut and solenoid loosen nut and turn plunger clockwise until lever touches stop screw Retighten nut If there is no clearance between jam nut and solenoid loosen the solenoid mount ing screws and reposition the solenoid as described at the beginning of this section 1 Ref 804 250 A 802 649 OM 217 455 Page 35 A complete Parts List is available at www MillerWelds com B Checking Throttle Solenoid 7 Check for non binding movement of link with sole noid in energized position A Stop engine If the engine does not stay at idle speed verify the the throttle solenoid and linkage is installed properly Adjusting Throttle Solenoid Throttle Solenoid Jam Nut Solenoid Link Shoulder Bolt Throttle Lever Solenoid Rod Throttle Solenoid Mounting Screw Loosen jam nut remove shoulder bolt and remove link from throttle le ver Install link 5 8 in 16 mm on so lenoid rod Reconnect link to shoul der bolt and throttle lever O1 E GM Push solenoid rod into idle ener gized position and check for non binding lateral movement of throttle
13. 400 1 0 60 2 0 70 3 0 95 4 0 120 oa on us A d 20 2 ea 2 0 2ea 3 0 2 ea 4 0 3 ea 3 0 3 ea 3 0 500 2 0 70 3 0 95 40 120 xzo 2x95 2x120 8x95 3x95 This chart is a general guideline and may not suit all applications If cables overheat use next size larger cable Weld cable size AWG is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere mm for metric use S 0007 F For distances longer than those shown in this guide call a factory applications representative at 920 735 4505 Notes FF A complete Parts List is available on line at www MillerWelds com OM 217 455 Page 19 SECTION 6 OPERATING THE WELDING GENERATOR 6 1 S Control Switches Wares 79 RW A SET AT 7 10 FOR POWER WHILE WELDING SET AT 10 FOR MAX GENERATOR POWER RUN IDLE IDLE amp LOCK RUN START GLOW PLUGS NOTICE Disconnect equipment from auxil iary power receptacles during start up and shutdown Some equipment can be damaged by changes in frequency as engine rpms change during start up and shutdown 1 Engine Control Switch Use switch to start engine select speed and stop engine In Run Idle position engine runs at idle speed at no load and weld power speed under load In Run position engine runs at weld power speed IS Place switch in Run posi
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15. A 226 796 A OM 217 455 Page 47 13 2 Generator Power Curve The ac generator power curve shows the generator power avail able in amperes at the receptacles 300 150 250 125 200 100 2 9 150 75 o 100 50 50 25 0 0 0 0 40 80 120 160 AC Amperes At 120 Volts 20 40 60 80 AC Amperes At 240 Volts 200 240 100 120 226 791 A 13 3 Duty Cycle WELD AMPERES 300 275 250 225 200 150 o Continuous Welding 100 Duty Cycle at 250 Amperes DC CC 10 20 50 40 50 60 70 80 DUTY CYCLE Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating NOTICE Exceeding duty cycle can damage unit and void warranty 200 293 OM 217 455 Page 48 13 4 Stick Mode Volt Ampere Curves The volt ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator Curves of other settings fall between the A CC DC Stick Mode ENEE 90 80 70 60 O1 DC Volts eo CD IO 0 50 100 150 200 250 300 350 400 DC Amps B CC AC STICK Mode 90 80 70 60 50 AC Volts 40 30 20 10 0 50 100 150 200 250 300 AC Amps 226 792 A 226 793 A OM 217 455 Page 49 13 5 MIG Mode Volt Ampere Curve
16. AT 10 FOR MAX GENERATOR POWER A RUNIDLE CHARGE STICK 60 140 LZ 30 200 Place switch in Charge position before OE lw connecting charging cables and start ing engine RUN sQ Use switch to select weld or battery charge CC CV DC Welder Battery Chargers Generator output see table in Section 8 2 sx MADE DEA 4 Coarse Range Switch 5 Fine Control Use Coarse Range switch and Fine Control to set charge current A Do not change Coarse Range or Weld Process switch position while welding 3 or battery charging Charging current automatically stops when terminal voltage is 15 to 25 percent above required battery voltage 228 649 A 8 2 Determining Battery Charging Current 1 1 Battery Charging Current Chart J Find battery cold crank amp CCA rating on 400 battery Use CCA rating on chart to find charge 2 current setting for battery lt 350 EXAMPLE If battery CCA rating is 500 charg E ing current from chart is 100 amperes 300 Do not exceed charging current found on chart For longer battery life use lowest 5 250 charge rate possible O Z 200 T 150 I 100 f E 50 S 0 0 500 1000 1500 2000 BATTERY COLD CRANK AMP RATING CCA 142 975 B OM 217 455 Page 27 IS A complete Parts List is available at www MillerWelds com 8 3 Battery Charge Cable Connections
17. About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as micro processors computers and computer driven equipmentsuch as robots e Be sure all equipment in the welding area is electromagnetically compatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e f interference still occurs the user m
18. California Proposition 65 Warnings A Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq A Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling 1 7 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 from Global Engineering Documents phone 1 877 413 5184 website www global ins com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 4221 Walney Road 5th Floor Chantilly VA 20151 phone 703 788 2700 website www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Mississauga 1 8 EMF Information Considerations
19. Considerations sur le soudage et les effets de basse fr quence et des champs magn tiques et lectriques Le courant de soudage pendant son passage dans les cables de sou dage causera des champs lectromagn tiques II y a eu et il y a encore un certain souci propos de tels champs Cependant apr s avoir exa min plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban bleu du National Research Council a conclu lt Laccumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lectriques haute fr quence repr sente un risque la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent tre examin es En attendant que les conclusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn ti ques pendant le soudage ou le coupage Pour r duire les champs magn tiques sur le poste de travail appliquer les proc dures suivantes Pour les moteurs essence A Les gaz d chappement des moteurs contiennent des pro duits chimiques dont l tat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Pour les moteurs diesel A Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l Etat
20. Electrode Holder Position 6 Arc Length Arc length is the distance from the electrode to the workpiece A short arc with correct amperage will give a sharp crackling sound 7 Slag Use a chipping hammer and wire brush to remove slag Remove slag and check weld bead before mak ing another weld pass stick 2007 04 ST 151 593 OM 217 455 Page 58 15 2 Electrode and Amperage Selection Chart AMPERAGE RANGE ELECTRODE DIAMETER 250 300 ELECTRODE POSITION PENETRATION 6010 DEEP MIN PREP ROUGH 6011 DEEP HIGHSPATTER 6013 LOW GENERAL 7014 SMOOTH EASY MED FAST 7018 LOW HYDROGEN LOW STRONG 7024 FLAT HORIZ LOW SMOOTH EASY FILLET FASTER NI CL y A V H y ALL LOW CAST IRON 308L y ALL LOW STAINLESS EP ELECTRODE POSITIVE REVERSE POLARITY EN ELECTRODE NEGATIVE STRAIGHT POLARITY Ref S 087 985 A 1 Electrode 2 Workpiece 3 Arc Drag electrode across workpiece like striking a match lift electrode slightly after touching work If arc goes out electrode was lifted to high If electrode sticks to work piece use a quick twist to free it S
21. IS A complete Parts List is available at www MillerWelds com 9 3 Servicing Air Cleaner A Stop engine t3 NOTICE Do not run engine without air cleaner or with dirty element Engine damage caused by using a damaged ele ment is not covered by the warranty OFF lt RUN IDLE IS The air cleaner primary element can be cleaned but the dirt holding capac ity of the filter is reduced with each cleaning The chance of dirt reaching the clean side of the filter while clean 4 ing and the possibility of filter damage 1 ad makes cleaning a risk Consider the CR risk of unwarrantable equipment damage when determining whether 2 to clean or replace the primary ele LE ment 3 If you decide to clean the primary ele ment we strongly recommend instal ling an optional safety element to pro vide additional engine protection Never clean a safety element Re place the safety element after servic ing the primary element three times Intake Manifold Service Indicator Optional Window 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 XX 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 Optional 5 Housing Safety Element Optional E GM Primary Element Cover
22. Improper joint preparation Material too thick Joint preparation and design must provide access to bottom of groove Improper weld technique Keep arc on leading edge of weld puddle Insufficient heat input Increase amperage Select larger electrode and increase amperage Reduce travel speed 15 18 Troubleshooting Excessive Penetration Excessive Penetration weld metal melting through base metal and hanging underneath weld Excessive Penetration Good Penetration Possible Causes Corrective Actions Excessive heat input Select lower amperage Use smaller electrode Increase and or maintain steady travel speed OM 217 455 Page 64 15 19 Troubleshooting Burn Through Burn Through weld metal melting completely through base metal resulting in holes where no metal remains Possible Causes Corrective Actions Excessive heat input Select lower amperage Use smaller electrode Increase and or maintain steady travel speed 15 20 Troubleshooting Waviness Of Bead Let b dil Waviness Of Bead weld metal that is not parallel and does not cover joint formed by base metal Possible Causes Corrective Actions Unsteady hand Use two hands Practice technique 15 21 Troubleshooting Distortion Distortion contraction of weld met al during welding that forces base metal to move a Base metal moves in the direction of the weld bead Possib
23. L poe cz n gon eres Too Short Normal Too Long ARC LENGTH SSS hs Se Slow Normal Fast TRAVEL SPEED S 0061 15 9 Electrode Movement During Welding LS Normally a single stringer bead is satisfactory for most narrow groove weld joints however for wide groove weld joints or bridging across gaps a weave bead or multiple stringer beads work better 1 Stringer Bead Steady Movement Along Seam 2 Weave Bead Side to Side Movement Along Seam 1 2 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode Do not let weave width exceed 2 1 2 times diameter of electrode 3 Z GC 9 S 0054 A OM 217 455 Page 61 15 10 Butt Joints 1 30 1 16 in 1 6 mm 1 Tack Welds Prevent edges of joint from drawing together ahead of electrode by tack welding the materials in position be fore final weld 2 Square Groove Weld Good for materials up to 3 16 in 5 mm thick 3 Single V Groove Weld Good for materials 3 16 3 4 in 5 19 mm thick Cut bevel with oxy acetylene or plasma cutting equip ment Remove scale from material after cutting A grinder can also be used to prepare bevels Create 30 degree angle of bevel on materials in V groove welding 4 Double V Groove Weld Good for materials thicker than 3 16 in 5 mm S 0662 15 11 Lap Joint 30
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25. Settings A complete Parts List is available at www MillerWelds com see a ac wep a Tools Needed 3 4 in A Stop engine EF This section provides general guide lines and may not suit all ap plications Typical Control Settings For Short Circuit Transfer Using 035 ER70S 3 Solid Wire And 75 25 Argon CO Gas gt Set Weld Process Selector switch to Wire DCEP position gt Set Coarse Range switch to Wire Low Range 17 22 volts position gt Set Fine Control to obtain minimum spatter gt Set wire feed speed between 100 300 ipm Typical Control Settings For Spray Transfer Using 035 ER70S 3 Solid Wire And 80 Or Higher Argon CO Gas gt SetWeld Process Selector switch to Wire position gt Set Coarse Range switch to Wire High Range 20 28 volts position gt Set wire feed speed between 320 500 ipm gt Set Fine control to 3 and increase for longer arc length Typical Control Settings Using 045 E71T 11 Self Shielded Flux Core Wire gt Set Weld Process Selector switch to Wire position DCEN gt Set Coarse Range switch to Wire Low Range 17 22 volts position gt Set Fine Control near minimum set ting gt Set wire feed speed between 125 200 ipm gt Doatest weld To increase arc length increase Fine Control set ting To shorten arc length reduce fine control sett
26. and tighten if necessary Check plug Engine Control switch and engine wiring harness connections Have Factory Authorized Service Agent check Engine Control switch S2 or circuit breaker CB8 Engine cranks but does not start Check fuel level and fault indicators on fuel gauge see Section 6 1 Open fuel valve see Section 5 6 Glow plug circuit breaker CB7 may be open see Section 9 5 Wait and retry Service inline fuel strainer and fuel filter see Section 8 2 Check battery and replace if necessary Check engine charging system according to engine manual Check fuel solenoid according to engine manual Have Factory Authorized Service Agent check glow Plug switch S6 glow plug and control relay CR3 Engine starts but stops when Engine Control switch S2 returns to Run Idle position Check oil level See Section 5 6 and fault indicators on fuel gauge see Section 6 1 Engine will not start if oil pressure is too low Check coolant level and fan belt see Section 5 6 and engine manual and check fault indicators on fuel gauge see Section 6 1 Engine will not start if engine temperature is too high Have Factory Authorized Service Agent check low oil pressure shutdown switch S5 and engine tem perature switch S4 Engine does not stop Stop engine by closing fuel valve see Section 5 6 Adjust shutdown solenoid see Section 9 4 Engine stopped during normal op
27. de travailler l quipement Ne pas toucher aux pi ces chaudes utiliser les outils recomman d s et porter des gants de soudage et des v tements pais pour viter les br lures DES PIECES DE METAL ou DES SA er LETES peuvent provoquer des bles sures dans les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la p riode de refroidissement des soudures elles risquent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial T LES FUMEES ET LES GAZ peuvent tre dangereux R Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereux pour votre sant e Eloigner votre t te des fum es Ne pas respirer les fum es e A l int rieur ventiler la zone et ou utiliser une ventilation forc e au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Sila ventilation est m diocre porter un respirateur anti vapeurs approuv e Lire et comprendre les sp cifications de s curit des mat riaux MSDS et les instructions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d graisseurs e Travailler dans un espace ferm seulement s il est bien ventil ou en portant un respirateur alimentation d air Demander toujours un surveillant dument form de se t
28. de Californie com me provoquant des cancers et des malformations cong nitales ou autres probl mes de procr ation LAW 5NS t l phone 800 463 6727 ou Toronto 416 747 4044 site Internet www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 de American National Standards Institute 11 West 43rd Street New York NY 10036 8002 t l phone 212 642 4900 site Internet www ansi org Standardfor Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de U S Government Printing Office Superin tendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 t l phone 1 866 512 1800 il y a 10 bureaux r gionaux le t l pho ne de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 1 Garder les c bles ensemble les torsader les scotcher ou les recouvrir d une housse 2 Disposer les c bles d un c t et distance de l op rateur 3 Ne pas courber pas et ne pas entourer pas les c bles autour de votre corps 4 Garder le poste de soudage et les c bles le plus loin possible de vous 5 Connecter la pin
29. eb ee KRN KN N e Min eee nee eee 9 4 Adjusting Engine Speed 9 5 Overload Protection nastics rop eR Ur UE UNE RE PARI UP RE ee 9 6 Troubleshooting Tables RR nee ue ERE CRESCE ER N ees OO OO TABLE OF CONTENTS SECTION 10 PARTS LIST EEE 41 10 1 Recommended Spare Parts rye rey YEA mn DA ne a Y re Y RU TRY 41 SECTION 11 ELECTRICAL DIAGRAMS sus 42 SECTION 12 RUN IN AND WETSTACKING 46 12 1 R reln And Wetstackirig uet eee PEE REI TRAD E PEE RYE drame n e 46 SECTION 13 PERFORMANCE DATA HH 47 13 1 Fuel Consumption Curves 47 13 2 Generator Power Curve ui 48 13 3 DULY GY CIS os Acca ner Ra Z da CN svat els ba aA E ie a 48 13 4 Stick Mode Volt Ampere Curves iii 49 13 5 MIG Mode Volt Ampere Curve ee 50 SECTION 14 GENERATOR POWER GUIDELINES 51 SECTION 15 STICK WELDING SMAW GUIDELINES 58 COMPLETE PARTS LIST www MillerWelds com OPTIONS AND ACCESSORIES WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING rom_2007 04 A Protect yourself and others from injury read and follow these precautions 1 1 Symbol Usage DANGER Indicates a hazardous situation which if not a
30. have GFCI receptacles use GFCI protected extension cord Maximum Allowable Cord Length in ft m for Conductor Size AWG Current Load Watts 4 6 8 10 12 14 Amperes 5 1200 700 213 450 137 225 84 200 61 7 1680 800 244 500 152 300 91 200 61 125 38 10 2400 800 244 550 168 350 107 225 69 125 38 100 31 15 3600 600 183 350 107 225 69 150 46 75 23 60 18 20 4800 450 137 275 84 175 53 100 31 60 18 25 6000 350 107 225 69 125 38 75 23 30 7000 300 91 175 53 100 31 75 23 35 8400 250 76 150 46 100 31 40 9600 225 69 125 38 75 23 45 10 800 200 61 125 38 50 12 000 175 53 100 31 Conductor size is based on maximum 2 voltage drop OM 217 455 Page 57 SECTION 15 STICK WELDING SMAW GUIDELINES EN 4 uf ES 15 1 Stick Welding Procedure Tools Needed Lm A Weld current starts when electrode touches work piece A Weld current can damage electronic parts in vehicles Disconnect both battery cables before welding on a vehicle Place work clamp as close to the weld as possible 1 Workpiece Make sure workpiece iS clean be fore welding 2 Work Clamp 3 Electrode A small diameter electrode requires less current than a large one Fol low electrode manufacturer s instructions when setting weld am perage see Section 15 2 4 Insulated Electrode Holder 5
31. is available at www MillerWelds com Notes HOBART INSTITUT OF WELDING TECHNOLOGY Start Your Professional 00 Trade square East Troy Ohio 45373 Over 80 000 trained Welding Career Now 1 800 332 9448 www welding org since 1930 OM 217 455 Page 30 A complete Parts List is available at www MillerWelds com SECTION 9 MAINTENANCE AND TROUBLESHOOTING e A Stop engine before maintaining ICS See Engine Manual and Maintenance Label for important start up service and storage information Service engine more often if used in severe conditions 9 1 Routine Maintenance k ue DU e A Recycle engine fluids 17 Check Change Q Clean Replace Reference AN tes dus TE EN Le A I D To be done by Factory Authorized Service Agent Every So ME Section 5 4 S a S 2 Hours NA Coolant Level Fuel Level Oil Level Q Oil Fuel Spills Every oT Hc i p A Hours si 2 Fuel Connections Fuel Connections Q Weld Terminals Every Section 9 2 100 9 3 Engine Hours Manual Air Cleaner Hoses Belt Tension Q Battery Terminals Every SE WAR 7 Engine 200 I uu Lien S Manual Hours wr Section 9 2 Oil Filter Unreadable Labe
32. link at throttle lever If link binds loos en solenoid mounting screws Move the solenoid slightly until the link moves freely with solenoid in re laxed and energized positions Tighten screws Tighten jam nut Go to Step C Tools Needed PrTUTUTUTTTTTTTT TTTTTTTT 3 e 3 8 7 16 in 5 32 in Check for non binding movement of link with solenoid in relaxed position Oo 9 LJ Ref 804 250 A 802 649 OM 217 455 Page 36 C Making Engine Speed Adjustments A complete Parts List is available at www MillerWelds com RP C7 is parallel with throttle lever Do not twist solenoid boot while adjusting engine speed Be sure throttle link Idle 2375 2450 rpm 39 6 40 8 Hz Weld Power 3675 3750 rpm 61 3 62 5 Hz Tools Needed 3 8 7 16 in 10 14 mm Before adjusting engine speed verify throttle solenoid is installed properly see Section B on previous page Check engine speeds with a tachometer see table If necessary adjust speeds as follows Start engine and run until warm Turn V A control to max Adjusting Idle Speed Turn Engine Con
33. out put terminal Slide weld cable terminal onto weld output terminal and secure with nut so that weld cable terminal is tight against copper bar Do not place anything between weld cable terminal and copper bar Make sure that the surfaces of the weld cable terminal and copper bar are clean Tools Needed IT 34in Ref 804 249 A 228 647 A 803 778 A OM 217 455 Page 18 A complete Parts List is available at www MillerWelds com 5 6 Selecting Weld Cable Sizes gt Weld Cable Size and Total Cable Copper Length in Weld Circuit Not Exceeding Weld Output Terminals A Turn off power before connecting to weld output terminals 150 ft 200 ft 250 ft 300 ft 350 ft 400 A Do not use worn 100 ft 30 m or Less ae tna 45m 60m ZO m 90m 105 m 120 m sized or poorly spliced cables 10 60 60 100 Maal Duty Duty 10 100 Duty Cycle P Cycle Cycle 100 4 20 4 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 80 2 85 1 50 1 0 60 2 0 70 3 0 95 4 0 120 4 0 120 9 2 85 1 50 1 0 60 2 0 70 3 0 95 4 0 120 UU 2ea 2 0 2ea 2 ea 300 1 50 1 0 60 2 0 70 3 0 95 4 O 120 e Fei ey 2 ea 2 0 2ea 2 ea 2 ea 4 0 350 1 0 60 2 0 70 3 0 95 4 0 120 oan oe et S 2 ea 2 0 2ea 2 ea 4 0 2 ea 4 0
34. parts e Wear dry hole free insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground e Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process e If AC output is required use remote output control if present on unit e Additionalsafety precautions are required when any of the follow ing electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomatic DC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone e Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards e Properly install and ground this equipment according to its Owner s Manual and national state and local codes EF Indicates special i
35. plugs etc connected to the receptacle Press button to reset re ceptacle and resume operation o EF At least once a month run engine at weld power speed and press Test button to verify GFCI is working properly NB Combined output of all receptacles limited to wane ON Uis o BA aba ELECTRODE 10 kVA kW rating of the generator EXAMPLE If 20 A is drawn from each 120 V duplex receptacle only 21 A is available at the 240V receptacle 2 x 120 V x 20 A 240 V x 21 A 10 kVA kW 120 240 803 750 B Ref 211 362 A OM 217 455 Page 25 A complete Parts List is available at www MillerWelds com 7 2 Simultaneous Weld And Power Weld Current in Amperes Total Power in Watts 120 V Full kVA Receptacle 240 V Full kVA Receptacle Amperes Amperes 250 2200 18 9 180 3500 29 14 125 5200 43 21 90 8000 66 33 0 10 500 Peak 88 44 7 3 Wiring Instructions For Optional 240 Volt Single Phase Plug NEMA 14 50P E RP Current Available in Amperes 240 V Each 120 V Duplex Receptacle Receptacle 42 0 37 5 32 10 27 15 22 20 V x A Watts One 240 V load or two 120 V loads L aR 240 V AC The plug can be wired for a 240 V 2 wire load or a 120 240V
36. power to prevent motor damage Motor requires more power than generator can supply Ref ST 800 396 A S 0625 OM 217 455 Page 55 14 10 Typical Connections To Supply Standby Power Utility Electrical Service Transfer Switch Essential Loads Fused Disconnect Switch If Required Welding Generator Output A Have only qualified persons perform these connections according to all applicable codes and safety practices A Properly install and ground this equipment according to its Owner s Manual and na tional state and local codes x Customer supplied equipment is required if generator will sup ply standby power during emergencies or power out ages 1 Utility Electrical Service 2 Transfer Switch Double Throw Switch transfers the electrical load from electric utility service to the generator Transfer load back to electric utility when service is re stored Install correct switch customer supplied Switch rating must be same as or greater than the branch overcurrent protection 3 Fused Disconnect Switch Install correct switch customer supplied if required by electrical code 4 Welding Generator Output Generator output voltage and wir ing must be consistent with regular utility system voltage and wiring Connect generator with temporary or permanent wiring suitable fo
37. pressuris e risque d explosion Porteur de simulateur cardiaque ou autre im plants m dicaux rester distance e Utiliser seulement des bouteilles de gaz protecteur r gulateurs e Les porteurs d implants doivent d abord consulter leur m decin tuyaux et raccords convenables pour cette application sp cifique avant de s approcher des op rations de soudage l arc de sou les maintenir ainsi que les l ments associ s en bon tat dage par points de gougeage du coupage plasma ou de chauf Ne pas tenir la t te en face de la sortie en ouvrant la soupape de la fage par induction bouteille Si des BOUTEILLES sont endomma e Maintenirle chapeau de protection sur la soupape sauf en cas g es elles pourront exploser d utilisation ou de branchement de la bouteille Des bouteilles de gaz protecteur contiennent du ga e Utiliser les quipements corrects les bonnes proc dures et suffi sous haute pression Si une bouteille est endomme samment de personnes pour soulever et d placer les bouteilles g e elle peut exploser Du fait que les bouteilles de gaz for normalement partie du proc d de soudage les manipuler ave pr caution e Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s curit 2 3 Dangers existant en relation avec le moteur L EXPLOSION DE LA BATTERIE peu e Seul
38. 2 HP 8200 2200 2HP 10550 2850 3 HP 15900 3900 5 HP 23300 6800 High Torque e g Barn 1 1 2 HP 8100 2000 Cleaners Silo Unloaders 5HP 23300 6000 Silo Hoists Bunk Feeders 7 1 2 HP 35000 8000 10 HP 46700 10700 3 1 2 cu ft Mixer 1 2 HP 3300 1000 High Pressure 1 8 Gal Min 500 PSI 3150 950 Washer 2 gal min 550 PSI 4500 1400 2 gal min 700 PSI 6100 1600 Refrigerator or Freezer 3100 800 Shallow Well Pump 1 8 HP 2150 750 1 2 HP 3100 1000 Sump Pump 1 3 HP 2100 800 1 2 HP 3200 1050 OM 217 455 Page 53 14 7 Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Dril 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 6in 1720 720 8in 3900 1400 10 in 5200 1600 Air Compressor 1 2 HP 3000 1000 1HP 6000 1500 1 1 2 HP 8200 2200 2HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1 3 HP 2100 700 Elec Hedge Trimmer 18 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
39. 2 X wj ul Z lt 43 35 ale i RUN IDLE X 2 RUN x x x amp START X X CLOSED TO B TERMINAL Hh 42 rh BASE PANEL GROUND GROUND amp WARNING e Do not touch live electrical parts ka e Disconnect input power Or stop N engine before servicing Do not operate with covers removed ELECTRIC Have only qualified persons install SHOCK HAZARD use or service this unit 231 607 B OM 217 455 Page 45 SECTION 12 RUN IN AND WETSTACKING run in D722 9 05 12 1 Run In And Wetstacking 1 Welding Generator Run in procedures for this engine should not be required Put unit into regular service 2 Engine Exhaust Pipe Wetstacking is unburned fuel and oil in the exhaust pipe and occurs if the engine is run too long at light load or idle rpm If exhaust pipe is coated with a wet black tar like substance contact factory service for procedures to properly dry engine and seat piston rings OM 217 455 Page 46 SECTION 13 PERFORMANCE DATA 13 1 Fuel Consumption Curves On a typical job using 1 8 in 7018 electrodes 125 amps 20 duty cycle expect about 24 hours of op eration Welding at 150 amps at 40 duty cycle uses approximately 1 2 gal lon per hour or about 20 hours of operation Weld Fuel Consumption 100 150 200 250 300 DC WELD AMPERES AT 100 DUTY CYCLE Auxiliary Power Fuel Consumption 2 3 4 5 6 7 8 AUXILARY POWER KW AT 100 DUTY CYCLE 226795
40. 2 o cR N aw oi PLG36 PLG39 PLG39 PRESSURE 49 RC36 IV W mcso YN RC3O N C x 12 VOLT pu s5g m STARTER RED O 2 WHT gt LS 4AL 19 44 a on ALK RC39 2 a SA PLG39 S BCE INS clow 12 VOLT PLG36 56 208 BATTERY NEGATIVE 42 ak 42 42 42 42 42 42 Tl 11 T1 Tl Tl ITI TI Figure 11 2 Circuit Diagram For Welding Generator With Battery Charging Option OM 217 455 Page 44 70 A B C D E d bo b 42 42 62 80 90 87 42 42 G2 EO GO 67 F O 1T 42 V VV OC TS GI e CB3 z r H 21 5 704 702 707 87 amp o 90 2 42 loup ON POWER ds EXCITATION amp 2 81 Fciz TS ge VV N REVOLVING FIELD OC HE CB2 90 fh pg N x ON WELD 42 GND JO L _ 13 PEZ 4j GFCI 2 H CT1 AC Z 20 42 80 27 alle a ph ET x A CB1 1 amp 2 xO x 4 84 23 c RC1 Ry 3 C 77 4 Z4 le DC Z 21 P m Jo 25 25 ELECT Der 9 L A L O 3 OE T VR1 g i o JO 24 o oO 1 m S S CHARGE sul T UE NS L L 42 Z m pur d WORK 27 27 CHARGE _ e e e e O POSITION S
41. 3 wire load See circuit diagram 1 Plug Wired for 120 240 V 3 Wire Load When wired for 120 V loads each duplex receptacle shares a load with one half of 240 V receptacle 2 Plug Wired for 240 V 2 Wire Load Neutral Silver Terminal Load 1 Brass Terminal Load 2 Brass Terminal Ground Green Terminal Amperes Available using 120 240 V Plug NO E Qo Tools Needed zin plug1 11 03 120 813 D OM 217 455 Page 26 A complete Parts List is available at www MillerWelds com SECTION 8 OPERATING OPTIONAL BATTERY CHARGER 8 1 Battery Charge Controls Lay A Have only qualified persons charge ERE batteries A Do not use battery charger for jump starting NOTICE D o not use generator power ac re ceptacles while using optional battery charger Low voltage at receptacles may damage tools and other equipment 1 Charge Voltage Switch 36V BATTERY a DO NOT SWITCH WHILE WELDING NO CAMBIE CUANDO SE EST SOLDANDO Place switch in position matching voltage of battery being charged 24V BATTERY OFF 12V BATTERY EF Before connecting charging cables place Charge Voltage switch in position match ing voltage of battery being charged 2 Battery Charging Switch Place switch in On position to turn on charging current Place switch in Off position to turn off charging current 3 Weld Process Switch SET AT 700 FOR POWER WHILE WELDING SET
42. 50 A 25 V Continuous 9 5 KVA KW Water Cooled CC DC 40 250A 100 Duty 72 Single Phase Three Cylinder Cycle 84 42 A 120 240 V AC 12 gal Four Cycle 60Hz 45 L Tank 18 8 HP while not welding Diesel Engine 275 25 V 60 Duty CVDC 17 28V eh 41 7 250 A 28 V 100 Duty Cycle OM 217 455 Page 12 A complete Parts List is available at www MillerWelds com 4 2 Dimensions Weights and Operating Angles Dimensions 35 1 2 in 902 mm Height To Top Of Exhaust Width 20 in 608 mm Depth 53 in 1346 mm A 20 in 508 mm B 16 1 2 in 419 mm C 1 3 4 in 44 mm D 6 1 16 in 154 mm E 32 3 4 in 832 mm F 51 3 8 in 1305 mm G 13 32 in 10 mm Dia Weight 700 Ib 318 kg Lifting Eye Weight Rating 1280 Ibs 580 kg E Engine End G 4 Holes 800 426 gt gt could tip Do not exceed tilt angles or engine could be damaged or unit could tip Do not move or operate unit where it 804 249 A 4 3 Dimensions For Units With Optional Running Gear Dimensions Height All Running Gear Options 42 1 2 in 1079 mm To Top Of Handle Assembly E32 oo Protective Cage Width 26 in 660 mm Running Gear Width 32 in 813 mm Protective Cage Length 48 in 1219 mm
43. Agent check brushes slip rings and integrated rectifiers SR2 SR3 Low weld output Check control settings Check fuse F1 and replace if open see Section 9 5 Check engine speed and adjust if necessary see Section 9 4 Service air cleaner see Section 8 2 Have Factory Authorized Service Agent check brushes slip rings and integrated rectifiers SR2 SR3 High weld output Check control settings Check engine speed and adjust if necessary see Section 9 4 Erratic weld output Check control settings Tighten and clean connections to electrode and workpiece Use dry properly stored electrodes for Stick and TIG welding Remove excessive coils from weld cables Clean and tighten connections both inside and outside welding generator Check engine speed and adjust if necessary see Section 9 4 Have Factory Authorized Service Agent check brushes slip rings and integrated rectifiers SR2 SR3 B Generator Power Trouble Remedy No or low generator power output at ac receptacles weld output okay Reset supplementary protectors see Section 7 1 Press optional GFCI receptacle Reset button see Section 7 1 Check fuse F2 and replace if open see Section 9 5 Check engine ignition wiring connections Have Factory Authorized Service Agent check brushes slip rings and integrated rectifier SR3 No generator power or w
44. IN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province miller warr 2007 01 Owner s Record Please com
45. Plug Remove thermostat housing plug Add cool ant to radiator until coolant is at bottom of fill er neck and coolant trickles out of thermo stat housing plug hole This ensures all air is purged from the system Reinstall plug and radiator cap Check cool ant level in overflow bottle Engine coolant is a mixture of water and ethylene glycol base antifreeze A solution of 50 antifreeze and 50 water must be used in this engine Do not use 100 anti freeze or severe damage will occur OM 217 455 Page 32 IS A complete Parts List is available at www MillerWelds com Bl veel Lee ajuawenunuoa sopunBas oz ap sew iod asado sej eounn square 94S 010 je opuend o 9 o0L 4 09 ap eque 97S9 opuens O OgJ90O 7S9 asainbad as ON 97OM 2908JB esed 1349 SN ON JO1OUU e OJeAes OuED Bulunoo enbiod auejeBuoonue sp 00L 9Sh ON JO10U 9199 ue enBe ep 0G uoo ajuejeBuoonue 0S ap UOIOnIOS eun Jesn aqap SS J010UU jap eU TITIO E snonuiuoo SDUO29S 0Z Ugy e1oui 10 eje1ado JeAaN unem si euiBue UeyM 10 2 01 4 06 e oqe ueym p nb jou uoneiado BloN Burejs 104 19449 SN jou oq L9G9 LG891 eYoqny 029491 H3TIIW s6nld MOD LLOZ6 L88GL eloqny 6S7Z81 H3TIIN Jnooo M eBewep eJeAes 10 ozeel 9ue 00L ssn jou oq SuIBug SIU Ul DeSh aq snu CI Tn pue 9 Z991J JUE 9 09 Jo UONN OS V Buijoo9 aul6u3 seJou 000Z epe sejiqoose sej BoBldUaey SB7O07 0001 BOB sozipejeqsel sojjjue A Sg dO2S9 SB
46. S4 gt gt FS1 E go N AA T 20 EK RC39 Q fe ie S N PLG39 LOW OIL RC36 A D PRESSURE _ 12 VOLT PLG36 N C 56 GLOW BATTERY s5d PLUG NEGATIVE 42 de 42 42 42 42 42 42 T7 T T Tl TT 77 TI OM 217 455 Page 42 Figure 11 1 Circuit Diagram For Welding Generator C F A B D E d bo dh on 42 42 Z 60 GO 87 42 42 G2 GO GO 67 42 120V Y W G GS GI OO CB3 ITH z F lL 30 a GFCI RECEPTACLE RC3 OPTION 120V ES VY Y Y Wc KK e He EA CB3 e yim 5 42 42 GND N 42 T A CA CO rm i GFCI 3 CB2 64 VY Y RC2 OQ TS oO HE 80 CB2 20 Nm o S EA oN BS 42 GND Li 2 as A 2 A 54 so i x X X GFCI 2 A 7 AX 83 RC1 oe Y WX i 42 240V amp oN 84 28 i OQ DC Z 240V AN RCI Y W X D 29 Jlo sn Sot ee ee eee eee EA eae ELECT ope 9 M 8 Q5 26 o 9 T 10 6 gt VR1 O 11 5 0 25 35 M4 oO L_ 1 2 3 Es l 30 e O WORK POSITION S2 amp Luz lt 4 8 alz2 b RUN IDLE X Z RUN x x X amp START X X CLOSED TO B ERMINAL BASE PANEL S2 PLG8 GROUND GROUND START BATTERY RUN IDLE amp WARNING e Do not touch live electrical parts AUN e Disconnect input
47. TION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 2 1 Signification des symboles 2 2 Dangers relatifs au soudage l arc 2 3 Dangers existant en relation avec le moteur 2 4 Dangers li s l air comprim 2 5 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 2 6 Proposition californienne 65 Avertissements 2 7 Principales normes de s curit eee eee eee e eee e eee eens 278 Information EMF 2m TE ad pace Rae Oo went RR SECTION 3 DEFINITIONS 5 SECTION 4 SPECIFICATIONS 60 0633 TEE 4 1 Weld Power and Engine Specifications 4 2 Dimensions Weights and Operating Angles 4 3 Dimensions For Units With Optional Running Gear SECTION 5 INSTALLATION ole ge Vette ex ehe KTC RPR eee 5 1 Installing Welding Generator 5 2 installing Exha st Pipen 5er eene eee de ue Eque Rede ed prog EU p eue 5 9 Gonnecting the Ballery eerte rece EE see og orm odd pea ig ad wg D Y nt 5 4 Overview And Engine Prestart Checks
48. Watt Generator MADE IN B 86 na APPLETON WI VW WP EAR 4 SET AT 7 10 FOR POWER WHILE WELDING SET AT 10 FOR MAX GENERATOR POWER e RUN IDLE or IDLE LOCK RUN START GLOW PLUGS 1 Weld Process Selector Switch NOTICE Do not switch while welding Use switch to select type of weld output Wire GMAW Welding Use a positive position for Direct Current Electrode Positive DCEP and a negative position for Direct Current Electrode Negative Stick SMAW and TIG GTAW Welding Use a positive position for Direct Current Elec trode Positive DCEP and a negative posi tion for Direct Current Electrode Negative Use AC position for alternating current 2 Coarse Range Switch NOTICE Do not switch while welding Use switch to select weld amperage range when Weld Process Selector switch is in Stick Tig position or voltage range when switch is in Wire position gt For best arc starts and when using weld and generator power together use a low Coarse Range setting with the Fine con trol set at 7 or higher Ref 228 647 A 3 Fine Control Use control to select weld amperage Stick Tig or voltage Wire within the range selected by the Coarse Range switch Control may be adjusted while welding Set control at 10 for maximum generator power Weld output would be about 124 A DC based on control settings shown 8096 of 60 to 140 A Settings shown are typical for welding
49. ce sur la pi ce aussi pr s que possible de la soudure En ce qui concerne les implants m dicaux Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de soudage par points de gougeage du coupage plasma ou de chauffage par induc tion Si le m decin approuve il est recommand de suivre les proc dures pr c dentes OM 217 455 Page 11 IS A complete Parts List is available at www MillerWelds com SECTION 3 DEFINITIONS 3 1 Symbol Definitions Fast Fast Slow D Stop Engine Run Weld Power c Run ldle y _ gt Slow Idle l Read Operator s A V Start Engine Manual Amperes Volts 3 Se Engine Oil Fuel Battery Engine Engine Check Valve Do not switch while Temperature Clearance CU mi welding A Work Connection e Positive Negative Alteinating Current Output AC Welding Arc if MIG GMAW oh Electrode my Wire ji 3 Stick SMAW S TIG GTAW Protective Earth h Hours S Seconds e Time D Ground DN E Circuit Protector 4 1 Weld Power and Engine Specifications Also see Performance Data in Section 13 Rated Maximum ione Kb ce eod Welding Open Circuit Generator Power Rating Re Engine 9 Output Voltage pacity 250 A 25 V CC AC 40 250 A 100 Duty 80 Cycle Feak 10 5 KVA KW Kubota D722 2
50. coolant mixture Running out of fuel air in fuel lines Using gasoline Using ether to start engine Wetstacking Engine Left Side Engine stops if oil pressure is low engine coolant temperature is high or fuel level is low Some conditions may cause engine IR damage before the engine shuts down 13 D Oil Check oil level often and do not use the oil pressure shutdown system to moni tor oil level Engine Temperature Incorrect engine temperature can damage engine Do not 9 9 1 run engine without a properly working ther 18 mostat and radiator cap o Keep radiator and air intake clean col base antifreeze and 50 water must Et be used in this engine Do not use 100 antifreeze or severe damage will occur M A f Coolant A solution of 5096 ethylene gly 15 Fuel Engine will shut down if fuel level is 17 Q low Air in the fuel system causes starting S problems Do not use gasoline Using ether voids warranty 16 Wetstacking If unburned fuel and oil col lect in exhaust pipe during run in see Sec tion 12 x To improve cold weather starting Keep battery in good condition Store battery in warm area Use fuel formulated for co
51. d during start up In Start position and Engine Control switch in Run or Run Idle engine is locked in idle speed In Run lIdle position and Engine Control switch in Run Idle engine runs at idle speed at no load and weld power speed under load In Run Idle position and Engine Control switch in Run engine runs at weld power speed Ref 228 647 A To Start Use glow plug switch if necessary Turn Engine Control switch to Start position Release switch when engine starts E If the engine does not start let engine come to a complete stop before attempt ing restart To Stop Turn Engine Control switch to Off position Close fuel valve to stop engine if Engine Control switch does not work see Section 5 4 4 FuelGauge Maintenance Display See insert from maintenance label OM 217 455 Page 20 6 2 Weld Output Controls EF A complete Parts List is available at www MillerWelds com J e f AN a WARNING ELECTRIC SHOCK CZ KILL DO NOT USE AC OUTPUT IN DAMP REAS 76 IF MOVEMENT IS CONFINED OR A DANGER OF FALUNG USEAC OUTPUT ONLY IF REQUIAI FOR THE WELDING PROCESS IFJHERE1S NEUTRAL BONDED TO FRAME NEUT RE RACGORDE AU BATI GND PE Oa DO NOT SWITCH WHILE WELDING NO CAMBIE CUANDO SEEST SOLDANDO 60 14 AMPS 1 8 40 100 AMPS 3 32 80 200 AMPS 6 32 100 250 AMPS 3167 CC CV AC DC Welder 10 000
52. dans un endroit l o des tincelles peuvent tomber sur des substances inflammables Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures Surveiller tout d clenchement d incendie et tenir un extincteur proximit Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient t pr par s correctement conform ment AWS F4 1 voir les nor mes de s curit Ne soudez pas si l air ambiant est charg de particules gaz OU va peurs inflammables vapeur d essence par exemple Brancher le c ble de masse sur la pi ce le plus pr s possible de la zone de soudage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provo quant des risques d lectrocution d tincelles et d incendie Ne pas utiliser le poste de soudage pour d geler des conduites ge l es En cas de non utilisation enlever la baguette delectrode du porte lectrode ou couper le fil la pointe de contact Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalon
53. e position Check for obstructed movement of solenoid linkage see Section 9 4 Have Factory Authorized Service Agent check idle module PC1 control relay CR2 control relay CR4 current transformer CT1 and throttle solenoid TS1 Engine does not remain at idle speed with Engine Control switch in Speed Lock position and Idle Lock switch in Idle position Check for obstructed movement of solenoid linkage see Section 9 4 Have Factory Authorized Service Agent check control relay CR2 control relay CR4 Idle Lock switch S7 and throttle solenoid TS1 Engine uses oil during run in period wetstacking occurs Dry engine see Section 12 and engine manual SECTION 10 PARTS LIST 10 1 Recommended Spare Parts Dia Part Mkgs No Description Quantity Recommended Spare Parts Da A I E VASE TAE 187441 Element Air Cleaner 1 WDR EM 202102 Element Air Cleaner Safety 1 RE EGGS on 213858 Filter Fuel In line 5 16x5 16 Mic 125 175 d RE 187442 Element Fuel Filter 1 D oe 187443 eli TE ER MR te Mine 187459 Belt Fan TA Mise GLOW PLUG 187820 Glow Plug 1 2 187819 Inlector ASSY LOANALOA AR Ra T e Rt rra d A sr ne 206421 Filter Kit Kubota 722 Includes air cleaner element fuel oil fi
54. ear Parts and Labor Unless Specified Motor Driven Guns w exception of Spoolmate Spoolguns Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Coolers and Electronic Controls Recorders Water Coolant Systems Non Integrated Flowgauge and Flowmeter Regulators No Labor HF Units Grids Spot Welders Load Banks Arc Stud Power Sources amp Arc Stud Guns Racks Running Gear Trailers Plasma Cutting Torches except APT amp SAF Models Field Options NOTE Field options are covered under True Blue for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater Bernard Branded Mig Guns No Labor Weldcraft Branded TIG Torches No Labor Subarc Wire Drive Assemblies 6 Months Batteries 90 Days Parts MIG Guns TIG Torches and Subarc SAW Guns Induction Heating Coils and Blankets Cables and Non Electronic Controls APT amp SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Millers True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Bobcat Trailblazer and Le
55. ecurely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists in inverters after stop ping engine e Stop engine on inverter and discharge input capacitors according to instructions in Maintenance Section before touching any parts HOT PARTS can cause severe burns e Do not touch hot parts bare handed e Allow cooling period before working on equip ment e To handle hot parts use proper tools and or wear heavy insu lated welding gloves and clothing to prevent burns cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet FLYING METAL or DIRT can injure eyes e Welding chipping wire brushing and grinding OM 217 455 Page 1 FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data She
56. ehicle frame by met al to metal contact Bed liners shipping skids and some running gear insu late the welding generator from the vehicle frame Al ways connect a ground wire from the generator equip ment grounding terminal to bare metal on the vehicle frame as shown If unit does not have GFCI re ceptacles use GFCI pro tected extension cord S 0854 OM 217 455 Page 51 14 3 Grounding When Supplying Building Systems 1 Equipment Grounding Terminal 2 Grounding Cable Use 10 AWG or larger insulated copper wire 3 Ground Device EF Use ground device as stated in electrical codes A Ground generator to system earth ground if supplying power to a premises home shop farm wiring system A Also see AWS Safety amp Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Generators ST 800 576 B 14 4 How Much Power Does Equipment Require VOLTS 115 2 AMPS 4 5 1 Hz 60 60W 1 Resistive Load A light bulb is a resistive load and requires a constant amount of power 2 Non Resistive Load Equipment with a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when running see Section 14 8 3 Rating Data Rating shows volts and amperes or watts required to run equipment Amperes x Volts Watts Example 1 If a drill uses 4 5 am peres at 115 v
57. eld output Be sure all equipment is disconnected from receptacles when starting unit Check fuses F1 and F2 and replace if open see Section 9 5 Check engine ignition wiring connections Have Factory Authorized Service Agent check brushes slip rings and integrated rectifiers SR2 and SR3 OM 217 455 Page 39 IS A complete Parts List is available at www MillerWelds com Trouble Remedy Low power output at ac receptacles Increase Fine control R1 setting to max Check fuse F2 and replace if open see Section 9 5 High power output at ac receptacles Check engine speed and adjust if necessary see Section 9 4 Erratic power output at ac receptacles Check fuel level Check engine speed and adjust if necessary see Section 9 4 Check receptacle wiring and connections Have Factory Authorized Service Agent check brushes and slip rings C Engine Maintenance Display Action noFUEL Place Engine Control switch in the Off position refuel and start engine HI H2O Coolant temperature is too high Allow engine to cool and check coolant level see Section 9 2 LO OIL Oil pressure is too low Allow engine to cool and check oil level see Section 9 2 Trouble Remedy Engine does not crank Supplementary protector CB8 may be open see Section 9 5 Wait and retry Check battery voltage Check battery connections
58. enir proximit Des fumees et des gaz de soudage peuvent d placer l air et abaisser le niveau d oxygene provoquant des blessures ou des accidents mortels S assurer que l air de respiration ne pr sente aucun danger e Ne pas souder dans des endroits situ s proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et for mer des gaz hautement toxiques et irritants e Ne pas souder des m taux munis d un rev tement tels que l acier galvanis plaqu en plomb ou au cadmium moins que le rev te ment n ait t enlev dans la zone de soudure que l endroit soit bien ventil et en portant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage LES ACCUMULATIONS DE GAZ ris quent de provoquer des blessures oi m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confin s ou se servir d un respirateur d adduction d air homologu LES RAYONS DE L ARC peuvent pro voquer des br lures dans les yeux e sur la peau Le rayonnement de l arc du proc d de soudag g n re des rayons visibles et invisibles intense ultraviolets et infrarouges susceptibles de provoquer des br lure dans les yeux et sur la peau Des tincelles sont projet es pendant s
59. ep ap OIOBdS 0 ye soueuous4 DuiUB ploD seouelealD eAIe gg dnoly 19g Menpg 10A ZL 96ESESd uospeuoq 0LZ0Z YATIIN 6vv9v XIM 989ZZ8d uospjeuog SLZESH UIMPIE4 2474 1 HATIIN ouenp jap lenueu le geh sousu O SLO 00L enue SSUAO 39S SSaj 10 SJnOu 00L LI 18 UB SQUOJIONASU Sej Bal BEIBJSUI ap Sajue ordu 9797S77907O2 Uoo OY 9 909 7 18 j uo suononujsui pee Buij ejsui asojaq N uea o YYM 49 Ill O9S t LEZSL eloqny cbZ8Ld TTIW USWA 491 ISn Jepuoo9S sel0y 002 epeo OMY la elqwed anou 002 Alana ay 9BueuO 09145 SBunseH 8S8ELZ HATIIN ueluoo unyng xew G ulw Gp ON BURIED A Z yum 18 2 1b o g 10 19 2 1b sz z V6v9cHd Weld 20 41 sbunseH 0ZT66 EG8GL 1OdT 8L HATIIN souew 0 SBJOY 002 Ole Se PWIOU SeuololpuoD AISOOSIA AISOOSIA sousw o seJou 00L ejBuis On 10feui 0 29 49 99 IdV 0 2IA12S ep uo1989 opepusw0seyY 3429W Ssal 10 SINOY 002 suonipuoo IBUJJOU Ssal 10 sunou 00L 1eneq 10 49 09 99 SEJI IMS ldV p pu wwos y SOH AI U z L OJUSUEIIEIG eenbeu2 Z MOO un puy dsnd UETSPEEWEBY io urea ol BARS sezaid o soued guapo opueno alas ap OSUJnU e 4olou jap uoroeoyioedse el eq 4olou ep olelduoo opeplno le eed Jolou lep jenuew ja SA sued 5ul 9D O U8JA JequnN jenas pue uoneolyloeds euiBu3 eAID 2489 eul6uae slelduoo 104 enuey eulbuy 39S ANION3 ZZZq VLOGN 1V9404 804 197 A Ref 803 111 A 227 727 OM 217 455 Page 33
60. er la maintenance e N utiliser que les pi ces de rechange recommand es par le constructeur 2 5 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Risque D INCENDIE OU D EXPLO SION e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Ne pas installer l appareil proximit de pro duits inflammables e Ne pas surcharger l installation lectrique s assurer que l ali mentation est correctement dimensionn e et prot g e avant de mettre l appareil en service BEEN LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage pour lever l appareil et les accessoires correctement install es seuls PAS les bouteilles de gaz Ne pas d passer le poids nominal maximal de l ceilleton voir les sp cifications e Ne lever et ne soutenir l appareil qu avec de l quipement appropri et en suivant les proc dures ad quates e Enutilisant 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 217 455 Page 9 LE SURCHAUFFEMENT peut endom mager le moteur lectrique Arr ter ou d connecter l quipement avant de d marrer ou d arr ter le moteur e Ne pas laisser tourner le moteur trop lentement sous risque d en dommager le moteur lectrique cause d une tension et d une fr quence trop faibles e Ne pas brancher de m
61. eration Check fuel level and fault indicators on fuel gauge see Section 6 1 Open fuel valve see Section 5 6 Check oil level See Section 5 6 and fault indicators on fuel gauge see Section 6 1 Engine will not start if oil pressure is too low Check coolant level and fan belt see Section 5 6 and engine manual and check fault indicators on fuel gauge see Section 6 1 Engine stops if engine temperature is too high Have Factory Authorized Service Agent check low oil pressure shutdown switch S5 and engine tem perature switch S4 OM 217 455 Page 40 IS A complete Parts List is available at www MillerWelds com Trouble Remedy Battery discharges between uses Clean top of battery with baking soda and water solution rinse with clear water Periodically recharge battery approximately every 3 months Replace battery Check voltage regulator according to engine manual Engine does not return to idle speed when load is removed with Engine Control switch in Run Idle position Remove all weld and generator power loads Check for obstructed movement of solenoid linkage see Section 9 4 Have Factory Authorized Service Agent check idle module PC1 current transformer CT1 idle lock Switch S7 throttle solenoid TS1 and Engine Control switch S2 Engine does not remain at weld power speed when power or weld load is applied with Engine Control switch in Run ldl
62. ery e Replace damaged battery e Flush eyes and skin immediately with water ENGINE HEAT can cause fire e Do not locate unit on over or near combustible surfaces or flammables e Keep exhaust and exhaust pipes way from flammables EXHAUST SPARKS can cause fire e Do not let engine exhaust sparks cause fire e Use approved engine exhaust spark arrestor in required areas see applicable codes TRAPPED AIR PRESSURE AND WHIPPING RY HOSES can cause injury e Release air pressure from tools and system be fore servicing adding or changing attach ments or opening compressor oil drain or oil fill cap OM 217 455 Page 3 HOT METAL from air arc cutting and gouging can cause fire or explosion Lh 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 Let system cool down before touching or ser vicing READ INSTRUCTIONS e Read Owner s Manual before using or servic ing unit Stop engine and release air pressure before servicing Use only genuine replacement parts from the manufacturer 1 5 Additional Symbols For Installation Operation And Maintenance FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly s
63. es des personnes qualifi es sont autoris es enlever les por tes panneaux recouvrements ou dispositifs de protection pour RENDRE AVEUGLE effectuer s il y a lieu des travaux d entretien et de d pannage e Toujours porter une protection faciale des gants e Pour emp cher tout d marrage accidentel pendant les travaux en caoutchouc et v tements de protection lors d entretien d brancher le c ble n gatif de batterie de la borne d une intervention sur la batterie e Ne pas approcher les mains cheveux v tements l ches et outils x x des organes mobiles Arr ter le moteur avant de d brancher ou de brancher les c bles 9 de batterie e Remettre en place les panneaux ou les dispositifs de protection et e Eviterd des tincell til t illant fermer les portes la fin des travaux d entretien et avant de faire viter de provoquer des tincelles avec les outils en travaillant sur d marrer le moteur la batterie en ME A e Avant d intervenir d poser les bougies ou injecteurs pour viter la e Ne pas utiliser le poste de soudage pour charger les batteries ou HT j mise en route accidentelle du moteur des v hicules de d marrage rapide JM e Bloquerle volant moteur pour viter sa rotation lors d une interven e Observer la polarit correcte et sur les batteries tion sur le g n rateur e D brancher le c ble n gatif en premier lieu Le rebrancher en E dernier lieu DES PIECES CHAUDES peuve
64. ets MSDSs and the manufacturer s instructions for metals consumables coatings cleaners and degreasers e Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe e Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases e Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded l BUILDUP OF GAS can injure or kill e Shut off shielding gas supply when not in use e Always ventilate confined spaces or use ap proved air supplied respirator ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld e Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards e Wear approved safe
65. gend models 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this 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 HERE
66. inders contain gas under high pres sure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks physical damage slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Use the right equipment correct procedures and sufficient num ber of persons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Engine Hazards BATTERY EXPLOSION can BLIND e Always wear a face shield rubber gloves and protective clothing when working on a battery e Stop engine before disconnecting or connect
67. ing battery cables or servicing battery Do not allow tools to cause sparks when working on a battery Do not use welder to charge batteries or jump start vehicles Observe correct polarity and on batteries Disconnect negative cable first and connect it last FUEL can cause fire or explosion e Stop engine and let it cool off before checking or adding fuel e Do not add fuel while smoking or if unit is near any sparks or open flames Do not overfill tank allow room for fuel to expand Do not spill fuel If fuel is spilled clean up before starting engine Dispose of rags in a fireproof container Always keep nozzle in contact with tank when fueling MOVING PARTS can cause injury e Keep away from fans belts and rotors Q e Keep all doors panels covers and guards closed and securely in place e Stop engine before installing or connecting unit e Have only qualified people remove doors panels covers or guards for maintenance and troubleshooting as necessary To prevent accidental starting during servicing disconnect negative battery cable from battery e Keep hands hair loose clothing and tools away from moving parts e Reinstall doors panels covers or guards when servicing is finished and before starting engine e Before working on generator remove spark plugs or injectors to keep engine from kicking back or starting e Block flywheel so that it will not turn while wor
68. ing or increase wire feed speed Work Clamp Wire Feeder MIG Gun Gun Trigger Plug Voltage Sensing Clamp oar GM Gas Cylinder 75 25 Argon CO Gas for Short Circuit Transfer 80 Argon Or Higher CO For Spray Transfer 7 Gas Hose Connect work cable to welding generator Work terminal Connect cable from wire feeder to cable from welding generator Electrode terminal Ref 804 249 A Ref 228 647 A Ref 802 766 C OM 217 455 Page 23 IS A complete Parts List is available at www MillerWelds com 6 5 Typical MIG Connections And Settings Using Weld Control And Spoolgun OPM ae Sohn Tools Needed 3Q e8 3 4 in A Stop engine This section provides general guide lines and may not suit all applications Typical Settings For 4043 035 Aluminum On 1 8 in Material gt Set Weld Process Selector switch to Wire DCEP position gt Set Coarse Range switch to Wire Low 17 22 volts position gt Set Fine Control to desired voltage arc length Start with a low voltage setting about 4 to prevent burnback oa BR WD DO NOT SWITCH WHILE WELDING NO GAMBIE CUANDO SEEST 60 vi ilt K_ Not Used N ap To Work Set wire feed speed between 240 270 ipm For 1 4 i
69. ing or taping them or using a cable cover 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 Keep welding power source and cables as far away from operator as practical 5 Connect work clamp to workpiece as close to the weld as possible About Implanted Medical Devices Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding spot welding gouging plasma arc cutting or induction heating operations If cleared by your doctor then following the above procedures is recom mended OM 217 455 Page 5 SECTION 2 CONSIGNES DE SECURITE LIRE AVANT UTILISATION rom_2007 04fre A Se prot ger ainsi que toute autre personne travaillant sur les lieux contre les tincelles et le m tal chaud Signification des symboles 2 1 DANGER Indique une situation dangereuse qui si on Fevite pas peut donner la mort ou des blessures graves Les dangers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dan gers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte NOTE Indique des d clarations pas en relation avec des blessures personnelles 2 2 Dangers relatifs au soudage l arc A Les symboles pr sent s ci apres sont utili
70. iques pour stocker d placer ou exp dier des cartes de circuits imprimes OM 217 455 Page 10 entrainer des blessures e Utiliser les supports de la remorque ou des blocs pour soutenir le poids e Installer convenablement le poste sur la remor que comme indiqu dans le manuel s y rappor tant LIRE LES INSTRUCTIONS e Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil e N utiliser que les pi ces de rechange recom mand es par le constructeur e Effectuer la maintenance et le service du moteur et du compres seur d air suivant les instructions dans ce manuel ou le manuel du moteur compresseur si applicable RI El UNE REMORQUE QUI BASCULE peut LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Lerayonnement haute fr quence H F peut provoquer des interf rences avec les quipe ments de radio navigation et de communica tion les services de s curit et les ordinateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l instal lation e L utilisateur est tenu de faire corriger rapidement par un lectri cien qualifi les interf rences r sultant de l installation e Sile FCC signale des interf rences arr ter imm diatement l ap pareil Effectuer r guli rement le contr le et l entretien de l installation e Maintenir soigneusement ferm s les po
71. ive date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Miller must be notified in writing within thirty 80 days of such defect or failure at which time Miller will provide instructions on the warranty claim procedures to be followed Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the delivery date of the equipment to the original end user purchaser and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Process Controllers Semi Automatic and Automatic Wire Feeders Inverter Power Sources Unless Otherwise Stated Water Coolant Systems Integrated Intellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Y
72. ized rated and protected to handle this unit FALLING UNIT can cause injury e Use lifting eye to lift unit and properly installed accessories only NOT gas cylinders Do not exceed maximum lift eye weight rating see Specifications e Lift and support unit only with proper equipment and correct procedures e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit OVERHEATING can damage motors e Turn off or unplug equipment before starting or stopping engine e Do not let low voltage and frequency caused by low engine speed damage electric motors e Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable L3 FLYING SPARKS can cause injury e Wear a face shield to protect eyes and face e Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face hand and body protection e Sparks can cause fires keep flammables away N MOVING PARTS can cause injury e Keep away from moving parts e Keep away from pinch points such as drive rolls 3 OM 217 455 Page 4 WELDING WIRE can cause injury e Do not press gun trigger until instructed to do so e Do not point gun toward any part of the body TT K other people or any metal when threading welding wire OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle Reduce current or red
73. king on generator components HOT PARTS can cause severe burns Do not touch hot parts bare handed e Allow cooling period before working on equip ment e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns 1 4 Compressed Air Hazards BREATHING COMPRESSED AIR can cause serious injury or death e Do not use compressed air for breathing e Use only for cutting gouging and tools COMPRESSED AIR can cause injury e Wear approved safety goggles e Do not direct air stream toward self or others STEAM AND HOT COOLANT can burn e f possible check coolant level when engine is cold to avoid scalding e Always check coolant level at overflow tank if present on unit instead of radiator unless told otherwise in maintenance section or engine manual e Ifthe engine is warm checking is needed and there is no over flow tank follow the next two statements e Wear safety glasses and gloves and put a rag over radiator cap e Turn cap slightly and let pressure escape slowly before completely removing cap Using a generator indoors CAN KILL YOU IN MINUTES e Generator exhaust contains carbon monoxide This is a poison you cannot see or smell e NEVER use inside a home or garage EVEN IF doors and windows are open e Only use OUTSIDE and far away from windows doors and vents BATTERY ACID can BURN SKIN and EYES e Do not tip batt
74. ld weather diesel fuel can gel in cold weather Contact local fuel supplier for fuel i information Use correct grade oil for cold weather Engine Right Side 804 249 A 804 250 A OM 217 455 Page 17 IS A complete Parts List is available at www MillerWelds com 5 5 Connecting to Weld Output Terminals WORK 120 240V X 50 A MAIN BREAKER ON OFF MAIN BREAKER vf ELECTRODE Do not place anything between weld cable terminal and copper bar Correct Installation Incorrect Installation 1 Work Weld Output Terminal 2 Electrode Weld Output Terminal Connect work cable to Work terminal Connect electrode holder cable or electrode weld cable to Electrode ter minal for Stick and MIG welding Connect torch cable to Electrode ter minal for TIG welding Use Process Selector switch to select type of weld output see Section 6 2 See Sections 6 3 thru 6 5 for typi cal process connections and control settings Failure to properly connect weld cables may cause exces sive heat and start a fire or damage your machine 3 Weld Output Terminal 4 Supplied Weld Output Terminal Nut 5 Weld Cable Terminal 6 Copper Bar Remove supplied nut from weld
75. le Causes Corrective Actions Excessive heat input Use restraint clamp to hold base metal in position Make tack welds along joint before starting welding operation Select lower amperage for electrode Increase travel speed Weld in small segments and allow cooling between welds OM 217 455 Page 65 Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual 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 C Miller Effective January 1 2007 Equipment with a serial number preface of LH or newer This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Miller equipment sold after the effect
76. ls Fuel Filters Every Engine 500 Manual Hours Section 9 4 Flush Radiator Weld Cables Slip Rings Brushes 1500 Hours Every Section 9 2 800 Hours Valve Clearance Every REAR Engine 2000 A Manual Hours Section 9 2 Fuel Hoses X Fuel Hoses X Coolant amp Hoses OM 217 455 Page 31 9 2 IS A complete Parts List is available at www MillerWelds com Maintenance Label And Engine Maintenance Activities ww w A Stop engine and let cool Oil And Fuel 1 OilDrain Valve 2 OilFilter Change engine oil and filter according to en gine manual NOTICE Close valve and valve cap before adding oil and running engine Fill crankcase with new oil to full mark on dip stick see Section 5 4 3 Fuel Lines Replace fuel lines if cracked or worn 4 Inline Fuel Strainer Install new filter as shown 5 Euel Filter Replace filter according to engine manual Wipe up any spilled fuel Start engine and check for fuel leaks A Stop engine tighten connections as necessary and wipe up fuel Coolant 6 Radiator Cap 7 Radiator Drain Cocks One located on bottom of radiator Drain engine coolant according to proce dure in engine manual Add engine coolant as follows 8 Thermostat Housing
77. lters 1 acting Ea F1 F2 169296 Fuse Mintr GI 25 Amp 125 Volt 2 Optional FF A complete Parts List is available on line at www Miller Welds com OM 217 455 Page 41 SECTION 11 ELECTRICAL DIAGRAMS 105 yr B qx PLG6 RC6 SR 110 hee 2 102 gt 2 gt 104s 45 TE F2 707 gt 3 gt PLG6 RC6 LAG 4 72 RI 111 R2 AT 4 703 104 102 107 81 20 90 1084 xz NV EXCITATION POWER 82 4 r eg 112 SE REVOLVING FIELD 429 n 43 T LZ ET s 25 431 HE WELD 7 O x PC O R j F n 63 a CT AC Z 20 42 21 22 1 1 23 40 v L 3 1 K 24 PLe8 y K 25 10 61 LEVEL SENDER SR1 72 42 rx S 46 57 58 1 l 1 A A A A A A A A RC5 7 2 1 9 5 6 4 8 3 PLG5 ALTERNATOR IG al CT DOR o L gt gt RX 60 42 CR PLG36 PLG39 PLG39 49 RC36 IV V2pcss Yl RC39 2 VOLT pu WATER m STARTER AED TEMP o 2 m WHT
78. mation on wiring optional 240 V single phase plug 2 120V 20 A Duplex Receptacle RC2 3 120 V 20 A Duplex Receptacle RC3 RC2 and RC3 supply 60 Hz single phase power at weld power speed Maximum out put from RC2 or RC3 is 2 4 kVA kW 2 3 4 Supplementary Protector CB1 o CB1 protects receptacles RC1 RC2 and RC3 from overload If CB1 opens the recep tacles do not work Place switch in On posi tion to reset 5 Supplementary Protector CB2 6 Supplementary Protector CB3 8 od CB2 protects RC2 and CB3 protects RC3 from overload If a supplementary protector O opens the receptacle does not work EF Press button to reset If supplementary f ow protector continues to open contact 120 240V Factory Authorized Service Agent c V tn 4 A Hoi ea 120V i Power is still present at the 240 volt WORK ON OFF lt MAIN BREAKER ELECTRODE receptacle if CB2 and or CB3 trips Unplug power cord before attempting to service accessories or tools 7 Optional 120 V 20 A AC GFCI Recep tacles GFCI 2 and GFCI 3 GFCI2 and GFCI3 supply 60 Hz single 4 phase power at weld power speed Maxi mum output from GFCI 2 or GFCI 3 is 2 4 kVAkW Circuit protection is the same as standard receptacles If a ground fault is detected the GFCI Reset button pops out and the circuit opens to dis connect the faulty equipment Check for damaged tools cords
79. may contain flammable dust gas or liquid vapors such as gasoline Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire haz ards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap Remove any combustibles such as a butane lighter or matches from your person before doing any welding After completion of work inspect area to ensure it is free of sparks glowing embers and flames Use only correct fuses or circuit breakers Do not oversize or by pass them Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby n NOISE can damage hearing Noise from some processes or equipment can dam age hearing e Wear approved ear protection if noise level is high MAGNETIC FIELDS can affect Implanted Medical Devices e Wearers of Pacemakers and other Implanted Medical Devices should keep away Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding spot welding gouging plasma arc cutting or induction heating operations CYLINDERS can explode if damaged Shielding gas cyl
80. n 6 mm and thicker materials set Coarse Range switch to Wire High and Fine Control to 6 In crease decrease Fine Control setting to increase decrease arc length Weld Control Spoolgun Optional Contactor Recommended Reed Switch Weld Cable Customer Supplied Weld Control Weld Terminal Ref 804 249 A Ref 228 647 A Ref 802 750 A 7 Weld Power Cable From Spoolgun 8 Work Clamp 9 Gas Hose 10 100 Argon Cylinder 11 Trigger Control Cord 12 Input Power Cord Route weld cable from welding generator Electrode terminal through reed switch to unused contactor terminal Connect weld cable from spoolgun to weld control weld terminal item 6 Connect work cable to welding generator Work terminal OM 217 455 Page 24 IS A complete Parts List is available at www MillerWelds com SECTION 7 OPERATING AUXILIARY EQUIPMENT 7 1 Generator Power Receptacles A If unit does not have GFCI recep tacles use GFCI protected extension cord NOTICE Disconnect equipment from auxil iary power receptacles during start up and shutdown Some equipment can be dam aged by changes in frequency as engine rpms change during start up and shutdown x Generator power decreases as weld current increases Set Fine Control R1 at 10 for full genera tor power 1 240 V 50 A AC Receptacle RC1 RC1 supplies 60 Hz single phase power at weld power speed Maximum output is 10 kVA kW See section 7 3 for infor
81. nit where air flow is restricted or engine may over heat Mounting 1 Cross Supports Mount unit on flat surface or use cross supports to support base Grounding 2 Equipment Grounding Terminal On Front Panel 3 Grounding Cable Not Supplied 4 Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insu lated copper wire install2 12 06 Ref 800 652 Ref 800 477 A 803 274 804 712 OM 217 455 Page 14 IS A complete Parts List is available at www MillerWelds com 5 2 Installing Exhaust Pipe oe A Stop engine and let cool AP A Do not blow exhaust toward right side of unit where air inlet is or air cleaner may require frequent service Point ex haust pipe in desired direction but always away from front panel and direction of travel SK RUN IDLE Tools Needed 1 2 in 804 196 A Ref 228 647 A 5 3 Connecting the Battery A Connect negative cable last Tools Needed I 1 2 in 804 250 A Ref 228 647 Ref S 0756 D OM 217 455 Page 15 IS A complete Parts List is available at www MillerWelds com 5 4 Overview And Engine Prestart Checks 1 Generator Power Receptacles see 7 Radiator Cap 13 Oil Drain Section 7 8 Engine Maintenance Label Inside Door 14 Oil Dipstick 2 Ned Outpu
82. nstructions APA This group of symbols means Warning Watch Out ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult sym bols and related instructions below for necessary actions to avoid the hazards e Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet e When making input connections attach proper grounding conduc tor first double check connections Keep cords dry free of oil and grease and protected from hot metal and sparks e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual e Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present e Wear a safety harness if working above floor level Keep all panels and covers s
83. nt provoquer des br lures graves LE CARBURANT MOTEUR peut provo quer un incendie ou une explosion e Ne pas toucher mains nues les parties chau des Arr ter le moteur avant de v rifier le niveau de e Pr voir une p riode de refroidissement avant de carburant ou de faire le plein travailler l quipement Ne pas faire le plein en fumant ou proche d une source d tincelles Ne pas toucher aux pi ces chaudes utiliser les outils recomman ou d une flamme nue d s et porter des gants de soudage et des v tements pais pour viter les br lures LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT CHAUD peuvent provoquer des br lures e Ne pas faire le plein de carburant ras bord pr voir de l espace pour son expansion e Faire attention de ne pas renverser de carburant Nettoyer toul carburant renvers avant de faire d marrer le moteur Jeter les chiffons dans un r cipient ignifuge Toujours garder le pistolet en contact avec le r servoir lors du e Il est preferable de verifier le liquide de refroi dissement une fois le moteur refroidi pour viter remplissage de se br ler La DES ORGANES MOBILES peuvent pro e Toujours v rifier le niveau de liquide de refroidissement dans le voquer des blessures vase d expansion si pr sent et non dans le radiateur sauf si pr cis autrement dans la section maintenance du manuel du e Ne pas approcher les mains des ventilateurs R ER moteur courroie
84. olts calculate its run ning power requirement in watts 4 5 x 115 V 520 W The load applied by the drill is 520 watts Example 2 If three 200 watt flood lamps are used with the drill from Ex ample 1 add the individual loads to calculate total load 3 x 200W 520 W 1120 W The total load applied by the three flood lamps and drill is 1120 watts S 0623 OM 217 455 Page 52 14 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 14 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 1HP 6100 1600 1 1
85. oste souder manuel AC avec tension vide r duite Dans la plupart des cas un poste courant continu de type CV est recommand Et ne pas tra vailler seul e Couper l alimentation ou arr ter le moteur avant de proc der l installation la r paration ou l entretien de l appareil D verrouiller l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de s curit e Installer et mettre la terre correctement cet appareil conform ment son manuel d utilisation et aux codes nationaux provinciaux et municipaux e Toujours v rifier la terre du cordon d alimentation V rifier et s assurer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre e En effectuant les raccordements d entr e fixer d abord le conduc teur de mise la terre appropri et contre v rifier les connexions e Les c bles doivent tre exempts d humidit d huile et de graisse prot gez les contre les tincelles et les pi ces m talliques chau des e V rifier fr quemment le cordon d alimentation pour voir s il n est pas endommag ou d nud remplacer le cordon imm diatement S il est endommag un c ble d nud peut provoquer une lectro cution Mettre l appareil hors tension quand on ne l utilise pas Ne pas utiliser des c bles us s endommag s de grosseur insuffi sante ou mal
86. oteur de 50 ou de 60 Hz la prise de 100 Hz n LES TINCELLES VOLANTES ris quent de provoquer des blessures N e Porter un cran facial pour prot ger le visage et les yeux e Aff ter l lectrode au tungst ne uniquement la meuleuse dot e de protecteurs Cette manceuv re est ex cuter dans un endroit s r lorsque l on porte l quipement homologu de protection du visage des mains et du corps e Les tincelles risquent de causer un incendie loigner toute sub stance inflammable DES ORGANES MOBILES peuvent provoquer des blessures e Ne pas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande LES FILS DE SOUDAGE peuvent provoquer des blessures e Ne pas appuyer sur la g chette avant d en avoir re u l instruction e Ne pas diriger le pistolet vers soi d autres per sonnes ou toute pi ce m canique en enga geant le fil de soudage Tm i L EMPLOI EXCESSIF peut SURCHAUFFER L QUIPEMENT e Laisser l quipement refroidir respecter le fac teur de marche nominal e R duire le courant ou le facteur de marche avant de poursuivre le soudage e Ne pas obstruer les passages d air du poste Pa LES CHARGES LECTROSTATI QUES peuvent endommager les circuits imprim s e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antistat
87. oudage Porter un casque de soudage approuv muni de verres filtrants appropri pour prot ger visage et yeux pendant le soudage voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit Porter des lunettes de s curit avec crans lat raux meme sous votre casque Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les blouissements et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc Porter des v tements confectionn s avec des mati res r sistan tes et ignifuges cuir coton lourd ou laine et des bottes de protection FRA LE SOUDAGE peut provoquer un in cendie ou une explosion Le soudage effectu sur des conteneurs ferm s tel que des r servoirs tambours ou des conduites pet provoquer leur clatement Des tincelles peuver tre projet es de l arc de soudure La projection d tincelles des pi ce chaudes et des quipements chauds peut provoquer des incendies e des br lures Le contact accidentel de l lectrode avec des objet m talliques peut provoquer des tincelles une explosion un surchau fement ou un incendie Avant de commencer le soudage v rifier s assurer que l endroit ne pr sente pas de danger D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneusement avec des protections homologu s Ne pas souder
88. ovoquent des mal formations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants A Les batteries les bornes et autres accessoires contiennent du plomb et des compos s a base de plomb produits chimi ques dont l tat de Californie reconnait qu ils provoquent des cancers et des malformations congenitales ou autres problemes de procr ation Se laver les mains apr s manipu lation 2 7 Principales normes de s curit Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com National Electrical Code NFPA Standard 70 de National Fire Protec tion Association P O Box 9101 Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de Compressed Gas Association 4221 Walney Road 5th Floor Chan tilly VA 20151 t l phone 703 788 2700 site Internet www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 de Canadian Standards Association 5060 Mississauga Ontario Canada 2 8 Information EMF
89. 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 Diece ou le c ble de retour Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine Ne pas toucher des porte lectrodes connect s deux machines en m me temps cause de la pr sence d une tension vide dou bl e e N utiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment ce manuel Porter un harnais de s curit quand on travaille en hauteur Maintenir solidement en place tous les panneaux et capots Fixer le c ble de retour de facon obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s possible de la soudure e lsoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique Une tension DC importante subsiste l int rieur des onduleurs apr s avoir coup l alimentation e Couper l alimentation du poste et d charger les condensateurs d entr e comme indiqu dans la Section Maintenance avant de toucher des composants DES PI CES CHAUDES peuvent provoquer des br lures graves e Ne pas toucher mains nues les parties chau des e Pr voir une p riode de refroidissement avant
90. plete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks To locate a Distributor or Service Agency visit www millerwelds com or call 1 800 4 A Miller File a claim for loss or damage during shipment Contact the Delivering Carrier to For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA 2007 Miller Electric Mfg Co 2007 01 Miller Electric Mfg Co An Illinois Tool Works Company 1635 West Spencer Street Appleton WI 54914 USA International Headquarters USA USA Phone 920 735 4505 Auto Attended USA amp Canada FAX 920 735 4134 International FAX 920 735 4125 European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 www MillerWelds com un Miller
91. power or stop S engine before servicing Do not operate with covers removed ELECTRIC Have only qualified persons install SHOCK HAZARD use or service this unit 228 719 B OM 217 455 Page 43 RC1 PLe10 gei see LS 3 1 ZZ namo PC2 SSR1 m dr dol 116 127 5055 ROBE 4 2 QEPPE 105 yg 121 LN His i He PLG6 RC6 N sR X 772 2 42 4 x 102 L edsdesiss izv d sev 22 24v 10t 4 gt F2 H NE I 3 PLG6 RC6 a Vom e CR6 87 le _ CR5 N SR LZ S CR5 ed sg 27 SKE meri p pru AT SR ON OFF E X 112 pu 4 777 122 ER 43 43 lg 40 LY IT a po le O S7 47 42 R G i i IDLE P s BOARD G 9 E E 42 22 al Y Tue Ver oo es NE S EZA SENDER 25 ak Rag 46 45 41 2 c LY S6 57 oo 46 a EN x WR OT eq VE S 9 46 45 43 59 52 51 57 s A A A A A ARCS 7 2 1 9 5 6 4 8 3 A A PLCS ALTERNATOR Fd le mer o PLG38 m iss WATER 8 B QN TEMP 2 e
92. pprouv es e Ne pas diriger le jet d air vers d autres ou Soi m me L AIR COMPRIME EMMAGASINE ET DES TUYAUX SOUS PRESSION peuvent provo quer des blessures e Rel cher la pression d air de l outillage ou du syst me avant d effectuer la maintenance avant de changer ou de rajouter des l ments ou avant d ouvrir la purge ou le bouchon de remplissage d huile LA CHALEUR DU MOTEUR peut pro voquer un incendie e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Tenir distance les produits inflammables de l chappement LES TINCELLES L CHAPPEMENT peuvent provoquer un incendie e Emp cher les tincelles d chappement du moteur de provoquer un incendie Utiliser uniquement un pare tincelles approuv voir codes en vigueur Le METAL CHAUD lors du coupage et gougeage plasma peut provoquer un in cendie ou une explosion Ne pas couper ou gouger proximit de pro duits inflammables e Surveillez et garder un extincteur proximit DES PIECES CHAUDES peuvent provo quer des br lures et blessures Ne pas toucher le compresseur ou d autres l ments du circuit air comprim chauds Laisser l ensemble se refroidir avant de toucher ou d effectuer la maintenance LIRE LES INSTRUCTIONS e Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil Arr ter le moteur et rel cher la pression avant d effectu
93. 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 volt age and frequency 5 Essential Loads Generator output may not meet the electrical requirements of the prem ises If generator does not produce enough output to meet all require ments connect only essential loads pumps freezers heaters etc See Section 14 4 OM 217 455 Page 56 14 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 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 4 If unit does not
94. rtes et les panneaux des sources de haute fr quence maintenir les clateurs une dis tance correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique risque de provo quer des interf rences pour l quipement lec tronique sensible tel que les ordinateurs et l quipementcommand par ordinateur tel que les robots e Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement e Pour r duire la possibilit d interf rence maintenir les c bles de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre e Veiller souder une distance de 100 metres de tout quipe ment lectronique sensible e Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi e En cas dinterferences apr s avoir pris les mesures pr c den tes il incombe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de c bles blind s l utilisation de filtres de ligne ou la pose de protec teurs dans la zone de travail 2 6 Proposition californienne 65 Avertissements A Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l tat de Californie reconna t qu ils pr
95. s s tout au long du pr sent manuel pour attirer votre attention et identifier les ris ques de danger Lorsque vous voyez un symbole soyez vigilant et suivez les directives mentionn es afin d viter tout danger Les consignes de s curit pr sent es ci apr s ne font que r sumer l information contenue dans les normes de s curit enumerees a la section 2 7 Veuillez lire et respecter toutes ces normes de s curit L installation l utilisation l entretien et les r parations ne doivent tre confi s qu des personnes qualifi es Au cours de l utilisation tenir toute personne l cart et plus particuli rementles enfants gt gt UN CHOC LECTRIQUE peut tuer Un simple contact avec des pi ces lectriques peut provoquer une lectrocution ou des blessures graves L lectrode et le circuit de soudage sont sous tension d s que l appareil est sur ON Le circuit d entr e et les circuits internes de l appareil sont galement sous tension ce moment l En soudage semi automatique ou automatique le fil le d vidoir le logement des galets d entrainement et les pi ces m talliques en contact avec le fil de soudage sont sous tension Des mat riels mal install s ou mal mis la terre pr sentent un danger e Ne jamais toucher les pi ces lectriques sous tension e Porter des gants et des v tements de protection secs ne compor tant pas de trous e S isoler de la pi ce et de la terre au moyen de
96. s et autres pi ces en mouvement e Sile moteur est chaud et que le liquide doit tre v rifi op rer com e Maintenir ferm s et fixement en place les portes panneaux re me suivant couvrements et dispositifs de protection e Mettre des lunettes de s curit et des gants placer un torchon sur Arr ter le moteur avant d installer ou brancher l appareil le bouchon du radiateur OM 217 455 Page 8 e Devisser le bouchon l g rement et laisser la vapeur s chapper avant d enlever le bouchon L utilisation d un groupe autonome l int rieur PEUT VOUS TUER EN QUELQUES MINUTES e Les fumees d un groupe autonome contient du monoxyde de carbone C est un poison invisi ble et inodore e JAMAIS utiliser dans une maison ou garage m me avec les portes et fen tres ouvertes e Uniquementutiliser EXTERIEUR loin des portes fen tres et bouches a ration L ACIDE DE LA BATTERIE peut pro voquer des br lures dans les YEUX et sur la PEAU e Ne pas renverser la batterie e Remplacer une batterie endommag e e Rincer imm diatement les yeux et la peau l eau 2 4 Dangers li s l air comprim RESPIRER L AIR COMPRIM peut pro voquer des blessures graves ou causer la mort e Ne pas utiliser l air comprim pour respirer e Utiliser l air comprim seulement pour le cou page gougeage et les outils pneumatiques L AIR COMPRIM peut provoquer des blessures e Porter des lunettes de s curit a
97. s sans revers des chaussures hautes et un couvre chef Avant de souder retirer toute substance combustible de vos po ches telles qu un allumeur au butane ou des allumettes Une fois le travail achev assurez vous qu il ne reste aucune tra ce d tincelles incandescentes ni de flammes Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter OM 217 455 Page 7 e Suivre les recommandations dans OSHA 1910 252 a 2 iv et e Prot ger les bouteilles de gaz comprim d une chaleur excessive NFPA 51B pour les travaux chaud et avoir de la surveillance et un des chocs m caniques des dommages physiques du laitier des extincteur proximit flammes ouvertes des tincelles et des arcs LE BRUIT peut affecter l ouie e Placer les bouteilles debout en les fixant dans un support station naire ou dans un porte bouteilles pour les emp cher de tomber ou Le bruit des processus et des quipements peut affec de se renverser l ouie e Tenirles bouteilles loign es des circuits de soudage ou autres v ircuits lectriques e Porter des protections approuv s pour les ore laaa ns les si le niveau sonore est trop lev e Ne jamais placer une torche de soudage sur une bouteille gaz LES CHAMPS MAGNETIQUES peuv e Une lectrode de soudage ne doit jamais entrer en contact avec ent affecter des implants m dicaux une bouteille e Ne jamais souder une bouteille
98. se F1 F1 protects the weld excitation winding from overload If F3 opens weld output stops or is low 2 Fuse F2 F2 protects the generator power excitation winding from overload If F4 opens generator power output stops or is low 3 Circuit Breaker CB7 CB7 protects the engine glow plug circuit If CB7 opens the glow plug will not heat CB7 automatically re sets when the fault is corrected 4 Supplementary Protector CB8 CB8 protects the engine battery cir cuit If CB8 opens the engine will not crank CB8 automatically re sets when the fault is corrected Replace any open fuses Close door and or reinstall cover before operating unit 804 253 A Ref 804 250 A OM 217 455 Page 38 EF A complete Parts List is available at www MillerWelds com 9 6 Troubleshooting Tables A Welding Trouble Remedy Low or no weld output generator pow er output okay at ac receptacles Check control settings Check weld connections Check fuse F1 and replace if open see Section 9 5 Have Factory Authorized Service Agent check brushes slip rings integrated rectifiers SR2 and SR3 and main rectifier SR1 No weld output or generator power out put at ac receptacles Be sure all equipment is disconnected from receptacles when starting unit Check fuses F1 and F2 and replace if open see Section 9 5 Check plug PLG6 connection Have Factory Authorized Service
99. st the solenoids Adjust the engine speed according to the instructions in Section C A Checking Fuel Solenoid Lay pu ear A Stop engine c3 Tools Needed If the engine does not start and stop when 3 e using the Engine Control switch check 7 16 in the position of the fuel solenoid 10 14 mm Adjusting Fuel Solenoid Position 1 Fuel Solenoid 2 Stop Screw 3 Fuel Solenoid Mounting Screws Verify mounting D bracket is recessed C from edge of engine P Stop screw is factory set and should not be adjusted When properly adjusted the solenoid bracket is slightly recessed from the edge ofthe engine block and the solenoid link age easily travels between the stop screw and the fuel solenoid internal stop If adjustment is necessary loosen the so lenoid mounting screws and push the so lenoid bracket back toward engine as far as possible Continue pushing on solenoid bracket in a clockwise direction while tightening mounting screws 4 Shutdown Lever Stop screw Stop Screw Jam Nut Fuel Solenoid Jam Nut Plunger Tighten mounting screws when solenoid is in correct position D co 4 0o Oi Stop screw is factory set and should not be adjusted Hold throttle solenoid in idle energized position If shutdown lever is touching or within 1 16 in of stop screw fuel solenoid is properly adjusted If lever is more than
100. t Terminals see Section 55 9 Oji Fill Cap 15 Inline Fuel Strainer 3 Operator Controls see Section 6 t 4 Fuel Gauge Maintenance Display 10 Thermostat Housing Plug 16 Air Cleaner 5 Fuel Filler Cap 11 OilFilter 17 Fuel Filter 6 Exhaust Pipe 12 Coolant Overflow Bottle 18 Fuel Shut Off Valve OM 217 455 Page 16 A complete Parts List is available at www MillerWelds com A Engine shown with Engine must be cold and on a level sur doors removed Doors face See maintenance label Section 9 2 must be in place when for fluid specifications engineis running Starting engine for the first time Add fresh fuel to bottom of filler neck Open fuel shut off valve If coolant level is below bottom of radiator filler neck add coolant to overflow bottle Run in period first 100 hours Engine may use oil and wetstacking may occur during run in see Section 12 Check oil several times daily during run in 11 Daily pre start checks Add fresh fuel to bottom of filler neck Check oil If oil is not up to full mark on dip stick add oil Unit is shipped with 10W30 engine oil Check coolant level in overflow bottle If coolant is below Low level add coolant un til level in tank is between Low and Full lev els If overflow bottle coolant level was low check coolant level in radiator see Sec tion 9 2 Engine damage can result from 12 Low oil level High engine temperature Incorrect
101. tapis ou d autres moyens isolants suffisamment grands pour emp cher le contact physique ventuel avec la pi ce ou la terre Ne passe servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou l ou on risque de tomber e Se servir d une source lectrique courant lectrique UNIQUE MENT si le proc d de soudage le demande e Sil tilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip e Des pr cautions de s curit suppl mentaires sont requises dans des environnements risque comme les endroits humides ou lorsque l on porte des v tements mouill s sur des structures m talliques au sol grillages et chafaudages dans des positions assises genoux et allong es ou quand il y a un risque important de contact accidentel avec la pi ce ou le sol Dans ces cas utiliser les appareils suivants dans l ordre de pr f rence 1 un poste OM 217 455 Page 6 F Indique des instructions sp cifiques APA Ce groupe de symboles veut dire Avertissement Attention DANGER DE CHOC ELECTRIQUE PIECES EN MOUVEMENT et PIECES CHAUDES Consulter les symboles et les instructions ci dessous y aff rant pour les actions n cessaires afin d viter le danger souder DC semi automatique de type CV MIG MAG 2 un poste souder manuel lectrode enrob e DC 3 un p
102. tion to operate most MIG equipment 2 Glow Plug Switch 4 MAINTENANCE DISPLAYS interval position 3 times ENGINE HOURS With engine off place Engine Control switch in RUN IDLE position Displays hours while running OIL CHANGE INDICATOR With engine off place Engine Control switch into the RUN position to see hours before next oil change Oil hours start at 100 and count down to O oil change due NOTE Negative hours indicate when past recommended oil change TO RESET Cycle Engine Control switch from the RUN IDLE to RUN LOW FUEL SHUTDOWN Engine will shut off prior to running out of fuel to prevent loss of fuel in the system Display will read noFUEL Turn the machine off add fuel and restart HIGH COOLANT TEMPERATURE SHUTDOWN Engine will shut off and display will read HI H20 See Owner s Manual for coolant information Turn Engine Control switch OFF to reset shutdown LOW OIL PRESSURE SHUTDOWN Engine will shut off and display will read LO OIL Turn Engine Control switch OFF to reset shutdown Glow Plug Time 70 F 21 C 32 F 0 C 4 F 20 C 0 seconds 10 seconds 20 seconds 20 seconds Do not use glow plugs longer than Do not use ether to start engine Using ether voids warranty If necessary push switch down before start up See glow plug table for operating informa tion 3 Idle Lock Switch Use switch to lock engine in idle spee
103. trol switch to Run Idle position Throttle Solenoid Idle Speed Jam Nut Plunger Throttle Link Throttle Lever Loosen jam nut While holding throttle link with a 3 8 in wrench turn plunger clock wise to increase idle speed or counter clockwise to decrease idle speed Qn E GM IS After adjusting idle speed verify the throttle link is parallel with the throttle lever If necessary loosen the idle speed jam nut and reposition the throttle link gt Do not twist solenoid boot while ad justing engine speed Tighten jam nut Adjusting Weld Power Speed Start engine and run until warm Turn V A control to max 6 Weld Speed Jam Nut 7 Adjustment Screw Turn Engine Control switch to Run posi tion Loosen nut and turn screw counter clockwise to increase speed Turn screw clockwise to decrease speed Tighten nut Ref 804 250 A 801 963 OM 217 455 Page 37 IS A complete Parts List is available at www MillerWelds com 9 5 Overload Protection PY CP OFF EOD AUN IDLE RUN Component Panel Tools Needed E lt 38in CD A Stop engine EF When a circuit breaker or fuse opens it usually indicates a more serious problem exists Contact a Factory Authorized Service Agent 1 Fu
104. ty glasses with side shields under your helmet e Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc e Wear protective clothing made from durable flame resistant mate rial leather heavy cotton or wool and foot protection FM WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Do not weld where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas e Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side OM 217 455 Page 2 Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards Do not weld where the atmosphere
105. uce duty cycle before starting to weld again Do not block or filter airflow to unit STATIC ESD can damage PC boards e Puton grounded wrist strap BEFORE handling e boards or parts Use proper static proof bags and boxes to store move or ship PC boards Use tongue jack or blocks to support weight Properly install welding generator onto trailer y E TILTING OF TRAILER can cause injury e according to instructions supplied with trailer READ INSTRUCTIONS Read Owner s Manual before using or servic ing unit Use only genuine replacement parts from the manufacturer Perform engine and air compressor mainte nance and service according to this manual and the engine air compressor if applicable manuals H F RADIATION can cause interference e High frequency H E can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation e The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation e f notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference 1 6
106. uick business and easy With Miller you can count on years NII 00012000 of reliable service with proper maintenance And if for some reason the unit needs repair QUALITY SYSTEM there s a Troubleshooting section that will help you figure out what the problem is The Miller is the first welding parts list will then help you to decide the equipment manufacturer in s the U S A ta be iegisterad to exact part you may need to fix the problem the ISO 9001 2000 Quality Warranty and service information for your System Standard particular model are also provided Miller Electric manufactures a full line of welders and welding related equipment For information on other quality Miller products contact your local Miller distributor to receive the latest full line catalog or individual specification sheets To locate your nearest distributor or service agency call 1 800 4 A Miller or visit us at www MillerWelds com on the web Mill mer Mil_Thank 4 05 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 131 Symbol E Te LTTE 1 2 Are Welding Hazards TTT 1 9 Engine Hazards TTT 1 4 Compressed Air Hazards se 1 5 Additional Symbols For Installation Operation And Maintenance eee 1 6 California Proposition 65 Warnings 1 7 Principal Safety Standards lt ieai ss K KR NTR KR a RT RR aan 1 8 EMF Information SEC
107. ust take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area For Gasoline Engines A Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive harm For Diesel Engines A Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Ontario Canada L4W 5NS phone 800 463 6727 or in Toronto 416 747 4044 website www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 25 West 43rd Street New York NY 10036 8002 phone 212 642 4900 website www ansi org Standardfor Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 web site www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 Keep cables close together by twist
108. voided will result in death or serious injury The possible hazards are shown in the adjoining symbols or explained in the text Indicates a hazardous situation which if not avoided could result in death or serious injury The possible hazards are shown in the adjoining symbols or ex plained in the text NOTICE Indicates statements not related to personal injury 1 2 Arc Welding Hazards A The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 7 Read and follow all Safety Standards A Only qualified persons should install operate maintain and repair this unit A During operation keep everybody especially children away FA e ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equip ment is a hazard e Do not touch live electrical
109. with a 7018 1 8 electrode See Sections 6 3 thru 6 5 for typical pro cess connections and control settings OM 217 455 Page 21 IS A complete Parts List is available at www MillerWelds com 6 3 Typical Stick Welding Connections And Control Settings CR p 7 eo Stop engine Wy RE RV NC 42m This section provides general guidelines and may not suit all M applications Typical Settings For 7018 1 8 in Electrode Oa c DONOTSWITCH WHILE WELDING No CAMBE CUANDO BEEST SOLDANDO gt Set Weld Process Selector switch to Stick position gt Set Coarse Range switch to 60 140 1 8 position gt Set Fine control at 7 or higher for best results Consult the amperage selection tables below if welding with other electrodes 1 Work Clamp 2 Electrode Holder Connect Work cable to Work terminal and Electrode holder cable to Elec trode terminal on welding generator Lu a D AMPERAGE E Lb RANGE i 8 8 8 LU Lo T ql 6010 ET amp 5 32 6011 346 5 64 3 32 6013 1 8 5 32 3 16 3 32 7018 1 8 5 32 3 32 7024 A Tools Needed 3 32 et 34in NO 1 8 ln 5 32 3 32 308L 1 8 5 32 m Ref 804 249 A Ref 228 647 A OM 217 455 Page 22 6 4 Typical MIG Welding Connections And

Miller Electric 250 Welder User Manual

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