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Bobcat 225

1. POSITION A BCDEF ulul z S2 l all 110 o o db o 3 RUN IDLE ol x 42 82 80 90 81 RUN EIE 42 82 a 90 81 START x 42 GROUND O sa en X CLOSED TO pr 105 me Zas TERMINAL PLG6 RC6 O CLOSED TO BASE GROUND SR 110 Se t 102 gt 2 gt 104 CES ge 120V 106 F2 Se Y W G PLG6 Rce 103 104 80 83 83 85 X 2 a a2 A SR OR 90 K e 90 pa 111 k EXCITATION POWER 82 RCS ct D4 111 B1 42 120V e 33 4 REVOLVING FIELD T7 Y W G 42 WELD 42 48 PLG12 2 S2 PLG8 84 86 45 oc 1 8 START 2 CTI cB2 RC2 HOUR METER BAT gt 80 IDLE CONTROL RUN IDLE 2 80 EE gt GROUND gt 83 A TN TN 7N E 17 Tao RUN gt OC z 42 CB1 149 82 84 49 OC s I 43 43 RC1 52 46 45 A 47 Y W X G rca RC4 RC4 RC A 240V 2 6 3 1 4 ge PLG4 A PLG4 PLG4 A PLG DC Z ow oL BRN 5 PRESSURE EL wHT 29 BLU N O 6 l o _ vo fase D N wee sto ELECT gt 12 VOLT RED T amp 8 lt lt 9 7 co ZE STARTER 19 LA w AN V q1 T 24 NSi M y 24 G Lo 11 5 o 10 N Dee RED IGN ed 12 4 __ EN ALTERNATOR FSU ue SE COIL
2. 7 3 Wire Load Current Available in Amperes When wired for 120 V loads each duplex receptacle shares a load 240 V Each 120 V Duplex with one half of 240 V receptacle Receptacle Receptacle 2 Plug Wired for 240 V 2 Wire 0 20 Load 5 20 3 Neutral Silver Terminal 10 20 4 Load 1 Brass Terminal 15 20 5 Load 2 Brass Terminal 20 20 6 Ground Green Terminal 25 15 7 Amperes Available using 30 10 120 240 V Plug 35 5 40 0 V x A Watts Tools Needed One 240 V load or two 120 V loads s ER plugt 11 03 120 813 D OM 4434 Page 38 gt A complete Parts List is available at www MillerWelds com SECTION 8 MAINTENANCE tenance Label In Ma 8 1 290 661 HATIIN NHVANS 960 08 HATIIN 06ZHD SLL 9b HATIIN 0 ZH93 SLO OEZ HATIIW ZH2 HAIHOM sBnId eds z pue ae Jeng pue WO IV Sapnu Wy 48414 pue dn eunL 8 S o 18 s WO SOUEA UONEZIOY NY SW9JSAS d7 uo YIOM 0 p p u slu uu aInb i uoneouso 10 Aajeap euedoid J290 Ino YIM Y9849 810N Pumese pue BuIuee o Aquisssesip l lduioS sinoy OOS e equeuo Asepuooas wo 2NPIS91 uleig SINOU 00S HOLVT nS3t 9d1 youbew eui lu ue l2 ayy eo59e d ti sinou QOS e EU ERRA ETa ETE E D bleu Suqap pue LIP Jo eau d y sul 1p dsu puanbaly e XKIGINASSV 43ZIHOdVA s unssatd Sa OSe Dd7 KINO W3LSAS TVMVYGHLIM GINO SANI9ON
3. Ka S 0641 Possible Causes Corrective Actions Welding wire extends too far out of nozzle Be sure welding wire extends not more than 1 2 in 13 mm beyond nozzle Unsteady hand Support hand on solid surface or use two hands 14 14 Troubleshooting Distortion Distortion contraction of weld metal during welding that forces i Base metal moves in the direction of the weld bead S 0642 Possible 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 voltage range and or reduce wire feed speed Increase travel speed Weld in small segments and allow cooling between welds OM 4434 Page 71 14 15 Common MIG Shielding Gases This is a general chart for common gases and where they are used Many different combinations mixtures of shielding gases have been developed over the years The most commonly used shielding gases are listed in the following table Q O N OM 4434 Page 72 Heavy Thicknesses Single Pass Welding Only 90 HE 7 1 2 AR 2 1 2 CO2 Also for GMAW P All Positions Application Gas Short Circuiting Spray Arc Short Circuiting Spray Arc Short Circuiting Spray Arc Steel Steel Stainless Steel Stainless Steel Aluminum Aluminum Argon All Positions All Positions Flat amp
4. 200 294 WELD POSITION FLAT HORIZONTAL VERTICAL OVERHEAD WELD JOINT BUTT BUTT TYPES 1G oe il Y GROOVE d K FILLET Ref AWS ANSI D1 1 T JOINT 1F T JOINT 2F Ref 804 248 A OM 4434 Page 21 gt A complete Parts List is available at www MillerWelds com SECTION 5 INSTALLATION 5 1 Serial Number And Rating Label Location The serial number and rating information for this product is located on the back Use rating label to determine input power requirements and or rated output For future reference write serial number in space provided on back cover of this manual 5 2 Installing Welding Generator A Do not move or operate unit where it could tip A Do not lift unit from end 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 NOTICE Do not install unit where air flow is restricted or engine may over heat See Section 4 2 for lifting eye rat ing Mounting A Do not mount unit by support ing the base only at the four mounting holes Do not use flexible mounts Use cross supports to adequately sup port unit and prevent damage to base 1 Cross Supports Mount unit on flat surface or use cross supports to support base see Section 4 2
5. OM 4434 Page 28 gt A complete Parts List is available at www MillerWelds com Notes N A HOBART INSTITUT Start Your Professional GE Over 80 000 400 Trade Square East Troy Ohio 45373 1 800 332 9448 www welding org Welding Career Now trained since 1930 OM 4434 Page 29 gt A complete Parts List is available at www MillerWelds com SECTION 6 OPERATING THE WELDING GENERATOR 6 1 Front Panel Controls ORME SE G 2i DO NOT SWITCH WHILE WELDING NO CAMBIE CUANDO SEEST SOLDANDO D om GND PE WIRE 1928 VOLTS MADE IN IA n APPLETON WI WW a on SET AT 7 HILE WELDING SET AT 10 FOR MAX GENERATOR POWER ga RUN IDLE 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 gt Place switch in Run position to operate most MIG equipment 2 Engine Choke Control Use control to change engine air fuel mix To Start pull out choke and turn Engine Con trol switch to Start position Release switch and slowly push choke in when engine starts gt If the engine does not start let engine come to a complete stop bef
6. install2 2008 01 Ref 800 652 Ref 800 477 A 803 274 A 804 712 OM 4434 Page 22 gt A complete Parts List is available at www MillerWelds com 5 3 Grounding Generator To Truck Or Trailer Frame GND PE A Always ground generator A 2 3 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 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 GFCl pro tected extension cord 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 frame to vehicle frame by met al to metal contact rot_grnd 2008 01 800 652 D OM 4434 Page 23 gt A complete Parts List is available at www MillerWelds com 5 4 Engine Prestart Checks Subaru Powered Units Check all fluids daily Engine must be cold and on a level surface Unit is shipped with 10W30 engine oil
7. Fe 45316 BACK PANEL IS REMOVED FOR BATTERY ACCESS Support Assembly Dimensions a 1 500 he 105 Y 6 750 Tr 16 500 32 750 LOCATE FEAR SUPPORT UNDER ENG NE LOCATE FRONT CROSS 5 730 APPROX MATELY 1 BEH ND ES il EC 5 250 MIN MIMIMUM GAGE 12 MINIMUM WIDTH 3 2 000 be 803 572 Ref 232 769 240 844 A OM 4434 Page 17 gt A complete Parts List is available at www MillerWelds com 4 3 Dimensions For Units With Optional Running Gear Dimensions oo All Running Gear Options 42 1 2 in 1079 mm To Top Of Handle Assembly Height Protective Cage Width 26 in 660 mm Cel Running Gear Width aa N S 32 in 813 mm Protective Cage Length SE y k CAE 48 in 1219 mm Running Gear Length 45 1 2 in 1156 mm 4 4 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 AC CC Ka DI GC DC CC ps DC CV lt o z a l DI 10 15 20 25 30 40 50 60 70 80 90 100 DUTY CY
8. DE J FALLING EQUIPMENT can injure e Use lifting eye to lift unit and properly installed A FLYING SPARKS can injure accessories only NOT gas cylinders Do not exceed maximum lift eye weight rating see a e Wear a face shield to protect eyes and face Specifications Ca e Shape tungsten electrode only on grinder with e Use equipment of adequate capacity to lift and proper guards in a safe location wearing proper support unit face hand and body protection e If using lift forks to move unit be sure forks are long enough to e Sparks can cause fires keep flammables away extend beyond opposite side of unit e Keep equipment cables and cords away from moving vehicles MOVING PARTS can injure when working from an aerial location e Follow the guidelines in the Applications Manual for the Revised e Keep away from moving parts NIOSH Lifting Equation Publication No 94 110 when manu e Keep away from pinch points such as drive ally lifting heavy parts or equipment rolls OM 4434 Page 5 WELDING WIRE can injure e Do not press gun trigger until instructed to do so e Do not point gun toward any part of the body other people or any metal when threading welding wire pots 1 OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle e Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit as N STATIC ESD can damage PC boards
9. Too Short Normal Too Long Travel Speed SSS Ewen Ge Slow Normal Fast S 0061 13 8 Electrode Movement During Welding fW e s Noraly a sings Z KR CS Normally a single stringer Ev Wy ES N bead is satisfactory for most narrow groove weld joints however for wide groove weld joints or bridging across gaps a weave bead or multiple 2 stringer beads work better 1 Stringer Bead Steady Movement Along Seam 2 Weave Bead Side to Side Movement Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the elec trode Do not let weave width ex 3 ceed 2 1 2 times diameter of Es electrode S 0054 A OM 4434 Page 62 13 9 Groove Butt Joints W SE 1 1 Tack Welds Prevent edges of joint from draw ing together ahead of electrode by tack welding the materials in posi tion before 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 oxyacetylene or plasma cutting equipment 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 0062 13 10 Lap
10. OM 4434 218 653P 2010 04 Miller Stick SMAW Welding am VG GMAW Welding N Flux Cored FCAW Welding Pd Non Critical TIG GTAW A Welding Description a Engine Driven Welding Generator Bobcat 225 OWNER S MANUAL File Engine Drive w i Visit our website at www MillerWelds com From Miller to You Thank you and congratulations on choosing Miller Now you can get the job done and get it done right We know you don t have time to do it any other way That s why when Niels Miller first started building arc welders in 1929 he made sure his products offered long lasting value and superior quality Like you his customers couldn t afford anything less Miller products had to be more than the best they could be They had to be the best you could buy Today the people that build and sell Miller products continue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 1 U E 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 2 every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most hassle free warranty in the We ve made installation and operation quick business
11. gt Follow run in procedure in en gine manual NOTICE This unit has a low oil pressure shutdown switch Howev er some conditions may cause en gine damage before the engine shuts down Check oil level often and do not use the oil pressure shutdown system to monitor oil level Oil Fill Oil Check Fuel Add fresh fuel before starting en gine the first time see maintenance label for specifications Always leave filler neck empty to allow room for expansion Check fuel lev el on a cold engine before use each day Oil Do not exceed the Full mark on the oil level dipstick The fuel pump may operate errati cally if crankcase is overfilled Gasoline After fueling check oil with unit on level surface If oil is not up to full mark on dipstick add oil see main tenance label To improve cold weather starting Keep battery in good condition Store battery in warm area Use correct grade oil for cold weather Do not weld cut drill or grind on base Boftunt down using holes provided In baso only 803 755 E 217 015 A OM 4434 Page 24 gt A complete Parts List is available at www MillerWelds com 5 5 Engine Prestart Checks Kohler Powered Units located Inside base Donotweld eut drill or grind on base Bolt unit down using holes provided In base only Check all fluids daily Engine must
12. 3 x 200W 520 W 1120 W The total load applied by the three flood lamps and drill is 1120 watts S 0623 OM 4434 Page 53 12 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 12 6 Approximate Power Requ irements For Farm Home Equipment Farm Home Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 Milker Vacuum Pump 2 HP 10500 2800 FARM DUTY MOTORS 1 3 HP 1720 720 Std e g Conveyors 1 2 HP 2575 975 Feed Augers Air 3 4 HP 4500 1400 Compressors 1 HP 6100 1600 1 1 2 HP 8200 2200 2 HP 10550 2850 3 HP 15900 3900 5 HP 23300 6800 High Torque e g Barn 1 1 2 HP 8100 2000 Cleaners Silo Unloaders 5 HP 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 Pres
13. During operation keep everybody especially children away 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 equipmentis a hazard Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit Additional safety 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
14. des personnes qualifi es A Au cours de l utilisation tenir toute personne l cart et plus particuli rementles enfants UN CHOC ELECTRIQUE peut tuer Un simple contact avec des pi ces lectriques peut provoquer une lectrocution ou des blessures gra ves 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 galementsous tension ce moment la En soudage semi automatique ou automatique le fil le d vidoir le logement des galets d entrainement et les pi ces m talliques en contact avec le fil de soudage sont sous tension Des mat riels mal install s ou mal mis la terre pr sentent un danger Ne jamais toucher les pi ces lectriques sous tension Porter des gants et des v tements de protection secs ne compor tant pas de trous e S isoler de la pi ce et de la terre au moyen de tapis ou d autres moyens isolants suffisamment grands pour emp cher le contact physique ventuel avec la pi ce ou la terre e Ne pas se servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou l o on risque de tomber e Se servir d une source lectrique courant lectrique UNIQUE MENT si le proc d de soudage le demande e Si l utilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l
15. operation 7 57 2 00 6 62 G79 5 67 1 50 4 73 1 25 lL 378 100 Kc 2 84 0 75 1 89 0 50 095 025 IDLE 2200 RPM 0 25 50 5 100 125 150 175 200 225 250 275 WELD AMPERES AT 100 DUTY CYCLE l O 10 20 30 40 50 60 70 80 9 0 10 0 1 0 POWER KVA AT 1007 DUTY CYCLE 179 939 OM 4434 Page 19 gt A complete Parts List is available at www MillerWelds com 4 7 Volt Ampere Curves The volt ampere curve shows the A For CC AC Mode minimum and maximum voltage and amperage output capabilities of 80 the welding generator Curves of all other settings fall between the curves shown 70 60 50 40 AC VOLTS 30 20 ae e e B For CC DC Mode 80 70 60 50 40 DC VOLTS a LN EE 2 AWN TNS EE ENS Sb Se DER 50 100 300 350 400 DC AMPERES C For CV DC Mode DC VOLTS 0 100 200 300 400 500 600 700 800 DC AMPERES 166 024 A 166 025 A 166 026 A OM 4434 Page 20 gt A complete Parts List is available at www MillerWelds com 4 8 Generator Power Curve The generator power curve shows the generator power in amperes available at the receptacles 280 140 240 120 Wal D 200 100 gt 160 80 120 60 Qa O 80 40 lt 40 20 o o 0 20 40 0 10 20 60 80 100 120 140 160 180 200 220 AC POWER AMPERES AT 120V 30 40 50 60 70 80 90 100 110 AC POWER AMPERES AT 240V
16. 2200 2300 rpm 86 6 38 3 Hz 3675 3750 rpm 61 3 62 5 Hz Top View After tuning engine check engine speeds with a tachometer see table If necessary adjust speeds as follows Start engine and run until warm Turn Fine Control to 10 Remove rear panel and air cleaner to access idle speed adjustments Remove top cover to access weld power speed adjustments Idle Speed Adjustment Move Engine Control switch to Run Idle position 1 Throttle Solenoid 2 Mounting Screws 3 Idle Speed Screw Loosen mounting screws Adjust solenoid position so engine runs at idle speed If necessary back out idle speed screw so solenoid can be moved to correct position Tight en mounting screws Be sure sole noid linkage works smoothly Turn idle speed screw for fine ad justments Weld Power Speed Adjustment Move Engine Control switch to Run position 4 Weld Power Speed Adjustment Nut 5 Lock Nut Loosen lock nut Turn adjustment nut until engine runs at weld power speed Tighten lock nut A Stop engine Reinstall air cleaner rear panel and top cover Tools Needed HB 1 4 3 8 in 803 752 C 801 209 A OM 4434 Page 46 gt A complete Parts List is available at www MillerWelds com SECTION 9 TROUBLESHOOTING 9 1 Welding Troubleshooting Trouble Remedy Low or no weld output generato
17. If earth grounding of the workpiece is required ground it directly with a separate cable Do not touch electrode if you are in contact with the work ground or another electrode from a different machine Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present e Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical Insulate work clamp when not connected to workpiece to prevent contact with any metal object Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists in inverter power sources AFTER stopping engine Stop engine on inverter and discharge input capacitors according to instructions in Maintenance Section before touching any parts HOT PARTS can burn 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 nS lated welding gloves and clothing to prevent burns FLYING METAL or DIRT can injure eyes e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw
18. CONSIGNES DE S CURIT LIRE AVANT UTILISATION 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 Signification des symboles Dangers relatifs au soudage l arc Dangers existant en relation avec le moteur Dangers li s l hydraulique Dangers li s l air comprim Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Proposition californienne 65 Avertissements Principales normes de s curit Informations relatives aux CEM SECTION 3 DEFINITIONS SECTION A SPECIFICATIONS Weld Power and Engine Specifications Dimensions Weights And Operating Angles Dimensions For Units With Optional Running Gear Duty Cycle Fuel Consumption Subaru Powered Units Fuel Consumption Kohler Powered Units Volt Ampere Curves Generator Power Curve SECTION 5 INSTALLATION Serial Number And Rating Label Location 5 1 5 2 5 3 5 4 5 5 5 6 5 7 5 8 5 9 6 1 6
19. P e Puton grounded wrist strap BEFORE handling N boards or parts Ro e Use proper static proof bags and boxes to store move or ship PC boards ze TILTING OF TRAILER can injure lt _ e Use tongue jack or blocks to support weight e Properly install welding generator onto trailer according to instructions supplied with trailer READ INSTRUCTIONS e Read and follow all labels and the Owner s Manual carefully before installing operating or servicing unit Read the safety information at the beginning of the manual and in each section Use only genuine replacement parts from the manufacturer if e Perform maintenance and service according to the Owner s Manuals industry standards and national state and local codes 1 7 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 gt 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 gt This product contains chemicals including lead known to the state of California to cause cancer birth defects or other reproductive harm Wash hands after use OM 44
20. Tapping Technique 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 0049 S 0050 OM 4434 Page 60 13 4 Positioning Electrode Holder CH 4 Gs Z ar e 1 End View Of Work Angle fas SE a 2 Side View Of Electrode Angle Groove Welds van 10 30 3 s Fillet Welds S 0060 13 5 Poor Weld Bead Characteristics Large Spatter Deposits Rough Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration Q N S 0053 A 13 6 Good Weld Bead Characteristics EN 4 RE AB er e 1 Fine Spatter gt eh Wy ee IR 2 Uniform Bead 3 Moderate Crater During Welding Weld a new bead or layer for each 1 8 in 8 2 mm thickness in metals being welded 4 No Overlap 5 Good Penetration into Base Metal S 0052 B OM 4434 Page 61 13 7 Conditions That Affect Weld Bead Shape SEET sa gt Weld bead shape is affected Af A by electrode angle arc length travel speed and thick ness of base metal Correct Angle Angle Too Small 10 30 Angle Too Large Electrode Angle I SE d gt amm 2 e 3 Drag E Ke Arc Length An s e oo
21. and easy With Miller you can count on years NII 0001 of reliable service with proper maintenance And if for some reason the unit needs repair 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 SE I exact part you may need to fix the problem the ISO 9001 Quality System Warranty and service information for your Standard particular model are also provided REGISTERED QUALITY SYSTEM 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 2009 09 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 Symbol Usage Arc Welding Hazards Engine Hazards Hydraulic Hazards Compressed Air Hazards Additional Symbols For Installation Operation And Maintenance California Proposition 65 Warnings Principal Safety Standards EMF Information SECTION 2
22. ch ant ou de batterie d entretien e Eviter de provoquer des tincelles avec les outils en travaillant sur la batterie e Ne pas utiliser l appareil de soudage pour charger des batteries ou faire d marrer des v hicules l aide de c bles de d marrage sauf si l appareil dispose d une fonctionnalit de charge de batterie destin e cet usage e Observer la polarit correcte et sur les batteries e D brancher le c ble n gatif en premier lieu Le rebrancher en dernier lieu e Les sources d tincelles flammes nues cigarettes et autres sources d inflammation doivent tre maintenues l cart des batteries Ces derni res produisent des gaz explosifs en fonctionnementnormal et en cours de charge e Respecter les consignes du fabricant de la batterie pour travailler sur une batterie ou proximit Le COURANT DE CHARGE DE BATTERIE peut provoquer des blessures la fonctionnalit de charge de batterie n est pas disponible sur tous les mod les e Les op rations de charge de batterie ne doivent tre effectu es que par des personnes qualifi es e Ne charger que des batteries plomb acide Ne pas utiliser le chargeur de batterie pour alimenter un autre circuit lectrique basse tension ou pour charger des batteries s ches e Ne pas charger une batterie gel e e Ne pas utiliser de c bles de charge endommag s Ne pas charger une batterie dont les bornes sont desserr es ou pr sentant
23. 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 1 8 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com Safe Practices for the Preparation of Containers and Piping for Welding and Cutting American Welding Society Standard AWS F4 1 from Glob al Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Quincy MA 02269 phone 1 800 344 3555 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 Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Ontario Canada L4W 5NS phone 800 463 6727 website www csa international org Battery Chargers CSA Standard C22 2 NO 107 2 01 from Canadian Standards Association Standards Sales 5060 Spectru
24. Horizontal Flat amp Horizontal o Argon 1 O gt Fillet Fillet Flat amp Horizontal Flat amp Horizontal O Argon 2 Os Fillet Fillet Flat amp Horizontal Argon 5 O gt Fillet Flat amp Horizontal Argon eet All Positions Fillet A 25 Flat amp Horizontal AO at amp Morizonta All Positions All Positions COo Fillet Argon 50 Si CO All Positions Flat amp Horizontal CO EES All Positions Fillet Helium All Positions2 Argon Helium All Positions2 Tri Mix4 All Positions Globular Transfer 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 2010 Equipment with a serial number preface of MA or newer This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in mater
25. Kohler ERR F6 215621 Fuse 30 Amp Ato Type Subaru 1 DR RAT AS p bo ech 215984 Filter Fuel In line 250 Kohler EE 230015 Tune up amp Filter Kit Kohler Includes 1 ST DS SIT ates 230016 Air Filter Element Kohler EE 066698 Oil Filter Kohler ENEE 215985 Filter Fuel w Clamps dee EE 067007 Spark Plug 5212552584 MURS Soa anda dada RN Ech d 2 reel deeg 230017 Air Filter Wrapper s ST 237857 Filter Fuel In line 250 Subaru 1 a ya 199062 Tune up amp Filter Kit Subaru Includes 1 ead kaa oo A E eps 198755 Element Air Filter 1 A Sie ENS 1987544 su GI TEE EENG E base e EA 241408 Filter Fuel w Clamps 1 TR D E ee Aen 198777 e Spark RO gta ren oe aware eh ANG Aes 1 gt A complete Parts List is available on line at www MillerWelds com OM 4434 Page 49 SECTION 11 ELECTRICAL DIAGRAMS
26. Road Suite 211 Milwaukee WI 53222 3219 phone 414 778 3344 website www nfpa com 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 OSHA Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov U S Consumer Product Safety Commission CPSC 4330 East West Highway Bethesda MD 20814 phone 301 504 7923 website WWW CpSC gov Applications Manual for the Revised NIOSH Lifting Equation The Na tional Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 phone 1 800 232 4636 website www cdc gov NIOSH 4 Keep head and trunk as far away from the equipment in the welding circuit as possible 5 Connect work clamp to workpiece as close to the weld as possible 6 Do not work next to sit or lean on the welding power source 7 Do not weld whilst carrying the welding power source or wire feeder 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
27. 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 E Customer supplied equipment is required if generator will sup ply standby power during emergencies or power out ages 1 Utility Electrical Service 2 Transfer Switch Double Throw Switch transfers the electrical load from electric utility service to the generator Transfer load back to electric utility when service is re stored Install correct switch customer supplied Switch rating must be same as or greater than the branch overcurrent protection 3 Fused Disconnect Switch Install correct switch customer supplied if required by electrical code 4 Welding Generator Output Generator output voltage and wir ing must be consistent with regular utility system voltage and wiring Connect generator with temporary or permanent wiring suitable for the installation Turn off or unplug all equipment connected to generator before starting or stopping engine When starting or stopping the engine has low speed which causes low volt age and frequency 5 Essential Loads Generator o
28. be cold and on a level surface Unit is shipped with 10W30 engine oil gt Follow run in procedure in en gine manual NOTICE This unit has a low oil pressure shutdown switch Howev er some conditions may cause en gine damage before the engine shuts down Check oil level often and do not use the oil pressure shutdown system to monitor oil level Fuel Add fresh fuel before starting en gine the first time see maintenance label for specifications Always leave filler neck empty to allow room for expansion Check fuel lev el on a cold engine before use each day Oil gt Do not exceed the Fu mark on the oil level dipstick The fuel pump may operate errati cally if crankcase is overfilled After fueling check oil with unit on level surface If oil is not up to full mark on dipstick add oil see main tenance label To improve cold weather starting Keep battery in good condition Store battery in warm area Use correct grade oil for cold weather 803 754 D 217 015 A OM 4434 Page 25 gt A complete Parts List is available at www MillerWelds com 5 6 Installing Exhaust Pipe Engine backfire can cause se lt vere burns or other injuries Do not point exhaust pipe toward control panel Keep away from exhaust outlet Point exhaust pipe in desired di rection but always away from front panel and direction of trav el gt Be sure to tighten exhaust c
29. mes de procr ation Se laver les mains apr s manipu lation Pour les moteurs essence A Les gaz d chappement des moteurs contiennent des pro duits chimiques dont I Etat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Pour les moteurs diesel Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l tat de Californie com me provoquant des cancers et des malformations cong nitales ou autres probl mes de procr ation 2 8 Principales normes de s curit Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com Safe Practices for the Preparation of Containers and Piping for Welding and Cutting American Welding Society Standard AWS F4 1 from Glob al Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Quincy MA 02269 phone 1 800 344 3555 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 Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association
30. 1 0 60 Weld Output 150 3 30 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 3 0 95 Terminals Turn off power before 200 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 4 0 120 connecting to weld output terminals 250 2 85 1 50 1 0 60 2 0 70 3 0 95 4 0 120 _ A Do not use worn damaged under 2 ea 2 0 2 ea 3 0 2 ea 3 0 sized or poorly 300 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2x70 2x95 2x95 spliced cables 2 ea 2 0 2ea 3 0 20a 3 0 2ea 4 350 4 0 60 2 0 70 3 0 95 4 0 120 oon oe ne aa CH 2 ea 2 0 2ea 3 0 2ea 4 0 2 ea 4 400 1 0 60 2 0 70 3 0 95 4 0 120 ooo a d Ge oa Ba 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 2x70 2x95 2x120 3x95 3x95 This chart is a general guideline and may not suit all applications If cable overheats use next size larger cable Weld cable size AWG is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere mm for metric use For distances longer than those shown in this guide call a factory applications rep at 920 735 4505 Miller or 1 800 332 3281 Hobart Ref S 0007 G 2009 08 Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual
31. 2 6 3 6 4 6 5 7 1 7 2 7 3 7 4 Installing Welding Generator Grounding Generator To Truck Or Trailer Frame Engine Prestart Checks Subaru Powered Units Engine Prestart Checks Kohler Powered Units Installing Exhaust Pipe Connecting Or Replacing the Weld Output Terminals Battery a2 sen Sea E ER SE cides th ave etic e Ab eee Connecting To Weld Output Terminals 5 10 Selecting Weld Cable Sizes SECTION 6 OPERATING THE WELDING GENERATOR Front Panel Controls Cold Weather Engine Operation Typical Stick Welding Connections And Control Settings Typical MIG Welding Connections And Settings Typical MIG Connections And Settings Using Weld Control And Spoolgun SECTION 7 OPERATING AUXILIARY EQUIPMENT Standard Receptacles Optional Generator Power Receptacles Simultaneous Weld And Power Wiring Optional 240 Volt Plug DON NOAA Q QG GQ G OC G G G GO GO GO ND N N N N N D NN N N N N N ch A ch O JO OO NN O O O O1 N N N O oO oO O OO Q Q GQ N TABLE OF CONTENTS SECTION 8 MAINTENA
32. 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 4434 Page 58 SECTION 13 STICK WELDING SMAW GUIDELINES 13 1 Stick Welding Procedure OES ae SE Tools Needed My Equipment Needed Constant Current Welding Power Source 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 F gt Always wear appropriate per sonal protective clothing 1 Workpiece Make sure workpiece is clean be fore welding 2 Work Clamp 3 Electrode A small diameter electrode re quires less current than a large one Follow electrode manufactur er s instructions when setting weld amperage see Section 13 2 4 Insulated Electrode Holder 5 Electrode Holder Position 6 Arc Length Arc length is the distance from the electrode to the workpie
33. FAX 920 735 4125 For International Locations Visit www MillerWelds com C Miller
34. G Weld Cables YQ Slip Rings Valve Clearance Lk Brushes OM 4434 Page 40 8 3 Servicing Optional Spark Arrestor gt A complete Parts List is available at www MillerWelds com Pers Tools Needed DIT 1 4 in My SN A Stop engine and let cool 1 Spark Arrestor Screen Clean and inspect screen Replace spark arrestor if screen wires are broken or missing Ref 803 572 A Ref 183 175 A 8 4 Servicing Air Cleaner ER Subaru Powered Kohler Powered A Stop engine NOTICE Do not run engine with out air cleaner or with dirty element 1 Precleaner Wash precleaner with soap and wa ter solution Allow precleaner to air dry completely Spread 1 tablespoon SAE 30 oil evenly into precleaner Squeeze out excess oil 2 Element Replace element if damaged dirty or oily aircleaner3 11 04 802 772 803 070 S 0759 OM 4434 Page 41 gt A complete Parts List is available at www MillerWelds com 8 5 Overload Protection A E A Stop engine Disconnect gt A E N negative battery cable OFF 1 Fuse F1 See Section 10 1 gt Fuse F6 located in harness behind left side door F1 protects the weld excitation winding from overload If F1 opens weld output stops or is low 2 Fuse F2 See Section 10 1 F2 protects the generator power excitation winding from overload
35. HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0 Motor Start Code Running Amperage Motor HP Motor Voltage To find starting amperage Step 1 Find code and use table to find kVA HP If code is not listed P N L AC MOTOR 2 multiply running amperage by six to 1 SE VOLTS 230 AMPS 25477 find starting amperage 3 CODE M Hz 60 Step 2 Find Motor HP and Volts x HP 1 4 PHASE 1 Step 3 Determine starting amper age see example Welding generator amperage out put must be at least twice the motor s 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 12 9 How Much Power Can Generator Supply 1 Limit Load To 90 Of Generator Output Always start non resistive motor loads in order from largest to small est and add resistive loads last 2 5 Second Rule If motor does not start within 5 seconds turn off power to prevent motor damage Motor requires more power than generator can supply Ref ST 800 396 A S 0625 OM 4434 Page 56 12 10 Typical Connections To Supply Standby Power Utility Electrical
36. If F2 opens generator power output stops or is low 3 Fuse F6 See Section 10 1 F6 protects the engine wiring sys tem from overload If F6 opens engine will not crank Replace any open fuses Reinstall cover before operating NOTICE If a fuse opens it usually indicates a more serious problem exists Contact a Factory Autho rized Service Agent d gt Fuses F1 F2 located on bracket behind left side panel Tools Needed Ko ey S 3 8 in 803 750 C 161001 A Notes OM 4434 Page 42 gt A complete Parts List is available at www MillerWelds com 8 6 Changing Engine Oil Oil Filter and Fuel Filter Subaru Powered Units Ka 1 OilDrain Valve gt we VA ar ee A Stop engine and let cool 2 OU Filter Change engine oil and filter accord ing to engine owner s manual NOTICE Close valve and valve cap before adding oil and running engine Oil Fill Fill crankcase with new oil to full mark on dipstick see Section 5 4 3 FuelFilter 4 Fuel Une Replace line if cracked or worn Install new filter Wipe up any spilled fuel Oil Check Start engine and check for fuel leaks NS A Stop engine tighten connec tion
37. JA SR1 L L 1 3 STATOR SHUT OFF FUEL 42 A T VOLT SOLENOID Geer 27 e REG kat Pha RECT 2 A T7 rh T7 T7 7 ELECTRIC FUEL rh rh KOHLER ENGINE OPTION Bee OPTION BARE ROUND OM 4434 Page 50 Figure 11 1 Circuit Diagram For Welding Generator eae GFCI 3 GFCI 80 83 VV NZ RECEPTACLE OO He OPTION 90 90 90 SH 42 GND b A A ah cB2 GFCI 2 BA oon 86 Y V V EC 80 90 NT SH 42 GND N A A A 80 81 ee TS A ER si CBI A B C D E F 82 ay g 84 mo o o d b o 42 82 80 90 81 RC1 42 82 80 90 81 Y W X G Se 42 240V A3 2 6 5 3 1 4 Aasch prea PLG4 PLG4 A RED YEL BLU PN LOW OIL GRA pr PRESSURE BLK Es N O D8 19 Sp V TI te x dt yY A B 2 VOLT es RED RED x 4 STARTER ELECTR FUEL A reif SHUT OFF PUMP SOLENOID VOLT Ze REG ac RECT ELECTRIC FUEL rh ER h h PUMP OPTION SUBARU ENGINE OPTION amp WARNING Do not touch live electrical parts Disconnect input power or stop engine before servicing Do not operate with covers removed Have only qualified persons install use or service this unit ELECTRIC SHOCK HAZARD 239 805 B OM 4434 Page 51 SECTION 12 GENERATOR POWER GUIDELINES gt The views in this
38. O B at a Miller authorized service facility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER Some states in the U S A 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
39. Standards Sales 5060 Spectrum Way Suite 100 Ontario Canada L4W 5NS phone 800 463 6727 website www csa international org Battery Chargers CSA Standard C22 2 NO 107 2 01 from Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Ontario Canada L4W 5NS phone 800 463 6727 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 2 9 Informations relatives aux CEM Le courant lectrique qui traverse tout conducteur g n re des champs lectromagn tiques CEM a certains endroits Le courant de soudage cr e un CEM autour du circuit et du mat riel de soudage Les CEM peuvent cr er des interf rences avec certains implants m dicaux comme des stimulateurs cardiaques Des mesures de protection pour les porteurs d implants m dicaux doivent tre prises par exemple des restrictions d acc s pour les passants ou une valuation individuelle des risques pour les soudeurs Tous les soudeurs doivent appliquer les proc dures suivantes pour minimiser l exposition aux CEM provenant du circuit de soudage 1 Rassembler les c bles en les torsadant ou en les attachant avec du ruban adh sif ou avec une housse 2 Ne pas se tenir au milieu des c bles de soudage Disposer les c bles d un c t et distance de l op rateur 8 Ne pas courber et ne pas entourer les c bles autour de votre co
40. and copper bar Make sure that the sur faces of the weld cable terminal and copper bar are clean 1 Correct Weld Cable Connection 2 Incorrect Weld Cable Connection 3 Weld Output Terminal 4 Supplied Weld Output Terminal Nut 5 Weld Cable Terminal 6 Copper Bar Remove supplied nut from weld output terminal Slide weld cable terminal onto weld output terminal and secure with nut so that weld cable terminal is tight against cop per bar Tools Needed S 3 4 in 803 778 B OM 4434 Page 27 gt A complete Parts List is available at www MillerWelds com 5 10 Selecting Weld Cable Sizes NOTICE The Total Cable Length in Weld Circuit see table below is the combined length of both weld cables For example if the power source is 100 ft 80 m from the workpiece the total cable length in the weld circuit is 200 ft 2 cables x 100 ft Use the 200 ft 60 m column to determine cable size Weld Cable Size and Total Cable Copper Length in Weld Circuit Not Exceeding 150ft 200ft 250ft 300ft 350ft 400Tt 100 ft 30m orLess 45m 60m 70m 80m 105 m 120 m Welding 10 60 60 100 Duty Duty 10 100 Duty Cycle Amperes Cycle Cycle gt 100 4 20 4 20 4 20 3 80 2 35 1 50 1 0 60
41. 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 Block flywheel so that it will not turn while working on generator components 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 HOT PARTS can burn 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 insulated welding gloves and clothing to prevent burns 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 an
42. e Before working on compressed air system turn off and lockout tagout unit release pressure and be sure air pressure cannot be accidentally applied OM 4434 Page 4 e HYDRAULIC FLUID is FLAMMABLE do not work on hydraulics near sparks or flames do not smoke near hydraulic fluid e Reinstall doors panels covers or guards when servicing is finished and before starting unit e f ANY fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury or gan grene may result e MOVING PARTS can injure e Keep away from moving parts such as fans lt belts and rotors e Keep all doors panels covers and guards closed and securely in place e Keep hands hair loose clothing and tools away from moving parts e Before working on hydraulic system turn off and lockout tagout unit release pressure and be sure hydraulic pressure cannot be accidentally applied e Have only qualified people remove guards or covers for maint enance and troubleshooting as necessary e Reinstall doors panels covers or guards when servicing is finished and before starting engine HOT PARTS AND FLUID can burn e Do not touch hot parts bare handed or allow hot fluid to contact skin 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 READ INSTRUCT
43. l entretien est termin et avant de mettre en marche l appareil e En cas de p n tration d un QUELCONQUE liquide dans la peau celui ci doit tre retir chirurgicalement sous quelques heures par OM 4434 Page 11 un m decin familiaris avec ce type de blessure faute de quoi la gangr ne pourrait appara tre g Les PI CES MOBILES peuvent causer des blessures lt e S abstenirde toucher des parties mobiles telles que des ventilateurs courroies et rotors e Maintenir ferm s et verrouill s les portes panneaux recouvrements et dispositifs de protection Ne pas approcher les mains cheveux v tements l ches et outils des organes mobiles Avant d intervenir sur le circuit hydraulique couper l alimentation lectrique verrouiller et tiqueter l appareil d tendre la pression et s assurer que le circuit hydraulique ne peut tre remis sous pression par inadvertance Demander seulement un personnel qualifi d enlever les dispositifs de s curit ou les recouvrements pour effectuer s il y a lieu des travaux d entretien et de d pannage Remettre en place les portes panneaux recouvrements ou dispositifs de protection la fin des travaux d entretien et avant de mettre le moteur en marche 2 5 Dangers li s l air comprim Un QUIPEMENT PNEUMATIQUE risque WE de provoquer des blessures ou m me la mort e Une installation ou une utilisation incorrecte de cet appareil pourrait condui
44. off slag e Wear approved safety glasses with side shields even under your welding helmet OM 4434 Page 1 FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instructions for metals consumables coatings cleaners and degreasers e Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe e Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases e Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded BUILDUP OF GAS can injure or kill e Shut off shieldin
45. open contact Factory Authorized Service Agent Combined output of all receptacles limited to the rating of the generator Kohler powered model 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 24 A 10 5 kVA kW Subaru powered model example If 20 Ais drawn from each 120 V duplex receptacle only 23 A is available at the 240V receptacle 2 x 120 V x 20 A 240 V x 26 A 11 0 kVA kW 120 240V N CB1 50 A MAIN BREAKER 120V A KEE MAIN BREAKER E 803 750 C Ref 240 947 A OM 4434 Page 36 gt A complete Parts List is available at www MillerWelds com 7 2 Optional Generator Power Receptacles gt JA 4 gt NA If unit does not have GFCI recep d J tacles use GFCl protected exten sion cord Generator power decreases as weld current increases Set Fine Control R1 at 10 for full genera tor power Combined output of all receptacles limited to the rating of the generator Maximum output is 10 5 KVA KW for Kohler powered models 11 KVA KW for Subaru powered models CSA GFCI Receptacle Option 1 120 V 20 A AC GFCI Receptacles GFCI 2 and GFCI 3 GFCI2 and GFCI3 supply 60 Hz single ge phase power at weld power speed Maxi 50 A MAILBREAKER NS mum output
46. outils et circuits avant d entretenir ajouter ou changer des accessoires et avant d ouvrir le bouchon de vidange ou de remplissage d huile du compresseur Les PIECES MOBILES peuvent causer des blessures e S abstenir de toucher des parties mobiles telles que des ventilateurs courroies et rotors e Maintenir ferm s et verrouill s les portes panneaux recouvrements et dispositifs de protection e Ne pas approcher les mains cheveux v tements laches et outils des organes mobiles e Avant d intervenir sur le circuit d air comprim couper l alimentation lectrique verrouiller et tiqueter l appareil d tendre la pression et s assurer que le circuit d air ne peut tre mis sous pression par inadvertance e Demander seulement un personnel qualifi d enlever les dispositifs de s curit ou les recouvrements pour effectuer s il y a lieu des travaux d entretien et de d pannage e Remettre en place les portes panneaux recouvrements ou dispositifs de protection la fin des travaux d entretien et avant de mettre le moteur en marche DES PI CES CHAUDES peuvent provoquer des br lures graves e Ne pas toucher de pi ces chaudes du compresseur ou du circuit d air e Pr voir une p riode de refroidissement avant d intervenir sur l quipement e Ne pas toucher aux pi ces chaudes utiliser les outils recommand s et porter des gants de soudage et des v tements pais pour viter les br lur
47. pannage faire retirer les portes panneaux recouvrements ou dispositifs de protection uniquement par du personnel qualifi Pour emp cher tout d marrage accidentel pendant les travaux d entretien d brancher le c ble n gatif de batterie de la borne Ne pas approcher les mains cheveux v tements l ches et outils des organes mobiles Remettre en place les portes panneaux recouvrements ou dispositifs de protection la fin des travaux d entretien et avant de mettre le moteur en marche Avant d intervenir d poser les bougies ou injecteurs pour viter la mise en route accidentelle du moteur Bloquer le volant moteur pour viter sa rotation lors d une intervention sur le g n rateur LES TINCELLES CHAPPEMENT peuvent provoquer un incendie e Emp cher les tincelles d chappement du moteur de provoquer un incendie e Utiliser uniquement un pare tincelles approuv voir codes en vigueur LES PI CES CHAUDES peuvent provoquer des br lures e Ne pas toucher des parties chaudes mains nues e Pr voir une p riode de refroidissement avant de travailler l quipement e Ne pas toucher aux pi ces chaudes utiliser les outils recomman d s et porter des gants de soudage et des v tements pais pour viter les br lures LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT CHAUD peuvent provoquer des br lures e l est pr f rable de v rifier le liquide de refroi dissement une f
48. presented 1 a semiautomatic DC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards Properly install and ground this equipment according to its Owner s Manual and national state and local codes E Indicates special instructions AEN This group of symbols means Warning Watch Out ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult sym bols and related instructions below for necessary actions to avoid the hazards Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet When making input connections attach proper grounding conduc tor first double check connections Keep cords dry free of oil and grease and protected from hot metal and sparks 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
49. 004 ci u uuuoulAu3 INO 104 MOO tunt PUY Ysng nuvans WWu3THOy WO ured OL sued Buap u uA JSQUNN elas pue uoleoyioads ug SAIN 2189 u u 31 duio5 10 enuey sulbuy 88S S3NISN3 d1 0 8ZH9 YATHOM S3NISN3 Sven S9H3 NHVANS OEZHOI EZHIO HTIHOH OM 4434 Page 39 8 2 Routine Maintenance gt A complete Parts List is available at www MillerWelds com wale e A as LAY eg Recycle engine A Stop engine before maintaining See Engine Manual and Maintenance Label for important start up service and storage fluids information Service engine more often if used in severe conditions 1 Check Change Q Clean Replace Reference To be done by Factory Authorized Service Agent Every Section 5 4 H P gt Hours 17 Fuel Level 1 Oil Level Q Oil Fuel Spills Every Section 8 3 G Hours Q Spark Arrestor Screen Every SS Section 8 4 25 O Hours Q Air Cleaner Wrapper Every 50 A Hours al 2 Q Weld Terminals Every Engine 100 Manual Hours Section 8 4 8 6 Q Battery Terminals Q Cooling System x Air Cleaner Element Every k Z SEN 4A S gt Engine 200 4 St gt LR Manual Hours ES Section 8 6 B w Unreadable Labels i Spark Plug Gap Oil Filter Fuel Filter Every Engine 500 Manual Hours
50. 34 Page 6 H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation e The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation e If 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 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 must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area
51. 4 Page 48 gt A complete Parts List is available at www MillerWelds com Trouble Remedy Battery Discharges between uses Clean battery terminals and posts with baking soda and water solution rinse with clear water Periodically recharge battery approximately every 3 months Replace battery Check voltage regulator and connections according to engine manual Engine idles but does not come up to weld speed Have Factory Authorized Service Agent check hour meter idle module and current transformer CT1 Unstable or sluggish engine speeds Readjust throttle linkage if necessary Check throttle solenoid TS1 for smooth operation Check oil level Oil level should not exceed Full mark on dipstick Fuel pump will operate erratically if crankcase is overfilled Tune up engine according to engine manual Engine does not return to idle speed Remove weld and generator power loads Check throttle linkage for smooth non binding operation Have Factory Authorized Service Agent check hour meter idle module current transformer CT1 Engine Control switch S2 and throttle solenoid TS1 SECTION 10 PARTS LIST 10 1 Recommended Spare Parts Dia Part Mkgs No Description Quantity Recommended Spare Parts EE F1 F2 169296 Fuse Mintr GI 25 Amp 125 Volt 2 dun athe ii F6 021718 Fuse Mintr GI 30 Amp 32 Volt
52. CLE O Continuous Welding 100 Duty Cycle at 225 Amperes CC AC 210 Amperes CC DC 200 Amperes CV DC 119 454 A OM 4434 Page 18 gt A complete Parts List is available at www MillerWelds com 4 5 Fuel Consumption Subaru Powered Units On a typical job using 1 8 in 7018 electrodes 125 amps 20 duty K Sy cycle expect about 20 hours of op eration KL lt lt n O Welding at 150 amps at 40 duty E 3 cycle uses approximately 3 4 gal g n lon per hour or about 16 hours of zj gt operation 7 57 1 67 2 00 AUX POWER 6 62 1 46 1 75 F CV WELD 5 67 1 25 1 50 L AS IWELR 4 73 1 04 1 25 F 3 78 0 84 1 00 F 2 84 0 63 0 75 f 1 89 0 42 0 50 F m IDLE 2200 RPM 0 95 0 21 0 25 f 0 1 1 1 1 1 1 H 1 1 1 0 25 50 75 100 125 150 175 200 225 250 275 WELD AMPERES AT 100 DUTY CYCLE L i l i l i l i i i l J 1 0 2 0 3 0 4 0 5 0 60 7 0 8 0 9 0 10 0 11 0 POWER KVA AT 100 DUTY CYCLE 220 571 4 6 Fuel Consumption Kohler Powered Units On a typical job using 1 8 in 7018 electrodes 125 amps 20 duty DC N cycle expect about 20 hours of op E J i N lt eration GE O Welding at 150 amps at 40 duty 1 cycle uses approximately 3 4 gal UI lon per hour or about 16 hours of
53. Contactor Recommended Reed Switch Weld Cable Customer Supplied Weld Control Weld Terminal Weld Power Cable From Spoolgun Work Clamp 9 Gas Hose 10 Argon Cylinder 11 Trigger Control Cord D JO Om Q N Typical Settings For 4043 035 Aluminum On ny 1 8 in Material 7 Note Coarse Range and Weld Process switch settings OD we DONOT SWITCH VHILE WELDING NO CAMBIE CUANDO SEEST SOLDANDO Connect to unused contactor terminal 5 el Plug and sensing lead not 2 used in this application 12 Input Power Cord F gt Be sure to use the correct size weld cables see Section 5 10 Route weld cable from welding generator Electrode terminal through reed switch to unused contactor terminal Connect weld cable from spoolgun to weld control weld ter minal item 6 Connect work cable to welding generator Work terminal Insert trigger control plug item 11 into weld control receptacle Tighten threaded collar Connect ac power cord item 12 to 120 volt ac receptacle on welding generator 802 847 C 240 947 A Connect gas hose from spoolgun to regula tor on Argon bottle Reinstall weld control wrapper Typical Settings For 4043 035 Aluminum On 1 8 in Material gt Set Weld Process Selector switch to Wire DCEP posit
54. INES 52 SECTION 13 STICK WELDING SMAW GUIDELINES 59 SECTION 14 MIG WELDING GMAW GUIDELINES 66 COMPLETE PARTS LIST www MillerWelds com WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING rom_2010 03 A Protect yourself and others from injury read follow and save these important safety precautions and operating instructions 1 1 Symbol Usage DANGERI Indicates a hazardous situation which if not avoided will result in death or serious injury The possible hazards are shown in the adjoining symbols or explained in the text Indicates a hazardous situation which if not avoided could result in death or serious injury The possible hazards are shown in the adjoining symbols or ex plained in the text NOTICE Indicates statements not related to personal injury 1 2 Arc Welding Hazards A A 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 8 Read and follow all Safety Standards Only qualified persons should install operate maintain and repair this unit
55. IONS e Read and follow all labels and the Owner s Manual carefully before installing operating or servicing unit Read the safety information at the beginning of the manual and in each section e Use only genuine replacement parts from the manufacturer e Perform maintenance and service according to the Owner s Manuals industry standards and national state and local codes e Do not work on compressed air system with unit running unless you are a qualified person and following the manufacturer s in structions e Do not modify or alter compressor or manufacturer supplied equipment Do not disconnect disable or override any safety equipmentin the compressed air system e Use only components and accessories approved by the manufac turer e Keep away from potential pinch points or crush points created by equipment connected to the compressed air system e Do not work under or around any equipment that is supported only by air pressure Properly support equipment by mechanical means y HOT METAL from air arc cutting and MOVING PARTS can injure h f gouging can cause fire or explosion e Keep away from moving parts such as fans e Do not cut or gouge near flammables belts and rotors e Watch for fire keep extinguisher nearby e Keep all doors panels covers and guards closed and securely in place e Keep hands hair loose clothing and tools away from moving COMPRESSED AIR ca
56. Joint gt Bw CH i x 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 13 11 Tee Joint 1 Electrode 2 Fillet Weld Keep arc short and move at defi nite 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 13 8 Remove slag before making another weld pass S 0060 S 0058 A S 0061 OM 4434 Page 63 13 12 Weld Test D i 3 n 51 76 mm yo lt 6 4mm es 1 4 in 4 gt 2 BS e 1 Vise 2 Weld Joint 3 Hammer Strike weld joint in direction shown A good weld bends over but does not break Co 2To3 wk 51 76 mm lt 3 S 0057 B 13 13 Troubleshooting 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 Remove all grease oi
57. Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t e Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r 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 e Ne soudez pas si l air ambiant est charg de particules gaz ou va peurs inflammables vapeur d essence par exemple e 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 e Ne pas utiliser le poste de soudage pour d geler des conduites ge l es e En cas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact e Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans revers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos po ches telles qu un allumeur au butane ou des allumettes e Une fois le travail achev assurez vous qu il ne reste aucune tra ce d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissa
58. NCE 39 8 1 Maintenance ET EE 39 8 2 Routine Maintenance nu nel uapa tn ENEE EE ae 40 8 3 Servicing Optional Spark Arrestor 2 41 8 4 Servicing Aif Cleaner usu O Aa A a TE Y pu usu ac ga ar en ne 41 8 5 QOWerl ad Protections aa E au u fa de He s eke aye sa reste Casu dae ale AE deeg ens 42 8 6 Changing Engine Oil Oil Filter and Fuel Filter Subaru Powered Units 43 8 7 Changing Engine Oil Oil Filter and Fuel Filter Kohler Powered Units 44 8 8 Adjusting Engine Speed Subaru Powered Units 45 8 9 Adjusting Engine Speed Kohler Powered Units 46 SECTION 9 TROUBLESHOOTING 47 9 1 Welding Troubl shooting n soisi an ENTREE N ananas kuqa ss u seiyuu ee 47 9 2 Generator Power Troubleshooting 47 9 3 Engine Troubleshooting 2 EN ENN ates a tee da cea asas NIE Coben One ecb eee dante 48 SECTION 10 PARTS LIST NENNEN NN ENEE dE AEN EN E NIR SEN AA NN nies E NNN 49 10 1 Recommended Spare Parts 49 SECTION 11 ELECTRICAL DIAGRAMS 50 SECTION 12 GENERATOR POWER GUIDEL
59. NG GMAW GUIDELINES AKTE KK e EE Ss 14 1 Typical MIG Process Connections Using A Voltage Sensing Wire Feeder A Weld current can damage electronic parts in vehicles Disconnect both battery cables before welding on a vehicle Place work clamp as Constant close to the weld as possible Current CC Or Constant Voltage sensing wire feeders are Voltage CV used with constant current CC or Power Source Constant voltage CV power sources 14 pin receptacle not re quired If using a CC or CV welding power source without a weld output con tactor use optional secondary con tactor For GMAW use optional gas valve Voltage Sensing Wire Feeder Workpiece Electrode Lead Work Clamp Voltage Sensing Clamp Work Lead 802 488 14 2 Holding And Positioning Welding Gun Welding wire is energized when gun trigger is pressed Before lowering helmet and pressing trigger be sure wire is no more than 1 2 in 13 mm past end of nozzle and tip of wire is positioned correctly on seam 1 Hold Gun and Control Gun Trigger 2 Workpiece 3 Work Clamp 4 Electrode Extension Stickout 1 4 to 1 2 in 6 To 13 mm 5 Cradle Gun and Rest Hand on Workpiece 0 15 KH k 45 0 15 l o o N 90 90 er S a 39 End View Of Work Angle Side View Of Gun Angle End View Of Work Angle Side View O
60. ST IRON soa Ep y au Low STAINLESS EP ELECTRODE POSITIVE REVERSE POLARITY EN ELECTRODE NEGATIVE STRAIGHT POLARITY MIN PREP ROUGH HIGH SPATTER GENERAL SMOOTH EASY 6011 In ELECTRODE 6013 SMOOTH EASY HORIZ LOW 7014 E OO re D WE Pau fr el Sais PENETRATION 515 E E DT st 7018 Tools Needed S 3 4in 7024 CO z 803 847 C 240 947 A 087 985 A Ref S 0653 OM 4434 Page 32 A Solid Wire Applications gt A complete Parts List is available at www MillerWelds com 6 4 Typical MIG Welding Connections And Settings W SEE Note Coarse Range Fine Control and Weld Process switch settings Tools Needed oe 3 4 in Typical Control Settings For 035 ER70S 3 Solid Wire Short Circuit Transfer an o T DONOT SWITCH WHILE WELDING NO CAMBIE CUANDO SEEST SOLDANDO A Stop engine CS This section provides general guide lines and may not suit all ap plications The control panel shows the typical settings for welding with 035 ER70S 3 solid wire Use Argon based shielding gas Work Clamp Wire Feeder MIG Gun Gun Trigger Plug Voltage Sensing Clamp O O1 Co NN Gas Cylinder 75 25 Argon Based Gas for Short Circuit Transfer 80 Argon Or Higher For Spray Transfer 7 Gas Hose Connect work cable to welding generator Work terminal C
61. al system or to charge dry cell batteries Do not charge a frozen battery Do not use damaged charging cables Do not charge a battery that has loose terminals or one showing damage such as a cracked case or cover e Before charging battery select correct charger voltage to match battery voltage e Set battery charging controls to the Off position before connect ing to battery Do not allow battery charging clips to touch each other Keep charging cables away from vehicle hood door or moving parts i y FUEL can cause fire or explosion d 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 Le MOVING PARTS can injure e Keep away from moving parts such as fans A belts and rotors e Keep all doors panels covers and guards closed and securely in place Stop engine before installing or connecting unit Have only qualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary e To prevent accidental starting during servicing disconnect negative battery cable from battery Keep hands hair loose clothing and tools away from moving parts Reinstall
62. and run until warm Remove rear panel and air cleaner to access idle speed adjustments Remove top cover to access weld power speed adjustments Idle Speed Adjustment Move Engine Control switch to Run Idle position 1 Throttle Solenoid 2 Mounting Screws 3 Idle Speed Screw Loosen mounting screws Adjust solenoid position so engine runs at idle speed If necessary back out idle speed screw so solenoid can be moved to correct position Tight en mounting screws Be sure sole noid linkage works smoothly Turn idle speed screw for fine adjustments Weld Power Speed Adjustment Move Engine Control switch to Run position 4 Jam Nut 5 Lock Nut 6 Weld Power Speed Adjustment Screw Loosen jam nut and lock nut Turn adjustment screw until engine runs at weld power speed Tighten jam nut and then tighten lock nut A Stop engine Reinstall air cleaner rear panel and top cover SE 2200 2300 rpm 86 6 38 3 Hz 3675 3750 rpm 61 3 62 5 Hz db Tools Needed a 8 10m0 O 8 mm m 803 755 OM 4434 Page 45 gt A complete Parts List is available at www MillerWelds com 8 9 Adjusting Engine Speed Kohler Powered Units GO E
63. 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 4434 Page 8 P gt Indique des instructions sp cifiques AEN Ce groupe de symboles veut dire Avertissement Attention DANGER DE CHOC ELECTRIQUE PIECES EN MOUVEMENT et PIECES CHAUDES Consulter les symboles et les instructions ci dessous y aff rant pour les actions n cessaires afin d viter le danger souder DC semi automatique de type CV MIG MAG 2 un poste souder manuel lectrode enrob e DC 3 un poste 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
64. availler proximit d une source de soudage ni s asseoir ou se pencher dessus 7 Ne pas souder tout en portant la source de soudage ou le d vidoir 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 4434 Page 15 gt A complete Parts List is available at www MillerWelds com SECTION 3 DEFINITIONS 3 1 Symbol Definitions Fast Fast Slow D Stop Engine lt Run Weld Power Tess Run idle lt 2 Slow Idle der Start Engine SE A Amperes V Volts lt TA Engine Oil Fuel Battery Engine 2 lt Engine d Check Val D t switch whil Engine Choke de KN S 7 A welds wale work Connection Positive Negative Ny a CG Output Welding Arc if MIG GMAW oh Electrode WV vig iB Stick GMAW TIG GTAW h Hours S Seconds e Time s SC Se Circuit Protector Temperature 4 1 Weld Power and Engine Specifications This unit uses either a Subaru EH 65 or a Kohler CH 23 engine Differences between models are noted throughout this manual Rated Maximum Ra a ege Weld
65. aximum penetration Keep arc on leading edge of weld puddle Be sure welding wire extends not more than 1 2 in 13 mm beyond nozzle Insufficient heat input Select higher wire feed speed and or select higher voltage range Reduce travel speed 14 11 Troubleshooting Incomplete Fusion Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead S 0637 Possible Causes Corrective Actions Workpiece dirty Remove all grease oil moisture rust paint undercoating and dirt from work surface before welding Insufficient heat input Select higher voltage range and or adjust wire feed speed 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 Use correct gun angle of 0 to 15 degrees 14 12 Troubleshooting Burn Through Burn Through weld metal melting completely through base metal resulting in holes where no metal remains S 0640 Possible Causes Corrective Actions Excessive heat input Select lower voltage range and reduce wire feed speed Increase and or maintain steady travel speed OM 4434 Page 70 14 13 Troubleshooting Waviness Of Bead Wiswi Waviness Of Bead weld metal that is not parallel and does not cover joint formed by base metal
66. by 1 NOISE can damage hearing Noise from some processes or equipment can dam age hearing e Wear approved ear protection if noise level is high ELECTRIC AND MAGNETIC FIELDS EMF can affect Implanted Medical Devices e Wearers of Pacemakers and other Implanted Medical Devices should keep away Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding spot welding gouging plasma arc cutting or induction heating operations CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pres sure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks physical damage slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators 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 Kee
67. ce 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 making another weld pass stick 2010 02 151 593 OM 4434 Page 59 13 2 Electrode and Amperage Selection Chart ES 8 ST RCS Ex AMPERAGE RANGE ELECTRODE DIAMETER 100 150 200 250 300 350 ELECTRODE POSITION PENETRATION A DEEP ALL DEEP MIN PREP ROUGH HIGH SPATTER ALL LOW GENERAL ALL MED SMOOTH EASY FAST ALL MED LOW HYDROGEN STRONG FLAT HORIZ FILLET LOW SMOOTH EASY FASTER NI CL EP ALL LOW CAST IRON 308L EP ALL LOW STAINLESS EP ELECTRODE POSITIVE REVERSE POLARITY EN ELECTRODE NEGATIVE STRAIGHT POLARITY Ref S 087 985 A 13 3 Striking an Arc 1 Electrode 2 Workpiece 3 Arc Scratch Technique Drag electrode across workpiece like striking a match lift electrode slightly after touching work If arc goes out electrode was lifted too high If electrode sticks to work piece use a quick twist to free it
68. ction 8 8 or 8 9 Check receptacle wiring and connections Have Factory Authorized Service Agent check brushes and slip rings 9 3 Engine Troubleshooting Trouble Remedy Engine will not crank Check fuse F6 and replace if open see Section 8 5 Check battery voltage Check battery connections and tighten if necessary Check plug PLG4 and plug PLG8 connections Have Factory Authorized Service Agent check Engine Control switch S2 Engine will not start Check fuel level Check battery voltage Check battery connections and tighten if necessary Check oil level see Section 5 4 or 5 5 Check low oil pressure shutdown switch Have Factory Authorized Service Agent check fuel shutoff solenoid FS1 and diode D8 Engine starts but stops when Engine Control switch returns to Run position Check oil level Check and refill crankcase with proper viscosity oil for operating temperature if necessary Check low oil pressure shutdown switch Engine stopped during normal operation Check fuel level Check oil level see Section 5 4 or 5 5 Check low oil pressure shutdown switch Periodically recharge battery approximately every 3 months Replace battery Check voltage regulator and connections according to engine manual Have Factory Authorized Service Agent check fuel shutoff solenoid FS1 OM 443
69. d adjust if necessary see Section 8 8 or 8 9 Have Factory Authorized Service Agent check brushes slip rings and integrated rectifiers SR2 SR3 9 2 Generator Power Troubleshooting Trouble Remedy No or low generator power output at ac receptacles weld output okay Reset supplementary protectors see Section 7 1 or 7 2 Press optional GFCI receptacle Reset button see Section 7 2 Check fuse F2 and replace if open see Section 8 5 Check plug PLG6 connection Have Factory Authorized Service Agent check brushes slip rings and integrated rectifier SR3 OM 4434 Page 47 gt A complete Parts List is available at www MillerWelds com Trouble Remedy No generator power or weld output Be sure all equipment is disconnected from receptacles when starting unit Check fuses F1 and F2 and replace if open see Section 8 5 Check plug PLG6 connection Have Factory Authorized Service Agent check brushes slip rings capacitor C1 and integrated rectifi ers SR2 and SR3 Low power output at ac receptacles Check fuse F2 and replace if open see Section 8 5 Increase Fine control R1 setting to max High power output at ac receptacles Check engine speed and adjust if necessary see Section 8 8 or 8 9 Erratic power output at ac receptacles Check fuel level Check engine speed and adjust if necessary see Se
70. d far away from windows doors and vents BATTERY ACID can BURN SKIN and EYES e Do not tip battery e Replace damaged battery e Flush eyes and skin immediately with water ENGINE HEAT can cause fire e Do not locate unit on over or near combustible surfaces or flammables e Keep exhaust and exhaust pipes way from flammables OM 4434 Page 3 1 4 Hydraulic Hazards HYDRAULIC EQUIPMENT can injure or kill e Incorrect installation or operation of this unit could result in equipment failure and personal injury Only qualified persons should install op erate and service this unit according to its Owner s Manual industry standards and na tional state and local codes e Do not exceed the rated output or capacity of the hydraulic pump or any equipment in the hydraulic system Design hydraulic sys tem so failure of any hydraulic component will not put people or property at risk e Before working on hydraulic system turn off and lockout tagout unit release pressure and be sure hydraulic pressure cannot be accidentally applied e Do not work on hydraulic system with unit running unless you are a qualified person and following the manufacturer s instructions e Do not modify or alter hydraulic pump or manufacturer supplied equipment Do not disconnect disable or override any safety equipmentin the hydraulic system e Use only components accessories approved by the manufac turer e Keep away from potential
71. d1 0 ZH9 YATHOm Seil pue sBnid yueds 101s S81 Au0 sn A3trtid8 HON 0 Z0 LO G9X NANS LZZ 864 HATIIN NYVENS DASE O4 uoiduieuo ZOZELZL 12140 200 290 HATIN H3T1HO Sepp deg 6nig eds 0 0 0 deg Bnig eds opeBede 1ojou 18 uo2 sopunB s s ap olu p S898A 91 NOY 31qI N H uol9 sod ap JOJO ap OUD 9 81019 HYAHVIH VHVd 21189 Jap OQUEL jap OJU 9 opesed aigos p as nb ueoipui seaneBou se10H 3L0N Jeep 19 JeIQUIeD eyssseu as opuens espedied one el 0189 seu aANUILUSIP A 4 ane ap OUD a ens nui gjezued 00 US uezu luioo 8 89 Op SEIOU SEI 911998 Sp OIQUUEO op Sajue uepanb nb seJoy se 184 med eyoueW NAY UDIDISOd ej Ua HOLOW 13d TOHLNO9 18 eBuod opeBede Joloui o UO9 3L139V 20 OISINVD 14d OIVAHALNI JOJOW UD SEIOU SE JOA Bred juojei euoiew d 1qI NDH uol91sod ei ue JOJOW ep Ionuo2o Ja eBuod opeBede sozow ja U09 OHLANOHOH SAHOCIGAW SOT 20 O1N3ININ3LNVIN 20 S3NOION d HO aulbue spuo9es UIUUNM S uun uonisod NNY 0 STGI NNY 24 Woy Yop Ms OO SUIBUZ 9 949 13S34 OL Temau aGueyo jlo pepuewwooe jsed u uA payeoipul sanoy aAneban ILON enp s eBueus 110 pue seysey J UO9I U9U 1M 0 0 UMOP 1uno2o pue sAe dsIp 1 uoa YOUSIM OO Je Heys sunoy WO ebueyp jio Dau aile SINOY 39S 0 uorIsod NNY 94 OI YOUMs lonluoO eulBuz oeld yo u Bu UNA IVAH31NI 3DNVHO TIO sinou aUIBUS MIA o uonisod a1ql N ti u Yous jo4u09 ulBu3
72. de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial LES FUMEES ET LES GAZ peu vent tre dangereux 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 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 Si la ventilation est m diocre porter un respirateur anti vapeurs approuv e Lire et comprendre les sp cifications de s curit des mat riaux MSDS et les instructions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d graisseurs e Travailler dans un espace ferm seulement s il est bien ventil ou en portant un respirateur alimentation d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent d placer l air et abaisser le niveau d oxyg ne provoquant des blessures ou des accidents mortels S assurer que l air de respiration ne pr sente aucun danger e Ne pas souder dans des endroits situ s proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et for mer des gaz hautement toxiques et irritants e Ne pas souder des m taux munis d un rev t
73. e les grouper et les poser aussi bas que possible ex par terre Veiller souder une distance de 100 m tres de tout quipe ment lectronique sensible Veiller ce que ce poste de soudage soit pos et mis a la terre conform ment a ce mode d emploi En cas d interf rences apr s avoir pris les mesures pr c den tes il incombe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de c bles blind s l utilisation de filtres de ligne ou la pose de protec teurs dans la zone de travail 2 7 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 provoquent des mal formations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants Les batteries les bornes et autres accessoires contiennent du plomb et des compos s base de plomb produits chimi ques dont P tat de Californie reconna t qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apr s manipu lation A Ce produit contient des produits chimiques compris du plomb dont l tat de Californie reconna t qu ils provoquent OM 4434 Page 14 des cancers et des malformations cong nitales ou autres probl
74. ead or layer for each 1 8 in 3 2 mm thickness in metals oO N being welded 4 No Overlap 5 Good Penetration into Base Metal S 0052 B OM 4434 Page 68 14 7 Troubleshooting Excessive Spatter Excessive Spatter scattering of molten metal particles that cool to solid form near weld bead S 0636 Possible Causes Corrective Actions Wire feed speed too high Select lower wire feed speed Voltage too high Select lower voltage range Electrode extension stickout too long Use shorter electrode extension stickout Workpiece dirty Remove all grease oil moisture rust paint undercoating and dirt from work surface before welding Insufficient shielding gas at welding arc Increase flow of shielding gas at regulator flowmeter and or prevent drafts near welding arc Dirty welding wire Use clean dry welding wire Eliminate pickup of oil or lubricant on welding wire from feeder or liner 14 8 Troubleshooting Porosity ann Porosity small cavities or holes resulting from gas pockets in weld metal LEED S 0635 Possible Causes Corrective Actions Insufficient shielding gas at welding arc Increase flow of shielding gas at regulator flowmeter and or prevent drafts near welding arc Remove spatter from gun nozzle Check gas hoses for leaks Place nozzle 1 4 to 1 2 in 6 13 mm from workpiece Hold g
75. ement 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 P LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confin s ou se servir d un respirateur d adduction d air homologu LES RAYONS DE L ARC peuvent provoquer des br lures dans les yeux et sur la peau Le rayonnement de l arc du proc d de soudage g n re des rayons visibles et invisibles intenses ultraviolets et infrarouges susceptibles de provoquer des br lures dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage e Porter un casque de soudage approuv muni de verres filtrants appropri pour prot ger visage et yeux pour prot ger votre visage et vos yeux pendant le soudage ou pour regarder voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit e Porter des lunettes de s curit avec crans lat raux m me sous votre casque e Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les blouissements et les tincelles p
76. ent de fa on appropri e par un moyen m canique M TAL CHAUD provenant du d cou page ou du gougeage l arc risque de provoquer un incendie ou une explo sion e Ne pas d couper ou gouger proximit de produits inflammables e Attention aux risques d incendie tenir un extincteur proximit OM 4434 Page 12 LES PI CES ET LIQUIDES CHAUDS peuvent provoquer des br lures e Ne pas toucher les pi ces chaudes main nue ni laisser des liquides chauds entrer en contact avec la peau Pr voir une p riode de refroidissement avant d intervenir sur l quipement Ne pas toucher aux pi ces chaudes utiliser les outils recommand s et porter des gants de soudage et des v tements pais pour viter les br lures LIRE LES INSTRUCTIONS e Lire et appliquer les instructions sur les tiquettes et le Mode d emploi avant P l installation l utilisation ou entretien de l appareil Lire les informations de s curit au d but du manuel et dans chaque section e N utiliser que les pi ces de rechange recommand es par le constructeur e Effectuer l entretien en respectant les manuels d utilisation les normes industrielles et les codes nationaux d tat et locaux L AIR COMPRIM risque de provoquer des blessures ou m me la mort e Avant d intervenir sur le circuit d air comprim couper l alimentation lectrique verrouiller et tiqueter l appareil d tendre la pr
77. eoeid yo euIBUS UM AILIN HDOH SNOLLON d SONVNALNIVIN YILIN eddeim 91l 3 Ap sepnioul LV 0L92E 292 Mueqns 994 861 HATIIN INHVaNS 491l d AY S 20 80 2 1 lUuoy ELZ 290 HATIIN NR S G0 80 2 13140 210 O Z H3TIIN 08ZH23 S S0 80p2 18140 10 082 HATIIN ECHO H3THO 10ddeiM 49714 Aw S 0 804b 19IUOM ZZZ 290 HATIIN 08ZH29 S 0 80 2 18 40 9LO DES HATIIN 08ZH23 S 0 80 2 1140Y 910 0 Z HATIIN EHD H3 T1HO1 Jeu IenueN saumo aas sinou 00 S9IAS8S Jet Wd 00 2 00 2 peo7 ON Wd 0SZ SZ96 p ds uBiH p ds u 5ud uu sdwy 0 O 8L 4 0 18 99ucguuuop q BuptugiS gs dnoin 19g Aroyeg HOA ZL V 2L0G9 92 nieqns Z 8 LEZ HITIN nuvans S Ztr0S0S 1 lu0y ZL L 9b HATIIN S 120S0G2 18140 OLL 972 HATIIW 0 8ZH23 2Z0S0SZ 42140 v86 SLZ HATIIN 2HO HATHOM Ioueul13 xeIN 04 ultu euepo 8 pepeelun topip ui jap so5 nu sop soj u 8 99 jap sanju ja S Uueiug NHVENS JOpipaw jap 4A 7 SBOJBU Se 4 U jap ISAIu jo e UAULN HTIHON IN3T1I3HgOS ON yORSdIP uo s jou Z u wmgl q jena Ito d y iNYVaNS Yonsd p uo siew 4 9 7 u w q jana llo REN e wl TT Ee LON Od suenb 1 Ajayewixoiddy surya ou Ayoede IO 00 L08S9 8tz NEQNS YSZ 861 HATIIN NHVANS S 100S0Z 18140 869 990 HATIIN H31HO1M sinou 00c sinoy 004 euoses sould ens peiy jen4 any d7 Bursn j Jouf 10 SS 110 pesn 610
78. es LIRE LES INSTRUCTIONS e Lire et appliquer les instructions sur les tiquettes et le Mode d emploi avant l installation l utilisation ou l entretien de l appareil Lire les informations de s curit au d but du manuel et dans chaque section B e N utiliser que les pi ces de rechange recommand es par le constructeur e Effectuer l entretien en respectant les manuels d utilisation les normes industrielles et les codes nationaux d tat et locaux 2 6 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Z Risque D INCENDIE OU h d D EXPLOSION 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 Pali mentation est correctement dimensionn e et prot g e avant de mettre l appareil en service LA CHUTE DE L QUIPEMENT peut provoquer des blessures 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 illeton voir les sp cifications e Utiliser un quipement de levage de capacit suffisante pour lever l appareil e En utilisant des fourches de levage pour d placer l unit s assu rer que les fourches sont suffisamment longues pour d
79. ession et s assurer que le circuit d air ne peut tre mis sous pression par inadvertance e D tendre la pression avant de d brancher ou de brancher des canalisations d air e Avant d utiliser l appareil contr ler les composants du circuit d air comprim les branchements et les flexibles en recherchant tout signe de d t rioration de fuite et d usure Ne pas diriger un jet d air vers soi m me ou vers autrui Pour intervenir sur un circuit d air comprim porter un quipement de protection tel que des lunettes de s curit des gants de cuir une chemise et un pantalon en tissu r sistant des chaussures montantes et une coiffe Pour rechercher des fuites utiliser de l eau savonneuse ou un d tecteur ultrasons jamais les mains nues En cas de d tection de fuite ne pas utiliser l quipement Remettre les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de mettre en marche l appareil En cas d injection d air dans la peau ou le corps demander imm diatementune assistance m dicale L INHALATION D AIR COMPRIM risque de provoquer des blessures ou m me la mort e Ne pas inhaler d air comprim e Utiliser l air comprim uniquement pour d couper ou gouger ainsi que pour l outillage pneumatique Une PRESSION D AIR R SIDUELLE 3 ET DES FLEXIBLES QUI FOUETTENT risquent de provoquer des blessures AY e D tendrela pression pneumatique des
80. f Gun Angle GROOVE WELDS FILLET WELDS S 0421 A OM 4434 Page 66 14 3 Conditions That Affect Weld Bead Shape 3 Weld bead shape depends on gun angle direction of travel electrode extension stickout travel speed thickness of base metal wire feed speed weld current and voltage ai i du b 4 10 l ine gt 3 lt lt Perpendicular Drag GUN ANGLES AND WELD BEAD PROFILES Short Normal Long ELECTRODE EXTENSIONS STICKOUT I Le Lv Short Normal Long FILLET WELD ELECTRODE EXTENSIONS STICKOUT E gas Oe Slow Normal Fast GUN TRAVEL SPEED S 0634 OM 4434 Page 67 14 4 Gun Movement During Welding CS 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 works better 1 Stringer Bead Steady Movement Along Seam 2 Weave Bead Side To Side 1 2 Movement Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode 3 KY S 0054 A 14 5 Poor Weld Bead Characteristics Large Spatter Deposits Rough Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration Q N A S 0053 A 14 6 Good Weld Bead Characteristics Fine Spatter Uniform Bead Moderate Crater During Welding Weld a new b
81. f weld puddle Insufficient heat input Increase amperage Select larger electrode and increase amperage Reduce travel speed w e Excessive Penetration Good Penetration Excessive Penetration weld metal melting through base metal and hanging underneath weld Possible Causes Corrective Actions Excessive heat input Select lower amperage Use smaller electrode Increase and or maintain steady travel speed 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 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 Base metal moves in the direction of the weld bead Distortion contraction of weld metal during welding that forces base metal to move Possible 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 4434 Page 65 SECTION 14 MIG WELDI
82. from GFCI 2 or GFCI 3 is 2 4 oy ore MAN EEA kVA kW 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 plugs etc con nected to the receptacle Press button to re set receptacle and resume operation A Power is still present at the 240 volt receptacle when only one circuit breaker trips Unplug power cord before attempt ing to service accessories or tools 120 240V N F gt At least once a month run engine at weld power speed and press Test but ton to verify GFCI is working properly Ref 240 947 A Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual OM 4434 Page 37 gt A complete Parts List is available at www MillerWelds com 7 3 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 11 000 92 46 7 4 Wiring Optional 240 Volt Plug The plug can be wired for a 240 V e Ei ar 2 wire load or a 120 240V 3 wire load See circuit diagram 1 Plug Wired for 120 240 V
83. g 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 safety glasses with side shields under your helmet e Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc e Wear protective clothing made from durable flame resistant mate rial leather heavy cotton or wool and foot protection AMA 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 you
84. g with the Fine con trol set at 7 or higher 6 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 110 A DC based on control settings shown 80 of 70 to 150 A Settings shown are typical for welding with a 7018 1 8 electrode EF See Sections 6 3 thru 6 5 for typical pro cess connections and control settings OM 4434 Page 30 gt A complete Parts List is available at www MillerWelds com 6 2 Cold Weather Engine Operation 1 Engine Control Switch Carburetor Icing Carburetor icing causes the unit to drop below the normal idle speed and then stall This condition occurs when the temperature is near freezing and the rela Infrequently tive humidity is high Ice forms on the throttle plate and inner bore of the carbu Loaded retor The engine typically restarts without problems but soon stalls again Treat gasoline with a fuel de icer product isopropyl alcohol RUN IDLE RUN amp Place the Engine Control switch in the Run position e Run engine only when expecting to frequently load it Breather Icing Oil breather pulse line icing occurs in severe cold continuously below 0 F Moisture accumulates in the oil from piston ring blow by if the engine is exten sively idled This may cause vacuu
85. ial 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 only to include SCRs diodes and discrete rectifier modules 2 3 Years Parts and Labor Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer Inverter Power Sources Unless Otherwise Stated Plasma Arc Cutting Power Sources Process Controllers Semi Automatic and Automatic Wire Feeders Smith 30 Series Flowgauge and Flowmeter Regulators No Labor Transformer Rectifier Power Sources Wa
86. ing Open Circuit Generator Power Rating e Engine g Output Voltage EES 225 A 25 V Subaru EH 65 CC AG 50 225A 100 Duty 80 Air Cooled Two Cylinder Cycle Peak 11 0 kVA kW ponr yee t 210 A 25 V Continuous 9 5 kVA kW ipa asoine Engine CC DC 50 210A 100 Duty 80 Single Phase SCH Gr 8 or Cycle 92 46 A 120 240 V AC Got Tan 60 Hz while not welding __ Kohler CH 23 200 A 20 V Air Cooled Two Cylinder CV DC 19 28V 100 Duty 33 Four Cycle 23 HP Cycle Gasoline Engine OM 4434 Page 16 gt A complete Parts List is available at www MillerWelds com 4 2 Dimensions Weights And Operating Angles Wa A Do not exceed tilt angles or engine could be damaged or unit could tip Do not move or operate unit where it could tip Weight 562 Ib 254 kg Lifting Eye Weight Rating 1280 Ib 580 kg Le 30838 L GAS CAP ETH 5657 T R130 400 MN 400 MIN TO REMOVE TO REMOVE PANEL PANEL I U a ise 1 i N O i 9 406 MOUNT U eop s 700 Le 43 489 FOR SPARK F FOR UL FILTER Z T PLUG ACCESS Le 22454 gt 1 ACCESS TD PLUG ACCESS Z AR FILTER 3 Le 19 593 et s S DPSTICK e DL FL 31 127 14928 HE J 27 999 15096 rmen oll 100 t 14 928 80 6518 e 3275 MOUNT HOLES 7881
87. ion gt Set Coarse Range switch to Wire 19 28 volts position gt Get Fine Control to desired voltage arc length Start with a low voltage setting about 4 to prevent burnback gt Set wire feed speed between 240 270 ipm OM 4434 Page 35 gt A complete Parts List is available at www MillerWelds com SECTION 7 OPERATING AUXILIARY EQUIPMENT 7 1 Standard Receptacles gt A If unit does not have GFCI re ceptacles use GFClI protected j J extension cord gt Generator power decreases as weld current increases Set Fine Control R1 at 10 for full generator power 1 240 V 50 A AC Receptacle RC1 RC1 supplies 60 Hz single phase power at weld power speed Maxi mum output is 10 5 kVA kW for Kohler powered models 11 kVA kW for Subaru powered models 2 120 V 20 A AC Duplex Recep tacle RC2 3 120 V 20 AAC Duplex Recep tacle RC3 RC2 and RC3 supply 60 Hz single phase power at weld power speed Maximum output from RC2 or RC3 is 2 4 KVA KW 4 Supplementary Protector CB1 CB1 protects receptacles RC1 RC2 and RC3 from overload If CB1 opens the receptacles do not work Place switch in On position to reset 5 Supplementary Protector CB2 6 Supplementary Protector CB3 CB2 protects RC2 and CB3 protects RC8 from overload If a supplementa ry protector opens the receptacle does not work F gt Press button to reset If supple mentary protector continues to
88. is recom mended OM 4434 Page 7 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION Ire rom 2010 03 A Pour carter les risques de blessure pour vous m me et pour autrui lire appliquer et ranger en lieu s r ces consignes relatives aux pr cautions de s curit et au mode op ratoire 2 1 Signification des symboles DANGER Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dangers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte 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 apr s sont utilis s tout au long du pr sent manuel pour attirer votre attention et identifier les ris ques de danger Lorsque vous voyez un symbole soyez vigilant et suivez les directives mentionn es afin d viter tout danger Les consignes de s curit pr sent es ci apr s ne font que r sumer l information contenue dans les normes de s curit num r es la section 2 8 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
89. l moisture rust paint coatings slag and dirt from work surface before welding 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 Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead 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 OM 4434 Page 64 CP Lack of Penetration Good Penetration Lack Of Penetration shallow fusion between weld metal and base metal Possible Causes Corrective Actions 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 o
90. lamp nuts Exhaust clamp supplied with muffler Tools Needed 1 2 in 803 751 Ref 240 947 A Connect negative battery cable last To connect battery open right side en gine access door 1 Battery Holddown To change battery remove rear panel with baffle and battery holddown Be sure battery cables are not pinched when installing battery Tools Needed I 3 8 1 2 in 803 754 D 803 752 C Ref S 0756 D OM 4434 Page 26 gt A complete Parts List is available at www MillerWelds com 5 8 Weld Output Terminals A Stop engine A Failure to properly connect weld cables may cause exces sive heat and start a fire or damage your machine 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 1 See Sections 6 3 thru 6 5 for typi cal process connections and control settings 803 750 B Ref 240 947 A A Stop engine N A Failure to properly connect weld cables may cause ex cessive heat and start a fire or damage your machine 1 2 F gt Do not place anything between weld cable terminal
91. 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 2010 01 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks To locate a Distributor or Service Agency visit www millerwelds com or call 1 800 4 A Miller Contact the Delivering Carrier to File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department ORIGINAL INSTRUCTIONS PRINTED IN USA 2010 Miller Electric Mfg Co 2010 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
92. m Way Suite 100 Ontario Canada L4W 5NS phone 800 463 6727 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 1 9 EMF Information Electric current flowing through any conductor causes localized electric and magnetic fields EMF Welding current creates an EMF field around the welding circuit and welding equipment EMF fields may inter fere with some medical implants e g pacemakers Protective measures for persons wearing medical implants have to be taken For example access restrictions for passers by or individual risk assess ment for welders All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 1 Keep cables close together by twisting or taping them or using a cable cover 2 Do not place your body between welding cables Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 25 West 43rd Street New York NY 10036 phone 212 642 4900 web site www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org For Standards about hydraulic systems contact the National Fluid Power Association Publications Department 3333 North Mayfair
93. m line freezing oil breather tube freezing or ice in the carburetor All of these cause operating problems Due to ice in the lines the engine may not restart until it is warmed to above freezing Frequently Load engine and reduce idle times t t engine shutd Loaded oad engine and reauce idle times to prevent engine snutaowns Use an electric fuel pump to avoid pulse line freezing Ge RUN IDLE RUN lt START oer Install engine cold weather kit Both Kohler 1 800 544 2444 and Subaru 1 800 277 6246 offer kits for cold weather operation The user can install these kits Both kits pull heated air from the muffler surface into the carburetor and shut the cold air off This increases engine temperature during operation in both idle and high speed gt When the ambient temperatures become warmer above 45 F the air flow will have to be returned to normal Ref 240 947 Notes http www millerwelds com service replacementparts html Choose Genuine Select to review spare parts requirements such as filters spark plugs and fuses Choose Service Parts to download complete parts listing Consumables Y P e Finding the right parts and Download Owners consumables has never Manuals for complete been easier parts listing OM 4434 Page 31 gt A complete Parts List is available at www MillerWelds com 6 3 Typical Stick Welding Connectio
94. mp cher de tomber ou de se renverser Tenir les bouteilles loign es des circuits de soudage ou autres circuits lectriques Ne jamais placer une torche de soudage sur une bouteille gaz Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille Ne jamais souder une bouteille pressuris e risque d explosion Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat Ne pas tenir la t te en face de la sortie en ouvrant la soupape de la bouteille Maintenir le chapeau de protection sur la soupape sauf en cas d utilisation ou de branchement de la bouteille Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s cu rit 2 3 Dangers existant en relation avec le moteur L EXPLOSION DE LA BATTERIE peut provoquer des blessures e Toujours porter une protection faciale des gants en caoutchouc et v tements de protec tion lors d une intervention sur la batterie e Arr ter le moteur avant de d brancher ou de brancher des c bles de batterie des c bles de chargeur de batterie le cas
95. mponents such as contact tips cutting nozzles contactors brushes relays work station table tops and welding curtains or parts that fail due to normal wear Exception brushes and relays are covered on all engine driven products 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
96. n injure or kill parts e Before working on compressed air system turn off and lockout e Before working on compressed air system tagout unit release pressure and be sure air pressure cannot be turn off and lockout tagout unit release pres accidentally applied sure and be sure air pressure cannot be acci dentally applied e Relieve pressure before disconnecting or con necting air lines Have only qualified people remove guards or covers for maint enance and troubleshooting as necessary Reinstall doors panels covers or guards when servicing is finished and before starting engine e Check compressed air system components and all connections and hoses for damage leaks and wear before operating unit Do not direct air stream toward self or others e Wear protective equipment such as safety glasses hearing pro tection leather gloves heavy shirt and trousers high shoes and a cap when working on compressed air system e Use soapy water or an ultrasonic detector to search for leaks never use bare hands Do not use equipment if leaks are found HOT PARTS can burn e Do not touch hot compressor or air system parts e Allow cooling period before working on equip e Reinstall doors panels covers or guards when servicing is ment finished and before starting unit e To handle hot parts use proper tools and or wear heavy insu e If ANY air is injected into the skin or body seek medical help im lated
97. nationaux d tat et locaux LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences 1 e Le rayonnement haute fr quence H F peut provoquer des interf rences avec les quipe ments de radio navigation et de communica tion les services de s curit et les ordinateurs Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation Si le 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 Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distan ce 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 Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement Pour r duire la possibilit d interf rence maintenir les cables de soudage aussi courts que possibl
98. nce ne pas les ponter e Suivre les recommandations dans OSHA 1910 252 a 2 iv et NFPA 51B pour les travaux chaud et avoir de la surveillance et un extincteur proximit LE BRUIT peut affecter l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv s pour les oreilles si le niveau sonore est trop lev OM 4434 Page 9 Les CHAMPS LECTROMAGN TIQUES CEM peuvent affecter les implants m dicaux e Les porteurs de stimulateurs cardiaques et autres implants m dicaux doivent rester distance e Les porteurs d implants m dicaux doivent consulter leur m decin et le fabricant du dispositif avant de s approcher de la zone o se d roule du soudage l arc du soudage par points du gougeage de la d coupe plasma ou une op ration de chauffage par induction Si des BOUTEILLES sont endomma g es elles pourront exploser Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endomma g e elle peut exploser Du fait que les bouteilles de gaz font normalement partie du proc d de soudage les manipuler avec pr caution e Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques des dommages physiques du laitier des flammes ouvertes des tincelles et des arcs Placer les bouteilles debout en les fixant dans un support station naire ou dans un porte bouteilles pour les e
99. ns And Control Settings CN e a amp ap A Stop engine Wy RE Ii CS This section provides general guidelines and may not suit all applications For best arc starts and best The control panel shows the typi results using weld and generator cal settings for welding with a power together use a low 7018 1 8 in electrode Consult Coarse Range setting and the 2 the ampere lection tabl Fine control set at 7 or higher amperage selection tables below if welding with other elec trodes 1 Work Clamp 2 Electrode Holder Connect Work cable to Work terminal and Electrode holder cable to Elec trode terminal on welding generator N OLE gt Be sure to use the correct size weld cables see Section 5 10 For best performance set the Coarse Range switch to the low est range that covers the desired weld amperage Use the Fine control to select the desired am perage within the range se lected When properly set the Fine control is normally setat 7 or higher Typical Settings For 7018 1 8 in Electrode Typical Settings For 7018 1 8 in Electrode 2 gt Set Weld Process Selector switch to Stick position gt Set Coarse Range switch to 70 150 1 8 position gt Get Fine control at 7 or higher for best results Electrode Selection Table Beneath Cover AMPERAGE USAGE 601 601 6013 EPE 7024 EP EN a CA
100. ois le moteur refroidi pour viter de se br ler e Toujours v rifier le niveau de liquide de refroidissement dans le vase d expansion si pr sent et non dans le radiateur sauf si pr cis autrement dans la section maintenance du manuel du moteur e Sile moteur est chaud et que le liquide doit tre v rifi op rer com me suivant 2 4 Dangers li s l hydraulique Les QUIPEMENTS HYDRAULIQUES peuvent provoquer des blessures ou m me la mort e Une installation ou une utilisation incorrecte de cet appareil pourrait conduire des d g ts mat riels ou corporels Seul un personnel qualifi est autoris installer faire fonctionner et r parer cet appareil conform ment son manuel d utilisation aux normes industrielles et aux codes nationaux d tat ou locaux e Ne pas d passer le d bit nominal ou la capacit de la pompe hydraulique ou de tout quipement du circuit hydraulique Concevoir le circuit hydraulique de telle sorte que la d faillance d un composant hydraulique ne risque pas de provoquer un accident mat riel ou corporel e Avant d intervenir sur le circuit hydraulique couper l alimentation lectrique verrouiller et tiqueter l appareil d tendre la pression et s assurer que le circuit hydraulique ne peut tre remis sous pression par inadvertance e Ne pas intervenir sur le circuit hydraulique lorsque l appareil fonctionne Seul un personnel qualifi et appliquant les c
101. onnect cable from wire feeder to cable from welding generator Electrode terminal gt Be sure to use the correct size weld cables see Section 5 10 Loosen MIG gun securing knob Insert gun end through opening in feeder and position as close as possible to drive rolls without touching Tighten knob See wire feeder manual for wire thread ing procedure Insert gun trigger plug item 4 into matching receptacle and tighten threaded collar Connect gas hose from feeder to regula tor on cylinder Typical Control Settings For Short Circuit Transfer Using 035 ER70S 3 Solid Wire And 75 25 Argon Based Gas gt Set Weld Process Selector switch to Wire DCEP position gt Set Coarse Range switch to Wire 19 28 volts position gt Set Fine Control to obtain minimum spatter gt Set wire feed speed between 150 300 ipm 803 847 C 802 766 240 947 A OM 4434 Page 33 gt A complete Parts List is available at www MillerWelds com B Self Shielded Flux Core Wire Applications Typical Control Settings For 045 71T 11 Self Shielded Flux Core Wire Note Coarse Range Fine Control and Weld Process switch settings OL PER Tools Needed IF 3 4 in A Stop engine This section provides general guidelines and may not suit all applications The control panel shows the typi cal settings for welding with 045 71T 11 self shielded flux c
102. onsignes du fabricant est autoris le faire e Ne pas modifier ou alt rer la pompe hydraulique ou les quipements fournis par le fabricant Ne pas d brancher d sactiver ou neutraliser les quipements de s curit du circuit hydraulique e Utiliser uniquement des composants et accessoires homologu s par le fabricant e Se tenir l cart de tout point pr sentant un danger de pincement ou d crasement cr par l quipement raccord au circuit hydraulique e Mettre des lunettes de s curit et des gants placer un torchon sur le bouchon du radiateur e D visser le bouchon l g rement et laisser la vapeur s chapper avant d enlever le bouchon L utilisation d un groupe autonome l int rieur PEUT VOUS TUER EN QUELQUES MINUTES e Les fum es d un groupe autonome contient du monoxyde de carbone C est un poison invisi ble et inodore e JAMAIS utiliser dans une maison ou garage m me avec les portes et fen tres ouvertes e Uniquementutiliser l 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 G LA CHALEUR DU MOTEUR peut pro d voquer un incendie e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Tenir distance les
103. ore wire Work Clamp Wire Feeder MIG Gun Gun Trigger Plug a Co N Voltage Sensing Clamp Connect work cable to welding gen erator Work terminal Connect cable from wire feeder to cable from weld ing generator Electrode terminal F gt Be sure to use the correct size weld cables see Section 5 10 Loosen MIG gun securing knob In sert gun end through opening in feed er and position as close as possible to drive rolls without touching Tight en knob See wire feeder manual for wire threading procedure Insert gun trigger plug item 4 into matching receptacle and tighten threaded collar Typical Control Settings Using 045 71T 11 Self Shielded Flux Core Wire gt Set Weld Process Selector switch to Wire position DCEN gt Set Coarse Range switch to Wire 19 28 volts position gt Set Fine Control near minimum setting gt Set wire feed speed between 125 200 ipm gt Do a test weld To increase arc length increase Fine Control setting To shorten arc length reduce fine control setting or in crease wire feed speed 803 847 C 802 766 240 947 A OM 4434 Page 34 gt A complete Parts List is available at www MillerWelds com 6 5 Typical MIG Connections And Settings Using Weld Control And Spoolgun Tools Needed S 3 4 in F gt This section provides general guide lines and may not suit all applications Weld Control Spoolgun Optional
104. ore attempt ing restart To Stop turn Engine Control switch to Off position 3 Engine Hour Meter Idle Control Hour Meter With engine off place Engine Control switch in Run Idle position to view en gine hours 1 Oil Change Interval With engine off place En gine Control switch in the Run position to see hours before next oil change Oil hours start at 100 and count down to 0 zero oil change due gt Negative hours indicated when past rec ommended oil change interval To reset cycle Engine Control switch from Run Idle to Run three times within five sec onds engine off 4 Weld Process Selector Switch NOTICE Do not switch under load 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 GMAW 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 5 Coarse Range Switch 2 Ref 240 947 A NOTICE Do not switch under load 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 settin
105. p 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 injure e Always wear a face shield rubber gloves and protective clothing when working on a battery e Stop engine before disconnecting or connect ing battery cables battery charging cables if applicable or servicing battery e Do not allow tools to cause sparks when working on a battery e Do not use welder to charge batteries or jump start vehicles un less the unit has a battery charging feature designed for this pur pose Observe correct polarity and on batteries Disconnect negative cable first and connect it last Keep sparks flames cigarettes and other ignition sources away from batteries Batteries produce explosive gases during normal operation and when being charged e Follow battery manufacturer s instructions when working on or near a battery BATTERY CHARGING OUTPUT can injure Battery charging feature not present on all models e Have only qualified persons do battery charging work e Charge lead acid batteries only Do not use battery charger to supply power to an extra low voltage electric
106. passer du c t oppos de l appareil e Tenir l quipement c bles et cordons distance des v hicules mobiles lors de toute op ration en hauteur e Suivre les consignes du Manuel des applications pour l quation de levage NIOSH r vis e Publication N 94 110 lors du levage manuelle de pi ces ou quipements lourds LE SURCHAUFFEMENT peut endommager le moteur lectrique d marrer ou d arr ter le moteur e Ne pas laisser tourner le moteur trop lentement sous risque d en dommagerle moteur lectrique cause d une tension et d une fr quence trop faibles e Ne pas brancher de moteur de 50 ou de 60 Hz la prise de 100 Hz s il y a lieu e Arr ter ou d connecter l quipement avant de LES TINCELLES PROJET ES peuvent provoquer des blessures 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 ma noeuvre est ex cuter dans un endroit sir lors que l on porte l quipement homologu de pro tection du visage des mains et du corps e Les tincelles risquent de causer un incendie loigner toute substance inflammable Les PI CES MOBILES peuvent causer 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 su
107. pinch points or crush points created by equipmentconnected to the hydraulic system e Do not work under or around any equipment that is supported only by hydraulic pressure Properly support equipment by mechanical means HYDRAULIC FLUID can injure or kill e Before working on hydraulic system turn off and lockout tagout unit release pressure and be sure hydraulic pressure cannot be accidentally applied e Relieve pressure before disconnecting or con necting hydraulic lines e Check hydraulic system components and all con nections and hoses for damage leaks and wear before operating unit e Wear protective equipment such as safety glasses leather gloves heavy shirt and trousers high shoes and a cap when working on hydraulic system e Use a piece of paper or cardboard to search for leaks never use bare hands Do not use equipment if leaks are found 1 5 Compressed Air Hazards COMPRESSED AIR EQUIPMENT can injure or kill e Incorrect installation or operation of this unit could result in equipment failure and personal injury Only qualified persons should install op erate and service this unit according to its Owner s Manual industry standards and na tional state and local codes e Do not exceed the rated output or capacity of the compressor or any equipment in the compressed air system Design compressed air system so failure of any component will not put people or prop erty at risk
108. produits inflammables de l chappement e Ne pas intervenir sous ou autour d un quipement qui n est soutenu que par la pression hydraulique Soutenir l quipement de fa on appropri e par un moyen m canique Le LIQUIDE HYDRAULIQUE risque de provoquer des blessures ou m me la mort e Avant d intervenir sur le circuit hydraulique couper l alimentation lectrique verrouiller et tiqueter l appareil d tendre la pression et s assurer que le circuit hydraulique ne peut tre remis sous pression par inadvertance e D tendre la pression avant de d brancher ou de brancher des canalisations hydrauliques e Avant d utiliser l appareil contr ler les composants du circuit hydraulique les branchements et les flexibles en recherchant tout signe de d t rioration de fuite et d usure e Pour intervenir sur un circuit hydraulique porter un quipement de protection tel que des lunettes de s curit des gants de cuir une chemise et un pantalon en tissu r sistant des chaussures montantes et une coiffe e Pour rechercher des fuites utiliser un morceau de papier ou de carton jamais les mains nues En cas de d tection de fuite ne pas utiliser l quipement e Le LIQUIDE HYDRAULIQUE est INFLAMMABLE Ne pas intervenir sur des composants hydrauliques proximit d tincelles ou de flammes ne pas fumer proximit de liquide hydraulique e Remettre les portes panneaux recouvrements ou dispositifs de protection quand
109. 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 e Mettre l appareil hors tension quand on ne l utilise pas e Ne pas utiliser des c bles us s endommag s de grosseur insuffi sante ou mal piss s e Ne pas enrouler les c bles autour du corps e Si la pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct ne pas utiliser le connecteur de pi ce ou le c ble de retour e Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine e 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 ma
110. r venir toute personne sur les lieux de ne pas regarder l arc e 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 F LE SOUDAGE peut provoquer un ITER incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincelles des pi ces chaudes et des quipements chauds peut provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un surchauffement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger e D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneusement avec des protections homologu s e Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables e Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud e Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures e Surveiller tout d clenchement d incendie et tenir un extincteur proximit e
111. r la g chette avant den 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 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 ET ka e Ne pas obstruer les passages d air du poste ee OM 4434 Page 13 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 antistatiques pour stocker d placer ou exp dier des cartes de circuits imprimes UNE REMORQUE QUI BASCULE peut provoquer 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 Lire et appliquer les instructions sur les tiquettes et le Mode d emploi avant l installation l utilisation ou entretien de l appareil Lire les informations de s curit au d but du manuel et dans chaque section e N utiliser que les pi ces de rechange recommand es par le constructeur e Effectuer l entretien en respectant les manuels d utilisation les normes industrielles et les codes
112. r pow er output okay at ac receptacles Check control settings Check weld connections Check fuse F1 and replace if open see Section 8 5 Have Factory Authorized Service Agent check brushes slip rings capacitor C1 and integrated rectifi ers SR2 and SR3 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 8 5 Check plug PLG6 connection Have Factory Authorized Service Agent check brushes slip rings capacitor C1 and integrated rectifi ers SR2 and SR3 Low weld output Check fuse F1 and replace if open see Section 8 5 Check control settings Check engine speed and adjust if necessary see Section 8 8 or 8 9 Service air cleaner according to engine manual Have Factory Authorized Service Agent check brushes slip rings capacitor C1 and integrated rectifi ers SR2 and SR3 High weld output Check control settings Check engine speed and adjust if necessary see Section 8 8 or 8 9 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 an
113. re des d g ts mat riels ou corporels Seul un personnel qualifi est autoris installer utiliser et entretenir cet appareil conform ment son manuel d utilisation aux normes industrielles et aux codes nationaux d tat ou locaux Ne pas d passer le d bit nominal ou la capacit du compresseur ou de tout quipement du circuit d air comprim Concevoir le circuit d air comprim de telle sorte que la d faillance d un composant ne risque pas de provoquer un accident mat riel ou corporel Avant d intervenir sur le circuit d air comprim couper l alimentation lectrique verrouiller et tiqueter l appareil d tendre la pression et s assurer que le circuit d air ne peut tre mis sous pression par inadvertance Ne pas intervenir sur le circuit d air comprim lorsque l appareil fonctionne Seul un personnel qualifi est autoris et appliquant les consignes du fabricant Ne pas modifier ou alt rer le compresseur ou les quipements fournis par le fabricant Ne pas d brancher d sactiver ou neutraliser les quipements de s curit du circuit d air comprim Utiliser uniquement des composants et accessoires homologu s par le fabricant Se tenir l cart de tout point pr sentant un danger de pincement ou d crasement cr par l quipement raccord au circuit d air comprim Ne pas intervenir sous ou autour d un quipement qui n est soutenu que par la pression pneumatique Soutenir l quipem
114. rps 25 West 43rd Street New York NY 10036 phone 212 642 4900 web site www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org For Standards about hydraulic systems contact the National Fluid Power Association Publications Department 3333 North Mayfair Road Suite 211 Milwaukee WI 53222 3219 phone 414 778 3344 website www nfpa com 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 OSHA Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov U S Consumer Product Safety Commission CPSC 4330 East West Highway Bethesda MD 20814 phone 301 504 7923 website WWW CpSC gov Applications Manual for the Revised NIOSH Lifting Equation The Na tional Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 phone 1 800 232 4636 website www cdc gov NIOSH 4 Maintenir la t te et le torse aussi loin que possible du mat riel du circuit de soudage 5 Connecter la pince sur la pi ce aussi pr s que possible de la soudure 6 Ne pas tr
115. rself 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 4434 Page 2 Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire haz ards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap Remove any combustibles such as a butane lighter or matches from your person before doing any welding After completion of work inspect area to ensure it is free of sparks glowing embers and flames 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 near
116. s as necessary and wipe up fuel Reset oil maintenance countdown by flipping Engine Control switch from Run ldle to Run three times Tools Needed 803 755 240 947 A S 0842 OM 4434 Page 43 gt A complete Parts List is available at www MillerWelds com 8 7 Changing Engine Oil Oil Filter and Fuel Filter Kohler Powered Units AY 22 A Stop engine and let cool we z r Vi 1 OilDrain Valve 2 1 2 D x 7 in Hose N 3 Oil Filter Change engine oil and filter accord ing to engine owner s manual A Close valve and valve cap before adding oil and running engine Fill crankcase with new oil to full mark on dipstick see Section 5 5 4 Fuel Filter 5 Fuel Une Replace line if cracked or worn Install new filter Wipe up any spilled fuel Start engine and check for fuel leaks A Stop engine tighten connec tions as necessary and wipe 4 up fuel Tools Needed Se u 803 754 D S 0842 OM 4434 Page 44 gt A complete Parts List is available at www MillerWelds com 8 8 Adjusting Engine Speed Subaru Powered Units After tuning engine check engine aw speeds with a tachometer see table If necessary adjust speeds as follows Start engine
117. section are intended to be representative of all engine driven welding generators Your unit may differ from those shown 12 1 Selecting Equipment z 1 Generator Power Receptacles Neutral Bonded To Frame 2 3 Prong Plug From Case Grounded Equipment 3 2 Prong Plug From Double Insulated Equipment yt JI gt Be sure equipment has double gt insulated symbol and or word ing on it A Do not use 2 prong plug un less equipment is double in 120 sulated gen_pwr 2008 01 ST 800 577 A Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards A Also see AWS Safety amp Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Generators 1 Equipment Grounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger 1 2 insulated copper wire GND PE Gene ZE al to metal contact CD Electrically bond generator frame to vehicle frame by met C Bed liners shipping skids and some running gear insu late the welding generator aa 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 A If unit does not ha
118. sure 1 8 Gal Min 500 PSI 3150 950 Washer 2 gal min 550 PSI 4500 1400 2 gal min 700 PSI 6100 1600 Refrigerator or Freezer 3100 800 Shallow Well Pump 1 3 HP 2150 750 1 2 HP 3100 1000 Sump Pump 1 3 HP 2100 800 1 2 HP 3200 1050 OM 4434 Page 54 12 7 Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1 4 in 350 350 3 8 in 400 400 1 2 in 600 600 Circular Saw 6 1 2 in 500 500 7 1 4 in 900 900 8 1 4 in 1400 1400 Table Saw 9 in 4500 1500 10in 6300 1800 Band Saw 14 in 2500 1100 Bench Grinder 6in 1720 720 8in 3900 1400 10in 5200 1600 Air Compressor 1 2 HP 3000 1000 1 HP 6000 1500 1 1 2 HP 8200 2200 2 HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1 3 HP 2100 700 Elec Hedge Trimmer 18 in 400 400 Flood Lights HID 125 100 Metal Halide 313 250 Mercury 1000 Sodium 1400 Vapor 1250 1000 Submersible Pump 400 gph 600 200 Centrifugal Pump 900 gph 900 500 Floor Polisher 3 4 HP 16 in 4500 1400 1 HP 20 in 6100 1600 High Pressure Washer 1 2 HP 3150 950 3 4 HP 4500 1400 1 HP 6100 1600 55 gal Drum Mixer 1 4 HP 1900 700 Wet amp Dry Vac 1 7 HP 900 900 2 1 2 HP 1300 1300 OM 4434 Page 55 12 8 Power Required To Start Motor Single Phase Induction Motor Starting Requirements Motor Start G H J K L M N P Code KVA
119. t riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment ce manuel e Porter un harnais de s curit quand on travaille en hauteur e Maintenir solidement en place tous les panneaux et capots e Fixer le c ble de retour de fa on obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s pos sible de la soudure e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique Il reste une TENSION DC NON N GLIGEABLE dans les sources de soudage onduleur UNE FOIS le moteur coup 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 LES PI CES CHAUDES peuvent provoquer des br lures e Ne pas toucher mains nues les parties chau des e Pr voir une p riode de refroidissement avant de travailler l quipement e 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 r SALETES peuvent provoquer des blessures 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
120. ter Coolant Systems Integrated 3 2 Years Parts Auto Darkening Helmet Lenses No Labor 4 1 Year Parts and Labor Unless Specified Automatic Motion Devices CoolBelt and CoolBand Blower Unit No Labor External Monitoring Equipment and Sensors Field Options NOTE Field options are covered for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater Flowgauge and Flowmeter Regulators No Labor RFCS Foot Controls Except RFCS RJ45 Fume Extractors HF Units ICE Plasma Cutting Torches No Labor Induction Heating Power Sources Coolers and Electronic Controls Recorders Load Banks Motor Driven Guns w exception of Spoolmate Spoolguns PAPR Blower Unit No Labor Positioners and Controllers Racks Running Gear Trailers Spot Welders Subarc Wire Drive Assemblies Water Coolant Systems Non Integrated Weldcraft Branded TIG Torches No Labor Work Stations Weld Tables No Labor 6 Months Parts Batteries Bernard Guns No Labor Tregaskiss Guns No Labor 6 90 Days Parts Accessory Kits Canvas Covers Induction Heating Coils and Blankets Cables and Non Electronic Controls M Guns MIG Guns and Subarc SAW Guns Remote Controls and RFCS RJ45 Replacement Parts No labor Roughneck Guns Spoolmate Spoolguns Millers True Blue Limited Warranty shall not apply to 1 Consumable co
121. un near bead at end of weld until molten metal solidifies Wrong gas Use welding grade shielding gas change to different gas Dirty welding wire Use clean dry welding wire Eliminate pick up of oil or lubricant on welding wire from feeder or liner Workpiece dirty Remove all grease oil moisture rust paint coatings and dirt from work surface before welding Use a more highly deoxidizing welding wire contact supplier Welding wire extends too far out of nozzle Be sure welding wire extends not more than 1 2 in 13 mm beyond nozzle 14 9 Troubleshooting Excessive Penetration E E Excessive Penetration weld metal melting through base metal and hanging underneath weld Excessive Penetration Good Penetration S 0639 Possible Causes Corrective Actions Excessive heat input Select lower voltage range and reduce wire feed speed Increase travel speed OM 4434 Page 69 14 10 Troubleshooting Lack Of Penetration Lack Of Penetration shallow fusion between weld metal and base metal Lack of Penetration Good Penetration S 0638 Possible Causes Corrective Actions Improper joint preparation Material too thick Joint preparation and design must provide access to bottom of groove while maintaining proper welding wire extension and arc characteristics Improper weld technique Maintain normal gun angle of 0 to 15 degrees to achieve m
122. une d t rioration comme par exemple un bo tier ou un couvercle fissur e Avant de charger une batterie s lectionner la tension de charge correspondant la tension de la batterie e R gler les commandes de charge de batterie sur la position d arr t avant de brancher la batterie Veiller ce que les pinces de charge ne se touchent pas OM 4434 Page 10 e Ranger les c bles de charge distance du capot des portes et des pi ces mobiles du v hicule LE CARBURANT MOTEUR peut pro voquer un incendie ou une explosion e Arr ter le moteur avant de v rifier le niveau de carburant ou de faire le plein Ne pas faire le plein en fumant ou proche d une source d tincel les ou d une flamme nue Ne pas faire le plein de carburant ras bord pr voir de l espace pour son expansion Faire attention de ne pas renverser de carburant Nettoyer tout carburant renvers avant de faire d marrer le moteur Jeter les chiffons dans un r cipient ignifuge Toujours garder le pistolet en contact avec le r servoir lors du remplissage 4 Les PIECES MOBILES peuvent causer des blessures d e S abstenir de toucher des parties mobiles telles que des ventilateurs courroies et rotors Maintenir ferm s et verrouill s les portes panneaux recouvrements et dispositifs de protection Arr ter le moteur avant d installer ou brancher l appareil Lorsque cela est n cessaire pour des travaux d lentretien et de d
123. utput 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 12 4 OM 4434 Page 57 12 11 Selecting Extension Cord Use Shortest Cord Possible Cord Lengths for 120 Volt Loads e A If unit does not have GFCI receptacles use GFCI protected extension cord Maximum Allowable Cord Length in ft m for Conductor Size AWG Curren 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 e A If unit does not have GFCI receptacles use GFCI protected extension cord Maximum Allowable Cord Length in ft m for Conductor Size AWG Current Load Watts 4 6 8 10 12 14 Amperes 5 1200 700 213 450 137 225 84 200
124. ve GFCI re ceptacles use GFCl pro tected extension cord 800 652 D OM 4434 Page 52 12 3 Grounding When Supplying Building Systems S 1 Equipment Grounding Terminal 2 Grounding Cable Use 10 AWG or larger insulated 1 2 copper wire GND PE Ca 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 12 4 How Much Power Does Equipment Require 1 Resistive Load gt N 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 12 8 3 VOLTS 115 3 Rating Data 2 AMPS 4 5 Rating shows volts and amperes or 1 Hz 60 watts required to run equipment u Amperes x Volts Watts 60W Example 1 If a drill uses 4 5 am peres at 115 volts calculate its run ning power requirement in watts 4 5 A x 115 V 520 W ae 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
125. welding gloves and clothing to prevent burns mediately BREATHING COMPRESSED AIR can in jure or kill READ INSTRUCTIONS e Do not use compressed air for breathing e Use only for cutting gouging and tools e Read and follow all labels and the Owner s Manual carefully before installing operating or servicing unit Read the safety information at the beginning of the manual and in each TRAPPED AIR PRESSURE AND WHIPPING section HOSES can injure 4 e Use only genuine replacement parts from the manufacturer e Perform maintenance and service according to the Owner s Manuals industry standards and national state and local codes 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 1 6 Additional Symbols For Installation Operation And Maintenance CA bi FIRE OR EXPLOSION hazard OVERHEATING can damage motors e Turn off or unplug equipment before starting or stopping engine e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not let low voltage and frequency caused by e Do not overload building wiring be sure power supply system is low engine speed damage electric motors properly sized rated and protected to handle this unit e Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable

Bobcat 225

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