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Manuel d'utilisation

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1. ON ep A opueuorounj JOJOW UO HOLONW 1430 SINCE ID 594 uorioisod ep 10j0ui 81919 Ved xonsdip uo sejou 2 NIHOH oiquieo opesed 91405 e es enb uezipul SPIOH 310 uo 4 2 7 Gey HATHOM LON OG ep suenb c Ajoyewxoiddy 0 uepuerosep 001 ue uezueluoo SBJOY se eyeoe ep uepenb 00 L08S9 8 c 861 HATIIN NIGOH enb seJou se esed uoroisod ej ue YHOLOW 13 00901 42 40 869 990 HATIIN 79114 IO JOYLNOD Jojow uoo 3 1132 V OISIAVO OTVAHALNI e sanougoz IO ue SBJOY Se JOA ered NNY sinouooL 77777777777 uoioisod e ue JOJOW uoo llo esn 501 OLN3ININA3INVMW SANOIONNA ony d7 Buisn jJ 10 95 uogeoyisse Idv
2. Fuel Add fresh fuel before starting engine the first time see maintenance label for specifications Always leave filler neck empty to allow room for expan sion Check fuel level on a cold en gine before use each day Oil Check Cil Fill To check fuel level turn Engine Con trol switch to Run ldle position LED s indicate fuel level in tank Cil Do not exceed Full mark on the oil level dipstick The fuel pump may operate erratically 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 mainte nance label Use front panel meters to determine hours until next recommended oil change see Section 6 1 To improve cold weather starting Keep battery in good condition Store battery in warm area Use correct grade oil for cold weather Close top service door Gasoline Ref 808 571 A Ref 803 572 A OM 4426 Page 17 5 A complete Parts List is available at www MillerWelds com Always wear a face shield rubber gloves and protective clothing when working on a battery Remove battery from unit 1 Vent Caps 2 Sulfuric Acid Electrolyte 1 265 Specific Gravity 3 Well Fill each cell with electrolyte to bottom of well maximum Do not overfill battery cells Wait ten minutes and check elect
3. A 14 Socket Socket Information A 24 volts ac Protected by supplementary protector CB4 24 VOLTS AC OUTPUT B Contact closure to A completes 24 volt ac contac CONTACTOR tor control circuit and keeps engine at Run speed in all Wire modes 115 volts ac Protected by supplementary protec 115 VOLTS AC IDEEN senile J Contact closure to completes 115 volts ac CONTACTOR contactor control circuit C 10 volts dc output to remote control REMOTE D Remote control circuit common OUTPUT CONTROL E to 10 volts dc input command signal from remote control F Current feedback 1 volt per 100 amperes A N AMPERAGE VOLTAGE H Voltage feedback 1 volt per 10 arc volts Circuit common for 24 and 115 volts ac circuits GND Chassis The remaining sockets are not used Notes OM 4426 Page 22 Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual 5 A complete Parts List is available at www MillerWelds com Notes D Work like a Pro Pros weld and cut 4 Nt safely Read the E safety rules at NN the beginning of this manual OM 4426 Page 23 5 A complete Parts List is available at www MillerWelds com SECTION 6 OPERATING WELDING GENERATOR 6 1 Front Panel Controls See Section 6 2 METER MAINTENANCE FUNCTIONS HOUR METER with engine off place Engine Control
4. MAN SPENTER vs ON ITS OFF _ 4 MAIN BREAKER dam x Weld output terminals on units with DC output only 803 571 Ref 216 170 204 353 Ref 216 169 A OM 4426 Page 20 5 A complete Parts List is available at www MillerWelds com 5 8 Connecting To Weld Output Terminals Stop engine A Failure to properly connect weld cables may cause ex cessive heat and start a fire or damage your machine Weld Output Terminal Supplied Weld Output Terminal Nut Weld Cable Terminal 4 Copper Bar RUN IDLE START 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 Do not place anything be tween weld cable terminal and anything between weld cable terminal copper bar Make sure that the and copper bar surfaces of the weld cable termi nal and copper bar are clean Tools Needed 92 12 Win Correct Installation Incorrect Installation 803 778 A 5 9 Selecting Weld Cable Sizes Weld Cable Size and Total Cable Copper Length in Weld Circuit 1 Not 100 ft 30 m or Less 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 45m 60m 70m 90m 105 m 120 m Weld Output Terminals A Stop engine before 10 60 60 100 connecti
5. ER S 0 80 2 HATIIN H31HOM som pue yseds 1015 1591 951 lenueyy SOUMO ees 00277777 JUL A3vHd8 YON Ul G20 0 O ZOPLO S9X ZZZ 861 HATIIN NIGOH eds OCT OACL OH Ul O 0 0 9 5 o o 19140 200 290 YATIN HS THOM Bnid 5 gs 108 o0 0 n n v v v n6 n8 21 enuen S JeuMQ ees pueBe7 OUIJOSEE TP V cL0S89 69c UIqQOY 86 SEC NIHOH 00 c 00cc peo ON 222 09098 786 SLZ HS THON OSZE SZ9 peeds uBiH poods 7 jong ewe ered enDedy 5 91 sooenu so ep sepepiooJeA Jely ered ojesn SOP SOJ 9Jjue NIHOH HOLON 14d soj Nn uororsod 4opipeui jap 4 7 ej JOJOW YINS eieinbse eno ue 5920 4 SE
6. Jenue N 5 19 ees 104 Ae dsip 19591 YO UINL 5 91 51 peeds 195 pue 04 esf 5 ejdsip pue sewn uonisod JIAI NNY Woy YoUMs ejo o LOH a Mined 100 Aue 5 10j99Jes sseooJd 941 pue 5 3NION 2 req 9940 M seuin uonisod NNY oi 5 13938 MOO usnd s esau jsed ueuM pereoipur sunoy 0 umop 1unoo pue QO Egs sunoy peu SJNOY ees oi uonisod eu 2 eoejd ym IYAHALNI 39NVHO sinou uonisod YOUMS eoejd yo e yalaw SANIDNGE SVO S9Hz3 P9H3 uled OL oreo 10 995 4426 32 8 2 Routine Maintenance Note 5 5 A complete Parts List is available
7. 7 2 Optional Receptacles 7 3 Simultaneous Weld And Power 7 4 Wiring Instructions For Optional 240 Single Phase Plug NEMA 14 50P SECTION 8 MAINTENANCE TROUBLESHOOTING 8 1 Maintenance Label 8 2 Routine Maintenance 8 3 Servicing Optional Spark Arrestor 8 4 Servicing Air Cleaner 8 5 Changing Engine Oil Oil Filter And Fuel Filter Kohler Powered Units 8 6 Changing Engine Oil Oil Filter and Fuel Filter Robin Powered Units 8 7 Adjusting Engine Speed Kohler Powered Units 8 8 Adjusting Engine Speed Robin Powered Units 8 9 Overload Protection 8 10 Welding Troubleshooting 8 11 Generator Power Troubleshooting 8 12 Engine Troubleshooting SECTION 9 PARTS 5 9 1 Recommended Spare Parts SECTION 10 ELECTRICAL DIAGRAMS SECTION 11 GENERATOR POWER GUIDELINES COMPLETE PARTS LIST www MillerWelds com OPTIONS AND ACCESSORIES WARRANTY 30 30 30 31 31 32 32 33 34 34 35 36 37 38 39 40 41 41 43 43 44 48 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING
8. E Rae Compressed Air Hazards IRR Ox ei en d e e I en Re eal ees Additional Symbols For Installation Operation And Maintenance California Proposition 65 Warnings P rineipal Salety Standards se ccs de sles te etn eee ea EMF IniommaiOn ss A o ena ard ah SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 Signification des ative cas ie Red atts othe cte o e He olet e abe Dangers relatifs au soudage l arc Dangers existant en relation avec le moteur Dangers lies a Vall COMpPIIMG as xa dcc e date EU Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Proposition californienne 65 Avertissements Principales normes de Selle s HR aeter Redi m dtes dta ncs beate CD aac d d id Intormasuon EME si oos duas d itt A aa Meal ee SECTION 3 DEFINITIONS FRE Eae kw S OR acd RE 3 1 oymbolDelllitllOris dtp OEC ar Ce pete aee
9. 117 116 RC17 1 gt RC17 2 gt RC11 1 V V 11 3 RC12 1 12 3 RC12 4 12 5 13 1 13 2 RC15 3 13 4 NN NN NN A WHAT 27 20 725 726 747 142 143 144 PLG31 4 RC31 4 PLG31 3 RC31 3 PLG31 2 RC31 2 PLG31 1 RC31 1 107 02 103 000090000000000000 EXCITER REVOLVING FIELD 0000909000909000000 00 0900 97 80 90 22 CT1 1 82 A 84 LINE CB1 LOAD VOLTAGE FEEDBACK A A ELECTRODE POS S1 B C ELECTRODE WARNING ELECTRIC SHOCK HAZARD 104 090 9 Q EXCITER FIELD COMMON MAIN FIELD Vice COLLECTOR RINGS 74 d CIRCUIT CHASSIS COMMON COMMON DC Z EB ONY Y CV 28 78 22 14 10 126 74 Y Do not touch live electrical parts e Disconnect input power or stop engine before servicing Do not operate with covers removed e Have only qualified persons install use or service this unit 223 714 B OM 4426 Page 45 S2 PLG8 S2 POSITION MODE 45 1 lt RUN 46 lt gt 42 2 lt lt RUN IDLE 47 3 amp START 47 46 45 43 47 47 22 RC5 RC5 5 3 1 4 2 PLG5 PLG5 55 a uM PLG5 6 5 3 1 4 2 PLGS RED YEL WHT LAN LOW OIL PRESSURE N O 751 AK
10. BIETER NEA E se De SECTION 4 gt SPECIFICATIONS 2544 dE ad aie drea 4 1 4 2 4 3 4 4 4 5 4 6 4 7 Weld Power And Engine Specifications Dimensions Weights and Operating Fuel Consumption CUES 4x v xd mx ot RR AUR Ghee eda eee tede Generator POWET CUNE oer indeed e 6 ae ee ee Stick And MIG Mode Volt Ampere Curves TIG Mode Volt Ampere Curves SECTION 5 INSTALLATION ux ex uei Tdi cae S 5 1 5 2 5 3 5 4 5 5 5 6 5 7 5 8 5 9 Installing Welding Generator s ci caus erae kc ote eee DD eee e e oes Engine Prestart Checks Kohler Powered Units Engine Prestart Checks Robin Powered Activating The Dry Charge Battery If Connecting the Battery rer ioc Ce Oe aM alee be ade eed Installing EXxhausb RIPE sic dave d ed pars Welc Output Terminals su as dat e fs e RE o Rn eui m RO a Connecting To
11. 7 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 Use switch in combination with meters to de termine total engine hours and hours until 1 Engine Control Switch Carburetor Icing next recommended oil change see items 3 and 4 earlier in this section 5 The unit will not return to idle speed when the remote contactor is on and Process Contactor switch is in any Wire position The unit will return to idle speed in all other modes 8 Engine Choke Control Use control to change engine air fuel mix when starting engine To Start pull out choke and turn Engine Control switch to Start position Release switch and slowly push choke in when engine starts If the engine does not start let the engine come to a complete stop before attempting restart gt During cold weather some gasoline en gines encounter difficulties that are easi ly remedied See Section 6 3 and 8 12 To Stop turn Engine Control switch to Off position 9 DC Polarity AC Switch AC DC Models Only not switch under load Use switch to select AC weld output or polar ity of DC weld output 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 tive humid
12. 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 Millers option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Miller authorized service facility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHE
13. CONTROL PCB 1 RC4 Gi 777 RC4 Al 705 1 gt CRON 6 l RC4 E 709 KRC14 5 ee RCIA _ lt 1224 amp RCI4 4 RC4 J 773 RC 4 8 I gt RC4 Hi 772 l RC4 770 A RCI4 1 I 4 11 42 l RC4 Kl 42 Lon J RECEPTACLE OPTION B 1T GFCI 3 es z Ep 8 fes 42 c GFCI 2 64 52 er 5 He 90 SH C46 42 SN m 80 87 TOP Er 42 220 84 RC1 85 Y WX 2401 Figure 10 2 Circuit Diagram For Welding Generator Models With DC Output Only OM 4426 Page 46 RC26 2 152 EID ER RC26 3 737 MAIN FELD RC25 2 gt 734 Rc25 1 gt PLG31 4 RC31 4 2 PLG31 3 RC31 3 RO27 2 gt gt B mcn COLLECTOR RINGS RC27 1 gt PLG31 1 RC31 1 2 lt RC26 6 gt RC26 4 gt gt 27 lt 1039 1041 lt JO gt ees RC11 1 T 11 3 gt 37 6012 1 gt RC12 3 gt gt 2 RC13 1 gt gt 747 RCI3 2 gt 742 013 3 gt PET RC13 4 gt gt 120V Y WG amp J CBS BS ROS 45 F E D B A 42 o 7 O 1T 277 GO 77742 20 92 120V Y WG RC2 46 CT2 42 e D D 2 _ 4 D p CIRCUIT CHASSIS 20 COMMON COMMON LORS 3 3 42 42 Px 24 LINE CB1 LOAD ywx RCI 24
14. Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet 1 3 Engine Hazards BATTERY EXPLOSION can BLIND e Always wear a face shield rubber gloves and protec tive clothing when working on a battery e Stop engine before disconnecting or connecting bat tery cables or servicing battery Do not allow tools to cause sparks when working on a battery Do not use welder to charge batteries or jump start vehicles Observe correct polarity and on batteries Disconnect negative cable first and connect it last FUEL can cause fire or explosion e Stop engine and let it cool off before checking or add ing fuel e Do not add fuel while smoking or if unit is near any sparks or open flames Do not overfill tank allow room for fuel to expand Do not spill fuel If fuel is spilled clean up before starting engine Dispose of rags in a fireproof container OM 4426 Page 2 Always keep nozzle in contact with tank when fueling HOT PARTS can cause severe burns e Do not touch hot parts bare handed Allow cooling period before working on equipment To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to pre vent burns NOISE can damage hearing Noise from some processes or equipment can damage hear
15. jue ex he every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most We ve made installation and operation quick and easy With Miller you can count on years 00012000 of reliable service with proper maintenance And if for some reason the unit needs repair QUALITY SYSTEM there s a Troubleshooting section that will help you figure out what the problem is The Miller is the first welding parts list will then help you to decide the equipment manufacturer in 252 exact part you may need to fix problem the ISO 9001 2000 Quality Warranty and service information for your System Standard particular model are also provided Miller Electric manufactures a full line of welders and welding related equipment For information on other quality Miller products contact your local Miller distributor to receive the latest full line catalog or individual specification sheets To locate your nearest distributor or service agency call 1 800 4 A Miller or visit us at www MillerWelds com on the web 2 Miller Mil Thank 4 05 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 124 1 2 1 3 1 4 1 5 1 6 1 7 1 8 EP TU Arc Welding Hazards eae ee eles 2 5 ee
16. 198755 Element Air Filter 1 EIE AET EA 19815472 OEE Beso WEE ee 215985 Filter Clamps Fuel 1 4 in Line d PR 1997 nie RON A 4426 Page 43 SECTION 10 ELECTRICAL DIAGRAMS S2 POSITION MODE 52 pod 1 RUN a D 2 RUN IDLE 47 3 START 47 PC1 47 77 amp RC24 14 KRC24 13 47 lt lt RC24 3 52 lt 24 2 42 24 6 5 T lOO N N N CN PLG5 A das ee ee p LOW OIL PRESSURE ease 5 M 1 ol a RED pom ELECTRIC ATA ANAN HN nr 0 Pos Llc 0 lt 15 4 555 50505 BLACK 2 c cx c eee amp 1 FUEL LEVEL 167 LRCTS 1 OPTON SENDING 2 KOHLER ENGINE UNIT oo ea M 4 14 PIN PC2 REMOTE xU MT CONTROL PCB r RC4 G 2 CIRCUIT COMMON 277 A A P I RC4 A 705 5 3 1 4 2 l M 24VAC SOURCE HESS aud I RC4 B 706 RC4 E 29 REMOTE COMMAND lt RC14 5 CIRCUIT COMMON SRAD 2
17. 5 A complete Parts List is available at www MillerWelds com 4 5 Duty Cycle 100 Duty Cycle at 280 Amperes DC Duty cycle is the percentage of 10 minutes that unit can weld at rated a load without overheating Exceeding duty cycle can damage unit and void warranty Continuous Welding AC 2 is not available on all models MIG FCAW 0 10 20 30 40 50 60 70 80 90 1 DUTY CYCLE WELDING AMPERES Notes HOBART INSTITUT _ OF WELDING TECHNOLOGY _ Start Your Professional Square East Troy Ohio 45373 Over 80 000 trained Welding Career Now 1 800 332 9448 www welding org since 1930 OM 4426 Page 12 4 6 DC VOLTS DC VOLTS AC VOLTS 5 A complete Parts List is available at www MillerWelds com Stick And MIG Mode Volt Ampere Curves volt ampere curves show the CC DC Stick Mode minimum and maximum voltage and amperage output capabilities of the welding generator Curves of other settings fall between the curves shown 5 s 150 200 250 300 350 450 500 DC AMPERES CV DC MIG Mode 40 0 200 400 600 800 DC AMPERES CC AC STICK Mode AC output is not available on all models 1 200 250 300 350 5 228 632 220 313 A 228 631 4426 13 5 A complete Parts List is available at www MillerWelds com 4 7 TIG Mode Volt Ampere Curves A CC AC
18. TIG 1 TIG Electrode 2 Workpiece Turn gas on Touch tungsten electrode to workpiece at weld start point Hold electrode to workpiece for 1 second and slowly lift electrode Arc is started when electrode is lifted Normal open circuit voltage is not present before tungsten electrode touches workpiece only a low sensing voltage is present between electrode and workpiece The solid state output 1 contactor does not energize until after Second electrode is touching workpiece This allows electrode to touch workpiece without overheating sticking or getting contaminated Application Lift Arc is used for the DCEN GTAW process when HF Start method is not permitted Do NOT Strike Like A Match OM 4426 Page 27 5 A complete Parts List is available at www MillerWelds com 6 7 Ending TIG Arc With Auto Crater And Auto Stop Maintain shielding gas coverage and eliminate tungsten and work piece contamination by using Auto Crater or Auto Stop to end the arc Using Auto Crater Remote control is not needed when using Auto Crater e Lift torch slightly to start Auto Crater end current is re Ending Arc Using Auto Crater Move Torch duced While Welding Lift Torch Back Down e Lower torch Shielding gas continues until shut off d Maintain Using Auto Stop Visible Shielding Ramps Gas e Lift torch slightly to start Auto Reduction Down Coverage Stop Lift higher than that nee
19. Visit our website at www MillerWelds com Q Miller Trailblazer 302 Trailblazer 275 DC 55 4426 215 348 2007 01 Processes MIG GMAW Welding Flux Cored FCAW Stick SMAW Welding 2 N TIG GTAW Welding Air Plasma Cutting and Gouging with Spectrum Unit Air Carbon Arc CAC A Cutting and Gouging lt 2 Description AC 3 Engine Driven Welding Generator AC Available On AC DC Models Only OWNER S MANUAL File Engine Drive di 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 Ir 5 BL El Her 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 boleu
20. 42 KOHLER ENGINE ee i a a PRE ECCE et MI Sero ER 1 A A A A A A CIRCUIT COMMON PLG5 5 24VAC SOURCE ud 29 AK 24 LOW OIL PRESSURE a CIRCUIT COMMON 7 COMMAND REF cr LT 12 VOLT 115VAC CONTACTOR STARTER 191 1V 10V 1V 100A FUEL 115VAC SOURCE SOLENOID CHASSIS COMMON EE a ERN SC CR UR zu t E EE ES 70 IE SI Toe E m 71 6 5 3 1 4 2 PLCS PLES RED YEL YEL LOW OIL PRESSURE N O ee 4 rif _ 12 voir STARTER pu es i ALTERNATOR FS1 AK KOHLER LP ENGINE a Mr IT TP M DM EET Pr ee 47 77 RC24 14 PCI lt RC24 13 POWER PCB 22 lt 24 3 52 lt 24 2 lt 24 6 N M NNN NNN QN O O Q c c c cr Y cx dc c NN v V SF I 5 N X NN AUN NEN M N O o N 4454444 de n lt 015 5 FUEL LEVEL 7 A RC15 1 SENDING UNIT RC15 2 14 PIN PC2 REMOTE
21. 5 At least once a month run engine at weld power speed and press Test but ton to verify GFCI is working properly Ref 216 170 5 A complete Parts List is available at www MillerWelds com 7 3 Simultaneous Weld And Power 00 M 7 4 Wiring Instructions For Optional 240 Volt Single Phase Plug NEMA 14 50P The plug can be wired for a 240 V 2 wire load or a 120 240V 3 wire load See circuit diagram 1 Plug Wired for 120 240 V 3 Wire Load When wired for 120 V loads each duplex receptacle shares a load with one half of 240 V receptacle 2 Plug Wired for 240 V 2 Wire Load Neutral Silver Terminal Load 1 Brass Terminal Load 2 Brass Terminal Ground Green Terminal Mo Amperes Available using 120 240 V Plug Current Available in Amperes 240 V Each 120 V Duplex Receptacle Receptacle 0 Tools Needed Watts One 240 V load or two 120 V loads plug1 11 03 120 813 D OM 4426 Page 31 5 A complete Parts List is available at www MillerWelds com SECTION 8 MAINTENANCE amp TROUBLESHOOTING tenance Label Main 8 1 se 290 661 HATIIN NIHOH LV 0L92E C92 861 HATIIN NIGOH sBni4 eds pue 304 pue ZLO OF HATIIN H3HOM
22. En cas d impossibilit les recouvrir soigneusement avec des protections homologu s Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables e Se prot ger et d autres personnes de la projection d tincelles 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 Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r ser voirs tambours ou conduites moins qu ils n aient t pr par s correctement conform ment a AWS F4 1 voir les normes de s curit e Brancher le cable 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 incon nus ventuels en provoquant des risques d lectrocution et d incendie 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 provoquant des risques d lectrocution d tincelles et d incendie pas utiliser le poste de soudage pour d geler des conduites gel es e En cas de utilisation en
23. pas laisser tourner le moteur trop lentement sous risque d endommager le moteur lectrique cause d une tension et d une fr quence trop faibles pas brancher de moteur de 50 ou 60 Hz la prise de 100 Hz s il y a lieu LES ETINCELLES VOLANTES risquent de provoquer des blessures e Porter un cran facial pour prot ger le visage et les yeux e Affdter l lectrode au tungst ne uniquement la meuleuse dot e de protec teurs Cette man uvre est ex cuter dans un endroit s r lorsque l on porte l quipement homologu de protection du visage des mains et du corps Les tincelles risquent de causer un incendie loigner toute substance in flammable e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Tenir distance les produits inflammables de l chappement LES TINCELLES A L CHAPPEMENT peuvent provoquer un incendie e Emp cher les tincelles d chappement du moteur de provoquer un incendie e Utiliser uniquement un pare tincelles approuv voir codes en vigueur Le METAL CHAUD lors du coupage et gougeage plasma peut provoquer un in cendie ou une explosion e Ne pas couper ou gouger proximit de produits in flammables e Surveillez et garder un extincteur proximit DES PIECES CHAUDES peuvent provo quer des br lures et blessures e Ne pas toucher le compresseur ou d autres l ments du circui
24. rom nd 3 05 Warning Protect yourself and others from injury read and follow these precautions 1 1 Symbol Usage 4 A Marks a special safety message Means Warning Watch Out There are possible hazards with this procedure The possible hazards are shown in the adjoining symbols Means Note not safety related 1 2 Arc Welding Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Stan dards listed in Section 1 7 Read and follow all Safety Standards Only qualified persons should install operate maintain and re pair this unit During operation keep everybody especially children away ELECTRIC SHOCK can kill R Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard Do not touch live electrical parts Wear dry ho
25. 063 in 14 Gauge 078 in 1 8 in 125 in 3 16 in 188 in 1 4 in 25 in 5 16 in 313 in 3 8 in 375 in 1 2 in 5 in OM 4426 Page 19 5 A complete Parts List is available at www MillerWelds com 5 7 Weld Output Terminals Stop engine not connect to CC and CV terminals at the same time AC DC Models 1 Work Weld Output Terminal 2 Stick TIG CC Weld Output Terminal 3 Wire CV Weld Output Terminal For MIG welding connect work cable to Work terminal and wire feeder cable to Wire CV terminal For Stick TIG welding connect work cable to Work terminal and electrode holder TIG torch cable to Stick TIG CO terminal RUN IDLE START DC Models 4 Negative Weld Output Terminal 5 Stick TIG Weld Output Terminal 6 Wire Weld Output Terminal For MIG welding connect work cable to Negative terminal and wire feeder cable to CV Wire terminal For Stick welding connect work cable to Negative terminal and electrode holder cable to CC Stick TIG terminal For TIG welding connect work cable to CC Stick TIG terminal and elec trode holder cable to Negative 3 terminal A C ome 2 6 x Weld output terminals on o TF T an units with AC DC output MAI BHEARER 5 A re CV WORK ON OFF lt MAIN id x Ke 4 M
26. 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 4426 Page 54 Warranty Questions Call 1 800 4 A MILLER for your local Miller distributor Your distributor also gives you Service You always get the fast reliable response you need Most replacement parts can be in your hands in 24 hours Support Need fast answers to the tough welding questions Contact your distributor The expertise of the distributor and Miller is there to help you every step of the way 2 Miller Effective January 1 2007 Equipment with a serial number preface of LH or newer This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS O
27. Cleaners Silo Unloaders 5 HP 23300 6000 Silo Hoists Bunk Feeders 7 1 2 HP 35000 8000 10 HP 46700 10700 3 1 2 cu ft Mixer 1 2 HP 3300 1000 High Pressure 1 8 Gal Min 500 PSI 3150 950 Washer 2 gal min 550 PSI 4500 1400 2 gal min 700 PSI 6100 1600 Refrigerator or Freezer 3100 800 Shallow Well Pump 1 3 HP 2150 750 1 2 HP 3100 1000 Sump Pump 1 3 HP 2100 800 1 2 HP 3200 1050 OM 4426 Page 50 11 7 Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1 4 in 350 350 3 8 in 400 400 1 2 in 600 600 Circular Saw 6 1 2 in 500 500 7 1 4 in 900 900 8 1 4 in 1400 1400 Table Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 2500 1100 Bench Grinder Gin 1720 720 8in 3900 1400 10 in 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 13
28. EIU Do not exceed tilt angles or engine could Depth 45 3 8 in 1153 mm D be damaged or unit could tip A 20 in 508 mm G A s not move or operate unit where it could 4 Holes 16 1 2 in 419 mm C 1 3 4 in 44 mm E D 6 1 16in 154 mm F E 32 3 4 in 832 mm F 45 3 8 in 1153 mm G 13 32 in 10 mm Dia Weight Robin 580 Ib 263 kg Kohler 580 Ib 263 kg Lifting Eye Weight Rating Engine End 1280 Ib 580 kg 800 426 803 572 A OM 4426 Page 10 5 A complete Parts List is available at www MillerWelds com 4 3 Fuel Consumption Curves On a typical job using 1 8 in 7018 electrodes 125 amps 20 duty cycle expect about 20 hours of op eration Welding at 150 amps at 40 duty cycle uses approximately 3 4 gal lon per hour or about 16 hours of operation Generator Power LITERS HR as I lt 50 100 150 200 250 DC WELD AMPERES AT 100 DUTY CYCLE 2 4 6 8 KW AT 100 DUTY CYCLE 206 135 206 136 4 4 Generator Power Curve The ac generator power curve shows the generator power avail able in amperes at the receptacles Tools and motors are designed to Operate within 10 of 120 240 VAC 24 10 500 WATTS t 20 40 60 80 100 120 140 160 180 200 AC AMPERES At 120 V 10 20 30 40 50 60 70 80 90 AC AMPERES AT 240 V Ref 220 807 A OM 4426 Page 11
29. EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting OM 4426 Page 4 ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as microprocessors computers and computer driven equipment such as robots e Besure all equipment in the welding area is electro magnetically compatible e Toreduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive electronic equipment e sure this welding machine is installed and grounded according to this manual e f interference still occurs the user must take extra measures such
30. In CV mode weld output is controlled through remote control only If no remote voltage amperage control is connected to the Remote receptacle the front panel Voltage Amperage control ad justs voltage and amperage 3 And4 Displays Displays can show weld process information voltage and amperage or maintenance in formation hourmeter oil change count down or rpm Meter Weld Functions In Wire modes Voltmeter displays preset weld voltage when not welding Meters display actual volt age and amperage when welding and for five seconds after welding has stopped In Stick and TIG modes Voltmeter reads ON and Ammeter displays preset amperage when not welding Meters display actual volt age and amperage when welding and for five seconds after welding has stopped Meter Engine Maintenance Functions See inset from maintenance label 5 FuelLevel Indicator With Engine running or Engine Control switch in Run or Run Idle position LED s in dicate fuel left in tank 6 Voltage Amperage Control Use control to select weld voltage or amperage Control may be adjusted while welding With Process Contactor switch in any Stick or TIG setting use control to adjust amper age With Process Contactor switch in any Wire position use control to adjust voltage When a remote voltage amperage control is connected to Remote receptacle RC4 con trol sets the maximum amperage in Stick and TIG modes but has no effect in MIG modes
31. TIG Mode 80 70 60 50 AC VOLTS 40 30 20 10 0 B CC DC TIG Mode 100 150 AC AMPERES DC VOLTS 0 50 4426 14 150 DC AMPERES The volt ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator Curves of other settings fall between the curves shown AC output is not available on all models 220 312 A 220 311 A 5 A complete Parts List is available at www MillerWelds com SECTION 5 INSTALLATION 5 1 Installing Welding Generator Do not weld on base Welding on base can cause fuel tank fire or explosion Bolt unit down using holes provided in base Always securely fasten weld ing generator onto transport vehicle or trailer and comply with all DOT and other applica ble codes not mount unit by support ing the base only at the four mounting holes Use cross supports to adequately sup port unit and prevent damage to base A Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards A lf unit does not have re ceptacles use GFCI protected extension cord Do not install unit where air flow is restricted or engine may overheat Mounting 1 Cross Supports Mount unit on flat surface or use cross supports to support base Grounding 2 Equipment G
32. Weld Output Terminals Selecting Weld Cable SIZES xxu d du ERO SE SUE ET QUEEN MERE d M eS 5 10 Remote Receptacle Information SECTION 6 OPERATING WELDING GENERATOR 6 1 6 2 6 3 6 4 6 5 6 6 6 7 6 8 Front Panel Controls See Section 6 2 Description Of Front Panel Controls See Section 6 1 Cold Weather Engine Operation Process Contactor Switch On AC DC Stick Start Procedure Scratch Start Technique TG LItAr Start PrOGOGGHEIO cs cu we ehe icd tdt cuc wy Salar t rc rad Ending The TIG Arc With Auto Crater And Auto Stop Remote Voltage Amperage Control 1 NOTA BB RA ND NM MO PMO NYO NM HAH HH HSH SB SB SS N BB D TABLE OF CONTENTS SECTION 7 OPERATING AUXILIARY EQUIPMENT 7 1 Generator Power Receptacles And Supplementary 5
33. at www MillerWelds com Also see Voltmeter Ammeter displays to assist in scheduling maintenance see Section 6 1 The Voltmeter and Ammeter display total engine operating hours at start up Follow the storage procedure in the engine owner s manual if the unit will not be used for an Inside Unit extended period Stop engine before maintaining See Engine Manual and Maintenance Label Recycle engine for important start up service and storage fluids information Service engine more often if used in severe conditions Check Change Clean Replace Reference To be done by Factory Authorized Service Agent Every Section 5 2 8 lt Ps 5 3 6 2 Hours Fuel Level Oil Level Meters for next oil Oil Fuel Spills change interval Every Section 8 3 2 Hours N Spark Arrestor Screen Air Cleaner Wrapper Every 50 px Hours NT Weld Terminals Every Engine 100 Manual Hours Section 8 4 8 5 8 6 Cooling System Q Oil x Air Cleaner Element Every I Engine 200 eft Manual Hours 2222221 Section 8 5 Din x Unreadable Labels Spark Plug Gap Oil Filter Fuel Filter Every Engine 500 Manual Hours AP x Weld Cables Slip Rings Valve Clearance w Brushes Every 1000 Hours OM 4426 Page 33 5 A complete Parts List is available at www MillerWelds com 8 3 Servicin
34. num r es la section 2 7 Veuillez lire et respecter toutes ces normes de s curit L installation l utilisation l entretien et les r parations ne doivent tre confi s qu des personnes qualifi es Au cours de l utilisation tenir toute personne l cart et plus particu lierement les enfants UN CHOC LECTRIQUE peut tuer Un simple contact avec des pi ces lectriques peut provo quer une lectrocution ou des blessures graves L lectrode et le circuit de soudage sont sous tension d s que l appareil est sur ON Le circuit d entr e et les circuits internes de l appareil sont galement sous tension ce moment l En soudage semi automatique ou automatique le fil le d vidoir le logement des galets d entrainement et les pi ces m talliques en contact avec le fil de soudage sont sous tension Des mat riels mal install s ou mal mis a la terre pr sentent un danger Ne jamais toucher les pi ces lectriques sous tension Porter des gants et des v tements de protection secs ne comportant pas de trous S isoler de la pi ce et de la terre au moyen de tapis ou d autres moyens iso lants suffisamment grands pour emp cher le contact physique ventuel avec la pi ce ou la terre Ne pas se servir de source lectrique courant lectrique dans les zones hu mides dans les endroits confin s ou l ou on risque de tomber Se servir d une source lectrique courant lectrique UNIQUEMENT si le proc d de
35. peau l eau 2 4 Dangers li s l air comprim RESPIRER L AIR COMPRIM peut pro voquer des blessures graves ou causer la mort pas utiliser l air comprim pour respirer e Utiliser l aii comprim seulement pour le coupage gou geage et les outils pneumatiques L AIR COMPRIM peut provoquer des blessures e Porter des lunettes de s curit approuv es pas diriger le jet d air vers d autres ou soi m me 5 L AIR COMPRIME EMMAGASINE DES TUYAUX SOUS PRESSION peuvent provo quer des blessures e Relacher la pression d air de ou du syste me avant d effectuer la maintenance avant de chan ger ou de rajouter des l ments ou avant d ouvrir la purge ou le bouchon de remplissage d huile 4r VY 2 5 LA CHUTE DE L APPAREIL peut blesser e Ultiliser un ceilleton de levage pour lever l appareil et les accessoires correctement install s Ne pas d passer le poids nominal maximal de l oeilleton voir les sp cifications e Nelever et ne soutenir l appareil qu avec de l quipement appropri et en suivant les proc dures ad quates e utilisant des fourches de levage pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil LE SURCHAUFFEMENT peut endom mager le moteur lectrique Arr ter ou d connecter l quipement avant de d marrer ou d arr ter le moteur
36. 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 e Do not weld where flying sparks can strike flammable material e Protect yourself and others from flying sparks and hot metal alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas e Watch for fire and keep a fire extinguisher nearby e Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side e Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards e Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards e Do not use welder to thaw frozen pipes e Remove stick electrode from holder or cut off welding wire at contact tip when not in use e Wear oil free protective garments such as leather gloves heavy shirt cuf fless trousers high shoes and a cap e Remove any combustibles such as a butane lighter or matches from your person before doing any welding e Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby FLYING METAL can injure eyes 2
37. setting for smooth weld performance A stable weld puddle with little arc snap gives excellent weld bead appearance with minimal spatter Medium Soft Arc Position 2 This setting provides a low to medium dig arc force that gives a slightly more fluid weld puddle more arc snap and reduces the potential for electrode sticking at shorter arc lengths Medium Stiff Arc Position 3 This setting provides medium dig arc force for open root vertical up joints or joints that do not require additional current for fit up inconsistencies 803 571 A 216 170 A Stiff Arc E6010 Position 4 This setting provides a high dig arc force for open root vertical down joints where additional current is needed to compensate for tight joint fit up without the need to increase overall welding current This setting is rec ommended for those who prefer a very stiff arc with 6010 electrodes The dig circuit is disabled when switch is in Wire or TIG positions TIG Positions TIG Remote On Off Use this position for AC or DC TIG welding using remote on off control Electrode Hot Lift Arc w Auto Crater TIG DC only With switch in this position normal open circuit voltage is not present between the electrode and workpiece A solid state contactor energizes after the electrode touches the workpiece preventing overheating sticking or con tamination of the electrode See Sections 6 5 and 6 6 End the arc u
38. 00 1300 OM 4426 Page 51 11 8 Power Required To Start Motor Single Phase Induction Motor Starting Requirements Motor Start G H J K L M N P Code KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0 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 multiply running amperage by six to find starting amperage Step 2 Find Motor HP and Volts Step 3 Determine starting amper age see example Welding generator amperage out put must be at least twice the 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 11 9 How Much Power Can Generator Supply 1 Limit Load To 90 Of Generator Output Always start non resistive motor loads in order from largest to small est and add resistive loads last 2 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 4426 Page 52 11 10 Typical Connections To Supply Standby Power Have only qualified persons perform these connections
39. 0V C48 42 DC Z VOLTAGE FEEDBACK CC 27 EET 26 TAP 28 2 c C49 WORK LEM rH 747 PLG6 142 743 144 WARNING e Do not touch live electrical parts e Disconnect input power stop engine before servicing e Do not operate with covers removed ELECTRIC Have only qualified persons install SHOCK HAZARD use or service this unit 223 713 B OM 4426 Page 47 SECTION 11 GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine driven welding generators Your unit may differ from those shown 11 1 Selecting Equipment Generator Power Receptacles Neutral Bonded To Frame 3 Prong Plug From Case Grounded Equipment 2 Prong Plug From Double Insulated Equipment sure equipment has double insulated symbol and or word ing on it Do not use 2 prong plug un less equipment is double in sulated gen pwr 10 06 Ref ST 159 730 ST 800 577 A Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards Also see AWS Safety amp Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Generators Equipment Grounding Terminal On Front Panel Grounding Cable Not Supplied Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insulated copper wire Electrically bond generato
40. 28 X r14 3 i COMMAND REF gt RC4 c _727 ERRER EIE 115 CONTACTOR gt RCA J 777 lt RC14 8 12 VOLT ER gt RC4 HI lt 14 2 l 1V 1004 gt 770 RC14 1 N E DL ND 115VAC SOURCE 42 aurem ELECTRIC CHASSIS COMMON amu 42 PUMP REE BUCK OR CS 1 l ROBIN ENGINE option RECEPTACLE a 4 OPTION gt Ne A A A A 6 5 3 1 PLG5 A PLoS RED YEL BRN gy 683 25 GFCI 3 H LOW OIL KE 655 4 GND COS l EE s 12 VOLT E STARTER GFCI 2 4 MEN FS1 je pow 1 2 NM P 22 02 of KOHLER LP ENGINE 85 G qe 240 1 Figure 10 1 Circuit Diagram For Welding Generator Models With AC DC Output OM 4426 Page 44 RC26 2 26 3 RC25 2 RC25 1 27 2 RC27 1 RC26 6 RC26 4 V V V V RC22 1 RC22 3 E V y y y y I li N 5 N ua IN lt RC23 1 lt RC23 2
41. 5 5 A complete Parts List is available at www MillerWelds com 6 4 Process Contactor Switch On AC DC Models ELECTRODE HOT 1 Process Contactor Switch Weld output terminals are energized when Process Contactor switch is in an Electrode Hot position and the engine is running 5 The unit will not return to idle speed when Process Contactor switch is in a Wire position and the remote contactor is on closure between pins A and B on remote receptacle Use switch to select weld process and weld output on off control see table below and Section 5 10 Place switch in Remote positions to turn weld output on and off with a device con nected to the remote receptacle Place switch in Electrode Hot positions for weld output to be on whenever the engine is running Wire Positions Use Wire positions for MIG welding using a voltage sensing wire feeder Electrode Hot or wire feeder using remote control Stick Positions Use Stick positions for stick SMAW and air carbon arc CAC A cutting and gouging When switch is in a Stick mode select one of four dig settings to provide additional am perage during short arc length conditions and help prevent electrodes from sticking See Stick position descriptions following reading L to R Soft Arc E 7018 Position 1 This setting provides a low dig arc force
42. 8 Have Factory Authorized Service Agent check circuit boards PC1 and PC2 Weld output cannot be adjusted Have Factory Authorized Service Agent check field current control board PC2 Erratic weld output Check control settings Clean and tighten connections both inside and outside unit Check and secure lead connections to remote control Be sure connection to work piece is clean and tight Remove excessive coils from weld cables Use dry properly stored electrodes Check and adjust engine speed see Section 8 7 or 8 8 Have Factory Authorized Service Agent check brushes slip rings and circuit boards PC1 and PC2 Check shielding gas ensure proper shielding gas coverage while welding No remote voltage amperage control Check and tighten connections to Remote receptacle RC4 see Section 5 10 Check and secure lead connections to remote control No front panel voltage amperage control Disconnect remote control from Remote receptacle RC4 if not needed for weld process see Section 5 10 No 24 volt ac power output at Remote receptacle RC4 Reset supplementary protector CB4 see Section 8 9 No 115 volt ac power output at Remote receptacle RC4 Reset supplementary protector s CB1 and or CB3 see Section 7 1 Lack of high frequency difficulty in establishing Gas Tungsten Arc Weld ing arc Use proper size tungsten for welding amperage R
43. B1 50 A MAIN BREAKER 4426 30 MAIN BREAKER 1 Generator Power Receptacles And Supplementary Protectors 20V N MAIN BREAKER 3 Ref 216 170 mote Receptacle RC4 from overload If CB2 opens RC2 does not work If CB3 opens RC3 does not work and the 115 volt ac output to RC4 stops Press button to re set If supplementary protector continues to open contact Factory Authorized Ser vice Agent Combined output of all receptacles limited to 10 kVA kW rating of the generator EXAMPLE If 20 A is drawn from each 120 V duplex receptacle only 20 A is available at the 240 V receptacle 2 x 120 V x 20 A 240 V x 20 A 9 6 KVA KW unit does not recep tacles use GFCl protected exten sion cord Generator power decreases as weld current increases Combined output of all receptacles limited to 10 kVA kW rating of the generator GFCI Receptacle Option 1 120V20A AC GFCI Receptacles GFCI 2 and GFCI 3 GFCI2 and GFCI3 supply 60 Hz single phase power at weld power speed Maxi mum output from GFCI 2 or GFCI 3 is 2 4 kVA kW Circuit protection is the same as standard receptacles If a ground fault is detected the GFCI Re set button pops out and the circuit opens to disconnect the faulty equipment Check for damaged tools cords plugs etc con nected to the receptacle Press button to reset receptacle and resume operation
44. OT PARTS can cause burns and injury e Do not touch hot compressor or air system parts e Let system cool down before touching or servicing READ INSTRUCTIONS e Read Owner s Manual before using or servicing unit Stop engine and release air pressure before servicing e Use only genuine Miller Hobart replacement parts 1 5 Additional Symbols For Installation Operation And Maintenance FALLING UNIT can cause injury e Use lifting eye to lift unit and properly installed acces sories only Do not exceed maximum lift eye weight rating see Specifications e Lift and support unit only with proper equipment and correct procedures e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit OVERHEATING can damage motors e Turn off or unplug equipment before starting or stop ping engine e Do not let low voltage and frequency caused by low engine speed damage electric motors e Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable 24 e Sparks cause fires keep flammables away FLYING SPARKS can cause injury e Wear a face shield to protect eyes and face e Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face hand and body protection OVERUSE can cause OVERHEATING Allow cooling period follow rated duty cycle e Reduce current or reduce duty cycle befor
45. R IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Miller must be notified in writing within thirty 30 days of such defect or failure at which time Miller will provide instructions on the warranty claim procedures to be followed Miller shall honor warranty claims on 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 the original end user purchaser and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Process Controllers Semi Automatic and Automatic Wire Feeders Inverter Power Sources Unless Otherwise Stated Water Coolant Systems Integrated Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified Motor Driven Guns w exception of Spoolmate Spoolguns Positioners and Controllers Automatic Motion Devices RFCS Foot Controls nduct
46. THER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province miller_warr 2007 01 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Addre
47. according to all applicable codes and safety practices Properly install and ground this equipment according to its Owner s Manual and na tional state and local codes lc Fused Utility Disconneel Welding Electrical Transfer Switch Switch Generator Customer supplied equipment Service If Required Output 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 Essential from electric utility service to the Loads generator Transfer load back to electric utility when service is re stored Install correct switch customer supplied Switch rating must be same as or greater than the branch overcurrent protection 3 Fused Disconnect Switch Install correct switch customer supplied if required by electrical code 4 Welding Generator Output Generator output voltage and wir ing must be consistent with regular utility system voltage and wiring Connect generator with temporary or permanent wiring suitable for the installation Turn off or unplug all equipment connected to generator before starting or stopping engine When starting or stopping the engine has low speed which causes low volt age and frequency 5 Essential Loads Generator output may not meet the electrical requirements of the prem ises If generator does not produce enough output to meet all re
48. are Engine Oil 2 Battery Engine Ox Engine M Amperes V Volts f MIG Nu E Stick SMAW TIG a Lift Arc TIG Positive Negative Ny gt Output 4 Hours S Seconds D n n Do not switch while Remote Constant welding E Receptacle OH CC Current olo Wire Feed i Electrode Negative CV US TS Circuit Protector Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual OM 4426 Page 9 5 A complete Parts List is available at www MillerWelds com SECTION 4 SPECIFICATIONS 4 1 Weld Power And Engine Specifications Rated Maximum Weld sni Welding Open Circuit Output P es C is su s Engine Output Voltage Range 9 Robin EH65 280 A 25 V 100 Air Cooled CC DC Duty Cycle 50 20 300A Four Continuous 9 5 kVA Cycle kW 80 40 A a LE 300 A 25 V 100 120 240 V AC 60 Hz ga asoline Engine CV DC Duty Cycle 35 13 35V Single Phase Peak 10 5 kVA kW Kohler CH 23 w Weld Contactor Off Air Cooled 200 A 25 V 60 Two Cylinder CC AC Duty Cycle 60 35 225A Four Cycle 23 HP Gasoline Engine AC DC Models Only 4 2 Dimensions Weights and Operating Angles Dimensions A 33 1 2 in 851 mm B 4 Height To Top Of Exhaust C S
49. 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 shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the 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 Wear approved safety glasses with side shields under your helmet 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 material leather heavy cotton or wool and foot protection OM 4426 Page 1 WIE 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
50. as moving the welding machine using shielded cables using line filters or shielding the work area For Gasoline Engines Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm For Diesel Engines Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm levard Rexdale Ontario Canada M9W 1R3 phone 800 463 6727 or in Toronto 416 747 4044 website www csa international org Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 11 West 42nd Street New York NY 10036 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov To reduce magnetic fields in the workplace use the following p
51. ated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards MOVING PARTS can cause injury e Keep away from fans belts and rotors n e Keep all doors panels covers and guards closed and securely in place Stop engine before installing or connecting unit Have only qualified people remove doors panels covers or guards for maintenance and troubleshooting as necessary To prevent accidental starting during servicing disconnect negative battery cable from battery Keep hands hair loose clothing and tools away from moving parts Reinstall doors panels covers or guards when servicing is finished and before starting engine Before working on generator remove spark plugs or injectors to keep engine from kicking back or starting Block flywheel so that it will not turn while working on generator compo nents HOT PARTS can cause severe burns Do not touch hot engine parts Allow cooling period before maintaining e Wear protective gloves and clothing when working on a hot engine STEAM AND HOT COOLANT can burn e f possible check coolant level when engine is cold to avoid scalding e Always check coolant level at overflow tank if pres ent on unit instead of radiator unless told otherwise in maintenance section or engine manual engine is warm checking is needed and there is no overflow tank follow the next two statements Wear safety glasses a
52. ctionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre En effectuant les raccordements d entr e fixer d abord le conducteur de mise la terre appropri et contre v rifier les connexions V rifier fr quemment le cordon d alimentation pour voir s il n est pas endom mag ou d nud remplacer le cordon imm diatement s il est endommag un c ble d nud peut provoquer une lectrocution Mettre l appareil hors tension quand on ne l utilise pas Ne pas utiliser des c bles us s endommag s de grosseur insuffisante ou mal piss s Ne pas enrouler les c bles autour du corps Si la pi ce soud e doit tre mise la terre le faire directement avec un cable distinct ne pas utiliser le connecteur de pi ce ou le cable de retour Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine Ne pas toucher des porte lectrodes connect s deux machines en m me temps cause de la pr sence d une tension vide doubl e N utiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment ce manuel Ce groupe de symboles signi fie Mise en garde Soyez vigi lant Il y a des risques de dan ger reli s aux CHOCS LEC TRIQUES aux PIECES EN MOUVEMENT et aux PIECES CHAUDES Repor tez vous aux symboles et aux directives ci dessous afin de co
53. d air Demander toujours un surveillant 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 dan ger Ne pas souder dans des endroits situ s proximit d op rations de d grais sage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et former des gaz hautement toxiques et irritants Ne pas souder des m taux munis d un rev tement tels que l acier galvanis plaqu en plomb ou au cadmium moins que le rev tement n ait t enlev dans la zone de soudure que l endroit soit bien ventil et en portant un respi rateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage LES ACCUMULATIONS DE GAZ ris quent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utili sation e Veiller toujours bien a rer les espaces confin s ou se servir d un respira teur d adduction d air homologu LES RAYONS DE L ARC peuvent pro voquer des br lures dans les yeux et sur la peau Le rayonnement de l arc du proc d de soudage g n re des rayons visibles et invisibles intenses ultraviolets et infrarou ges susceptibles de provoquer des br
54. ded to start Auto Crater e Arc stops e Move torch back down to maintain gas coverage and prevent contamination Ending Arc Using Auto Stop While Welding Lift Torch To End Arc Move Torch Back Down To Lift Higher Maintain Gas Than You Arc Ends Shielding Would To Start Auto Crater Coverage Marketing WM OM 4426 Page 28 6 8 Remote Voltage Amperage Control rN 5 A complete Parts List is available at www MillerWelds com 1 Remote Receptacle RC4 Connect optional remote voltage amperage V A control to RC4 see Section 5 10 With remote control connected weld output in a CC mode Stick TIG is determined by a combina tion of front panel and remote con trol voltage amperage settings In CV mode Wire weld output is controlled through remote control only 2 Remote Hand Control Optional 3 Remote Foot Control Optional gt Engine runs at weld power speed in Wire mode whenever a device connected to the re Switch present on AC DC models only REMOTE Connect Remote gt Select Polarity By V A Control To Using DC Polarity AC Remote Switch If Present Or Receptacle RC4 By Changing Cable Connections Mid Range About 160 A mote receptacle makes clo sure between pins A and B In all other modes the engine runs at idle speed unt
55. e starting to weld again e Do not block or filter airflow to unit STATIC ESD can damage PC boards 79 5 gt a e Put on grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards TILTING OF TRAILER can cause injury SPD e Use tongue jack or blocks to support weight e Properly install welding generator onto trailer accord ing to instructions supplied with trailer OM 4426 Page 3 READ INSTRUCTIONS e Use only genuine MILLER Hobart replacement parts e Perform engine and air compressor if applicable maintenance and service according to this manual and the engine air compressor if applicable manu als H F RADIATION can cause interference e High frequency H F can interfere with radio naviga tion safety services computers and communica tions equipment e Have only qualified persons familiar with electronic equipment perform this installation e The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation e lf notified by the FCC about interference stop using the equipment at once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference 1 6 Cali
56. eave filler neck empty to allow room for expan sion Check fuel level on a cold en gine before use each day To check fuel level turn Engine Con trol switch to Run ldle position LED s indicate fuel level in tank Cil Do not exceed Full mark on the oil level dipstick The fuel pump may operate erratically 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 mainte nance label Use front panel meters to determine hours until next recommended oil change see Section 6 1 To improve cold weather starting Keep battery in good condition Store battery in warm area Use correct grade oil for cold weather Close top service door Gasoline Ref 808 571 A Ref 803 573 A OM 4426 Page 16 5 A complete Parts List is available at www MillerWelds com 5 3 Engine Prestart Checks Robin Powered Units Check all fluids daily Engine must be cold and on a level surface Unit is N shipped with 10W30 engine oil 5 Follow run in procedure in en gine manual OOOOO 5 This unit has a low oil pressure shutdown switch However some conditions may cause en gine damage before the engine shuts down Check oil level often and do not use the oil pressure 4 Q shutdown system to monitor oil level Open top service door
57. ed by the drill is 520 watts Example 2 If three 200 watt flood lamps are used with the drill from Ex ample 1 add the individual loads to calculate total load 3 x 200W 520 W 1120 W The total load applied by the three flood lamps and drill is 1120 watts OM 4426 Page 49 11 5 Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1 8 HP 800 300 1 6 HP 1225 500 1 4 HP 1600 600 1 3 HP 2100 700 1 2 HP 3175 875 Capacitor Start Induction Run 1 3 HP 2020 720 1 2 HP 3075 975 3 4 HP 4500 1400 1 HP 6100 1600 1 1 2 HP 8200 2200 2 HP 10550 2850 3 HP 15900 3900 5 HP 23300 6800 Capacitor Start Capacitor Run 1 1 2 HP 8100 2000 5 HP 23300 6000 7 1 2 HP 35000 8000 10 HP 46700 10700 Fan Duty 1 8 HP 1000 400 1 6 HP 1400 550 1 4 HP 1850 650 1 3 HP 2400 800 1 2 HP 3500 1100 11 6 Approximate Power Requirements For Farm Home Equipment Farm Home Equipment Rating Starting Watts Running Watts Stock Tank 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
58. educe leakage of high frequency from torch or work cable check grounding remove excessive coils from weld cables use shorter weld cables etc Check cables and torch for cracked or deteriorated insulation or bad connections Repair or replace necessary parts OM 4426 Page 40 5 A complete Parts List is available at www MillerWelds com Trouble Remedy Wandering arc poor control of arc direction Reduce gas flow rate Select proper size tungsten Properly prepare tungsten Tungsten electrode oxidizing and not remaining bright after conclusion of weld Shield weld zone from drafts Increase postflow time Check and tighten all gas fittings Properly prepare tungsten 8 11 Generator Power Troubleshooting Trouble Remedy No power output Reset supplementary protectors CB1 CB2 and or CB3 see Section 7 1 Have Factory Authorized Service Agent check brushes slip rings and circuit boards PC1 and PC2 Low power output Check and clean air cleaner as necessary Check engine speed and adjust if necessary see Section 8 7 or 8 8 See engine manual High power output Check engine speed and adjust if necessary see Section 8 7 or 8 8 Erratic power output Have Factory Authorized Service Agent check brushes slip rings and field current control board PC2 Check receptacle wiring and connections Check
59. ependant apr s avoir examin plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban bleu du National Research Council a conclu L accumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lec triques haute fr quence repr sente un risque la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent tre examin es En attendant que les conclusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn tiques pendant le soudage ou le coupage Pour r duire les champs magn tiques sur le poste de travail appliquer les OM 4426 Page 8 LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique risque de provoquer des in terf rences pour l quipement lectronique sensible tel que les ordinateurs et l quipement command par ordi nateur tel que les robots e Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement e Pourr duire la possibilit d interf rence maintenir les c bles de souda ge aussi courts que possible les grouper et les poser aussi bas que pos sible ex par terre e Veiller souder une distance de 100 m tres de tout quipement lec tronique sensible e Veiller ce que ce poste de so
60. er product peratures engine starts and goes to idle but stalls after a few minutes Place Engine Control switch in the Run position until unit has been in operation and loaded for a peri od of time During operation in severe cold weath Install engine manufacturer s kit for cold weather operation er engine starts and goes to idle but stalls after a few minutes OM 4426 Page 42 5 A complete Parts List is available at www MillerWelds com SECTION 9 PARTS LIST NOTE A complete Parts List is available on line at www MillerWelds com 9 1 Recommended Spare Parts Dia Part Mkgs No Description Quantity Recommended Spare Parts den a F6 021718 Fuse GI 30 Amp 32 Volt 1 mM each an 230015 Filter Kit Kohler Includes 1 M nian Res 230016 Air Filter Element 1 066599 Ra med Geek unte eed e 215985 Filter Fuel w Clamps amp 1 4 in Fuel Line 1 067007 SpA PI toa 2 RS E 230017 2 32 Air Fiter Wrapper anus Res E death eene 1 See ising Ben 199062 Tune up Filter Kit Robin includes 1
61. follows Start engine and run until warm Open top cover access panel to ac cess speed adjustments Idle Speed Adjustment Move Engine Control switch to Run ldle position 1 Throttle Solenoid 2 Mounting Screws 3 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 Stop engine Close and secure top cover access panel 803 572 A 5 A complete Parts List is available at www MillerWelds com 8 9 Overload Protection a AWE xf RUN IDLE START Stop engine Open left side door 5 When a supplementary protec tor or fuse opens it usually in dicates a more serious prob lem exists Contact a Factory Authorized Service Agent 1 Supplementary Protector CB4 CB4 protects the stator winding supplying 24 volt ac output to Re mote receptacle RC4 If CB4 opens 24 volt ac output to RC4 stops Supplementary _ protectors CB1 and CB3 protect the stator windi
62. fornia Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq A Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling 1 7 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 phone 703 412 0900 website www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Bou 1 8
63. g n rateur DES PIECES CHAUDES peuvent provo quer des br lures et blessures e Ne pas toucher les parties chaudes du moteur e Laisser l ensemble se refroidir avant d effectuer la maintenance e Porter des gants et des v tements de protection pour travailler sur un moteur chaud LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT CHAUD peuvent provoquer des br lures est pr f rable de v rifier le liquide de refroidissement une fois le moteur refroidi pour viter de se br ler e Toujours v rifier le niveau de liquide de refroidissement dans le vase d expan sion si pr sent et non dans le radiateur sauf si pr cis autrement dans la section maintenance du manuel du moteur Sile moteur est chaud et que le liquide doit tre v rifi op rer comme suivant e Mettre des lunettes de s curit et des gants placer un torchon sur le bouchon du radiateur De visser le bouchon l g rement et laisser la vapeur s chapper avant d enle ver le bouchon LES ACCUMULATIONS DE GAZ ris quent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confin s ou se servir d un respi rateur d adduction d air homologu 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
64. g Optional Spark Arrestor Stop engine and let cool 1 Spark Arrestor Screen Clean and inspect screen Replace spark arrestor if screen wires are broken or missing Tools Needed J C 4 4 i Ref 803 572 A Ref 183 175 A 8 4 Servicing Air Cleaner Stop engine Robin Powered Kohler Powered Do run engine without air cleaner or with dirty element 1 Wash precleaner with soap and wa ter solution Allow precleaner to air dry completely Ge RUN IDLE Spread 1 tablespoon SAE 30 oil evenly into precleaner Squeeze out excess oil START 2 Element Replace element if damaged dirty or oily aircleaner3 11 04 802 772 803 070 S 0759 OM 4426 Page 34 5 A complete Parts List is available at www MillerWelds com 8 5 Changing Engine Oil Oil Filter And Fuel Filter Kohler Powered Units Stop engine and let cool 1 Oil Drain Valve 2 Oil Filter Change engine oil and filter accord ing to engine manual Close valve and valve cap before adding oil and run ning engine RUN Co RUN IDLE Fill crankcase with new oil to full mark on dipstick see Section 5 2 3 Fuel Filter 4 Fuel Line Replace line if cracked or worn Install new filter Wipe up any spilled fuel START Start engine and check for fuel leaks Stop engine tighten connec tions as necessary and wipe up fuel Reset oil main
65. ge regulator according to engine manual Engine stopped during normal Check fuel level see Section 5 2 or 5 3 operation Check oil level see Section 5 2 or 5 3 Low oil pressure shutdown stops engine if oil pressure is too low Oil level too high reduces capacity of the fuel pump Have Factory Authorized Service Agent check fuel shutoff solenoid FS1 according to engine manual Have Factory Authorized Service Agent check low oil pressure shutdown switch S5 Engine does not return to idle speed Be sure Engine Control switch S2 is in Run Idle position Remove all weld and generator power loads Place Process Contactor switch in Electrode Hot position or turn off remote contactor The unit will not return to idle speed when Process Contactor switch is in a remote position and the remote contactor is on Turn off remote device connected to Remote receptacle RC4 see Section 5 10 Check for obstructed movement of solenoid linkage see Section 8 7 or 8 8 Have Factory Authorized Service Agent check circuit board PC1 and current transformer Engine does not remain at weld power Place Engine Control switch in the Run position for small loads speed when power or weld load is applied with Engine Control switch in Run ldle position Check for obstructed movement of solenoid linkage see Section 8 7 or 8 8 During operation in near freezing tem Treat fuel with isopropyl alcohol de ic
66. governor according to engine manual 8 12 Engine Troubleshooting Trouble Remedy Engine will not crank Check fuse F6 and replace if open see Section 8 9 Check battery voltage Check battery connections and tighten if necessary Check plug PLG5 and plug PLG8 connections Have Factory Authorized Service Agent check Engine Control switch S2 Engine does not start Check fuel level see Section 5 2 or 5 3 Check battery and replace if necessary Check engine charging system according to engine manual Have Factory Authorized Service Agent check fuel shutoff solenoid FS1 according to engine manual See engine manual Engine starts but stops when Engine Control switch returns to Run ldle position Check oil level see Section 5 2 or 5 3 Low oil pressure shutdown stops engine if oil pressure is too low Use correct grade oil for operating temperature see Section 8 1 Have Factory Authorized Service Agent check low oil pressure shutdown switch S5 OM 4426 Page 41 5 A complete Parts List is available at www MillerWelds com Trouble Remedy Battery discharges between uses Place Engine Control switch in Off position when unit is not running Clean top of battery with baking soda and water solution rinse with clear water Periodically recharge battery approximately every 3 months Replace battery Check volta
67. il a load is applied In Example Process Stick Using Remote On Off Min 25 ACC DC Max 160 A CC DC Max 160 A DC VOLTAGE mm Min 25 A DC Set V A Control Adjust Remote V A Control Stick Welding Only 803 571 A 216 170 A S 0769 S 0774 OM 4426 Page 29 5 A complete Parts List is available at www MillerWelds com SECTION 7 OPERATING AUXILIARY EQUIPMENT 7 1 A unit does not have recep tacles use GFCl protected exten sion cord 5 Generator power decreases as weld current increases 1 240V 50A AC Receptacle RC1 supplies 60 Hz single phase power at weld power speed Maximum output is 9 5 KVA KW 2 120 V 20 A AC Duplex Receptacle RC2 120 V 20 A AC Duplex Receptacle RC3 120 240V N CB1 50 A MAIN BREAKER ON CTI LIS HOFF 2 4 RC2 and RC3 supply 60 Hz single phase power at weld power speed Maximum out put from RC2 or is 2 4 kVA kW 20 A x 120 V 4 Supplementary Protector CB1 CB1 protects receptacles RC1 RC2 RCS and 115 volt ac output to Remote Recep tacle RC4 from overload If CB1 opens the receptacles do not work and 115 volt ac out put to Remote Receptacle RC4 stops Place switch in On position to reset 5 Supplementary Protector CB2 6 Supplementary Protector CB3 CB2 protects RC2 from overload CB3 pro tects RC3 and the 115 volt ac output to Re 7 2 Optional GFCI Receptacles 120 240V N C
68. incy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org OSHA Occupational Safety and Health Standards for General Industry Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de U S Government Printing Office Superintendent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux r gionaux le t l phone de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov proc dures suivantes 1 Maintenir les c bles ensemble en les tordant ou en les envelop pant 2 Disposer les c bles d un c t et distance de l op rateur 3 Ne pas courber pas et ne pas entourer pas les c bles autour de votre corps 4 Garder le poste de soudage et les cables le plus loin possible de VOUS 5 Connecter la pince sur la pi ce aussi pr s que possible de la sou dure En ce qui concerne les stimulateurs cardiaques Les porteurs de stimulateur cardiaque doivent consulter leur m decin avant de souder ou d approcher des op rations de soudage Si le m decin approuve il est recommand de suivre les proc dures pr c dentes 5 A complete Parts List is available at www MillerWelds com SECTION 3 DEFINITIONS 3 1 Symbol Definitions Fast Fast Slow 5 Stop Engine Run Weld Power lt Run Idle x ES Slow Idle 2 Start Engine Fuel
69. ing e Wear approved ear protection if noise level is high MAGNETIC FIELDS can affect pacemakers e Pacemaker wearers keep away e Wearers should consult their doctor before going near arc welding gouging or spot welding opera tions CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechanical shocks 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 fittings de signed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Use the right equipment correct procedures and sufficient number of per sons to llift and move cylinders Read and follow instructions on compressed gas cylinders associ
70. insi 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 e Maintenir le chapeau de protection sur la soupape sauf en cas d utilisation ou de branchement de la bouteille e Utiliser les quipements corrects les bonnes proc dures et suffisamment de personnes pour soulever et d placer les bouteilles e Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association men tionn dans les principales normes de s curit 2 3 Dangers existant en relation avec le moteur L EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE e Toujours porter une protection faciale des gants en caout chouc et v tements de protection lors d une intervention sur la batterie Arr ter le moteur avant de d brancher ou de brancher les cables de batterie Eviter de provoquer des tincelles avec les outils en travaillant sur la batterie e pas utiliser le poste de soudage pour charger les batteries ou des v hicu les de d marrage rapide Observer la polarit correcte et sur les batteries e D brancher le c ble n gatif en premier lieu Le rebrancher en dernier lieu LE CARBURANT MOTEUR peut provo quer un incendie ou une explosion Arr ter le moteur avant de v rifier le niveau de carburant ou de faire le plein e Ne pas faire le plein en fumant ou proche d une
71. ion Heating Power Sources Coolers and Electronic Controls Recorders Water Coolant Systems Non Integrated Flowgauge and Flowmeter Regulators No Labor HF Units Grids Spot Welders Load Banks Arc Stud Power Sources amp Arc Stud Guns Racks Running Gear Trailers Plasma Cutting Torches except APT amp SAF Models Field Options NOTE Field options are covered under True Blue for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater Bernard Branded Mig Guns No Labor Weldcraft Branded TIG Torches No Labor Subarc Wire Drive Assemblies 4 6 Months Batteries 5 90 Days Parts MIG Guns TIG Torches and Subarc SAW Guns Induction Heating Coils and Blankets Cables and Non Electronic Controls amp SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Millers True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Bobcat Trailblazer and Legend models 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any
72. ity is high Ice forms on the throttle plate and inner bore of the carbu Infrequently retor The engine typically restarts without problems but soon stalls again Loaded Ld e Treat gasoline with a fuel de icer product isopropyl alcohol e Place the Engine Control switch in the Run position Run engine only when expecting to frequently load it RUN IDLE g y P g q y Breather Icing START 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 vacuum 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 e Load engine and reduce idle times to prevent engine shutdowns e Use an electric fuel pump to avoid pulse line freezing e Install engine cold weather kit Both Kohler 1 800 544 2444 and Robin 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 RUN IDLE START 5 When the ambient temperatures become warmer above 45 F the air flow will have to be returned to normal Ref 216 170 OM 4426 Page 2
73. le 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 e Donotuse AC output in damp areas if movement is confined or if there isa danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit Additional safety precautions are required when any of the following electri cally hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoidable or accidental contact with the workpiece or ground For these conditions use the following equipment in order present ed 1 a semiautomatic DC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit voltage In most situations use of a DC constant voltage wire welder is recommended And do not work alone e Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards e Properly install and ground this equipment according to its Owner s Manual and national state and local codes e Always verify the supply ground check and be sure that inp
74. lever 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 chaus sures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes e Suivre les recommandations dans OSHA 1910 252 a 2 iv et 518 pour les travaux chaud et avoir de la surveillance et un extincteur proximit DES PARTICULES VOLANTES wre a peuvent blesser les yeux Le soudage l caillement le passage de la pi ce la bros se en fil de fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la p riode de re froidissement des soudures elles risquent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial DES PIECES CHAUDES peuvent provoquer des br lures graves e Ne pas toucher mains nues les parties chaudes e Pr voir une p riode de refroidissement avant de travailler l quipement Ne pas toucher aux pi ces chaudes utiliser les outils recommand s et por ter des gants de soudage et des v tements pais pour viter les br lures LE BRUIT peut affecter l ouie Le bruit des processus et des quipements peut affecter Porter des protections approuv s
75. lures dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage Porter un casque de soudage approuv muni de verres filtrants appropri pour prot ger visage et yeux pendant le soudage voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit Porter des lunettes de s curit avec crans lat raux m me sous votre cas que Avoir recours des crans protecteurs ou des rideaux pour prot ger les au tres contre les rayonnements les blouissements et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc Porter des v tements confectionn s avec des mati res r sistantes et ignifu ges cuir coton lourd ou laine et des bottes de protection OM 4426 Page 5 LE SOUDAGE peut provoquer un in DES cendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer leur clatement Des tincelles peuvent tre projet es de l arc de 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
76. nd gloves and put a rag over radiator cap Turn cap slightly and let pressure escape slowly before completely re moving cap e Use equipment outside in open well ventilated ar eas e f used in a closed area vent engine exhaust outside and away from any building air intakes 1 4 Compressed Air Hazards BREATHING COMPRESSED AIR can cause serious injury or death e Do not use compressed air for breathing e Use only for cutting gouging and tools COMPRESSED AIR can cause injury e Wear approved safety goggles e Do not direct air stream toward self or others 9 TRAPPED AIR PRESSURE AND WHIPPING HOSES can cause injury 4r LY e Release air pressure from tools and system before servicing adding or changing attachments or open ing compressor oil drain or oil fill cap BATTERY ACID can BURN SKIN and EYES e Do not tip battery e Replace damaged battery e Flush eyes and skin immediately with water ENGINE HEAT can cause fire e Do not locate unit on over or near combustible surfaces or flammables e Keep exhaust and exhaust pipes way from flam mables EXHAUST SPARKS can cause fire e Do notlet engine exhaust sparks cause fire e Use approved engine exhaust spark arrestor in re quired areas see applicable codes HOT METAL from air arc cutting and gouging can cause fire or explosion e Do not cut or gouge near flammables e Watch for fire keep extinguisher nearby H
77. ng supplying 115 volt ac output to Remote Receptacle RC4 see Section 7 1 Press button to reset 2 Fuse F6 See Parts List F6 protects the engine wiring sys tem from overload If F6 opens engine will not crank Replace fuse if open Close left side door 803 773 A Ref 216 170 OM 4426 Page 39 5 A complete Parts List is available at www MillerWelds com 8 10 Welding Troubleshooting Trouble No weld output Check weld control settings Check weld connections Disconnect equipment from generator power receptacles during start up Increase front panel and or remote voltage amperage control settings see Sections 5 10 and 6 1 Check and secure connections to Remote receptacle RC4 see Sections 5 10 Have Factory Authorized Service Agent check brushes slip rings and circuit boards PC1 and PC2 Low weld output Check control settings Increase front panel and or remote voltage amperage control settings see Sections 5 10 and 6 1 Check and clean air cleaner as necessary see Section 8 4 Check engine speed and adjust if necessary see Section 8 7 or 8 8 Have Factory Authorized Service Agent check brushes slip rings and circuit boards PC1 and PC2 See engine manual High weld output Check control settings Check and adjust engine speed see Section 8 8 or 8 7 Check for obstructed movement of solenoid linkage see Section 8 7 or 8
78. ngto weld out Welding Duty Duty 10 10096 Duty Cycle put terminals Amperes Cycle Cycle not use worn dam aged undersized or poorly spliced cables 100 4 20 4 20 4 20 3 30 2 35 1 50 1 0 60 1 0 60 150 3 30 3 30 2 85 1 50 1 0 60 2 0 70 3 0 95 3 0 95 200 3 30 2 85 1 50 1 0 60 2 0 70 3 0 95 4 0 120 4 0 120 250 2 85 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2 300 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2 en 2 os 2 a 2 ea 2 0 2 3 0 2 3 0 2 ea 4 0 350 1 0 60 2 0 70 3 0 95 4 0 120 Tn mes o Ox D 2 ea 2 0 2 3 0 2 4 0 2 ea 4 0 400 1 0 60 2 0 70 3 0 95 4 0 120 27 mes ox 50 ox io This chart is a general guideline and may not suit all applications If cables overheat use next size larger cable Weld cable size AWG is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere mm for metric use S 0007 F For distances longer than those shown in this guide call a factory applications representative at 920 735 4505 OM 4426 Page 21 5 A complete Parts List is available at www MillerWelds com 5 10 Remote Receptacle Information NOTE gt Engine runs at weld power speed whenever a device connected to the remote receptacle is running 803 571
79. nnaitre les mesu res prendre pour viter tout danger Porter un harnais de s curit quand on travaille en hauteur Maintenir solidement en place tous les panneaux et capots Fixer le c ble de retour de facon obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s possible de la soudure Isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique Une tension DC importante subsiste l int rieur des onduleurs apr s avoir coup l alimentation Couper l alimentation du poste et d charger les condensateurs d entr e com me indiqu dans la Section Maintenance avant de toucher des composants LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereux pour votre sant Eloigner votre t te des fum es Ne pas respirer les fum es A l int rieur ventiler la zone et ou utiliser une ventilation forc e au niveau de l arc pour l vacuation des fum es et des gaz de soudage Si la ventilation est m diocre porter un respirateur anti vapeurs approuv 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 Travailler dans un espace ferm seulement s il est bien ventil ou en portant un respirateur alimentation
80. nuel du moteur compresseur si applicable LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Lerayonnement haute fr quence H F peut provoquer des interf rences avec les quipements de radio navigation et de communication les services de s curit et les ordinateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installation e L utilisateur est tenu de faire corriger rapidement par un lectricien quali fi les interf rences r sultant de l installation e Sile FCC signale des interf rences arr ter imm diatement l appareil e Effectuer r guli rement le contr le et l entretien de l installation e Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distance correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles 2 6 Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l Etat de Californie reconnait qu ils provoquent des malformations 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 chimiques dont l Etat de Cali fornie reconnait qu il
81. pour les oreilles si le ni veau sonore est trop lev LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques e Porteurs de stimulateur cardiaque restez distance e Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s approcher des op ra tions de soudage l arc de gougeage ou de soudage par points Si des BOUTEILLES sont endomma g es elles pourront exploser Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endommag e elle peut exploser Du fait que les bouteilles de gaz font 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 e Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser Tenir les bouteilles loign es des circuits de soudage ou autres circuits lectri ques 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 rac cords convenables pour cette application sp cifique les maintenir a
82. quire ments connect only essential loads pumps freezers heaters etc See Section 11 4 OM 4426 Page 53 11 11 Selecting Extension Cord Use Shortest Cord Possible Cord Lengths for 120 Volt Loads If unit does not receptacles use GFCI protected extension cord Maximum Allowable Cord Length in ft m for Conductor Size AWG Current Load Watts 4 6 8 10 12 14 Amperes 5 600 350 106 225 68 137 42 100 30 7 840 400 122 250 76 150 46 100 30 62 19 10 1200 400 122 275 84 175 53 112 34 62 19 50 15 15 1800 300 91 175 53 112 34 75 23 37 11 30 9 20 2400 225 68 137 42 87 26 50 15 30 9 25 3000 175 53 112 34 62 19 37 11 30 3600 150 46 87 26 50 15 37 11 35 4200 125 38 75 23 50 15 40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 2 voltage drop Cord Lengths for 240 Volt Loads If unit does not receptacles use GFCI protected extension Maximum Allowable Cord Length in ft m for Conductor Size AWG current Load Watts 4 6 8 10 12 14 Amperes 5 1200 700 213 450 137 225 84 200 61 7 1680 800 244 500 152 300 91 200 61 125 38 10 2400 800 244 550 168 350 107 225 69 125 38 100 31 15 3600 600 183 350 107
83. r frame to vehicle frame by met al to metal contact Bed liners shipping skids and some running gear insu late the welding generator from the vehicle frame Al ways connect a ground wire from the generator equip ment grounding terminal to bare metal on the vehicle frame as shown If unit does not have GFCI re ceptacles use GFCI pro tected extension cord S 0854 OM 4426 Page 48 11 3 Grounding When Supplying Building Systems 1 Equipment Grounding Terminal 2 Grounding Cable Use 10 AWG or larger insulated copper wire 3 Ground Device Use ground device as stated in electrical codes Ground generator to system earth ground if supplying power to a premises home shop farm wiring system Also see AWS Safety amp Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Generators ST 800 576 B 1 Resistive Load A light bulb is a resistive load and requires a constant amount of power 2 Non Resistive Load VOLTS 115 th AMPS 45 quipment with a motor is non re 60 sistive load and requires approxi mately six times more power while starting the motor than when running see Section 11 8 3 Rating Data Rating shows volts and amperes or watts required to run equipment Amperes x Volts Watts Example 1 If a drill uses 4 5 am peres at 115 volts calculate its run ning power requirement in watts 4 5 115 V 520W The load appli
84. ro lyte level If necessary add electro lyte to raise to proper level Reins tall vent caps 4 Battery Charger Read and follow all instruc tions supplied with battery charger Charge battery for 12 minutes at 30 amperes or 30 minutes at 5 am peres Disconnect charging cables and install battery 5 When electrolyte is low add only distilled water to cells to maintain proper level 5 A For 30 Minutes OR 5 Tools Needed drybatti 6 05 S 0886 Connect negative cable last RUN IDLE START Tools Needed 2 120 Ref 803 573 A Ref 202 069 A Ref S 0756 D OM 4426 Page 18 5 A complete Parts List is available at www MillerWelds com 5 6 Installing Exhaust Pipe Stop engine and let cool Engine backfire can cause se vere burns or other injuries Do not point exhaust pipe to ward control panel Keep away from exhaust outlet Do not point exhaust pipe to ward LP fuel tank if equipped Do not point exhaust pipe to Ge A wards shielding gas tank if RUN IDLE equipped Point exhaust pipe in desired di rection but always away from front panel and direction of travel Tools Needed 1 2 803 891 Ref 216 170 S MATERIAL THICKNESS REFERENCE CHART 24 Gauge 025 in 22 Gauge 031 in 20 Gauge 037 in 18 Gauge 050 in 16 Gauge
85. rocedures 1 Keepcables close together by twisting or taping them 2 Arrange cables to one side and away from the operator 3 Do not or drape cables around your body 4 Keep welding power source and cables as far away from operator as practical 5 Connect work clamp to workpiece as close to the weld as possible About Pacemakers Pacemaker wearers consult your doctor before welding or going near welding operations If cleared by your doctor then following the above procedures is recommended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION rom fre 3 05 Avertissement Prot gez vous et les autres des blessures lisez et suivez ces pr cautions 2 1 A Signification des symboles Signifie Mise en garde Soyez vigilant Cette proc dure pr sente des risques de danger Ceux ci sont identifi s par des symboles adjacents aux directives Identifie un message de s curit particulier gt Signifie NOTA n est pas relatif la s curit 2 2 Dangers relatifs au soudage l arc A gt gt sh 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 risques 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
86. rounding Terminal On Front Panel 3 Grounding Cable Not Supplied 4 Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insu lated copper wire Inadequate support flexible mounts 1 Grounding Bed liners shipping skids and some running gears insulate the welding generator from the vehicle frame Always connect a ground wire from the generator equipment grounding termi nal to bare metal on the vehicle frame as shown Electrically bond generator frame to vehicle frame by metal to metal contact install2 12 06 Ref 800 652 Ref 800 477 A 803 274 A 804 712 4426 Page 15 5 A complete Parts List is available at www MillerWelds com 5 2 Engine Prestart Checks Kohler Powered Units Check all fluids daily Engine must be cold and on a level surface Unit is shipped with 10W30 engine oil 2 Follow run in procedure in en gine manual 5 This unit has a low oil pressure shutdown switch However 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 Open top service door Fuel Add fresh fuel before starting engine Oil Check Fill the first time see maintenance label for specifications Always l
87. s provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apres manipulation 2 7 Principales normes de s curit eafety in Welding Cutting and Allied Processes ANSI Standard Z49 1 de Global Engineering Documents t l phone 1 877 413 5184 site In ternet www global ihs com Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping American Welding Society Standard AWS F4 1 de Global Engineering Documents t l phone 1 877 413 5184 site In ternet www global ihs com National Electrical Code NFPA Standard 70 de National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 t l phone 703 412 0900 site Internet www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 de Canadian Standards Association Standards Sales 178 Rexdale 2 8 Information EMF Consid rations sur le soudage et les effets de basse fr quence et des champs magn tiques et lectriques Le courant de soudage pendant son passage dans les c bles de souda ge causera des champs lectromagn tiques y a eu et il y a encore un certain souci propos de tels champs C
88. sing either the Auto Crater or Auto Stop feature see Section 6 7 Process Contactor Switch Settings Switch Setting Process Output On Off Control Electrode Hot Wire MIG GMAW Electrode Hot Electrode Hot Stick Select Preferred Dig Stick SMAW Electrode Hot Electrode Hot Stick Air Carbon Arc CAC A Cutting And Gouging Select Any Dig Electrode Hot Electrode Hot Lift Arc w Auto Crater TIG GTAW Lift Arc w Auto Crater GTAW DC Only Electrode Hot TIG Remote On Off GTAW With HF Unit Pulsing Device Or Remote Control AC or DC At Remote Receptacle Stick Remote On Off Stick SMAW With Remote On Off At Remote Receptacle Wire Wire Feeder CV Using Remote MIG GMAW At Remote Receptacle OM 4426 Page 26 5 A complete Parts List is available at www MillerWelds com 6 5 Stick Start Procedure Scratch Start Technique With Stick selected start arc as follows 1 Electrode 2 Workpiece 3 Arc Drag electrode across workpiece like striking a match lift electrode slightly after touching work If arc goes out electrode was lifted to high If electrode sticks to workpiece use a quick twist to free it 6 6 TIG Lift Arc Start Procedure Select Lift Arc Scratch Start TIG at Process Contactor switch to achieve great arc starts with either procedure Perform Lift Arc starting method as follows Lift Arc
89. soudage le demande 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 appareil en est quip Des pr cautions de s curit suppl mentaires sont requises dans des envi ronnements risque comme les endroits humides ou lorsque l on porte des v tements mouill s sur des structures m talliques au sol grillages et cha faudages dans des positions assises genoux et allong es ou quand il y a un risque important de contact accidentel avec la pi ce ou le sol Dans ces cas utiliser les appareils suivants dans l ordre de pr f rence 1 un poste souder DC semi automatique de type CV MIG MAG 2 un poste souder manuel lectrode enrob e DC 3 un poste souder manuel AC avec tension vide r duite Dans la plupart des cas un poste courant continu de type CV est re command Et ne pas travailler seul Couper l alimentation ou arr ter le moteur avant de proc der l installation la r paration ou l entretien de l appareil D verrouiller l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de s curit Installer et mettre la terre correctement cet appareil conform ment son manuel d utilisation et aux codes nationaux provinciaux et municipaux Toujours v rifier la terre du cordon d alimentation V rifier et s assurer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du se
90. source d tincelles ou d une flamme nue e Ne pas faire le plein de carburant ras bord pr voir de l espace pour son expansion e Faire attention de ne pas renverser de carburant Nettoyer tout carburant renvers avant de faire d marrer le moteur e Jeter les chiffons dans un r cipient ignifuge DES ORGANES MOBILES peuvent pro voquer des blessures e Ne pas approcher les mains des ventilateurs courroies et autres pi ces en mouvement e Maintenir ferm s et fixement en place les portes panneaux recouvre ments et dispositifs de protection 4426 6 Arr ter le moteur avant d installer ou brancher l appareil e Seules des personnes qualifi es sont autoris es enlever les portes pan neaux recouvrements ou dispositifs de protection pour effectuer s il y a lieu des travaux d entretien et de d pannage e Pour emp cher tout d marrage accidentel pendant les travaux d entretien d brancher le c ble n gatif de batterie de la borne e pas approcher les mains cheveux v tements laches et outils des organes mobiles e Remettre en place les panneaux ou les dispositifs de protection et fermer les portes la fin des travaux d entretien et avant de faire d marrer le moteur e Avant d intervenir d poser les bougies ou injecteurs pour viter la mise en route accidentelle du moteur e Bloquer le volant moteur pour viter sa rotation lors d une intervention sur le
91. ss 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 PRINTED IN USA 2007 Miller Electric Mfg Co 2007 01 Miller Electric Mfg Co An Illinois Tool Works Company 1635 West Spencer Street Appleton WI 54914 USA International Headquarters USA USA Phone 920 735 4505 Auto Attended USA amp Canada FAX 920 735 4134 International FAX 920 735 4125 European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 www MillerWelds com Miller
92. switch in RUN position to view engine hours e OIL CHANGE INTERVAL with engine off place Engine Control switch into the RUN IDLE position to see hours before next oil change Oil hours start at 100 and count down to 0 oil change due NOTE Negative hours indicated when past recommended oil change interval TO RESET Cycle Engine Control switch from the RUN IDLE to RUN position 3 times e ENGINE RPN s With engine running and the Process Selector switch in any Stick HOT position cycle Engine Control switch from the RUN IDLE to RUN position 3 times and meters will display Engine RPM s Use to check and set both idle and run speed RPM s Accuracy is x16 RPM s Turn machine off to reset display RUN Ref 216 170 Ref 227 723 A OM 4426 Page 24 5 A complete Parts List is available at www MillerWelds com 6 2 Description Of Front Panel Controls See Section 6 1 1 Process Contactor Switch See Section 6 4 for Process Contactor switch information 2 Remote Receptacle Use receptacle to connect remote control or wire feeder When a remote voltage amperage control is connected to the Remote receptacle the Auto Sense Remote feature automatically switches voltage amperage control to the re mote control See Sections 5 10 and 6 8 With remote voltage amperage control con nected weld output in CC mode is deter mined by a combination of front panel and re mote control voltage amperage settings
93. t air comprim chauds e Laisser l ensemble se refroidir avant de toucher ou d effectuer la mainte nance LIRE LES INSTRUCTIONS e Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil e Arr ter le moteur et rel cher la pression avant d ef fectuer la maintenance e Utiliser uniquement des pi ces de rechange Miller Hobart Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance L EMPLOI EXCESSIF peut SURCHAUFFER L EQUIPEMENT Laisser l quipement refroidir respecter le facteur de marche nominal R duire le courant ou le facteur de marche avant de poursuivre le soudage e pas obstruer les passages d air du poste 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 boites antistatiques pour stocker d placer OU exp dier des cartes de circuits imprimes D UNE REMORQUE QUI BASCULE peut entrainer des blessures e Utiliser les supports de la remorque ou des blocs pour soutenir le poids e Installer convenablement le poste sur la remorque com me indiqu dans le manuel s y rapportant OM 4426 Page 7 LIRE LES INSTRUCTIONS e Utiliser seulement les pieces de rechange d origine e Effectuer la maintenance du moteur et du compresseur si applicable suivant ce manuel et le ma
94. tenance countdown by flipping Engine Control switch from Run Idle to Run three times Tools Needed Te Ref 803 573 A S 0842 OM 4426 Page 35 5 A complete Parts List is available at www MillerWelds com 8 6 Changing Engine Oil Oil Filter and Fuel Filter Robin Powered Units rae Y XY Stop engine and let cool 2 Oil Filter Change engine oil and filter accord Oil Fill tee ing to engine owner s manual Close valve and valve cap before adding oil and running engine START Oil Check Fill crankcase with new oil to full mark on dipstick see Section 5 3 3 Fuel Filter 4 Fuel Line TAi Replace line if cracked or worn new filter Wipe up any spilled Full Start engine and check for fuel leaks 5 Stop engine tighten connec tions as necessary and wipe up fuel Reset oil maintenance countdown by flipping Engine Control switch ES 2 from Run Idle to Run three times e Tools Needed HEN Te gt 803 572 S 0842 OM 4426 Page 36 5 A complete Parts List is available at www MillerWelds com 8 7 Adjusting Engine Speed Kohler Powered Units NARMS 2200 2300 rpm 36 6 38 3 Hz 3675 3750 rpm 61 3 62 5 Hz Tools Needed J 1 4 3 8 in After
95. to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists in inverters after stop ping engine e Stop engine on inverter and discharge input capacitors according to instructions in Maintenance Section before touching any parts FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health e 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 watchperson nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breathing air is safe e Do not weld in locations near degreasing cleaning or spraying operations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases Do weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld
96. tuning engine check engine speeds with a tachometer see table If necessary adjust speeds as follows Start engine and run until warm Turn A V control to 10 Open top cover access panel to ac cess speed adjustments Idle Speed Adjustment Move Engine Control switch to Run ldle position 1 Throttle Solenoid 2 Mounting Screws 3 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 Weld Power Speed Adjustment Nut 5 Lock Nut Loosen lock nut Turn adjustment nut until engine runs at weld power speed Tighten lock nut Close and secure top cover access panel Stop engine 803 573 801 209 A OM 4426 Page 37 5 A complete Parts List is available at www MillerWelds com 8 8 Adjusting Engine Speed Robin Powered Units of 2200 2300 rpm 36 6 38 3 Hz 3675 3750 rpm 61 3 62 5 Hz Tools Needed p 10mm IE 8mm OM 4426 Page 38 B os After tuning engine check engine speeds with a tachometer see table If necessary adjust speeds as
97. udage soit pos et mis la terre conform ment ce mode d emploi e cas d interf rences apr s avoir pris les mesures pr c dentes il in combe a l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de c bles blind s l utilisation de fil tres de ligne ou la pose de protecteurs dans la zone de travail Proposition californienne 65 Avertissements Pour les moteurs essence Les gaz d chappement des moteurs contiennent des produits chimi ques dont l 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 Lesgazd chappement des moteurs diesel et certains de leurs compo sants sont reconnus par l Etat de Californie comme provoquant des cancers et des malformations cong nitales ou autres probl mes de pro cr ation Boulevard Rexdale Ontario Canada M9W 183 800 463 6727 ou Toronto 416 747 4044 site www csa international org telephone Internet Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 de American National Standards Institute 11 West 42nd Street New York NY 10036 8002 t l phone 212 642 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 1 Battery March Park Qu
98. ut power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet e When making input connections attach proper grounding conductor first double check connections e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a sep arate cable e Do not touch electrode if you are in contact with the work ground or anoth er electrode from a different machine e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazards e Do not touch electrode holders connected to two welding machines at the same time since double open circuit voltage will be present Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or work table as near the weld as practical e Insulate work clamp when not connected

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