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Miller Electric 401DXQ User's Manual

Contents

1. Stop engine and let cool 1 Oil Filter 2 Oil Drain Valve 3 Oil Fill Cap 4 Primary Fuel Filter Fuel Water Separator Petcock Secondary Fuel Filter Fuel Shutoff Valve Fuel Line o O1 Sludge Drain Plug To change oil and filter See engine manual Close oil drain valve and cap and place in holder before adding oil and running en gine To drain water from fuel system Open primary fuel filter petcock and drain water into metal container Close petcock when water free fuel flows To replace primary fuel filter Close shutoff valve and turn filter counterclockwise Remove filter Apply thin coat of fuel to gasket on new filter Install new filter and turn clockwise Open shutoff valve Bleed air from fuel system accord ing to engine manual Inspect fuel line and replace if cracked or worn To replace secondary fuel filter See engine manual To drain sludge from fuel tank Put metal container under drain and remove sludge drain plug Re install plug when done After servicing start engine and check for fuel leaks Stop engine tighten connec tions as necessary and wipe up spilled fuel Close doors Tools Needed 7 6in Ref ST 188 449 ST 801 334 Ref 5 176 697 Ref 5 0842 OM 173 413 Page 30
2. 3 Check Fluid FUEL Wipe Up Ai Levels See WATER From Fuel Spills Section 4 4 System See i Section 7 4 50h Clean And Service Air Filter Tighten See Section 7 3 Weld 1 2 Terminals 100h Check air cleaner hoses e for cracks and loose clamps WARNI A Clean Replace Cooling FL ET Unreadable System Labels Check And Clean Spark Arrestor See Section 7 7 500h Repair Or Check Replace Belt Cracked Tension Cables 750h Change Oil Change Oil See Section Filter See 7 4 Section 7 4 173 413 26 Blow Out Or Vacuum Inside During Heavy Service Clean Monthly Service Welding Change Fuel Generator Brushes Filters See And Slip Rings Section 7 4 Service More Often In Dirty Conditions a SLUDSE Tank See Section 7 4 Check Valve Clearance 3000h Clean Set Injectors Notes OM 173 413 Page 27 Maintenance Label 6 2 Weve eer bd g Q xe 9691 11 zineg 189098 uospreuoq oc gt 8 2100 w 0 Ul LIC 990 HATIIN zZ vr YATIIW 2 4 L Q V 4G 9008 4AA 9 02 1 18 926 INLSV ZY LY 698z S9 109 LS NIG Brey XIM 6 11 1 8 2r 9L9S1z8d Tasala 929261 HATIIN SSSSSASASSA AN x Qb z 9 76 S 9 9 91
3. 5 1 3 Dangers existant en relation avec le moteur 6 1 4 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance s c 22 RE NEES A ERRARE EM aa 7 1 5 Principales normes de 8 1 6 Information sur les champs lectromagn tiques 8 SECTION 2 DEFINITIONS 22 35 43 REIR RE motte e E EIE EMERE A Yeu 9 2 1 Warning Label Definitions RR 9 2 2 Manufacturers Rating Label For CE Products 12 2 3 Symbols And Definitions 13 SECTION 3 1 22 p x x ER ek xx mac maire eee ee ie 14 3 1 Weld Power And Engine Specifications 14 3 2 Dimensions Weights And Operating Angles 14 3 3 Duty Cycle And Overheating 15 3 4 Volt Ampere Curves 15 3 5 AC Auxiliary 16 3 6 Fuel CONSUMPTION LE 05r dee Honest S Gea ne e ae 16 SECTION 4 INSTALLATION 0 0c cece etter nnn nnnm mm n nnn
4. Stop engine Do not touch hot exhaust pipe engine parts or load bank grid Keep exhaust and pipe away from flammables gt gt 1 Resistance Grid Use grid sized for generator rated output Turn Off grid 2 Welding Generator Place A V range switch in maxi mum position A V control in mini mum position and Output Selector switch if present in either DC position 3 Weld Cables Connect grid to generator weld output terminals using proper size weld cables with correct connec tors polarity is not important 4 Voltmeter 5 Clamp On Ammeter Connect voltmeter and ammeter as shown if not provided on generator Start engine and run for several minutes Set grid switches and then adjust generator A V control so load equals rated generator output see nameplate Check generator and meters after first five minutes then every fifteen minutes to be sure generator is loaded properly Check oil level frequently dur ing run in add oil if needed After one hour minimum place A V control in minimum position then shut down grid to remove load Run engine several minutes at no load Stop engine and let cool 6 Engine Exhaust Pipe Repeat procedure if wetstacking is present S 0684 OM 173 413 Page 38 SECTION 10 AUXILIARY POWER GUIDELINES 10 1 Selecting Equipment 1 Auxiliary Power Receptacles Neutral Bonded To Frame 2 3
5. Bee PR SPEC ete 1 Me HIR 035 776 KEY 375 375 x 2 000 OT uui um ur T ae al 044 374 STATOR excitor 1 22e 173 068 ENDBELL gen consisting 1 143 220 O RING 2 859 ID x 189CS 1 5 23 uode 173 323 BARREL rectifier 1 24 SR3 106 430 DIODE ASSEMBLY consisting of 1 nr PD su nad 048 420 CAPACITOR rectifier 2 ig sem ncs dd fite 106 64T meor CAPACITOR Coi bet Rae ete nix d DOLI n uri 106 425 2 INSULATOR rii desee ke Deletes 1 Wierd veut teers 037 956 DIODE rect 275A 300V 3 28 VR1 R4 046819 SUPPRESSOR tenes 1 Recommended Spare Parts When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 173 413 Page 51 Hardware is common and not available unle
6. 1 se serait reed 601 879 NUT stl hex full fnsh 500 13 1 TET m 601880 NUT stl hex jam 500 13 d m 175013 PANEL side eee tes D Rees esi dete 1 ENT cease ido ER 175 012 PANEL side ves pias aig en eet digs ERES ORO RES 1 prea ee eer 173 322 DOOR side LH 0 1 173 321 DOOR Side AERE ean aan J qubd dcs 004 130 BRACKET support door 2 Deu A 173346 LATCH paddle 2 oM D E AN 176 751 LABEL diesel engine maintenance 1 RUNE HR iat 176 108 LABEL warning battery explosion 1 1738 343 COVER ERR LAE 1 Rants uu edt 176 105 LABEL general precautionary 1 iue dct ed cw du art 176 104 LABEL warning falling equipment 2 Ni CD ya tke 035 968 WASHER flat 3 625 ID x 5 875 OD x 062thk 1 RM TT HS 195 869 CABLE TIE 0 17 500 weather resistant 1 uus Boost ue 173324 SKIRT base LH tees 1 173325 SKIRT base RH 1 TOM ENS 107 972 TANK fuel 11 gal consisting of 1
7. 1 ras esters 010 146 CLAMP nyl 625clp dia 1 OMe eor E e 181 122 PANEL mtg components 1 91 SR1 2 4 035 704 RECTIFIER integ 40 800V 3 D8 ius 192307 KIT diode w washers 1 93 D1 C1 D9 C9 189 701 DIODE CAPACITOR 2 C8 170674 CAPACITOR BOARD 1 ies OD B6 030844 RESISTOR WW fxd 25W 25 ohm 1 96 CR2 059 267 RELAY encl 12VDC 1 MOSAICO 173317 PANEL front lower 1 a Figure 11 3 PANEL front w components 1 xo OS in Sues ete 129074 2 REACTOR o a tet ate bed ets Do do IR en 1 100 CT1 105370 TRANSFORMER current 1 aS TOT 188 237 UPRIGHT base front 1 ass 108 163 FRAME mtg reactor 8 fuel tank 1 103 R23 128 862 RESISTOR WW adj 375W 50 ohm 2 25 were 085
8. 150 300 125 250 3 KW 0 100 200 r L x 75 150 Fr i L lt 50 40 25 50 8 1 1 1 5 10 15 20 25 AC AMPERES IN 240V MODE 10 20 30 40 50 AC AMPERES IN 120V MODE rsb3 1 2 92 ST 109 365 C 3 6 Fuel Consumption The curve shows typical fuel use under weld or power loads ac ac D 2 C zj 7 57 1 67 2 00 6 81 1 50 180 F 6 06 1 33 160 F 5 30 1 17 140 F 4 54 1 00 120 F 5 79 0 83 100 F 3 03 0 67 0 80 F 2 27 0 50 O60 F 1 51 0 33 0 40 0 76 0 17 0 20 F 0 00 0 00 0 00 1 0 50 100 150 200 250 300 350 400 450 500 WELD AMPERES 100 DUTY CYCLE SB 137 487 A OM 173 413 Page 16 SECTION 4 INSTALLATION 4 1 Installing Welding Generator Movement Airflow Clearance Location Do Not Lift Unit From End Grounding 1 Generator Base 2 Metal Vehicle Frame 3 4 3 Equipment Grounding Terminal 4 Grounding Cable Use 10 AWG or larger insulated OR copper wire If unit does not have GFCI re ceptacles use GFCI DL protected extension cord Electrically bond generator frame to uz vehicle frame by metal to metal uu 2 contact install 3 96 Ref ST 800 652 Ref ST 800 477 A ST 158 936 A 5 0854 OM 173 413 Page 17 4 2 Activating The Dry Charge Battery ay 5 A For 30 Minutes OR ES 30 A For 12 Minutes
9. Remove battery from unit 1 Eye Protection Safety Glasses Or Face Shield 2 Rubber Gloves 3 Vent Caps 4 Sulfuric Acid Electrolyte 1 265 Specific Gravity 5 Well Fill each cell with electrolyte to bottom of well maximum Do not overfill battery cells Wait ten minutes and check electro lyte level If necessary add electro lyte to raise to proper level Reins tall vent caps 6 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 EF When electrolyte is low add only distilled water to cells to maintain proper level Tools Needed SS gt drybatti 2 96 5 0886 173 413 18 4 3 Connecting The Battery pu Connect Negative Cable Last Tools Needed 1 2in ST 156 011 Ref ST 188 449 5 0756 4 4 Engine Prestart Checks Check all fluids daily Engine must be cold and on a level surface 1 Exhaust Pipe Follow run in procedure in engine manual If unburned fuel and oil col lect in exhaust pipe during run in see Section 9 Run engine near rated output during run in period 2 Fuel Do not use gasoline Gaso line will damage engine Diesel Add fresh diesel fuel before starting engine the first time see mainte nance
10. 10 992 290 H3TIIN 35 40 3S qo IdY 0981 4 0 2 81 00S gt 99108 0021 ESSA 2 99 Z90 HATIIN 3NION3 ZLNAG 173 413 28 7 3 Servicing Air Cleaner Blow Inspect Stop engine Air Cleaner Service Indicator Optional Window Reset Button Service air cleaner element if red band appears in window A green band means air cleaner is okay Press button to reset indicator not run engine without air cleaner or with dirty element Clean or replace element if dirty or damaged Replace element yearly or after six cleanings 5 Dust Ejector Dust Cover Element Safety Element Optional Body To Clean air filter oN o Wipe off cover and body Remove cover and dump out dust Wipe dust from inside cover and body with damp cloth Remove element s and reinstall cover Do clean air cleaner body with air hose Clean element s with compressed air only Keep nozzle at least 1 in 25 mm from inside of element Max air pressure 100 psi 690 kPa Replace element s if it has holes or damaged gaskets Reinstall element s and cover dust ejector down aircleaner4 9 99 802 495 Ref S 0698 B OM 173 413 Page 29 7 4 Oil And Fuel System Components CL w APES
11. 8 api 115000 f 8l ote ead ec bettie 1 Sy Em 605 288 FITTING pipe galv plug sq hd 250 1 020 185 FITTING pipe brs elb st 1 8NPT 1 ERE 073 432 FITTING hose brs barbed 3 16tbg x 1 8NPT 1 nu deen eee 134 834 HOSE nprn SAE 187 ID 410 OD 1 Sx Mess eese 192 757 FITTING hose brs splice 3 16tbg x 3 16tbg 1 mir 089517 STRAB fueltank ae Ae a et qe 2 dus TAE a hen diebns 78488 ROD a al hix xw TEES ES 1 esate ae 188235 UPRIGHT base center 1 xs dose utem 188 250 sels gee eta ERI Ru Peres SPUR ELM 1 Levante sive she 17 3 326 SB 189 365 STRIP mtg xfmr base pan 1 Sete b eee 108 081 TERMINAL PROTECTOR battery post 2 ecd TO ub LAE ix 124941 CABLE bat pos nine Bee ibi pal owe E 1 ced o UE IS 089914 BOLT L stl 312 18 9 000 1 124 668 HOLD DOWN battery 1 sal hati agitate ads 010460 STUD stl 312 18 x 10 000 1 032 453
12. BATTERY ACID can BURN SKIN and EYES e Donottip battery e Replace damaged battery e Flush eyes and skin immediately with water ENGINE EXHAUST GASES can kill Use equipment outside in open well ventilated areas e If used in a closed area vent engine exhaust outside and away from any building air intakes ENGINE HEAT can cause fire e Do not locate unit on over or near combustible surfaces or flammables e Keep exhaust and exhaust pipes way from flammables EXHAUST SPARKS can cause fire Do not let engine exhaust sparks cause fire Use approved engine exhaust spark arrestor in required areas see applicable codes 1 4 Additional Symbols For Installation Operation And Maintenance FALLING UNIT can cause injury Use lifting eye to lift unit only NOT running gear gas cylinders trailer or any other accessories Use equipment of adequate capacity to lift and support unit e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit FLYING SPARKS can cause injury y 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 Sparks can cause fires keep flammables away N OVERHEATING can damage motors e Turn off or unplug equipment before starting or stopping engine e Do not let low volta
13. Maximum Allowable Cord Length in ft m for Conductor Size AWG Nds Load Watts 4 6 8 10 12 14 5 1200 700 213 450 137 225 84 200 61 7 1680 800 244 500 152 300 91 200 61 125 38 10 2400 800 244 550 168 350 107 225 69 125 38 100 31 15 3600 600 183 350 107 225 69 150 46 75 23 60 18 20 4800 450 137 275 84 175 53 100 31 60 18 25 6000 350 107 225 69 125 38 75 23 30 7000 300 91 175 53 100 31 75 23 35 8400 250 76 150 46 100 31 40 9600 225 69 125 38 75 23 45 10 800 200 61 125 38 50 12 000 175 53 100 31 Conductor size is based on maximum 2 voltage drop OM 173 413 Page 45 SECTION 11 PARTS LIST Hardware is common and not available unless listed Figure 11 1 Main Assembly OM 173 413 Page 46 T j P P AX 24 FIG 11 2 ST 801 345 J OM 173 413 Page 47 ltem Dia Part Mkgs No Description Quantity Figure 11 1 Main Assembly xu dl tee he teed 175657 TERMINAL output bracket 1 A E A A 175 724 BRACKET brace terminal weld output 1 Neg 039046 TERMINAL pwr output black consisting of 1 Pos 039047 TERMINAL pwr output red consisting of
14. Si la pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct ne pas utiliser le connecteur de pi ce ou le c ble de retour pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine rom nd fre 11 98 APA Ce groupe de symboles signifie Mise en garde Soyez vigilant y a des risques de danger reli s aux CHOCS LECTRIQUES aux PIECES EN MOUVEMENT et aux PIECES CHAUDES Reportez vous aux symboles et aux directives ci dessous afin de conna tre les mesures prendre pour viter tout danger e Nuutiliser 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 e Porter un harnais de s curit quand on travaille en hauteur e Maintenir solidement en place tous les panneaux et capots e Fixerle 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 apres avoir coup l alimentation Couper l alimentation du poste et d charger les condensateurs d entr e comme indiqu dans la Section Maintenance avant de toucher des compo sants LES RAYONS DE L
15. DIODE ASSEMBLY reverse polarity consisting of 1 Ed 048 420 CAPACITOR rectifier 2 C de 106 641 CAPACITOR 0 n 1 E NN EC E 037 957 DIODE rect 275A 300V 3 Gaiden 106 425 INSULATOR x5 rite tes eb bre Lex Settee dels ide ges Sea BS 2 CAEDE 173 066 BRACKET mtg brushholder 1 HO HAS no 018614 BRUSH SET consisting of 3 189 151299 gt BRUSH contact uoi tesa Ie 1 us re 600 270 HOLDER brush 2 1 2 CU usce 152 044 5 1 do 176 106 LABEL warning moving parts can cause serious injury 2 ne 124855 GUARD stator 1 PA LE 174 002 STATOR gen consisting of 1 lo ede Au 039 207 BAFFLE airgen 00 ccc e mnn 1 16 y 089 736 ROTOR gen consisting of 1 Tf es a tit het 024 617 RING retaining external eh 1 TO eu restes 053 390 BEARING ball took E ER EX ears 1 Anna 089737 sea
16. Equipment with a serial number preface of LA or newer This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Miller must be notified in writing within thirty 30 days of such defect or failure at which time Miller will provide 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 date that the equipment was delivered to the original retail purchaser or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifie
17. max control circuit that resets the Amperage Voltage Con trol to maximum when the arc breaks When an arc is struck weld output con trol returns to the front panel or remote control setting The Amperage Voltage Control adjusts amperage only when welding and does not adjust open circuit voltage 1 Ampere Range Switch Do not switch under load 2 Amperage Voltage Control Control adjusts amperage within range se lected by Ampere Range switch Weld output would be 140 A DC with controls set as shown 50 of 90 to 190 A 3 DC Voltmeter Optional 4 DC Ammeter Optional 5 Remote A V Switch And Receptacle See Section 5 3 6 Magnetic Shutdown Switch Optional Use switch during start up to bypass option al engine shutdown system System stops engine if oil pressure is too low or oil temper ature is too high 7 Engine Control Switch To Start turn switch to Start while pressing Shutdown switch Release switches when engine starts E If the engine does not start let engine come to a complete stop before attempt ing restart In Run position engine runs at weld power speed In Run ldle position optional engine Ref ST 188 449 runs at idle speed at no load and weld speed with load applied To Stop turn switch to Off position 8 Battery Charging Warning Light Light goes on when battery is not charging 9 Oil Pressure Warning Light Light goes on if oil pressure is too low Light al
18. ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway New York NY 10018 Cutting And Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 1 Keep cables close together by twisting or taping them 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 Keep welding power source and cables as far away from operator as practical 5 Connect work clamp to workpiece as close to the weld as possi ble About Pacemakers Pacemaker wearers consult your doctor first If cleared by your doctor then following the above procedures is recommended SECTION 1 CONSIGNES SECURITE AVANT UTILISATION 1 1 Signification des symboles un message de s curit particulier 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 Signifie NOTA n est pas relatif la s curit 1 2 Dangers relatifs au soudage l arc Les symboles pr sent s ci apr s sont utilis s tout au long du pr sent manuel pour attirer votre attention et identifier les ris ques de danger Lorsque vous voyez un symbole soyez vigilant et suivez les directives mentionn es afin d viter tout danger Les consignes de s curit pr sent es ci apres ne font que r sumer l inf
19. CABLE bat 1 m 111 352 BATTERY stor 12V 500 1 LE cr cial aie Fig re T1 2 GENERATOR di beg iere Dreh gn ite meet et ee it ou neg lane 1 EE 188239 BRACKET mtg engine LH 1 173 304 COVER air baffle bottom 1 CRD Maka 173307 COVER air baffle top 1 ids es 109591 CLAMP muffler 1 750dia 2 siu iu Due eee 176 745 a PIPE exhaust eter aie eri 1 buc DO duit eed aid eus 176 744 PIPE muffler extension elbow 1 ses etis 046 545 RESTRICTION INDICATOR 1 Uso I ph 010089 FITTING brs coupling 1 8 1 OO Pelis 197613 AIR CLEANER intake consisting of 1 197 678 BODY air cleaner 1 Aid en 197829 BRACKET mig air cleaner 2 iau OON aite kii s 197679 ELEMENT air cleaner safety 1 TECTA DENS 197 676 ELEMENT air cleaner 1 Boc Er 197 677 COVER ASSY air c
20. ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazards Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists after stopping engine on inverters e Stop engine on inverter and discharge input capacitors according to instructions in Maintenance Section before touching any parts 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 Weara welding helmet fitted with a proper shade of filter to protect your face and eyes from arc rays and sparks when welding or watching see ANSI 249 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc Wear protective clothing made from durable flame resistant mate rial wool and leather and foot protection FUMES AND G
21. provoquer des interf rences e Lenergie lectromagn tique risque de provoquer des interf rences pour l quipement lectronique sensible tel que les ordinateurs et l quipement com mand par ordinateur tel que les robots Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement e Pour r duire la possibilit d interf rence maintenir les c bles de souda ge aussi courts que possible les grouper et les poser aussi bas que pos sible ex par terre Veiller souder une distance de 100 m tres de tout quipement lec tronique sensible Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi e En cas diinterf rences apr s avoir pris les mesures pr c dentes il in 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 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de la Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 R gles de s curit en soudage coupage et proc d s connexes norme CSA W117 2 de l Association canadienne de normalisation vente de normes 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protec t
22. there is no overflow tank follow the next two statements e Wear safety glasses and gloves and put a rag over radiator cap e Turn cap slightly and let pressure escape slowly before completely removing cap d MOVING PARTS can cause injury Keep away from fans belts and rotors Keep doors panels covers and guards closed and securely in place Stop engine before installing or connecting unit Have only qualified people remove guards or covers for maint enance and troubleshooting as necessary e To prevent accidental starting during servicing disconnect negative battery cable from battery e Keep hands hair loose clothing and tools away from moving parts e Reinstall panels or guards and close doors when servicing is finished and before starting engine Before working on generator remove spark plugs or injectors to keep engine from kicking back or starting Block flywheel so that it will not turn while working on generator components BATTERY EXPLOSION can BLIND e Always wear a face shield rubber gloves and protective clothing when working on a battery e Stop engine before disconnecting or connect ing battery cables or servicing battery Do not allow tools to cause sparks when working on a battery Do not use welder to charge batteries or jump start vehicles Observe correct polarity and on batteries Disconnect negative cable first and connect it last
23. 1 SOON eil oa EV md 173320 GUARD blower 1 ECHTE 010671 SPRING extension 312 OD x 042 wire x 1 875 pl 1 ero tout 173903 ENGINE Deutz 1 Luton 127 648 CLEVIS throttle 1 ake 127994 BALE JOINT 250 28 idan val Ped 1 sas Dreams ss 175936 ROD throttle 1 EDD eese ceci 6126388 NUT 250 28 EH iaa aa ate ea Yee ek XX HE X RR 1 194 036 BRACKET arm throttle 1 Los duda La 010021 CLAMP stl cush 562dia x 343mtg hole 1 Rue lores auia 072 082 BUSHING stl 265 ID 499 OD 59310 2 Lose bebe NEA ds 118679 SCREW 6 1 0 30 2 us Dita 125 663 BALL JOINT 250 28 1 1 Wiis are 175937 BRACKET support solenoid 1 59 TS1 124974 SOLENOID 12VDC 0 1 POOR 188 246 BRACKET mtg engine RH 1 iux Ol seht 071890 RETAINER mount eng gen 1 vv 02 at Tus 071 73
24. 17 4 1 Installing Welding Generator 17 4 2 Activating The Dry Charge 18 4 3 Gonnecting The Battery esteret Tenes eese Lotte me teen anes eed 19 4 4 Engine Prestart Checks 24 D x oem oux RR RR REESE ERREUR AME 19 4 5 Installing Muffler Pipe 0 20 4 6 Connecting To Weld Output Terminals 20 4 7 Selecting Weld Cable Sizes 21 SECTION 5 OPERATING THE WELDING GENERATOR 22 5 1 FrontPanel Controls cere kl iT eee beds 22 522 Manual Shutoff Levers a sus aie a ed 23 5 3 Remote A V Control iu sense dh erem op ae oy heed oan 23 SECTION 6 OPERATING AUXILIARY EQUIPMENT 24 6 1 120 Volt And 240 Volt Duplex Receptacles 24 6 2 Optional Auxiliary Power Receptacles 24 6 3 Connecting Optional Auxiliary Power Plant 25 SECTION 7 MAINTENANCE amp TROUBLESHOOTING 26 7 1 Routine Maintenance 26 7 9 Mai
25. 656 STRIP MGreSiStOr doe ner dada bad Aveneda dak 1 a NOD aan ee 145 282 FITTING hose brs barbed elbow M 5 16TBG x 4 2 op WOO ss 175432 VALVE shutoff fuel 1 097 829 BOLT J stl 250 20 x 2 750 4 een 175465 FITTING pipe brs adapter extender 1 8 x 1 8 120 1 nre 116045 CONNECTOR amp SOCKETS 1 m 165669 CONNECTOR amp SOCKETS 1 Sinis aceite aces tende deus 168071 CONNECTOR amp SOCKETS 1 When ordering a component originally displaying a precautionary label the label should also be ordered Recommended Spare Parts OPTIONAL To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor Hardware is common and not available unless listed ST 110 922 E Figure 11 2 Generator OM 173 413 Page 50 Item Dia Par No Description Quantity Figure 11 2 Generator Figure 11 1 24 c 106 426 s INSULATORS suis Ihr eden a PR inate ees 4 E aU ERRS pid 106 440 BUS BAR rectifier 2 9 SR3 106 427
26. 7 5 Adjusting Engine Speed Ch After tuning engine check engine ET no load speed with a tachometer see table for no load speeds If necessary adjust speed as follows Start engine and run until warm Turn Amperage Voltage Control to 100 Standard Models 1 Engine Speed Adjustment Screw 2 Locking Nut Loosen nut Turn screw until engine 1850 rpm runs at 1850 rpm Tighten nut Models With Automatic Idle 1250 rom Optional 3 Throttle Rod 4 Locknut Loosen locknuts Place engine control switch in Run ldle position De Turn throttle rod until engine runs at idle speed Tighten locknuts 5 Engine Speed Adjustment Screw 6 Locknut Place engine control switch in Run position Loosen locknut Turn screw until engine runs at weld power speed Model Standard Models Tighten locknut Stop engine Models With Automatic Idle Optional Tools Needed m TT 38 7 16 in Ref ST 801 344 A OM 173 413 Page 31 7 6 Overload Protection Stop engine ar t3 When a fuse opens it usually in dicates a more serious prob lem exists Contact a Factory Authorized Service Agent 1 Magnetic Shutdown Switch MS1 2 Fuse F See Parts List For Rating Fuse F protects magnetic shut down switch MS1 3 Throttle Solenoid Fuse F4 F4 protects the throttle solenoid from overload on model
27. ARC peuvent pro voquer des br lures dans les yeux et sur la peau Le rayonnement de l arc du proc d de soudage g n re des rayons visibles et invisibles intenses ultraviolets et infrarouges susceptibles de provoquer des br lures dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage Porter un casque de soudage muni d un cran de filtre appropri pour t ger votre visage et vos yeux pendant le soudage ou pour regarder voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit e Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev e Utiliser des crans ou des barri res pour prot ger des tiers de l clair et de l blouissement demander aux autres personnes de ne pas regarder l arc e Porter des v tements de protection constitu dans une mati re durable r sistant au feu laine ou cuir et une protection des pieds 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 e ventiler la zone et ou utiliser un chappement au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Sila ventilation est insuffisante utiliser un respirateur alimentation d air homologu e Lire les sp cifications de s curit des mat riaux MSDSs et les
28. Check and tighten connections both inside and outside unit Have Factory Authorized Service Agent check brushes and slip rings and field excitation circuit Low or high weld output Adjust engine speed see Section 7 5 Have Factory Authorized Service Agent check field current regulator board PC1 Low open circuit voltage Check engine speed and adjust if necessary see Section 7 5 Have Factory Authorized Service Agent check integrated rectifier SR2 Amperage Voltage control R1 and resistor R2 Maximum weld output only in each ampere range Have Factory Authorized Service Agent check Amperage Voltage control R1 capacitor C8 diode D8 integrated rectifier SR4 and control relay CR2 B Auxiliary Power Trouble Remedy No output at receptacles auxiliary power Reset circuit breaker CB1 and or CB2 see Section 6 1 or 6 2 Disconnect equipment from ac receptacles RC1 and RC2 during start up Have Factory Authorized Service Agent check brushes and slip rings and field excitation circuit Low or high output at auxiliary power receptacles Adjust engine speed see Section 7 5 OM 173 413 Page 33 C Engine Trouble Remedy Engine does not start Check fuel level Open fuel valve see Section 4 4 Check optional shutdown switch fuse F and replace if open see Section 7 6 Check battery and replace if necessary Ch
29. D Item 4 is not necessary if circuit protection is already present in welding generator auxiliary 240 V 120 240 Volt Y 60 Hz Three Wire Service 120 2 F 2 240 V i YO 120 V Load lt 1 i 120 V SY D QO 7 CB RAT or ME 6 240 V 120 240 Volt 120 V Single Phase Three Wire 120 V Generator Output Connection Ground power output circuit S 0405 A OM 173 413 Page 44 10 11 Selecting Extension Cord Use Shortest Cord Possible Lengths for 120 Volt Loads If unit does not have GFCI receptacles use GFCI protected extension cord Maximum Allowable Cord Length in ft m for Conductor Size AWG Load Watts 4 6 8 10 12 14 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 have GFCI receptacles use GFCI protected extension cord
30. However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures OM 173 413 Page 4 ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots Be sure all equipment in the welding area 15 electromagnetically compatible To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor Locate welding operation 100 meters from any sensitive elec tronic equipment Be sure this welding machine is installed and grounded according to this manual e f interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protection
31. MOTORS 1 3 HP 1720 720 Std e g Conveyors 1 2 HP 2575 975 Feed Augers Air 3 4 HP 4500 1400 Compressors 1HP 6100 1600 1 1 2 HP 8200 2200 2 HP 10550 2850 3 HP 15900 3900 5 HP 23300 6800 High Torque e g Barn 1 1 2 HP 8100 2000 Cleaners Silo Unloaders 5 HP 23300 6000 Silo Hoists Bunk Feeders 7 1 2 HP 35000 8000 10 HP 46700 10700 3 1 2 cu ft Mixer 1 2 HP 3300 1000 High 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 173 413 Page 41 10 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 4500 1500 10 in 6300 1800 Band Saw 14 in 2500 1100 Bench Grinder 6in 1720 720 8in 3900 1400 10 in 5200 1600 Air Compressor 1 2 HP 3000 1000 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 18 400 400 Flood Lights HID 125 100 Metal Halide 313 250 Mercury 1000 Sodium 1400 Vapor 1250 1000 Submersible Pump 400 gph 600 200 Ce
32. Prong Plug From Case Grounded Equipment 3 2 Prong Plug From Double Insulated Equipment Be sure equipment has this symbol and or wording aux pwr 2 99 Ref ST 159 730 ST 800 577 10 2 Grounding Generator To Truck Or Trailer Frame 1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grounding Terminal 4 Grounding Cable Use 10 AWG or larger insulated copper wire If unit does not have GFCI re ceptacles use GFCl pro tected extension cord GND PE ENTM Electrically bond generator H 2 frame to vehicle frame by metal to metalcontact OR S 0854 OM 173 413 Page 39 10 3 Grounding When Supplying Building Systems 1 Equipment Grounding Terminal 1 2 2 Grounding Cable GND PE 3 Use 10 AWG or larger insulated copper wire 3 Ground Device Ground generator to system earth ground if supplying power to a premises home shop farm wiring system Use ground device as stated in electrical codes ST 800 576 B 10 4 How Much Power Does Equipment Require 3 1 Resistive Load ee us A light bulb is a resistive load and 1 Hz 60 requires a constant amount of pow er 2 Non Resistive Load Equipmentwith a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when run ning see Section 10 8 3 Rating Data Rating shows volts an
33. REMOTE CONTROL FACILITIES i 240V iL ACCESSORY QU 9j Ds By Ap 1 UNITED SB ei 3 PLG8 1 8 m 8 E CB1 CB3 2 CB4 RC1 RC2 AA 110v 702 16 MR HE 97 H 2 2 42 727 mh A rh PE G L G L PE L aj f at 5 GFCI OPTION Do Co Bo o EN TE1 EL 11 4 48 8 Cy CB2 GFCI1 120V 240v nm yTy zol 42 yH Ho 5 3 102 22 BRITISH E sour N d S is 1 AFRICAN RCI Na rh OPTION 240V L 2 51 5 8 g ki 47 GR W 2 id S1 PLG1 z WHEN MS OPTION IS USED 1 x x x 57 49 ON HM THAT COMES SA PLG8 4 4 FROM PL2 amp INSTALL ON LOOSE LEAD 49 2 X 2 LS s IN HARNESS INSTALL LOOSE LEAD 44 IN 3 p5 HARNESS TO X CLOSED TO B Y TERMINAL r 1 ANPLG7 2 LI B S me A t Ire e zu ol 8_ PLG5 2 V PLG5 6 V 58 x 6 2 UN 115 69 UNITED CB KINGDOM 77 40 L OPTION CA2x 6 1271 s B do 76 p d 240V PE L VPLc7 12 VOLT L STARTER 1 12 VOLT BATTERY AUTOMATIC 42 47 IDLE CONTROL OPTIONAL TT SERIES WITH LINE 19 AZ SC 190 651 A A D 5 43 45 107 SHUNT IS CONNE
34. Ss REIS 172684 NUT 312 18 x 50 hex 2 Lus MB iota iss 172071 CLAMP hose 520 605clp dia 3 M 010 323 CLAMP hose 250 625clp 1 LOG Pink ga nap da 084 210 HOSE SAE 312 ID x 560 OD x 19 000 2 BONES Jean ses 192 744 FILTER fuel spin on 1 81 CR98 CR99 090 104 RELAY 12VDC SPST 2 82 Idle mod 142724 MODULE pull to idle 5 pin 1 e Bol spera 4176 775 BRACKET mtg comp panel auto idle 1 84 F4 073429 FUSE mintr gl slo blo 15A 32V 1 esq 046 432 HOLDER fuse mintr 250 x 1 250 panel mtg 1 nr c ac 178 507 INSULATION terminal strip 1 026 947 STAND OFF insul 250 20 x 1 000 lg 1 Bf as vus TT seus 038621 BLOCK term 30A 4P een 1 038 620 LINK jumper term blk 2 OM 173 413 Page 49 No Mkgs No Description Quantity Figure 11 1 Main Assembly Continued c 081 499 BRACKET mtg strip terminal
35. and weld outputs are live at the same time Disconnect or insulate unused cables Lx Have qualified person install according to circuit diagram and Auxiliary Power Guidelines Section 10 Remove junction box cover 1 Lead 93 2 Lead 92 3 Lead 91 4 Lead 90 Neutral 5 Lead 42 Circuit Grounding Lead Lead 42 connects to front panel Ground stud 6 Grounding Terminal 7 Jumper Lead 42 8 Isolated Neutral Terminal Jumper 42 is connected to lead 90 at factory Jumper 42 may be dis connected from neutral to meet applicable electrical codes 9 User Supplied Leads 10 Load Terminals Connect leads to terminals 11 Fuses F1 F2 And F3 F1 F2 and F3 protect each load line from overload Set Engine Control switch to Run when using auxiliary power Tools Needed ES em Ref 5 188 059 173 413 25 SECTION 7 MAINTENANCE amp TROUBLESHOOTING NOTE 7 gt Follow the storage procedure in the engine owner s manual if the unit will not be used for an extended period 7 1 Routine Maintenance EU CL w Stop engine before maintaining Recycle See also Engine Manual and Maintenance Label Ser engine fluids vice engine more often if used in severe conditions To be done by Factory Authorized Service Agent 8h
36. are shown in the adjoining symbols EF 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 Standards listed in Section 1 5 Read and follow all Safety Standards Only qualified persons should install operate maintain and repair this unit During operation keep everybody especially children away FA ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard Do not touch live electrical parts e Wear dry hole free insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground Do use AC output in damp areas if movement is confined or if there
37. d connecter l quipement avant de d marrer ou d arr ter le moteur Ne pas laisser tourner le moteur trop lentement sous risque d endommager le moteur lectrique cause d une tension et d une fr quence trop faibles Ne pas brancher de moteur de 50 ou de 60 Hz la prise de 100 Hz s il ya lieu L EMPLOI EXCESSIF peut SURCHAUFFER L QUIPEMENT marche nominal e R duire le courant ou le facteur de marche avant de poursuivre le soudage Ne pas obstruer les passages d air du poste iU Iss T Laisser l quipement refroidir respecter le facteur de LES CHARGES ELECTROSTATIQUES 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 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 comme indiqu dans le manuel s y rapportant LIRE LES INSTRUCTIONS e Utiliser seulement les pi ces de rechange d origine Effecteur la maintenance et la mise en service d apr s le manuel et celui du moteur OM 173 413 Page 7 LE RAYONNEMENT HAUTE FR QUENCE risque de provoquer des interf rences Le rayonnement haute fr quence p
38. 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 Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud Ne pas souder dans un endroit l ou des tincelles peuvent tomber sur des substances inflammables e D placer toutes les substances inflammables une distance de 10 7 m l arc de soudage En cas d impossibilit les recouvrir soigneusement avec des protections homologu s e Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures Surveiller tout d clenchement d incendie et tenir un extincteur proximit Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t e Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r ser voirs tambours ou conduites moins qu ils n aient t pr par s correctement conform ment AWS 4 1 voir les normes de s curit e Brancher le c ble sur la pi ce le plus pr s possible de la zone de soudage pour viter le transport du courant sur une longue dist
39. is shut down Clean battery terminals and posts with baking soda and water solution rinse with clear water Periodically recharge battery approximately every three months Replace battery Engine uses oil during run in period wetstacking occurs Dry engine see Section 9 See engine manual OM 173 413 Page 34 SECTION 8 ELECTRICAL DIAGRAM REV FIELD o Lo amp WARNING e Do not touch live electrical parts Disconnect input power or stop engine before servicing Do not operate with covers removed ELECTRIC Have only qualified persons install SHOCK HAZARD use or service this unit a um A D C B P 2 m RC3 703 AUSTRALIAN 212 1 OPTION cB1 STD Y PLG8 9 GEN 42 s Y gt RMT 42 707 rh GR zi H CRT 7 AK si gt 12 si l N E A REMOTE CONTROL nc PLG8 7 RCI
40. 0 TUBING stl 875 OD 12ga wall x 2 500 4 uM 072848 TUBING nprn 875 ID x 2 500 OD x 2 000 4 oue sete E 173929 BRACKET mtg solenoid 1 222 B Vis 176 528 FITTING hose brs barbed elb fem 1 2tbg x 1 2NPT 1 ep OO m 113 854 HOSE SAE 500 ID x 780 OD order by ft 2ft ry 023 562 CLAMP hose 312 875clp dia 2 s gt cereos 165271 VALVE oil drain 3 8 18NPTF 1 exe ates py ibe ie 176 529 FITTING hose brs barbed fem 1 2tbg x 3 8NPT 1 cuc is fus de en e 173336 FITTING adapter oil drain 1 rap 175076 GUARD stator 1 hs 188 561 BASE filter fuel includes items 73 thru 77 1 145282 FITTING hose brs barbed elb 5 16tbg x 1 4NPT 2 PA n 080389 SCREW 312 18 x 1 000 cap hexhd 2 179661 BASE filter w adapter and vent 1 sns D vos omi dett sets 175431 BRACKET mtg separator fuel 1 m 603 107 HOSE nprn slit bk 156 ID x 343 OD order by ft 1ft eec d asse
41. 35 W Spencer Street Appleton WI 54914 USA Declares that the product B u ee 401 conforms to the following Directives and Standards Directives Low Voltage Directive 73 23 EEC Machinery Directives 89 392 EEC 91 368 EEC 93 C 133 04 93 68 EEC Noise Emission Directive 79 113 EEC Noise level of Welding Generators 84 535 EEC Electromagnetic compatibility Directives 89 336 EEC 92 31 EEC Standards Safety Requirements for Arc Welding Equipment Part 1 EN 60974 1 1990 Safety Requirements for Arc Welding Equipment IEC 60974 1 11 21 97 Final Draft Rotating Electrical Machines Part 1 Rating and Performance IEC 34 1 1994 Rotating Electrical Machines Part 5 Classification of degrees of protection provided by enclosure of rotating electrical machines IP code IEC 34 5 1991 Insulation coordination for equipment within low voltage systems Part 1 Principles requirements and test IEC 664 1 1992 Electromagnetic compatibility EMC Product standard for arc welding equipment EN50199 August 1995 European Contact Mr Luigi Vacchini Managing Director MILLER Europe S P A Via Privata Iseo 6 E 20098 San Giuliano Milanese Italy Telephone 39 02 98290 1 Fax 39 02 98290203 dec_con1 5 98 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 Symbol Usage Marks a special safety message Means Warning Watch Out There are possible hazards With this procedure The possible hazards
42. ASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes e f inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator e Read the Material Safety Data Sheets MSDSs and the manufacturers instructions for metals consumables coatings cleaners and degreasers Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe e Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases e Do not weld on coated metals such as galvanized lead cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and if necessary while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded OM 173 413 Page 1 AWE WELDING can cause fire or explo T2 sion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc Th
43. CTED IN H 4 le en IDLE_ CONTROL LECTRODE r POSITIVE WORK WELD METERS OPTIONAL POLARITY SWITCH OPTIONAL WITH THE_POLARITY SWITCH OPTION LEADS 19 amp 30 GO TO THE POLARITY SWITCH RATHER THAN THE OUTPUT STUDS THE OUTPUT STUDS ARE LABELED ELECTRODE AND WORK OM 173 413 Page 35 For Welding Generator it Diagram Ircul Figure 8 1 C SECTION 9 RUN IN PROCEDURE run_in1 6 96 9 1 Wetstacking 1 Welding Generator Run diesel engines near rated out put during run in period to properly Seat piston rings and prevent wets tacking See nameplate or rating label to find rated output Do not idle engine longer than necessary Piston rings seat faster if engine runs at weld power rpm and the welding generator is kept loaded during run in 2 Engine Exhaust Pipe Wetstacking is unburned fuel and oil in the exhaust pipe and occurs during run in if the engine is run too long at light load or idle rpm If exhaust pipe is coated with a wet black tar like substance dry the engine using one of the following run in procedures See the engine manual for addition al engine run in information OM 173 413 Page 36 9 2 Run In Procedure Using Load Bank SN CL
44. OM 173 413M August 2000 Ex Miller Stick SMAW Welding The Power of Blue Air Carbon Arc CAC A and Gouging With Optional Equipment Flux Cored FCAW With Voltage Sensing Wire Feeder Description Da g Engine Driven Welding Generator Big Blue 401DXQ C Viitcurwebsto t OWNER S MANUAL www MillerWelds com From Miller to You Thank you and congratulations on choosing Miller Now you can get the job done and get it done right We know you don t have time to do it any other way That s why when Niels Miller first started building arc welders in 1929 he made sure his products offered long lasting value and superior quality Like you his customers couldn t afford anything less Miller products had to be more than the best they could be They had to be the best you could buy Today the people that build and sell Miller products continue the T RU E BI E tradition They re just as committed to providing equipment and service oR WARRANTY 9 that meets the high standards of quality and value established in 1929 Working as hard as you do This Owner s Manual is designed to help you get the most out of your every power source from Miller is backed by the most Miller products Please take time to read the Safety precautions They will hassle free warranty in the help you protect yourself against potential ha
45. THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the 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 7 00 Ow
46. ain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 173 413 Page 53 ltem Par Description Quantity 114 193 Figure 11 4 Switch Range Figure 11 3 1 ade 114 235 BRACKET mtg switch consisting of 1 010 671 SPRING ext x 312 OD x 042 wire x 1 875pld 1 ANCIEN 017428 LOCATOR quadrant 1 oe S a teri ete 004 998 CONTACT BOARD ASSEMBLY switch range consisting of 1 noc nC LU cats mH 011 980 CONTACT BOARD movable switc 2 sun Buses eR 011 645 CONTACT ASSEMBLY movable consisting of 3 UC nee 011075 SPRING Dressule v c senos enr DER A hale RIAM 1 BeBe Do D de 011953 CON TAG Tc ed at tra under t ope ach tube eee 2 dui Meade 011 074 SPRING pressure 1 sns WO aecenas ec 011 644 CONTACT stationary 15 ee 004 999 CONTACT BOARD stationary 2 Map EC 011 012 SHIM guide contact board 3 D LS s e aes 100623 GUIDE contact boar
47. ance par des che mins inconnus ventuels en provoquant des risques d lectrocution et d incendie Ne pas utiliser le poste de soudage pour d geler des conduites gel es e En cas de non utilisation enlever la baguette d lectrode du porte lectro de ou couper le fil la pointe de contact e Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans revers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes DES PARTICULES VOLANTES f peuvent blesser les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques vo lantes Pendant la p riode de refroidissement des soudures elles ris quent de projeter du laitier Porter des lunettes de s curit avec crans lat raux ou un cran facial 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 Veiller toujours bien a rer les espaces confin s ou se servir d un respi rateur d adduction d air homologu DES PIECES CHAUDES peuvent provoquer des br lures graves e Pr voir une p riode de refroidissement avant d effec tuer des travaux d entretien e Porter des gants
48. appareil sur au dessus ou proximit de surfaces inflammables e Tenir distance les produits inflammables de l chappement LES TINCELLES L CHAPPEMENT peuvent provoquer un incendie e Emp cher les tincelles d chappement du moteur de provoquer un incendie e Utiliser uniquement un pare tincelles approuv voir codes en vigueur 1 4 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage uniquement pour soulever l appareil lui m me sans chariot de bouteilles de gaz remorque ou autres accessoires e Utiliser un quipement de levage de capacit sante pour lever l appareil En utilisant des fourches de levage pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil N gt LES ETINCELLES VOLANTES 5 quent de provoquer des blessures Porter un cran facial pour prot ger le visage et les yeux Affuterr l lectrode au tungst ne uniquement la meuleuse dot e de tecteurs Cette manoeuvre est ex cuter dans un endroit s r lorsque l on porte l quipement homologu de protection du visage des mains et du corps Les tincelles risquent de causer un incendie loigner toute substance inflammable LE SURCHAUFFEMENT peut endom mager le moteur lectrique Arr ter ou
49. ation 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 5 Principal Safety Standards Safety in Welding and Cutting ANSI Standard 249 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safety and Health Standards OSHA 29 CFR 1910 from Superinten dent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Batterymarch Park Quincy MA 02269 1 6 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
50. ck for faulty tools plugged in re ceptacle Press button to reset EF At least once a month run engine at weld power speed and press test but ton to verify GFCI is working properly 2 240 V 13A AC British Receptacle RC1 3 240 V 16 A AC South African Recep tacle RC1 Ref ST 188 449 Ref ST 169 671 A 4 240 V 10A AC Australian Receptacle RC1 5 Circuit Breaker CB1 Receptacle supplies 60 Hz single phase power at weld power speed Maximum out put is KVA KW CB1 protects the receptacle from overload If CB1 opens the receptacle does not work 120 volts may still be present at the 240 V receptacle Combined output of all receptacles is 3 kW OM 173 413 Page 24 6 3 Connecting Optional Auxiliary Power Plant SN i we 11 1 12 S er J N dT 2 F2 EN 3 Er 4 N 5 8 6 Single Three Output Phase Phase 93 1 3 Volts 120 240 240 91 Amps 31 24 KVA KW 7 5 10 80 Frequency 60 Hz Engine Speed 1850 RPM Max Fuse Size 35 Amperes 2s Lead 42 connects to GROUND stud on front of unit Jumper 42 is connected to 90 at factory Stop engine Power
51. d amperes or watts required to run equipment AMPERES x VOLTS WATTS EXAMPLE 1 If a drill uses 4 5 amperes at 115 volts calculate its running power requirementin watts 4 5Ax 115 V 520 W The load applied by the drill is 520 watts EXAMPLE 2 If three 200 watt flood lamps are used with the drill from Example 1 add the individual loads to calculate total load 200 W 200 W 200 W 520 W 1120 W The total load applied by the three flood lamps and drill is 1120 watts S 0623 OM 173 413 Page 40 10 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 10 6 Approximate Power Requirements For Farm Home Equipment Farm Home Equipment Rating Starting Watts Running Watts Stock Tank De lcer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 Milker Vacuum 2HP 10500 2800 FARM DUTY
52. d movable 3 Hardware is common and not available unless listed 5 6 BR Includes 8 9 Item 7 A X N SM ao d ST 011 273 vr ST 011 100 Figure 11 4 Switch Range To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 173 413 Page 54 Par Description Quantity OPTIONAL EQUIPMENT 043096 RECEPTACLE 120V GFCI 1 a ENGINE PROTECTION PACKAGE consisting of 1 042318 AUTOMATIC SHUTDOWN low oil pres 8 hi temp Figure 11 1 Figure 11 3 1 043088 AUTOMATIC IDLE Figure 11 1 Figure 11 3 1 041671 SERVICE INDICATOR KIT Figure 11 1 cee cee eee 1 OM 173 413 Page 55 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 Miller The Power of Blue Effective January 1 2000
53. d une source lectrique courant lectrique UNIQUEMENT si le proc d de soudage le demande e Sil utilisation d une source lectrique acourant lectrique s av re n ces saire se servir de la fonction de t l commande si l appareil en est quip Couper l alimentation ou arr ter le moteur avant de proc der l installation la r paration ou l entretien de l appareil D verrouiller l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de s curit e Installer et mettre la terre correctement cet appareil conform ment son manuel d utilisation et aux codes nationaux provinciaux et municipaux Toujours v rifier la terre du cordon d alimentation V rifier et s assurer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre e En effectuant les raccordements d entr e fixer d abord le conducteur de mise la terre appropri et contre v rifier les connexions e V rifier fr quemment le cordon d alimentation pour voir s il n est pas en dommag ou d nud remplacer le cordon imm diatement s il est endommag un 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
54. e gaz e Une lectrode de soudage ne doit jamais entrer en contact avec une bou teille Ne jamais souder une bouteille pressuris e risque d explosion Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat Ne pas tenir la t te en face de la sortie en ouvrant la soupape de la bouteille Maintenir le chapeau de protection sur la soupape sauf en cas d utilisation ou de branchement de la bouteille e Lire et suivre les instructions concernant les bouteilles de gaz comprim les quipements associ s et les publication P 1 CGA num r es dans les normes de s curit 1 3 Dangers existant en relation avec le moteur LE CARBURANT MOTEUR peut pro voquer un incendie ou explo sion Arr ter le moteur avant de v rifier le niveau de carbu rant ou de faire le plein Ne pas faire le plein en fumant ou proche d une sour ce d tincelles ou d une flamme nue Ne pas faire le plein de carburant ras bord pr voir de l espace pour son expansion e Faire attention de ne pas renverser de carburant Nettoyer tout carbu rant renvers avant de faire d marrer le moteur e Jeter les chiffons dans un r cipient ignifuge OM 173 413 Page 6 LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT CHAUD peuvent provoquer des br lures e est pr f rable de
55. e Nega tive DCEN reverse cable connections For FCAW welding connect work cable to terminal and wire feeder cable to terminal Tools Needed 3 4 Ref ST 801 344 OM 173 413 Page 20 4 7 Selecting Weld Cable Sizes Total Cable Copper Length In Weld Circuit Not Exceeding wating momo ES BS aS Rs BS hea 60 cee Duty 10 100 Duty Cycle 100 4 4 4 3 2 1 1 0 1 0 150 3 3 2 1 1 0 2 0 3 0 3 0 200 3 2 1 1 0 2 0 3 0 4 0 4 0 250 2 1 1 0 2 0 3 0 4 0 2 2 0 2 2 0 300 1 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 3 0 350 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 3 0 2 4 0 400 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 4 0 2 4 0 500 2 0 3 0 4 0 2 2 0 2 3 0 2 4 0 3 3 0 3 3 0 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 Contact your dis tributor for the mm equivalent weld cable sizes 5 0007 173 413 21 SECTION 5 OPERATING THE WELDING GENERATOR 5 1 Front Panel Controls Ona 55 120 PY AN nen 50 40 0 26 5 20 90 10 100 A V RC1 RC2 230V 13A 115V 15A 1 60Hz 1 60Hz CBif N CB2 A zO SO This unit has
56. e flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding Protect yourself and others from flying sparks and hot metal Do not weld where flying sparks can strike flammable material e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas e Watch for fire and keep a fire extinguisher nearby e Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side e Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards e Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock and fire hazards e Do not use welder to thaw frozen pipes e Remove stick electrode from holder or cut off welding wire at contact tip when not in use e Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap e Remove any combustibles such as a butane lighter or matches from y
57. eck connections to Engine Control switch Check oil level Optional automatic shutdown system stops engine if oil pressure gets too low or oil tem perature gets too high See engine manual Have Factory Authorized Service Agent check engine charging system Engine suddenly stops Check optional magnetic shutdown switch fuse F and replace if open see Section 7 6 Check oil level Optional automatic shutdown system stops engine if oil pressure gets too low or oil tem perature gets too high Engine slowly stopped unable to restart engine Check fuel level Open fuel valve see Section 4 4 Engine does not stop when Engine Con trol switch is placed in Off position Use manual shutoff lever to stop engine see Section 5 2 Check connections to Engine Control switch Have Factory Authorized Service Agent check engine fuel solenoid Engine remains at idle speed when En gine Control switch is placed in Run ldle position and an arc is struck Models with automatic idle option only Have Factory Authorized Service Agent check Engine Control switch and idle module Engine will not run at idle speed Models with automatic idle option only Check throttle solenoid fuse F4 and replace if open see Section 7 6 Have Factory Authorized Service Agent check Engine Control switch and idle module Battery discharges between uses Make sure Engine Control switch is in Off position when unit
58. et des v tements de protection pour travailler sur un moteur chaud e Ne pas toucher mains nues les parties chaudes du moteur ni les pi ces r cemment soud es LE BRUIT peut affecter l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques Porteurs de stimulateur cardiaque restez distance Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de gougeage ou de soudage par points Si des BOUTEILLES sont endomma g es elles pourront exploser Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endommag e elle peut exploser Du fait que les bouteilles de gaz font normale ment partie du proc d de soudage les manipuler avec pr caution e Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques du laitier des flammes ouvertes des tincelles et des arcs Placerles bouteilles debout en les fixant dans un support stationnaire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e Tenir les bouteilles loign es des circuits de soudage ou autres circuits lectriques jamais placer une torche de soudage sur une bouteill
59. eut provoquer des interf rences avec les quipements de radio navigation et de communication les services de s curit et les ordinateurs 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 Effectuer r guli rement le contr le et l entretien de l installation e Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distance correcte et utiliser une terre et et un blindage pour r duire les interf rences ventuelles 1 5 Principales normes de s curit Safety in Welding and Cutting norme ANSI Z49 1 de l American Weld ing Society 550 N W Lejeune Rd Miami FL 33126 Safety and Health Sandards OSHA 29 CFR 1910 du Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practice for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances norme AWS F4 1 de l American Welding Society 550 N W Lejeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 de la National Fire Protec tion Association Batterymarch Park Quincy MA 02269 LE SOUDAGE L ARC risque de
60. ge 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 i OVERUSE can cause OVERHEAT ING z a7 Nc 2 Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again Do not block or filter airflow to unit STATIC ESD can damage PC boards J e Puton grounded wrist strap BEFORE handling ASS boards or parts Ro e Use proper static proof bags and boxes to store move or ship PC boards N TILTING OF TRAILER can cause injury Use tongue jack or blocks to support weight e Properly install welding generator onto trailer according to instructions supplied with trailer dus READ INSTRUCTIONS Use only genuine MILLER replacement parts e Perform engine maintenance and service according to this manual and the engine manual OM 173 413 Page 3 H F RADIATION can cause interference High frequency H F interfere with radio navigation safety services computers and communications equipment Have only qualified persons familiar with electronic equipment perform this installation e The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e f notified by the FCC about interference stop using the equipmentat once Have the install
61. instruc tions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d graisseurs e Travailler dans un espace ferm seulement s il est bien ventil ou en por tant un respirateur alimentation d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent d placer l air et abaisser le niveau d oxyg ne provoquant des blessures ou des accidents mortels S assurer que l air de respiration ne pr sente aucun danger Ne pas souder dans des endroits situ s proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et former des gaz hautement toxiques et irritants pas souder des m taux munis d un rev tement tels que l acier galvani S plaqu en plomb ou au cadmium moins que le rev tement n ait t enlev dans la zone de soudure que l endroit soit bien ventil et si n ces saire en portant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage OM 173 413 Page 5 LE SOUDAGE peut provoquer un in gee 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
62. ion norme ANSI Z87 1 de l American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme NFPA 51B de la National Fire Protection Association Batterymarch Park Quincy MA 02269 1 6 Information sur les champs lectromagn tiques Donn es sur le soudage lectrique et sur les effets pour l organisme des champs magn tiques basse fr quence Le courant de soudage pendant son passage dans les c bles de sou causera des champs lectromagn tiques y a eu et a encore un certain souci propos de tels champs Cependant apr s avoir ex amin 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 Re search Council a conclu L accumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lectriques haute fr quence repr sente un risque la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent tre examin es En attendant que les con clusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn ti ques pendant le soudage ou le coupage OM 173 413 Page 8 Afin de r duire les champs lectromagn tiques dans l environnement de travail respecter les consignes suivantes 1 Garder les c bles ensembles en les torsadant o
63. is a danger of falling Use AC output ONLY if required for the welding process f AC output is required use remote output control if present on unit 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 input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet e When making input connections attach proper grounding conduc tor first double check connections e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable Do nottouch electrode if you are in contact with the work ground or another electrode from a different machine Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual rom nd 11 98 pv This group of symbols means Warning Watch Out possible
64. label for specifications Fill fuel tank up to 1 2 in 13 mm from top to allow room for expansion Open fuel shut off valve Do not run out of fuel or air enters fuel system and causes starting problems See engine manual to bleed air from fuel system 3 Oil Change engine oil and filter af ter first 50 hours of operation After fueling check oil with unit on level surface If oil is not up to full mark on dipstick add oil see main tenance label To improve cold weather starting Keep battery in good condition Store battery in warm area off concrete surface Use fuel formulated for cold weather diesel fuel can gel in cold weather Contact local fuel supplier for fuel Valve Open formation Use correct grade oil for cold weather Ref ST 801 344 Ref S 176 697 OM 173 413 Page 19 4 5 Installing Muffler Pipe Stop engine and let cool Do not blow exhaust toward air cleaner or air intake o View Tools 3 ce 1 2in 57 801 376 4 6 Connecting To Weld Output Terminals pu oh 1 Positive Weld Output DN Terminal 2 Negative Weld Output Ter minal For Stick welding Direct Current Electrode Positive DCEP con nect work cable to terminal and electrode holder cable to terminal For Direct Current Electrod
65. leaner 1 OO 197 675 DUST EJECTOR air cleaner 1 010 863 CLAMP hose 1 125 3 000clp dia 3 OM 173 413 Page 48 Mkgs No Description Quantity Figure 11 1 Main Assembly Continued CEER IPC 124985 HOSE air 1 4D o RUE 023 313 CLAMP hose 1 312 3 250clp dia 2 ME ES 173303 BAFFLE air sides amp bottom 1 179 915 2 BAFFLE alt ee es ELLE 1 173 306 BOX air exha sl C an c cre c 1 m POMMES 175 0787 GUARD belt LH ts neal e Ela 1 176 106 LABEL warning moving parts 2 n TRUE 173319 BOX air intake engine 1 DURS QM EN TEE 067 274 DIFFUSOR ASSEMBLY 1 173302 HOSE CWC flexaust 2 500 ID x 6 000 lg 1 sires manana ceases us 605 409 CLAMP hose 1 875 3 750clp 1 ee 173 310 rea vies tite aian dater de ahead it 1 pep ilL LI 175 077 GUARD nar e nets
66. ner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip For Service Call 1 800 4 A Miller or see our website at www MillerWelds com to locate 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 sovice and Miller Electric Mfg Co Replacement Parts An Illinois Tool Works Company 1635 West Spencer Street Training Schools Videos Books Appleton WI 54914 USA ae International Headquarters USA Technical Manuals Servicing Information USA Phone 920 735 4505 Auto Attended and Parts USA amp Canada FAX 920 735 4134 International FAX 920 735 4125 Circuit Diag rams European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 Welding Process Handbooks www MillerWelds com Contact the Delivering Carrier for File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or equipment manufacturers Transportation Department Miller The Power of Blue PRINTED IN USA 2000 Miller Electric Mfg Co 6 00
67. not affected by weld output RC1 RC2 230V 13A 115V 15A 1 60Hz 1 60Hz 00 1 240V 15 A AC Receptacle RC1 2 120V 15A AC Receptacle RC2 Receptacles supply 60 Hz single phase power at weld power speed 3 Circuit Breakers CB1 And CB2 CB1 protects RC1 and CB2 protects RC2 from overload If CB1 or CB2 opens the re Ref ST 188 449 ceptacle does not work 120 volts may still be present at RC2 Maximum output from each duplex recep tacle is 1 8 kVA kW and 3 kVA kW from all receptacles EXAMPLE If 10 A is drawn from RC1 only 5A is available at RC2 240 V x 10 A 120 V x 5 A 3 0 KVA KW 6 2 Optional Auxiliary Power Receptacles 1 RC2 115V 15 1 60Hz RC1 230V 13A 1 60Hz CBA CB zO 0 If unit does not have recep tacles use GFCl protected exten sion cord If circuit breaker continues to open contact Factory Authorized Service Agent gt Auxiliary power is not affected by weld output GFCI Receptacle Option 1 120 V 15A AC Receptacle GFCI1 Auxiliary power output and circuit breaker MOV protection is the as standard tacles see Section 6 1 If a ground fault is detected GFCI Reset button pops out and receptacle does not work Che
68. ntenance Label ceo rede gain conden e 28 7 8 Servicing Air Cleaner sae E EE 29 7 4 Oil And Fuel System Components 30 7 5 Adjusting Engine Speed 31 7 6 Overload Protection ues hut oe NP ONERE NE eee 32 7 7 Optional Spark Arrestor Inspection And Cleaning 32 7 8 Troubleshooting rr PRG 33 SECTION 8 ELECTRICAL DIAGRAM et 35 SECTION 9 RUN IN PROCEDURE uses 36 RE 36 9 2 Run In Procedure Using Load 37 9 3 Run In Procedure Using Resistance Grid 38 SECTION 10 AUXILIARY POWER GUIDELINES 39 SECTION PARTS LIST Rd 46 SECTION 11 PARTS LIST ke RR b ERRARE EAR Gene te aa genes 46 OPTIONS ACCESSORIES WARRANTY Declaration of Conformity for European Community CE Products NOTE IE This information is provided for units with CE certification see rating label unit Manufacturer s Name Miller Electric Mfg Co Manufacturer s Address 16
69. ntrifugal Pump 900 gph 900 500 Floor Polisher 3 4 HP 16 in 4500 1400 1 HP 20 6100 1600 High Pressure Washer 1 2 HP 3150 950 3 4 HP 4500 1400 1 HP 6100 1600 55 gal Drum Mixer 1 4 HP 1900 700 Wet amp Dry Vac 1 7 HP 900 900 2 1 2 HP 1300 1300 OM 173 413 Page 42 10 8 Power Required To Start Motor AG MOTOR 1 Motor Start Code 2 2 Running Amperage 1 VOLTS 230 AMPS 254177 XE 3 Motor HP 3 CODE M Hz 60 4 Motor Voltage up 1 4 PHASE 1 To find starting Step 1 Find code and use table to find If code is not listed multiply running amperage by six to find starting amperage Step 2 Find Motor HP and Volts Step 3 Determine starting amper age see example Welding generator amperage out put must be at least twice the Single Phase Induction Motor Starting Requirements motor s running amperage Motor Start Code G H J K L M N P KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0 kVA HP x HP x 1000 VOLTS EXAMPLE Calculate the starting amperage required for a 230 V 1 4 HP motor with a motor start code of M Volts 230 1 4 Using Table Code M results in KVA HP 11 2 STARTING AMPERAGE 11 2 x 1 4 x 1000 122 Staring th t ires 12 2 7 290 12 arting the motor requires 12 2 amperes 10 9 Much Generator Supply 1 Limit L
70. oad To 90 Of Generator Output Always start non resistive motor loads in order from largest to small est and add resistive loads last 2 5Second Rule If motor does not start within 5 seconds turn off power to prevent motor damage Motor requires more power than generator can supply Ref ST 800 396 A S 0625 OM 173 413 Page 43 10 10 Typical Connections To Supply Standby Power CL Customersupplied equipment is required if generator is to supply standby power during emergencies or power outages 1 Power Company Service Meter 2 Branch Overcurrent Protection 3 Double Pole Double Throw Transfer Switch Obtain and install correct switch Switch rating must be same as or greater than the branch overcurrent protection 4 Circuit Breakers or Fused Disconnect Switch Obtain and install correct switch 5 Extension Cord Select as shown in Section 10 11 6 Generator Connections Connect terminals or plug of ade quate amperage capacity to cord Follow all applicable codes and safety practices 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 7 Load Connections
71. ode 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 e Protect compressed gas cylinders from excessive heat mechani cal shocks slag open flames sparks and arcs e Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition e Turn face away from valve outlet when opening cylinder valve e Keep protective cap in place over valve except when cylinder is in use or connected for use e Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards STEAM AND HOT COOLANT can burn e f possible check coolant level when engine is cold to avoid scalding e Always check coolant level at overflow tank if present on unit instead of radiator unless told otherwise in maintenance section or engine manual e Ifthe engine is warm checking is needed and
72. of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq amp WARNING 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 CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm The following terms are used interchangeably throughout this manual Stick SMAW TIG GTAW TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 1 Symbol Usage sicud ten dates Aa 1 1 2 Arc Welding Hazards 1 128 Engine Hazards 28 a ne Sake Xen ee Km Cu Re aee 2 1 4 Additional Symbols For Installation Operation And Maintenance 3 1 5 Principal Safety Standards 4 1 6 EME Information sca c e RESI ne eee ex ke Xn eee Veal uie 4 SECTION 1 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 1 1 Signification des symboles 5 1 2 Dangers relatifs au soudage larc
73. ons in numbered sequence shown Once dead battery is charged disconnect cables in sequence shown 3 96 S 176 106 Warning Watch Out There are possible hazards as shown by the symbols Moving parts such as fans rotors and belts can cut fingers and hands and cause injury Keep away from moving parts 3 96 OM 173 413 Page 10 Tu Warning Watch Out There are possible hazards as shown by the symbols Hot muffler and exhaust pipes can cause severe burns Do not touch hot muffler or pipes 3 96 4 5 176 103 3 5 6 Warning Watch Out There are possible hazards as shown by the symbols Engine fuel plus flames or sparks can cause fire Do not smoke while fueling or if near fuel Stop engine before fueling Do not fuel a hot engine Use Diesel Fuel only 3 96 Warning Watch Out There are possible hazards as shown by the symbols Falling equipment can cause serious injury and damage Use lifting eye to lift or move unit only Use proper equipment when lifting Do not use lifting eye to lift and support unit and trailer or other heavy devices or accessories 3 96 OM 173 413 Page 11 S 177 571 1 2 pP b API CD MILL 2104D CD SE CD SF Remove unit from shipping crate Remove Owner s Manual from unit Follow ins
74. ormation contenue dans les normes de s cu rit num r es la section 1 5 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 particulierement les enfants pum UN CHOC LECTRIQUE peut tuer Un simple contact avec des pi ces lectriques peut provoquer une lectrocution ou des blessures graves L lectrode et le circuit de soudage sont sous tension d s que l appareil est sur ON Le circuit d entr e et les circuits internes de l appareil sont galement sous tension ce moment l En soudage semi automatique ou automatique le fil le d vidoir le logement des galets d entrainement et les pi ces m talliques en contact avec le fil de soudage sont sous tension Des mat riels mal install s ou mal mis la terre pr sentent un danger Ne jamais toucher les pi ces lectriques sous tension Porter des gants et des v tements de protection secs ne comportant pas de trous e Siisoler 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 humides dans les endroits confin s ou l ou on risque de tomber servir
75. our person before doing any welding FLYING METAL can injure eyes 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 a BUILDUP OF GAS can injure or kill Shut off shielding gas supply when not in use e Always ventilate confined spaces or use ap proved air supplied respirator 1 3 Engine Hazards 7 y FUEL can cause fire or explosion o Stop engine and let it cool off before checking or adding fuel Do not add fuel while smoking or if unit is near any sparks or open flames e Do not overfill tank allow room for fuel to expand Do not spill fuel If fuel is spilled clean up before starting engine e Dispose of rags in a fireproof container OM 173 413 Page 2 HOT PARTS can cause severe burns Allow cooling period before maintaining e Wear protective gloves and clothing when working on a hot engine e Do not touch hot engine parts or just welded parts bare handed NOISE damage hearing Noise from some processes or equipment can damage Wear approved ear protection if noise level 15 high MAGNETIC FIELDS can affect pacemak ers Pacemaker wearers keep away Wearers should consult their doctor before going near arc welding gouging or spot welding operations CYLINDERS can expl
76. rer le moteur Avant d intervenir d poser les bougies ou injecteurs pour viter la mise en route accidentelle du moteur Bloquer le volant moteur pour viter sa rotation lors d une intervention sur le g n rateur L EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE Toujours porter une protection faciale des gants en caoutchouc et v tements de protection lors d une in tervention sur la batterie Arr ter le moteur avant de d brancher ou de brancher les c bles de batterie Eviter de provoquer des tincelles avec les outils en travaillant sur la batterie Ne pas utiliser le poste de soudage pour charger les batteries ou des v hicules de d marrage rapide Observer la polarit correcte et sur les batteries D brancher le c ble n gatif en premier lieu Le rebrancher en dernier lieu L ACIDE DE LA BATTERIE peut pro voquer des br lures dans les YEUX et sur la PEAU Ne pas renverser la batterie e Remplacer une batterie endommag e e Rincer imm diatement les yeux et la peau l eau LES GAZ D CHAPPEMENT DU MOTEUR peuvent provoquer des accidents mortels e Utiliser l quipement l ext rieur dans des zones ou vertes et bien ventil es e cas d utilisation dans un endroit ferm vacuer les gaz d chappe ment du moteur vers l ext rieur distance des entr es d air dans les b ti ments LA CHALEUR DU MOTEUR peut pro voquer un incendie Ne pas placer l
77. round S While Welding umen 2 Current X Duty Cycle U Rated No Load U Conventional Rated Load 0 Voltage Average 2 Load Voltage n Speed Rated Idle Rated No Load h Speed Hours S Seconds 1 ING Single Phase Hz Hertz OM 173 413 Page 13 SECTION 3 SPECIFICATIONS 3 1 Weld Power And Engine Specifications Maximum Rated Welding Amperage Open Auxiliary Fuel Sound Output Range Circuit Power Rating Engine Capacity Power IP Rating Voltage DC Single Phase Deutz F3L 1011 400 A 30 V DC 96 Air Oil Cooled 11 3 US gal 100Lwa 23 E 40 400 26 13 A Three Cylinder 40 Duty Cycle Average 120 240 V AC 29 HP Diesel Geer 60 Hz Engine 3 2 Dimensions Weights And Operating Angles Dimensions Height 40 1 2 in 1029 mm Width 24 5 8 in 625 mm Depth 56 in 1422 mm N A 23 1 4 in 591 mm B 24 5 8 in 625 mm M C 11 16 in 17 mm D 2 7 8 in 73 mm E 4 1 2 in 114 mm F 22 9 16 in 573 mm G 27in 686 mm H 30 3 8 in 772 mm J 41 1 4 in 1048 mm K 51 1 8 in 1299 mm L 54 in 1372 mm M 21 32 in 16 7 mm Dia 4 Holes N 1 2 in 12 7 mm Dia 10 Holes Weight 1500 Ib 680 kg tt Wo Ref ST 110 850 F Do not exceed tilt angles or engine could be damaged or unit co
78. rs Inverters input and output rectifiers only 2 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Semi Automatic and Automatic Wire Feeders Inverter Power Supplies Intellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor DS 2Wire Feeder Motor Driven Guns w exception of Spoolmate 185 amp Spoolmate 250 Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Water Coolant Systems HFUnits Grids Maxstar 140 Spot Welders Load Banks Miller Cyclomatic Equipment 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 4 6 Months Batteries 5 90 Days Parts MIG Guns TIG Torches Induction Heating Coils and Blankets APT ZIPCUT PLAZCUT Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate 185 amp Spoolmate 250 Canvas Covers Millers True Blue amp Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relay
79. s or parts that fail due to normal wear 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Miller s option 1 repair or 2 replacement or where authorized in writing by Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Miller authorized service facility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW
80. s with auto matic idle option Check fuses and replace if open Tools Needed Ref ST 801 344 Ref ST 156 199 B ST 801 320 A 7 7 Optional Spark Arrestor Inspection And Cleaning Stop engine and let cool 1 Spark Arrestor 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole 3 Exhaust Pipe Start engine and run at idle speed to blow out cleanout hole If nothing blows out of hole briefly cover end of exhaust pipe with fireproof material Stop engine and let cool Reinstall cleanout plug Tools Needed 6 3 8in ST 800 523 Ref ST 188 449 OM 173 413 Page 32 7 8 Troubleshooting Ee 4 NU A Welding Trouble Remedy No weld output Check position of Ampere Range switch Place A V control switch in Panel position or place switch in Remote position and connect remote amper age control to Remote A V receptacle see Section 5 3 Check and secure connections to Remote A V receptacle Have Factory Authorized Service Agent check brushes and slip rings and field excitation circuit Disconnect equipment from ac receptacles RC1 and RC2 during start up Erratic weld output Use dry properly stored electrode Be sure connection to work piece is clean and tight Remove excessive coils from weld cables
81. so goes on if oil temperature is too high if unit has automatic shutdown option Stop engine and fix trouble if either light goes on 10 Engine Hour Meter 11 Oil Temperature Gauge Switch Optional 12 Oil Pressure Gauge Switch Optional OM 173 413 Page 22 5 2 Manual Shutoff Lever w 1 Manual Shutoff Lever Use lever to stop engine if en control switch does not work Ref ST 80 gine 1 344 5 3 Remote A V Control 5 A N Xo 1 AN Control Switch Use switch to select front pan remote amperage control el or 2 Remote A V Receptacle RC3 Connect optional remote control to RC3 120 240 90 190 4 Example Combination Remote Amperage Control 55 120 OO MIN 70 of f 7o 80 90 100 In Example Range 90 to 190 A Percentage Of Range 50 140 A DC 50 of 90 to 1 90 140 A DC Min 66 A DC AN Set Switch Set Range Set Percentage Adjust Optional Remote Control S 0774 173 413 P 23 SECTION 6 OPERATING AUXILIARY EQUIPMENT 6 1 120 Volt And 240 Volt Duplex Receptacles d If unit does not have GFCI recep tacles use GFCI protected exten sion cord If a circuit breaker continues to open contact Factory Authorized Service Agent Auxiliary power is
82. ss listed al 18 22 13 1 19 17 16 2 p AY P 15 1 2 ST 801 358 C Figure 11 3 Panel Front w Components OM 173 413 Page 52 Item Dia Par No Mkgs No Description Quantity Figure 11 3 Panel Front w Components Figure 11 1 Item 98 eds etis S3 114193 SWITCH range Figure 11 4 1 R1 605 960 RHEOSTAT WW 300W 34 ohm 1 8 51 011 072 SWITCH magnetic consisting of 1 mom DE F 048317 FUSE mintr gl 14A 32V 1 SNC E 011 609 SWITCH tgl SPDT 15A 125VAC 1 m dere gat tas Saya a he 032 897 RECEPTACLE twlk grd 2P3W 15 125V 1 ROT ns 604 103 RECEPTACLE str dx grd 2P3W 15 250V 1 025 234 PLUG str grd 2P3W 15 250V 1 CC 170 901 RECEPTACLE str dx grd 2P3W 15A 125V 1 M RSR CE 073 690 PLUG str grd 2P3W 15 125V Arrow Hart 5965V 1 8 CB1 2 139 266 CIRCUIT BREAKER man reset 1P 15A 250VAC 2 148 723 KNOB DONET Le E 1 PLATE ident control ra
83. t weld near flammables 3 2 Welding sparks can cause fires Have a fire extinguisher nearby and have a watchperson ready to use it 3 3 Do not weld on drums or any closed containers 4 Arc rays can burn eyes injure skin 4 1 Wear hat and safety glasses Use ear protection and button shirt collar Use welding helmet with correct shade of filter Wear complete body protection 5 not remove or paint over cover the label 6 Engine fuel plus flames Sparks can cause fire 6 1 Do not smoke while fueling or if near fuel 6 2 Stop engine before fueling 6 3 Do not fuel a hot engine 7 Engine exhaust gases can kill 7 1 Vent exhaust outside 7 2 Use unit outside 5 176 105 A 3 96 OM 173 413 Page 9 12 Qo O1 11 12 Warning Watch Out There are possible hazards as shown by the symbols Do not smoke and keep matches and flames away from battery Sparks can cause battery gases to explode Battery explosion can blind and injure Wear a face shield Battery acid can burn skin Do not spill acid Read Owner s Manual Wear rubber gloves Dead battery Engine block Fully charged battery Do not connect last negative cable to dead battery connect instead to engine block Jumper cables observe polarity and make connecti
84. ting order by model and serial number 1 xs sis es 021385 BOOT toggle switch lever 1 dieses 129 860 GAUGE pressure oil 15 20 1 chen cf 129 837 GAUGE SWITCH temp oil 250 deg 1 ds eae te Rae 128 829 oil line 44 000 1 8NPT x 10mm 1 a aca odora lia a are 128633 FITTING pipe brs adapter 1 8NPT x 12 MM 1 119014 LEVER switch black 1 xc db eese 082 788 HOLDER light ind 2 16 PL1 2 048 155 BULB incand flg base 12 2 Apis p AERE ERE 082 789 LENS light ind red 2 ey HM 145247 METER hour 4 40VDC 1 sated dO quad dt etis 019 754 HANDLE switch range 1 NAMEPLATE order by model and serial number 1 Ars 51 176 606 SWITCH ignition 4posn 1 VES 127 618 PANEL front upper 1 Me Oat TRE NA 189 404 SPACER nylon 0 1 OPTIONAL Recommended Spare Parts To maint
85. tructions to install muffler Read Owner s Manual Read labels on unit Use Diesel Fuel only and fill fuel tank Leave room for expansion Warning Watch Out There are possible hazards as shown by the symbols Read Owner s Manual Follow instructions to activate battery Check oil level Add oil if necessary During the first 50 hours of operation keep welding load above 200 amperes Do not weld below 200 amperes of output After the first 50 hours of operation change the oil and oil filter 3 96 x O 3E 325A 250A pum 50A 12V 400A 26V 1 60 Hz 120 240V 3kVA 13 13A S 176 255 A OM 173 413 Page 12 2 3 Symbols And Definitions Welding SMAW Welding GTAW Fast Slow Slow D Stop Engine gt Run Weld Power Run Idle ldle j Start Engine e Time Temperature Fuel dA Engine Oil Remote Panel Local 9v Check Injectors Check Valve Battery V Pump Clearance Engine Volts D A Amperes E Shielded Metal Arc b Arc Force DIG Gas Tungsten Arc Engine Driven Three Phase Al Read Operator s OE EC Alternator With Ja Engine EN Manual Circuit Rectifier Positive Negative A ee Protective Earth Do Not Switch t Rated Welding G
86. u en les attachant avec du ruban adh sif 2 Mettre tous les c bles du c t oppos de l op rateur 3 Ne pas courber pas et ne pas entourer pas les c bles autour de votre corps 4 Garder le poste de soudage et les c bles le plus loin possible de vous 5 Relier la pince de masse le plus pr s possible la zone de soudure Consignes relatives aux stimulateurs cardiaques Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur docteur Si vous tes d clar apte par votre docteur il est alors recommand de respecter les consignes ci dessus SECTION 2 DEFINITIONS 2 1 Warning Label Definitions Warning Watch Out There are possible hazards as shown by the symbols Become trained and read the instructions before working on the machine or welding 1 Electric shock from welding electrode or wiring can kill 1 1 Wear dry insulating gloves Do not touch electrode with bare hand Do not wear wet or damaged gloves 1 2 Protect yourself from electric shock by insulating yourself from work and ground 1 8 Do not work on unit if engine is running Stop engine first 2 Breathing welding fumes be hazardous to your health 2 1 Keep your head out of the fumes 2 2 Use forced ventilation or local exhaust to remove the fumes 2 3 Use ventilating fan to remove fumes 3 Welding sparks can cause explosion or fire 3 1 Keep flammables away from welding Do no
87. uld tip Do not move or operate unit where it could tip angles1 3 96 OM 173 413 Page 14 3 3 Cycle Overheating Exceeding duty cycle damage unit void EH iul 100 Cycle At 250 Amperes Duty Cycle is percentage of 10 min B utes that unit can weld at rated load 5 73 A5 without overheating warranty Continuous Welding 6096 Duty Cycle At 325 Amperes 6 Minutes Welding 4 Minutes Resting 1000 800 a 500 400 Q lt 30 3 250 mms 200 15 100 10 15 20 25 30 40 50 60 80 100 A DUTY CYCLE rduty1 5 95 SB 070 999 3 4 Volt Ampere Curves The volt ampere curves show the minimum and maximum voltage and amperage output capabilities of 100 the welding generator Curves of other settings fall between the RANGES ae curves shown 80 90 190 120 240 200 MAX 0 60 gt O 40 20 100 200 300 400 DUO G gt lt Un SB 183 882 OM 173 413 Page 15 3 5 AC Auxiliary Power The ac power curve shows the aux iliary power in amperes available at the 120 and 240 volt receptacles
88. v rifier le liquide de refroidissement une fois le moteur refroidi pour viter de se br ler Toujours v rifier le niveau de liquide de refroidissement dans le vase d expansion si pr sent et non dans le radiateur sauf si pr cis autre ment dans la section maintenance du manuel du moteur e Sile moteur est chaud et que le liquide doit tre v rifi op rer comme suivant e des lunettes de s curit et des gants placer un torchon sur le bouchon du radiateur e D visser le bouchon l g rement et laisser la vapeur s chapper avant d enlever le bouchon N DES ORGANES MOBILES peuvent provoquer des blessures Ne pas approcher les mains des ventilateurs cour roies et autres pi ces en mouvement e Maintenir ferm s et fixement en place les portes panneaux recouvrements et dispositifs de protection Arr ter le moteur avant d installer ou brancher l appareil Demander seulement un personnel qualifi d enlever les dispositifs de S curit ou les recouvrements pour effectuer s il y a lieu des travaux d entretien et de d pannage Pour emp cher tout d marrage accidentel pendant les travaux d entre tien d brancher le c ble n gatif de batterie de la borne Ne pas approcher les mains cheveux v tements l ches et outils des or ganes mobiles Remettre en place les panneaux ou les dipositifs de protection et fermer les portes la fin des travaux d entretien et avant de faire d mar
89. w Stop engine Do not touch hot exhaust engine parts or load bank grid Keep exhaust and pipe away from flammables 1 Load Bank Turn all load bank switches Off If needed connect load bank to 115 volts ac wall receptacle or genera tor auxiliary power receptacle gt gt 2 Welding Generator Place A V range switch in maxi mum position A V control in mini mum position and Output Selector switch if present in either DC position 3 Weld Cables Connect load bank to generator weld output terminals using proper size weld cables with correct connectors Observe correct polarity Start engine and run for several minutes Set load bank switches and then adjust generator A V control so load equals rated generator output see nameplate Check generator and load bank meters after first five minutes then every fifteen minutes to be sure generator is loaded properly Check oil level frequently dur ing run in add oil if needed After one hour minimum place A V control in minimum position then turn off load bank to remove load Run engine several minutes at no load Stop engine and let cool 4 Engine Exhaust Pipe Repeat procedure if wetstacking is present 5 0683 173 413 37 9 3 Run In Procedure Using Resistance Grid SN CL w
90. zards on the worksite We ve business made installation and operation quick and easy With Miller you can count on years of reliable service with proper maintenance And if for some reason the unit needs repair there s a REGISTERED QUALITY SYSTEM Troubleshooting section that will help you Miller is the first welding figure out what the problem is The parts list equipment manufacturer in ine USS Avia 515090 will then help you to decide which exact part the ISO 9001 Quality System you may need to fix the problem Warranty and Service information for your particular model are also provided Miller offers a Technical Manual which provides more detailed service and parts information for your unit To obtain a Technical Manual contact your local distributor Your distributor can also supply you with Welding Process Manuals such as SMAW GTAW GMAW and GMAW P Miller Electric manufactures a full line of welders and welding related equipment For information on other quality Miller products contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets To locate your nearest distributor or service agency call 1 800 4 A Miller or visit us at www MillerWelds com on the web Miller The Power of Blue amp WARNING This product when used for welding or cutting produces fumes or gases which contain chemicals known to the State

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