Miller Bobcat 225 User Manual

OM-4434 218 653J

2007−11

Processes

Stick (SMAW) Welding

MIG (GMAW) Welding
Flux Cored (FCAW) Welding

Non-Critical TIG (GTAW)
Welding

Description

Engine Driven Welding Generator

™

Bobcat 225

Visit our website at

www.MillerWelds.com

File: Engine Drive

From Miller to You

Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.

That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.

Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.

This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.

We’ve 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 Troubleshooting section that will
help you figure out what the problem is. The

Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001:2000 Quality
System Standard.

parts list will then help you to decide the
exact part you may need to fix the problem.
Warranty and service information for your
particular model are also provided.

Working as hard as you do

− every power source from
Miller is backed by the most
hassle-free warranty in the
business.

Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest

distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.

Mil_Thank 2005−04

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Arc Welding Hazards 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Engine Hazards 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. Compressed Air Hazards 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Additional Symbols For Installation, Operation, And Maintenance 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6. California Proposition 65 Warnings 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-7. Principal Safety Standards 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-8. EMF Information 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 6 . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Signification des symboles 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Dangers relatifs au soudage à l’arc 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Dangers existant en relation avec le moteur 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4. Dangers liés à l’air comprimé 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance 9 . . . . .

2-6. Proposition californienne 65 Avertissements 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-7. Principales normes de sécurité 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-8. Information EMF 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − DEFINITIONS 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − SPECIFICATIONS 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Weld, Power, and Engine Specifications 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Dimensions, Weights, and Operating Angles 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Dimensions For Units With Optional Running Gear 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Fuel Consumption (Robin-Powered Units) 14

4-5. Fuel Consumption (Kohler-Powered Units) 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Volt-Ampere Curves 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Generator Power Curve 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. Duty Cycle 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − INSTALLATION 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Installing Welding Generator 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Engine Prestart Checks (Robin-Powered Units) 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Engine Prestart Checks (Kohler-Powered Units) 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Installing Exhaust Pipe 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Connecting Or Replacing the Battery 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. Connecting to Weld Output Terminals 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7. Selecting Weld Cable Sizes* 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − OPERATING THE WELDING GENERATOR 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Front Panel Controls 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Cold Weather Engine Operation 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Typical Stick Welding Connections And Control Settings 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. Typical MIG Welding Connections And Settings 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-5. Typical MIG Connections And Settings Using Weld Control And Spoolgun 29 . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − OPERATING AUXILIARY EQUIPMENT 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Standard Receptacles 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Optional Generator Power Receptacles 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3. Simultaneous Weld And Power 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-4. Wiring Optional 240 Volt Plug 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − MAINTENANCE (ROBIN-POWERED UNITS) 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1. Maintenance Label (Robin-Powered Units) 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2. Routine Maintenance (Robin-Powered Units) 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3. Servicing Air Cleaner (Robin-Powered Units) 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-4. Servicing Optional Spark Arrestor (Robin-Powered Units) 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS

8-5. Changing Engine Oil, Oil Filter, and Fuel Filter (Robin-Powered Units) 36 . . . . . . . . . . . . . . . . . . . . . . . .

8-6. Adjusting Engine Speed (Robin-Powered Units) 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-7. Overload Protection (Robin-Powered Units) 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − MAINTENANCE − (KOHLER-POWERED UNITS) 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1. Maintenance Label (Kohler-Powered Units) 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-2. Routine Maintenance (Kohler-Powered Units) 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3. Servicing Air Cleaner (Kohler−Powered Units) 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-4. Changing Engine Oil, Oil Filter, and Fuel Filter (Kohler-Powered Units) 42 . . . . . . . . . . . . . . . . . . . . . . . .

9-5. Adjusting Engine Speed (Kohler-Powered Units) 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-6. Overload Protection (Kohler-Powered Units) 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-7. Servicing Optional Spark Arrestor (Kohler-Powered Units) 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 − TROUBLESHOOTING 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-1. Welding Troubleshooting 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-2. Generator Power Troubleshooting 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-3. Engine Troubleshooting 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 − PARTS LIST 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-1. Recommended Spare Parts 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 12 − ELECTRICAL DIAGRAMS 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 13 − GENERATOR POWER GUIDELINES 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 14 − STICK WELDING (SMAW) GUIDELINES 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 15 − MIG WELDING (GMAW) GUIDELINES 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-1. Typical MIG Process Connections Using A Voltage-Sensing Wire Feeder 65 . . . . . . . . . . . . . . . . . . . . .

15-2. Holding And Positioning Welding Gun 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-3. Conditions That Affect Weld Bead Shape 66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-4. Gun Movement During Welding 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-5. Poor Weld Bead Characteristics 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-6. Good Weld Bead Characteristics 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-7. Troubleshooting − Excessive Spatter 68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-8. Troubleshooting − Porosity 68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-9. Troubleshooting − Excessive Penetration 68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-10. Troubleshooting − Lack Of Penetration 69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-11. Troubleshooting − Incomplete Fusion 69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-12. Troubleshooting − Burn-Through 69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-13. Troubleshooting − Waviness Of Bead 70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-14. Troubleshooting − Distortion 70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-15. Common MIG Shielding Gases 71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COMPLETE PARTS LIST - www.MillerWelds.com
OPTIONS AND ACCESSORIES
WARRANTY

SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING

rom_2007−04

Protect yourself and others from injury — read and follow these precautions.

1-1. Symbol Usage

DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.

Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or ex­plained in the text.

NOTICE − Indicates statements not related to personal injury.

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 1-7. Read and
follow all Safety Standards.

Only qualified persons should install, operate, maintain, and
repair this unit.

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or
severe burns. The electrode and work circuit is

electrically live whenever the output is on. The input
power circuit and machine internal circuits are also live when power is
on. In semiautomatic or automatic wire welding, the wire, wire reel,
drive roll housing, and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly grounded equip­ment is a hazard.

 Do not touch live electrical parts.
 Wear dry, hole-free insulating gloves and body protection.
 Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work
or ground.

 Do not use AC output in damp areas, if movement is confined, or if

there is a danger of falling.

 Use AC output ONLY if required for the welding process.
 If AC output is required, use remote output control if present on

unit.

 Additional safety precautions are required when any of the follow-

ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoid­able or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt­age. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!

 Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).

 Properly install and ground this equipment according to its

Owner’s Manual and national, state, and local codes.

 Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym­bols and related instructions below for necessary actions to avoid the
hazards.

 Always verify the supply ground — check and be sure that input

power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.

 When making input connections, attach proper grounding conduc-

tor first − double-check connections.

 Keep cords dry, free of oil and grease, and protected from hot metal

and sparks.

 Frequently inspect input power cord for damage or bare wiring —

replace cord immediately if damaged — bare wiring can kill.

 Turn off all equipment when not in use.
 Do not use worn, damaged, undersized, or poorly spliced cables.
 Do not drape cables over your body.
 If earth grounding of the workpiece is required, ground it directly

with a separate cable.

 Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

 Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

 Do not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will be
present.

 Wear a safety harness if working above floor level.
 Keep all panels and covers securely in place.
 Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

 Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

 Do not connect more than one electrode or work cable to any

single weld output terminal.

SIGNIFICANT DC VOLTAGE exists in inverters after stop­ping engine.

 Stop engine on inverter and discharge input capacitors according

to instructions in Maintenance Section before touching any parts.

HOT PARTS can cause severe burns.

 Do not touch hot parts bare handed.
 Allow cooling period before working on equip-

ment.

 To handle hot parts, use proper tools and/or wear heavy, insu-

lated welding gloves and clothing to prevent burns.

FLYING METAL or DIRT can injure eyes.

 Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool,
they can throw off slag.

 Wear approved safety glasses with side shields even under your

welding helmet.

OM-4434 Page 1

FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing these

fumes and gases can be hazardous to your health.

 Keep your head out of the fumes. Do not breathe the fumes.
 If inside, ventilate the area and/or use local forced ventilation at the

arc to remove welding fumes and gases.

 If ventilation is poor, wear an approved air-supplied respirator.
 Read and understand the Material Safety Data Sheets (MSDSs)

and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.

 Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watch­person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath­ing air is safe.

 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.

 Do not weld on coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.

 Do not weld on closed containers such as tanks, drums, or pipes,

unless they are properly prepared according to AWS F4.1 (see
Safety Standards).

 Do not weld where the atmosphere may contain flammable dust,

gas, or liquid vapors (such as gasoline).

 Connect work cable to the work as close to the welding area as

practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire haz­ards.

 Do not use welder to thaw frozen pipes.
 Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

 Wear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap.

 Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

 After completion of work, inspect area to ensure it is free of sparks,

glowing embers, and flames.

 Use only correct fuses or circuit breakers. Do not oversize or by-

pass them.

 Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B

for hot work and have a fire watcher and extinguisher nearby.

NOISE can damage hearing.

BUILDUP OF GAS can injure or kill.

 Shut off shielding gas supply when not in use.
 Always ventilate confined spaces or use ap-

proved air-supplied respirator.

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense

visible and invisible (ultraviolet and infrared) rays that

can burn eyes and skin. Sparks fly off from the weld.
 Wear an approved welding helmet fitted with a proper shade of filter

lenses to protect your face and eyes from arc rays and sparks
when welding or watching (see ANSI Z49.1 and Z87.1 listed in
Safety Standards).

 Wear approved safety glasses with side shields under your

helmet.

 Use protective screens or barriers to protect others from flash,

glare, and sparks; warn others not to watch the arc.

 Wear protective clothing made from durable, flame-resistant mate-

rial (leather, heavy cotton, or wool) and foot protection.

WELDING can cause fire or explosion.

Welding on closed containers, such as tanks, drums,

or pipes, can cause them to blow up. Sparks can fly off

from the welding arc. The flying sparks, hot workpiece,
and hot equipment can cause fires and burns. Accidental contact of
electrode to metal objects can cause sparks, explosion, overheating,
or fire. Check and be sure the area is safe before doing any welding.

 Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

 Do not weld where flying sparks can strike flammable material.
 Protect yourself and others from flying sparks and hot metal.
 Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

 Watch for fire, and keep a fire extinguisher nearby.
 Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

Noise from some processes or equipment can dam­age hearing.

 Wear approved ear protection if noise level is

high.

MAGNETIC FIELDS can affect Implanted
Medical Devices.

 Wearers of Pacemakers and other Implanted

Medical Devices should keep away.

 Implanted Medical Device wearers should consult their doctor

and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high pres­sure. If damaged, a cylinder can explode. Since gas
cylinders are normally part of the welding process, be
sure to treat them carefully.

 Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, physical damage, slag, open flames, sparks, and arcs.

 Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

 Keep cylinders away from any welding or other electrical circuits.
 Never drape a welding torch over a gas cylinder.
 Never allow a welding electrode to touch any cylinder.
 Never weld on a pressurized cylinder — explosion will result.
 Use only correct shielding gas cylinders, regulators, hoses, and fit-

tings designed for the specific application; maintain them and
associated parts in good condition.

 Turn face away from valve outlet when opening cylinder valve.
 Keep protective cap in place over valve except when cylinder is in

use or connected for use.

 Use the right equipment, correct procedures, and sufficient num-

ber of persons to lift and move cylinders.

 Read and follow instructions on compressed gas cylinders,

associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.

OM-4434 Page 2

1-3. Engine Hazards

BATTERY EXPLOSION can BLIND.

 Always wear a face shield, rubber gloves, and

protective clothing when working on a battery.

 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.

FUEL can cause fire or explosion.

 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.

 Do not overfill tank — allow room for fuel to expand.
 Do not spill fuel. If fuel is spilled, clean up before starting engine.
 Dispose of rags in a fireproof container.
 Always keep nozzle in contact with tank when fueling.

MOVING PARTS can cause injury.

 Keep away from fans, belts, and rotors.
 Keep all doors, panels, covers, and guards

closed and securely in place.

 Stop engine before installing or connecting unit.
 Have only qualified people remove doors, panels, covers, or

guards for maintenance and troubleshooting as necessary.

 To prevent accidental starting during servicing, disconnect

negative (−) battery cable from battery.

 Keep hands, hair, loose clothing, and tools away from moving

parts.

 Reinstall doors, panels, covers, or guards when servicing is

finished and before starting engine.

 Before working on generator, remove spark plugs or injectors to

keep engine from kicking back or starting.

 Block flywheel so that it will not turn while working on generator

components.

STEAM AND HOT COOLANT can burn.

 If possible, check coolant level when engine is

cold to avoid scalding.

 Always check coolant level at overflow tank, if

present on unit, instead of radiator (unless told
otherwise in maintenance section or engine
manual).

 If the engine is warm, checking is needed, and there is no over-

flow tank, follow the next two statements.

 Wear safety glasses and gloves and put a rag over radiator cap.
 Turn cap slightly and let pressure escape slowly before

completely removing cap.

Using a generator indoors CAN KILL
YOU IN MINUTES.

 Generator exhaust contains carbon monoxide.

This is a poison you cannot see or smell.

 NEVER use inside a home or garage, EVEN IF

doors and windows are open.

 Only use OUTSIDE and far away from windows, doors, and

vents.

BATTERY ACID can BURN SKIN and EYES.

 Do not tip battery.
 Replace damaged battery.
 Flush eyes and skin immediately with water.

ENGINE HEAT can cause fire.

 Do not locate unit on, over, or near combustible

surfaces or flammables.

 Keep exhaust and exhaust pipes way from

flammables.

HOT PARTS can cause severe burns.

 Do not touch hot parts bare handed.
 Allow cooling period before working on equip-

ment.

 To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves and
clothing to prevent burns.

1-4. Compressed Air Hazards

BREATHING COMPRESSED AIR can
cause serious injury or death.

 Do not use compressed air for breathing.
 Use only for cutting, gouging, and tools.

COMPRESSED AIR can cause injury.

 Wear approved safety goggles.
 Do not direct air stream toward self or others.

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.

TRAPPED AIR PRESSURE AND WHIPPING
HOSES can cause injury.

 Release air pressure from tools and system be-

fore servicing, adding or changing attach­ments, or opening compressor oil drain or oil fill
cap.

OM-4434 Page 3

HOT METAL from air arc cutting and

READ INSTRUCTIONS.

gouging can cause fire or explosion.

 Do not cut or gouge near flammables.
 Watch for fire; keep extinguisher nearby.

HOT PARTS can cause burns and injury.

 Do not touch hot compressor or air system

parts.

 Let system cool down before touching or ser-

vicing.

 Read Owner’s Manual before using or servic-

ing unit.

 Stop engine and release air pressure before

servicing.

 Use only genuine replacement parts from the

manufacturer.

1-5. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

 Do not install or place unit on, over, or near

combustible surfaces.

 Do not install unit near flammables.

 Do not overload building wiring − be sure power supply system is

properly sized, rated, and protected to handle this unit.

FALLING UNIT can cause injury.

 Use lifting eye to lift unit and properly installed

accessories only, NOT gas cylinders. Do not
exceed maximum lift eye weight rating (see
Specifications).

 Lift and support unit only with proper equipment

and correct procedures.

 If using lift forks to move unit, be sure forks are long enough to

extend beyond opposite side of unit.

OVERHEATING can damage motors.

 Turn off or unplug equipment before starting or

stopping engine.

 Do not let low voltage and frequency caused by

low engine speed damage electric motors.

 Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle

where applicable.

FLYING SPARKS can cause injury.

WELDING WIRE can cause injury.

 Do not press gun trigger until instructed to do

so.

 Do not point gun toward any part of the body,

other people, or any metal when threading
welding wire.

OVERUSE can cause OVERHEATING.

 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.

 Put on grounded wrist strap BEFORE handling

boards or parts.

 Use proper static-proof bags and boxes to

store, move, or ship PC boards.

TILTING OF TRAILER can cause injury.

 Use tongue jack or blocks to support weight.
 Properly install welding generator onto trailer

according to instructions supplied with trailer.

 Wear a face shield to protect eyes and face.
 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.

MOVING PARTS can cause injury.

 Keep away from moving parts.
 Keep away from pinch points such as drive

rolls.

OM-4434 Page 4

READ INSTRUCTIONS.

 Read Owner’s Manual before using or servic-

ing unit.

 Use only genuine replacement parts from the

manufacturer.

 Perform engine and air compressor mainte-

nance and service according to this manual
and the engine/air compressor (if applicable)
manuals.

H.F. RADIATION can cause interference.

ARC WELDING can cause interference.

 High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and
communications equipment.

 Have only qualified persons familiar with

electronic equipment perform this installation.

 The user is responsible for having a qualified electrician

promptly correct any interference problem resulting from the
installation.

 If notified by the FCC about interference, stop using the

equipment at once.

 Have the installation regularly checked and maintained.
 Keep high-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.

1-6. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)

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.

 Electromagnetic energy can interfere with

sensitive electronic equipment such as micro­processors, computers, and computer-driven
equipment such as robots.

 Be sure all equipment in the welding area is

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.

 If interference still occurs, the user must take extra measures

such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.

For Gasoline Engines:

Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproduc­tive harm.

For Diesel Engines:

Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.

1-7. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: [phone], website:
www.global.ihs.com).

Recommended Safe Practices for the Preparation for Welding and Cut­ting of Containers and Piping, American Welding Society Standard

AWS F4.1, from Global Engineering Documents (phone:
1-877-413-5184, website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (phone:
617-770-3000, website: www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 4221 Walney Road, 5th Floor,
Chantilly, VA 20151 (phone: [phone], website:www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 5060 Mississauga,

1-8. EMF Information

Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields

Welding current, as it flows through welding cables, will cause electro­magnetic 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
committee’s judgment, has not demonstrated that exposure to power­frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.

To reduce magnetic fields in the workplace, use the following
procedures:

Ontario, Canada L4W 5NS (phone: [phone] or in Toronto
416-747-4044, website: www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protec­tion, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036–8002 (phone:
212-642-4900, website: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,

P.O. Box 9101, Quincy, MA 02269-9101 (phone: [phone], web­site: www.nfpa.org.

OSHA, Occupational Safety and Health Standards for General Indus­try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super­intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: [phone]) (there are 10 Regional Offices—phone for
Region 5, Chicago, is 312-353-2220, website: www.osha.gov).

1. Keep cables close together by twisting or taping them, or using a
cable cover.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep welding power source and cables as far away from
operator as practical.

5. Connect work clamp to workpiece as close to the weld as
possible.

About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom­mended.

OM-4434 Page 5

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT

UTILISATION

rom_2007−04fre

Se protéger, ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud.

2-1. Signification des symboles

DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.

Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dan­gers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.

NOTE − Indique des déclarations pas en relation avec des blessures
personnelles.

2-2. Dangers relatifs au soudage à l’arc

Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les ris­ques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne
font que résumer l’information contenue dans les normes de
sécurité énumérées à la section 2-7. Veuillez lire et respecter
toutes ces normes de sécurité.

L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées.

Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrement les enfants.

UN CHOC ÉLECTRIQUE peut tuer.

Un simple contact avec des pièces électriques peut
provoquer une électrocution ou des blessures graves.

L’électrode et le circuit de soudage sont sous tension
dès que l’appareil est sur ON. Le circuit d’entrée et les circuits
internes de l’appareil sont également sous tension à ce moment-là.
En soudage semi-automatique ou automatique, le fil, le dévidoir, le
logement des galets d’entraînement et les pièces métalliques en
contact avec le fil de soudage sont sous tension. Des matériels mal
installés ou mal mis à la terre présentent un danger.

 Ne jamais toucher les pièces électriques sous tension.
 Porter des gants et des vêtements de protection secs ne compor-

tant pas de trous.

 S’isoler de la pièce et de la terre au moyen de tapis ou d’autres

moyens isolants suffisamment grands pour empêcher le contact
physique éventuel avec la pièce ou la terre.

 Ne pas se servir de source électrique à courant électrique dans les

zones humides, dans les endroits confinés ou là où on risque de
tomber.

 Se servir d’une source électrique à courant électrique UNIQUE-

MENT si le procédé de soudage le demande.

 Si l’utilisation d’une source électrique à courant électrique s’avère

nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.

 Des précautions de sécurité supplémentaires sont requises dans

des environnements à risque comme: les endroits humides ou
lorsque l’on porte des vêtements mouillés; sur des structures mé­talliques au sol, grillages et échafaudages; dans des positions
assises, à genoux et allongées; ou quand il y a un risque important
de contact accidentel avec la pièce ou le sol. Dans ces cas utiliser
les appareils suivants dans l’ordre de préférence: 1) un poste à

OM-4434 Page 6

 Indique des instructions spécifiques.

Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.

souder DC semi−automatique de type CV (MIG/MAG), 2) un poste
à souder manuel (électrode enrobée) DC, 3) un poste à souder
manuel AC avec tension à vide réduite. Dans la plupart des cas, un
poste courant continu de type CV est recommandé. Et, ne pas tra­vailler seul!

 Couper l’alimentation ou arrêter le moteur avant de procéder à

l’installation, à la réparation ou à l’entretien de l’appareil.
Déverrouiller l’alimentation selon la norme OSHA 29 CFR

1910.147 (voir normes de sécurité).

 Installer et mettre à la terre correctement cet appareil conformé-

ment à son manuel d’utilisation et aux codes nationaux,
provinciaux et municipaux.

 Toujours vérifier la terre du cordon d’alimentation − Vérifier et

s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.

 En effectuant les raccordements d’entrée fixer d’abord le conduc-

teur de mise à la terre approprié et contre-vérifier les connexions.

 Les câbles doivent être exempts d’humidité, d’huile et de graisse;

protégez−les contre les étincelles et les pièces métalliques chau­des.

 Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est

pas endommagé ou dénudé − remplacer le cordon immédiatement
s’il est endommagé − un câble dénudé peut provoquer une électro­cution.

 Mettre l’appareil hors tension quand on ne l’utilise pas.
 Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-

sante ou mal épissés.

 Ne pas enrouler les câbles autour du corps.
 Si la pièce soudée doit être mise à la terre, le faire directement

avec un câble distinct − ne pas utiliser le connecteur de pièce ou le
câble de retour.

 Ne pas toucher l’électrode quand on est en contact avec la pièce,

la terre ou une électrode provenant d’une autre machine.

 Ne pas toucher des porte électrodes connectés à deux machines

en même temps à cause de la présence d’une tension à vide dou­blée.

 N’utiliser qu’un matériel en bon état. Réparer ou remplacer

sur-le-champ les pièces endommagées. Entretenir l’appareil
conformément à ce manuel.

 Porter un harnais de sécurité quand on travaille en hauteur.
 Maintenir solidement en place tous les panneaux et capots.
 Fixer le câble de retour de façon à obtenir un bon contact métal-

métal avec la pièce à souder ou la table de travail, le plus près
possible de la soudure.

 Isoler la pince de masse quand pas mis à la pièce pour éviter le

contact avec tout objet métallique.

Une tension DC importante subsiste à l’intérieur

-

e

­r

e

s

u

e

n

o
e

e

e

u
n

e

f

e

des onduleurs après avoir coupé l’alimentation.

 Couper l’alimentation du poste et décharger les condensateurs

d’entrée comme indiqué dans la Section Maintenance avant de
toucher des composants.

DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.

 Ne pas toucher à mains nues les parties chau

des.

 Prévoir une période de refroidissement avant d

travailler à l’équipement.

 Ne pas toucher aux pièces chaudes, utiliser les outils recomman

dés et porter des gants de soudage et des vêtements épais pou
éviter les brûlures.

DES PIECES DE METAL ou DES SA-

LETES peuvent provoquer des bles-

sures dans les yeux.

 Le soudage, l’écaillement, le passage de la pièce à la brosse en

fil de fer, et le meulage génèrent des étincelles et des particules
métalliques volantes. Pendant la période de refroidissement des
soudures, elles risquent de projeter du laitier.

 Porter des lunettes de sécurité avec écrans latéraux ou un écran

facial.

LES FUMÉES ET LES GAZ peuvent êtr
dangereux.

Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.

 Eloigner votre tête des fumées. Ne pas respirer les fumées.
 À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au

niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.

 Si la ventilation est médiocre, porter un respirateur anti-vapeurs

approuvé.

 Lire et comprendre les spécifications de sécurité des matériaux

(MSDS) et les instructions du fabricant concernant les métaux, les
consommables, les revêtements, les nettoyants et les dégraisseurs.

 Travailler dans un espace fermé seulement s’il est bien ventilé ou

en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.

 Ne pas souder dans des endroits situés à proximité d’opérations

de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et for­mer des gaz hautement toxiques et irritants.

 Ne pas souder des métaux munis d’un revêtement, tels que l’acier

galvanisé, plaqué en plomb ou au cadmium à moins que le revête­ment n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.

LES ACCUMULATIONS DE GAZ ri
quent de provoquer des blessures o
même la mort.

 Fermer l’alimentation du gaz protecteur en cas d

non utilisation.

 Veiller toujours à bien aérer les espaces confinés ou se servir d’u

respirateur d’adduction d’air homologué.

LES RAYONS DE L’ARC peuvent pr
voquer des brûlures dans les yeux
sur la peau.

Le rayonnement de l’arc du procédé de soudag

génère des rayons visibles et invisibles intense
(ultraviolets et infrarouges) susceptibles de provoquer des brûlure
dans les yeux et sur la peau. Des étincelles sont projetées pendant l
soudage.

 Porter un casque de soudage approuvé muni de verres filtrants

approprié pour protéger visage et yeux pendant le soudage
(voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).

 Porter des lunettes de sécurité avec écrans latéraux même sous

votre casque.

 Avoir recours à des écrans protecteurs ou à des rideaux pour

protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.

 Porter des vêtements confectionnés avec des matières résistan-

tes et ignifuges (cuir, coton lourd ou laine) et des bottes de
protection.

LE SOUDAGE peut provoquer un in

cendie ou une explosion.

Le soudage effectué sur des conteneurs fermés tel

que des réservoirs, tambours ou des conduites pe

provoquer leur éclatement. Des étincelles peuve
être projetées de l’arc de soudure. La projection d’étincelles, des pièce
chaudes et des équipements chauds peut provoquer des incendies
des brûlures. Le contact accidentel de l’électrode avec des objet
métalliques peut provoquer des étincelles, une explosion, un surchau
fement ou un incendie. Avant de commencer le soudage, vérifier
s’assurer que l’endroit ne présente pas de danger.

 Déplacer toutes les substances inflammables à une distance de

10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.

 Ne pas souder dans un endroit là où des étincelles peuvent tomber

sur des substances inflammables.

 Se protéger et d’autres personnes de la projection d’étincelles et

de métal chaud.

 Des étincelles et des matériaux chauds du soudage peuvent

facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.

 Surveiller tout déclenchement d’incendie et tenir un extincteur à

proximité.

 Le soudage effectué sur un plafond, plancher, paroi ou séparation

peut déclencher un incendie de l’autre côté.

 Ne pas effectuer le soudage sur des conteneurs fermés tels que

des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 (voir les nor­mes de sécurité).

 Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou va-

peurs inflammables (vapeur d’essence, par exemple).

 Brancher le câble de masse sur la pièce le plus près possible de la

zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provo­quant des risques d’électrocution, d’étincelles et d’incendie.

 Ne pas utiliser le poste de soudage pour dégeler des conduites ge-

lées.

 En cas de non utilisation, enlever la baguette d’électrode du porte-

électrode ou couper le fil à la pointe de contact.

 Porter des vêtements de protection dépourvus d’huile tels que des

gants en cuir, une chemise en matériau lourd, des pantalons sans
revers, des chaussures hautes et un couvre chef.

 Avant de souder, retirer toute substance combustible de vos po-

ches telles qu’un allumeur au butane ou des allumettes.

 Une fois le travail achevé, assurez−vous qu’il ne reste aucune tra-

ce d’étincelles incandescentes ni de flammes.

 Utiliser exclusivement des fusibles ou coupe−circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

OM-4434 Page 7

 Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et

c

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a

a
n

e

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s

o

e

s

e

t

o

,

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­r

NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.

LE BRUIT peut affecter l’ouïe.

Le bruit des processus et des équipements peut affe
l’ouïe.

 Porter des protections approuvés pour les or

les si le niveau sonore est trop élevé.

LES CHAMPS MAGNETIQUES peuvent affec­ter des implants médicaux.

 Porteur de simulateur cardiaque ou autre im-

plants médicaux, rester à distance.

 Les porteurs d’implants doivent d’abord consulter leur médecin

avant de s’approcher des opérations de soudage à l’arc, de sou­dage par points, de gougeage, du coupage plasma ou de chauf­fage par induction.

Si des BOUTEILLES sont endomm
gées, elles pourront exploser.

Des bouteilles de gaz protecteur contiennent du g

sous haute pression. Si une bouteille est endomm
gée, elle peut exploser. Du fait que les bouteilles de gaz fo
normalement partie du procédé de soudage, les manipuler av
précaution.

 Protéger les bouteilles de gaz comprimé d’une chaleur excessive,

des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.

 Placer les bouteilles debout en les fixant dans un support station-

naire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.

 Tenir les bouteilles éloignées des circuits de soudage ou autres

circuits électriques.

 Ne jamais placer une torche de soudage sur une bouteille à gaz.
 Une électrode de soudage ne doit jamais entrer en contact avec

une bouteille.

 Ne jamais souder une bouteille pressurisée − risque d’explosion.
 Utiliser seulement des bouteilles de gaz protecteur, régulateurs,

tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.

 Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la

bouteille.

 Maintenir le chapeau de protection sur la soupape, sauf en cas

d’utilisation ou de branchement de la bouteille.

 Utiliser les équipements corrects, les bonnes procédures et suffi-

samment de personnes pour soulever et déplacer les bouteilles.

 Lire et suivre les instructions sur les bouteilles de gaz comprimé,

l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas
Association) mentionné dans les principales normes de sécurité.

2-3. Dangers existant en relation avec le moteur

L’EXPLOSION DE LA BATTERIE peu
RENDRE AVEUGLE.

 Toujours porter une protection faciale, des gant

en caoutchouc et vêtements de protection lor
d’une intervention sur la batterie.

 Arrêter le moteur avant de débrancher ou de brancher les câbles

de batterie.

 Eviter de provoquer des étincelles avec les outils en travaillant sur

la batterie.

 Ne pas utiliser le poste de soudage pour charger les batteries ou

des véhicules de démarrage rapide.

 Observer la polarité correcte (+ et −) sur les batteries.
 Débrancher le câble négatif (–) en premier lieu. Le rebrancher en

dernier lieu.

LE CARBURANT MOTEUR peut prov
quer un incendie ou une explosion.

 Arrêter le moteur avant de vérifier le niveau d

carburant ou de faire le plein.

 Ne pas faire le plein en fumant ou proche d’une source d’étincelle

ou d’une flamme nue.

 Ne pas faire le plein de carburant à ras bord; prévoir de l’espac

pour son expansion.

 Faire attention de ne pas renverser de carburant. Nettoyer tou

carburant renversé avant de faire démarrer le moteur.

 Jeter les chiffons dans un récipient ignifuge.
 Toujours garder le pistolet en contact avec le réservoir lors du

remplissage.

DES ORGANES MOBILES peuvent pr
voquer des blessures.

 Ne pas approcher les mains des ventilateurs

courroies et autres pièces en mouvement.

 Maintenir fermés et fixement en place les portes, panneaux, re-

couvrements et dispositifs de protection.

 Arrêter le moteur avant d’installer ou brancher l’appareil.

OM-4434 Page 8

 Seules des personnes qualifiées sont autorisées à enlever les por-

tes, panneaux, recouvrements ou dispositifs de protection pour
effectuer, s’il y a lieu, des travaux d’entretien et de dépannage.

 Pour empêcher tout démarrage accidentel pendant les travaux

d’entretien, débrancher le câble négatif (−) de batterie de la borne.

 Ne pas approcher les mains, cheveux, vêtements lâches et outils

des organes mobiles.

 Remettre en place les panneaux ou les dispositifs de protection et

fermer les portes à la fin des travaux d’entretien et avant de faire
démarrer le moteur.

 Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la

mise en route accidentelle du moteur.

 Bloquer le volant moteur pour éviter sa rotation lors d’une interven-

tion sur le générateur.

DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.

 Ne pas toucher à mains nues les parties chau

des.

 Prévoir une période de refroidissement avant d

travailler à l’équipement.

 Ne pas toucher aux pièces chaudes, utiliser les outils recomman

dés et porter des gants de soudage et des vêtements épais pou
éviter les brûlures.

LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT CHAUD peuvent
provoquer des brûlures.

 Il est préférable de vérifier le liquide de refroi-

dissement une fois le moteur refroidi pour éviter
de se brûler.

 Toujours vérifier le niveau de liquide de refroidissement dans le

vase d’expansion (si présent), et non dans le radiateur (sauf si pré­cisé autrement dans la section maintenance du manuel du
moteur).

 Si le moteur est chaud et que le liquide doit être vérifié, opérer com-

me suivant.

 Mettre des lunettes de sécurité et des gants, placer un torchon sur

le bouchon du radiateur.

 Dévisser le bouchon légèrement et laisser la vapeur s’échapper

t
,

e

-

e

s

r

u

avant d’enlever le bouchon.

L’utilisation d’un groupe autonome
à l’intérieur PEUT VOUS TUER EN
QUELQUES MINUTES.

 Les fumées d’un groupe autonome contient du

monoxyde de carbone. C’est un poison invisi­ble et inodore.

 JAMAIS utiliser dans une maison ou garage,

même avec les portes et fenêtres ouvertes.

 Uniquement utiliser à l’EXTERIEUR, loin des portes, fenêtres et

bouches aération.

L’ACIDE DE LA BATTERIE peut pro­voquer des brûlures dans les YEUX et
sur la PEAU.

 Ne pas renverser la batterie.
 Remplacer une batterie endommagée.

 Rincer immédiatement les yeux et la peau à l’eau.

2-4. Dangers liés à l’air comprimé

LA CHALEUR DU MOTEUR peut pro­voquer un incendie.

 Ne pas placer l’appareil sur, au-dessus ou à

proximité de surfaces inflammables.

 Tenir à distance les produits inflammables de l’échappement.

LES ÉTINCELLES À L’ÉCHAPPEMENT
peuvent provoquer un incendie.

 Empêcher les étincelles d’échappement du

moteur de provoquer un incendie.

 Utiliser uniquement un pare-étincelles

approuvé − voir codes en vigueur.

RESPIRER L’AIR COMPRIMÉ peut pro­voquer des blessures graves ou causer
la mort.

 Ne pas utiliser l’air comprimé pour respirer.
 Utiliser l’air comprimé seulement pour le cou-

page, gougeage et les outils pneumatiques.

L’AIR COMPRIMÉ peut provoquer
des blessures.

 Porter des lunettes de sécurité approuvées.
 Ne pas diriger le jet d’air vers d’autres ou

soi-même.

L’AIR COMPRIME EMMAGASINE ET DES
TUYAUX SOUS PRESSION peuvent provo­quer des blessures.

 Relâcher la pression d’air de l’outillage ou du

système avant d’effectuer la maintenance,
avant de changer ou de rajouter des éléments
ou avant d’ouvrir la purge ou le bouchon de
remplissage d’huile.

 Laisser l’ensemble se refroidir avant de toucher ou d’effectuer la

maintenance.

 N’utiliser que les pièces de rechange recommandées par le

constructeur.

Le METAL CHAUD lors du coupage et
gougeage plasma peut provoquer un in­cendie ou une explosion.

 Ne pas couper ou gouger à proximité de pro-

duits inflammables.

 Surveillez et garder un extincteur à proximité.

DES PIECES CHAUDES peuvent provo­quer des brûlures et blessures.

 Ne pas toucher le compresseur ou d’autres

éléments du circuit air comprimé chauds.

LIRE LES INSTRUCTIONS.

 Lisez le manuel d’instructions avant l’utilisation

ou la maintenance de l’appareil.

 Arrêter le moteur et relâcher la pression avant

d’effectuer la maintenance.

2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

Risque D’INCENDIE OU D’EXPLO­SION.

 Ne pas placer l’appareil sur, au-dessus ou

à proximité de surfaces inflammables.

 Ne pas installer l’appareil à proximité de pro-

duits inflammables.

 Ne pas surcharger l’installation électrique − s’assurer que l’ali-

mentation est correctement dimensionnée et protégée avant de
mettre l’appareil en service.

 En utilisant des fourches de levage pour déplacer l’unité, s’assure

que les fourches sont suffisamment longues pour dépasser d
côté opposé de l’appareil.

LA CHUTE DE L’APPAREIL peut blesser.

 Utiliser l’anneau de levage pour lever l’appareil e

les accessoires correctement installées seuls
PAS les bouteilles de gaz. Ne pas dépasser l
poids nominal maximal de l’œilleton (voir les spé
cifications).

 Ne lever et ne soutenir l’appareil qu’avec d

l’équipement approprié et en suivant le
procédures adéquates.

OM-4434 Page 9

LE SURCHAUFFEMENT peut endom-

e

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-

,

t

a

-

n

u

-

mager le moteur électrique.

 Arrêter ou déconnecter l’équipement avant d

démarrer ou d’arrêter le moteur.

 Ne pas laisser tourner le moteur trop lentement sous risque d’en

dommager le moteur électrique à cause d’une tension et d’une fré
quence trop faibles.

 Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz

s’il y a lieu.

LES ÉTINCELLES VOLANTES ris­quent de provoquer des blessures.

 Porter un écran facial pour protéger le visage e

les yeux.

 Affûter l’électrode au tungstène uniquement à l

meuleuse dotée de protecteurs. Cette manœuv
re est à exécuter dans un endroit sûr lorsque l’o
porte l’équipement homologué de protection d
visage, des mains et du corps.

 Les étincelles risquent de causer un incendie − éloigner toute sub

stance inflammable.

DES ORGANES MOBILES peuvent
provoquer des blessures.

 Ne pas s’approcher des organes mobiles.
 Ne pas s’approcher des points de coincement

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuvent
provoquer des blessures.

 Ne pas appuyer sur la gâchette avant d’en

avoir reçu l’instruction.

 Ne pas diriger le pistolet vers soi, d’autres per-

sonnes ou toute pièce mécanique en enga­geant le fil de soudage.

L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.

 Laisser l’équipement refroidir ; respecter le fac-

teur de marche nominal.

 Réduire le courant ou le facteur de marche

avant de poursuivre le soudage.

 Ne pas obstruer les passages d’air du poste.

LES CHARGES ÉLECTROSTATI­QUES peuvent endommager les
circuits imprimés.

 Établir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pièces.

 Utiliser des pochettes et des boîtes antistatiques pour stocker,

déplacer ou expédier des cartes de circuits imprimes.

UNE REMORQUE QUI BASCULE peut
entraîner des blessures.

 Utiliser les supports de la remorque ou des

blocs pour soutenir le poids.

 Installer convenablement le poste sur la remor-

que comme indiqué dans le manuel s’y rappor­tant.

LIRE LES INSTRUCTIONS.

 Lisez le manuel d’instructions avant l’utilisation

ou la maintenance de l’appareil.

 N’utiliser que les pièces de rechange recom-

mandées par le constructeur.

 Effectuer la maintenance et le service du moteur et du compres-

seur d’air suivant les instructions dans ce manuel ou le manuel
du moteur/compresseur (si applicable).

LE RAYONNEMENT HAUTE FRÉ­QUENCE (H.F.) risque de provoquer
des interférences.

 Le rayonnement haute fréquence (H.F.) peut

provoquer des interférences avec les équipe­ments de radio−navigation et de communica­tion, les services de sécurité et les ordinateurs.

 Demander seulement à des personnes qualifiées familiarisées

avec des équipements électroniques de faire fonctionner l’instal­lation.

 L’utilisateur est tenu de faire corriger rapidement par un électri-

cien qualifié les interférences résultant de l’installation.

 Si le FCC signale des interférences, arrêter immédiatement l’ap-

pareil.

 Effectuer régulièrement le contrôle et l’entretien de l’installation.
 Maintenir soigneusement fermés les portes et les panneaux des

sources de haute fréquence, maintenir les éclateurs à une dis­tance correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.

LE SOUDAGE À L’ARC risque de
provoquer des interférences.

 L’énergie électromagnétique risque de provo-

quer des interférences pour l’équipement élec­tronique sensible tel que les ordinateurs et
l’équipement commandé par ordinateur tel que
les robots.

 Veiller à ce que tout l’équipement de la zone de soudage soit

compatible électromagnétiquement.

 Pour réduire la possibilité d’interférence, maintenir les câbles de

soudage aussi courts que possible, les grouper, et les poser
aussi bas que possible (ex. par terre).

 Veiller à souder à une distance de 100 mètres de tout équipe-

ment électronique sensible.

 Veiller à ce que ce poste de soudage soit posé et mis à la terre

conformément à ce mode d’emploi.

 En cas d’interférences après avoir pris les mesures précéden-

tes, il incombe à l’utilisateur de prendre des mesures supplé­mentaires telles que le déplacement du poste, l’utilisation de câ­bles blindés, l’utilisation de filtres de ligne ou la pose de protec­teurs dans la zone de travail.

OM-4434 Page 10

2-6. Proposition californienne 65 Avertissements

Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des mal­formations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)

Les batteries, les bornes et autres accessoires contiennent
du plomb et des composés à base de plomb, produits chimi­ques dont l’État de Californie reconnaît qu’ils provoquent des
cancers et des malformations congénitales ou autres
problèmes de procréation. Se laver les mains après manipu­lation.

2-7. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
de Global Engineering Documents (téléphone : 1-877-413-5184, site
Internet : www.global.ihs.com).

Recommended Safe Practices for the Preparation for Welding and Cut­ting of Containers and Piping, American Welding Society Standard

AWS F4.1 de Global Engineering Documents (téléphone :
1-877-413-5184, site Internet : www.global.ihs.com).

National Electrical Code, NFPA Standard 70, de National Fire Protec­tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (téléphone :
617-770-3000, site Internet : www.nfpa.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chan­tilly, VA 20151 (téléphone : 703-788-2700, site Internet :
www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, de
Canadian Standards Association, 5060 Mississauga, Ontario, Canada

Pour les moteurs à essence :

Les gaz d’échappement des moteurs contiennent des pro­duits chimiques dont l’État de Californie reconnaît qu’ils
provoquent des cancers et des malformations congénitales
ou autres problèmes de procréation.

Pour les moteurs diesel :

Les gaz d’échappement des moteurs diesel et certains de
leurs composants sont reconnus par l’État de Californie com­me provoquant des cancers et des malformations
congénitales ou autres problèmes de procréation.

L4W 5NS (téléphone : 800-463-6727 ou à Toronto 416-747-4044, site
Internet : www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protec­tion, ANSI Standard Z87.1, de American National Standards Institute,

11 West 43rd Street, New York, NY 10036-8002 (téléphone :
212-642-4900, site Internet : www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, de National Fire Protection Association,

P.O. Box 9101, Quincy, MA 02269-9101 (téléphone : 617-770-3000,
site Internet : www.nfpa.org).

OSHA, Occupational Safety and Health Standards for General Indus­try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, de U.S. Government Printing Office, Superin­tendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(téléphone : 1-866-512-1800) (il y a 10 bureaux régionaux−−le télépho-
ne de la région 5, Chicago, est 312-353-2220, site Internet :
www.osha.gov).

2-8. Information EMF

Considérations sur le soudage et les effets de basse fréquence et des
champs magnétiques et électriques.

Le courant de soudage, pendant son passage dans les câbles de sou­dage, causera des champs électromagnétiques. Il y a eu et il y a encore
un certain souci à propos de tels champs. Cependant, après avoir exa­miné plus de 500 études qui ont été faites pendant une période de
recherche de 17 ans, un comité spécial ruban bleu du National
Research Council a conclu : « L’accumulation de preuves, suivant le
jugement du comité, n’a pas démontré que l’exposition aux champs
magnétiques et champs électriques à haute fréquence représente un
risque à la santé humaine ». Toutefois, des études sont toujours en
cours et les preuves continuent à être examinées. En attendant que les
conclusions finales de la recherche soient établies, il vous serait
souhaitable de réduire votre exposition aux champs électromagnéti­ques pendant le soudage ou le coupage.

Pour réduire les champs magnétiques sur le poste de travail, appliquer
les procédures suivantes :

1. Garder les câbles ensemble, les torsader, les scotcher, ou les
recouvrir d’une housse.

2. Disposer les câbles d’un côté et à distance de l’opérateur.

3. Ne pas courber pas et ne pas entourer pas les câbles autour de
votre corps.

4. Garder le poste de soudage et les câbles le plus loin possible de
vous.

5. Connecter la pince sur la pièce aussi près que possible de la
soudure.

Des implants médicaux :

Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induc­tion. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.

OM-4434 Page 11

3-1. Symbol Definitions

84/42 A, 120/240 V AC

Air-Cooled, T

 A complete Parts List is available at www.MillerWelds.com

SECTION 3 − DEFINITIONS

h

Stop Engine

Start Engine

Engine Oil Fuel Battery (Engine) Engine

Engine Choke

Positive Negative

Welding Arc

(Electrode)

Hours

Fast

(Run, Weld/Power)

Read Operator’s

Manual A

Check Valve

Clearance

MIG (GMAW),

Wire

Seconds Time

Fast/Slow
(Run/Idle)

Amperes

Do not switch while

welding

Alternating Current

(AC)

Stick (SMAW) TIG (GTAW)

V

Slow (Idle)

Volts

Work Connection

Output

Protective Earth

(Ground)

s

Circuit Protector Temperature

SECTION 4 − SPECIFICATIONS

4-1. Weld, Power, and Engine Specifications

 This unit uses either a Robin EH-65 or a Kohler CH-23 engine. Differences between models are noted throughout this manual.

Welding

Mode

CC/AC 50 − 225 A

CC/DC 50 − 210 A

CV/DC 19 − 28 V

Weld Output

Range

Rated

Welding

Output

225 A, 25 V,

100% Duty

Cycle

210 A, 25 V,

100% Duty

Cycle

200 A, 20 V,

100% Duty

Cycle

Maximum

Open Circuit

Voltage

80

80

33

Generator Power Rating

Robin EH−65

Peak: 10 kVA/kW

Continuous: 9.5 kVA/kW,

Single-Phase,

60 Hz

(while not welding)

Kohler CH−23

Peak: 10.5 kVA/kW

Continuous: 9.5 kVA/kW,

Single-Phase,

88/44 A, 120/240 V AC,

60 Hz

(while not welding)

,

Fuel

Capacity

12 gal

(45 L) Tank

Engine

Robin EH-65

Air-Cooled, Two-Cylinder,

Four-Cycle, 22 HP

Gasoline Engine

Kohler CH-23

­Four-Cycle, 23 HP

Gasoline Engine

or

-

wo-Cylinder,

OM-4434 Page 12

4-2. Dimensions, Weights, and Operating Angles

A

C

D

be damaged or unit could tip

p

G

! Do not move or operate unit where it could

F

25

25

Robin-P

d Unit: 560 lb (254 kg)

C

Dimensions

Height

Width 20 in (508 mm)
Depth 45-3/8 in (1153 mm)

A 20 in (508 mm)
B 16-1/2 in (419 mm)
C 1-3/4 in (44 mm)
D 6-1/16 in (154 mm)
E 32-3/4 in (832 mm)
F 45-3/8 in (1153 mm)
G 13/32 in (10 mm) Dia.

Kohler-Powered Unit: 562 lb (254 kg)

Lifting Eye Weight Rating: 1280 lbs

33-1/2 in (851 mm)

(To Top Of Exhaust)

Weight

owere

(580 kg)

C

D

E

F

A

B

Engine End

 A complete Parts List is available at www.MillerWelds.com

! Do not exceed tilt angles or engine could

G

4 Holes

800 426

be damaged or unit could tip.

! Do not move or o

tip.

25°
25°

erate unit where it could

.

25°

25°

4-3. Dimensions For Units With Optional Running Gear

Dimensions

All Running Gear Options:

Height

A

B

C

D

42-1/2 in (1079 mm)

(To Top Of Handle

Assembly)

Protective Cage Width:

26 in (660 mm)

Running Gear Width:

32 in (813 mm)

Protective Cage Length:

48 in (1219 mm)

Running Gear Length:

45−1/2 in (1156 mm)

A

B

D

B

OM-4434 Page 13

4-4. Fuel Consumption (Robin-Powered Units)

 A complete Parts List is available at www.MillerWelds.com

On a typical job using 1/8 in 7018
electrodes (125 amps, 20% duty
cycle), expect about 20 hours of op­eration.

Welding at 150 amps at 40% duty
cycle uses approximately 3/4 gal­lon per hour, or about 16 hours of
operation.

4-5. Fuel Consumption (Kohler-Powered Units)

220 571

On a typical job using 1/8 in 7018
electrodes (125 amps, 20% duty
cycle), expect about 20 hours of op­eration.

Welding at 150 amps at 40% duty
cycle uses approximately 3/4 gal­lon per hour, or about 16 hours of
operation.

OM-4434 Page 14

179 939

4-6. Volt-Ampere Curves

 A complete Parts List is available at www.MillerWelds.com

A. For CC/AC Mode

B. For CC/DC Mode

The volt-ampere curve shows the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
other settings fall between the
curves shown.

C. For CV/DC Mode

166 024-A / 166 025-A / 166 026-A

OM-4434 Page 15

4-7. Generator Power Curve

 A complete Parts List is available at www.MillerWelds.com

The generator power curve shows
the generator power in amperes
available at the receptacles.

4-8. Duty Cycle

200 294

Duty cycle is the percentage of 10
minutes that unit can weld at rated
load without overheating.

NOTICE − Exceeding duty cycle
can damage unit and void warranty.

OM-4434 Page 16

100% Duty Cycle at 225 Amperes CC/AC, 210 Amperes CC/DC, 200 Amperes CV/DC

Continuous Welding

119 454-A

 A complete Parts List is available at www.MillerWelds.com

5

SECTION 5 − INSTALLATION

-1. Installing Welding Generator

! Do not weld on base. Welding

on base can cause fuel tank fire
or explosion. Bolt unit down

Movement

Location / Airflow Clearance

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

Mounting

! Do not lift unit from end.

OR

OR

18 in

18 in

(460 mm)

18 in

(460 mm)

using holes provided in base.

! Always securely fasten weld-

ing generator onto transport
vehicle or trailer and comply
with all DOT and other applica­ble codes.

! Do not mount unit by support-

ing the base only at the four
mounting holes. Use cross­supports to adequately sup­port unit and prevent damage
to base.

! Always ground generator

frame to vehicle frame to pre­vent electric shock and static
electricity hazards.

! If unit does not have GFCI re-

ceptacles, use GFCI-protected
extension cord.

NOTICE − Do not install unit where air
flow is restricted or engine may
overheat.

Mounting:

1 Cross-Supports
Mount unit on flat surface or use

cross-supports to support base.

Grounding:

2 Equipment Grounding Terminal

(On Front Panel)
3 Grounding Cable (Not Supplied)
4 Metal Vehicle Frame
Connect cable from equipment

ground terminal to metal vehicle
frame. Use #10 AWG or larger insu­lated copper wire.

Inadequate support.

Grounding

GND/PE

OR

! Do not use flexible mounts.

2

3

4

! Bed liners, shipping skids, and some running gears in-

sulate the welding generator from the vehicle frame. Al­ways connect a ground wire from the generator equip­ment grounding terminal to bare metal on the vehicle
frame as shown.

Electrically bond generator frame to
vehicle frame by metal-to-metal contact.

1

install2 12/06 − Ref. 800 652 / Ref. 800 477-A / 803 274-A / 804 712

OM-4434 Page 17

 A complete Parts List is available at www.MillerWelds.com

5-2. Engine Prestart Checks (Robin-Powered Units)

Oil Fill

Oil Check

Full

Full

Gasoline

Check all fluids daily. Engine must
be cold and on a level surface. Unit
is shipped with 10W30 engine oil.

 Follow run-in procedure in en-

gine manual.

NOTICE − This unit has a low oil
pressure shutdown switch. Howev­er, some conditions may cause en­gine damage before the engine
shuts down. Check oil level often
and do not use the oil pressure
shutdown system to monitor oil
level.

Fuel

To help prime the fuel system at ini­tial start-up, fill tank with fresh fuel
(see maintenance label for specifi­cations). Always leave filler neck
empty to allow room for expansion.
Check fuel level on a cold engine
before use each day.

Oil

 Do not exceed the ”Full” mark

on the oil level dipstick. The
fuel pump may operate errati­cally if crankcase is overfilled.

After fueling, check oil with unit on
level surface. If oil is not up to full
mark on dipstick, add oil (see main­tenance label).

 To improve cold weather

starting:

Keep battery in good condition.
Store battery in warm area.

Use correct grade oil for cold
weather.

OM-4434 Page 18

803 848-C / 217 015-A

 A complete Parts List is available at www.MillerWelds.com

5-3. Engine Prestart Checks (Kohler-Powered Units)

Full

Full

Gasoline

Check all fluids daily. Engine must
be cold and on a level surface. Unit
is shipped with 10W30 engine oil.

 Follow run-in procedure in en-

gine manual.

NOTICE − This unit has a low oil
pressure shutdown switch. Howev­er, some conditions may cause en­gine damage before the engine
shuts down. Check oil level often
and do not use the oil pressure
shutdown system to monitor oil
level.

Fuel

To help prime the fuel system at ini­tial start-up, fill tank with fresh fuel
(see maintenance label for specifi­cations). Always leave filler neck
empty to allow room for expansion.
Check fuel level on a cold engine
before use each day.

Oil

 Do not exceed the ”Full” mark

on the oil level dipstick. The
fuel pump may operate errati­cally if crankcase is overfilled.

After fueling, check oil with unit on
level surface. If oil is not up to full
mark on dipstick, add oil (see main­tenance label).

 To improve cold weather

starting:

Keep battery in good condition.
Store battery in warm area.

Use correct grade oil for cold
weather.

803 847-C / 217 015-A

OM-4434 Page 19

5-4. Installing Exhaust Pipe

Tools Needed:
1/2 in

5-5. Connecting Or Replacing the Battery

Connecting The Battery

 A complete Parts List is available at www.MillerWelds.com

! Engine backfire can cause se-

vere burns or other injuries. Do
not point exhaust pipe toward
control panel. Keep away from
exhaust outlet.

! Point exhaust pipe in desired di-

rection but always away from
front panel and direction of trav­el.

 Be sure to tighten exhaust clamp

nuts. Exhaust clamp supplied with
muffler.

803 847 / Ref 801 681 / Ref. 228 199-A

Replacing The Battery

! Connect negative (−)

cable last.

+

−

−

+

 Remove end panel to replace battery.

! Connect negative (−)

cable last.

+

−

Tools Needed:

3/8, 1/2 in

OM-4434 Page 20

−

+

803 847-C / 803 849 / Ref. S-0756-D

5-6. Connecting to Weld Output Terminals

1 2

 A complete Parts List is available at www.MillerWelds.com

! Stop engine.

1 Work Weld Output Terminal
2 Electrode Weld Output Terminal
Connect work cable to Work terminal.

Connect electrode holder cable or
electrode weld cable to Electrode ter­minal for Stick and MIG welding.

Connect torch cable to Electrode ter­minal for TIG welding.

Use Process Selector switch to
select type of weld output (see
Section 6-1).

 See Sections 6-3 thru 6-5 for typi-

cal process connections and
control settings.

! Failure to properly connect

weld cables may cause exces­sive heat and start a fire, or
damage your machine.

3 Weld Output Terminal
4 Supplied Weld Output Terminal

Nut
5 Weld Cable Terminal
6 Copper Bar
Remove supplied nut from weld out-

put terminal. Slide weld cable terminal
onto weld output terminal and secure
with nut so that weld cable terminal is
tight against copper bar. Do not

place anything between weld cable
terminal and copper bar. Make
sure that the surfaces of the weld
cable terminal and copper bar are
clean.

6

3

4

5

Correct Installation

Do not place

anything between

weld cable terminal

and copper bar.

Tools Needed:

3/4 in

Incorrect Installation

803 847-C / Ref. 228 199-A / 803 778-A

OM-4434 Page 21

5-7. Selecting Weld Cable Sizes*

Weld Output

! Turn off power before

! Do not

se worn

spliced cables

100 ft (30 m) or Less

Welding

Amperes

100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)

10 − 60%

Duty

Cycle

 A complete Parts List is available at www.MillerWelds.com

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit

Not Exceeding***

150 ft

(45 m)

60 − 100%

Duty

Cycle

200 ft

(60 m)

250 ft

(70 m)

10 − 100% Duty Cycle

300 ft

(90 m)

350 ft

(105 m)

400 ft

(120 m)

Weld Output

Terminals

! Turn off power before

connecting to weld
output terminals.

damaged, under-

u

sized, or poorly
spliced cables.

* This chart is a general guideline and may not suit all applications. If cables overheat, use next size larger cable.

**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use S-0007-F

***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.

,

.

150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)

200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)

250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)

300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)

350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)

400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)

500 2/0 (70) 3/0 (95) 4/0 (120)

2 ea. 2/0

(2x70)

2 ea. 2/0

(2x70)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

3 ea. 3/0

(3x95)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

2 ea. 4/0

(2x120)

3 ea. 3/0

(3x95)

Notes

OM-4434 Page 22

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

Notes

 A complete Parts List is available at www.MillerWelds.com

OM-4434 Page 23

 A complete Parts List is available at www.MillerWelds.com

SECTION 6 − OPERATING THE WELDING GENERATOR

6-1. Front Panel Controls

4

6

5

3

1 Engine Control Switch
Use switch to start engine, select speed, and

stop engine. In Run/Idle position, engine runs
at idle speed at no load, and weld/power speed
under load. In Run position, engine runs at
weld/power speed.

 Place switch in Run position to operate

most MIG equipment.

2 Engine Choke Control
Use control to change engine air-fuel mix.
To Start: pull out choke and turn Engine Con-

trol switch to Start position. Release switch
and slowly push choke in when engine starts.

 If the engine does not start, let engine

come to a complete stop before attempt­ing restart.

To Stop: turn Engine Control switch to Off
position.

3 Engine Hour Meter/Idle Control
Hour Meter: With engine off, place Engine

Control switch in Run/Idle position to view en­gine hours.

OM-4434 Page 24

1

Oil Change Interval: With engine off, place En­gine Control switch in the Run position to see
hours before next oil change. Oil hours start at
100 and count down to 0 (zero) (oil change
due).

 Negative hours indicated when past rec-

ommended oil change interval.

To reset, cycle Engine Control switch from
Run/Idle to Run three times within five sec­onds (engine off).

4 Weld Process Selector Switch

NOTICE − Do not switch under load.

Use switch to select type of weld output.
Wire (GMAW) Welding: Use a positive (+)

position for Direct Current Electrode Positive
(DCEP) and a negative (−) position for Direct
Current Electrode Negative.

Stick (SMAW) and TIG (GTAW Welding): Use
a positive (+) position for Direct Current Elec­trode Positive (DCEP) and a negative (−) posi-
tion for Direct Current Electrode Negative.
Use AC position for alternating current.

5 Coarse Range Switch

2

NOTICE − Do not switch under load.

Use switch to select weld amperage range
when Weld Process Selector switch is in Stick/
Tig position, or voltage range when switch is in
Wire position.

Ref. 228 199-A

 For best arc starts and when using weld

and generator power together, use a low
Coarse Range setting with the Fine con­trol set at 7 or higher.

6 Fine Control
Use control to select weld amperage (Stick/

Tig) or voltage (Wire) within the range selected
by the Coarse Range switch. Control may be
adjusted while welding.

Set control at 10 for maximum generator
power.

Weld output would be about 110 A DC based
on control settings shown (80% of 70 to 150
A). Settings shown are typical for welding with
a 7018 (1/8) electrode.

 See Sections 6-3 thru 6-5 for typical pro-

cess connections and control settings.

6-2. Cold Weather Engine Operation

1

Infrequently
Loaded

Frequently
Loaded

Ref. 216 170

 A complete Parts List is available at www.MillerWelds.com

1 Engine Control Switch

Carburetor Icing

Carburetor icing causes the unit to drop below the normal idle speed and then
stall. This condition occurs when the temperature is near freezing and the rela­tive humidity is high. Ice forms on the throttle plate and inner bore of the carbu­retor. The engine typically restarts without problems but soon stalls again.

 Treat gasoline with a fuel de−icer product (isopropyl alcohol).
 Place the Engine Control switch in the Run position.
 Run engine only when expecting to frequently load it.

Breather Icing

Oil breather/pulse line icing occurs in severe cold (continuously below 0F).
Moisture accumulates in the oil from piston ring blow−by if the engine is exten­sively idled. This may cause vacuum line freezing, oil breather tube freezing
or ice in the carburetor. All of these cause operating problems. Due to ice in
the lines, the engine may not restart until it is warmed to above freezing.

 Load engine and reduce idle times to prevent engine shutdowns.
 Use an electric fuel pump to avoid pulse line freezing.
 Install engine cold−weather kit.

Both Kohler (1-800-544-2444) and Robin (1-800-277-6246) offer kits for cold
weather operation. The user can install these kits. Both kits pull heated air from
the muffler surface into the carburetor and shut the cold air off. This increases
engine temperature during operation in both idle and high speed.

 When the ambient temperatures become warmer (above 45_F) the air

flow will have to be returned to normal.

Notes

http://www.millerwelds.com/service/replacementparts.html

Choose Genuine Select to review spare parts requirements such

as filters, spark plugs, and fuses.

Choose Service Parts to download complete parts listing.

OM-4434 Page 25

 A complete Parts List is available at www.MillerWelds.com

6-3. Typical Stick Welding Connections And Control Settings

For best arc starts and best
results using weld and generator
power together, use a low
Coarse Range setting and the
Fine control set at 7 or higher.

Typical Settings For 7018 (1/8 in) Electrode

1

2

Electrode Selection Table (Beneath Cover)

! Stop engine.

 This section provides general

guidelines and may not suit all
applications.

 The control panel shows the typi-

cal settings for welding with a
7018 (1/8 in) electrode. Consult
the amperage selection tables
below if welding with other elec­trodes.

1 Work Clamp
2 Electrode Holder
Connect Work cable to Work terminal

and Electrode holder cable to Elec­trode terminal on welding generator.

 Be sure to use the correct size

weld cables (see Section 5-7).

 For best performance, set the

Coarse Range switch to the low­est range that covers the desired

weld amperage. Use the Fine
control to select the desired am­perage within the range se­lected. When properly set, the
Fine control is normally set at 7
or higher.

Typical Settings For 7018 (1/8 in)
Electrode:

> Set Weld Process Selector

switch to + Stick position.

> Set Coarse Range switch to

70-150 (1/8”) position.

> Set Fine control at 7 or higher

for best results.

ELECTRODE

6010

&

6011

6013

7014

7018

7024

Ni-Cl

308L

DIAMETER

3/32

1/8
5/32
3/16
7/32

1/4
1/16
5/64
3/32

1/8
5/32
3/16
7/32

1/4
3/32

1/8
5/32
3/16
7/32

1/4
3/32

1/8
5/32
3/16
7/32

1/4
3/32

1/8
5/32
3/16
7/32

1/4
3/32

1/8
5/32
3/16
3/32

1/8
5/32

50

100

150

AMPERAGE

200

RANGE

250

300

350

400

AC

450

6010
6011
6013

7014

7018

7024

NI-CL

308L

*EP = ELECTRODE POSITIVE (REVERSE POLARITY)
EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)

DC*

ELECTRODE

EP
EP

EP,EN

EP,EN

EP

EP,EN

EP
EP

POSITION

ALL
ALL
ALL

ALL

ALL

FLAT

HORIZ

FILLET

ALL
ALL

PENETRATION

DEEP

MIN. PREP, ROUGH

DEEP

LOW

MED

LOW

LOW

LOW
LOW

Tools Needed:

3/4 in

803 847-C / 228 199-A / 087 985-A / Ref. S-0653

USAGE

HIGH SPATTER

GENERAL

SMOOTH, EASY,

FAST

LOW HYDROGEN,

STRONG

SMOOTH, EASY,

FASTER

CAST IRON
STAINLESS

OM-4434 Page 26

 A complete Parts List is available at www.MillerWelds.com

6-4. Typical MIG Welding Connections And Settings

A. Solid Wire Applications

Typical Control Settings For .035 (ER70S-3)

Solid Wire − Short Circuit Transfer

Note Coarse Range,

Fine Control, and

Weld Process switch

settings.

6

7

Quick connector

2

3

! Stop engine.

 This section provides general guide-

lines and may not suit all ap­plications.

 The control panel shows the typical

settings for welding with .035
(ER70S-3) solid wire. Use Argon­based shielding gas.

1 Work Clamp
2 Wire Feeder
3 MIG Gun
4 Gun Trigger Plug

5 Voltage Sensing Clamp
6 Gas Cylinder:

75/25 Argon-Based Gas for Short
Circuit Transfer

80% Argon (Or Higher) For Spray

Transfer
7 Gas Hose
Connect work cable to welding generator

Work terminal. Connect cable from wire
feeder to cable from welding generator
Electrode terminal.

 Be sure to use the correct size weld

cables (see Section 5-7).

Loosen MIG gun securing knob. Insert
gun end through opening in feeder and
position as close as possible to drive rolls
without touching. Tighten knob.

See wire feeder manual for wire thread­ing procedure.

Insert gun trigger plug (item 4) into
matching receptacle and tighten
threaded collar.

Connect gas hose from feeder to regula­tor on cylinder.

Typical Control Settings For Short
Circuit Transfer Using .035 (ER70S-3)
Solid Wire And 75/25 Argon-Based
Gas:

> Set Weld Process Selector switch

to Wire + (DCEP) position.

> Set Coarse Range switch to Wire

19-28 volts position.

> Set Fine Control to obtain minimum

spatter.

> Set wire feed speed between

150-300 ipm.

Tools Needed:

3/4 in

5

1

4

Work

803 847-C / 802 766 / 228 199-A

OM-4434 Page 27

B. Self-Shielded Flux Core Wire Applications

Typical Control Settings For .045 (71T-11) Self-Shielded Flux Core Wire

Note Coarse Range,

Fine Control, and

Weld Process switch

settings.

Quick connector

2

 A complete Parts List is available at www.MillerWelds.com

! Stop engine.

 This section provides general

guidelines and may not suit all
applications.

 The control panel shows the typi-

cal settings for welding with .045
(71T-11) self-shielded flux core

wire.
1 Work Clamp
2 Wire Feeder
3 MIG Gun

4 Gun Trigger Plug
5 Voltage Sensing Clamp
Connect work cable to welding gen-

erator Work terminal. Connect cable
from wire feeder to cable from weld­ing generator Electrode terminal.

 Be sure to use the correct size

weld cables (see Section 5-7).

Loosen MIG gun securing knob. In­sert gun end through opening in feed­er and position as close as possible
to drive rolls without touching. Tight­en knob.

See wire feeder manual for wire
threading procedure.

Insert gun trigger plug (item 4) into
matching receptacle and tighten
threaded collar.

Typical Control Settings Using
.045 (71T-11) Self-Shielded Flux
Core Wire :

> Set Weld Process Selector

switch to Wire − position

(DCEN).

> Set Coarse Range switch to

Wire 19-28 volts position.

> Set Fine Control near minimum

setting.

> Set wire feed speed between

125-200 ipm.

3

> Do a test weld. To increase arc

length, increase Fine Control

setting. To shorten arc length,

reduce fine control setting or in-

crease wire feed speed.

Tools Needed:

OM-4434 Page 28

3/4 in

5

4

Work

1

803 847-C / 802 766 / 228 199-A

 A complete Parts List is available at www.MillerWelds.com

6-5. Typical MIG Connections And Settings Using Weld Control And Spoolgun

Typical Settings For
4043 (.035) Aluminum On
1/8 in Material:

Tools Needed:

3/4 in

9

Note Coarse Range and Weld

Process switch settings.

10

8

Work

2

 This section provides general guide-

lines and may not suit all applications.

1 Weld Control
2 Spoolgun
3 Optional Contactor (Recommended)
4 Reed Switch
5 Weld Cable (Customer-Supplied)
6 Weld Control Weld Terminal
7 Weld Power Cable From Spoolgun
8 Work Clamp
9 Gas Hose
10 Argon Cylinder
11 Trigger Control Cord

Connect to unused
contactor terminal.

6

11

12 Input Power Cord

 Be sure to use the correct size weld

Route weld cable from welding generator
Electrode terminal through reed switch to
unused contactor terminal. Connect weld
cable from spoolgun to weld control weld ter­minal (item 6).

Connect work cable to welding generator
Work terminal.

Insert trigger control plug (item 11) into weld
control receptacle. Tighten threaded collar.

Connect ac power cord (item 12) to 120 volt
ac receptacle on welding generator.

1

4 5 7

cables (see Section 5-7).

Left Side View

12

5

Plug and sensing lead not
used in this application.

3

6

Connect gas hose from spoolgun to regula­tor on Argon bottle.

Reinstall weld control wrapper.

Typical Settings For 4043 (.035)
Aluminum On 1/8 in Material:

802 847-C / 228 199-A

> Set Weld Process Selector switch to

Wire + (DCEP) position.

> Set Coarse Range switch to Wire

19-28 volts position.

> Set Fine Control to desired voltage

(arc length). Start with a low voltage
setting (about 4) to prevent burnback.

> Set wire feed speed between 240-270

ipm.

OM-4434 Page 29

SECTION 7 − OPERATING AUXILIARY EQUIPMENT

7-1. Standard Receptacles

 A complete Parts List is available at www.MillerWelds.com

21563

! If unit does not have GFCI re-

ceptacles, use GFCI-protected
extension cord.

 Generator power decreases as

weld current increases.
Set Fine Control R1 at 10 for full
generator power.

1 240 V 50 A AC Receptacle RC1
RC1 supplies 60 Hz single-phase

power at weld/power speed. Maxi­mum output is 10 kVA/kW.

2 120 V 20 A AC Duplex Recep-

tacle RC2

3 120 V 20 A AC Duplex Recep-

tacle RC3

RC2 and RC3 supply 60 Hz single­phase power at weld/power speed.
Maximum output from RC2 or RC3 is

2.4 kVA/kW.
4 Supplementary Protector CB1
CB1 protects receptacles RC1, RC2,

and RC3 from overload. If CB1
opens, the receptacles do not work.
Place switch in On position to reset.

5 Supplementary Protector CB2
6 Supplementary Protector CB3
CB2 protects RC2 and CB3 protects

RC3 from overload. If a supplementa­ry protector opens, the receptacle
does not work.

 Press button to reset. If supple-

mentary protector continues to
open, contact Factory
Authorized Service Agent.

Combined output of all receptacles
limited to 10 kVA/kW rating of the gen­erator.

EXAMPLE: If 20 A is drawn from
each 120 V duplex receptacle, only
21 A is available at the 240V
receptacle:

2 x (120 V x 20 A) + (240 V x 21 A) =
10 kVA/kW

OM-4434 Page 30

4

803 847-C / Ref. 228 199-A

7-2. Optional Generator Power Receptacles

1

 A complete Parts List is available at www.MillerWelds.com

! If unit does not have GFCI recep-

tacles, use GFCI-protected exten­sion cord.

 Generator power decreases as weld

current increases.

Set Fine Control R1 at 10 for full genera­tor power.

Combined output of all receptacles limited to
10 kVA/kW rating of the generator.

CSA/GFCI Receptacle Option

1 120 V 20 A AC GFCI Receptacles

GFCI-2 and GFCI-3

GFCI2 and GFCI3 supply 60 Hz single­phase power at weld/power speed. Maxi­mum output from GFCI-2 or GFCI-3 is 2.4
kVA/kW. Circuit protection is the same as
standard receptacles.

If a ground fault is detected, the GFCI Reset
button pops out and the circuit opens to dis­connect the faulty equipment. Check for
damaged tools, cords, plugs, etc. con­nected to the receptacle. Press button to re­set receptacle and resume operation.

! Power is still present at the 240 volt

receptacle when only one circuit
breaker trips.
Unplug power cord before attempt­ing to service accessories or tools.

 At least once a month, run engine at

weld/power speed and press Test but­ton to verify GFCI is working properly.

Notes

Ref. 228 199-A

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-4434 Page 31

7-3. Simultaneous Weld And Power

 A complete Parts List is available at www.MillerWelds.com

Weld Current in Amperes Total Power in Watts 120 V Full kVA Receptacle

Amperes

250 2200 18 9
180 3500 29 14
125 5200 43 21

90 8000 66 33

0 10,000 Robin Engine

10,500 Kohler Engine

84 Robin Engine

88 Kohler Engine

7-4. Wiring Optional 240 Volt Plug

Current Available in Amperes

240 V

Receptacle*

10
15
20
25
30
35
40

Each 120 V Duplex

Receptacle

0
5

20
20
20
20
20
15
10

5
0

V x A = Watts

*One 240 V load or two 120 V loads.

7

1

3

4

120V

120V

240V

6

2

240 V Full kVA Receptacle

Amperes

42 Robin Engine

44 Kohler Engine

The plug can be wired for a 240 V,
2-wire load or a 120/240V, 3-wire
load. See circuit diagram.

1 Plug Wired for 120/240 V,

3-Wire Load

When wired for 120 V loads, each
duplex receptacle shares a load
with one half of 240 V receptacle.

2 Plug Wired for 240 V, 2-Wire

Load
3 Neutral (Silver) Terminal
4 Load 1 (Brass)Terminal
5 Load 2 (Brass) Terminal
6 Ground (Green) Terminal
7 Amperes Available using

120/240 V Plug

5

Tools Needed:

120 V
AC

3

4

240V

56

240 V
AC

120 V
AC

plug1 11/03 − 120 813-D

OM-4434 Page 32

SECTION 8 − MAINTENANCE (ROBIN-POWERED UNITS)

8-1. Maintenance Label (Robin-Powered Units)

 A complete Parts List is available at www.MillerWelds.com

OM-4434 Page 33

8-2. Routine Maintenance (Robin-Powered Units)

Recycle engine

 A complete Parts List is available at www.MillerWelds.com

! Stop engine before maintaining.

 See Engine Manual and Maintenance Label

fluids.

for important start-up, service, and storage
information. Service engine more often if
used in severe conditions.

Every

8

Hours

Every

20

Hours

Every

25

Hours

Every

50

Hours

Every

100

Hours

Every

200

Hours

 = Check  = Change  = Clean  = Replace
* To be done by Factory Authorized Service Agent

 Fuel Level  Oil Level  Oil, Fuel Spills

 Spark Arrestor Screen

 Air Cleaner Wrapper

 Weld Terminals

 Battery Terminals  Cooling System  Oil  Air Cleaner Element

Reference

Section 5-2

Section 8-4

Section 8-3

Engine
Manual,
Section 8-3,
8-5

Engine
Manual,
Section 8-5

Every

500

Hours

 Unreadable Labels  Spark Plug Gap  Oil Filter  Fuel Filter

 Weld Cables  Slip Rings*

 Brushes*

Valve Clearance*

Engine
Manual

OM-4434 Page 34

8-3. Servicing Air Cleaner (Robin-Powered Units)

 A complete Parts List is available at www.MillerWelds.com

! Stop engine.

NOTICE − Do not run engine with-
out air cleaner or with dirty element.

1 Precleaner
Wash precleaner with soap and wa-

1

ter solution. Allow precleaner to air
dry completely.

Spread 1 tablespoon SAE 30 oil

2

evenly into precleaner. Squeeze
out excess oil.

2 Element
Replace element if damaged, dirty,

or oily.

oil

8-4. Servicing Optional Spark Arrestor (Robin-Powered Units)

1

aircleaner3 11/04 − 803 070 / S-0759

! Stop engine and let cool.

1 Spark Arrestor Screen
Clean and inspect screen. Replace

spark arrestor if screen wires are
broken or missing.

Tools Needed:

1/4 in

Ref. 803 848-C / Ref. 801 682

OM-4434 Page 35

 A complete Parts List is available at www.MillerWelds.com

8-5. Changing Engine Oil, Oil Filter, and Fuel Filter (Robin-Powered Units)

! Stop engine and let cool.

1 Oil Drain Valve
2 1/2 ID x 7 in Hose
3 Oil Filter
Change engine oil and filter accord-

ing to engine owner’s manual.

! Close valve and valve cap

before adding oil and
running engine.

Oil Fill

Oil Check

Full

Fill crankcase with new oil to full
mark on dipstick (see Section 5-2).

4 Fuel Filter
5 Fuel Line
Replace line if cracked or worn.

Install new filter. Wipe up any spilled
fuel.

Start engine, and check for fuel
leaks.

! Stop engine, tighten connec-

tions as necessary, and wipe
up fuel.

4

5

3

2

1

Tools Needed:

OM-4434 Page 36

803 848-C / 802 921-A / S-0842

 A complete Parts List is available at www.MillerWelds.com

8-6. Adjusting Engine Speed (Robin-Powered Units)

2200 − 2300 rpm

(36.6 − 38.3 Hz)

3675 − 3750 rpm

(61.3 − 62.5 Hz)

1

2

4

6

5

After tuning engine, check engine
speeds with a tachometer (see
table). If necessary, adjust speeds
as follows:

Start engine and run until warm.
Remove rear panel and air cleaner

to access idle speed adjustments.
Remove top cover to access weld/
power speed adjustments.

Idle Speed Adjustment

Move Engine Control switch to
Run/Idle position.

1 Throttle Solenoid
2 Mounting Screws
3 Idle Speed Screw
Loosen mounting screws. Adjust

solenoid position so engine runs at
idle speed. If necessary, back out
idle speed screw so solenoid can

3

be moved to correct position. Tight­en mounting screws. Be sure sole­noid linkage works smoothly.

Turn idle speed screw for fine
adjustments.

Weld/Power Speed Adjustment

Move Engine Control switch to Run
position.

4 Jam Nut
5 Lock Nut
6 Weld/Power Speed

Adjustment Screw

Loosen jam nut and lock nut. Turn
adjustment screw until engine runs
at weld/power speed. Tighten jam
nut, and then tighten lock nut.

! Stop engine.

Reinstall air cleaner, rear panel,
and top cover.

Tools Needed:

10 mm

8 mm

803 848-C / 802 457

OM-4434 Page 37

8-7. Overload Protection (Robin-Powered Units)

21

 Fuse F6 located in

harness behind left
side door.

3

 Fuses F1, F2 located on

bracket behind left side
panel.

Tools Needed:

 A complete Parts List is available at www.MillerWelds.com

! Stop engine. Disconnect

negative (−) battery cable.

1 Fuse F1 (See Section 11-1)
F1 protects the weld excitation

winding from overload. If F1 opens,
weld output stops or is low.

2 Fuse F2 (See Section 11-1)
F2 protects the generator power

excitation winding from overload. If
F2 opens, generator power output
stops or is low.

3 Fuse F6 (See Section 11-1)
F6 protects the engine wiring sys-

tem from overload. If F6 opens,
engine will not crank.

Replace any open fuses. Reinstall
cover before operating.

NOTICE − If a fuse opens, it usually
indicates a more serious problem
exists. Contact a Factory Autho­rized Service Agent.

3/8 in

Notes

803 848-C

MATERIAL THICKNESS REFERENCE CHART

24 Gauge (.025 in)
22 Gauge (.031 in)
20 Gauge (.037 in)

18 Gauge (.050 in)
16 Gauge (.063 in)
14 Gauge (.078 in)

1/8 in (.125 in)

3/16 in (.188 in)

1/4 in (.25 in)

OM-4434 Page 38

5/16 in (.313 in)

3/8 in (.375 in)

1/2 in (.5 in)

 A complete Parts List is available at www.MillerWelds.com

SECTION 9 − MAINTENANCE − (KOHLER-POWERED UNITS)

9-1. Maintenance Label (Kohler-Powered Units)

OM-4434 Page 39

9-2. Routine Maintenance (Kohler-Powered Units)

Recycle engine

 A complete Parts List is available at www.MillerWelds.com

! Stop engine before maintaining.

 See Engine Manual and Maintenance Label

fluids.

for important start-up, service, and storage
information. Service engine more often if
used in severe conditions.

Every

8

Hours

Every

20

Hours

Every

25

Hours

Every

50

Hours

Every

100

Hours

Every

200

Hours

 = Check  = Change  = Clean  = Replace
* To be done by Factory Authorized Service Agent

 Fuel Level  Oil Level  Oil, Fuel Spills

 Spark Arrestor Screen

 Air Cleaner Wrapper

 Weld Terminals

 Battery Terminals  Cooling System  Oil  Air Cleaner Element

Reference

Section 5-3

Section 9-7

Section 9-3

Engine
Manual,
Section 9-3,
9-4

Engine
Manual,
Section 9-4

Every

500

Hours

 Unreadable Labels  Spark Plug Gap  Oil Filter  Fuel Filter

Engine
Manual

 Weld Cables  Slip Rings*

 Brushes*

OM-4434 Page 40

 A complete Parts List is available at www.MillerWelds.com

9-3. Servicing Air Cleaner (Kohler−Powered Units)

! Stop engine.

NOTICE − Do not run engine with-
out air cleaner or with dirty element.

1 Precleaner
Wash precleaner with soap and wa-

ter solution. Allow precleaner to air
dry completely.

1

2

Spread 1 tablespoon SAE 30 oil
evenly into precleaner. Squeeze
out excess oil.

2 Element
Replace element if damaged, dirty,

or oily.

Notes

oil

aircleaner3 11/04 − 802 772 / S-0759

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-4434 Page 41

 A complete Parts List is available at www.MillerWelds.com

9-4. Changing Engine Oil, Oil Filter, and Fuel Filter (Kohler-Powered Units)

! Stop engine and let cool.

1 Oil Drain Valve
2 1/2 ID x 7 in Hose
3 Oil Filter
Change engine oil and filter accord-

ing to engine owner’s manual.

! Close valve and valve cap

Full

4

before adding oil and
running engine.

Fill crankcase with new oil to full
mark on dipstick (see Section 5-3).

4 Fuel Filter
5 Fuel Line
Replace line if cracked or worn.

Install new filter. Wipe up any spilled
fuel.

Start engine, and check for fuel
leaks.

! Stop engine, tighten connec-

tions as necessary, and wipe
up fuel.

5

3

2

1

Tools Needed:

OM-4434 Page 42

803 847-C / S-0842

 A complete Parts List is available at www.MillerWelds.com

9-5. Adjusting Engine Speed (Kohler-Powered Units)

2200 − 2300 rpm

(36.6 − 38.3 Hz)

3675 − 3750 rpm

(61.3 − 62.5 Hz)

1

5

4

3

Top View

2

After tuning engine, check engine
speeds with a tachometer (see
table). If necessary, adjust speeds
as follows:

Start engine and run until warm.
Turn Fine Control to 10.

Remove rear panel and air cleaner
to access idle speed adjustments.
Remove top cover to access weld/
power speed adjustments.

Idle Speed Adjustment

Move Engine Control switch to
Run/Idle position.

1 Throttle Solenoid
2 Mounting Screws
3 Idle Speed Screw
Loosen mounting screws. Adjust

solenoid position so engine runs at
idle speed. If necessary, back out
idle speed screw so solenoid can
be moved to correct position. Tight­en mounting screws. Be sure sole­noid linkage works smoothly.

Turn idle speed screw for fine ad­justments.

Weld/Power Speed Adjustment

Move Engine Control switch to Run
position.

4 Weld/Power Speed

Adjustment Nut
5 Lock Nut
Loosen lock nut. Turn adjustment

nut until engine runs at weld/power
speed. Tighten lock nut.

! Stop engine.

Reinstall air cleaner, rear panel,
and top cover.

Tools Needed:

1/4, 3/8 in

803 849 / 801 209-A

OM-4434 Page 43

9-6. Overload Protection (Kohler-Powered Units)

21

 Fuse F6 located in

harness behind left
side door.

3

 Fuses F1, F2 located on

bracket behind left side
panel.

 A complete Parts List is available at www.MillerWelds.com

! Stop engine. Disconnect

negative (−) battery cable.

1 Fuse F1 (See Section 11-1)
F1 protects the weld excitation

winding from overload. If F1 opens,
weld output stops or is low.

2 Fuse F2 (See Section 11-1)
F2 protects the generator power

excitation winding from overload. If
F2 opens, generator power output
stops or is low.

3 Fuse F6 (See Section 11-1)
F6 protects the engine wiring sys-

tem from overload. If F6 opens,
engine will not crank.

Replace any open fuses. Reinstall
cover before operating.

 If a fuse opens, it usually indi-

cates a more serious problem
exists. Contact a Factory Au­thorized Service Agent.

Tools Needed:

3/8 in

9-7. Servicing Optional Spark Arrestor (Kohler-Powered Units)

1

803 847-C

! Stop engine and let cool.

1 Spark Arrestor Screen
Clean and inspect screen. Replace

spark arrestor if screen wires are
broken or missing.

Tools Needed:

OM-4434 Page 44

1/4 in

803 847-C / Ref. 801 682-A

 A complete Parts List is available at www.MillerWelds.com

SECTION 10 − TROUBLESHOOTING

10-1. Welding Troubleshooting

Trouble Remedy

Low or no weld output; generator pow­er output okay at ac receptacles.

No weld output or generator power out­put at ac receptacles.

Low weld output. Check fuse F1, and replace if open (see Section 8-7 or 9-6).

High weld output. Check control settings.

Erratic weld output. Check control settings.

Check control settings.

Check weld connections.

Check fuse F1, and replace if open (see Section 8-7 or 9-6).

Have Factory Authorized Service Agent check brushes, slip rings, capacitor C1, and integrated rectifi­ers SR2 and SR3.

Be sure all equipment is disconnected from receptacles when starting unit.

Check fuses F1 and F2, and replace if open (see Section 8-7 or 9-6).

Check plug PLG6 connection.

Have Factory Authorized Service Agent check brushes, slip rings, capacitor C1, and integrated rectifi­ers SR2 and SR3.

Check control settings.

Check engine speed, and adjust if necessary (see Section 8-6 or 9-5).

Service air cleaner according to engine manual.

Have Factory Authorized Service Agent check brushes, slip rings, capacitor C1, and integrated rectifi­ers SR2 and SR3.

Check engine speed, and adjust if necessary (see Section 8-6 or 9-5).

Tighten and clean connections to electrode and workpiece.

Use dry, properly-stored electrodes for Stick and TIG welding.

Remove excessive coils from weld cables.

Clean and tighten connections both inside and outside welding generator.

Check engine speed, and adjust if necessary (see Section 8-6 or 9-5).

Have Factory Authorized Service Agent check brushes, slip rings, and integrated rectifiers SR2, SR3.

10-2. Generator Power Troubleshooting

Trouble Remedy

No or low generator power output at ac
receptacles; weld output okay.

Reset supplementary protectors (see Section 7-1 or 7-2).
Press optional GFCI receptacle Reset button (see Section 7-2).
Check fuse F2, and replace if open (see Section 8-7 or 9-6).

Check plug PLG6 connection.

Have Factory Authorized Service Agent check brushes, slip rings, and integrated rectifier SR3.

OM-4434 Page 45

 A complete Parts List is available at www.MillerWelds.com

C

Trouble Remedy

No generator power or weld output. Be sure all equipment is disconnected from receptacles when starting unit.

Check fuses F1 and F2, and replace if open (see Section 8-7 or 9-6).

Check plug PLG6 connection.

Have Factory Authorized Service Agent check brushes, slip rings, capacitor C1, and integrated rectifi­ers SR2 and SR3.

Low power output at ac receptacles. Check fuse F2, and replace if open (see Section 8-7 or 9-6).

Increase Fine control R1 setting to max.

High power output at ac receptacles. Check engine speed, and adjust if necessary (see Section 8-6 or 9-5).

Erratic power output at ac receptacles. Check fuel level.

Check engine speed, and adjust if necessary (see Section 8-6 or 9-5).

Check receptacle wiring and connections.

Have Factory Authorized Service Agent check brushes and slip rings.

10-3. Engine Troubleshooting

Trouble Remedy

Engine will not crank. Check fuse F6, and replace if open (see Section 8-7 or 9-6).

Check battery voltage.

Check battery connections and tighten if necessary.

Check plug PLG4 and plug PLG8 connections.

Have Factory Authorized Service Agent check Engine Control switch S2.

Engine will not start. Check fuel level.

Check battery voltage.

Check battery connections and tighten if necessary.

Check oil level (see Section 5-2 or 5-3).

Check low oil pressure shutdown switch.

Have Factory Authorized Service Agent check fuel shutoff solenoid FS1 and diode D8. (FS1 optional on
Robin-powered units.)

Engine starts but stops when Engine

ontrol switch returns to Run position.

Engine stopped during normal
operation.

Check oil level.

Check and refill crankcase with proper viscosity oil for operating temperature, if necessary.

Check low oil pressure shutdown switch.

Check fuel level.

Check oil level (see Section 5-2 or 5-3).

Check low oil pressure shutdown switch.

Periodically recharge battery (approximately every 3 months).

Replace battery.

Check voltage regulator and connections according to engine manual.

Have Factory Authorized Service Agent check fuel shutoff solenoid FS1 (FS1 optional on Robin-powered
units).

OM-4434 Page 46

 A complete Parts List is available at www.MillerWelds.com

Trouble Remedy

Battery Discharges between uses. Clean battery, terminals, and posts with baking soda and water solution; rinse with clear water.

Periodically recharge battery (approximately every 3 months).

Replace battery.

Check voltage regulator and connections according to engine manual.

Engine idles but does not come up to
weld speed.

Unstable or sluggish engine speeds. Readjust throttle linkage if necessary. Check throttle solenoid TS1 for smooth operation.

Engine does not return to idle speed. Remove weld and generator power loads.

Have Factory Authorized Service Agent check hour meter/idle module, and current transformer CT1.

Check oil level. Oil level should not exceed Full mark on dipstick. Fuel pump will operate erratically if
crankcase is overfilled.

Tune-up engine according to engine manual.

Check throttle linkage for smooth, non-binding operation.

Have Factory Authorized Service Agent check hour meter/idle module, current transformer CT1, Engine
Control switch S2, and throttle solenoid TS1.

SECTION 11 − PARTS LIST

11-1. Recommended Spare Parts

Dia.

Mkgs.

F1, F2 169296 Fuse, Mintr Gl 25. Amp 125 Volt 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F6 021718 Fuse, Mintr Gl 30. Amp 32 Volt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

 A complete Parts List is available on-line at www.MillerWelds.com.

Part

No.

Description

Recommended Spare Parts

215984 Filter, Fuel In−line .250 (Kohler)1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

230015 Tune−up & Filter Kit, Kohler (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

230016 Air Filter Element, Kohler 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

066698 Oil Filter, Kohler 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

215985 Filter, Fuel w/Clamps & 1/4 in Fuel Line 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

067007 Spark Plug 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

230017 Air Filter Wrapper 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

066113 Filter, Fuel In−line .250 (Robin) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

199062 Tune−up & Filter Kit, Robin (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

198755 Element, Air Filter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

198754 Filter, Oil 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

215985 Filter, Fuel w/Clamps & 1/4 Fuel Line 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

198777 Spark Plug 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

OM-4434 Page 47

SECTION 12 − ELECTRICAL DIAGRAMS

OM-4434 Page 48

Figure 12-1. Circuit Diagram For Welding Generator

228 461-A

OM-4434 Page 49

SECTION 13 − GENERATOR POWER GUIDELINES

 The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown.

13-1. Selecting Equipment

1 Generator Power Receptacles

− Neutral Bonded To Frame

2 3-Prong Plug From Case

Grounded Equipment

3 2-Prong Plug From Double

Insulated Equipment

 Be sure equipment has double

1

2

3

OR

insulated symbol and/or word­ing on it.

Do not use 2-prong plug un­less equipment is double in­sulated.

gen_pwr 2007−04 − Ref. ST-159 730 / ST-800 577

13-2. Grounding Generator To Truck Or Trailer Frame

1

GND/PE

2

3

Always ground generator
frame to vehicle frame to pre­vent electric shock and static
electricity hazards.

Also see AWS Safety &
Health Fact Sheet No. 29,
Grounding of Portable And
Vehicle Mounted Welding
Generators.

1 Equipment Grounding

Terminal (On Front Panel)

2 Grounding Cable (Not

Supplied)
3 Metal Vehicle Frame
Connect cable from equipment

ground terminal to metal vehicle
frame. Use #10 AWG or larger
insulated copper wire.

 Electrically bond generator

frame to vehicle frame by met-

al-to-metal contact.

Bed liners, shipping skids,

and some running gear insu-

late the welding generator

from the vehicle frame. Al-

ways connect a ground wire

from the generator equip-

ment grounding terminal to

bare metal on the vehicle

frame as shown.

If unit does not have GFCI re-

ceptacles, use GFCI-pro-

tected extension cord.

S-0854

OM-4434 Page 50

13-3. Grounding When Supplying Building Systems

1 2

GND/PE

2

3

1 Equipment Grounding

Terminal
2 Grounding Cable
Use #10 AWG or larger insulated

copper wire.
3 Ground Device

 Use ground device as stated in

electrical codes.

Ground generator to system

earth ground if supplying

power to a premises (home,

shop, farm) wiring system.

Also see AWS Safety &

Health Fact Sheet No. 29,

Grounding of Portable And

Vehicle Mounted Welding

Generators.

13-4. How Much Power Does Equipment Require?

3

2

1

3

VOLTS 115
AMPS
Hz

4.5
60

ST-800 576-B

1 Resistive Load
A light bulb is a resistive load and

requires a constant amount of power.
2 Non-Resistive Load
Equipment with a motor is a non-re-

sistive load and requires approxi­mately six times more power while
starting the motor than when running
(see Section 13-8).

3 Rating Data
Rating shows volts and amperes, or

watts required to run equipment.

Amperes x Volts = Watts

Example 1: If a drill uses 4.5 am-

peres at 115 volts, calculate its run­ning power requirement in watts.

4.5 A x 115 V = 520 W
The load applied by the drill is 520

watts.
Example 2: If three 200 watt flood

lamps are used with the drill from Ex­ample 1, add the individual loads to
calculate total load.

(3 x 200W) + 520 W = 1120 W
The total load applied by the three

flood lamps and drill is 1120 watts.

S-0623

OM-4434 Page 51

13-5. 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

13-6. Approximate Power Requirements For Farm/Home Equipment

Farm/Home Equipment Rating Starting Watts Running Watts

Stock Tank De-Icer 1000 1000
Grain Cleaner 1/4 HP 1650 650
Portable Conveyor 1/2 HP 3400 1000
Grain Elevator 3/4 HP 4400 1400
Milk Cooler 2900 1100
Milker (Vacuum Pump) 2 HP 10500 2800
FARM DUTY MOTORS 1/3 HP 1720 720
Std. (e.g. Conveyors, 1/2 HP 2575 975
Feed Augers, Air 3/4 HP 4500 1400
Compressors) 1 HP 6100 1600

1-1/2 HP 8200 2200

2 HP 10550 2850
3 HP 15900 3900

5 HP 23300 6800
High Torque (e.g. Barn 1-1/2 HP 8100 2000
Cleaners, Silo Unloaders, 5 HP 23300 6000
Silo Hoists, Bunk Feeders) 7-1/2 HP 35000 8000

10 HP 46700 10700
3-1/2 cu. ft. Mixer 1/2 HP 3300 1000
High 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-4434 Page 52

13-7. Approximate Power Requirements For Contractor Equipment

Contractor Rating Starting Watts Running Watts

Hand Drill 1/4 in 350 350

3/8 in 400 400
1/2 in 600 600

Circular Saw 6-1/2 in 500 500

7-1/4 in 900 900
8-1/4 in 1400 1400

Table Saw 9 in 4500 1500

10 in 6300 1800
Band Saw 14 in 2500 1100
Bench Grinder 6 in 1720 720

8 in 3900 1400

10 in 5200 1600
Air Compressor 1/2 HP 3000 1000

1 HP 6000 1500

1-1/2 HP 8200 2200

2 HP 10500 2800
Electric Chain Saw 1-1/2 HP, 12 in 1100 1100

2 HP, 14 in 1100 1100

Electric Trimmer Standard 9 in 350 350

Heavy Duty 12 in 500 500
Electric Cultivator 1/3 HP 2100 700
Elec. Hedge Trimmer 18 in 400 400
Flood Lights HID 125 100

Metal Halide 313 250

Mercury 1000

Sodium 1400

Vapor 1250 1000
Submersible Pump 400 gph 600 200
Centrifugal Pump 900 gph 900 500
Floor Polisher 3/4 HP, 16 in 4500 1400

1 HP, 20 in 6100 1600

High Pressure Washer 1/2 HP 3150 950

3/4 HP 4500 1400

1 HP 6100 1600
55 gal Drum Mixer 1/4 HP 1900 700
Wet & Dry Vac 1.7 HP 900 900

2-1/2 HP 1300 1300

OM-4434 Page 53

13-8. Power Required To Start Motor

Single-Phase Induction Motor Starting Requirements

Motor Start

Code

KVA/HP 6.3 7.1 8.0 9.0 10.0 11.2 12.5 14.0

G H J K L M N P

1 Motor Start Code
2 Running Amperage

4
1

VOLTS AMPS

3

CODE 60

HP

AC MOTOR

230 2.5

M

1/4

Hz
PHASE

1

2

3 Motor HP
4 Motor Voltage
To find starting amperage:

Step 1: Find code and use table to
find kVA/HP. If code is not listed,
multiply running amperage by six to
find starting amperage.

Step 2: Find Motor HP and Volts.
Step 3: Determine starting amper-

age (see example).
Welding generator amperage out-

put must be at least twice the
motor’s running amperage.

(kVA/HP x HP x 1000) / Volts =

Starting Amperage

Example: Calculate starting amper­age required for a 230 V, 1/4 HP mo­tor with a motor start code of M.

Volts = 230, HP = 1/4, kVA/HP =

11.2
(11.2 x 1/4 x 1000) / 230 = 12.2A
Starting the motor requires 12.2

amperes.

S-0624

13-9. How Much Power Can Generator Supply?

1

2

1 Limit Load To 90% Of

Generator Output

Always start non-resistive (motor)
loads in order from largest to small­est, and add resistive loads last.

2 5 Second Rule
If motor does not start within 5

seconds, turn off power to prevent
motor damage. Motor requires
more power than generator can
supply.

OM-4434 Page 54

Ref. ST-800 396-A / S-0625

13-10. Typical Connections To Supply Standby Power

123

Utility

Electrical

Service

Transfer Switch

5

Essential

Loads

Fused

Disconnect

Switch

(If Required)

4

Welding

Generator

Output

Have only qualified persons
perform these connections
according to all applicable
codes and safety practices.

Properly install and ground
this equipment according to
its Owner’s Manual and na­tional, state, and local codes.

 Customer-supplied equipment

is required if generator will sup­ply standby power during
emergencies or power out­ages.

1 Utility Electrical Service
2 Transfer Switch (Double-Throw)
Switch transfers the electrical load

from electric utility service to the
generator. Transfer load back to
electric utility when service is re­stored.

Install correct switch (customer­supplied). Switch rating must be
same as or greater than the branch
overcurrent protection.

3 Fused Disconnect Switch
Install correct switch (customer-

supplied) if required by electrical
code.

4 Welding Generator Output
Generator output voltage and wir-

ing must be consistent with regular
(utility) system voltage and wiring.

Connect generator with temporary
or permanent wiring suitable for the
installation.

Turn off or unplug all equipment
connected to generator before
starting or stopping engine. When
starting or stopping, the engine has
low speed which causes low volt­age and frequency.

5 Essential Loads
Generator output may not meet the

electrical requirements of the prem­ises. If generator does not produce
enough output to meet all require­ments, connect only essential
loads (pumps, freezers, heaters,
etc. − See Section 13-4).

OM-4434 Page 55

13-11. Selecting Extension Cord (Use Shortest Cord Possible)

Cord 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)*

Current

(Amperes)

5 600 350 (106) 225 (68) 137 (42) 100 (30)

7 840 400 (122) 250 (76) 150 (46) 100 (30) 62 (19)

10 1200 400 (122) 275 (84) 175 (53) 112 (34) 62 (19) 50 (15)

15 1800 300 (91) 175 (53) 112 (34) 75 (23) 37 (11) 30 (9)

20 2400 225 (68) 137 (42) 87 (26) 50 (15) 30 (9)

25 3000 175 (53) 112 (34) 62 (19) 37 (11)

30 3600 150 (46) 87 (26) 50 (15) 37 (11)

35 4200 125 (38) 75 (23) 50 (15)

40 4800 112 (34) 62 (19) 37 (11)

45 5400 100 (30) 62 (19)

50 6000 87 (26) 50 (15)

*Conductor size is based on maximum 2% voltage drop

Cord Lengths for 240 Volt Loads

If unit does not have GFCI receptacles, use GFCI-protected extension cord.

Load (Watts) 4 6 8 10 12 14

Current

(Amperes)

5 1200 700 (213) 450 (137) 225 (84) 200 (61)

7 1680 800 (244) 500 (152) 300 (91) 200 (61) 125 (38)

10 2400 800 (244) 550 (168) 350 (107) 225 (69) 125 (38) 100 (31)

15 3600 600 (183) 350 (107) 225 (69) 150 (46) 75 (23) 60 (18)

20 4800 450 (137) 275 (84) 175 (53) 100 (31) 60 (18)

25 6000 350 (107) 225 (69) 125 (38) 75 (23)

30 7000 300 (91) 175 (53) 100 (31) 75 (23)

35 8400 250 (76) 150 (46) 100 (31)

40 9600 225 (69) 125 (38) 75 (23)

45 10,800 200 (61) 125 (38)

50 12,000 175 (53) 100 (31)

*Conductor size is based on maximum 2% voltage drop

Load (Watts) 4 6 8 10 12 14

Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*

OM-4434 Page 56

SECTION 14 − STICK WELDING (SMAW) GUIDELINES

14-1. Stick Welding Procedure

Weld current starts when elec­trode touches workpiece.

Weld current can damage elec­tronic parts in vehicles. Discon­nect both battery cables before
welding on a vehicle. Place work
clamp as close to the weld as
possible.

1 Workpiece
Make sure workpiece is clean be-

5

4

2

3

6

1

7

fore welding.
2 Work Clamp
3 Electrode
A small diameter electrode requires

less current than a large one. Fol­low electrode manufacturer’s
instructions when setting weld am­perage (see Section 14-2).

4 Insulated Electrode Holder
5 Electrode Holder Position
6 Arc Length
Arc length is the distance from the

electrode to the workpiece. A short
arc with correct amperage will give
a sharp, crackling sound.

7 Slag
Use a chipping hammer and wire

brush to remove slag. Remove slag
and check weld bead before mak­ing another weld pass.

Tools Needed:

stick 2007−04 − ST-151 593

OM-4434 Page 57

14-2. Electrode and Amperage Selection Chart

RANGE

AMPERAGE

ELECTRODE

6010

&

6011

6013

7014

7018

7024

Ni-Cl

308L

DIAMETER

3/32

1/8
5/32
3/16
7/32

1/4
1/16
5/64
3/32

1/8
5/32
3/16
7/32

1/4
3/32

1/8
5/32
3/16
7/32

1/4
3/32

1/8
5/32
3/16
7/32

1/4
3/32

1/8
5/32
3/16
7/32

1/4
3/32

1/8
5/32
3/16
3/32

1/8
5/32

50

100

150

200

250

300

350

400

450

AC

DC*

ELECTRODE

EP

6010

EP

6011

EP,EN

6013

EP,EN

7014

EP

7018

EP,EN

7024

EP

NI-CL

EP

308L

*EP = ELECTRODE POSITIVE (REVERSE POLARITY)
EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)

POSITION

ALL
ALL
ALL

ALL

ALL

FLAT
HORIZ
FILLET

ALL
ALL

PENETRATION

DEEP
DEEP

LOW

MED

LOW

LOW

LOW
LOW

USAGE

MIN. PREP, ROUGH

HIGH SPATTER

GENERAL

SMOOTH, EASY,

FAST

LOW HYDROGEN,

STRONG

SMOOTH, EASY,

FASTER

CAST IRON
STAINLESS

Ref. S-087 985-A

14-3. Striking an Arc − Scratch Start Technique

1

3

14-4. Striking an Arc − Tapping Technique

1

3

1 Electrode
2 Workpiece
3 Arc
Drag electrode across workpiece

2

like striking a match; lift electrode
slightly after touching work. If arc
goes out electrode was lifted to
high. If electrode sticks to work­piece, use a quick twist to free it.

S-0049

1 Electrode
2 Workpiece
3 Arc
Bring electrode straight down to

workpiece; then lift slightly to start

2

arc. If arc goes out, electrode was
lifted too high. If electrode sticks to
workpiece, use a quick twist to free it.

S-0050

OM-4434 Page 58

14-5. Positioning Electrode Holder

90° 90°

End View of Work Angle Side View of Electrode Angle

10°-30°

GROOVE WELDS

45°

45°

End View of Work Angle Side View of Electrode Angle

14-6. Poor Weld Bead Characteristics

FILLET WELDS

2

3

10°-30°

S-0060

1 Large Spatter Deposits
2 Rough, Uneven Bead
3 Slight Crater During Welding
4 Bad Overlap
5 Poor Penetration

1

4

14-7. Good Weld Bead Characteristics

5

1 Fine Spatter
2 Uniform Bead
3 Moderate Crater During

Welding

Weld a new bead or layer for each
1/8 in. (3.2 mm) thickness in metals
being welded.

1

5234

4 No Overlap
5 Good Penetration into Base

Metal

OM-4434 Page 59

S-0053-A

S-0052-B

14-8. Conditions That Affect Weld Bead Shape

 Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal.

Angle Too Small

Too Short

Slow

Correct Angle

10° - 30°

Drag

ELECTRODE ANGLE

Normal Too Long

ARC LENGTH

Normal Fast

TRAVEL SPEED

Angle Too Large

Spatter

S-0061

14-9. Electrode Movement During Welding

 Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps,

a weave bead or multiple stringer beads work better.

1 Stringer Bead − Steady

Movement Along Seam

1

3

2

2 Weave Bead − Side to Side

Movement Along Seam
3 Weave Patterns
Use weave patterns to cover a wide

area in one pass of the electrode.
Do not let weave width exceed
2-1/2 times diameter of electrode.

S-0054-A

OM-4434 Page 60

14-10. Butt Joints

1

14-11. Lap Joint

2

Single-Layer Fillet Weld

1 Tack Welds

2

1/16 in

(1.6 mm)

3

30°
Or Less

11

30°

4

30°
Or Less

3

Multi-Layer Fillet Weld

Prevent edges of joint from drawing
together ahead of electrode by tack
welding the materials in position be­fore final weld.

2 Square Groove Weld
Good for materials up to 3/16 in (5

mm) thick.
3 Single V-Groove Weld
Good for materials 3/16 − 3/4 in

(5-19 mm) thick. Cut bevel with oxy­acetylene or plasma cutting equip­ment. Remove scale from material
after cutting. A grinder can also be
used to prepare bevels.

Create 30 degree angle of bevel on
materials in V-groove welding.

4 Double V-Groove Weld
Good for materials thicker than 3/16

in (5 mm).

S-0662

1 Electrode
2 Single-Layer Fillet Weld
Move electrode in circular motion.
3 Multi-Layer Fillet Weld
Weld a second layer when a heavi-

er fillet is needed. Remove slag be­fore making another weld pass.
Weld both sides of joint for maxi­mum strength.

S-0063 / S-0064

14-12. Tee Joint

2

1

45°

Or Less

1 Electrode
2 Fillet Weld
Keep arc short and move at definite

rate of speed. Hold electrode as
shown to provide fusion into the
corner. Square edge of the weld
surface.

For maximum strength weld both

2

1

3

sides of upright section.
3 Multi-Layer Deposits
Weld a second layer when a heavi-

er fillet is needed. Use any of the
weaving patterns shown in Section
14-9. Remove slag before making
another weld pass.

S-0060 / S-0058-A / S-0061

OM-4434 Page 61

14-13. Weld Test

3

2 To 3 in

(51-76 mm)

2 To 3 in

(51-76 mm)

1/4 in

(6.4 mm)

2
1

2

14-14. Troubleshooting − Porosity

Porosity − small cavities or holes resulting from gas
pockets in weld metal.

Possible Causes Corrective Actions

Arc length too long. Reduce arc length.

1 Vise
2 Weld Joint
3 Hammer

3

1

Strike weld joint in direction shown.
A good weld bends over but does
not break.

S-0057-B

Damp electrode. Use dry electrode.

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before

welding.

14-15. Troubleshooting − Excessive Spatter

Excessive Spatter − scattering of molten metal particles
that cool to solid form near weld bead.

Possible Causes Corrective Actions

Amperage too high for electrode. Decrease amperage or select larger electrode.

Arc length too long or voltage too high. Reduce arc length or voltage.

OM-4434 Page 62

14-16. Troubleshooting − Incomplete Fusion

Incomplete Fusion − failure of weld metal to fuse completely with
base metal or a preceeding weld bead.

Possible Causes Corrective Actions

Insufficient heat input. Increase amperage. Select larger electrode and increase amperage.

Improper welding technique. Place stringer bead in proper location(s) at joint during welding.

Adjust work angle or widen groove to access bottom during welding.

Momentarily hold arc on groove side walls when using weaving technique.

Keep arc on leading edge of weld puddle.

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before

welding.

14-17. Troubleshooting − Lack Of Penetration

Lack Of Penetration − shallow fusion between weld metal and
base metal.

Lack of Penetration Good Penetration

Possible Causes Corrective Actions

Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove.

Improper weld technique. Keep arc on leading edge of weld puddle.

Insufficient heat input. Increase amperage. Select larger electrode and increase amperage.

Reduce travel speed.

14-18. Troubleshooting − Excessive Penetration

Excessive Penetration − weld metal melting through base metal and
hanging underneath weld.

Excessive Penetration

Possible Causes Corrective Actions

Excessive heat input. Select lower amperage. Use smaller electrode.

Good Penetration

Increase and/or maintain steady travel speed.

OM-4434 Page 63

14-19. Troubleshooting − Burn-Through

Burn-Through − weld metal melting completely through base metal resulting
in holes where no metal remains.

Possible Causes Corrective Actions

Excessive heat input. Select lower amperage. Use smaller electrode.

Increase and/or maintain steady travel speed.

14-20. Troubleshooting − Waviness Of Bead

Waviness Of Bead − weld metal that is not parallel and does not cover
joint formed by base metal.

Possible Causes Corrective Actions

Unsteady hand. Use two hands. Practice technique.

14-21. Troubleshooting − Distortion

Distortion − contraction of weld met­al during welding that forces base
metal to move.

Base metal moves

in the direction of

the weld bead.

Possible Causes Corrective Actions

Excessive heat input. Use restraint (clamp) to hold base metal in position.

Make tack welds along joint before starting welding operation.

Select lower amperage for electrode.

Increase travel speed.

Weld in small segments and allow cooling between welds.

OM-4434 Page 64

SECTION 15 − MIG WELDING (GMAW) GUIDELINES

15-1. Typical MIG Process Connections Using A Voltage-Sensing Wire Feeder

! Weld current can damage

electronic parts in vehicles.
Disconnect both battery
cables before welding on a
vehicle. Place work clamp as
close to the weld as possible.

Voltage sensing wire feeders are
used with constant current (CC) or
constant voltage (CV) power
sources (14 pin receptacle not re­quired).

If using a CC or CV welding power
source without a weld output con­tactor, use optional secondary con­tactor.

For GMAW, use optional gas valve.

Gun

Workpiece

Work Clamp Voltage

Sensing Clamp

Voltage

Sensing Wire

Feeder

Constant

Current (CC)

Or Constant

Voltage (CV)

Power Source

Electrode Lead

Work Lead

802 488

15-2. Holding And Positioning Welding Gun

 Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger, be sure wire is no more than 1/2 in (13 mm)

past end of nozzle, and tip of wire is positioned correctly on seam.

1 Hold Gun and Control Gun

Trigger
2 Workpiece
3 Work Clamp
4 Electrode Extension (Stickout)

1/4 to 1/2 in (6 To 13 mm)
5 Cradle Gun and Rest Hand on

Workpiece

0°-15°

5

90° 90°

4

0°-15°

1

2

3

45°

45°

End View Of Work Angle Side View Of Gun Angle

GROOVE WELDS

End View Of Work Angle Side View Of Gun Angle

FILLET WELDS

S-0421-A

OM-4434 Page 65

15-3. Conditions That Affect Weld Bead Shape

 Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed

(weld current), and voltage.

10°

Push

Perpendicular Drag

GUN ANGLES AND WELD BEAD PROFILES

Short Normal Long

ELECTRODE EXTENSIONS (STICKOUT)

Short Normal Long

10°

FILLET WELD ELECTRODE EXTENSIONS (STICKOUT)

Slow Normal Fast

GUN TRAVEL SPEED

S-0634

OM-4434 Page 66

15-4. Gun Movement During Welding

 Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps,

a weave bead or multiple stringer beads works better.

1 Stringer Bead − Steady

1 2

3

Movement Along Seam
2 Weave Bead − Side To Side

Movement Along Seam
3 Weave Patterns
Use weave patterns to cover a wide

area in one pass of the electrode.

S-0054-A

15-5. Poor Weld Bead Characteristics

1 Large Spatter Deposits

1

2 Rough, Uneven Bead
3 Slight Crater During Welding
4 Bad Overlap
5 Poor Penetration

2

15-6. Good Weld Bead Characteristics

2

4

3

4

3

5

1 Fine Spatter
2 Uniform Bead

1

5

3 Moderate Crater During

Welding
Weld a new bead or layer for each

1/8 in (3.2 mm) thickness in metals
being welded.

4 No Overlap
5 Good Penetration into Base

Metal

S-0053-A

S-0052-B

OM-4434 Page 67

15-7. Troubleshooting − Excessive Spatter

Excessive Spatter − scattering of molten metal particles that
cool to solid form near weld bead.

S-0636

Possible Causes Corrective Actions

Wire feed speed too high. Select lower wire feed speed.

Voltage too high. Select lower voltage range.

Electrode extension (stickout) too long. Use shorter electrode extension (stickout).

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.

Insufficient shielding gas at welding arc. Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.

Dirty welding wire. Use clean, dry welding wire.

Eliminate pickup of oil or lubricant on welding wire from feeder or liner.

15-8. Troubleshooting − Porosity

Porosity − small cavities or holes resulting from gas pockets
in weld metal.

S-0635

Possible Causes Corrective Actions

Insufficient shielding gas at welding arc. Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.

Remove spatter from gun nozzle.

Check gas hoses for leaks.

Place nozzle 1/4 to 1/2 in (6-13 mm) from workpiece.

Hold gun near bead at end of weld until molten metal solidifies.

Wrong gas. Use welding grade shielding gas; change to different gas.

Dirty welding wire. Use clean, dry welding wire.

Eliminate pick up of oil or lubricant on welding wire from feeder or liner.

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before welding.

Use a more highly deoxidizing welding wire (contact supplier).

Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.

15-9. Troubleshooting − Excessive Penetration

Excessive Penetration − weld metal melting through base metal
and hanging underneath weld.

Excessive Penetration

Possible Causes Corrective Actions

Excessive heat input. Select lower voltage range and reduce wire feed speed.

OM-4434 Page 68

Good Penetration

Increase travel speed.

S-0639

15-10. Troubleshooting − Lack Of Penetration

Lack Of Penetration − shallow
fusion between weld metal and
base metal.

Lack of Penetration Good Penetration

Possible Causes Corrective Actions

S-0638

Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while

maintaining proper welding wire extension and arc characteristics.

Improper weld technique. Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.

Keep arc on leading edge of weld puddle.

Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.

Insufficient heat input. Select higher wire feed speed and/or select higher voltage range.

Reduce travel speed.

15-11. Troubleshooting − Incomplete Fusion

Incomplete Fusion − failure of weld metal to fuse completely with
base metal or a preceeding weld bead.

Possible Causes Corrective Actions

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before

welding.

Insufficient heat input. Select higher voltage range and/or adjust wire feed speed.

S-0637

Improper welding technique. Place stringer bead in proper location(s) at joint during welding.

Adjust work angle or widen groove to access bottom during welding.

Momentarily hold arc on groove side walls when using weaving technique.

Keep arc on leading edge of weld puddle.

Use correct gun angle of 0 to 15 degrees.

15-12. Troubleshooting − Burn-Through

Burn-Through − weld metal melting completely through base metal
resulting in holes where no metal remains.

Possible Causes Corrective Actions

Excessive heat input. Select lower voltage range and reduce wire feed speed.

Increase and/or maintain steady travel speed.

S-0640

OM-4434 Page 69

15-13. Troubleshooting − Waviness Of Bead

Waviness Of Bead − weld metal that is not parallel and does not cover
joint formed by base metal.

Possible Causes Corrective Actions

Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.

Unsteady hand. Support hand on solid surface or use two hands.

15-14. Troubleshooting − Distortion

Distortion − contraction of weld metal during welding that forces
base metal to move.

Base metal moves

in the direction of

the weld bead.

Possible Causes Corrective Actions

Excessive heat input. Use restraint (clamp) to hold base metal in position.

S-0641

S-0642

Make tack welds along joint before starting welding operation.

Select lower voltage range and/or reduce wire feed speed.

Increase travel speed.

Weld in small segments and allow cooling between welds.

OM-4434 Page 70

15-15. Common MIG Shielding Gases

This is a general chart for common gases and where they are used. Many different combinations (mixtures) of
shielding gases have been developed over the years. The most commonly used shielding gases are listed in the
following table.

Application

Gas

Spray Arc Steel

Short Circuiting

Steel

Spray Arc

Stainless Steel

Short Circuiting

Stainless Steel

Spray Arc

Aluminum

Argon All Positions

Argon + 1% O

Argon + 2% O

Argon + 5% O

Argon + 8% CO

Argon + 25%

CO

2

Argon + 50%

CO

2

CO

2

Flat & Horizontal

2

Flat & Horizontal

2

Flat & Horizontal

2

Flat & Horizontal

2

Flat & Horizontal

Flat & Horizontal

Fillet

Fillet

Fillet

Fillet

Fillet

Fillet

5

Flat & Horizontal

Fillet

5

Flat & Horizontal

Fillet

5

5

All Positions

1

All Positions All Positions

All Positions

1

All Positions

5

5

3

Helium All Positions

Argon + Helium All Positions

Short Circuiting

5

2

2

Aluminum

All Positions

4

Tri-Mix

1 Globular Transfer
2 Heavy Thicknesses
3 Single Pass Welding Only
4 90% HE + 7-1/2% AR + 2-1/2% CO
5 Also for GMAW-P, All Positions

All Positions

2

OM-4434 Page 71

Notes

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.

Effective January 1, 2007

(Equipment with a serial number preface of “LH” or newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other

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 delivery date of the
equipment to the original end-user purchaser, and not to exceed
one year after the equipment is shipped to a North American
distributor or eighteen months after the equipment is shipped to
an International distributor.

1. 5 Years Parts — 3 Years Labor

* Original main power rectifiers

2. 3 Years — Parts and Labor

* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Inverter Power Sources (Unless Otherwise Stated)
* Water Coolant Systems (Integrated)
* Intellitig
* Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the
engine manufacturer.)

3. 1 Year — Parts and Labor Unless Specified

* Motor Driven Guns (w/exception of Spoolmate

Spoolguns)
* Positioners and Controllers
* Automatic Motion Devices
* RFCS Foot Controls
* Induction Heating Power Sources, Coolers, and

Electronic

Controls/Recorders
* Water Coolant Systems (Non-Integrated)
* Flowgauge and Flowmeter Regulators (No Labor)
* HF Units
* Grids
* Spot Welders
* Load Banks
* Arc Stud Power Sources & Arc Stud Guns
* Racks
* Running Gear/Trailers
* Plasma Cutting Torches (except APT & SAF

Models)
* Field Options

(NOTE: Field options are covered under True Blue®

for the remaining warranty period of the product they

are installed in, or for a minimum of one year —

whichever is greater.)
* Bernard-Branded Mig Guns (No Labor)
* Weldcraft-Branded TIG Torches (No Labor)
* Subarc Wire Drive Assemblies

4. 6 Months — Batteries

5. 90 Days — Parts

* MIG Guns/TIG Torches and Subarc (SAW) Guns

guarantees or warranties expressed or implied.

* Induction Heating Coils and Blankets, Cables, and

Non-Electronic Controls
* APT & SAF Model Plasma Cutting Torches
* Remote Controls
* Accessory (Kits)
* Replacement Parts (No labor)
* Spoolmate Spoolguns
* Canvas Covers

Miller’s True Blue® Limited Warranty shall not apply to:

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, slip rings, relays
or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)

2. Items furnished by Miller, but manufactured by others, such
as engines or trade accessories. These items are covered
by the manufacturer’s warranty, if any.

3. Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable and
necessary maintenance, or equipment which has been
used for operation outside of the specifications for the
equipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED 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 2007−01

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

For Service

Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information

and Parts)
Circuit Diagrams
Welding Process Handbooks

To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller

Miller Electric Mfg. Co.

An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA

International Headquarters−USA

USA Phone: [phone] Auto-Attended
USA & Canada FAX: [phone]
International FAX: [phone]

European Headquarters −
United Kingdom

Phone: [phone]
FAX: [phone]

www.MillerWelds.com

Contact the Delivering Carrier to:

File a claim for loss or damage during
shipment.

For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.

PRINTED IN USA © 2007 Miller Electric Mfg. Co.2007−01