Miller Electric 250 User Manual

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OM-217 455H

2007−05−21

Processes

Stick (SMAW) Welding

MIG (GMAW) Welding Flux Cored (FCAW) Welding

Non-Critical TIG (GTAW) Welding

Description

Engine Driven Welding Generator

™

Bobcat 250 Diesel

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 4/05

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

SECTION 5 −

5-1. Installing Welding Generator 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Installing Exhaust Pipe 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Connecting the Battery 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Overview And Engine Prestart Checks 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Connecting to Weld Output Terminals 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. Selecting Weld Cable Sizes* 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − OPERATING THE WELDING GENERATOR 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Engine Control Switches 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Weld Output Controls 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Typical Stick Welding Connections And Control Settings 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. Typical MIG Welding Connections And Settings 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-5. Typical MIG Connections And Settings Using Weld Control And Spoolgun 24 . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − OPERATING AUXILIARY EQUIPMENT 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Generator Power Receptacles 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Simultaneous Weld And Power 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P) 26 . . . . . . . . . . . . . . . . . .

SECTION 8 − OPERATING OPTIONAL BATTERY CHARGER 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1. Battery Charge Controls 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2. Determining Battery Charging Current 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3. Battery Charge Cable Connections 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-4. Battery Charging Procedure 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − MAINTENANCE AND TROUBLESHOOTING 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1. Routine Maintenance 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-2. Maintenance Label And Engine Maintenance Activities 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3. Servicing Air Cleaner 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-4. Adjusting Engine Speed 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-5. Overload Protection 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-6. Troubleshooting Tables 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS

SECTION 10 − PARTS LIST 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-1. Recommended Spare Parts 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 − ELECTRICAL DIAGRAMS 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 12 − RUN-IN AND WETSTACKING 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12-1. Run-In And Wetstacking 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 13 − PERFORMANCE DATA 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-1. Fuel Consumption Curves 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-2. Generator Power Curve 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-3. Duty Cycle 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-4. Stick Mode Volt-Ampere Curves 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-5. MIG Mode Volt-Ampere Curve 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 14 − GENERATOR POWER GUIDELINES 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 15 − STICK WELDING (SMAW) GUIDELINES 58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING

rom_2007−04

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.

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

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

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

there is a danger of falling.

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

unit.

D 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!

D 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).

D 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.

D 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.

D When making input connections, attach proper grounding conduc-

tor first − double-check connections.

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

and sparks.

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

replace cord immediately if damaged — bare wiring can kill.

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

with a separate cable.

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

or another electrode from a different machine.

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

parts at once. Maintain unit according to manual.

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

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

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

or worktable as near the weld as practical.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

D 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.

D Stop engine on inverter and discharge input capacitors according

to instructions in Maintenance Section before touching any parts.

HOT PARTS can cause severe burns.

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

ment.

D 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.

D Welding, chipping, wire brushing, and grinding

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

D Wear approved safety glasses with side shields even under your

welding helmet.

OM-217 455 Page 1

FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing these

fumes and gases can be hazardous to your health.

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

arc to remove welding fumes and gases.

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

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

D 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.

D 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.

D 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.

D 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).

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

gas, or liquid vapors (such as gasoline).

D 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.

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

contact tip when not in use.

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

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

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

from your person before doing any welding.

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

glowing embers, and flames.

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

pass them.

D 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.

D Shut off shielding gas supply when not in use. D 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. D 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).

D Wear approved safety glasses with side shields under your

helmet.

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

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

D 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.

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

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

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

easily go through small cracks and openings to adjacent areas.

D Watch for fire, and keep a fire extinguisher nearby. D 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.

D Wear approved ear protection if noise level is

high.

MAGNETIC FIELDS can affect Implanted Medical Devices.

D Wearers of Pacemakers and other Implanted

Medical Devices should keep away.

D 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.

D Protect compressed gas cylinders from excessive heat, mechani-

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

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

support or cylinder rack to prevent falling or tipping.

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

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

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

use or connected for use.

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

ber of persons to lift and move cylinders.

D Read and follow instructions on compressed gas cylinders,

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

OM-217 455 Page 2

1-3. Engine Hazards

BATTERY EXPLOSION can BLIND.

D Always wear a face shield, rubber gloves, and

protective clothing when working on a battery.

D Stop engine before disconnecting or connect-

ing battery cables or servicing battery.

D Do not allow tools to cause sparks when working on a battery. D Do not use welder to charge batteries or jump start vehicles. D Observe correct polarity (+ and −) on batteries. D Disconnect negative (−) cable first and connect it last.

FUEL can cause fire or explosion.

D Stop engine and let it cool off before checking or

adding fuel.

D Do not add fuel while smoking or if unit is near

any sparks or open flames.

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

MOVING PARTS can cause injury.

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

closed and securely in place.

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

guards for maintenance and troubleshooting as necessary.

D To prevent accidental starting during servicing, disconnect

negative (−) battery cable from battery.

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

parts.

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

finished and before starting engine.

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

keep engine from kicking back or starting.

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

components.

STEAM AND HOT COOLANT can burn.

D If possible, check coolant level when engine is

cold to avoid scalding.

D Always check coolant level at overflow tank, if

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

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

flow tank, follow the next two statements.

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

completely removing cap.

Using a generator indoors CAN KILL YOU IN MINUTES.

D Generator exhaust contains carbon monoxide.

This is a poison you cannot see or smell.

D NEVER use inside a home or garage, EVEN IF

doors and windows are open.

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

vents.

BATTERY ACID can BURN SKIN and EYES.

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

ENGINE HEAT can cause fire.

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

surfaces or flammables.

D Keep exhaust and exhaust pipes way from

flammables.

HOT PARTS can cause severe burns.

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

ment.

D 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.

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

COMPRESSED AIR can cause injury.

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

EXHAUST SPARKS can cause fire.

D Do not let engine exhaust sparks cause fire. D Use approved engine exhaust spark arrestor in

required areas — see applicable codes.

TRAPPED AIR PRESSURE AND WHIPPING HOSES can cause injury.

D Release air pressure from tools and system be-

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

OM-217 455 Page 3

HOT METAL from air arc cutting and

READ INSTRUCTIONS.

gouging can cause fire or explosion.

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

HOT PARTS can cause burns and injury.

D Do not touch hot compressor or air system

parts.

D Let system cool down before touching or ser-

vicing.

D Read Owner’s Manual before using or servic-

ing unit.

D Stop engine and release air pressure before

servicing.

D Use only genuine replacement parts from the

manufacturer.

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

FIRE OR EXPLOSION hazard.

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

combustible surfaces.

D Do not install unit near flammables.

D 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.

D Use lifting eye to lift unit and properly installed

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

D Lift and support unit only with proper equipment

and correct procedures.

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

extend beyond opposite side of unit.

OVERHEATING can damage motors.

D Turn off or unplug equipment before starting or

stopping engine.

D Do not let low voltage and frequency caused by

low engine speed damage electric motors.

D 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.

D Do not press gun trigger until instructed to do

so.

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

other people, or any metal when threading welding wire.

OVERUSE can cause OVERHEATING.

D Allow cooling period; follow rated duty cycle. D Reduce current or reduce duty cycle before

starting to weld again.

D Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

TILTING OF TRAILER can cause injury.

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

according to instructions supplied with trailer.

D Wear a face shield to protect eyes and face. D Shape tungsten electrode only on grinder with

proper guards in a safe location wearing proper face, hand, and body protection.

D Sparks can cause fires — keep flammables away.

MOVING PARTS can cause injury.

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

rolls.

OM-217 455 Page 4

READ INSTRUCTIONS.

D Read Owner’s Manual before using or servic-

ing unit.

D Use only genuine replacement parts from the

manufacturer.

D 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.

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

navigation, safety services, computers, and communications equipment.

D Have only qualified persons familiar with

electronic equipment perform this installation.

D The user is responsible for having a qualified electrician

promptly correct any interference problem resulting from the installation.

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

equipment at once.

D Have the installation regularly checked and maintained. D 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.

D Electromagnetic energy can interfere with

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

D Be sure all equipment in the welding area is

electromagnetically compatible.

D To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

D Be sure this welding machine is installed and grounded

according to this manual.

D 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: 1-877-413-5184, 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: 703-788-2700, website:www.cganet.com).

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

1-8. EMF Information

Considerations 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: 800-463-6727 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: 617-770-3000, 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: 1-866-512-1800) (there are 10 Regional Offices—phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).

1. Keep cables close together by 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-217 455 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.

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

tant pas de trous.

D 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.

D 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.

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

MENT si le procédé de soudage le demande.

D 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.

D 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-217 455 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!

D 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).

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

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

D 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.

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

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

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

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

D 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.

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

sante ou mal épissés.

D Ne pas enrouler les câbles autour du corps. D 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.

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

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

D Ne pas toucher des porte électrodes connectés à deux machines

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

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

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

D Porter un harnais de sécurité quand on travaille en hauteur. D Maintenir solidement en place tous les panneaux et capots. D 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.

D 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

o e

u n

des onduleurs après avoir coupé l’alimentation.

D 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.

D Ne pas toucher à mains nues les parties chau

des.

D Prévoir une période de refroidissement avant d

travailler à l’équipement.

D 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 SALETES peuvent provoquer des blessures dans les yeux.

D 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.

D 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.

D Eloigner votre tête des fumées. Ne pas respirer les fumées. D 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.

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

approuvé.

D 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.

D 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.

D 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.

D 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.

D Fermer l’alimentation du gaz protecteur en cas d

non utilisation.

D 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.

D 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).

D Porter des lunettes de sécurité avec écrans latéraux même sous

votre casque.

D 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.

D 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.

D 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.

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

sur des substances inflammables.

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

de métal chaud.

D Des étincelles et des matériaux chauds du soudage peuvent

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

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

proximité.

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

peut déclencher un incendie de l’autre côté.

D 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).

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

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

D 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.

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

lées.

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

électrode ou couper le fil à la pointe de contact.

D 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.

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

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

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

ce d’étincelles incandescentes ni de flammes.

D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

OM-217 455 Page 7

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

a n

s s

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.

D Porter des protections approuvés pour les or

les si le niveau sonore est trop élevé.

LES CHAMPS MAGNETIQUES peuvent affecter des implants médicaux.

D Porteur de simulateur cardiaque ou autre im-

plants médicaux, rester à distance.

D 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.

D 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.

D 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.

D Tenir les bouteilles éloignées des circuits de soudage ou autres

circuits électriques.

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

une bouteille.

D Ne jamais souder une bouteille pressurisée − risque d’explosion. D 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.

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

bouteille.

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

d’utilisation ou de branchement de la bouteille.

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

samment de personnes pour soulever et déplacer les bouteilles.

D 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.

D Toujours porter une protection faciale, des gant

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

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

de batterie.

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

la batterie.

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

des véhicules de démarrage rapide.

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

dernier lieu.

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

D Arrêter le moteur avant de vérifier le niveau d

carburant ou de faire le plein.

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

ou d’une flamme nue.

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

pour son expansion.

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

carburant renversé avant de faire démarrer le moteur.

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

remplissage.

DES ORGANES MOBILES peuvent pr voquer des blessures.

D Ne pas approcher les mains des ventilateurs

courroies et autres pièces en mouvement.

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

couvrements et dispositifs de protection.

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

OM-217 455 Page 8

D 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.

D Pour empêcher tout démarrage accidentel pendant les travaux

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

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

des organes mobiles.

D 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.

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

mise en route accidentelle du moteur.

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

tion sur le générateur.

DES PIÈCES CHAUDES peuvent provoquer des brûlures graves.

D Ne pas toucher à mains nues les parties chau

des.

D Prévoir une période de refroidissement avant d

travailler à l’équipement.

D 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.

D Il est préférable de vérifier le liquide de refroi-

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

D 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).

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

me suivant.

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

le bouchon du radiateur.

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

t ,

avant d’enlever le bouchon.

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

D Les fumées d’un groupe autonome contient du

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

D JAMAIS utiliser dans une maison ou garage,

même avec les portes et fenêtres ouvertes.

D 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.

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

D 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.

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

proximité de surfaces inflammables.

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

LES ÉTINCELLES À L’ÉCHAPPEMENT peuvent provoquer un incendie.

D Empêcher les étincelles d’échappement du

moteur de provoquer un incendie.

D Utiliser uniquement un pare-étincelles

approuvé − voir codes en vigueur.

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

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

page, gougeage et les outils pneumatiques.

L’AIR COMPRIMÉ peut provoquer des blessures.

D Porter des lunettes de sécurité approuvées. D 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.

D 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.

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

maintenance.

D 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.

D Ne pas couper ou gouger à proximité de pro-

duits inflammables.

D Surveillez et garder un extincteur à proximité.

DES PIECES CHAUDES peuvent provoquer des brûlures et blessures.

D Ne pas toucher le compresseur ou d’autres

éléments du circuit air comprimé chauds.

LIRE LES INSTRUCTIONS.

D Lisez le manuel d’instructions avant l’utilisation

ou la maintenance de l’appareil.

D 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.

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

à proximité de surfaces inflammables.

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

duits inflammables.

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

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

D 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.

D 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).

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

l’équipement approprié et en suivant le procédures adéquates.

OM-217 455 Page 9

LE SURCHAUFFEMENT peut endom-

mager le moteur électrique.

D Arrêter ou déconnecter l’équipement avant d

démarrer ou d’arrêter le moteur.

D 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.

D 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.

D Porter un écran facial pour protéger le visage e

les yeux.

D 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.

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

stance inflammable.

DES ORGANES MOBILES peuvent provoquer des blessures.

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

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuvent provoquer des blessures.

D Ne pas appuyer sur la gâchette avant d’en

avoir reçu l’instruction.

D 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.

D Laisser l’équipement refroidir ; respecter le fac-

teur de marche nominal.

D Réduire le courant ou le facteur de marche

avant de poursuivre le soudage.

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

LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.

D Établir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pièces.

D 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.

D Utiliser les supports de la remorque ou des

blocs pour soutenir le poids.

D Installer convenablement le poste sur la remor-

que comme indiqué dans le manuel s’y rapportant.

LIRE LES INSTRUCTIONS.

D Lisez le manuel d’instructions avant l’utilisation

ou la maintenance de l’appareil.

D N’utiliser que les pièces de rechange recom-

mandées par le constructeur.

D 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.

D 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.

D Demander seulement à des personnes qualifiées familiarisées

avec des équipements électroniques de faire fonctionner l’installation.

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

cien qualifié les interférences résultant de l’installation.

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

pareil.

D Effectuer régulièrement le contrôle et l’entretien de l’installation. D 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.

D 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.

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

compatible électromagnétiquement.

D 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).

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

ment électronique sensible.

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

conformément à ce mode d’emploi.

D 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-217 455 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.

En ce qui concerne les 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-217 455 Page 11

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

SECTION 3 − DEFINITIONS

3-1. Symbol Definitions

Stop Engine

Start Engine

Engine Oil Fuel Battery (Engine) Engine

Temperature

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)

Slow (Idle)

Work Connection

Protective Earth

(Ground)

Circuit Protector

Volts

Output

SECTION 4 − SPECIFICATIONS

4-1. Weld, Power, and Engine Specifications

. Also see Performance Data in Section 13.

Welding

Mode

CC/AC 40 − 250 A

CC/DC 40 − 250 A

CV/DC 17 − 28 V

Weld Output

Range

Rated

Welding

Output

250 A, 25 V,

100% Duty

Cycle

250 A, 25 V,

100% Duty

Cycle

275 A, 25 V,

60% Duty

Cycle

250 A, 28 V,

100% Duty

Cycle

Maximum

Open Circuit

Voltage

Generator Power Rating

Continuous: 9.5 kVA/kW,

84/42 A, 120/240 V AC,

Peak: 10.5 kVA/kW

Single-Phase,

60 Hz

(while not welding)

Fuel

Capacity

12 gal

(45 L) Tank

Engine

Kubota D722

Water-Cooled,

Three-Cylinder

Four-Cycle

18.8 HP

Diesel Engine

OM-217 455 Page 12

4-2. Dimensions, Weights, and Operating Angles

could tip

Engine End

00 lb (318 kg)

Dimensions

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

Height

Width 20 in (508 mm)

Depth 53 in (1346 mm)

A 20 in (508 mm)

B 16-1/2 in (419 mm)

C 1-3/4 in (44 mm)

D 6-1/16 in (154 mm)

E 32-3/4 in (832 mm)

F 51-3/8 in (1305 mm)

G 13/32 in (10 mm) Dia.

Lifting Eye Weight Rating

35-1/2 in (902 mm)

(To Top Of Exhaust)

Weight

1280 lbs (580 kg)

! Do not exceed tilt angles or engine could

be damaged or unit could tip.

4 Holes

800 426

! Do not move or operate unit where it

could tip.

20° 20°

20°

804 249-A

4-3. Dimensions For Units With Optional Running Gear

Dimensions

All Running Gear Options:

Height

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)

OM-217 455 Page 13

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

SECTION 5 − INSTALLATION

5-1. Installing Welding Generator

Movement

Location / Airflow Clearance

18 in

(460 mm)

18 in

(460 mm)

Mounting

! Do not lift unit from end.

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

! Do not weld on base. Welding

on base can cause fuel tank fire or explosion. Bolt unit down using holes provided in base.

! Always securely fasten weld-

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

OM-217 455 Page 14

GND/PE

! Do not use flexible mounts.

! Bed liners, shipping skids, and some running

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

gears insulate 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.

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

5-2. Installing Exhaust Pipe

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

! Stop engine and let cool. ! Do not blow exhaust toward

right side of unit where air inlet is or air cleaner may require frequent service. Point exhaust pipe in desired direction but always away from front panel and direction of travel.

Tools Needed:

1/2 in

5-3. Connecting the Battery

Tools Needed:

1/2 in

804 196-A / Ref. 228 647-A

! Connect negative (−)

cable last.

804 250-A / Ref 228 647 / Ref. S-0756-D

−

OM-217 455 Page 15

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

5-4. Overview And Engine Prestart Checks

1 Generator Power Receptacles (see

Section 7) 2 Weld Output Terminals (see Section 5-5) 3 Operator Controls (see Section 6) 4 Fuel Gauge/Maintenance Display 5 Fuel Filler Cap 6 Exhaust Pipe

7 Radiator Cap 8 Engine Maintenance Label (Inside Door) 9 Oil Fill Cap 10 Thermostat Housing Plug 11 Oil Filter 12 Coolant Overflow Bottle

13 Oil Drain 14 Oil Dipstick 15 Inline Fuel Strainer 16 Air Cleaner 17 Fuel Filter 18 Fuel Shut Off Valve

OM-217 455 Page 16

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

! Engine shown with

doors removed. Doors must be in place when engine is running.

Engine Left Side

Engine must be cold and on a level surface. See maintenance label (Section 9-2) for fluid specifications.

Starting engine for the first time:

Add fresh fuel to bottom of filler neck. Open fuel shut-off valve.

If coolant level is below bottom of radiator filler neck, add coolant to overflow bottle.

Run-in period (first 100 hours):

Engine may use oil and wetstacking may occur during run-in (see Section 12). Check oil several times daily during run-in.

Daily pre-start checks:

Add fresh fuel to bottom of filler neck. Check oil. If oil is not up to full mark on dip-

stick, add oil. Unit is shipped with 10W30 engine oil.

Check coolant level in overflow bottle. If coolant is below Low level, add coolant until level in tank is between Low and Full levels. If overflow bottle coolant level was low, check coolant level in radiator (see Section 9-2).

Engine damage can result from:

S Low oil level S High engine temperature S Incorrect coolant mixture S Running out of fuel (air in fuel lines) S Using gasoline S Using ether to start engine S Wetstacking

Engine stops if oil pressure is low, engine coolant temperature is high, or fuel level is low. Some conditions may cause engine damage before the engine shuts down.

Oil: Check oil level often and do not use the oil pressure shutdown system to monitor oil level.

Engine Temperature: Incorrect engine temperature can damage engine. Do not run engine without a properly working thermostat and radiator cap.

Keep radiator and air intake clean. Coolant: A solution of 50% ethylene gly-

col base antifreeze and 50% water must be used in this engine. Do not use 100% antifreeze or severe damage will occur.

Fuel: Engine will shut down if fuel level is low. Air in the fuel system causes starting problems.

Do not use gasoline. Using ether voids warranty.

Wetstacking: If unburned fuel and oil collect in exhaust pipe during run-in, see Section 12.

. To improve cold weather starting:

Engine Right Side

Keep battery in good condition. Store battery in warm area. Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier for fuel information. Use correct grade oil for cold weather.

804 249-A / 804 250-A

OM-217 455 Page 17

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

5-5. Connecting to Weld Output Terminals

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 6-2).

. 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.

Correct Installation

Do not place

anything between

weld cable terminal

and copper bar.

Tools Needed:

3/4 in

Incorrect Installation

OM-217 455 Page 18

Ref. 804 249-A / 228 647-A / 803 778-A

5-6. Selecting Weld Cable Sizes*

Weld Output

Terminals

! Turn off power before

connecting to weld output terminals.

! Do not use worn,

damaged, undersized, or poorly spliced cables.

Welding

Amperes

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

150 3 (30) 3 (30) 2 (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)

100 ft (30 m) or Less

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)

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)

* 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.

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

. A complete Parts List is available

on-line at www.MillerWelds.com

OM-217 455 Page 19

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

SECTION 6 − OPERATING THE WELDING GENERATOR

6-1. Engine Control Switches

NOTICE − Disconnect equipment from auxil- iary power receptacles during start−up and shutdown. Some equipment can be damaged by changes in frequency as engine rpms change during start-up and shutdown.

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

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

. Place switch in Run position to operate

most MIG equipment.

2 Glow Plug Switch

Glow Plug Time

If necessary, push switch down before startup. See glow plug table for operating information.

3 Idle Lock Switch

Use switch to lock engine in idle speed during start-up. In Start position and Engine Control switch in Run or Run/Idle, engine is locked in idle speed. In Run/Idle position and Engine Control switch in Run/Idle, engine runs at idle speed at no load and weld/power speed under load.

In Run/Idle position and Engine Control switch in Run, engine runs at weld/power speed.

70°F (21°C)

32°F (0°C)

−4°F (−20°C)

Do not use glow plugs longer than 20 seconds. Do not use ether to start engine. Using ether voids warranty.

0 seconds 10 seconds 20 seconds

Ref. 228 647-A

To Start: Use glow plug switch if necessary. Turn Engine Control switch to Start position. Release switch 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.

. Close fuel valve to stop engine if Engine

Control switch does not work (see Section 5-4).

4 Fuel Gauge/Maintenance Display See insert from maintenance label.

OM-217 455 Page 20

6-2. Weld Output Controls

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

1 Weld Process Selector Switch

NOTICE − Do not switch while welding.

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

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

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

2 Coarse Range Switch

NOTICE − Do not switch while welding.

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

. 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.

Ref. 228 647-A

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

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

Set control at 10 for maximum generator power.

Weld output would be about 124 A DC based on control settings shown (80% of 60 to 140 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.

OM-217 455 Page 21

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

6-3. Typical Stick Welding Connections And Control Settings

! Stop engine.

. This section provides general

guidelines and may not suit all applications.

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

> Set Weld Process Selector

switch to + Stick position.

> Set Coarse Range switch to

60-140 (1/8”) position.

> Set Fine control at 7 or higher

for best results.

. Consult the amperage selection

tables below if welding with other electrodes.

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

and Electrode holder cable to Electrode terminal on welding generator.

OM-217 455 Page 22

Tools Needed:

3/4 in

Ref. 804 249-A / Ref 228 647-A

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

6-4. Typical MIG Welding Connections And Settings

! Stop engine.

. This section provides general guide-

lines and may not suit all applications.

Typical Control Settings For Short Circuit Transfer Using .035 (ER70S-3) Solid Wire And 75/25 Argon/CO2 Gas:

> Set Weld Process Selector switch

to Wire + (DCEP) position.

> Set Coarse Range switch to Wire/

Low Range (17-22 volts) position.

> Set Fine Control to obtain minimum

spatter.

> Set wire feed speed between

100-300 ipm.

Typical Control Settings For Spray Transfer Using .035 (ER70S-3) Solid Wire And 80% Or Higher Argon/CO Gas:

> Set Weld Process Selector switch

to Wire + position.

> Set Coarse Range switch to Wire/

High Range (20-28 volts) position.

> Set wire feed speed between

320-500 ipm.

> Set Fine control to 3 and increase

for longer arc length.

Typical Control Settings Using .045 (E71T-11) Self-Shielded Flux Core Wire:

> Set Weld Process Selector switch

to Wire − position (DCEN).

> Set Coarse Range switch to Wire/

Low Range (17-22 volts) position.

> Set Fine Control near minimum set-

ting.

> Set wire feed speed between

125-200 ipm.

> Do a test weld. To increase arc

length, increase Fine Control setting. To shorten arc length, reduce fine control setting or increase wire

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

5 Voltage Sensing Clamp 6 Gas Cylinder:

Tools Needed:

3/4 in

Work

75/25 Argon/CO2 Gas for Short

Circuit Transfer

80% Argon (Or Higher)/CO2 For

Spray Transfer 7 Gas Hose Connect work cable to welding generator

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

Ref. 804 249-A / Ref 228 647-A / Ref. 802 766-C

OM-217 455 Page 23

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

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

Tools Needed:

3/4 in

Work

! Stop engine.

. This section provides general guide-

lines and may not suit all applications.

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

> Set Weld Process Selector switch to

Wire + (DCEP) position.

> Set Coarse Range switch to Wire/Low

(17-22 volts) position.

> Set Fine Control to desired voltage

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

Left Side View

4 5 7

> Set wire feed speed between 240-270

ipm. For 1/4 in. (6 mm) and thicker materials, set Coarse Range switch to Wire/High and Fine Control to 6. Increase/decrease Fine Control setting

to increase/decrease arc length. 1 Weld Control 2 Spoolgun 3 Optional Contactor (Recommended) 4 Reed Switch 5 Weld Cable (Customer-Supplied) 6 Weld Control Weld Terminal

Not Used

To Work

Ref. 804 249-A / Ref. 228 647-A / Ref. 802 750-A

7 Weld Power Cable From Spoolgun 8 Work Clamp 9 Gas Hose 10 100% Argon Cylinder 11 Trigger Control Cord 12 Input Power Cord Route weld cable from welding generator

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

Connect work cable to welding generator Work terminal.

OM-217 455 Page 24

SECTION 7 − OPERATING AUXILIARY EQUIPMENT

7-1. Generator Power Receptacles

803 750-B / Ref. 211 362-A

. 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.

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

weld/power speed. Maximum output is 10 kVA/kW. See section 7-3 for information on wiring optional 240 V single-phase plug.

2 120 V 20 A Duplex Receptacle RC2 3 120 V 20 A Duplex Receptacle RC3 RC2 and RC3 supply 60 Hz single-phase

power at weld/power speed. Maximum 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 supplementary

protector continues to open, contact Factory Authorized Service Agent.

! Power is still present at the 240 volt

receptacle if CB2 and/or CB3 trips. Unplug power cord before attempting to service accessories or tools.

7 Optional 120 V 20 A AC GFCI Recep-

tacles GFCI-2 and GFCI-3

GFCI2 and GFCI3 supply 60 Hz 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.

. At least once a month, run engine at

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

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-217 455 Page 25

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

7-2. Simultaneous Weld And Power

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

Amperes

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

90 8000 66 33

0 10,500 (Peak) 88 44

240 V Full kVA Receptacle

Amperes

7-3. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P)

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

1 Plug Wired for 120/240 V,

3-Wire Load

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

2 Plug Wired for 240 V, 2-Wire

Load 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

Current Available in Amperes

240 V

Receptacle*

42 37 32 27 22

*One 240 V load or two 120 V loads.

Each 120 V Duplex

Receptacle

5 10 15 20

V x A = Watts

120V

240V

240 V AC

120 V AC 120 V AC

Tools Needed:

OM-217 455 Page 26

plug1 11/03 − 120 813-D

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

SECTION 8 − OPERATING OPTIONAL BATTERY CHARGER

8-1. Battery Charge Controls

! Have only qualified persons charge

batteries.

! Do not use battery charger for jump

starting.

NOTICE − D o not use generator power ac re- ceptacles while using optional battery charger. Low voltage at receptacles may damage tools and other equipment.

1 Charge Voltage Switch Place switch in position matching voltage of

battery being charged.

. Before connecting charging cables, place

Charge Voltage switch in position matching voltage of battery being charged.

2 Battery Charging Switch Place switch in On position to turn on charging

current. Place switch in Off position to turn off charging current.

3 Weld Process Switch

! Place switch in Charge position before

connecting charging cables and starting engine.

Use switch to select weld or battery charge output (see table in Section 8-2).

4 Coarse Range Switch 5 Fine Control Use Coarse Range switch and Fine Control to

set charge current.

! Do not change Coarse Range or Weld

Process switch position while welding or battery charging.

. Charging current automatically stops

when terminal voltage is 15 to 25 percent above required battery voltage.

228 649-A

8-2. Determining Battery Charging Current

400

350

300

250

200

150

100

BATTERY CHARGING CURRENT (AMPS)

BATTERY COLD CRANK AMP RATING (CCA)

500 1000 1500 2000

1 Battery Charging Current Chart Find battery cold crank amp (CCA) rating on

battery. Use CCA rating on chart to find charge current setting for battery.

EXAMPLE: If battery CCA rating is 500, charging current from chart is 100 amperes.

Do not exceed charging current found on chart. For longer battery life, use lowest charge rate possible.

OM-217 455 Page 27

142 975-B

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

8-3. Battery Charge Cable Connections

! Stop engine. ! Do not charge a battery which has

loose terminals or one showing damage such as a cracked case or cover.

! Have only qualified persons do bat-

tery charging work.

! Keep cables away from moving

parts.

! Do not use damaged cables. ! Be sure charger output voltage

matches battery voltage.

−

! Read BCI Battery Service Manual

before charging.

. Before connecting to battery, place

Charge Voltage switch in position matching voltage of battery being charged.

1 Battery 2 Battery Charging Cables Use less than 20 feet (6.1 m) of AWG #1 or

larger cable. 3 Terminal Lug Use lugs of proper amperage capacity and

hole size for connecting to charge output terminals.

Ref. 228 649-A / Ref. 804 397-A / S-0714

Install suitable connectors on remaining ends of battery cables.

4 Battery Charge Positive (+) Output

Terminal

5 Battery Charge Negative (−) Output

Terminal

. Connect charging cables to battery

charge output terminals before connecting to battery terminals.

Connect Battery Charge Positive (+) cable to battery positive (+) terminal, and battery Charge Negative (−) cable to battery negative (−) terminal.

OM-217 455 Page 28

8-4. Battery Charging Procedure

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

In Example: Battery Voltage = 12 Volts Battery CCA Rating = 500 Charge Current = 100 A (See Section 8-2) Coarse Range Setting = 60 to 140 A V/A Control Setting = 50%

Stop Engine.

Determine Charge Current From

Battery CCA Rating And Chart

(See Section 8-2).

Turn Off Battery Charging

Switch.

Set Charge Voltage Switch To

Voltage Of Battery Being

Charged (12, 24, Or 36 Volt).

NOTICE − Do not switch under load.

Set Coarse Range Switch And

Fine Control To Obtain Correct

Charging Current.

NOTICE − Do not switch under load.

Set Weld Process Switch To

Charge Position.

−

Connect Cables (Observe

Correct Polarity).

Start Engine.

Turn On Battery

Charging Switch.

Charge 10

Minutes

Stop Engine.

Charge 10 minutes.

Check Battery Voltage.

Continue Charging If

Necessary.

OM-217 455 Page 29

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

Notes

Start Your Professional

Welding Career Now!

OM-217 455 Page 30

400 Trade Square East, Troy, Ohio 45373

1-800-332-9448 www.welding.org

Over 80,000 trained

since 1930!

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

SECTION 9 − MAINTENANCE AND TROUBLESHOOTING

9-1. Routine Maintenance

! Stop engine before maintaining.

Recycle engine

fluids.

. See Engine Manual and Maintenance Label

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

Every

Hours

Every

Hours

Every

100

Hours

Every

200

Hours

n = Check Z = Change ~ = Clean l = Replace

n Coolant Level n Fuel Level n Oil Level ~ Oil, Fuel Spills

n Fuel Connections n Fuel Connections ~ Weld Terminals

~ Air Cleaner Element n Air Cleaner Hoses n Belt Tension ~ Battery Terminals

Z Oil

* To be done by Factory Authorized Service Agent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5/16 in. (8 mm)

Reference

Section 5-4

Section 9-2, 9-3, Engine Manual

Engine Manual, Section 9-2

Every

500

Hours

Every

800

Hours

Every

2000

Hours

Z Oil Filter n Radiator Hoses l Unreadable Labels Z Fuel Filters

Engine Manual, Section 9-4

n Fan Belt ~ Flush Radiator nl Weld Cables n Slip Rings*

n Brushes* l 1500 Hours*

n Engine Speed

Section 9-2

n Valve Clearance*

Engine Manual, Section 9-2

nl Fuel Hoses nl Fuel Hoses nl Coolant & Hoses

OM-217 455 Page 31

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

9-2. Maintenance Label And Engine Maintenance Activities

! Stop engine and let cool.

Oil And Fuel

1 Oil Drain Valve 2 Oil Filter Change engine oil and filter according to en-

gine manual.

NOTICE − Close valve and valve cap before adding oil and running engine.

Fill crankcase with new oil to full mark on dipstick (see Section 5-4).

3 Fuel Lines Replace fuel lines if cracked or worn. 4 Inline Fuel Strainer Install new filter as shown.

5 Fuel Filter Replace filter according to engine manual. Wipe up any spilled fuel. Start engine, and check for fuel leaks.

! Stop engine, tighten connections as

necessary, and wipe up fuel.

Coolant

6 Radiator Cap 7 Radiator Drain Cocks (One located on

bottom of radiator)

Drain engine coolant according to procedure in engine manual.

Add engine coolant as follows:

8 Thermostat Housing Plug Remove thermostat housing plug. Add cool-

ant to radiator until coolant is at bottom of filler neck and coolant trickles out of thermostat housing plug hole. This ensures all air is purged from the system.

Reinstall plug and radiator cap. Check coolant level in overflow bottle.

Engine coolant is a mixture of water and ethylene glycol base antifreeze. A solution of 50% antifreeze and 50% water must be used in this engine. Do not use 100% antifreeze or severe damage will occur.

OM-217 455 Page 32

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

804 197-A / Ref 803 111-A / 227 727

OM-217 455 Page 33

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

9-3. Servicing Air Cleaner

! Stop engine.

NOTICE − Do not run engine without air cleaner or with dirty element. Engine damage caused by using a damaged element is not covered by the warranty.

. The air cleaner primary element can

be cleaned but the dirt holding capacity of the filter is reduced with each cleaning. The chance of dirt reaching the clean side of the filter while cleaning and the possibility of filter damage makes cleaning a risk. Consider the risk of unwarrantable equipment damage when determining whether to clean or replace the primary element.

Keep nozzle 2 in (51 mm) from element.

Optional

Blow Inspect

85 7

If you decide to clean the primary element, we strongly recommend installing an optional safety element to provide additional engine protection. Never clean a safety element. Replace the safety element after servicing the primary element three times.

1 Intake Manifold 2 Service Indicator (Optional) 3 Window 4 Reset Button Service air cleaner element if red band

appears in window. A green band means air cleaner is okay. Press button to reset indicator.

Clean or replace primary element if dirty (see note above before cleaning). Re- place primary element if damaged. Replace primary element yearly or after six cleanings.

5 Housing 6 Safety Element (Optional) 7 Primary Element 8 Cover 9 Dust Ejector

To clean air filter:

Wipe off cover and housing. Remove cover and dump out dust. Remove element(s). Wipe dust from inside cover and housing with damp cloth. Reinstall safety element (if present). Reinstall cover.

NOTICE − Do not clean housing with air hose.

Clean primary element with compressed air only.

Air pressure must not exceed 100 psi (690 kPa). Use 1/8 in (3 mm) nozzle and keep nozzle at least 2 in (51 mm) from inside of element. Replace primary element if it has holes or damaged gaskets.

Reinstall primary element and cover (dust ejector down).

OM-217 455 Page 34

aircleaner1 9/02− ST-153 929-B / ST-153 585 / Ref. S-0698-B

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

9-4. Adjusting Engine Speed

. If the engine does not start and stop properly, verify the fuel solenoid is installed properly before adjusting engine speed (see Section A following).

If the engine does not stay at idle speed, verify the throttle solenoid is installed and adjusted properly before adjusting engine speed (see Section B following).

If the engine runs properly but the speeds are incorrect, do not adjust the solenoids. Adjust the engine speed according to the instructions in Section C.

A. Checking Fuel Solenoid

Tools Needed:

7/16 in

10, 14 mm

Verify mounting bracket is recessed from edge of engine.

Tighten mounting screws when solenoid is in correct position.

If the engine does not start and stop when using the Engine Control switch, check the position of the fuel solenoid.

Adjusting Fuel Solenoid Position

1 Fuel Solenoid 2 Stop Screw 3 Fuel Solenoid Mounting Screws

. Stop screw is factory-set and should

not be adjusted.

When properly adjusted, the solenoid bracket is slightly recessed from the edge of the engine block and the solenoid linkage easily travels between the stop screw and the fuel solenoid internal stop.

If adjustment is necessary, loosen the solenoid mounting screws and push the solenoid bracket back toward engine as far as possible.

Continue pushing on solenoid bracket in a clockwise direction while tightening mounting screws.

4 Shutdown Lever 5 Stop screw 6 Stop Screw Jam Nut 7 Fuel Solenoid Jam Nut 8 Plunger

. Stop screw is factory-set and should

not be adjusted.

Hold throttle solenoid in idle (energized) position. If shutdown lever is touching or within 1/16 in of stop screw, fuel solenoid is properly adjusted.

If lever is more than 1/16 in. from stop screw, check for clearance between jam

! Stop engine.

nut and fuel solenoid. If there is clearance between jam nut and solenoid, loosen nut and turn plunger clockwise until lever touches stop screw. Retighten nut.

If there is no clearance between jam nut and solenoid, loosen the solenoid mounting screws and reposition the solenoid as described at the beginning of this section.

Ref. 804 250-A / 802 649

OM-217 455 Page 35

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

B. Checking Throttle Solenoid

1 2 3

5/8 in (16 mm)

! Stop engine.

If the engine does not stay at idle speed, verify the the throttle solenoid and linkage is installed properly.

Adjusting Throttle Solenoid

1 Throttle Solenoid 2 Jam Nut 3 Solenoid Link 4 Shoulder Bolt 5 Throttle Lever 6 Solenoid Rod 7 Throttle Solenoid Mounting

Screw

Loosen jam nut, remove shoulder bolt, and remove link from throttle lever. Install link 5/8 in (16 mm) on solenoid rod. Reconnect link to shoulder bolt and throttle lever.

Push solenoid rod into idle (energized) position and check for nonbinding lateral movement of throttle link at throttle lever. If link binds, loosen solenoid mounting screws. Move the solenoid slightly until the link moves freely with solenoid in re- laxed and energized positions. Tighten screws.

Tighten jam nut. Go to Step C.

Tools Needed:

Check for non-binding movement of link with solenoid in energized position.

Check for non-binding movement of link with solenoid in relaxed position.

3/8, 7/16 in

5/32 in

Ref. 804 250-A / 802 649

OM-217 455 Page 36

C. Making Engine Speed Adjustments

Be sure throttle link is parallel with throttle lever.

Do not twist solenoid boot while adjusting engine speed.

Idle

Weld/Power

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

. Before adjusting engine speed, verify

throttle solenoid is installed properly

2375−2450 rpm

39.6−40.8 Hz

3675−3750 rpm

61.3−62.5 Hz

(see Section B on previous page).

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

Start engine and run until warm. Turn V/A control to max.

Adjusting Idle Speed

Turn Engine Control switch to Run/Idle position.

1 Throttle Solenoid 2 Idle Speed Jam Nut 3 Plunger 4 Throttle Link 5 Throttle Lever Loosen jam nut. While holding throttle link

with a 3/8 in wrench, turn plunger clockwise to increase idle speed or counterclockwise to decrease idle speed.

. After adjusting idle speed, verify the

throttle link is parallel with the throttle lever. If necessary, loosen the idle speed jam nut and reposition the throttle link.

. Do not twist solenoid boot while ad-

justing engine speed.

Tighten jam nut.

Adjusting Weld/Power Speed

Start engine and run until warm. Turn V/A control to max.

6 Weld Speed Jam Nut 7 Adjustment Screw Turn Engine Control switch to Run posi-

tion. Loosen nut and turn screw counterclockwise to increase speed. Turn screw clockwise to decrease speed. Tighten nut.

Tools Needed:

3/8, 7/16 in 10, 14 mm

Ref. 804 250-A / 801 963

OM-217 455 Page 37

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

9-5. Overload Protection

Tools Needed:

3/8 in

Component Panel

. When a circuit breaker or fuse

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

1 Fuse F1 F1 protects the weld excitation

winding from overload. If F3 opens, weld output stops or is low.

2 Fuse F2 F2 protects the generator power

excitation winding from overload. If F4 opens, generator power output stops or is low.

3 Circuit Breaker CB7 CB7 protects the engine glow plug

circuit. If CB7 opens, the glow plug will not heat. CB7 automatically resets when the fault is corrected.

4 Supplementary Protector CB8 CB8 protects the engine battery cir-

cuit. If CB8 opens, the engine will not crank. CB8 automatically resets when the fault is corrected.

Replace any open fuses. Close door and/or reinstall cover before operating unit.

! Stop engine.

OM-217 455 Page 38

804 253-A / Ref 804 250-A

9-6. Troubleshooting Tables

A. Welding

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 control settings.

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 9-5).

Have Factory Authorized Service Agent check brushes, slip rings, integrated rectifiers SR2 and SR3, and main rectifier SR1.

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

Check fuses F1 and F2, and replace if open (see Section 9-5).

Check plug PLG6 connection.

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

Check fuse F1, and replace if open (see Section 9-5).

Check engine speed, and adjust if necessary (see Section 9-4).

Service air cleaner (see Section 8-2)

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

Check engine speed, and adjust if necessary (see Section 9-4).

Tighten and clean connections to electrode and workpiece.

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

Remove excessive coils from weld cables.

Clean and tighten connections both inside and outside welding generator.

Check engine speed, and adjust if necessary (see Section 9-4).

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

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

B. Generator Power

Trouble Remedy

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

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

Reset supplementary protectors (see Section 7-1). Press optional GFCI receptacle Reset button (see Section 7-1). Check fuse F2, and replace if open (see Section 9-5).

Check engine ignition wiring connections.

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

Check fuses F1 and F2, and replace if open (see Section 9-5).

Check engine ignition wiring connections.

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

OM-217 455 Page 39

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

Trouble Remedy

Low power output at ac receptacles. Increase Fine control R1 setting to max.

Check fuse F2, and replace if open (see Section 9-5).

High power output at ac receptacles. Check engine speed, and adjust if necessary (see Section 9-4).

Erratic power output at ac receptacles. Check fuel level.

Check engine speed, and adjust if necessary (see Section 9-4).

Check receptacle wiring and connections.

Have Factory Authorized Service Agent check brushes and slip rings.

C. Engine

Maintenance Display Action

noFUEL Place Engine Control switch in the Off position, refuel, and start engine.

HI H2O Coolant temperature is too high. Allow engine to cool and check coolant level (see Section 9-2).

LO OIL Oil pressure is too low. Allow engine to cool and check oil level (see Section 9-2).

Trouble Remedy

Engine does not crank. Supplementary protector CB8 may be open (see Section 9-5). Wait and retry.

Check battery voltage.

Check battery connections and tighten if necessary.

Check plug Engine Control switch and engine wiring harness connections.

Have Factory Authorized Service Agent check Engine Control switch S2 or circuit breaker CB8.

Engine cranks but does not start. Check fuel level and fault indicators on fuel gauge (see Section 6-1).

Open fuel valve (see Section 5-6).

Glow plug circuit breaker CB7 may be open (see Section 9-5). Wait and retry.

Service inline fuel strainer and fuel filter (see Section 8-2).

Check battery and replace if necessary.

Check engine charging system according to engine manual.

Check fuel solenoid according to engine manual.

Have Factory Authorized Service Agent check glow Plug switch S6, glow plug, and control relay CR3.

Engine starts but stops when Engine Control switch S2 returns to Run/Idle position.

Check oil level (see Section 5-6) and fault indicators on fuel gauge (see Section 6-1). Engine will not start if oil pressure is too low.

Check coolant level and fan belt (see Section 5-6 and engine manual), and check fault indicators on fuel gauge (see Section 6-1). Engine will not start if engine temperature is too high.

Have Factory Authorized Service Agent check low oil pressure shutdown switch S5 and engine temperature switch S4.

Engine does not stop. Stop engine by closing fuel valve (see Section 5-6). Adjust shutdown solenoid (see Section 9-4).

Engine stopped during normal operation.

OM-217 455 Page 40

Check fuel level and fault indicators on fuel gauge (see Section 6-1).

Open fuel valve (see Section 5-6).

Check oil level (see Section 5-6) and fault indicators on fuel gauge (see Section 6-1). Engine will not start if oil pressure is too low.

Check coolant level and fan belt (see Section 5-6 and engine manual), and check fault indicators on fuel gauge (see Section 6-1). Engine stops if engine temperature is too high.

Have Factory Authorized Service Agent check low oil pressure shutdown switch S5 and engine temperature switch S4.

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

Trouble Remedy

Battery discharges between uses. Clean top of battery with baking soda and water solution; rinse with clear water.

Periodically recharge battery (approximately every 3 months).

Replace battery.

Check voltage regulator according to engine manual.

Engine does not return to idle speed when load is removed with Engine Control switch in Run/Idle position.

Remove all weld and generator power loads.

Check for obstructed movement of solenoid linkage (see Section 9-4).

Have Factory Authorized Service Agent check idle module PC1, current transformer CT1, idle lock switch S7, throttle solenoid TS1, and Engine Control switch S2.

Engine does not remain at weld/power speed when power or weld load is applied with Engine Control switch in Run/Idle position.

Engine does not remain at idle speed with Engine Control switch in Speed Lock position and Idle Lock switch in Idle position.

Engine uses oil during run-in period; wetstacking occurs.

Check for obstructed movement of solenoid linkage (see Section 9-4).

Have Factory Authorized Service Agent check idle module PC1, control relay CR2, control relay CR4, current transformer CT1, and throttle solenoid TS1.

Check for obstructed movement of solenoid linkage (see Section 9-4).

Have Factory Authorized Service Agent check control relay CR2, control relay CR4, Idle Lock switch S7, and throttle solenoid TS1.

Dry engine (see Section 12 and engine manual).

SECTION 10 − PARTS LIST

10-1. Recommended Spare Parts

Dia.

Mkgs.

Part

No.

Recommended Spare Parts

Description

Quantity

187441 Element, Air Cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦202102 Element, Air Cleaner Safety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213858 Filter, Fuel In−line 5/16x5/16 Mic 125 −175 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187442 Element, Fuel Filter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187443 Oil Filter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187459 Belt, Fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GLOW PLUG 187820 Glow Plug 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187819 Injector Assy, 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

206421 Filter Kit, Kubota 722 (Includes air cleaner element, fuel, oil filters) 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

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

♦Optional

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

OM-217 455 Page 41

SECTION 11 − ELECTRICAL DIAGRAMS

OM-217 455 Page 42

Figure 11-1. Circuit Diagram For Welding Generator

228 719-B

OM-217 455 Page 43

Figure 11-2. Circuit Diagram For Welding Generator With Battery Charging Option

OM-217 455 Page 44

231 607-B

OM-217 455 Page 45

SECTION 12 − RUN-IN AND WETSTACKING

12-1. Run-In And Wetstacking

run_in_D722 9/05

1 Welding Generator Run-in procedures for this engine

should not be required. Put unit into regular service.

2 Engine Exhaust Pipe Wetstacking is unburned fuel and

oil in the exhaust pipe and occurs if the engine is run too long at light load or idle rpm.

If exhaust pipe is coated with a wet, black, tar-like substance, contact factory service for procedures to properly dry engine and seat piston rings.

OM-217 455 Page 46

SECTION 13 − PERFORMANCE DATA

13-1. Fuel Consumption Curves

On a typical job using 1/8 in 7018 electrodes (125 amps, 20% duty cycle), expect about 24 hours of operation.

Welding at 150 amps at 40% duty cycle uses approximately 1/2 gallon per hour, or about 20 hours of operation.

2.00

1.75

1.50

1.25

1.00

US Gal./Hr.

0.75

0.50

0.25

0.00

2.00

1.75

Weld Fuel Consumption

IDLE

50 100

150 200 250 300 350 400

DC WELD AMPERES AT 100% DUTY CYCLE

Auxiliary Power Fuel Consumption

1.50

1.25

1.00

US Gal./Hr.

0.75

0.50

0.25

0.00

IDLE

012345678910

AUXILARY POWER KW AT 100% DUTY CYCLE

226795-A / 226 796-A

OM-217 455 Page 47

13-2. Generator Power Curve

150

300

125

250

100

200

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

150

AC Volts

100

0 40 80 120 160 200 240

13-3. Duty Cycle

AC Amperes At 120 Volts

20 40 60 80 100 120

AC Amperes At 240 Volts

226 791-A

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.

Continuous Welding

100% Duty Cycle at 250 Amperes

OM-217 455 Page 48

200 293

13-4. Stick Mode Volt-Ampere Curves

A. CC/DC Stick Mode

DC Volts

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

B. CC/AC STICK Mode

50 100 150 200 250 300 350 400

AC Volts

DC Amps

50 100 150 200 250 300

AC Amps

226 792-A / 226 793-A

OM-217 455 Page 49

13-5. MIG Mode Volt-Ampere Curve

DC Volts

0 100 200 300 400 500 600 700 800

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

DC Amps

226 794-A

OM-217 455 Page 50

SECTION 14 − 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.

14-1. 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

insulated symbol and/or wording on it.

! Do not use 2-prong plug un-

less equipment is double insulated.

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

14-2. Grounding Generator To Truck Or Trailer Frame

GND/PE

! 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-217 455 Page 51

14-3. Grounding When Supplying Building Systems

1 2

GND/PE

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.

14-4. How Much Power Does Equipment Require?

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 14-8).

3 Rating Data Rating shows volts and amperes, or

watts required to run equipment.

Amperes x Volts = Watts

Example 1: If a drill uses 4.5 am-

peres at 115 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.

OM-217 455 Page 52

S-0623

14-5. Approximate Power Requirements For Industrial Motors

Industrial Motors Rating Starting Watts Running Watts

Split Phase 1/8 HP 800 300

1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 2100 700 1/2 HP 3175 875

Capacitor Start-Induction Run 1/3 HP 2020 720

1/2 HP 3075 975 3/4 HP 4500 1400

1 HP 6100 1600

1-1/2 HP 8200 2200

2 HP 10550 2850 3 HP 15900 3900 5 HP 23300 6800

Capacitor Start-Capacitor Run 1-1/2 HP 8100 2000

5 HP 23300 6000

7-1/2 HP 35000 8000

10 HP 46700 10700

Fan Duty 1/8 HP 1000 400

1/6 HP 1400 550 1/4 HP 1850 650 1/3 HP 2400 800 1/2 HP 3500 1100

14-6. Approximate Power 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-217 455 Page 53

14-7. 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-217 455 Page 54

14-8. 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

CODE 60

AC MOTOR

230 2.5

1/4

Hz PHASE

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

14-9. How Much Power Can Generator Supply?

1 Limit Load To 90% Of

Generator Output

Always start non-resistive (motor) loads in order from largest to 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.

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

OM-217 455 Page 55

14-10. Typical Connections To Supply Standby Power

123

Utility

Electrical

Service

Transfer Switch

Essential

Loads

Fused

Disconnect

Switch

(If Required)

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 14-4).

OM-217 455 Page 56

14-11. 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

Load (Watts) 4 6 8 10 12 14

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 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

OM-217 455 Page 57

SECTION 15 − STICK WELDING (SMAW) GUIDELINES

15-1. 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 before 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 15-2).

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:

OM-217 455 Page 58

stick 2007−04 − ST-151 593

15-2. 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

100

150

200

250

300

350

400

450

DC*

ELECTRODE

6010

6011

EP,EN

6013

EP,EN

7014

7018

EP,EN

7024

NI-CL

308L

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

POSITION

ALL ALL ALL

ALL

FLAT

HORIZ

FILLET

ALL ALL

PENETRATION

DEEP DEEP

LOW

MED

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

15-3. Striking an Arc − Scratch Start Technique

15-4. Striking an Arc − Tapping Technique

1 Electrode 2 Workpiece 3 Arc Drag electrode across workpiece

like striking a match; lift electrode slightly after touching work. If arc goes out electrode was lifted to high. If electrode sticks to workpiece, use a quick twist to free it.

S-0049

1 Electrode 2 Workpiece 3 Arc Bring electrode straight down to

workpiece; then lift slightly to start

arc. If arc goes out, electrode was lifted too high. If electrode sticks to workpiece, use a quick twist to free it.

S-0050

OM-217 455 Page 59

15-5. Positioning Electrode Holder

90° 90°

End View of Work Angle Side View of Electrode Angle

10°-30°

GROOVE WELDS

45°

End View of Work Angle Side View of Electrode Angle

15-6. Poor Weld Bead Characteristics

FILLET WELDS

10°-30°

S-0060

1 Large Spatter Deposits 2 Rough, Uneven Bead 3 Slight Crater During Welding 4 Bad Overlap 5 Poor Penetration

15-7. Good Weld Bead Characteristics

OM-217 455 Page 60

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.

5234

4 No Overlap 5 Good Penetration into Base

Metal

S-0053-A

S-0052-B

15-8. 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

15-9. 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

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-217 455 Page 61

15-10. Butt Joints

15-11. Lap Joint

Single-Layer Fillet Weld

1 Tack Welds

30°

1/16 in

(1.6 mm)

30° Or Less

Multi-Layer Fillet Weld

30° Or Less

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

15-12. Tee Joint

OM-217 455 Page 62

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

sides of upright section. 3 Multi-Layer Deposits Weld a second layer when a heavi-

er fillet is needed. Use any of the weaving patterns shown in Section 15-9. Remove slag before making another weld pass.

S-0060 / S-0058-A / S-0061

15-13. Weld Test

2 To 3 in

(51-76 mm)

2 To 3 in

(51-76 mm)

1/4 in

(6.4 mm)

2 1

15-14. Troubleshooting − Porosity

Porosity − small cavities or holes resulting from gas pockets in weld metal.

Possible Causes Corrective Actions

Arc length too long. Reduce arc length.

1 Vise 2 Weld Joint 3 Hammer

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.

15-15. Troubleshooting − Excessive Spatter

Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead.

Possible Causes Corrective Actions

Amperage too high for electrode. Decrease amperage or select larger electrode.

Arc length too long or voltage too high. Reduce arc length or voltage.

OM-217 455 Page 63

15-16. Troubleshooting − Incomplete Fusion

Incomplete Fusion − failure of weld metal to fuse completely with base metal or a preceeding weld bead.

Possible Causes Corrective Actions

Insufficient heat input. Increase amperage. Select larger electrode and increase amperage.

Improper welding technique. Place stringer bead in proper location(s) at joint during welding.

Adjust work angle or widen groove to access bottom during welding.

Momentarily hold arc on groove side walls when using weaving technique.

Keep arc on leading edge of weld puddle.

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before

welding.

15-17. Troubleshooting − Lack Of Penetration

Lack Of Penetration − shallow fusion between weld metal and base metal.

Lack of Penetration Good Penetration

Possible Causes Corrective Actions

Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove.

Improper weld technique. Keep arc on leading edge of weld puddle.

Insufficient heat input. Increase amperage. Select larger electrode and increase amperage.

Reduce travel speed.

15-18. Troubleshooting − Excessive Penetration

Excessive Penetration − weld metal melting through base metal and hanging underneath weld.

Excessive Penetration

Possible Causes Corrective Actions

Excessive heat input. Select lower amperage. Use smaller electrode.

OM-217 455 Page 64

Good Penetration

Increase and/or maintain steady travel speed.

15-19. Troubleshooting − Burn-Through

Burn-Through − weld metal melting completely through base metal resulting in holes where no metal remains.

Possible Causes Corrective Actions

Excessive heat input. Select lower amperage. Use smaller electrode.

Increase and/or maintain steady travel speed.

15-20. Troubleshooting − Waviness Of Bead

Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal.

Possible Causes Corrective Actions

Unsteady hand. Use two hands. Practice technique.

15-21. Troubleshooting − Distortion

Distortion − contraction of weld 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-217 455 Page 65

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at the beginning of this manual.

Warranty Questions?

Call 1-800-4-A-MILLER for your local Miller distributor.

Your distributor also gives you ...

Service

You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.

Support

Need fast answers to the tough welding questions? Contact your distributor. The expertise of the distributor and Miller is there to help you, every step of the way.

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: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125

European Headquarters − United Kingdom

Phone: 44 (0) 1204-593493 FAX: 44 (0) 1204-598066

www.MillerWelds.com

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.

Miller Electric 250 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual