Miller Electric 280 NT User Manual

OM-4430 217 243R

2007−04

Processes

Stick (SMAW) Welding

TIG (GTAW) Welding

MIG (GMAW) Welding &
Flux Cored (FCAW) Welding
With Voltage Sensing Feeder

Description

Engine Driven Welding Generator



Miller Legend 302

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

3-1. Symbol Definitions 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − SPECIFICATIONS 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Description 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Weld, Power, And Engine Specifications 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Dimensions, Weights, and Operating Angles 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Dimensions For Units With Optional Running Gear 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Fuel Consumption While Welding And Using Generator Power 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Generator Power Curve 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Duty Cycle 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. TIG Mode Volt-Ampere Curves 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-9. Stick And MIG Mode Volt-Ampere Curves 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − INSTALLATION 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Installing Welding Generator 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Engine Prestart Checks 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Connecting Or Replacing The Battery 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Installing Exhaust Pipe 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Connecting To Weld Output Terminals 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. Selecting Weld Cable Sizes* 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7. Remote Receptacle Information 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

6-2. Description Of Engine Controls (See Section 6-1) 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Cold Weather Engine Operation 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. Controlling Engine Speed And Weld/Generator Output 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-5. Process Switch 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-6. Stick Start Procedure − Scratch Start Technique 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-7. TIG Lift-Arc Start Procedure 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-8. Remote Voltage/Amperage Control 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

7-1. 60 Hz Generator Power Receptacles And Supplementary Protectors 30 . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Variable Frequency (Hz) Generator Power Receptacle RC3 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P) 32 . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS

SECTION 8 − MAINTENANCE & TROUBLESHOOTING 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1. Routine Maintenance 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2. Maintenance Label 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3. Servicing Optional Spark Arrestor 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-4. Servicing Air Cleaner 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-5. Changing Engine Oil, Oil Filter, And Fuel Filter 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-6. Overload Protection 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-7. Troubleshooting 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − PARTS LIST 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1. Recommended Spare Parts 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 − ELECTRICAL DIAGRAMS 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 − GENERATOR POWER GUIDELINES 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING

rom_2007−04

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

1-1. Symbol Usage

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

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

NOTICE − Indicates statements not related to personal injury.

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-7. Read and
follow all Safety Standards.

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

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

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

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

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

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

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

there is a danger of falling.

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

unit.

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

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

 Disconnect input power or stop engine before installing or

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

 Properly install and ground this equipment according to its

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

 Indicates special instructions.

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

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

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

 When making input connections, attach proper grounding conduc-

tor first − double-check connections.

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

and sparks.

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

replace cord immediately if damaged — bare wiring can kill.

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

with a separate cable.

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

or another electrode from a different machine.

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

parts at once. Maintain unit according to manual.

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

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

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

or worktable as near the weld as practical.

 Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

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

single weld output terminal.

SIGNIFICANT DC VOLTAGE exists in inverters after stop­ping engine.

 Stop engine on inverter and discharge input capacitors according

to instructions in Maintenance Section before touching any parts.

HOT PARTS can cause severe burns.

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

ment.

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

lated welding gloves and clothing to prevent burns.

FLYING METAL or DIRT can injure eyes.

 Welding, chipping, wire brushing, and grinding

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

 Wear approved safety glasses with side shields even under your

welding helmet.

OM-4430 Page 1

FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing these

fumes and gases can be hazardous to your health.

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

arc to remove welding fumes and gases.

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

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

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

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

 Do not weld in locations near degreasing, cleaning, or spraying op-

erations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.

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

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

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

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

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

gas, or liquid vapors (such as gasoline).

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

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

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

contact tip when not in use.

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

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

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

from your person before doing any welding.

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

glowing embers, and flames.

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

pass them.

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

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

NOISE can damage hearing.

BUILDUP OF GAS can injure or kill.

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

proved air-supplied respirator.

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense

visible and invisible (ultraviolet and infrared) rays that

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

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

 Wear approved safety glasses with side shields under your

helmet.

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

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

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

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

WELDING can cause fire or explosion.

Welding on closed containers, such as tanks, drums,

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

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

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

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

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

easily go through small cracks and openings to adjacent areas.

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

cause fire on the hidden side.

Noise from some processes or equipment can dam­age hearing.

 Wear approved ear protection if noise level is

high.

MAGNETIC FIELDS can affect Implanted
Medical Devices.

 Wearers of Pacemakers and other Implanted

Medical Devices should keep away.

 Implanted Medical Device wearers should consult their doctor

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

CYLINDERS can explode if damaged.

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

 Protect compressed gas cylinders from excessive heat, mechani-

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

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

support or cylinder rack to prevent falling or tipping.

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

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

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

use or connected for use.

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

ber of persons to lift and move cylinders.

 Read and follow instructions on compressed gas cylinders,

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

OM-4430 Page 2

1-3. Engine Hazards

BATTERY EXPLOSION can BLIND.

 Always wear a face shield, rubber gloves, and

protective clothing when working on a battery.

 Stop engine before disconnecting or connect-

ing battery cables or servicing battery.

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

FUEL can cause fire or explosion.

 Stop engine and let it cool off before checking or

adding fuel.

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

any sparks or open flames.

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

MOVING PARTS can cause injury.

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

closed and securely in place.

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

guards for maintenance and troubleshooting as necessary.

 To prevent accidental starting during servicing, disconnect

negative (−) battery cable from battery.

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

parts.

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

finished and before starting engine.

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

keep engine from kicking back or starting.

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

components.

STEAM AND HOT COOLANT can burn.

 If possible, check coolant level when engine is

cold to avoid scalding.

 Always check coolant level at overflow tank, if

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

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

flow tank, follow the next two statements.

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

completely removing cap.

Using a generator indoors CAN KILL
YOU IN MINUTES.

 Generator exhaust contains carbon monoxide.

This is a poison you cannot see or smell.

 NEVER use inside a home or garage, EVEN IF

doors and windows are open.

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

vents.

BATTERY ACID can BURN SKIN and EYES.

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

ENGINE HEAT can cause fire.

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

surfaces or flammables.

 Keep exhaust and exhaust pipes way from

flammables.

HOT PARTS can cause severe burns.

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

ment.

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

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

1-4. Compressed Air Hazards

BREATHING COMPRESSED AIR can
cause serious injury or death.

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

COMPRESSED AIR can cause injury.

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

EXHAUST SPARKS can cause fire.

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

required areas — see applicable codes.

TRAPPED AIR PRESSURE AND WHIPPING
HOSES can cause injury.

 Release air pressure from tools and system be-

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

OM-4430 Page 3

HOT METAL from air arc cutting and

READ INSTRUCTIONS.

gouging can cause fire or explosion.

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

HOT PARTS can cause burns and injury.

 Do not touch hot compressor or air system

parts.

 Let system cool down before touching or ser-

vicing.

 Read Owner’s Manual before using or servic-

ing unit.

 Stop engine and release air pressure before

servicing.

 Use only genuine replacement parts from the

manufacturer.

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

FIRE OR EXPLOSION hazard.

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

combustible surfaces.

 Do not install unit near flammables.

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

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

FALLING UNIT can cause injury.

 Use lifting eye to lift unit and properly installed

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

 Lift and support unit only with proper equipment

and correct procedures.

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

extend beyond opposite side of unit.

OVERHEATING can damage motors.

 Turn off or unplug equipment before starting or

stopping engine.

 Do not let low voltage and frequency caused by

low engine speed damage electric motors.

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

where applicable.

FLYING SPARKS can cause injury.

WELDING WIRE can cause injury.

 Do not press gun trigger until instructed to do

so.

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

other people, or any metal when threading
welding wire.

OVERUSE can cause OVERHEATING.

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

starting to weld again.

 Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

 Put on grounded wrist strap BEFORE handling

boards or parts.

 Use proper static-proof bags and boxes to

store, move, or ship PC boards.

TILTING OF TRAILER can cause injury.

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

according to instructions supplied with trailer.

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

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

 Sparks can cause fires — keep flammables away.

MOVING PARTS can cause injury.

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

rolls.

OM-4430 Page 4

READ INSTRUCTIONS.

 Read Owner’s Manual before using or servic-

ing unit.

 Use only genuine replacement parts from the

manufacturer.

 Perform engine and air compressor mainte-

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

H.F. RADIATION can cause interference.

ARC WELDING can cause interference.

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

navigation, safety services, computers, and
communications equipment.

 Have only qualified persons familiar with

electronic equipment perform this installation.

 The user is responsible for having a qualified electrician

promptly correct any interference problem resulting from the
installation.

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

equipment at once.

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

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

1-6. California Proposition 65 Warnings

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

Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.

 Electromagnetic energy can interfere with

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

 Be sure all equipment in the welding area is

electromagnetically compatible.

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

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

 Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

 Be sure this welding machine is installed and grounded

according to this manual.

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

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

For Gasoline Engines:

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

For Diesel Engines:

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

1-7. Principal Safety Standards

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

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

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

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

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

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

1-8. EMF Information

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

Welding current, as it flows through welding cables, will cause electro­magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power­frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.

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

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

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

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

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

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

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

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

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

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

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

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

About Implanted Medical Devices:

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

OM-4430 Page 5

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT

UTILISATION

rom_2007−04fre

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

2-1. Signification des symboles

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

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

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

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

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

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

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

UN CHOC ÉLECTRIQUE peut tuer.

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

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

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

tant pas de trous.

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

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

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

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

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

MENT si le procédé de soudage le demande.

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

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

 Des précautions de sécurité supplémentaires sont requises dans

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

OM-4430 Page 6

 Indique des instructions spécifiques.

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

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

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

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

1910.147 (voir normes de sécurité).

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

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

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

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

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

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

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

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

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

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

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

sante ou mal épissés.

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

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

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

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

 Ne pas toucher des porte électrodes connectés à deux machines

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

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

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

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

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

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

contact avec tout objet métallique.

Une tension DC importante subsiste à l’intérieur

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des onduleurs après avoir coupé l’alimentation.

 Couper l’alimentation du poste et décharger les condensateurs

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

DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.

 Ne pas toucher à mains nues les parties chau

des.

 Prévoir une période de refroidissement avant d

travailler à l’équipement.

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

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

DES PIECES DE METAL ou DES SA­LETES peuvent provoquer des bles­sures dans les yeux.

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

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

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

facial.

LES FUMÉES ET LES GAZ peuvent êtr
dangereux.

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

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

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

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

approuvé.

 Lire et comprendre les spécifications de sécurité des matériaux

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

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

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

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

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

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

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

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

 Fermer l’alimentation du gaz protecteur en cas d

non utilisation.

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

respirateur d’adduction d’air homologué.

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

Le rayonnement de l’arc du procédé de soudag

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

 Porter un casque de soudage approuvé muni de verres filtrants

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

 Porter des lunettes de sécurité avec écrans latéraux même sous

votre casque.

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

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

 Porter des vêtements confectionnés avec des matières résistan-

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

LE SOUDAGE peut provoquer un in

cendie ou une explosion.

Le soudage effectué sur des conteneurs fermés tel

que des réservoirs, tambours ou des conduites pe

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

 Déplacer toutes les substances inflammables à une distance de

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

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

sur des substances inflammables.

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

de métal chaud.

 Des étincelles et des matériaux chauds du soudage peuvent

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

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

proximité.

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

peut déclencher un incendie de l’autre côté.

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

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

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

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

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

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

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

lées.

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

électrode ou couper le fil à la pointe de contact.

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

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

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

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

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

ce d’étincelles incandescentes ni de flammes.

 Utiliser exclusivement des fusibles ou coupe−circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

OM-4430 Page 7

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

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

LE BRUIT peut affecter l’ouïe.

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

 Porter des protections approuvés pour les or

les si le niveau sonore est trop élevé.

LES CHAMPS MAGNETIQUES peuv­ent affecter des implants médicaux.

 Porteur de simulateur cardiaque ou autre im-

plants médicaux, rester à distance.

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

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

Si des BOUTEILLES sont endomm
gées, elles pourront exploser.

Des bouteilles de gaz protecteur contiennent du g

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

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

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

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

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

 Tenir les bouteilles éloignées des circuits de soudage ou autres

circuits électriques.

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

une bouteille.

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

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

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

bouteille.

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

d’utilisation ou de branchement de la bouteille.

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

samment de personnes pour soulever et déplacer les bouteilles.

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

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

2-3. Dangers existant en relation avec le moteur

L’EXPLOSION DE LA BATTERIE peu
RENDRE AVEUGLE.

 Toujours porter une protection faciale, des gant

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

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

de batterie.

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

la batterie.

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

des véhicules de démarrage rapide.

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

dernier lieu.

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

 Arrêter le moteur avant de vérifier le niveau d

carburant ou de faire le plein.

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

ou d’une flamme nue.

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

pour son expansion.

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

carburant renversé avant de faire démarrer le moteur.

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

remplissage.

DES ORGANES MOBILES peuvent pr
voquer des blessures.

 Ne pas approcher les mains des ventilateurs

courroies et autres pièces en mouvement.

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

couvrements et dispositifs de protection.

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

OM-4430 Page 8

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

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

 Pour empêcher tout démarrage accidentel pendant les travaux

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

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

des organes mobiles.

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

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

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

mise en route accidentelle du moteur.

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

tion sur le générateur.

DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.

 Ne pas toucher à mains nues les parties chau

des.

 Prévoir une période de refroidissement avant d

travailler à l’équipement.

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

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

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

 Il est préférable de vérifier le liquide de refroi-

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

 Toujours vérifier le niveau de liquide de refroidissement dans le

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

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

me suivant.

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

le bouchon du radiateur.

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

t
,

e

-

e

s

r

u

avant d’enlever le bouchon.

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

 Les fumées d’un groupe autonome contient du

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

 JAMAIS utiliser dans une maison ou garage,

même avec les portes et fenêtres ouvertes.

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

bouches aération.

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

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

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

2-4. Dangers liés à l’air comprimé

LA CHALEUR DU MOTEUR peut pro­voquer un incendie.

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

proximité de surfaces inflammables.

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

LES ÉTINCELLES À L’ÉCHAPPEMENT
peuvent provoquer un incendie.

 Empêcher les étincelles d’échappement du

moteur de provoquer un incendie.

 Utiliser uniquement un pare-étincelles

approuvé − voir codes en vigueur.

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

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

page, gougeage et les outils pneumatiques.

L’AIR COMPRIMÉ peut provoquer
des blessures.

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

soi-même.

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

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

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

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

maintenance.

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

constructeur.

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

 Ne pas couper ou gouger à proximité de pro-

duits inflammables.

 Surveillez et garder un extincteur à proximité.

DES PIECES CHAUDES peuvent provo­quer des brûlures et blessures.

 Ne pas toucher le compresseur ou d’autres

éléments du circuit air comprimé chauds.

LIRE LES INSTRUCTIONS.

 Lisez le manuel d’instructions avant l’utilisation

ou la maintenance de l’appareil.

 Arrêter le moteur et relâcher la pression avant

d’effectuer la maintenance.

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

Risque D’INCENDIE OU D’EXPLO­SION.

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

à proximité de surfaces inflammables.

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

duits inflammables.

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

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

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

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

LA CHUTE DE L’APPAREIL peut blesser.

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

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

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

l’équipement approprié et en suivant le
procédures adéquates.

OM-4430 Page 9

LE SURCHAUFFEMENT peut endom-

e

-

-

,

t

a

­n
u

-

mager le moteur électrique.

 Arrêter ou déconnecter l’équipement avant d

démarrer ou d’arrêter le moteur.

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

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

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

s’il y a lieu.

LES ÉTINCELLES VOLANTES ris­quent de provoquer des blessures.

 Porter un écran facial pour protéger le visage e

les yeux.

 Affûter l’électrode au tungstène uniquement à l

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

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

stance inflammable.

DES ORGANES MOBILES peuvent
provoquer des blessures.

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

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuvent
provoquer des blessures.

 Ne pas appuyer sur la gâchette avant d’en

avoir reçu l’instruction.

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

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

L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.

 Laisser l’équipement refroidir ; respecter le fac-

teur de marche nominal.

 Réduire le courant ou le facteur de marche

avant de poursuivre le soudage.

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

LES CHARGES ÉLECTROSTATI­QUES peuvent endommager les
circuits imprimés.

 Établir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pièces.

 Utiliser des pochettes et des boîtes antistatiques pour stocker,

déplacer ou expédier des cartes de circuits imprimes.

UNE REMORQUE QUI BASCULE peut
entraîner des blessures.

 Utiliser les supports de la remorque ou des

blocs pour soutenir le poids.

 Installer convenablement le poste sur la remor-

que comme indiqué dans le manuel s’y rappor­tant.

LIRE LES INSTRUCTIONS.

 Lisez le manuel d’instructions avant l’utilisation

ou la maintenance de l’appareil.

 N’utiliser que les pièces de rechange recom-

mandées par le constructeur.

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

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

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

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

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

 Demander seulement à des personnes qualifiées familiarisées

avec des équipements électroniques de faire fonctionner l’instal­lation.

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

cien qualifié les interférences résultant de l’installation.

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

pareil.

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

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

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

 L’énergie électromagnétique risque de provo-

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

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

compatible électromagnétiquement.

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

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

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

ment électronique sensible.

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

conformément à ce mode d’emploi.

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

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

OM-4430 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-4430 Page 11

3-1. Symbol Definitions

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

SECTION 3 − DEFINITIONS

Stop Engine

Start Engine Panel/Local Temperature Fuel

Engine Oil Engine Choke

Engine

MIG (GMAW),

Wire

Positive Negative

Time

h

Fast

(Run, Weld/Power)

Read Operator’s

Manual

Stick (SMAW) TIG (GTAW) Circuit Protector

Hours

A

s

Fast/Slow
(Run/Idle)

Check Valve

Clearance

Amperes

Alternating Current

(AC)

Seconds

V

Slow (Idle)

Battery (Engine)

Volts

Output

Protective Earth

(Ground)

Do not switch while

Notes

welding

Wire Feed

Remote

Receptacle

Electrode

Positive

Work Connection

Electrode Negative

Work like a Pro!

Constant

CC

CV

Current

Constant

Voltage

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-4430 Page 12

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

13 − 35 V

1800 rpm

(45 L)

Four Cycle,

B

!

D

G

p

SECTION 4 − SPECIFICATIONS

4-1. Description

This multiprocess engine-driven welder and AC generator provides low speed generator AC power and DC weld out­put for quiet, fuel-efficient operation. At 1800 rpm, this unit produces 5 kW/kVA 60 Hz 120/240 Volt AC generator
power. Achieve high quality Stick and TIG welding results at either 3000 or 3600 rpm. A special variable frequency
(60-120 Hz) receptacle provides 2.4 kW/kVA 120 Volt AC generator power continuously.

4-2. Weld, Power, And Engine Specifications

Welding

Mode

CC/DC

CV/DC

Rated

Welding

Output

280 A, 25 V, 100%

Duty Cycle

300 A, 25 V, 100%

Duty Cycle

Maximum

Open-Circuit

Voltage

50 20 − 300 A

35 − −

Amperage

Range In

CC Mode

Voltage
Range In
CV Mode

4-3. Dimensions, Weights, and Operating Angles

Dimensions

Height 34 in (864 mm)

Width 20−1/2 in (521 mm)

Depth 45-1/2 in (1156 mm)

A 20 in (508 mm)

B 16-1/2 in (419 mm)

C

A

B

Generator

Power Rating

5.5 kVA/kW (Peak)

5 kVA/kW (Continuous)

42/21 A,

120/240 V AC,

60 Hz,

Single-Phase at

1800 rpm

And

2.4 kVA/kW, 20 A,
120 V AC,

60-120 Hz,
Single-Phase
At All Speeds

Do not exceed tilt angles or engine could
be damaged or unit could tip.

! Do not move or operate unit where it could

G

4 Holes

tip.

Fuel

Capacity

12 gal

Tank

Engine

Kohler CH-23

Air-Cooled,

Two-Cylinder,

Four-Cycle,

23 HP Gasoline or

25 HP LP Engine

w/Electronic

Governor

C 1−3/4 in (44 mm)

D 5 in (127 mm)

E 32-3/4 in (832 mm)

F 44-1/4 in (1124 mm)

G 13/32 in (10 mm) Dia.

Weight

590 lb (267 kg)

Lifting Eye Weight Rating

1280 lb (580 kg)

E

F

25°

25°
25°

Engine End

800 426

OM-4430 Page 13

25°

803 983

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

C

4-4. Dimensions For Units With Optional Running Gear

Dimensions

All Running Gear Options:

Height

42-1/2 in (1079 mm)

(To Top Of Handle

Assembly)

A

B

C

Protective Cage Width:

26 in (660 mm)

Running Gear Width:

32 in (813 mm)

Protective Cage Length:

48 in (1219 mm)

A

D

Running Gear Length:

45−1/2 in (1156 mm)

B

4-5. Fuel Consumption While Welding And Using Generator Power

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

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

LITERS/HR.

7.57

6.62

U.S. GAL./HR.

2.00

1.75

A 2kW generator load at 50% duty
cycle uses less than 1/2 gallon per
hour providing over 24 hours of op­eration.

D

B

5.67

4.73

3.78

2.84

1.98

0.95

0.00

OM-4430 Page 14

1.50

1.25

1.00

0.75

0.50

0.25

Idle (At

1800 RPM)

Generator

at 1 kW

3600 RPM Weld

Generator

at 2 kW

3000 RPM Weld

Generator

at 3 kW

Generator

at 4 kW

0.00
0 100 150 200 250 300

DC WELD AMPERES AT 100% DUTY CYCLE

Generator

at 5 kW

207 967

4-6. Generator Power Curve

300

250

200

150

AC VOLTS

100

50

0

0 5 10 15 20 25 30

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

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

AC AMPERES

Notes

WELD JOINT

TYPES

GROOVE

FILLET

Ref. AWS/ANSI D1.1

FLAT VERTICALHORIZONTAL OVERHEADWELD POSITION:

BUTT

1G

T−JOINT

1F

BUTT

2G

T−JOINT

2F

BUTT

3G

T−JOINT

3F

T−JOINT

4F

222 553

BUTT

4G

Ref. 804 248-A

OM-4430 Page 15

4-7. Duty Cycle

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

325

300

275

WELD AMPERES

250

225

200

175

100% Duty Cycle at 280 Amperes DC/CC

Continuous Welding

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.

MIG/FCAW

STICK

150

010

20

30

% DUTY CYCLE

4-8. TIG Mode Volt-Ampere Curves

50
45

40
35
30
25
20

DC VOLTS

15

Min

10

5
0

0 100 200 300 400

3000RPM Max

DC AMPERES

40

50

60

70

3600RPM Max

80 90

100

Ref. 207 925

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.

OM-4430 Page 16

222 558

4-9. Stick And MIG Mode Volt-Ampere Curves

A. CC/DC Stick Mode

100

80

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

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 VOLTS

60

40

3000RPM Max

3600RPM Max

Min

20

0

0 200 400 600

DC AMPERES

B. CV/DC MIG Mode

40

35

30

3600RPM Max

3000RPM Max

25

20

20V Preset

15

DC VOLTS

Min

10

5

0

0 200 400 600

DC AMPERES

222 555 / 222 556 / 222 557

OM-4430 Page 17

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

5

SECTION 5 − INSTALLATION

-1. Installing Welding Generator

! Do not weld on base. Welding

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

Movement

! Do not lift unit from end.

OR

Location / Airflow Clearance

OR

18 in

(460 mm)

(460 mm)

Mounting

18 in

18 in

(460 mm)

(460 mm)

18 in

(460 mm)

18 in

using holes provided in base.

! Always securely fasten weld-

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

! Do not mount unit by support-

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

! Always ground generator

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

! If unit does not have GFCI re-

ceptacles, use GFCI-protected
extension cord.

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

Mounting:

1 Cross-Supports
Mount unit on flat surface or use

cross-supports to support base.

Grounding:

2 Equipment Grounding Terminal

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

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

Inadequate support.

Grounding

GND/PE

OM-4430 Page 18

! Do not use flexible mounts.

2

3

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

4

OR

1

! Bed liners, shipping skids, and some running

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

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

5-2. Engine Prestart Checks

Full

Empty

Full

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

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

 Follow run-in procedure in engine

manual.

 This unit has a low oil pressure

shutdown switch. However, some
conditions may cause engine
damage before the engine shuts
down. Check oil level often and do
not use the oil pressure shutdown
system to monitor oil level.

Fuel

Add fresh fuel before starting engine
the first time (see maintenance label for
specifications). Always leave filler
neck empty to allow room for expan­sion. Check fuel level on a cold engine
before use each day.

To check fuel level, turn Engine Control
switch to either Run/Idle position.
LED’s indicate fuel level in tank.

Oil

 Do not exceed the ”Full” mark on

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

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

Use front panel meters to determine
hours until next recommended oil
change (see Section 6-1).

 To improve cold weather starting:

Gasoline

Full

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

Use correct grade oil for cold
weather.

803 983−A / Ref 216 172-D

OM-4430 Page 19

5-3. Connecting Or Replacing The Battery

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

! Connect negative (−)

cable last.

+

−

Replacing The Battery

Tools Needed:

3/8, 1/2 in

 Remove end panel to replace battery.

! Connect negative (−)

cable last.

+

803 847 / 803 849 / Ref. S-0756-D Ref 216 172-D / Ref 803 983−A

−

−

+

OM-4430 Page 20

5-4. Installing Exhaust Pipe

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

! Stop engine and let cool.
! Engine backfire can cause se-

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

! Point exhaust pipe in desired

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

Tools Needed:

1/2 in

Notes

Ref 216 172-D / 803 891

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-4430 Page 21

5-5. Connecting To Weld Output Terminals

1

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

! Stop engine.
! Do not connect to CC and CV

terminals at the same time.

1 Negative (−) Weld Output

Terminal

2 Stick/TIG (CC) Weld Output

Terminal
3 Wire /CV Weld Output Terminal
For MIG welding, connect work cable

to Negative (−) terminal and wire
feeder cable to Wire (CV) terminal.

For Stick welding, connect work
cable to Negative (−) terminal and
electrode holder cable to Stick/TIG
(CC) terminal.

32

For TIG welding, connect work cable
to Stick/TIG (CC) terminal and elec­trode holder to Negative (−) terminal.

! Failure to properly connect

weld cables may cause exces-

sive heat and start a fire, or

damage your machine.

4 Weld Output Terminal
5 Supplied Weld Output Terminal

Nut
6 Weld Cable Terminal
7 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.

4

5

6

Tools Needed:

7

Do not place

anything between

weld cable terminal

and copper bar.

Correct Installation Incorrect Installation

3/4 in

216 172-D / 803 984−A / 803 778-A

OM-4430 Page 22

5-6. Selecting Weld Cable Sizes*

D

M

G

A/V

AMPERAGE

Weld Output

Terminals

! Stop engine 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)

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

**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = 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. 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. 4/0

(2x120)

2 ea. 4/0

(2x120)

5-7. Remote Receptacle Information

 Engine runs at weld speed (3000 or 3600 rpm) whenever a device connected to the remote receptacle is running.

Socket* Socket Information

AJ

K

B

L

NH

C

F

E

I

24 VOLTS AC

115 VOLTS AC

A 24 volts ac. Protected by supplementary protector

CB4.

B Not used.

I 115 volts ac. Protected by supplementary protec-

tor CB3.

*The remaining sockets are not used.

J Not used.

C +10 volts dc output to remote control.

D Remote control circuit common.

VOLTAGE

GND

E 0 to +10 volts dc input command signal from

remote control.

G Circuit common for 24 and 115 volts ac circuits.

K Chassis common.

OM-4430 Page 23

SECTION 6 − OPERATING WELDING GENERATOR

6-1. Front Panel Controls

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

2

1

3

4

5

6

9

8

1 Process Switch
See Section 6-5 for Process switch informa-

tion.
2 Remote Receptacle
Use receptacle to connect remote control.
When a remote voltage/amperage control is

connected to the Remote receptacle, the
Auto Sense Remote feature automatically
switches voltage/amperage control to the re­mote control (see Sections 5-7 and 6-8).

With remote voltage/amperage control con­nected, weld output in CC mode is deter­mined by a combination of front panel and re­mote control voltage/amperage settings.

If no remote voltage/amperage control is
connected to the Remote receptacle, the
front panel Voltage/Amperage control ad­justs voltage and amperage.

3 And 4 Displays
Displays can show weld process information

(voltage and amperage) or maintenance in­formation (hourmeter or oil change count­down).

Meter Weld Functions: In Wire mode, Volt­meter displays preset weld voltage when not
welding. Meters display actual voltage and
amperage when welding and for five sec­onds after welding has stopped.

In Stick and TIG modes, Voltmeter reads ON
and Ammeter displays preset amperage
when not welding. Meters display actual volt­age and amperage when welding and for five
seconds after welding has stopped.

Meter Engine Maintenance Functions:

Meters display engine hours when Engine
Control switch is in the Run/Idle 3600/2400
position but engine is not running.

Meter Oil Change Countdown: With en­gine off, place Engine Control switch in Run/
Idle 3000/1800 position to see hours before
next recommended oil change. Oil change
hours start at 100 (fresh oil) and count down
to 0 (oil change due). The meters display
negative (−) hours if 100 hours is exceeded.
After changing oil, reset counter by cycling
Engine Control switch between Run/Idle
positions three times.

Place Engine Control switch in Off position
after reading meters.

7

Ref 216 172-D

5 Fuel Level Indicator
With Engine running or Engine Control

switch in either Run/Idle position, LED’s indi­cate fuel left in tank.

6 Voltage/Amperage Control
Use control to select weld voltage or

amperage. Control may be adjusted while
welding.

 For maximum weld output (above 220

Amps), run unit at 3600 rpm. For weld
output below 220 Amps, operate unit at
3000 or 3600 rpm.

With Process switch in any Stick or TIG set­ting, use control to adjust amperage. With
Process switch in Wire position, use control
to adjust voltage. When a remote voltage/
amperage control is connected to Remote
receptacle RC4, control sets the maximum
amperage in Stick and TIG modes, but has
no effect in MIG mode.

7 Engine Control Switch (see Section 6-2)
8 Engine Choke Control (see Section 6-2)
9 Engine Speed Control Switch (see Sec-

tion 6-2)

OM-4430 Page 24

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

6-2. Description Of Engine Controls (See Section 6-1)

Engine Control Switch

Use switch to start engine, select speed, and
stop engine. Use switch in combination with
Engine Speed Control switch to select en­gine speed.

In Run/Idle 3600/2400 RPM position, engine
runs at 2400 rpm no weld load and 3600 rpm
under weld load.

In Run/Idle 3000/1800 RPM position, engine
runs at 1800 rpm no weld load and 3000 rpm
under weld load.

In either position, engine speed is deter­mined by weld load and position of Engine
Speed Control switch.

 Generator power is available at recep-

tacles RC1 and RC2 only at 1800 rpm.
If generator is not locked at 1800 rpm,
engine speed increases in response to
weld load and generator power output
stops at receptacles RC1 and RC2.
Generator power load does not affect
engine speed.

Engine Choke Control

Use control to change engine air-fuel mix
when starting engine.

To Start: pull out choke and turn Engine
Control switch to Start position. Release
switch and slowly push choke in when
engine starts.

With Speed Control switch in Weld, the
engine starts at 3000 rpm and remains there
for two minutes. Engine speed then reduces
to 2000 rpm.

The engine speed reduces from 3000 rpm to
2000 rpm when the Speed Control switch is
toggled within the first two minutes of
operation and no load is applied.

When an auxiliary power load is applied to 60
Hz receptacle RC1 or RC2, engine speed
reduces to 1800 rpm.

6-3. Cold Weather Engine Operation

1 Engine Control Switch

Carburetor Icing

1

Infrequently
Loaded

Frequently
Loaded

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

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

Breather Icing

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

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

Kohler offers a kit for cold weather operation. Contact engine manufacturer for kit
information (1-800-544-2444). The user can install these kits. The kit pulls heated
air from the muffler surface into the carburetor and shuts the cold air off. This in­creases engine temperature during operation in both idle and high speed.

 When the ambient temperatures become warmer (above 45_F) the air flow will

 If the engine does not start, let the

engine come to a complete stop before
attempting restart.

 During cold weather some gasoline en-

gines encounter difficulties that are easi­ly remedied. See Section 6-3 and 8-7.

To Stop: turn Engine Control switch to Off
position.

Engine Speed Control Switch

Use switch to control engine auto idle func­tion. Place switch in Generator Lock position
when not welding to lock engine speed at
1800 rpm for generator power at 60 Hz ac re­ceptacles RC1 and RC2 (generator power is
always available at 60−120 Hz receptacle
RC3. See Section 7-2.)

Place switch in Weld position to allow engine
speeds to be determined by position of En­gine Control switch. The Speed Control
switch is not needed at start−up.

have to be returned to normal.

Ref. 216 172

OM-4430 Page 25

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

6-4. Controlling Engine Speed And Weld/Generator Output

Engine Controls

Either
Run/Idle
position.

Engine Speed

1800 rpm

(Power Speed)

Continuous

Generator Power

Output

5 kW/kVA Total From

All AC Receptacles

Weld Output

Welding Not

Recommended

 Set engine controls as shown

to obtain the corresponding
weld and generator power out­put.

NOTICE − Disconnect equipment
from auxiliary 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.

No Load: 2400 rpm

(Idle Speed)

Load: 3600 rpm

(Weld Speed)

No Load: 1800 rpm

(Idle Speed)

Load: 3000 rpm

(Weld Speed)

2.4 kW/kVA at 60-120
Hz From AC

Receptacle RC3 Only

5 kW/kVA Total From

All AC Receptacles

At 1800 rpm.

At 3000 rpm, Output

Available Only At 2.4

kW/kVA 60-120 Hz AC

Receptacle RC3

3600 rpm:

20 − 300 A

3000 rpm:

20 − 220 A

Ref 216 172-D

OM-4430 Page 26

6-5. Process Switch

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

1

1 Process Switch

! Weld output terminals are energized

when Process switch is in an Elec­trode Hot position and the engine is
running.

 The unit will not return to idle speed

when Process switch is in a Wire or TIG
position and the remote contactor is on
(closure between pins A and B on re­mote receptacle).

Use switch to select weld process (see
table below and Section 5-7).

Wire Position:

Use Wire position for MIG welding using a
voltage sensing wire feeder.

Stick Positions:

Use Stick positions for stick (SMAW) and
air carbon arc (CAC-A) cutting and
gouging.

When switch is in a Stick mode, select one
of four dig settings to provide additional am­perage during short arc length conditions
and help prevent electrodes from “sticking”.
See Stick position descriptions following
(reading L to R):

Soft Arc (E 7018) (Position 1) - This setting
provides a low dig/arc force setting for
smooth weld performance. A stable weld
puddle with little arc “snap” gives excellent
weld bead appearance with minimal
spatter.

Medium Soft Arc (Position 2) - This setting
provides a low to medium dig/arc force that
gives a slightly more fluid weld puddle,
more arc “snap”, and reduces the potential
for electrode sticking at shorter arc lengths.

Medium Stiff Arc (Position 3) - This setting
provides medium dig/arc force for open root
vertical up joints or joints that do not require
additional current for fit up inconsistencies.

Stiff Arc (E6010) (Position 4) - This setting
provides a high dig/arc force for open root
vertical down joints where additional
current is needed to compensate for tight
joint fit up without the need to increase
overall welding current. This setting is rec­ommended for those who prefer a very stiff
arc with 6010 electrodes.

The dig circuit is disabled when switch is in
Wire or TIG positions.

TIG Position:

Electrode Hot − Lift-Arc™/Scratch Start TIG
(Provides great DC starts with either start­ing method) - With switch in this position,
normal open-circuit voltage is not present
between the electrode and workpiece. A
solid-state contactor energizes after the
electrode touches the workpiece,
preventing overheating, sticking, or con­tamination of the electrode (see Sections
6-6 and 6-7).

Process Switch Settings

Switch Setting Process Output On/Off Control

Electrode Hot − Wire MIG (GMAW) Electrode Hot

Ref 216 172-D / 803 984

Electrode Hot − Stick

Electrode Hot − Scratch

Start TIG

Air Carbon Arc (CAC-A) Cutting And Gouging

Stick (SMAW),

Scratch Start TIG (GTAW) Electrode Hot

Electrode Hot

OM-4430 Page 27

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

6-6. Stick Start Procedure − Scratch Start Technique

1

2

3

With Stick selected, start arc as
follows:

1 Electrode
2 Workpiece
3 Arc
Drag electrode across workpiece like

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

6-7. TIG Lift-Arc™ Start Procedure

Lift-Arc Start Method

“Touch”

1

1

Second

Select Lift-Arc/Scratch Start TIG at
Process switch to achieve great arc
starts with either procedure. Perform
Lift-Arc starting method as follows:

Lift-Arc  TIG

1 TIG Electrode
2 Workpiece
Turn gas on. Touch tungsten

electrode to workpiece at weld start

2

point. Hold electrode to workpiece
for 1 second, and slowly lift electrode.
Arc is started when electrode is lifted.

Normal open-circuit voltage is not
present before tungsten electrode
touches workpiece; only a low sensing
voltage is present between electrode
and workpiece. The solid-state output
contactor does not energize until after
electrode is touching workpiece. This
allows electrode to touch workpiece
without overheating, sticking, or
getting contaminated.

Application:

Lift-Arc is used for the DCEN GTAW
process when HF Start method is not
permitted.

OM-4430 Page 28

Do NOT Strike Like A Match!

6-8. Remote Voltage/Amperage Control

1

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

1 Remote Receptacle RC4
Connect optional remote voltage/

amperage (V/A) control to RC4 (see
Section 5-7).

With remote control connected, weld
output in a CC mode (Stick, TIG) is
determined by a combination of front
panel and remote control voltage/
amperage settings. In CV mode
(Wire), weld output is controlled
through remote control only.

2 Remote Hand Control

(Optional)

3 Remote Foot Control (Optional)

 Engine runs at weld/power

speed in Wire and TIG mode
whenever a device connected to
the remote receptacle makes
closure between pins A and B.
This unit does not have remote
contactor control. Output is al­ways on.

Connect Remote

V/A Control To

Remote

Receptacle RC4

Set Process

Set V/A Control

(Mid-Range: About 160 A)

Process = Stick (Using Remote On/Off)

In Example:

Min = 20 A CC/DC

Max = 160 A CC/DC

3

2

Max (160 A DC)

Min (20 A DC)

Adjust Remote V/A Control

(Stick Welding Only)

803 984−A / 216 172-D / S-0769 / S-0774

OM-4430 Page 29

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

SECTION 7 − OPERATING AUXILIARY EQUIPMENT

7-1. 60 Hz Generator Power Receptacles And Supplementary Protectors

! If unit does not have GFCI re-

ceptacles, use GFCI-protected
extension cord.

NOTICE − Disconnect equipment
from auxiliary 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.

 Weld output and 60 Hz generator

power output at receptacles RC1
and RC2 are not always available
at the same time. When welding,
generator power is available from
AC receptacle RC3 only (see
Section 7-2).

 Generator power is available at

receptacles RC1 and RC2 only at
1800 rpm. If generator is not
locked at 1800 rpm, engine
speed increases in response to
weld load and generator power
output stops at receptacles RC1
and RC2. Generator power load
does not affect engine speed.

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

power at 1800 rpm. Maximum output
is 5 kVA/kW (20 A at 240 volts ac). For
60 Hz generator power at RC1, set
controls as shown in table.

2 120 V 20 A AC Duplex

Receptacle RC2

RC2 supplies 60 Hz single-phase
power at 1800 rpm. Maximum output
from RC2 is 2.4 kVA/kW (20 A at 120
volts ac).

3 Supplementary Protector CB1
CB1 protects receptacles RC1 and

RC2 from overload. If CB1 opens, the
receptacles do not work. Place switch
in On position to reset.

4 Supplementary Protector CB2
CB2 protects RC2 from overload. If

CB2 opens, the receptacle does not
work. Press button to reset.

 If supplementary protector con-

tinues to open, contact Factory
Authorized Service Agent.

Combined output of all receptacles
limited to 5 kVA/kW continuous rating
of the generator.

EXAMPLE: If 10 A is drawn from 120
V duplex receptacle RC2, only 16 A is
available at 240 V receptacle RC1.

(120 V x 10 A) + (240 V x 16 A) = 5
kVA/kW

1

Engine Controls

Either
Run/Idle
position.

4

2

See Section

7-2 for RC3
information.

3

Controlling Engine Speed And Weld/Generator Power Output

Generator Power

Engine Speed

1800 rpm

(Power Speed)

Continuous

No Load: 2400 rpm

(Idle Speed)

Load: 3600 rpm

(Weld Speed)

No Load: 1800 rpm

(Idle Speed)

Load: 3000 rpm

(Weld Speed)

kW/kVA 60-120 Hz AC

Output

5 kW/kVA Total From

All AC Receptacles

2.4 kW/kVA at 60-120
Hz From AC

Receptacle RC3 Only

5 kW/kVA Total From

All AC Receptacles

At 1800 rpm.

At 3000 rpm, Output

Available Only At 2.4

Receptacle RC3

Weld Output

Welding Not

Recommended

3600 rpm:

20 − 300 A

3000 rpm:

20 − 220 A

OM-4430 Page 30

Ref. 211 909

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

7-2. Variable Frequency (Hz) Generator Power Receptacle RC3

2

1

NOTICE − Do not operate equipment
requiring a constant frequency from
variable frequency receptacle RC3.

1 120 V 20 A Variable Frequency

AC Receptacle RC3

Receptacle supplies single-phase
power continuously. Frequency (Hz)
of generator power output changes
with engine speed. Total output avail­able is 2.4 kVA/kW.

2 Supplementary Protector CB3
CB3 protects receptacle RC3 and

115 volt ac output to Remote Recep­tacle RC4 from overload. If CB3
opens, the receptacle does not work
and 115 volt ac output at RC4 stops.

 Press button to reset. If supple-

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

Notes

Ref. 216 172-D

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-4430 Page 31

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

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

Tools Needed:

Current Available in Amperes

240 V

Receptacle*

20
15
10

5
0

Each 120 V Duplex

Receptacle

0

5
10
15
20

V x A = Watts

*One 240 V load or two 120 V loads.

7

1

3

4

120V

240V

120V

6

3

4

5

2

240V

240 V AC

120 V AC 120 V AC

56

OM-4430 Page 32

plug1 11/03 − 120 813-D

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

SECTION 8 − MAINTENANCE & TROUBLESHOOTING

8-1. Routine Maintenance

 Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period.

! 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

8

Hours

Every

25

Hours

Every

50

Hours

Every

100

Hours

Every

200

Hours

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

 Fuel Level  Oil Level  Oil, Fuel Spills

 Spark Arrestor Screen  Air Cleaner Wrapper

 Weld Terminals

 Battery Terminals  Cooling System  Oil  Air Cleaner Element

Reference

Section 5-2

Section 8-3,
8-4

Engine
Manual,
Section 8-4,
8-5

Engine
Manual,
Section 8-5

Every

500

Hours

 Unreadable Labels  Spark Plug Gap  Oil Filter  Fuel Filter

 Weld Cables  Slip Rings*

 Brushes*

OM-4430 Page 33

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

8-2. Maintenance Label

 Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period.

OM-4430 Page 34

8-3. Servicing Optional Spark Arrestor

1

Tools Needed:

1/4 in

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

! Stop engine and let cool.

1 Spark Arrestor Screen
Clean and inspect screen. Replace

spark arrestor if screen wires are
broken or missing.

8-4. Servicing Air Cleaner

803 983−A / Ref 216 172-D

! Stop engine.

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

1 Precleaner
Wash precleaner with soap and wa-

ter solution. Allow precleaner to air

1

2

dry completely.
Spread 1 tablespoon SAE 30 oil

evenly into precleaner. Squeeze
out excess oil.

2 Element
Replace element if damaged, dirty,

or oily.

oil

aircleaner3 11/04 − 802 772 / S-0759

OM-4430 Page 35

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

8-5. Changing Engine Oil, Oil Filter, And Fuel Filter

Full

! Stop engine and let cool.

1 Oil Drain Valve
2 Oil Filter
Change engine oil and filter accord-

ing to engine 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 8-2).

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

Install new filter. Wipe up any spilled
fuel.

Start engine, and check for fuel
leaks.

! Stop engine, tighten connec-

tions as necessary, and wipe
up fuel.

Tools Needed:

3

4

2

1

OM-4430 Page 36

803 983−A / Ref 216 172-D / S-0842

8-6. Overload Protection

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

! Stop engine.

Open left side door.

 When a supplementary protec-

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

1 Supplementary Protector CB4
CB4 protects the stator winding

supplying 24 volt ac output to Re­mote receptacle RC4. If CB4
opens, 24 volt ac output to RC4
stops.

 Supplementary Protector CB3

protect the stator winding sup­plying 115 volt ac output to Re­mote Receptacle RC4 (see
Section 7-1).

Press button to reset.
2 Fuse F6 (See Parts List)
F6 protects the engine wiring sys-

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

Replace fuse if open.
Close left side door.

1

2

803 773−A / Ref. 216 172-D

OM-4430 Page 37

8-7. Troubleshooting

A. Welding

Trouble Remedy

No weld output. Check weld control settings.

Check weld connections.

Disconnect equipment from generator power receptacles during start-up.

Increase front panel and/or remote control voltage/amperage control setting (see Sections 6-1 and
6-8).

Check and secure connections to Remote receptacle RC4 (see Sections 5-7).

Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.

Low weld output. Check weld control settings.

Change position of Engine Control switch and Speed Control switch to achieve desired engine speed.

Increase front panel and/or remote control voltage/amperage control setting (see Sections 6-1 and
6-8).

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

Check and clean air cleaner as necessary (see Section 8-4).

Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.

See engine manual.

High weld output. Check control settings.

Check for obstructed movement of solenoid linkage.

Have Factory Authorized Service Agent check circuit boards PC1 and PC2.

Weld output cannot be adjusted. Have Factory Authorized Service Agent check field current control board PC2.

Erratic weld output. Check control settings.

Clean and tighten connections both inside and outside unit.

Be sure connection to work piece is clean and tight.

Remove excessive coils from weld cables.

Use dry, properly stored electrodes.

Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.

No remote fine amperage control. Check and tighten connections to Remote receptacle RC4 (see Section 5-7).

No front panel voltage/amperage con­trol.

No 24 volt ac output at Remote
receptacle RC4.

Disconnect remote control from Remote Receptacle RC4 if not needed for weld process (see Section
6-8).

Reset supplementary protector CB4 (see Section 8-6).

No 115 volt ac output at Remote
receptacle RC4.

OM-4430 Page 38

Reset supplementary protector CB3 (see Section 7-2).

Trouble Remedy

Lack of high frequency; difficulty in
establishing Gas Tungsten Arc Weld­ing arc.

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

Use proper size tungsten for welding amperage.

Reduce leakage of high frequency from torch or work cable (check grounding, remove excessive
coils from weld cables, use shorter weld cables, etc.).

Check cables and torch for cracked or deteriorated insulation or bad connections. Repair or replace
necessary parts.

Wandering arc − poor control of arc
direction.

Tungsten electrode oxidizing and not
remaining bright after conclusion of
weld.

Reduce gas flow rate.

Select proper size tungsten. Properly prepare tungsten.

Shield weld zone from drafts.

Increase postflow time.

Check and tighten all gas fittings.

Properly prepare tungsten.

B. 60 Hz Generator Power Receptacles RC1 And RC2

Trouble Remedy

No power output at 60 Hz ac recep­tacles RC1 or RC2.

Low power output at 60 Hz ac recep­tacles RC1 or RC2.

High power output at 60 Hz ac recep­tacles RC1 or RC2.

Reset supplementary protectors CB1 and/or CB2 (see Section 7-1).

Stop welding, or place Speed Control switch in Generator Lock position to run engine at 1800 rpm. 60
Hz receptacles RC1 and RC2 work only at 1800 rpm.

Check receptacle wiring and connections.

Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.

Check and clean air cleaner as necessary.

Check engine electronic governor system. See engine manual.

Check engine electronic governor system. See engine manual.

Erratic power output at 60 Hz ac
receptacles RC1 or RC2.

Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1, PC2, and
PC7.

Check receptacle wiring and connections.

Check governor according to engine manual.

C. Variable Frequency Generator Power Receptacle RC3

Trouble Remedy

No generator power output at ac re­ceptacle RC3.

Low generator power output at ac re­ceptacle RC3.

Reset supplementary protector CB4 (see Section 7-2).

Check receptacle RC3 for continuity and proper connections. Replace receptacle if necessary.

Have Factory Authorized Service Agent check brushes and slip rings, and circuit boards PC1, PC2, and
PC7.

Turn Engine Control switch to Run/Idle 3600/2400 RPM position.

OM-4430 Page 39

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

D. Engine

Trouble Remedy

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

Check battery voltage.

Check battery connections and tighten if necessary.

Check plug PLG5 and plug PLG8 connections.

Have Factory Authorized Service Agent check Engine Control switch S2.

Engine does not start. Check fuel level (see Section 5-2).

Check battery and replace if necessary.

Have Factory Authorized Service Agent check fuel shutoff solenoid FS1 according to engine manual.

Check engine charging system according to engine manual.

See engine manual.

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

Battery discharges between uses. Place Engine Control switch in Off position when unit is not running.

Engine stopped during normal
operation.

Check oil level (see Section 5-2). Low oil pressure shutdown stops engine if oil pressure is too low.
Engine also stops if oil level is too high.

Use correct grade oil for operating temperature. (see Section 8-2).

Have Factory Authorized Service Agent check low oil pressure shutdown switch S5.

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.

Check fuel level (see Section 5-2).

Check oil level (see Section 5-2). Low oil pressure shutdown stops engine if oil pressure is too low.
Engine also stops if oil level is too high.

Have Factory Authorized Service Agent check low oil pressure shutdown switch S5.

Have Factory Authorized Service Agent check fuel shutoff solenoid FS1 according to engine manual.

Engine does not return to idle speed. Place Engine Control switch S2 in either Run/Idle position.

Remove all weld and generator power loads.

Turn off remote contactor. The unit will not return to idle speed when the remote contactor is on.

Turn off remote device connected to Remote receptacle RC4 (see Section 5-7).

Check for obstructed movement of solenoid linkage.

Have Factory Authorized Service Agent check circuit board PC2 and current transformer CT1.

Engine does not go to weld speed. Place Speed Control switch in Weld position.

Check for obstructed movement of solenoid linkage.

During operation in near freezing tem­peratures, engine starts and goes to
idle but stalls after a few minutes.

During operation in severe cold weath­er, engine starts and goes to idle but
stalls after a few minutes.

Treat fuel with isopropyl alcohol de-icer product.

Place Engine Control switch in the Run position until unit has been in operation and loaded for a peri­od of time.

Install engine manufacturer’s kit for cold-weather operation.

OM-4430 Page 40

SECTION 9 − PARTS LIST

9-1. Recommended Spare Parts

Dia.

Mkgs.

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

Part

No.

Recommended Spare Parts

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

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

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

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

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

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

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

Notes

Description

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

Quantity

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

Choose Genuine Select to review spare parts requirements such

as filters, spark plugs, and fuses.

Choose Service Parts to download complete parts listing.

OM-4430 Page 41

SECTION 10 − ELECTRICAL DIAGRAMS

OM-4430 Page 42

Figure 10-1. Circuit Diagram For Welding Generator Models

232 961-A

OM-4430 Page 43

SECTION 11 − GENERATOR POWER GUIDELINES

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

11-1. Selecting Equipment

1 Generator Power Receptacles

− Neutral Bonded To Frame

2 3-Prong Plug From Case

Grounded Equipment

3 2-Prong Plug From Double

Insulated Equipment

 Be sure equipment has double

1

2

3

OR

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

insulated symbol and/or word­ing on it.

! Do not use 2-prong plug un-

less equipment is double in­sulated.

11-2. Grounding Generator To Truck Or Trailer Frame

1

GND/PE

2

3

! Always ground generator

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

! Also see AWS Safety &

Health Fact Sheet No. 29,
Grounding of Portable And
Vehicle Mounted Welding
Generators.

1 Equipment Grounding

Terminal (On Front Panel)

2 Grounding Cable (Not

Supplied)
3 Metal Vehicle Frame
Connect cable from equipment

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

 Electrically bond generator

frame to vehicle frame by met-

al-to-metal contact.

! Bed liners, shipping skids,

and some running gear insu-

late the welding generator

from the vehicle frame. Al-

ways connect a ground wire

from the generator equip-

ment grounding terminal to

bare metal on the vehicle

frame as shown.

! If unit does not have GFCI re-

ceptacles, use GFCI-pro-

tected extension cord.

OM-4430 Page 44

S-0854

11-3. Grounding When Supplying Building Systems

1 2

GND/PE

2

3

1 Equipment Grounding

Terminal
2 Grounding Cable
Use #10 AWG or larger insulated

copper wire.
3 Ground Device

 Use ground device as stated in

electrical codes.

! Ground generator to system

earth ground if supplying

power to a premises (home,

shop, farm) wiring system.

! Also see AWS Safety &

Health Fact Sheet No. 29,

Grounding of Portable And

Vehicle Mounted Welding

Generators.

11-4. How Much Power Does Equipment Require?

3

2

1

3

VOLTS 115
AMPS
Hz

4.5
60

ST-800 576-B

1 Resistive Load
A light bulb is a resistive load and

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

sistive load and requires approxi­mately six times more power while
starting the motor than when running
(see Section 11-8).

3 Rating Data
Rating shows volts and amperes, or

watts required to run equipment.

Amperes x Volts = Watts

Example 1: If a drill uses 4.5 am-

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

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

watts.
Example 2: If three 200 watt flood

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

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

flood lamps and drill is 1120 watts.

S-0623

OM-4430 Page 45

11-5. Approximate Power Requirements For Industrial Motors

Industrial Motors Rating Starting Watts Running Watts

Split Phase 1/8 HP 800 300

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

Capacitor Start-Induction Run 1/3 HP 2020 720

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

1 HP 6100 1600

1-1/2 HP 8200 2200

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

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

5 HP 23300 6000

7-1/2 HP 35000 8000

10 HP 46700 10700

Fan Duty 1/8 HP 1000 400

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

11-6. Approximate Power Requirements For Farm/Home Equipment

Farm/Home Equipment Rating Starting Watts Running Watts

Stock Tank 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-4430 Page 46

11-7. Approximate Power Requirements For Contractor Equipment

Contractor Rating Starting Watts Running Watts

Hand Drill 1/4 in 350 350

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

Circular Saw 6-1/2 in 500 500

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

Table Saw 9 in 4500 1500

10 in 6300 1800
Band Saw 14 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-4430 Page 47

11-8. Power Required To Start Motor

Single-Phase Induction Motor Starting Requirements

Motor Start

Code

KVA/HP 6.3 7.1 8.0 9.0 10.0 11.2 12.5 14.0

G H J K L M N P

1 Motor Start Code
2 Running Amperage

4
1

VOLTS AMPS

3

CODE 60

HP

AC MOTOR

230 2.5

M

1/4

Hz
PHASE

1

2

3 Motor HP
4 Motor Voltage
To find starting amperage:

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

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

age (see example).
Welding generator amperage out-

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

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

Starting Amperage

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

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

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

amperes.

S-0624

11-9. How Much Power Can Generator Supply?

1

2

1 Limit Load To 90% Of

Generator Output

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

2 5 Second Rule
If motor does not start within 5

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

OM-4430 Page 48

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

11-10. Typical Connections To Supply Standby Power

123

Utility

Electrical

Service

Transfer Switch

5

Essential

Loads

Fused

Disconnect

Switch

(If Required)

4

Welding

Generator

Output

! Have only qualified persons

perform these connections
according to all applicable
codes and safety practices.

! Properly install and ground

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

 Customer-supplied equipment

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

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

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

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

3 Fused Disconnect Switch
Install correct switch (customer-

supplied) if required by electrical
code.

4 Welding Generator Output
Generator output voltage and wir-

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

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

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

5 Essential Loads
Generator output may not meet the

electrical requirements of the prem­ises. If generator does not produce
enough output to meet all require­ments, connect only essential
loads (pumps, freezers, heaters,
etc. − See Section 11-4).

OM-4430 Page 49

11-11. 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
OM-4430 Page 50

Load (Watts) 4 6 8 10 12 14

Notes

SOCKET/WRENCH SELECTION TABLE

(U.S. STANDARD)

Specifications Socket or Wrench Size Specifications Socket or Wrench Size

Bolt

Diameter

1/4 in .250 in 3/8 in 7/16 in 6 mm .2362 in 10 mm 10 mm

5/16 in .3125 in 1/2 in 9/16 in 8 mm .3150 in 14 mm 14 mm

3/8 in .375 in 9/16 in 5/8 in 10 mm .3937 in 17 mm 17 mm

7/16 in .4375 in 5/8 in 3/4 in 12 mm .4724 in 19 mm 19 mm

1/2 in .500 in 3/4 in 13/16 in 14 mm .5512 in 22 mm 22 mm

9/16 in .5625 in 7/8 in 7/8 in 16 mm .6299 in 24 mm 24 mm

5/8 in .625 in 15/16 in 1 in 18 mm .7087 in 27 mm 27 mm
3/4 in .750 in 1-1/8 in 1-1/8 in 22 mm .8661 in 32 mm 32 mm
7/8 in .875 in 1-5/16 in 1-5/16 in 24 mm .9449 in 36 mm 36 mm

1 in 1.000 in 1-1/2 in 1-1/2 in

Decimal

Equivalent

Bolt Nut

SOCKET/WRENCH SELECTION TABLE

(METRIC)

Bolt

Diameter

U.S.

Decimal

Equivalent

Bolt Nut

OM-4430 Page 51

Notes

OM-4430 Page 52

Welding Symbols

Ref. AWS/ANSI A2.4

Warranty Questions?

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

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step of the way.

Effective January 1, 2007

(Equipment with a serial number preface of “LH” or newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other

LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
material and workmanship at the time it is shipped by Miller. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.

Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time
periods. All warranty time periods start on the delivery date of the
equipment to the original end-user purchaser, and not to exceed
one year after the equipment is shipped to a North American
distributor or eighteen months after the equipment is shipped to
an International distributor.

1. 5 Years Parts — 3 Years Labor

* Original main power rectifiers

2. 3 Years — Parts and Labor

* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Inverter Power Sources (Unless Otherwise Stated)
* Water Coolant Systems (Integrated)
* Intellitig
* Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the
engine manufacturer.)

3. 1 Year — Parts and Labor Unless Specified

* Motor Driven Guns (w/exception of Spoolmate

Spoolguns)
* Positioners and Controllers
* Automatic Motion Devices
* RFCS Foot Controls
* Induction Heating Power Sources, Coolers, and

Electronic

Controls/Recorders
* Water Coolant Systems (Non-Integrated)
* Flowgauge and Flowmeter Regulators (No Labor)
* HF Units
* Grids
* Spot Welders
* Load Banks
* Arc Stud Power Sources & Arc Stud Guns
* Racks
* Running Gear/Trailers
* Plasma Cutting Torches (except APT & SAF

Models)
* Field Options

(NOTE: Field options are covered under True Blue®

for the remaining warranty period of the product they

are installed in, or for a minimum of one year —

whichever is greater.)
* Bernard-Branded Mig Guns (No Labor)
* Weldcraft-Branded TIG Torches (No Labor)
* Subarc Wire Drive Assemblies

4. 6 Months — Batteries

5. 90 Days — Parts

* MIG Guns/TIG Torches and Subarc (SAW) Guns

guarantees or warranties expressed or implied.

* Induction Heating Coils and Blankets, Cables, and

Non-Electronic Controls
* APT & SAF Model Plasma Cutting Torches
* Remote Controls
* Accessory (Kits)
* Replacement Parts (No labor)
* Spoolmate Spoolguns
* Canvas Covers

Miller’s True Blue® Limited Warranty shall not apply to:

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, slip rings, relays
or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)

2. Items furnished by Miller, but manufactured by others, such
as engines or trade accessories. These items are covered
by the manufacturer’s warranty, if any.

3. Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable and
necessary maintenance, or equipment which has been
used for operation outside of the specifications for the
equipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.

Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.

In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available,
but may vary from province to province.

miller_warr 2007−01

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

For Service

Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information

and Parts)
Circuit Diagrams
Welding Process Handbooks

To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller

Miller Electric Mfg. Co.

An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA

International Headquarters−USA

USA Phone: [phone] Auto-Attended
USA & Canada FAX: [phone]
International FAX: [phone]

European Headquarters −
United Kingdom

Phone: [phone]
FAX: [phone]

www.MillerWelds.com

Contact the Delivering Carrier to:

File a claim for loss or damage during
shipment.

For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.

PRINTED IN USA © 2007 Miller Electric Mfg. Co.2007−01