Miller Electric Renegade 180 User Manual

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OM-228 042B 2007−09

Processes

MIG (GMAW) Welding Flux Cored (FCAW) Welding

Description

Engine Driven Welding Power Source/ Wire Feeder/Generator

Renegade 180

Visit our website at

www.MillerWelds.com

File: Engine Drive

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From Miller to You

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

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

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

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

We’ve made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there’s a Troubleshooting section that will help you figure out what the problem is. The

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

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

Working as hard as you do

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

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

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

Mil_Thank 2005−04

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TABLE OF CONTENTS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

4-1. Description 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Weld, Power, And Engine Specifications 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Gun Specifications 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Dimensions, Weights, And Operating Angles 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Volt-Ampere Curves 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Fuel Consumption 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Power Source Duty Cycle 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. Gun Duty Cycle And Overheating 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-9. Generator Power Curve 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − INSTALLATION 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Installing Welding Generator 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Grounding Generator When Supplying Building Systems 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Engine Prestart Checks 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Connecting The Battery (Electric Start Models Only) 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Installing Welding Gun 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. Work Cable Routing Inside Unit 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7. Weld Process/Polarity Table 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-8. Changing Weld Polarity 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-9. Connecting Single−Phase, 230 Volt AC Utility Input Power 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-10. Electrical Service Guide 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-11. Installing Wire Spool And Adjusting Hub Tension 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-12. Threading The Welding Gun 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − OPERATING THE WELDING GENERATOR 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Controls (See Section 6-2) 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Description Of Controls (See Section 6-1) 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Weld Parameter Chart 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. Stainless Steel And 100% CO2 Weld Parameters 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

7-1. Generator Power Panel Receptacles 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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TABLE OF CONTENTS

SECTION 8 − MAINTENANCE 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1. Power Source Routine Maintenance 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2. Gun Routine Maintenance 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3. Welding Power Source Overload Protection 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-4. Drive Motor Protection And Tip Saver/Short Circuit Protection 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-5. Changing Drive Roll Or Wire Inlet Guide 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-6. Replacing Gun Contact Tip 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-7. Maintaining Gun 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-8. Replacing Switch And/Or Head Tube 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-9. Servicing Air Cleaner 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-10. Adjusting Engine Speed 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − TROUBLESHOOTING 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 − PARTS LIST 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-1. Recommended Spare Parts 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 − ELECTRICAL DIAGRAMS 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 12 − MIG WELDING (GMAW) GUIDELINES 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 13 − GENERATOR POWER GUIDELINES 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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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-228 042 Page 1

Page 6

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-228 042 Page 2

Page 7

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-228 042 Page 3

Page 8

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-228 042 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.

Page 9

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: 1-877-413-5184, website: www.global.ihs.com).

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

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

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

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

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

1-8. EMF Information

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

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

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

Ontario, Canada L4W 5NS (phone: 800-463-6727 or in Toronto 416-747-4044, website: www.csa-international.org).

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

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

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

P.O. Box 9101, Quincy, MA 02269-9101 (phone: 617-770-3000, website: www.nfpa.org.

OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are 10 Regional Offices—phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).

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

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

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

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

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

About Implanted Medical Devices:

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

OM-228 042 Page 5

Page 10

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-228 042 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.

Page 11

Une tension DC importante subsiste à l’intérieur

o e

u n

des onduleurs après avoir coupé l’alimentation.

 Couper l’alimentation du poste et décharger les condensateurs

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

DES PIÈCES CHAUDES peuvent provoquer des brûlures graves.

 Ne pas toucher à mains nues les parties chau

des.

 Prévoir une période de refroidissement avant d

travailler à l’équipement.

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

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

DES PIECES DE METAL ou DES SA-

LETES peuvent provoquer des bles-

sures dans les yeux.

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

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

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

facial.

LES FUMÉES ET LES GAZ peuvent êtr dangereux.

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

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

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

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

approuvé.

 Lire et comprendre les spécifications de sécurité des matériaux

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

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

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

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

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

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

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

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

 Fermer l’alimentation du gaz protecteur en cas d

non utilisation.

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

respirateur d’adduction d’air homologué.

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

Le rayonnement de l’arc du procédé de soudag

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

 Porter un casque de soudage approuvé muni de verres filtrants

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

 Porter des lunettes de sécurité avec écrans latéraux même sous

votre casque.

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

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

 Porter des vêtements confectionnés avec des matières résistan-

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

LE SOUDAGE peut provoquer un in

cendie ou une explosion.

Le soudage effectué sur des conteneurs fermés tel

que des réservoirs, tambours ou des conduites pe

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

 Déplacer toutes les substances inflammables à une distance de

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

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

sur des substances inflammables.

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

de métal chaud.

 Des étincelles et des matériaux chauds du soudage peuvent

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

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

proximité.

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

peut déclencher un incendie de l’autre côté.

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

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

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

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

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

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

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

lées.

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

électrode ou couper le fil à la pointe de contact.

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

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

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

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

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

ce d’étincelles incandescentes ni de flammes.

 Utiliser exclusivement des fusibles ou coupe−circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

OM-228 042 Page 7

Page 12

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

a n

s s

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

LE BRUIT peut affecter l’ouïe.

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

 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-228 042 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.

Page 13

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

t ,

avant d’enlever le bouchon.

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

 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-228 042 Page 9

Page 14

LE SURCHAUFFEMENT peut endom-

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-228 042 Page 10

Page 15

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.

About Implanted Medical Devices:

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-228 042 Page 11

Page 16

3-1. Symbol Definitions

 Complete Parts List available at www. MillerWelds.com

SECTION 3 − DEFINITIONS

Engine Choke

Engine Oil Fuel Circuit Protector Engine

Positive Negative

Hours

Off Temperature Input

Wire Speed

Spool Gun

Read Operator’s

Manual A

Direct Current

(DC)

GMAW Gun

Trigger

Amperes

Alternating Current

(AC)

Time

Shielding Gas

Input

Volts

Output

Protective Earth

(Ground)

Single-Phase 230

Input Volt Power

Over Temperature

SECTION 4 − SPECIFICATIONS

4-1. Description

This unit is an engine driven welding power source/wire feeder with auxiliary power capability. The welding power source/wire feeder can also use utility power to provide weld output (no auxiliary power available in this mode).

4-2. Weld, Power, And Engine Specifications

Rated Welding

Output

135 A @ 22.5

Volts DC, 30%

Duty Cycle At 60

Hz Input

Wire Type

And Dia

Amperage

Range

30 − 180

Solid/

Stainless

.024 − .035

in.

(0.6 − 0.9

mm)

Maximum Open-

Circuit Voltage

35 19.5

Flux Cored

.030 − .045 in.

(0.8 − 1.2 mm)

Amperes Input at

Rated Load Output

230 V, 60 Hz,

Single-Phase

KVA/KW

4.60 KVA

3.75 KW

40 − 720 IPM (1.0 − 18.3 m/min) At No Load

20 − 700 IPM (0.5 − 17.8 m/min) Feeding Wire

Generator

Power Rating

Single-Phase,

5.0 kVA/kW (Peak)

4.5 kVA/kW

(Continuous)

40/20 A,

120/240 V AC,

60 Hz

Wire Feed Speed Range

Engine

Kohler CS10

Air-Cooled,

One-Cylinder,

Four-Cycle, 10 HP (300 CC), Gasoline Engine

(Recoil or Electric

Start)

Fuel

Capacity

1.8 Gal (6.9 L)

Tank

OM-228 042 Page 12

Page 17

4-3. Gun Specifications

Do not exceed tilt angles or engine

it could tip

Air-Cooled Welding Guns For GMAW And FCAW Welding

 Using gasless flux cored wire reduces gun duty cycle.

M-15 Feeds .023 To .045 in. (0.6 To 1.1 mm) Hard Or Flux Cored Wires .045 in. (1.1 mm) wire requires liner change to MILLER Part No. 194012 in addition to contact tip change Duty Cycle Rating: 100%: 150 A With CO 60%: 200 A With CO Weight With 15 ft (4.6 m) Power Cable: 6.0 lb (2.7 kg) Identified With  On Power Cable

Ref. 800 797-D

Shielding Gas; 120 A With Mixed Gases

Shielding Gas; 150 A With Mixed Gases

4-4. Dimensions, Weights, And Operating Angles

Dimensions

Height 31 in (787 mm)

Width 32 in (813 mm)

Length 41 in (1041 mm)

A 31-5/8 in (803 mm) B 10-9/16 in (268 mm) C 13-25/64 in (340 mm) D 22-3/4 in (577 mm) E 1-9/16 in (40 mm) F 19-5/8 in (498 mm) G 13/32 in (10 mm) Dia.

Weight

275 lb (125 kg) Recoil Start

307 lb (140 kg) Electric Start

Optional Lifting Eye

Weight Rating

430 lb (195 kg)

NOTICE − Optional lifting eye may not be installed on units with optional cylinder rack.

Engine End

 Complete Parts List available at www. MillerWelds.com

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

Do not move or operate unit where

Holes

803 403

it could tip.

15° 15°

15°

804 476-C

4-5. Volt-Ampere Curves

40 35 30 25

DC Voltage

15 10

5 0

20 40 60 80 100 120 140 160 180 200

This welding power source can be powered by the unit engine or utility power via a wall receptacle.

The volt-ampere curve shows the minimum and maximum voltage

Wall Maximum

and amperage output capabilities of the unit. Curves of all other settings fall between the curves shown.

Generator

Wall Minimum

Maximum

DC Amperage

233 243

OM-228 042 Page 13

Page 18

4-6. Fuel Consumption

1.00

0.80

0.60

0.40

US Gal./Hr.

0.20

0.00 01 23456

Auxiliary Power Kw At 100% Duty Cycle

4-7. Power Source Duty Cycle

300 250

 Complete Parts List available at www. MillerWelds.com

233 244

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.

200

150 135

105

DC Amperes

10 15 20 25 30 40 50 60 70 80 100

% Duty Cycle

30% duty cycle at 135 amps, 60 Hz 20% duty cycle at 130 amps, 50 Hz

3 Minutes Welding 7 Minutes Resting

Overheating

A or V

OM-228 042 Page 14

Minutes

Reduce Duty Cycle

230 343-A

Page 19

4-8. Gun Duty Cycle And Overheating

100%dutycycle

60%dutycycle

 Complete Parts List available at www. MillerWelds.com

See Section 4-3. Specifications for amperage rating and duty cycle.

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

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

Continuous Welding

Overheating

6 Minutes Welding 4 Minutes Resting

4-9. Generator Power Curve

300

250

240 Volt

200

150

AC Volts

100

120 Volt

Minutes

A or V

Reduce Duty Cycle

sduty1 5/95

The ac generator power curves show the generator power available in amperes at the receptacles.

20 40 60 80

100 120

AC Amperes

233 242

OM-228 042 Page 15

Page 20

SECTION 5 − INSTALLATION

5-1. Installing Welding Generator

 Complete Parts List available at www. MillerWelds.com

Movement

Location

 Shown with

standard running gear and optional cylinder rack.

Always securely fasten welding generator onto transport vehicle or trailer and comply with all DOT and other applicable codes.

Airflow Clearance

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

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

GND/PE

Always ground generator frame to vehicle frame to prevent electric shock and static

Ref. install 11/02 − Ref. 800 652 / 804 476-C / S-0854

electricity hazards.

1 Metal Vehicle Frame 2 Equipment Grounding

Terminal

3 Grounding Cable

Bed liners, shipping skids, and some running gear 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.

Use #10 AWG or larger insulated copper wire to make metal-to-metal grounding connection.

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

OM-228 042 Page 16

Page 21

 Complete Parts List available at www. MillerWelds.com

5-2. Grounding Generator When Supplying Building Systems

GND/PE

1 2

Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system.

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.

Notes

WELD JOINT

TYPES

800 576-B

FLAT VERTICALHORIZONTAL OVERHEADWELD POSITION:

BUTT

GROOVE

FILLET

Ref. AWS/ANSI D1.1

T−JOINT

Ref. 804 248-A

OM-228 042 Page 17

Page 22

5-3. Engine Prestart Checks

1/2 in

(13 mm)

Gasoline

Full

 Complete Parts List 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.

1 Fuel Valve Open valve.

 Fuel valve is shown in the open

position. Always close fuel valve after stopping unit. Moving unit with fuel valve open may cause carburetor flooding and make starting difficult.

Fuel

Add fresh fuel before starting engine the first time (see engine manual for specifications). Fill fuel tank up to 1/2 in. (13 mm) from top to allow room for expansion. Check fuel level on a cold engine before use each day.

Oil

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

Unit stops if oil level is too low. Unit cannot be restarted until sufficient oil is added.

5-4. Connecting The Battery (Electric Start Models Only)

! Connect negative (−)

cable last.

804 971-A

! Turn Engine Switch to Off

(electric start models only).

−

Tools Needed:

1/2 in

OM-228 042 Page 18

805 052-A / 803 466

Page 23

5-5. Installing Welding Gun

 Complete Parts List available at www. MillerWelds.com

5-6. Work Cable Routing Inside Unit

1 Drive Assembly 2 Gun Securing Knob 3 Gun End Loosen knob. Insert gun end

through opening until it bottoms

against drive assembly. Tighten knob.

4 Gun Trigger Plug Insert into receptacle, and tighten

threaded collar. 5 Mig Gun/Spool Gun Select

Switch

Place switch in position for gun being used.

Close door.

804 755-B

1 Work Clamp Lead 2 Wire Drive Lead 3 Positive Output Terminal 4 Negative Output Terminal Route work cable to output termi-

nal. See Section 5-7 for connections.

Close door.

804 755-B

OM-228 042 Page 19

Page 24

5-7. Weld Process/Polarity Table

Weld P

Weld Polari

 Complete Parts List available at www. MillerWelds.com

rocess

GMAW − Solid wire with shield-

DCEP − Reverse polarity Connect to positive (+) out-

ing gas FCAW − Self-shielding wire −

DCEN − Straight Polarity Connect to negative (−)

no shielding gas

5-8. Changing Weld Polarity

Wire Drive Lead Work Clamp Lead

Cable Connections

Connect to negative (−) output

put terminal

terminal Connect to positive (+) output

output terminal

terminal

 Connection hardware must be

tightened with proper tools. Do not just hand tighten hardware. A loose electrical connection will cause poor weld performance and excessive heating at the terminal block.

1 Lead Connections For Direct

Current Electrode Negative

(DCEN)

2 Lead Connections For Direct

Current Electrode Positive (DCEP)

Always read and follow wire manufacturer’s recommended polarity, and see Section 5-7.

Close door.

Ref. 230 748-B

OM-228 042 Page 20

Page 25

 Complete Parts List available at www. MillerWelds.com

5-9. Connecting Single−Phase, 230 Volt AC Utility Input Power

Tools Needed:

=GND/PE Earth Ground

230 VAC, 1

 Shown with optional cylinder rack

 This unit can provide weld out-

put using the engine to power the welding power source/wire feeder OR single−phase 230 volt ac utility power can be used to power the welding power source/wire feeder.

Installation must meet all National and Local Codes − have only qualified persons make this installation.

Disconnect and lockout/tagout input power before connecting input conductors from unit.

Always connect green or green/yellow conductor to supply grounding terminal first, and never to a line terminal.

1 Rating Label Supply correct input power. 2 Black And White Input

Conductor (L1 And L2)

3 Green Or Green/Yellow

Grounding Conductor 4 Input Power Cord. 5 Disconnect Device (switch

shown in the OFF position) 6 Disconnect Device Grounding

Terminal 7 Disconnect Device Line

Terminals Connect green or green/yellow

grounding conductor to disconnect device grounding terminal first.

Connect input conductors L1 and L2 to disconnect device line terminals.

8 Over-Current Protection Select type and size of over-current

protection using Section 5-10 (fused disconnect switch shown).

Close and secure door on disconnect device. Remove lockout/tagout device, and place switch in the On position.

9 Plug (NEMA 6-50P) 10 Receptacle (NEMA 6-50R) Connect plug to receptacle.

Special installation may be

required where gasoline or

volatile liquids are present −

see NEC Article 511 or CEC

Section 20.

Ref. 802 085 / Ref. 803 766-B / 804 476-C

OM-228 042 Page 21

Page 26

 Complete Parts List available at www. MillerWelds.com

5-10. Electrical Service Guide

60 Hz Single Phase

Input Voltage 230 Input Amperes At Rated Output 20 Max Recommended Standard Fuse Rating In Amperes

Circuit Breaker 1, Time-Delay

Normal Operating

Min Input Conductor Size In AWG

Max Recommended Input Conductor Length In Feet (Meters)

Min Grounding Conductor Size In AWG

Reference: 2005 National Electrical Code (NEC) (including article 630) 1 Choose a circuit breaker with time-current curves comparable to a Time Delay Fuse. 2 “Time-Delay” fuses are UL class “RK5” .

3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and

above). 4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table

310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.

Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated branch circuit that applies to the rated output and duty cycle of the welding power source.

25 30 14 67

(20)

5-11. Installing Wire Spool And Adjusting Hub Tension

Installing 4 in. (102 mm) Wire Spool

Installing 8 in. (203 mm) Wire Spool

1 Adapter 2 Retaining Ring When a slight force is needed to

turn spool, tension is set.

OM-228 042 Page 22

Tools Needed:

1/2 in

803 012 / 803 013 -B / Ref. 802 444-C

Page 27

Notes

 Complete Parts List available at www. MillerWelds.com

Ref. AWS/ANSI D1.1

WELD JOINT

TYPES

FILLETGROOVE

WELD POSITION:

FLAT

BUTT

T−JOINT

HORIZONTAL

T−JOINT

VERTICAL

BUTT

OVERHEAD

T−JOINT

BUTT

T−JOINT

OM-228 042 Page 23

Ref. 804 248-A

Page 28

5-12. Threading The Welding Gun

 Complete Parts List available at www. MillerWelds.com

Tools Needed:

6 in

(150 mm)

.024 Groove.030/.035 Groove

Stamped .024

Stamped .030/.035

OM-228 042 Page 24

Tighten

1 2 3 4

Pressure

Indicator

Scale

804 755-B / Ref. 229 573-A

Page 29

WOOD

Tighten

 Complete Parts List available at www. MillerWelds.com

1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Pressure Adjustment Knob 5 Drive Roll 6 Gun Conduit Cable Lay gun cable out straight. Open

pressure assembly. Pull about 6 in. (150 mm) of wire off

spool. Hold tightly to keep it from unraveling. Cut off end.

Pull wire through guides into gun; continue to hold wire tightly.

Be sure wire is positioned in proper feed roll groove. Close and tighten pressure assembly. Let go of wire.

Use pressure indicator scale to set desired drive roll pressure. Begin with a setting of 3. If necessary, make additional adjustments after trying initial setting.

1 2 3 4

Remove gun nozzle and contact tip.

Turn power on. Press gun trigger until wire comes

out of gun. Be sure that tip matches wire diam-

eter. Reinstall contact tip and nozzle.

Feed wire to check drive roll pressure. Tighten knob enough to prevent slipping. Cut off wire.

Close door.

OM-228 042 Page 25

Page 30

 Complete Parts List available at www. MillerWelds.com

SECTION 6 − OPERATING THE WELDING GENERATOR

6-1. Controls (See Section 6-2)

Electric Start Models

OM-228 042 Page 26

Recoil Start Models

229 573 / 804 971-B

Page 31

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

 Complete Parts List available at www. MillerWelds.com

1 Engine Switch Use switch to control ignition circuit. For Recoil Start: Turn switch to On position

when starting engine. Turn switch to Off position to stop engine. Engine cannot be started with switch in the Off position.

For Electric Start: Turn switch to Start position when starting engine. Switch returns to Run position when engine starts. Turn switch to Off position to stop engine.

Engine stops if oil level is too low. Engine cannot be restarted until sufficient oil is added.

2 Low Oil Pressure Light Light goes on and engine stops if engine oil

level is too low. Engine cannot be restarted until sufficient oil

is added.

NOTICE − Stop engine and add oil if light goes on (see Section 5-3).

3 Starter Handle 4 Choke Control Use control to change engine air/fuel mix.

Move control to far right if starting a cold en-

gine. Move control to far left if starting a warm engine.

To Start:

 Open fuel valve (see Section 5-3).  Set choke.  For Recoil Start: Turn Engine switch to

On and pull starter handle.

 For Electric Start: Turn Engine switch to

Start. When engine starts, allow switch to return to Run position.

 Open choke as engine warms.

NOTICE − If the engine does not start, let engine come to a complete stop before attempting restart.

To Stop:

 Turn Engine switch to Off.

 Always close fuel valve after stopping

unit. Moving unit with fuel valve open may cause carburetor flooding and make starting difficult.

5 Wire Speed Control Turn control clockwise to increase wire feed

speed. (see weld parameter chart in welding power source or Section 6-3).

6 Voltage Control Turn control clockwise to increase voltage

(see weld parameter chart in welding power source or Section 6-3).

7 Gun Trigger Receptacle 8 Wall/Generator Switch Use switch to select source of power for weld-

ing power source. Place switch in Generator position for welding

power source to run on generator input power. Place switch in Wall position for the welding

power source to run on utility power. Place switch in Off position before connecting to utility power.

 With switch in the Wall position and the

generator not running, the auxiliary power receptacles do not work.

9 Over Temperature Light Light flashes when unit has overheated and

weld output is not available. Allow fan to run to cool unit. When light goes out, unit is ready for service.

OM-228 042 Page 27

Page 32

6-3. Weld Parameter Chart

 Complete Parts List available at www. MillerWelds.com

OM-228 042 Page 28

Ref. 230 748C

Page 33

6-4. Stainless Steel And 100% CO2 Weld Parameters

Select Wire Type, Polarity, and Shielding Wire Si

90% HE/7.5% Ar/ 2.5% CO2

 Complete Parts List available at www. MillerWelds.com

Select Wire Type, Polarity, and Shielding

Gas

Solid ER70S−6 (DCEP)

100% CO2 Shielding Gas

Stainless Steel (DCEP)

Tri−Mix Shielding Gas

90% HE/7.5% Ar/ 2.5% CO2

Aluminum 4043 (DCEP)

100% Argon Shielding Gas

Solid ER70S−6 (DCEP)

100% CO2 Shielding Gas

Stainless Steel (DCEP)

Tri−Mix Shielding Gas

90% HE/7.5% Ar/ 2.5% CO2

Aluminum 4043 (DCEP)

100% Argon Shielding Gas

20 ga 18 ga 16 ga 14 ga 1/8 in. 3/16 in. 1/4 in. 5/16 in.

Material Thickness

Shop Settings (Wall or Premise Power, 230 V 1 Ph)

0.024 3.2/25 3.5/25 4.0/40 4.5/50 5.0/60 7.0/85 −−− −−−

0.030 3.0/15 3.5/20 4.0/25 4.5/35 5.5/45 6.0/55 6.5/65 10.0/75

0.035 −−− 3.0/12 4.0/20 4.5/30 5.5/35 6.0/40 6.5/50 10.0/55

0.024 3.5/30 3.5/45 4.0/50 4.5/70 5.0/80 6.0/95 −−− −−−

0.030 3.5/25 3.5/30 4.0/45 5.0/60 5.0/70 6.0/85 7.5/95 −−−

0.035 −−− 2.5/20 3.5/25 4.0/40 4.5/50 6.0/65 7.5/80 −−−

0.030 2.0/70 2.0/70 4.0/70 5.0/70 8.0/95 10/100

0.035 2.5/65 4.0/60 5.0/65 8.0/90 10/90

Field Setting (Generator Power)

0.024 3.5/25 3.5/25 4.0/40 4.5/50 5.0/60 10.0/70 −−− −−−

0.030 3.0/15 3.5/20 4.0/25 5.0/35 6.0/45 10.0/55 10.0/65 −−−

0.035 −−− 3.0/12 4.0/20 10.0/30 10.0/35 −−− −−− −−−

0.024 3.5/30 3.5/45 4.0/50 5.5/70 10.0/80 10.0/95 −−− −−−

0.030 4.5/25 4.5/30 6.0/45 10.0/60 10.0/70 10.0/85 −−− −−−

0.035 −−− 3.0/20 4.0/25 6.0/40 10.0/50 −−− −−− −−−

0.030 4.0/70 4.0/70 6.0/70 10/75

0.035 4.5/60 6.0/60 10/65

OM-228 042 Page 29

Page 34

SECTION 7 − OPERATING AUXILIARY EQUIPMENT

7-1. Generator Power Panel Receptacles

 Complete Parts List available at www. MillerWelds.com

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

 Generator power decreases as weld

current increases.

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

weld/power speed. Maximum output is 5 kVA/kW (peak) or 4.5 kVA/kW (continuous).

2 120 V 20 A AC Duplex Receptacle

RC2

3 120 V 20 A AC Duplex Receptacle

RC3

RC2 and RC3 supply 60 Hz single-phase power at weld/power speed. Maximum output from RC2 or RC3 is 2.4 kVA/kW.

NOTICE − Do not parallel the two 120 VAC duplex receptacles.

4 Supplementary Protector CB1 CB1 protects the receptacles from over-

load. If CB1 opens, the receptacles do not work. Move switch to the On position to reset.

229 573-A

 If supplementary protector continues

to open, contact Factory Authorized Service Agent.

Combined output of all receptacles limited to 4.5 kVA/kW continuous rating of the generator (See Section 13 − Generator Power Guidelines).

EXAMPLE: If 10 A is drawn from each 120 volt duplex receptacle, only 8 A is available from the 240 V receptacle.

2 x (120 V x 10 A) + (240 V x 8 A) = 4.5 kVA/ KW.

OM-228 042 Page 30

Page 35

 Complete Parts List available at www. MillerWelds.com

SECTION 8 − MAINTENANCE

8-1. Power Source 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

Hours

Every

Hours

Every

Hours

Every

100

Hours

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

 Fuel Level  Oil Level  Oil, Fuel Spills

 Air Cleaner Precleaner

 Weld Terminals

 Oil  Air Cleaner Element  Cooling System  Spark Plug Gap

Reference

Section 5-3

Section 8-9

Engine Manual, Section 8-9

Every

200

Hours

Every

300

Hours

Every

500

Hours

Every

1000

Hours

 Battery Terminals (Electric Start Models)

 Unreadable Labels

Engine Manual

Valve Clearance*

Engine Manual

 Weld Cables  Slip Rings*

 Brushes*

 Inside Unit

OM-228 042 Page 31

Page 36

8-2. Gun Routine Maintenance

 = Check  = Change  = Clean  = Replace Reference

 Complete Parts List available at www. MillerWelds.com

Stop engine and disconnect gun before maintaining.

Every Spool Of Wire

 Gun Casing  Nozzle,  Contact Tip

Every 3 Months

 Cracked Parts  Cracked Parts  Cracked Parts  Cracked Parts

8-3. Welding Power Source Overload Protection

Section 8-7

1 Supplementary Protector CB2 CB2 protects unit from overload. If

the unit is using 230 volts ac input power and CB2 opens, unit shuts down.

Reset supplementary protector.

 Shown with optional cylinder rack

804 476-C

8-4. Drive Motor Protection And Tip Saver/Short Circuit Protection

A. Drive Motor Protection

Drive motor protection circuit protects drive motor from overload. If drive motor becomes inoperative, release gun trigger and wait until protection circuit resets allowing drive motor to feed wire again.

B. Tip Saver/Short Circuit Protection

The tip saver/short circuit protection extends contact tip life and protects internal components from damage. If contact tip is shorted to workpiece, the unit shuts down the welding output. To resume operation, release gun trigger to reset unit. If the contact tip has stuck to the workpiece, release gun trigger, turn off unit, and remove contact tip from workpiece. Check contact tip and replace if damaged. Turn on unit to continue operation.

OM-228 042 Page 32

Page 37

8-5. Changing Drive Roll Or Wire Inlet Guide

.024 Groove.030/.035 Groove

 Complete Parts List available at www. MillerWelds.com

1 Inlet Wire Guide Remove guide by pressing on

barbed area or cutting off one end near housing and pulling it out of hole. Push new guide into hole from rear until it snaps in place.

2 Drive Roll The drive roll consists of two differ-

ent sized grooves. The stamped markings on the end surface of the drive roll refer to the groove on the opposite side of the drive roll. The groove closest to the motor shaft is the proper groove to thread (see Section 5-12).

3 Retaining Pin To secure drive roll, locate open slot

and push drive roll completely over retaining pin, then rotate drive roll 1/4 turn to closed slot.

Stamped .024

Stamped .030/.035

8-6. Replacing Gun Contact Tip

802 984

Turn Off power before replacing contact tip.

1 Nozzle 2 Contact Tip Cut off welding wire at contact tip.

Remove nozzle. Remove contact tip and install new

contact tip. Reinstall nozzle.

Tools Needed:

Ref. 802 399-A

OM-228 042 Page 33

Page 38

8-7. Maintaining Gun

 Complete Parts List available at www. MillerWelds.com

Turn off welding power source/wire feeder.

1 Nozzle 2 Contact Tip

3 Adapter 4 Head Tube Cut off wire and disconnect gun

from feeder Remove nozzle contact tip and

adapter from head tube. 5 Liner Unscrew and remove liner. Lay gun cable out straight before

installing new liner. Blow out gun casing. Reassemble gun in reverse order

from taking it apart. Be sure liner stickout is approximately 3/4 in. (20 mm).

 Wire size stamped on tip −

check and match wire size.

 Thread wire according to Sec-

tion 5-12.

Tools Needed:

OM-228 042 Page 34

3/8 in

3/4 in

(20 mm)

Ref. 800 797-D

Page 39

8-8. Replacing Switch And/Or Head Tube

 Complete Parts List available at www. MillerWelds.com

Turn off welding power source/wire feeder and disconnect gun.

1 Handle Locking Nut 2 Switch Housing 3 Handle 4 Vise 5 Head Tube 6 Jam Nut Remove handle locking nut. Remove switch housing. Install

new switch and connect leads (polarity is not important). Reassemble in reverse order.

Secure head tube in vise. Loosen jam nut. Remove from vise

and turn head tube out by hand. Hand tighten head tube into cable

connector. Place head tube in vise and tighten until nuts are tight.

Remove from vise. Reposition handle and install switch housing. Secure with handle locking nut.

Tools Needed:

19 mm

Ref. ST-800 795-C

OM-228 042 Page 35

Page 40

8-9. Servicing Air Cleaner

Standard Model Shown

 Complete Parts List available at www. MillerWelds.com

Stop engine.

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

1 Precleaner 2 Paper Element

 Do not wash paper element or

clean with compressed air.

Remove cover. Wash precleaner with soap and wa-

ter solution. Allow precleaner to air dry completely.

Dip precleaner in clean engine oil. Squeeze out excess oil. The engine will smoke if precleaner contains too much oil.

Replace paper element if dirty, oily, or damaged.

OM-228 042 Page 36

oil

aircleaner6 9/00 − 803 404 / 805 055

Page 41

8-10. Adjusting Engine Speed

 Complete Parts List available at www. MillerWelds.com

After tuning engine, check engine speed. See table for proper no load speed. If necessary, adjust speed as follows:

3750 ± 30 rpm (62 Hz)

Start engine and run until warm. 1 Adjustment Screw To increase speed, turn screw in

(clockwise). To decrease speed, turn screw out (counterclockwise).

Stop engine. Close fuel valve.

Tools Needed:

804 971-A

OM-228 042 Page 37

Page 42

 Complete Parts List available at www. MillerWelds.com

SECTION 9 − TROUBLESHOOTING

9-1. Troubleshooting

A. Welding

Trouble Remedy

No weld output or generator power output at ac receptacles.

 AC receptacles provide auxiliary

power only while engine is running.

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

Low weld output. Check Weld Output control setting.

High weld output. Check Wire Speed and Voltage control settings.

Erratic weld output. Check Wire Speed and Voltage control settings. Check wire feed for erratic condition.

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

Place switch in Wall position or start engine and place switch in Generator position.

Over temperature light is flashing. Allow unit to cool with fan running until thermostat TP1 resets and light turns off.

Have Factory Authorized Service Agent check brushes, slip rings, rotor, stator, and integrated rectifier SR2.

Place switch in Generator position to obtain weld output.

Check weld connections. Check Spool Gun/Mig Gun switch position. Have Factory Authorized Service Agent check stator, integrated rectifier SR2, stabilizer Z1, and main

rectifier SR1.

Check engine speed, and adjust if necessary (see Section 8-10). Service engine air cleaner. Check weld cable size and length. Have Factory Authorized Service Agent check stator, integrated rectifier SR2, stabilizer Z1, and main

rectifier SR1.

Check engine speed, and adjust if necessary (see Section 8-10).

Tighten and clean connections to electrode and workpiece. Remove excessive coils from work lead and gun power cable. Clean and tighten connections both inside and outside welding generator. Check engine speed, and adjust if necessary (see Section 8-10). Check throttle/governor linkage for smooth, non-binding operation.

B. Generator Power

Trouble Remedy

No output at generator power ac receptacles; no weld output.

 AC receptacles provide auxiliary

power only while engine is running.

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

High output at generator power ac receptacles.

OM-228 042 Page 38

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

Have Factory Authorized Service Agent check brushes, slip rings, rotor, stator, and integrated rectifier SR2.

Reset and check supplementary protector (see Section 7-1).

Check receptacle wiring and connections. Have Factory Authorized Service Agent check stator windings and connections at terminal block 1T. Check engine speed, and adjust if necessary (see Section 8-10).

Page 43

 Complete Parts List available at www. MillerWelds.com

)

Trouble

Low output at generator power ac receptacles.

Erratic output at generator power ac receptacles.

C. Wire Feeder

Trouble Remedy

No weld output; wire does not feed; fan

oes not run.

No weld output; wire does not feed; fan motor continues to run.

Remedy

Check engine speed, and adjust if necessary (see Section 8-10 ). Open circuit voltage is reduced as engine speed drops.

Check fuel level. Have Factory Authorized Service Agent check connections at terminal block 1T. Check receptacle supplementary protector, wiring, and connections. Check throttle linkage for smooth, non-binding operation. Service air cleaner according to engine manual. Check engine speed, and adjust if necessary (see Section 8-10).

Secure power cord plug in receptacle (see Section 5-9).

Replace building line fuse or reset circuit breaker if open.

Place Wall/Generator switch in Wall position.

Reset welding power source supplementary protector if open.

Thermostat TP1 open (overheating). Allow fan to run with gun trigger switch off; thermostat closes when unit has cooled.

Secure gun trigger leads (see Section 5-5).

Check position of Spool Gun/Mig Gun switch.

No weld output; wire feeds.

Low weld output. Connect unit to proper input voltage or check for low line voltage.

Electrode wire feeding stops during welding.

Connect work clamp to get good metal to metal contact.

Replace contact tip (see Section 8-6).

Check for proper polarity connections (see Section 5-8).

Check thumbscrew securing gun end to feed head adapter and tighten if necessary.

Place voltage control in desired position (see Section 6-3).

Straighten gun cable and/or replace damaged parts. Adjust drive roll pressure (see Section 5-12). Change to proper drive roll groove (see Section 8-5). Readjust hub tension (see Section 5-11). Replace contact tip if blocked (see Section 8-6). Oversized tip may be required for some wires. Clean or replace wire inlet guide or liner if dirty or plugged (see Section 8-5 or Section 8-7). Replace drive roll or pressure bearing if worn or slipping (see Section 8-5). Secure gun trigger leads or repair leads (see Section 5-5). Check and clear any restrictions at drive assembly and liner (see Section 5-12 or Section 8-7). Release gun trigger and allow gun and motor protection circuitry to reset. Have Factory Authorized Service Agent check drive motor.

D. Engine

Trouble Remedy

Engine will not crank (Electric Start Models Only

Check and replace ignition fuse (see engine manual)

Check battery voltage.

Check battery connections and tighten if necessary.

Have Factory Authorized Service Agent check engine ignition system.

OM-228 042 Page 39

Page 44

Trouble Remedy

Engine will not start. Check fuel level (see Section 5-3).

Move choke control to correct position (see Section 6-1).

Open fuel valve (see Section 5-3). Close fuel valve before moving unit or carburetor may flood and make starting difficult.

Be sure engine switch is On.

Check oil level (see Section 5-3). Engine stops if oil level is too low. Refill crankcase with proper viscosity oil for operating temperature.

Have Factory Authorized Service Agent check low oil level shutdown switch.

Check battery voltage (electric start models only).

Check battery connections and tighten if necessary (electric start models only).

 Complete Parts List available at www. MillerWelds.com

Engine stopped during normal operation.

Unstable or sluggish engine speeds. Check engine speed, and adjust if necessary (see Section 8-10).

Battery discharges between uses (Electric Start Models Only).

Check fuel level (see Section 5-3).

Open fuel valve (see Section 5-3). Close fuel valve before moving unit or carburetor may flood and make starting difficult.

Check oil level (see Section 5-3). Engine stops if oil level is too low.

Check throttle/governor linkage for smooth, non-binding operation.

Tune-up engine according to engine manual.

Clean battery terminals and posts with baking soda and water solution; rinse with clear water.

Periodically recharge battery (approximately every 3 months).

Replace battery.

Check engine battery charging circuit and connections according to engine manual.

SECTION 10 − PARTS LIST

 A complete parts list is available at www.MillerWelds.com.

10-1. Recommended Spare Parts

Part

No.

Description

Quantity

221581 Tune−up & Filter Kit, Kohler (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

203960 Spark Plug, Kohler (CS8/10/12) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

221579 Air Filter, Kohler (CS10−recoil) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

221580 Air Filter Pre−cleaner, Kohler (CS10−recoil) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

169715 Nozzle, Slip Type .500 Orf Flush 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

087299 Tip, Contact Scr .023 Wire X 1.125 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

000067 Tip, Contact Scr .030 Wire X 1.125 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

000068 Tip, Contact Scr .035 Wire X 1.125 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

000069 Tip, Contact Scr .045 Wire X 1.125 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

194010 Liner, Monocoil .023/.025 Wire X 15ft (Consisting Of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

194011 Liner, Monocoil .030/.035 Wire X 15ft (Consisting Of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

194012 Liner, Monocoil .035−.045 Wire X 15 ft (Consisting Of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

079975 O-ring, .187 Id X .103cs Rbr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-228 042 Page 40

Recommended Spare Parts

Page 45

SECTION 11 − ELECTRICAL DIAGRAMS

235 289-A

Figure 11-1. Circuit Diagram For Welding Generator

OM-217 454 Page 41

Page 46

SECTION 12 − MIG WELDING (GMAW) GUIDELINES

12-1. Typical MIG Process Connections

Regulator/

Flowmeter

Wire Feeder/

Power Source

Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible.

Shielding Gas

Gas Hose

Gun

Work Clamp

Workpiece

Renegade 2007−04/ Ref. 802 982-A

OM-228 042 Page 42

Page 47

12-2. Typical MIG Process Control Settings

 These settings are guidelines only. Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. Test welds to be sure

they comply to specifications.

1/8 or

.125 in

and wire type, joint design, fitup, position, shielding gas, etc. affect settings. Test welds to be sure they comply to specifications.

1 Convert Material Thickness to

Amperage (A) (.001 in = 1 ampere) .125 = 125 A

 Material thickness determines weld

 These settings are guidelines only. Material

parameters.

2 Select Wire Size

Wire Size

.030 in .035 in .045 in

3 Select Wire Speed (Amperage) 125 A based on 1/8 in (3 mm) material thickness.

(ipm = inch per minute)

Wire Size (Approx.)

.030 in .035 in .045 in

Amperage Range

40 − 145 A 50 − 180 A 75 − 250 A

Suggested

2 in per amp

1.6 in per amp 1 in per amp

Wire Speed

2 x 125 A = 250 ipm

1.6 x 125 A = 200 ipm 1 x 125 A = 125 ipm

 Wire speed (amperage) controls weld pene-

tration (wire speed = burn-off rate).

4 Select Voltage Low Voltage: wire stubs into work

High Voltage: arc is unstable (spatter) Set voltage midway between high/low voltage.

 Voltage controls height and width of weld

bead.

804 476 / 229 573

OM-228 042 Page 43

Page 48

12-3. Holding And Positioning Welding Gun

 Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger, be sure wire is no more than 1/2 in (13 mm)

past end of nozzle, and tip of wire is positioned correctly on seam.

0°-15°

90° 90°

gun trigger is pressed. Before lowering helmet and pressing trigger, be sure wire is no more than 1/2 in (13 mm) past end of nozzle, and tip of wire is positioned correctly on seam.

1 Hold Gun And Control Gun

Trigger 2 Workpiece 3 Work Clamp 4 Electrode Extension (Stickout)

1/4 To 1/2 in (6 To 13 mm) 5 Cradle Gun And Rest Hand On

Workpiece

Groove Welds

6 End View Of Work Angle 7 Side View Of Gun Angle

Fillet Welds

8 End View Of Work Angle 9 Side View Of Gun Angle

 Welding wire is energized when

OM-228 042 Page 44

45°

0°-15°

S-0421-A

Page 49

12-4. Conditions That Affect Weld Bead Shape



Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed (weld current), and voltage.

 Weld bead shape depends on

gun angle, direction of travel,

10°

electrode extension (stickout), travel speed, thickness of base metal, wire feed speed (weld current), and voltage.

Gun Angles And Weld Bead Profiles

1 Push 2 Perpendicular 3 Drag

Electrode Extensions (Stickout)

4 Short 5 Normal 6 Long

Fillet Weld Electrode Extension (Stickout)

7 Short 8 Normal 9 Long

Gun Travel Speed

10 Slow 11 Normal 12 Fast

S-0634-A

OM-228 042 Page 45

Page 50

12-5. Gun Movement During Welding

 Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps,

a weave bead or multiple stringer beads works better.

1 Stringer Bead − Steady

1 2

Movement Along Seam

2 Weave Bead − Side To Side

Movement Along Seam 3 Weave Patterns Use weave patterns to cover a wide

area in one pass of the electrode.

S-0054-A

12-6. Poor Weld Bead Characteristics

1 Large Spatter Deposits

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

12-7. Good Weld Bead Characteristics

1 Fine Spatter 2 Uniform Bead

3 Moderate Crater During

Welding Weld a new bead or layer for each

1/8 in (3.2 mm) thickness in metals being welded.

4 No Overlap 5 Good Penetration into Base

Metal

S-0053-A

S-0052-B

OM-228 042 Page 46

Page 51

12-8. Troubleshooting − Excessive Spatter

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

S-0636

Possible Causes Corrective Actions

Wire feed speed too high. Select lower wire feed speed.

Voltage too high. Select lower voltage range.

Electrode extension (stickout) too long. Use shorter electrode extension (stickout).

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

Insufficient shielding gas at welding arc. Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.

Dirty welding wire. Use clean, dry welding wire.

Eliminate pickup of oil or lubricant on welding wire from feeder or liner.

Wrong polarity. Configure polarity as shown in Section 5-8. Always read and follow wire manufacturer’s

recommended polarity, and see Section 5-7.

12-9. Troubleshooting − Porosity

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

S-0635

Possible Causes Corrective Actions

Insufficient shielding gas at welding arc. Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.

Remove spatter from gun nozzle.

Check gas hoses for leaks.

Place nozzle 1/4 to 1/2 in (6-13 mm) from workpiece.

Hold gun near bead at end of weld until molten metal solidifies.

Wrong gas. Use welding grade shielding gas; change to different gas.

Dirty welding wire. Use clean, dry welding wire.

Eliminate pick up of oil or lubricant on welding wire from feeder or liner.

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

Use a more highly deoxidizing welding wire (contact supplier).

Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.

Wrong polarity. Configure polarity as shown in Section 5-8. Always read and follow wire manufacturer’s

recommended polarity, and see Section 5-7.

OM-228 042 Page 47

Page 52

12-10. Troubleshooting − Excessive Penetration

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

Excessive Penetration

Possible Causes Corrective Actions

Excessive heat input. Select lower voltage range and reduce wire feed speed.

Wrong polarity. Configure polarity as shown in Section 5-8. Always read and follow wire manufacturer’s

Good Penetration

Increase travel speed.

recommended polarity, and see Section 5-7.

S-0639

12-11. Troubleshooting − Lack Of Penetration

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

Lack of Penetration Good Penetration

Possible Causes Corrective Actions

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

maintaining proper welding wire extension and arc characteristics.

Improper weld technique. Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.

Keep arc on leading edge of weld puddle.

Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.

S-0638

Insufficient heat input. Select higher wire feed speed and/or select higher voltage range.

Reduce travel speed.

Wrong polarity. Configure polarity as shown in Section 5-8. Always read and follow wire manufacturer’s

recommended polarity, and see Section 5-7.

12-12. Troubleshooting − Incomplete Fusion

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

S-0637

Possible Causes Corrective Actions

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

Insufficient heat input. Select higher voltage range and/or adjust wire feed speed.

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

welding.

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

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

Keep arc on leading edge of weld puddle.

Use correct gun angle of 0 to 15 degrees.

Wrong polarity. Configure polarity as shown in Section 5-8. Always read and follow wire manufacturer’s

OM-228 042 Page 48

recommended polarity, and see Section 5-7.

Page 53

12-13. Troubleshooting − Burn-Through

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

Possible Causes Corrective Actions

Excessive heat input. Select lower voltage range and reduce wire feed speed.

Increase and/or maintain steady travel speed.

S-0640

Wrong polarity. Configure polarity as shown in Section 5-8. Always read and follow wire manufacturer’s

recommended polarity, and see Section 5-7.

12-14. Troubleshooting − Waviness Of Bead

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

S-0641

Possible Causes Corrective Actions

Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.

Unsteady hand. Support hand on solid surface or use two hands.

12-15. Troubleshooting − Distortion

Distortion − contraction of weld metal during welding that forces base metal to move.

Base metal moves

in the direction of

the weld bead.

S-0642

Possible Causes Corrective Actions

Excessive heat input. Use restraint (clamp) to hold base metal in position.

Make tack welds along joint before starting welding operation.

Select lower voltage range and/or reduce wire feed speed.

Increase travel speed.

Weld in small segments and allow cooling between welds.

OM-228 042 Page 49

Page 54

12-16. Common MIG Shielding Gases

This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed over the years. The most commonly used shielding gases are listed in the following table.

Application

Gas

Argon All Positions

Argon + 25% CO

Tri-Mix

1 Globular Transfer 2 Single Pass Welding Only 3 90% HE + 7-1/2% AR + 2-1/2% CO

Spray Arc Steel Short Circuiting Steel

Flat & Horizontal1 Fillet All Positions All Positions

Flat & Horizontal1 Fillet All Positions

Short Circuiting

Stainless Steel

All Positions

Short Circuiting

Aluminum

OM-228 042 Page 50

Page 55

SECTION 13 − GENERATOR POWER GUIDELINES

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

13-1. Selecting Equipment

1 Generator Power Receptacles

− Neutral Bonded To Frame

2 3-Prong Plug From Case

Grounded Equipment

3 2-Prong Plug From Double

Insulated Equipment

 Be sure equipment has double

insulated symbol and/or wording on it.

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

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

13-2. Grounding Generator To Truck Or Trailer Frame

GND/PE

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

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

1 Equipment Grounding

Terminal (On Front Panel)

2 Grounding Cable (Not

Supplied) 3 Metal Vehicle Frame Connect cable from equipment

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

 Electrically bond generator

frame to vehicle frame by met-

al-to-metal contact.

Bed liners, shipping skids,

and some running gear insu-

late the welding generator

from the vehicle frame. Al-

ways connect a ground wire

from the generator equip-

ment grounding terminal to

bare metal on the vehicle

frame as shown.

If unit does not have GFCI re-

ceptacles, use GFCI-pro-

tected extension cord.

S-0854

OM-228 042 Page 51

Page 56

13-3. Grounding When Supplying Building Systems

1 2

GND/PE

1 Equipment Grounding

Terminal 2 Grounding Cable Use #10 AWG or larger insulated

copper wire. 3 Ground Device

 Use ground device as stated in

electrical codes.

Ground generator to system

earth ground if supplying

power to a premises (home,

shop, farm) wiring system.

Also see AWS Safety &

Health Fact Sheet No. 29,

Grounding of Portable And

Vehicle Mounted Welding

Generators.

13-4. How Much Power Does Equipment Require?

VOLTS 115 AMPS Hz

4.5 60

ST-800 576-B

1 Resistive Load A light bulb is a resistive load and

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

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

3 Rating Data Rating shows volts and amperes, or

watts required to run equipment.

Amperes x Volts = Watts

Example 1: If a drill uses 4.5 am-

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

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

watts. Example 2: If three 200 watt flood

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

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

flood lamps and drill is 1120 watts.

OM-228 042 Page 52

S-0623

Page 57

13-5. Approximate Power Requirements For Industrial Motors

Industrial Motors Rating Starting Watts Running Watts

Split Phase 1/8 HP 800 300

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

Capacitor Start-Induction Run 1/3 HP 2020 720

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

1 HP 6100 1600

1-1/2 HP 8200 2200

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

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

5 HP 23300 6000

7-1/2 HP 35000 8000

10 HP 46700 10700

Fan Duty 1/8 HP 1000 400

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

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

Farm/Home Equipment Rating Starting Watts Running Watts

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

1-1/2 HP 8200 2200

2 HP 10550 2850 3 HP 15900 3900

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

10 HP 46700 10700 3-1/2 cu. ft. Mixer 1/2 HP 3300 1000 High Pressure 1.8 Gal/Min 500 PSI 3150 950 Washer 2 gal/min 550 PSI 4500 1400 2 gal/min 700 PSI 6100 1600 Refrigerator or Freezer 3100 800 Shallow Well Pump 1/3 HP 2150 750

1/2 HP 3100 1000

Sump Pump 1/3 HP 2100 800

1/2 HP 3200 1050

OM-228 042 Page 53

Page 58

13-7. Approximate Power Requirements For Contractor Equipment

Contractor Rating Starting Watts Running Watts

Hand Drill 1/4 in 350 350

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

Circular Saw 6-1/2 in 500 500

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

Table Saw 9 in 4500 1500

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

8 in 3900 1400

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

1 HP 6000 1500

1-1/2 HP 8200 2200

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

2 HP, 14 in 1100 1100

Electric Trimmer Standard 9 in 350 350

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

Metal Halide 313 250

Mercury 1000

Sodium 1400

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

1 HP, 20 in 6100 1600

High Pressure Washer 1/2 HP 3150 950

3/4 HP 4500 1400

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

2-1/2 HP 1300 1300

OM-228 042 Page 54

Page 59

13-8. Power Required To Start Motor

Single-Phase Induction Motor Starting Requirements

Motor Start

Code

KVA/HP 6.3 7.1 8.0 9.0 10.0 11.2 12.5 14.0

G H J K L M N P

1 Motor Start Code 2 Running Amperage

4 1

VOLTS AMPS

CODE 60

AC MOTOR 230 2.5 M 1/4

Hz PHASE

3 Motor HP 4 Motor Voltage To find starting amperage:

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

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

age (see example). Welding generator amperage out-

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

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

Starting Amperage

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

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

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

amperes.

S-0624

13-9. How Much Power Can Generator Supply?

1 Limit Load To 90% Of

Generator Output

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

2 5 Second Rule If motor does not start within 5

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

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

OM-228 042 Page 55

Page 60

13-10. Typical Connections To Supply Standby Power

123

Utility

Electrical

Service

Transfer Switch

Essential

Loads

Fused

Disconnect

Switch

(If Required)

Welding

Generator

Output

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

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

 Customer-supplied equipment

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

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

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

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

3 Fused Disconnect Switch Install correct switch (customer-

supplied) if required by electrical code.

4 Welding Generator Output Generator output voltage and wir-

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

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

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

5 Essential Loads Generator output may not meet the

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

OM-228 042 Page 56

Page 61

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

Cord Lengths for 120 Volt Loads

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

Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*

Current

(Amperes)

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

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

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

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

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

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

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

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

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

45 5400 100 (30) 62 (19)

50 6000 87 (26) 50 (15)

*Conductor size is based on maximum 2% voltage drop

Cord Lengths for 240 Volt Loads

Load (Watts) 4 6 8 10 12 14

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

Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*

Current

(Amperes)

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

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

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

15 3600 600 (183) 350 (107) 225 (69) 150 (46) 75 (23) 60 (18)

20 4800 450 (137) 275 (84) 175 (53) 100 (31) 60 (18)

25 6000 350 (107) 225 (69) 125 (38) 75 (23)

30 7000 300 (91) 175 (53) 100 (31) 75 (23)

35 8400 250 (76) 150 (46) 100 (31)

40 9600 225 (69) 125 (38) 75 (23)

45 10,800 200 (61) 125 (38)

50 12,000 175 (53) 100 (31)

*Conductor size is based on maximum 2% voltage drop

Load (Watts) 4 6 8 10 12 14

OM-228 042 Page 57

Page 62

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

OM-228 042 Page 58

Decimal

Equivalent

Bolt Nut

SOCKET/WRENCH SELECTION TABLE

(METRIC)

Bolt

Diameter

U.S.

Decimal

Equivalent

Bolt Nut

Page 63

Warranty Questions?

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

Your distributor also gives you ...

Service

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

Support

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

Effective January 1, 2007

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

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

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

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

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

1. 5 Years Parts — 3 Years Labor

* Original main power rectifiers

2. 3 Years — Parts and Labor

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

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

3. 1 Year — Parts and Labor Unless Specified

* Motor Driven Guns (w/exception of Spoolmate

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

Electronic

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

Models) * Field Options

(NOTE: Field options are covered under True Blue®

for the remaining warranty period of the product they

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

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

4. 6 Months — Batteries

5. 90 Days — Parts

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

guarantees or warranties expressed or implied.

* Induction Heating Coils and Blankets, Cables, and

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

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

1. Consumable components; such as contact tips,

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

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

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

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

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

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

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

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

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

miller_warr 2007−01

Page 64

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

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

Distributor

Address

City

State Zip

For Service

Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

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

and Parts) Circuit Diagrams Welding Process Handbooks

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

Miller Electric Mfg. Co.

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

International Headquarters−USA

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

European Headquarters − United Kingdom

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

www.MillerWelds.com

Contact the Delivering Carrier to:

File a claim for loss or damage during shipment.

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

Miller Electric Renegade 180 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual