Miller Electric 280 Nt Users Manual O4430r(ECO806)

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OM-4430

217 243R

2007−04

Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
MIG (GMAW) Welding &
Flux Cored (FCAW) Welding
With Voltage Sensing Feeder

Description

Engine Driven Welding Generator

Miller Legend 302


File: Engine Drive
Visit our website at

www.MillerWelds.com

From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
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 parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard.
particular model are also provided.

Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.

Mil_Thank 4/05

Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.

TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-7. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-8. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . .
2-6. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-8. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Dimensions, Weights, and Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Dimensions For Units With Optional Running Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Fuel Consumption While Welding And Using Generator Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. TIG Mode Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Stick And MIG Mode Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Connecting Or Replacing The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Remote Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − OPERATING WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Description Of Engine Controls (See Section 6-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Cold Weather Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Controlling Engine Speed And Weld/Generator Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Process Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Stick Start Procedure − Scratch Start Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. TIG Lift-Arc Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-8. Remote Voltage/Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. 60 Hz Generator Power Receptacles And Supplementary Protectors . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Variable Frequency (Hz) Generator Power Receptacle RC3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P) . . . . . . . . . . . . . . . . . .

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TABLE OF CONTENTS
SECTION 8 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Servicing Optional Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5. Changing Engine Oil, Oil Filter, And Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-7. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.

 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.

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 following 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.

 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 conductor 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 machines 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 equipment.
 To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.

FLYING METAL or DIRT can injure eyes.
 Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
 Wear approved safety glasses with side shields even under your
welding helmet.
OM-4430 Page 1

FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health.
 Keep your head out of the fumes. Do not breathe the fumes.
 If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
 If ventilation is poor, wear an approved air-supplied respirator.
 Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.
 Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
 Do not weld in locations near degreasing, cleaning, or spraying operations. 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 bypass 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.

Noise from some processes or equipment can damage hearing.

 Shut off shielding gas supply when not in use.
 Always ventilate confined spaces or use approved air-supplied respirator.

 Wear approved ear protection if noise level is
high.

MAGNETIC FIELDS can affect Implanted
Medical Devices.

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 material (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.

OM-4430 Page 2

 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, mechanical 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 fittings 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 number 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.

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 connecting 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 overflow 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 equipment.
 To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.

EXHAUST SPARKS can cause fire.
 Do not let engine exhaust sparks cause fire.
 Use approved engine exhaust spark arrestor in
required areas — see applicable codes.

1-4. 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.

TRAPPED AIR PRESSURE AND WHIPPING
HOSES can cause injury.
 Release air pressure from tools and system before servicing, adding or changing attachments, or opening compressor oil drain or oil fill
cap.

COMPRESSED AIR can cause injury.
 Wear approved safety goggles.
 Do not direct air stream toward self or others.
OM-4430 Page 3

HOT METAL from air arc cutting and
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.

READ INSTRUCTIONS.
 Read Owner’s Manual before using or servicing unit.
 Stop engine and release air pressure before
servicing.
 Use only genuine replacement parts from the
manufacturer.

 Do not touch hot compressor or air system
parts.
 Let system cool down before touching or servicing.

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.
 Wear a face shield to protect eyes and face.
 Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
 Sparks can cause fires — keep flammables away.

MOVING PARTS can cause injury.
 Keep away from moving parts.
 Keep away from pinch points such as drive
rolls.

OM-4430 Page 4

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.

READ INSTRUCTIONS.
 Read Owner’s Manual before using or servicing unit.
 Use only genuine replacement parts from the
manufacturer.
 Perform engine and air compressor maintenance and service according to this manual
and the engine/air compressor (if applicable)
manuals.

H.F. RADIATION 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.

ARC WELDING can cause interference.






 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 electronic 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.

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.

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,

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).

1-8. 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:

1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from
operator as practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.

OM-4430 Page 5

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
rom_2007−04fre

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

2-1. Signification des symboles
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
NOTE − Indique des déclarations pas en relation avec des blessures
personnelles.

 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.

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.

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).

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

 Installer et mettre à la terre correctement cet appareil conformément à son manuel d’utilisation et aux codes nationaux,
provinciaux et municipaux.

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

 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.

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 comportant 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 UNIQUEMENT si le procédé de soudage le demande.
 Si l’utilisation d’une source électrique à courant électrique s’avère
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.
 Des précautions de sécurité supplémentaires sont requises dans
des environnements à risque comme: les endroits humides ou
lorsque l’on porte des vêtements mouillés; sur des structures métalliques au sol, grillages et échafaudages; dans des positions
assises, à genoux et allongées; ou quand il y a un risque important
de contact accidentel avec la pièce ou le sol. Dans ces cas utiliser
les appareils suivants dans l’ordre de préférence: 1) un poste à
OM-4430 Page 6

 En effectuant les raccordements d’entrée fixer d’abord le conducteur 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 insuffisante 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 métalmétal avec la pièce à souder ou la table de travail, le plus près
possible de la soudure.
 Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.

Une tension DC importante subsiste à l’intérieur
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 chaudes.
 Prévoir une période de refroidissement avant de
travailler à l’équipement.
 Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.

DES PIECES DE METAL ou DES SALETES peuvent provoquer des blessures dans les yeux.
 Le soudage, l’écaillement, le passage de la pièce à la brosse en
fil de fer, et le meulage génèrent des étincelles et des particules
métalliques volantes. Pendant la période de refroidissement des
soudures, elles risquent de projeter du laitier.
 Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.

LES FUMÉES ET LES GAZ peuvent être
dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.

LES RAYONS DE L’ARC peuvent pro
voquer des brûlures dans les yeux e
sur la peau.
Le rayonnement de l’arc du procédé de soudage
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 le
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 résistantes 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 peu
provoquer leur éclatement. Des étincelles peuven
être projetées de l’arc de soudure. La projection d’étincelles, des pièce
chaudes et des équipements chauds peut provoquer des incendies e
des brûlures. Le contact accidentel de l’électrode avec des objet
métalliques peut provoquer des étincelles, une explosion, un surchauf
fement ou un incendie. Avant de commencer le soudage, vérifier e
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.

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

 Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.

 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.

 Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.

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

 Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.

 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 ris
quent de provoquer des blessures ou
même la mort.
 Fermer l’alimentation du gaz protecteur en cas de
non utilisation.
 Veiller toujours à bien aérer les espaces confinés ou se servir d’un
respirateur d’adduction d’air homologué.

 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 vapeurs 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 gelées.
 En cas de non utilisation, enlever la baguette d’électrode du porteélectrode 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 poches telles qu’un allumeur au butane ou des allumettes.
 Une fois le travail achevé, assurez−vous qu’il ne reste aucune trace d’étincelles incandescentes ni de flammes.
 Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
OM-4430 Page 7

 Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
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 affec
l’ouïe.
 Porter des protections approuvés pour les ore
les si le niveau sonore est trop élevé.

LES CHAMPS MAGNETIQUES peuvent affecter des implants médicaux.
 Porteur de simulateur cardiaque ou autre implants 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.

 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 stationnaire 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.

Si des BOUTEILLES sont endomma
gées, elles pourront exploser.

 Maintenir le chapeau de protection sur la soupape, sauf en cas
d’utilisation ou de branchement de la bouteille.

Des bouteilles de gaz protecteur contiennent du ga
sous haute pression. Si une bouteille est endomma
gée, elle peut exploser. Du fait que les bouteilles de gaz fon
normalement partie du procédé de soudage, les manipuler ave
précaution.

 Utiliser les équipements corrects, les bonnes procédures et suffisamment 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.

 Seules des personnes qualifiées sont autorisées à enlever les portes, panneaux, recouvrements ou dispositifs de protection pour
effectuer, s’il y a lieu, des travaux d’entretien et de dépannage.

 Toujours porter une protection faciale, des gants
en caoutchouc et vêtements de protection lors
d’une intervention sur la batterie.

 Pour empêcher tout démarrage accidentel pendant les travaux
d’entretien, débrancher le câble négatif (−) de batterie de la borne.

 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 provo
quer un incendie ou une explosion.
 Arrêter le moteur avant de vérifier le niveau de
carburant ou de faire le plein.
 Ne pas faire le plein en fumant ou proche d’une source d’étincelles
ou d’une flamme nue.
 Ne pas faire le plein de carburant à ras bord; prévoir de l’espace
pour son expansion.
 Faire attention de ne pas renverser de carburant. Nettoyer tout
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 pro
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, recouvrements et dispositifs de protection.
 Arrêter le moteur avant d’installer ou brancher l’appareil.
OM-4430 Page 8

 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 intervention sur le générateur.

DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
 Ne pas toucher à mains nues les parties chaudes.
 Prévoir une période de refroidissement avant de
travailler à l’équipement.
 Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.

LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT CHAUD peuvent
provoquer des brûlures.
 Il est préférable de vérifier le liquide de refroidissement 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 comme suivant.
 Mettre des lunettes de sécurité et des gants, placer un torchon sur
le bouchon du radiateur.

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

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.

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

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

 Ne pas utiliser l’air comprimé pour respirer.
 Utiliser l’air comprimé seulement pour le coupage, gougeage et les outils pneumatiques.

 Ne pas couper ou gouger à proximité de produits inflammables.
 Surveillez et garder un extincteur à proximité.

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.

DES PIECES CHAUDES peuvent provoquer des brûlures et blessures.
 Ne pas toucher le compresseur ou d’autres
éléments du circuit air comprimé chauds.
 Laisser l’ensemble se refroidir avant de toucher ou d’effectuer la
maintenance.

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.
 N’utiliser que les pièces de rechange recommandées par le
constructeur.

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 produits inflammables.
 Ne pas surcharger l’installation électrique − s’assurer que l’alimentation est correctement dimensionnée et protégée avant de
mettre l’appareil en service.

LA CHUTE DE L’APPAREIL peut blesser.
 Utiliser l’anneau de levage pour lever l’appareil et
les accessoires correctement installées seuls,
PAS les bouteilles de gaz. Ne pas dépasser le
poids nominal maximal de l’œilleton (voir les spécifications).
 Ne lever et ne soutenir l’appareil qu’avec de
l’équipement approprié et en suivant les
procédures adéquates.
 En utilisant des fourches de levage pour déplacer l’unité, s’assurer
que les fourches sont suffisamment longues pour dépasser du
côté opposé de l’appareil.

OM-4430 Page 9

UNE REMORQUE QUI BASCULE peut
entraîner des blessures.

LE SURCHAUFFEMENT peut endommager le moteur électrique.

 Utiliser les supports de la remorque ou des
blocs pour soutenir le poids.
 Installer convenablement le poste sur la remorque comme indiqué dans le manuel s’y rapportant.

 Arrêter ou déconnecter l’équipement avant de
démarrer ou d’arrêter le moteur.
 Ne pas laisser tourner le moteur trop lentement sous risque d’endommager le moteur électrique à cause d’une tension et d’une fréquence 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 et
les yeux.
 Affûter l’électrode au tungstène uniquement à la
meuleuse dotée de protecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l’on
porte l’équipement homologué de protection du
visage, des mains et du corps.
 Les étincelles risquent de causer un incendie − éloigner toute substance inflammable.

LIRE LES INSTRUCTIONS.
 Lisez le manuel d’instructions avant l’utilisation
ou la maintenance de l’appareil.
 N’utiliser que les pièces de rechange recommandées par le constructeur.
 Effectuer la maintenance et le service du moteur et du compresseur 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.

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

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

L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
 Laisser l’équipement refroidir ; respecter le facteur 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.

OM-4430 Page 10

 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 électricien qualifié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement l’appareil.
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.







 L’énergie électromagnétique risque de provoquer 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 équipement 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 précédentes, 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.

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.

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.

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

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 téléphone de la région 5, Chicago, est 312-353-2220, site Internet :
www.osha.gov).

2-8. Information EMF
Considérations sur le soudage et les effets de basse fréquence et des
champs magnétiques et électriques.
Le courant de soudage, pendant son passage dans les câbles de soudage, causera des champs électromagnétiques. Il y a eu et il y a encore
un certain souci à propos de tels champs. Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de
recherche de 17 ans, un comité spécial ruban bleu du National
Research Council a conclu : « L’accumulation de preuves, suivant le
jugement du comité, n’a pas démontré que l’exposition aux champs
magnétiques et champs électriques à haute fréquence représente un
risque à la santé humaine ». Toutefois, des études sont toujours en
cours et les preuves continuent à être examinées. En attendant que les
conclusions finales de la recherche soient établies, il vous serait
souhaitable de réduire votre exposition aux champs électromagnétiques pendant le soudage ou le coupage.
Pour réduire les champs magnétiques sur le poste de travail, appliquer
les procédures suivantes :

1. Garder les câbles ensemble, les torsader, les scotcher, ou les
recouvrir d’une housse.
2. Disposer les câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber pas et ne pas entourer pas les câbles autour de
votre corps.
4. Garder le poste de soudage et les câbles le plus loin possible de
vous.
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.

OM-4430 Page 11

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

SECTION 3 − DEFINITIONS
3-1. Symbol Definitions
Stop Engine

Fast
(Run, Weld/Power)

Fast/Slow
(Run/Idle)

Slow (Idle)

Start Engine

Panel/Local

Temperature

Fuel

Engine Oil

Engine Choke

Check Valve
Clearance

Battery (Engine)

Engine

Read Operator’s
Manual

MIG (GMAW),
Wire

Stick (SMAW)

TIG (GTAW)

Circuit Protector

Positive

Negative

Alternating Current
(AC)

Output

Seconds

Protective Earth
(Ground)

Time

h

Hours

A

s

V

Amperes

Volts

Do not switch while
welding

Remote
Receptacle

Work Connection

CC

Constant
Current

Wire Feed

Electrode
Positive

Electrode Negative

CV

Constant
Voltage

Notes

Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

OM-4430 Page 12

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

SECTION 4 − SPECIFICATIONS
4-1. Description
This multiprocess engine-driven welder and AC generator provides low speed generator AC power and DC weld output for quiet, fuel-efficient operation. At 1800 rpm, this unit produces 5 kW/kVA 60 Hz 120/240 Volt AC generator
power. Achieve high quality Stick and TIG welding results at either 3000 or 3600 rpm. A special variable frequency
(60-120 Hz) receptacle provides 2.4 kW/kVA 120 Volt AC generator power continuously.

4-2. Weld, Power, And Engine Specifications
Welding
Mode

CC/DC

Rated
Welding
Output

Maximum
Open-Circuit
Voltage

280 A, 25 V, 100%
Duty Cycle

Amperage
Range In
CC Mode

50

Voltage
Range In
CV Mode

20 − 300 A

13 − 35 V

CV/DC

300 A, 25 V, 100%
Duty Cycle

35

Generator
Power Rating
5.5 kVA/kW (Peak)
5 kVA/kW (Continuous)
42/21 A,
120/240 V AC,
60 Hz,
Single-Phase at
1800 rpm
And
2.4 kVA/kW, 20 A,
120 V AC,
60-120 Hz,
Single-Phase
At All Speeds

−−

Fuel
Capacity

Engine

12 gal
(45 L)
Tank

Kohler CH-23
Air-Cooled,
Two-Cylinder,
Four-Cycle,
Four Cycle,
23 HP Gasoline or
25 HP LP Engine
w/Electronic
Governor

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

34 in (864 mm)

Width

20−1/2 in (521 mm)

Depth

45-1/2 in (1156 mm)

A

20 in (508 mm)

B

16-1/2 in (419 mm)

C

1−3/4 in (44 mm)

A
B
C

D

D

5 in (127 mm)

E

32-3/4 in (832 mm)

F

44-1/4 in (1124 mm)

G

13/32 in (10 mm) Dia.

G
4 Holes

F

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

!

Do not move or operate unit where it could
p
tip.

E

2 °
25
25°

25°

25°

Weight
590 lb (267 kg)

!

Engine End

Lifting Eye Weight Rating
800 426

1280 lb (580 kg)

803 983

OM-4430 Page 13

 A complete Parts List is available at www.MillerWelds.com
4-4. Dimensions For Units With Optional Running Gear
Dimensions

Height

All Running Gear Options:
42-1/2 in (1079 mm)
(To Top Of Handle
Assembly)

C
A

Protective Cage Width:
26 in (660 mm)

B

Running Gear Width:
32 in (813 mm)

C

Protective Cage Length:
48 in (1219 mm)

D

A
B

Running Gear Length:
45−1/2 in (1156 mm)

D

B

LITERS/HR.

U.S. GAL./HR.

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

7.57

2.00

6.62

1.75

5.67

1.50

4.73

1.25

3.78

1.00

2.84

0.75

1.98

0.50

0.95

0.25

0.00

0.00

On a typical job using 1/8 in 7018
electrodes (125 amps, 20% duty
cycle), expect over 20 hours of operation.
Welding at 150 amps at 40% duty
cycle uses approximately 3/4 gallon per hour, or about 16 hours of
operation.
A 2kW generator load at 50% duty
cycle uses less than 1/2 gallon per
hour providing over 24 hours of operation.

3600 RPM Weld
3000 RPM Weld
Idle (At
1800 RPM)
Generator
at 1 kW

0

100

Generator
at 2 kW

150

Generator
at 3 kW

200

Generator
at 4 kW

250

Generator
at 5 kW

300

DC WELD AMPERES AT 100% DUTY CYCLE
207 967

OM-4430 Page 14

 A complete Parts List is available at www.MillerWelds.com
4-6. Generator Power Curve
The ac generator power curve
shows the generator power available in amperes at the receptacles.

300

AC VOLTS

250
200
150
100
50
0

0

5

10

15
AC AMPERES

20

25

30

222 553

Notes

WELD POSITION: FLAT
WELD JOINT
TYPES

HORIZONTAL

BUTT
1G

VERTICAL

BUTT
2G

FILLET
Ref. AWS/ANSI D1.1

T−JOINT
1F

BUTT
4G

BUTT
3G
T−JOINT
2F

GROOVE

OVERHEAD

T−JOINT
4F
T−JOINT
3F

Ref. 804 248-A

OM-4430 Page 15

 A complete Parts List is available at www.MillerWelds.com
4-7. Duty Cycle
100% Duty Cycle at 280 Amperes DC/CC

Duty cycle is the percentage of 10
minutes that unit can weld at rated
load without overheating.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.

Continuous Welding

325
MIG/FCAW

300
275

STICK

WELD AMPERES

250
225
200
175
150
0

10

20

30

40

50

70

60

80

90

% DUTY CYCLE

100
Ref. 207 925

4-8. TIG Mode Volt-Ampere Curves
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of
other settings fall between the
curves shown.

50
45
40

3600RPM Max

DC VOLTS

35

3000RPM Max

30
25
20

Min

15
10
5
0

0

100

200

300

400

DC AMPERES
222 558

OM-4430 Page 16

 A complete Parts List is available at www.MillerWelds.com
4-9. Stick And MIG Mode Volt-Ampere Curves
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of
other settings fall between the
curves shown.

A. CC/DC Stick Mode
100

DC VOLTS

80

60

3600RPM Max
3000RPM Max

40
Min
20
0

0

200

DC AMPERES

400

600

400

600

B. CV/DC MIG Mode

40
3600RPM Max

35

DC VOLTS

30

3000RPM Max

25
20V Preset

20
15

Min

10
5
0

0

200

DC AMPERES

222 555 / 222 556 / 222 557

OM-4430 Page 17

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

SECTION 5 − INSTALLATION
5-1. Installing Welding Generator

Movement

!

Do not lift unit from end.

!

Do not weld on base. Welding
on base can cause fuel tank fire
or explosion. Bolt unit down
using holes provided in base.

!

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

!

Do not mount unit by supporting the base only at the four
mounting holes. Use crosssupports to adequately support unit and prevent damage
to base.

!

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

!

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

OR

Location / Airflow Clearance

OR

18 in
(460 mm)

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

18 in
(460 mm)

18 in
(460 mm)

Mounting:
1

Cross-Supports

Mount unit on flat surface or use
cross-supports to support base.
Grounding:
2

18 in
(460 mm)

18 in
(460 mm)

3
4

Mounting

Equipment Grounding Terminal
(On Front Panel)
Grounding Cable (Not Supplied)
Metal Vehicle Frame

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

OR
Inadequate support.

!
Grounding

Do not use flexible mounts.

2
3

GND/PE

!

1

Bed liners, shipping skids, and some running
gears insulate the welding generator from the
vehicle frame. Always connect a ground wire
from the generator equipment grounding terminal to bare metal on the vehicle frame as shown.

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

4

OM-4430 Page 18

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

 A complete Parts List is available at www.MillerWelds.com
5-2. Engine Prestart Checks
Check all fluids daily. Engine must be
cold and on a level surface. Unit is
shipped with 10W30 engine oil.

 Follow run-in procedure in engine
manual.

 This unit has a low oil pressure

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

Full

Fuel

Empty

Add fresh fuel before starting engine
the first time (see maintenance label for
specifications). Always leave filler
neck empty to allow room for expansion. Check fuel level on a cold engine
before use each day.
To check fuel level, turn Engine Control
switch to either Run/Idle position.
LED’s indicate fuel level in tank.
Oil

 Do not

exceed the ”Full” mark on
the oil level dipstick. The fuel
pump may operate erratically if
crankcase is overfilled.
Check oil with unit on level surface. If
oil is not up to full mark on dipstick, add
oil (see maintenance label).
Full

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

 To improve cold weather starting:
Keep battery in good condition.
Store battery in warm area.
Full

Use correct grade oil for cold
weather.

Gasoline

803 983−A / Ref 216 172-D

OM-4430 Page 19

 A complete Parts List is available at www.MillerWelds.com
5-3. Connecting Or Replacing The Battery

!

Connect negative (−)
cable last.

−

+

Replacing The Battery

 Remove end panel to replace battery.

!

Connect negative (−)
cable last.

−

+
+

−

Tools Needed:
3/8, 1/2 in
803 847 / 803 849 / Ref. S-0756-D Ref 216 172-D / Ref 803 983−A

OM-4430 Page 20

 A complete Parts List is available at www.MillerWelds.com
5-4. Installing Exhaust Pipe
!

Stop engine and let cool.

!

Engine backfire can cause severe burns or other injuries.
Do not point exhaust pipe toward control panel. Keep away
from exhaust outlet.

!

Point exhaust pipe in desired
direction but always away
from front panel and direction
of travel.

Tools Needed:
1/2 in

Ref 216 172-D / 803 891

Notes

Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

OM-4430 Page 21

 A complete Parts List is available at www.MillerWelds.com
5-5. Connecting To Weld Output Terminals
!

Stop engine.

!

Do not connect to CC and CV
terminals at the same time.

1

Negative (−) Weld Output
Terminal
Stick/TIG (CC) Weld Output
Terminal
Wire /CV Weld Output Terminal

2
3

For MIG welding, connect work cable
to Negative (−) terminal and wire
feeder cable to Wire (CV) terminal.
For Stick welding, connect work
cable to Negative (−) terminal and
electrode holder cable to Stick/TIG
(CC) terminal.
1

2

3

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

!

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

4
5

Weld Output Terminal
Supplied Weld Output Terminal
Nut
Weld Cable Terminal
Copper Bar

6
7

Remove supplied nut from weld output terminal. Slide weld cable terminal onto weld output terminal and secure with nut so that weld cable terminal is tight against copper bar. Do not
place anything between weld
cable terminal and copper bar.
Make sure that the surfaces of the
weld cable terminal and copper
bar are clean.

4

7

Do not place
anything between
weld cable terminal
and copper bar.
5
6

Correct Installation

Incorrect Installation

Tools Needed:
3/4 in

OM-4430 Page 22

216 172-D / 803 984−A / 803 778-A

 A complete Parts List is available at www.MillerWelds.com
5-6. Selecting Weld Cable Sizes*

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***

Weld Output
Terminals

!

Stop engine before
connecting to weld
output terminals.

!

Do not use worn,
damaged,
undersized,
or
poorly
spliced cables.

* This

100 ft (30 m) or Less

150 ft
(45 m)

200 ft
(60 m)

250 ft
(70 m)

300 ft
(90 m)

350 ft
400 ft
(105 m) (120 m)

Welding
Amperes

10 − 60%
Duty
Cycle

60 − 100%
Duty
Cycle

100

4 (20)

4 (20)

4 (20)

3 (30)

2 (35)

1 (50)

1/0 (60)

1/0 (60)

150

3 (30)

3 (30)

2 (35)

1 (50)

1/0 (60)

2/0 (70)

3/0 (95)

3/0 (95)

200

3 (30)

2 (35)

1 (50)

1/0 (60)

2/0 (70)

3/0 (95)

4/0 (120)

4/0 (120)

250

2 (35)

1 (50)

1/0 (60)

2/0 (70)

3/0 (95)

4/0 (120)

2 ea. 2/0
(2x70)

2 ea. 2/0
(2x70)

300

1 (50)

1/0 (60)

2/0 (70)

3/0 (95)

4/0 (120)

2 ea. 2/0
(2x70)

2 ea. 3/0
(2x95)

2 ea. 3/0
(2x95)

350

1/0 (60)

2/0 (70)

3/0 (95)

4/0 (120)

2 ea. 2/0
(2x70)

2 ea. 3/0
(2x95)

2 ea. 3/0
(2x95)

2 ea. 4/0
(2x120)

400

1/0 (60)

2/0 (70)

3/0 (95)

4/0 (120)

2 ea. 2/0
(2x70)

2 ea. 3/0
(2x95)

2 ea. 4/0
(2x120)

2 ea. 4/0
(2x120)

10 − 100% Duty Cycle

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

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

S-0007-F

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

5-7. Remote Receptacle Information
 Engine runs at weld speed (3000 or 3600 rpm) whenever a device connected to the remote
A
B

K

J

I

H
C L N
D M
G
E F

24 VOLTS AC

115 VOLTS AC

A/V
AMPERAGE
VOLTAGE

GND

receptacle is running.

Socket*

Socket Information

A

24 volts ac. Protected by supplementary protector
CB4.

B

Not used.

I

115 volts ac. Protected by supplementary protector CB3.

J

Not used.

C

+10 volts dc output to remote control.

D

Remote control circuit common.

E

0 to +10 volts dc input command signal from
remote control.

G

Circuit common for 24 and 115 volts ac circuits.

K

Chassis common.

*The remaining sockets are not used.

OM-4430 Page 23

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

SECTION 6 − OPERATING WELDING GENERATOR
6-1. Front Panel Controls

2
1

3

4

5

6

9

8

7
Ref 216 172-D

1

Process Switch

See Section 6-5 for Process switch information.
2

Remote Receptacle

Use receptacle to connect remote control.
When a remote voltage/amperage control is
connected to the Remote receptacle, the
Auto Sense Remote feature automatically
switches voltage/amperage control to the remote control (see Sections 5-7 and 6-8).
With remote voltage/amperage control connected, weld output in CC mode is determined by a combination of front panel and remote control voltage/amperage settings.
If no remote voltage/amperage control is
connected to the Remote receptacle, the
front panel Voltage/Amperage control adjusts voltage and amperage.
3 And 4

Displays

Displays can show weld process information
(voltage and amperage) or maintenance information (hourmeter or oil change countdown).

OM-4430 Page 24

Meter Weld Functions: In Wire mode, Voltmeter displays preset weld voltage when not
welding. Meters display actual voltage and
amperage when welding and for five seconds after welding has stopped.
In Stick and TIG modes, Voltmeter reads ON
and Ammeter displays preset amperage
when not welding. Meters display actual voltage and amperage when welding and for five
seconds after welding has stopped.
Meter Engine Maintenance Functions:
Meters display engine hours when Engine
Control switch is in the Run/Idle 3600/2400
position but engine is not running.
Meter Oil Change Countdown: With engine off, place Engine Control switch in Run/
Idle 3000/1800 position to see hours before
next recommended oil change. Oil change
hours start at 100 (fresh oil) and count down
to 0 (oil change due). The meters display
negative (−) hours if 100 hours is exceeded.
After changing oil, reset counter by cycling
Engine Control switch between Run/Idle
positions three times.
Place Engine Control switch in Off position
after reading meters.

5 Fuel Level Indicator
With Engine running or Engine Control
switch in either Run/Idle position, LED’s indicate fuel left in tank.
6 Voltage/Amperage Control
Use control to select weld voltage or
amperage. Control may be adjusted while
welding.

 For maximum weld output (above 220

Amps), run unit at 3600 rpm. For weld
output below 220 Amps, operate unit at
3000 or 3600 rpm.
With Process switch in any Stick or TIG setting, use control to adjust amperage. With
Process switch in Wire position, use control
to adjust voltage. When a remote voltage/
amperage control is connected to Remote
receptacle RC4, control sets the maximum
amperage in Stick and TIG modes, but has
no effect in MIG mode.
7 Engine Control Switch (see Section 6-2)
8 Engine Choke Control (see Section 6-2)
9 Engine Speed Control Switch (see Section 6-2)

 A complete Parts List is available at www.MillerWelds.com
6-2. Description Of Engine Controls (See Section 6-1)

 If

Engine Control Switch
Use switch to start engine, select speed, and
stop engine. Use switch in combination with
Engine Speed Control switch to select engine speed.
In Run/Idle 3600/2400 RPM position, engine
runs at 2400 rpm no weld load and 3600 rpm
under weld load.
In Run/Idle 3000/1800 RPM position, engine
runs at 1800 rpm no weld load and 3000 rpm
under weld load.
In either position, engine speed is determined by weld load and position of Engine
Speed Control switch.

Engine Choke Control

 Generator power is available at recep-

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

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

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

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

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

Use control to change engine air-fuel mix
when starting engine.
To Start: pull out choke and turn Engine
Control switch to Start position. Release
switch and slowly push choke in when
engine starts.
With Speed Control switch in Weld, the
engine starts at 3000 rpm and remains there
for two minutes. Engine speed then reduces
to 2000 rpm.

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

 During cold weather some gasoline en-

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

To Stop: turn Engine Control switch to Off
position.
Engine Speed Control Switch

6-3. Cold Weather Engine Operation
1

Engine Control Switch

Carburetor Icing
1

Infrequently
Loaded

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


Treat gasoline with a fuel de−icer product (isopropyl alcohol).



Place the Engine Control switch in the Run position.



Run engine only when expecting to frequently load it.

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

Frequently
Loaded



Load engine and reduce idle times to prevent engine shutdowns.



Use an electric fuel pump to avoid pulse line freezing.



Install engine cold−weather kit.

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

 When the ambient temperatures become warmer (above 45_F) the air flow will
have to be returned to normal.

Ref. 216 172

OM-4430 Page 25

 A complete Parts List is available at www.MillerWelds.com
6-4. Controlling Engine Speed And Weld/Generator Output
 Set engine controls as shown

to obtain the corresponding
weld and generator power output.

Engine Controls
Engine Speed
Either
Run/Idle
position.

1800 rpm
(Power Speed)
Continuous

Generator Power
Output

5 kW/kVA Total From
All AC Receptacles

No Load: 2400 rpm
(Idle Speed)
Load: 3600 rpm
(Weld Speed)

No Load: 1800 rpm
(Idle Speed)
Load: 3000 rpm
(Weld Speed)

Weld Output

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

Welding Not
Recommended

3600 rpm:
20 − 300 A
2.4 kW/kVA at 60-120
Hz From AC
Receptacle RC3 Only

5 kW/kVA Total From
All AC Receptacles
At 1800 rpm.

3000 rpm:
20 − 220 A

At 3000 rpm, Output
Available Only At 2.4
kW/kVA 60-120 Hz AC
Receptacle RC3

Ref 216 172-D

OM-4430 Page 26

 A complete Parts List is available at www.MillerWelds.com
6-5. Process Switch
1

1

Process Switch

!

Weld output terminals are energized
when Process switch is in an Electrode Hot position and the engine is
running.

 The unit will not return to idle speed

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

Use switch to select weld process (see
table below and Section 5-7).
Wire Position:
Use Wire position for MIG welding using a
voltage sensing wire feeder.
Stick Positions:
Use Stick positions for stick (SMAW) and
air carbon arc (CAC-A) cutting and
gouging.

When switch is in a Stick mode, select one
of four dig settings to provide additional amperage during short arc length conditions
and help prevent electrodes from “sticking”.
See Stick position descriptions following
(reading L to R):
Soft Arc (E 7018) (Position 1) - This setting
provides a low dig/arc force setting for
smooth weld performance. A stable weld
puddle with little arc “snap” gives excellent
weld bead appearance with minimal
spatter.
Medium Soft Arc (Position 2) - This setting
provides a low to medium dig/arc force that
gives a slightly more fluid weld puddle,
more arc “snap”, and reduces the potential
for electrode sticking at shorter arc lengths.
Medium Stiff Arc (Position 3) - This setting
provides medium dig/arc force for open root
vertical up joints or joints that do not require
additional current for fit up inconsistencies.

Stiff Arc (E6010) (Position 4) - This setting
provides a high dig/arc force for open root
vertical down joints where additional
current is needed to compensate for tight
joint fit up without the need to increase
overall welding current. This setting is recommended for those who prefer a very stiff
arc with 6010 electrodes.
The dig circuit is disabled when switch is in
Wire or TIG positions.
TIG Position:
Electrode Hot − Lift-Arc™/Scratch Start TIG
(Provides great DC starts with either starting method) - With switch in this position,
normal open-circuit voltage is not present
between the electrode and workpiece. A
solid-state contactor energizes after the
electrode touches
the
workpiece,
preventing overheating, sticking, or contamination of the electrode (see Sections
6-6 and 6-7).
Ref 216 172-D / 803 984

Process Switch Settings
Switch Setting

Process

Output On/Off Control

Electrode Hot − Wire

MIG (GMAW)

Electrode Hot

Electrode Hot − Stick

Stick (SMAW),
Air Carbon Arc (CAC-A) Cutting And Gouging

Electrode Hot

Electrode Hot − Scratch
Start TIG

Scratch Start TIG (GTAW)

Electrode Hot

OM-4430 Page 27

 A complete Parts List is available at www.MillerWelds.com
6-6.

Stick Start Procedure − Scratch Start Technique
With Stick selected, start arc as
follows:
1
2
3

Electrode
Workpiece
Arc

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

1

2

3

6-7. TIG Lift-Arc™ Start Procedure
Select Lift-Arc/Scratch Start TIG at
Process switch to achieve great arc
starts with either procedure. Perform
Lift-Arc starting method as follows:
Lift-Arc  TIG

Lift-Arc Start Method
1

“Touch”

1
Second

2

1

TIG Electrode

2

Workpiece

Turn gas on. Touch tungsten
electrode to workpiece at weld start
point. Hold electrode to workpiece
for 1 second, and slowly lift electrode.
Arc is started when electrode is lifted.
Normal open-circuit voltage is not
present before tungsten electrode
touches workpiece; only a low sensing
voltage is present between electrode
and workpiece. The solid-state output
contactor does not energize until after
electrode is touching workpiece. This
allows electrode to touch workpiece
without overheating, sticking, or
getting contaminated.
Application:
Lift-Arc is used for the DCEN GTAW
process when HF Start method is not
permitted.

Do NOT Strike Like A Match!

OM-4430 Page 28

 A complete Parts List is available at www.MillerWelds.com
6-8. Remote Voltage/Amperage Control
1

Remote Receptacle RC4

Connect optional remote voltage/
amperage (V/A) control to RC4 (see
Section 5-7).
With remote control connected, weld
output in a CC mode (Stick, TIG) is
determined by a combination of front
panel and remote control voltage/
amperage settings. In CV mode
(Wire), weld output is controlled
through remote control only.

1

2
3

Remote Hand Control
(Optional)
Remote Foot Control (Optional)

 Engine

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

In Example:
Process = Stick (Using Remote On/Off)
Min = 20 A CC/DC
Max = 160 A CC/DC

3

2

Max (160 A DC)

Min (20 A DC)
Connect Remote
V/A Control To
Remote
Receptacle RC4

Set Process

Set V/A Control
(Mid-Range: About 160 A)

Adjust Remote V/A Control
(Stick Welding Only)

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

OM-4430 Page 29

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

SECTION 7 − OPERATING AUXILIARY EQUIPMENT
7-1. 60 Hz Generator Power Receptacles And Supplementary Protectors
!
4
1

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

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

2

 Weld output and 60 Hz generator

See Section
7-2 for RC3
information.

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

 Generator power is available at

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

1
3

Controlling Engine Speed And Weld/Generator Power Output
Engine Controls
Engine Speed
Either
Run/Idle
position.

1800 rpm
(Power Speed)
Continuous

Generator Power
Output

2
Weld Output

Welding Not
Recommended

Load: 3600 rpm
(Weld Speed)

3600 rpm:
20 − 300 A
2.4 kW/kVA at 60-120
Hz From AC
Receptacle RC3 Only

Supplementary Protector CB1

CB1 protects receptacles RC1 and
RC2 from overload. If CB1 opens, the
receptacles do not work. Place switch
in On position to reset.
4

No Load: 2400 rpm
(Idle Speed)

120 V 20 A AC Duplex
Receptacle RC2

RC2 supplies 60 Hz single-phase
power at 1800 rpm. Maximum output
from RC2 is 2.4 kVA/kW (20 A at 120
volts ac).
3

5 kW/kVA Total From
All AC Receptacles

240 V 50 A AC Receptacle RC1

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

Supplementary Protector CB2

CB2 protects RC2 from overload. If
CB2 opens, the receptacle does not
work. Press button to reset.

 If supplementary protector continues to open, contact Factory
Authorized Service Agent.

Combined output of all receptacles
limited to 5 kVA/kW continuous rating
of the generator.
No Load: 1800 rpm
(Idle Speed)
Load: 3000 rpm
(Weld Speed)

5 kW/kVA Total From
All AC Receptacles
At 1800 rpm.

EXAMPLE: If 10 A is drawn from 120
V duplex receptacle RC2, only 16 A is
available at 240 V receptacle RC1.
3000 rpm:
20 − 220 A

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

At 3000 rpm, Output
Available Only At 2.4
kW/kVA 60-120 Hz AC
Receptacle RC3
Ref. 211 909

OM-4430 Page 30

 A complete Parts List is available at www.MillerWelds.com
7-2. Variable Frequency (Hz) Generator Power Receptacle RC3
2
1

NOTICE − Do not operate equipment
requiring a constant frequency from
variable frequency receptacle RC3.
1

120 V 20 A Variable Frequency
AC Receptacle RC3

Receptacle supplies single-phase
power continuously. Frequency (Hz)
of generator power output changes
with engine speed. Total output available is 2.4 kVA/kW.
2

Supplementary Protector CB3

CB3 protects receptacle RC3 and
115 volt ac output to Remote Receptacle RC4 from overload. If CB3
opens, the receptacle does not work
and 115 volt ac output at RC4 stops.

 Press button to reset. If supple-

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

Ref. 216 172-D

Notes

Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

OM-4430 Page 31

 A complete Parts List is available at www.MillerWelds.com
7-3. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P)
The plug can be wired for a 240 V,
2-wire load or a 120/240V, 3-wire
load. See circuit diagram.
1

7
Current Available in Amperes

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

240 V
Each 120 V Duplex
Receptacle*
Receptacle
20
15
10
5
0

Plug Wired for 120/240 V,
3-Wire Load

0
5
10
15
20
V x A = Watts

1

3
4

*One 240 V load or two 120 V loads.

120V

2

Plug Wired for 240 V, 2-Wire
Load

3

Neutral (Silver) Terminal

4

Load 1 (Brass)Terminal

5

Load 2 (Brass) Terminal

6

Ground (Green) Terminal

7

Amperes Available using
120/240 V Plug

5

120V

240V

6

Tools Needed:
2

3
4

240V

6

5

240 V AC

120 V AC

120 V AC

plug1 11/03 − 120 813-D

OM-4430 Page 32

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

SECTION 8 − MAINTENANCE & TROUBLESHOOTING
8-1. Routine Maintenance
 Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period.
!
Recycle engine
fluids.

 = Check
	 = Change

 = Clean
* To be done by Factory Authorized Service Agent

Stop engine before maintaining.

 See

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

 = Replace

Reference

Every
8
Hours

Section 5-2

 Fuel Level

 Oil Level


 Oil, Fuel Spills

Every
25
Hours

Section 8-3,
8-4


 Spark Arrestor Screen


 Air Cleaner Wrapper

Every
50
Hours

 Weld Terminals
Every
100
Hours

Engine
Manual,
Section 8-4,
8-5

 Battery Terminals


 Cooling System

	 Oil

 Air Cleaner Element

Every
200
Hours

Engine
Manual,
Section 8-5

 Unreadable Labels

 Spark Plug Gap

 Weld Cables


 Slip Rings*
 Brushes*

	 Oil Filter

 Fuel Filter

Every
500
Hours

OM-4430 Page 33

 A complete Parts List is available at www.MillerWelds.com
8-2. Maintenance Label
 Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period.

OM-4430 Page 34

 A complete Parts List is available at www.MillerWelds.com
8-3. Servicing Optional Spark Arrestor
!

Stop engine and let cool.

1

Spark Arrestor Screen

Clean and inspect screen. Replace
spark arrestor if screen wires are
broken or missing.

1

Tools Needed:
1/4 in

803 983−A / Ref 216 172-D

8-4. Servicing Air Cleaner
!

Stop engine.

NOTICE − Do not run engine without air cleaner or with dirty element.
1

1

2

Precleaner

Wash precleaner with soap and water solution. Allow precleaner to air
dry completely.
Spread 1 tablespoon SAE 30 oil
evenly into precleaner. Squeeze
out excess oil.
2

Element

Replace element if damaged, dirty,
or oily.

oil

aircleaner3 11/04 − 802 772 / S-0759

OM-4430 Page 35

 A complete Parts List is available at www.MillerWelds.com
8-5. Changing Engine Oil, Oil Filter, And Fuel Filter
!

Stop engine and let cool.

1

Oil Drain Valve

2

Oil Filter

Change engine oil and filter according to engine manual.
NOTICE − Close valve and valve
cap before adding oil and running
engine.

Full

Fill crankcase with new oil to full
mark on dipstick (see Section 8-2).
3

Fuel Filter

4

Fuel Line

Replace line if cracked or worn.
Install new filter. Wipe up any spilled
fuel.
Start engine, and check for fuel
leaks.

!

Stop engine, tighten connections as necessary, and wipe
up fuel.

3

4
2

1

Tools Needed:

803 983−A / Ref 216 172-D / S-0842

OM-4430 Page 36

 A complete Parts List is available at www.MillerWelds.com
8-6. Overload Protection
!

Stop engine.

Open left side door.

 When a supplementary protec-

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

1

Supplementary Protector CB4

CB4 protects the stator winding
supplying 24 volt ac output to Remote receptacle RC4. If CB4
opens, 24 volt ac output to RC4
stops.

 Supplementary Protector CB3

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

Press button to reset.
2

Fuse F6 (See Parts List)

F6 protects the engine wiring system from overload. If F6 opens,
engine will not crank.
Replace fuse if open.
Close left side door.

1
2

803 773−A / Ref. 216 172-D

OM-4430 Page 37

 A complete Parts List is available at www.MillerWelds.com
8-7. Troubleshooting

A. Welding
Trouble
No weld output.

Remedy
Check weld control settings.
Check weld connections.
Disconnect equipment from generator power receptacles during start-up.
Increase front panel and/or remote control voltage/amperage control setting (see Sections 6-1 and
6-8).
Check and secure connections to Remote receptacle RC4 (see Sections 5-7).
Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.

Low weld output.

Check weld control settings.
Change position of Engine Control switch and Speed Control switch to achieve desired engine speed.
Increase front panel and/or remote control voltage/amperage control setting (see Sections 6-1 and
6-8).
Check and clean air cleaner as necessary (see Section 8-4).
Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.
See engine manual.

High weld output.

Check control settings.
Check for obstructed movement of solenoid linkage.
Have Factory Authorized Service Agent check circuit boards PC1 and PC2.

Weld output cannot be adjusted.

Have Factory Authorized Service Agent check field current control board PC2.

Erratic weld output.

Check control settings.
Clean and tighten connections both inside and outside unit.
Be sure connection to work piece is clean and tight.
Remove excessive coils from weld cables.
Use dry, properly stored electrodes.
Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.

No remote fine amperage control.

Check and tighten connections to Remote receptacle RC4 (see Section 5-7).

No front panel voltage/amperage control.

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

No 24 volt ac output at Remote
receptacle RC4.

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

No 115 volt ac output at Remote
receptacle RC4.

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

OM-4430 Page 38

 A complete Parts List is available at www.MillerWelds.com
Trouble
Lack of high frequency; difficulty in
establishing Gas Tungsten Arc Welding arc.

Remedy
Use proper size tungsten for welding amperage.

Reduce leakage of high frequency from torch or work cable (check grounding, remove excessive
coils from weld cables, use shorter weld cables, etc.).
Check cables and torch for cracked or deteriorated insulation or bad connections. Repair or replace
necessary parts.
Wandering arc − poor control of arc
direction.

Reduce gas flow rate.
Select proper size tungsten. Properly prepare tungsten.

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

Shield weld zone from drafts.

Increase postflow time.
Check and tighten all gas fittings.
Properly prepare tungsten.

B. 60 Hz Generator Power Receptacles RC1 And RC2
Trouble
No power output at 60 Hz ac receptacles RC1 or RC2.

Remedy
Reset supplementary protectors CB1 and/or CB2 (see Section 7-1).
Stop welding, or place Speed Control switch in Generator Lock position to run engine at 1800 rpm. 60
Hz receptacles RC1 and RC2 work only at 1800 rpm.
Check receptacle wiring and connections.
Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.

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

Check and clean air cleaner as necessary.
Check engine electronic governor system. See engine manual.

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

Check engine electronic governor system. See engine manual.

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

Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1, PC2, and
PC7.
Check receptacle wiring and connections.
Check governor according to engine manual.

C. Variable Frequency Generator Power Receptacle RC3
Trouble
No generator power output at ac receptacle RC3.

Remedy
Reset supplementary protector CB4 (see Section 7-2).
Check receptacle RC3 for continuity and proper connections. Replace receptacle if necessary.
Have Factory Authorized Service Agent check brushes and slip rings, and circuit boards PC1, PC2, and
PC7.

Low generator power output at ac receptacle RC3.

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

OM-4430 Page 39

 A complete Parts List is available at www.MillerWelds.com
D. Engine
Trouble
Engine will not crank.

Remedy
Check fuse F6, and replace if open (see Section 8-6).
Check battery voltage.
Check battery connections and tighten if necessary.
Check plug PLG5 and plug PLG8 connections.
Have Factory Authorized Service Agent check Engine Control switch S2.

Engine does not start.

Check fuel level (see Section 5-2).
Check battery and replace if necessary.
Have Factory Authorized Service Agent check fuel shutoff solenoid FS1 according to engine manual.
Check engine charging system according to engine manual.
See engine manual.

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

Check oil level (see Section 5-2). Low oil pressure shutdown stops engine if oil pressure is too low.
Engine also stops if oil level is too high.
Use correct grade oil for operating temperature. (see Section 8-2).
Have Factory Authorized Service Agent check low oil pressure shutdown switch S5.

Battery discharges between uses.

Place Engine Control switch in Off position when unit is not running.
Clean top of battery with baking soda and water solution; rinse with clear water.
Periodically recharge battery (approximately every 3 months).
Replace battery.
Check voltage regulator according to engine manual.

Engine stopped during normal
operation.

Check fuel level (see Section 5-2).
Check oil level (see Section 5-2). Low oil pressure shutdown stops engine if oil pressure is too low.
Engine also stops if oil level is too high.
Have Factory Authorized Service Agent check low oil pressure shutdown switch S5.
Have Factory Authorized Service Agent check fuel shutoff solenoid FS1 according to engine manual.

Engine does not return to idle speed.

Place Engine Control switch S2 in either Run/Idle position.
Remove all weld and generator power loads.
Turn off remote contactor. The unit will not return to idle speed when the remote contactor is on.
Turn off remote device connected to Remote receptacle RC4 (see Section 5-7).
Check for obstructed movement of solenoid linkage.
Have Factory Authorized Service Agent check circuit board PC2 and current transformer CT1.

Engine does not go to weld speed.

Place Speed Control switch in Weld position.
Check for obstructed movement of solenoid linkage.

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

Treat fuel with isopropyl alcohol de-icer product.

Place Engine Control switch in the Run position until unit has been in operation and loaded for a period of time.
During operation in severe cold weather, engine starts and goes to idle but
stalls after a few minutes.

OM-4430 Page 40

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

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

SECTION 9 − PARTS LIST
9-1. Recommended Spare Parts
Dia.
Mkgs.

Part
No.

Description

Quantity

Recommended Spare Parts
. . . . . . . . . . . F6 . . . . .
....................
....................
....................
....................
....................
....................
....................

021718
215984
230015
230016
066698
215985
067007
230017

. . Fuse, Mintr Gl 30. Amp 32 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Filter, Fuel In−line .250 Kohler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Tune−up & Filter Kit, Kohler (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Air Filter Element, Kohler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Oil Filter, Kohler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Filter, Fuel w/Clamps & 1/4 in Fuel Line . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Air Filter Wrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1
1
1
1
1
1
2
1

Notes

http://www.millerwelds.com/service/replacementparts.html
Choose Genuine Select to review spare parts requirements such
as filters, spark plugs, and fuses.
Choose Service Parts to download complete parts listing.

OM-4430 Page 41

SECTION 10 − ELECTRICAL DIAGRAMS

Figure 10-1. Circuit Diagram For Welding Generator Models
OM-4430 Page 42

232 961-A

OM-4430 Page 43

SECTION 11 − GENERATOR POWER GUIDELINES
 The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown.
11-1. Selecting Equipment

1
2
3

Generator Power Receptacles
− Neutral Bonded To Frame
3-Prong Plug From Case
Grounded Equipment
2-Prong Plug From Double
Insulated Equipment

 Be sure equipment has double
insulated symbol and/or wording on it.

1
2

!

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

3
OR

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

11-2. Grounding Generator To Truck Or Trailer Frame

!

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)
Grounding Cable (Not
Supplied)
Metal Vehicle Frame

2
1
GND/PE

3
2

Connect cable from equipment
ground terminal to metal vehicle
frame. Use #10 AWG or larger
insulated copper wire.
3

 Electrically

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

!

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.

!

If unit does not have GFCI receptacles, use GFCI-protected extension cord.
S-0854

OM-4430 Page 44

11-3. Grounding When Supplying Building Systems
1
1

2

2

GND/PE

Equipment Grounding
Terminal
Grounding Cable

Use #10 AWG or larger insulated
copper wire.
3

Ground Device

 Use ground device as stated in
electrical codes.

2

3

!

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.

ST-800 576-B

11-4. How Much Power Does Equipment Require?
1

Resistive Load

A light bulb is a resistive load and
requires a constant amount of power.
3
2
1

VOLTS 115
AMPS 4.5
Hz
60

2

3
3

Non-Resistive Load

Equipment with a motor is a non-resistive load and requires approximately six times more power while
starting the motor than when running
(see Section 11-8).
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 amperes at 115 volts, calculate its running power requirement in watts.
4.5 A x 115 V = 520 W
The load applied by the drill is 520
watts.
Example 2: If three 200 watt flood
lamps are used with the drill from Example 1, add the individual loads to
calculate total load.
(3 x 200W) + 520 W = 1120 W
The total load applied by the three
flood lamps and drill is 1120 watts.

S-0623

OM-4430 Page 45

11-5. Approximate Power Requirements For Industrial Motors
Industrial Motors
Split Phase

Capacitor Start-Induction Run

Capacitor Start-Capacitor Run

Fan Duty

Rating

Starting Watts

Running Watts

1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP

800
1225
1600
2100
3175
2020
3075
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
1000
1400
1850
2400
3500

300
500
600
700
875
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
400
550
650
800
1100

11-6. Approximate Power Requirements For Farm/Home Equipment
Farm/Home Equipment
Stock Tank De-Icer
Grain Cleaner
Portable Conveyor
Grain Elevator
Milk Cooler
Milker (Vacuum Pump)
FARM DUTY MOTORS
Std. (e.g. Conveyors,
Feed Augers, Air
Compressors)

High Torque (e.g. Barn
Cleaners, Silo Unloaders,
Silo Hoists, Bunk Feeders)
3-1/2 cu. ft. Mixer
High Pressure 1.8 Gal/Min
Washer 2 gal/min
2 gal/min
Refrigerator or Freezer
Shallow Well Pump
Sump Pump

OM-4430 Page 46

Rating
1/4 HP
1/2 HP
3/4 HP
2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/2 HP
500 PSI
550 PSI
700 PSI
1/3 HP
1/2 HP
1/3 HP
1/2 HP

Starting Watts

Running Watts

1000
1650
3400
4400
2900
10500
1720
2575
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
3300
3150
4500
6100
3100
2150
3100
2100
3200

1000
650
1000
1400
1100
2800
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
1000
950
1400
1600
800
750
1000
800
1050

11-7. Approximate Power Requirements For Contractor Equipment
Contractor
Hand Drill

Circular Saw

Table Saw
Band Saw
Bench Grinder

Air Compressor

Electric Chain Saw
Electric Trimmer
Electric Cultivator
Elec. Hedge Trimmer
Flood Lights

Submersible Pump
Centrifugal Pump
Floor Polisher
High Pressure Washer

55 gal Drum Mixer
Wet & Dry Vac

Rating

Starting Watts

Running Watts

1/4 in
3/8 in
1/2 in
6-1/2 in
7-1/4 in
8-1/4 in
9 in
10 in
14 in
6 in
8 in
10 in
1/2 HP
1 HP
1-1/2 HP
2 HP
1-1/2 HP, 12 in
2 HP, 14 in
Standard 9 in
Heavy Duty 12 in
1/3 HP
18 in
HID
Metal Halide
Mercury
Sodium
Vapor
400 gph
900 gph
3/4 HP, 16 in
1 HP, 20 in
1/2 HP
3/4 HP
1 HP
1/4 HP
1.7 HP
2-1/2 HP

350
400
600
500
900
1400
4500
6300
2500
1720
3900
5200
3000
6000
8200
10500
1100
1100
350
500
2100
400
125
313
1000
1400
1250
600
900
4500
6100
3150
4500
6100
1900
900
1300

350
400
600
500
900
1400
1500
1800
1100
720
1400
1600
1000
1500
2200
2800
1100
1100
350
500
700
400
100
250

1000
200
500
1400
1600
950
1400
1600
700
900
1300

OM-4430 Page 47

11-8. Power Required To Start Motor
Single-Phase Induction Motor Starting Requirements
Motor Start
Code

G

H

J

K

L

M

N

P

KVA/HP

6.3

7.1

8.0

9.0

10.0

11.2

12.5

14.0

4
1
3

AC MOTOR
VOLTS 230
AMPS 2.5
CODE M
Hz
60
HP
1/4
PHASE 1

1
2
3
4

2

Motor Start Code
Running Amperage
Motor HP
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 amperage (see example).
Welding generator amperage output must be at least twice the
motor’s running amperage.
(kVA/HP x HP x 1000) / Volts =
Starting Amperage
Example: Calculate starting amperage required for a 230 V, 1/4 HP motor with a motor start code of M.
Volts = 230, HP = 1/4, kVA/HP =
11.2
(11.2 x 1/4 x 1000) / 230 = 12.2A
Starting the motor requires 12.2
amperes.
S-0624

11-9. How Much Power Can Generator Supply?
1

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

1

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-4430 Page 48

11-10. Typical Connections To Supply Standby Power

1

2
Utility
Electrical
Service

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.

4

3
Transfer Switch

!

Fused
Disconnect
Switch
(If Required)

Welding
Generator
Output

 Customer-supplied equipment

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

5
Essential
Loads

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 (customersupplied) if required by electrical
code.
4 Welding Generator Output
Generator output voltage and wiring must be consistent with regular
(utility) system voltage and wiring.
Connect generator with temporary
or permanent wiring suitable for the
installation.
Turn off or unplug all equipment
connected to generator before
starting or stopping engine. When
starting or stopping, the engine has
low speed which causes low voltage and frequency.
5 Essential Loads
Generator output may not meet the
electrical requirements of the premises. If generator does not produce
enough output to meet all requirements, connect only essential
loads (pumps, freezers, heaters,
etc. − See Section 11-4).

OM-4430 Page 49

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

Cord Lengths for 120 Volt Loads
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)

Load (Watts)

5

600

7

840

10

1200

15

4

6

8

10

12

14

350 (106)

225 (68)

137 (42)

100 (30)

400 (122)

250 (76)

150 (46)

100 (30)

62 (19)

400 (122)

275 (84)

175 (53)

112 (34)

62 (19)

50 (15)

1800

300 (91)

175 (53)

112 (34)

75 (23)

37 (11)

30 (9)

20

2400

225 (68)

137 (42)

87 (26)

50 (15)

30 (9)

25

3000

175 (53)

112 (34)

62 (19)

37 (11)

30

3600

150 (46)

87 (26)

50 (15)

37 (11)

35

4200

125 (38)

75 (23)

50 (15)

40

4800

112 (34)

62 (19)

37 (11)

45

5400

100 (30)

62 (19)

50

6000

87 (26)

50 (15)

*Conductor size is based on maximum 2% voltage drop

Cord Lengths for 240 Volt Loads
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)

Load (Watts)

5

1200

7

1680

10

2400

15

4

8

10

12

14

700 (213)

450 (137)

225 (84)

200 (61)

800 (244)

500 (152)

300 (91)

200 (61)

125 (38)

800 (244)

550 (168)

350 (107)

225 (69)

125 (38)

100 (31)

3600

600 (183)

350 (107)

225 (69)

150 (46)

75 (23)

60 (18)

20

4800

450 (137)

275 (84)

175 (53)

100 (31)

60 (18)

25

6000

350 (107)

225 (69)

125 (38)

75 (23)

30

7000

300 (91)

175 (53)

100 (31)

75 (23)

35

8400

250 (76)

150 (46)

100 (31)

40

9600

225 (69)

125 (38)

75 (23)

45

10,800

200 (61)

125 (38)

50

12,000

175 (53)

100 (31)

*Conductor size is based on maximum 2% voltage drop
OM-4430 Page 50

6

Notes

SOCKET/WRENCH SELECTION TABLE
(U.S. STANDARD)
Specifications

Socket or Wrench Size

SOCKET/WRENCH SELECTION TABLE
(METRIC)
Specifications

Socket or Wrench Size

Bolt
Diameter

Decimal
Equivalent

Bolt

Nut

Bolt
Diameter

U.S.
Decimal
Equivalent

Bolt

Nut

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-4430 Page 51

Notes

Welding Symbols
Ref. AWS/ANSI A2.4

OM-4430 Page 52

Effective January 1, 2007
(Equipment with a serial number preface of “LH” or newer)
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.

This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions
* Induction Heating Coils and Blankets, Cables, and
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
Non-Electronic Controls
its original retail purchaser that new Miller equipment sold after
* APT & SAF Model Plasma Cutting Torches
the effective date of this limited warranty is free of defects in
* Remote Controls
material and workmanship at the time it is shipped by Miller. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
* Accessory (Kits)
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
* Replacement Parts (No labor)
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Spoolmate Spoolguns
Within the warranty periods listed below, Miller will repair or
* Canvas Covers
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

2.

3 Years — Parts and Labor

*
*
*
*
*
*
*
*
*

3.

Original main power rectifiers
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.)

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

Miller’s True Blue® Limited Warranty shall not apply to:
1.

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

2.

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

3.

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

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available,
but may vary from province to province.

miller_warr 2007−01

Owner’s Record
Please complete and retain with your personal records.
Model Name

Serial/Style Number

Purchase Date

(Date which equipment was delivered to original customer.)

Distributor
Address
City
State

Zip

For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.
Contact your Distributor for:

Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair

Miller Electric Mfg. Co.

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

Contact the Delivering Carrier to:

File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.

PRINTED IN USA

© 2007 Miller Electric Mfg. Co. 2007−01

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



---

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