Miller Electric 280 Nt Users Manual O4430r(ECO806)

280 NT to the manual b860b762-6ce5-4af0-8a92-75cde2fadb06

2015-02-02

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Miller Legend 302



Processes

Description

TIG (GTAW) Welding

Stick (SMAW) Welding

MIG (GMAW) Welding &

Flux Cored (FCAW) Welding

With Voltage Sensing Feeder

Engine Driven Welding Generator

OM-4430 217 243R

2007−04

File: Engine Drive

Visit our website at

www.MillerWelds.com

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.

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

parts list will then help you to decide the

exact part you may need to fix the problem.

Warranty and service information for your

particular model are also provided.

Miller is the first welding

equipment manufacturer in

the U.S.A. to be registered to

the ISO 9001:2000 Quality

System Standard.

Working as hard as you do

− every power source from

Miller is backed by the most

hassle-free warranty in the

business.

From Miller to You

Mil_Thank 4/05

TABLE OF CONTENTS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

TABLE OF CONTENTS

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

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

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

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

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

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

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

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

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

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

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

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

COMPLETE PARTS LIST - www.MillerWelds.com

OPTIONS AND ACCESSORIES

WARRANTY

OM-4430 Page 1

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 ex-

plained 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 sym-

bols 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.

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 equip-

ment is a hazard.

ELECTRIC SHOCK can kill.

Do not touch live electrical parts.

Wear dry, hole-free insulating gloves and body protection.

Insulate yourself from work and ground using dry insulating mats

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

or ground.

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

there is a danger of falling.

Use AC output ONLY if required for the welding process.

If AC output is required, use remote output control if present on

unit.

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

ing electrically hazardous conditions are present: in damp

locations or while wearing wet clothing; on metal structures such

as floors, gratings, or scaffolds; when in cramped positions such

as sitting, kneeling, or lying; or when there is a high risk of unavoid-

able 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 volt-

age. 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 conduc-

tor first − double-check connections.

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

and sparks.

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

replace cord immediately if damaged — bare wiring can kill.

Turn off all equipment when not in use.

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

Do not drape cables over your body.

If earth grounding of the workpiece is required, ground it directly

with a separate cable.

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

or another electrode from a different machine.

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

parts at once. Maintain unit according to manual.

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

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

present.

Wear a safety harness if working above floor level.

Keep all panels and covers securely in place.

Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

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

single weld output terminal.

SIGNIFICANT DC VOLTAGE exists in inverters after stop-

ping engine.

Stop engine on inverter and discharge input capacitors according

to instructions in Maintenance Section before touching any parts.

HOT PARTS can cause severe burns.

Do not touch hot parts bare handed.

Allow cooling period before working on equip-

ment.

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

lated welding gloves and clothing to prevent burns.

FLYING METAL or DIRT can injure eyes.

Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool,

they can throw off slag.

Wear approved safety glasses with side shields even under your

welding helmet.

OM-4430 Page 2

Welding produces fumes and gases. Breathing these

fumes and gases can be hazardous to your health.

FUMES AND GASES can be hazardous.

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 watch-

person nearby. Welding fumes and gases can displace air and

lower the oxygen level causing injury or death. Be sure the breath-

ing air is safe.

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

erations. The heat and rays of the arc can react with vapors to form

highly toxic and irritating gases.

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

cadmium plated steel, unless the coating is removed from the weld

area, the area is well ventilated, and while wearing an air-supplied

respirator. The coatings and any metals containing these elements

can give off toxic fumes if welded.

BUILDUP OF GAS can injure or kill.

Shut off shielding gas supply when not in use.

Always ventilate confined spaces or use ap-

proved air-supplied respirator.

Arc rays 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.

ARC RAYS can burn eyes and skin.

Wear an approved welding helmet fitted with a proper shade of filter

lenses to protect your face and eyes from arc rays and sparks

when welding or watching (see ANSI Z49.1 and Z87.1 listed in

Safety Standards).

Wear approved safety glasses with side shields under your

helmet.

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

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

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

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

Welding 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.

WELDING can cause fire or explosion.

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.

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 haz-

ards.

Do not use welder to thaw frozen pipes.

Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

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

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

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

from your person before doing any welding.

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

glowing embers, and flames.

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

pass them.

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

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

NOISE can damage hearing.

Noise from some processes or equipment can dam-

age hearing.

Wear approved ear protection if noise level is

high.

MAGNETIC FIELDS can affect Implanted

Medical Devices.

Wearers of Pacemakers and other Implanted

Medical Devices should keep away.

Implanted Medical Device wearers should consult their doctor

and the device manufacturer before going near arc welding, spot

welding, gouging, plasma arc cutting, or induction heating

operations.

Shielding gas cylinders contain gas under high pres-

sure. If damaged, a cylinder can explode. Since gas

cylinders are normally part of the welding process, be

sure to treat them carefully.

CYLINDERS can explode if damaged.

Protect compressed gas cylinders from excessive heat, mechani-

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

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

support or cylinder rack to prevent falling or tipping.

Keep cylinders away from any welding or other electrical circuits.

Never drape a welding torch over a gas cylinder.

Never allow a welding electrode to touch any cylinder.

Never weld on a pressurized cylinder — explosion will result.

Use only correct shielding gas cylinders, regulators, hoses, and fit-

tings designed for the specific application; maintain them and

associated parts in good condition.

Turn face away from valve outlet when opening cylinder valve.

Keep protective cap in place over valve except when cylinder is in

use or connected for use.

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

ber of persons to lift and move cylinders.

Read and follow instructions on compressed gas cylinders,

associated equipment, and Compressed Gas Association (CGA)

publication P-1 listed in Safety Standards.

OM-4430 Page 3

1-3. Engine Hazards

BATTERY EXPLOSION can BLIND.

Always wear a face shield, rubber gloves, and

protective clothing when working on a battery.

Stop engine before disconnecting or connect-

ing battery cables or servicing battery.

Do not allow tools to cause sparks when working on a battery.

Do not use welder to charge batteries or jump start vehicles.

Observe correct polarity (+ and −) on batteries.

Disconnect negative (−) cable first and connect it last.

FUEL can cause fire or explosion.

Stop engine and let it cool off before checking or

adding fuel.

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

any sparks or open flames.

Do not overfill tank — allow room for fuel to expand.

Do not spill fuel. If fuel is spilled, clean up before starting engine.

Dispose of rags in a fireproof container.

Always keep nozzle in contact with tank when fueling.

MOVING PARTS can cause injury.

Keep away from fans, belts, and rotors.

Keep all doors, panels, covers, and guards

closed and securely in place.

Stop engine before installing or connecting unit.

Have only qualified people remove doors, panels, covers, or

guards for maintenance and troubleshooting as necessary.

To prevent accidental starting during servicing, disconnect

negative (−) battery cable from battery.

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

parts.

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

finished and before starting engine.

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

keep engine from kicking back or starting.

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

components.

HOT PARTS can cause severe burns.

Do not touch hot parts bare handed.

Allow cooling period before working on equip-

ment.

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

wear heavy, insulated welding gloves and

clothing to prevent burns.

STEAM AND HOT COOLANT can burn.

If possible, check coolant level when engine is

cold to avoid scalding.

Always check coolant level at overflow tank, if

present on unit, instead of radiator (unless told

otherwise in maintenance section or engine

manual).

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

flow tank, follow the next two statements.

Wear safety glasses and gloves and put a rag over radiator cap.

Turn cap slightly and let pressure escape slowly before

completely removing cap.

Using a generator indoors CAN KILL

YOU IN MINUTES.

Generator exhaust contains carbon monoxide.

This is a poison you cannot see or smell.

NEVER use inside a home or garage, EVEN IF

doors and windows are open.

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

vents.

BATTERY ACID can BURN SKIN and EYES.

Do not tip battery.

Replace damaged battery.

Flush eyes and skin immediately with water.

ENGINE HEAT can cause fire.

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

surfaces or flammables.

Keep exhaust and exhaust pipes way from

flammables.

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.

COMPRESSED AIR can cause injury.

Wear approved safety goggles.

Do not direct air stream toward self or others.

TRAPPED AIR PRESSURE AND WHIPPING

HOSES can cause injury.

Release air pressure from tools and system be-

fore servicing, adding or changing attach-

ments, or opening compressor oil drain or oil fill

cap.

OM-4430 Page 4

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.

Do not touch hot compressor or air system

parts.

Let system cool down before touching or ser-

vicing.

READ INSTRUCTIONS.

Read Owner’s Manual before using or servic-

ing unit.

Stop engine and release air pressure before

servicing.

Use only genuine replacement parts from the

manufacturer.

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

FIRE OR EXPLOSION hazard.

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

combustible surfaces.

Do not install unit near flammables.

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

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

FALLING UNIT can cause injury.

Use lifting eye to lift unit and properly installed

accessories only, NOT gas cylinders. Do not

exceed maximum lift eye weight rating (see

Specifications).

Lift and support unit only with proper equipment

and correct procedures.

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

extend beyond opposite side of unit.

OVERHEATING can damage motors.

Turn off or unplug equipment before starting or

stopping engine.

Do not let low voltage and frequency caused by

low engine speed damage electric motors.

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

where applicable.

FLYING SPARKS can cause injury.

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.

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 servic-

ing unit.

Use only genuine replacement parts from the

manufacturer.

Perform engine and air compressor mainte-

nance and service according to this manual

and the engine/air compressor (if applicable)

manuals.

OM-4430 Page 5

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 micro-

processors, computers, and computer-driven

equipment such as robots.

Be sure all equipment in the welding area is

electromagnetically compatible.

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

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

Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

Be sure this welding machine is installed and grounded

according to this manual.

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

such as moving the welding machine, using shielded cables,

using line filters, or shielding the work area.

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 reproduc-

tive 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 Cut-

ting 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 Protec-

tion 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 Protec-

tion, 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, web-

site: www.nfpa.org.

OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,

and Part 1926, Subpart J, from U.S. Government Printing Office, Super-

intendent 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 electro-

magnetic 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 power-

frequency 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 recom-

mended.

OM-4430 Page 6

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 dan-

gers 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 ris-

ques de danger. Lorsque vous voyez un symbole, soyez

vigilant et suivez les directives mentionnées afin d’éviter tout

danger. Les consignes de sécurité présentées ci-après ne

font que résumer l’information contenue dans les normes de

sécurité énumérées à la section 2-7. Veuillez lire et respecter

toutes ces normes de sécurité.

L’installation, l’utilisation, l’entretien et les réparations ne

doivent être confiés qu’à des personnes qualifiées.

Au cours de l’utilisation, tenir toute personne à l’écart et plus

particulièrement les enfants.

Un 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.

UN CHOC ÉLECTRIQUE peut tuer.

Ne jamais toucher les pièces électriques sous tension.

Porter des gants et des vêtements de protection secs ne compor-

tant pas de trous.

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

moyens isolants suffisamment grands pour empêcher le contact

physique éventuel avec la pièce ou la terre.

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

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

tomber.

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

MENT si le procédé de soudage le demande.

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

nécessaire, se servir de la fonction de télécommande si l’appareil

en est équipé.

Des précautions de sécurité supplémentaires sont requises dans

des environnements à risque comme: les endroits humides ou

lorsque l’on porte des vêtements mouillés; sur des structures mé-

talliques 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

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 tra-

vailler seul!

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

l’installation, à la réparation ou à l’entretien de l’appareil.

Déverrouiller l’alimentation selon la norme OSHA 29 CFR

1910.147 (voir normes de sécurité).

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

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

provinciaux et municipaux.

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

s’assurer que le fil de terre du cordon d’alimentation est bien

raccordé à la borne de terre du sectionneur ou que la fiche du

cordon est raccordée à une prise correctement mise à la terre.

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

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

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

protégez−les contre les étincelles et les pièces métalliques chau-

des.

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 électro-

cution.

Mettre l’appareil hors tension quand on ne l’utilise pas.

Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-

sante ou mal épissés.

Ne pas enrouler les câbles autour du corps.

Si la pièce soudée doit être mise à la terre, le faire directement

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

câble de retour.

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

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

Ne pas toucher des porte électrodes connectés à deux machines

en même temps à cause de la présence d’une tension à vide dou-

blée.

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

sur-le-champ les pièces endommagées. Entretenir l’appareil

conformément à ce manuel.

Porter un harnais de sécurité quand on travaille en hauteur.

Maintenir solidement en place tous les panneaux et capots.

Fixer le câble de retour de façon à obtenir un bon contact métal-

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

possible de la soudure.

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

contact avec tout objet métallique.

OM-4430 Page 7

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 chau

des.

Prévoir une période de refroidissement avant d

travailler à l’équipement.

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

dés et porter des gants de soudage et des vêtements épais pou

éviter les brûlures.

DES PIECES DE METAL ou DES SA-

LETES peuvent provoquer des bles-

sures dans les yeux.

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

fil de fer, et le meulage génèrent des étincelles et des particules

métalliques volantes. Pendant la période de refroidissement des

soudures, elles risquent de projeter du laitier.

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

facial.

LES FUMÉES ET LES GAZ peuvent êtr

dangereux.

Le soudage génère des fumées et des gaz. Leur

inhalation peut être dangereux pour votre santé.

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

À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au

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

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

approuvé.

Lire et comprendre les spécifications de sécurité des matériaux

(MSDS) et les instructions du fabricant concernant les métaux, les

consommables, les revêtements, les nettoyants et les dégraisseurs.

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

en portant un respirateur à alimentation d’air. Demander toujours à

un surveillant dûment formé de se tenir à proximité. Des fumées et

des gaz de soudage peuvent déplacer l’air et abaisser le niveau

d’oxygène provoquant des blessures ou des accidents mortels.

S’assurer que l’air de respiration ne présente aucun danger.

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

de dégraissage, de nettoyage ou de pulvérisation. La chaleur et

les rayons de l’arc peuvent réagir en présence de vapeurs et for-

mer 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 revête-

ment n’ait été enlevé dans la zone de soudure, que l’endroit soit

bien ventilé, et en portant un respirateur à alimentation d’air. Les

revêtements et tous les métaux renfermant ces éléments peuvent

dégager des fumées toxiques en cas de soudage.

LES ACCUMULATIONS DE GAZ ri

quent de provoquer des blessures o

même la mort.

Fermer l’alimentation du gaz protecteur en cas d

non utilisation.

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

respirateur d’adduction d’air homologué.

LES RAYONS DE L’ARC peuvent pr

voquer des brûlures dans les yeux

sur la peau.

Le rayonnement de l’arc du procédé de soudag

génère des rayons visibles et invisibles intense

(ultraviolets et infrarouges) susceptibles de provoquer des brûlure

dans les yeux et sur la peau. Des étincelles sont projetées pendant l

soudage.

Porter un casque de soudage approuvé muni de verres filtrants

approprié pour protéger visage et yeux pendant le soudage

(voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).

Porter des lunettes de sécurité avec écrans latéraux même sous

votre casque.

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

protéger les autres contre les rayonnements les éblouissements

et les étincelles ; prévenir toute personne sur les lieux de ne pas

regarder l’arc.

Porter des vêtements confectionnés avec des matières résistan-

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

protection.

Le soudage effectué sur des conteneurs fermés tel

que des réservoirs, tambours ou des conduites pe

provoquer leur éclatement. Des étincelles peuve

être projetées de l’arc de soudure. La projection d’étincelles, des pièce

chaudes et des équipements chauds peut provoquer des incendies

des brûlures. Le contact accidentel de l’électrode avec des objet

métalliques peut provoquer des étincelles, une explosion, un surchau

fement ou un incendie. Avant de commencer le soudage, vérifier

s’assurer que l’endroit ne présente pas de danger.

LE SOUDAGE peut provoquer un in

cendie ou une explosion.

Déplacer toutes les substances inflammables à une distance de

10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir

soigneusement avec des protections homologués.

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

sur des substances inflammables.

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

de métal chaud.

Des étincelles et des matériaux chauds du soudage peuvent

facilement passer dans d’autres zones en traversant de petites

fissures et des ouvertures.

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

proximité.

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

peut déclencher un incendie de l’autre côté.

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

des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été

préparés correctement conformément à AWS F4.1 (voir les nor-

mes de sécurité).

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

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

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

zone de soudage pour éviter le transport du courant sur une

longue distance par des chemins inconnus éventuels en provo-

quant des risques d’électrocution, d’étincelles et d’incendie.

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

lées.

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

électrode ou couper le fil à la pointe de contact.

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

gants en cuir, une chemise en matériau lourd, des pantalons sans

revers, des chaussures hautes et un couvre chef.

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

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

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

ce d’étincelles incandescentes ni de flammes.

Utiliser exclusivement des fusibles ou coupe−circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

OM-4430 Page 8

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 affe

l’ouïe.

Porter des protections approuvés pour les or

les si le niveau sonore est trop élevé.

LES CHAMPS MAGNETIQUES peuv-

ent affecter des implants médicaux.

Porteur de simulateur cardiaque ou autre im-

plants médicaux, rester à distance.

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

avant de s’approcher des opérations de soudage à l’arc, de sou-

dage par points, de gougeage, du coupage plasma ou de chauf-

fage par induction.

Si des BOUTEILLES sont endomm

gées, elles pourront exploser.

Des bouteilles de gaz protecteur contiennent du g

sous haute pression. Si une bouteille est endomm

gée, elle peut exploser. Du fait que les bouteilles de gaz fo

normalement partie du procédé de soudage, les manipuler av

précaution.

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

des chocs mécaniques, des dommages physiques, du laitier, des

flammes ouvertes, des étincelles et des arcs.

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

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

de se renverser.

Tenir les bouteilles éloignées des circuits de soudage ou autres

circuits électriques.

Ne jamais placer une torche de soudage sur une bouteille à gaz.

Une électrode de soudage ne doit jamais entrer en contact avec

une bouteille.

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

Utiliser seulement des bouteilles de gaz protecteur, régulateurs,

tuyaux et raccords convenables pour cette application spécifique;

les maintenir ainsi que les éléments associés en bon état.

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

bouteille.

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

d’utilisation ou de branchement de la bouteille.

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

samment de personnes pour soulever et déplacer les bouteilles.

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

l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas

Association) mentionné dans les principales normes de sécurité.

2-3. Dangers existant en relation avec le moteur

L’EXPLOSION DE LA BATTERIE peu

RENDRE AVEUGLE.

Toujours porter une protection faciale, des gant

en caoutchouc et vêtements de protection lor

d’une intervention sur la batterie.

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

de batterie.

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

la batterie.

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

des véhicules de démarrage rapide.

Observer la polarité correcte (+ et −) sur les batteries.

Débrancher le câble négatif (–) en premier lieu. Le rebrancher en

dernier lieu.

LE CARBURANT MOTEUR peut prov

quer un incendie ou une explosion.

Arrêter le moteur avant de vérifier le niveau d

carburant ou de faire le plein.

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

ou d’une flamme nue.

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

pour son expansion.

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

carburant renversé avant de faire démarrer le moteur.

Jeter les chiffons dans un récipient ignifuge.

Toujours garder le pistolet en contact avec le réservoir lors du

remplissage.

DES ORGANES MOBILES peuvent pr

voquer des blessures.

Ne pas approcher les mains des ventilateurs

courroies et autres pièces en mouvement.

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

couvrements et dispositifs de protection.

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

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

tes, panneaux, recouvrements ou dispositifs de protection pour

effectuer, s’il y a lieu, des travaux d’entretien et de dépannage.

Pour empêcher tout démarrage accidentel pendant les travaux

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

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

des organes mobiles.

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

fermer les portes à la fin des travaux d’entretien et avant de faire

démarrer le moteur.

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

mise en route accidentelle du moteur.

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

tion sur le générateur.

DES PIÈCES CHAUDES peuvent

provoquer des brûlures graves.

Ne pas toucher à mains nues les parties chau

des.

Prévoir une période de refroidissement avant d

travailler à l’équipement.

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

dés et porter des gants de soudage et des vêtements épais pou

éviter les brûlures.

LA VAPEUR ET LE LIQUIDE DE

REFROIDISSEMENT CHAUD peuvent

provoquer des brûlures.

Il est préférable de vérifier le liquide de refroi-

dissement une fois le moteur refroidi pour éviter

de se brûler.

Toujours vérifier le niveau de liquide de refroidissement dans le

vase d’expansion (si présent), et non dans le radiateur (sauf si pré-

cisé autrement dans la section maintenance du manuel du

moteur).

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

me suivant.

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

le bouchon du radiateur.

OM-4430 Page 9

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 invisi-

ble 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 pro-

voquer des brûlures dans les YEUX et

sur la PEAU.

Ne pas renverser la batterie.

Remplacer une batterie endommagée.

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

LA CHALEUR DU MOTEUR peut pro-

voquer 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.

2-4. Dangers liés à l’air comprimé

RESPIRER L’AIR COMPRIMÉ peut pro-

voquer des blessures graves ou causer

la mort.

Ne pas utiliser l’air comprimé pour respirer.

Utiliser l’air comprimé seulement pour le cou-

page, gougeage et les outils pneumatiques.

L’AIR COMPRIMÉ peut provoquer

des blessures.

Porter des lunettes de sécurité approuvées.

Ne pas diriger le jet d’air vers d’autres ou

soi-même.

L’AIR COMPRIME EMMAGASINE ET DES

TUYAUX SOUS PRESSION peuvent provo-

quer 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.

Le METAL CHAUD lors du coupage et

gougeage plasma peut provoquer un in-

cendie ou une explosion.

Ne pas couper ou gouger à proximité de pro-

duits inflammables.

Surveillez et garder un extincteur à proximité.

DES PIECES CHAUDES peuvent provo-

quer 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’EXPLO-

SION.

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

à proximité de surfaces inflammables.

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

duits inflammables.

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

mentation est correctement dimensionnée et protégée avant de

mettre l’appareil en service.

LA CHUTE DE L’APPAREIL peut blesser.

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

les accessoires correctement installées seuls

PAS les bouteilles de gaz. Ne pas dépasser l

poids nominal maximal de l’œilleton (voir les spé

cifications).

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

l’équipement approprié et en suivant le

procédures adéquates.

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

que les fourches sont suffisamment longues pour dépasser d

côté opposé de l’appareil.

OM-4430 Page 10

LE SURCHAUFFEMENT peut endom-

mager le moteur électrique.

Arrêter ou déconnecter l’équipement avant d

démarrer ou d’arrêter le moteur.

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

dommager le moteur électrique à cause d’une tension et d’une fré

quence trop faibles.

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

s’il y a lieu.

LES ÉTINCELLES VOLANTES ris-

quent de provoquer des blessures.

Porter un écran facial pour protéger le visage e

les yeux.

Affûter l’électrode au tungstène uniquement à l

meuleuse dotée de protecteurs. Cette manœuv

re est à exécuter dans un endroit sûr lorsque l’o

porte l’équipement homologué de protection d

visage, des mains et du corps.

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

stance inflammable.

DES ORGANES MOBILES peuvent

provoquer des blessures.

Ne pas s’approcher des organes mobiles.

Ne pas s’approcher des points de coincement

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuvent

provoquer des blessures.

Ne pas appuyer sur la gâchette avant d’en

avoir reçu l’instruction.

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

sonnes ou toute pièce mécanique en enga-

geant le fil de soudage.

L’EMPLOI EXCESSIF peut

SURCHAUFFER L’ÉQUIPEMENT.

Laisser l’équipement refroidir ; respecter le fac-

teur de marche nominal.

Réduire le courant ou le facteur de marche

avant de poursuivre le soudage.

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

LES CHARGES ÉLECTROSTATI-

QUES peuvent endommager les

circuits imprimés.

Établir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pièces.

Utiliser des pochettes et des boîtes antistatiques pour stocker,

déplacer ou expédier des cartes de circuits imprimes.

UNE REMORQUE QUI BASCULE peut

entraîner des blessures.

Utiliser les supports de la remorque ou des

blocs pour soutenir le poids.

Installer convenablement le poste sur la remor-

que comme indiqué dans le manuel s’y rappor-

tant.

LIRE LES INSTRUCTIONS.

Lisez le manuel d’instructions avant l’utilisation

ou la maintenance de l’appareil.

N’utiliser que les pièces de rechange recom-

mandées par le constructeur.

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

seur d’air suivant les instructions dans ce manuel ou le manuel

du moteur/compresseur (si applicable).

LE RAYONNEMENT HAUTE FRÉ-

QUENCE (H.F.) risque de provoquer

des interférences.

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

provoquer des interférences avec les équipe-

ments de radio−navigation et de communica-

tion, les services de sécurité et les ordinateurs.

Demander seulement à des personnes qualifiées familiarisées

avec des équipements électroniques de faire fonctionner l’instal-

lation.

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

cien qualifié les interférences résultant de l’installation.

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

pareil.

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

Maintenir soigneusement fermés les portes et les panneaux des

sources de haute fréquence, maintenir les éclateurs à une dis-

tance correcte et utiliser une terre et un blindage pour réduire les

interférences éventuelles.

LE SOUDAGE À L’ARC risque de

provoquer des interférences.

L’énergie électromagnétique risque de provo-

quer des interférences pour l’équipement élec-

tronique sensible tel que les ordinateurs et

l’équipement commandé par ordinateur tel que

les robots.

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

compatible électromagnétiquement.

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

soudage aussi courts que possible, les grouper, et les poser

aussi bas que possible (ex. par terre).

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

ment électronique sensible.

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

conformément à ce mode d’emploi.

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

tes, il incombe à l’utilisateur de prendre des mesures supplé-

mentaires telles que le déplacement du poste, l’utilisation de câ-

bles blindés, l’utilisation de filtres de ligne ou la pose de protec-

teurs dans la zone de travail.

OM-4430 Page 11

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 mal-

formations 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 chimi-

ques 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 manipu-

lation.

Pour les moteurs à essence :

Les gaz d’échappement des moteurs contiennent des pro-

duits 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 com-

me 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 Cut-

ting 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 Protec-

tion 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, Chan-

tilly, 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 Protec-

tion, 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 Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,

and Part 1926, Subpart J, de U.S. Government Printing Office, Superin-

tendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954

(téléphone : 1-866-512-1800) (il y a 10 bureaux régionaux−−le télépho-

ne de la région 5, Chicago, est 312-353-2220, site Internet :

www.osha.gov).

2-8. Information EMF

Considérations sur le soudage et les effets de basse fréquence et des

champs magnétiques et électriques.

Le courant de soudage, pendant son passage dans les câbles de sou-

dage, causera des champs électromagnétiques. Il y a eu et il y a encore

un certain souci à propos de tels champs. Cependant, après avoir exa-

miné 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 électromagnéti-

ques 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 induc-

tion. Si le médecin approuve, il est recommandé de suivre les

procédures précédentes.

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

OM-4430 Page 12

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 AAmperes VVolts

MIG (GMAW),

Wire Stick (SMAW) TIG (GTAW) Circuit Protector

Positive Negative Alternating Current

(AC) Output

Time hHours sSeconds Protective Earth

(Ground)

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.

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

OM-4430 Page 13

SECTION 4 − SPECIFICATIONS

4-1. Description

This multiprocess engine-driven welder and AC generator provides low speed generator AC power and DC weld out-

put 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

Rated

Welding

Output

Maximum

Open-Circuit

Voltage

Amperage

Range In

CC Mode

Voltage

Range In

CV Mode

Generator

Power Rating Fuel

Capacity Engine

CC/DC 280 A, 25 V, 100%

Duty Cycle 50 20 − 300 A

13 − 35 V

5.5 kVA/kW (Peak)

5 kVA/kW (Continuous)

42/21 A,

120/240 V AC,

60 Hz,

Single-Phase at

1800 rpm 12 gal

(45 L)

Kohler CH-23

Air-Cooled,

Two-Cylinder,

Four-Cycle,

CV/DC 300 A, 25 V, 100%

Duty Cycle 35 − −

−

1800 rpm

And

2.4 kVA/kW, 20 A,

120 V AC,

60-120 Hz,

Single-Phase

At All Speeds

(45 L)

Tank

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) A

Width 20−1/2 in (521 mm)

!Do not exceed tilt angles or engine could

Depth 45-1/2 in (1156 mm)

Do not exceed tilt angles or engine could

be damaged or unit could tip.

A20 in (508 mm)

!Do not move or operate unit where it could

tip.

B16-1/2 in (419 mm) 4 Holes

C 1−3/4 in (44 mm) E

D5 in (127 mm) F

E32-3/4 in (832 mm)

2°

F44-1/4 in (1124 mm) 25°

G13/32 in (10 mm) Dia. 25°

25°

Weight

Engine End

25°

590 lb (267 kg) Engine End

Lifting Eye Weight Rating

800 426 803 983

1280 lb (580 kg)

800 426 803 983

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

OM-4430 Page 14

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)

AProtective Cage Width:

26 in (660 mm) D

BRunning Gear Width:

32 in (813 mm)

CProtective Cage Length:

48 in (1219 mm) B

DRunning Gear Length:

45−1/2 in (1156 mm)

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

207 967

3000 RPM Weld

0.00

0.25

0.50

0.75

1.00

1.25

1.50

1.75

2.00

0 100 150 200 250 300

DC WELD AMPERES AT 100% DUTY CYCLE

U.S. GAL./HR.

1.98

0.95

2.84

3.78

5.67

4.73

6.62

7.57

LITERS/HR.

0.00

3600 RPM Weld

Generator

at 5 kW

Generator

at 2 kW

Generator

at 1 kW

Generator

at 3 kW

Idle (At

1800 RPM)

On a typical job using 1/8 in 7018

electrodes (125 amps, 20% duty

cycle), expect over 20 hours of op-

eration.

Welding at 150 amps at 40% duty

cycle uses approximately 3/4 gal-

lon 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 op-

eration.

Generator

at 4 kW

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OM-4430 Page 15

222 553

The ac generator power curve

shows the generator power avail-

able in amperes at the receptacles.

4-6. Generator Power Curve

AC AMPERES

AC VOLTS

0 5 10 15 20 25 30

100

150

200

250

300

Notes

BUTT BUTT

T−JOINT T−JOINT

FILLET

GROOVE

FLAT VERTICALHORIZONTAL OVERHEADWELD POSITION:

WELD JOINT

TYPES

Ref. AWS/ANSI D1.1

Ref. 804 248-A

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OM-4430 Page 16

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.

100% Duty Cycle at 280 Amperes DC/CC

Continuous Welding

4-7. Duty Cycle

Ref. 207 925

010

20 30 40 50 60 100

70 80 90

150

175

200

225

250

275

300

% DUTY CYCLE

WELD AMPERES

325

MIG/FCAW

STICK

222 558

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.

4-8. TIG Mode Volt-Ampere Curves

DC AMPERES

DC VOLTS

0 100 200 300 400

Min

3000RPM Max

3600RPM Max

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OM-4430 Page 17

222 555 / 222 556 / 222 557

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

B. CV/DC MIG Mode

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

DC AMPERES

DC VOLTS

0 200 400 600

Min

20V Preset

3000RPM Max

3600RPM Max

DC AMPERES

DC VOLTS

0 200 400 600

100

Min

3000RPM Max

3600RPM Max

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OM-4430 Page 18

SECTION 5 − INSTALLATION

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

!Do not weld on base. Welding

on base can cause fuel tank fire

or explosion. Bolt unit down

using holes provided in base.

!Always securely fasten weld-

ing generator onto transport

vehicle or trailer and comply

with all DOT and other applica-

ble codes.

!Do not mount unit by support-

ing the base only at the four

mounting holes. Use cross-

supports to adequately sup-

port unit and prevent damage

to base.

!Always ground generator

frame to vehicle frame to pre-

vent electric shock and static

electricity hazards.

!If unit does not have GFCI re-

ceptacles, use GFCI-protected

extension cord.

NOTICE − Do not install unit where air

flow is restricted or engine may over-

heat.

Mounting:

1 Cross-Supports

Mount unit on flat surface or use

cross-supports to support base.

Grounding:

2 Equipment Grounding Terminal

(On Front Panel)

3 Grounding Cable (Not Supplied)

4 Metal Vehicle Frame

Connect cable from equipment

ground terminal to metal vehicle

frame. Use #10 AWG or larger insu-

lated copper wire.

Electrically bond generator frame to

vehicle frame by metal-to-metal contact.

GND/PE

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm) 18 in

(460 mm)

18 in

(460 mm)

Movement

Location / Airflow Clearance

Grounding

!Do not lift unit from end.

-1. Installing Welding Generator

Mounting

Inadequate support.

!Do not use flexible mounts.

!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 termi-

nal to bare metal on the vehicle frame as shown.

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OM-4430 Page 19

5-2. Engine Prestart Checks

803 983−A / Ref 216 172-D

Full

Check all fluids daily. Engine must be

cold and on a level surface. Unit is

shipped with 10W30 engine oil.

Follow run-in procedure in engine

manual.

This unit has a low oil pressure

shutdown switch. However, some

conditions may cause engine

damage before the engine shuts

down. Check oil level often and do

not use the oil pressure shutdown

system to monitor oil level.

Fuel

Add fresh fuel before starting engine

the first time (see maintenance label for

specifications). Always leave filler

neck empty to allow room for expan-

sion. Check fuel level on a cold engine

before use each day.

To check fuel level, turn Engine Control

switch to either Run/Idle position.

LED’s indicate fuel level in tank.

Oil

Do not exceed the ”Full” mark on

the oil level dipstick. The fuel

pump may operate erratically if

crankcase is overfilled.

Check oil with unit on level surface. If

oil is not up to full mark on dipstick, add

oil (see maintenance label).

Use front panel meters to determine

hours until next recommended oil

change (see Section 6-1).

To improve cold weather starting:

Keep battery in good condition.

Store battery in warm area.

Use correct grade oil for cold

weather.

Full

Gasoline

Full

Empty

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OM-4430 Page 20

5-3. Connecting Or Replacing The Battery

+−

!Connect negative (−)

cable last.

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

3/8, 1/2 in

Tools Needed:

Replacing The Battery

+−

Remove end panel to replace battery.

!Connect negative (−)

cable last.

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OM-4430 Page 21

5-4. Installing Exhaust Pipe

Ref 216 172-D / 803 891

!Stop engine and let cool.

!Engine backfire can cause se-

vere burns or other injuries.

Do not point exhaust pipe to-

ward control panel. Keep away

from exhaust outlet.

!Point exhaust pipe in desired

direction but always away

from front panel and direction

of travel.

Tools Needed:

1/2 in

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at

the beginning

of this manual.

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OM-4430 Page 22

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

2 Stick/TIG (CC) Weld Output

Terminal

3 Wire /CV Weld Output Terminal

For MIG welding, connect work cable

to Negative (−) terminal and wire

feeder cable to Wire (CV) terminal.

For Stick welding, connect work

cable to Negative (−) terminal and

electrode holder cable to Stick/TIG

(CC) terminal.

For TIG welding, connect work cable

to Stick/TIG (CC) terminal and elec-

trode holder to Negative (−) terminal.

!Failure to properly connect

weld cables may cause exces-

sive heat and start a fire, or

damage your machine.

4 Weld Output Terminal

5 Supplied Weld Output Terminal

Nut

6 Weld Cable Terminal

7 Copper Bar

Remove supplied nut from weld out-

put terminal. Slide weld cable termi-

nal onto weld output terminal and se-

cure with nut so that weld cable termi-

nal 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.

216 172-D / 803 984−A / 803 778-A

Tools Needed:

Do not place

anything between

Correct Installation Incorrect Installation

weld cable terminal

and copper bar.

3/4 in

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OM-4430 Page 23

5-6. Selecting Weld Cable Sizes*

Weld Output

Terminals

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

Not Exceeding***

!Stop engine before

connecting to weld

output terminals.

!Do not use worn,

damaged, under-

sized, or poorly

spliced cables.

100 ft (30 m) or Less 150 ft

(45 m) 200 ft

(60 m) 250 ft

(70 m) 300 ft

(90 m) 350 ft

(105 m) 400 ft

(120 m)

Welding

Amperes

10 − 60%

Duty

Cycle

60 − 100%

Duty

Cycle 10 − 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)

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

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

( ) = mm2 for metric use S-0007-F

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

5-7. Remote Receptacle Information

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

Socket* Socket Information

BKI

LNH

24 VOLTS AC A24 volts ac. Protected by supplementary protector

CB4.

CLNH

DMG

BNot used.

DMG

EF115 VOLTS AC I115 volts ac. Protected by supplementary protec-

tor CB3.

JNot used.

A/V

C+10 volts dc output to remote control.

A/V

AMPERAGE

DRemote control circuit common.

AMPERAGE

VOLTAGE E0 to +10 volts dc input command signal from

remote control.

GND

GCircuit common for 24 and 115 volts ac circuits.

GND KChassis common.

*The remaining sockets are not used.

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OM-4430 Page 24

SECTION 6 − OPERATING WELDING GENERATOR

6-1. Front Panel Controls

Ref 216 172-D

1 Process Switch

See Section 6-5 for Process switch informa-

tion.

2 Remote Receptacle

Use receptacle to connect remote control.

When a remote voltage/amperage control is

connected to the Remote receptacle, the

Auto Sense Remote feature automatically

switches voltage/amperage control to the re-

mote control (see Sections 5-7 and 6-8).

With remote voltage/amperage control con-

nected, weld output in CC mode is deter-

mined by a combination of front panel and re-

mote control voltage/amperage settings.

If no remote voltage/amperage control is

connected to the Remote receptacle, the

front panel Voltage/Amperage control ad-

justs voltage and amperage.

3 And 4 Displays

Displays can show weld process information

(voltage and amperage) or maintenance in-

formation (hourmeter or oil change count-

down).

Meter Weld Functions: In Wire mode, Volt-

meter displays preset weld voltage when not

welding. Meters display actual voltage and

amperage when welding and for five sec-

onds after welding has stopped.

In Stick and TIG modes, Voltmeter reads ON

and Ammeter displays preset amperage

when not welding. Meters display actual volt-

age 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 en-

gine 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 indi-

cate 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 set-

ting, use control to adjust amperage. With

Process switch in Wire position, use control

to adjust voltage. When a remote voltage/

amperage control is connected to Remote

receptacle RC4, control sets the maximum

amperage in Stick and TIG modes, but has

no effect in MIG mode.

7 Engine Control Switch (see Section 6-2)

8 Engine Choke Control (see Section 6-2)

9 Engine Speed Control Switch (see Sec-

tion 6-2)

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OM-4430 Page 25

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

Engine Control Switch

Use switch to start engine, select speed, and

stop engine. Use switch in combination with

Engine Speed Control switch to select en-

gine 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 deter-

mined by weld load and position of Engine

Speed Control switch.

Generator power is available at recep-

tacles RC1 and RC2 only at 1800 rpm.

If generator is not locked at 1800 rpm,

engine speed increases in response to

weld load and generator power output

stops at receptacles RC1 and RC2.

Generator power load does not affect

engine speed.

Engine Choke Control

Use control to change engine air-fuel mix

when starting engine.

To Start: pull out choke and turn Engine

Control switch to Start position. Release

switch and slowly push choke in when

engine starts.

With Speed Control switch in Weld, the

engine starts at 3000 rpm and remains there

for two minutes. Engine speed then reduces

to 2000 rpm.

The engine speed reduces from 3000 rpm to

2000 rpm when the Speed Control switch is

toggled within the first two minutes of

operation and no load is applied.

When an auxiliary power load is applied to 60

Hz receptacle RC1 or RC2, engine speed

reduces to 1800 rpm.

If the engine does not start, let the

engine come to a complete stop before

attempting restart.

During cold weather some gasoline en-

gines encounter difficulties that are easi-

ly remedied. See Section 6-3 and 8-7.

To Stop: turn Engine Control switch to Off

position.

Engine Speed Control Switch

Use switch to control engine auto idle func-

tion. Place switch in Generator Lock position

when not welding to lock engine speed at

1800 rpm for generator power at 60 Hz ac re-

ceptacles RC1 and RC2 (generator power is

always available at 60−120 Hz receptacle

RC3. See Section 7-2.)

Place switch in Weld position to allow engine

speeds to be determined by position of En-

gine Control switch. The Speed Control

switch is not needed at start−up.

6-3. Cold Weather Engine Operation

Ref. 216 172

1 Engine Control Switch

Carburetor Icing

Carburetor icing causes the unit to drop below the normal idle speed and then stall.

This condition occurs when the temperature is near freezing and the relative humid-

ity is high. Ice forms on the throttle plate and inner bore of the carburetor. The engine

typically restarts without problems but soon stalls again.

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

Place the Engine Control switch in the Run position.

Run engine only when expecting to frequently load it.

Breather Icing

Oil breather/pulse line icing occurs in severe cold (continuously below 0F). Mois-

ture 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 carbure-

tor. All of these cause operating problems. Due to ice in the lines, the engine may

not restart until it is warmed to above freezing.

Load engine and reduce idle times to prevent engine shutdowns.

Use an electric fuel pump to avoid pulse line freezing.

Install engine cold−weather kit.

Kohler offers a kit for cold weather operation. Contact engine manufacturer for kit

information (1-800-544-2444). The user can install these kits. The kit pulls heated

air from the muffler surface into the carburetor and shuts the cold air off. This in-

creases 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.

Frequently

Loaded

Infrequently

Loaded

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OM-4430 Page 26

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

Ref 216 172-D

Set engine controls as shown

to obtain the corresponding

weld and generator power out-

put.

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.

1800 rpm

(Power Speed)

Continuous

No Load: 2400 rpm

(Idle Speed)

Load: 3600 rpm

(Weld Speed)

Either

Run/Idle

position.

Engine Controls

Engine Speed

Generator Power

Output Weld Output

5 kW/kVA Total From

All AC Receptacles

2.4 kW/kVA at 60-120

Hz From AC

Receptacle RC3 Only

No Load: 1800 rpm

(Idle Speed)

Load: 3000 rpm

(Weld Speed)

Welding Not

Recommended

3600 rpm:

20 − 300 A

3000 rpm:

20 − 220 A

5 kW/kVA Total From

All AC Receptacles

At 1800 rpm.

At 3000 rpm, Output

Available Only At 2.4

kW/kVA 60-120 Hz AC

Receptacle RC3

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OM-4430 Page 27

1 Process Switch

!Weld output terminals are energized

when Process switch is in an Elec-

trode 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 re-

mote 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 am-

perage 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 rec-

ommended 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 start-

ing 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 con-

tamination of the electrode (see Sections

6-6 and 6-7).

6-5. Process Switch

Ref 216 172-D / 803 984

Process Switch Settings

Switch Setting

Process

Output On/Off Control

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

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OM-4430 Page 28

6-6. Stick Start Procedure − Scratch Start Technique

With Stick selected, start arc as

follows:

1 Electrode

2 Workpiece

3 Arc

Drag electrode across workpiece like

striking a match; lift electrode slightly

after touching work. If arc goes out

electrode was lifted to high. If

electrode sticks to workpiece, use a

quick twist to free it.

6-7. TIG Lift-Arc™ Start Procedure

Select Lift-Arc/Scratch Start TIG at

Process switch to achieve great arc

starts with either procedure. Perform

Lift-Arc starting method as follows:

Lift-Arc  TIG

1 TIG Electrode

2 Workpiece

Turn gas on. Touch tungsten

electrode to workpiece at weld start

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.

Second

“Touch”

Lift-Arc Start Method

Do NOT Strike Like A Match!

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OM-4430 Page 29

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.

2 Remote Hand Control

(Optional)

3 Remote Foot Control (Optional)

Engine runs at weld/power

speed in Wire and TIG mode

whenever a device connected to

the remote receptacle makes

closure between pins A and B.

This unit does not have remote

contactor control. Output is al-

ways on.

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

Process = Stick (Using Remote On/Off)

In Example:

Max = 160 A CC/DC

Min = 20 A CC/DC

Max (160 A DC)

Min (20 A DC)

Connect Remote

V/A Control To

Remote

Receptacle RC4

Set V/A Control

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

(Stick Welding Only)

Set Process

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OM-4430 Page 30

SECTION 7 − OPERATING AUXILIARY EQUIPMENT

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

Ref. 211 909

!If unit does not have GFCI re-

ceptacles, use GFCI-protected

extension cord.

NOTICE − Disconnect equipment

from auxiliary power receptacles dur-

ing start−up and shutdown. Some

equipment can be damaged by

changes in frequency as engine rpms

change during start-up and shut-

down.

Weld output and 60 Hz generator

power output at receptacles RC1

and RC2 are not always available

at the same time. When welding,

generator power is available from

AC receptacle RC3 only (see

Section 7-2).

Generator power is available at

receptacles RC1 and RC2 only at

1800 rpm. If generator is not

locked at 1800 rpm, engine

speed increases in response to

weld load and generator power

output stops at receptacles RC1

and RC2. Generator power load

does not affect engine speed.

1 240 V 50 A AC Receptacle RC1

RC1 supplies 60 Hz single-phase

power at 1800 rpm. Maximum output

is 5 kVA/kW (20 A at 240 volts ac). For

60 Hz generator power at RC1, set

controls as shown in table.

2 120 V 20 A AC Duplex

Receptacle RC2

RC2 supplies 60 Hz single-phase

power at 1800 rpm. Maximum output

from RC2 is 2.4 kVA/kW (20 A at 120

volts ac).

3 Supplementary Protector CB1

CB1 protects receptacles RC1 and

RC2 from overload. If CB1 opens, the

receptacles do not work. Place switch

in On position to reset.

4 Supplementary Protector CB2

CB2 protects RC2 from overload. If

CB2 opens, the receptacle does not

work. Press button to reset.

If supplementary protector con-

tinues to open, contact Factory

Authorized Service Agent.

Combined output of all receptacles

limited to 5 kVA/kW continuous rating

of the generator.

EXAMPLE: If 10 A is drawn from 120

V duplex receptacle RC2, only 16 A is

available at 240 V receptacle RC1.

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

kVA/kW

Controlling Engine Speed And Weld/Generator Power Output

1800 rpm

(Power Speed)

Continuous

No Load: 2400 rpm

(Idle Speed)

Load: 3600 rpm

(Weld Speed)

Either

Run/Idle

position.

Engine Controls

Engine Speed

Generator Power

Output Weld Output

5 kW/kVA Total From

All AC Receptacles

2.4 kW/kVA at 60-120

Hz From AC

Receptacle RC3 Only

No Load: 1800 rpm

(Idle Speed)

Load: 3000 rpm

(Weld Speed)

Welding Not

Recommended

3600 rpm:

20 − 300 A

3000 rpm:

20 − 220 A

5 kW/kVA Total From

All AC Receptacles

At 1800 rpm.

At 3000 rpm, Output

Available Only At 2.4

kW/kVA 60-120 Hz AC

Receptacle RC3

See Section

7-2 for RC3

information.

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

OM-4430 Page 31

Ref. 216 172-D

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

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 avail-

able is 2.4 kVA/kW.

2 Supplementary Protector CB3

CB3 protects receptacle RC3 and

115 volt ac output to Remote Recep-

tacle 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 Autho-

rized Service Agent.

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at

the beginning

of this manual.

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

OM-4430 Page 32

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

plug1 11/03 − 120 813-D

The plug can be wired for a 240 V,

2-wire load or a 120/240V, 3-wire

load. See circuit diagram.

1 Plug Wired for 120/240 V,

3-Wire Load

When wired for 120 V loads, each

duplex receptacle shares a load

with one half of 240 V receptacle.

2 Plug Wired for 240 V, 2-Wire

Load

3 Neutral (Silver) Terminal

4 Load 1 (Brass)Terminal

5 Load 2 (Brass) Terminal

6 Ground (Green) Terminal

7 Amperes Available using

120/240 V Plug

240V

120V

Tools Needed:

240 V AC

120 V AC 120 V AC

*One 240 V load or two 120 V loads.

Current Available in Amperes

240 V

Receptacle* Each 120 V Duplex

Receptacle

V x A = Watts

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

OM-4430 Page 33

SECTION 8 − MAINTENANCE & TROUBLESHOOTING

8-1. Routine Maintenance

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

!Stop engine before maintaining.

See Engine Manual and Maintenance Label

for important start-up, service, and storage

information. Service engine more often if

used in severe conditions.

Recycle engine

fluids.

 = Check  = Change  = Clean  = Replace

* To be done by Factory Authorized Service Agent Reference

Every

Hours

Section 5-2

 Fuel Level  Oil Level  Oil, Fuel Spills

Every

Hours

Section 8-3,

8-4

 Spark Arrestor Screen  Air Cleaner Wrapper

Every

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  Oil Filter  Fuel Filter

Every

500

Hours

 Weld Cables  Slip Rings*

 Brushes*

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

OM-4430 Page 34

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.

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

OM-4430 Page 35

!Stop engine and let cool.

1 Spark Arrestor Screen

Clean and inspect screen. Replace

spark arrestor if screen wires are

broken or missing.

8-3. Servicing Optional Spark Arrestor

1/4 in

803 983−A / Ref 216 172-D

Tools Needed:

8-4. Servicing Air Cleaner

aircleaner3 11/04 − 802 772 / S-0759

!Stop engine.

NOTICE − Do not run engine with-

out air cleaner or with dirty element.

1 Precleaner

Wash precleaner with soap and wa-

ter solution. Allow precleaner to air

dry completely.

Spread 1 tablespoon SAE 30 oil

evenly into precleaner. Squeeze

out excess oil.

2 Element

Replace element if damaged, dirty,

or oily.

oil

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

OM-4430 Page 36

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

803 983−A / Ref 216 172-D / S-0842

!Stop engine and let cool.

1 Oil Drain Valve

2 Oil Filter

Change engine oil and filter accord-

ing to engine manual.

NOTICE − Close valve and valve

cap before adding oil and running

engine.

Fill crankcase with new oil to full

mark on dipstick (see Section 8-2).

3 Fuel Filter

4 Fuel Line

Replace line if cracked or worn.

Install new filter. Wipe up any spilled

fuel.

Start engine, and check for fuel

leaks.

!Stop engine, tighten connec-

tions as necessary, and wipe

up fuel.

Full

Tools Needed:

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

OM-4430 Page 37

!Stop engine.

Open left side door.

When a supplementary protec-

tor or fuse opens, it usually indi-

cates a more serious problem

exists. Contact a Factory Au-

thorized Service Agent.

1 Supplementary Protector CB4

CB4 protects the stator winding

supplying 24 volt ac output to Re-

mote receptacle RC4. If CB4

opens, 24 volt ac output to RC4

stops.

Supplementary Protector CB3

protect the stator winding sup-

plying 115 volt ac output to Re-

mote Receptacle RC4 (see

Section 7-1).

Press button to reset.

2 Fuse F6 (See Parts List)

F6 protects the engine wiring sys-

tem from overload. If F6 opens,

engine will not crank.

Replace fuse if open.

Close left side door.

803 773−A / Ref. 216 172-D

8-6. Overload Protection

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

OM-4430 Page 38

8-7. Troubleshooting

A. Welding

Trouble Remedy

No weld output. Check weld control settings.

Check weld connections.

Disconnect equipment from generator power receptacles during start-up.

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

6-8).

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

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

Low weld output. Check weld control settings.

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

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

6-8).

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 con-

trol. 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).

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

OM-4430 Page 39

Trouble Remedy

Lack of high frequency; difficulty in

establishing Gas Tungsten Arc Weld-

ing arc.

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 Remedy

No power output at 60 Hz ac recep-

tacles RC1 or RC2. Reset supplementary protectors CB1 and/or CB2 (see Section 7-1).

Stop welding, or place Speed Control switch in Generator Lock position to run engine at 1800 rpm. 60

Hz receptacles RC1 and RC2 work only at 1800 rpm.

Check receptacle wiring and connections.

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

Low power output at 60 Hz ac recep-

tacles 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 recep-

tacles 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 Remedy

No generator power output at ac re-

ceptacle RC3. Reset supplementary protector CB4 (see Section 7-2).

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

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

PC7.

Low generator power output at ac re-

ceptacle RC3. Turn Engine Control switch to Run/Idle 3600/2400 RPM position.

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

OM-4430 Page 40

D. Engine

Trouble Remedy

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

Check battery voltage.

Check battery connections and tighten if necessary.

Check plug PLG5 and plug PLG8 connections.

Have Factory Authorized Service Agent check Engine Control switch S2.

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

Check battery and replace if necessary.

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

Check engine charging system according to engine manual.

See engine manual.

Engine starts but stops when Engine

Control switch returns to either Run/

Idle position.

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 tem-

peratures, 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 peri-

od of time.

During operation in severe cold weath-

er, engine starts and goes to idle but

stalls after a few minutes.

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

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

OM-4430 Page 41

SECTION 9 − PARTS LIST

9-1. Recommended Spare Parts

Description

Part

No.

Dia.

Mkgs.

Recommended Spare Parts

Quantity

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

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

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

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

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

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

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

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

Notes

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 42

SECTION 10 − ELECTRICAL DIAGRAMS

Figure 10-1. Circuit Diagram For Welding Generator Models

OM-4430 Page 43

232 961-A

OM-4430 Page 44

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

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

1 Generator Power Receptacles

− Neutral Bonded To Frame

2 3-Prong Plug From Case

Grounded Equipment

3 2-Prong Plug From Double

Insulated Equipment

Be sure equipment has double

insulated symbol and/or word-

ing on it.

!Do not use 2-prong plug un-

less equipment is double in-

sulated.

!Always ground generator

frame to vehicle frame to pre-

vent electric shock and static

electricity hazards.

!Also see AWS Safety &

Health Fact Sheet No. 29,

Grounding of Portable And

Vehicle Mounted Welding

Generators.

1 Equipment Grounding

Terminal (On Front Panel)

2 Grounding Cable (Not

Supplied)

3 Metal Vehicle Frame

Connect cable from equipment

ground terminal to metal vehicle

frame. Use #10 AWG or larger

insulated copper wire.

Electrically bond generator

frame to vehicle frame by met-

al-to-metal contact.

!Bed liners, shipping skids,

and some running gear insu-

late the welding generator

from the vehicle frame. Al-

ways connect a ground wire

from the generator equip-

ment grounding terminal to

bare metal on the vehicle

frame as shown.

!If unit does not have GFCI re-

ceptacles, use GFCI-pro-

tected extension cord.

11-2. Grounding Generator To Truck Or Trailer Frame

S-0854

GND/PE

OM-4430 Page 45

11-3. Grounding When Supplying Building Systems

ST-800 576-B

1 Equipment Grounding

Terminal

2 Grounding Cable

Use #10 AWG or larger insulated

copper wire.

3 Ground Device

Use ground device as stated in

electrical codes.

!Ground generator to system

earth ground if supplying

power to a premises (home,

shop, farm) wiring system.

!Also see AWS Safety &

Health Fact Sheet No. 29,

Grounding of Portable And

Vehicle Mounted Welding

Generators.

GND/PE

1 2

11-4. How Much Power Does Equipment Require?

S-0623

1 Resistive Load

A light bulb is a resistive load and

requires a constant amount of power.

2 Non-Resistive Load

Equipment with a motor is a non-re-

sistive load and requires approxi-

mately six times more power while

starting the motor than when running

(see Section 11-8).

3 Rating Data

Rating shows volts and amperes, or

watts required to run equipment.

Amperes x Volts = Watts

Example 1: If a drill uses 4.5 am-

peres at 115 volts, calculate its run-

ning 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 Ex-

ample 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.

VOLTS 115

4.5

AMPS

OM-4430 Page 46

11-5. Approximate Power Requirements For Industrial Motors

Industrial Motors Rating Starting Watts Running Watts

Split Phase 1/8 HP 800 300

1/6 HP 1225 500

1/4 HP 1600 600

1/3 HP 2100 700

1/2 HP 3175 875

Capacitor Start-Induction Run 1/3 HP 2020 720

1/2 HP 3075 975

3/4 HP 4500 1400

1 HP 6100 1600

1-1/2 HP 8200 2200

2 HP 10550 2850

3 HP 15900 3900

5 HP 23300 6800

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

5 HP 23300 6000

7-1/2 HP 35000 8000

10 HP 46700 10700

Fan Duty 1/8 HP 1000 400

1/6 HP 1400 550

1/4 HP 1850 650

1/3 HP 2400 800

1/2 HP 3500 1100

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

Farm/Home Equipment Rating Starting Watts Running Watts

Stock Tank De-Icer 1000 1000

Grain Cleaner 1/4 HP 1650 650

Portable Conveyor 1/2 HP 3400 1000

Grain Elevator 3/4 HP 4400 1400

Milk Cooler 2900 1100

Milker (Vacuum Pump) 2 HP 10500 2800

FARM DUTY MOTORS 1/3 HP 1720 720

Std. (e.g. Conveyors, 1/2 HP 2575 975

Feed Augers, Air 3/4 HP 4500 1400

Compressors) 1 HP 6100 1600

1-1/2 HP 8200 2200

2 HP 10550 2850

3 HP 15900 3900

5 HP 23300 6800

High Torque (e.g. Barn 1-1/2 HP 8100 2000

Cleaners, Silo Unloaders, 5 HP 23300 6000

Silo Hoists, Bunk Feeders) 7-1/2 HP 35000 8000

10 HP 46700 10700

3-1/2 cu. ft. Mixer 1/2 HP 3300 1000

High Pressure 1.8 Gal/Min 500 PSI 3150 950

Washer 2 gal/min 550 PSI 4500 1400

2 gal/min 700 PSI 6100 1600

Refrigerator or Freezer 3100 800

Shallow Well Pump 1/3 HP 2150 750

1/2 HP 3100 1000

Sump Pump 1/3 HP 2100 800

1/2 HP 3200 1050

OM-4430 Page 47

11-7. Approximate Power Requirements For Contractor Equipment

Contractor Rating Starting Watts Running Watts

Hand Drill 1/4 in 350 350

3/8 in 400 400

1/2 in 600 600

Circular Saw 6-1/2 in 500 500

7-1/4 in 900 900

8-1/4 in 1400 1400

Table Saw 9 in 4500 1500

10 in 6300 1800

Band Saw 14 in 2500 1100

Bench Grinder 6 in 1720 720

8 in 3900 1400

10 in 5200 1600

Air Compressor 1/2 HP 3000 1000

1 HP 6000 1500

1-1/2 HP 8200 2200

2 HP 10500 2800

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

2 HP, 14 in 1100 1100

Electric Trimmer Standard 9 in 350 350

Heavy Duty 12 in 500 500

Electric Cultivator 1/3 HP 2100 700

Elec. Hedge Trimmer 18 in 400 400

Flood Lights HID 125 100

Metal Halide 313 250

Mercury 1000

Sodium 1400

Vapor 1250 1000

Submersible Pump 400 gph 600 200

Centrifugal Pump 900 gph 900 500

Floor Polisher 3/4 HP, 16 in 4500 1400

1 HP, 20 in 6100 1600

High Pressure Washer 1/2 HP 3150 950

3/4 HP 4500 1400

1 HP 6100 1600

55 gal Drum Mixer 1/4 HP 1900 700

Wet & Dry Vac 1.7 HP 900 900

2-1/2 HP 1300 1300

OM-4430 Page 48

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

S-0624

1 Motor Start Code

2 Running Amperage

3 Motor HP

4 Motor Voltage

To find starting amperage:

Step 1: Find code and use table to

find kVA/HP. If code is not listed,

multiply running amperage by six to

find starting amperage.

Step 2: Find Motor HP and Volts.

Step 3: Determine starting amper-

age (see example).

Welding generator amperage out-

put must be at least twice the

motor’s running amperage.

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

Starting Amperage

Example: Calculate starting amper-

age required for a 230 V, 1/4 HP mo-

tor 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.

VOLTS AMPS

230 2.5

1/4

PHASE

CODE 60

AC MOTOR

11-9. How Much Power Can Generator Supply?

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

1 Limit Load To 90% Of

Generator Output

Always start non-resistive (motor)

loads in order from largest to small-

est, and add resistive loads last.

2 5 Second Rule

If motor does not start within 5

seconds, turn off power to prevent

motor damage. Motor requires

more power than generator can

supply.

OM-4430 Page 49

11-10. Typical Connections To Supply Standby Power

Transfer Switch

Essential

Loads

Fused

Disconnect

Switch

(If Required)

Utility

Electrical

Service

1234

Welding

Generator

Output

!Have only qualified persons

perform these connections

according to all applicable

codes and safety practices.

!Properly install and ground

this equipment according to

its Owner’s Manual and na-

tional, state, and local codes.

Customer-supplied equipment

is required if generator will sup-

ply standby power during

emergencies or power out-

ages.

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 re-

stored.

Install correct switch (customer-

supplied). Switch rating must be

same as or greater than the branch

overcurrent protection.

3 Fused Disconnect Switch

Install correct switch (customer-

supplied) if required by electrical

code.

4 Welding Generator Output

Generator output voltage and wir-

ing must be consistent with regular

(utility) system voltage and wiring.

Connect generator with temporary

or permanent wiring suitable for the

installation.

Turn off or unplug all equipment

connected to generator before

starting or stopping engine. When

starting or stopping, the engine has

low speed which causes low volt-

age and frequency.

5 Essential Loads

Generator output may not meet the

electrical requirements of the prem-

ises. If generator does not produce

enough output to meet all require-

ments, connect only essential

loads (pumps, freezers, heaters,

etc. − See Section 11-4).

OM-4430 Page 50

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) 4 6 8 10 12 14

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

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

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

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

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

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

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

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

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

45 5400 100 (30) 62 (19)

50 6000 87 (26) 50 (15)

*Conductor size is based on maximum 2% voltage drop

Cord Lengths for 240 Volt Loads

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

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

Current

(Amperes) Load (Watts) 4 6 8 10 12 14

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

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

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

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

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

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

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

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

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

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

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

*Conductor size is based on maximum 2% voltage drop

OM-4430 Page 51

Notes

SOCKET/WRENCH SELECTION TABLE

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

(METRIC)

Specifications Socket or Wrench Size 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 52

Notes

Welding Symbols

Ref. AWS/ANSI A2.4

Warranty Questions?

Call

1-800-4-A-MILLER

for your local

Miller distributor.

miller_warr 2007−01

Your distributor also gives

you ...

Service

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reliable response you

need. Most replacement

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hands in 24 hours.

Support

Need fast answers to the

tough welding questions?

Contact your distributor.

The expertise of the

distributor and Miller is

there to help you, every

step of the way.

Effective January 1, 2007

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

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

guarantees or warranties expressed or implied.

LIMITED WARRANTY − Subject to the terms and conditions

below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to

its original retail purchaser that new Miller equipment sold after

the effective date of this limited warranty is free of defects in

material and workmanship at the time it is shipped by Miller. THIS

WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER

WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE

WARRANTIES OF MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Miller will repair or

replace any warranted parts or components that fail due to such

defects in material or workmanship. Miller must be notified in

writing within thirty (30) days of such defect or failure, at which

time Miller will provide instructions on the warranty claim

procedures to be followed.

Miller shall honor warranty claims on warranted equipment listed

below in the event of such a failure within the warranty time

periods. All warranty time periods start on the delivery date of the

equipment to the original end-user purchaser, and not to exceed

one year after the equipment is shipped to a North American

distributor or eighteen months after the equipment is shipped to

an International distributor.

1. 5 Years Parts — 3 Years Labor

* Original main power rectifiers

2. 3 Years — Parts and Labor

* Transformer/Rectifier Power Sources

* Plasma Arc Cutting Power Sources

* Process Controllers

* Semi-Automatic and Automatic Wire Feeders

* Inverter Power Sources (Unless Otherwise Stated)

* Water Coolant Systems (Integrated)

* Intellitig

* Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the

engine manufacturer.)

3. 1 Year — Parts and Labor Unless Specified

* Motor Driven Guns (w/exception of Spoolmate

Spoolguns)

* Positioners and Controllers

* Automatic Motion Devices

* RFCS Foot Controls

* Induction Heating Power Sources, Coolers, and

Electronic

Controls/Recorders

* Water Coolant Systems (Non-Integrated)

* Flowgauge and Flowmeter Regulators (No Labor)

* HF Units

* Grids

* Spot Welders

* Load Banks

* Arc Stud Power Sources & Arc Stud Guns

* Racks

* Running Gear/Trailers

* Plasma Cutting Torches (except APT & SAF

Models)

* Field Options

(NOTE: Field options are covered under True Blue®

for the remaining warranty period of the product they

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

whichever is greater.)

* Bernard-Branded Mig Guns (No Labor)

* Weldcraft-Branded TIG Torches (No Labor)

* Subarc Wire Drive Assemblies

4. 6 Months — Batteries

5. 90 Days — Parts

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

* Induction Heating Coils and Blankets, Cables, and

Non-Electronic Controls

* APT & SAF Model Plasma Cutting Torches

* Remote Controls

* Accessory (Kits)

* Replacement Parts (No labor)

* Spoolmate Spoolguns

* Canvas Covers

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

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, slip rings, relays

or parts that fail due to normal wear. (Exception:

brushes, slip rings, and relays are covered on Bobcat,

Trailblazer, and Legend models.)

2. Items furnished by Miller, but manufactured by others, such

as engines or trade accessories. These items are covered

by the manufacturer’s warranty, if any.

3. Equipment that has been modified by any party other than

Miller, or equipment that has been improperly installed,

improperly operated or misused based upon industry

standards, or equipment which has not had reasonable and

necessary maintenance, or equipment which has been

used for operation outside of the specifications for the

equipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND

USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS

TRAINED AND EXPERIENCED IN THE USE AND

MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the

exclusive remedies shall be, at Miller’s option: (1) repair; or (2)

replacement; or, where authorized in writing by Miller in

appropriate cases, (3) the reasonable cost of repair or

replacement at an authorized Miller service station; or (4)

payment of or credit for the purchase price (less reasonable

depreciation based upon actual use) upon return of the goods at

customer’s risk and expense. Miller’s option of repair or

replacement will be F.O.B., Factory at Appleton, Wisconsin, or

F.O.B. at a Miller authorized service facility as determined by

Miller. Therefore no compensation or reimbursement for

transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES

PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE

REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR

DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR

CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF

PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY

OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND

ANY IMPLIED WARRANTY, GUARANTY OR

REPRESENTATION AS TO PERFORMANCE, AND ANY

REMEDY FOR BREACH OF CONTRACT TORT OR ANY

OTHER LEGAL THEORY WHICH, BUT FOR THIS

PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION

OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,

INCLUDING ANY IMPLIED WARRANTY OF

MERCHANTABILITY OR FITNESS FOR PARTICULAR

PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT

FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED

BY MILLER.

Some states in the U.S.A. do not allow limitations of how long an

implied warranty lasts, or the exclusion of incidental, indirect,

special or consequential damages, so the above limitation or

exclusion may not apply to you. This warranty provides specific

legal rights, and other rights may be available, but may vary from

state to state.

In Canada, legislation in some provinces provides for certain

additional warranties or remedies other than as stated herein,

and to the extent that they may not be waived, the limitations and

exclusions set out above may not apply. This Limited Warranty

provides specific legal rights, and other rights may be available,

but may vary from province to province.

Miller Electric Mfg. Co.

An Illinois Tool Works Company

1635 West Spencer Street

Appleton, WI 54914 USA

International Headquarters−USA

USA Phone: 920-735-4505 Auto-Attended

USA & Canada FAX: 920-735-4134

International FAX: 920-735-4125

European Headquarters −

United Kingdom

Phone: 44 (0) 1204-593493

FAX: 44 (0) 1204-598066

www.MillerWelds.com

Model Name Serial/Style Number

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

Distributor

Address

City

State Zip

Please complete and retain with your personal records.

Always provide Model Name and Serial/Style Number.

Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Welding Supplies and Consumables

Options and Accessories

Personal Safety Equipment

Service and Repair

Replacement Parts

Training (Schools, Videos, Books)

Technical Manuals (Servicing Information

and Parts)

Circuit Diagrams

Welding Process Handbooks

Contact the Delivering Carrier to:

For Service

Owner’s Record

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.

Contact your Distributor for:

To locate a Distributor or Service Agency visit

www.millerwelds.com or call 1-800-4-A-Miller

Miller Electric 280 Nt Users Manual O4430r(ECO806)

280 NT to the manual b860b762-6ce5-4af0-8a92-75cde2fadb06

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