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OM-404

April 2002

175 611T

Processes
Stick (SMAW) Welding MIG (GMAW) Welding Flux Cored (FCAW) Welding Non-Critical TIG (GTAW) Welding

Description

Engine Driven Welding Generator

Bobcat 225D

Visit our website at

www.MillerWelds.com

From Miller to You


Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you dont have time to do it any other way. Thats 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 couldnt 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. Theyre just as committed to providing equipment and service that meets the high standards of quality and value established in 1929. This Owners 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. Weve 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, theres a Troubleshooting section that will help you figure out what the problem is. The Miller is the first welding parts list will then help you to decide the equipment manufacturer in exact part you may need to fix the problem. the U.S.A. to be registered to the ISO 9001 Quality System Warranty and service information for your Standard. particular model are also provided.
Working as hard as you do every power source from Miller is backed by the most hassle-free warranty in the business.

Miller offers a Technical Manual which provides more detailed service and parts information for your unit. To obtain a Technical Manual, contact your local distributor. Your distributor can also supply you with Welding Process Manuals such as SMAW, GTAW, GMAW, and GMAW-P.

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 orindividual catalog 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.

TABLE OF CONTENTS
SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . 1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 1 CONSIGNES DE SCURIT LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . 1-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Dangers relatifs au soudage larc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. Principales normes de scurit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6. Information sur les champs lectromagntiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 2 DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 3 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Weld, Power, and Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Dimensions, Weights, and Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3. Auxiliary Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5. Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3. Activating The Dry Charge Battery (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 5 OPERATING WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 6 OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. Standard Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2. CSA Receptacle Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3. GFCI, South African, And Australian Auxiliary Power Receptacle Options . . . . . . . . . . . . . . 6-4. Wiring Optional 120/240 Volt Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 7 MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3. Inspecting And Cleaning Optional Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4. Changing Engine Oil, Oil Filter, And Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 8 ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 9 GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 10 RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 11 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPTIONS AND ACCESSORIES WARRANTY 1 1 1 2 3 4 4 5 5 5 6 7 8 8 9 9 9 9 10 10 10 11 11 12 12 13 14 15 15 16 17 17 18 18 19 20 21 22 22 24 25 26 27 27 29 31 32 39 39 40 41 42

WARNING
This product, when used for welding or cutting, 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.)

WARNING
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.

CALIFORNIA Proposition 65 Warning


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

The following terms are used interchangeably throughout this manual: TIG = GTAW Stick = SMAW

SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING


rom _nd_11/98

1-1. Symbol Usage


Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards.

. Means Note; not safety related. 1-2. Arc Welding Hazards


Y 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 1-5. Read and follow all Safety Standards. Y Only qualified persons should install, operate, maintain, and repair this unit. Y During operation, keep everybody, especially children, away.

D Wear a safety harness if working above floor level. D Keep all panels and covers securely in place. D Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical. D Insulate work clamp when not connected to workpiece to prevent contact with any metal object. D Do not connect more than one electrode or work cable to any single weld output terminal.

ELECTRIC SHOCK can kill.


Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard. D Do not touch live electrical parts. D Wear dry, hole-free insulating gloves and body protection. D Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. D Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling. D Use AC output ONLY if required for the welding process. D If AC output is required, use remote output control if present on unit. D Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards). D Properly install and ground this equipment according to its Owners Manual and national, state, and local codes. D Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet. D When making input connections, attach proper grounding conductor first double-check connections. D Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill. D Turn off all equipment when not in use. D Do not use worn, damaged, undersized, or poorly spliced cables. D Do not drape cables over your body. D If earth grounding of the workpiece is required, ground it directly with a separate cable. D Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine. D Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual.

SIGNIFICANT DC VOLTAGE exists after stopping engine on inverters.


D Stop engine on inverter and discharge input capacitors according to instructions in Maintenance Section before touching any parts.

ARC RAYS can burn eyes and skin.


Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. Wear a welding helmet fitted with a proper shade of filter 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 and glare; warn others not to watch the arc. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection.

D D D D

FUMES AND GASES can be hazardous.


Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases. D If ventilation is poor, use an approved air-supplied respirator. D Read the Material Safety Data Sheets (MSDSs) and the manufacturers instructions for metals, consumables, coatings, cleaners, and degreasers. D Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe. D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases. D Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded. OM-404 Page 1

WELDING can cause fire or explosion.


Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding. D Protect yourself and others from flying sparks and hot metal. D Do not weld where flying sparks can strike flammable material. D Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. D Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. D Watch for fire, and keep a fire extinguisher nearby. D Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side. D Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared according to AWS F4.1 (see Safety Standards). D 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 and fire hazards. D Do not use welder to thaw frozen pipes. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use. D Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. D Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding.

HOT PARTS can cause severe burns.


D Allow cooling period before maintaining. D Wear protective gloves and clothing when working on a hot engine. D Do not touch hot engine parts or just-welded parts bare-handed.

NOISE can damage hearing.


Noise from some processes or equipment can damage hearing. D Wear approved ear protection if noise level is high.

MAGNETIC FIELDS can affect pacemakers. D Pacemaker wearers keep away. D Wearers should consult their doctor before going near arc welding, gouging, or spot welding operations.

CYLINDERS can explode if damaged.


Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully. D Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs. D Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping.

FLYING METAL can injure eyes.


D Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag. D Wear approved safety glasses with side shields even under your welding helmet.

D Keep cylinders away from any welding or other electrical circuits. D Never drape a welding torch over a gas cylinder. D Never allow a welding electrode to touch any cylinder. D Never weld on a pressurized cylinder explosion will result. D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition. D Turn face away from valve outlet when opening cylinder valve. D Keep protective cap in place over valve except when cylinder is in use or connected for use. D Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards.

BUILDUP OF GAS can injure or kill.


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

1-3. Engine Hazards


FUEL can cause fire or explosion.
D Stop engine and let it cool off before checking or adding fuel. D Do not add fuel while smoking or if unit is near any sparks or open flames.

STEAM AND HOT COOLANT can burn.


D If possible, check coolant level when engine is cold to avoid scalding. D Always check coolant level at overflow tank, if present on unit, instead of radiator (unless told otherwise in maintenance section or engine manual). D If the engine is warm, checking is needed, and there is no overflow tank, follow the next two statements. D Wear safety glasses and gloves and put a rag over radiator cap. D Turn cap slightly and let pressure escape slowly before completely removing cap.

D Do not overfill tank allow room for fuel to expand. D Do not spill fuel. If fuel is spilled, clean up before starting engine. D Dispose of rags in a fireproof container. OM-404 Page 2

MOVING PARTS can cause injury.


D Keep away from fans, belts, and rotors. D Keep all doors, panels, covers, and guards closed and securely in place. D Stop engine before installing or connecting unit. D Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary. D To prevent accidental starting during servicing, disconnect negative () battery cable from battery. D Keep hands, hair, loose clothing, and tools away from moving parts. D Reinstall panels or guards and close doors when servicing is finished and before starting engine. D Before working on generator, remove spark plugs or injectors to keep engine from kicking back or starting. D Block flywheel so that it will not turn while working on generator components.

BATTERY ACID can BURN SKIN and EYES.


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

ENGINE EXHAUST GASES can kill.


D Use equipment outside in open, well-ventilated areas. D If used in a closed area, vent engine exhaust outside and away from any building air intakes.

ENGINE HEAT can cause fire.


D Do not locate unit on, over, or near combustible surfaces or flammables. D Keep exhaust and exhaust pipes way from flammables.

BATTERY EXPLOSION can BLIND.


D Always wear a face shield, rubber gloves, and protective clothing when working on a battery. D Stop engine before disconnecting or connecting battery cables or servicing battery. D D D D 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.

EXHAUST SPARKS can cause fire.


D Do not let engine exhaust sparks cause fire. D Use approved engine exhaust spark arrestor in required areas see applicable codes.

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

FALLING UNIT can cause injury.


D Use lifting eye to lift unit only, NOT running gear, gas cylinders, trailer, or any other accessories. D Use equipment of adequate capacity to lift and support unit. D If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.

OVERUSE can cause OVERHEATING.


D Allow cooling period; follow rated duty cycle. D Reduce current or reduce duty cycle before starting to weld again. D Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.


D Put on grounded wrist strap BEFORE handling boards or parts. D Use proper static-proof bags and boxes to store, move, or ship PC boards.

FLYING SPARKS can cause injury.


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

TILTING OF TRAILER can cause injury.


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

OVERHEATING can damage motors.


D Turn off or unplug equipment before starting or stopping engine. D Do not let low voltage and frequency caused by low engine speed damage electric motors. D Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable.

READ INSTRUCTIONS.
D Use only genuine MILLER replacement parts. D Perform engine maintenance and service according to this manual and the engine manual. OM-404 Page 3

H.F. RADIATION can cause interference.


D High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. D Have only qualified persons familiar with electronic equipment perform this installation. 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.


D Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer-driven equipment such as robots. D Be sure all equipment in the welding area is electromagnetically compatible. To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor. Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area.

D D D D

D D D D

1-5. Principal Safety Standards


Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402. Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American Welding Society Standard AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202. Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3. Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018. Cutting And Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

1-6. EMF Information


Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the National Research Council concluded that: The body of evidence, in the committees judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard. However, studies are still going forth and evidence continues to be examined. Until the final conclusions of the research are reached, you may wish to minimize your exposure to electromagnetic fields when welding or cutting. To reduce magnetic fields in the workplace, use the following procedures: 1. Keep cables close together by twisting or taping them. 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 Pacemakers: Pacemaker wearers consult your doctor first. If cleared by your doctor, then following the above procedures is recommended.

OM-404 Page 4

SECTION 1 CONSIGNES DE SCURIT LIRE AVANT UTILISATION


rom _nd_fre 11/98

1-1. Signification des symboles


Signifie Mise en garde ! Soyez vigilant ! Cette procdure prsente des risques de danger ! Ceux-ci sont identifis par des symboles adjacents aux directives.
Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des risques de danger relis aux CHOCS LECTRIQUES, aux PICES EN MOUVEMENT et aux PICES CHAUDES. Reportez-vous aux symboles et aux directives ci-dessous afin de connatre les mesures prendre pour viter tout danger.

Y Identifie un message de scurit particulier.

. Signifie NOTA ; nest pas relatif la scurit. 1-2. Dangers relatifs au soudage larc
Y Les symboles prsents ci-aprs sont utiliss tout au long du prsent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez vigilant et suivez les directives mentionnes afin dviter tout danger. Les consignes de scurit prsentes ci-aprs ne font que rsumer linformation contenue dans les normes de scurit numres la section 1-5. Veuillez lire et respecter toutes ces normes de scurit. Y Linstallation, lutilisation, lentretien et les rparations ne doivent tre confis qu des personnes qualifies. Y Au cours de lutilisation, tenir toute personne lcart et plus particulirement les enfants.

D D D D D

Nutiliser quun matriel en bon tat. Rparer ou remplacer sur-le-champ les pices endommages. Entretenir lappareil conformment ce manuel. Porter un harnais de scurit quand on travaille en hauteur. Maintenir solidement en place tous les panneaux et capots. Fixer le cble de retour de faon obtenir un bon contact mtal-mtal avec la pice souder ou la table de travail, le plus prs possible de la soudure. Isoler la pince de masse quand pas mis la pice pour viter le contact avec tout objet mtallique.

Une tension DC importante subsiste lintrieur des onduleurs aprs avoir coup lalimentation.
D Couper lalimentation du poste et dcharger les condensateurs dentre comme indiqu dans la Section Maintenance avant de toucher des composants.

UN CHOC LECTRIQUE peut tuer.


Un simple contact avec des pices lectriques peut provoquer une lectrocution ou des blessures graves. Llectrode et le circuit de soudage sont sous tension ds que lappareil est sur ON. Le circuit dentre et les circuits internes de lappareil sont galement sous tension ce moment-l. En soudage semi-automatique ou automatique, le fil, le dvidoir, le logement des galets dentranement et les pices mtalliques en contact avec le fil de soudage sont sous tension. Des matriels mal installs ou mal mis la terre prsentent un danger. D D D D D D D D D Ne jamais toucher les pices lectriques sous tension. Porter des gants et des vtements de protection secs ne comportant pas de trous. Sisoler de la pice et de la terre au moyen de tapis ou dautres moyens isolants suffisamment grands pour empcher le contact physique ventuel avec la pice ou la terre. Ne pas se servir de source lectrique courant lectrique dans les zones humides, dans les endroits confins ou l o on risque de tomber. Se servir dune source lectrique courant lectrique UNIQUEMENT si le procd de soudage le demande. Si lutilisation dune source lectrique courant lectrique savre ncessaire, se servir de la fonction de tlcommande si lappareil en est quip. Couper lalimentation ou arrter le moteur avant de procder linstallation, la rparation ou lentretien de lappareil. Dverrouiller lalimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de scurit). Installer et mettre la terre correctement cet appareil conformment son manuel dutilisation et aux codes nationaux, provinciaux et municipaux. Toujours vrifier la terre du cordon dalimentation Vrifier et sassurer que le fil de terre du cordon dalimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccorde une prise correctement mise la terre. En effectuant les raccordements dentre fixer dabord le conducteur de mise la terre appropri et contre-vrifier les connexions. Vrifier frquemment le cordon dalimentation pour voir sil nest pas endommag ou dnud remplacer le cordon immdiatement sil est endommag un cble dnud peut provoquer une lectrocution. Mettre lappareil hors tension quand on ne lutilise pas. Ne pas utiliser des cbles uss, endommags, de grosseur insuffisante ou mal pisss. Ne pas enrouler les cbles autour du corps. Si la pice soude doit tre mise la terre, le faire directement avec un cble distinct ne pas utiliser le connecteur de pice ou le cble de retour. Ne pas toucher llectrode quand on est en contact avec la pice, la terre ou une lectrode provenant dune autre machine. D D D D D D

LES RAYONS DE LARC peuvent provoquer des brlures dans les yeux et sur la peau.
Le rayonnement de larc du procd de soudage gnre des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brlures dans les yeux et sur la peau. Des tincelles sont projetes pendant le soudage. D D D D Porter un casque de soudage muni dun cran de filtre appropri pour protger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.1 numr dans les normes de scurit). Porter des protections approuvs pour les oreilles si le niveau sondre est trop lev. Utiliser des crans ou des barrires pour protger des tiers de lclair et de lblouissement; demander aux autres personnes de ne pas regarder larc. Porter des vtements de protection constitu dans une matire durable, rsistant au feu (laine ou cuir) et une protection des pieds.

LES FUMES ET LES GAZ peuvent tre dangereux.


Le soudage gnre des fumes et des gaz. Leur inhalation peut tre dangereux pour votre sant. Eloigner votre tte des fumes. Ne pas respirer les fumes. linterieur, ventiler la zone et/ou utiliser un chappement au niveau de larc pour lvacuation des fumes et des gaz de soudage. Si la ventilation est insuffisante, utiliser un respirateur alimentation dair homologu. Lire les spcifications de scurit des matriaux (MSDSs) et les instructions du fabricant concernant les mtaux, les consommables, les revtements, les nettoyants et les dgraisseurs. Travailler dans un espace ferm seulement sil est bien ventil ou en portant un respirateur alimentation dair. Demander toujours un surveillant dment form de se tenir proximit. Des fumes et des gaz de soudage peuvent dplacer lair et abaisser le niveau doxygne provoquant des blessures ou des accidents mortels. Sassurer que lair de respiration ne prsente aucun danger. Ne pas souder dans des endroits situs proximit doprations de dgraissage, de nettoyage ou de pulvrisation. La chaleur et les rayons de larc peuvent ragir en prsence de vapeurs et former des gaz hautement toxiques et irritants. Ne pas souder des mtaux munis dun revtement, tels que lacier galvanis, plaqu en plomb ou au cadmium moins que le revtement nait t enlev dans la zone de soudure, que lendroit soit bien ventil, et si ncessaire, en portant un respirateur alimentation dair. Les revtements et tous les mtaux renfermant ces lments peuvent dgager des fumes toxiques en cas de soudage.

D D D D D D D

OM-404 Page 5

LE SOUDAGE peut provoquer un incendie ou une explosion.


Le soudage effectu sur des conteneurs ferms tels que des rservoirs, tambours ou des conduites peut provoquer leur clatement. Des tincelles peuvent tre projetes de larc de soudure. La projection dtincelles, des pices chaudes et des quipements chauds peut provoquer des incendies et des brlures. Le contact accidentel de llectrode avec des objets mtalliques peut provoquer des tincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vrifier et sassurer que lendroit ne prsente pas de danger. D D D D D D D D Se protger et dautres personnes de la projection dtincelles et de mtal chaud. Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables. Dplacer toutes les substances inflammables une distance de 10,7 m de larc de soudage. En cas dimpossibilit les recouvrir soigneusement avec des protections homologus. Des tincelles et des matriaux chauds du soudage peuvent facilement passer dans dautres zones en traversant de petites fissures et des ouvertures. Surveiller tout dclenchement dincendie et tenir un extincteur proximit. Le soudage effectu sur un plafond, plancher, paroi ou sparation peut dclencher un incendie de lautre ct. Ne pas effectuer le soudage sur des conteneurs ferms tels que des rservoirs, tambours, ou conduites, moins quils naient t prpars correctement conformment AWS F4.1 (voir les normes de scurit). Brancher le cble sur la pice le plus prs possible de la zone de soudage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provoquant des risques dlectrocution et dincendie. Ne pas utiliser le poste de soudage pour dgeler des conduites geles. En cas de non utilisation, enlever la baguette dlectrode du porte-lectrode ou couper le fil la pointe de contact. Porter des vtements de protection dpourvus dhuile tels que des gants en cuir, une chemise en matriau lourd, des pantalons sans revers, des chaussures hautes et un couvre chef. Avant de souder, retirer toute substance combustible de vos poches telles quun allumeur au butane ou des allumettes. D

DES PICES CHAUDES peuvent provoquer des brlures graves.


Prvoir une priode de refroidissement avant deffectuer des travaux dentretien. D Porter des gants et des vtements de protection pour travailler sur un moteur chaud. Ne pas toucher mains nues les parties chaudes du moteur ni les pices rcemment soudes. D

LE BRUIT peut affecter loue.


Le bruit des processus et des quipements peut affecter loue. D Porter des protections approuvs pour les oreilles si le niveau sondre est trop lev.

LES CHAMPS MAGNTIQUES peuvent affecter les stimulateurs cardiaques.


D D Porteurs de stimulateur cardiaque, restez distance. Les porteurs dun stimulateur cardiaque doivent dabord consulter leur mdecin avant de sapprocher des oprations de soudage larc, de gougeage ou de soudage par points.

D D D D

Si des BOUTEILLES sont endommages, elles pourront exploser.


Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endommage, elle peut exploser. Du fait que les bouteilles de gaz font normalement partie du procd de soudage, les manipuler avec prcaution. Protger les bouteilles de gaz comprim dune chaleur excessive, des chocs mcaniques, du laitier, des flammes ouvertes, des tincelles et des arcs. Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empcher de tomber ou de se renverser. Tenir les bouteilles loignes des circuits de soudage ou autres circuits lectriques. Ne jamais placer une torche de soudage sur une bouteille gaz. Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille. Ne jamais souder une bouteille pressurise risque dexplosion. Utiliser seulement des bouteilles de gaz protecteur, rgulateurs, tuyaux et raccords convenables pour cette application spcifique; les maintenir ainsi que les lments associs en bon tat. Ne pas tenir la tte en face de la sortie en ouvrant la soupape de la bouteille. Maintenir le chapeau de protection sur la soupape, sauf en cas dutilisation ou de branchement de la bouteille. Lire et suivre les instructions concernant les bouteilles de gaz comprim, les quipements associs et les publication P-1 CGA numres dans les normes de scurit.

DES PARTICULES VOLANTES peuvent blesser les yeux.


D Le soudage, lcaillement, le passage de la pice la brosse en fil de fer, et le meulage gnrent des tincelles et des particules mtalliques volantes. Pendant la priode de refroidissement des soudures, elles risquent de projeter du laitier.
D Porter des lunettes de scurit avec crans latraux ou un cran facial.

D D D D D

LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou mme la mort.


Fermer lalimentation du gaz protecteur en cas de non utilisation. Veiller toujours bien arer les espaces confins ou se servir dun respirateur dadduction dair homologu. D

D D D

1-3. Dangers existant en relation avec le moteur


LE CARBURANT MOTEUR peut provoquer un incendie ou une explosion.
Arrter le moteur avant de vrifier le niveau de carburant ou de faire le plein. D Ne pas faire le plein en fumant ou proche dune source dtincelles ou dune flamme nue. Ne pas faire le plein de carburant ras bord; prvoir de lespace pour son expansion. Faire attention de ne pas renverser de carburant. Nettoyer tout carburant renvers avant de faire dmarrer le moteur. Jeter les chiffons dans un rcipient ignifuge. D

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


Il est prfrable de vrifier le liquide de refroidissement une fois le moteur refroidi pour viter de se brler. Toujours vrifier le niveau de liquide de refroidissement dans le vase dexpansion (si prsent), et non dans le radiateur (sauf si prcis autrement dans la section maintenance du manuel du moteur). Si le moteur est chaud et que le liquide doit tre vrifi, oprer comme suivant : Mettre des lunettes de scurit et des gants, placer un torchon sur le bouchon du radiateur. Dvisser le bouchon lgrement et laisser la vapeur schapper avant denlever le bouchon. D

D D D D

D D D

OM-404 Page 6

DES ORGANES MOBILES peuvent provoquer des blessures.


Ne pas approcher les mains des ventilateurs, courroies et autres pices en mouvement. D Maintenir ferms et fixement en place les portes, panneaux, recouvrements et dispositifs de protection. Arrter le moteur avant dinstaller ou brancher lappareil. Demander seulement un personnel qualifi denlever les dispositifs de scurit ou les recouvrements pour effectuer, sil y a lieu, des travaux dentretien et de dpannage. Pour empcher tout dmarrage accidentel pendant les travaux dentretien, dbrancher le cble ngatif () de batterie de la borne. Ne pas approcher les mains, cheveux, vtements lches et outils des organes mobiles. Remettre en place les panneaux ou les dipositifs de protection et fermer les portes la fin des travaux dentretien et avant de faire dmarrer le moteur. Avant dintervenir, dposer les bougies ou injecteurs pour viter la mise en route accidentelle du moteur. Bloquer le volant moteur pour viter sa rotation lors dune intervention sur le gnrateur. D

LACIDE DE LA BATTERIE peut provoquer des brlures dans les YEUX et sur la PEAU.
D D D Ne pas renverser la batterie. Remplacer une batterie endommage. Rincer immdiatement les yeux et la peau leau.

D D D D D D D

LES GAZ DCHAPPEMENT DU MOTEUR peuvent provoquer des accidents mortels.


Utiliser lquipement lextrieur dans des zones ouvertes et bien ventiles. En cas dutilisation dans un endroit ferm vacuer les gaz dchappement du moteur vers lextrieur distance des entres dair dans les btiments. D

LEXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE.


Toujours porter une protection faciale, des gants en caoutchouc et vtements de protection lors dune intervention sur la batterie. Arrter le moteur avant de dbrancher ou de brancher les cbles de batterie. Eviter de provoquer des tincelles avec les outils en travaillant sur la batterie. Ne pas utiliser le poste de soudage pour charger les batteries ou des vhicules de dmarrage rapide. Observer la polarit correcte (+ et ) sur les batteries. Dbrancher le cble ngatif () en premier lieu. Le rebrancher en dernier lieu. D

LA CHALEUR DU MOTEUR peut provoquer un incendie.


D D Ne pas placer lappareil sur, au-dessus ou proximit de surfaces inflammables. Tenir distance les produits inflammables de lchappement.

D D D D D

LES TINCELLES LCHAPPEMENT peuvent provoquer un incendie.


D D Empcher les tincelles dchappement du moteur de provoquer un incendie. Utiliser uniquement un pare-tincelles approuv voir codes en vigueur.

1-4. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance


LA CHUTE DE LAPPAREIL peut blesser.
D D D Utiliser lanneau de levage uniquement pour soulever lappareil lui-mme ; sans chariot, de bouteilles de gaz, remorque, ou autres accessoires. Utiliser un quipement de levage de capacit suffisante pour lever lappareil.

LEMPLOI EXCESSIF peut SURCHAUFFER LQUIPEMENT.


D D D Laisser lquipement refroidir ; respecter le facteur de marche nominal. Rduire le courant ou le facteur de marche avant de poursuivre le soudage. Ne pas obstruer les passages dair du poste.

En utilisant des fourches de levage pour dplacer lunit, sassurer que les fourches sont suffisamment longues pour dpasser du ct oppos de lappareil.

LES TINCELLES VOLANTES risquent de provoquer des blessures.


D D Porter un cran facial pour protger le visage et les yeux.

LES CHARGES LECTROSTATIQUES peuvent endommager les circuits imprims.


D D tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pices. Utiliser des pochettes et des botes antistatiques pour stocker, dplacer ou expdier des cartes de circuits imprimes.

Affuterr llectrode au tungstne uniquement la meuleuse dote de protecteurs. Cette manoeuvre est excuter dans un endroit sr lorsque lon porte lquipement homologu de protection du visage, des mains et du corps. Les tincelles risquent de causer un incendie loigner toute substance inflammable.

UNE REMORQUE QUI BASCULE peut entraner des blessures.


D Utiliser les supports de la remorque ou des blocs pour soutenir le poids. Installer convenablement le poste sur la remorque comme indiqu dans le manuel sy rapportant.

LE SURCHAUFFEMENT peut endommager le moteur lectrique.


Arrter ou dconnecter lquipement avant de dmarrer ou darrter le moteur. D Ne pas laisser tourner le moteur trop lentement sous risque dendommager le moteur lectrique cause dune tension et dune frquence trop faibles. Ne pas brancher de moteur de 50 ou de 60 Hz la prise de 100 Hz, sil y a lieu. D

LIRE LES INSTRUCTIONS.


D D Utiliser seulement les pices de rechange dorigine. Effecteur la maintenance et la mise en service daprs le manuel et celui du moteur.

OM-404 Page 7

LE RAYONNEMENT HAUTE FRQUENCE (H.F.) risque de provoquer des interfrences.


Le rayonnement haute frquence (H.F.) peut provoquer des interfrences avec les quipements de radionavigation et de communication, les services de scurit et les ordinateurs. Demander seulement des personnes qualifies familiarises avec des quipements lectroniques de faire fonctionner linstallation. Lutilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interfrences rsultant de linstallation. Si le FCC signale des interfrences, arrter immdiatement lappareil. Effectuer rgulirement le contrle et lentretien de linstallation. Maintenir soigneusement ferms les portes et les panneaux des sources de haute frquence, maintenir les clateurs une distance correcte et utiliser une terre et et un blindage pour rduire les interfrences ventuelles. D

LE SOUDAGE LARC risque de provoquer des interfrences.


Lnergie lectromagntique risque de provoquer des interfrences pour lquipement lectronique sensible tel que les ordinateurs et lquipement command par ordinateur tel que les robots. Veiller ce que tout lquipement de la zone de soudage soit compatible lectromagntiquement. Pour rduire la possibilit dinterfrence, maintenir les cbles de soudage aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre). Veiller souder une distance de 100 mtres de tout quipement lectronique sensible. Veiller ce que ce poste de soudage soit pos et mis la terre conformment ce mode demploi. En cas dinterfrences aprs avoir pris les mesures prcdentes, il incombe lutilisateur de prendre des mesures supplmentaires telles que le dplacement du poste, lutilisation de cbles blinds, lutilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail. D

D D D D D

D D D D D

1-5. Principales normes de scurit


Safety in Welding and Cutting, norme ANSI Z49.1, de lAmerican Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402. Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme AWS F4.1, de lAmerican Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126 National Electrical Code, NFPA Standard 70, de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202. Rgles de scurit en soudage, coupage et procds connexes, norme CSA W117.2, de lAssociation canadienne de normalisation, vente de normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3. Safe Practices For Occupation And Educational Eye And Face Protection, norme ANSI Z87.1, de lAmerican National Standards Institute, 1430 Broadway, New York, NY 10018. Cutting and Welding Processes, norme NFPA 51B, de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

1-6. Information sur les champs lectromagntiques


Donnes sur le soudage lectrique et sur les effets, pour lorganisme, des champs magntiques basse frquence Le courant de soudage, pendant son passage dans les cbles de soudage, causera des champs lectromagntiques. Il y a eu et il y a encore un certain souci propos de tels champs. Cependant, aprs avoir examin plus de 500 tudes qui ont t faites pendant une priode de recherche de 17 ans, un comit spcial ruban bleu du National Research Council a conclu: Laccumulation de preuves, suivant le jugement du comit, na pas dmontr que lexposition aux champs magntiques et champs lectriques haute frquence reprsente un risque la sant humaine. Toutefois, des tudes sont toujours en cours et les preuves continuent tre examines. En attendant que les conclusions finales de la recherche soient tablies, il vous serait souhaitable de rduire votre exposition aux champs lectromagntiques pendant le soudage ou le coupage. Afin de rduire les champs lectromagntiques dans lenvironnement de travail, respecter les consignes suivantes : 1 2 3 4 5 Garder les cbles ensembles en les torsadant ou en les attachant avec du ruban adhsif. Mettre tous les cbles du ct oppos de loprateur. Ne pas courber pas et ne pas entourer pas les cbles autour de votre corps. Garder le poste de soudage et les cbles le plus loin possible de vous. Relier la pince de masse le plus prs possible de la zone de soudure.

Consignes relatives aux stimulateurs cardiaques : Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur docteur. Si vous tes dclar apte par votre docteur, il est alors recommand de respecter les consignes cidessus.

OM-404 Page 8

SECTION 2 DEFINITIONS
2-1. Symbol Definitions
Stop Engine Fast (Run, Weld/Power) Fast/Slow (Run/Idle) Slow (Idle)

Start Engine

Glow Plug

Temperature

Fuel

Engine Oil

Check Injectors/ Pump

Check Valve Clearance

Battery (Engine)

Engine

Read Operators Manual

Amperes

Volts

Gas Metal Arc Welding (GMAW)

Shielded Metal Arc Welding (SMAW)

Gas Tungsten Arc Welding (TIG) Alternating Current (AC)

Circuit Breaker

Positive

Negative

Output

Time

Hours

Seconds

Protective Earth (Ground)

Do not switch while welding

Welding Arc (Electrode)

Work Connection

SECTION 3 SPECIFICATIONS
3-1. Weld, Power, and Engine Specifications
Welding Mode Weld Output Range Rated Welding Output 225 A, 25 V, 100% Duty Cycle Maximum Open Circuit Voltage 80 Peak: 8.5 kW/kVA CC/DC 50 210 A 210 A, 25 V, 100% Duty Cycle 72 Continuous: 8 kVA/kW, Single-Phase, 70/35 A, 120/240 V AC, 50/60 Hz, (while not welding) 10 gal (38 L) Tank Deutz/Ruggerini MD-151 Air-Cooled, Two-Cylinder, Diesel Engine Generator Power Rating Fuel Capacity Engine

CC/AC

50 225 A

CV/DC

17 28 V

200 A, 20 V, 100% Duty Cycle

33

OM-404 Page 9

3-2. Dimensions, Weights, and Operating Angles


Dimensions Height Width Depth A B C D E F G 31 in (787 mm) 18-3/4 in (476 mm) 46 in (1164 mm) 18 in (457 mm) 16-1/2 in (419 mm) 3/4 in (19 mm) F 3-1/8 in (79 mm) 32-3/4 in (832 mm) 45-1/2 in (1156 mm) 13/32 in (10 mm) Dia. Weight 564 lb (256 kg) Engine End
800 426

A B C Y Do not exceed tilt angles or engine could be damaged or unit could tip. G 4 Holes Y Do not move or operate unit where it could tip.

25 25 25 25

3-3. Generator Power Curve


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

182 719

3-4. Fuel Consumption


The fuel consumption curve shows typical fuel use under weld or power loads.

SB-145 981

OM-404 Page 10

3-5. Duty Cycle


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

Continuous Welding 100% Duty Cycle at 225 Amperes CC/AC, 210 Amperes CC/DC, 200 Amperes CV/DC

SB-119 454-A

3-6. Volt-Ampere Curves


A. For CC/AC Mode
The volt-ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the curves shown.

B. For CC/DC Mode

C. For CV/DC Mode

166 024-A / 166 025-A / 166 026-A

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SECTION 4 INSTALLATION
4-1. Installing Welding Generator
Y Do not weld on base. Welding on base can cause fuel tank fire or explosion. Bolt unit down using holes provided in base. 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) Y Always securely fasten welding generator onto transport vehicle or trailer and comply with all DOT and other applicable codes. Y Always ground generator frame to vehicle frame to prevent electric shock and static electricity hazards. 1 2 3 4 Generator Base Metal Vehicle Frame Equipment Grounding Terminal Grounding Cable

Movement Y Do not lift unit from end.

Airflow Clearance

OR

18 in (460 mm) Location Grounding

18 in (460 mm)

1
GND/PE

3 4

Use #10 AWG or larger insulated copper wire. OR OR Y If unit does not have GFCI receptacles, use GFCIprotected extension cord.

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

install1 10/00 Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854

Notes

OM-404 Page 12

4-2. Engine Prestart Checks


Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. Oil may be added at either oil fill.

. This unit has a low oil pressure


Full 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. Follow run-in procedure in engine manual. If unburned fuel and oil collect in exhaust pipe during run-in, see Section 10. Fuel

Diesel

Fuel Gauge On Tank

Y Do not use gasoline. Gasoline will damage engine. Add fresh diesel fuel before starting engine the first time (see maintenance label for specifications). Fill fuel tank to bottom of filler neck to allow room for expansion. Do not run out of fuel or air enters fuel system and causes starting problems. See engine manual to bleed air from fuel system. Oil After fueling, check oil with unit on level surface. If oil is not up to full mark on dipstick, add oil (see maintenance label).

. To
Full

improve starting:

cold

weather

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

Ref. 151 983 / Ref. 801 331-G

OM-404 Page 13

4-3. Activating The Dry Charge Battery (If Applicable)


Remove battery from unit. 1 2 3 4 5 Eye Protection Safety Glasses Or Face Shield Rubber Gloves Vent Caps Sulfuric Acid Electrolyte (1.265 Specific Gravity) Well

4 1 3

Fill each cell with electrolyte to bottom of well (maximum). Y Do not overfill battery cells. Wait ten minutes and check electrolyte level. If necessary, add electrolyte to raise to proper level. Reinstall vent caps. 6 Battery Charger Y Read and follow all instructions supplied with battery charger. Charge battery for 12 minutes at 30 amperes or 30 minutes at 5 amperes. Disconnect charging cables and install battery.

. When electrolyte

is low, add only distilled water to cells to maintain proper level.

5 A For 30 Minutes

OR

+
30 A For 12 Minutes Tools Needed:

drybatt1 2/96 S-0886

OM-404 Page 14

4-4. Connecting The Battery

Y Connect negative () cable last.

Tools Needed: 3/8, 1/2 in


Ref. 800 394-B / Ref. 192 785 / Ref. S-0756-D

4-5. Connecting To Weld Output Terminals


1 2 Work Weld Output Terminal Electrode Weld Output Terminal

Tools Needed: 3/4 in

Connect work cable to Work terminal. Connect electrode holder cable or electrode weld cable to Electrode terminal for Stick and MIG welding. Connect torch cable to Electrode terminal for TIG welding. Use Process Selector switch to select type of weld output (see Section 5-1).

801 458-A / Ref. 192 785

OM-404 Page 15

4-6. Selecting Weld Cable Sizes*


Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding*** 100 ft (30 m) or Less Weld Output Terminals
Y Turn off power before connecting to weld output terminals. Y Do not use worn, damaged, undersized, or poorly spliced cables. 100 150 200 250

150 ft (45 m)

200 ft (60 m)

250 ft (70 m)

300 ft (90 m)

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

Welding Amperes

10 60% Duty Cycle

60 100% Duty Cycle

10 100% Duty Cycle

4 (20) 3 (30) 3 (30) 2 (35)

4 (20) 3 (30) 2 (35) 1 (50)

4 (20) 2 (35) 1 (50) 1/0 (60)

3 (30) 1 (50) 1/0 (60) 2/0 (70)

2 (35) 1/0 (60) 2/0 (70) 3/0 (95)

1 (50) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95)

1/0 (60) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 3/0 (2x95)

1/0 (60) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 4/0 (2x120)

300

1 (50)

1/0 (60)

2/0 (70)

3/0 (95)

4/0 (120) 2 ea. 2/0 (2x70)

350
* This

1/0 (60)

2/0 (70)

3/0 (95)

4/0 (120)

chart is a general guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), 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-E

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

Notes

OM-404 Page 16

SECTION 5 OPERATING WELDING GENERATOR


5-1. Front Panel Controls

Glow Plug Time


8

t
0s 10 s 20 s 70F (21C) 32F (0C) 4F (20C) 1 Engine Control Switch

Right Side

Ref. 192 785 / Ref. 801 434

. Place switch in Run position to operate . If the engine does not start, let engine
most GMAW equipment. 2 Glow Plug Switch (Optional) If necessary, push switch up before start-up (see table). 3 Idle Lock Switch Use switch to lock engine in idle speed during start-up. In Start position and Engine Control switch in Run or Run/Idle, engine is locked in idle speed. In Run/Idle position and Engine Control switch in Run/Idle, engine runs at idle speed at no load and weld/power speed under load.

Use switch to start engine, select speed, and stop engine. In Run/Idle position, engine runs at idle speed at no load, and weld/power speed under load. In Run position, engine runs at weld/power speed.

In Run/Idle position and Engine Control switch in Run, engine runs at weld/power speed. To start: move idle lock switch and engine control switch to Start. Release engine control switch when engine starts. come to a complete stop before attempting restart.

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

. For best arc starts, use lowest amperage range possible.

Move idle lock switch to Run/Idle after engine warms. To stop: move engine control switch to Off. 4 Weld Process Selector Switch Use switch to select type of weld output. Use a positive (+) position for Direct Current Electrode Positive (DCEP) and a negative () position for Direct Current Electrode Negative. Use AC position for alternating current.

6 Fine Adjust Control Use control to select weld amperage (Stick/ Tig) or voltage (Wire) within the range selected by the Coarse Adjust switch. Control may be adjusted while welding. Weld output would be 110 amps DC with control settings as shown (50% of 70 to 150). Scale is for reference only. 7 Engine Hour Meter 8 Manual Shutoff Lever Turn lever counterclockwise to stop engine if engine control switch does not work. OM-404 Page 17

SECTION 6 OPERATING AUXILIARY EQUIPMENT


6-1. Standard Receptacles
Y If unit does not have GFCI receptacles, use GFCIprotected extension cord.

. Generator
6 4 5 1 2

power decreases as weld current increases. Set Fine Adjust control R1 at 10 for full generator power. 120 V 20 A AC Duplex Receptacle RC3 120 V 20 A AC Duplex Receptacle RC2

2 3 1

RC3 and RC2 supply 60 Hz singlephase power at weld/power speed. Maximum output from RC3 or RC2 is 2.4 kVA/kW (CSA: 1.8 kVA/kW). 3 120/240 V 50 A AC Receptacle RC1

RC1 supplies 60 Hz single-phase power at weld/power speed. Maximum output is 8.5 kVA/kW. 4 5 6 Circuit Breaker CB3 Circuit Breaker CB4 Circuit Breakers CB1 And CB2

CB3 protects RC2 and CB4 protects RC3 from overload. If a circuit breaker opens, the receptacle does not work. Press button to reset breaker. 7 CB1 and CB2 protect RC1 from overload. If CB1 or CB2 opens, RC1 and one of the 120 volt receptacles does not work. 120 volts may still be present at RC1. Y Power is still present at the 240 volt receptacle when only one circuit breaker trips. Unplug power cord before attempting to service accessories or tools. Combined output of all receptacles limited to 8.5 kVA/kW rating of the generator. EXAMPLE: If 20 A is drawn from each 120 V duplex receptacle, only 15 A is available at the 240V receptacle: 2 x (120 V x 20 A) + (240 V x 15 A) = 8.4 kVA/kW 7 Generator Power While Welding Chart (For Reference Only)

SIMULTANEOUS WELDING AND POWER WITH FINE ADJUST SET AT 10 Weld Current In Amperes 210 140 90 Total Power In Watts 1000 4300 6000 120V Receptacle Amperes 8 36 50 240V Receptacle Amperes 4 18 25

Ref. S-166 360-A

Ref. 192 785

OM-404 Page 18

6-2. CSA Receptacle Option


Y If unit does not have GFCI receptacles, use GFCIprotected extension cord. 1 120/240 V 50 A AC Receptacle RC1

RC1 supplies 60 Hz single-phase power at weld/power speed. Maximum output is 10 kVA/kW. 1 5 2 6 3 2 3 120 V 20 A AC Duplex Receptacle RC2 120 V 20 A AC Duplex Receptacle RC3

RC2 and RC3 supply 60 Hz singlephase power at weld/power speed. Maximum output from RC2 or RC3 is 2.4 kVA/kW. 4 Circuit Breaker CB1 CB1 protects the ac receptacles from overload. If CB1 opens, the ac receptacles do not work.

. Move

5 6

CB1 toggle switch to On position to reset circuit breaker. If breaker continues to open, contact Factory Authorized Service Agent. Circuit Breaker CB2 Circuit Breaker CB3

CB2 protects RC2 and CB3 protects RC3 from overload. If a circuit breaker opens, the receptacle does not work. 4

. Press
7

button to reset circuit breaker. If breaker continues to open, contact Factory Authorized Service Agent. Combined output of all receptacles limited to 8.5 kVA/kW rating of the generator. EXAMPLE: If 20 A is drawn from each 120 V duplex receptacle, only 15 A is available at the 240V receptacle: 2 x (120 V x 20 A) + (240 V x 15 A) = 8.4 kVA/kW 7 Generator Power While Welding Label

SIMULTANEOUS WELDING AND POWER WITH FINE ADJUST SET AT 10 Weld Current In Amperes 210 140 90 Total Power In Watts 1000 4300 6000 120V Receptacle Amperes 8 36 50 240V Receptacle Amperes 4 18 25

See Owners Manual for additional information.


S-166 360-A

203 683

OM-404 Page 19

6-3. GFCI, South African, And Australian Generator Power Receptacle Options
Y If unit does not have GFCI receptacles, use GFCIprotected extension cord.

. Generator power decreases as


weld current increases. Set Fine Adjust control R1 at 10 for full generator power. Combined output of all receptacles limited to 8.5 kVA/kW rating of the generator. GFCI Receptacle Option 1 120 V 20 A AC GFCI Receptacles GFCI2 And GFCI3

GFCI2 and GFCI3 supply 60 Hz single-phase power at weld/power speed. Maximum output from GFCI2 or GFCI3 is 2.4 kVA/kW. Circuit breaker protection is the same as standard receptacles. If a ground fault is detected, the GFCI Reset button pops out and the circuit opens to disconnect the faulty equipment. Check for damaged tools, cords, plugs, etc. connected to the receptacle. Press button to reset receptacle and resume operation.

. At

least once a month, run engine at weld/power speed and press Test button to verify GFCI is working properly.

South African And Australian Receptacle Options 2 240 V 16 A AC South African Receptacles RC1, RC2, And RC3 240 V 15 A AC Australian Receptacles RC1, RC2, And RC3

3 2

Receptacles supply 60 Hz singlephase power at weld/power speed. Maximum output from each receptacle is 3.6 kVA/kW. 4 4 Circuit Breakers CB1, CB2, CB3

CB1, CB2, and CB3 protect RC1, RC2, and RC3 from overload. If a circuit breaker opens, the receptacle does not work. Press button to reset breaker. 5 Circuit Breaker CB4 CB4 protects all the receptacles from overload. If CB4 opens, none of the receptacles work.

Ref. 192 785 / Ref. 182 441-A / Ref. 181 719-A

OM-404 Page 20

6-4. Wiring Optional 120/240 Volt Plug


1 3 7 Current Available In Amperes 240 V Receptacle* 35 30 25 20 15 V x A = Watts *One 240 V load or two 120 V loads. Each 120 V Duplex Receptacle 0 5 10 15 20 120V 120V 240V 6 2 3 4 4 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 5 3 4 5 6 7 Plug Wired For 240 V, 2-Wire Load Neutral (Silver) Terminal Load 1 (Brass)Terminal Load 2 (Brass) Terminal Ground (Green) Terminal Amperes Available Using 120/240 V Plug

240V 6

5 Tools Needed:

120 813-D

Notes

OM-404 Page 21

SECTION 7 MAINTENANCE AND TROUBLESHOOTING


7-1. Maintenance

Note

Follow the storage procedure in the engine owners manual if the unit will not be used for an extended period.

Y Stop engine before maintaining. Recycle engine fluids.

. See also Engine Manual and maintenance label.


Maintain more often if used in severe conditions. * To be done by Factory Authorized Service Agent.

8h
Check Fluid Levels. See Section 4-2. Service Air Filter.

Wipe Up Spills.

50 h
Clean And Tighten Weld Terminals. Service Air Filter Element.

100 h
Clean Cooling System. See Engine Manual. Clean And Tighten Battery Connections.

200 h
Change Oil. See Section 7-4 And Maintenance Label. Change Oil Filter. See Section 7-4.

Check Valve Clearance.*

Replace Fuel Filter. See Section 7-4.

Replace Damaged Or Unreadable Labels.

250 h
Check And Clean Spark Arrestor. See Section 7-3. OM-404 Page 22

500 h
Service Welding Generator Brushes And Slip Rings. Service More Often In Dirty Conditions.* Repair Or Replace Cracked Cables And Cords. Clean/Set Injectors.*

1000 h
Blow Out Or Vacuum Inside.

Notes

OM-404 Page 23

40

Check daily. +30 +86


30
Pull

Push And Turn CCW

C +40
50

SAE 15W-40

+32
10W

SAE 10W-30

+5 -18 Single Viscosity Oils Do NOT use ether.

20W

OM-404 Page 24 Air Filter Service . . . . . . . 50 hours or less see Owners Manual 12 Volt Battery . . BCI Group 58 + Cranking Performance at 0F (-18C) . . . . . . . . 430 Amps

DEUTZ/RUGGERINI MD151 DIESEL ENGINE

7-2. Maintenance Label

See Engine Manual for complete engine care. Give Engine Specification and Serial Number when ordering parts.

To Drain Oil:

F +104
+68 +59 Engine RPM No Load Weld/Power . . . . 3750 Idle . . . . . . . . . . . 2000

Valve Clearance Cold Intake . . . 0.006 in (0.15 mm) Exhaust . 0.006 in (0.15 mm)

1/2 in. ID Hose

Engine Cooling Avoid recirculation of air from hot air exit to blower intake.

Injectors . . . . . . . . . . . . . . MILLER 066 852, Deutz 77-644-56 Have only trained technician maintain injection pump and injectors. AIR, WATER, or GASOLINE will harm the injection system.

+20 Recommended +10 Oil . . . . . . . . . . . . . . API Service Classification CD, SF/CD, CC/CD or better 0 Oil Change . . . . . . 200 hours or less -10 Oil Filter Change . . normal conditions - 200 hours -20 or less Oil Filter . . . . . . . . . MILLER 066 702, Deutz 77-175-24 MultiOil Capacity . . . . . . 1.9 qt (1.8 L) or Viscosity Oils 2 qt (1.9 L) with filter change

Fuel Grade . . . . . . . . . . . 1-D or 2-D Cetane No. 40 min. (.5% max. Sulfur content) Primary Fuel Filter . . . . . MILLER 066 113 Secondary Fuel Filter . . . MILLER 066 893, Deutz 77-175-19

Diesel

Spark Arrestor Inspection And Service . . . . . . . . . . 250 operating hours see Owners Manual Optional
S-173 094-B

Fill filter with clean fuel before installing read instructions on filter.

7-3. Inspecting And Cleaning Optional Spark Arrestor


Y Stop engine and let cool. 1 2 Spark Arrestor Cleanout Plug

Remove plug and remove dirt covering cleanout hole. 3 Exhaust Pipe Start engine and run at idle speed to blow out cleanout hole. If nothing blows out of hole, briefly cover end of exhaust pipe with fireproof material. Y Stop engine and let cool. Reinstall cleanout plug.

Tools Needed:

5/16 in
Ref. 801 331-G / 800 497 -A / Ref. 192 785

OM-404 Page 25

7-4. Changing Engine Oil, Oil Filter, And Fuel Filter


Y Stop engine and let cool. 1 2 3 4 5 Oil Drain Valve 1/2 ID x 12 In Hose Oil Filter Oil Fill Cap Oil Dipstick

Change engine oil and filter according to engine Owners Manual. Oil may be added at either oil fill. 6 7 Fuel Line Primary Fuel Filter

4 3 4

Replace line if cracked or worn. Install new filter. Wipe up any spilled fuel. 8 Secondary Fuel Filter Remove filter and install new filter element according to engine Owners Manual. Replace fuel line if cracked or worn. Wipe up spilled fuel. 9 Hand Primer Push lever 10 to 12 times to prime injector system. Start engine and check for fuel leaks. Y Stop engine, tighten connections as necessary, and wipe up spilled fuel. Tools Needed:

2 8

Ref. 192 785 / Ref. 801 331-G / 801 434-A / S-0842

OM-404 Page 26

7-5. Adjusting Engine Speed


Engine speeds have been factory set and should not require adjustment. After tuning engine, check engine speeds with a tachometer. See table for proper no load engine speeds. If necessary, adjust speeds as follows: Idle Speed Adjustment: 2000 rpm 4 3 3750 rpm 1 2 Throttle Cable Throttle Cable Stop Screw

Start engine and run at idle speed. Loosen screw and adjust cable until engine runs at correct idle speed. Do not allow slack in cable. Tighten screw. Weld/Power Speed Adjustment: Run engine at weld/power speed. 3 4 Weld/Power Speed Screw Weld/Power Speed Jam Nut

Loosen jam nut. Turn screw clockwise to decrease speed and counterclockwise to increase speed. 2 Tighten jam nut. Y Stop engine.

Tools Needed:

Right Side

1/4 in, 8mm


Ref. 801 434-A

7-6. Overload Protection


A. Time Delay Relay CB7 And Fusible Link (Optional With Glow Plug)

Internal time delay relay CB7 and the fusible link protect the optional glow plug system from overheating. If glow plugs overheat, CB7 automatically stops the heating process. Wait one minute for CB7 to automatically reset before using glow plugs. If the engine is hard to start in cold weather, check the fusible link and replace if open.

NOTE

When a circuit breaker or fuse opens, it usually indicates a more serious problem exists. Contact a Factory Authorized Service Agent.
OM-404 Page 27

B. Circuit Breaker CB8


1 Circuit Breaker CB8

CB8 protects the idle solenoid. If CB8 opens, engine drops to idle speed. Check throttle solenoid and cable for obstructions and throttle linkage for proper adjustment. Press button to reset circuit breaker.

. When a circuit breaker opens,


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

801 458-A / Ref. 192 785

C. Fuse F1
Y Stop engine and disconnect battery negative () cable. Remove top cover. 1 1 Fuse F1 (See Parts List For Rating)

F1 protects the exciter stator from overload. Replace F1 if open. Reinstall top cover before operating unit.

. When a fuse opens, it usually

indicates a more serious problem exists. Contact a Factory Authorized Service Agent.

Tools Needed:

3/8, 1/2 in
Ref. 801 477-C

OM-404 Page 28

7-7. Troubleshooting

A. Welding
Trouble
No weld output. Check control settings (see Section 5-1). Check weld connections. Check fuse F1 and replace if open (see Section 7-6). Be sure all equipment is disconnected from receptacles when starting unit. Have Factory Authorized Service Agent check brushes, slip rings, and integrated rectifier SR2. Low weld output. Check control settings (see Section 5-1). Check fuse F1 and replace if open (see Section 7-6). Check and adjust engine speed (see Section 7-5). Service air cleaner according to engine manual. Have Factory Authorized Service Agent check brushes and slip rings. High weld output. Check control settings (see Section 5-1). Check and adjust engine speed (see Section 7-5). Erratic weld output. Check control settings (see Section 5-1). Tighten and clean connections to electrode and workpiece. Use dry, properly-stored electrodes for SMAW and GTAW. Remove excessive coils from weld cables. Tighten and clean connections both inside and outside welding generator. Check and adjust engine speed (see Section 7-5). Have Factory Authorized Service Agent check brushes and slip rings.

Remedy

B. Generator Power
Trouble
No output at generator power receptacles.

Remedy
Reset circuit breakers (see Sections 6-1 and 6-3). Press optional GFCI receptacle Reset button (see Section 6-3). Check fuse F1 and replace if open (see Section 7-6). Have Factory Authorized Service Agent check brushes, slip rings, and integrated rectifier SR2.

High power output. Low power output.

Check and adjust engine speed (see Section 7-5). Increase Fine Adjust control R1 setting. Check fuse F1 and replace if open (see Section 7-6).

Erratic power output.

Check fuel level (see Section 4-2). Check and adjust engine speed (see Section 7-5). Check receptacle wiring and connections. Have Factory Authorized Service Agent check brushes and slip rings. OM-404 Page 29

C. Engine
Trouble
Engine will not crank.

Remedy
Check plug PLG4 connection and plug PLG8 connection. Check battery voltage. Check battery connections, and tighten if necessary. Have Factory Authorized Service Agent check continuity and connections of Engine Control switch S2, and replace if necessary.

Engine will not start.

Check fuel level (see Section 4-2). Check battery and engine charging system. Check oil level. Check low oil pressure shutdown switch (see Section 4-2). Wait one minute for optional glow plug system time delay relay CB7 to reset (see Section 7-6). Have Factory Authorized Service Agent check optional glow plug system fusible link and relay CR2, and replace if necessary (see Section 7-6). Have Factory Authorized Service Agent check Engine Control switch S2, and replace if necessary. See engine manual.

Engine starts, but stops when Engine Control switch returns to Run position.

Check oil level. Check low oil pressure shutdown switch S4 (see Section 4-2). Have Factory Authorized Service Agent check Engine Control switch S2 and fuel solenoid, and replace if necessary.

Battery discharges between uses.

Clean battery terminals and posts with baking soda solution; rinse with clear water. Periodically recharge battery (approximately every three months). Have Factory Authorized Service Agent check voltage regulator. Replace battery.

Unstable or sluggish engine speeds.

Check fuel level (see Section 4-2). Readjust throttle linkage if necessary (see Section 7-5). Tune engine according to engine manual.

Engine stops during normal operation.

Check fuel level (see Section 4-2). Check oil level. Check low oil pressure shutdown switch (see Section 4-2). Have Factory Authorized Service Agent check Engine Control switch S2 and fuel solenoid, and replace if necessary.

Engine idles but does not reach weld speed.

Check and reset circuit breaker CB8 (see Section 7-6). Check solenoid linkage for obstructions. Move Idle Lock switch to Run/Idle position (see Section 5-1). Have Factory Authorized Service Agent check Engine Control switch S2, and replace if necessary. Have Factory Authorized Service Agent check control relay CR1, current transformer CT1, throttle solenoid TS1, throttle linkage, and idle module PC1.

Engine uses oil during run-in period; Dry engine (see Section 10 and engine manual). wetstacking occurs. Engine will not stop. Stop engine using manual shut off lever. Have Factory Authorized Service Agent check unit.

OM-404 Page 30

SECTION 8 ELECTRICAL DIAGRAM

SC-182 630-B

Figure 8-1. Circuit Diagram For Welding Generator


OM-404 Page 31

SECTION 9 GENERATOR POWER GUIDELINES


9-1. Selecting Equipment
1 2 3 Generator Power Receptacles Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment

3 OR Be sure equipment has this symbol and/or wording.

aux_pwr 3/02 Ref. ST-159 730 / ST-800 577

9-2. Grounding Generator To Truck Or Trailer Frame


1 2 3 4 Generator Base Metal Vehicle Frame Equipment Grounding Terminal Grounding Cable

Use #10 AWG or larger insulated copper wire. Y If unit does not have GFCI receptacles, use GFCI-protected extension cord. 1
GND/PE

OR

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

S-0854

OM-404 Page 32

9-3. Grounding When Supplying Building Systems


1 1
GND/PE

Equipment Grounding Terminal Grounding Cable

Use #10 AWG or larger insulated copper wire. 3 Ground Device Y Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system.

Use ground device as stated in electrical codes. 3

ST-800 576-B

9-4. How Much Power Does Equipment Require?


1 3 2 1 VOLTS 115 AMPS 4.5 Hz 60 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-resistive load and requires approximately six times more power while starting the motor than when running (see Section 9-8). 3 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 amperes at 115 volts, calculate its running power requirement in watts. 4.5 A x 115 V = 520 W The load applied by the drill is 520 watts.

EXAMPLE 2: If three 200 watt flood lamps are used with the drill from Example 1, add the individual loads to calculate total load. (200 W + 200 W + 200 W) + 520 W = 1120 W The total load applied by the three flood lamps and drill is 1120 watts.
S-0623

OM-404 Page 33

9-5. Approximate Power Requirements For Industrial Motors


Industrial Motors Split Phase Rating 1/8 HP 1/6 HP 1/4 HP 1/3 HP 1/2 HP 1/3 HP 1/2 HP 3/4 HP 1 HP 1-1/2 HP 2 HP 3 HP 5 HP 1-1/2 HP 5 HP 7-1/2 HP 10 HP 1/8 HP 1/6 HP 1/4 HP 1/3 HP 1/2 HP Starting Watts 800 1225 1600 2100 3175 2020 3075 4500 6100 8200 10550 15900 23300 8100 23300 35000 46700 1000 1400 1850 2400 3500 Running Watts 300 500 600 700 875 720 975 1400 1600 2200 2850 3900 6800 2000 6000 8000 10700 400 550 650 800 1100

Capacitor Start-Induction Run

Capacitor Start-Capacitor Run

Fan Duty

9-6. Approximate Power Requirements For Farm/Home Equipment


Farm/Home Equipment Stock Tank De-Icer Grain Cleaner Portable Conveyor Grain Elevator Milk Cooler Milker (Vacuum Pump) FARM DUTY MOTORS Std. (e.g. Conveyors, Feed Augers, Air Compressors) Rating Starting Watts 1000 1650 3400 4400 2900 10500 1720 2575 4500 6100 8200 10550 15900 23300 8100 23300 35000 46700 3300 3150 4500 6100 3100 2150 3100 2100 3200 Running Watts 1000 650 1000 1400 1100 2800 720 975 1400 1600 2200 2850 3900 6800 2000 6000 8000 10700 1000 950 1400 1600 800 750 1000 800 1050

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

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

OM-404 Page 34

9-7. Approximate Power Requirements For Contractor Equipment


Contractor Hand Drill Rating 1/4 in 3/8 in 1/2 in 6-1/2 in 7-1/4 in 8-1/4 in 9 in 10 in 14 in 6 in 8 in 10 in 1/2 HP 1 HP 1-1/2 HP 2 HP 1-1/2 HP, 12 in 2 HP, 14 in Standard 9 in Heavy Duty 12 in 1/3 HP 18 in HID Metal Halide Mercury Sodium Vapor 400 gph 900 gph 3/4 HP, 16 in 1 HP, 20 in 1/2 HP 3/4 HP 1 HP 1/4 HP 1.7 HP 2-1/2 HP Starting Watts 350 400 600 500 900 1400 4500 6300 2500 1720 3900 5200 3000 6000 8200 10500 1100 1100 350 500 2100 400 125 313 1000 1400 1250 600 900 4500 6100 3150 4500 6100 1900 900 1300 Running Watts 350 400 600 500 900 1400 1500 1800 1100 720 1400 1600 1000 1500 2200 2800 1100 1100 350 500 700 400 100 250

Circular Saw

Table Saw Band Saw Bench Grinder

Air Compressor

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

Submersible Pump Centrifugal Pump Floor Polisher High Pressure Washer

55 gal Drum Mixer Wet & Dry Vac

1000 200 500 1400 1600 950 1400 1600 700 900 1300

OM-404 Page 35

9-8. Power Required To Start Motor


4 1 3 AC MOTOR VOLTS 230 AMPS 2.5 CODE M Hz 60 HP 1/4 PHASE 1 2 1 2 3 4 Motor Start Code Running Amperage Motor HP Motor Voltage

To find starting amperage: Step 1: Find code and use table to find kVA/HP. If code is not listed, multiply running amperage by six to find starting amperage. Step 2: Find Motor HP and Volts. Step 3: Determine starting amperage (see example). Welding generator amperage output must be at least twice the motors running amperage. N 12.5 P 14.0

Single-Phase Induction Motor Starting Requirements Motor Start Code KVA/HP G 6.3 H 7.1 J 8.0 K 9.0 L 10.0 M 11.2

kVA/HP x HP x 1000 VOLTS

= STARTING AMPERAGE

EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4 HP motor with a motor start code of M. Volts = 230 HP = 1/4 Using Table, Code M results in kVA/HP = 11.2

11.2 x 1/4 x 1000 = 12.2 A Starting the motor requires 12.2 amperes. 230

S-0624

9-9. How Much Power Can Generator Supply?


1 Limit Load To 90% Of Generator Output

Always start non-resistive (motor) loads in order from largest to smallest, and add resistive loads last. 1 2 5 Second Rule If motor does not start within 5 seconds, turn off power to prevent motor damage. Motor requires more power than generator can supply.

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

OM-404 Page 36

9-10. Typical Connections To Supply Standby Power


Y Have only qualified persons perform these connections according to all applicable codes and safety practices. 1 2 3 Power Company Service Meter Main and Branch Overcurrent Protection Double-Pole, Double-Throw Transfer Switch

. Customer-supplied equipment is required if


generator is to supply standby power during emergencies or power outages. 1 240 V 120/240 Volt 60 Hz Three-Wire Service

Obtain and install correct switch. Switch rating must be same as or greater than the branch overcurrent protection. 4 120 V 120 V Neutral Circuit Breakers or Fused Disconnect Switch

Obtain and install correct circuit breakers or switch. 5 3 6 Extension Cord Generator Connections Select as shown in Section 9-11. Connect terminals or plug of adequate amperage capacity to cord. Follow all applicable codes and safety practices. Turn off or unplug all equipment connected to generator before starting or stopping engine. When starting or stopping, the engine has low speed which causes low voltage and frequency. 7 CB or F1 Item 4 is not necessary if circuit protection is already present in generator power circuit. Load Connections

2 240 V

120 V Load 120 V

4 7

6 240 V 120/240 Volt Single-Phase Three-Wire Generator Output Connection 120 V 120 V Ground

S-0405-A

OM-404 Page 37

9-11. Selecting Extension Cord (Use Shortest Cord Possible)

Cord Lengths for 120 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current (Amperes) 5 7 10 15 20 25 30 35 40 45 50 Load (Watts) 600 840 1200 1800 2400 3000 3600 4200 4800 5400 6000 400 (122) 300 (91) 225 (68) 175 (53) 150 (46) 125 (38) 112 (34) 100 (30) 87 (26) 400 (122) 275 (84) 175 (53) 137 (42) 112 (34) 87 (26) 75 (23) 62 (19) 62 (19) 50 (15) 4 6 8 350 (106) 250 (76) 175 (53) 112 (34) 87 (26) 62 (19) 50 (15) 50 (15) 37 (11) 10 225 (68) 150 (46) 112 (34) 75 (23) 50 (15) 37 (11) 37 (11) 12 137 (42) 100 (30) 62 (19) 37 (11) 30 (9) 14 100 (30) 62 (19) 50 (15) 30 (9)

*Conductor size is based on maximum 2% voltage drop

Cord Lengths for 240 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current (Amperes) 5 7 10 15 20 25 30 35 40 45 50 Load (Watts) 1200 1680 2400 3600 4800 6000 7000 8400 9600 10,800 12,000 800 (244) 600 (183) 450 (137) 350 (107) 300 (91) 250 (76) 225 (69) 200 (61) 175 (53) 800 (244) 550 (168) 350 (107) 275 (84) 225 (69) 175 (53) 150 (46) 125 (38) 125 (38) 100 (31) 4 6 8 700 (213) 500 (152) 350 (107) 225 (69) 175 (53) 125 (38) 100 (31) 100 (31) 75 (23) 10 450 (137) 300 (91) 225 (69) 150 (46) 100 (31) 75 (23) 75 (23) 12 225 (84) 200 (61) 125 (38) 75 (23) 60 (18) 14 200 (61) 125 (38) 100 (31) 60 (18)

*Conductor size is based on maximum 2% voltage drop

OM-404 Page 38

SECTION 10 RUN-IN PROCEDURE


run_in1 8/01

10-1. Wetstacking
Y Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur. 1 2 Welding Generator Run diesel engines near rated voltage and current during run-in period to properly seat piston rings and prevent wetstacking. See nameplate, rating label, or specifications section in this manual to find rated voltage and current.

1 2

Do not idle engine longer than necessary. Piston rings seat faster if engine runs at weld/ power rpm, and the welding generator is kept loaded during run-in. Engine Exhaust Pipe

Wetstacking is unburned fuel and oil in the exhaust pipe and occurs during run-in if the engine is run too long at light load or idle rpm. If exhaust pipe is coated with a wet, black, tar-like substance, dry the engine using one of the following run-in procedures. See the engine manual for additional engine run-in information.

OM-404 Page 39

10-2. Run-In Procedure Using Load Bank


Y Stop engine. Y Do not touch hot exhaust pipe, engine parts, or load bank/grid. 4 2 1 Y Keep exhaust and pipe away from flammables. Y Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur. 1 Load Bank Turn all load bank switches Off. If needed, connect load bank to 115 volts ac wall receptacle or generator auxiliary power receptacle. 2 Welding Generator Place A/V range switch in maximum position, A/V control in minimum position, and Output Selector switch (if present) in either DC position. 3 Weld Cables Connect load bank to generator weld output terminals using proper size weld cables with correct connectors. Observe correct polarity. Start engine and run for several minutes. 3 Set load bank switches and then adjust generator A/V control so load equals rated voltage and current of generator (see nameplate, rating label, or the specifications section in this manual). Check generator and load bank meters after first five minutes then every fifteen minutes to be sure generator is loaded properly.

. Check oil level frequently during run-in; add oil if needed. After one hour (minimum) place A/V control in minimum position, then turn off load bank to remove load. Run engine several minutes at no load. Y Stop engine and let cool. 4 Engine Exhaust Pipe Repeat procedure if wetstacking is present.

S-0683

OM-404 Page 40

10-3. Run-In Procedure Using Resistance Grid


Y Stop engine. Y Do not touch hot exhaust pipe, engine parts, or load bank/grid. 6 2 Y Keep exhaust and pipe away from flammables. Y Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur. 1 Resistance Grid Use grid sized for generator rated output. 1 Turn Off grid. 2 Welding Generator Place A/V range switch in maximum position, A/V control in minimum position, and Output Selector switch (if present) in either DC position. 3 Weld Cables Connect grid to generator weld output terminals using proper size weld cables with correct connectors (polarity is not important). 4 Voltmeter 5 Clamp-On Ammeter Connect voltmeter and ammeter as shown, if not provided on generator. 3 5 Start engine and run for several minutes. Set grid switches and then adjust generator A/V control so load equals rated voltage and current of the generator (see nameplate, rating label, or the specifications section in this manual). Check generator and meters after first five minutes then every fifteen minutes to be sure generator is loaded properly.

. Check oil level frequently during run-in; add oil if needed. After one hour (minimum), place A/V control in minimum position, then shut down grid to remove load. Run engine several minutes at no load. Y Stop engine and let cool. 6 Engine Exhaust Pipe Repeat procedure if wetstacking is present.

S-0684

OM-404 Page 41

SECTION 11 PARTS LIST

ST-801 516-K

Figure 11-1. Main Assembly


OM-404 Page 42

65

Item No.

Dia. Mkgs.

Part No.

Description Figure 11-1. Main Assembly

Quantity

. . . 1 . . . . . . . . . . . . . . . . . . 192 041 . . . LABEL, use diesel fuel only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 2 . . . . . . . . . . . . . . . . . . 181 881 . . . GROMMET, filler neck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 3 . . . . . . . . . . . . . . . . . . 147 601 . . . CAP, tank screw-on w/vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 4 . . . . . . . . . . . . . . . . . . 200 795 . . . LABEL,warning gen. precautionary csa . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 5 . . . . . . . . . . . . . . . . . +205 763 . . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 6 . . . . . . . . . . . . . . . . . . 169 329 . . . PANEL, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 7 . . . . . . . . . . . . . . . . . . 205 736 . . . UPRIGHT, base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 8 . . . . . . . . . . . . . . . . . . 205 734 . . . SEAL, weather lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 9 . . . . . . . . . . . . . . . . . . 194 253 . . . PANEL, rear lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 10 . . . . . . . . . . . . . . . . . . Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 . . . . . . . . . . . . . . . . . . 191 427 . . . TANK, fuel 10 gal (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . . . . . 124 253 . . . . BUSHING, tank fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . . . . . . . . . . . . 187 502 . . . . FITTING, stand pipe hose .250 x 7.325 lg 90 . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . . . . . 182 922 . . . . BUSHING, tank fuel 1.210 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . . . . . 182 925 . . . . GAUGE, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . . . . . 172 681 . . . . FITTING, hose stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL, return line (see engine parts list) . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . . . . . 107 816 . . . HOSE, SAE .250 ID x .500 OD (order by ft) . . . . . . . . . . . . . . . . . . . . 1ft . . . 12 . . . . . . . . . . . . . . . . . . 172 707 . . . SEAL, fuel hose fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 13 . . . . . . . . . . . . . . . . . . 066 113 . . . FILTER, fuel in-line .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 14 . . . . . . . . . . . . . . . . . . Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 . . . . . . . . . . . . . . . . . . 141 975 . . . WASHER, flat copper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 16 . . . . . . . . . . . . . . . . . . 177 123 . . . SWITCH, pressure oil 4PSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 17 . . . . . . . . . . . . . . . . . . 142 118 . . . FITTING, pipe brs adapter 1/8NPT x 8m16G . . . . . . . . . . . . . . . . . 1 . . . 18 . . . . . . . . . . . . . . . . . +172 635 . . . ENGINE, diesel elec start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 19 . . . . . . . . . . . . . . . . . . 142 322 . . . BRACKET, mtg fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BASE, fuel filter (see engine parts list) . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 21 . . . . . . . . . . . . . . . . . . 066 893 . . . ELEMENT, fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 22 . . . . . . . . . . . . . . . . . . 165 271 . . . VALVE, oil drain 3/8-18NPTF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 23 . . . . . . . . . . . . . . . . . . 172 634 . . . FITTING, adapter oil drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 24 . . . . . . . . . . . . . . . . . . 149 610 . . . STOP, cable throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 25 . . . . . . . . . . . . . . . . . . 150 203 . . . SPRING, cprsn .372 OD x .051 wire x 1.500 . . . . . . . . . . . . . . . . . . . . 1 . . . 26 . . . . . . . . . . . . . . . . . . 176 897 . . . ARM, throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 27 . . . . . . . . . . . . . . . . . . 172 668 . . . CONTROL, push/pull . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 28 . . . . . . . TS1 . . . . . . 179 385 . . . SOLENOID, 12VDC 44A pull/hold w/o spring . . . . . . . . . . . . . . . . . . . 1 . . . 29 . . . . . . . . . . . . . . . . . . 174 803 . . . BRACKET, mtg solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 30 . . . . . . . . . . . . . . . . . . 066 702 . . . OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 31 . . . . . . . . . . . . . . . . . . Fig 11-3 . . . GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 32 . . . . . . . . . . . . . . . . . . Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 . . . . . . . . . . . . . . . . . . 082 319 . . . CABLE, bat neg 17.750 (battery to engine block) . . . . . . . . . . . . . . . . 1 . . . 33 . . . . . . . . . . . . . . . . . . 172 669 . . . CABLE, bat neg 11.000 (engine block to case) . . . . . . . . . . . . . . . . . . 1 . . . 34 . . . . . . . . . . . . . . . . . . 182 935 . . . HOLD DOWN, battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 35 . . . . . . . . . . . . . . . . . . 186 896 . . . BRACKET, battery tray support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 36 . . . . . . . . . . . . . . . . . . 168 385 . . . LABEL, warning battery explosion can blind . . . . . . . . . . . . . . . . . . . . 1 . . . 37 . . . . . . . . . . . . . . . . . +201 174 . . . DOOR, access battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 38 . . . . . . . . . . . . . . . . . . 173 921 . . . CABLE, bat pos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 39 . . . . . . . . . . . . . . . . . . 167 677 . . . BATTERY, stor 12V 430crk 75rsv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 40 . . . . . . . . . . . . . . . . . +201 280 . . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 41 . . . . . . . . . . . . . . . . . . 173 094 . . . LABEL, engine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 42 . . . . . . . . . . . . . . . . . . 181 057 . . . COVER, base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 43 . . . . . . . . . . . . . . . . . . 183 771 . . . STAB/REACTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 44 . . . . . . AC-Z . . . . . . 176 301 . . . . REACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 45 . . . . . . DC-Z . . . . . . 183 179 . . . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . . . . . 164 920 . . . . BRACKET, mtg stab/reactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 46 . . . . . . . . . . . . . . . . . . 188 434 . . . BRACKET, mtg generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 47 . . . . . . . . . . . . . . . . . . 166 094 . . . MOUNT, engine vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OM-404 Page 43

Item No.

Dia. Mkgs.

Part No.

Description Figure 11-1. Main Assembly (Continued)

Quantity

. . . 48 . . . . . . . . . . . . . . . . . . 172 714 . . . . . . 49 . . . . . . . . . . . . . . . . . . 172 719 . . . . . . 50 . . . . . . . . . . . . . . . . . . 127 854 . . . . . . 51 . . . . . . . . . . . . . . . . . . 172 720 . . . . . . 52 . . . . . . . . . . . . . . . . . . 172 625 . . . . . . 53 . . . . . . . 1T . . . . . . . 172 661 . . . . . . 54 . . . . . . . . . . . . . . . . . . 173 734 . . . . . . 55 . . . . . . . SR1 . . . . . . 192 682 . . . . . . 56 . . . . . . . . . . . . . . . . . . 180 628 . . . . . . 57 . . . . . . . . . . . . . . . . . . Fig 11-2 . . . . . . 58 . . . . . . . CT1 . . . . . . 179 494 . . . . . . 59 . . . . . . . . . . . . . . . . . . 177 136 . . . . . . 60 . . . . . . . C1 . . . . . . . 176 719 . . . . . . 61 . . . . . . . . . . . . . . . . . . 172 731 . . . . . . 62 . . . . . . . F1 . . . . . . *169 296 . . . . . . 63 . . . . . . SR2,3 . . . . . 200 759 . . . . . . 64 . . . . . . . R2 . . . . . . . 184 278 . . . . . . . . . . . . . . . RC4 . . . . . . 116 045 . . . . . . . . . . . . . . . PLG6 . . . . . 136 810 . . . . . . . . . . . . . . . PLG4 . . . . . 135 556 . . . . . . . . . . . . . . . RC6 . . . . . . 168 844 . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 503 . . . . . . 65 . . . . . . . . . . . . . . . . . . 197 930 . . .

BRACKET, engine mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRACKET, mtg engine lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLAMP, stl cush 1.312dia x .343mtg hole . . . . . . . . . . . . . . . . . . . . . . BRACKET, mtg engine upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRACKET, mtg rectifier/components . . . . . . . . . . . . . . . . . . . . . . . . . . . BLOCK, stud connection 6 position . . . . . . . . . . . . . . . . . . . . . . . . . . . . LINK, jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RECTIFIER, si 1 ph 240A 400PIV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, front lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSFORMER, current sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLAMP, capacitor 2.500dia clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAPACITOR, elctlt 1000uf 75VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOLDER, fuse mintr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUSE, mintr gl 25A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RECTIFIER, integ 35A 600V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RESISTOR, WW adj 225W 5 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR, rect 4 pin/skt rcpt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KIT, label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL, warning do not weld on base . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 2

OPTIONAL +When ordering a component originally displaying a precautionary label, the label should also be ordered. *Recommended Spare Parts. To maintain the factory original performance of your equipment, use only Manufacturers Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. Item No. Dia. Mkgs. Part No. Description Figure 11-2. Panel, Front w/Components (Fig 11-1 Item 57) . . . 1 . . . . . . . S1 . . . . . . . 184 754 . . . ... 2 ............................. . . . 3 . . . . . . . . . . . . . . . . . . 207 845 . . . . . . 3 . . . . . . . . . . . . . . . . 183 171 . . . . . . 3 . . . . . . . . . . . . . . . . 185 161 . . . . . . 3 . . . . . . . . . . . . . . . . 203 681 . . . . . . 4 . . . . . . . . . . . . . . . . . . 186 058 . . . . . . 5 . . . . . . . S3 . . . . . . . 183 148 . . . . . . 6 . . . . . . . R1 . . . . . . . 117 243 . . . . . . 7 . . . . . . . PC1 . . . . . . 186 224 . . . . . . 8 . . . . . . CR1 . . . . . . 173 069 . . . . . . 9 . . . . . . . S2 . . . . . . . 176 606 . . . . . . 10 . . . . . . RC2,3 . . . . . 141 432 . . . . . . 10 . . . . . GFCI2,3 . . 151 981 . . . . . . 11 . . . . . . CB1,2 . . . . . 195 955 . . . . . . 11 . . . . . . . CB1 . . . . 200 929 . . . . . . . . . . . . . . . . . . . . . . . . . 202 631 . . . . . . . . . . . . . . . . . . . . . . . . . 202 630 . . . . . . 12 . . . . . . CB3,4 . . . . . 093 996 . . . . . . 12 . . . . . . CB3,4 . . . 093 995 . . . . . . 13 . . . . . . . S5 . . . . . . . 011 609 . . . . . . . . . . . . . . . . . . . . . . . . . . . 021 385 . . . . . . 14 . . . . . . . CB8 . . . . . . 083 432 . . . . . . 15 . . . . . . . HM . . . . . . 145 247 . . .
OM-404 Page 44

Quantity

SWITCH, polarity 5 position (Weld Process) . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, front (w/battery charger option) . . . . . . . . . . . . . . . . . . . . . . . . PANEL, front (w/Australian or South African receptacle option) . . . . PANEL, front (w/CSA receptacle option) . . . . . . . . . . . . . . . . . . . . . . . . COVER, dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWITCH, selector 4 position (Coarse Adjustment) . . . . . . . . . . . . . . . RHEOSTAT, WW 100W 10 ohm (Fine Adjustment) . . . . . . . . . . . . . . MODULE, weld/power 7 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RELAY, encl 12VDC SPDT 15A 125VDC . . . . . . . . . . . . . . . . . . . . . . . SWITCH, ignition 4 position w/out handle (Engine) . . . . . . . . . . . . . . . RECEPTACLE, str dx grd 2P3W 20A 125V . . . . . . . . . . . . . . . . . . . . . RECEPTACLE, str dx grd 2P3W 15/20A 125VAC GFI . . . . . . . . . . . CIRCUIT BREAKER, man reset 1P 50A 125VAC . . . . . . . . . . . . . . . . CIRCUIT BREAKER, man reset 2p 50a 240vac screw90 (CSA) . . COVER, circuit breaker (CSA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRKT, mtg ckt breaker cover (CSA) . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT BREAKER, man reset 1P 20A 250VAC . . . . . . . . . . . . . . . . CIRCUIT BREAKER, man reset 1P 15A 250VAC . . . . . . . . . . . . . . . . SWITCH, tgl SPDT 15A 125VDC (Idle Lock) . . . . . . . . . . . . . . . . . . . . BOOT, tgl switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT BREAKER, man reset 1P 10A 250VDC . . . . . . . . . . . . . . . METER, hour 12-24VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 1 1 1 2 1 1 1 1 1 2 2 2 1 1 1 2 2 1 1 1 1

Item No.

Dia. Mkgs.

Part No.

Description Figure 11-2. Panel, Front w/Components (Fig 11-1 Item 57) (Continued)

Quantity

. . . 16 . . . . . . . . . . . . . . . . . . . . . 17 . . . . . R3,VR1 . . . . . . . . 18 . . . Work, Elect . . . . . . 19 . . . . . . . . . . . . . . . . . . . . . 20 . . . . . . . . . . . . . . . . . . . . . 21 . . . . . . . . . . . . . . . . . . . . . 22 . . . . . . . . . . . . . . . . . . . . . 23 . . . . . . . . . . . . . . . . . . . . . 24 . . . . . . RC1 . . . . . . ........................ . . . 25 . . . . . . . . . . . . . . . . . . . . . 26 . . . . . . . . . . . . . . . . . . . . . 27 . . . . . . . . . . . . . . . . . .

119 014 . . . 046 819 . . . 099 255 . . . 083 030 . . . 010 915 . . . 601 836 . . . 159 921 . . . 147 195 . . . 182 954 . . . 119 172 . . . 148 956 . . . 097 924 . . . 200 532 . . .

LEVER, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SUPPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TERMINAL, pwr output neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STUD, brs .250-20 x 1.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WASHER, flat .250 ID brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NUT, .250-20 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEZEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NUT, .375-27 nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RECEPTACLE, str 3P4W 50A 125/250V . . . . . . . . . . . . . . . . . . . . . . . PLUG, str 50A 125/250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL, warning CSA circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 2 1 3 3 1 5 1 1 2 1 1

. Hardware is common and

1 5 2 3 4 6 7 8 9 10 11 12 13 14 26 25

not available unless listed.

27

15 24 23

19 20 21 17

16

22

18

18
ST-801 517-C

Figure 11-2. Panel, Front w/Components OPTIONAL To maintain the factory original performance of your equipment, use only Manufacturers Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-404 Page 45

Item No.

Part No.

Description Figure 11-3. Generator (Fig 11-1 Item 31)

Quantity

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

1 2 3 4 5 6 7 8 9 10 11 12 13

. . . . . +205 901 . . . . . . 183 419 . . . . . . 079 624 . . . . . . 013 367 . . . . . . 179 647 . . . . . . 189 974 . . . . . . 178 527 . . . . . . 174 828 . . . . . . 189 743 . . . . . . 181 134 . . . . . . 181 143 . . . . . . 180 556 . . . . . . 142 156

. . HOUSING, generator front assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ORING, 1.984 id x .139 cs 70 duro viton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCREW, .37516 x 2.25 hex hdpln stl pld full thlkg pa . . . . . . . . . . . . . . . . . . . . . . LABEL, warning moving parts can cause serious injury . . . . . . . . . . . . . . . . . . . . . . . . STUD, stl .31218+24 x 18.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADAPTER, housing generator rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOUSING, generator rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCREW, M 81.2X 45 hex hdpln 8.8 pln . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ROTOR, generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAN, rotor gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEARING, ball rdl sgl row .984 x 2.047 x .591 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOLDER, brush elec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCREW, .375-16 x 1.75 hexwhd .81d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7

1 1 1 1 1 1 1 4 1 1 1 1 4

6 5

4 1 8 2 11 10 9

12

13
Ref. 173 092-G

Figure 11-3. Generator +When ordering a component originally displaying a precautionary label, the label should also be ordered. *Recommended Spare Parts. To maintain the factory original performance of your equipment, use only Manufacturers Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-404 Page 46

Effective January 1, 2001 (Equipment with a serial number preface of LB or newer)


Warranty Questions?
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 date that the equipment was delivered to the original retail purchaser, or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor. 1. 5 Years Parts 3 Years Labor

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


Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor. The expertise of the distributor and Miller is there to help you, every step of the way.

* * * * * *

APT, ZIPCUT & PLAZCUT Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts (No labor) Spoolmate Spoolguns Canvas Covers

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

2.

3.

* *
2.

Original main power rectifiers Inverters (input and output rectifiers only) Transformer/Rectifier Power Sources Plasma Arc Cutting Power Sources Semi-Automatic and Automatic Wire Feeders Inverter Power Supplies Intellitig Engine Driven Welding Generators (NOTE: Engines are warranted separately by the engine manufacturer.) DS-2 Wire Feeder Motor Driven Guns (w/exception of Spoolmate Spoolguns) Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Water Coolant Systems HF Units Grids Maxstar 140 Spot Welders Load Banks Miller Cyclomatic Equipment 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.)

3 Years Parts and Labor

* * * * * *

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 Millers 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 customers risk and expense. Millers option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility as determined by Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed. TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY. ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER. Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state. In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province.
miller_warr 10/01

3.

1 Year Parts and Labor

* * * * * * * * * * * * * * * * *

4. 5.

6 Months Batteries 90 Days Parts

* *

MIG Guns/TIG Torches Induction Heating Coils and Blankets

Owners Record
Please complete and retain with your personal records.
Model Name Purchase Date Distributor Address City State Zip Serial/Style Number
(Date which equipment was delivered to original customer.)

For Service
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.


Contact your Distributor for: Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training (Schools, Videos, Books) Technical Manuals (Servicing Information and Parts) Circuit Diagrams Welding Process Handbooks Miller Electric Mfg. Co.
An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International HeadquartersUSA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 European Headquarters United Kingdom Phone: 44 (0) 1204-593493 FAX: 44 (0) 1204-598066
www.MillerWelds.com

Contact the Delivering Carrier for:


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

File a claim for loss or damage during shipment.

PRINTED IN USA

2002 Miller Electric Mfg. Co.

1/02