Miller Electric Welding System Renegade 180 User Manual
OM-228 042B  
Processes  
2007−09  
MIG (GMAW) Welding  
Flux Cored (FCAW) Welding  
Description  
Engine Driven Welding Power Source/  
Wire Feeder/Generator  
t
Renegade 180  
File: Engine Drive  
Visit our website at  
www.MillerWelds.com  
Download from Www.Somanuals.com. All Manuals Search And Download.  
TABLE OF CONTENTS  
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
1-4. Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
1-5. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
1-6. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
1-7. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
1-8. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . .  
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
2-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
2-4. Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . .  
2-6. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
1
1
1
3
3
4
5
5
5
6
6
6
8
9
9
11  
2-7. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11  
2-8. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
11  
12  
12  
4-1. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12  
4-2. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12  
4-3. Gun Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13  
4-4. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13  
4-5. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13  
4-6. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14  
4-7. Power Source Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14  
4-8. Gun Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15  
4-9. Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15  
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
16  
5-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16  
5-2. Grounding Generator When Supplying Building Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17  
5-3. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18  
5-4. Connecting The Battery (Electric Start Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18  
5-5. Installing Welding Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19  
5-6. Work Cable Routing Inside Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19  
5-7. Weld Process/Polarity Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20  
5-8. Changing Weld Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20  
5-9. Connecting Single−Phase, 230 Volt AC Utility Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21  
5-10. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22  
5-11. Installing Wire Spool And Adjusting Hub Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22  
5-12. Threading The Welding Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24  
SECTION 6 − OPERATING THE WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
26  
6-1. Controls (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26  
6-2. Description Of Controls (See Section 6-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27  
6-3. Weld Parameter Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28  
6-4. Stainless Steel And 100% CO2 Weld Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29  
SECTION 7 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
30  
7-1. Generator Power Panel Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30  
Download from Www.Somanuals.com. All Manuals Search And Download.  
TABLE OF CONTENTS  
SECTION 8 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
31  
8-1. Power Source Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31  
8-2. Gun Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32  
8-3. Welding Power Source Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32  
8-4. Drive Motor Protection And Tip Saver/Short Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32  
8-5. Changing Drive Roll Or Wire Inlet Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33  
8-6. Replacing Gun Contact Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33  
8-7. Maintaining Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34  
8-8. Replacing Switch And/Or Head Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35  
8-9. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36  
8-10. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37  
SECTION 9 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
SECTION 10 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
38  
40  
10-1. Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40  
SECTION 11 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
SECTION 12 − MIG WELDING (GMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
SECTION 13 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
COMPLETE PARTS LIST - www.MillerWelds.com  
41  
42  
51  
OPTIONS AND ACCESSORIES  
WARRANTY  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING  
rom_2007−04  
Protect yourself and others from injury — read and follow these precautions.  
1-1. Symbol Usage  
DANGER! − Indicates a hazardous situation which, if  
not avoided, will result in death or serious injury. The  
possible hazards are shown in the adjoining symbols  
or explained in the text.  
.
I
n
d
i
c
a
t
e
s
s
p
e
c
i
a
l
i
n
s
t
r
u
c
t
i
o
n
s
.
Indicates a hazardous situation which, if not avoided,  
could result in death or serious injury. The possible  
hazards are shown in the adjoining symbols or ex-  
plained in the text.  
This group of symbols means Warning! Watch Out! ELECTRIC  
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-  
bols and related instructions below for necessary actions to avoid the  
hazards.  
NOTICE − Indicates statements not related to personal injury.  
1-2. Arc Welding Hazards  
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  
groundedreceptacle outlet.  
When making input connections, attach proper grounding conduc-  
tor first − double-check connections.  
Keep cords dry, free of oil and grease, and protected from hot metal  
and sparks.  
Frequentlyinspect input power cord for damage or bare wiring —  
replace cord immediately if damaged — bare wiring can kill.  
Turn off all equipment when not in use.  
Do not use worn, damaged, undersized, or poorly spliced cables.  
Do not drape cables over your body.  
The symbols shown below are used throughout this manual  
to call attention to and identify possible hazards. When you  
see the symbol, watch out, and follow the related instructions  
to avoid the hazard. The safety information given below is  
only a summary of the more complete safety information  
found in the Safety Standards listed in Section 1-7. Read and  
follow all Safety Standards.  
D
D
D
Only qualified persons should install, operate, maintain, and  
repair this unit.  
D
D
D
D
During operation, keep everybody, especially children, away.  
If earth grounding of the workpiece is required, ground it directly  
with a separate cable.  
ELECTRIC SHOCK can kill.  
D
D
D
Do not touch electrode if you are in contact with the work, ground,  
or another electrode from a different machine.  
Use only well-maintained equipment. Repair or replace damaged  
parts at once. Maintain unit according to manual.  
Do not touch electrode holders connected to two welding ma-  
chines at the same time since double open-circuit voltage will be  
present.  
Wear a safety harness if working above floor level.  
Keep all panels and covers securely in place.  
Touching live electrical parts can cause fatal shocks or  
severe burns. The electrode and work circuit is  
electrically live whenever the output is on. The input  
power circuit and machine internal circuits are also live when power is  
on. In semiautomatic or automatic wire welding, the wire, wire reel,  
drive roll housing, and all metal parts touching the welding wire are  
electrically live. Incorrectly installed or improperly grounded equip-  
ment is a hazard.  
D
D
D
D
D
D
Do not touch live electrical parts.  
Clamp work cable with good metal-to-metal contact to workpiece  
or worktable as near the weld as practical.  
Wear dry, hole-free insulating gloves and body protection.  
Insulate yourself from work and ground using dry insulating mats  
or covers big enough to prevent any physical contact with the work  
or ground.  
D
D
Insulate work clamp when not connected to workpiece to prevent  
contact with any metal object.  
Do not connect more than one electrode or work cable to any  
single weld output terminal.  
D
Do not use AC output in damp areas, if movement is confined, or if  
there is a danger of falling.  
SIGNIFICANT DC VOLTAGE exists in inverters after stop-  
ping engine.  
D
D
Use AC output ONLY if required for the welding process.  
D
Stop engine on inverter and discharge input capacitors according  
to instructions in Maintenance Section before touching any parts.  
If AC output is required, use remote output control if present on  
unit.  
D
Additionalsafety precautions are required when any of the follow-  
ing electrically hazardous conditions are present: in damp  
locations or while wearing wet clothing; on metal structures such  
as floors, gratings, or scaffolds; when in cramped positions such  
as sitting, kneeling, or lying; or when there is a high risk of unavoid-  
able or accidental contact with the workpiece or ground. For these  
conditions, use the following equipment in order presented: 1) a  
semiautomaticDC constant voltage (wire) welder, 2) a DC manual  
(stick) welder, or 3) an AC welder with reduced open-circuit volt-  
age. In most situations, use of a DC, constant voltage wire welder  
is recommended. And, do not work alone!  
HOT PARTS can cause severe burns.  
D
D
Do not touch hot parts bare handed.  
Allow cooling period before working on equip-  
ment.  
D
To handle hot parts, use proper tools and/or wear heavy, insu-  
lated welding gloves and clothing to prevent burns.  
FLYING METAL or DIRT can injure eyes.  
D
Welding, chipping, wire brushing, and grinding  
cause sparks and flying metal. As welds cool,  
they can throw off slag.  
D
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
Wear approved safety glasses with side shields even under your  
welding helmet.  
Properly install and ground this equipment according to its  
Owner’s Manual and national, state, and local codes.  
OM-228 042 Page 1  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
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).  
FUMES AND GASES can be hazardous.  
Welding produces fumes and gases. Breathing these  
fumes and gases can be hazardous to your health.  
D
D
Do not weld where the atmosphere may contain flammable dust,  
gas, or liquid vapors (such as gasoline).  
D
D
Keep your head out of the fumes. Do not breathe the fumes.  
If inside, ventilate the area and/or use local forced ventilation at the  
arc to remove welding fumes and gases.  
Connect work cable to the work as close to the welding area as  
practical to prevent welding current from traveling long, possibly  
unknown paths and causing electric shock, sparks, and fire haz-  
ards.  
D
D
If ventilation is poor, wear an approved air-supplied respirator.  
D
D
Do not use welder to thaw frozen pipes.  
Read and understand the Material Safety Data Sheets (MSDSs)  
and the manufacturer’s instructions for metals, consumables,  
coatings, cleaners, and degreasers.  
Remove stick electrode from holder or cut off welding wire at  
contact tip when not in use.  
D
D
D
D
D
Wear oil-free protective garments such as leather gloves, heavy  
shirt, cuffless trousers, high shoes, and a cap.  
D
Work in a confined space only if it is well ventilated, or while  
wearing an air-supplied respirator. Always have a trained watch-  
person nearby. Welding fumes and gases can displace air and  
lower the oxygen level causing injury or death. Be sure the breath-  
ing air is safe.  
Do not weld in locations near degreasing, cleaning, or spraying op-  
erations. The heat and rays of the arc can react with vapors to form  
highly toxic and irritating gases.  
Do not weld on coated metals, such as galvanized, lead, or  
cadmiumplated steel, unless the coating is removed from the weld  
area, the area is well ventilated, and while wearing an air-supplied  
respirator. The coatings and any metals containing these elements  
can give off toxic fumes if welded.  
Remove any combustibles, such as a butane lighter or matches,  
from your person before doing any welding.  
After completion of work, inspect area to ensure it is free of sparks,  
glowing embers, and flames.  
D
D
Use only correct fuses or circuit breakers. Do not oversize or by-  
pass them.  
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B  
for hot work and have a fire watcher and extinguisher nearby.  
NOISE can damage hearing.  
Noise from some processes or equipment can dam-  
age hearing.  
BUILDUP OF GAS can injure or kill.  
D
D
Shut off shielding gas supply when not in use.  
Always ventilate confined spaces or use ap-  
proved air-supplied respirator.  
D
Wear approved ear protection if noise level is  
high.  
MAGNETIC FIELDS can affect Implanted  
Medical Devices.  
ARC RAYS can burn eyes and skin.  
D
Wearers of Pacemakers and other Implanted  
Medical Devices should keep away.  
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.  
D
ImplantedMedical Device wearers should consult their doctor  
and the device manufacturer before going near arc welding, spot  
welding, gouging, plasma arc cutting, or induction heating  
operations.  
D
Wear an approved welding helmet fitted with a proper shade of filter  
lenses to protect your face and eyes from arc rays and sparks  
when welding or watching (see ANSI Z49.1 and Z87.1 listed in  
Safety Standards).  
Wear approved safety glasses with side shields under your  
helmet.  
Use protective screens or barriers to protect others from flash,  
glare, and sparks; warn others not to watch the arc.  
Wear protective clothing made from durable, flame-resistant mate-  
rial (leather, heavy cotton, or wool) and foot protection.  
CYLINDERS can explode if damaged.  
D
D
D
Shielding gas cylinders contain gas under high pres-  
sure. If damaged, a cylinder can explode. Since gas  
cylinders are normally part of the welding process, be  
sure to treat them carefully.  
D
D
Protect compressed gas cylinders from excessive heat, mechani-  
cal shocks, physical damage, slag, open flames, sparks, and arcs.  
Install cylinders in an upright position by securing to a stationary  
support or cylinder rack to prevent falling or tipping.  
WELDING can cause fire or explosion.  
D
D
D
D
D
Keep cylinders away from any welding or other electrical circuits.  
Never drape a welding torch over a gas cylinder.  
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,  
Never allow a welding electrode to touch any cylinder.  
Never weld on a pressurized cylinder — explosion will result.  
and hot equipment can cause fires and burns. Accidental contact of  
electrodeto metal objects can cause sparks, explosion, overheating,  
or fire. Check and be sure the area is safe before doing any welding.  
Use only correct shielding gas cylinders, regulators, hoses, and fit-  
tings designed for the specific application; maintain them and  
associated parts in good condition.  
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
D
Turn face away from valve outlet when opening cylinder valve.  
D
D
D
Do not weld where flying sparks can strike flammable material.  
Protect yourself and others from flying sparks and hot metal.  
Keep protective cap in place over valve except when cylinder is in  
use or connected for use.  
Be alert that welding sparks and hot materials from welding can  
easily go through small cracks and openings to adjacent areas.  
D
D
Use the right equipment, correct procedures, and sufficient num-  
ber of persons to lift and move cylinders.  
D
D
Watch for fire, and keep a fire extinguisher nearby.  
Read and follow instructions on compressed gas cylinders,  
associated equipment, and Compressed Gas Association (CGA)  
publication P-1 listed in Safety Standards.  
Be aware that welding on a ceiling, floor, bulkhead, or partition can  
cause fire on the hidden side.  
OM-228 042 Page 2  
Download from Www.Somanuals.com. All Manuals Search And Download.  
1-3. Engine Hazards  
STEAM AND HOT COOLANT can burn.  
BATTERY EXPLOSION can BLIND.  
D
If possible, check coolant level when engine is  
cold to avoid scalding.  
D
Always wear a face shield, rubber gloves, and  
protective clothing when working on a battery.  
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
Stop engine before disconnecting or connect-  
ing 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.  
D
If the engine is warm, checking is needed, and there is no over-  
flow tank, follow the next two statements.  
Disconnect negative (−) cable first and connect it last.  
D
D
Wear safety glasses and gloves and put a rag over radiator cap.  
Turn cap slightly and let pressure escape slowly before  
completely removing cap.  
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.  
Using a generator indoors CAN KILL  
YOU IN MINUTES.  
D
D
D
D
Do not overfill tank — allow room for fuel to expand.  
Do not spill fuel. If fuel is spilled, clean up before starting engine.  
Dispose of rags in a fireproof container.  
D
Generator exhaust contains carbon monoxide.  
This is a poison you cannot see or smell.  
Always keep nozzle in contact with tank when fueling.  
D
NEVER use inside a home or garage, EVEN IF  
doors and windows are open.  
D
Only use OUTSIDE and far away from windows, doors, and  
vents.  
MOVING PARTS can cause injury.  
D
D
Keep away from fans, belts, and rotors.  
Keep all doors, panels, covers, and guards  
closed and securely in place.  
BATTERY ACID can BURN SKIN and EYES.  
D
D
Stop engine before installing or connecting unit.  
D
D
D
Do not tip battery.  
Replace damaged battery.  
Flush eyes and skin immediately with water.  
Have only qualified people remove doors, panels, covers, or  
guards for maintenance and troubleshooting as necessary.  
D
D
D
D
D
To prevent accidental starting during servicing, disconnect  
negative (−) battery cable from battery.  
Keep hands, hair, loose clothing, and tools away from moving  
parts.  
ENGINE HEAT can cause fire.  
Reinstall doors, panels, covers, or guards when servicing is  
finished and before starting engine.  
D
Do not locate unit on, over, or near combustible  
surfaces or flammables.  
Before working on generator, remove spark plugs or injectors to  
keep engine from kicking back or starting.  
D
Keep exhaust and exhaust pipes way from  
flammables.  
Block flywheel so that it will not turn while working on generator  
components.  
HOT PARTS can cause severe burns.  
D
D
Do not touch hot parts bare handed.  
Allow cooling period before working on equip-  
ment.  
To handle hot parts, use proper tools and/or  
wear heavy, insulated welding gloves and  
clothing to prevent burns.  
EXHAUST SPARKS can cause fire.  
D
D
Do not let engine exhaust sparks cause fire.  
Use approved engine exhaust spark arrestor in  
required areas — see applicable codes.  
D
1-4. Compressed Air Hazards  
TRAPPED AIR PRESSURE AND WHIPPING  
HOSES can cause injury.  
BREATHING COMPRESSED AIR can  
cause serious injury or death.  
D
Release air pressure from tools and system be-  
fore servicing, adding or changing attach-  
ments, or opening compressor oil drain or oil fill  
cap.  
D
D
Do not use compressed air for breathing.  
Use only for cutting, gouging, and tools.  
COMPRESSED AIR can cause injury.  
D
D
Wear approved safety goggles.  
Do not direct air stream toward self or others.  
OM-228 042 Page 3  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
HOT METAL from air arc cutting and  
gouging can cause fire or explosion.  
READ INSTRUCTIONS.  
D
D
D
Read Owner’s Manual before using or servic-  
ing unit.  
Stop engine and release air pressure before  
servicing.  
Use only genuine replacement parts from the  
manufacturer.  
D
D
Do not cut or gouge near flammables.  
Watch for fire; keep extinguisher nearby.  
HOT PARTS can cause burns and injury.  
D
D
Do not touch hot compressor or air system  
parts.  
Let system cool down before touching or ser-  
vicing.  
1-5. Additional Symbols For Installation, Operation, And Maintenance  
FIRE OR EXPLOSION hazard.  
WELDING WIRE can cause injury.  
D
Do not install or place unit on, over, or near  
combustiblesurfaces.  
D
Do not press gun trigger until instructed to do  
so.  
D
Do not install unit near flammables.  
D
Do not point gun toward any part of the body,  
other people, or any metal when threading  
welding wire.  
D
Do not overload building wiring − be sure power supply system is  
properly sized, rated, and protected to handle this unit.  
FALLING UNIT can cause injury.  
OVERUSE can cause OVERHEATING.  
D
Use lifting eye to lift unit and properly installed  
accessories only, NOT gas cylinders. Do not  
exceed maximum lift eye weight rating (see  
Specifications).  
Lift and support unit only with proper equipment  
and correct procedures.  
D
D
Allow cooling period; follow rated duty cycle.  
Reduce current or reduce duty cycle before  
starting to weld again.  
D
Do not block or filter airflow to unit.  
D
D
If using lift forks to move unit, be sure forks are long enough to  
extend beyond opposite side of unit.  
STATIC (ESD) can damage PC boards.  
D
Put on grounded wrist strap BEFORE handling  
boards or parts.  
OVERHEATING can damage motors.  
D
Use proper static-proof bags and boxes to  
store, move, or ship PC boards.  
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.  
TILTING OF TRAILER can cause injury.  
D
Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle  
where applicable.  
D
D
Use tongue jack or blocks to support weight.  
Properly install welding generator onto trailer  
according to instructions supplied with trailer.  
FLYING SPARKS can cause injury.  
D
D
Wear a face shield to protect eyes and face.  
Shape tungsten electrode only on grinder with  
proper guards in a safe location wearing proper  
face, hand, and body protection.  
READ INSTRUCTIONS.  
D
D
D
Read Owner’s Manual before using or servic-  
ing unit.  
Use only genuine replacement parts from the  
manufacturer.  
Perform engine and air compressor mainte-  
nance and service according to this manual  
and the engine/air compressor (if applicable)  
manuals.  
D
Sparks can cause fires — keep flammables away.  
MOVING PARTS can cause injury.  
D
D
Keep away from moving parts.  
Keep away from pinch points such as drive  
rolls.  
OM-228 042 Page 4  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
H.F. RADIATION can cause interference.  
ARC WELDING can cause interference.  
D
High-frequency (H.F.) can interfere with radio  
navigation, safety services, computers, and  
communicationsequipment.  
Have only qualified persons familiar with  
electronic equipment perform this installation.  
D
Electromagnetic energy can interfere with  
sensitive electronic equipment such as micro-  
processors, computers, and computer-driven  
equipmentsuch as robots.  
Be sure all equipment in the welding area is  
electromagneticallycompatible.  
D
D
D
D
The user is responsible for having a qualified electrician  
promptly correct any interference problem resulting from the  
installation.  
D
D
D
D
To reduce possible interference, keep weld cables as short as  
possible, close together, and down low, such as on the floor.  
If notified by the FCC about interference, stop using the  
equipmentat once.  
Locate welding operation 100 meters from any sensitive elec-  
tronic equipment.  
D
D
Have the installation regularly checked and maintained.  
Be sure this welding machine is installed and grounded  
according to this manual.  
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.  
If interference still occurs, the user must take extra measures  
such as moving the welding machine, using shielded cables,  
using line filters, or shielding the work area.  
1-6. California Proposition 65 Warnings  
For Gasoline Engines:  
Welding or cutting equipment produces fumes or gases  
which contain chemicals known to the State of California to  
cause birth defects and, in some cases, cancer. (California  
Health & Safety Code Section 25249.5 et seq.)  
Engine exhaust contains chemicals known to the State of  
California to cause cancer, birth defects, or other reproduc-  
tive harm.  
For Diesel Engines:  
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  
reproductiveharm. Wash hands after handling.  
Diesel engine exhaust and some of its constituents are  
known to the State of California to cause cancer, birth  
defects, and other reproductive harm.  
1-7. Principal Safety Standards  
Safety inWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,  
from Global Engineering Documents (phone: 1-877-413-5184, website:  
www.global.ihs.com).  
Ontario, Canada L4W 5NS (phone: 800-463-6727 or in Toronto  
416-747-4044,website: www.csa-international.org).  
Safe Practice For Occupational And Educational Eye And Face Protec-  
tion, ANSI Standard Z87.1, from American National Standards Institute,  
25 West 43rd Street, New York, NY 10036–8002 (phone:  
212-642-4900,website: www.ansi.org).  
Standard for Fire Prevention During Welding, Cutting, and Other Hot  
Work, NFPA Standard 51B, from National Fire Protection Association,  
P.O. Box 9101, Quincy, MA 02269-9101 (phone: 617-770-3000, web-  
site: www.nfpa.org.  
Recommended Safe Practices for the Preparation for Weldingand Cut-  
ting of Containers and Piping, American Welding Society Standard  
AWS F4.1, from Global Engineering Documents (phone:  
1-877-413-5184,website: www.global.ihs.com).  
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-  
tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (phone:  
617-770-3000,website: www.nfpa.org and www. sparky.org).  
OSHA, Occupational Safety and Health Standards for General Indus-  
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,  
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-  
intendentof Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954  
(phone: 1-866-512-1800) (there are 10 Regional Offices—phone for  
Region 5, Chicago, is 312-353-2220, website: www.osha.gov).  
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,  
from Compressed Gas Association, 4221 Walney Road, 5th Floor,  
Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).  
Code for Safety in Welding and Cutting, CSA Standard W117.2, from  
CanadianStandards Association, Standards Sales, 5060 Mississauga,  
1-8. EMF Information  
Considerations About Welding And The Effects Of Low Frequency  
Electric And Magnetic Fields  
1. Keep cables close together by twisting or taping them, or using a  
cable cover.  
2. Arrange cables to one side and away from the operator.  
3. Do not coil or drape cables around your body.  
4. Keep welding power source and cables as far away from  
operator as practical.  
5. Connect work clamp to workpiece as close to the weld as  
possible.  
Welding current, as it flows through welding cables, will cause electro-  
magnetic fields. There has been and still is some concern about such  
fields. However, after examining more than 500 studies spanning 17  
years of research, a special blue ribbon committee of the National  
Research Council concluded that: “The body of evidence, in the  
committee’s judgment, has not demonstrated that exposure to power-  
frequency electric and magnetic fields is a human-health hazard.”  
However, studies are still going forth and evidence continues to be  
examined.Until the final conclusions of the research are reached, you  
may wish to minimize your exposure to electromagnetic fields when  
welding or cutting.  
About Implanted Medical Devices:  
ImplantedMedical Device wearers should consult their doctor and the  
device manufacturer before performing or going near arc welding, spot  
welding, gouging, plasma arc cutting, or induction heating operations.  
If cleared by your doctor, then following the above procedures is recom-  
mended.  
To reduce magnetic fields in the workplace, use the following  
procedures:  
OM-228 042 Page 5  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT  
UTILISATION  
rom_2007−04fre  
Se protéger, ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud.  
2-1. Signification des symboles  
DANGER! − Indique une situation dangereuse qui si on  
l’évite pas peut donner la mort ou des blessures graves.  
Les dangers possibles sont montrés par les symboles  
joints ou sont expliqués dans le texte.  
.
I
n
d
i
q
u
e
d
e
s
i
n
s
t
r
u
c
t
i
o
n
s
s
p
é
c
i
f
i
q
u
e
s
.
Indique une situation dangereuse qui si on l’évite pas  
peut donner la mort ou des blessures graves. Les dan-  
gers possibles sont montrés par les symboles joints ou  
sont expliqués dans le texte.  
Ce groupe de symboles veut dire Avertissement! Attention! DANGER  
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES  
CHAUDES. Consulter les symboles et les instructions ci-dessous y  
afférant pour les actions nécessaires afin d’éviter le danger.  
NOTE − Indique des déclarations pas en relation avec des blessures  
personnelles.  
2-2. Dangers relatifs au soudage à l’arc  
souder DC semi−automatique de type CV (MIG/MAG), 2) un poste  
à souder manuel (électrode enrobée) DC, 3) un poste à souder  
manuelAC avec tension à vide réduite. Dans la plupart des cas, un  
poste courant continu de type CV est recommandé. Et, ne pas tra-  
vailler seul!  
Les symboles présentés ci-après sont utilisés tout au long du  
présent manuel pour attirer votre attention et identifier les ris-  
ques de danger. Lorsque vous voyez un symbole, soyez  
vigilant et suivez les directives mentionnées afin d’éviter tout  
danger. Les consignes de sécurité présentées ci-après ne  
font que résumer l’information contenue dans les normes de  
sécurité énumérées à la section 2-7. Veuillez lire et respecter  
toutes ces normes de sécurité.  
D
Couper l’alimentation ou arrêter le moteur avant de procéder à  
l’installation, à la réparation ou à l’entretien de l’appareil.  
Déverrouiller l’alimentation selon la norme OSHA 29 CFR  
1910.147(voir normes de sécurité).  
D
D
Installer et mettre à la terre correctement cet appareil conformé-  
ment à son manuel d’utilisation et aux codes nationaux,  
provinciaux et municipaux.  
L’installation, l’utilisation, l’entretien et les réparations ne  
doivent être confiés qu’à des personnes qualifiées.  
Toujours vérifier la terre du cordon d’alimentation − Vérifier et  
s’assurer que le fil de terre du cordon d’alimentation est bien  
raccordé à la borne de terre du sectionneur ou que la fiche du  
cordon est raccordée à une prise correctement mise à la terre.  
Au cours de l’utilisation, tenir toute personne à l’écart et plus  
particulièrementles enfants.  
UN CHOC ÉLECTRIQUE peut tuer.  
D
D
En effectuant les raccordements d’entrée fixer d’abord le conduc-  
teur de mise à la terre approprié et contre-vérifier les connexions.  
Un simple contact avec des pièces électriques peut  
provoquerune électrocution ou des blessures graves.  
L’électrode et le circuit de soudage sont sous tension  
Les câbles doivent être exempts d’humidité, d’huile et de graisse;  
protégez−les contre les étincelles et les pièces métalliques chau-  
des.  
dès que l’appareil est sur ON. Le circuit d’entrée et les circuits  
internes de l’appareil sont également sous tension à ce moment-là.  
En soudage semi-automatique ou automatique, le fil, le dévidoir, le  
logement des galets d’entraînement et les pièces métalliques en  
contact avec le fil de soudage sont sous tension. Des matériels mal  
installés ou mal mis à la terre présentent un danger.  
D
Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est  
pas endommagé ou dénudé − remplacer le cordon immédiatement  
s’il est endommagé − un câble dénudé peut provoquer une électro-  
cution.  
D
D
Mettre l’appareil hors tension quand on ne l’utilise pas.  
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-  
sante ou mal épissés.  
D
D
Ne jamais toucher les pièces électriques sous tension.  
Porter des gants et des vêtements de protection secs ne compor-  
tant pas de trous.  
D
D
Ne pas enrouler les câbles autour du corps.  
Si la pièce soudée doit être mise à la terre, le faire directement  
avec un câble distinct − ne pas utiliser le connecteur de pièce ou le  
câble de retour.  
D
D
S’isoler de la pièce et de la terre au moyen de tapis ou d’autres  
moyens isolants suffisamment grands pour empêcher le contact  
physique éventuel avec la pièce ou la terre.  
D
D
Ne pas toucher l’électrode quand on est en contact avec la pièce,  
la terre ou une électrode provenant d’une autre machine.  
Ne pas se servir de source électrique à courant électrique dans les  
zones humides, dans les endroits confinés ou là où on risque de  
tomber.  
Ne pas toucher des porte électrodes connectés à deux machines  
en même temps à cause de la présence d’une tension à vide dou-  
blée.  
D
D
Se servir d’une source électrique à courant électrique UNIQUE-  
MENT si le procédé de soudage le demande.  
D
N’utiliser qu’un matériel en bon état. Réparer ou remplacer  
sur-le-champ les pièces endommagées. Entretenir l’appareil  
conformémentà ce manuel.  
Si l’utilisation d’une source électrique à courant électrique s’avère  
nécessaire, se servir de la fonction de télécommande si l’appareil  
en est équipé.  
D
D
D
Porter un harnais de sécurité quand on travaille en hauteur.  
Maintenir solidement en place tous les panneaux et capots.  
D
Des précautions de sécurité supplémentaires sont requises dans  
des environnements à risque comme: les endroits humides ou  
lorsque l’on porte des vêtements mouillés; sur des structures mé-  
talliques au sol, grillages et échafaudages; dans des positions  
assises, à genoux et allongées; ou quand il y a un risque important  
de contact accidentel avec la pièce ou le sol. Dans ces cas utiliser  
les appareils suivants dans l’ordre de préférence: 1) un poste à  
Fixer le câble de retour de façon à obtenir un bon contact métal-  
métal avec la pièce à souder ou la table de travail, le plus près  
possible de la soudure.  
D
Isoler la pince de masse quand pas mis à la pièce pour éviter le  
contact avec tout objet métallique.  
OM-228 042 Page 6  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
Une tension DC importante subsiste à l’intérieur  
des onduleurs après avoir coupé l’alimentation.  
LES RAYONS DE L’ARC peuvent pro  
voquer des brûlures dans les yeux e  
sur la peau.  
D
Couper l’alimentation du poste et décharger les condensateurs  
d’entrée comme indiqué dans la Section Maintenance avant de  
toucher des composants.  
Le rayonnement de l’arc du procédé de soudage  
génère des rayons visibles et invisibles intense  
(ultraviolets et infrarouges) susceptibles de provoquer des brûlure  
dans les yeux et sur la peau. Des étincelles sont projetées pendant le  
soudage.  
DES PIÈCES CHAUDES peuvent  
provoquer des brûlures graves.  
D
Ne pas toucher à mains nues les parties chau-  
des.  
Prévoir une période de refroidissement avant de  
travailler à l’équipement.  
D
Porter un casque de soudage approuvé muni de verres filtrants  
approprié pour protéger visage et yeux pendant le soudage  
(voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).  
D
D
D
Porter des lunettes de sécurité avec écrans latéraux même sous  
votre casque.  
D
Ne pas toucher aux pièces chaudes, utiliser les outils recomman-  
dés et porter des gants de soudage et des vêtements épais pour  
éviter les brûlures.  
Avoir recours à des écrans protecteurs ou à des rideaux pour  
protéger les autres contre les rayonnements les éblouissements  
et les étincelles ; prévenir toute personne sur les lieux de ne pas  
regarder l’arc.  
D
Porter des vêtements confectionnés avec des matières résistan-  
tes et ignifuges (cuir, coton lourd ou laine) et des bottes de  
protection.  
DES PIECES DE METAL ou DES SA-  
LETES peuvent provoquer des bles-  
sures dans les yeux.  
LE SOUDAGE peut provoquer un in  
cendie ou une explosion.  
D
D
Le soudage, l’écaillement, le passage de la pièce à la brosse en  
fil de fer, et le meulage génèrent des étincelles et des particules  
métalliquesvolantes. Pendant la période de refroidissement des  
soudures, elles risquent de projeter du laitier.  
Le soudage effectué sur des conteneurs fermés tel  
que des réservoirs, tambours ou des conduites peu  
provoquer leur éclatement. Des étincelles peuven  
être projetées de l’arc de soudure. La projection d’étincelles, des pièce  
chaudes et des équipements chauds peut provoquer des incendies e  
des brûlures. Le contact accidentel de l’électrode avec des objet  
métalliquespeut provoquer des étincelles, une explosion, un surchauf  
fement ou un incendie. Avant de commencer le soudage, vérifier e  
s’assurer que l’endroit ne présente pas de danger.  
Porter des lunettes de sécurité avec écrans latéraux ou un écran  
facial.  
LES FUMÉES ET LES GAZ peuvent être  
dangereux.  
D
Déplacer toutes les substances inflammables à une distance de  
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir  
soigneusementavec des protections homologués.  
Le soudage génère des fumées et des gaz. Leur  
inhalationpeut être dangereux pour votre santé.  
D
D
D
Ne pas souder dans un endroit là où des étincelles peuvent tomber  
sur des substances inflammables.  
D
Eloigner votre tête des fumées. Ne pas respirer les fumées.  
D
D
D
À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au  
niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.  
Se protéger et d’autres personnes de la projection d’étincelles et  
de métal chaud.  
Des étincelles et des matériaux chauds du soudage peuvent  
facilement passer dans d’autres zones en traversant de petites  
fissures et des ouvertures.  
Si la ventilation est médiocre, porter un respirateur anti-vapeurs  
approuvé.  
Lire et comprendre les spécifications de sécurité des matériaux  
(MSDS) et les instructions du fabricant concernant les métaux, les  
consommables, les revêtements, les nettoyants et les dégraisseurs.  
D
D
D
Surveiller tout déclenchement d’incendie et tenir un extincteur à  
proximité.  
Le soudage effectué sur un plafond, plancher, paroi ou séparation  
peut déclencher un incendie de l’autre côté.  
D
Travailler dans un espace fermé seulement s’il est bien ventilé ou  
en portant un respirateur à alimentation d’air. Demander toujours à  
un surveillant dûment formé de se tenir à proximité. Des fumées et  
des gaz de soudage peuvent déplacer l’air et abaisser le niveau  
d’oxygène provoquant des blessures ou des accidents mortels.  
S’assurer que l’air de respiration ne présente aucun danger.  
Ne pas effectuer le soudage sur des conteneurs fermés tels que  
des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été  
préparés correctement conformément à AWS F4.1 (voir les nor-  
mes de sécurité).  
D
D
Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou va-  
peurs inflammables (vapeur d’essence, par exemple).  
D
D
Ne pas souder dans des endroits situés à proximité d’opérations  
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et  
les rayons de l’arc peuvent réagir en présence de vapeurs et for-  
mer des gaz hautement toxiques et irritants.  
Brancher le câble de masse sur la pièce le plus près possible de la  
zone de soudage pour éviter le transport du courant sur une  
longue distance par des chemins inconnus éventuels en provo-  
quant des risques d’électrocution, d’étincelles et d’incendie.  
Ne pas souder des métaux munis d’un revêtement, tels que l’acier  
galvanisé, plaqué en plomb ou au cadmium à moins que le revête-  
ment n’ait été enlevé dans la zone de soudure, que l’endroit soit  
bien ventilé, et en portant un respirateur à alimentation d’air. Les  
revêtementset tous les métaux renfermant ces éléments peuvent  
dégager des fumées toxiques en cas de soudage.  
D
D
D
Ne pas utiliser le poste de soudage pour dégeler des conduites ge-  
lées.  
En cas de non utilisation, enlever la baguette d’électrode du porte-  
électrode ou couper le fil à la pointe de contact.  
Porter des vêtements de protection dépourvus d’huile tels que des  
gants en cuir, une chemise en matériau lourd, des pantalons sans  
revers, des chaussures hautes et un couvre chef.  
LES ACCUMULATIONS DE GAZ ris  
quent de provoquer des blessures ou  
même la mort.  
D
D
D
Avant de souder, retirer toute substance combustible de vos po-  
ches telles qu’un allumeur au butane ou des allumettes.  
D
Fermer l’alimentation du gaz protecteur en cas de  
non utilisation.  
Une fois le travail achevé, assurez−vous qu’il ne reste aucune tra-  
ce d’étincelles incandescentes ni de flammes.  
D
Veiller toujours à bien aérer les espaces confinés ou se servir d’un  
respirateurd’adduction d’air homologué.  
Utiliser exclusivement des fusibles ou coupe−circuits appropriés.  
Ne pas augmenter leur puissance; ne pas les ponter.  
OM-228 042 Page 7  
Download from Www.Somanuals.com. All Manuals Search And Download.  
D
Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et  
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un  
extincteur à proximité.  
D
D
D
Protéger les bouteilles de gaz comprimé d’une chaleur excessive,  
des chocs mécaniques, des dommages physiques, du laitier, des  
flammes ouvertes, des étincelles et des arcs.  
Placer les bouteilles debout en les fixant dans un support station-  
naire ou dans un porte-bouteilles pour les empêcher de tomber ou  
de se renverser.  
LE BRUIT peut affecter l’ouïe.  
Le bruit des processus et des équipements peut affec  
l’ouïe.  
Tenir les bouteilles éloignées des circuits de soudage ou autres  
circuits électriques.  
D
Porter des protections approuvés pour les ore  
les si le niveau sonore est trop élevé.  
D
D
Ne jamais placer une torche de soudage sur une bouteille à gaz.  
Une électrode de soudage ne doit jamais entrer en contact avec  
une bouteille.  
LES CHAMPS MAGNETIQUES peuvent affec-  
ter des implants médicaux.  
D
D
Ne jamais souder une bouteille pressurisée − risque d’explosion.  
D
Porteur de simulateur cardiaque ou autre im-  
plants médicaux, rester à distance.  
Utiliser seulement des bouteilles de gaz protecteur, régulateurs,  
tuyaux et raccords convenables pour cette application spécifique;  
les maintenir ainsi que les éléments associés en bon état.  
D
Les porteurs d’implants doivent d’abord consulter leur médecin  
avant de s’approcher des opérations de soudage à l’arc, de sou-  
dage par points, de gougeage, du coupage plasma ou de chauf-  
fage par induction.  
D
D
D
D
Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la  
bouteille.  
Si des BOUTEILLES sont endomma  
gées, elles pourront exploser.  
Maintenir le chapeau de protection sur la soupape, sauf en cas  
d’utilisationou de branchement de la bouteille.  
Utiliser les équipements corrects, les bonnes procédures et suffi-  
samment de personnes pour soulever et déplacer les bouteilles.  
Des bouteilles de gaz protecteur contiennent du ga  
sous haute pression. Si une bouteille est endomma  
gée, elle peut exploser. Du fait que les bouteilles de gaz fon  
normalement partie du procédé de soudage, les manipuler ave  
précaution.  
Lire et suivre les instructions sur les bouteilles de gaz comprimé,  
l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas  
Association) mentionné dans les principales normes de sécurité.  
2-3. Dangers existant en relation avec le moteur  
D
Seules des personnes qualifiées sont autorisées à enlever les por-  
tes, panneaux, recouvrements ou dispositifs de protection pour  
effectuer, s’il y a lieu, des travaux d’entretien et de dépannage.  
L’EXPLOSION DE LA BATTERIE peu  
RENDRE AVEUGLE.  
D
D
D
Pour empêcher tout démarrage accidentel pendant les travaux  
d’entretien,débrancher le câble négatif (−) de batterie de la borne.  
D
Toujours porter une protection faciale, des gants  
en caoutchouc et vêtements de protection lors  
d’une intervention sur la batterie.  
Ne pas approcher les mains, cheveux, vêtements lâches et outils  
des organes mobiles.  
D
D
D
Arrêter le moteur avant de débrancher ou de brancher les câbles  
de batterie.  
Remettreen place les panneaux ou les dispositifs de protection et  
fermer les portes à la fin des travaux d’entretien et avant de faire  
démarrer le moteur.  
Eviter de provoquer des étincelles avec les outils en travaillant sur  
la batterie.  
D
D
Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la  
mise en route accidentelle du moteur.  
Ne pas utiliser le poste de soudage pour charger les batteries ou  
des véhicules de démarrage rapide.  
Bloquerle volant moteur pour éviter sa rotation lors d’une interven-  
tion sur le générateur.  
D
D
Observer la polarité correcte (+ et −) sur les batteries.  
Débrancher le câble négatif (–) en premier lieu. Le rebrancher en  
dernier lieu.  
DES PIÈCES CHAUDES peuvent  
provoquer des brûlures graves.  
LE CARBURANT MOTEUR peut provo  
quer un incendie ou une explosion.  
D
Ne pas toucher à mains nues les parties chau-  
des.  
D
Prévoir une période de refroidissement avant de  
travailler à l’équipement.  
D
Arrêter le moteur avant de vérifier le niveau de  
carburant ou de faire le plein.  
D
Ne pas toucher aux pièces chaudes, utiliser les outils recomman-  
dés et porter des gants de soudage et des vêtements épais pour  
éviter les brûlures.  
D
Ne pas faire le plein en fumant ou proche d’une source d’étincelles  
ou d’une flamme nue.  
D
D
Ne pas faire le plein de carburant à ras bord; prévoir de l’espace  
pour son expansion.  
LA VAPEUR ET LE LIQUIDE DE  
REFROIDISSEMENT CHAUD peuvent  
provoquer des brûlures.  
Faire attention de ne pas renverser de carburant. Nettoyer tout  
carburant renversé avant de faire démarrer le moteur.  
D
D
Jeter les chiffons dans un récipient ignifuge.  
D
Il est préférable de vérifier le liquide de refroi-  
dissementune fois le moteur refroidi pour éviter  
de se brûler.  
Toujours garder le pistolet en contact avec le réservoir lors du  
remplissage.  
DES ORGANES MOBILES peuvent pro  
voquer des blessures.  
D
Toujours vérifier le niveau de liquide de refroidissement dans le  
vase d’expansion (si présent), et non dans le radiateur (sauf si pré-  
cisé autrement dans la section maintenance du manuel du  
moteur).  
D
Ne pas approcher les mains des ventilateurs,  
courroies et autres pièces en mouvement.  
D
D
Si le moteur est chaud et que le liquide doit être vérifié, opérer com-  
me suivant.  
D
Maintenirfermés et fixement en place les portes, panneaux, re-  
couvrements et dispositifs de protection.  
Mettre des lunettes de sécurité et des gants, placer un torchon sur  
le bouchon du radiateur.  
D
Arrêter le moteur avant d’installer ou brancher l’appareil.  
OM-228 042 Page 8  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
D
Dévisser le bouchon légèrement et laisser la vapeur s’échapper  
avant d’enlever le bouchon.  
LA CHALEUR DU MOTEUR peut pro-  
voquer un incendie.  
L’utilisation d’un groupe autonome  
à l’intérieur PEUT VOUS TUER EN  
QUELQUES MINUTES.  
D
Ne pas placer l’appareil sur, au-dessus ou à  
proximité de surfaces inflammables.  
D
Tenir à distance les produits inflammables de l’échappement.  
D
Les fumées d’un groupe autonome contient du  
monoxyde de carbone. C’est un poison invisi-  
ble et inodore.  
LES ÉTINCELLES À L’ÉCHAPPEMENT  
peuvent provoquer un incendie.  
D
JAMAIS utiliser dans une maison ou garage,  
même avec les portes et fenêtres ouvertes.  
D
Empêcher les étincelles d’échappement du  
moteur de provoquer un incendie.  
D
Uniquementutiliser à l’EXTERIEUR, loin des portes, fenêtres et  
bouches aération.  
D
Utiliser uniquement un pare-étincelles  
approuvé − voir codes en vigueur.  
L’ACIDE DE LA BATTERIE peut pro-  
voquer des brûlures dans les YEUX et  
sur la PEAU.  
D
D
Ne pas renverser la batterie.  
Remplacer une batterie endommagée.  
D
Rincer immédiatement les yeux et la peau à l’eau.  
2-4. Dangers liés à l’air comprimé  
Le METAL CHAUD lors du coupage et  
gougeage plasma peut provoquer un in-  
cendie ou une explosion.  
RESPIRER L’AIR COMPRIMÉ peut pro-  
voquer des blessures graves ou causer  
la mort.  
D
Ne pas couper ou gouger à proximité de pro-  
duits inflammables.  
Surveillez et garder un extincteur à proximité.  
D
D
Ne pas utiliser l’air comprimé pour respirer.  
Utiliser l’air comprimé seulement pour le cou-  
page, gougeage et les outils pneumatiques.  
D
DES PIECES CHAUDES peuvent provo-  
quer des brûlures et blessures.  
L’AIR COMPRIMÉ peut provoquer  
des blessures.  
D
Ne pas toucher le compresseur ou d’autres  
éléments du circuit air comprimé chauds.  
D
D
Porter des lunettes de sécurité approuvées.  
Ne pas diriger le jet d’air vers d’autres ou  
soi-même.  
D
Laisser l’ensemble se refroidir avant de toucher ou d’effectuer la  
maintenance.  
L’AIR COMPRIME EMMAGASINE ET DES  
TUYAUX SOUS PRESSION peuvent provo-  
quer des blessures.  
LIRE LES INSTRUCTIONS.  
D
Lisez le manuel d’instructions avant l’utilisation  
ou la maintenance de l’appareil.  
D
Relâcher la pression d’air de l’outillage ou du  
système avant d’effectuer la maintenance,  
avant de changer ou de rajouter des éléments  
ou avant d’ouvrir la purge ou le bouchon de  
remplissaged’huile.  
D
Arrêter le moteur et relâcher la pression avant  
d’effectuer la maintenance.  
D
N’utiliser que les pièces de rechange recommandées par le  
constructeur.  
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance  
Risque D’INCENDIE OU D’EXPLO-  
SION.  
LA CHUTE DE L’APPAREIL peut blesser.  
D
Utiliser l’anneau de levage pour lever l’appareil et  
les accessoires correctement installées seuls,  
PAS les bouteilles de gaz. Ne pas dépasser le  
poids nominal maximal de l’œilleton (voir les spé-  
cifications).  
D
Ne pas placer l’appareil sur, au-dessus ou  
à proximité de surfaces inflammables.  
D
Ne pas installer l’appareil à proximité de pro-  
duits inflammables.  
D
Ne lever et ne soutenir l’appareil qu’avec de  
l’équipement approprié et en suivant les  
procédures adéquates.  
D
Ne pas surcharger l’installation électrique − s’assurer que l’ali-  
mentationest correctement dimensionnée et protégée avant de  
mettre l’appareil en service.  
D
En utilisant des fourches de levage pour déplacer l’unité, s’assurer  
que les fourches sont suffisamment longues pour dépasser du  
côté opposé de l’appareil.  
OM-228 042 Page 9  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
UNE REMORQUE QUI BASCULE peut  
entraîner des blessures.  
LE SURCHAUFFEMENT peut endom-  
mager le moteur électrique.  
D
Utiliser les supports de la remorque ou des  
blocs pour soutenir le poids.  
D
Arrêter ou déconnecter l’équipement avant de  
démarrer ou d’arrêter le moteur.  
D
Installer convenablement le poste sur la remor-  
que comme indiqué dans le manuel s’y rappor-  
tant.  
D
D
Ne pas laisser tourner le moteur trop lentement sous risque d’en-  
dommagerle moteur électrique à cause d’une tension et d’une fré-  
quence trop faibles.  
Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz,  
s’il y a lieu.  
LIRE LES INSTRUCTIONS.  
D
Lisez le manuel d’instructions avant l’utilisation  
ou la maintenance de l’appareil.  
D
N’utiliser que les pièces de rechange recom-  
mandées par le constructeur.  
LES ÉTINCELLES VOLANTES ris-  
quent de provoquer des blessures.  
D
Effectuer la maintenance et le service du moteur et du compres-  
seur d’air suivant les instructions dans ce manuel ou le manuel  
du moteur/compresseur (si applicable).  
D
Porter un écran facial pour protéger le visage et  
les yeux.  
D
Affûter l’électrode au tungstène uniquement à la  
meuleuse dotée de protecteurs. Cette manœuv-  
re est à exécuter dans un endroit sûr lorsque l’on  
porte l’équipement homologué de protection du  
visage, des mains et du corps.  
LE RAYONNEMENT HAUTE FRÉ-  
QUENCE (H.F.) risque de provoquer  
des interférences.  
D
Le rayonnement haute fréquence (H.F.) peut  
provoquer des interférences avec les équipe-  
ments de radio−navigation et de communica-  
tion, les services de sécurité et les ordinateurs.  
D
Les étincelles risquent de causer un incendie − éloigner toute sub-  
stance inflammable.  
D
Demander seulement à des personnes qualifiées familiarisées  
avec des équipements électroniques de faire fonctionner l’instal-  
lation.  
DES ORGANES MOBILES peuvent  
provoquer des blessures.  
D
Ne pas s’approcher des organes mobiles.  
Ne pas s’approcher des points de coincement  
tels que des rouleaux de commande.  
D
D
L’utilisateurest tenu de faire corriger rapidement par un électri-  
cien qualifié les interférences résultant de l’installation.  
D
Si le FCC signale des interférences, arrêter immédiatement l’ap-  
pareil.  
D
D
Effectuer régulièrement le contrôle et l’entretien de l’installation.  
LES FILS DE SOUDAGE peuvent  
provoquer des blessures.  
Maintenirsoigneusement fermés les portes et les panneaux des  
sources de haute fréquence, maintenir les éclateurs à une dis-  
tance correcte et utiliser une terre et un blindage pour réduire les  
interférences éventuelles.  
D
Ne pas appuyer sur la gâchette avant d’en  
avoir reçu l’instruction.  
D
Ne pas diriger le pistolet vers soi, d’autres per-  
sonnes ou toute pièce mécanique en enga-  
geant le fil de soudage.  
LE SOUDAGE À L’ARC risque de  
provoquer des interférences.  
D
L’énergie électromagnétique risque de provo-  
quer des interférences pour l’équipement élec-  
tronique sensible tel que les ordinateurs et  
l’équipementcommandé par ordinateur tel que  
les robots.  
L’EMPLOI EXCESSIF peut  
SURCHAUFFER L’ÉQUIPEMENT.  
D
D
D
Laisser l’équipement refroidir ; respecter le fac-  
teur de marche nominal.  
Réduire le courant ou le facteur de marche  
avant de poursuivre le soudage.  
D
D
Veiller à ce que tout l’équipement de la zone de soudage soit  
compatibleélectromagnétiquement.  
Pour réduire la possibilité d’interférence, maintenir les câbles de  
soudage aussi courts que possible, les grouper, et les poser  
aussi bas que possible (ex. par terre).  
Ne pas obstruer les passages d’air du poste.  
D
D
D
Veiller à souder à une distance de 100 mètres de tout équipe-  
ment électronique sensible.  
LES CHARGES ÉLECTROSTATI-  
QUES peuvent endommager les  
circuits imprimés.  
Veiller à ce que ce poste de soudage soit posé et mis à la terre  
conformément à ce mode d’emploi.  
En cas d’interférences après avoir pris les mesures précéden-  
tes, il incombe à l’utilisateur de prendre des mesures supplé-  
mentairestelles que le déplacement du poste, l’utilisation de câ-  
bles blindés, l’utilisation de filtres de ligne ou la pose de protec-  
teurs dans la zone de travail.  
D
Établir la connexion avec la barrette de terre  
avant de manipuler des cartes ou des pièces.  
D
Utiliser des pochettes et des boîtes antistatiques pour stocker,  
déplacer ou expédier des cartes de circuits imprimes.  
OM-228 042 Page 10  
Download from Www.Somanuals.com. All Manuals Search And Download.  
2-6. Proposition californienne 65 Avertissements  
Pour les moteurs à essence :  
Les équipements de soudage et de coupage produisent des  
fumées et des gaz qui contiennent des produits chimiques  
dont l’État de Californie reconnaît qu’ils provoquent des mal-  
formations congénitales et, dans certains cas, des cancers.  
(Code de santé et de sécurité de Californie, chapitre 25249.5  
et suivants)  
Les gaz d’échappement des moteurs contiennent des pro-  
duits chimiques dont l’État de Californie reconnaît qu’ils  
provoquent des cancers et des malformations congénitales  
ou autres problèmes de procréation.  
Pour les moteurs diesel :  
Les batteries, les bornes et autres accessoires contiennent  
du plomb et des composés à base de plomb, produits chimi-  
ques dont l’État de Californie reconnaît qu’ils provoquent des  
cancers et des malformations congénitales ou autres  
problèmesde procréation. Se laver les mains après manipu-  
lation.  
Les gaz d’échappement des moteurs diesel et certains de  
leurs composants sont reconnus par l’État de Californie com-  
me provoquant des cancers et des malformations  
congénitalesou autres problèmes de procréation.  
2-7. Principales normes de sécurité  
Safety inWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,  
de Global Engineering Documents (téléphone : 1-877-413-5184, site  
Internet : www.global.ihs.com).  
L4W 5NS (téléphone : 800-463-6727 ou à Toronto 416-747-4044, site  
Internet : www.csa-international.org).  
Safe Practice For Occupational And Educational Eye And Face Protec-  
tion, ANSI Standard Z87.1, de American National Standards Institute,  
11 West 43rd Street, New York, NY 10036-8002 (téléphone :  
212-642-4900,site Internet : www.ansi.org).  
RecommendedSafe Practices for the Preparation for Welding and Cut-  
ting of Containers and Piping, American Welding Society Standard  
AWS F4.1 de Global Engineering Documents (téléphone  
1-877-413-5184,site Internet : www.global.ihs.com).  
:
Standard for Fire Prevention During Welding, Cutting, and Other Hot  
Work, NFPA Standard 51B, de National Fire Protection Association,  
P.O. Box 9101, Quincy, MA 02269-9101 (téléphone : 617-770-3000,  
site Internet : www.nfpa.org).  
National Electrical Code, NFPA Standard 70, de National Fire Protec-  
tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (téléphone :  
617-770-3000, site Internet : www.nfpa.org).  
OSHA, Occupational Safety and Health Standards for General Indus-  
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,  
and Part 1926, Subpart J, de U.S. Government Printing Office, Superin-  
tendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954  
(téléphone: 1-866-512-1800) (il y a 10 bureaux régionaux−−le télépho-  
ne de la région 5, Chicago, est 312-353-2220, site Internet :  
www.osha.gov).  
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,  
de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chan-  
tilly, VA 20151 (téléphone  
www.cganet.com).  
:
703-788-2700, site Internet  
:
Code for Safety in Welding and Cutting, CSA Standard W117.2, de  
CanadianStandards Association, 5060 Mississauga, Ontario, Canada  
2-8. Information EMF  
Considérationssur le soudage et les effets de basse fréquence et des  
champs magnétiques et électriques.  
1. Garder les câbles ensemble, les torsader, les scotcher, ou les  
recouvrir d’une housse.  
2. Disposer les câbles d’un côté et à distance de l’opérateur.  
3. Ne pas courber pas et ne pas entourer pas les câbles autour de  
votre corps.  
Le courant de soudage, pendant son passage dans les câbles de sou-  
dage, causera des champs électromagnétiques. Il y a eu et il y a encore  
un certain souci à propos de tels champs. Cependant, après avoir exa-  
miné plus de 500 études qui ont été faites pendant une période de  
recherche de 17 ans, un comité spécial ruban bleu du National  
Research Council a conclu : « L’accumulation de preuves, suivant le  
jugement du comité, n’a pas démontré que l’exposition aux champs  
magnétiqueset champs électriques à haute fréquence représente un  
risque à la santé humaine ». Toutefois, des études sont toujours en  
cours et les preuves continuent à être examinées. En attendant que les  
conclusions finales de la recherche soient établies, il vous serait  
souhaitablede réduire votre exposition aux champs électromagnéti-  
ques pendant le soudage ou le coupage.  
4. Garder le poste de soudage et les câbles le plus loin possible de  
vous.  
5. Connecter la pince sur la pièce aussi près que possible de la  
soudure.  
About Implanted Medical Devices:  
Les porteurs d’implants doivent d’abord consulter leur médecin avant  
de s’approcher des opérations de soudage à l’arc, de soudage par  
points, de gougeage, du coupage plasma ou de chauffage par induc-  
tion. Si le médecin approuve, il est recommandé de suivre les  
procédures précédentes.  
Pour réduire les champs magnétiques sur le poste de travail, appliquer  
les procédures suivantes :  
OM-228 042 Page 11  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
.
C
o
m
p
l
e
t
e
P
a
r
t
s
L
i
s
t
a
v
a
i
l
a
b
l
e
a
t
w
w
w
.
M
i
l
l
e
r
W
e
l
d
s
.
c
o
m
SECTION 3 − DEFINITIONS  
3-1. Symbol Definitions  
Read Operator’s  
Manual  
Engine Choke  
Amperes  
Volts  
A
V
Engine Oil  
Positive  
Fuel  
Circuit Protector  
Engine  
Output  
Alternating Current  
(AC)  
Negative  
Direct Current  
(DC)  
Protective Earth  
(Ground)  
Hours  
Time  
Input  
h
Single-Phase 230  
Input Volt Power  
Off  
Temperature  
GMAW Gun  
Trigger  
Shielding Gas  
Input  
Wire Speed  
Spool Gun  
Over Temperature  
SECTION 4 − SPECIFICATIONS  
4-1. Description  
This unit is an engine driven welding power source/wire feeder with auxiliary power capability. The welding power  
source/wire feeder can also use utility power to provide weld output (no auxiliary power available in this mode).  
4-2. Weld, Power, And Engine Specifications  
Amperes Input at  
Rated Load Output  
230 V, 60 Hz,  
Fuel  
Capacity  
Maximum Open-  
Circuit Voltage  
DC  
Rated Welding  
Output  
Amperage  
Range  
Generator  
Power Rating  
KVA/KW  
Engine  
Single-Phase  
Kohler CS10  
Air-Cooled,  
One-Cylinder,  
Four-Cycle,  
10 HP (300 CC),  
Gasoline Engine  
(Recoil or Electric  
Start)  
Single-Phase,  
5.0 kVA/kW  
(Peak)  
4.5 kVA/kW  
(Continuous)  
40/20 A,  
135 A @ 22.5  
Volts DC, 30%  
Duty Cycle At 60  
Hz Input  
1.8 Gal  
(6.9 L)  
Tank  
4.60 KVA  
3.75 KW  
30 − 180  
35  
19.5  
120/240 V AC,  
60 Hz  
Solid/  
Stainless  
Flux Cored  
Wire Feed Speed Range  
Wire Type  
And Dia  
.024 − .035  
in.  
(0.6 − 0.9  
mm)  
.030 − .045 in.  
(0.8 − 1.2 mm)  
40 − 720 IPM (1.0 − 18.3 m/min) At No Load  
20 − 700 IPM (0.5 − 17.8 m/min) Feeding Wire  
OM-228 042 Page 12  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
.
C
o
m
p
l
e
t
e
P
a
r
t
s
L
i
s
t
a
v
a
i
l
a
b
l
e
a
t
w
w
w
.
M
i
l
l
e
r
W
e
l
d
s
.
c
o
m
4-3. Gun Specifications  
Air-CooledWelding Guns For GMAW And FCAW Welding  
.
U
s
i
n
g
g
a
s
l
e
s
s
f
l
u
x
c
o
r
e
d
w
i
r
e
r
e
d
u
c
e
s
g
u
n
d
u
t
y
c
y
c
l
e
.
M-15 Feeds .023 To .045 in. (0.6 To 1.1 mm) Hard Or Flux Cored Wires  
.045 in. (1.1 mm) wire requires liner change to MILLER Part No. 194012 in addition to contact tip change  
Duty Cycle Rating:  
100%: 150 A With CO Shielding Gas; 120 A With Mixed Gases  
2
60%: 200 A With CO Shielding Gas; 150 A With Mixed Gases  
2
Weight With 15 ft (4.6 m) Power Cable: 6.0 lb (2.7 kg)  
Identified With  
z
z
O
n
P
o
w
e
r
C
a
b
l
e
Ref. 800 797-D  
4-4. Dimensions, Weights, And Operating Angles  
Dimensions  
Height  
31 in (787 mm)  
32 in (813 mm)  
Width  
D
Length  
41 in (1041 mm)  
31-5/8 in (803 mm)  
10-9/16 in (268 mm)  
13-25/64in (340 mm)  
22-3/4 in (577 mm)  
1-9/16 in (40 mm)  
19-5/8 in (498 mm)  
13/32 in (10 mm) Dia.  
Weight  
A
B
C
D
E
F
Do not exceed tilt angles or engine  
could be damaged or unit could tip.  
B
C
Do not move or operate unit where  
it could tip.  
A
G
15°  
275 lb (125 kg) Recoil Start  
307 lb (140 kg) Electric Start  
15°  
15°  
G
4
15°  
Holes  
Optional Lifting Eye  
Weight Rating  
F
E
430 lb (195 kg)  
Engine End  
803 403  
804 476-C  
NOTICE − Optional lifting eye may not  
be installed on units with optional cylin-  
der rack.  
4-5. Volt-Ampere Curves  
This welding power source can be  
powered by the unit engine or utility  
power via a wall receptacle.  
40  
35  
30  
25  
The volt-ampere curve shows the  
minimum and maximum voltage  
and amperage output capabilities of  
the unit. Curves of all other settings  
fall between the curves shown.  
Wall Maximum  
20  
15  
10  
5
Generator  
Maximum  
Wall Minimum  
0
0
20  
40  
60  
80  
100 120 140 160 180 200  
DC Amperage  
233 243  
OM-228 042 Page 13  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
.
C
o
m
p
l
e
t
e
P
a
r
t
s
L
i
s
t
a
v
a
i
l
a
b
l
e
a
t
w
w
w
.
M
i
l
l
e
r
W
e
l
d
s
.
c
o
m
4-6. Fuel Consumption  
1.00  
0.80  
0.60  
0.40  
0.20  
0.00  
0
1
2
3
4
5
6
Auxiliary Power Kw At 100% Duty Cycle  
233 244  
4-7. Power Source Duty Cycle  
Duty cycle is the percentage of 10  
minutes that unit can weld at rated  
load without overheating.  
NOTICE − Exceeding duty cycle  
can damage unit and void warranty.  
300  
250  
200  
150  
135  
105  
80  
60  
50  
10  
15  
20 25 30  
40  
50 60 70 80 100  
% Duty Cycle  
30% duty cycle at 135 amps, 60 Hz  
20% duty cycle at 130 amps, 50 Hz  
3 Minutes Welding  
7 Minutes Resting  
Overheating  
A or V  
0
15  
OR  
Reduce Duty Cycle  
Minutes  
230 343-A  
OM-228 042 Page 14  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
.
C
o
m
p
l
e
t
e
P
a
r
t
s
L
i
s
t
a
v
a
i
l
a
b
l
e
a
t
w
w
w
.
M
i
l
l
e
r
W
e
l
d
s
.
c
o
m
4-8. Gun Duty Cycle And Overheating  
See Section 4-3. Specifications for  
amperage rating and duty cycle.  
Duty Cycle is percentage of 10  
minutes that unit can weld at rated  
load without overheating.  
60%dutycycle  
100%dutycycle  
NOTICE − Exceeding duty cycle  
can damage unit and void warranty.  
6 Minutes Welding  
ContinuousWelding  
4 Minutes Resting  
Overheating  
0
A or V  
15  
OR  
Reduce Duty Cycle  
Minutes  
sduty1 5/95  
4-9. Generator Power Curve  
The ac generator power curves  
show the generator power available  
in amperes at the receptacles.  
300  
250  
240 Volt  
200  
150  
120 Volt  
100  
50  
0
0
20  
40  
60  
AC Amperes  
80  
100  
120  
233 242  
OM-228 042 Page 15  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
.
C
o
m
p
l
e
t
e
P
a
r
t
s
L
i
s
t
a
v
a
i
l
a
b
l
e
a
t
w
w
w
.
M
i
l
l
e
r
W
e
l
d
s
.
c
o
m
SECTION 5 − INSTALLATION  
5-1. Installing Welding Generator  
Airflow Clearance  
Movement  
18 in  
(460 mm)  
18 in  
(460 mm)  
18 in  
(460 mm)  
.
S
h
o
w
n
w
i
t
h
standard  
running gear  
and optional  
cylinder rack.  
18 in  
(460 mm)  
18 in  
(460 mm)  
Location  
Do not install unit where air  
flow is restricted or engine  
may overheat.  
Always securely fasten welding  
generator onto transport vehicle  
or trailer and comply with all DOT  
and other applicable codes.  
Always ground generator  
frame to vehicle frame to pre-  
vent electric shock and static  
electricity hazards.  
2
1
2
Metal Vehicle Frame  
3
GND/PE  
Equipment Grounding  
Terminal  
3
Grounding Cable  
Bed liners, shipping skids,  
and some running gear insu-  
late the welding generator  
from the vehicle frame. Al-  
ways connect a ground wire  
from the generator equip-  
ment grounding terminal to  
bare metal on the vehicle  
frame as shown.  
Use #10 AWG or larger insulated  
copper wire to make metal-to-metal  
groundingconnection.  
1
If unit does not have GFCI  
receptacles, use  
GFCI-  
protected extension cord.  
Ref. install 11/02 − Ref. 800 652 / 804 476-C / S-0854  
OM-228 042 Page 16  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
.
C
o
m
p
l
e
t
e
P
a
r
t
s
L
i
s
t
a
v
a
i
l
a
b
l
e
a
t
w
w
w
.
M
i
l
l
e
r
W
e
l
d
s
.
c
o
m
5-2. Grounding Generator When Supplying Building Systems  
Ground generator to sys-  
tem earth ground if supply-  
ing power to a premises  
(home, shop, farm) wiring  
system.  
1
2
GND/PE  
1
2
EquipmentGrounding  
Terminal  
Grounding Cable  
Use #10 AWG or larger insulated  
copper wire.  
3
Ground Device  
.
U
s
e
g
r
o
u
n
d
d
e
v
i
c
e
a
s
s
t
a
t
e
d
in electrical codes.  
2
3
800 576-B  
Notes  
WELD POSITION: FLAT  
HORIZONTAL  
VERTICAL  
OVERHEAD  
BUTT  
1G  
BUTT  
4G  
WELD JOINT  
TYPES  
BUTT  
2G  
BUTT  
3G  
T−JOINT  
T−JOINT  
2F  
GROOVE  
4F  
T−JOINT  
FILLET  
Ref. AWS/ANSI D1.1  
T−JOINT  
3F  
Ref. 804 248-A  
1F  
OM-228 042 Page 17  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
.
C
o
m
p
l
e
t
e
P
a
r
t
s
L
i
s
t
a
v
a
i
l
a
b
l
e
a
t
w
w
w
.
M
i
l
l
e
r
W
e
l
d
s
.
c
o
m
5-3. Engine Prestart Checks  
Check all fluids daily. Engine must  
be cold and on a level surface. Unit  
is shipped with 10W30 engine oil.  
1/2 in  
(13 mm)  
1
Fuel Valve  
Full  
Open valve.  
.
F
u
e
l
v
a
l
v
e
i
s
s
h
o
w
n
i
n
t
h
e
o
p
e
n
position. Always close fuel  
valve after stopping unit. Mov-  
ing unit with fuel valve open  
may cause carburetor flooding  
and make starting difficult.  
Gasoline  
Fuel  
Add fresh fuel before starting  
engine the first time (see engine  
manual for specifications). Fill fuel  
tank up to 1/2 in. (13 mm) from top  
to allow room for expansion. Check  
fuel level on a cold engine before  
use each day.  
1
Oil  
After fueling, check oil with unit on  
level surface. If oil is not up to full  
mark on dipstick, add oil (see en-  
gine manual).  
Unit stops if oil level is too low. Unit  
cannot be restarted until sufficient  
oil is added.  
Full  
804 971-A  
5-4. Connecting The Battery (Electric Start Models Only)  
!
Turn Engine Switch to Off  
(electric start models only).  
!
Connect negative (−)  
cable last.  
+
−
Tools Needed:  
1/2 in  
805 052-A / 803 466  
OM-228 042 Page 18  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
.
C
o
m
p
l
e
t
e
P
a
r
t
s
L
i
s
t
a
v
a
i
l
a
b
l
e
a
t
w
w
w
.
M
i
l
l
e
r
W
e
l
d
s
.
c
o
m
5-5. Installing Welding Gun  
1
2
3
Drive Assembly  
Gun Securing Knob  
Gun End  
1
5
Loosen knob. Insert gun end  
through opening until it bottoms  
against drive assembly. Tighten  
knob.  
2
3
4
Gun Trigger Plug  
Insert into receptacle, and tighten  
threaded collar.  
5
Mig Gun/Spool Gun Select  
Switch  
Place switch in position for gun be-  
ing used.  
Close door.  
4
804 755-B  
5-6. Work Cable Routing Inside Unit  
1
Work Clamp Lead  
2
3
4
Wire Drive Lead  
Positive Output Terminal  
Negative Output Terminal  
Route work cable to output termi-  
nal. See Section 5-7 for connec-  
tions.  
Close door.  
2
1
3
4
804 755-B  
OM-228 042 Page 19  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
.
C
o
m
p
l
e
t
e
P
a
r
t
s
L
i
s
t
a
v
a
i
l
a
b
l
e
a
t
w
w
w
.
M
i
l
l
e
r
W
e
l
d
s
.
c
o
m
5-7. Weld Process/Polarity Table  
Cable Connections  
Weld Process  
Weld Polarity  
Wire Drive Lead  
Work Clamp Lead  
GMAW − Solid wire with shield- DCEP − Reverse polarity  
ing gas  
Connect to positive (+) out- Connect to negative (−) output  
put terminal  
terminal  
FCAW − Self-shielding wire −  
no shielding gas  
DCEN − Straight Polarity  
Connect to negative (−)  
output terminal  
Connect to positive (+) output  
terminal  
5-8. Changing Weld Polarity  
.
C
o
n
n
e
c
t
i
o
n
h
a
r
d
w
a
r
e
m
u
s
t
b
e
tightenedwith proper tools. Do  
not just hand tighten hardware.  
A loose electrical connection  
will cause poor weld perfor-  
mance and excessive heating  
at the terminal block.  
1
2
Lead Connections For Direct  
Current Electrode Negative  
(DCEN)  
2
1
Lead Connections For Direct  
Current Electrode Positive  
(DCEP)  
Always read and follow wire  
manufacturer’s recommended po-  
larity, and see Section 5-7.  
Close door.  
Ref. 230 748-B  
OM-228 042 Page 20  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
.
C
o
m
p
l
e
t
e
P
a
r
t
s
L
i
s
t
a
v
a
i
l
a
b
l
e
a
t
w
w
w
.
M
i
l
l
e
r
W
e
l
d
s
.
c
o
m
5-9. Connecting Single−Phase, 230 Volt AC Utility Input Power  
.
T
h
i
s
u
n
i
t
c
a
n
p
r
o
v
i
d
e
w
e
l
d
o
u
t
-
put using the engine to power  
the welding power source/wire  
feeder OR single−phase 230  
volt ac utility power can be  
used to power the welding pow-  
er source/wire feeder.  
1
6
=GND/PE Earth Ground  
8
Installationmust meet all Na-  
tional and Local Codes −  
have only qualified persons  
make this installation.  
5
Disconnect and lockout/tag-  
out input power before con-  
necting input conductors  
from unit.  
7
L1  
L2  
Always connect green or  
green/yellow conductor to  
supply grounding terminal  
first, and never to a line ter-  
minal.  
2
3
10  
L2  
1
Rating Label  
4
L1  
Supply correct input power.  
2
3
Black And White Input  
Conductor (L1 And L2)  
Green Or Green/Yellow  
Grounding Conductor  
230 VAC, 1  
4
5
Input Power Cord.  
Disconnect Device (switch  
shown in the OFF position)  
6
7
Disconnect Device Grounding  
Terminal  
Disconnect Device Line  
Terminals  
Connect green or green/yellow  
groundingconductor to disconnect  
device grounding terminal first.  
Connect input conductors L1 and  
L2 to disconnect device line termi-  
nals.  
8
Over-Current Protection  
Select type and size of over-current  
protection using Section 5-10  
(fused disconnect switch shown).  
1
Close and secure door on discon-  
nect device. Remove lockout/tag-  
out device, and place switch in the  
On position.  
9
Plug (NEMA 6-50P)  
10 Receptacle (NEMA 6-50R)  
Connect plug to receptacle.  
Special installation may be  
required where gasoline or  
volatile liquids are present −  
see NEC Article 511 or CEC  
Section 20.  
9
Tools Needed:  
.
S
h
o
w
n
w
i
t
h
o
p
t
i
o
n
a
l
c
y
l
i
n
d
e
r
r
a
c
k
Ref. 802 085 / Ref. 803 766-B / 804 476-C  
OM-228 042 Page 21  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
.
C
o
m
p
l
e
t
e
P
a
r
t
s
L
i
s
t
a
v
a
i
l
a
b
l
e
a
t
w
w
w
.
M
i
l
l
e
r
W
e
l
d
s
.
c
o
m
5-10. Electrical Service Guide  
60 Hz  
Single  
Phase  
Input Voltage  
230  
20  
Input Amperes At Rated Output  
Max Recommended Standard Fuse Rating In Amperes  
1
2
Circuit Breaker , Time-Delay  
Normal Operating  
25  
30  
14  
3
4
Min Input Conductor Size In AWG  
67  
(20)  
Max Recommended Input Conductor Length In Feet (Meters)  
4
Min Grounding Conductor Size In AWG  
14  
Reference: 2005 National Electrical Code (NEC) (including article 630)  
1 Choose a circuit breaker with time-current curves comparable to a Time Delay Fuse.  
2 “Time-Delay” fuses are UL class “RK5” .  
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and  
above).  
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table  
310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.  
Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard. These  
recommendationsare for a dedicated branch circuit that applies to the rated output and duty cycle of the welding power source.  
5-11. Installing Wire Spool And Adjusting Hub Tension  
1
2
Adapter  
Installing 4 in. (102 mm) Wire Spool  
RetainingRing  
When a slight force is needed to  
turn spool, tension is set.  
Installing 8 in. (203 mm) Wire Spool  
1
2
Tools Needed:  
1/2 in  
803 012 / 803 013 -B / Ref. 802 444-C  
OM-228 042 Page 22  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
.
C
o
m
p
l
e
t
e
P
a
r
t
s
L
i
s
t
a
v
a
i
l
a
b
l
e
a
t
w
w
w
.
M
i
l
l
e
r
W
e
l
d
s
.
c
o
m
Notes  
Ref. AWS/ANSI D1.1  
WELD JOINT  
TYPES  
GROOVE  
FILLET  
WELD POSITION:  
FLAT  
BUTT  
1G  
T−JOINT  
1F  
HORIZONTAL  
BUTT  
2G  
T−JOINT  
2F  
VERTICAL  
BUTT  
3G  
T−JOINT  
3F  
OVERHEAD  
BUTT  
4G  
T−JOINT  
4F  
Ref. 804 248-A  
OM-228 042 Page 23  
Download from Www.Somanuals.com. All Manuals Search And Download.  
.
C
o
m
p
l
e
t
e
P
a
r
t
s
L
i
s
t
a
v
a
i
l
a
b
l
e
a
t
w
w
w
.
M
i
l
l
e
r
W
e
l
d
s
.
c
o
m
5-12. Threading The Welding Gun  
4
6
Tools Needed:  
1
2
3
5
6 in  
(150 mm)  
.030/.035 Groove  
Stamped .024  
.024 Groove  
Stamped .030/.035  
Tighten  
Pressure  
Indicator  
Scale  
1
2
3
4
804 755-B / Ref. 229 573-A  
OM-228 042 Page 24  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
.
C
o
m
p
l
e
t
e
P
a
r
t
s
L
i
s
t
a
v
a
i
l
a
b
l
e
a
t
w
w
w
.
M
i
l
l
e
r
W
e
l
d
s
.
c
o
m
1
2
3
4
5
6
Wire Spool  
Welding Wire  
Inlet Wire Guide  
Pressure Adjustment Knob  
Drive Roll  
Gun Conduit Cable  
Lay gun cable out straight. Open  
pressure assembly.  
Pull about 6 in. (150 mm) of wire off  
spool. Hold tightly to keep it from  
unraveling. Cut off end.  
Pull wire through guides into gun;  
continue to hold wire tightly.  
Be sure wire is positioned in proper  
feed roll groove. Close and tighten  
pressure assembly. Let go of wire.  
Use pressure indicator scale to set  
desired drive roll pressure. Begin  
with a setting of 3. If necessary,  
make additional adjustments after  
trying initial setting.  
Tighten  
Remove gun nozzle and contact  
tip.  
1
2
3
4
Turn power on.  
WOOD  
Press gun trigger until wire comes  
out of gun.  
Be sure that tip matches wire diam-  
eter. Reinstall contact tip and  
nozzle.  
Feed wire to check drive roll pres-  
sure. Tighten knob enough to pre-  
vent slipping. Cut off wire.  
Close door.  
OM-228 042 Page 25  
Download from Www.Somanuals.com. All Manuals Search And Download.  
. CompleteParts List available at www. MillerWelds.com  
SECTION 6 − OPERATING THE WELDING GENERATOR  
6-1. Controls (See Section 6-2)  
8
9
5
6
7
4
Electric Start Models  
3
2
1
Recoil Start Models  
4
1
2
229 573 / 804 971-B  
OM-228 042 Page 26  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
.
C
o
m
p
l
e
t
e
P
a
r
t
s
L
i
s
t
a
v
a
i
l
a
b
l
e
a
t
w
w
w
.
M
i
l
l
e
r
W
e
l
d
s
.
c
o
m
6-2. Description Of Controls (See Section 6-1)  
1
Engine Switch  
gine. Move control to far left if starting a warm  
engine.  
To Start:  
6
Voltage Control  
Use switch to control ignition circuit.  
Turn control clockwise to increase voltage  
(see weld parameter chart in welding power  
source or Section 6-3).  
For Recoil Start: Turn switch to On position  
when starting engine. Turn switch to Off posi-  
tion to stop engine. Engine cannot be started  
with switch in the Off position.  
D
D
D
Open fuel valve (see Section 5-3).  
Set choke.  
For Recoil Start: Turn Engine switch to  
On and pull starter handle.  
7
8
Gun Trigger Receptacle  
Wall/Generator Switch  
For Electric Start: Turn switch to Start position  
when starting engine. Switch returns to Run  
positionwhen engine starts. Turn switch to Off  
position to stop engine.  
Use switch to select source of power for weld-  
ing power source.  
D
D
For Electric Start: Turn Engine switch to  
Start. When engine starts, allow switch  
to return to Run position.  
Place switch in Generator position for welding  
power source to run on generator input power.  
Open choke as engine warms.  
Enginestops if oil level is too low. Engine can-  
not be restarted until sufficient oil is added.  
NOTICE − If the engine does not start, let  
enginecome to a complete stop before at-  
temptingrestart.  
Place switch in Wall position for the welding  
power source to run on utility power. Place  
switch in Off position before connecting to util-  
ity power.  
2
Low Oil Pressure Light  
Light goes on and engine stops if engine oil  
level is too low.  
To Stop:  
D
Turn Engine switch to Off.  
Engine cannot be restarted until sufficient oil  
is added.  
. With switch in the Wall position and the  
generatornot running, the auxiliary power  
receptacles do not work.  
. Always close fuel valve after stopping  
unit. Moving unit with fuel valve open may  
cause carburetor flooding and make  
starting difficult.  
NOTICE − Stop engine and add oil if light  
goes on (see Section 5-3).  
3
4
9
Over Temperature Light  
Starter Handle  
Choke Control  
5
Wire Speed Control  
Light flashes when unit has overheated and  
weld output is not available. Allow fan to run to  
cool unit. When light goes out, unit is ready for  
service.  
Turn control clockwise to increase wire feed  
speed. (see weld parameter chart in welding  
Use control to change engine air/fuel mix.  
Move control to far right if starting a cold en- power source or Section 6-3).  
OM-228 042 Page 27  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
.
C
o
m
p
l
e
t
e
P
a
r
t
s
L
i
s
t
a
v
a
i
l
a
b
l
e
a
t
w
w
w
.
M
i
l
l
e
r
W
e
l
d
s
.
c
o
m
6-3. Weld Parameter Chart  
Ref. 230 748C  
OM-228 042 Page 28  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
.
C
o
m
p
l
e
t
e
P
a
r
t
s
L
i
s
t
a
v
a
i
l
a
b
l
e
a
t
w
w
w
.
M
i
l
l
e
r
W
e
l
d
s
.
c
o
m
6-4. Stainless Steel And 100% CO2 Weld Parameters  
Material Thickness  
Select Wire Type, Polarity, and Shielding  
Wire Size  
Gas  
20 ga  
18 ga  
16 ga  
14 ga  
1/8 in. 3/16 in. 1/4 in. 5/16 in.  
Shop Settings (Wall or Premise Power, 230 V 1 Ph)  
Solid ER70S−6 (DCEP)  
0.024  
0.030  
0.035  
0.024  
0.030  
0.035  
0.030  
0.035  
3.2/25  
3.0/15  
−−−  
3.5/25  
3.5/20  
3.0/12  
3.5/45  
3.5/30  
2.5/20  
2.0/70  
4.0/40  
4.0/25  
4.0/20  
4.0/50  
4.0/45  
3.5/25  
2.0/70  
2.5/65  
4.5/50  
4.5/35  
4.5/30  
4.5/70  
5.0/60  
4.0/40  
4.0/70  
4.0/60  
5.0/60  
5.5/45  
5.5/35  
5.0/80  
5.0/70  
4.5/50  
5.0/70  
5.0/65  
7.0/85  
6.0/55  
6.0/40  
6.0/95  
6.0/85  
6.0/65  
8.0/95  
8.0/90  
−−−  
−−−  
100% CO2 Shielding Gas  
6.5/65 10.0/75  
6.5/50 10.0/55  
Stainless Steel (DCEP)  
Tri−Mix Shielding Gas  
90% HE/7.5% Ar/ 2.5% CO2  
3.5/30  
3.5/25  
−−−  
−−−  
−−−  
−−−  
−−−  
7.5/95  
7.5/80  
10/100  
10/90  
Aluminum 4043 (DCEP)  
100% Argon Shielding Gas  
Field Setting (Generator Power)  
Solid ER70S−6 (DCEP)  
0.024  
0.030  
0.035  
0.024  
0.030  
0.035  
0.030  
0.035  
3.5/25  
3.0/15  
−−−  
3.5/25  
3.5/20  
3.0/12  
3.5/45  
4.5/30  
3.0/20  
4.0/70  
4.0/40  
4.0/25  
4.5/50  
5.0/35  
5.0/60 10.0/70  
−−−  
−−−  
−−−  
−−−  
−−−  
−−−  
−−−  
100% CO2 Shielding Gas  
6.0/45 10.0/55 10.0/65  
4.0/20 10.0/30 10.0/35  
4.0/50 5.5/70 10.0/80 10.0/95  
6.0/45 10.0/60 10.0/70 10.0/85  
−−−  
−−−  
−−−  
−−−  
−−−  
Stainless Steel (DCEP)  
Tri−Mix Shielding Gas  
90% HE/7.5% Ar/ 2.5% CO2  
3.5/30  
4.5/25  
−−−  
4.0/25  
4.0/70  
4.5/60  
6.0/40 10.0/50  
−−−  
Aluminum 4043 (DCEP)  
100% Argon Shielding Gas  
6.0/70  
6.0/60  
10/75  
10/65  
OM-228 042 Page 29  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
. CompleteParts List available at www. MillerWelds.com  
SECTION 7 − OPERATING AUXILIARY EQUIPMENT  
7-1. Generator Power Panel Receptacles  
1
2
4
3
229 573-A  
If unit does not have GFCI recep-  
tacles, use GFCI-protected exten-  
sion cord.  
3
120 V 20 A AC Duplex Receptacle  
RC3  
. If supplementary protector continues  
to open, contact Factory Authorized  
Service Agent.  
RC2 and RC3 supply 60 Hz single-phase  
power at weld/power speed. Maximum  
output from RC2 or RC3 is 2.4 kVA/kW.  
.
G
e
n
e
r
a
t
o
r
p
o
w
e
r
d
e
c
r
e
a
s
e
s
a
s
w
e
l
d
Combinedoutput of all receptacles limited  
to 4.5 kVA/kW continuous rating of the  
generator (See Section 13 − Generator  
Power Guidelines).  
current increases.  
NOTICE − Do not parallel the two 120 VAC  
duplex receptacles.  
1
240 V AC Receptacle RC1  
RC1 supplies 60 Hz single-phase power at  
weld/power speed. Maximum output is 5  
kVA/kW (peak) or 4.5 kVA/kW (continu-  
ous).  
EXAMPLE:If 10 A is drawn from each 120  
volt duplex receptacle, only 8 A is available  
from the 240 V receptacle.  
4
Supplementary Protector CB1  
CB1 protects the receptacles from over-  
load. If CB1 opens, the receptacles do not  
work. Move switch to the On position to re-  
set.  
2
120 V 20 A AC Duplex Receptacle  
RC2  
2 x (120 V x 10 A) + (240 V x 8 A) = 4.5 kVA/  
KW.  
OM-228 042 Page 30  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
.
C
o
m
p
l
e
t
e
P
a
r
t
s
L
i
s
t
a
v
a
i
l
a
b
l
e
a
t
w
w
w
.
M
i
l
l
e
r
W
e
l
d
s
.
c
o
m
SECTION 8 − MAINTENANCE  
8-1. Power Source Routine Maintenance  
. Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period.  
Stop engine before maintaining.  
.
S
e
e
E
n
g
i
n
e
M
a
n
u
a
l
a
n
d
M
a
i
n
t
e
n
a
n
c
e
L
a
b
e
l
Recycle engine  
fluids.  
for important start-up, service, and storage  
information. Service engine more often if  
used in severe conditions.  
n
=
C
h
e
c
k
Z
=
C
h
a
n
g
e
~
=
C
l
e
a
n
l
=
R
e
p
l
a
c
e
Reference  
Section 5-3  
* To be done by Factory Authorized Service Agent  
Every  
8
Hours  
n
F
u
e
l
L
e
v
e
l
n
O
i
l
L
e
v
e
l
~
O
i
l
,
F
u
e
l
S
p
i
l
l
s
Every  
25  
Hours  
Section 8-9  
~
A
i
r
C
l
e
a
n
e
r
P
r
e
c
l
e
a
n
e
r
Every  
50  
Hours  
~
W
e
l
d
T
e
r
m
i
n
a
l
s
Every  
100  
Hours  
Engine  
Manual,  
Section 8-9  
Z
O
i
l
n
l
A
i
r
C
l
e
a
n
e
r
E
l
e
m
e
n
t
~
C
o
o
l
i
n
g
S
y
s
t
e
m
n
S
p
a
r
k
P
l
u
g
G
a
p
n
~
B
a
t
t
e
r
y
T
e
r
m
i
n
a
l
s
(Electric Start Models)  
Every  
200  
Hours  
l
U
n
r
e
a
d
a
b
l
e
L
a
b
e
l
s
Every  
300  
Hours  
Engine  
Manual  
n
V
a
l
v
e
C
l
e
a
r
a
n
c
e
*
Every  
500  
Hours  
Engine  
Manual  
n
l
W
e
l
d
C
a
b
l
e
s
n
n
~
S
l
i
p
R
i
n
g
s
*
l
Brushes*  
Every  
1000  
Hours  
OR  
~
I
n
s
i
d
e
U
n
i
t
OM-228 042 Page 31  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
.
C
o
m
p
l
e
t
e
P
a
r
t
s
L
i
s
t
a
v
a
i
l
a
b
l
e
a
t
w
w
w
.
M
i
l
l
e
r
W
e
l
d
s
.
c
o
m
8-2. Gun Routine Maintenance  
Stop engine and dis-  
connect gun before  
maintaining.  
n
=
C
h
e
c
k
Z
=
C
h
a
n
g
e
~
=
C
l
e
a
n
l
=
R
e
p
l
a
c
e
Reference  
Section 8-7  
Every  
Spool  
Of Wire  
~
G
u
n
C
a
s
i
n
g
~
N
o
z
z
l
e
,
n
C
o
n
t
a
c
t
T
i
p
Every 3  
Months  
Section 8-7  
l
C
r
a
c
k
e
d
P
a
r
t
s
l
C
r
a
c
k
e
d
P
a
r
t
s
l
C
r
a
c
k
e
d
P
a
r
t
s
l
C
r
a
c
k
e
d
P
a
r
t
s
8-3. Welding Power Source Overload Protection  
1
SupplementaryProtector CB2  
CB2 protects unit from overload. If  
the unit is using 230 volts ac input  
power and CB2 opens, unit shuts  
down.  
1
Reset supplementary protector.  
.
S
h
o
w
n
w
i
t
h
o
p
t
i
o
n
a
l
c
y
l
i
n
d
e
r
r
a
c
k
804 476-C  
8-4. Drive Motor Protection And Tip Saver/Short Circuit Protection  
A. Drive Motor Protection  
Drive motor protection circuit protects drive motor from overload. If drive motor becomes inoperative, release gun trigger and wait until protection circuit  
resets allowing drive motor to feed wire again.  
B. Tip Saver/Short Circuit Protection  
The tip saver/short circuit protection extends contact tip life and protects internal components from damage. If contact tip is shorted to workpiece, the  
unit shuts down the welding output. To resume operation, release gun trigger to reset unit. If the contact tip has stuck to the workpiece, release gun  
trigger, turn off unit, and remove contact tip from workpiece. Check contact tip and replace if damaged. Turn on unit to continue operation.  
OM-228 042 Page 32  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
.
C
o
m
p
l
e
t
e
P
a
r
t
s
L
i
s
t
a
v
a
i
l
a
b
l
e
a
t
w
w
w
.
M
i
l
l
e
r
W
e
l
d
s
.
c
o
m
8-5. Changing Drive Roll Or Wire Inlet Guide  
1
Inlet Wire Guide  
Remove guide by pressing on  
barbed area or cutting off one end  
near housing and pulling it out of  
hole. Push new guide into hole from  
rear until it snaps in place.  
2
Drive Roll  
1
The drive roll consists of two differ-  
ent sized grooves. The stamped  
markings on the end surface of the  
drive roll refer to the groove on the  
opposite side of the drive roll. The  
groove closest to the motor shaft is  
the proper groove to thread (see  
Section 5-12).  
2
3
Retaining Pin  
To secure drive roll, locate open slot  
and push drive roll completely over  
retaining pin, then rotate drive roll  
1/4 turn to closed slot.  
3
.030/.035 Groove  
Stamped .024  
.024 Groove  
Stamped .030/.035  
802 984  
8-6. Replacing Gun Contact Tip  
Turn Off power before  
replacing contact tip.  
1
Nozzle  
2
Contact Tip  
Cut off welding wire at contact tip.  
Remove nozzle.  
Remove contact tip and install new  
contact tip. Reinstall nozzle.  
2
1
Tools Needed:  
Ref. 802 399-A  
OM-228 042 Page 33  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
.
C
o
m
p
l
e
t
e
P
a
r
t
s
L
i
s
t
a
v
a
i
l
a
b
l
e
a
t
w
w
w
.
M
i
l
l
e
r
W
e
l
d
s
.
c
o
m
8-7. Maintaining Gun  
Turn off welding power  
source/wire feeder.  
3
1
2
3
4
Nozzle  
Contact Tip  
Adapter  
4
1
Head Tube  
2
Cut off wire and disconnect gun  
from feeder  
Remove nozzle contact tip and  
adapter from head tube.  
5
Liner  
Unscrew and remove liner.  
Lay gun cable out straight before  
installingnew liner.  
5
Blow out gun casing.  
Reassemble gun in reverse order  
from taking it apart. Be sure liner  
stickout is approximately 3/4 in. (20  
mm).  
.
W
i
r
e
s
i
z
e
s
t
a
m
p
e
d
o
n
t
i
p
−
check and match wire size.  
.
T
h
r
e
a
d
w
i
r
e
a
c
c
o
r
d
i
n
g
t
o
S
e
c
-
tion 5-12.  
3/4 in  
(20 mm)  
5
Tools Needed:  
3/8 in  
Ref. 800 797-D  
OM-228 042 Page 34  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
.
C
o
m
p
l
e
t
e
P
a
r
t
s
L
i
s
t
a
v
a
i
l
a
b
l
e
a
t
w
w
w
.
M
i
l
l
e
r
W
e
l
d
s
.
c
o
m
8-8. Replacing Switch And/Or Head Tube  
Turn off welding power  
source/wire feeder and dis-  
connect gun.  
1
1
2
3
4
5
6
Handle Locking Nut  
Switch Housing  
Handle  
Vise  
3
Head Tube  
Jam Nut  
2
Remove handle locking nut.  
Remove switch housing. Install  
new switch and connect leads (po-  
larity is not important). Reassemble  
in reverse order.  
4
5
Secure head tube in vise.  
Loosen jam nut. Remove from vise  
and turn head tube out by hand.  
Hand tighten head tube into cable  
connector. Place head tube in vise  
and tighten until nuts are tight.  
Remove from vise. Reposition han-  
dle and install switch housing. Se-  
cure with handle locking nut.  
6
Tools Needed:  
19 mm  
Ref. ST-800 795-C  
OM-228 042 Page 35  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
.
C
o
m
p
l
e
t
e
P
a
r
t
s
L
i
s
t
a
v
a
i
l
a
b
l
e
a
t
w
w
w
.
M
i
l
l
e
r
W
e
l
d
s
.
c
o
m
8-9. Servicing Air Cleaner  
Stop engine.  
NOTICE − Do not run engine with-  
out air cleaner or with dirty element.  
1
2
Precleaner  
Paper Element  
.
D
o
n
o
t
w
a
s
h
p
a
p
e
r
e
l
e
m
e
n
t
o
r
1
clean with compressed air.  
Remove cover.  
Wash precleaner with soap and wa-  
ter solution. Allow precleaner to air  
dry completely.  
2
Dip precleaner in clean engine oil.  
Squeeze out excess oil. The engine  
will smoke if precleaner contains  
too much oil.  
Replace paper element if dirty, oily,  
or damaged.  
Standard Model Shown  
oil  
aircleaner6 9/00 − 803 404 / 805 055  
OM-228 042 Page 36  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
.
C
o
m
p
l
e
t
e
P
a
r
t
s
L
i
s
t
a
v
a
i
l
a
b
l
e
a
t
w
w
w
.
M
i
l
l
e
r
W
e
l
d
s
.
c
o
m
8-10. Adjusting Engine Speed  
After tuning engine, check engine  
speed. See table for proper no load  
speed. If necessary, adjust speed  
as follows:  
Start engine and run until warm.  
3750 30 rpm (62 Hz)  
1
Adjustment Screw  
To increase speed, turn screw in  
(clockwise). To decrease speed,  
turn screw out (counterclockwise).  
Stop engine. Close fuel  
valve.  
1
Tools Needed:  
804 971-A  
OM-228 042 Page 37  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
.
C
o
m
p
l
e
t
e
P
a
r
t
s
L
i
s
t
a
v
a
i
l
a
b
l
e
a
t
w
w
w
.
M
i
l
l
e
r
W
e
l
d
s
.
c
o
m
SECTION 9 − TROUBLESHOOTING  
9-1. Troubleshooting  
A. Welding  
Trouble  
Remedy  
No weld output or generator power out- Be sure all equipment is disconnected from receptacles when starting unit.  
put at ac receptacles.  
Place switch in Wall position or start engine and place switch in Generator position.  
.
A
C
r
e
c
e
p
t
a
c
l
e
s
p
r
o
v
i
d
e
a
u
x
i
l
i
a
r
y
power only while engine is running.  
Over temperature light is flashing. Allow unit to cool with fan running until thermostat TP1 resets and light  
turns off.  
Have Factory Authorized Service Agent check brushes, slip rings, rotor, stator, and integrated rectifier  
SR2.  
No weld output; generator power out-  
put okay at ac receptacles.  
Place switch in Generator position to obtain weld output.  
Check weld connections.  
Check Spool Gun/Mig Gun switch position.  
Have Factory Authorized Service Agent check stator, integrated rectifier SR2, stabilizer Z1, and main  
rectifier SR1.  
Low weld output.  
Check Weld Output control setting.  
Check engine speed, and adjust if necessary (see Section 8-10).  
Service engine air cleaner.  
Check weld cable size and length.  
Have Factory Authorized Service Agent check stator, integrated rectifier SR2, stabilizer Z1, and main  
rectifier SR1.  
High weld output.  
Check Wire Speed and Voltage control settings.  
Check engine speed, and adjust if necessary (see Section 8-10).  
Check Wire Speed and Voltage control settings. Check wire feed for erratic condition.  
Tighten and clean connections to electrode and workpiece.  
Erratic weld output.  
Remove excessive coils from work lead and gun power cable.  
Clean and tighten connections both inside and outside welding generator.  
Check engine speed, and adjust if necessary (see Section 8-10).  
Check throttle/governor linkage for smooth, non-binding operation.  
B. Generator Power  
Trouble  
Remedy  
No output at generator power ac re-  
ceptacles; no weld output.  
Be sure all equipment is disconnected from receptacles when starting unit.  
Have Factory Authorized Service Agent check brushes, slip rings, rotor, stator, and integrated rectifier  
SR2.  
.
A
C
r
e
c
e
p
t
a
c
l
e
s
p
r
o
v
i
d
e
a
u
x
i
l
i
a
r
y
power only while engine is running.  
No output at generator power ac re-  
ceptacles; weld output okay.  
Reset and check supplementary protector (see Section 7-1).  
Check receptacle wiring and connections.  
Have Factory Authorized Service Agent check stator windings and connections at terminal block 1T.  
Check engine speed, and adjust if necessary (see Section 8-10).  
High output at generator power ac  
receptacles.  
OM-228 042 Page 38  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
.
C
o
m
p
l
e
t
e
P
a
r
t
s
L
i
s
t
a
v
a
i
l
a
b
l
e
a
t
w
w
w
.
M
i
l
l
e
r
W
e
l
d
s
.
c
o
m
Trouble  
Remedy  
Low output at generator power ac Check engine speed, and adjust if necessary (see Section 8-10 ). Open circuit voltage is reduced as  
receptacles. engine speed drops.  
Erratic output at generator power ac Check fuel level.  
receptacles.  
Have Factory Authorized Service Agent check connections at terminal block 1T.  
Check receptacle supplementary protector, wiring, and connections.  
Check throttle linkage for smooth, non-binding operation.  
Service air cleaner according to engine manual.  
Check engine speed, and adjust if necessary (see Section 8-10).  
C. Wire Feeder  
Trouble  
Remedy  
Secure power cord plug in receptacle (see Section 5-9).  
No weld output; wire does not feed; fan  
does not run.  
Replace building line fuse or reset circuit breaker if open.  
Place Wall/Generator switch in Wall position.  
Reset welding power source supplementary protector if open.  
No weld output; wire does not feed; fan ThermostatTP1 open (overheating). Allow fan to run with gun trigger switch off; thermostat closes when  
motor continues to run.  
unit has cooled.  
Secure gun trigger leads (see Section 5-5).  
Check position of Spool Gun/Mig Gun switch.  
Connect work clamp to get good metal to metal contact.  
Replace contact tip (see Section 8-6).  
No weld output; wire feeds.  
Check for proper polarity connections (see Section 5-8).  
Check thumbscrew securing gun end to feed head adapter and tighten if necessary.  
Connect unit to proper input voltage or check for low line voltage.  
Low weld output.  
Place voltage control in desired position (see Section 6-3).  
Electrode wire feeding stops during  
welding.  
Straightengun cable and/or replace damaged parts.  
Adjust drive roll pressure (see Section 5-12).  
Change to proper drive roll groove (see Section 8-5).  
Readjust hub tension (see Section 5-11).  
Replace contact tip if blocked (see Section 8-6). Oversized tip may be required for some wires.  
Clean or replace wire inlet guide or liner if dirty or plugged (see Section 8-5 or Section 8-7).  
Replace drive roll or pressure bearing if worn or slipping (see Section 8-5).  
Secure gun trigger leads or repair leads (see Section 5-5).  
Check and clear any restrictions at drive assembly and liner (see Section 5-12 or Section 8-7).  
Release gun trigger and allow gun and motor protection circuitry to reset.  
Have Factory Authorized Service Agent check drive motor.  
D. Engine  
Trouble  
Remedy  
Check and replace ignition fuse (see engine manual)  
Check battery voltage.  
Engine will not crank (Electric Start Mod-  
els Only)  
Check battery connections and tighten if necessary.  
Have Factory Authorized Service Agent check engine ignition system.  
OM-228 042 Page 39  
Download from Www.Somanuals.com. All Manuals Search And Download.  
.
C
o
m
p
l
e
t
e
P
a
r
t
s
L
i
s
t
a
v
a
i
l
a
b
l
e
a
t
w
w
w
.
M
i
l
l
e
r
W
e
l
d
s
.
c
o
m
Trouble  
Engine will not start.  
Remedy  
Check fuel level (see Section 5-3).  
Move choke control to correct position (see Section 6-1).  
Open fuel valve (see Section 5-3). Close fuel valve before moving unit or carburetor may flood and make  
starting difficult.  
Be sure engine switch is On.  
Check oil level (see Section 5-3). Engine stops if oil level is too low. Refill crankcase with proper viscosity  
oil for operating temperature.  
Have Factory Authorized Service Agent check low oil level shutdown switch.  
Check battery voltage (electric start models only).  
Check battery connections and tighten if necessary (electric start models only).  
Check fuel level (see Section 5-3).  
Engine stopped during normal  
operation.  
Open fuel valve (see Section 5-3). Close fuel valve before moving unit or carburetor may flood and make  
starting difficult.  
Check oil level (see Section 5-3). Engine stops if oil level is too low.  
Check engine speed, and adjust if necessary (see Section 8-10).  
Check throttle/governor linkage for smooth, non-binding operation.  
Tune-up engine according to engine manual.  
Unstable or sluggish engine speeds.  
Battery discharges between uses (Elec- Clean battery terminals and posts with baking soda and water solution; rinse with clear water.  
tric Start Models Only).  
Periodically recharge battery (approximately every 3 months).  
Replace battery.  
Check engine battery charging circuit and connections according to engine manual.  
SECTION 10 − PARTS LIST  
. A complete parts list is available at www.MillerWelds.com.  
10-1. Recommended Spare Parts  
Part  
No.  
Description  
Quantity  
Recommended Spare Parts  
. . . . . . . . . . . 221581 . . Tune−up & Filter Kit, Kohler (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . 203960 . . Spark Plug, Kohler (CS8/10/12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . 221579 . . Air Filter, Kohler (CS10−recoil) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . 221580 . . Air Filter Pre−cleaner, Kohler (CS10−recoil) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . 169715 . . Nozzle, Slip Type .500 Orf Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . 087299 . . Tip, Contact Scr .023 Wire X 1.125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . 000067 . . Tip, Contact Scr .030 Wire X 1.125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . 000068 . . Tip, Contact Scr .035 Wire X 1.125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . 000069 . . Tip, Contact Scr .045 Wire X 1.125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . 194010 . . Liner, Monocoil .023/.025 Wire X 15ft (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . 194011 . . Liner, Monocoil .030/.035 Wire X 15ft (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . 194012 . . Liner, Monocoil .035−.045 Wire X 15 ft (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . 079975 . . . . O-ring, .187 Id X .103cs Rbr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
OM-228 042 Page 40  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
SECTION 11 − ELECTRICAL DIAGRAMS  
Figure 11-1. Circuit Diagram For Welding Generator  
OM-217 454 Page 41  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
SECTION 12 − MIG WELDING (GMAW) GUIDELINES  
12-1. Typical MIG Process Connections  
Weld current can damage  
electronic parts in vehicles.  
Disconnect both battery  
cables before welding on a  
vehicle. Place work clamp as  
close to the weld as possible.  
Regulator/  
Flowmeter  
Wire Feeder/  
Power Source  
Gas Hose  
Shielding Gas  
Gun  
Work Clamp Workpiece  
Renegade 2007−04/ Ref. 802 982-A  
OM-228 042 Page 42  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
12-2. Typical MIG Process Control Settings  
.
T
h
e
s
e
s
e
t
t
i
n
g
s
a
r
e
g
u
i
d
e
l
i
n
e
s
o
n
l
y
.
M
a
t
e
r
i
a
l
a
n
d
w
i
r
e
t
y
p
e
,
j
o
i
n
t
d
e
s
i
g
n
,
f
i
t
u
p
,
p
o
s
i
t
i
o
n
,
s
h
i
e
l
d
i
n
g
g
a
s
,
e
t
c
.
a
f
f
e
c
t
s
e
t
t
i
n
g
s
.
T
e
s
t
w
e
l
d
s
t
o
b
e
s
u
r
e
they comply to specifications.  
.
T
h
e
s
e
s
e
t
t
i
n
g
s
a
r
e
g
u
i
d
e
l
i
n
e
s
o
n
l
y
.
M
a
t
e
r
i
a
l
1
and wire type, joint design, fitup, position,  
shieldinggas, etc. affect settings. Test welds  
to be sure they comply to specifications.  
1/8 or  
.125 in  
1
Convert Material Thickness to  
Amperage (A)  
(.001 in = 1 ampere)  
.125 = 125 A  
.
M
a
t
e
r
i
a
l
t
h
i
c
k
n
e
s
s
d
e
t
e
r
m
i
n
e
s
w
e
l
d
parameters.  
2
Select Wire Size  
2
Amperage Range  
Wire Size  
.030 in  
.035 in  
.045 in  
40 − 145 A  
50 − 180 A  
75 − 250 A  
3
Select Wire Speed (Amperage)  
125 A based on 1/8 in (3 mm) material thickness.  
(ipm = inch per minute)  
Wire  
Size  
Wire Speed  
(Approx.)  
Suggested  
3
.030 in 2 in per amp  
2 x 125 A = 250 ipm  
.035 in 1.6 in per amp 1.6 x 125 A = 200 ipm  
.045 in 1 in per amp  
1 x 125 A = 125 ipm  
.
W
i
r
e
s
p
e
e
d
(
a
m
p
e
r
a
g
e
)
c
o
n
t
r
o
l
s
w
e
l
d
p
e
n
e
-
tration (wire speed = burn-off rate).  
4
4
Select Voltage  
Low Voltage: wire stubs into work  
High Voltage: arc is unstable (spatter)  
Set voltage midway between high/low voltage.  
.
V
o
l
t
a
g
e
c
o
n
t
r
o
l
s
h
e
i
g
h
t
a
n
d
w
i
d
t
h
o
f
w
e
l
d
bead.  
804 476 / 229 573  
OM-228 042 Page 43  
Download from Www.Somanuals.com. All Manuals Search And Download.  
12-3. Holding And Positioning Welding Gun  
.
W
e
l
d
i
n
g
w
i
r
e
i
s
e
n
e
r
g
i
z
e
d
w
h
e
n
g
u
n
t
r
i
g
g
e
r
i
s
p
r
e
s
s
e
d
.
B
e
f
o
r
e
l
o
w
e
r
i
n
g
h
e
l
m
e
t
a
n
d
p
r
e
s
s
i
n
g
t
r
i
g
g
e
r
,
b
e
s
u
r
e
w
i
r
e
i
s
n
o
m
o
r
e
t
h
a
n
1
/
2
i
n
(
1
3
m
m
)
past end of nozzle, and tip of wire is positioned correctly on seam.  
.
W
e
l
d
i
n
g
w
i
r
e
i
s
e
n
e
r
g
i
z
e
d
w
h
e
n
1
gun trigger is pressed. Before  
lowering helmet and pressing  
trigger, be sure wire is no more  
than 1/2 in (13 mm) past end of  
nozzle, and tip of wire is posi-  
tioned correctly on seam.  
3
2
1
Hold Gun And Control Gun  
Trigger  
2
3
4
Workpiece  
Work Clamp  
5
Electrode Extension (Stickout)  
1/4 To 1/2 in (6 To 13 mm)  
5
Cradle Gun And Rest Hand On  
Workpiece  
Groove Welds  
4
6
7
End View Of Work Angle  
Side View Of Gun Angle  
Fillet Welds  
8
9
End View Of Work Angle  
Side View Of Gun Angle  
0°-15°  
90°  
90°  
6
7
0°-15°  
45°  
8
9
45°  
S-0421-A  
OM-228 042 Page 44  
Download from Www.Somanuals.com. All Manuals Search And Download.  
12-4. Conditions That Affect Weld Bead Shape  
.
W
e
l
d
b
e
a
d
s
h
a
p
e
d
e
p
e
n
d
s
o
n
g
u
n
a
n
g
l
e
,
d
i
r
e
c
t
i
o
n
o
f
t
r
a
v
e
l
,
e
l
e
c
t
r
o
d
e
e
x
t
e
n
s
i
o
n
(
s
t
i
c
k
o
u
t
)
,
t
r
a
v
e
l
s
p
e
e
d
,
t
h
i
c
k
n
e
s
s
o
f
b
a
s
e
m
e
t
a
l
,
w
i
r
e
f
e
e
d
s
p
e
e
d
(weld current), and voltage.  
.
W
e
l
d
b
e
a
d
s
h
a
p
e
d
e
p
e
n
d
s
o
n
gun angle, direction of travel,  
electrode extension (stickout),  
1
travel speed, thickness of base  
10°  
metal, wire feed speed (weld  
current), and voltage.  
Gun Angles And Weld Bead  
Profiles  
1
2
3
Push  
Perpendicular  
Drag  
2
3
10°  
Electrode Extensions (Stickout)  
4
5
6
Short  
Normal  
Long  
Fillet Weld Electrode Extension  
(Stickout)  
7
8
9
Short  
Normal  
Long  
6
5
Gun Travel Speed  
10 Slow  
4
11 Normal  
12 Fast  
9
8
7
11  
10  
12  
S-0634-A  
OM-228 042 Page 45  
Download from Www.Somanuals.com. All Manuals Search And Download.  
12-5. Gun Movement During Welding  
.
N
o
r
m
a
l
l
y
,
a
s
i
n
g
l
e
s
t
r
i
n
g
e
r
b
e
a
d
i
s
s
a
t
i
s
f
a
c
t
o
r
y
f
o
r
m
o
s
t
n
a
r
r
o
w
g
r
o
o
v
e
w
e
l
d
j
o
i
n
t
s
;
h
o
w
e
v
e
r
,
f
o
r
w
i
d
e
g
r
o
o
v
e
w
e
l
d
j
o
i
n
t
s
o
r
b
r
i
d
g
i
n
g
a
c
r
o
s
s
g
a
p
s
,
a weave bead or multiple stringer beads works better.  
1
2
3
Stringer Bead − Steady  
Movement Along Seam  
1
2
Weave Bead − Side To Side  
Movement Along Seam  
Weave Patterns  
Use weave patterns to cover a wide  
area in one pass of the electrode.  
3
S-0054-A  
12-6. Poor Weld Bead Characteristics  
1
2
3
4
5
Large Spatter Deposits  
Rough, Uneven Bead  
1
Slight Crater During Welding  
Bad Overlap  
Poor Penetration  
2
4
3
5
S-0053-A  
12-7. Good Weld Bead Characteristics  
1
2
3
Fine Spatter  
Uniform Bead  
Moderate Crater During  
Welding  
1
Weld a new bead or layer for each  
1/8 in (3.2 mm) thickness in metals  
being welded.  
4
5
No Overlap  
Good Penetration into Base  
Metal  
2
4
3
5
S-0052-B  
OM-228 042 Page 46  
Download from Www.Somanuals.com. All Manuals Search And Download.  
12-8. Troubleshooting − Excessive Spatter  
Excessive Spatter − scattering of molten metal particles that  
cool to solid form near weld bead.  
S-0636  
Possible Causes  
Wire feed speed too high.  
Corrective Actions  
Select lower wire feed speed.  
Voltage too high.  
Select lower voltage range.  
Use shorter electrode extension (stickout).  
Electrode extension (stickout) too long.  
Workpiece dirty.  
Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.  
Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.  
Use clean, dry welding wire.  
Insufficient shielding gas at welding arc.  
Dirty welding wire.  
Eliminate pickup of oil or lubricant on welding wire from feeder or liner.  
Wrong polarity.  
Configure polarity as shown in Section 5-8. Always read and follow wire manufacturer’s  
recommendedpolarity, and see Section 5-7.  
12-9. Troubleshooting − Porosity  
Porosity − small cavities or holes resulting from gas pockets  
in weld metal.  
S-0635  
Possible Causes  
Corrective Actions  
Insufficient shielding gas at welding arc.  
Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.  
Remove spatter from gun nozzle.  
Check gas hoses for leaks.  
Place nozzle 1/4 to 1/2 in (6-13 mm) from workpiece.  
Hold gun near bead at end of weld until molten metal solidifies.  
Use welding grade shielding gas; change to different gas.  
Use clean, dry welding wire.  
Wrong gas.  
Dirty welding wire.  
Eliminate pick up of oil or lubricant on welding wire from feeder or liner.  
Workpiece dirty.  
Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before welding.  
Use a more highly deoxidizing welding wire (contact supplier).  
Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.  
Wrong polarity.  
Configure polarity as shown in Section 5-8. Always read and follow wire manufacturer’s  
recommendedpolarity, and see Section 5-7.  
OM-228 042 Page 47  
Download from Www.Somanuals.com. All Manuals Search And Download.  
12-10. Troubleshooting − Excessive Penetration  
Excessive Penetration − weld metal melting through base metal  
and hanging underneath weld.  
Excessive Penetration Good Penetration  
S-0639  
Possible Causes  
Corrective Actions  
Excessive heat input.  
Select lower voltage range and reduce wire feed speed.  
Increase travel speed.  
Wrong polarity.  
Configure polarity as shown in Section 5-8. Always read and follow wire manufacturer’s  
recommendedpolarity, and see Section 5-7.  
12-11. Troubleshooting − Lack Of Penetration  
Lack Of Penetration − shallow  
fusion between weld metal and  
base metal.  
Lack of Penetration Good Penetration  
S-0638  
Possible Causes  
Corrective Actions  
Improper joint preparation.  
Improper weld technique.  
Material too thick. Joint preparation and design must provide access to bottom of groove while  
maintaining proper welding wire extension and arc characteristics.  
Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.  
Keep arc on leading edge of weld puddle.  
Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.  
Select higher wire feed speed and/or select higher voltage range.  
Reduce travel speed.  
Insufficient heat input.  
Wrong polarity.  
Configure polarity as shown in Section 5-8. Always read and follow wire manufacturer’s  
recommendedpolarity, and see Section 5-7.  
12-12. Troubleshooting − Incomplete Fusion  
Incomplete Fusion − failure of weld metal to fuse completely with  
base metal or a preceeding weld bead.  
S-0637  
Possible Causes  
Workpiece dirty.  
Corrective Actions  
Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before  
welding.  
Insufficient heat input.  
Select higher voltage range and/or adjust wire feed speed.  
Place stringer bead in proper location(s) at joint during welding.  
Adjust work angle or widen groove to access bottom during welding.  
Momentarily hold arc on groove side walls when using weaving technique.  
Keep arc on leading edge of weld puddle.  
Improper welding technique.  
Use correct gun angle of 0 to 15 degrees.  
Wrong polarity.  
Configure polarity as shown in Section 5-8. Always read and follow wire manufacturer’s  
recommendedpolarity, and see Section 5-7.  
OM-228 042 Page 48  
Download from Www.Somanuals.com. All Manuals Search And Download.  
12-13. Troubleshooting − Burn-Through  
Burn-Through− weld metal melting completely through base metal  
resulting in holes where no metal remains.  
S-0640  
Possible Causes  
Excessive heat input.  
Corrective Actions  
Select lower voltage range and reduce wire feed speed.  
Increase and/or maintain steady travel speed.  
Wrong polarity.  
Configure polarity as shown in Section 5-8. Always read and follow wire manufacturer’s  
recommendedpolarity, and see Section 5-7.  
12-14. Troubleshooting − Waviness Of Bead  
Waviness Of Bead − weld metal that is not parallel and does not cover  
joint formed by base metal.  
S-0641  
Possible Causes  
Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.  
Unsteady hand. Support hand on solid surface or use two hands.  
Corrective Actions  
12-15. Troubleshooting − Distortion  
Distortion − contraction of weld metal during welding that forces  
base metal to move.  
Base metal moves  
in the direction of  
the weld bead.  
S-0642  
Possible Causes  
Corrective Actions  
Excessive heat input.  
Use restraint (clamp) to hold base metal in position.  
Make tack welds along joint before starting welding operation.  
Select lower voltage range and/or reduce wire feed speed.  
Increase travel speed.  
Weld in small segments and allow cooling between welds.  
OM-228 042 Page 49  
Download from Www.Somanuals.com. All Manuals Search And Download.  
12-16.  
Common MIG Shielding Gases  
This is a general chart for common gases and where they are used. Many different combinations (mixtures) of  
shielding gases have been developed over the years. The most commonly used shielding gases are listed in the  
following table.  
Application  
Gas  
Short Circuiting  
Stainless Steel  
Short Circuiting  
Aluminum  
Spray Arc Steel  
Short Circuiting Steel  
Argon  
All Positions  
1
2
Argon + 25% CO  
Flat & Horizontal Fillet  
All Positions  
All Positions  
All Positions  
2
1
CO  
Flat & Horizontal Fillet  
2
3
Tri-Mix  
All Positions  
1
2
3
Globular Transfer  
Single Pass Welding Only  
90% HE + 7-1/2% AR + 2-1/2% CO  
2
OM-228 042 Page 50  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SECTION 13 − GENERATOR POWER GUIDELINES  
. The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown.  
13-1. Selecting Equipment  
1
2
3
Generator Power Receptacles  
− Neutral Bonded To Frame  
3-Prong Plug From Case  
Grounded Equipment  
2-Prong Plug From Double  
Insulated Equipment  
. Be sure equipment has double  
insulated symbol and/or word-  
ing on it.  
1
2
Do not use 2-prong plug un-  
less equipment is double in-  
sulated.  
3
OR  
gen_pwr 2007−04 − Ref. ST-159 730 / ST-800 577  
13-2. Grounding Generator To Truck Or Trailer Frame  
Always ground generator  
frame to vehicle frame to pre-  
vent electric shock and static  
electricity hazards.  
Also see AWS Safety  
&
Health Fact Sheet No. 29,  
Grounding of Portable And  
Vehicle Mounted Welding  
Generators.  
1
2
3
EquipmentGrounding  
Terminal (On Front Panel)  
Grounding Cable (Not  
Supplied)  
1
Metal Vehicle Frame  
2
GND/PE  
Connect cable from equipment  
ground terminal to metal vehicle  
frame. Use #10 AWG or larger  
insulated copper wire.  
3
. Electrically bond generator  
frame to vehicle frame by met-  
al-to-metal contact.  
Bed liners, shipping skids,  
and some running gear insu-  
late the welding generator  
from the vehicle frame. Al-  
ways connect a ground wire  
from the generator equip-  
ment grounding terminal to  
bare metal on the vehicle  
frame as shown.  
If unit does not have GFCI re-  
ceptacles, use GFCI-pro-  
tected extension cord.  
S-0854  
OM-228 042 Page 51  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
13-3. Grounding When Supplying Building Systems  
1
2
EquipmentGrounding  
Terminal  
1
2
Grounding Cable  
GND/PE  
Use #10 AWG or larger insulated  
copper wire.  
3
Ground Device  
.
U
s
e
g
r
o
u
n
d
d
e
v
i
c
e
a
s
s
t
a
t
e
d
i
n
electrical codes.  
Ground generator to system  
earth ground if supplying  
power to a premises (home,  
shop, farm) wiring system.  
Also see AWS Safety  
&
Health Fact Sheet No. 29,  
Grounding of Portable And  
Vehicle Mounted Welding  
Generators.  
2
3
ST-800 576-B  
13-4. How Much Power Does Equipment Require?  
1
Resistive Load  
A light bulb is a resistive load and  
requires a constant amount of power.  
2
Non-Resistive Load  
3
VOLTS 115  
Equipment with a motor is a non-re-  
sistive load and requires approxi-  
mately six times more power while  
starting the motor than when running  
(see Section 13-8).  
2
AMPS 4.5  
Hz  
60  
1
3
Rating Data  
Rating shows volts and amperes, or  
watts required to run equipment.  
3
Amperes x Volts = Watts  
Example 1: If a drill uses 4.5 am-  
peres at 115 volts, calculate its run-  
ning power requirement in watts.  
4.5 A x 115 V = 520 W  
The load applied by the drill is 520  
watts.  
Example 2: If three 200 watt flood  
lamps are used with the drill from Ex-  
ample 1, add the individual loads to  
calculate total load.  
(3 x 200W) + 520 W = 1120 W  
The total load applied by the three  
flood lamps and drill is 1120 watts.  
S-0623  
OM-228 042 Page 52  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
13-5. Approximate Power Requirements For Industrial Motors  
Industrial Motors  
Rating  
Starting Watts  
Running Watts  
Split Phase  
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  
800  
1225  
1600  
2100  
3175  
2020  
3075  
4500  
6100  
8200  
10550  
15900  
23300  
8100  
23300  
35000  
46700  
1000  
1400  
1850  
2400  
3500  
300  
500  
600  
700  
875  
Capacitor Start-Induction Run  
720  
975  
1400  
1600  
2200  
2850  
3900  
6800  
2000  
6000  
8000  
10700  
400  
1-1/2 HP  
2 HP  
3 HP  
5 HP  
Capacitor Start-Capacitor Run  
Fan Duty  
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  
550  
650  
800  
1100  
13-6. Approximate Power Requirements For Farm/Home Equipment  
Farm/HomeEquipment  
Stock Tank De-Icer  
Rating  
Starting Watts  
Running Watts  
1000  
1650  
3400  
4400  
2900  
10500  
1720  
2575  
4500  
6100  
8200  
10550  
15900  
23300  
8100  
23300  
35000  
46700  
3300  
3150  
4500  
6100  
3100  
2150  
3100  
2100  
3200  
1000  
650  
Grain Cleaner  
1/4 HP  
1/2 HP  
3/4 HP  
Portable Conveyor  
Grain Elevator  
1000  
1400  
1100  
2800  
720  
Milk Cooler  
Milker (Vacuum Pump)  
FARM DUTY MOTORS  
Std. (e.g. Conveyors,  
Feed Augers, Air  
Compressors)  
2 HP  
1/3 HP  
1/2 HP  
3/4 HP  
1 HP  
975  
1400  
1600  
2200  
2850  
3900  
6800  
2000  
6000  
8000  
10700  
1000  
950  
1-1/2 HP  
2 HP  
3 HP  
5 HP  
High Torque (e.g. Barn  
1-1/2 HP  
5 HP  
Cleaners, Silo Unloaders,  
Silo Hoists, Bunk Feeders)  
7-1/2 HP  
10 HP  
1/2 HP  
500 PSI  
550 PSI  
700 PSI  
3-1/2 cu. ft. Mixer  
High Pressure 1.8 Gal/Min  
Washer 2 gal/min  
2 gal/min  
1400  
1600  
800  
Refrigerator or Freezer  
Shallow Well Pump  
1/3 HP  
1/2 HP  
1/3 HP  
1/2 HP  
750  
1000  
800  
Sump Pump  
1050  
OM-228 042 Page 53  
Download from Www.Somanuals.com. All Manuals Search And Download.  
13-7. Approximate Power Requirements For Contractor Equipment  
Contractor  
Rating  
Starting Watts  
Running Watts  
Hand Drill  
1/4 in  
3/8 in  
350  
400  
350  
400  
1/2 in  
600  
600  
Circular Saw  
Table Saw  
6-1/2 in  
7-1/4 in  
8-1/4 in  
9 in  
500  
500  
900  
900  
1400  
4500  
6300  
2500  
1720  
3900  
5200  
3000  
6000  
8200  
10500  
1100  
1100  
350  
1400  
1500  
1800  
1100  
720  
10 in  
Band Saw  
14 in  
Bench Grinder  
6 in  
8 in  
1400  
1600  
1000  
1500  
2200  
2800  
1100  
1100  
350  
10 in  
Air Compressor  
1/2 HP  
1 HP  
1-1/2 HP  
2 HP  
Electric Chain Saw  
Electric Trimmer  
Electric Cultivator  
1-1/2 HP, 12 in  
2 HP, 14 in  
Standard 9 in  
Heavy Duty 12 in  
1/3 HP  
500  
500  
2100  
400  
700  
Elec. Hedge Trimmer  
Flood Lights  
18 in  
400  
HID  
125  
100  
Metal Halide  
Mercury  
Sodium  
Vapor  
313  
250  
1000  
1400  
1250  
600  
1000  
200  
Submersible Pump  
Centrifugal Pump  
Floor Polisher  
400 gph  
900 gph  
3/4 HP, 16 in  
1 HP, 20 in  
1/2 HP  
900  
500  
4500  
6100  
3150  
4500  
6100  
1900  
900  
1400  
1600  
950  
High Pressure Washer  
3/4 HP  
1400  
1600  
700  
1 HP  
55 gal Drum Mixer  
Wet & Dry Vac  
1/4 HP  
1.7 HP  
900  
2-1/2 HP  
1300  
1300  
OM-228 042 Page 54  
Download from Www.Somanuals.com. All Manuals Search And Download.  
13-8. Power Required To Start Motor  
Single-PhaseInduction Motor Starting Requirements  
Motor Start  
Code  
G
H
J
K
L
M
N
P
KVA/HP  
6.3  
7.1  
8.0  
9.0  
10.0  
11.2  
12.5  
14.0  
1
2
3
4
Motor Start Code  
Running Amperage  
Motor HP  
4
1
3
AC MOTOR  
2
Motor Voltage  
VOLTS 230  
AMPS 2.5  
To find starting amperage:  
CODE  
HP  
M
Hz  
60  
Step 1: Find code and use table to  
find kVA/HP. If code is not listed,  
multiplyrunning amperage by six to  
find starting amperage.  
1/4  
PHASE 1  
Step 2: Find Motor HP and Volts.  
Step 3: Determine starting amper-  
age (see example).  
Welding generator amperage out-  
put must be at least twice the  
motor’s running amperage.  
(kVA/HP x HP x 1000) / Volts =  
Starting Amperage  
Example: Calculate starting amper-  
age required for a 230 V, 1/4 HP mo-  
tor with a motor start code of M.  
Volts = 230, HP = 1/4, kVA/HP =  
11.2  
(11.2 x 1/4 x 1000) / 230 = 12.2A  
Starting the motor requires 12.2  
amperes.  
S-0624  
13-9. How Much Power Can Generator Supply?  
1
Limit Load To 90% Of  
Generator Output  
Always start non-resistive (motor)  
loads in order from largest to small-  
est, and add resistive loads last.  
2
5 Second Rule  
1
If motor does not start within 5  
seconds, turn off power to prevent  
motor damage. Motor requires  
more power than generator can  
supply.  
2
Ref. ST-800 396-A / S-0625  
OM-228 042 Page 55  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
13-10. Typical Connections To Supply Standby Power  
Have only qualified persons  
perform these connections  
according to all applicable  
codes and safety practices.  
4
1
2
3
Fused  
Disconnect  
Switch  
Properly install and ground  
this equipment according to  
its Owner’s Manual and na-  
tional, state, and local codes.  
Welding  
Generator  
Output  
Utility  
Electrical  
Service  
Transfer Switch  
(If Required)  
.
C
u
s
t
o
m
e
r
-
s
u
p
p
l
i
e
d
e
q
u
i
p
m
e
n
t
is required if generator will sup-  
ply standby power during  
emergencies or power out-  
ages.  
5
1 Utility Electrical Service  
Essential  
Loads  
2 Transfer Switch (Double-Throw)  
Switch transfers the electrical load  
from electric utility service to the  
generator. Transfer load back to  
electric utility when service is re-  
stored.  
Install correct switch (customer-  
supplied). Switch rating must be  
same as or greater than the branch  
overcurrent protection.  
3 Fused Disconnect Switch  
Install correct switch (customer-  
supplied) if required by electrical  
code.  
4 Welding Generator Output  
Generator output voltage and wir-  
ing must be consistent with regular  
(utility) system voltage and wiring.  
Connect generator with temporary  
or permanent wiring suitable for the  
installation.  
Turn off or unplug all equipment  
connected to generator before  
starting or stopping engine. When  
starting or stopping, the engine has  
low speed which causes low volt-  
age and frequency.  
5 Essential Loads  
Generator output may not meet the  
electrical requirements of the prem-  
ises. If generator does not produce  
enough output to meet all require-  
ments, connect only essential  
loads (pumps, freezers, heaters,  
etc. − See Section 13-4).  
OM-228 042 Page 56  
Download from Www.Somanuals.com. All Manuals Search And Download.  
13-11. Selecting Extension Cord (Use Shortest Cord Possible)  
Cord Lengths for 120 Volt Loads  
If unit does not have GFCI receptacles, use GFCI-protected extension cord.  
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*  
Current  
(Amperes)  
Load (Watts)  
4
6
8
10  
12  
14  
5
600  
350 (106)  
250 (76)  
175 (53)  
112 (34)  
87 (26)  
62 (19)  
50 (15)  
50 (15)  
37 (11)  
225 (68)  
150 (46)  
112 (34)  
75 (23)  
50 (15)  
37 (11)  
37 (11)  
137 (42)  
100 (30)  
62 (19)  
37 (11)  
30 (9)  
100 (30)  
62 (19)  
50 (15)  
30 (9)  
7
840  
400 (122)  
275 (84)  
175 (53)  
137 (42)  
112 (34)  
87 (26)  
10  
15  
20  
25  
30  
35  
40  
45  
50  
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)  
75 (23)  
62 (19)  
62 (19)  
50 (15)  
*Conductor size is based on maximum 2% voltage drop  
Cord Lengths for 240 Volt Loads  
If unit does not have GFCI receptacles, use GFCI-protected extension cord.  
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*  
Current  
(Amperes)  
Load (Watts)  
4
6
8
10  
12  
14  
5
1200  
1680  
2400  
3600  
4800  
6000  
7000  
8400  
9600  
10,800  
12,000  
700 (213)  
500 (152)  
350 (107)  
225 (69)  
175 (53)  
125 (38)  
100 (31)  
100 (31)  
75 (23)  
450 (137)  
300 (91)  
225 (69)  
150 (46)  
100 (31)  
75 (23)  
225 (84)  
200 (61)  
125 (38)  
75 (23)  
200 (61)  
125 (38)  
100 (31)  
60 (18)  
7
800 (244)  
550 (168)  
350 (107)  
275 (84)  
225 (69)  
175 (53)  
150 (46)  
125 (38)  
125 (38)  
100 (31)  
10  
15  
20  
25  
30  
35  
40  
45  
50  
800 (244)  
600 (183)  
450 (137)  
350 (107)  
300 (91)  
250 (76)  
225 (69)  
200 (61)  
175 (53)  
60 (18)  
75 (23)  
*Conductor size is based on maximum 2% voltage drop  
OM-228 042 Page 57  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Notes  
SOCKET/WRENCH SELECTION TABLE  
(U.S. STANDARD)  
SOCKET/WRENCH SELECTION TABLE  
(METRIC)  
Specifications  
Bolt Decimal  
Socket or Wrench Size  
Specifications  
U.S.  
Socket or Wrench Size  
Bolt  
Bolt  
Nut  
Decimal  
Bolt  
Nut  
Diameter Equivalent  
Diameter  
Equivalent  
1/4 in  
5/16 in  
3/8 in  
7/16 in  
1/2 in  
9/16 in  
5/8 in  
3/4 in  
7/8 in  
1 in  
.250 in  
.3125 in  
.375 in  
.4375 in  
.500 in  
.5625 in  
.625 in  
.750 in  
.875 in  
1.000 in  
3/8 in  
1/2 in  
7/16 in  
9/16 in  
5/8 in  
6 mm  
8 mm  
.2362 in  
.3150 in  
.3937 in  
.4724 in  
.5512 in  
.6299 in  
.7087 in  
.8661 in  
.9449 in  
10 mm  
14 mm  
17 mm  
19 mm  
22 mm  
24 mm  
27 mm  
32 mm  
36 mm  
10 mm  
14 mm  
17 mm  
19 mm  
22 mm  
24 mm  
27 mm  
32 mm  
36 mm  
9/16 in  
5/8 in  
10 mm  
12 mm  
14 mm  
16 mm  
18 mm  
22 mm  
24 mm  
3/4 in  
3/4 in  
13/16 in  
7/8 in  
7/8 in  
15/16 in  
1-1/8 in  
1-5/16 in  
1-1/2 in  
1 in  
1-1/8 in  
1-5/16 in  
1-1/2 in  
OM-228 042 Page 58  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Effective January 1, 2007  
(Equipment with a serial number preface of “LH” or newer)  
This limited warranty supersedes all previous Miller warranties and is exclusive with no other  
guarantees or warranties expressed or implied.  
Warranty Questions?  
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.  
*
Induction Heating Coils and Blankets, Cables, and  
Non-Electronic Controls  
APT & SAF Model Plasma Cutting Torches  
Remote Controls  
Call  
1-800-4-A-MILLER  
for your local  
Miller distributor.  
*
*
*
*
*
*
Accessory (Kits)  
Replacement Parts (No labor)  
Spoolmate Spoolguns  
Canvas Covers  
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.  
Your distributor also gives  
you ...  
Miller’s True Blue® Limited Warranty shall not apply to:  
Service  
1. Consumable components; such as contact tips,  
cutting nozzles, contactors, brushes, slip rings, relays  
or parts that fail due to normal wear. (Exception:  
brushes, slip rings, and relays are covered on Bobcat,  
Trailblazer, and Legend models.)  
You always get the fast,  
reliable response you  
need. Most replacement  
parts can be in your  
hands in 24 hours.  
Miller shall honor warranty claims on warranted equipment listed  
below in the event of such a failure within the warranty time  
periods. All warranty time periods start on the delivery date of the  
equipment to the original end-user purchaser, and not to exceed  
one year after the equipment is shipped to a North American  
distributor or eighteen months after the equipment is shipped to  
an International distributor.  
2. Items furnished by Miller, but manufactured by others, such  
as engines or trade accessories. These items are covered  
by the manufacturer’s warranty, if any.  
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.  
3. Equipment that has been modified by any party other than  
Miller, or equipment that has been improperly installed,  
improperly operated or misused based upon industry  
standards, or equipment which has not had reasonable and  
necessary maintenance, or equipment which has been  
used for operation outside of the specifications for the  
equipment.  
1. 5 Years Parts — 3 Years Labor  
*
Original main power rectifiers  
2. 3 Years — Parts and Labor  
*
*
*
*
*
*
*
*
Transformer/Rectifier Power Sources  
Plasma Arc Cutting Power Sources  
Process Controllers  
Semi-Automatic and Automatic Wire Feeders  
Inverter Power Sources (Unless Otherwise Stated)  
Water Coolant Systems (Integrated)  
Intellitig  
Engine Driven Welding Generators  
(NOTE: Engines are warranted separately by the  
engine manufacturer.)  
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND  
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS  
TRAINED AND EXPERIENCED IN THE USE AND  
MAINTENANCE OF WELDING EQUIPMENT.  
In the event of a warranty claim covered by this warranty, the  
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)  
replacement; or, where authorized in writing by Miller in  
appropriate cases, (3) the reasonable cost of repair or  
replacement at an authorized Miller service station; or (4)  
payment of or credit for the purchase price (less reasonable  
depreciation based upon actual use) upon return of the goods at  
customer’s risk and expense. Miller’s option of repair or  
replacement will be F.O.B., Factory at Appleton, Wisconsin, or  
F.O.B. at a Miller authorized service facility as determined by  
Miller. Therefore no compensation or reimbursement for  
transportation costs of any kind will be allowed.  
3. 1 Year — Parts and Labor Unless Specified  
*
Motor Driven Guns (w/exception of Spoolmate  
Spoolguns)  
Positioners and Controllers  
Automatic Motion Devices  
RFCS Foot Controls  
Induction Heating Power Sources, Coolers, and  
Electronic  
Controls/Recorders  
*
*
*
*
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.  
*
*
*
*
*
*
*
*
*
*
Water Coolant Systems (Non-Integrated)  
Flowgauge and Flowmeter Regulators (No Labor)  
HF Units  
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND  
Grids  
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,  
Spot Welders  
Load Banks  
Arc Stud Power Sources & Arc Stud Guns  
Racks  
Running Gear/Trailers  
Plasma Cutting Torches (except APT & SAF  
Models)  
Field Options  
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.  
*
(NOTE: Field options are covered under True Blue®  
for the remaining warranty period of the product they  
are installed in, or for a minimum of one year —  
whichever is greater.)  
Bernard-Branded Mig Guns (No Labor)  
Weldcraft-Branded TIG Torches (No Labor)  
Subarc Wire Drive Assemblies  
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,  
4. 6 Months — Batteries  
5. 90 Days — Parts  
*
MIG Guns/TIG Torches and Subarc (SAW) Guns  
but may vary from province to province.  
miller_warr 2007−01  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Owner’s Record  
Please complete and retain with your personal records.  
Model Name  
Purchase Date  
Distributor  
Address  
Serial/Style Number  
(Date which equipment was delivered to original customer.)  
City  
State  
Zip  
For Service  
Contact a DISTRIBUTOR or SERVICE AGENCY near you.  
Always provide Model Name and Serial/Style Number.  
Contact your Distributor for:  
Welding Supplies and Consumables  
Options and Accessories  
Personal Safety Equipment  
Service and Repair  
Miller Electric Mfg. Co.  
An Illinois Tool Works Company  
1635 West Spencer Street  
Appleton, WI 54914 USA  
Replacement Parts  
Training (Schools, Videos, Books)  
International Headquarters−USA  
USA Phone: 920-735-4505 Auto-Attended  
USA & Canada FAX: 920-735-4134  
International FAX: 920-735-4125  
Technical Manuals (Servicing Information  
and Parts)  
Circuit Diagrams  
European Headquarters −  
United Kingdom  
Phone: 44 (0) 1204-593493  
FAX: 44 (0) 1204-598066  
Welding Process Handbooks  
To locate a Distributor or Service Agency visit  
www.millerwelds.com or call 1-800-4-A-Miller  
www.MillerWelds.com  
Contact the Delivering Carrier to:  
File a claim for loss or damage during  
shipment.  
For assistance in filing or settling claims, contact  
your distributor and/or equipment manufacturer’s  
Transportation Department.  
PRINTED IN USA  
© 2007 Miller Electric Mfg. Co.2007−01  
Download from Www.Somanuals.com. All Manuals Search And Download.  

Miele Freezer KF 7540 SN User Manual
Milnor Computer Hardware KXMIC00155 User Manual
Murray Lawn Mower MX17542LT User Manual
NEC Computer Monitor FP1375X User Manual
Network Technologies Switch ST C5KVM 600 CE User Manual
NeumannBerlin Microphone TLM 170 i User Manual
Nikon Camera Lens 2198 User Manual
Oregon Scientific Radar Detector MR238 User Manual
Oregon Scientific Thermometer EMR812 User Manual
Ozaki Worldwide Speaker EM96926 User Manual