OM-413

February 2001

184 558K

Processes
Stick (SMAW) Welding TIG (GTAW) Welding

Description

Engine Driven Welding Generator

Miller LeGend NT

Visit our website at

www.MillerWelds.com

From Miller to You

Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you dont have time to do it any other way. Thats why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldnt afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. Today, the people that build and sell Miller products continue the tradition. Theyre just as committed to providing equipment and service that meets the high standards of quality and value established in 1929. This Owners Manual is designed to help you get the most out of your Miller products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite. Weve made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, theres a Troubleshooting section that will Miller is the first welding help you figure out what the problem is. The equipment manufacturer in parts list will then help you to decide which the U.S.A. to be registered to the ISO 9001 Quality System exact part you may need to fix the problem. Standard. Warranty and service information for your particular model are also provided.
Working as hard as you do every power source from Miller is backed by the most hassle-free warranty in the business.

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

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

TABLE OF CONTENTS
SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . 1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 1 CONSIGNES DE SCURIT LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . 1-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Dangers relatifs au soudage larc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. Principales normes de scurit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6. Information sur les champs lectromagntiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 2 DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 3 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3. Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5. Auxiliary Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Activating The Dry Charge Battery (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7. Selecting Weld Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8. Optional Remote 14 Receptacle RC1 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 5 OPERATING WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 6 OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. 100 Hz Auxiliary Power Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2. 60 Hz Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3. Wiring Optional 240 Volt Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 7 MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5. Changing Engine Oil, Oil Filter, And Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7. Servicing Optional Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 8 ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 9 AUXILIARY POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 10 STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 11 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPTIONS AND ACCESSORIES WARRANTY 1 1 1 2 3 4 4 5 5 5 6 7 8 8 9 9 9 10 10 11 11 12 12 12 13 14 14 15 15 16 16 17 17 18 18 19 20 21 21 22 23 23 24 25 26 29 30 37 46

WARNING
This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.)

WARNING
Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.

WARNING
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

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

SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING

rom _nd_11/98

1-1. Symbol Usage

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

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

Y The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-5. Read and follow all Safety Standards. Y Only qualified persons should install, operate, maintain, and repair this unit. Y During operation, keep everybody, especially children, away.

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

ELECTRIC SHOCK can kill.

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

SIGNIFICANT DC VOLTAGE exists after stopping engine on inverters.

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

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes from arc rays and sparks when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards). Wear approved safety glasses with side shields under your helmet. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection.

D D D D

FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases. D If ventilation is poor, use an approved air-supplied respirator. D Read the Material Safety Data Sheets (MSDSs) and the manufacturers instructions for metals, consumables, coatings, cleaners, and degreasers. D Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe. D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases. D Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded. OM-413 Page 1

WELDING can cause fire or explosion.

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

HOT PARTS can cause severe burns.

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

NOISE can damage hearing.

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

MAGNETIC FIELDS can affect pacemakers.

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

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully. D Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs. D Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping. D Keep cylinders away from any welding or other electrical circuits. D Never drape a welding torch over a gas cylinder. D Never allow a welding electrode to touch any cylinder. D Never weld on a pressurized cylinder explosion will result. D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition. D Turn face away from valve outlet when opening cylinder valve. D Keep protective cap in place over valve except when cylinder is in use or connected for use. D Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards.

FLYING METAL can injure eyes.

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

BUILDUP OF GAS can injure or kill.

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

1-3. Engine Hazards

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

STEAM AND HOT COOLANT can burn.

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

D Do not overfill tank allow room for fuel to expand. D Do not spill fuel. If fuel is spilled, clean up before starting engine. D Dispose of rags in a fireproof container. OM-413 Page 2

MOVING PARTS can cause injury.

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

BATTERY ACID can BURN SKIN and EYES.

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

ENGINE EXHAUST GASES can kill.

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

ENGINE HEAT can cause fire.

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

BATTERY EXPLOSION can BLIND.

D Always wear a face shield, rubber gloves, and protective clothing when working on a battery. D Stop engine before disconnecting or connecting battery cables or servicing battery. D D D D Do not allow tools to cause sparks when working on a battery. Do not use welder to charge batteries or jump start vehicles. Observe correct polarity (+ and ) on batteries. Disconnect negative () cable first and connect it last.

EXHAUST SPARKS can cause fire.

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

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

FALLING UNIT can cause injury.

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

OVERUSE can cause OVERHEATING.

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

STATIC (ESD) can damage PC boards.

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

FLYING SPARKS can cause injury.

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

TILTING OF TRAILER can cause injury.

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

OVERHEATING can damage motors.

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

READ INSTRUCTIONS.
D Use only genuine MILLER replacement parts. D Perform engine maintenance and service according to this manual and the engine manual. OM-413 Page 3

H.F. RADIATION can cause interference.

D High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. D Have only qualified persons familiar with electronic equipment perform this installation. The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation. If notified by the FCC about interference, stop using the equipment at once. Have the installation regularly checked and maintained. Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference.

ARC WELDING can cause interference.

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

D D D D

D D D D

1-5. Principal Safety Standards

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

1-6. EMF Information

Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the National Research Council concluded that: The body of evidence, in the committees judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard. However, studies are still going forth and evidence continues to be examined. Until the final conclusions of the research are reached, you may wish to minimize your exposure to electromagnetic fields when welding or cutting. To reduce magnetic fields in the workplace, use the following procedures: 1. Keep cables close together by twisting or taping them. 2. Arrange cables to one side and away from the operator. 3. Do not coil or drape cables around your body. 4. Keep welding power source and cables as far away from operator as practical. 5. Connect work clamp to workpiece as close to the weld as possible. About Pacemakers: Pacemaker wearers consult your doctor first. If cleared by your doctor, then following the above procedures is recommended.

OM-413 Page 4

SECTION 1 CONSIGNES DE SCURIT LIRE AVANT UTILISATION

rom _nd_fre 11/98

1-1. Signification des symboles

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

Y Identifie un message de scurit particulier.

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

D D D D D

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

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

UN CHOC LECTRIQUE peut tuer.

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

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

LES FUMES ET LES GAZ peuvent tre dangereux.

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

D D D D D D D

OM-413 Page 5

LE SOUDAGE peut provoquer un incendie ou une explosion.

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

DES PICES CHAUDES peuvent provoquer des brlures graves.

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

LE BRUIT peut affecter loue.

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

LES CHAMPS MAGNTIQUES peuvent affecter les stimulateurs cardiaques.

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

D D D D

Si des BOUTEILLES sont endommages, elles pourront exploser.

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

DES PARTICULES VOLANTES peuvent blesser les yeux.

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

D D D D D

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

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

D D D

1-3. Dangers existant en relation avec le moteur

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

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

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

D D D

D D D D

OM-413 Page 6

DES ORGANES MOBILES peuvent provoquer des blessures.

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

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

D D D D D D D

LES GAZ DCHAPPEMENT DU MOTEUR peuvent provoquer des accidents mortels.

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

LEXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE.

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

LA CHALEUR DU MOTEUR peut provoquer un incendie.

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

D D D D D

LES TINCELLES LCHAPPEMENT peuvent provoquer un incendie.

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

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

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

LEMPLOI EXCESSIF peut SURCHAUFFER LQUIPEMENT.

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

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

LES TINCELLES VOLANTES risquent de provoquer des blessures.

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

LES CHARGES LECTROSTATIQUES peuvent endommager les circuits imprims.

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

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

UNE REMORQUE QUI BASCULE peut entraner des blessures.

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

LE SURCHAUFFEMENT peut endommager le moteur lectrique.

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

LIRE LES INSTRUCTIONS.

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

OM-413 Page 7

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

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

LE SOUDAGE LARC risque de provoquer des interfrences.

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

D D D D D

D D D D D

1-5. Principales normes de scurit

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

1-6. Information sur les champs lectromagntiques

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

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

OM-413 Page 8

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

Start Engine

Read Operators Manual

Amperes

Volts

Engine Oil

Fuel

Battery (Engine)

Engine

Engine Choke

Check Valve Clearance

Do not switch while welding

Work Connection

Positive

Negative

Alternating Current (AC)

Output

Welding Arc (Electrode)

Protective Earth (Ground)

Stick (SMAW)

TIG (GTAW)

Hours

Seconds

Time

On

Circuit Breaker

Temperature

Panel/Local

Remote

Unlocked

Locked

SECTION 3 SPECIFICATIONS
3-1. Weld, Power, And Engine Specifications
Welding Mode CC/AC Weld Output Range 35 225 A Rated Welding Output 225 A, 25 V, 100% Duty Cycle 200 A, 25 V, 100% Duty Cycle Maximum OpenCircuit Voltage 80 Auxiliary Power Rating Single-Phase, 5 kVA/kW, 42/21 A, 120/240 V AC, 60 Hz And Single-Phase, 1 kVA/kW, 9 A, 115 V AC, 100 Hz

Fuel Capacity

Engine

10 gal (38 L) Tank

CC/DC

25 200 A

72

Onan Performer P218 Air-Cooled, Two-Cylinder, Four-Cycle, 18 HP Gasoline Engine

OM-413 Page 9

3-2. Dimensions, Weights, And Operating Angles

Dimensions Height Width Depth A B C D E F G 33-1/2 in (851 mm) 18-3/4 in (476 mm) 46 in (1164 mm) D 18 in (457 mm) 16-1/2 in (419 mm) 3/4 in (19 mm) E 3-1/8 in (79 mm) 32-3/4 in (832 mm) 45-1/2 in (1156 mm) 13/32 in (10 mm) Dia. Weight Engine End 590 lb (267 kg)
800 426

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

G 4 Holes

F 25 25

25 25

3-3. Duty Cycle

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

Continuous Welding 100% Duty Cycle at 225 Amperes CC/AC, 200 Amperes CC/DC
SB-115 570

OM-413 Page 10

3-4. Volt-Ampere Curves

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

B. For CC/DC Mode

185 621 / 185 622

3-5. Auxiliary Power Curve

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

185 623

OM-413 Page 11

3-6. Fuel Consumption

185 620

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

Movement Y Do not lift unit from end.

Airflow Clearance

OR

18 in (460 mm) Location Grounding 3

Generator Base Metal Vehicle Frame Equipment Grounding Terminal Grounding Cable

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

OR

OR

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

2
install1 10/00 Ref. 800 652 / Ref. 800 477-A / 158 936-A / S-0854

OM-413 Page 12

4-2. Activating The Dry Charge Battery (If Applicable)

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

4 1 3

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

. When electrolyte

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

5 A For 30 Minutes

Tools Needed:

OR

+
30 A For 12 Minutes glasses
drybatt1 1/98 S-0886

rubbergloves

OM-413 Page 13

4-3. Connecting The Battery

Y Connect negative () cable last.

Tools Needed: 3/8, 1/2 in

Ref. 800 394-C / Ref. 203 096 / Ref. S-0756-D

4-4. Engine Prestart Checks

Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. Full Full Gasoline

. This unit has a low oil pressure

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

. Follow run-in procedure in enFuel Add fresh fuel before starting engine the first time (see maintenance label for specifications). Fill fuel tank up to 1/2 in. (13 mm) from top to allow room for expansion. Check fuel level on a cold engine before use each day. Oil After fueling, check oil with unit on level surface. If oil is not up to full mark on dipstick, add oil (see maintenance label).

. To

improve starting:

cold

weather

Keep battery in good condition. Store battery in warm area off concrete surface. Use correct grade oil for cold weather.

Ref. 801 757-B / 800 395-B

OM-413 Page 14

4-5. Installing Exhaust Pipe

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

. Point exhaust pipe in desired

direction but always away from front panel and direction of travel.

Tools Needed: 1/2 in

801 681 / Ref. 203 096

4-6. Connecting To Weld Output Terminals

Y Use only one set of terminals at a time. 1 2 3 4 AC Work Weld Output Terminal AC Electrode Weld Output Terminal DC Negative () Weld Output Terminal DC Positive (+) Weld Output Terminal

For Stick welding Direct Current Electrode Positive (DCEP), connect work cable to DC () terminal and electrode cable to DC (+) terminal. For Direct Current Electrode Negative (DCEN), reverse cable connections. For most DC TIG welding applications, connect work cable to DC (+) terminal and torch cable to DC () terminal.

Tools Needed: 3/4 in

Ref. 801 757-B / Ref. 203 096

OM-413 Page 15

4-7. Selecting Weld Cable Sizes

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

150 ft (45 m)

200 ft (60 m)

250 ft (70 m)

300 ft (90 m)

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

Welding Amperes

10 60% Duty Cycle

60 100% Duty Cycle

10 100% Duty Cycle

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

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

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

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

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

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

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

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

300

1 (50)

1/0 (60)

2/0 (70)

3/0 (95)

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

350
* This

1/0 (60)

2/0 (70)

3/0 (95)

4/0 (120)

chart is a general guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), use next size larger cable. **Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. ( ) = mm2 for metric use
S-0007-E

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

4-8. Optional Remote 14 Receptacle RC1 Information

A B J I

Socket*

Socket Information

H C L N D M G E F

Contact closure to B completes 15 volts dc contactor control circuit.

15 volts dc.

+4.5 volts dc output to remote control.

Remote control circuit common.

A
*The remaining sockets are not used.
801 757-B

0 to +4.5 volts dc input command signal from remote control.

Chassis common.

OM-413 Page 16

SECTION 5 OPERATING WELDING GENERATOR

5-1. Front Panel Controls

7 3

Using Idle Lock Switch

+ + +
1 Engine Control Switch 3 Use switch to start engine, select speed, and stop engine. In Run/Idle position, engine runs at power/idle rpm at no load, and weld rpm under weld or 100 Hz auxiliary power receptacle load. In Run position, engine runs at weld rpm. 2 Idle Lock Switch Use switch to lock engine at power/idle speed (see Table). In Unlock position, Engine Control switch and optional Remote Control switch determine engine speed.
OR

= = =

1860 rpm (Power/Idle)

No Load: 1860 rpm (Power/Idle) Load: 3000 rpm (Weld)

3000 rpm (Weld)

Ref. 203 096

Engine Choke Control

Coarse Adjust Switch

Use control to change engine air-fuel mix. To Start: pull out choke and turn Engine Control switch to Start position. Release switch and slowly push choke in when engine starts.

Y Do not switch under load. Use switch to select weld amperage range.

. For best arc starts, use lowest amperage

range possible. 6 Fine Adjust Control Use control to select weld amperage within the range selected by the Coarse Adjust switch. Control may be adjusted while welding. Scale is for reference only. Weld output would be 88 A DC with control settings as shown (50% of 70 to 105 A). 7 Engine Hour Meter OM-413 Page 17

. If the engine does not start, let the engine

come to a complete stop before attempting restart. To Stop: turn Engine Control switch to Off position. 4 Remote Control Switch (Optional) Use switch to select front panel or remote amperage control (see Section 4-8).

. Optional Remote Control switch overrides

Idle Lock.

5-2. Remote Control (Optional)

Y Weld output terminals are energized when Remote Control switch is in Panel/On position and engine is running. 1 Remote 14 Receptacle RC1 Connect optional remote control to RC1 (see Section 4-8). In Example: Range = 70 to 105 A DC Percentage of Range = 50% Min = 70 A DC Max = 88 A DC (50% of 70 to 105)

Max (88 A DC)

Min (70 A DC) Set Switch Set Coarse Adjust Set Fine Adjust (%) Adjust Remote Control
Ref. 801 757-B / Ref. 203 096

SECTION 6 OPERATING AUXILIARY EQUIPMENT

6-1. 100 Hz Auxiliary Power Receptacle
Y Do not operate 50/60 Hz or 60 Hz equipment from 100 Hz receptacle. 1 2 115 V 9 A 100 Hz AC Receptacle RC4

Receptacle supplies single-phase power at weld speed only. Total output available is 1 kVA/kW. 2 Circuit Breaker CB10 CB10 protects receptacle from overload. If CB10 opens, receptacle does not work.

. Press

button to reset circuit breaker. If breaker continues to open, contact a Factory Authorized Service Agent.

Ref. 203 096

OM-413 Page 18

6-2. 60 Hz Auxiliary Power Receptacles

Y If unit does not have GFCI receptacles, use GFCIprotected extension cord. 1 2 1 8 5 2 6 3 3 240 V 50 A Receptacle RC1 120 V 20 A AC Receptacle RC2 120 V 20 A AC Receptacle RC3

Receptacles supply 60 Hz singlephase power at power/idle speed only. Maximum output from RC1 is 5 kVA/kW. Maximum output from either RC2 or RC3 is 2.4 kVA/kW (CSA: 1.8 kVA/kW). For 60 Hz auxiliary power, set controls as shown in table.

. Weld output and 60 Hz auxiliary

4 120 V 15 A AC GFCI Receptacles GFCI2 and GFCI3 (Optional)

power output are not available at the same time.

If a ground fault is detected, the GFCI receptacle Reset button pops out and the circuit opens to disconnect the faulty equipment. Check for damaged tools, cords, plugs, etc. connected to the receptacle. Press button to reset receptacle and resume operation.

. At least once a month, run en-

gine at power/idle speed and press Test button to verify GFCI is working properly. Circuit Breaker CB3 Circuit Breaker CB4

5 6 7

CB3 protects RC2 and CB4 protects RC3 from overload. If CB3 or CB4 opens, the receptacle does not work. 7 Circuit Breaker CB1 CB1 protects all the 60 Hz receptacles from overload. If CB1 opens, RC1, RC2 and RC3 do not work.

For 60 Hz Auxiliary Power Only

For 60 Hz Auxiliary Power OR Weld Output

. Press button or move lever to

On position to reset circuit breaker. If breaker continues to open, contact a Factory Authorized Service Agent. Total Auxiliary Power Output

Combined output of receptacles limited to the 5 kVA/kW output of the generator: EXAMPLE: If 10 A is drawn from RC2, only 16 A is available at RC1: (120 V x 10 A) + (240 V x 16 A) = 5.0 kVA/kW Any Position
PANEL ON PANEL ON

Ref. 203 096

OM-413 Page 19

6-3. Wiring Optional 240 Volt Plug

1 7 4 Current Available in Amperes 240 V Receptacle* 20 15 10 5 0 Each 120 V Duplex Receptacle 0 5 10 15 20 120V 120V 240V 6 2 3 4 5 3 The plug can be wired for a 240 V, 2-wire load or a 120/240V, 3-wire load. See circuit diagram. 1 Plug Wired for 120/240 V, 3-Wire Load

When wired for 120 V loads, each duplex receptacle shares a load with one half of 240 V receptacle. 2 3 4 5 6 7 Plug Wired for 240 V, 2-Wire Load Neutral (Silver) Terminal Load 1 (Brass)Terminal Load 2 (Brass) Terminal Ground (Green) Terminal Amperes Available using 120/240 V Plug

V x A = Watts *One 240 V load or two 120 V loads.

240V

Tools Needed:

120 813-D

OM-413 Page 20

SECTION 7 MAINTENANCE AND TROUBLESHOOTING

7-1. Routine Maintenance

NOTE

Follow the storage procedure in the engine owners manual if the unit will not be used for an extended period.
Y Stop engine before maintaining. Recycle engine fluids.

. See also Engine Manual and maintenance label. Service engine more often if used in severe conditions. To be done by Factory Authorized Service Agent. *

8h
Wipe up spills. Check fluid levels. See Section 4-4.

20 h
Check and clean spark arrestor screen. See Section 7-7.

25 h
Service air filter wrapper (foam element).See Section 7-3. Clean cooling system. See Engine Manual.

50 h
Clean and tighten weld terminals.

100 h
Change oil. See Section 7-5 and maintenance label. Change oil filter. See Section 7-5 and maintenance label. Clean and tighten battery connections.

Service air filter element. See Section 7-3.

200 h
Check valve clearance.* Replace fuel filter. See Section 7-5. Check spark plugs.

Replace unreadable labels.

500 h
Repair or replace cracked cables. Service welding generator brushes and slip rings. Service more often in dirty conditions.*

1000 h
Remove cylinder head deposits.* Clean crankcase breather valve. Blow out or vacuum inside. During heavy service, clean monthly OR

OM-413 Page 21

7-2. Maintenance Label

OM-413 Page 22

7-3. Servicing Air Cleaner

Y Stop engine. 1 Y Do not run engine without air cleaner or with dirty element. 1 2 Wrapper (Foam Element) Wash wrapper with soap and water solution. Allow wrapper to air dry completely. Spread 1 tablespoon SAE 30 oil evenly into wrapper. Squeeze out excess oil. 2 Element Replace element if dirty, oily, or damaged.

aircleaner3 1/97 156 852 / Ref. 203 096 / S-0759

7-4. Overload Protection

Y Stop engine. Disconnect negative () battery cable. 1 1 2 Fuse F1 (See Parts List) F1 protects the exciter excitation winding from overload. If F1 opens, weld output stops. 2 Fuse F6 (See Parts List) F6 protects the engine throttle solenoid from overload. If F6 opens, the engine will not run at weld speed. Replace any open fuses. Reinstall cover before operating.

. When a fuse opens, it usually

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

Tools Needed:

3/8 in

Ref. 801 757-B / Ref. 203 096

OM-413 Page 23

7-5. Changing Engine Oil, Oil Filter, And Fuel Filter

Y Stop engine and let cool. 1 2 3 Oil Drain Valve 1/2 ID x 12 in Hose Oil Filter

Change engine oil and filter according to engine owners manual. Y Close valve and valve cap before adding oil and running engine. Fill crankcase with new oil to full mark on dipstick (see Section 7-2). 4 5 Fuel Filter Fuel Line

Full

Replace line if cracked or worn. Install new filter. Wipe up any spilled fuel. Start engine, and check for fuel leaks. Y Stop engine, tighten connections as necessary, and wipe up fuel. 4

Tools Needed:

Ref. 801 757-B / 800 395-B / Ref. 203 096 / S-0842

OM-413 Page 24

7-6. Adjusting Engine Speed

After tuning engine, check engine speeds with a tachometer. See table for proper no load speeds. If necessary, adjust speeds as follows: 1860 50 rpm 3000 50 rpm Remove cover. Start engine, and rotate Fine Adjust control to 10. 1 2 3 1 4 5 Carburetor Throttle Solenoid Power/Idle Speed Rod Lock Nut Adjustment Nut

Power/Idle Speed Adjustment

Loosen lock nut and rotate adjustment nut until engine runs at power/ idle speed. Tighten lock nut. Weld Speed Adjustment Place Engine Control switch in Run position. 5 9 6 7 Lock Nut Hex Swivel Loosen nut. Rotate swivel until engine runs at weld speed. Tighten lock nut. 8 4 3 2 9 Weld Speed Governor Spring Power/Idle Speed Governor Spring

If a spring becomes loose or disconnected, reattach as shown. Y Stop engine. Reinstall cover.

Top View

Tools Needed: 3/8, 5/16, 7/16 in

Ref. 801 757-B

OM-413 Page 25

7-7. Servicing Optional Spark Arrestor

Y Stop engine and let cool. 1 Spark Arrestor Screen Clean and inspect screen. Replace spark arrestor if screen wires are broken or missing.

Tools Needed: 1/4 in

Ref. 801 682-A / Ref. 203 096

7-8. Troubleshooting

A. Welding
Trouble No weld output. Remedy Check fuse F1 and replace if necessary (see Section 7-4). Be sure all equipment is disconnected from receptacles when starting unit. Have Factory Authorized Service Agent check brushes and slip rings, integrated rectifier SR2, and voltage regulator board PC2. No or erratic weld output. Check control settings. Clean and tighten connections to electrode and workpiece. Use dry, properly-stored electrodes for Stick and TIG welding. Check internal and external connections to weld output terminals; check connections at stabilizer. Remove excessive coils from weld cables. Clean and tighten connections both inside and outside welding generator. Low or high weld output. Check control settings. Check and adjust engine speed (see Section 7-6). Lack of high frequency when TIG welding; difficulty in starting an arc. Use proper size tungsten. Check optional high frequency arc starting unit. Be sure that torch is not close to any grounded metal. Check cables and torch for cracked or deteriorated insulation or bad connections. Repair or replace necessary parts.

OM-413 Page 26

Trouble Wandering arc when TIG welding poor control of arc direction. Reduce gas flow rate. Select proper size tungsten. Properly prepare tungsten. TIG tungsten electrode oxidizing and not remaining bright after weld. Shield weld zone from drafts. Increase postflow time. Check and tighten all gas fittings. Properly prepare tungsten.

Remedy

Repair torch parts if water has leaked into torch.

B. 60 Hz Auxiliary Power
Trouble No auxiliary power output. Remedy Reset circuit breakers (see Section 6-2). Check Engine Control and Idle Lock switch settings. 60 Hz auxiliary power available only at power/idle speed (see table in Section 5-1). Check receptacle(s) for continuity and proper connections. Replace receptacle(s) if necessary. Check fuse F1 and replace if necessary (see Section 7-4). Have Factory Authorized Service Agent check brushes and slip rings, control relay CR2, integrated rectifier SR2, and idle module. Low auxiliary power output. Check and adjust engine speed (see Section 7-6). Check fuse F1 and replace if necessary (see Section 7-4). Have Factory Authorized Service Agent check brushes and slip rings, integrated rectifier SR2, control relay CR3, and voltage regulator board PC2. High auxiliary power output. Check and adjust engine speed (see Section 7-6). Have Factory Authorized Service Agent check voltage regulator board PC2.

C. 100 Hz Auxiliary Power

Trouble No auxiliary power output. Reset circuit breaker CB10 (see Section 6-1). Check receptacle RC4 for continuity and proper connections. Replace receptacle if necessary. Check fuse F1 and replace if necessary (see Section 7-4). Have Factory Authorized Service Agent check brushes and slip rings, and integrated rectifier SR2. Low auxiliary power output. Run engine at weld speed (see Sections 5-1 and 6-1). Remedy

D. Engine
Trouble Engine will not crank. Check battery voltage. Check battery connections and tighten if necessary. Check plug PLG5 and plug PLG8 connections. Have Factory Authorized Service Agent check Engine Control switch S1. Remedy

OM-413 Page 27

Trouble Engine will not start. Check fuel level. Check battery voltage.

Remedy

Check battery connections and tighten if necessary. Check oil level (see Section 4-4). Check low oil pressure shutdown switch (see engine manual). Check plug PLG5 and plug PLG8 connections. Engine starts, but stops when Engine Check oil level (see Section 4-4). Control switch returns to Run position. Check and refill crankcase with proper viscosity oil for operating temperature, if necessary. Check low oil pressure shutdown switch (see engine manual). Check plug PLG5 and plug PLG8 connections. Engine stopped during normal operation. Check fuel level. Check oil level (see Section 4-4). Check low oil pressure shutdown switch (see engine manual). Periodically recharge battery (approximately every 3 months). Replace battery. Check voltage regulator and connections according to engine manual. Engine idles, but does not run at weld speed. Move Idle/Lock switch to Unlock position. Check fuse F6, and replace if open (see Section 7-4). Have Factory Authorized Service Agent check Engine Control switch, idle module PC1, throttle solenoid TS1, control relay CR1, and current transformer CT1. Engine does not return to idle speed. Remove weld and auxiliary power loads. Move Engine Control switch to Run/Idle position. Check throttle linkage for smooth, non-binding operation. Have Factory Authorized Service Agent check Engine Control switch, idle module PC1, throttle solenoid TS1, control relay CR1, and current transformer CT1. Unstable or sluggish engine speeds. Readjust throttle linkage if necessary. Check throttle solenoid TS1 for smooth operation. Tune-up engine according to engine manual. Battery discharges between uses. Clean battery, terminals, and posts with baking soda and water solution; rinse with clear water. Periodically recharge battery (approximately every 3 months). Replace battery. Check voltage regulator and connections according to engine manual.

OM-413 Page 28

SECTION 8 ELECTRICAL DIAGRAM

203 098

Figure 8-1. Circuit Diagram For Welding Generator

OM-413 Page 29

SECTION 9 AUXILIARY POWER GUIDELINES

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

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

aux_pwr 2/99 Ref. ST-159 730 / ST-800 577

9-2. Grounding Generator To Truck Or Trailer Frame

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

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

OR

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

S-0854

OM-413 Page 30

9-3. Grounding When Supplying Building Systems

1 1
GND/PE

Equipment Grounding Terminal Grounding Cable

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

Use ground device as stated in electrical codes. 2 3

ST-800 576-B

9-4. How Much Power Does Equipment Require?

1 3 2 1 VOLTS 115 AMPS 4.5 Hz 60 Resistive Load A light bulb is a resistive load and requires a constant amount of power. 2 Non-Resistive Load Equipment with a motor is a non-resistive load and requires approximately six times more power while starting the motor than when running (see Section 9-8). 3 3 Rating Data Rating shows volts and amperes, or watts required to run equipment. AMPERES x VOLTS = WATTS EXAMPLE 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power requirement in watts. 4.5 A x 115 V = 520 W The load applied by the drill is 520 watts.

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

OM-413 Page 31

9-5. Approximate Power Requirements For Industrial Motors

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

Capacitor Start-Induction Run

Capacitor Start-Capacitor Run

Fan Duty

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

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

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

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

OM-413 Page 32

9-7. Approximate Power Requirements For Contractor Equipment

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

Circular Saw

Table Saw Band Saw Bench Grinder

Air Compressor

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

Submersible Pump Centrifugal Pump Floor Polisher High Pressure Washer

55 gal Drum Mixer Wet & Dry Vac

1000 200 500 1400 1600 950 1400 1600 700 900 1300

OM-413 Page 33

9-8. Power Required To Start Motor

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

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

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

kVA/HP x HP x 1000 VOLTS

= STARTING AMPERAGE

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

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

S-0624

9-9. How Much Power Can Generator Supply?

1 Limit Load To 90% Of Generator Output

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

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

OM-413 Page 34

9-10. Typical Connections To Supply Standby Power

1 2 3 Power Company Service Meter Main and Branch Overcurrent Protection Double-Pole, Double-Throw Transfer Switch

. Customer-supplied equipment is required if

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

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

Obtain and install correct circuit breakers or switch. 120 V 120 V Neutral 5 6 Extension Cord Generator Connections Select as shown in Section 9-11. Connect terminals or plug of adequate amperage capacity to cord. Follow all applicable codes and safety practices. Turn off or unplug all equipment connected to generator before starting or stopping engine. When starting or stopping, the engine has low speed which causes low voltage and frequency. 7 4 Load Connections

2 240 V

120 V Load 120 V

7 CB or F1 Item 4 is not necessary if circuit protection is already present in welding generator auxiliary power output circuit. 5 240 V 120/240 Volt Single-Phase Three-Wire Generator Output Connection 120 V 120 V Ground

S-0405-A

OM-413 Page 35

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

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

*Conductor size is based on maximum 2% voltage drop

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

*Conductor size is based on maximum 2% voltage drop

OM-413 Page 36

SECTION 10 STICK WELDING (SMAW) GUIDELINES

10-1. Stick Welding Procedure

Y Weld current starts when electrode touches workpiece. Y 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. 1 5 4 2 Workpiece Make sure workpiece is clean before welding. 2 3 Work Clamp Electrode

A small diameter electrode requires less current than a large one. Follow electrode manufacturers instructions when setting weld amperage (see Section 10-2). 4 5 6 Insulated Electrode Holder Electrode Holder Position Arc Length

3 6 1 7

Arc length is the distance from the electrode to the workpiece. A short arc with correct amperage will give a sharp, crackling sound. 7 Slag Use a chipping hammer and wire brush to remove slag. Remove slag and check weld bead before making another weld pass.

Tools Needed:

stick 12/96 ST-151 593

OM-413 Page 37

10-2. Electrode and Amperage Selection Chart

ELECTRODE AMPERAGE RANGE 100 150 200 250 300

DIAMETER

350

400

450

PENETRATION

50

ELECTRODE

POSITION

6010 & 6011

6013

7014

7018

7024

Ni-Cl

308L

3/32 1/8 5/32 3/16 7/32 1/4 1/16 5/64 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 3/32 1/8 5/32

6010 6011 6013 7014 7018 7024 NI-CL 308L

EP EP EP,EN EP,EN EP EP,EN EP EP

ALL ALL ALL ALL ALL FLAT HORIZ FILLET ALL ALL

DEEP DEEP LOW MED LOW LOW LOW LOW

MIN. PREP, ROUGH HIGH SPATTER GENERAL SMOOTH, EASY, FAST LOW HYDROGEN, STRONG SMOOTH, EASY, FASTER CAST IRON STAINLESS

*EP = ELECTRODE POSITIVE (REVERSE POLARITY) EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)

USAGE Ref. S-087 985-A

DC*

10-3. Striking an Arc Scratch Start Technique

1 1 2 3 Electrode Workpiece Arc

AC

Drag electrode across workpiece like striking a match; lift electrode slightly after touching work. If arc goes out electrode was lifted to high. If electrode sticks to workpiece, use a quick twist to free it.
S-0049

10-4. Striking an Arc Tapping Technique

1 1 2 3 Electrode Workpiece Arc

Bring electrode straight down to workpiece; then lift slightly to start arc. If arc goes out, electrode was lifted too high. If electrode sticks to workpiece, use a quick twist to free it.

3
S-0050

OM-413 Page 38

10-5. Positioning Electrode Holder

10-30 90 90

End View of Work Angle

Side View of Electrode Angle

GROOVE WELDS

45

10-30

45

End View of Work Angle

Side View of Electrode Angle FILLET WELDS

S-0060

10-6. Poor Weld Bead Characteristics

1 2 3 4 5 1 Large Spatter Deposits Rough, Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration

S-0053-A

10-7. Good Weld Bead Characteristics

1 2 3 Fine Spatter Uniform Bead Moderate Crater During Welding

Weld a new bead or layer for each 1/8 in. (3.2 mm) thickness in metals being welded. 1 4 5 4 5 No Overlap Good Penetration into Base Metal

S-0052-B

OM-413 Page 39

10-8. Conditions That Affect Weld Bead Shape

NOTE

Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal.
Correct Angle 10 - 30

Angle Too Small

Angle Too Large

Drag ELECTRODE ANGLE

Spatter

Too Short

Normal ARC LENGTH

Too Long

Slow

Normal TRAVEL SPEED

Fast
S-0061

10-9. Electrode Movement During Welding

NOTE

Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads work better.
1 1 2 2 3 Stringer Bead Steady Movement Along Seam Weave Bead Side to Side Movement Along Seam Weave Patterns

Use weave patterns to cover a wide area in one pass of the electrode. Do not let weave width exceed 2-1/2 times diameter of electrode.

S-0054-A

OM-413 Page 40

10-10.Butt Joints
1 2 1 Tack Welds Prevent edges of joint from drawing together ahead of electrode by tack welding the materials in position before final weld. 2 Square Groove Weld Good for materials up to 3/16 in (5 mm) thick. 3 1/16 in (1.6 mm) 30 Single V-Groove Weld Good for materials 3/16 3/4 in (5-19 mm) thick. Cut bevel with oxyacetylene or plasma cutting equipment. Remove scale from material after cutting. A grinder can also be used to prepare bevels. 4 Create 30 degree angle of bevel on materials in V-groove welding. 4 Double V-Groove Weld Good for materials thicker than 3/16 in (5 mm).
S-0662

10-11.Lap Joint
30 Or Less 1 30 Or Less 1 1 2 3 Electrode Single-Layer Fillet Weld Multi-Layer Fillet Weld

Move electrode in circular motion. Weld a second layer when a heavier fillet is needed. Remove slag before making another weld pass. Weld both sides of joint for maximum strength.

2 Single-Layer Fillet Weld

3 Multi-Layer Fillet Weld

S-0063 / S-0064

10-12.Tee Joint
1 2 1 Electrode Fillet Weld

Keep arc short and move at definite rate of speed. Hold electrode as shown to provide fusion into the corner. Square edge of the weld surface. 2 For maximum strength weld both sides of upright section. 3 Multi-Layer Deposits Weld a second layer when a heavier fillet is needed. Use any of the weaving patterns shown in Section 10-9. Remove slag before making another weld pass. 1

45 Or Less

3
S-0060 / S-0058-A / S-0061

OM-413 Page 41

10-13.Weld Test
3 1 2 3 3 2 To 3 in (51-76 mm) 2 To 3 in (51-76 mm) 2 1 Vise Weld Joint Hammer

Strike weld joint in direction shown. A good weld bends over but does not break.

1/4 in (6.4 mm)

2 1

S-0057-B

10-14.Troubleshooting Porosity
Porosity small cavities or holes resulting from gas pockets in weld metal.

Possible Causes Arc length too long. Damp electrode. Workpiece dirty. Reduce arc length. Use dry electrode.

Corrective Actions

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

10-15.Troubleshooting Excessive Spatter

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

Possible Causes Amperage too high for electrode. Arc length too long or voltage too high.

Corrective Actions Decrease amperage or select larger electrode. Reduce arc length or voltage.

OM-413 Page 42

10-16.Troubleshooting Incomplete Fusion

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

Possible Causes Insufficient heat input. Improper welding technique.

Corrective Actions Increase amperage. Select larger electrode and increase amperage. 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.

Workpiece dirty.

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

10-17.Troubleshooting Lack Of Penetration

Lack Of Penetration shallow fusion between weld metal and base metal. Lack of Penetration Possible Causes Improper joint preparation. Improper weld technique. Insufficient heat input. Good Penetration Corrective Actions Material too thick. Joint preparation and design must provide access to bottom of groove. Keep arc on leading edge of weld puddle. Increase amperage. Select larger electrode and increase amperage. Reduce travel speed.

10-18.Troubleshooting Excessive Penetration

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

Possible Causes Excessive heat input.

Corrective Actions Select lower amperage. Use smaller electrode. Increase and/or maintain steady travel speed.

OM-413 Page 43

10-19.Troubleshooting Burn-Through
Burn-Through weld metal melting completely through base metal resulting in holes where no metal remains.

Possible Causes Excessive heat input.

Corrective Actions Select lower amperage. Use smaller electrode. Increase and/or maintain steady travel speed.

10-20.Troubleshooting Waviness Of Bead

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

Possible Causes Unsteady hand. Use two hands. Practice technique.

Corrective Actions

10-21.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. Possible Causes Excessive heat input. Corrective Actions Use restraint (clamp) to hold base metal in position. Make tack welds along joint before starting welding operation. Select lower amperage for electrode. Increase travel speed. Weld in small segments and allow cooling between welds.

OM-413 Page 44

Notes

OM-413 Page 45

SECTION 11 PARTS LIST

. Hardware is common and
not available unless listed.

Figure 11-1. Main Assembly

OM-413 Page 46

ST-801 812-E

Item No.

Dia. Mkgs.

Part No.

Description Figure 11-1. Main Assembly

Quantity

. . 1 . . . . . . . . . . . . . . . . . 181 881 . . 2 . . . . . . . . . . . . . . . . . 147 601 . . 3 . . . . . . . . . . . . . . . . . 108 487 . . 4 . . . . . . . . . . . . . . . . . 183 433 . . 5 . . . . . . . . . . . . . . . . +183 221 . . 5 . . . . . . . . . . . . . . . . 185 354 . . 6 . . . . . . . . . . . . . . . . . 182 365 . . 6 . . . . . . . . . . . . . . . . 185 351 . . 7 . . . . . . . . . . . . . . . . . 183 626 . . . . . . . . . . . . . . . . . . . . . . 185 323 . . 8 . . . . . . . . . . . . . . Figure 11-3 . . 9 . . . . . . . . . . . . . . . . . 186 670 . . 10 . . . . . . . . . . . . . . . . 181 789 . . 11 . . . . . . . . . . . . . . . . 165 271 . . 12 . . . . . . . . . . . . . . . . 176 891 . . 13 . . . . . . . . . . . . . . . . 183 314 . . 14 . . . . . . . . . . . . . . . +184 600 . . 15 . . . . . . . . . . . . . . . . 183 434 . . 16 . . . . . . . . . . . . . . . . 065 313 . . 17 . . . . TS1 . . . . . . 186 308 . . 18 . . . . . . . . . . . . . . . . 185 182 . . 19 . . . . . . . . . . . . . . . . 192 796 . . 20 . . . . . . . . . . . . . . . . 064 646 . . 21 . . . . . . . . . . . . . . . . 128 533 . . 22 . . . . . . . . . . . . . . . . 128 431 . . . . . . . . . . . F6 . . . . . . . *192 395 . . . . . . . . . . . . . . . . . . . . . . 192 868 . . . . . . . . . . . . . . . . . . . . . 192 093 . . 23 . . . . . . . . . . . . . Figure 11-4 . . 24 . . . . . . . . . . . . . . . . 167 731 . . 25 . . . . . . . . . . . . . . . . 182 935 . . 26 . . . . . . . . . . . . . . . . 168 385 . . 27 . . . . . . . . . . . . . . . . 182 897 . . 28 . . . . . . . . . . . . . . . . 167 730 . . . . . . . . . . . . . . . . . . . . . . 165 600 . . 29 . . . . . . . . . . . . . . . . 168 037 . . 30 . . . . . . . . . . . . . . . . 182 845 . . 31 . . . . . . . . . . . . . . . . 197 930 . . 32 . . . . . . . . . . . . . . . . 181 057 . . 33 . . . . DC-Z . . . . . . 184 313 . . 34 . . . . . . . . . . . . . . . . 183 980 . . 35 . . . . . . . . . . . . . . . . 164 920 . . 36 . . . . AC-Z . . . . . . 184 312 . . 37 . . . . . . . . . . . . . . . . 182 928 . . 38 . . . . . . . . . . . . . . . . 159 905 . . 39 . . . . . . . . . . . . . . . . 186 667 . . 40 . . . . . . . . . . . . . . . . 121 652 . . 41 . . . . . . . . . . . . . . . . 174 001 . . 42 . . . . SR1 . . . . . . 142 503 . . 43 . . . . . . . . . . . . . . . . 180 628 . . 44 . . . . . . . . . . . . . Figure 11-2 . . 45 . . . . CT1 . . . . . . 184 486 . . 46 . . . . . . . . . . . . . . . . 182 079 . . . . . . . . . . . . . . . . . . . . . . 178 632 . . . . . . . . . . . . . . . . . . . . . . 124 253 . . . . . . . . . . . . . . . . . . . . . . 182 922 . . . . . . . . . . . . . . . . . . . . . . 182 925

. . GROMMET, plastic fill neck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAP, tank w/vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL, warning falling equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PIPE, exhaust elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COVER, top stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, rear upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, rear upper stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BAFFLE, engine air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SEAL BAFFLE, engine air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRACKET, w/components w/harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UPRIGHT BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SEAL, barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VALVE, oil drain 3/8NPT (Included w/engine) . . . . . . . . . . . . . . . . . . . . . . . LABEL, engine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLAMP, muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE, gas electric start (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . MUFFLER, exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GASKET, muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SOLENOID, 12VDC 46A (includes solenoid control module) . . . . . . . . . . BRACKET, mtg solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE KIT, solenoid control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPRING, high speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LINK, throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWIVEL, inline .250-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUSE, mintr gl slo-blo 10A 32 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INDICATOR/CAP ASSEMBLY (Dipstick) . . . . . . . . . . . . . . . . . . . . . . . . . PUMP, electric fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CABLE, bat pos 19.500 No. 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOLDDOWN, battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL, warning battery explosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DOOR, access battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CABLE, bat neg 29.00 No. 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CABLE, bat neg 18.500 6ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BATTERY, stor 12V 430 crk dry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAN, base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL, warning do not weld on base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COVER, base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRACKET, mtg rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRACKET, mtg stab/reactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRACKET, mtg generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRACKET, mtg engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, rear lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FILTER KIT, fuel w/clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SEAL, fuel hose fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RECTIFIER, si 1PH 300A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, lower front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSFORMER, current sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TANK, fuel (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FITTING, stand pipe hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUSHING, fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUSHING, fuel tank 1.210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GAUGE, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

OM-413 Page 47

Item No.

Dia. Mkgs.

Part No.

Description Figure 11-1. Main Assembly (Continued)

Quantity

. . 47 . . . . . . . . . . . . . . . . 182 367 . . 47 . . . . . . . . . . . . . . . 185 352 . . 48 . . . . . . . . . . . . . . . . 182 366 . . 48 . . . . . . . . . . . . . . . 185 353 . . 49 . . . . . . . . . . . . . . . . 182 761 . . 50 . . . . . . . . . . . . . . . . 192 042 . . . . . . . . . . PLG8 . . . . . . 177 859 . . . . . . . . . . PLG5 . . . . . . 116 045 . . . . . . . . . . PLG1 . . . . . . 168 071

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

PANEL, side RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, side RH stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, side LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, side RH stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL, warning engine fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR, body 5 terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 1 1 1 1 1 1

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

5 6 7 8 9

. Hardware is common and

3 2 1

not available unless listed.

29 11 28

10

27 25 26

15 20 21 22 19 18 30 23 24 17 16 14 13 12

ST-801 813-E

Figure 11-2. Front Panel w/Components

OM-413 Page 48

Item No.

Dia. Mkgs.

Part No.

Description Figure 11-2. Front Panel w/Components (Figure 11-1 Item 43)

Quantity

. . 1 . . . . . CB10 . . . . . . 083 432 . . .. 2 ............................ . . 3 . . . . . . . . . . . . . . . . . 188 313 . . . . 4 . . . . . . . . . . . . . . . . . 186 058 . . . . 5 . . . . . . S4 . . . . . . . 162 673 . . . . 6 . . . . . . R1 . . . . . . . 081 712 . . . . 7 . . . . . . S3 . . . . . . . . 011 611 . . . . . . . . . . . . . . . . . . . . . . . . 021 385 . . . . 8 . . . . . . S1 . . . . . . . 176 606 . . . . 9 . . . . RC2,3 . . . . . 141 432 . . . . 9 . . . . GFCI2,3 . . . 147 939 . . . . 10 . . . . CB1 . . . . . . 203 095 . . . . 11 . . . . CB3,4 . . . . . 093 996 . . . . 11 . . . . CB3,4 . . . . 093 995 . . . . 12 . . . . . HM . . . . . . . 145 247 . . . . 13 . . . . . . . . . . . . . . . . 199 031 . . . . 14 . . . . . . . . . . . . . . . . 119 014 . . . . 15 . . . R3,VR1 . . . . . 046 819 . . . . 16 . . . . . . . . . . . . . . . . 039 047 . . . . 17 . . . . . . . . . . . . . . . . 039 046 . . . . 18 . . . . PC4 . . . . . . 148 021 . . . . 19 . . . . . . . . . . . . . . . . 073 756 . . . . 20 . . . . . . . . . . . . . . . . 083 030 . . . . 21 . . . . . . . . . . . . . . . . 010 915 . . . . 22 . . . . . . . . . . . . . . . . 601 836 . . . . 23 . . . . . . . . . . . . . . . . 099 255 . . . . 24 . . . . . . . . . . . . . . . . 159 921 . . . . 25 . . . . . . . . . . . . . . . . 188 039 . . . . 26 . . . . RC1 . . . . . . 182 954 . . . . . . . . . . . . . . . . . . . . . . . . 119 172 . . . . 27 . . . . RC4 . . . . . . 188 263 . . . . 28 . . . . . . . . . . . . . . . . 148 956 . . . . 29 . . . . . . . . . . . . . . . . 097 924 . . . . 30 . . . . . . . . . . . . . . . . 203 016 . .

CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COVER, dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWITCH, selector 7 pos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RHEOSTAT, WW 100W 30 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWITCH, tgl DPDT 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOOT, tgl switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWITCH, ignition 4 position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RECEPTACLE, str dx grd 2P3W 20A 125VAC . . . . . . . . . . . . . . . . . . . . RECEPTACLE, str dx grd 2P3W 15A 125VAC . . . . . . . . . . . . . . . . . . . . CIRCUIT BREAKER, man reset 2p 25a 240vac screw90 . . . . . . . . . CIRCUIT BREAKER, 1P 20A 250VAC . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT BREAKER, man reset 1P 15A 250VAC . . . . . . . . . . . . . . . . . METER, hour 12-24VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONTROL, push/pull . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEVER, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SUPPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TERMINAL, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TERMINAL, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT CARD, filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STAND-OFF, 6-32 x .625 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STUD, brs .250-20 x 1.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WASHER, flat brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NUT, .250-20 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TERMINAL, pwr output neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEZEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COVER, receptacle w/gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RECEPTACLE, str 3P4W 50A 125/250VAC . . . . . . . . . . . . . . . . . . . . . . PLUG, str 50A 125/250V RECEPTACLE, 3P3W 15A 125V hinged . . . . . . . . . . . . . . . . . . . . . . . . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOOT, circuit breaker 2 pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 1 1 1 1 1 1 2 2 1 2 2 1 1 1 1 1 1 1 2 1 3 3 2 1 1 1 1 1 1 1

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

OM-413 Page 49

Item No.

Dia. Mkgs.

Part No.

Description Figure 11-3. Bracket w/Components (Figure 11-1 Item 8)

Quantity

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

1 . . . . . . . . . . . . . . . . . 173 734 2 . . . . . . 1T . . . . . . . 172 661 3 . . . . . . . . . . . . . . . . . 172 731 4 . . . . . . F1 . . . . . . . *083 596 5 . . . . . SR2 . . . . . . 035 704 6 . . . . . . T1 . . . . . . . 184 417 7 . . . . . D2,3 . . . . . . 135 184 8 . . . . . R2,4 . . . . . . 008 951 9 . . . . . PC2 . . . . . . 160 888 10 . . . . . . . . . . . . . . . . 176 478 11 . . . . . . . . . . . . . . . . 184 420 12 . . . . CR3 . . . . . . 044 588 13 . . . . CR1 . . . . . . 173 069 14 . . . . CR2 . . . . . . 113 247 15 . . . . PC1 . . . . . . 186 224

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

LINK, jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BLOCK, stud connection 6P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOLDER, fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUSE, mintr 12A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSFORMER, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIODE BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RESISTOR, WW adj 180 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT CARD ASSEMBLY, voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . STAND-OFF, PC card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRACKET, mtg components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RELAY, encl 12VDC 3PDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RELAY, encl 12VDC SPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RELAY, encl 12VDC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MODULE, pull to weld/power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 1 1 1 1 1 2 2 1 4 1 1 1 1 1

. Hardware is common and

2 1

not available unless listed. 3

PC2 9

15

14 10 13 12 7 11

ST-801 814-A

Figure 11-3. Bracket w/Components *Recommended Spare Parts. To maintain the factory original performance of your equipment, use only Manufacturers Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-413 Page 50

Item No.

Part No.

Description Figure 11-4. Generator (Figure 11-1 Item 22)

Quantity

. . 1 . . . . . . . . . . . . . . . . . 182 092 . . 2 . . . . . . . . . . . . . . . . +184 363 . . 3 . . . . . . . . . . . . . . . . . 153 297 . . 4 . . . . . . . . . . . . . . . . . 143 220 . . 5 . . . . . . . . . . . . . . . . . 183 981 . . 6 . . . . . . . . . . . . . . . . . 107 313 . . 7 . . . . . . . . . . . . . . . . . 008 917 . . 8 . . . . . . . . . . . . . . . . . 134 981 . . 9 . . . . . . . . . . . . . . . . . 017 702 . . 10 . . . . . . . . . . . . . . . . 049 286 . . 11 . . . . . . . . . . . . . . . . 017 624 . . 12 . . . . . . . . . . . . . . . . 053 390 . . 13 . . . . . . . . . . . . . . . . 024 617 . . . . . . . . . . . . . . . . . . . . . . 602 348 . . 14 . . . . . . . . . . . . . . . . 007 250 . . 15 . . . . . . . . . . . . . . . . 047 878 . . 16 . . . . . . . . . . . . . . . . 161 306 . . 17 . . . . . . . . . . . . . . . . *126 984 . . 18 . . . . . . . . . . . . . . . . 005 614 . . . . . . . . . . PLG6 . . . . . . 130 204 . . . . . . . . . . RC6 . . . . . . 168 165

. . LABEL, warning moving parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHROUD, generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENDBELL, gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-RING, 2.859 ID x .139CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STATOR, gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BAFFLE, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WASHER, flat stl .343 ID x 2.250 OD x .187thk . . . . . . . . . . . . . . . . . . . . . ADAPTER, fan rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADAPTER, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ROTOR ASSEMBLY, gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAN, rotor gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEARING, ball rdl sgl row 1.37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RETAINING RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KEY, stl .250 x .250 x .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRACKET, mtg brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BAR, retaining brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAP, brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRUSH w/SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOLDER, brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 8 7

2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 3 3 1 1

. Hardware is common and

not available unless listed.

6 11 5 3 13 1 2 4 10

12

14 18 17 16 15

ST-801 818

Figure 11-4. Generator +When ordering a component originally displaying a precautionary label, the label should also be ordered. *Recommended Spare Parts. To maintain the factory original performance of your equipment, use only Manufacturers Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-413 Page 51

Effective January 1, 2000 (Equipment with a serial number preface of LA or newer)

Warranty Questions?
This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied.
LIMITED WARRANTY Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS. Within the warranty periods listed below, Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be followed. Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the date that the equipment was delivered to the original retail purchaser, or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor. 1. 5 Years Parts 3 Years Labor

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

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

* * * * * *

APT, ZIPCUT & PLAZCUT Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts (No labor) Spoolmate 185 & Spoolmate 250 Canvas Covers

Millers True Blue Limited Warranty shall not apply to: 1. Consumable components; such as contact tips, cutting nozzles, contactors, brushes, slip rings, relays or parts that fail due to normal wear. Items furnished by Miller, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturers warranty, if any. Equipment that has been modified by any party other than Miller, or equipment that has been improperly installed, improperly operated or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of the specifications for the equipment.

2.

3.

* *
2.

Original main power rectifiers Inverters (input and output rectifiers only) Transformer/Rectifier Power Sources Plasma Arc Cutting Power Sources Semi-Automatic and Automatic Wire Feeders Inverter Power Supplies Intellitig Engine Driven Welding Generators (NOTE: Engines are warranted separately by the engine manufacturer.) DS-2 Wire Feeder Motor Driven Guns (w/exception of Spoolmate 185 & Spoolmate 250) Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Water Coolant Systems HF Units Grids Maxstar 140 Spot Welders Load Banks Miller Cyclomatic Equipment Running Gear/Trailers Plasma Cutting Torches (except APT & SAF Models) Field Options (NOTE: Field options are covered under True Blue for the remaining warranty period of the product they are installed in, or for a minimum of one year whichever is greater.)

3 Years Parts and Labor

* * * * * *

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT. In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Millers option: (1) repair; or (2) replacement; or, where authorized in writing by Miller in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customers risk and expense. Millers option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility as determined by Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed. TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY. ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER. Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state. In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province.
miller_warr 7/00

3.

1 Year Parts and Labor

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

4. 5.

6 Months Batteries 90 Days Parts

* *

MIG Guns/TIG Torches Induction Heating Coils and Blankets

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

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

Always provide Model Name and Serial/Style Number.

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

Contact the Delivering Carrier for:

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

File a claim for loss or damage during shipment.

PRINTED IN USA

2001 Miller Electric Mfg. Co.

1/01