Miller Bblue 800 Duo PDF
Miller Bblue 800 Duo PDF
Miller Bblue 800 Duo PDF
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Mil_Thank 2009−09
TABLE OF CONTENTS
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
Always wear a face shield, rubber gloves, and Do not let engine exhaust sparks cause fire.
protective clothing when working on a battery. Use approved engine exhaust spark arrestor in
Stop engine before disconnecting or connect- required areas — see applicable codes.
ing battery cables, battery charging cables (if
applicable), or servicing battery. HOT PARTS can burn.
Do not allow tools to cause sparks when working on a battery.
Do not use welder to charge batteries or jump start vehicles un- Do not touch hot parts bare handed.
less the unit has a battery charging feature designed for this pur- Allow cooling period before working on equip-
pose. ment.
Observe correct polarity (+ and −) on batteries. To handle hot parts, use proper tools and/or
Disconnect negative (−) cable first and connect it last. wear heavy, insulated welding gloves and
Keep sparks, flames, cigarettes, and other ignition sources clothing to prevent burns.
away from batteries. Batteries produce explosive gases during
normal operation and when being charged.
Follow battery manufacturer’s instructions when working on or
near a battery.
STEAM AND HOT COOLANT can burn.
If possible, check coolant level when engine is
FUEL can cause fire or explosion. cold to avoid scalding.
Stop engine and let it cool off before checking or Always check coolant level at overflow tank, if
adding fuel. present on unit, instead of radiator (unless told
otherwise in maintenance section or engine manual).
Do not add fuel while smoking or if unit is near If the engine is warm, checking is needed, and there is no over-
any sparks or open flames. flow tank, follow the next two statements.
Do not overfill tank — allow room for fuel to expand. Wear safety glasses and gloves and put a rag over radiator cap.
Do not spill fuel. If fuel is spilled, clean up before starting engine. Turn cap slightly and let pressure escape slowly before
Dispose of rags in a fireproof container. completely removing cap.
Always keep nozzle in contact with tank when fueling.
Using a generator indoors CAN KILL
YOU IN MINUTES.
MOVING PARTS can injure.
Generator exhaust contains carbon monoxide.
Keep away from moving parts such as fans, This is a poison you cannot see or smell.
belts, and rotors. NEVER use inside a home or garage, EVEN IF
Keep all doors, panels, covers, and guards doors and windows are open.
closed and securely in place. Only use OUTSIDE and far away from windows, doors, and
vents.
Stop engine before installing or connecting unit.
Have only qualified persons remove doors, panels, covers, or BATTERY ACID can BURN SKIN and EYES.
guards for maintenance and troubleshooting as necessary.
To prevent accidental starting during servicing, disconnect Do not tip battery.
negative (−) battery cable from battery. Replace damaged battery.
Keep hands, hair, loose clothing, and tools away from moving
Flush eyes and skin immediately with water.
parts.
Reinstall doors, panels, covers, or guards when servicing is
finished and before starting engine.
ENGINE HEAT can cause fire.
Before working on generator, remove spark plugs or injectors to
Do not locate unit on, over, or near combustible
keep engine from kicking back or starting. surfaces or flammables.
Block flywheel so that it will not turn while working on generator
Keep exhaust and exhaust pipes way from
components.
flammables.
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 100, Ontario, Canada L4W 5NS (phone: 800-463-6727, website:
is available as a free download from the American Welding Society at www.csa-international.org).
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com). Safe Practice For Occupational And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, from American National Standards Institute,
Safe Practices for the Preparation of Containers and Piping for Welding 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-
and Cutting, American Welding Society Standard AWS F4.1, from Glob- site: www.ansi.org).
al Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot
Safe Practices for Welding and Cutting Containers that have Held Com- Work, NFPA Standard 51B, from National Fire Protection Association,
bustibles, American Welding Society Standard AWS A6.0, from Global Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.)
Engineering Documents (phone: 1-877-413-5184, OSHA, Occupational Safety and Health Standards for General Indus-
website: www.global.ihs.com). try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
National Electrical Code, NFPA Standard 70, from National Fire Protec- and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
www.nfpa.org and www. sparky.org). (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, www.osha.gov).
from Compressed Gas Association, 14501 George Carter Way,
Suite 103, Chantilly, VA 20151 (phone: 703-788-2700, Portable Generators Safety Alert, U.S. Consumer Product Safety Com-
website:www.cganet.com). mission (CPSC), 4330 East West Highway, Bethesda, MD 20814
Safety in Welding, Cutting, and Allied Processes, CSA Standard (phone: 301-504-7923, website: www.cpsc.gov/cpscpub/pubs/port-
W117.2, from Canadian Standards Association, Standards Sales, 5060 gen.pdf).
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone: Applications Manual for the Revised NIOSH Lifting Equation, The Na-
800-463-6727, website: www.csa-international.org). tional Institute for Occupational Safety and Health (NIOSH), 1600
Battery Chargers, CSA Standard C22.2 NO 107.2−01, from Canadian Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
Standards Association, Standards Sales, 5060 Spectrum Way, Suite www.cdc.gov/NIOSH).
Le courant électrique qui traverse tout conducteur génère des champs 3. Ne pas courber et ne pas entourer les câbles autour de votre
électromagnétiques (CEM) à certains endroits. Le courant issu d’un corps.
soudage à l’arc (et de procédés connexes, y compris le soudage par 4. Maintenir la tête et le torse aussi loin que possible du matériel du
points, le gougeage, le découpage plasma et les opérations de circuit de soudage.
chauffage par induction) crée un champ électromagnétique (CEM) 5. Connecter la pince sur la pièce aussi près que possible de la
autour du circuit de soudage. Des mesures de protection pour les soudure.
porteurs d’implants médicaux doivent être prises: par exemple, des
6. Ne pas travailler à proximité d’une source de soudage, ni
restrictions d’accès pour les passants ou une évaluation individuelle
s’asseoir ou se pencher dessus.
des risques pour les soudeurs. Tous les soudeurs doivent appliquer les
procédures suivantes pour minimiser l’exposition aux CEM provenant 7. Ne pas souder tout en portant la source de soudage ou le
du circuit de soudage: dévidoir.
En ce qui concerne les implants médicaux :
1. Rassembler les câbles en les torsadant ou en les attachant avec Les porteurs d’implants doivent d’abord consulter leur médecin avant
du ruban adhésif ou avec une housse. de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induc-
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les tion. Si le médecin approuve, il est recommandé de suivre les
câbles d’un côté et à distance de l’opérateur. procédures précédentes.
OM-259 705 Page 13
OM-259 705 Page 14
Complete Parts List available at www.MillerWelds.com
SECTION 3 − DEFINITIONS
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.
Safe2 2012−05
Protect yourself from electric shock by insulating yourself from work and ground.
Safe3 2012−05
Safe6 2012−05
Safe8 2012−05
Safe10 2012−05
Safe12 2012−05
Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.
Safe14 2012−05
Safe16 2012−05
Safe20 2012−05
Safe21 2012−05
Safe22 2012−05
Safe23 2012−05
Safe24 2012−05
Use lift eye to lift unit and properly installed accessories only, not gas cylinders. Do not exceed maximum lift eye
rating (see Specifications).
Safe25 2012−05
Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.
Safe38 2012−05
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Safe40 2012−05
Remove unit from shipping crate. Remove Owner’s Manual from unit.
Follow instructions to install muffler.
Safe46 2012−05
Safe47 2012−05
Safe48 2012−05
0 - 50 h std
During the first 50 hours of operation keep welding load above 200
amperes. Do not weld below 200 amperes of output.
Safe54 2012−05
50 h std
After the first 50 hours of operation, change the engine oil and filter.
Safe55 2012−05
Never use generator inside a home or garage, even if doors and win-
dows are open.
Safe87 2012−07
Only use generator outside and far away from windows, doors, and
vents.
Safe88 2012−07
Do not use ether. Using ether voids warranty. See engine Owner’s Manual.
Safe89 2012−07
Safe90 2012−07
Safe91 2012−07
Certified/Trained
Positive Negative Welding Arc
Mechanic
Air Temperature Or
Flux Cored Arc Alternating
Engine Output
Welding (FCAW) Current
Temperature
h s 1
Time Hours Seconds Single Phase
3
Read Operator’s Do Not Switch
Three Phase Circuit Protection
Manual While Welding
S P1max Hz
ing In An Environ-
Maximum Power Three-Phase
ment With In- G
3 Hertz
Consumption Alternator With
creased Risk Of
Rectifier
Electric Shock
X Duty Cycle
U0 Rated No Load
Voltage (Average) U2 Conventional
Load Voltage
n
Rated Load
Speed
n1 Rated Idle
Speed n0 Rated No Load
Speed I Current I2 Rated Welding
Current
Direct Current
* With Low OCV Voltage Reducing Device (VRD) switch enabled, open−circuit voltage is 13 to 15 volts DC until arc initiation for Stick Welding.
B* 57.9 in. (1470 mm) ! Do not move or operate unit where it could
tip.
C* 46.375 in. (1178 mm)
A
D* 11.5625 in. (294 mm) B C
E 27-1/2 in. (699 mm)
F 1 in. (25 mm)
30
G 29-13/16 in. (757 mm)
H 30
9/16 in. (14 mm) Dia.
H
4 Holes 20
D 20
* With mounting brackets in center
position. Dimensions vary with
location of mounting brackets.
F
Weight E 907 535−1
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
80
DC VOLTS
Parallel Mode
60
Dual Operator
40
20
0
0 100 200 300 400 500 600 700 800
DC AMPERES
B. TIG Mode
100
80
DC VOLTS
Parallel Mode
60
40
Dual Operator
20
0
0 100 200 300 400 500 600 700 800 900
DC AMPERES
C. MIG Mode
50
30
DC VOLTS
10
0
0 100 200 300 400 500 600 700 800
DC AMPERES
259 678-A
−10
OM-259 705 Page 21
Complete Parts List available at www.MillerWelds.com
4-8. AC Generator Power Curves
The AC power curve shows the
A. Single Phase 4 kW generator power in amperes.
280
260
AC VOLTS
240
220
200
180
0 10 20 30 40
AC AMPERES
B. Single Phase 12 kW
140 280
135 270
130 260
125 250
AC VOLTS
120 240
115 230
110 220
105 210
100 200
95 190
90 180
0 10 20 30 40 50 60 70 80 90 100
AC AMPERES
C. Three Phase 20 kW
280
260
AC VOLTS
240
220
200
180
0 10 20 30 40 50 60
AC AMPERES
253 021-A / 254 115-A / 254 114-A
4.50
4.25
4.00
3.75 With Air Output
3.50
3.25 No Air Output
3.00
US Gal./Hr.
2.75
2.50
2.25
2.00
1.75 Dual Weld Mode
1.50
1.25
1.00
0.75
IDLE
0.50
0.25
0.00
0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800
259 680-A
Notes
Airflow Clearance
Movement 18 in.
(460 mm)
18 in.
18 in. (460 mm)
(460 mm)
OR OR
18 in.
18 in. (460 mm)
(460 mm)
Location/Mounting
Welding Bolting
Unit In Unit In
Place 2 Place 3
2
OR
OR
1 1
Tools Needed:
9/16 in. install3 2013-06 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712
Movement ! Do not weld on base. Welding on 3 1/2 in Bolt And Washer (Minimum −
base can cause fuel tank fire or ex- Not Supplied)
! Do not move or operate unit where
plosion. Weld only on the four 4 3/8-16 x 1 in. Screws (Supplied)
it could tip.
mounting brackets or bolt unit
To Bolt Unit In Place:
See Section 4-5 for lifting eye rating. down.
NOTICE − Do not mount unit by supporting Remove hardware securing the four
Airflow Clearance the base only at the four mounting brack- mounting brackets to the base. Reverse
NOTICE − Do not install unit where air flow ets. Use cross-supports to adequately brackets and reattach to base with original
is restricted or engine may overheat. support unit and prevent damage to base. hardware.
Location/Mounting 1 Cross-Supports Mount unit to truck or trailer with 1/2 in. (12
mm) or larger hardware (not supplied).
! Always securely fasten welding 2 Mounting Brackets (Supplied)
To Weld Unit In Place:
generator onto transport vehicle or Mount unit on flat surface or use cross-
trailer and comply with all DOT and supports to support base. Secure unit with Weld unit to truck or trailer only at the four
other applicable codes. mounting brackets. mounting brackets.
1 2
GND/PE
! Always ground generator frame to frame. Always connect a ground 1 Equipment Grounding Terminal (On
vehicle frame to prevent electric wire from the generator equipment Front Panel)
shock and static electricity hazards. grounding terminal to bare metal on 2 Grounding Cable (Not Supplied)
the vehicle frame as shown.
! Also see AWS Safety & Health Fact 3 Metal Vehicle Frame
Sheet No. 29, Grounding of Portable
! Use GFCI protection when operat- Connect cable from equipment ground
And Vehicle Mounted Welding Gen-
ing auxiliary equipment. If unit does terminal to metal vehicle frame. Use #8
erators.
not have GFCI receptacles, use AWG or larger insulated copper wire.
! Bed liners, shipping skids, and GFCI-protected extension cord. Do
some running gear insulate the not use GFCI receptacles to power Electrically bond generator frame to ve-
welding generator from the vehicle life support equipment. hicle frame by metal-to-metal contact.
Tools Needed:
1/2 in. Ref. 907 535−1 / 907 535−3 / Exhaust3
+ −
Tools Needed:
1/2 in.
! Connect negative (−) cable last. Do not allow the battery cables to Never disconnect the battery while
NOTICE − Wait two minutes after engine touch opposing terminals. When connect- the engine is running.
shutdown before disconnecting battery or ing the battery cables attach the positive
(+) cable to the positive (+) battery termin- Never use a quick battery charger to
engine controller may be damaged. start the engine.
al first, followed by negative (−) cable to
Battery is most easily accessed through negative (−) battery terminal. Do not charge battery with Engine
the rear panel. Remove battery access Control switch On.
panel from rear panel. Connect battery, Never start the engine when the
negative cable last. Reinstall battery ac- cables are loose or poorly connected to Always disconnect the negative (−)
cess panel. the battery terminals. battery cable before charging battery.
! Stop engine.
1 Battery Disconnect Switch
The battery disconnect switch dis-
connects battery voltage from the
circuit. When the switch is turned
Off, the front panel controls do not
work.
To run unit, turn switch to On posi-
tion. To prevent unit from running,
turn switch to Off position.
The switch may be locked using a
customer-supplied padlock.
907 535−2
Full
Coolant
Overflow
Tank
Full
Diesel
Full
! Stop engine.
! Failure to properly connect weld
cables may cause excessive heat
and start a fire, or damage your ma-
chine.
Tools Needed:
3/4 in. Do not place anything between weld
1 2 cable terminal and copper bar. Make
sure that the surfaces of the weld
cable terminal and copper bar are
clean.
1 Correct Weld Cable Connection
6
3 2 Incorrect Weld Cable Connection
3 Weld Output Terminal
4 Supplied Weld Output Terminal Nut
5 Weld Cable Terminal
6 Copper Bar
Remove supplied nut from weld output
terminal. Slide weld cable terminal onto
4 weld output terminal and secure with nut
so that weld cable terminal is tight against
copper bar.
5
803 778-B
Notes
3/4 in.
1
1
258 836
! Stop engine. 1 Electrode Holder Cables For Stick/TIG Direct Current Electrode
Negative (DCEN), connect work cables to
NOTICE − Do not exceed machine duty 2 Work Cables
Positive (+) terminals and electrode holder
cycle.
For Stick/TIG welding Direct Current Elec- cables to Negative (−) terminals.
Use Dual Operator mode for CC and trode Positive (DCEP), connect work
cables to Negative (−) terminals and elec-
CV welding (see Section 6-2).
trode holder cables to Positive (+) ter- Be sure Process Selector switches
See Section 5-15 for proper cable size. minals. are set correctly. See Section 6-4.
3/4 in.
1
2
1
258 836
! Stop engine. work cable must be able to carry combined other end of work jumper cable to Welder A
! Failure to properly size and connect weld output of both modules (see Section (left) Negative (−) terminal.
weld cables may cause excessive 5-15 for proper cable size).
Connect electrode holder cables to Positive
heat and start a fire, or damage your NOTICE − Do not exceed machine duty (+) terminals.
machine. cycle.
NOTICE − When making weld connections For Stick/TIG Direct Current Electrode
with a common work cable, connect weld Use Dual Operator mode for CC and Negative (DCEN), connect common work
cable of adequate size between Negative CV welding (see Section 6-2). cable and work jumper cable to Welder B
(−) weld output terminals, and connect a (right) Positive (+) terminal. Connect other
1 Electrode Holder Cables
single weld cable of adequate size from end of work jumper cable to Welder A (left)
Welder B (right) Negative (−) terminal to the 2 Work Jumper Cable Positive (+) terminal.
workpiece. 3 Common Work Cable Connect electrode holder cables to Nega-
NOTICE − When using these connections For Stick/TIG welding Direct Current Elec- tive (−) terminals.
as a common work terminal, all connec- trode Positive (DCEP), connect common
tions must be of the same polarity. work cable and work jumper cable to Weld- Be sure Process Selector switches are
NOTICE − For common work connection, er B (right) Negative (−) terminal. Connect set correctly. See Section 6-4.
3/4 in.
1
1
258 836
! Stop engine. 1 Wire Feeder Cables For MIG and FCAW Direct Current Elec-
trode Negative (DCEN), connect work
NOTICE − Do not exceed machine duty
2 Work Cables cables to Positive (+) terminals and wire
cycle.
feeder cables to Negative (−) terminals.
Use Dual Operator mode for CC and For MIG and FCAW welding Direct Current
Electrode Positive (DCEP), connect work
CV welding (see Section 6-2).
cables to Negative (−) terminals and wire Be sure Process Selector switches are
See Section 5-15 for proper cable size. feeder cables to Positive (+) terminals. set correctly. See Section 6-4.
3/4 in.
258 836
! Stop engine. weld output of both modules (see Section mon work cable and work jumper cable to
5-15 for proper cable size). Welder B (right) Negative (−) terminal.
! Failure to properly size and connect Connect other end of work jumper cable to
weld cables may cause excessive NOTICE − Do not exceed machine duty
Welder A (left) Negative (−) terminal.
heat and start a fire, or damage your cycle.
machine.
For common work connection, work Connect wire feeder cables to Positive (+)
terminals.
NOTICE − When making weld connections cable must be able to carry combined
with a common work cable, connect weld weld output of both CC weld output ter-
For MIG and FCAW Direct Current Elec-
cable of adequate size between Negative minals (see Section 5-15 for proper
trode Negative (DCEN), connect common
(−) weld output terminals, and connect a cable size).
work cable and work jumper cable to Weld-
single weld cable of adequate size from
Welder B (right) Negative (−) terminal to the Use Dual Operator mode for CC and er B (right) Positive (+) terminal. Connect
CV welding (see Section 6-2). other end of work jumper cable to Welder
workpiece. A (left) Positive (+) terminal.
1 Wire Feeder Cables
NOTICE − When using these connections Connect wire feeder cables to Negative (−)
as a common work terminal, all connec- 2 Work Jumper Cable
terminals.
tions must be of the same polarity. 3 Common Work Cable
NOTICE − For common work connection, For MIG and FCAW welding Direct Current Be sure Process Selector switches
work cable must be able to carry combined Electrode Positive (DCEP), connect com- are set correctly. See Section 6-4.
3/4 in.
3
2
258 836
! Stop engine. For Stick/TIG welding Direct Current Elec- For MIG and FCAW welding Direct Current
trode Positive (DCEP), connect work Electrode Positive (DCEP), connect work
NOTICE − Do not exceed machine duty
cable to Negative (−) terminal and elec- cable to Negative (−) terminal and wire
cycle.
trode holder cable to Positive (+) terminal. feeder cable to Positive (+) terminal.
Use Dual Operator mode for CC and For Stick/TIG Direct Current Electrode For MIG and FCAW Direct Current Elec-
CV welding (see Section 6-2).
Negative (DCEN), connect work cable to trode Negative (DCEN), connect work
See Section 5-15 for proper cable size. Positive (+) terminal and electrode holder cable to Positive (+) terminal and wire feed-
1 Electrode Holder Cable cable to Negative (−) terminal. er cable to Negative (−) terminal.
2 Wire Feeder Cable Be sure Process Selector switches Be sure Process Selector switches
3 Work Cables are set correctly. See Section 6-4. are set correctly. See Section 6-4.
Tools Needed:
3/4 in.
3
2
! Stop engine. 5-15 for proper cable size). Connect electrode holder cable to one Pos-
! Failure to properly size and connect itive (+) terminal.
NOTICE − Do not exceed machine duty
weld cables may cause excessive cycle. Connect wire feeder cable to remaining
heat and start a fire, or damage your Positive(+) terminal.
machine. Use Dual Operator mode for CC and Be sure Process Selector switches are
NOTICE − When making weld connections CV welding (see Section 6-2).
set correctly. See Section 6-4.
with a common work cable, connect weld 1 Electrode Holder Cable
cable of adequate size between Negative For Direct Current Electrode Negative
(−) weld output terminals, and connect a 2 Wire Feeder Cable (DCEN), connect common work cable and
single weld cable of adequate size from work jumper cable to Welder B (right) Posit-
Welder B (right) Negative (−) terminal to the 3 Work Jumper Cable ive (+) terminal. Connect other end of work
workpiece. jumper cable to Welder A (left) Positive (+)
4 Common Work Cable
terminal.
NOTICE − When using these connections For Direct Current Electrode Positive
as a common work terminal, all connec- Connect electrode holder cable to one
(DCEP), connect common work cable and Negative (−) terminal, and wire feeder
tions must be of the same polarity. work jumper cable to Welder B (right) Neg- cable to remaining Negative (−) terminal.
NOTICE − For common work connection, ative (−) terminal. Connect other end of
work cable must be able to carry combined work jumper cable to Welder A (left) Nega- Be sure Process Selector switches are
weld output of both modules (see Section tive (−) terminal. set correctly. See Section 6-4.
Tools Needed:
3/4 in.
1
2
258 836
! Stop engine. Use Single Operator mode for CC weld- For Stick/TIG welding Direct Current Elec-
trode Positive (DCEP), connect work cable
ing only. Welder B weld output termi-
to Negative (−) terminal and electrode hold-
NOTICE − Do not exceed machine duty nals are disabled in Single Operator
mode. (see Section 6-2). er cable to Positive (+) terminal.
cycle.
For Stick/TIG Direct Current Electrode Neg-
ative (DCEN), connect work cable to Posit-
Welder B (right) weld output terminals See Section 5-15 for proper cable size. ive (+) terminal and electrode holder cable
are disabled in Single Operator mode. to Negative (−) receptacle.
Connect only to Welder A (left) termi- 1 Electrode Holder Cable
nals for Single Operator mode opera- Be sure Process Selector switch is set
tion. 2 Work Cable correctly. See Section 6-4.
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
100 ft (30 m) or Less
(45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
10 − 60% 60 − 100%
Welding Duty Duty 10 − 100% Duty Cycle
Amperes Cycle Cycle AWG (mm2)
AWG (mm2) AWG (mm2)
100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)
Weld Output
Terminals 150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)
200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)
! Turn off power be-
fore connecting to 2x2/0 2x2/0
weld output termi- 250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x70)
nals.
2x2/0 2x3/0 2x3/0
! Do not use worn, 300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x95)
damaged, under-
sized, or repaired 2x2/0 2x3/0 2x3/0 2x4/0
cables. 350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x95) (2x120)
Notes
Not all models have contactor control. See description of front panel controls and
circuit diagram.
K Chassis common.
GND
Notes
Open Position
1
Closed Position
907 535−1
! Air pressure is present at air shutoff Be sure valve is in open position when us- The air compressor will not start if still under
valve whenever Engine Display on ing air compressor. pressure. If air compressor is turned off,
front panel indicates air pressure. The compressor runs and air pressure is wait for air pressure to bleed off (about 20
available whenever the engine is running seconds) before turning air compressor on
1 3/4 in. NPT Air Pressure
and the front panel Compressor switch is again.
Fitting
moved to the On position (see Section 6-2).
2 Air Shutoff Valve Run engine at weld/power speed for maxi-
mum air compressor output. Compressor Using the air compressor does not sig-
Connect air hose with 3/4 in. NPT fitting (not output is reduced when engine is running at nificantly affect weld or generator pow-
supplied) to air shutoff valve. idle speed. er output.
Notes
5 4 3
7 8 9 11 1
10
12
Engine Starting Controls age with the contactor on. Voltmeter displays
voltage at the weld output terminals, but not
If a remote device connected to Remote
1 Engine Control Switch Receptacle is faulty or is disconnected
necessarily the welding arc due to resistance
during operation, the meters display Help
Use switch to start engine, select engine of cable and connections. 25 (see Section 8-8). Clear fault by stop-
speed, and stop engine.
To set voltage, turn Process/Contactor switch ping and restarting the unit or by turning
In Run position, engine runs at weld/power to MIG or FCAW position. Turn V/A control Process/Contactor switch to another
speed. In Run/Idle position, engine runs at until desired voltage is displayed on Voltme- position.
idle speed with no generator power or weld ter. When welding is finished, voltmeter dis- 10 Welder Selector Switch
load, and weld/power speed with load ap- plays weld voltage and then defaults to preset
plied. voltage. Use switch to select Dual Operator or Single
Operator welding mode.
The air compressor load does not affect en- Weld Controls
gine speed. Run engine at weld/power speed Place switch in Welder A/Welder B (dual op-
5 Arc Control
for maximum air compressor output. erator) position for CC and CV output from
See Section 6-5 for Arc Control information. Welder A (left) and Welder B (right) weld out-
NOTICE − Diesel engines in MILLER equip-
put terminals. Control the weld output from the
ment are meant to operate optimally at mod- 6 Voltage/Amperage Control
terminals on each side using the weld con-
erate to rated load. Using light or no load for
With Process/Contactor switch in any Stick or trols on that same side.
extended periods of time may cause wet-
TIG setting, use control to adjust amperage.
stacking or engine damage. If unburned fuel Place switch in Welder A (single operator)
With Process/Contactor switch in any Wire
and oil collect in exhaust pipe, see Section 14. position for weld output from Welder A (left)
(MIG or FCAW) position, use control to adjust
To Start: see Section 6-3 for engine starting voltage. Control limits the remote amperage weld output terminals only.
sequence. in Stick or TIG mode, but has no effect in Wire
modes.
Welder B (right) weld output terminals are
To Stop: turn Engine Control switch to Off disabled in Single Operator mode. Con-
position. 7 Process/Contactor Switch nect only to Welder A (left) terminals for
2 Engine Display See Section 6-4 for Process/Contactor Single Operator operation.
switch information. Compressor Controls
See Section 16 for engine display infor-
mation. 8 24 Volts AC Overload Protection 11 Air Compressor Switch
Weld Meters See Section 8-7 for overload protection in-
Use switch to turn air compressor on and off.
formation.
Air pressure is present at the compressor air
Weld meters also work in combination to 9 Remote Control Receptacle shutoff valve whenever the compressor is
display troubleshooting help codes (see running. The compressor shuts off when the
Section 8-8). Use receptacle to connect remote controls,
engine stops. To use air, the compressor must
wire feeders, and tools requiring 24 VAC.
3 DC Ammeter be turned on each time the engine is started.
When a remote control is connected to the
Ammeter displays preset amperage (Stick The air compressor will not start if still under
Remote receptacle, the Auto Sense Remote
and TIG only) when not welding, and actual pressure. If air compressor is turned off, wait
feature automatically switches voltage/am-
output amperage when welding. for air pressure to bleed off (about 20 sec-
perage control to the remote control (see Sec-
onds) before turning air compressor on again.
To set amperage, turn Process/Contactor tion 6-9).
switch to Stick or TIG position. Turn V/A con- 12 Air Shutoff Valve
With remote control connected, weld output is
trol until desired amperage is displayed on ! Air pressure is present at valve when-
determined by a combination of front panel
Ammeter. When welding is finished, ammeter ever Air Pressure display (part of en-
and remote control voltage/amperage set-
displays weld amperage and then defaults to gine display, see Section 13) indicates
tings.
preset amperage. air pressure.
If no remote control is connected to the Re-
4 DC Voltmeter
mote receptacle, the front panel Voltage/Am- Close valve to stop air flow when connecting
Voltmeter displays preset voltage (MIG weld- perage control adjusts voltage and amper- or changing tools or air hoses (see Section
ing) with contactor off, and actual output volt- age. 5-17).
Wait to Start/Preheating
NOTICE − Do not use ether. The Wait to Start display appears when the Once this message clears, the engine can
Engine Control switch is placed in the Run be started.
If engine does not start, let engine or Run/Idle position. Glow plugs function Turn Engine Control switch to Start. Re-
come to a complete stop before at- automatically according to ambient tem- lease Engine Control switch when engine
tempting restart. starts.
perature. The operator needs to pause at
To Start: either switch position while the engine con- To Stop: turn Engine Control switch to Off
1 Wait to Start/Preheating Display troller goes through the preheat sequence. position.
1 Process/Contactor Switch
! Weld output terminals are ener-
gized when Process/Contactor
switch is in an Electrode Hot
position and the engine is run-
ning.
Use switch to select weld process and
weld output on/off control (see table be-
low).
1
Place switch in Remote On/Off Switch
Required positions to turn weld output on
and off with a device connected to the
Remote 14 receptacle.
Place switch in Electrode Hot positions
for weld output to be on whenever the en-
gine is running.
Use Stick mode for air carbon arc
(CAC-A) cutting and gouging.
Use the Lift-Arc TIG mode for TIG
(GTAW) welding using the Lift-Arc TIG
starting procedure (see Section 6-8).
MIG solid wire uses a voltage sensing (VS) feeder that does not require a control cable
ELECTRODE HOT Electrode Hot – MIG VS back to the welding generator.
FCAW (Flux Cored Arc Welding) uses a voltage sensing (VS) feeder that does not re-
Electrode Hot – FCAW VS quire a control cable back to the welding generator.
Electrode Hot - Stick Stick welding with or without a remote amperage control. Strike an arc to start welding.
Lift Arc TIG: touch tungsten to work and lift to start welding. Uses circuitry internal to the
Electrode Hot – TIG Lift Arc welding generator to aid arc start. Can be used with or without a remote control.
High Frequency TIG or Scratch Start TIG welding. High frequency TIG starting with re-
REMOTE ON/OFF REQUIRED
Remote ON/OFF Required - TIG mote foot control allows remote On/Off and Amperage control. Another typical application
is a simple TIG rig with a remote control device.
Stick welding with RFC-14 control allows remote On/Off and Amperage control. This can
Remote On/Off Required - Stick help eliminate accidental arc strikes.
FCAW using a constant speed feeder. Use feeders with remote voltage control, or use a
Remote On/Off Required - FCAW Spoolmatic 30A with WC 24 control.
MIG solid wire using a constant speed feeder. Use feeders with remote voltage control, or
Remote On/Off Required - MIG use a Spoolmatic 30A with WC 24 control.
Notes
257 145-A
OFF
1
907 535-2
WM Marketing
Notes
1 Remote 14 Receptacle
2 3 Connect optional remote control to receptacle
(see Section 5-16).
CC Welding
In Example:
Min = 20 A DC
Max = 205 A DC
Voltmeter Shows Open-Circuit
Voltage When Not Welding, Arc
Voltage While Welding
85 205
Ammeter Shows Preset
Output When Not Welding,
Actual Amperage While
Welding
28
Electrode Hot: Voltmeter tog-
gles between preset and ac-
tual output when not welding,
actual voltage while welding.
0 Min (20 A DC)
Notes
8 5 4 3
6 7
Single-Phase Generator Power erator winding from overload. If CB6 (240 V x 13 A) + (120 V x 7 A) =
! Use GFCI protection when operat- opens, RC1, RC2, GFCI1 and GFCI2 do 4.0 kVA/kW
ing auxiliary equipment. If unit not work. Place switch in On position to re-
6 120/240 V 50 A Receptacle RC5
does not have GFCI receptacles, set.
use GFCI-protected extension RC5 is connected to the three-phase gen-
CB7 protects GFCI1 from overload. If CB7 erator and supplies 60 Hz single-phase
cord. Do not use GFCI receptacles opens, GFCI1 does not work. Press but-
to power life support equipment. power at weld/power speed. Maximum
ton to reset. output from RC5 is 12 kVA/kW. Power
! Unplug power cord before attempt- available at RC5 is reduced when welding.
ing to service accessories or tools. CB8 protects GFCI2 from overload. If CB8
opens, GFCI2 does not work. Press but- Three-Phase Generator Power
1 120 V 20 A AC GFCI ton to reset.
Receptacle GFCI1 or GFCI2 7 240 V 50 A Three-Phase Receptacle
RC4
! Test GFCI monthly. See Section 7-2 If a supplementary protector contin-
for GFCI information and for reset- ues to open, contact Factory Autho- RC4 is connected to the three-phase gen-
ting and testing procedures. rized Service Agent. erator and supplies 60 Hz three-phase
power at weld/power speed. Maximum
2 240 V 30 A AC Twistlock output from RC4 is 20 kVA/kW. Power
Receptacle RC1 or RC2 Generator power is not affected by available at RC4 is reduced when welding.
weld output.
Receptacles supply 60 Hz single-phase 8 Supplementary Protector CB1
power at weld/power speed. Maximum output is 2.4 kVA/kW from
GFCI1 and 4 kVA/kW from RC1. Maxi- Supplementary protector CB1 protects
3 Supplementary Protector CB6 three-phase receptacle RC4,
mum output from all receptacles is 4 kVA/
4 Supplementary Protector CB7 kW. single-phase receptacle RC5, and the
load wires from overload. If CB1 opens, all
5 Supplementary Protector CB8 EXAMPLE: If 13 A is drawn from RC1, only generator output stops and the recept-
CB6 protects RC1 and RC2, and the gen- 7 A is available at GFCI1: acles do not work.
2
3
4
! Test and reset GFCI
only at Run speed.
RotGFCI1 2012−05
! Use GFCI protection when operat- If a ground fault is detected, the GFCI Reset Check for damaged or wet tools, cords,
ing auxiliary equipment. If unit does button pops out, and the circuit opens to plugs, etc. connected to the receptacle.
not have GFCI receptacles, use disconnect power to the faulty equipment. Start engine and operate at Run (weld/
GFCI-protected extension cord. Do A GFCI receptacle does not protect against power) speed. Press GFCI Reset button.
not use GFCI receptacle to power circuit overloads, short circuits, or shocks Reconnect equipment to GFCI receptacle.
life support equipment. not related to ground faults. Reset and test If GFCI Reset button pops out again, check
GFCI receptacle according to the following the equipment and repair or replace if faulty.
! Unplug power cord before attempt- procedures.
ing to service accessories or tools. Testing GFCI Receptacles
Resetting/Testing GFCI Receptacle
1 120 V 20 A AC GFCI Receptacle
! Test GFCI monthly. See Testing
GFCI testing must be done with engine
2 GFCI Receptacle Test Button GFCI Receptacle. running at Run (weld/power) speed.
! Do not test or reset GFCI recept- Start engine and operate at Run (weld/
3 GFCI Receptacle Reset Button
acles at idle speed/low voltage or power) speed.
4 GFCI Indicator Light (LED) the GFCI will be damaged and not Press the GFCI Test button. The GFCI Re-
provide protection from electric set button should pop out.
GFCI Receptacles shock caused by a ground fault.
Press the GFCI Reset button.
GFCI receptacles protect the user from ! If LED blinks, stop using GFCI re-
electric shock if a ground fault occurs in ceptacle and have it replaced by a Have GFCI replaced by a Factory Au-
equipment connected to the receptacle. A Factory Authorized Service Agent. thorized Service Agent if any of the fol-
ground fault occurs when electrical current lowing occur:
Resetting GFCI Receptacles
takes the shortest path to ground (which GFCI does not trip when tested
could be through a person) rather than fol- If a GFCI fault occurs, stop engine and dis- LED blinks
low its intended safe path. connect equipment from GFCI receptacle. GFCI does not reset.
Primary Fuel Filter Fuel Level Oil Level Oil, Fuel Spills
= Clean unit exterior, in-
cluding stainless steel, fre-
quently to prevent rust and
corrosion.
Coolant Level
Every Section 8-4
100
Hours
Battery Terminals Air Cleaner Hoses Air Cleaner Element Weld Terminals
Every Engine
250 1/2 in.
(13 mm) Manual
Hours
1
Replace
Damaged Brushes
GenBrush1 2012−05 / Ref 190 823
Tools Needed:
255 858
! Stop engine.
2 1 ! Do not run engine without air
cleaner or with dirty element. En-
gine damage caused by using a
damaged element is not covered
by the warranty.
Tools Needed:
4 5 3
907 535−2
! Stop engine and let cool. formation. on the Engine Display, see Sections 13-12
and 13-13.
! After servicing, start engine and To replace fuel filters:
check for fuel leaks. Stop engine, To drain sludge from fuel tank:
tighten connections as necessary, For primary fuel filter, disconnect water sen-
sor connection. ! Beware of fire. Do not smoke and
and wipe up spilled fuel.
keep sparks and flames away from
1 Oil Filter Turn filter counterclockwise. Remove filter. drained fuel. Dispose of drained fuel
2 Oil Drain Valve And Hose in an environmentally-safe manner.
Apply thin coat of fuel to gasket on new filter. Do not leave unit unattended while
3 Oil Fill Cap Fill filter with fuel. Install filter and turn clock- draining fuel tank.
4 Primary Fuel Filter wise. For primary fuel filter, reconnect water
sensor. Bleed air from fuel system accord- ! Properly lift unit and secure in a level
5 Secondary Fuel Filter ing to engine manual. position. Use adequate blocks or
stands to support unit while drain-
6 Fuel Tank Sludge Drain Valve
Inspect fuel line, and replace if cracked or ing fuel tank.
To change oil and filter: worn. Attach 1/2 ID hose to drain valve. Put metal
Route oil drain hose and valve through hole Close doors. container under drain, and use screwdriver
in base. See engine manual and engine to open sludge drain valve. Close valve
maintenance label for oil/filter change in- To reset service reminder intervals shown when sludge has drained. Remove hose.
9
8
10
11
3
4
7
6
5
803 229
! Stop engine. from overload. If F1 opens, weld and gen- CB11 protects the 12 volts DC supply to the
erator power is low or stops entirely. If F2 engine ECU. If CB11 opens, the engine will
When a supplementary protector, cir- opens, weld output is low or stops entirely. stop. Since the ECU generates error mes-
cuit breaker or fuse opens, it usually in- 4 kVA/kW generator power is still available. sages, no error message may appear on
dicates a more serious problem exists. the Engine Display.
Contact Factory Authorized Service 5 Supplementary Protector CB14
Air dryer overload protection, see Section 10 Supplementary Protector CB12
Agent.
6-11. CB12 protects the fuel pump circuit. If
See Section 9-4 for air compressor
6 Supplementary Protector CB3 CB12 opens, the fuel pump does not work
overload protection. and the unit will stop.
See Section 6-11 for air dryer overload 7 Supplementary Protector CB4
11 VRD Switch
protection. CB3 protects the engine weld control cir-
See Section 6-6 for VRD switch informa-
1 Supplementary Protector CB9/CB29 cuit. If CB3 opens, weld output stops,
tion.
CB9 and CB29 protect the 24 volt AC out- meters will be blank; however, generator
power is still available. 12 Circuit Breaker CB10 (Not Shown)
put to remote receptacles. If CB opens,
weld output and 24 volt output to remote re- CB4 protects the field flashing circuit. If CB10 protects the engine battery circuit. If
ceptacle stops. CB4 opens, the generator may not excite at CB10 opens, the engine will not crank.
start-up and weld and generator power out- CB10 automatically resets when the fault is
2 Supplementary Protector CB15 corrected.
put may not be available.
Compressor overload protection, see Sec- 13 Circuit Breaker CB13 (Not Shown)
tion 9-4. 8 Supplementary Protector CB2
CB13 protects the glow plug circuit. If
3 Fuse F1 CB2 protects the engine control circuit. If CB13 opens, the glow plug will not operate.
4 Fuse F2 CB2 opens, the engine does not crank. CB13 automatically resets when the fault is
F1 and F2 protect the stator exciter winding 9 Supplementary Protector CB11 corrected.
2
HL.P 20
3
HL.P 21
4 HL.P 22
5 HL.P 25
HL.P 26
Use the Voltmeter/Ammeter help displays side) on the heat sink has failed. If this dis- and then disconnected. Clear fault by stop-
to diagnose and correct fault conditions. play is shown, have Factory Authorized ping and restarting the unit or by turning
Service Agent check TH1 (each side), and Process/Contactor switch to another posi-
When a help code is displayed normal- the wiring between TH1 and PC1/PC21. tion. If problem continues, have Factory
ly weld output has stopped but genera- Authorized Service Agent check the re-
tor power output may be okay. 3 Help 22 Display
mote device, filter board PC5/PC25, and
Indicates the IBGT module heat sink (each
To reset help displays, stop unit and side) has overheated. If this display is
main control module PC1/PC21.
then restart. See item 4 below to reset 5 Help 26 Display
shown, check generator cooling system
Help 25 display. and/or reduce duty cycle. Keep engine ac- Indicates a fault when attempting to oper-
1 Help 20 Display cess door closed when running to maintain ate the unit in single operator mode (out-
proper cooling air flow past the heat sinks. puts internally paralleled). Help 26 indic-
Indicates a failure of meter display module
Allow unit to cool before restarting. If prob- ates a failure of either side A or side B or
PC2/PC22, or the wiring between
lem continues, have Factory Authorized the communications between them which
PC2/PC22 and main control module PC1
Service Agent check unit. prevents the unit from being operated in
(A Side)/PC21 (B Side), or PC1/PC21. If
the single operator mode. Return to dual
this display is shown, have Factory Autho- 4 Help 25 Display operator mode and check for output at both
rized Service Agent check PC1/PC21,
Indicates a remote device connected to sides. If output is normal, contact Factory
PC2/PC22, and the wiring between them.
Remote Receptacle RC14 may be faulty. Authorized Service Agent to check internal
2 Help 21 Display Help 25 is also displayed whenever a re- wiring and communications between
Thermistor TH1 in the IGBT module (each mote device has been connected to RC14 sides.
803 511
Notes
Recycle air
compressor
fluids.
! Stop engine before maintaining.
Unreadable Labels Belt Tension Air Cleaner Hoses Air Filter Element
Air/Oil Separator
! Stop engine.
NOTICE − Do not run air compressor
without air cleaner or with dirty element.
1 Compressor damage caused by using a
damaged element is not covered by the
warranty.
1 Compressor Air Cleaner
The air cleaner primary element can
be cleaned but the dirt holding capac-
ity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while clean-
ing and the possibility of filter damage
makes cleaning a risk. Consider the
risk of unwarrantable equipment
damage when determining whether
to clean or replace the primary ele-
ment.
Blow Inspect
aircleaner1 9/02* − 803 228 / 153 929-B / 153 585 / Ref. S-0698-B
907 535−2
7
4
Too
High
2
Full Full
3
Too
Low
1
Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 8-8). Also see Engine Information Display to
assist in troubleshooting engine related problems (see Section 13).
A. Welding
Trouble Remedy
No weld output; generator power output Place Process/Contactor switch in an Electrode Hot position, or place switch in a Remote On/Off Re-
okay at AC receptacles. quired position and connect remote contactor to Remote 14 receptacle (see Sections 5-16).
Reset supplementary protector CB9 and/or CB29 (see Section 8-7). Check for faulty remote device
connected to Remote 14 receptacle.
If VRD switch S5 is On, check voltage feedback wires at output terminals and have Factory Authorized
Service Agent check main control board PC1 or PC21.
Have Factory Authorized Service Agent check filter board PC5 and/or PC25 and connections.
Check fuse F2, and replace if open (see Section 8-7). Have Factory Authorized Service Agent check
brushes and slip rings, weld excitation circuit, and the rotor.
No weld output or generator power out- Disconnect equipment from generator power receptacles during start-up.
put at AC receptacles.
Check fuses F1 and F2, and replace if open (see Section 8-7). Have Factory Authorized Service Agent
check integrated rectifier SR2, capacitor C6, and the rotor.
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
Erratic weld output. Check and tighten connections inside and outside unit.
Have Factory Authorized Service Agent check brushes and slip rings.
Check fuses F1 and F2, and replace if open (see Section8-7). Have Factory Authorized Service Agent
check integrated rectifier SR2, capacitor C6, and the rotor.
Place VRD switch S5 in Off position and try welding. If machine operates normally, have Factory Autho-
rized Service Agent check S5 and Main Control Board PC1 and PC21.
Low open-circuit voltage. Have engine Factory Authorized Service Agent check engine speed.
High open-circuit voltage with VRD Have Factory Authorized Service Agent check IGBT Modules PM1, PM2, PM21, and PM22; check and
switch On. replace Main Control Boards PC1 and PC21.
No remote fine amperage or voltage Check and secure connections to Remote 14 receptacle (see Section 5-16).
control.
Trouble Remedy
No remote fine amperage or voltage Repair or replace remote control device.
control (Continued).
Have Factory Authorized Service Agent check current sensing devices, and connections.
Constant speed wire feeder does not Reset supplementary protector CB9 or CB29 (see Section 8-7).
work.
Min or max CV weld output only. Check position of Voltage/Amperage Adjust control and Process/Contactor switch.
Have Factory Authorized Service Agent check Amperage/Voltage Adjust Control and field current
regulator board.
With VRD switch S5 On, machine does Have Factory Authorized Service Agent check and replace Main Control Board PC1 or PC21.
not return to low open−circuit voltage at
the end of weld.
Trouble Remedy
No generator power output at AC recept- Reset receptacle supplementary protectors. Reset GFCI receptacle.
acles; weld output okay.
Check fuse F1, and replace if open (see Section 8-7). Have Factory Authorized Service Agent check inte-
grated rectifiers SR1 and SR2, resistor R3, and capacitor C6.
No generator power or weld output. Disconnect equipment from generator power receptacles during start-up.
Check fuses F1 and F2, and replace if open (see Section 8-7). Have Factory Authorized Service Agent
check integrated rectifiers SR1 and SR2, capacitor C6, and the rotor.
Reset supplementary protector CB4. Have Factory Authorized Service Agent check integrated rectifier
SR1 .
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
High output at generator power AC re- Have engine Factory Authorized Service Agent check engine speed.
ceptacles.
Have Factory Authorized Service Agent adjust generator power field current resistor R3.
Low output at generator power AC re- Have engine Factory Authorized Service Agent check engine speed.
ceptacles.
Check fuse F1, and replace if open (see Section 8-7). Have Factory Authorized Service Agent check inte-
grated rectifier SR2, resistor R3, and capacitor C6.
Have Factory Authorized Service Agent check brushes and slip rings.
Trouble Remedy
No or low output at three-phase gener- Reset supplementary protector CB1 (see Section 7-1).
ator/receptacle RC5.
Erratic output at three-phase generator/ Have Factory Authorized Service Agent check brushes and slip rings.
receptacle RC5.
Trouble Remedy
Engine will not crank. Supplementary protector CB2 open. Reset CB2.
Check battery connections and tighten if necessary. Check battery, and replace if necessary.
Circuit breaker CB10 may be open. CB10 automatically resets when fault is corrected (see Section 8-7).
Have Factory Authorized Service Agent check engine wiring harness and components.
Have Factory Authorized Service Agent check control relay CR5 and Engine Control switch S1.
Check battery and replace if necessary. Check engine charging system according to engine manual.
Have Factory Authorized Service Agent check control relay CR5. Have engine Factory Authorized
Service Agent check fuel pump and fuel system.
Engine starts, but stops when Engine Check oil level. Automatic shutdown system stops engine if oil pressure is too low or engine temperature
Control switch is released. is too high (see Section 5-6). Automatic shutdown system is inhibited for 30 seconds after start-up.
Engine hard to start in cold weather. Keep battery in good condition. Store battery in warm area off cold surface.
Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier for
fuel information.
Use correct grade oil for cold weather (see maintenance label and engine manual).
Engine suddenly stops. Check oil level. Automatic shutdown system stops engine if oil pressure is too low or engine temperature
is too high (see Section 5-6). Automatic shutdown system is inhibited for 30 seconds after start-up.
Check engine air and fuel filters (see Sections8-4 and 8-6).
Battery discharges between uses. Turn Engine Control switch off when unit is not running.
Clean top of battery with baking soda and water solution; rinse with clear water.
Engine idles, but does not come up to Have engine Factory Authorized Service Agent check speed control.
weld speed.
Engine does not run at idle speed. Have Factory Authorized Service Agent check control relays CR3 and CR4/CR24.
Engine uses oil during run-in period; Dry engine according to run-in procedure (see Section 14).
wetstacking occurs.
E. Air Compressor
Trouble Remedy
Air compressor does not operate; no air Place Air Compressor switch in On position. The air compressor will not start if still under pressure. If
pressure at air shutoff valve. compressor is turned off, wait for air pressure to bleed off (about 20 seconds) before turning compressor
on again.
Check compressor belt tension. Be sure correct belt is used and is properly installed.
Have Factory Authorized Service Agent check Air Compressor switch S10, control relay CR10, air pres-
sure switch S11, temperature switch S12, compressor control circuit, and air compressor clutch.
Clean debris from radiator. Automatic shutdown stops compressor if compressor temperature is too high.
Low air pressure. Check for leaks in air lines and hoses.
Have Factory Authorized Service Agent check compressor for rated output.
High air pressure. Adjust compressor air pressure (see Section 9-6).
Pneumatic tools freeze up because of Install optional air dryer/filter kit (Part No. 195 117).
moisture in compressed air.
Oil in air from compressor. Check compressor oil level (see Section 9-5). If oil level is too high, system becomes saturated with oil.
Check connections of control lines (see air compressor circuit diagram in Section 12).
Have Factory Authorized Service Agent check for blocked separator scavenge check valve/filter orifice.
Oil in compressor air cleaner. Have Factory Authorized Service Agent verify compressor inlet valve is operating properly.
258 833-C
Hide
Wait to Start/Preheating 2
1
Glow plugs turn on automatically as de- switch position while the engine controller
goes through the preheat sequence. Once
a few seconds. It can also be found as a
1-up screen (see Section 13-7).
termined by ambient temperature.
this message clears, the engine can be The 6-Up Display then appears as the de-
Compressor oil information appears
only on models with air compressor. started. fault. The engine can be started when the
1 Wait to Start/Preheating Display 2 Service Reminder Display 6-Up Display appears.
The Wait to Start display appears when the The Service Reminder display shows ser- If the Enter/Diagnostic function button is
Engine Control switch is in the Run or Run/ vicing intervals in hours counting down pressed while in this display, the DM2 dia-
Idle position and glow plugs are functioning. from engine manufacturer recommended gnostic screen appears. (see Section
The operator needs to pause at either service intervals. This display appears for 13-11).
1
0 PSI 0.0 H 0 PSI 0.0 H
9
3
32 F 0% 32 F 0%
8
4
1 6-Up Display With Engine RPM 2 6-Up Display With Air Compressor 4 Engine Coolant Temperature
Pressure (Models With Air 5 Engine RPM
This is the default screen configuration. If Compressor)
6 Compressor Air Pressure
the operator wants to toggle to the 1-Up The air compressor must be on and air
pressure must be available for this display 7 Battery Voltage
Display, press the View function button.
The Oil Pressure 1-Up Display appears to appear. 8 Fuel Level
(see Section 13-6). 3 Engine Oil Pressure 9 Engine Hourmeter
0 105
0 RPM 0 VDC
0 PSI
n/min
2
Oil Pressure
0H
Machine Hours
15 18
12
9
125 6
100 150 3
75
50
175
200 0 0V
25 225
250 Battery Potential
0F
Coolant Temperature
125
100
75
100 50
75 25
50 0 0%
25 Percent Load@RPM
0 0%
Fuel Level
Engine Oil
1000 1500
500 2000
0H
n/min
0H
Compressor Oil Compressor Hours
0H
Engine Oil
0H
Service Reminders
100
2
75
50
25
0
Fuel Level
4 5
NO FUEL
Hide
12 13
1 of 1 Warning
OC: 1
This is an abbreviated list of faults. These faults can commonly be remedied by the operator. If other faults appear, contact Factory Authorized
Service Agent.
Contrast
0 7
Units
English
7
9 10
Configuration 0.0.0.0
Bootloader 00.00. 00.00
Firmware 00.00. 00.00
Part Number XX−XX−XXXX
Version
NOTICE − Diesel engines in MILLER equipment are meant to operate optimally at moderate to rated load. Using light or no load for extended periods
of time may cause wetstacking or other engine damage. Do not idle engine longer than necessary.
14-1. Wetstacking
2 NOTICE − Do not perform run-in
procedure at less than 20 volts weld
output and do not exceed duty cycle
or equipment damage may occur.
1 Welding Generator
Run diesel engines near rated volt-
age and current during run-in period
to properly seat piston rings and
prevent wetstacking. See name-
plate, rating label, or specifications
section in this manual to find rated
voltage and current.
1 NOTICE − Do not idle engine longer
than necessary. Piston rings only
seat correctly if engine runs at weld/
power rpm, and the welding genera-
tor is kept loaded during run-in.
2 Engine Exhaust Pipe
Wetstacking is unburned fuel and oil
in the exhaust pipe and occurs
during run-in if the engine is run too
long at light load or idle rpm.
If exhaust pipe is coated with a wet,
black, tar-like substance, dry the
engine using one of the following
run-in procedures.
See the engine manual for additional
engine run-in information.
2
1
+
3 6
S-0683 / S-0684
Drill, 1/18” to 3/8” 3.75 6.25 8.75 25 Burring Tool, Large 3.6 6.0 8.4 24
Drill, 3/8” to 5/16” 5.25 8.75 12.25 35 Rammers, Small 3.9 3.25 9.1 13
Screwdriver,
#2 to #6 Screw 1.8 3.0 4.2 12 Rammers, Medium 5.1 8.5 11.9 34
Screwdriver,
#6 to 5/16” Screw 3.6 6.0 8.4 24 Rammers, Large 6.0 10.0 14.0 40
Tapper, to 3/8” 3.0 5.0 7.0 20 Backfill Tamper 3.75 6.25 8.75 25
Nutsetters, to 3/8” 3.6 6.0 8.4 24 Compression Riveter 0.2 cu. ft. per cycle
Impact Wrench, 1-1/4” 8.25 13.75 19.2 55 Scaling Hammer 1.3 3.0 4.2 12
Die Grinder, Small 2.25 3.75 5.3 15 Chipping Hammer 4.5 7.5 10.5 30
Die Grinder, Medium 3.6 6.0 8.4 24
Riveting Hammer,
Horizontal Grinder, 2” 3.0 5.0 7.0 20 Light 2.25 3.75 5.25 15
Always check with tool manufacturers for actual air consumption of tools being used. The above is based on averages and should not be
considered accurate for any particular make of tool.
Above tools are rated based upon typical “on-load” performance characteristics.
For other values, adjust the C.F. air consumption on a proportional basis.
The cubic feet (C.F.) air consumption for 1 minute may also be expressed as air consumption in cubic feet per minute (C.F.M.)
2 3
OR
1 2
GND/PE
800 652-D
! Always ground generator frame to 3 Metal Vehicle Frame frame. Always connect a ground
vehicle frame to prevent electric wire from the generator equipment
Connect cable from equipment ground grounding terminal to bare metal on
shock and static electricity hazards. terminal to metal vehicle frame. Use #8 the vehicle frame as shown.
! Also see AWS Safety & Health Fact AWG or larger insulated copper wire.
Sheet No. 29, Grounding of Portable
And Vehicle Mounted Welding Gen- Electrically bond generator frame to ve- ! Use GFCI protection when operat-
erators. hicle frame by metal-to-metal contact. ing auxiliary equipment. If unit does
not have GFCI receptacles, use
1 Equipment Grounding Terminal (On ! Bed liners, shipping skids, and GFCI-protected extension cord. Do
Front Panel) some running gear insulate the not use GFCI receptacles to power
2 Grounding Cable (Not Supplied) welding generator from the vehicle life support equipment.
ST-800 576-B
S-0623
S-0624
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
2 supply.
Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected exten-
sion cord. Do not use GFCI receptacles to power life support equipment.
Current
Load (Watts) 4 6 8 10 12 14
(Amperes)
7 840 400 (122) 250 (76) 150 (46) 100 (30) 62 (19)
10 1200 400 (122) 275 (84) 175 (53) 112 (34) 62 (19) 50 (15)
15 1800 300 (91) 175 (53) 112 (34) 75 (23) 37 (11) 30 (9)
Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected exten-
sion cord. Do not use GFCI receptacles to power life support equipment.
Current
Load (Watts) 4 6 8 10 12 14
(Amperes)
7 1680 800 (244) 500 (152) 300 (91) 200 (61) 125 (38)
10 2400 800 (244) 550 (168) 350 (107) 225 (69) 125 (38) 100 (31)
15 3600 600 (183) 350 (107) 225 (69) 150 (46) 75 (23) 60 (18)
20 4800 450 (137) 275 (84) 175 (53) 100 (31) 60 (18)
! Whenever possible and practical, use DC weld output instead of AC weld output.
17-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten )
Not all tungsten electrode manufacturers use the same colors to identify tungsten type. Contact the tungsten electrode manufacturer or reference
the product packaging to identify the tungsten you are using.
17-2. Preparing Tungsten Electrode For Welding With Phase Control Machines
! Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires. Use
local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety infor-
mation. Consider using tungsten containing ceria, lanthana, or yttria instead of thoria. Grinding dust from
thoriated electrodes contains low-level radioactive material. Properly dispose of grinder dust in an environ-
mentally safe way. Wear proper face, hand, and body protection. Keep flammables away.
75 15
Welding direction
20
90
70
75
20
15
10
20-40
90
75 75
15
15
30
ST-162 003 / S-0792
Distributor
Address
City
State Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Contact the Delivering Carrier to: File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA 2013 Miller Electric Mfg. Co. 2013−01