Bobcat 250 Diesel PDF

OM-217 455H
20070521
Processes
Stick (SMAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Non-Critical TIG (GTAW)
Welding
Description
Engine Driven Welding Generator
Bobcat 250 Diesel
File: Engine Drive

Visit our website at
www.MillerWelds.com
From Miller to You

Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you dont have time to do
it any other way.
Thats why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldnt afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. Theyre just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owners Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
Weve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
theres a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard.
particular model are also provided.
Miller Electric manufactures a full line

of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 4/05
Working as hard as you do

every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-7. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-8. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage larc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Dangers lis lair comprim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance . . . . .
2-6. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7. Principales normes de scurit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-8. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Weld, Power, and Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Dimensions, Weights, and Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Dimensions For Units With Optional Running Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Connecting the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Overview And Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Connecting to Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 OPERATING THE WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Engine Control Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Weld Output Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Typical Stick Welding Connections And Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Typical MIG Welding Connections And Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Typical MIG Connections And Settings Using Weld Control And Spoolgun . . . . . . . . . . . . . . . . . . . . .
SECTION 7 OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Generator Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Simultaneous Weld And Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P) . . . . . . . . . . . . . . . . . .
SECTION 8 OPERATING OPTIONAL BATTERY CHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Battery Charge Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Determining Battery Charging Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Battery Charge Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Battery Charging Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Maintenance Label And Engine Maintenance Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-4. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-5. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-6. Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS
SECTION 10 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1. Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 RUN-IN AND WETSTACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-1. Run-In And Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 13 PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-1. Fuel Consumption Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-2. Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-3. Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-4. Stick Mode Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-5. MIG Mode Volt-Ampere Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 14 GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 15 STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPLETE PARTS LIST - www.MillerWelds.com
OPTIONS AND ACCESSORIES
WARRANTY
41
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SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING

rom_200704
Protect yourself and others from injury read and follow these precautions.
1-1. Symbol Usage

DANGER! Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE Indicates statements not related to personal injury.
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC

SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards

The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-7. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
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 Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
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 Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
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.
D Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
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.
SIGNIFICANT DC VOLTAGE exists in inverters after stopping engine.

D Stop engine on inverter and discharge input capacitors according
to instructions in Maintenance Section before touching any parts.
HOT PARTS can cause severe burns.

D Do not touch hot parts bare handed.
D Allow cooling period before working on equipment.
D To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
FLYING METAL or DIRT can injure eyes.

D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side shields even under your
welding helmet.
OM-217 455 Page 1
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 local forced ventilation at the
arc to remove welding fumes and gases.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand 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 while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
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 Do not weld where the atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
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, sparks, 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.
D After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
D Use only correct fuses or circuit breakers. Do not oversize or bypass them.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
NOISE can damage hearing.
BUILDUP OF GAS can injure or kill.
Noise from some processes or equipment can damage hearing.
D Shut off shielding gas supply when not in use.

D Always ventilate confined spaces or use approved air-supplied respirator.
D Wear approved ear protection if noise level is

high.
MAGNETIC FIELDS can affect Implanted

Medical Devices.
ARC RAYS can burn eyes and skin.
D
D
D
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 an approved welding helmet fitted with a proper shade of filter
lenses to protect your face and eyes from arc rays and sparks
when welding or watching (see ANSI Z49.1 and Z87.1 listed in
Safety Standards).
Wear approved safety glasses with side shields under your
helmet.
Use protective screens or barriers to protect others from flash,
glare, and sparks; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton, or wool) and foot protection.
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 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 Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
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.
OM-217 455 Page 2
D Wearers of Pacemakers and other Implanted

Medical Devices should keep away.
D Implanted Medical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
CYLINDERS can explode if damaged.
D
D
D
D
D
D
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.
Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder explosion will result.
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 Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
1-3. Engine Hazards

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.
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.
D
D
D
D
Do not overfill tank allow room for fuel to expand.

Do not spill fuel. If fuel is spilled, clean up before starting engine.
Dispose of rags in a fireproof container.
Always keep nozzle in contact with tank when fueling.
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 doors, panels, covers, or
guards 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 doors, panels, covers, or guards 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.
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.
Using a generator indoors CAN KILL

YOU IN MINUTES.
D Generator exhaust contains carbon monoxide.
This is a poison you cannot see or smell.
D NEVER use inside a home or garage, EVEN IF
doors and windows are open.
D Only use OUTSIDE and far away from windows, doors, and
vents.
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 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.
HOT PARTS can cause severe burns.

D Do not touch hot parts bare handed.
D Allow cooling period before working on equipment.
D To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
EXHAUST SPARKS can cause fire.

D Do not let engine exhaust sparks cause fire.
D Use approved engine exhaust spark arrestor in
required areas see applicable codes.
1-4. Compressed Air Hazards

BREATHING COMPRESSED AIR can
cause serious injury or death.
D Do not use compressed air for breathing.
D Use only for cutting, gouging, and tools.
TRAPPED AIR PRESSURE AND WHIPPING

HOSES can cause injury.
D Release air pressure from tools and system before servicing, adding or changing attachments, or opening compressor oil drain or oil fill
cap.
COMPRESSED AIR can cause injury.

D Wear approved safety goggles.
D Do not direct air stream toward self or others.
OM-217 455 Page 3
HOT METAL from air arc cutting and

gouging can cause fire or explosion.
D Do not cut or gouge near flammables.
D Watch for fire; keep extinguisher nearby.
HOT PARTS can cause burns and injury.
READ INSTRUCTIONS.
D Read Owners Manual before using or servicing unit.
D Stop engine and release air pressure before
servicing.
D Use only genuine replacement parts from the
manufacturer.
D Do not touch hot compressor or air system

parts.
D Let system cool down before touching or servicing.
1-5. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING UNIT can cause injury.

D Use lifting eye to lift unit and properly installed
accessories only, NOT gas cylinders. Do not
exceed maximum lift eye weight rating (see
Specifications).
D Lift and support unit only with proper equipment
and correct procedures.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
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.
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.
MOVING PARTS can cause injury.

D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
OM-217 455 Page 4
WELDING WIRE can cause injury.

D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
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.
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.
READ INSTRUCTIONS.
D Read Owners Manual before using or servicing unit.
D Use only genuine replacement parts from the
manufacturer.
D Perform engine and air compressor maintenance and service according to this manual
and the engine/air compressor (if applicable)
manuals.
H.F. RADIATION can cause interference.
D
D
D
D
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
D
D
D
D Electromagnetic energy can interfere with

sensitive electronic equipment such as microprocessors, 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.
1-6. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
For Gasoline Engines:

Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive harm.
For Diesel Engines:
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
1-7. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard
AWS F4.1, from Global Engineering Documents (phone:
1-877-413-5184, website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, Quincy, MA 02269-9101 (phone:
617-770-3000, website: www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 4221 Walney Road, 5th Floor,
Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 5060 Mississauga,
Ontario, Canada L4W 5NS (phone: 800-463-6727 or in Toronto

416-747-4044, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 100368002 (phone:
212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, Quincy, MA 02269-9101 (phone: 617-770-3000, website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 Regional Officesphone for
Region 5, Chicago, is 312-353-2220, website: www.osha.gov).
1-8. EMF Information

Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause 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, or using a

cable cover.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from
operator as practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
OM-217 455 Page 5
SECTION 2 CONSIGNES DE SCURIT LIRE AVANT

UTILISATION
rom_200704fre
Se protger, ainsi que toute autre personne travaillant sur les lieux, contre les tincelles et le mtal chaud.
2-1. Signification des symboles

DANGER! Indique une situation dangereuse qui si on
lvite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrs par les symboles
joints ou sont expliqus dans le texte.
Indique une situation dangereuse qui si on lvite pas
peut donner la mort ou des blessures graves. Les dangers possibles sont montrs par les symboles joints ou
sont expliqus dans le texte.
NOTE Indique des dclarations pas en relation avec des blessures
personnelles.
. Indique des instructions spcifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER

DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
affrant pour les actions ncessaires afin dviter le danger.
2-2. Dangers relatifs au soudage larc

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 2-7. Veuillez lire et respecter
toutes ces normes de scurit.
souder DC semiautomatique de type CV (MIG/MAG), 2) un poste

souder manuel (lectrode enrobe) DC, 3) un poste souder
manuel AC avec tension vide rduite. Dans la plupart des cas, un
poste courant continu de type CV est recommand. Et, ne pas travailler seul!
D 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).
Linstallation, lutilisation, lentretien et les rparations ne

doivent tre confis qu des personnes qualifies.
D Installer et mettre la terre correctement cet appareil conformment son manuel dutilisation et aux codes nationaux,
provinciaux et municipaux.
Au cours de lutilisation, tenir toute personne lcart et plus

particulirement les enfants.
D 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.
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 Ne jamais toucher les pices lectriques sous tension.
D Porter des gants et des vtements de protection secs ne comportant pas de trous.
D 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.
D Ne pas se servir de source lectrique courant lectrique dans les
zones humides, dans les endroits confins ou l o on risque de
tomber.
D Se servir dune source lectrique courant lectrique UNIQUEMENT si le procd de soudage le demande.
D Si lutilisation dune source lectrique courant lectrique savre
ncessaire, se servir de la fonction de tlcommande si lappareil
en est quip.
D Des prcautions de scurit supplmentaires sont requises dans
des environnements risque comme: les endroits humides ou
lorsque lon porte des vtements mouills; sur des structures mtalliques au sol, grillages et chafaudages; dans des positions
assises, genoux et allonges; ou quand il y a un risque important
de contact accidentel avec la pice ou le sol. Dans ces cas utiliser
les appareils suivants dans lordre de prfrence: 1) un poste
OM-217 455 Page 6
D En effectuant les raccordements dentre fixer dabord le conducteur de mise la terre appropri et contre-vrifier les connexions.
D Les cbles doivent tre exempts dhumidit, dhuile et de graisse;
protgezles contre les tincelles et les pices mtalliques chaudes.
D 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.
D Mettre lappareil hors tension quand on ne lutilise pas.
D Ne pas utiliser des cbles uss, endommags, de grosseur insuffisante ou mal pisss.
D Ne pas enrouler les cbles autour du corps.
D 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.
D Ne pas toucher llectrode quand on est en contact avec la pice,
la terre ou une lectrode provenant dune autre machine.
D Ne pas toucher des porte lectrodes connects deux machines
en mme temps cause de la prsence dune tension vide double.
D Nutiliser quun matriel en bon tat. Rparer ou remplacer
sur-le-champ les pices endommages. Entretenir lappareil
conformment ce manuel.
D Porter un harnais de scurit quand on travaille en hauteur.
D Maintenir solidement en place tous les panneaux et capots.
D Fixer le cble de retour de faon obtenir un bon contact mtalmtal avec la pice souder ou la table de travail, le plus prs
possible de la soudure.
D 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.
DES PICES CHAUDES peuvent

provoquer des brlures graves.
D Ne pas toucher mains nues les parties chaudes.
D Prvoir une priode de refroidissement avant de
travailler lquipement.
D Ne pas toucher aux pices chaudes, utiliser les outils recommands et porter des gants de soudage et des vtements pais pour
viter les brlures.
DES PIECES DE METAL ou DES SALETES peuvent provoquer des blessures dans 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.
LES FUMES ET LES GAZ peuvent tre

dangereux.
Le soudage gnre des fumes et des gaz. Leur
inhalation peut tre dangereux pour votre sant.
LES RAYONS DE LARC peuvent pro

voquer des brlures dans les yeux e
sur la peau.
Le rayonnement de larc du procd de soudage
gnre des rayons visibles et invisibles intense
(ultraviolets et infrarouges) susceptibles de provoquer des brlure
dans les yeux et sur la peau. Des tincelles sont projetes pendant le
soudage.
D Porter un casque de soudage approuv muni de verres filtrants
appropri pour protger visage et yeux pendant le soudage
(voir ANSI Z49.1 et Z87.1 numr dans les normes de scurit).
D Porter des lunettes de scurit avec crans latraux mme sous
votre casque.
D Avoir recours des crans protecteurs ou des rideaux pour
protger les autres contre les rayonnements les blouissements
et les tincelles ; prvenir toute personne sur les lieux de ne pas
regarder larc.
D Porter des vtements confectionns avec des matires rsistantes et ignifuges (cuir, coton lourd ou laine) et des bottes de
protection.
LE SOUDAGE peut provoquer un in

cendie ou une explosion.
Le soudage effectu sur des conteneurs ferms tel
que des rservoirs, tambours ou des conduites peu
provoquer leur clatement. Des tincelles peuven
tre projetes de larc de soudure. La projection dtincelles, des pice
chaudes et des quipements chauds peut provoquer des incendies e
des brlures. Le contact accidentel de llectrode avec des objet
mtalliques peut provoquer des tincelles, une explosion, un surchauf
fement ou un incendie. Avant de commencer le soudage, vrifier e
sassurer que lendroit ne prsente pas de danger.
D 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.
D Eloigner votre tte des fumes. Ne pas respirer les fumes.
D Ne pas souder dans un endroit l o des tincelles peuvent tomber

sur des substances inflammables.
D lintrieur, ventiler la zone et/ou utiliser une ventilation force au

niveau de larc pour lvacuation des fumes et des gaz de soudage.
D Se protger et dautres personnes de la projection dtincelles et

de mtal chaud.
D Si la ventilation est mdiocre, porter un respirateur anti-vapeurs

approuv.
D Des tincelles et des matriaux chauds du soudage peuvent

facilement passer dans dautres zones en traversant de petites
fissures et des ouvertures.
D Lire et comprendre les spcifications de scurit des matriaux

(MSDS) et les instructions du fabricant concernant les mtaux, les
consommables, les revtements, les nettoyants et les dgraisseurs.
D 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.
D 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.
D 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 en portant un respirateur alimentation dair. Les
revtements et tous les mtaux renfermant ces lments peuvent
dgager des fumes toxiques en cas de soudage.
LES ACCUMULATIONS DE GAZ ris

quent de provoquer des blessures ou
mme la mort.
D Fermer lalimentation du gaz protecteur en cas de
non utilisation.
D Veiller toujours bien arer les espaces confins ou se servir dun
respirateur dadduction dair homologu.
D Surveiller tout dclenchement dincendie et tenir un extincteur

proximit.
D Le soudage effectu sur un plafond, plancher, paroi ou sparation
peut dclencher un incendie de lautre ct.
D 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).
D Ne soudez pas si lair ambiant est charg de particules, gaz, ou vapeurs inflammables (vapeur dessence, par exemple).
D Brancher le cble de masse 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, dtincelles et dincendie.
D Ne pas utiliser le poste de soudage pour dgeler des conduites geles.
D En cas de non utilisation, enlever la baguette dlectrode du portelectrode ou couper le fil la pointe de contact.
D 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.
D Avant de souder, retirer toute substance combustible de vos poches telles quun allumeur au butane ou des allumettes.
D Une fois le travail achev, assurezvous quil ne reste aucune trace dtincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupecircuits appropris.
Ne pas augmenter leur puissance; ne pas les ponter.
OM-217 455 Page 7
D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et

NFPA 51B pour les travaux chaud et avoir de la surveillance et un
extincteur proximit.
LE BRUIT peut affecter loue.

Le bruit des processus et des quipements peut affec
loue.
D Porter des protections approuvs pour les ore
les si le niveau sonore est trop lev.
LES CHAMPS MAGNETIQUES peuvent affecter des implants mdicaux.

D Porteur de simulateur cardiaque ou autre implants mdicaux, rester distance.
D Les porteurs dimplants doivent dabord consulter leur mdecin
avant de sapprocher des oprations de soudage larc, de soudage par points, de gougeage, du coupage plasma ou de chauffage par induction.
D Protger les bouteilles de gaz comprim dune chaleur excessive,

des chocs mcaniques, des dommages physiques, du laitier, des
flammes ouvertes, des tincelles et des arcs.
D 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.
D Tenir les bouteilles loignes des circuits de soudage ou autres
circuits lectriques.
D Ne jamais placer une torche de soudage sur une bouteille gaz.
D Une lectrode de soudage ne doit jamais entrer en contact avec
une bouteille.
D Ne jamais souder une bouteille pressurise risque dexplosion.
D 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.
D Ne pas tenir la tte en face de la sortie en ouvrant la soupape de la
bouteille.
Si des BOUTEILLES sont endomma

ges, elles pourront exploser.
D Maintenir le chapeau de protection sur la soupape, sauf en cas

dutilisation ou de branchement de la bouteille.
Des bouteilles de gaz protecteur contiennent du ga

sous haute pression. Si une bouteille est endomma
ge, elle peut exploser. Du fait que les bouteilles de gaz fon
normalement partie du procd de soudage, les manipuler ave
prcaution.
D Utiliser les quipements corrects, les bonnes procdures et suffisamment de personnes pour soulever et dplacer les bouteilles.
D Lire et suivre les instructions sur les bouteilles de gaz comprim,
lquipement connexe et le dpliant P-1 de la CGA (Compressed Gas
Association) mentionn dans les principales normes de scurit.
2-3. Dangers existant en relation avec le moteur

LEXPLOSION DE LA BATTERIE peu
RENDRE AVEUGLE.
D Seules des personnes qualifies sont autorises enlever les portes, panneaux, recouvrements ou dispositifs de protection pour
effectuer, sil y a lieu, des travaux dentretien et de dpannage.
D Toujours porter une protection faciale, des gants

en caoutchouc et vtements de protection lors
dune intervention sur la batterie.
D Pour empcher tout dmarrage accidentel pendant les travaux

dentretien, dbrancher le cble ngatif () de batterie de la borne.
D Arrter le moteur avant de dbrancher ou de brancher les cbles

de batterie.
D Eviter de provoquer des tincelles avec les outils en travaillant sur
la batterie.
D Ne pas utiliser le poste de soudage pour charger les batteries ou
des vhicules de dmarrage rapide.
D Observer la polarit correcte (+ et ) sur les batteries.
D Dbrancher le cble ngatif () en premier lieu. Le rebrancher en
dernier lieu.
LE CARBURANT MOTEUR peut provo

quer un incendie ou une explosion.
D 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.
D Ne pas faire le plein de carburant ras bord; prvoir de lespace
pour son expansion.
D Faire attention de ne pas renverser de carburant. Nettoyer tout
carburant renvers avant de faire dmarrer le moteur.
D Jeter les chiffons dans un rcipient ignifuge.
D Toujours garder le pistolet en contact avec le rservoir lors du
remplissage.
DES ORGANES MOBILES peuvent pro

voquer des blessures.
D 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.
D Arrter le moteur avant dinstaller ou brancher lappareil.
OM-217 455 Page 8
D Ne pas approcher les mains, cheveux, vtements lches et outils

des organes mobiles.
D Remettre en place les panneaux ou les dispositifs de protection et
fermer les portes la fin des travaux dentretien et avant de faire
dmarrer le moteur.
D Avant dintervenir, dposer les bougies ou injecteurs pour viter la
mise en route accidentelle du moteur.
D Bloquer le volant moteur pour viter sa rotation lors dune intervention sur le gnrateur.
DES PICES CHAUDES peuvent

provoquer des brlures graves.
D Ne pas toucher mains nues les parties chaudes.
D Prvoir une priode de refroidissement avant de
travailler lquipement.
D Ne pas toucher aux pices chaudes, utiliser les outils recommands et porter des gants de soudage et des vtements pais pour
viter les brlures.
LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT CHAUD peuvent
provoquer des brlures.
D Il est prfrable de vrifier le liquide de refroidissement une fois le moteur refroidi pour viter
de se brler.
D 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).
D Si le moteur est chaud et que le liquide doit tre vrifi, oprer comme suivant.
D Mettre des lunettes de scurit et des gants, placer un torchon sur
le bouchon du radiateur.
D Dvisser le bouchon lgrement et laisser la vapeur schapper

avant denlever le bouchon.
Lutilisation dun groupe autonome

lintrieur PEUT VOUS TUER EN
QUELQUES MINUTES.
D Les fumes dun groupe autonome contient du
monoxyde de carbone. Cest un poison invisible et inodore.
D JAMAIS utiliser dans une maison ou garage,
mme avec les portes et fentres ouvertes.
D Uniquement utiliser lEXTERIEUR, loin des portes, fentres et
bouches aration.
LACIDE DE LA BATTERIE peut provoquer des brlures dans les YEUX et

sur la PEAU.
LA CHALEUR DU MOTEUR peut provoquer un incendie.

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

peuvent provoquer un incendie.
D Empcher les tincelles dchappement du
moteur de provoquer un incendie.
D Utiliser uniquement un pare-tincelles
approuv voir codes en vigueur.
D Ne pas renverser la batterie.

D Remplacer une batterie endommage.
D Rincer immdiatement les yeux et la peau leau.
2-4. Dangers lis lair comprim

RESPIRER LAIR COMPRIM peut provoquer des blessures graves ou causer
la mort.
Le METAL CHAUD lors du coupage et

gougeage plasma peut provoquer un incendie ou une explosion.
D Ne pas utiliser lair comprim pour respirer.

D Utiliser lair comprim seulement pour le coupage, gougeage et les outils pneumatiques.
D Ne pas couper ou gouger proximit de produits inflammables.

D Surveillez et garder un extincteur proximit.
LAIR COMPRIM peut provoquer

des blessures.
D Porter des lunettes de scurit approuves.
D Ne pas diriger le jet dair vers dautres ou
soi-mme.
LAIR COMPRIME EMMAGASINE ET DES

TUYAUX SOUS PRESSION peuvent provoquer des blessures.
D Relcher la pression dair de loutillage ou du
systme avant deffectuer la maintenance,
avant de changer ou de rajouter des lments
ou avant douvrir la purge ou le bouchon de
remplissage dhuile.
DES PIECES CHAUDES peuvent provoquer des brlures et blessures.

D Ne pas toucher le compresseur ou dautres
lments du circuit air comprim chauds.
D Laisser lensemble se refroidir avant de toucher ou deffectuer la
maintenance.
LIRE LES INSTRUCTIONS.

D Lisez le manuel dinstructions avant lutilisation
ou la maintenance de lappareil.
D Arrter le moteur et relcher la pression avant
deffectuer la maintenance.
D Nutiliser que les pices de rechange recommandes par le
constructeur.
2-5. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance

Risque DINCENDIE OU DEXPLOSION.
D Ne pas placer lappareil sur, au-dessus ou
proximit de surfaces inflammables.
D Ne pas installer lappareil proximit de produits inflammables.
D Ne pas surcharger linstallation lectrique sassurer que lalimentation est correctement dimensionne et protge avant de
mettre lappareil en service.
LA CHUTE DE LAPPAREIL peut blesser.

D Utiliser lanneau de levage pour lever lappareil et
les accessoires correctement installes seuls,
PAS les bouteilles de gaz. Ne pas dpasser le
poids nominal maximal de lilleton (voir les spcifications).
D Ne lever et ne soutenir lappareil quavec de
lquipement appropri et en suivant les
procdures adquates.
D En utilisant des fourches de levage pour dplacer lunit, sassurer
que les fourches sont suffisamment longues pour dpasser du
ct oppos de lappareil.
OM-217 455 Page 9
UNE REMORQUE QUI BASCULE peut

entraner des blessures.
LE SURCHAUFFEMENT peut endommager le moteur lectrique.
D Utiliser les supports de la remorque ou des

blocs pour soutenir le poids.
D Installer convenablement le poste sur la remorque comme indiqu dans le manuel sy rapportant.
D 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.
D Ne pas brancher de moteur de 50 ou de 60 Hz la prise de 100 Hz,
sil y a lieu.
LES TINCELLES VOLANTES risquent de provoquer des blessures.

D Porter un cran facial pour protger le visage et
les yeux.
D Affter llectrode au tungstne uniquement la
meuleuse dote de protecteurs. Cette manuvre est excuter dans un endroit sr lorsque lon
porte lquipement homologu de protection du
visage, des mains et du corps.
D Les tincelles risquent de causer un incendie loigner toute substance inflammable.
LIRE LES INSTRUCTIONS.

D Lisez le manuel dinstructions avant lutilisation
ou la maintenance de lappareil.
D Nutiliser que les pices de rechange recommandes par le constructeur.
D Effectuer la maintenance et le service du moteur et du compresseur dair suivant les instructions dans ce manuel ou le manuel
du moteur/compresseur (si applicable).
LE RAYONNEMENT HAUTE FRQUENCE (H.F.) risque de provoquer

des interfrences.
DES ORGANES MOBILES peuvent

provoquer des blessures.
D Ne pas sapprocher des organes mobiles.

D Ne pas sapprocher des points de coincement
tels que des rouleaux de commande.
LES FILS DE SOUDAGE peuvent

provoquer des blessures.
D
D
D
D Ne pas appuyer sur la gchette avant den

avoir reu linstruction.
D Ne pas diriger le pistolet vers soi, dautres personnes ou toute pice mcanique en engageant le fil de soudage.
LE SOUDAGE LARC risque de

provoquer des interfrences.
LEMPLOI EXCESSIF peut

SURCHAUFFER LQUIPEMENT.
D Laisser lquipement refroidir ; respecter le facteur de marche nominal.
D Rduire le courant ou le facteur de marche
avant de poursuivre le soudage.
D Ne pas obstruer les passages dair du poste.
LES CHARGES LECTROSTATIQUES peuvent endommager les

circuits imprims.
D tablir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pices.
D Utiliser des pochettes et des botes antistatiques pour stocker,
dplacer ou expdier des cartes de circuits imprimes.
OM-217 455 Page 10
D 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 un blindage pour rduire les
interfrences ventuelles.
D
D
D
D
D
D 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.
2-6. Proposition californienne 65 Avertissements

Les quipements de soudage et de coupage produisent des
fumes et des gaz qui contiennent des produits chimiques
dont ltat de Californie reconnat quils provoquent des malformations congnitales et, dans certains cas, des cancers.
(Code de sant et de scurit de Californie, chapitre 25249.5
et suivants)
Les batteries, les bornes et autres accessoires contiennent
du plomb et des composs base de plomb, produits chimiques dont ltat de Californie reconnat quils provoquent des
cancers et des malformations congnitales ou autres
problmes de procration. Se laver les mains aprs manipulation.
Pour les moteurs essence :

Les gaz dchappement des moteurs contiennent des produits chimiques dont ltat de Californie reconnat quils
provoquent des cancers et des malformations congnitales
ou autres problmes de procration.
Pour les moteurs diesel :
Les gaz dchappement des moteurs diesel et certains de
leurs composants sont reconnus par ltat de Californie comme provoquant des cancers et des malformations
congnitales ou autres problmes de procration.
2-7. Principales normes de scurit

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
de Global Engineering Documents (tlphone : 1-877-413-5184, site
Internet : www.global.ihs.com).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard
AWS F4.1 de Global Engineering Documents (tlphone :
1-877-413-5184, site Internet : www.global.ihs.com).
National Electrical Code, NFPA Standard 70, de National Fire Protection Association, P.O. Box 9101, Quincy, MA 02269-9101 (tlphone :
617-770-3000, site Internet : www.nfpa.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chantilly, VA 20151 (tlphone : 703-788-2700, site Internet :
www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, de
Canadian Standards Association, 5060 Mississauga, Ontario, Canada
L4W 5NS (tlphone : 800-463-6727 ou Toronto 416-747-4044, site

Internet : www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, de American National Standards Institute,
11 West 43rd Street, New York, NY 10036-8002 (tlphone :
212-642-4900, site Internet : www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, de National Fire Protection Association,
P.O. Box 9101, Quincy, MA 02269-9101 (tlphone : 617-770-3000,
site Internet : www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, de U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(tlphone : 1-866-512-1800) (il y a 10 bureaux rgionauxle tlphone de la rgion 5, Chicago, est 312-353-2220, site Internet :
www.osha.gov).
2-8. Information EMF

Considrations sur le soudage et les effets de basse frquence et des
champs magntiques et lectriques.
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.
Pour rduire les champs magntiques sur le poste de travail, appliquer
les procdures suivantes :
1. Garder les cbles ensemble, les torsader, les scotcher, ou les

recouvrir dune housse.
2. Disposer les cbles dun ct et distance de loprateur.
3. Ne pas courber pas et ne pas entourer pas les cbles autour de
votre corps.
4. Garder le poste de soudage et les cbles le plus loin possible de
vous.
5. Connecter la pince sur la pice aussi prs que possible de la
soudure.
En ce qui concerne les implants mdicaux :
Les porteurs dimplants doivent dabord consulter leur mdecin avant
de sapprocher des oprations de soudage larc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induction. Si le mdecin approuve, il est recommand de suivre les
procdures prcdentes.
OM-217 455 Page 11
. A complete Parts List is available at www.MillerWelds.com
SECTION 3 DEFINITIONS
3-1. Symbol Definitions
Stop Engine
Fast
(Run, Weld/Power)
Start Engine
Read Operators
Manual
Engine Oil
Fuel
Battery (Engine)
Engine
Temperature
Check Valve
Clearance
Do not switch while

welding
Work Connection
Positive
Negative
Alternating Current
(AC)
Output
Welding Arc
(Electrode)
MIG (GMAW),
Wire
Stick (SMAW)
TIG (GTAW)
Seconds
Time
Protective Earth
(Ground)
Hours
Fast/Slow
(Run/Idle)
Amperes
Slow (Idle)
Volts
Circuit Protector
SECTION 4 SPECIFICATIONS
4-1. Weld, Power, and Engine Specifications
. Also see Performance Data in Section 13.
Welding
Mode
CC/AC
Weld Output
Range
40 250 A
Rated
Welding
Output
Maximum
Open Circuit
Voltage
250 A, 25 V,
100% Duty
Cycle
80
Generator Power Rating
Fuel
Capacity
Peak: 10.5 kVA/kW

CC/DC
CV/DC
40 250 A
17 28 V
OM-217 455 Page 12
250 A, 25 V,
100% Duty
Cycle
275 A, 25 V,
60% Duty
Cycle
250 A, 28 V,
100% Duty
Cycle
72
41
Continuous: 9.5 kVA/kW,

Single-Phase,
84/42 A, 120/240 V AC,
60 Hz
(while not welding)
12 gal
(45 L) Tank
Engine
Kubota D722
Water-Cooled,
Three-Cylinder
Four-Cycle
18.8 HP
Diesel Engine
g

4-2. Dimensions, Weights, and Operating Angles
Dimensions
Height
35-1/2 in (902 mm)

(To Top Of Exhaust)
Width
20 in (508 mm)
Depth
53 in (1346 mm)
20 in (508 mm)
16-1/2 in (419 mm)
1-3/4 in (44 mm)
A
B
C
D
G
4 Holes
H l
F
D
6-1/16 in (154 mm)
32-3/4 in (832 mm)
51-3/8 in (1305 mm)
13/32 in (10 mm) Dia.
Do not exceed
D
d tilt
il angles
l or engine
i
could
ld
be damaged or unit could tip.
Do not move or operate unit where it

could tip.
E
20
20
20
20
Weight
Engine End
700 lb (318 kg)
800 426
Lifting Eye Weight Rating

1280 lbs (580 kg)
804 249-A
4-3. Dimensions For Units With Optional Running Gear

Dimensions
Height
All Running Gear Options:

42-1/2 in (1079 mm)
(To Top Of Handle
Assembly)
C
A
Protective Cage Width:

26 in (660 mm)
Running Gear Width:

32 in (813 mm)
Protective Cage Length:

48 in (1219 mm)
Running Gear Length:

451/2 in (1156 mm)
OM-217 455 Page 13
SECTION 5 INSTALLATION
5-1. Installing Welding Generator
Movement
Do not weld on base. Welding

on base can cause fuel tank fire
or explosion. Bolt unit down
using holes provided in base.
Always securely fasten welding generator onto transport

vehicle or trailer and comply
with all DOT and other applicable codes.
Do not mount unit by supporting the base only at the four

mounting holes. Use crosssupports to adequately support unit and prevent damage
to base.
Always ground generator

frame to vehicle frame to prevent electric shock and static
electricity hazards.
If unit does not have GFCI receptacles, use GFCI-protected

extension cord.
Do not lift unit from end.
OR
Location / Airflow Clearance
OR
18 in
(460 mm)
NOTICE Do not install unit where air

flow is restricted or engine may overheat.
18 in
(460 mm)
18 in
(460 mm)
Mounting:
1
Cross-Supports
Mount unit on flat surface or use

cross-supports to support base.
Grounding:
18 in
(460 mm)
18 in
(460 mm)
2
3
4
Mounting
Equipment Grounding Terminal

(On Front Panel)
Grounding Cable (Not Supplied)
Metal Vehicle Frame
Connect cable from equipment

ground terminal to metal vehicle
frame. Use #10 AWG or larger insulated copper wire.
OR
Inadequate support.
!
Grounding
Do not use flexible mounts.
2
3
GND/PE
Bed liners, shipping skids, and some running

gears insulate the welding generator from the
vehicle frame. Always connect a ground wire
from the generator equipment grounding terminal to bare metal on the vehicle frame as shown.
Electrically bond generator frame to

vehicle frame by metal-to-metal contact.
OM-217 455 Page 14
install2 12/06 Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712

5-2. Installing Exhaust Pipe
!
Stop engine and let cool.
Do not blow exhaust toward

right side of unit where air inlet
is or air cleaner may require
frequent service. Point exhaust pipe in desired direction
but always away from front
panel and direction of travel.
Tools Needed:
1/2 in
804 196-A / Ref. 228 647-A
5-3. Connecting the Battery
Connect negative ()
cable last.
Tools Needed:
1/2 in
804 250-A / Ref 228 647 / Ref. S-0756-D
OM-217 455 Page 15

5-4.
Overview And Engine Prestart Checks

7
8
10
9
1
1
2
3
4
5
6
Generator Power Receptacles (see

Section 7)
Weld Output Terminals (see Section 5-5)
Operator Controls (see Section 6)
Fuel Gauge/Maintenance Display
Fuel Filler Cap
Exhaust Pipe
OM-217 455 Page 16
7
8
Radiator Cap
Engine Maintenance Label (Inside Door)
13 Oil Drain
14 Oil Dipstick
9
10
11
12
Oil Fill Cap

Thermostat Housing Plug
Oil Filter
Coolant Overflow Bottle
15
16
17
18
Inline Fuel Strainer

Air Cleaner
Fuel Filter
Fuel Shut Off Valve

!
Engine must be cold and on a level surface. See maintenance label (Section 9-2)
for fluid specifications.
Engine shown with

doors removed. Doors
must be in place when
engine is running.
Starting engine for the first time:

Add fresh fuel to bottom of filler neck.
Open fuel shut-off valve.
If coolant level is below bottom of radiator
filler neck, add coolant to overflow bottle.
Run-in period (first 100 hours):
Engine may use oil and wetstacking may
occur during run-in (see Section 12).
Check oil several times daily during run-in.
Daily pre-start checks:
11
Add fresh fuel to bottom of filler neck.

Check oil. If oil is not up to full mark on dipstick, add oil. Unit is shipped with 10W30
engine oil.
Check coolant level in overflow bottle. If
coolant is below Low level, add coolant until level in tank is between Low and Full levels. If overflow bottle coolant level was low,
check coolant level in radiator (see Section 9-2).
14
Engine damage can result from:
12
S
S
S
S
S
S
S
13
Low oil level

High engine temperature
Incorrect coolant mixture
Running out of fuel (air in fuel lines)
Using gasoline
Using ether to start engine
Wetstacking
Engine stops if oil pressure is low, engine

coolant temperature is high, or fuel level is
low. Some conditions may cause engine
damage before the engine shuts down.
Engine Left Side
Oil: Check oil level often and do not use

the oil pressure shutdown system to monitor oil level.
Engine Temperature: Incorrect engine
temperature can damage engine. Do not
run engine without a properly working thermostat and radiator cap.
18
Keep radiator and air intake clean.

Coolant: A solution of 50% ethylene glycol base antifreeze and 50% water must
be used in this engine. Do not use 100%
antifreeze or severe damage will occur.
15
17
Fuel: Engine will shut down if fuel level is

low. Air in the fuel system causes starting
problems.
Do not use gasoline. Using ether voids
warranty.
16
Wetstacking: If unburned fuel and oil collect in exhaust pipe during run-in, see Section 12.
. To improve cold weather starting:

Keep battery in good condition. Store
battery in warm area.
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.
Engine Right Side

804 249-A / 804 250-A
OM-217 455 Page 17

5-5. Connecting to Weld Output Terminals
1
2
Work Weld Output Terminal

Electrode Weld Output Terminal
Connect work cable to Work terminal.

Connect electrode holder cable or
electrode weld cable to Electrode terminal for Stick and MIG welding.
Connect torch cable to Electrode terminal for TIG welding.
Use Process Selector switch to
select type of weld output (see
Section 6-2).
. See Sections 6-3 thru 6-5 for typical process connections and
control settings.
1
2
Failure to properly connect

weld cables may cause excessive heat and start a fire, or
damage your machine.
3
4
Weld Output Terminal

Supplied Weld Output Terminal
Nut
Weld Cable Terminal
Copper Bar
5
6
Remove supplied nut from weld output terminal. Slide weld cable terminal
onto weld output terminal and secure
with nut so that weld cable terminal is
tight against copper bar. Do not
place anything between weld cable
terminal and copper bar. Make
sure that the surfaces of the weld
cable terminal and copper bar are
clean.
Tools Needed:
3
3/4 in
Do not place
anything between
weld cable terminal
and copper bar.
4
5
Correct Installation
Incorrect Installation
Ref. 804 249-A / 228 647-A / 803 778-A
OM-217 455 Page 18

5-6. Selecting Weld Cable Sizes*
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
Weld Output
Terminals
Turn off power before

connecting to weld
output terminals.
Do not use worn,

damaged,
undersized,
or
poorly
spliced cables.
* This
100 ft (30 m) or Less
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
100
4 (20)
4 (20)
4 (20)
3 (30)
2 (35)
1 (50)
1/0 (60)
1/0 (60)
150
3 (30)
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
200
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
4/0 (120)
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 2/0
(2x70)
300
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
350
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
400
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
2 ea. 4/0
(2x120)
500
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
3 ea. 3/0
(3x95)
10 100% Duty Cycle
chart is a general guideline and may not suit all applications. If cables overheat, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
S-0007-F
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.
Notes
. A complete Parts List is available

on-line at www.MillerWelds.com
OM-217 455 Page 19
SECTION 6 OPERATING THE WELDING GENERATOR

6-1. Engine Control Switches
Glow Plug Time
70F (21C)
32F (0C)
4F (20C)
0 seconds
10 seconds
20 seconds
Do not use glow plugs longer than

20 seconds.
Do not use ether to start engine.
Using ether voids warranty.
2
Ref. 228 647-A
NOTICE Disconnect equipment from auxiliary power receptacles during startup and
shutdown. Some equipment can be damaged
by changes in frequency as engine rpms
change during start-up and shutdown.
1 Engine Control Switch
Use switch to start engine, select speed, and
stop engine. In Run/Idle position, engine runs
at idle speed at no load, and weld/power speed
under load. In Run position, engine runs at
weld/power speed.
. Place switch in Run position to operate

2
most MIG equipment.

Glow Plug Switch
OM-217 455 Page 20
If necessary, push switch down before startup. See glow plug table for operating information.
To Start: Use glow plug switch if necessary.

Turn Engine Control switch to Start position.
Release switch when engine starts.
. If the engine does not start, let engine
Idle Lock Switch
Use switch to lock engine in idle speed during

start-up. In Start position and Engine Control
switch in Run or Run/Idle, engine is locked in
idle speed. In Run/Idle position and Engine
Control switch in Run/Idle, engine runs at idle
speed at no load and weld/power speed under
load.
In Run/Idle position and Engine Control switch
in Run, engine runs at weld/power speed.
come to a complete stop before attempting restart.

To Stop: Turn Engine Control switch to Off
position.
. Close fuel valve to stop engine if Engine
Control switch does not work (see Section

5-4).
4 Fuel Gauge/Maintenance Display
See insert from maintenance label.

6-2. Weld Output Controls
Ref. 228 647-A
Weld Process Selector Switch
NOTICE Do not switch while welding.

Use switch to select type of weld output.
Wire (GMAW) Welding: Use a positive (+)
position for Direct Current Electrode Positive
(DCEP) and a negative () position for Direct
Current Electrode Negative.
Stick (SMAW) and TIG (GTAW Welding): Use
a positive (+) position for Direct Current Electrode Positive (DCEP) and a negative () position for Direct Current Electrode Negative.
Use AC position for alternating current.
Coarse Range Switch
NOTICE Do not switch while welding.

Use switch to select weld amperage range
when Weld Process Selector switch is in Stick/
Tig position, or voltage range when switch is in
Wire position.
. For best arc starts and when using weld

and generator power together, use a low
Coarse Range setting with the Fine control set at 7 or higher.
3 Fine Control
Use control to select weld amperage (Stick/
Tig) or voltage (Wire) within the range selected
by the Coarse Range switch. Control may be
adjusted while welding.
Set control at 10 for maximum generator
power.
Weld output would be about 124 A DC based
on control settings shown (80% of 60 to 140
A). Settings shown are typical for welding with
a 7018 (1/8) electrode.
. See Sections 6-3 thru 6-5 for typical process connections and control settings.
OM-217 455 Page 21

6-3. Typical Stick Welding Connections And Control Settings
!
Stop engine.
. This
section provides general

guidelines and may not suit all
applications.
Typical Settings For 7018 (1/8 in)
Electrode:
>
Set Weld Process Selector

switch to + Stick position.
>
Set Coarse Range switch to

60-140 (1/8) position.
>
Set Fine control at 7 or higher

for best results.
. Consult the amperage selection

1
2
tables below if welding with other

electrodes.
Work Clamp
Electrode Holder
Connect Work cable to Work terminal

and Electrode holder cable to Electrode terminal on welding generator.
1
Tools Needed:
3/4 in
Ref. 804 249-A / Ref 228 647-A
OM-217 455 Page 22

6-4. Typical MIG Welding Connections And Settings
!
Stop engine.
. This section provides general guide-
lines and may not suit all applications.

Typical Control Settings For Short
Circuit Transfer Using .035 (ER70S-3)
Solid Wire And 75/25 Argon/CO2 Gas:
>
Set Weld Process Selector switch

to Wire + (DCEP) position.
>
Set Coarse Range switch to Wire/

Low Range (17-22 volts) position.
>
Set Fine Control to obtain minimum

spatter.
>
Set wire feed speed between

100-300 ipm.
Typical Control Settings For Spray

Transfer Using .035 (ER70S-3) Solid
Wire And 80% Or Higher Argon/CO2
Gas:
6
7
>

to Wire + position.
>

High Range (20-28 volts) position.
>

320-500 ipm.
>
Set Fine control to 3 and increase

for longer arc length.
Typical Control Settings Using .045

(E71T-11) Self-Shielded Flux Core
Wire:
>

to Wire position (DCEN).
>

Low Range (17-22 volts) position.
>
Set Fine Control near minimum setting.
>

125-200 ipm.
>
Do a test weld. To increase arc

length, increase Fine Control setting. To shorten arc length, reduce
fine control setting or increase wire
feed speed.
Work Clamp
Wire Feeder
MIG Gun
1
2
3
4
Gun Trigger Plug
Voltage Sensing Clamp
Gas Cylinder:
75/25 Argon/CO2 Gas for Short
Circuit Transfer
80% Argon (Or Higher)/CO2 For

Spray Transfer
Work
1
Tools Needed:
3/4 in
Gas Hose
Connect work cable to welding generator

Work terminal. Connect cable from wire
feeder to cable from welding generator
Electrode terminal.
Ref. 804 249-A / Ref 228 647-A / Ref. 802 766-C
OM-217 455 Page 23

6-5. Typical MIG Connections And Settings Using Weld Control And Spoolgun
Tools Needed:
3/4 in
10
Work
12
Not Used
6
To Work
Left Side View
2
1
3
11
7
Ref. 804 249-A / Ref. 228 647-A / Ref. 802 750-A
Stop engine.
. This section provides general guide-
>
Set wire feed speed between 240-270

ipm. For 1/4 in. (6 mm) and thicker
materials, set Coarse Range switch to
Wire/High and Fine Control to 6. Increase/decrease Fine Control setting
to increase/decrease arc length.
lines and may not suit all applications.
Typical Settings For 4043 (.035)

Aluminum On 1/8 in Material:
>
Set Weld Process Selector switch to

Wire + (DCEP) position.
Weld Control
Spoolgun
>
Set Coarse Range switch to Wire/Low

(17-22 volts) position.
Optional Contactor (Recommended)
Reed Switch
Weld Cable (Customer-Supplied)
Weld Control Weld Terminal
>
Set Fine Control to desired voltage

(arc length). Start with a low voltage
setting (about 4) to prevent burnback.
OM-217 455 Page 24
7
8
9
10
11
12
Weld Power Cable From Spoolgun

Work Clamp
Gas Hose
100% Argon Cylinder
Trigger Control Cord
Input Power Cord
Route weld cable from welding generator

Electrode terminal through reed switch to
unused contactor terminal. Connect weld
cable from spoolgun to weld control weld
terminal (item 6).
Connect work cable to welding generator
Work terminal.
SECTION 7 OPERATING AUXILIARY EQUIPMENT

7-1. Generator Power Receptacles
!
If unit does not have GFCI receptacles, use GFCI-protected extension

cord.
NOTICE Disconnect equipment from auxiliary power receptacles during startup and
shutdown. Some equipment can be damaged by changes in frequency as engine
rpms change during start-up and shutdown.
. Generator
1
power decreases as weld

current increases.
Set Fine Control R1 at 10 for full generator power.
240 V 50 A AC Receptacle RC1
RC1 supplies 60 Hz single-phase power at

weld/power speed. Maximum output is 10
kVA/kW. See section 7-3 for information on
wiring optional 240 V single-phase plug.
2
120 V 20 A Duplex Receptacle RC2
120 V 20 A Duplex Receptacle RC3
RC2 and RC3 supply 60 Hz single-phase

power at weld/power speed. Maximum output from RC2 or RC3 is 2.4 kVA/kW.
2
5
3
6
Supplementary Protector CB1
CB1 protects receptacles RC1, RC2, and

RC3 from overload. If CB1 opens, the receptacles do not work. Place switch in On position to reset.
CB2 protects RC2 and CB3 protects RC3

from overload. If a supplementary protector
opens, the receptacle does not work.
. Press button to reset. If supplementary

protector continues to open, contact
Factory Authorized Service Agent.
Power is still present at the 240 volt

receptacle if CB2 and/or CB3 trips.
Unplug power cord before attempting
to service accessories or tools.
Optional 120 V 20 A AC GFCI Receptacles GFCI-2 and GFCI-3
GFCI2 and GFCI3 supply 60 Hz singlephase power at weld/power speed. Maximum output from GFCI-2 or GFCI-3 is 2.4
kVA/kW. Circuit protection is the same as
standard receptacles.
If a ground fault is detected, the GFCI Reset

button pops out and the circuit opens to disconnect the faulty equipment. Check for
damaged tools, cords, plugs, etc. connected
to the receptacle. Press button to reset receptacle and resume operation.
. At least once a month, run engine at
weld/power speed and press Test button

to verify GFCI is working properly.
Combined output of all receptacles limited to
10 kVA/kW rating of the generator.
EXAMPLE: If 20 A is drawn from each 120
V duplex receptacle, only 21 A is available at
the 240V receptacle:
803 750-B / Ref. 211 362-A
2 x (120 V x 20 A) + (240 V x 21 A) = 10 kVA/

kW
OM-217 455 Page 25

7-2. Simultaneous Weld And Power
Weld Current in Amperes
Total Power in Watts
120 V Full kVA Receptacle

Amperes
240 V Full kVA Receptacle

Amperes
250
2200
18
180
3500
29
14
125
5200
43
21
90
8000
66
33
10,500 (Peak)
88
44
7-3. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P)
The plug can be wired for a 240 V,
2-wire load or a 120/240V, 3-wire
load. See circuit diagram.
1
7
Current Available in Amperes
240 V
Receptacle*
Each 120 V Duplex

Receptacle
42
37
32
27
22
0
5
10
15
20
When wired for 120 V loads, each

duplex receptacle shares a load
with one half of 240 V receptacle.
120V
120V
240V
V x A = Watts
*One 240 V load or two 120 V loads.
Plug Wired for 120/240 V,

3-Wire Load
6
2
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
3
4
Tools Needed:
240V
240 V AC
120 V AC
120 V AC
plug1 11/03 120 813-D
OM-217 455 Page 26
SECTION 8 OPERATING OPTIONAL BATTERY CHARGER

8-1. Battery Charge Controls
Have only qualified persons charge

batteries.
Do not use battery charger for jump

starting.
NOTICE D o not use generator power ac receptacles while using optional battery charger.
Low voltage at receptacles may damage tools
and other equipment.
1
Charge Voltage Switch
Place switch in position matching voltage of

battery being charged.
. Before connecting charging cables,
place
Charge Voltage switch in position matching voltage of battery being charged.
Battery Charging Switch
Place switch in On position to turn on charging

current. Place switch in Off position to turn off
charging current.
3
Weld Process Switch
Place switch in Charge position before

connecting charging cables and starting engine.
Use switch to select weld or battery charge

output (see table in Section 8-2).
4
5
Coarse Range Switch

Fine Control
Use Coarse Range switch and Fine Control to

set charge current.
Do not change Coarse Range or Weld

Process switch position while welding
or battery charging.
. Charging
current automatically stops

when terminal voltage is 15 to 25 percent
above required battery voltage.
228 649-A
8-2. Determining Battery Charging Current
BATTERY CHARGING CURRENT (AMPS)
Battery Charging Current Chart
400
Find battery cold crank amp (CCA) rating on

battery. Use CCA rating on chart to find charge
current setting for battery.
350
EXAMPLE: If battery CCA rating is 500, charging current from chart is 100 amperes.
300
Do not exceed charging current found on

chart. For longer battery life, use lowest
charge rate possible.
250
200
150
100
50
0
0
500
1000
1500
BATTERY COLD CRANK AMP RATING (CCA)
2000
142 975-B
OM-217 455 Page 27

8-3. Battery Charge Cable Connections
Ref. 228 649-A / Ref. 804 397-A / S-0714
Stop engine.
Do not charge a battery which has

loose terminals or one showing
damage such as a cracked case or
cover.
. Before
Have only qualified persons do battery charging work.
Keep cables away from moving

parts.
Do not use damaged cables.
Be sure charger output voltage

matches battery voltage.
OM-217 455 Page 28
Read BCI Battery Service Manual

before charging.
connecting to battery, place

Charge Voltage switch in position
matching voltage of battery being
charged.
1 Battery
2 Battery Charging Cables
Use less than 20 feet (6.1 m) of AWG #1 or
larger cable.
3 Terminal Lug
Use lugs of proper amperage capacity and
hole size for connecting to charge output
terminals.
Install suitable connectors on remaining

ends of battery cables.
4
Battery Charge Positive (+) Output

Terminal
Battery Charge Negative () Output

Terminal
. Connect
charging cables to battery

charge output terminals before connecting to battery terminals.
Connect Battery Charge Positive (+) cable

to battery positive (+) terminal, and battery
Charge Negative () cable to battery negative () terminal.

8-4. Battery Charging Procedure
In Example:
Battery Voltage = 12 Volts
Battery CCA Rating = 500
Charge Current = 100 A (See Section 8-2)
Coarse Range Setting = 60 to 140 A
V/A Control Setting = 50%
Turn Off Battery Charging

Switch.
Stop Engine.
Set Weld Process Switch To

Charge Position.
Set Charge Voltage Switch To

Voltage Of Battery Being
Charged (12, 24, Or 36 Volt).
NOTICE Do not switch under load.
Determine Charge Current From

Battery CCA Rating And Chart
(See Section 8-2).
Start Engine.
Turn On Battery
Charging Switch.
Set Coarse Range Switch And

Fine Control To Obtain Correct
Charging Current.
NOTICE Do not switch under load.
Charge 10
Minutes
Stop Engine.
+
Connect Cables (Observe
Correct Polarity).
Charge 10 minutes.
Check Battery Voltage.
Continue Charging If
Necessary.
OM-217 455 Page 29
Notes
Start Your Professional

Welding Career Now!
OM-217 455 Page 30
400 Trade Square East, Troy, Ohio 45373

1-800-332-9448 www.welding.org
Over 80,000 trained

since 1930!
SECTION 9 MAINTENANCE AND TROUBLESHOOTING

9-1. Routine Maintenance
!
Recycle engine
fluids.
Stop engine before maintaining.
. See
Engine Manual and Maintenance Label

for important start-up, service, and storage
information. Service engine more often if
used in severe conditions.
n = Check
Z = Change
~ = Clean
l = Replace
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . * To be done by Factory Authorized Service Agent
Every
8
Hours
Reference
Section 5-4
n Coolant Level
n Fuel Level
n Oil Level
n Fuel Connections
n Fuel Connections
~ Weld Terminals
~ Oil, Fuel Spills
Every
50
Hours
Every
100
Hours
Section 9-2,
9-3, Engine
Manual
5/16 in.
(8 mm)
~ Air Cleaner Element
n Air Cleaner Hoses
n Belt Tension
~ Battery Terminals
Z Oil
Every
200
Hours
Engine
Manual,
Section 9-2
Z Oil Filter
n Radiator Hoses
l Unreadable Labels
Z Fuel Filters
Every
500
Hours
Engine
Manual,
Section 9-4
n Fan Belt
~ Flush Radiator
nl Weld Cables
n Slip Rings*
n Brushes* l 1500 Hours*
n Engine Speed
Every
800
Hours
Section 9-2
n Valve Clearance*
Every
2000
Hours
Engine
Manual,
Section 9-2
nl Fuel Hoses
nl Fuel Hoses
nl Coolant & Hoses
OM-217 455 Page 31

9-2.
Maintenance Label And Engine Maintenance Activities
Stop engine and let cool.
Oil And Fuel

1 Oil Drain Valve
2 Oil Filter
Change engine oil and filter according to engine manual.
NOTICE Close valve and valve cap before
adding oil and running engine.
Fill crankcase with new oil to full mark on dipstick (see Section 5-4).
3 Fuel Lines
Replace fuel lines if cracked or worn.
4 Inline Fuel Strainer
Install new filter as shown.
OM-217 455 Page 32
Fuel Filter
Add engine coolant as follows:
Replace filter according to engine manual.
Wipe up any spilled fuel.
Remove thermostat housing plug. Add coolant to radiator until coolant is at bottom of filler neck and coolant trickles out of thermostat housing plug hole. This ensures all air is
purged from the system.
Start engine, and check for fuel leaks.
Stop engine, tighten connections as

necessary, and wipe up fuel.
Coolant
6
Radiator Cap
Radiator Drain Cocks (One located on

bottom of radiator)
Drain engine coolant according to procedure in engine manual.
Thermostat Housing Plug
Reinstall plug and radiator cap. Check coolant level in overflow bottle.
Engine coolant is a mixture of water and
ethylene glycol base antifreeze. A solution
of 50% antifreeze and 50% water must be
used in this engine. Do not use 100% antifreeze or severe damage will occur.
804 197-A / Ref 803 111-A / 227 727
OM-217 455 Page 33

9-3. Servicing Air Cleaner
!
Stop engine.
NOTICE Do not run engine without air

cleaner or with dirty element. Engine
damage caused by using a damaged element is not covered by the warranty.
. The air cleaner primary element can
be cleaned but the dirt holding capacity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while cleaning 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 element.
4
1
2
If you decide to clean the primary element, we strongly recommend installing an optional safety element to provide additional engine protection.
Never clean a safety element. Replace the safety element after servicing the primary element three times.
1
2
3
4
Intake Manifold
Service Indicator (Optional)
Window
Reset Button
Service air cleaner element if red band

appears in window. A green band means
air cleaner is okay. Press button to reset
indicator.
Clean or replace primary element if dirty
(see note above before cleaning). Replace primary element if damaged. Replace primary element yearly or after six
cleanings.
Optional
5
9
Housing
Safety Element (Optional)
Primary Element
Cover
Dust Ejector
To clean air filter:

Wipe off cover and housing. Remove
cover and dump out dust. Remove element(s). Wipe dust from inside cover and
housing with damp cloth. Reinstall safety
element (if present). Reinstall cover.
Keep nozzle
2 in (51 mm)
from element.
NOTICE Do not clean housing with air

hose.
Clean primary element with compressed
air only.
Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in (3 mm) nozzle and
keep nozzle at least 2 in (51 mm) from
inside of element. Replace primary element if it has holes or damaged gaskets.
Blow
Inspect
Reinstall primary element and cover

(dust ejector down).
aircleaner1 9/02 ST-153 929-B / ST-153 585 / Ref. S-0698-B
OM-217 455 Page 34

9-4. Adjusting Engine Speed
. If the engine does not start and stop properly, verify the fuel solenoid is installed properly before adjusting engine speed (see Section A following).
If the engine does not stay at idle speed, verify the throttle solenoid is installed and adjusted properly before adjusting engine speed (see Section
B following).
If the engine runs properly but the speeds are incorrect, do not adjust the solenoids. Adjust the engine speed according to the instructions in
Section C.
A. Checking Fuel Solenoid

Tools Needed:
7/16 in
10, 14 mm
3
Verify mounting
bracket is recessed
from edge of engine.
1
Stop engine.
If the engine does not start and stop when

using the Engine Control switch, check
the position of the fuel solenoid.
Adjusting Fuel Solenoid Position
1
2
3
Fuel Solenoid
Stop Screw
Fuel Solenoid Mounting Screws
. Stop screw is factory-set and should

not be adjusted.
When properly adjusted, the solenoid

bracket is slightly recessed from the edge
of the engine block and the solenoid linkage easily travels between the stop screw
and the fuel solenoid internal stop.
Tighten mounting screws when

solenoid is in correct position.
If adjustment is necessary, loosen the solenoid mounting screws and push the solenoid bracket back toward engine as far
as possible.
Continue pushing on solenoid bracket in
a clockwise direction while tightening
mounting screws.
4
5
Shutdown Lever
Stop screw
Stop Screw Jam Nut
7
8
Fuel Solenoid Jam Nut

Plunger
. Stop screw is factory-set and should

not be adjusted.
Hold throttle solenoid in idle (energized)

position. If shutdown lever is touching or
within 1/16 in of stop screw, fuel solenoid
is properly adjusted.
If lever is more than 1/16 in. from stop
screw, check for clearance between jam
nut and fuel solenoid. If there is clearance
between jam nut and solenoid, loosen nut
and turn plunger clockwise until lever
touches stop screw. Retighten nut.
6 5
7
If there is no clearance between jam nut

and solenoid, loosen the solenoid mounting screws and reposition the solenoid as
described at the beginning of this section.
Ref. 804 250-A / 802 649
OM-217 455 Page 35

B. Checking Throttle Solenoid
!
Stop engine.
If the engine does not stay at idle

speed, verify the the throttle solenoid
and linkage is installed properly.
Adjusting Throttle Solenoid
1
2
3
4
5
6
7
Throttle Solenoid
Jam Nut
Solenoid Link
Shoulder Bolt
Throttle Lever
Solenoid Rod
Throttle Solenoid Mounting
Screw
Loosen jam nut, remove shoulder

bolt, and remove link from throttle lever. Install link 5/8 in (16 mm) on solenoid rod. Reconnect link to shoulder bolt and throttle lever.
4
Push solenoid rod into idle (energized) position and check for nonbinding lateral movement of throttle
link at throttle lever. If link binds, loosen solenoid mounting screws. Move
the solenoid slightly until the link
moves freely with solenoid in relaxed and energized positions.
Tighten screws.
Tighten jam nut.
Go to Step C.
5/8 in
(16 mm)
Tools Needed:
Check for non-binding

movement of link with solenoid in energized position.
3/8, 7/16 in
5/32 in
Check for non-binding

movement of link with
solenoid in relaxed
position.
Ref. 804 250-A / 802 649
OM-217 455 Page 36

C. Making Engine Speed Adjustments
. Before adjusting engine speed, verify

23752450 rpm
39.640.8 Hz
Idle
Weld/Power
36753750 rpm
61.362.5 Hz
throttle solenoid is installed properly

(see Section B on previous page).
Check engine speeds with a tachometer

(see table). If necessary, adjust speeds as
follows:
Start engine and run until warm. Turn V/A
control to max.
Adjusting Idle Speed
Turn Engine Control switch to Run/Idle
position.
1
2
3
4
5
Throttle Solenoid
Idle Speed Jam Nut
Plunger
Throttle Link
Throttle Lever
Loosen jam nut. While holding throttle link

with a 3/8 in wrench, turn plunger clockwise to increase idle speed or counterclockwise to decrease idle speed.
. After adjusting idle speed, verify the
Be sure throttle link

is parallel with
throttle lever.
throttle link is parallel with the throttle

lever. If necessary, loosen the idle
speed jam nut and reposition the
throttle link.
. Do not twist solenoid boot while adjusting engine speed.
Tighten jam nut.

6
Adjusting Weld/Power Speed

Start engine and run until warm. Turn V/A
control to max.
1
3
6
7
Do not twist
solenoid boot
while adjusting
engine speed.
Weld Speed Jam Nut

Adjustment Screw
Turn Engine Control switch to Run position. Loosen nut and turn screw counterclockwise to increase speed. Turn screw
clockwise to decrease speed. Tighten nut.
Tools Needed:
3/8, 7/16 in
10, 14 mm
Ref. 804 250-A / 801 963
OM-217 455 Page 37

9-5. Overload Protection
Tools Needed:
Stop engine.
. When a circuit breaker or fuse

opens, it usually indicates a
more serious problem exists.
Contact a Factory Authorized
Service Agent.
3/8 in
Component Panel
Fuse F1
F1 protects the weld excitation

winding from overload. If F3 opens,
weld output stops or is low.
2
1
2
Fuse F2
F2 protects the generator power

excitation winding from overload. If
F4 opens, generator power output
stops or is low.
3
Circuit Breaker CB7
CB7 protects the engine glow plug

circuit. If CB7 opens, the glow plug
will not heat. CB7 automatically resets when the fault is corrected.
4
CB8 protects the engine battery circuit. If CB8 opens, the engine will
not crank. CB8 automatically resets when the fault is corrected.
Replace any open fuses. Close
door and/or reinstall cover before
operating unit.
804 253-A / Ref 804 250-A
OM-217 455 Page 38

9-6. Troubleshooting Tables
A. Welding
Trouble
Low or no weld output; generator power output okay at ac receptacles.
Remedy
Check control settings.
Check weld connections.
Check fuse F1, and replace if open (see Section 9-5).
Have Factory Authorized Service Agent check brushes, slip rings, integrated rectifiers SR2 and SR3,
and main rectifier SR1.
No weld output or generator power output at ac receptacles.
Be sure all equipment is disconnected from receptacles when starting unit.

Check fuses F1 and F2, and replace if open (see Section 9-5).
Check plug PLG6 connection.
Have Factory Authorized Service Agent check brushes, slip rings, and integrated rectifiers SR2, SR3.
Low weld output.

Check engine speed, and adjust if necessary (see Section 9-4).
Service air cleaner (see Section 8-2)
High weld output.

Erratic weld output.

Tighten and clean connections to electrode and workpiece.
Use dry, properly-stored electrodes for Stick and TIG welding.
Remove excessive coils from weld cables.
Clean and tighten connections both inside and outside welding generator.
B. Generator Power
Trouble
No or low generator power output at ac
receptacles; weld output okay.
okay
Remedy
Reset supplementary protectors (see Section 7-1).
Press optional GFCI receptacle Reset button (see Section 7-1).
Check engine ignition wiring connections.
Have Factory Authorized Service Agent check brushes, slip rings, and integrated rectifier SR3.
No generator power or weld output.
Be sure all equipment is disconnected from receptacles when starting unit.

Check fuses F1 and F2, and replace if open (see Section 9-5).
Check engine ignition wiring connections.
Have Factory Authorized Service Agent check brushes, slip rings, and integrated rectifiers SR2 and
SR3.
OM-217 455 Page 39

Trouble
Low power output at ac receptacles.
Remedy
Increase Fine control R1 setting to max.
High power output at ac receptacles.
Erratic power output at ac receptacles.
Check fuel level.

Check receptacle wiring and connections.
Have Factory Authorized Service Agent check brushes and slip rings.
C. Engine
Maintenance Display
Action
noFUEL
Place Engine Control switch in the Off position, refuel, and start engine.
HI H2O
Coolant temperature is too high. Allow engine to cool and check coolant level (see Section 9-2).
LO OIL
Oil pressure is too low. Allow engine to cool and check oil level (see Section 9-2).
Trouble
Engine does not crank.
Remedy
Supplementary protector CB8 may be open (see Section 9-5). Wait and retry.
Check battery voltage.
Check battery connections and tighten if necessary.
Check plug Engine Control switch and engine wiring harness connections.
Have Factory Authorized Service Agent check Engine Control switch S2 or circuit breaker CB8.
Engine cranks but does not start.
Check fuel level and fault indicators on fuel gauge (see Section 6-1).
Open fuel valve (see Section 5-6).
Glow plug circuit breaker CB7 may be open (see Section 9-5). Wait and retry.
Service inline fuel strainer and fuel filter (see Section 8-2).
Check battery and replace if necessary.
Check engine charging system according to engine manual.
Check fuel solenoid according to engine manual.
Have Factory Authorized Service Agent check glow Plug switch S6, glow plug, and control relay CR3.
Engine starts but stops when Engine

Control switch S2 returns to Run/Idle
position.
Check oil level (see Section 5-6) and fault indicators on fuel gauge (see Section 6-1). Engine will not
start if oil pressure is too low.
Check coolant level and fan belt (see Section 5-6 and engine manual), and check fault indicators on
fuel gauge (see Section 6-1). Engine will not start if engine temperature is too high.
Have Factory Authorized Service Agent check low oil pressure shutdown switch S5 and engine temperature switch S4.
Engine does not stop.
Stop engine by closing fuel valve (see Section 5-6). Adjust shutdown solenoid (see Section 9-4).
Engine stopped during normal

operation.
Check fuel level and fault indicators on fuel gauge (see Section 6-1).
Open fuel valve (see Section 5-6).
Check oil level (see Section 5-6) and fault indicators on fuel gauge (see Section 6-1). Engine will not
start if oil pressure is too low.
Check coolant level and fan belt (see Section 5-6 and engine manual), and check fault indicators on
fuel gauge (see Section 6-1). Engine stops if engine temperature is too high.
Have Factory Authorized Service Agent check low oil pressure shutdown switch S5 and engine temperature switch S4.
OM-217 455 Page 40

Trouble
Remedy
Battery discharges between uses.
Clean top of battery with baking soda and water solution; rinse with clear water.
Periodically recharge battery (approximately every 3 months).
Replace battery.
Check voltage regulator according to engine manual.
Engine does not return to idle speed

when load is removed with Engine
Control switch in Run/Idle position.
Remove all weld and generator power loads.
Check for obstructed movement of solenoid linkage (see Section 9-4).

Have Factory Authorized Service Agent check idle module PC1, current transformer CT1, idle lock
switch S7, throttle solenoid TS1, and Engine Control switch S2.
Engine does not remain at weld/power
speed when power or weld load is
applied with Engine Control switch in
Run/Idle position.
Have Factory Authorized Service Agent check idle module PC1, control relay CR2, control relay CR4,
current transformer CT1, and throttle solenoid TS1.
Engine does not remain at idle speed
with Engine Control switch in Speed
Lock position and Idle Lock switch in
Idle position.
Have Factory Authorized Service Agent check control relay CR2, control relay CR4, Idle Lock switch
S7, and throttle solenoid TS1.
Engine uses oil during run-in period;
wetstacking occurs.
Dry engine (see Section 12 and engine manual).
SECTION 10 PARTS LIST

10-1. Recommended Spare Parts
Dia.
Mkgs.
Part
No.
Description
Quantity
Recommended Spare Parts

. . . . . . . . . . . . . . . . . . . . 187441
. . . . . . . . . . . . . . . . . . 202102
. . . . . . . . . . . . . . . . . . . . 213858
. . . . . . . . . . . . . . . . . . . . 187442
. . . . . . . . . . . . . . . . . . . . 187443
. . . . . . . . . . . . . . . . . . . . 187459
. . . . . . . . GLOW PLUG . 187820
. . . . . . . . . . . . . . . . . . . . 187819
. . . . . . . . . . . . . . . . . . . . 206421
. . . . . . . . . F1, F2 . . . 169296
Optional
..
..
..
..
..
..
..
..
..
..
Element, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Element, Air Cleaner Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter, Fuel Inline 5/16x5/16 Mic 125 175 . . . . . . . . . . . . . . . . . . . . . . . .
Element, Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Belt, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injector Assy, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter Kit, Kubota 722 (Includes air cleaner element, fuel, oil filters) . . . . .
Fuse, Mintr Gl 25. Amp 125 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
2
. A complete Parts List is available on-line at www.MillerWelds.com
OM-217 455 Page 41
SECTION 11 ELECTRICAL DIAGRAMS
Figure 11-1. Circuit Diagram For Welding Generator

OM-217 455 Page 42
228 719-B
OM-217 455 Page 43
Figure 11-2. Circuit Diagram For Welding Generator With Battery Charging Option
OM-217 455 Page 44
231 607-B
OM-217 455 Page 45
SECTION 12 RUN-IN AND WETSTACKING

run_in_D722 9/05
12-1. Run-In And Wetstacking

2
Welding Generator
Run-in procedures for this engine

should not be required. Put unit into
regular service.
2
Engine Exhaust Pipe
Wetstacking is unburned fuel and

oil in the exhaust pipe and occurs if
the engine is run too long at light
load or idle rpm.
OM-217 455 Page 46
If exhaust pipe is coated with a wet,

black, tar-like substance, contact
factory service for procedures to
properly dry engine and seat piston
rings.
SECTION 13 PERFORMANCE DATA

13-1. Fuel Consumption Curves
On a typical job using 1/8 in 7018
electrodes (125 amps, 20% duty
cycle), expect about 24 hours of operation.
Welding at 150 amps at 40% duty
cycle uses approximately 1/2 gallon per hour, or about 20 hours of
operation.
2.00
Weld Fuel Consumption
1.75
US Gal./Hr.
1.50
1.25
1.00
0.75
0.50
IDLE
0.25
0.00
150
200
250
300
100
DC WELD AMPERES AT 100% DUTY CYCLE
50
2.00
350
400
Auxiliary Power Fuel Consumption
1.75
US Gal./Hr.
1.50
1.25
1.00
0.75
0.50
IDLE
0.25
0.00
10
AUXILARY POWER KW AT 100% DUTY CYCLE

226795-A / 226 796-A
OM-217 455 Page 47
13-2. Generator Power Curve
AC Volts
The ac generator power curve

shows the generator power available in amperes at the receptacles.
300
150
250
125
200
100
150
75
100
50
50
25
40
80
120
160
20
AC Amperes At 120 Volts

40
60
80
AC Amperes At 240 Volts
200
240
100
120
226 791-A
13-3. Duty Cycle

Duty cycle is the percentage of 10
minutes that unit can weld at rated
load without overheating.
NOTICE Exceeding duty cycle
can damage unit and void warranty.
Continuous Welding
100% Duty Cycle at 250 Amperes
200 293
OM-217 455 Page 48
13-4. Stick Mode Volt-Ampere Curves

The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of
other settings fall between the
curves shown.
A. CC/DC Stick Mode

90
80
70
DC Volts
60
50
40
30
20
10
0
50
100
150
200
DC Amps
250
300
350
400
B. CC/AC STICK Mode
90
80
70
AC Volts
60
50
40
30
20
10
0
50
100
150
AC Amps
200
250
300
226 792-A / 226 793-A
OM-217 455 Page 49
13-5. MIG Mode Volt-Ampere Curve

The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of
other settings fall between the
curves shown.
45
40
35
DC Volts
30
25
20
15
10
5
0
100
200
300
400
DC Amps
500
600
700
800
226 794-A
OM-217 455 Page 50
SECTION 14 GENERATOR POWER GUIDELINES

. The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown.
14-1. Selecting Equipment
1
2
3
Generator Power Receptacles

Neutral Bonded To Frame
3-Prong Plug From Case
Grounded Equipment
2-Prong Plug From Double
Insulated Equipment
. Be sure equipment has double

insulated symbol and/or wording on it.
1
2
Do not use 2-prong plug unless equipment is double insulated.
3
OR
gen_pwr 200704 Ref. ST-159 730 / ST-800 577
14-2. Grounding Generator To Truck Or Trailer Frame
Always ground generator

frame to vehicle frame to prevent electric shock and static
electricity hazards.
Also see AWS Safety &

Health Fact Sheet No. 29,
Grounding of Portable And
Vehicle Mounted Welding
Generators.
Equipment Grounding
Terminal (On Front Panel)
Grounding Cable (Not
Supplied)
Metal Vehicle Frame
2
1
GND/PE
3
2
Connect cable from equipment

ground terminal to metal vehicle
frame. Use #10 AWG or larger
insulated copper wire.
3
. Electrically
bond generator
frame to vehicle frame by metal-to-metal contact.
Bed liners, shipping skids,

and some running gear insulate the welding generator
from the vehicle frame. Always connect a ground wire
from the generator equipment grounding terminal to
bare metal on the vehicle
frame as shown.
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
S-0854
OM-217 455 Page 51
14-3. 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
. Use ground device as stated in

electrical codes.
Ground generator to system

earth ground if supplying
power to a premises (home,
shop, farm) wiring system.
Also see AWS Safety &

Health Fact Sheet No. 29,
Grounding of Portable And
Vehicle Mounted Welding
Generators.
ST-800 576-B
14-4. How Much Power Does Equipment Require?

1
Resistive Load
A light bulb is a resistive load and

requires a constant amount of power.
3
2
1
VOLTS 115
AMPS 4.5
Hz
60
3
3
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 14-8).
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.
(3 x 200W) + 520 W = 1120 W
The total load applied by the three
flood lamps and drill is 1120 watts.
S-0623
OM-217 455 Page 52
14-5. Approximate Power Requirements For Industrial Motors

Industrial Motors
Split Phase
Capacitor Start-Induction Run
Capacitor Start-Capacitor Run
Fan Duty
Rating
Starting Watts
Running Watts
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
800
1225
1600
2100
3175
2020
3075
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
1000
1400
1850
2400
3500
300
500
600
700
875
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
400
550
650
800
1100
14-6. 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)
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
Rating
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
Starting Watts
Running Watts
1000
1650
3400
4400
2900
10500
1720
2575
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
3300
3150
4500
6100
3100
2150
3100
2100
3200
1000
650
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
OM-217 455 Page 53
14-7. Approximate Power Requirements For Contractor Equipment

Contractor
Hand Drill
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
OM-217 455 Page 54
Rating
Starting Watts
Running Watts
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
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
350
400
600
500
900
1400
1500
1800
1100
720
1400
1600
1000
1500
2200
2800
1100
1100
350
500
700
400
100
250
1000
200
500
1400
1600
950
1400
1600
700
900
1300
14-8. Power Required To Start Motor

Single-Phase Induction Motor Starting Requirements
Motor Start
Code
KVA/HP
6.3
7.1
8.0
9.0
10.0
11.2
12.5
14.0
4
1
3
AC MOTOR
VOLTS 230
AMPS 2.5
CODE M
Hz
60
HP
1/4
PHASE 1
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.
(kVA/HP x HP x 1000) / Volts =
Starting Amperage
Example: Calculate starting amperage required for a 230 V, 1/4 HP motor with a motor start code of M.
Volts = 230, HP = 1/4, kVA/HP =
11.2
(11.2 x 1/4 x 1000) / 230 = 12.2A
Starting the motor requires 12.2
amperes.
S-0624
14-9. 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.
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-217 455 Page 55
14-10. Typical Connections To Supply Standby Power
2
Utility
Electrical
Service
Have only qualified persons

perform these connections
according to all applicable
codes and safety practices.
Properly install and ground

this equipment according to
its Owners Manual and national, state, and local codes.
3
Transfer Switch
Fused
Disconnect
Switch
(If Required)
Welding
Generator
Output
. Customer-supplied equipment
is required if generator will supply standby power during

emergencies or power outages.
5
Essential
Loads
1 Utility Electrical Service

2 Transfer Switch (Double-Throw)
Switch transfers the electrical load
from electric utility service to the
generator. Transfer load back to
electric utility when service is restored.
Install correct switch (customersupplied). Switch rating must be
same as or greater than the branch
overcurrent protection.
3 Fused Disconnect Switch
Install correct switch (customersupplied) if required by electrical
code.
4 Welding Generator Output
Generator output voltage and wiring must be consistent with regular
(utility) system voltage and wiring.
Connect generator with temporary
or permanent wiring suitable for the
installation.
Turn off or unplug all equipment
connected to generator before
starting or stopping engine. When
starting or stopping, the engine has
low speed which causes low voltage and frequency.
5 Essential Loads
Generator output may not meet the
electrical requirements of the premises. If generator does not produce
enough output to meet all requirements, connect only essential
loads (pumps, freezers, heaters,
etc. See Section 14-4).
OM-217 455 Page 56
14-11. Selecting Extension Cord (Use Shortest Cord Possible)
Cord Lengths for 120 Volt Loads

Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)
Load (Watts)
600
840
10
1200
15
10
12
14
350 (106)
225 (68)
137 (42)
100 (30)
400 (122)
250 (76)
150 (46)
100 (30)
62 (19)
400 (122)
275 (84)
175 (53)
112 (34)
62 (19)
50 (15)
1800
300 (91)
175 (53)
112 (34)
75 (23)
37 (11)
30 (9)
20
2400
225 (68)
137 (42)
87 (26)
50 (15)
30 (9)
25
3000
175 (53)
112 (34)
62 (19)
37 (11)
30
3600
150 (46)
87 (26)
50 (15)
37 (11)
35
4200
125 (38)
75 (23)
50 (15)
40
4800
112 (34)
62 (19)
37 (11)
45
5400
100 (30)
62 (19)
50
6000
87 (26)
50 (15)
*Conductor size is based on maximum 2% voltage drop
Cord Lengths for 240 Volt Loads

Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)
Load (Watts)
1200
1680
10
2400
15
10
12
14
700 (213)
450 (137)
225 (84)
200 (61)
800 (244)
500 (152)
300 (91)
200 (61)
125 (38)
800 (244)
550 (168)
350 (107)
225 (69)
125 (38)
100 (31)
3600
600 (183)
350 (107)
225 (69)
150 (46)
75 (23)
60 (18)
20
4800
450 (137)
275 (84)
175 (53)
100 (31)
60 (18)
25
6000
350 (107)
225 (69)
125 (38)
75 (23)
30
7000
300 (91)
175 (53)
100 (31)
75 (23)
35
8400
250 (76)
150 (46)
100 (31)
40
9600
225 (69)
125 (38)
75 (23)
45
10,800
200 (61)
125 (38)
50
12,000
175 (53)
100 (31)
*Conductor size is based on maximum 2% voltage drop

OM-217 455 Page 57
SECTION 15 STICK WELDING (SMAW) GUIDELINES
15-1. Stick Welding Procedure

!
Weld current starts when

electrode touches workpiece.
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.
Workpiece
Make sure workpiece is clean before welding.
5
4
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 15-2).
3
6
1
4
5
6
Insulated Electrode Holder

Electrode Holder Position
Arc Length
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 200704 ST-151 593
OM-217 455 Page 58
7014
7018
7024
Ni-Cl
308L
ALL
DEEP
EP
ALL
DEEP
6013
EP,EN
ALL
LOW
GENERAL
7014
EP,EN
ALL
MED
7018
EP
ALL
LOW
SMOOTH, EASY,
FAST
LOW HYDROGEN,
STRONG
7024
EP,EN
NI-CL
EP
FLAT
HORIZ
FILLET
ALL
308L
EP
ALL
USAGE
PENETRATION
EP
6011
AC
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
DC*
450
400
350
300
AMPERAGE
RANGE
250
200
150
POSITION
6013
6010
ELECTRODE
6010
&
6011
100
50
DIAMETER
ELECTRODE
15-2. Electrode and Amperage Selection Chart
MIN. PREP, ROUGH

HIGH SPATTER
LOW
SMOOTH, EASY,
FASTER
LOW
CAST IRON
LOW
STAINLESS
*EP = ELECTRODE POSITIVE (REVERSE POLARITY)

EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)
Ref. S-087 985-A
15-3. Striking an Arc Scratch Start Technique

1
1
2
3
Electrode
Workpiece
Arc
Drag electrode across workpiece

like striking a match; lift electrode
slightly after touching work. If arc
goes out electrode was lifted to
high. If electrode sticks to workpiece, use a quick twist to free it.
S-0049
15-4. Striking an Arc Tapping Technique

1
1
2
3
2
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-217 455 Page 59
15-5. Positioning Electrode Holder

10-30
90
90
End View of Work Angle
Side View of Electrode Angle
GROOVE WELDS
10-30
45
45
End View of Work Angle
Side View of Electrode Angle

FILLET WELDS
S-0060
15-6. Poor Weld Bead Characteristics

1
2
3
4
5
Large Spatter Deposits

Rough, Uneven Bead
Slight Crater During Welding
Bad Overlap
Poor Penetration
1
2
S-0053-A
15-7. 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.
4
5
1
2
No Overlap
Good Penetration into Base
Metal
S-0052-B
OM-217 455 Page 60
15-8. Conditions That Affect Weld Bead Shape

. Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal.
Angle Too Small
Correct Angle
10 - 30
Angle Too Large
Drag
ELECTRODE ANGLE
Spatter
Normal
Too Short
Too Long
ARC LENGTH
Normal
Slow
Fast
TRAVEL SPEED
S-0061
15-9. Electrode Movement During Welding

. 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
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-217 455 Page 61
15-10. Butt Joints

1
1
2
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)
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.
30
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
15-11. Lap Joint

30
Or Less
30
Or Less
1
Single-Layer Fillet Weld
Electrode
Single-Layer Fillet Weld
Move electrode in circular motion.

3
Multi-Layer Fillet Weld
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.
1
2
Multi-Layer Fillet Weld

S-0063 / S-0064
15-12. Tee Joint

1
2
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.
45
Or Less
Electrode
Fillet Weld
For maximum strength weld both

sides of upright section.
Multi-Layer Deposits
Weld a second layer when a heavier fillet is needed. Use any of the
weaving patterns shown in Section
15-9. Remove slag before making
another weld pass.
1
OM-217 455 Page 62
S-0060 / S-0058-A / S-0061
15-13. Weld Test

1
2
3
Strike weld joint in direction shown.

A good weld bends over but does
not break.
3
2 To 3 in
(51-76 mm)
1/4 in
(6.4 mm)
Vise
Weld Joint
Hammer
2 To 3 in
(51-76 mm)
2
2
1
S-0057-B
15-14. Troubleshooting Porosity

Porosity small cavities or holes resulting from gas
pockets in weld metal.
Possible Causes
Corrective Actions
Arc length too long.
Reduce arc length.
Damp electrode.
Use dry electrode.
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
15-15. Troubleshooting Excessive Spatter

Excessive Spatter scattering of molten metal particles
that cool to solid form near weld bead.
Possible Causes
Corrective Actions
Amperage too high for electrode.
Decrease amperage or select larger electrode.
Arc length too long or voltage too high.
Reduce arc length or voltage.
OM-217 455 Page 63
15-16. Troubleshooting Incomplete Fusion
Incomplete Fusion failure of weld metal to fuse completely with

base metal or a preceeding weld bead.
Possible Causes
Corrective Actions
Insufficient heat input.
Increase amperage. Select larger electrode and increase amperage.
Improper welding technique.
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.
15-17. Troubleshooting Lack Of Penetration
Lack Of Penetration shallow fusion between weld metal and

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

Reduce travel speed.
15-18. Troubleshooting Excessive Penetration
Excessive Penetration weld metal melting through base metal and

hanging underneath weld.
Excessive Penetration
Possible Causes
Excessive heat input.
Good Penetration
Corrective Actions
Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
OM-217 455 Page 64
15-19. Troubleshooting Burn-Through

Burn-Through weld metal melting completely through base metal resulting
in holes where no metal remains.
Possible Causes
Corrective Actions
Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
15-20. 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.
Corrective Actions
Use two hands. Practice technique.
15-21. 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
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-217 455 Page 65
Notes
Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
Effective January 1, 2007

(Equipment with a serial number preface of LH or newer)
Warranty Questions?
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.
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
* Induction Heating Coils and Blankets, Cables, and
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
Non-Electronic Controls
its original retail purchaser that new Miller equipment sold after
* APT & SAF Model Plasma Cutting Torches
the effective date of this limited warranty is free of defects in
* Remote Controls
material and workmanship at the time it is shipped by Miller. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
* Accessory (Kits)
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
* Replacement Parts (No labor)
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Spoolmate Spoolguns
Within the warranty periods listed below, Miller will repair or
* Canvas Covers
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.
Miller shall honor warranty claims on warranted equipment listed

below in the event of such a failure within the warranty time
periods. All warranty time periods start on the delivery date of the
equipment to the original end-user purchaser, and not to exceed
one year after the equipment is shipped to a North American
distributor or eighteen months after the equipment is shipped to
an International distributor.
1.
5 Years Parts 3 Years Labor
2.
3 Years Parts and Labor
*
*
*
*
*
*
*
*
*
3.
Original main power rectifiers

Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Process Controllers
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (Unless Otherwise Stated)
Water Coolant Systems (Integrated)
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
1 Year Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
Motor Driven Guns (w/exception of Spoolmate

Spoolguns)
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources, Coolers, and
Electronic
Controls/Recorders
Water Coolant Systems (Non-Integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Spot Welders
Load Banks
Arc Stud Power Sources & Arc Stud Guns
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True Blue
for the remaining warranty period of the product they
are installed in, or for a minimum of one year
whichever is greater.)
Bernard-Branded Mig Guns (No Labor)
Weldcraft-Branded TIG Torches (No Labor)
Subarc Wire Drive Assemblies
4.
6 Months Batteries
5.
90 Days Parts
MIG Guns/TIG Torches and Subarc (SAW) Guns
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. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)
2.
Items furnished by Miller, but manufactured by others, such

as engines or trade accessories. These items are covered
by the manufacturers warranty, if any.
3.
Equipment that has been modified by any party other than

Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable and
necessary maintenance, or equipment which has been
used for operation outside of the specifications for the
equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND

USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at 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 200701
Owners Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.

Contact your Distributor for:
Welding Supplies and Consumables

Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
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 manufacturers
Transportation Department.
PRINTED IN USA
2007 Miller Electric Mfg. Co. 200701
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

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OM-217 455H

Engine Driven Welding Generator

Bobcat 250 Diesel

File: Engine Drive

From Miller to You

Miller Electric manufactures a full line

Working as hard as you do

SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING

1-1. Symbol Usage

. Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC

1-2. Arc Welding Hazards

ELECTRIC SHOCK can kill.

SIGNIFICANT DC VOLTAGE exists in inverters after stopping engine.

HOT PARTS can cause severe burns.

FLYING METAL or DIRT can injure eyes.

FUMES AND GASES can be hazardous.

D Do not weld on closed containers such as tanks, drums, or pipes,

NOISE can damage hearing.

BUILDUP OF GAS can injure or kill.

Noise from some processes or equipment can damage hearing.

D Shut off shielding gas supply when not in use.

D Wear approved ear protection if noise level is

MAGNETIC FIELDS can affect Implanted

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense

WELDING can cause fire or explosion.

OM-217 455 Page 2

D Wearers of Pacemakers and other Implanted

CYLINDERS can explode if damaged.

1-3. Engine Hazards

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

FUEL can cause fire or explosion.

Do not overfill tank allow room for fuel to expand.

MOVING PARTS can cause injury.

STEAM AND HOT COOLANT can burn.

Using a generator indoors CAN KILL

BATTERY ACID can BURN SKIN and EYES.

ENGINE HEAT can cause fire.

HOT PARTS can cause severe burns.

EXHAUST SPARKS can cause fire.

1-4. Compressed Air Hazards

TRAPPED AIR PRESSURE AND WHIPPING

COMPRESSED AIR can cause injury.

HOT METAL from air arc cutting and

HOT PARTS can cause burns and injury.

D Do not touch hot compressor or air system

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

FALLING UNIT can cause injury.

OVERHEATING can damage motors.

FLYING SPARKS can cause injury.

MOVING PARTS can cause injury.

OM-217 455 Page 4

WELDING WIRE can cause injury.

OVERUSE can cause OVERHEATING.

STATIC (ESD) can damage PC boards.

TILTING OF TRAILER can cause injury.

H.F. RADIATION can cause interference.

D High-frequency (H.F.) can interfere with radio