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miller du op welding machine

Transcript of miller du op welding machine

OM-494January 2005

191 862P

ProcessesStick (SMAW) Welding MIG (GMAW) Welding Flux Cored (FCAW) Welding TIG (GTAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging

Description

Dual-Operator Engine Driven Welding Generator

Miller DU-OP

Visit our website at

www.MillerWelds.com

From Miller to YouThank 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.Working as hard as you do every power source from Miller is backed by the most hassle-free warranty in the business.

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

Mil_Thank 7/03

TABLE OF CONTENTSSECTION 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. Principales normes de scurit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7. Information sur les champs lectromagntiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 3 DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 4 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5. AC Generator Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. Activating The Dry Charge Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6. Safety Information For Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7. Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8. Making Dual Operator CC Weld Connections w/ Separate Work Cables . . . . . . . . . . . . . . . . . . . . . . . . 5-9. Making Dual Operator Mode CC Weld Connections w/ Common Work Cable . . . . . . . . . . . . . . . . . . . 5-10. Making Dual Operator CV Weld Connections w/ Separate Work Cables . . . . . . . . . . . . . . . . . . . . . . . . 5-11. Making Dual Operator CV Weld Connections w/ Common Work Cable . . . . . . . . . . . . . . . . . . . . . . . . . 5-12. Making Dual Operator CC And CV Weld Connections w/ Separate Work Cables . . . . . . . . . . . . . . . . 5-13. Making Dual Operator CC And CV Weld Connections w/ Common Work Cable . . . . . . . . . . . . . . . . . 5-14. Making Single Operator CC Weld Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16. Installing Ether Cylinder (Optional Ether Starting Aid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18. Remote 14 Receptacle Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 6 OPERATING THE WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. Engine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2. Weld Controls (See Section 6-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3. Weld Control Descriptions (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 7 OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. 120 Volt And 240 Volt Duplex Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1 2 3 3 4 4 4 5 5 5 6 7 7 8 8 9 9 10 10 10 10 11 11 12 13 14 14 15 16 16 17 18 18 19 20 21 22 23 24 25 26 27 27 28 29 29 30 31 32 32

TABLE OF CONTENTSSECTION 8 MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6. Servicing Optional Ether Starting Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7. Checking And Replacing Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8. Resetting Fan Belt Safety Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9. Inspecting And Cleaning Optional Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10. Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 9 ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 10 RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 11 GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 12 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPTIONS AND ACCESSORIES WARRANTY 32 32 34 35 36 37 37 38 39 40 41 42 46 48 48 49 50 51 58

SECTION 1 SAFETY PRECAUTIONS READ BEFORE USINGrom _nd_8/03

Y Warning: Protect yourself and others from injury read and follow these precautions.

1-1. Symbol UsageMeans Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.Y Marks a special safety message.

. Means Note; not safety related. 1-2. Arc Welding HazardsY 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. Y Only qualified persons should install, operate, maintain, and repair this unit. Y During operation, keep everybody, especially children, away.

This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards.

D D D D D D

Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual. Wear a safety harness if working above floor level. Keep all panels and covers securely in place. Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical. Insulate work clamp when not connected to workpiece to prevent contact with any metal object. Do not connect more than one electrode or work cable to any single weld output terminal.

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 D D D D D D Do not touch live electrical parts. Wear dry, hole-free insulating gloves and body protection. Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling. Use AC output ONLY if required for the welding process. If AC output is required, use remote output control if present on unit. 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! 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). Properly install and ground this equipment according to its Owners Manual and national, state, and local codes. 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. When making input connections, attach proper grounding conductor first double-check connections. Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill. Turn off all equipment when not in use. Do not use worn, damaged, undersized, or poorly spliced cables. Do not drape cables over your body. If earth grounding of the workpiece is required, ground it directly with a separate cable. Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine.

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.

FUMES AND GASES can be hazardous.Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. D D D D D Keep your head out of the fumes. Do not breathe the fumes. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases. If ventilation is poor, use an approved air-supplied respirator. Read the Material Safety Data Sheets (MSDSs) and the manufacturers instructions for metals, consumables, coatings, cleaners, and degreasers. Work in a confined space only if it is well ventilated, or while wearing an airsupplied 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. 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. Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

D D

D

BUILDUP OF GAS can injure or kill.D D Shut off shielding gas supply when not in use. Always ventilate confined spaces or use approved air-supplied respirator.

D D

D D D D D D D

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

D D D D

OM-494 Page 1

WELDING can cause fire or explosion.Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding. D D D D D D D D Protect yourself and others from flying sparks and hot metal. Do not weld where flying sparks can strike flammable material. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Watch for fire, and keep a fire extinguisher nearby. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side. 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). Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock and fire hazards. Do not use welder to thaw frozen pipes. Remove stick electrode from holder or cut off welding wire at contact tip when not in use. Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding. Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot work and have a fire watcher and extinguisher nearby. D D D D D D D

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

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

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

CYLINDERS can explode if damaged.Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully. Protect compressed gas cylinders from excessive heat, mechanical shocks, 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. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition. Turn face away from valve outlet when opening cylinder valve. Keep protective cap in place over valve except when cylinder is in use or connected for use. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards.

D D D D D

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

D D D

1-3. Engine HazardsBATTERY EXPLOSION can BLIND.D D D D D D Always wear a face shield, rubber gloves, and protective clothing when working on a battery. Stop engine before disconnecting or connecting battery cables or servicing battery.

MOVING PARTS can cause injury.D D D D D D Keep away from fans, belts, and rotors. Keep all doors, panels, covers, and guards closed and securely in place.

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.

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

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

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.

OM-494 Page 2

STEAM AND HOT COOLANT can burn.D D If possible, check coolant level when engine is cold to avoid scalding. Always check coolant level at overflow tank, if present on unit, instead of radiator (unless told otherwise in maintenance section or engine manual).

BATTERY ACID can BURN SKIN and EYES.D D D Do not tip battery. Replace damaged battery. Flush eyes and skin immediately with water.

D D D

If the engine is warm, checking is needed, and there is no overflow tank, follow the next two statements. Wear safety glasses and gloves and put a rag over radiator cap. Turn cap slightly and let pressure escape slowly before completely removing cap.

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

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

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

1-4. Compressed Air HazardsBREATHING COMPRESSED AIR can cause serious injury or death.D D Do not use compressed air for breathing. Use only for cutting, gouging, and tools.

HOT METAL from air arc cutting and gouging can cause fire or explosion.D D Do not cut or gouge near flammables. Watch for fire; keep extinguisher nearby.

COMPRESSED AIR can cause injury.D D Wear approved safety goggles. Do not direct air stream toward self or others.

HOT PARTS can cause burns and injury.D D Do not touch hot compressor or air system parts. Let system cool down before touching or servicing.

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.

READ INSTRUCTIONS.D D Read Owners Manual before using or servicing unit. Stop engine and release air pressure before servicing.

1-5. Additional Symbols For Installation, Operation, And MaintenanceFALLING UNIT can cause injury.D D D Use lifting eye to lift unit only, NOT running gear, gas cylinders, trailer, or any other accessories. Use equipment of adequate capacity to lift and support unit. If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.

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

OVERHEATING can damage motors.D D D Turn off or unplug equipment before starting or stopping engine. Do not let low voltage and frequency caused by low engine speed damage electric motors.

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

Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable.

FLYING SPARKS can cause injury.D D Wear a face shield to protect eyes and face. Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection.

TILTING OF TRAILER can cause injury.D D Use tongue jack or blocks to support weight. Properly install welding generator onto trailer according to instructions supplied with trailer.

D

Sparks can cause fires keep flammables away.

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READ INSTRUCTIONS.D D Use only genuine MILLER/Hobart replacement parts. Perform engine and air compressor (if applicable) maintenance and service according to this manual and the engine/air compressor (if applicable) manuals. D D D D

ARC WELDING can cause interference.D Electromagnetic energy can interfere with sensitive electronic equipment such as microprocessors, computers, and computer-driven equipment such as robots. Be sure all equipment in the welding area is electromagnetically compatible.

D

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

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.

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.

1-6. California Proposition 65 WarningsY 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.) Y 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: Y Engine exhaust contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. For Diesel Engines: Y 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 StandardsSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (phone: 305-443-9353, website: www.aws.org). Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (phone: 305-443-9353, website: www.aws.org). National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, 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, 1735 Jefferson Davis Highway, Suite 1004, Arlington, VA 22202-4102 (phone: 703-412-0900, website: www.cganet.com). Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone: 800-463-6727 or in Toronto 416-747-4044, website: www.csa-international.org). Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 11 West 42nd 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, 1 Battery March Park, Quincy, MA 02269-9101 (phone: 617-770-3000, website: www.nfpa.org and www. sparky.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 (there are 10 Regional Officesphone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).

1-8. EMF InformationConsiderations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the National Research Council concluded that: The body of evidence, in the committees judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard. However, studies are still going forth and evidence continues to be examined. Until the final conclusions of the research are reached, you may wish to minimize your exposure to electromagnetic fields when welding or cutting. To reduce magnetic fields in the workplace, use the following procedures: 1. Keep cables close together by twisting or taping them. 2. Arrange cables to one side and away from the operator. 3. Do not coil or drape cables around your body. 4. Keep welding power source and cables as far away from operator as practical. 5. Connect work clamp to workpiece as close to the weld as possible. About Pacemakers: Pacemaker wearers consult your doctor first. If cleared by your doctor, then following the above procedures is recommended.

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SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATIONrom_fre 8/03

Y Avertissement: Protgez vous et les autres des blessures lisez et suivez ces prcautions.

2-1. Signification des symbolesSignifie Mise en garde ! Soyez vigilant ! Cette procdure prsente des risques de danger ! Ceux-ci sont identifis par des symboles adjacents aux directives.Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des risques de danger relis aux CHOCS LECTRIQUES, aux PICES EN MOUVEMENT et aux PICES CHAUDES. Reportez-vous aux symboles et aux directives ci-dessous afin de connatre les mesures prendre pour viter tout danger.

Y Identifie un message de scurit particulier.

. Signifie NOTA ; nest pas relatif la scurit. 2-2. Dangers relatifs au soudage larcY 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 2-6 . Veuillez lire et respecter toutes ces normes de scurit. Y Linstallation, lutilisation, lentretien et les rparations ne doivent tre confis qu des personnes qualifies. Y Au cours de lutilisation, tenir toute personne lcart et plus particulirement les enfants.

D D D D D D D D D D D D

En effectuant les raccordements dentre fixer dabord le conducteur de mise la terre appropri et contre-vrifier les connexions. Vrifier frquemment le cordon dalimentation pour voir sil nest pas endommag ou dnud remplacer le cordon immdiatement sil est endommag un cble dnud peut provoquer une lectrocution. Mettre lappareil hors tension quand on ne lutilise pas. Ne pas utiliser des cbles uss, endommags, de grosseur insuffisante ou mal pisss. Ne pas enrouler les cbles autour du corps. Si la pice soude doit tre mise la terre, le faire directement avec un cble distinct ne pas utiliser le connecteur de pice ou le cble de retour. Ne pas toucher llectrode quand on est en contact avec la pice, la terre ou une lectrode provenant dune autre machine. Nutiliser quun matriel en bon tat. Rparer ou remplacer sur-le-champ les pices endommages. Entretenir lappareil conformment ce manuel. Porter un harnais de scurit quand on travaille en hauteur. Maintenir solidement en place tous les panneaux et capots. Fixer le cble de retour de faon obtenir un bon contact mtal-mtal avec la pice souder ou la table de travail, le plus prs possible de la soudure. Isoler la pince de masse quand pas mis la pice pour viter le contact avec tout objet mtallique.

UN CHOC LECTRIQUE peut tuer.Un simple contact avec des pices lectriques peut provoquer une lectrocution ou des blessures graves. Llectrode et le circuit de soudage sont sous tension ds que lappareil est sur ON. Le circuit dentre et les circuits internes de lappareil sont galement sous tension ce moment-l. En soudage semi-automatique ou automatique, le fil, le dvidoir, le logement des galets dentranement et les pices mtalliques en contact avec le fil de soudage sont sous tension. Des matriels mal installs ou mal mis la terre prsentent un danger. D D D Ne jamais toucher les pices lectriques sous tension. Porter des gants et des vtements de protection secs ne comportant pas de trous. Sisoler de la pice et de la terre au moyen de tapis ou dautres moyens isolants suffisamment grands pour empcher le contact physique ventuel avec la pice ou la terre. Ne pas se servir de source lectrique courant lectrique dans les zones humides, dans les endroits confins ou l o on risque de tomber. Se servir dune source lectrique courant lectrique UNIQUEMENT si le procd de soudage le demande. Si lutilisation dune source lectrique courant lectrique savre ncessaire, se servir de la fonction de tlcommande si lappareil en est quip. ronnements 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 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! Couper lalimentation ou arrter le moteur avant de procder linstallation, la rparation ou lentretien de lappareil. Dverrouiller lalimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de scurit). Installer et mettre la terre correctement cet appareil conformment son manuel dutilisation et aux codes nationaux, provinciaux et municipaux. Toujours vrifier la terre du cordon dalimentation Vrifier et sassurer que le fil de terre du cordon dalimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccorde une prise correctement mise la terre. D D D D D

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.

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

D D D

D Des prcautions de scurit supplmentaires sont requises dans des envi-

D

D

D D

D

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LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou mme la mort.Fermer lalimentation du gaz protecteur en cas de non utilisation. Veiller toujours bien arer les espaces confins ou se servir dun respirateur dadduction dair homologu. D

D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et NFPA 51Bpour les travaux chaud et avoir de la surveillance et un extincteur proximit.

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

D

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

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

D

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

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

LES CHAMPS MAGNTIQUES peuvent affecter les stimulateurs cardiaques.D D Porteurs de stimulateur cardiaque, restez distance. Les porteurs dun stimulateur cardiaque doivent dabord consulter leur mdecin avant de sapprocher des oprations de soudage larc, de gougeage ou de soudage par points.

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

D D D D

2-3. Dangers existant en relation avec le moteurLES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou mme la mort.Fermer lalimentation du gaz protecteur en cas de non utilisation. Veiller toujours bien arer les espaces confins ou se servir dun respirateur dadduction dair homologu. D

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

D

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LEXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE.D Toujours porter une protection faciale, des gants en caoutchouc et vtements de protection lors dune intervention sur la batterie.

D D D D D

D D D D D

Arrter le moteur avant de dbrancher ou de brancher les cbles de batterie. Eviter de provoquer des tincelles avec les outils en travaillant sur la batterie. Ne pas utiliser le poste de soudage pour charger les batteries ou des vhicules de dmarrage rapide. Observer la polarit correcte (+ et ) sur les batteries. Dbrancher le cble ngatif () en premier lieu. Le rebrancher en dernier lieu.

Pour empcher tout dmarrage accidentel pendant les travaux dentretien, dbrancher le cble ngatif () de batterie de la borne. Ne pas approcher les mains, cheveux, vtements lches et outils des organes mobiles. Remettre en place les panneaux ou les dipositifs de protection et fermer les portes la fin des travaux dentretien et avant de faire dmarrer le moteur. Avant dintervenir, dposer les bougies ou injecteurs pour viter la mise en route accidentelle du moteur. Bloquer le volant moteur pour viter sa rotation lors dune intervention sur le gnrateur.

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.

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

D D D D

D D 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). Si le moteur est chaud et que le liquide doit tre vrifi, oprer comme suivant : Mettre des lunettes de scurit et des gants, placer un torchon sur le bouchon du radiateur. Dvisser le bouchon lgrement et laisser la vapeur schapper avant denlever le bouchon.

LA CHALEUR DU MOTEUR peut provoquer un incendie.D D Ne pas placer lappareil sur, au-dessus ou proximit de surfaces inflammables. Tenir distance les produits inflammables de lchappement.

DES ORGANES MOBILES peuvent provoquer des blessures.D D Ne pas approcher les mains des ventilateurs, courroies et autres pices en mouvement. Maintenir ferms et fixement en place les portes, panneaux, recouvrements et dispositifs de protection.

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

D D

Arrter le moteur avant dinstaller ou brancher lappareil. Demander seulement un personnel qualifi denlever les dispositifs de scurit ou les recouvrements pour effectuer, sil y a lieu, des travaux dentretien et de dpannage.

2-4. Dangers lis lair comprimRESPIRER LAIR COMPRIM peut provoquer des blessures graves ou causer la mort.D Ne pas utiliser lair comprim pour respirer. D Utiliser lair comprim seulement pour le coupage, gougeage et les outils pneumatiques.

Le METAL CHAUD lors du coupage et gougeage plasma peut provoquer un incendie ou une explosion.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.

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.

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.

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.

2-5. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenanceLA CHUTE DE LAPPAREIL peut blesser.D Utiliser lanneau de levage uniquement pour soulever lappareil lui-mme ; sans chariot, de bouteilles de gaz, remorque, ou autres accessoires.

D Utiliser un quipement de levage de capacit suffisante pour leverD

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

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

LIRE LES INSTRUCTIONS.D D Utiliser seulement les pices de rechange dorigine. Effectuer la maintenance du moteur et du compresseur (si applicable) suivant ce manuel et le manuel du moteur/compresseur (si applicable).

D

LES TINCELLES VOLANTES risquent de provoquer des blessures.D D Porter un cran facial pour protger le visage et les yeux. D D D D D

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

D

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

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

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

LES CHARGES LECTROSTATIQUES peuvent endommager les circuits imprims.D D tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pices. Utiliser des pochettes et des botes antistatiques pour stocker, dplacer ou expdier des cartes de circuits imprimes.

D D D D D

UNE REMORQUE QUI BASCULE peut entraner des blessures.D D Utiliser les supports de la remorque ou des blocs pour soutenir le poids. Installer convenablement le poste sur la remorque comme indiqu dans le manuel sy rapportant.

2-6. Principales normes de scuritSafety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, de lAmerican Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (tlphone : (305) 4439353, site Web : www.aws.org). Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, norme American Welding Society AWS F4.1, de lAmerican Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (tlphone : (305) 4439353, site Web : www.aws.org). National Electrical Code, norme NFPA 70, de la National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 022699101 (tlphone : (617) 7703000, sites Web : www.nfpa.org et www.sparky.org). Safe Handling of Compressed Gases in Cylinders, brochure CGA P1, de la Compressed Gas Association, 1735 Jefferson Davis Highway, Suite 1004, Arlington, VA 222024102 (tlphone : (703) 4120900, site Web : www.cganet.com). Code for Safety in Welding and Cutting, norme CSA W117.2, de la Canadian Standards Association, Standards Sales, 178 boulevard Rexdale, Rexdale (Ontario) Canada M9W 1R3 (tlphone : (800) 4636727 ou Toronto : (416) 7474044, site Web : www.csainternational.org). Practice For Occupational And Educational Eye And Face Protection, norme ANSI Z87.1, de lAmerican National Standards Institute, 11 West 42nd Street, New York, NY 100368002 (tlphone : (212) 6424900, site Web : www.ansi.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, norme NFPA 51B, de la National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 022699101 (tlphone : (617) 7703000, site Web : www.nfpa.org et www.sparky.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 lU.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10 bureaux rgionaux Tlphone pour la Rgion 5, Chicago : (312) 3532220, site Web : www.osha.gov).

2-7. Information sur les champs lectromagntiquesDonnes sur le soudage lectrique et les effets des champs magntiques basse frquence sur lorganisme En parcourant les cbles de soudage, le courant cre des champs lectromagntiques. Les effets potentiels de tels champs restent proccupants. Cependant, aprs avoir examin plus de 500 tudes qui ont t faites pendant une priode de recherche de 17 ans, un comit de spcialistes du National Research Council a conclu : Laccumulation de preuves na pas dmontr que lexposition aux champs magntiques et aux champs lectriques haute frquence constitue un risque pour la sant humaine . Toutefois, les tudes et lexamen des preuves se poursuivent. En attendant les conclusions finales de la recherche, il serait souhaitable de rduire lexposition aux champs lectromagntiques pendant le soudage ou le coupage. Afin de rduire les champs lectromagntiques en milieu de travail, respecter les consignes suivantes : 1. Garder les cbles ensemble en les torsadant ou en les fixant avec du ruban adhsif. 2. Mettre tous les cbles du ct oppos loprateur. 3. Ne pas senrouler les cbles autour du corps. 4. Garder le poste de soudage et les cbles le plus loin possible de soi. 5. Placer la pince de masse le plus prs possible de la zone de soudage. Consignes relatives aux stimulateurs cardiaques : Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur mdecin. Si ce dernier les dclare aptes, il leur est recommand de respecter les consignes ci-dessus.

OM-494 Page 8

SECTION 3 DEFINITIONS3-1. Symbols And DefinitionsStop Engine Start Engine Ether Starting Aid Engine

Do Not Switch While Welding Or Under Load

Battery (Engine)

Circuit Breaker

Engine Oil

Check Injectors/ Pump

Check Valve Clearance

Fuel

Protective Earth (Ground)

Positive

Negative

Certified/Trained Mechanic

Welding Arc

A

Amperes

V

Volts

Panel/Local

Remote

On

Temperature

Output (Contactor)

Alternating Current

Stick (SMAW) Welding

TIG (GTAW) Welding

MIG (GMAW) Welding

3 1

Three Phase

Time

h

Hours

s

Seconds

Single Phase

Read Operators Manual

OM-494 Page 9

SECTION 4 SPECIFICATIONS4-1. DescriptionThis unit has two CC/CV modules with separate weld controls for applications where two welding arcs are needed. A Welder Selector switch controls whether one or both sets of weld output terminals are active (see Section 6-2). When the unit is operated in the dual operator mode, each welder has CC and CV weld output available for Stick, TIG, and MIG welding. When in the single operator mode, CC weld output is available to the welder on the Welder B (right) side only (CV not active in single operator mode).

4-2. Weld, Power, And Engine SpecificationsWeld Mode Weld Stations Available1 (Right Side) 2 (Both Sides)

Weld Output

Weld Output Range30 600 A 15 300 A 10 32 V

Max. OpenCircuit Voltage85 85 49

Rated Welding Output550 A at 30 Volts DC, 40% Duty Cycle 275 A at 31 Volts DC, 40% Duty Cycle

Generator Power RatingSingle-Phase, 4 kVA/kW, 34/17 A, 120/240 V AC, 50/60 Hz (4 kVA/kW Shared By ( / y All R Receptacles) t l )

Engine

Fuel Capacity

Single

CC/DC CC/DC CV/DC

Dual

Deutz F3L-912 Air Cooled, Air-Cooled, Three-Cylinder, Th C li d 41.5 HP Diesel Engine

22.3 gal (84.4 L)

4-3. Dimensions, Weights, And Operating AnglesDimensionsHeight Width Depth A B C D E F G H J K L 47-5/8 in (1210 mm) 31-1/4 in (794 mm) 60-1/2 in (1537 mm) 59-1/8 in (1502 mm) 47-1/4 in (1200 mm) 43-1/4 in (1099 mm) 32-3/4 in (832 mm) 24-15/16 in (633 mm) 10-1/2 in (267 mm) 6-1/2 in (165 mm) 2-7/8 in (73 mm) 29-7/8 in (759 mm) 11/16 in (24 mm) 21/32 in (17 mm) Dia. 16 Holes K J H G F 20 20angles_1 8/99 158 699

L Engine End Y Do not exceed tilt angles or engine could be damaged or unit could tip. Y Do not move or operate unit where it could p tip. tip

C D E B

A

17.5 17 5 17.5

Weight2005 lb (909 kg)

OM-494 Page 10

4-4. Fuel ConsumptionThe curve shows typical fuel use under the combined weld loads of both sides (Welder A and Welder B).

7.57 6.62 5.67 4.73 3.78 2.84 1.98 0.95

1.70 1.46 1.25 1.04 0.83 0.62 0.40 0.21

2.00 1.75 1.50 1.25 1.00 0.75 0.50 0.25 0 0 50 100 150 200 250 300 350 400 450 500 550 600 DC WELD AMPERES AT 40% DUTY CYCLE CC CV

LITERS/HR.

IMP. GAL./HR.

U.S. GAL./HR.

195 711

4-5. AC Generator PowerThe ac power curve shows the generator power in amperes available at the 120 and 240 volt receptacles.

150 300 125 250 AC VOLTS 100 200 75 150 50 100 25 0 50 0 0 0 5 10 10 15 20 AC AMPERES IN 240V MODE 20 30 40 AC AMPERES IN 120V MODE 25 50 30 60

193 018

OM-494 Page 11

4-6. Duty Cycle And OverheatingDuty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. Dual Operator Mode 40% Duty Cycle At 275 Amperes From Each Side Single Operator Mode 40% Duty Cycle At 550 Amperes From Welder B side (Right) Y Exceeding duty cycle can damage unit and void warranty. If a weld module overheats, the High Temperature light goes on and the thermostat opens to stop weld output to that module. Wait fifteen minutes for module to cool. Reduce amperage, voltage, or duty cycle before welding. 4 Minutes Welding 6 Minutes Resting This unit has separate duty cycle ratings for each operating mode. If the unit is operated in the dual operator mode, the unit is rated at 40% duty cycle. This means each side of the unit can be operated at 275 amperes at 40% duty cycle. When the unit is operated in the single operator mode, the Welder B side (right) is rated at 40% duty cycle (550 A at 40% duty cycle).

Overheating

0 15 Minutes

A or V

OR Reduce Duty CycleRef. rduty1 5/95 194 313-A

OM-494 Page 12

4-7. Volt-Ampere CurvesA. CC/DC Single Mode

100 80 DC VOLTS 60 40 20 0 MIN MED MAX

The volt-ampere curve shows the minimum, medium, and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the curves shown.

0

100 200 300 400 500 600 700 800 900 1000 DC AMPERES

B. CC/DC Dual Mode

100 80 DC VOLTS 60 40 20 0 MIN MED MAX

0

50

100 150 200 250 300 350 400 450 500 DC AMPERES

C. CV/DC Mode

100 80 DC VOLTS 60 40 20 0 MAX MED MIN 0 100 200 300 400 500 600 700 800 900 1000 DC AMPERES

194 397 / 194 398 / 194 399

OM-494 Page 13

SECTION 5 INSTALLATION NOTEWhen facing the front panel, the Welder B controls and weld terminals are on the right and the Welder A controls and weld terminals are on the left.

5-1. Installing Welding Generator

Movement Y Do Not Lift Unit From End

Airflow Clearance 18 in (460 mm) 18 in (460 mm) OR 18 in (460 mm) 18 in (460 mm)

Location

18 in (460 mm) OR

Grounding 1GND/PE

2

Y Always securely fasten welding generator onto transport vehicle or trailer and comply with all DOT and other applicable codes. Y Always ground generator frame to vehicle frame to prevent electric shock and static electricity hazards. Y If unit does not have GFCI receptacles, use GFCI-protected extension cord.

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

1 3 2 3

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. Y Be sure equipment connected to the 240 V receptacles is GFCIprotected.install1 11/02* Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854

NotesWork like a Pro!Pros weld and cut safely. Read the safety rules at the beginning of this manual.

OM-494 Page 14

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

5

4 1 3

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

2

. When electrolyte

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

6

5 A For 30 Minutes

OR

+ 30 A For 12 Minutes Tools Needed:

drybatt1 2/96 S-0886

OM-494 Page 15

5-3. Connecting The Battery

Y Connect () Cable Last.

+

190 377

5-4. Installing Exhaust PipeY Stop engine and let cool. Y Do not blow exhaust toward air cleaner or air intake.

Top View

Tools Needed: 1/2 inexh_pipe2 4/96 154 089-A / 154 611 / 190 377

OM-494 Page 16

5-5. Engine Prestart ChecksCheck all fluids daily. Engine must be cold and on a level surface. Follow run-in procedure in engine manual. If unburned fuel and oil collect in exhaust pipe during run-in, see Section 10. Full Fuel Y Do not use gasoline. Gasoline will damage engine. Add diesel fuel before starting engine the first time (see maintenance label for specifications). Fill fuel tank up to 1/2 in. (13 mm) from top to allow room for expansion. Open fuel shut-off valve. Do not run out of fuel or air enters fuel system and causes starting problems. See engine manual to bleed air from fuel system. Oil After fueling, check oil with unit on level surface. If oil is not up to full mark on dipstick, add oil (see maintenance label).

1/2 in (13 mm)

Diesel

. Engine stops if oil pressure istoo low. Valve Open

. To

improve starting:

cold

weather

IKeep 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. Full Use correct grade oil for cold weather.Ref. 158 633-C / S-176 697

O

Notes

Start Your Professional Welding Career Now!

400 Trade Square East, Troy, Ohio 45373 1-800-332-9448 www.welding.org

Over 80,000 trained since 1930!OM-494 Page 17

5-6. Safety Information For Connecting To Weld Output Terminals

Y UNEXPECTED WELD OUTPUT can cause injury or fire. D D D Y D D D D Y Both weld outputs can be live (ON) when Welder Selector switch is in Welder A/Welder B position and engine is running. Disconnect or insulate any unused cables. Know where cables are located BEFORE starting engine. ELECTRIC SHOCK can kill; ARCING can burn skin or damage electrical connections. Do not connect welding output of different polarities to the same structure. See ANSI Z49.1 and OSHA Title 29, Chapter XVII, Part 1910, Subpart Q (addresses at beginning of manual). When welding on the same workpiece, all connections to the workpiece must be of the same polarity. Do not handle or come in contact with two live electrodes at the same time. ELECTRIC SHOCK can kill; TWO TIMES NORMAL OPEN-CIRCUIT VOLTS can exist between electrode holders of opposite polarity.

D Stop engine before making any weld output connections.

D Do not touch electrode holders of opposite polarity at the same time. D Separate electrode holders of opposite polarity to prevent contact. D Consult ANSI Z49.1 for common grounding safe practices.

5-7. Weld Output Terminals

Welder A (Left) Side

Welder B (Right) Side

3

2

1

1

2

3

. Dinse receptacles only on unitswith Polarity switch option.

4

Tools Needed: 3/4 inRef. 190 377 / 802 292-A / 802 554

Y Stop engine. 1 2 3 Negative () Weld Output Terminal CV Weld Output Terminal CC Weld Output Terminal

4

Dinse Weld Receptacles (Only On Units With Polarity Switch Option)

connections (CC only). If unit has the Polarity switch option, the Negative () weld output terminals are labeled Work receptacles and the CC weld output terminals are labeled Electrode receptacles.

See Sections 5-8 thru 5-13 for dual operator output connections for CC and CV welding. See Section 5-14 for single operator output

OM-494 Page 18

5-8. Making Dual Operator CC Weld Connections w/ Separate Work CablesTools Needed: 3/4 in

Direct Current Electrode Positive (DCEP) connections are shown.

Welder A (Left) Side

Welder B (Right) Side

Note position of Process Selector switches.

2

1

2

3

Ref. 190 377 / 802 292-A

Y Stop engine. Y Do not exceed machine duty cycle. CV welding (see Section 6-1). See Section 5-15 for proper cable size. 1 Strain Reliefs Route cables through strain reliefs.

. Use Dual Operator mode for CC and

2 Electrode Holder Cables 3 Work Cables For Stick/TIG welding Direct Current Electrode Positive (DCEP), connect work cables to Negative () terminals and electrode holder cables to CC terminals. For Stick/TIG Direct Current Electrode Negative (DCEN), connect work cables to

CC terminals and electrode holder cables to Negative () terminals. If unit has the Polarity switch option, connect work cables to Work receptacles and electrode holder cables to Electrode receptacles.

. Be sure Process Selector switches areset correctly. See Section 6-3. OM-494 Page 19

5-9. Making Dual Operator Mode CC Weld Connections w/ Common Work CableTools Needed: 3/4 in

Y INADEQUATE CABLE CONNECTIONS can cause serious damage to welding generator and create a hazardous condition. When making weld connections with a common work cable, connect a weld cable of adequate size between the Negative () weld terminals, and connect a single weld cable of adequate size from the Welder B (right) Negative () terminal to the workpiece. When using these connections as a common work terminal, all connections must be of the same polarity. For a common work cable connection, the work cable must be able to carry the combined weld output of both modules (see Section 5-15 for proper cable size).

Direct Current Electrode Positive (DCEP) connections are shown. Welder A (Left) Side Welder B (Right) Side

Note position of Process Selector switches.

1 4 2 3 2

Ref. 190 377 / 802 292-A

Y Stop engine. Y Do not exceed machine duty cycle.

4

Common Work Cable

. For common

work connection, work cable must be able to carry combined weld output of both CC weld output terminals (see Section 5-15 for proper cable size).

For Stick/TIG welding Direct Current Electrode Positive (DCEP), connect common work cable and work jumper cable to Welder B (right) Negative () terminal. Connect other end of work jumper cable to Welder A (left) Negative () terminal. Connect electrode holder cables to CC terminals. For Stick/TIG Direct Current Electrode Negative (DCEN), connect common work cable and work jumper cable to Welder B (right) CC terminal. Connect other end of

CV welding (see Section 6-1). 1 Strain Relief Route cables through strain reliefs. 2 Electrode Holder Cables 3 Work Jumper Cable OM-494 Page 20

. Use Dual Operator mode for CC and

work jumper cable to Welder A (left) CC terminal. Connect electrode holder cables to Negative () terminals. If unit has the Polarity switch option, connect common work cable and work jumper cable to Welder B (right) Work receptacle. Connect other end of work jumper cable to Welder A (left) Work receptacle. Connect electrode holder cables to Electrode receptacles.

. Be

sure Process Selector switches and optional Polarity switches are set correctly. See Section 6-3.

5-10. Making Dual Operator CV Weld Connections w/ Separate Work CablesTools Needed: 3/4 in

Direct Current Electrode Positive (DCEP) connections are shown.

Welder A (Left) Side

Welder B (Right) Side

Note position of Process Selector switches.

2

Note position of optional Polarity switch.

Note position of optional Polarity switch. 1

2

3

Ref. 190 377 / 802 292-A

Y Stop engine. Y Do not exceed machine duty cycle.

3

Work Cables

. Use Dual Operator mode for CC andCV welding (see Section 6-1). See Section 5-15 for proper cable size. 1 2 Strain Reliefs Wire Feeder Cables Route cables through strain reliefs.

For MIG and FCAW welding Direct Current Electrode Positive (DCEP), connect work cables to Negative () terminals and wire feeder cables to CV terminals. For MIG and FCAW Direct Current Electrode Negative (DCEN), connect work cables to CV terminals and wire feeder cables to Negative () terminals.

If unit has the Polarity switch option, connect work cables to Work receptacles and wire feeder cables to CV receptacles.

. Place optional Polarity switches in Re-

verse position when using CV weld receptacles. There is no CV weld output when switch is in Straight position. switches are set correctly. See Section 6-3. OM-494 Page 21

. Be sure Process Selector and Polarity

5-11. Making Dual Operator CV Weld Connections w/ Common Work CableTools Needed: 3/4 in

Y INADEQUATE CABLE CONNECTIONS can cause serious damage to welding generator and create a hazardous condition. When making weld connections with a common work cable, connect a weld cable of adequate size between the Negative () weld terminals, and connect a single weld cable of adequate size from the Welder B (right) Negative () terminal to the workpiece. When using these connections as a common work terminal, all connections must be of the same polarity. For a common work cable connection, the work cable must be able to carry the combined weld output of both modules (see Section 5-15 for proper cable size). Direct Current Electrode Positive (DCEP) connections are shown. Welder A (Left) Side Welder B (Right) Side

Note position of Process Selector switches.

Note position of optional Polarity switch. 2 3

1 4 2

Note position of optional Polarity switch.

Ref. 190 377 / 802 292-A

Y Stop engine. Y Do not exceed machine duty cycle.

4

Common Work Cable

. For common

work connection, work cable must be able to carry combined weld output of both CC weld output terminals (see Section 5-15 for proper cable size). CV welding (see Section 6-1).

For MIG and FCAW welding Direct Current Electrode Positive (DCEP), connect common work cable and work jumper cable to Welder B (right) Negative () terminal. Connect other end of work jumper cable to Welder A (left) Negative () terminal. Connect wire feeder cables to CV terminals. For MIG and FCAW Direct Current Electrode Negative (DCEN), connect common work cable and work jumper cable to Welder B (right) CV terminal. Connect other end of work jumper cable to Welder A (left) CV terminal.

. Use Dual Operator mode for CC and1 2 3 Strain Relief Wire Feeder Cables Work Jumper Cable Route cables through strain reliefs.

Connect wire feeder cables to Negative () terminals. If unit has the Polarity switch option, connect common work cable and work jumper cable to Welder B (right) Work receptacle. Connect other end of work jumper cable to Welder A (left) Work receptacle. Connect wire feeder cables to CV receptacles.

. Place optional Polarity switches in Re-

verse position when using CV weld receptacles. There is no CV weld output when switch is in Straight position. switches are set correctly. See Section 6-3.

. Be sure Process Selector and Polarity

OM-494 Page 22

5-12. Making Dual Operator CC And CV Weld Connections w/ Separate Work CablesTools Needed: 3/4 in

Direct Current Electrode Positive (DCEP) connections are shown.

Welder A (Left) Side

Welder B (Right) Side

Note position of Process Selector switches.

3

Note position of optional Polarity switch.

1

2

4 Y Stop engine. Y Do not exceed machine duty cycle. to Negative () terminal and electrode holder cable to CC terminal. For Stick/TIG Direct Current Electrode Negative (DCEN), connect work cable to CC terminal and electrode holder cable to Negative () terminal. set correctly. See Section 6-3. For MIG and FCAW welding Direct Current Electrode Positive (DCEP), connect work cable to Negative () terminal and wire feeder cable to CV terminal. For MIG and FCAW Direct Current Electrode Negative (DCEN), connect work cable to CV terminal and wire feeder cable to Negative () terminal.

Ref. 190 377 / 802 292-A

. Use Dual Operator mode for CC andCV welding (see Section 6-1). See Section 5-15 for proper cable size. 1 2 3 4 Strain Reliefs Electrode Holder Cable Wire Feeder Cable Work Cables Route cables through strain reliefs.

For Stick/TIG welding on units with Polarity switch option, connect work cable to Work receptacle and electrode cable to Electrode receptacle. For MIG/FCAW welding on units with Polarity switch option, connect work cable to Work receptacle and wire feeder cable to CV receptacle.

. Be sure Process Selector switches are

. Place optional Polarity switches in Re-

verse position when using CV weld receptacles. There is no CV weld output when switch is in Straight position.

For Stick/TIG welding Direct Current Electrode Positive (DCEP), connect work cable

. Be sure Process Selector and Polarity

switches are set correctly. See Section 6-3. OM-494 Page 23

5-13. Making Dual Operator CC And CV Weld Connections w/ Common Work CableTools Needed: 3/4 in

Y INADEQUATE CABLE CONNECTIONS can cause serious damage to welding generator and create a hazardous condition. When making weld connections with a common work cable, connect a weld cable of adequate size between the Negative () weld terminals, and connect a single weld cable of adequate size from the Welder B (right) Negative () terminal to the workpiece. When using these connections as a common work terminal, all connections must be of the same polarity. For a common work cable connection, the work cable must be able to carry the combined weld output of both modules (see Section 5-15 for proper cable size). Direct Current Electrode Positive (DCEP) connections are shown. Welder A (Left) Side Welder B (Right) Side

Note position of Process Selector switches.

Note position of optional Polarity switch. 3

1

5

2 4

Ref. 190 377 / 802 292-A

Y Stop engine. Y Do not exceed machine duty cycle.

. For

common work connection, work cable must be able to carry combined weld output of both CC weld output terminals (see Section 5-15 for proper cable size). welding (see Section 6-1).

For Direct Current Electrode Positive (DCEP), connect common work cable and work jumper cable to Welder B (right) Negative () terminal. Connect other end of work jumper cable to Welder A (left) Negative () terminal. Connect electrode holder cable to either CC terminal. Connect wire feeder cable to CV terminal on other side.

. Use Dual Operator mode for CC and CV1 2 3 4 5 Strain Reliefs Electrode Holder Cable Wire Feeder Cable Work Jumper Cable Common Work Cable Route cables through strain reliefs.

. Be sure Process Selector switches areset correctly. See Section 6-3. For Direct Current Electrode Negative (DCEN), connect common work cable and work jumper cable to Welder B (right) CC terminal. Connect other end of work jumper cable to Welder A (left) CV terminal.

Connect electrode holder cable to either Negative () terminal, and wire feeder cable to remaining Negative () terminal. If unit has the Polarity switch option, connect common work cable and work jumper cable to Welder B (right) Work receptacle. Connect other end of work jumper cable to Welder A (left) Work receptacle. Connect electrode holder cable to either Electrode receptacle. Connect wire feeder cable to CV receptacle on other side.

. Place optional

Polarity switch in Reverse position when using CV weld receptacle. There is no CV weld output when switch is in Straight position. switches are set correctly. See Section 6-3.

. Be sure Process Selector and Polarity

OM-494 Page 24

5-14. Making Single Operator CC Weld Connections

Direct Current Electrode Positive (DCEP) connections are shown.

Welder A (left) Terminals Inactive In Single Operator Mode

Welder B(Right) Side

Note position of Process Selector switch.

1

3

2

Tools Needed: 3/4 in Y Stop engine. Y Do not exceed machine duty cycle. Single Operator mode. (see Section 5-8).190 377 / 802 292-A

. Welder A (left) weld output terminals

. See Section 5-15 for proper cable size.See Section 5-15 for proper cable size. 1 Strain Relief Route cables through strain reliefs. 2 Electrode Holder Cable 3 Work Cable For Stick/TIG welding Direct Current Electrode Positive (DCEP), connect work cable

are disabled in Single Operator mode. Connect only to Welder B (right) terminals for Single Operator mode operation. ing only. Welder A and Welder B CV weld output terminals are disabled in

. Use Single Operator mode for CC weld-

to Negative () terminal and electrode holder cable to CC terminal. For Stick/TIG Direct Current Electrode Negative (DCEN), connect work cable to CC terminal and electrode holder cable to Negative () receptacle. If unit has the Polarity switch option, connect work cable to Work terminal and electrode holder cable to Electrode receptacle.

. Be sure Process Selector switch is setcorrectly. See Section 6-3. OM-494 Page 25

5-15. Selecting Weld Cable Sizes*Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding*** 100 ft (30 m) or Less Weld Output TerminalsY Turn off power before connecting to weld output terminals. Y Do not use worn, damaged, undersized, or poorly spliced cables. 100 150 200 250 300 350 400 500 600 700 800* This

150 ft (45 m)

200 ft (60 m)

250 ft (70 m)

300 ft (90 m)

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

Welding Amperes

10 60% Duty Cycle

60 100% Duty Cycle

10 100% Duty Cycle

4 (20) 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)

4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 2/0 (2x70)

4 (20) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 3/0 (2x95)

3 (30) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 4/0 (2x120) 2 ea. 4/0 (2x120)

2 (35) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 4/0 (2x120) 3 ea. 3/0 (3x95) 3 ea. 4/0 (3x120)

1 (50) 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) 3 ea. 3/0 (3x95) 3 ea. 4/0 (3x120) 3 ea. 4/0 (3x120)

1/0 (60) 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) 3 ea. 3/0 (3x95) 3 ea. 4/0 (3x120) 3 ea. 4/0 (3x120) 4 ea. 4/0 (4x120)

1/0 (60) 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) 3 ea. 3/0 (3x95) 3 ea. 4/0 (3x120) 4 ea. 4/0 (4x120) 4 ea. 4/0 (4x120)

chart is a general guideline and may not suit all applications. If cables overheat, use next size larger cable.S-0007-F

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

OM-494 Page 26

5-16. Installing Ether Cylinder (Optional Ether Starting Aid)Y Stop engine. Y Improper handling or exposure to ether can harm your health. Follow manufacturers safety instructions on cylinder. Y Do not use Ether Starting Aid while engine is running. Open right side door. 1 2 2 Ether Cylinder Nozzle

1

Remove cover and clean cylinder nozzle. 3 4 5 Clamp Fitting Cap Valve

3 4 5

6

Remove cap and clean fitting. Install cylinder on fitting. Tighten clamp.

. After installing cylinder, wait at6 least 10 minutes before using to let ether particles settle and prevent atomizer plugging. Put cap on fitting when cylinder is removed.ether1 7/96 153 382-A / 190 377 / 802 291-A

5-17. Remote 14 Receptacle Information

NOTE

Place Welder Selector switch in Welder A/Welder B position (dual operator mode) for both remote receptacles to work. Welder A (left) remote receptacle output contactor and control is disabled when switch is in Welder B position.

Socket*

Socket Information 24 volts ac. Protected by circuit breakers CB5 and CB6. Contact closure to A completes 24 volts ac contactor control circuit. Output to remote control; +10 volts dc in CV, 0 to +10 volts dc in CC. Remote control circuit common. 0 to +10 volts dc input command signal from remote control. Current feedback; 0 to +10 volts dc, 1 volt per 100 amperes. Voltage feedback; +1 volts dc per 10 arc volts. 115 volts, 15 amperes, 60 Hz ac. Protected by circuit breakers CB5 and CB6. Contact closure to I completes 115 volts ac contactor control circuit. Chassis common. Circuit common for 24 and 115 volts ac circuits.

24 VOLTS AC

A B C

REMOTE OUTPUT CONTROL

D E F H I J K

AMPERAGE VOLTAGE 115 VOLTS AC

A/V

GND*The remaining sockets are not used.

G

OM-494 Page 27

5-18. Remote 14 Receptacle ConnectionsDual Operator Operation A B K J I

H C L N D M G E F

OR A B J

K

I

H C L N M D G E F

OR

Single Operator Operation

A B

K

J

I60 AM 0 PS

H C L N D M G E F

OR

Ref. 802 291-A

OM-494 Page 28

SECTION 6 OPERATING THE WELDING GENERATOR NOTE6-1. Engine ControlsWhen facing the front panel, the Welder B controls and weld terminals are on the right and the Welder A side controls and weld terminals are on the left.

3

4

1

5

2

190 377

. See

Section 6-3 for weld control descriptions. 1 Engine Start Button 2 Manual Stop Control 3 Ether Starting Aid Switch (Optional) Push switch up and release while cranking engine to release eth