Miller MK420620R Owner's manual

OWNER’S MANUAL

OM-286503C

2020-02

Processes

Stick (SMAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

TIG (GTAW) Welding

Description

Engine Driven Welder/Generator

For product information,

Owner’s Manual translations,

and more, visit

www.MillerWelds.com

Bobcat

™

225

From Miller to You

Mil_Thank1

2019 01

Miller is the first welding

equipment manufacturer in the

U.S.A. to be registered to the

ISO 9001 Quality System

Standard.

Working as hard as you do −

every power source from

Miller is backed by the most

hassle-free warranty in the

business.

Mil_Thank 2019-01

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 don’t have time to do

it any other way.

That’s 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 couldn’t 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. They’re just as committed to providing equipment and

service that meets the high standards of quality and value established

in 1929.

This Owner’s 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. We’ve 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, there’s a

Troubleshooting section that will help you figure out what the problem

is, and our extensive service network is there to help fix the problem.

Warranty and maintenance information for your 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.

TABLE OF CONTENTS

SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1 Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-2 Perigos da soldagem a arco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-3 Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1-4 Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1-5 Perigos adicionais para instalação, operação e manutenção . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1-6 California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1-7 Principais Normas de Segurança . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1-8 EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT UTILISATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2-1 Symboles utilisés. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2-2 Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2-3 Dangers existant en relation avec le moteur. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2-4 Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2-5 Symboles de dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . . . . . . . . . . . . . . . . . 12

2-6 Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2-7 Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2-8 Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

SECTION 3 – DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3-1 Additional Safety Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3-2 Miscellaneous Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

SECTION 4 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4-1 Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4-2 Weld, Power, And Engine Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4-3 Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4-4 Regulatory Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4-5 Dimensions, Weights, And Operating Angles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4-6 Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4-7 Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4-8 Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4-9 Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

SECTION 5 – INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5-1 Installing Welder/Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5-2 Grounding Generator to Truck or Trailer Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5-3 Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5-4 Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5-5 Connecting Or Replacing The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

5-6 Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

5-7 Connecting Weld Output Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

5-8 Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

SECTION 6 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

6-1 Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

6-2 Using Wireless Remote . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

6-3 Cold Weather Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

6-4 Typical Stick Welding Connections And Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

6-5 Typical MIG Welding Connections and Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

6-6 Typical MIG Connections And Settings Using Weld Control And Spoolgun. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

6-7 Fuel/Hour Gauge Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

SECTION 7 – OPERATING AUXILIARY EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

7-1 Generator Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

7-2 GFCI Receptacle Information, Resetting, And Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

7-3 Simultaneous Weld And Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

7-4 Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

SECTION 8 – MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

8-1 Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

8-2 Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

8-3 Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

8-4 Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

8-5 Changing Engine Oil, Oil Filter, And Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

8-6 Adjusting Engine Speed (Kohler CH730 Carbureted Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

8-7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

SECTION 9 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

TABLE OF CONTENTS

9-1 Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

SECTION 10 – ELECTRICAL DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

SECTION 11 – GENERATOR POWER GUIDELINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

SECTION 12 – STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

SECTION 13 – GMAW WELDING (MIG) GUIDELINES WHEN USING A VOLTAGE-SENSING FEEDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

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OM-286503 Page 3

l Conecte o cabo "Obra" à Obra tão perto quanto possível do local

da solda para evitar que a corrente de soldagem passe por cami-

nhos longos e possivelmente ocultos e possa causar choques elé-

tricos, faíscas e incêndios.

l Não use uma máquina de soldar para descongelar tubulações.

l Retire o eletrodo revestido do porta-eletrodo ou corte o arame

de soldagem rente ao bico de contato quando não estiver

soldando.

l Para o seu corpo, use proteções feitas de materiais não-inflamá-

veis e de longa vida útil (couro, algodão grosso, lã). A proteção

corporal inclui o uso de peças de roupa sem óleo ou graxa tais co-

mo luvas de ,couro, camisa grossa, calças sem bainha, botas e

boné.

l Antes de começar a soldar, retire dos seus bolsos quaisquer obje-

tos combustíveis tais como um isqueiro ou fósforos.

l Depois de terminado um trabalho, inspecione a área para assegu-

rar-se de que não há faíscas, brasas ou chamas.

l Use somente fusíveis ou disjuntores de capacidade correta.

Não os sobredimensione ou curto-circuite.

l Siga os requisitos da OSHA 1910.252 (a) (2) (iv) e da NFPA 51B a

respeito de trabalhos a quente e mantenha um vigia e um extintor

por perto.

l Leia e compreenda as Especificações de Segurança (SDSs em

inglês) e as instruções dos fabricantes relativamente ao uso de

adesivos, revestimentos, produtos de limpeza, consumíveis, líqui-

dos refrigerantes, desengraxantes, fluxos e metais.

O RUÍDO pode afetar a audição

O ruído de certos processos ou equipamentos po-

de afetar a audição.

l Use protetores de ouvido aprovados quando o ní-

vel de ruído é alto.

CAMPOS ELÉTRICOS E

MAGNÉTICOS podem afetar

implantes médicos.

l Portadores de marca-passo ou de outros implan-

tes médicos devem se manter afastados.

l Portadores de implantes médicos devem consultar o seu Médico

e o fabricante do implante antes de se aproximar de um local de

soldagem a arco, soldagem por pontos, goivagem, corte a plasma

ou aquecimento por indução.

CILINDROS danificados podem

explodir.

Os cilindros de gás comprimido contêm gás sob al-

ta pressão. Se danificado, um cilindro pode explo-

dir. Como cilindros de gás são muitas vezes

usados em processos de soldagem, eles devem ser manuseados

com cuidado.

l Proteja cilindros de gás comprimido contra calor excessivo, cho-

ques mecânicos, danos físicos, escória de soldagem, chamas, fa-

íscas e arcos.

l Mantenha sempre os cilindros em posição vertical, presos a um

suporte fixo ou guardados em um quadro especial para evitar que

eles possam tombar.

l Mantenha os cilindros de gás afastados de circuitos de soldagem

ou de quaisquer outros circuitos elétricos.

l Nunca use um cilindro de gás como suporte de uma pistola ou to-

cha de soldar.

l Nunca deixe um eletrodo de soldagem entrar em contato com um

cilindro de gás.

l Nunca solde sobre um cilindro pressurizado — uma explosão po-

de ocorrer.

l Use somente cilindros de gás comprimido, reguladores de pres-

são, mangueiras e conexões próprios para cada aplicação espe-

cífica; mantenha-os e os seus acessórios em bom estado de

funcionamento.

l Vire e afaste o rosto quando abrir a válvula de um cilindro de gás.

Não fique de frente para o regulador de pressão ou atrás dele

quando abrir a válvula.

l Mantenha o capacete do cilindro sobre a válvula de saída do gás,

exceto quando o cilindro está sendo usado ou preparado para

uso.

l Use o equipamento adequado, os procedimentos corretos e o nú-

mero suficiente de pessoas para levantar, mover e transportar os

cilindros.

l Leia e siga as instruções dos fornecedores relativas aos cilindros

de gás e seus acessórios assim como a publicação P-1 da Com-

pressed Gas Association (CGA) listada nas Normas de

Segurança.

1-3. Engine Hazards

BATTERY EXPLOSION can injure.

l Always wear a face shield, rubber gloves, and pro-

tective clothing when working on a battery.

l Stop engine before disconnecting or connecting

battery cables, battery charging cables (if applica-

ble), or servicing battery.

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

l Do not use welder to charge batteries or jump start vehicles unless

the unit has a battery charging feature designed for this purpose.

l Observe correct polarity (+ and -) on batteries.

l Disconnect negative (-) cable first and connect it last.

l Keep sparks, flames, cigarettes, and other ignition sources away

from batteries. Batteries produce explosive gases during normal

operation and when being charged.

l Follow battery manufacturer’s instructions when working on or

near a battery. See Battery Service Manual (listed in Safety Stand-

ards) for additional information.

FUEL can cause fire or explosion.

l Stop engine and let it cool off before checking or

adding fuel.

l Do not add fuel while smoking or if unit is near any

sparks or open flames.

l Do not overfill tank — allow room for fuel to expand.

l Do not spill fuel. If fuel is spilled, clean up before starting engine.

l Dispose of rags in a fireproof container.

l Always keep nozzle in contact with tank when fueling.

MOVING PARTS can injure.

l Keep away from moving parts such as fans, belts,

and rotors.

l Keep all doors, panels, covers, and guards closed

and securely in place.

l Stop engine before installing or connecting unit.

l Have only qualified persons remove doors, panels, covers, or

guards for maintenance and troubleshooting as necessary.

l To prevent accidental starting during servicing, disconnect nega-

tive (-) battery cable from battery.

OM-286503 Page 4

l Keep hands, hair, loose clothing, and tools away from moving

parts.

l Reinstall doors, panels, covers, or guards when servicing is fin-

ished and before starting engine.

l Before working on generator, remove spark plugs or injectors to

keep engine from kicking back or starting.

l Block flywheel so that it will not turn while working on generator

components.

EXHAUST SPARKS can injure.

l Do not let engine exhaust sparks cause fire.

l Use approved engine exhaust spark arrestor in re-

quired areas — see applicable codes.

HOT PARTS can burn.

l Do not touch hot parts bare handed.

l Allow cooling period before working on equipment.

l To handle hot parts, use proper tools and/or wear

heavy, insulated welding gloves and clothing to

prevent burns.

STEAM AND HOT COOLANT can

burn.

l If possible, check coolant level when engine is cold

to avoid scalding.

l Always check coolant level at overflow tank, if

present on unit, instead of radiator (unless told otherwise in main-

tenance section or engine manual).

l If the engine is warm, checking is needed, and there is no overflow

tank, follow the next two statements.

l Wear safety glasses and gloves and put a rag over radiator cap.

l Turn cap slightly and let pressure escape slowly before completely

removing cap.

Using a generator indoors CAN KILL

YOU IN MINUTES.

l Generator exhaust contains carbon monoxide.

This is a poison you cannot see or smell.

l NEVER use inside a home or garage, EVEN IF

doors and windows are open.

l Only use OUTSIDE and far away from windows, doors, and vents.

BATTERY ACID can BURN SKIN and

EYES.

l Do not tip battery.

l Replace damaged battery.

l Flush eyes and skin immediately with water.

ENGINE HEAT can cause fire.

l Do not locate unit on, over, or near combustible

surfaces or flammables.

l Keep exhaust and exhaust pipes way from

flammables.

1-4. Compressed Air Hazards

COMPRESSED AIR EQUIPMENT can

injure or kill.

l Incorrect installation or operation of this unit could

result in equipment failure and personal injury. On-

ly qualified persons should install, operate, and

service this unit according to its Owner’s Manual, industry stand-

ards, and national, state, and local codes.

l Do not exceed the rated output or capacity of the compressor or

any equipment in the compressed air system. Design compressed

air system so failure of any component will not put people or prop-

erty at risk.

l Before working on compressed air system, turn off and lockout/

tagout unit, release pressure, and be sure air pressure cannot be

accidentally applied.

l Do not work on compressed air system with unit running unless

you are a qualified person and following the manufacturer’s

instructions.

l Do not modify or alter compressor or manufacturer-supplied

equipment. Do not disconnect, disable, or override any safety

equipment in the compressed air system.

l Use only components and accessories approved by the

manufacturer.

l Keep away from potential pinch points or crush points created by

equipment connected to the compressed air system.

l Do not work under or around any equipment that is supported only

by air pressure. Properly support equipment by mechanical

means.

HOT METAL from air arc cutting and

gouging can cause fire or explosion.

l Do not cut or gouge near flammables.

l Watch for fire; keep extinguisher nearby.

COMPRESSED AIR can injure or kill.

l Before working on compressed air system, turn off

and lockout/tagout unit, release pressure, and be

sure air pressure cannot be accidentally applied.

l Relieve pressure before disconnecting or connect-

ing air lines.

l Check compressed air system components and all

connections and hoses for damage, leaks, and

wear before operating unit.

l Do not direct air stream toward self or others.

l Wear protective equipment such as safety glasses, hearing pro-

tection, leather gloves, heavy shirt and trousers, high shoes, and a

cap when working on compressed air system.

l Use soapy water or an ultrasonic detector to search for leaks–

never use bare hands. Do not use equipment if leaks are found.

l Reinstall doors, panels, covers, or guards when servicing is fin-

ished and before starting unit.

l If ANY air is injected into the skin or body seek medical help

immediately.

BREATHING COMPRESSED AIR can

injure or kill.

l Do not use compressed air for breathing.

l Use only for cutting, gouging, and tools.

TRAPPED AIR PRESSURE AND

WHIPPING HOSES can injure.

l Release air pressure from tools and system before

servicing, adding or changing attachments, or

opening compressor oil drain or oil fill cap.

OM-286503 Page 5

MOVING PARTS can injure.

l Keep away from moving parts such as fans, belts

and rotors.

l Keep all doors, panels, covers, and guards closed

and securely in place.

l Keep hands, hair, loose clothing, and tools away from moving

parts.

l Before working on compressed air system, turn off and lockout/

tagout unit, release pressure, and be sure air pressure cannot be

accidentally applied.

l Have only qualified people remove guards or covers for mainte-

nance and troubleshooting as necessary.

l Reinstall doors, panels, covers, or guards when servicing is fin-

ished and before starting engine.

HOT PARTS can burn.

l Do not touch hot compressor or air system parts.

l Allow cooling period before working on equipment.

l To handle hot parts, use proper tools and/or wear heavy, insulated

welding gloves and clothing to prevent burns.

READ INSTRUCTIONS.

l Read and follow all labels and the Owner’s Manual

carefully before installing, operating, or servicing

unit. Read the safety information at the beginning

of the manual and in each section.

l Use only genuine replacement parts from the manufacturer.

l Perform installation, maintenance, and service according to the

Owner’s Manuals, industry standards, and national, state, and lo-

cal codes.

1-5. Perigos adicionais para instalação, operação e manutenção

Perigos de INCÊNDIOS ou

EXPLOSÕES.

l Não instale ou coloque a unidade sobre ou perto

de superfícies combustíveis.

l Não instale a unidade perto de materiais

inflamáveis.

l Não sobrecarregue a fiação elétrica do prédio - assegure-se de

que o circuito de alimentação elétrica é corretamente dimensiona-

do e protegido para atender aos requisitos da unidade.

Um EQUIPAMENTO que CAI pode

ferir.

l Use o olhal de levantamento somente para içar a

unidade e os seus acessórios corretamente insta-

lados, mas NÃO cilindros de gás. Não ultrapasse

a faixa de peso máxima do olhal de levantamento (veja

especificações).

l Use procedimentos e equipamento corretos de capacidade ade-

quada para levantar e apoiar a unidade.

l Quando se usa uma empilhadeira de garfo para transportar a uni-

dade, assegure-se de que o garfo é maior que a máquina.

l Mantenha o equipamento (cabos elétricos) afastados de veículos

em movimento quando trabalha em local elevado.

l Siga as orientações do "Applications Manual for the Revised

NIOSH Lifting Equation" (Manual de Aplicações para a equação

NIOSH revisada de Içamento) (Publicação No. 94-110) para le-

vantar equipamentos/peças pesados.

O SUPERAQUECIMENTO pode

danificar os motores.

l Desligue ou desconecte o equipamento antes de

iniciar ou parar o motor de combustão interna.

l Não deixe a baixa tensão e frequência causadas

por velocidade baixa do motor de combustão interna danificar os

motores elétricos.

l Use somente equipamentos adequados para operação em ener-

gia de 60 ou 50/60 Hz.

FAÍSCAS podem ferir.

l Use uma máscara para proteger os olhos e o

rosto.

l Para preparar um eletrodo de tungstênio, use proteções para o

rosto, as mãos e o corpo e um esmeril devidamente protegido e

instalado em local seguro.

l Faíscas podem causar incêndios — mantenha materiais inflamá-

veis afastados.

PEÇAS MÓVEIS podem ferir.

l Mantenha-se afastado de peças em movimento.

l Mantenha-se afastado de partes que, como as rol-

danas de tração, possam prender dedos ou peças

de vestuário.

A SAÍDA PARA A CARGA DE

BATERIA e A EXPLOSÃO DE UMA

BATERIA podem causar ferimentos.

Nem todos os Modelos oferecem a possibilidade

de carregar baterias.

l Use sempre uma máscara, luvas de borracha e roupa de proteção

quando trabalhar em uma bateria.

l Pare o motor de combustão interna antes de desconectar ou co-

nectar os cabos da bateria, os cabos de carga de bateria (se for o

caso) ou antes de executar alguma manutenção em uma bateria.

l Quando trabalhar em uma bateria, tome cuidado para que as fer-

ramentas usadas não gerem faíscas.

l Não use uma máquina de soldar para carregar baterias ou dar

partida a um veículo a não ser que ela tenha um carregador de

bateria incorporado previsto para este fim.

l Observe a polaridade correta (+ e -) das baterias.

l Primeiro, desconecte o cabo negativo (-) e conecte-o por último.

l Mantenha faíscas, chamas, cigarros e quaisquer outras possíveis

causas de ignição afastadas de baterias. As baterias geram gases

explosivos durante a sua operação normal e durante a sua carga.

l Siga as instruções do fabricante da bateria quando trabalhar em

ou perto de uma bateria. Consulte o Manual de Manutenção de

Baterias (listado em Normas de Segurança) para obter informa-

ções adicionais.

l Somente pessoas devidamente qualificadas devem carregar

baterias.

l Quando remover uma bateria de um veículo para carregá-la, des-

conecte o cabo negativo (-) primeiro e reconecte-o por último. Pa-

ra não criar arcos, assegure-se de que todos os acessórios estão

desligados.

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OM-286503 Page 7

For more information, go to www.P65Warnings.ca.gov/diesel.

1-7. Principais Normas de Segurança

Safety in Welding, Cutting, and Allied Processes, American Welding

Society standard ANSI Standard Z49.1. Website: http://www.aws.org.

Safe Practices for the Preparation of Containers and Piping for Weld-

ing and Cutting, American Welding Society Standard AWS F4.1 from

Global Engineering Documents. Website: www.global.ihs.com.

Safe Practices for Welding and Cutting Containers that have Held

Combustibles, American Welding Society Standard AWS A6.0 from

Global Engineering Documents. Website: www.global.ihs.com.

National Electrical Code, NFPA Standard 70 from National Fire Pro-

tection Association. Website: www.nfpa.org and www.sparky.org.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-

1 from Compressed Gas Association. Website: www.cganet.com.

Safety in Welding, Cutting, and Allied Processes, CSA Standard

W117.2 from Canadian Standards Association. Website: www.

csagroup.org.

Battery Chargers, CSA Standard C22.2 NO 107.2-01 from Canadian

Standards Association. Website: www.csagroup.org.

Safe Practice For Occupational And Educational Eye And Face Pro-

tection, ANSI Standard Z87.1, from American National Standards In-

stitute. Website: www.ansi.org.

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work, NFPA Standard 51B from National Fire Protection Association.

Website: www.nfpa.org.

OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Sub-

part N, Part 1910 Subpart Q, and Part 1926, Subpart J. Website:

www.osha.gov.

OSHA Important Note Regarding the ACGIH TLV, Policy Statement

on the Uses of TLVs and BEIs. Website: www.osha.gov.

Portable Generator Hazards Safety Alert from U.S. Consumer Prod-

uct Safety Commission (CPSC). Website: www.cpsc.gov.

Applications Manual for the Revised NIOSH Lifting Equation from the

National Institute for Occupational Safety and Health (NIOSH). Web-

site: www.cdc.gov/NIOSH.

For Standards regulating hydraulic systems, contact the National Flu-

id Power Association. Website: www.nfpa.com.

Battery Service Manual from the Battery Council International. Web-

site: www.batterycouncil.org.

ROM_bpg 2020–02

1-8. EMF Information

Electric current flowing through any conductor causes localized elec-

tric and magnetic fields (EMF). The current from arc welding (and al-

lied processes including spot welding, gouging, plasma arc cutting,

and induction heating operations) creates an EMF field around the

welding circuit. EMF fields can interfere with some medical implants,

e.g. pacemakers. Protective measures for persons wearing medical

implants have to be taken. For example, restrict access for passers

−by or conduct individual risk assessment for welders. All welders

should use the following procedures in order to minimize exposure to

EMF fields from the welding circuit:

1. Keep cables close together by twisting or taping them, or using a

cable cover.

2. Do not place your body between welding cables. Arrange cables

to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep head and trunk as far away from the equipment in the weld-

ing circuit as possible.

5. Connect work clamp to workpiece as close to the weld as

possible.

6. Do not work next to, sit or lean on the welding power source.

7. Do not weld whilst carrying the welding power source or wire

feeder.

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 opera-

tions. If cleared by your doctor, then following the above procedures

is recommended.

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OM-286503 Page 14

l Effectuer l’installation, l’entretien et toute intervention selon les

manuels d’utilisateurs, les normes nationales, provinciales et de

l’industrie, ainsi que les codes municipaux.

LE RAYONNEMENT HAUTE

FRÉQUENCE (H.F.) risque de

provoquer des interférences.

l Le rayonnement haute fréquence (H.F.) peut pro-

voquer des interférences avec les équipements de

radio-navigation et de communication, les services de sécurité et

les ordinateurs.

l Demander seulement à des personnes qualifiées familiarisées

avec des équipements électroniques de faire fonctionner

l’installation.

l L’utilisateur est tenu de faire corriger rapidement par un électricien

qualifié les interférences résultant de l’installation.

l Si le FCC signale des interférences, arrêter immédiatement

l’appareil.

l Effectuer régulièrement le contrôle et l’entretien de l’installation.

l Maintenir soigneusement fermés les portes et les panneaux des

sources de haute fréquence, maintenir les éclateurs à une dis-

tance correcte et utiliser une terre et un blindage pour réduire les

interférences éventuelles.

LE SOUDAGE À L’ARC risque de

provoquer des interférences.

l L’énergie électromagnétique risque de provoquer

des interférences pour l’équipement électronique

sensible tel que les ordinateurs et l’équipement

commandé par ordinateur tel que les robots.

l Veiller à ce que tout l’équipement de la zone de soudage soit

compatible électromagnétiquement.

l Pour réduire la possibilité d’interférence, maintenir les câbles de

soudage aussi courts que possible, les grouper, et les poser aussi

bas que possible (ex. par terre).

l Veiller à souder à une distance de 100 mètres de tout équipement

électronique sensible.

l Veiller à ce que ce poste de soudage soit posé et mis à la terre

conformément à ce mode d’emploi.

l En cas d’interférences après avoir pris les mesures précédentes,

il incombe à l’utilisateur de prendre des mesures supplémentaires

telles que le déplacement du poste, l’utilisation de câbles blindés,

l’utilisation de filtres de ligne ou la pose de protecteurs dans la

zone de travail.

2-6. Proposition californienne 65 Avertissements

AVERTISSEMENT – ce produit peut vous exposer à des pro-

duits chimiques tels que le plomb, reconnus par l’État de

Californie comme cancérigènes et sources de malforma-

tions ou d’autres troubles de la reproduction.

Pour plus d’informations, consulter www.P65Warnings.ca.gov.

Pour les moteurs diesel :

AVERTISSEMENT – les gaz d’échappement de moteurs die-

sel vous exposent à des produits chimiques, reconnus par

l’État de Californie comme cancérigènes et sources de mal-

formations ou d’autres troubles de la reproduction.

ll Toujours démarrer et faire tourner le moteur dans une

zone bien aérée.

ll Si la zone est fermée, diriger l’échappement vers

l’extérieur.

ll Ne pas modifier ni altérer le système d’échappement.

ll Ne pas faire tourner le moteur au ralenti, sauf si

nécessaire.

Pour plus d’informations, consulter www.P65Warnings.ca.gov/diesel.

2-7. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, American Welding

Society standard ANSI Standard Z49.1. Website: http://www.aws.org.

Safe Practices for the Preparation of Containers and Piping for Weld-

ing and Cutting, American Welding Society Standard AWS F4.1 from

Global Engineering Documents. Website: www.global.ihs.com.

Safe Practices for Welding and Cutting Containers that have Held

Combustibles, American Welding Society Standard AWS A6.0 from

Global Engineering Documents. Website: www.global.ihs.com.

National Electrical Code, NFPA Standard 70 from National Fire Pro-

tection Association. Website: www.nfpa.org and www.sparky.org.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-

1 from Compressed Gas Association. Website: www.cganet.com.

Safety in Welding, Cutting, and Allied Processes, CSA Standard

W117.2 from Canadian Standards Association. Website: www.

csagroup.org.

Battery Chargers, CSA Standard C22.2 NO 107.2-01 from Canadian

Standards Association. Website: www.csagroup.org.

Safe Practice For Occupational And Educational Eye And Face Pro-

tection, ANSI Standard Z87.1, from American National Standards In-

stitute. Website: www.ansi.org.

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work, NFPA Standard 51B from National Fire Protection Association.

Website: www.nfpa.org.

OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Sub-

part N, Part 1910 Subpart Q, and Part 1926, Subpart J. Website:

www.osha.gov.

OSHA Important Note Regarding the ACGIH TLV, Policy Statement

on the Uses of TLVs and BEIs. Website: www.osha.gov.

Portable Generator Hazards Safety Alert from U.S. Consumer Prod-

uct Safety Commission (CPSC). Website: www.cpsc.gov.

Applications Manual for the Revised NIOSH Lifting Equation from the

National Institute for Occupational Safety and Health (NIOSH). Web-

site: www.cdc.gov/NIOSH.

For Standards regulating hydraulic systems, contact the National Flu-

id Power Association. Website: www.nfpa.com.

Battery Service Manual from the Battery Council International. Web-

site: www.batterycouncil.org.

ROM_fre 2020–02

Page is loading ...

OM-286503 Page 16

F

Complete Parts List is available at www.MillerWelds.com

SECTION 3 – DEFINITIONS

3-1. Additional Safety Symbol Definitions

F

Some symbols are found only on CE products.

Warning! Watch Out! There are possible hazards as shown by the

symbols.

OM-

Become trained and read the instructions before working on the

machine or heating.

Safe85 2012 06

Connect green or green/yellow grounding conductor to ground

terminal.

Connect input conductors (L1, L2 And L3) to line terminals.

Safe86 2012 06

Never use generator inside a home or garage, even if doors and win-

dows are open.

Safe87 2012 07

Only use generator outside and far away from windows, doors, and

vents.

Safe88 2012 07

Do not use ether or other starting fluids. Using starting fluids voids warranty. See engine Owner’s Manual.

Safe89 2017 04

Hot muffler and exhaust pipe can cause severe burns.

Safe90 2017 04

Welding, cutting, drilling, or grinding on base can cause fire or explosion.

Safe91 2017 04

Do not spray water on CST units.

Safe92 2017 04

Door must be fully open during operation.

Safe93 2012 08

Drive rolls can injure fingers. Welding wire and drive parts are at welding voltage during operation keep hands

and metal objects away.

Safe95 2012 05

Never use generator inside a home or garage, even if doors and win-

dows are open.

OM-

Become trained and read the instructions before working on the

machine or heating.

Safe85 2012 06

Connect green or green/yellow grounding conductor to ground

terminal.

Connect input conductors (L1, L2 And L3) to line terminals.

Safe86 2012 06

Never use generator inside a home or garage, even if doors and win-

dows are open.

Safe87 2012 07

Only use generator outside and far away from windows, doors, and

vents.

Safe88 2012 07

Do not use ether or other starting fluids. Using starting fluids voids warranty. See engine Owner’s Manual.

Safe89 2017 04

Hot muffler and exhaust pipe can cause severe burns.

Safe90 2017 04

Welding, cutting, drilling, or grinding on base can cause fire or explosion.

Safe91 2017 04

Do not spray water on CST units.

Safe92 2017 04

Door must be fully open during operation.

Safe93 2012 08

Drive rolls can injure fingers. Welding wire and drive parts are at welding voltage during operation keep hands

and metal objects away.

Safe95 2012 05

Only use generator outside and far away from windows, doors, and

vents.

3-2. Miscellaneous Symbol Definitions

Amperage

Voltage

Seconds

Rated No-Load

Voltage (OCV)

Conventional Load

Voltage

Rated Welding

Current

Hours

Duty Cycle

Negative

Positive

Direct Current (DC)

Alternating Current

(AC)

Protective Earth

(Ground)

Output

Work Connection

Engine Temperature

Circuit Breaker

Supplementary

Protector

Clock

Engine Choke

Engine Start

(Engine RPM)

Engine Stop

Idle (Slow)

Run (Fast)

Engine

Air Filter

Battery (Engine)

Fuel

Engine Oil

Check Valve

Clearance

Call for

Maintenance

Read Operator’s

Manual

Engine-Driven

Generator with

Rectifier

Do Not Switch

While Welding

OM-286503 Page 17

F

Complete Parts List is available at www.MillerWelds.com

Shielded Metal Arc

Welding (SMAW)

Gas Metal Arc

Welding (GMAW)

Welding

Gas Tungsten Arc

Welding (GTAW) /

Tungsten Inert Gas

(TIG) Welding

Single Phase

Alternator

Hertz

Single Phase

OM-286503 Page 18

F

Complete Parts List is available at www.MillerWelds.com

SECTION 4 – SPECIFICATIONS

4-1. Serial Number And Rating Label Location

The serial number for this product is located on the front. The rating information for this product is located on the back. Use rating label to deter-

mine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual.

4-2. Weld, Power, And Engine Specifications

F

This equipment will deliver rated output at an ambient air temperature up to 104°F (40°C).

Welding Mode

Weld Output

Range

Rated Welding

Output

Maximum Open-

Circuit Voltage

Generator Power

Rating

Fuel Capacity Engine

CC/AC 60 - 160 A

150 A, 25 V,

100% Duty Cycle

80

Peak: 11.0 kVA/kW

Continuous: 9.5 kVA/

kW Single-Phase 80/

40 A, 120/240 VAC 60

Hz (while not welding)

12 gal (45 L)

Tank

Kohler CH730

Air-Cooled,

Two-Cylinder,

Four-Cycle,

23.5 HP Gaso-

line Engine

CC/DC 40 - 225 A

225 A, 25 V,

100% Duty Cycle

80

CV/DC 19 - 28 V

200 A, 20 V,

100% Duty Cycle

33

4-3. Environmental Specifications

A. Temperature Specifications

Operating Temperature Range* Storage/Transportation Temperature Range

–20 to 104°F (–29 to 40°C) –40 to 131°F (–40 to 55°C)

*Output is derated at temperatures above 104°F (40°C).

4-4. Regulatory Approval

This device complies with Part 15 of the FCC rules. Operation is subject to the following conditions:

1. This device may not cause harmful interference, and

2. This device may accept any interference received, including interference that may cause undesired operation.

WARNING! Changes or modifications not expressly approved by the party responsible for compliance could void the user’s authority to operate

this device.

Reception of the fob and receiver signal can be affected by the weather, environment, and/or area conditions.

OM-286503 Page 19

F

Complete Parts List is available at www.MillerWelds.com

4-5. Dimensions, Weights, And Operating Angles

 Complete Parts List available at www.MillerWelds.com

OM-2  503 Page 1

20°

251959-A

Do not exceed tilt angles or engine

could be damaged or unit could tip.

Do not move or operate unit where it

could tip.

Weight: 585 lb (266 kg) w/fuel

510 lb (232 kg) w/o fuel

Lifting Eye Weight Rating: 1280 lb (580 kg)



Complete Parts List available at www.MillerWelds.com

OM-2  503 Page 1

20

°

20

°

20

°

20

°

251959-A

Support Assembly Dimensions



Complete Parts List available at www.MillerWelds.com

OM-2  503 Page 1

20

°

20

°

20

°

20

°

251959-A

OM-286503 Page 20

F

Complete Parts List is available at www.MillerWelds.com

4-6. Duty Cycle And Overheating

 Complete Parts List available at www.MillerWelds.com

OM-2  503 Page 1

253770-A

Duty cycle is the percentage of 10 minutes

that unit can weld at rated load without

overheating.

NOTICE – Exceeding duty cycle can dam-

age unit and void warranty.

4-7. Fuel Consumption



Complete Parts List available at www.MillerWelds.com

OM-286503 Page 1

250314

Weld Amperes At 100% Duty Cycle

0

Power KVA At 100% Duty Cycle

U.S. Gal/Hr

Liters/Hr

25 50 75 100 125 150 175 200 225 250

0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0

0

0.95 0.25

1.89 0.50

2.84 0.75

3.78 1.00

4.73 1.25

5.67 1.50

6.62 1.75

7.57 2.00

WELD

IDLE 2400

AUX POWER

On a typical job using 1/8 in. 7018 electrodes

(125 amps, 20% duty cycle), expect about

20 hours of operation (22 hours with EFI

engine).

Welding at 150 amps at 40% duty cycle uses

approximately 3/4 gallon per hour. Expect

about 16 hours of operation with carbureted

engine.

OM-286503 Page 21

F

Complete Parts List is available at www.MillerWelds.com

4-8. Generator Power Curve

 Complete Parts List available at www.MillerWelds.com

OM-286503 Page 1

253767-A

0

50

100

150

200

250

300

0 20 40 60 80 100

AC VOLTS

AC AMPS

The generator power curve shows the gener-

ator power in amperes available at the

receptacles.

OM-286503 Page 22

F

Complete Parts List is available at www.MillerWelds.com

4-9. Volt-Ampere Curves

CC/AC Mode

 Complete Parts List available at www.MillerWelds.com

OM-286503 Page 1

253767-B

0

10

20

30

40

50

60

70

80

0 50 100 150 200 250

0

10

20

30

40

50

60

70

80

0 50 100 150 200 250 300 350 400

0

10

20

30

40

0 100 200 300 400 500 600 700 800

MIN

MAX

VOLTS

AMPS

VOLTS

AMPS

VOLTS

AMPS

MIN

MAX

A

B

C

RANGES

A = 80 225

B = 50 150

C = 40 110

CC/DC Mode



Complete Parts List available at www.MillerWelds.com

OM-286503 Page 1

253767-B

0

10

20

30

40

50

60

70

80

0 50 100 150 200 250

0

10

20

30

40

50

60

70

80

0 50 100 150 200 250 300 350 400

0

10

20

30

40

0 100 200 300 400 500 600 700 800

MIN

MAX

VOLTS

AMPS

VOLTS

AMPS

VOLTS

AMPS

MIN

MAX

A

B

C

RANGES

A = 80 225

B = 50 150

C = 40 110

CV/DC Mode

 Complete Parts List available at www.MillerWelds.com

OM-286503 Page 1

253767-B

0

10

20

30

40

50

60

70

80

0 50 100 150 200 250

0

10

20

30

40

50

60

70

80

0 50 100 150 200 250 300 350 400

0

10

20

30

40

0 100 200 300 400 500 600 700 800

MIN

MAX

VOLTS

AMPS

VOLTS

AMPS

VOLTS

AMPS

MIN

MAX

A

B

C

RANGES

A = 80 225

B = 50 150

C = 40 110

The volt-ampere curve shows the minimum

and maximum voltage and amperage output

capabilities of the welding generator. Curves

of all other settings fall between the curves

shown.

OM-286503 Page 23

F

Complete Parts List is available at www.MillerWelds.com

SECTION 5 – INSTALLATION

5-1. Installing Welder/Generator

Movement

OM-4410 Page 1

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

1-1. Installing Welder/Generator

1

Location/Airflow Clearance



Complete Parts List available at www.MillerWelds.com

OM-249336 Page 14

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

Mounting

OM-4410 Page 1

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

1-1. Installing Welder/Generator

1

Do not move or operate unit where

it could tip.

Do not lift unit from end.

Do not weld on base. Welding on

base can cause fuel tank fire or ex-

plosion. 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.

NOTICE – Do not install unit where airflow is

restricted or engine may overheat.

F

See Specifications for lifting eye rating.

Mounting:

Do not mount unit by supporting

the base only at the four mounting

holes. Do not use flexible mounts.

Use cross-supports to adequately

support unit and prevent damage

to base.

1 Cross-Supports

Mount unit on flat surface or use cross-sup-

ports to support base.

F

Go to MillerWelds. com for more infor-

mation on truck installations.

OM-286503 Page 24

F

Complete Parts List is available at www.MillerWelds.com

5-2. Grounding Generator to Truck or Trailer Frame

OM-236 948 Page 1

1-1. Grounding Generator To Truck Or Trailer Frame

1

3

2

GND/PE

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.

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.

Use GFCI protection when operating

auxiliary equipment. If unit does not

have GFCI receptacles, use GFCI-

protected extension cord. Do not

use GFCI receptacles to power life

support equipment.

1 Equipment Grounding Terminal (On

Front Panel)

2 Grounding Cable (Not Supplied)

3 Metal Vehicle Frame

Connect cable from equipment ground ter-

minal to metal vehicle frame. Use #8 AWG

or larger insulated copper wire.

F

Electrically bond generator frame to

vehicle frame by metal-to-metal

contact.

5-3. Installing Exhaust Pipe



Complete Parts List available at www.MillerWelds.com

OM-249336 Page 5

253857-A

OM-222 Page 1

allen_wrench

NGO’s

tools/

flathead philips head wrench

pliers

knife

heavy-duty workclamp light-duty workclamp wirecutter frontcutter

allen_set

needlenose

steelbrush nutdriver

chippinghammer

solderiron

stripcrimp

drill

torque wrench

socket wrench

hammer awl file

crimper

paintbrush

feelergauge flashlight ruler

toothbrush

greasegun

qtip (swab)

vicegrip

handream

punch

filterwrench

strapwrench

airgun

solvent pinextractor eprompuller pipewrench

torque screwdriver

crescent wrench

1/2 in.

Stop engine and let cool.

Engine backfire can cause severe

burns or other injuries. Do not

point exhaust pipe toward control

panel. Keep away from exhaust

outlet.

Do not point exhaust pipe toward

LP fuel tank (if equipped). Do not

point exhaust pipe towards shield-

ing gas tank (if equipped).

Point exhaust pipe in desired di-

rection but always away from front

panel and direction of travel.

OM-286503 Page 25

F

Complete Parts List is available at www.MillerWelds.com

5-4. Engine Prestart Checks

Check all fluids daily. Engine must be cold

and on a level surface. Unit is shipped with

10W30 engine oil.

F

Follow run-in procedure in engine

manual.

F

This unit has a low oil pressure shut-

down switch. However, some conditions

may cause engine damage before the

engine shuts down. Check oil level

often and do not use the oil pressure

shutdown system to monitor oil level.



Complete Parts List available at www.MillerWelds.com

OM-249336 Page 6

250916-A

0

1/2

1

H

0000

1

2

3

4

5

Fuel

1 Expansion Space

2 Gasoline

3 Full

Open left side access door.

NOTICE – Engine flooding may occur if fuel

level is above Max Fill Level on tank.

Add fresh fuel before starting engine the first

time (see maintenance label for specifica-

tions). Stop fueling when fuel level reaches

Max Fill Level on tank. Do not top off tank. Al-

ways leave room for expansion. Check fuel

level on a cold engine before use each day.

Close left side access door. Open top service

door.

 Complete Parts List available at www.MillerWelds.com

OM-249336 Page 6

250916-A

0

1/2

1

H

0000

1

2

3

4

5

Oil

4 Oil Fill

5 Oil Check

F

Do not exceed the "Full" mark on the oil

level dipstick. The fuel pump may oper-

ate erratically if crankcase is overfilled.

After fueling, check oil with unit on level sur-

face. If oil is not up to full mark on dipstick,

add oil (see maintenance label).

Use fuel/hourmeter to determine hours until

next recommended oil change (see Front

Panel Controls).

F

To improve cold weather starting:

Keep battery in good condition.

Store battery in warm area.

Use correct grade oil for cold weather.

Close top service door.

OM-286503 Page 26

F

Complete Parts List is available at www.MillerWelds.com

5-5. Connecting Or Replacing The Battery



Complete Parts List available at www.MillerWelds.com

OM-249336 Page 7

250916-A

+

1

OM-222 Page 1

allen_wrench

NGO’s

tools/

flathead philips head wrench

pliers

knife

heavy-duty workclamp light-duty workclamp wirecutter frontcutter

allen_set

needlenose

steelbrush nutdriver

chippinghammer

solderiron

stripcrimp

drill

torque wrench

socket wrench

hammer awl file

crimper

paintbrush

feelergauge flashlight ruler

toothbrush

greasegun

qtip (swab)

vicegrip

handream

punch

filterwrench

strapwrench

airgun

solvent pinextractor eprompuller pipewrench

torque screwdriver

crescent wrench

1/2 in.

Connect negative (-) battery cable

last.

Battery is most easily accessed through the

side door. Connect battery, negative cable

last. Close access door.

l Do not allow the battery cables to touch

opposing terminals. When connecting

the battery cables attach the positive (+)

cable to the positive (+) battery terminal

first, followed by negative (-) cable to

negative (-) battery terminal.

l Never start the engine when the cables

are loose or poorly connected to the bat-

tery terminals.

l Never disconnect the battery while the

engine is running.

l Never use a quick battery charger to

start the engine.

l Do not charge battery with Engine Con-

trol switch On.

l Always disconnect the negative (-) bat-

tery cable before charging battery.

1 Battery Holddown

To change battery, remove rear panel with

baffle and battery holddown.

Be sure battery cables and fuel tank vent

hose are not pinched when installing battery

and replacing rear panel.

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