Miller KF970957 Owner's manual

KF970957
Miller
Brand
Miller
Model
KF970957
Category
Welding System
Type
Owner's manual

This manual is also suitable for

Miller
March
1
996
Form:
OM-173413A
Effective
With
Serial
No.
KF970957
OWNERS
MANUAL
CE
Big
Bluefi
401
DXQ
CCIDC
Welding
Generator
For
SMAW
And
GTAW
Welding
Rated
Welding
Output
Amperage
Range
Maximum
Open-
Circuit
Voltage
DC
Auxiliary
Power
Rating
Engine
Fuel
Capacity
Sound
Power
IP
Rating
250
A,
30
V
DC,
100%
Duty
Cycle
325
A,
33
V
DC,
60%
Duty
Cycle
40
400
95
Single-Phase,
3
kVA/kW,
13/13
A,
120/240
V
AC,
60
Hz
Deutz
F3L-1011
Air/Oil-Cooled,
Three-Cylinder,
29
HP
Diesel
Engine
11.3
US
gal
(42.8
L)
100
Lwa
23
cover_om
4/95
-
ST-801
133-A
'
1996
MILLER
Electric
MIg.
Co.
PRINTED
IN
USA
I
LIMITED
WARRANTY
Subject
to
the
terms
and
conditions
below,
MILLER
Electric
Mtg.
Co.,
Appleton,
Wisconsin,
warrants
to
its
original
retail
purchaser
that
new
MILLER
equipment
sold
after
the
ettective
date
ot
this
limited
warranty
is
tree
ot
de
tects
in
material
and
workmanship
at
the
time
it
is
shipped
by
MILLER.
THIS
WAR
RANTY
IS
EXPRESSLY
IN
LIEU
OF
ALL
OTHER
WARRANTIES,
EXPRESS
OR
IMPLIED,
INCLUDING
THE
WARRANTIES
OF
MERCHANTABILITY
AND
FIT
NESS.
Within
the
warranty
periods
listed
below,
MILLER
will
repair
or
replace
any
war
ranted
parts
or
components
that
tail
due
to
such
detects
in
material
or
workmanship.
MILLER
must
be
notitied
in
writing
within
thirty
(30)
days
ot
such
detect
or
tailure,
at
which
time
MILLER
will
provide
instructions
on
the
werranty
clsim
procedures
to
be
totlowed.
MILLER
shall
honor
warranty
claims
on
warranted
equipment
listed
below
in
the
event
ot
such
a
tailure
within
the
warranty
time
periods.
All
warranty
time
periods
start
on
the
date
that
the
equipment
was
delivered
to
the
original
retell
purchsser,
or
one
year
after
the
equipment
is
sent
to
a
North
Americsn
distributor
or
eighteen
months
sher
the
equipment
is
sent
to
an
International
distributor.
1.
SYesrsPerts3YesrsLabor
Originsl
main
power
rectttiers
Inverters
jinput
and
output
rectitiers
only)
2.
3
Years
Parts
and
Lsbor
Trsnstormer/Rectitier
Power
Sources
Plasma
Arc
Cutting
Power
Sources
Semi-Automatic
and
Automatic
Wire
Feeders
Inverter
Power
Supplies
Intellitig
*
Robots
(1
year
labor)
3.
2
Years
Parts
and
Labor
Engine
Driven
Welding
Generators
(NOTE:
Engines
are
warmnted
separately
by
the
engine
manutacturer.)
Air
Compressors
4.
1
Year
Parts
and
Labor
Motor
Driven
Guns
Process
Controllers
IHPS
Power
Sources
Wster
Coolant
Systems
HF
Units
Grids
Spot
Welders
Load
Banks
SDX
Trenstormers
Miller
Cyclometic
Equipment
Running
Gear/Trailers
Plasma
Cutting
Torches
(escept
APT,
ZIPCUT
&
PLAZCUT
Models)
Tecumseh
Engines
Deutz
Engines
(outside
North
America)
-
Field
Options
(NOTE:
Field
options
are
covered
under
True
Bluefi
tor
the
remaining
warranty
period
ot
the
product
they
are
installed
in,
or
tor
a
minimum
ot
one
year
whichever
is
greater.)
5.
6
Months
Batteries
6.
go
Days
Parts
and
Labor
MIG
Guns/TIG
Torches
APT,
ZIPCUT
&
PLAZCUT
Model
Plasma
Cutting
Torches
Remote
Controls
Accessory
Kits
*
Replacement
Parts
MILLERS
True
Bluefi
Limited
Warranty
shall
not
apply
to:
t.
Items
turnished
by
MILLER,
but
msnutectured
by
others,
such
as
engines
or
trade
accessories.
These
items
are
covered
by
the
manutacturers
wsrranty,
it
any.
2.
Consumable
components;
such
as
contact
tips,
cutting
nozzles,
contactors
and
relays
or
parts
that
tail
due
to
norrssl
wear.
3.
Equipment
that
hss
been
moditied
by
any
party
other
than
MILLER,
or
equip
ment
that
hss
been
improperly
installed,
improperly
operated
or
misused
based
upon
industry
standards,
or
equipment
which
has
not
had
reasonable
end
necessary
maintenance,
or
equipment
which
has
been
used
tor
operation
outside
ot
the
speciticetions
tor
the
equipment.
MILLER
PRODUCTS
ARE
INTENDED
FOR
PURCHASE
AND
USE
BYCOMMER
CIAL/INDUSTRIAL
USERS
AND PERSONS
TRAINED
AND
EXPERIENCED
IN
THE USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT.
In
the
event
ot
a
warranty
claim
covered
by
this
werrsnty,
the
esclusive
remedies
shalt
be,
at
MILLERS
option:
(1)
repair;
or
(2)
replacement;
or,
where
authorized
in
writing
by
MILLER
in
eppropriste
ceses,
(3)
the
reasonable
cost
ot
repair
or
replace
ment
at
an
authorized
MILLER
service
station;
or
(4)
payment
ot
or
credit
br
the
pur
chase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
retum
ot
the
goods
at
customers
risk
and
expense.
MILLERS
option
ot
repeir
or
replacement
will
be
FOB.,
Fectory
at
Appleton,
Wisconsin,
or
FOB.
at
a
MILLER
authorized
ser
vice
tacility
as
determined
by
MILLER.
Theretore
no
compensation
or
reimburse
ment
tor
transportation
costs
ot
any
kind
will
be
allowed.
TO
THE
EXTENT
PERMITTED
BY
LAW,
THE
REMEDIES
PROVIDED
HEREIN
ARE
THE
SOLE
AND
EXCLUSIVE
REMEDIES.
IN
NO
EVENT
SHALL
MILLER
BE
LIABLE
FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL
DAMAGES
(INCLUDING
LOSS
OF
PROFIT),
WHETHER
BASED
ON
CON
TRACT,
TORT
OR
ANY
OTHER
LEGAL
THEORY.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPLIED
WAR
RANTY,
GUARANTY
OR
REPRESENTATION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
TORT
OR
ANY
OTHER
LEGAL
THEORY
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATtON,
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
IN
CLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
Some
ststes
in
the
U.S.A.
do
not
allow
limitations
ot
how
tong
en
implied
warranty
lasts,
or
the
exclusion
ot
incidentet,
indirect,
special
or
consequential
damages,
so
the
above
limitation
or
exclusion
may
not
apply
to
you.
This
warranty
provides
spe
citic
legal
rights,
end
other
rights
may
be
available,
but
may
vary
trom
state
to
state.
In
Canada,
legislation
in
some
provinces
provides
tor
certain
sdditionel
warranties
or
remedies
other
then
as
stated
herein,
and
to
the
extent
that
they
may
not
be
waived,
the
limitations
end
exclusions
set
out
above
may
not
apply.
This
Limited
Warranty
provides
specitic
legal
rights,
and
other
rights
may
be
available,
but
may
very
trom
province
to
province.
WHO
DO
I
CONTACT?
For
help,
To
file
a
claim
for
loss
or
damage
during
Miller
Electric
Mfg.
Co.
Contact
your
distributor
For
additional
information,
such
as
Technical
Manuals
(Service
And
Parts)
Engine
Manuals
Circuit
And
Wiring
Diagrams
shipment,
U
contact
the
delivering
carrier
For
assistance
in
filing
or
settling
claims,
contact
your
distributor
and/or
equipment
manufacturers
Transportation
Department
1~jjj5~
TL~1]
CALL:
414-735-4505
FAX:
800-637-2348
(in
USA),
or
414-735-4136
(outside
USA)
Process
Handbooks
Users
Guides
Djstributor
Directories
.
O~
WRITE:
Miller
Electric
Mfg.
Co.
contact
your
distributor
RO.
BOX
1079
Appleton,
WI
54912
USA
Always
provide
Model
Name
and
Serial
or
Style
Number
~.
1!
MILLERS
TRUE
BLUEfi
LIMITED
WARRANTY
Effective
February
7,
1996
(Equipment
with
a
serial
number
preface
of
KD
or
newer)
This
limited
warranty
supersedes
alt
previous
MILLER
werrsnties
end
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
iN
miller_wan
3/96
Declaration
of
Conformity
for
European
Community
(CE)
Products
N
OTE
~
This
in
formation
is
provided
for
units
with
CE
certification
(see
rating
label
on
unit).
Manufacturers
Name:
Miller
Electric
Mfg.
Co.
Manufacturers
Address:
1635
W.
Spencer
Street
Appleton,
WI
54914
USA
Declares
that
the
product:
Big
BI
ueTM
401
DXQ
con
forms
to
the
following
Directives
and
Standards:
Directives
Low
Voltage
Directive:
73/23/EEC
Machinery
Directives:
89/392/EEC,91
/368/EEC,
93/C
133/04,
93/68/EEC
Noise
Emission
Directive:
79/113/EEC
Noise
level
of
Welding
Generators:
84/535/EEC
Standards
Safety
Requirements
for
Arc
Welding
Equipment
Part
1:
EN
60974-1:
1990
Rotating
Electrical
Machines
Part
1:
Rating
and
Performance:
IEC
34-1:
1994
Rotating
Electrical
Machines
Part
5:
Classification
of
degrees
of
protection
provided
by
enclosure
of
rotating
electrical
machines
(IP
code):
IEC
34-5:
1991
Insulation
coordination
for
equipment
within
low-voltage
systems:
Part
1:
Principles,
requirements
and
test:
IEC
664-1:
1992
European
Contact:
Mr.
Luigi
Vacchini,
Managing
Director
MILLER
Europe
S.P.A.
Via
Privata
Iseo
20098
San
Giuliano
Milanese,
Italy
Telephone:
39(02)98290-1
Fax:
39(02)98281-552
dec_con
1
1/96
TABLE
OF
CONTENTS
SECTION
1
SAFETY
PRECAUTIONS
FOR
ARC
WELDING
1
1-1.
Symbol
Usage
1
1-2.
Arc
Welding
Hazards
1
1-3.
Engine
Hazards
2
1-4.
Additional
Installation,
Operation,
And
Maintenance
Hazards
3
1-5.
Principal
Safety
Standards
3
1-6.
EMF
Information
3
SECTION
2
DEFINITIONS
4
2-1.
Warning
Label
Definitions
4
2-2.
Manufacturers
Rating
Label
For
CE
Products
7
2-3.
Symbols
And
Definitions
8
SECTION
3-INSTALLATION
9
3-1.
Installing
Welding
Generator
9
3-2.
Dimensions,
Weights,
And
Operating
Angles
9
3-3.
Fuel
Consumption
10
3-4.
Activating
The
Dry
Charge
Battery
11
3-5.
Connecting
The
Battery
12
3-6.
Engine
Prestart
Checks
12
3-7.
Installing
Muffler
Pipe
13
3-8.
Weld
Output
Terminals
And
Selecting
Cable
Sizes
13
SECTION
4OPERATING
THE
WELDING
GENERATOR
14
4-1.
Duty
Cycle
And
Overheating
14
4-2.
Front
Panel
Controls
15
4-3.
Manual
Shutoff
Lever
16
4-4.
Remote
NV
Control
(Optional)
16
SECTION
5OPERATING
AUXILIARY
EQUIPMENT
17
5-1.
Auxiliary
Power
Receptacles
17
5-2.
Optional
British,
South
African,
And
Australian
Receptacles
18
SECTION
6-
MAINTENANCE
&
TROUBLESHOOTING
19
6-1.
Routine
Maintenance
19
6-2.
Maintenance
Label
20
6-3.
Servicing
Air
Cleaner
21
6-4.
Oil
And
Fuel
System
Components
22
6-5.
Adjusting
Engine
Speed
23
6-6.
Overload
Protection
24
6-7.
Optional
Spark
Arrestor
Inspection
And
Cleaning
24
6-8.
Troubleshooting
25
SECTION
7
ELECTRICAL
DIAGRAM
27
SECTION
8
RUN-IN
PROCEDURE
28
8-1.
Wetstacking
28
8-2.
Run-In
Procedure
Using
Load
Bank
29
8-3.
Run-In
Procedure
Using
Resistance
Grid
30
SECTION
9-
PARTS
LIST
32
OM-173
413-A
3196
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.
1.
Protect
compressed
gas
cylinders
from
excessive
heat,
mechanical
shocks,
slag,
open
flames,
sparks,
and
arcs.
2.
Install
cylinders
in
an
upright
position
by
securing
to
a
stationary
support
or
cylinder
rack
to
prevent
falling
or
tipping.
3.
Keep
cylinders
away
from
any
welding
or
other
electrical
circuits.
4.
Never
drape
a
welding
torch
over
a
gas
cylinder.
5.
Never
allow
a
welding
electrode
to
touch
any
cylinder.
6.
Never
weld
on
a
pressurized
cylinder
explosion
will
result.
7.
Use
only
correct
shielding
gas
cylinders,
regulators,
hoses,
and
fittings
designed
for
the
specific
application;
maintain
them
and
associated
parts
in
good
condition.
8.
Turn
face
away
from
valve
outlet
when
opening
cylinder
valve.
9.
Keep
protective
cap
in
place
over
valve
except
when
cylinder
is
in
use
or
connected
for
use.
10.
Read
and
follow
instructions
on
compressed
gas
cylinders,
associated
equipment,
and
CGA
publication
P-i
listed
in
Safety
Standards.
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.
1.
Protect
yourself
and
others
from
flying
sparks
and
hot
metal.
2.
Do
not
weld
where
flying
sparks
can
strike
flammable
material.
3.
Remove
all
flammables
within
35
ft
(10.7
m)
of
the
welding
arc.
If
this
is
not
possible,
tightly
cover
them
with
approved
covers.
4.
Be
alert
that
welding
sparks
and
hot
materials
from
welding
can
easily
go
through
small
cracks
and
openings
to
adjacent
areas.
5.
Watch
for
fire,
and
keep
a
fire
extinguisher
nearby.
6.
Be
aware
that
welding
on
a
ceiling,
floor,
bulkhead,
or
partition
can
cause
fire
on
the
hidden
side.
7.
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).
8.
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.
9.
Do
not
use
welder
to
thaw
frozen
pipes.
10.
Remove
stick
electrode
from
holder
or
cut
off
welding
wire
at
contact
tip
when
not
in
use.
ii.
Wear
oil-free
protective
garments
such
as
leather
gloves,
heavy
shirt,
cuffless
trousers,
high
shoes,
and
a
cap.
12.
Remove
any
combustibles,
such
as
a
butane
lighter
or
matches,
from
your
person
before
doing
any
welding.
1-3.
Engine
Hazards
ENGINE
EXHAUST
GASES
can
kill.
1.
Use
equipment
outside
in
open,
well-ventilated
areas.
Engines
produce
harmful
exhaust
gases.
2.
If
used
in
a
closed
area,
vent
engine
exhaust
outside
and
away
from
any
building
air
intakes.
ENGINE
FUEL
can
cause
fire
or
2.
Do
not
add
fuel
while
smoking
or
if
unit
is
near
any
sparks
or
explosion,
Engine
fuel
is
highly
flammable.
3.
open
flames.
Do
not
overfill
tank
allow
room
for
fuel
to
expand.
1.
Always
wear
a
face
shield
when
working
on
a
battery.
2.
Stop
engine
before
disconnecting
or
connecting
battery
cables.
3.
Do
not
allow
tools
to
cause
sparks
when
working
on
a
battery.
4.
Do
not
use
welder
to
charge
batteries
or
jump
start
vehicles.
5.
Observe
correct
polarity
(+
and
)
on
batteries.
STEAM
AND
PRESSURIZED
HOT
1.
If
the
engine
is
warm
and
checking
is
needed,
follow
steps
2
COOLANT
can
burn
face,
eyes,
and
and
3.
skin.
2.
Wear
safety
glasses
and
gloves
and
put
a
rag
over
cap.
It
is
best
to
check
coolant
level
when
engine
is
3.
Turn
cap
slightly
and
let
pressure
escape
slowly
before
cold
to
avoid
scalding.
completely
removing
cap.
£~
WARNING
A
I
1.
Stop
engine
and
let
it
cool
off
before
checking
or
adding
fuel.
4.
Do
not
spill
fuel.
If
fuel
is
spilled,
clean
up
before
starting
engine.
1.
MOVING
PARTS
can
cause
injury.
Moving
parts,
such
as
fans,
rotors,
and
belts
can
cut
fingers
and
hands
and
catch loose
clothing.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.
3.
4.
5.
6.
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
2.
Stop
engine
before
installing
or
connecting
unit.
finished
and
before
starting
engine.
SPARKS
can
cause
BATTERY
GASES
TO
EXPLODE;
BATTERY
ACID
can
burn
eyes
and
skin.
Batteries
contain
acid
and
generate
explosive
gases.
OM-173
413
Page
2
1-4.
Additional
Installation,
Operation,
And
Maintenance
Hazards
MOVING
PARTS
can
cause
injury.
1.
Before
working
of
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.
FLYING
PIECES
OF
METAL
or
DIRT
can
injure
eyes.
1.
Wear
safety
glasses
with
side
shields
or
tace
shield.
STATIC
ELECTRICITY
can
damage
parts
on
circuit
boards.
1.
Put
on
grounded
wrist
strap
BEFORE
handling
boards
or
parts.
2.
Use
proper
static-proof
bags
and
boxes
to
store,
move,
or
ship
PC
boards.
MAGNETIC
FIELDS
FROM
HIGH
CURRENTS
can
affect
pacemaker
operation.
1.
Pacemaker
wearers
keep
away.
2.
Wearers
should
consult
their
doctor
before
going
near
arc
welding,
gouging,
or
spot
welding
operations.
HOT
PARTS
can
cause
severe
burns.
1.
.Allow
cooling
period
before
maintaining.
2.
Wear
protective
gloves
and
clothing
when
working
on
a
hot
engine.
FALLING
EQUIPMENT
can
cause
serious
personal
injury
and
equipment
damage.
1.
Use
lifting
eye
to
lift
unit
only,
NOT
running
gear,
gas
cylinders,
or
any
other
accessories.
Use
equipment
of
adequate
capacity
to
lift
unit.
£~
WARNING
READ
INSTRUCTIONS.
1.
Use
only
genuine
MILLER
replacement
parts.
2.
Reinstall
injectors
and
bleed
air
from
fuel
system
according
to
engine
manual.
DO
NOT
LET
ENGINE
EXHAUST
SPARKS
CAUSE
FIRE.
1.
Use
approved
engine
exhaust
spark
arrestor
in
required
areas
see
applicable
codes.
cff
~1J
LOW
VOLTAGE
AND
FREQUENCY CAN
DAMAGE
electrical
equipment
such
as
MOTORS.
1.
Turn
off
or
unplug
equipment
before
starting
or
stopping
engine.
I
~
I I
OVERUSE
can
cause
OVERHEATED
EQUIPMENT.
1.
Allow
cooling
period.
2.
Reduce
current
or
reduce
duty
cycle
before
starting
to
weld
again.
3.
Follow
rated
duty
cycle.
~I
TILTING
OF
TRAILER
can
cause
injury.
1.
Use
tongue
jack
or
blocks
to
support
weight.
2.
Properly
install
welding
generator
onto
trailer
according
to
instructions
supplied
with
trailer.
1-5.
Principal
Safety
Standards
BATTERY
ACID
can
BURN
SKIN
AND
EYES.
1.
Donottip.
2.
Replace
damaged
battery.
3.
Flush
eyes
and
skin
immediately
with
water.
Safety
in
Welding
and
Cutting,
ANSI
Standard
Z49.
1,
from
American
Safe
Handling
of
Compressed
Gases
in
Cylinders,
CGA
Pamphlet
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami
FL
33126
P-i,
from
Compressed
Gas
Association,
1235
Jefferson
Davis
Safety
and
Health
Standards,
OSHA
29
CFR
1910,
from
Highway,
Suite
501,
Arlington,
VA
22202.
Superintendent
of
Documents,
U.S.
Government
Printing
Office,
Code
for
Safety
in
Welding
and
Cutting,
CSA
Standard
Wi
17.2,
from
Washington,
D.C.
20402.
Canadian
Standards
Association,
Standards
Sales,
178
Rexdale
Recommended
Safe
Practices
for
the
Preparation
for
Welding
and
Boulevard,
Rexdale,
Ontario,
Canada
M9W
1
R3.
Cutting
of
Containers
That
Have
Held
Hazardous
Substances,
Safe
Practices
For
Occupation
And
Educational
Eye
And
Face
American
Welding
Society
Standard
AWS
F4.
1,
from
American
Protection,
ANSI
Standard
Z87.1
from
American
National
Standards
Welding
Society,
550
N.W.
LeJeune
Rd.
Miami,
FL
33126
Institute,
1430
Broadway,
New
York,
NY
10018.
National
Electrical
Code,
NFPA
Standard
70,
from
National
Fire
Cutting
And
Welding
Processes,
NFPA
Standard
51
B,
from
National
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
1-6.
EMF
Information
Considerations
About
Welding
And
The
Effects
Of
Low
Frequency
To
reduce
magnetic
fields
in
the
workplace,
use
the
following
Electric
And
Magnetic
Fields
procedures:
.
The
following
is
a
quotation
from
the
General
Conclusions
Section
of
1.
Keep
cables
close
together
by
twisting
or
taping
them.
the
U.S.
Congress,
Office
of
Technology
Assessment,
Biological
Effects of
Power
Frequency
Electric
&
Magnetic
Fields
Background
2.
Arrange
cables
to
one
side
and
away
from
the
operator.
Paper,
OTA-BP-E-53
(Washington,
DC:
U.S.
Government
Printing
3.
Do
not
coil
or
drape
cables
around
the
body.
Office,
May
1989):.
.
.
there
is
now
a
very
large
volume
of
scientific
findings
based
on
experiments
at
the
cellular
level
and
from
studies
4.
Keep
welding
power
source
and
cables
as
far
away
as
with
animals
and
people
which
clearly
establish
that
low
frequency
practical.
magnetic
fields
can
interact
with,
and
produce
changes
in,
biological
systems.
While
most
of
this
work
is
of
very
high
quality,
the
results
are
5.
Connect
work
clamp
to
workpiece
as
close
to
the
weld
as
complex.
Current
scientific
understanding
does
not
yet
allow
us
to
possible.
interpret
the
evidence
in
a
single
coherent
framework.
Even
more
frustrating,
it
does
not
yet
allow
us
to
draw
definite
conclusions
about
About
Pacemakers.
questions
of
possible
risk
or
to
offer
clear
science-based
advice
on
The
above
procedures
are
also
recommended
for
pacemaker
strategies
to
minimize
or
avoid
potential
risks.
wearers.
Consult
your
doctor
for
complete
information.
OM-173
413
Page
3
SECTION
2-
DEFINITIONS
Become
trained
and
read
the
instructions
before
working
on
the
machine
or
welding.
1
Electric
shock
from
welding
electrode
or
wiring
can
kill.
1.1
Weardryinsulatinggloves.
Do
not
touch
electrode
with
bare
hand.
Do
not
wear
wet
or
damaged
gloves.
1.2
Protect
yourself
from
electric
shock
by
insulating
yourself
from
work
and
ground.
1.3
Do
not
work
on
unit
if
engine
is
running.
Stop
engine
first.
2
Breathing
welding
fumes
can
be
hazardous
to
your
health.
2.1
Keep
your
head
out
of
the
fumes.
2.2
Use
forced
ventilation
or
local
exhaust
to
remove
the
fumes.
2.3
Use
ventilating
fan
to
remove
fumes.
3
welding
sparks
can
cause
explosion
or
fire.
3.1
Keep
flammables
away
from
welding.
Do
not
weld
near
flammables.
3.2
welding
sparks
can
cause
fires.
Have
a
fire
extinguisher
nearby,
and
have
a
watchperson
ready
to
use
it.
3.3
Do
not
weld
on
drums
or
any
closed
containers.
4
Arc
rays
can
burn
eyes
and
injure
skin.
4.1
wear
hat
and
safety
glasses.
Use
ear
protection
and
button
shirt
collar.
Use
welding
helmet
with
correct
shade
of
filter.
wear
complete
body
protection.
5
Do
not
remove
or
paint
over
(cover)
the
label.
6
Engine
fuel
plus
flames
or
sparks
can
cause
fire.
6.1
Do
not
smoke
while
fueling
or
if
near
fuel.
6.2
Stop
engine
before
fueling.
6.3
Do
not
fuel
a
hot
engine.
7
Engine
exhaust
gases
can
kill.
7.1
Vent
exhaust
outside.
7.2
Use
unit
outside.
3/96
2-1.
Warning
Label
Definitions
warning!
watch
Out!
There
are
symbols.
possible
hazards
as
shown
by
the
OM-173
413
Page
4
1
Warning!
Watch
Out!
There
are
possible
hazards
as
shown
by
the
symbols.
2
Do
not
smoke
and
keep
matches
and
flames
away
from
battery.
3
Sparks
can
cause
battery
gases
to
explode.
Battery
explosion
can
blind
and
injure.
Wear
a
face
shield.
4
Battery
acid
can
burn
skin.
Do
not
spill
acid.
5
Read
Owners
Manual.
6
Wear
rubber
gloves.
7
Dead
battery
8
Engine
block
9
Fully
charged
battery
10
Do
not
connect
last
negative
cable
to
dead
battery
connect
instead
to
engine
block.
11
Jumper
cables
observe
polarity
and
make
connections
in
numbered
sequence
shown.
12
Once
dead
battery
is
charged,
disconnect
cables
in
sequence
shown.
3/96
2~
Warning!
Watch
Out!
There
are
possible
hazards
as
shown
by
the
symbols.
2
Moving
parts,
such
as
fans,
rotors,
and
belts,
can
cut
fingers
and
hands
and
cause
injury.
Keep
away
from
moving
parts.
3/96
S-176
106
OM-173
413
Page
5
2~
1
Warning!
Watch
Out!
There
are
possible
hazards
as
shown
by
the
symbols.
2
Hot
muffler
and
exhaust
pipes
can
cause
severe
burns.
Do
not
touch
hot
muffler
or
pipes.
3/96
S-176
230
1
Warning!
Watch
Out!
There
are
possible
hazards
as
shown
by
the
symbols.
3
2
Engine
fuel
plus
flames
or
sparks
can
cause
fire.
3
Do
not
smoke
while
fueling
or
if
near
fuel.
4
Stop
engine
before
fueling.
5
5
Do
not
fuel
a
hot
engine.
6
Use
Diesel
Fuel
Only.
6
3/96
1\
1
Warning!
Watch
Out!
There
are
possible
hazards
as
shown
by
the
symbols.
2
Falling
equipment
can
cause
serious
injury
and
damage.
3
Use
lifting
eye
to
lift
or
move
unit
only.
Use
proper
equipment
when
lifting.
4
Do
not
use
lifting
eye
to
lift
and
support
unit
and
trailer
or
other
heavy
devices
or
accessories.
3/96
OM-173
413
Page
6
2-2.
Manufacturers
Rating
Label
For
CE
Products
S-176
255-A
1
Remove
unit
from
shipping
crate.
Remove
Owners
Manual
from
unit.
Follow
instructions
to
install
muffler.
2
Read
Owners
Manual.
Read
labels
on
unit.
3
Use
Diesel
Fuel
only,
and
fill
fuel
tank.
Leave
room
for
expansion.
4
Warning?
Watch
Out?
There
are
possible
hazards
as
shown
by
the
symbols.
Read
Owners
Manual.
Follow
instructions
to
activate
battery.
___I~
Ij1~1
i;r~r
5
Check
oil
level.
Add
oil
if
necessary.
~7Œ41~~
O5OhStd.I.F
200At
0>~0A
During
the
first
50
hours
of
operation,
keep
welding
load
above
200
amperes.
Do
not
weld
below
200
amperes
of
output.
5OhStd.
After
the
first
50
hours
of
operation,
change
the
oil
and
oil
filter.
/
API
CD-MIL
L
2104D,
CD/SE,
CD/SF
3/96
EN
60974-1
404j21V
325A/33V
504/1
2V
4004/26V
I
I I
U2
26V~
23V1
20V
~
~0
92V
12
I
40041
325A 250A
=
1800
RPM
OM-173
413
Page
7
2-3.
Symbols
And
Definitions
OM-173
413
Page
8
SECTION
3-INSTALLATION
3-1.
Installing
Welding
Generator
Height
40-1/2
in
(1029
mm)
Width
24-5/8
in
(625
mm)
Depth
56
in
(1422
mm)
A
23-1/4
in
(591
mm)
B
24-5/8
in
(625
mm)
C
11/l6in(l7mm)
D
2-7/8
in
(73
mm)
E
4-1/2in(114)mm)
F
22-9/16
in
(573
mm)
G
27
in
(686
mm)
H
30-3/8
in
(772
mm)
J
41-1/4
in
(1048
mm)
L
54
in
(1372
mm)
Weight
M
21/32
in
(16.7
mm)
Dia.
4
Holes
Net:
1500
lb
(680
kg)
Location
Movement
Airflow
Clearance
A
Do
Not
Lift
Unit
From
End
18
in
~OR~
18
in
(460
mm)
Grounding
OR
Elect
ricallybond
generator
frame
to
vehicle
frame
by
metal-to-metal
contact.
18
in
(460
mm)
installl
3196
Ref.
sr-ooo
652
/
Ref.
ST-800
477-A/
ST-158
936-A/
5-0854
1
Generator
Base
2
Metal
Vehicle
Frame
3
Equipment
Grounding
Terminal
4
Grounding
Cable
Use
#10
AWG
or
larger
insulated
copper
wire.
A
If
unit
does
not
have
GFCI
receptacles,
use
GFCI
protected
extension
cord.
3-2.
Dimensions,
Weights,
And
Operating
Angles
Dimensions
A
Do
not
exceed
operatIng
angles
while
running
or
engine
damage
wIll
occur.
A
Do
not
move
or
operate
unit
where
It
could
tip.
Ref.
ST-lb
850-F
K
51-1/8
in
(1299
mm)
anglesi
11/95
N
1/2
in
(12.7
mm)
Dia.
10
Holes
Ship:
1587
lb
(720
kg)
OM-173
413
Page
9
3-3.
Fuel
Consumption
The
curve
shows
typical
fuel
use
under
weld
or
power
loads.
~
~
7.57
1.70
2.00
6.62
1.46
1.75
5.67
1.25
1.60
4.73
1.04
1.25
3.78
0.83
1.00
2.84
0.62
0.75
1850
R.P.M.
1.88 0.40
0.50
0.95
0.21
0.26
0
50
100
150
200
250
300
DC
WELD
AMPERES
AT
100%
D1J~(
CYCLE
SB-137
487
OM-173
413
Page
10
3-4.
Activating
The
Dry
Charge
Battery
5
A
For
30
Minutes
30
A
For
12
Minutes
Remove
battery
from
unit.
Eye
Protection
Safety
Glasses
Or
Face
Shield
Rubber
Gloves
Vent
Caps
Sulfuric
Acid
Electrolyte
(1.265
Specific
Gravity)
Fill
each
cell
with
electrolyte
to
bottom
of
well
(maximum).
A
Do
not
overfill
battery
cells.
Wait
ten
minutes
and
check
elec
trolyte
level.
If
necessary,
add
elec
trolyte
to
raise
to
proper
level.
Reinstall
vent
caps.
6
Battery
Charger
A
Read
and
follow
all
instruc
tions
supplied
with
battery
charger.
Charge
battery
for
12
minutes
at
30
amperes
or
30
minutes
at
5
am
peres.
Disconnect
charging
cables
and
install
battery.
When
electrolyte
is
low,
add
only
distilled
water
to
cells
to
maintain
proper
level.
Tools
Needed:
drybatil
2196
S-0886
0
OM-173
413
Page
11
3-5.
Connecting
The
Battery
3-6.
Engine
Prestart
Checks
OM-173
413
Page
12
3-7.
Installing
Muffler
Pipe
3-8.
Weld
Output
Terminals
And
Selecting
Cable
Sizes
A
ARC
WELDING
can
cause
Electromagnetic
Interference.
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.
~L~~E1
Weld
Output
Terminals
Welding
Amperes
Total
Cable
(Copper)
Length
In
Weld
Circuit
Not
Exceeding
lOOft(30m)OrLess
150ft
(45
m)
200ff
I
250ft
(60
m)
(70
m)
300ft
(90
m)
350ff
I
105_m)_
400ff
(120
m)
1060%
Duty
Cycle
60100%
Duty
Cycle
10
100%
Duty
Cycle
Ref.
ST-801
344
100
4
4 4
3 2
1
1/0 1/0
150
3
3
2
1
1/0
210
3/0 3/0
200
3 2
1
1/0
2/0 3/0
4/0
4/0
250
2
1
1/0
2/0 3/0
4/0
2-2/0
2-2/0
300
1
1/0
2/0 3/0
4/0
2-210
2-3/0
2-3/0
350
1/0
2/0 3/0
4/0
2-2/0
2-3/0
2-3/0 2-4/0
400
1/0
210
3/0
4/0
2-210 2-3/0
2-4/0
2-4/0
500
210 3/0
4/0
2-2/0 2-3/0 2-4/0
3-3/0 3-3/0
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.
5-0007-0
00I
A
Do
not
blow
exhaust
toward
air
cleaner
or
air
Intake.
ST-801
376
Tools
Needed:
~
1/2in
OM-173
413
Page
13
SECTION
4-
OPERATING
THE
WELDING
GENERATOR
4-1.
Duty
Cycle
And
Overheating
Duty
Cycle
is
percentage
of
10
minutes
that
unit
can
weld
at
rated
load
without
overheating.
A
Exceeding
duty
cycle
can
damage
unit
and
void
warranty.
40
70
X
DUTY
CYCLE
Cl)
w
9
Ui
6
Minutes
Welding
100%
Duty
Cycle
At
250
Amperes
Continuous
Welding
100
4
Minutes
Resting
60%
Duty
Cycle
At
325
Amperes
rdutyl
5/95
SB-070
999-B
OM-173
413
Page
14
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Miller KF970957 Owner's manual

KF970957
Miller
Brand
Miller
Model
KF970957
Category
Welding System
Type
Owner's manual
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