Miller Electric Metro 300DX User manual

Miller
August
1995
Effective With
Form:
Serial
No.
OM-1
56
368B
KF941 356
OWNERS
MANUAL
~_'
_I_
CE
Metro
300DX
CC/DC
Welding
Generator For
SMAW
And
GTAW
Welding
Rated
Welding
Output
Amperage
Range
Maximum
Open-
Circuit
Voltage
DC
Auxiiiary
Power
Rating
Engine

Fuel
Capacity
Sound
Power
iP
Rating
280
A,
31
VDC,
35%
Duty
Cycle
250
A,
30 V
DC,
60%
Duty
Cycle
225
A,
29
V
DC,
100%
Duty
Cycle
20280
72
AMS
(65 Average)
Single-Phasel
3-Phase,
7/10
kVA/kW,
32/15
A.
220/380
V
AC,
50Hz
Ruggenni
RD211
Air-Cooled,
Two-Cylinder,
20
HP Diesel
Engine
11.8
US
gal
(44.6
L)
98
Lwa
23
cover_om
4/95
-
Ref.
ST-158 934-B
'
1995
MILLER Electric
Mfg.
Co.
PRINTED
IN
USA

LIMITED
WARRANTY
Subject
to
the
terms
and
conditions
below,
MILLER
Electric
Mt
g.
Co.,
Appleton.
Wisconsin,
warrants
to
its
original
retail
purchaser
that
new
MILLER
equipment
sold
after the
effective
date
of
this limited
warranly
is free
of 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
pans
or
components
thaI
fall
due
to
such
defects
In
material
orworlcmanship.
MILLER
must
be
notified
in
writing
within
thIrty
(30)
days
of such delect
or
failure,
at
which time
MILLER
will
provide
instructions
on
the
warranty
claim
procedures
to
be
followed.
MILLER
shall honor
warranty
claims
on
warranted
equipment
listed
below in the
event
of
auch
a
failure
within the
warranty
time
periods.
All
warranty
lime
periods
start
on
the date that
the
equipment
was
delivered
10
the
original
retail
purchaser,
or
one
year
after
the
equipment
is
sent
to
a
North
American
distributor
or
eighteen
months
after the
equipment
is
sent to
an
International distributor.
1.
5YearsPafls-3YearsLabor

Original
main
power
rectifiers

Inverters
(input
and
output
rectifiers
only)
2.
3YearsPartsandLabor
*
Transformer/Rectifier
Power Sources

Plasma
Arc
Cutting
Power Sources
Semi-Automatic
and Automatic Wire
Feeders

Inverter Power
Supplies

Intellitig
*
Robots
2.
Consumable
components;
such
as
contact
tips,
cutting
nozzles,
contactors
and
relays
or
pans
that
tall due
to
normal
wear.
3.
Equipment
that has
been
modified
by
any
party
other
than
MILLER.
or
eqwp
ment
that
has
been
improperly
installed,
improperly
operated
or misused
based
upon
industry
standards,
or
equipment
which
has
nof
had
reasonable
and
necessary
maintenance,
or
equipment
which
has
been
used
for
operation
outside
of
the
specifications
for the
equipment.
MILLER
PRODUCTS ARE
INTENDED
FOR PURCHASE
AND USE
BY
COMMER
CIAL/iNDUSTRIAL USERS
AND
PERSONS
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE OF WELDING EQUIPMENT.
In the
event
of
a
warranty
claim
covered
by
this
warranty,
the
exclusive
remedies
shall
be,
at
MILLERS
option: (1) repair~
or
(2)
replacement;
or,
where
authorized
in
writing by
MILLER
in
appropriate
cases,
(3)
the
reasonable
cost
of
repair
or
replace
mental
an
authorized MILLER service
station;
or
(4)
payment
of
or
credit for
the
pur
chase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
retum
of
the
goods
at
customers
risk
and
expense.
MILLERS
option
of
repair
or
replecement
will be
FOB..
Factory
at
Appleton,
Wisconsin,
or
F.O.B.
at
a
MILLER authorized
ser
vice
facility
as
determined
by
MILLER.
Therefore
no
compensation
or
reimburse
ment
for
transportation
costs
of
any
kind
will
be allowed.
TO
THE
EXTENT
PERMflTED
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,
MIGNTARISE
BY
IMPLICATION,
OPERATION OF
LAW,
CUSTOM OF TRADE OR COURSE OF
DEALING,
IN
CLUDING
ANY
IMPLIED WARRANTY
OF
MERCHANTABILITY OR
FITNESS
FOR PARTICULAR
PURPOSE,
W~-l
RESPECT
TO ANY
AND ALL
EQUIPMENT
FURNISHED BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED BY MILLER.
Some
states
In
the
U.S.A.
do
not
allow limitations
of
how
long
an
Implied
warranty
lasts,
or Ihe
exclusion
of
incidental, indirect,
special
or
consequential
damages,
so
the
above limitation
or
exclusion
may
not
apply
to
you.
This
warranty
provides
spe
cific
legal
rights,
and
other
rights
may
be
available,
but
may
vary
from
state to
state.
In
Canada,
legislation
in
some
provinces
provides
for
certain
additional
warranties
or
remedies
other
than
as
stated
herein,
and
to
the
extent that
they
may
not
be
waived,
the
limitations
and exclusions
set out
above
may
not
apply.
This
Limited
Warranty
provides
specific
legal rights,
and other
rights
may
be
available,
but
may
vary
from
province
to
province.
WHO
DO
I
CONTACT?
For
help,

contaCt
your
distributor
For additional
information,
such
as
Technical Manuals
(Sen/ice
And
Parts)
Engine
Manuals
Circuit
And
Wiring
Diagrams
Process Handbooks
To file
a
claim
for
loss
or
damage
during
shipment,
U
contact
the
deliVering
carrier
For
assistance
In
filing
or
settling
claims,

contact
your
distributor
and/or
equipment
manufacturers
Transportation
Department
{TE~T]
Miller Electric
Mfg.
Co.

CALL:
~

FAX:
800-637-2348
(in USA),
or
414-735-4136
(outside USA)
Users
Guides
Distributor Directories

contact
your
distributor
a
I
I

WRITE:
Miller
Electric
Mfg.
Co.
P.0. Box
1079
Appleton,
WI 54912
USA
Always
provide
Model
Name
and
Serial
or
Style
Number
UI
MILLERS
TRUE
BLUEfi
LIMITED WARRANTY
Effective
January
1,
1995
(Equipment
with
a
serial
number
preface
of KD
or
newer)
This
limited
warranty
supersedes
all
previous
MILLER
warranties and is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
Implied.
L~
5.
6 Months

Batteries
6. 90
Days

Parts
end Labor
*
MIG Guns/TIG
Torches
-
APT.
ZIPCUT
&
PLAZCU1
Model Plasma
Cutting
Torches
*
Remote
Controls
*
Accessory
Kits
-
Replacement
Pans
MILLERS
True
Bluefi
Limited
Warranty
shall
not
apply
to:
1.
items furnished
by
MILLER,
but
manufactured
by
others,
such
as
engines
or
trade
accessories.
These
items
are
covered
by
the
manufacturers
warranty,
if
any.
3.
2YearsPartsendLabor
-
Engine
Driven
Welding
Generators
(NOTE:
Engines
are
warranted
separately
by
the
engine
manufacturer.)

Air
Compressors
4.
1
Year

Parts
end
Labor
-
Motor
Driven
Guns
-
Process Controllers
-
IHPS
Power Sources

Water
Coolant
Systems
-
HF
Units
*
Grids
-
Spot
Welders
Load Banks
-
SDX
Transformers
-
Running
GeardTrsiters
-
Plasma
Cutting
Torches
(except
APt
ZIPCUT
&
PLAZCUT
Models)
-
Tecumseh
Engines
Deutz
Engines
(outside
North
America)

Field
Options
(NOTE:
Field
options
are
covered
under True
Bluefi
for
the
remaining
warranty
period
of the
product
they
are
installed
in.
or
for
a
minimum
of
one
year

whichever
is
greater.)
mIller_wan
6/95

EI~RATA
SHEET
December
1,
1995
FORM:
OM-156
368B
Use above
FORM
number when
ordering
extra
manuals.
After this manual
was
printed,
refinements
in
equipment
design
occurred.
This sheet lists
exceptions
to
data
appearing
later
in
this manual.
CHANGES
TO
SECTION
6
ELECTRICAL
DIAGRAM
Replace Figure
6-1.
Circuit
Diagram
For
Welding
Generator
(see
Pages
2
and
3
on
this Errata
Sheet)
CHANGES TO
SECTION
8
PARTS LIST
Change
Parts List
as
follows:
Dia.
Part
Replaced
**
Mkgs.
No
With Description
Quantity
31-
Added
178 913
..
.
SOLENOID,
module
control
(Eff
w/KG020121)
....
1
31-54
.
.
.
TS1
....
176 625
178
903
...
SOLENOID,
throttle and
timing
module
(Effw/KG020121)
1
31-72
...
FS1
....
176 626
178 902
.
. .
SOLENOID,
fuel
(Eff
w/KG020121)
1
**First
digit
represents
page
no

digits
following
dash
represent
item
no.
BE
SURE TO
PROVIDE
MODEL
AND
SERIAL NUMBER WHEN
ORDERING
REPLACEMENT PARTS.

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iT-A
~
B
33 .12
37 30
44 44
35
A6C~p~F
310
0 0
77 72 &7 ~7
73
41
40 40 42 42 42
Figure
6-1.
Circuit
Diagram
For
Welding
Generator
2
lxxx
3
x
4
xx
5
I
XQ0$E0 TO 8 TEF~1IJAL
OLE
OQ~TRU
CT
t
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RO9/PLC~
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RO5/RG8
-~9
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210 0 0 0
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04
OM-156
368E
Page
2

RC7/I&G7
>-
>2
>-
>3>
SD-178
904
OM-156
368B
Page
3

C
1~
S

Declaration
of
Conformity
Manufacturers Name:
Miller
Electric
Mfg.
Co.
Manufacturers
Address:
1635
W.
Spencer
Street
Appleton,
WI
54914
USA
Declares that
the
product:
Ni ET R 0
300
DX
(product
name)
conforms
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 Pertormance:
IEC
34-1:1994
Rotating
Electrical Machines

Part
5:
Classification
of
degrees
of
protection
provided by
enclosure
of
rotating
electrical
machines
(IP
code):
lEG
34-5:
1991
Insulation coordination
for
equipment
within
low-voltage
systems:
Part
1.:
Principles,
requirements
and
test:
lEG
664-1:
1992
European
Contact:
Mr.
Roberto
Moletto
MILLER
Europe
S.P.A.
Via
Privata lseo
20098
San Giuliano
Milanese,
Italy
Telephone:
39(02)98290-1
Fax:
39(02)98281-552
dec_coni
7/95

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
INSTALLATION
4
2-1.
Installing
Welding
Generator
4
2-2.
Dimensions,
Weights,
And
Operating
Angles
4
2-3.
Fuel
Consumption
5
2-4.
Rating
Label
5
2-5.
Connecting Battery
And
Installing
Muffler
Pipe
6
2-6.
Engine
Prestart Checks
7
2-7.
Weld
Output
Terminals
And
Selecting
Cable Sizes
7
2-8.
Remote
14
Receptacle
RC1 Information
8
SECTION 3OPERATING
THE
WELDING GENERATOR
8
3-1.
Symbols
And
Definitions
8
3-2.
Front Panel
Controls
9
3-3.
Duty
Cycle
And
Overheating
10
3-4.
Remote
Amperage
Control
10
SECTION
4OPERATING
AUXILIARY
EQUIPMENT
11
4-1.
Auxiliary
Power
Receptacles
11
SECTION
5
MAINTENANCE
&
TROUBLESHOOTING
12
5-1.
Routine Maintenance
12
5-2.
Maintenance Label
13
5-3.
Changing
Engine
Oil
And Filter
14
5-4.
Changing
Fuel
Filters
15
5-5.
Servicing
Air
Cleaner
15
5-6.
Adjusting
Engine Speed
16
5-7.
Overload Protection
17
5-8.
Inspecting
And
Cleaning
Optional Spark
Arrestor
18
5-9.
Troubleshooting
18
SECTION
6
ELECTRICAL DIAGRAM
22
SECTION
7-
PARTS
LIST
24
Figure
7-1.
Main
Assembly
24
Figure
7-2.
Generator
29
Figure
7-3.
Panel,
Front
w/Components
30
Figure
7-4.
Component
Box
31
OM-156
388B -8195

SECTION
1
-
SAFETY PRECAUTIONS
FOR
ARC
WELDING
1-1.
Symbol
Usage
a
Means
Warning!
Watch
Out!
There
are
possible
hazards
with
this
procedure!
The
possible
hazards
are
shown
in
the
adjoining symbols.
sately_roml
4/95
~1!~~d~
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.
1-2.
Arc
Welding
Hazards
a
WARNING
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
1-5.
Read
and follow
all
Safety
Standards.
Only qualified
persons
should
install,
operate,
maintain,
and
repair
this unit.
ELECTRIC SHOCK
can
kill.
Touching
live
electrical
parts
can
cause
fatal
shocks
or
severe
bums.
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.
1.
Do
not
touch
live electrical
parts.
2. Wear
dry,
hole-free
insulating gloves
and
body
protection.
3. insulate
yourself
from
work
and
ground using dry
insulating
mats
or
covers
big
enough
to
prevent
any
physical
contactwith
the
work
or
ground.
4.
Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment. Lockout/tagout input
power
according
to
OSHA
29
CFR
191
0.147
(see Safety
Standards).
5.
Properly
install
and
ground
this
equipment
according
to
its
Owners
Manual and
national,
state,
and
local
codes.
6.
Always
verify
the
supply
ground

check
and be
sure
that
input
nnwer
~nrd nrniinrl wire
is ornnerhi
ennne~tad
tn
nrntind
NOISE
ARC RAYS
can
burn
eyes
and
skin;
NOISE
can
damage
hearing;
FLYING
SLAG OR SPARKS
can
injure
eyes.
Arc
rays
from
the
welding
process
produce
intense
visible and invisible
(ultraviolet
and
infrared)
rays
that
can
bum
eyes
and skin.
Noise from
some
processes
can
damage
hearing.
Chipping,
grinding,
and welds
cooling
throw
off
pieces
of
metal
or
slag.
1.
Use
approved
ear
plugs
or ear
muffs if
noise level is
high.
FUMES
AND
GASES
can
be hazardous
to
your
health.
Welding
produces
fumes
and
gases.
Breathing
these fumes
and
gases
can
be hazardous
to
your
health.
1.
Keep
your
head
out
of
the
fumes.
Do
not
breathe the fumes.
2.
If
inside,
ventilate the
area
and/or
use
exhaust
at
the
arc
to
remove
welding
fumes and
gases.
3. if
ventilation
is
poor,
use an
approved
air-supplied respirator.
4.
Read the
Material
Safety
Data Sheets
(MSDSs)
and the
manufacturers
instruction for
metals,
consumables,
coatings,
cleaners,
and
degreasers.
terminal in
disconnect box
or
that cord
plug
Is
connected
to
a
properly
grounded
receptacle
outlet.
7.
When
making input
connections,
attach
proper grounding
conductor first

double-check connections.
8.
Frequently
inspect input
power
cord
for
damage
or
bare
wiring

replace
cord
immediately
if
damaged

bare
wiring
can
kill.
9.
Turn off all
equipment
when
not
in
use.
10.
Do
not
use
worn,
damaged,
undersized,
or
poorly spliced
cables.
11.
Do
not
drape
cables
over
your
body.
12.
If
earth
grounding
of the
workpiece
is
required,
ground
it
directly
with
a
separate
cable

do
not
use
work
clamp
or
work
cable.
13.
Do
not
touch electrode
if
you
are
in
contact
with
the
work,
ground,
or
another
electrode
from
a
different machine.
14.
Use
only
well-maintained
equipment. Repair
or
replace
damaged
parts
at
once.
Maintain
unit
according
to
manual.
15.
Wear
a
safety
harness
if
working
above floor
level.
16.
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.
ARC
RAYS
2.
Wear
a
welding
helmet fitted
with
a
proper
shade
of
filter to
protect
your
face
and
eyes
when
welding
or
watching
(see
ANSI
Z49.1
and
Z87.1
listed in
Safety
Standards).
3.
Wear
approved safety
glasses
with
side shields.
4.
Use
protective
screens or
barriers
to
protect
others
from
flash
and
glare;
warn
others
not
to
watch the
arc.
5.
Wear
protective
clothing
made
from
durable,
flame-resistant
material
(wool
and
leather)
and
foot
protection.
5.
Work in
a
confined
space
only
if
it
is well
ventilated,
or
while
wearing
an
air-supplied
respirator. Always
have
a
trained
watchperson nearby. Welding
fumes
and
gases
can
displace
air
and lower the
oxygen
level
causing injury
or
death. Be
sure
the
breathing
air is safe.
6.
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.
7.
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.
A
Marks
a
special
safety
message.
~
Means
NOTE;
not
safety
related.
1
During operation,
keep
everybody,
especially
children,
away.
OM-156
368
Page
1

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.
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 bums.
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.
Connectwork
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.
11. 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
1.
If the
engine
is
warm
and
checking
is
needed,
follow
steps
2
and 3.
2.
Wear
safety
glasses
and
gloves
and
put
a
rag
over
cap.
3.
Turn
cap
slightly
and let
pressure escape
slowly
before
completely removing
cap.
1.
2.
____
a
WARNING
__
ENGINE EXHAUST GASES
can
kill.
Engines
produce
harmful
exhaust
gases.
1.
2.
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.
A
ENGINE
FUEL
can
cause
fire
or
2. Do
not
add
fuel while
smoking
or
if
unit is
near
any
sparks
or
explosion,
open
flames.
Engine
fuel
is
highly
flammable.
Do
~ot
overfill tank

allow
room
for fuel
to
expand.
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.
2.
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.
Stop
engine
before
installing
or
connecting
unit.
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
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.
1.
2.
3.
4.
5.
Always
wear
a
face shield when
working
on
a
battery.
Stop
engine
before
disconnecting
or
connecting battery
cables.
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.
STEAM
AND
PRESSURIZED
HOT
COOLANT
can
burn
face,
eyes,
and
skin.
It
Is best
to
check
coolant level
when
engine
Is
cold
to
avoid
scalding.
OM-156
368
Page
2

1-4.
Additional
Installation,
Operation,
And
Maintenance
Hazards
a
WARNING
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
face
shield.
STATIC ELECTRICITY
can
damage
parts
on
circuit
boards.
1. Put
on
grounded
wrist
strap
BEFORE
handling
boards
or
parts.
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.
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.
L
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
baftery.
3. Flush
eyes
and skin
immediately
with
water.
Safety in
Welding
and
Cutting,
ANSI Standard
Z49.i
,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,
US.- Government
Printing
~Office,
--fiode
for
Safetyin
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.i

from American
Protection,
ANSI Standard
Z87.1,from
American National
Standards
Welding
Society,
550
N.W.
LeJeune
Ad, 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
Electric
And
Magnetic
Fields
The
following
is
a
quotation
from
the
General Conclusions Section of
the
U.S.
Congress,
Office
of
Technology
Assessment,
Biological
Effects of Power
Frequency
Elect ric&
Magnetic
Fields
Background
Paper,
OTA-BP-E-53
(Washington,
DC:
U.S.
Government
Printing
Office,
May
1989):.
. .
there is
now a
very
large
volume of scientific
findings
based
on
experiments
at
the cellular level and
from studies
with animals
and
people
which
cleariy
establish that low
frequency
magnetic
fields
can
interact
with,
and
produce
changes
In,
biological
systems.
While
most
of
this work
is of
very
high quality,
the
results
are
complex.
Current
scientific
understanding
does
not
yet
allow
us
to
Interpret
the evidence in
a
single
coherent framework.
Even
more
frustrating,
it does
not
yet
allow
us
to
draw definite conclusions
about
questions
of
possible
risk
or
to
offer clear science-based advice
on
strategies
to
minimize
or
avoid
potential
risks.
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 the
body.
4.
Keep welding
power
source
and cables
as
far
away
as
practical.
5.
Connect
work
clamp
to
workpiece
as
close
to
the
weld
as
possible.
About Pacemakers:
The
above
procedures
are
also recommended
for
pacemaker
wearers.
Consult
your
doctor for
complete
informatIon.
OM-156
368
Page
3

SECTION
2-INSTALLATION
2-1.
Installing
Welding
Generator
2-2.
Dimensions,
Weights;And
Operating
Angles
Height
41
in
(1041 mm)
Width
30
in
(762
mm)
Depth
54-1/2 in
(1384 mm)
A
29
in
(737
mm)
B
36-3/4
in
(933 mm)
C
9/l6in(l4mm)Dia.
Weight
Net
960 lb
(435 kg)
Dimensions
A
Do
not
exceed
operating angles
while
running
or
engine damage
will
occur.
150
25
C
4
Holes
25
Sr-158
938
Ship
1070 lb
(485 kg)
OM-1
56 368
Page
4

2-3. Fuel
Consumption
ITT
,~,,
7tt+-
~ ~
y__
~OLEJ
I
;
~
I
~
-
A
~
~
IILII
POW~
~
cc
~
I I
I
I II
I
Q.
-J
~
4.73
1,04
1.25
3.78
0.84
1.00
2.84
063
0.75
1.89
0.42 0.50
0.95 0.21
025
0.00
0.00 0.00
I
I I
I
I
IIIIII I I
o
25 ~)
75
1~ 125 150 175
20]
225
2~Q 275
30)
DC
WELD AWERES
AT
630% DUTY
CYCLE
I
III
I
I
I
I I
I ~I
I I
O
I
2 3
4
5
6
7
8
9
13
11
12
POWER
KVA
AT
130%
DUTY
CYCLE
2-4.
Rating
Label
SA-175
807
EN
60974-1
Rating
label shown
includes
op
tional
48
volt
dinse
receptacle
in
formation.
20A121
V
280A/31
V
U0
=
65V
20A/11V
280A121V
35OHz
380V
1OkVA
1
50 Hz
220V
7kVA
1
50 Hz
48V
2.5kVA
50A
OM-156
368
Page
5

2-5.
Connecting
Battery
And
Installing
Muffler
Pipe
OM-1
56
368
Page
6

2-6.
Engine
Prestart Checks
Check
all
fluids
daily. Engine
must
be
cold and
on
a
level
surface.
Engine
stops
if
oil
pressure
is low.
A Heavy loading
during
first
50
hours
will
damage
en
gine. Keep
load less
than
225A
(weld)
or
7
kVA
(power)
for first
50
hours.
2-7.
Weld
Output
Terminals And
Selecting
Cable Sizes
Ref.
ST-159 219-D
Total
Cable
(Copper)
Length
in Weld
Circuit
Not
Exceeding
1060%
Duty
Cycle
100
ft
(30 m)
Or
Less
150ft
(45 m)
200ft
r
(60
m)
250ft
(70 m)
300ft
(90 m)
350ft
(105 m)
400ft
(120 m)
60 100%
Duty
Cycle
10100%
Duty Cycle
4 4 4
3
2 1
1/0
1/0
3
3 2 1
1/0 2/0 3/0
3/0
3
2 1
1/0 2/0 3/0 4/0
4/0
2 1
1/0
2/0 3/0 4/0 2-2/0 2-2/0
1
1/0 210 3/0 4/0 2-2/0 2-3/0
2-3/0
1/0
2/0
3/0 4/0 2-2/0 2-3/0 2-3/0
2-410
1/0 2/0
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.
3/0
4/0 2-2/0 2-3/0 2-4/0 2-4/0
S-0007-D
OM-156
366
Page
7

2-8.
Remote
14
Receptacle
RC1
Information
A 24
volts
ac
with
respect
to
socket
G.
B
Contact
closure
to
A
completes
24
volts
ac
contactor
control
circuit.
G Circuit
common
~for
24
volts
AC
circuit.
D
Remote
control circuit
common.
E
0
to
+10
volts dc
input
command
signal
from
remote
control
with
respect
to
socket
D.
*The
remaining
sockets
are
not
used.
SECTION
3-OPERATING
THE
WELDING GENERATOR
REMOTE
14
Sockete Socket Information
C
A
+10
volts
dc
output
to remote
control
with
respect
to
socket
D.
ST-Isa 934-B
K
Chassis
common.
3-1.
Symbols
And
Definitions
OM-156
368
Page
8

3-2.
Front
Panel Controls
8
9
Ret. ST-175
920-A
A
Heavy loading during
first
50
hours
will
damage engine. Keep
load less
than
225A
(weld)
or
7
kVA
(power)
for first
50
hours.
1
Engine
Control Switch Si
Use switch
to
operate
glow
plug
(optional

see
table),
start
engine,
select
speed,
and
stop
engine.
In
Run/Idle
position,
engine
runs
at
idle
speed
at
no
load,
and
weld/power speed
under
load.
In
Run
position,
engine
runs
at
weld/power speed.
2 Idle Lock
Switch S8
Use switch
to
lock
engine
in
idle
speed
dur
ing
start-up
(see
table).
Do
not
use ac re
ceptacles
with
switch
in
Idle
position.
To
Start:
move
Idle Lock
switch
to
Idle
posi
tion and
Engine
Control
switch
to
Start
posi
tion. Release.
Engine
Control. switch .when
engine
starts.
Do
not
crank
engine
while
fly
wheel is
turning.
Move Idle Lock switch
to
Run/Idle
position
after
engine
warms.
in
arc
starts,
and reduce the chance of the
electrode
freezing
in
the
puddle.
Set
at
minimum
for
Tig welding.
7
Amperage
Control R4
8
Voltmeter
Vi
(Optional)
10 Remote
Amperage
Control Switch S7
Use switch
to
select
front
panel
or
remote
amperage
control.
11
Remote
Output (Contactor)
Switch S6
7
1
2
Using
idle Lock
Switch
2100
rpm
(No Load)
3200
rpm
(Load)
3200
rpm
To
Stop:
turn
Engine
Control switch
to
Stop
9 Ammeter
Al
(Optional)
position.
3
Engine
Hour Meter
HM
4
Fuel
Gauge
FG
5
Engine
Oil
Pressure
Light
PL1
Engine
stops
and
light
goes
on
If oil
pres-
Use switch
to
control
remote
contactor
if
sure
is
too
low,
connected
to remote
14
receptacle
RC1
-
6
Arc
Force
(Dig)
Control
R5
Use control
to
automatically
increase
am
perage
as arc
length
is
decreased,
to
assist
A
Weld
output
terminals
are
energized
when switch S6 Is On
and
engine
Is
running.
OM-l
56368
Page
9

3-3.
Duty
Cycle
And
Overheating
3-4.
Remote
Amperage
Control
4~fl
2cXJ
~.
;
:
.
~-.
~-
3-1/2
Minutes
Welding
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
war
ranty.
3
35%
Duty
Cycle
At 280
Amperes
40 50 8) 70 80 8) fi)
Z
DUTY
CYCLE
6-1/2
Minutes
Resting
60%
Duty
Cycle
At
250
Amperes
6
Minutes
Welding
4
Minutes
Resting
100%
Duty Cycle
At
225
Amperes
Continuous
Welding
r!1~
dutyl
5/95/SB-176
134
A
Weld
output
terminals
are
energized
when
Remote
Output (Contactor)
switch
is
On
and
engine
is
running.
1
Remote
14
Receptacle
RC1
Connect
optional
remote
control
to
RC1
(see
Section
2-8).
1
0
I
1?
Set
Switches
....................~
A
Set Control
-*
Mm
(20
A
DC)
Max
(100ADC)C
~
Adjust
Remote
Control
Ref. ST-158 934-B
/
Ref. 5T-175
920-A
OM-156
368
Page
10

SECTION
4- OPERATING
AUXILIARY
EQUIPMENT
4-1.
Auxiliary
Power
Receptacles
(IJ~
Auxiliary
power
available
at
ac
recep
tacles decreases
as
weld
amperage
in
creases.
1
380
V
15
A
AC
Receptacle
RC1
2 220
V
16
A
AC
Receptacle
RC2
3 220
V
16
A
AC
Receptacle
RC3
RC1
supplies
50
Hz
three-phase
power
at
weld/power speed.
Maximum
output
is 10
kVA/kW.
RC2 and
RC3
supply
50
Hz
single-phase
power
at
weld/power
speed.
Maximum
output
from each
receptacle
is
3.3 kVA/kW.
Combined
output
of
receptacles
is limited
to
10
kVA/kW
output
of
generator.
If maximum
output
is
exceeded,
auxiliary
equipment
will
stop
or
not
run
properly.
4
Circuit Breakers
CB1, CB2,
And CB3
CB1
thru
CB3
protect
RC1 from
overload. If
a
circuit breaker opens,
power
is lost
on
one
phase
and
RC1
output
drops.
Voltage
may
still be
present
at
RC1.
If all
circuit breakers
open,
RC1
output
stops.
CB1
also
protects
RC2
from
overload.
If
CB1
opens,
RC2
output stops.
5
Circuit Breaker
CB1O
CB1O
protects
RC3 from overload. If CB1O
opens,
RC3
output
stops.
6
Ground
Fault
Circuit
Interrupter
GFCI1
7
48
V
50
A
AC Dinse
Receptacles
RC4
And
RC5
(Optional)
RC4
and
RC5
supply
50
Hz
single-phase
power
at
weld/power speed.
Maximum
output
is
2.5
kVAIkW.
Connect
equipment
neutral cable
to
E
(RC5)
receptacle
and
equipment
load cable
to
U+
(RC4) receptacle.
8
Circuit
Breaker CB4
(Optional)
CB4
protects
RC4
from
overload.
9
AuxIliary
Power
While
Welding
Table
35OHz 1-~50Hz
380V
220V
6
4
5
Ref.
SC-175
913
GFCI1
provides ground
fault
protection
for
RCI,
RC2,
and
RC3.
OM-156
368
Page
11

SECTION
5-
MAINTENANCE
&
TROUBLESHOOTING
5-1. Routine
Maintenance
Recycle
engine
fluids.
8 Hours
50 Hours
Clean
And
Tighten
Battery
Connections.
See Section
2-5
A Stop engine
before
maintaining.
OJ~
See
also
Engine
Manual
and
Mainte
nance
LabeL
Se,vice
engine
more
often
.during
severe
conditions.
4
Repair
Or
Repiace
Cracked
Cabies
fi
500 Hours
Blow
Out Or
Vacuum
inside.
During
Heavy
Service,
Clean
Monthly
fi
100 Hours
P
200 Hours
300
Hours
OM-156 368
Page
12