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Miller Electric PipePro 304, Owner'S Manual

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Processes

Description

TIG (GTAW) Welding

Stick (SMAW) Welding

MIG (GMAW) and Pulsed MIG

(GMAW-P) Welding

Engine Driven Welding Generator

OM-492

190 603BF

2007

−

05

PipePro 304

Air Carbon Arc (CAC-A)

Cutting and Gouging

Flux Cored (FCAW) Welding

Visit our website at

www.MillerWelds.com

™

File: Engine-Driven

Summary of Contents for PipePro 304

Page 1: ...SMAW Welding MIG GMAW and Pulsed MIG GMAW P Welding Engine Driven Welding Generator OM 492 190 603BF 2007 05 PipePro 304 Air Carbon Arc CAC A Cutting and Gouging Flux Cored FCAW Welding Visit our webs...

Page 2: ...tinue 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...

Page 3: ...ting Angles 13 4 3 Duty Cycle And Overheating 13 4 4 Volt Ampere Curves 14 4 5 Fuel Consumption 15 SECTION 5 INSTALLATION 16 5 1 Installing Welding Generator 16 5 2 Engine Prestart Checks 17 5 3 Addin...

Page 4: ...Cooling System 36 8 7 Replacing Throttle Solenoid TS1 37 8 8 Adjusting Engine Speed 38 8 9 Overload Protection 39 8 10 Voltmeter Ammeter Help Displays 40 8 11 Troubleshooting 41 SECTION 9 ELECTRICAL...

Page 5: ...risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC constant voltage wire welder 2 a DC man...

Page 6: ...ng can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on...

Page 7: ...s bare handed Allow cooling period before working on equip ment To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns STEAM AND HOT COOLANT can...

Page 8: ...e and frequency caused by low engine speed damage electric motors Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable FLYING SPARKS can cause injury Wear a face shield to...

Page 9: ...tion Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Assoc...

Page 10: ...appareil en est quip Des pr cautions de s curit suppl mentaires sont requises dans des environnements risque comme les endroits humides ou lorsque l on porte des v tements mouill s sur des structures...

Page 11: ...orter des lunettes de s curit avec crans lat raux m me sous votre casque Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les blouissements et les ti...

Page 12: ...les batteries D brancher le c ble n gatif en premier lieu Le rebrancher en dernier lieu LE CARBURANT MOTEUR peut provo quer un incendie ou une explosion Arr ter le moteur avant de v rifier le niveau...

Page 13: ...changer ou de rajouter des l ments ou avant d ouvrir la purge ou le bouchon de remplissage d huile Le METAL CHAUD lors du coupage et gougeage plasma peut provoquer un in cendie ou une explosion Ne pa...

Page 14: ...NSTRUCTIONS Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil N utiliser que les pi ces de rechange recom mand es par le constructeur Effectuer la maintenance et le se...

Page 15: ...nal Standards Institute 11 West 43rd Street New York NY 10036 8002 t l phone 212 642 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standar...

Page 16: ...tive Earth Ground Do not switch while welding 14 Remote 14 Receptacle Work Connection Glow Plug Wire Feed Electrode Positive Electrode Negative High Temperature SECTION 4 SPECIFICATIONS 4 1 Weld Power...

Page 17: ...1492 mm 20 20 20 G 13 32 in 10 mm Dia 20 Weight 925 lb 420 kg Front Panel End 925 lb 420 kg 800 426 Front Panel End 6 Minutes Welding 4 Minutes Resting 4 3 Duty Cycle And Overheating Duty Cycle is per...

Page 18: ...4 Volt Ampere Curves 178 652 178 653 Volt ampere curves show mini mum and maximum voltage and amperage output capabilities of unit Curves of other settings fall be tween curves shown A CC Mode B CV M...

Page 19: ...350 400 450 500 DC WELD AMPERES AT 100 DUTY CYCLE 3600 RPM 0 0 25 0 50 0 75 1 00 1 25 1 50 1 75 2 00 1 98 0 95 2 84 3 78 5 67 4 73 6 62 7 57 U S GAL HR LITERS HR IDLE Notes Work like a Pro Pros weld...

Page 20: ...flow is restricted or engine may over heat Mounting 1 Cross Supports Mount unit on flat surface or use cross supports to support base Grounding 2 Equipment Grounding Terminal On Front Panel 3 Groundin...

Page 21: ...use oil and wets tacking may occur during run in period Check oil several times daily during run in Coolant Check coolant level in recovery tank before starting unit the first time Add coolant if cool...

Page 22: ...nt is at bottom of filler neck This en sures all air is purged from the sys tem Reinstall screw and radiator cap Check coolant level in recovery tank see Section 5 2 Engine coolant is a mixture of wat...

Page 23: ...OM 492 Page 19 5 5 Installing Exhaust Pipe 802 173 B Ref 213 263 B Point exhaust pipe in desired direction but always away from front panel and direction of travel Tools Needed 1 2 in Notes...

Page 24: ...ct Current Elec trode Negative DCEN connect elec trode holder cable to Negative terminal on right and work cable to Positive ter minal on left 6 4 5 Do not place anything between Correct Installation...

Page 25: ...e size AWG is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere mm2 for metric use S 0007 F For distances longer than those shown in this guide call...

Page 26: ...51 mm Hose Clamp 3 1 3 4 x 2 in 44 x 51 mm Rubber Hose 4 Air Shutdown Valve Gator ESD 175 275 L3 5 1 3 4 x 16 1 2 in 44 x 419 mm Flexible Radiator Hose NAPA Part No FM68 Use thick walled rubber hose D...

Page 27: ...a constant engine coolant temperature See table for heater specifications To turn on heater connect heater plug to a 120 volt ac grounded re ceptacle To turn off heater disconnect plug Watts Volts 10...

Page 28: ...OM 492 Page 24 SECTION 6 OPERATING WELDING GENERATOR 6 1 Controls See Section 6 2 Ref 213 263 B 802 330 G 4 5 7 8 10 11 12 13 6 9 1 14 2 3...

Page 29: ...n 6 4 Source of control panel or remote for the amount of output is selected by the V A Control switch For Air Carbon Arc CAC A cutting and goug ing place switch in Stick position For best re sults pl...

Page 30: ...olts OCV Preset Amps V A 80 0 85 Actual Volts Actual Amps V A 24 5 85 V Sense Feeder Flashes OCV And Preset Blank V A 80 0 Actual Volts Actual Amps V A 24 5 250 6 4 Mode Switch Settings The Stick and...

Page 31: ...If operating at even lower temperatures contact a Factory Authorized Service Agent or Kubota Ser vice Center for coolant information Battery ReplacementBattery Rating 12 Volt 535 CCA minimum 90 RSV Gr...

Page 32: ...in On posi tion to reset 6 Supplementary Protectors CB2 And CB3 CB2 protects RC2 and CB3 protects RC3 from from overload If CB2 or CB3 opens the receptacle does not work Press button to reset 7 Suppl...

Page 33: ...faulty equip ment Check for damaged tools cords plugs etc connected to the receptacle Press button to reset re ceptacle and resume operation At least once a month run en gine at weld power speed and p...

Page 34: ...eceptacle shares a load with one half of 240 V receptacle 2 Plug Wired for 240 V 2 Wire Load 3 Neutral Silver Terminal 4 Load 1 Brass Terminal 5 Load 2 Brass Terminal 6 Ground Green Terminal 7 Amperes...

Page 35: ...OM 492 Page 31 SECTION 8 MAINTENANCE AND TROUBLESHOOTING 8 1 Maintenance Label...

Page 36: ...ion 8 3 Fuel Connections Weld Terminals Spark Arrestor Screen Every 100 Hours 5 16 in 8 mm Section 8 4 Engine Manual Air Cleaner Element Air Cleaner Hoses Belt Tension Battery Terminals Every 200 Hour...

Page 37: ...656 Stop engine and let cool 1 Cleanout Plug Remove plug and remove any dirt covering cleanout hole Start engine and run several min utes to blow out cleanout hole If nothing blows out of hole briefl...

Page 38: ...l engine protection Never clean a safety element Re place the safety element after servic ing the primary element three times Clean or replace primary element if dirty see note above before cleaning R...

Page 39: ...Open secondary fuel filter petcock and drain water into metal container Close pet cock when water free fuel flows To change fuel filters Install new primary fuel filter as shown Replace secondary fuel...

Page 40: ...adiator Cap 3 Radiator Air Bleed Screw Change coolant according to engine manual Add coolant according to Sec tion 5 3 Run engine until engine reaches normal operating temperature Loosen air bleed scr...

Page 41: ...mount of thread will be visible on plunger rod when the jam nut is tight ened Do not tighten jam nut yet Mount solenoid on bracket Move so lenoid plunger manually to align slot in throttle link with h...

Page 42: ...speed Turn rod counter clockwise to increase idle speed Tighten nut Be sure solenoid plunger rod pulls all the way in bottoms when en ergized If plunger rod does not pull all the way in readjust rod a...

Page 43: ...Press button to reset 3 Circuit Breaker CB7 4 Circuit Breaker CB8 5 Supplementary Protector CB10 CB7 protects the engine glow plug from overload If CB7 opens the glow plug does not work and engine may...

Page 44: ...n in the thermal protec tion circuitry located on the right side of the unit If this display is shown contact a Factory Authorized Service Agent 6 Help 5 Display Indicates the right side of the unit h...

Page 45: ...ing remote control be sure mode switch is in a position that provides output control at Remote 14 receptacle RC14 see Sections 5 8 and 6 1 Have Factory Authorized Service Agent check brushes slip ring...

Page 46: ...and tighten all gas fittings Properly prepare tungsten No 115 volt ac output at Remote 14 re ceptacle RC14 Reset supplementary protector CB5 see Section 8 9 No 24 volt ac output at Remote 14 re ceptac...

Page 47: ...returns to Run position Check oil level see Section 5 2 Engine will not start if oil pressure is too low Check coolant level and fan belt see Section 5 2 and engine manual Engine will not start if en...

Page 48: ...Have Factory Authorized Service Agent check voltage regulator board PC8 and current transformer CT1 Engine does not go to high run speed when generator power or large weld load is applied with Engine...

Page 49: ...OM 492 Page 45 Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual...

Page 50: ...OM 492 Page 46 SECTION 9 ELECTRICAL DIAGRAMS Figure 9 1 Circuit Diagram For Welding Generator...

Page 51: ...OM 492 Page 47 212 633 F...

Page 52: ...el or specifications section in this manual to find rated voltage and current Do not idle engine longer than necessary Piston rings seat faster if engine runs at weld power rpm and the welding generat...

Page 53: ...erminals using proper size weld cables with correct connectors Observe correct polarity Start engine and run for several minutes Set load bank switches and then adjust generator V A control so load eq...

Page 54: ...t important 4 Voltmeter 5 Clamp On Ammeter Connect voltmeter and ammeter as shown if not provided on generator Start engine and run for several minutes Set grid switches and then adjust generator V A...

Page 55: ...tric shock and static electricity hazards Also see AWS Safety Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Generators 1 EquipmentGrounding Terminal On Front Panel 2 Ground...

Page 56: ...load and requires a constant amount of power 2 Non Resistive Load Equipment with a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when r...

Page 57: ...ome Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 Mi...

Page 58: ...P 6000 1500 1 1 2 HP 8200 2200 2 HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1 3...

Page 59: ...ust be at least twice the motor s running amperage kVA HP x HP x 1000 Volts Starting Amperage Example Calculate starting amper age required for a 230 V 1 4 HP mo tor with a motor start code of M Volts...

Page 60: ...to electric utility when service is re stored Install correct switch customer supplied Switch rating must be same as or greater than the branch overcurrent protection 3 Fused Disconnect Switch Install...

Page 61: ...15 40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 2 voltage drop Cord Lengths for 240 Volt Loads If unit does not have GFCI receptacles use GFCI...

Page 62: ...ST Hardware is common and not available unless listed 2 3 1 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 104 93 Fig 12 2 102 101 1000 94 94 99 98 97 96 92 91 90 103 Fig 12 3...

Page 63: ...age 59 802 324 N 30 Fig 12 4 76 77 89 88 79 81 80 86 87 63 85 62 82 83 84 65 60 61 58 57 59 66 78 64 71 72 74 75 73 68 69 70 54 31 32 35 33 34 36 15 55 56 53 52 51 39 38 37 41 40 42 43 46 48 50 67 49...

Page 64: ...access removable 1 19 198 870 DOOR access removable stainless 1 20 209 344 SEAL lifting eye 1 21 090 281 LABEL caution do not use ether 1 22 168 385 LABEL warning battery explosion can blind 1 23 198...

Page 65: ...4 25 in dia 1 187 441 ELEMENT air cleaner 1 202 102 ELEMENT air cleaner safety 1 72 197 227 HOSE elbow air intake 1 73 032 453 CABLE bat neg 24 375 No 2 awg w clamp and 375 rng 1 74 204 875 HOLD DOWN...

Page 66: ...CTOR rect 250 1skt 1 row plug 1 PLG36 192 171 CONNECTOR rect 250 3skt 1 row plug 1 PLG37 192 168 CONNECTOR rect 250 1 pin 1 row rcpt 1 PLG39 092 670 CONNECTOR rect univ 084 3P S 1 row plug 1 192 167 S...

Page 67: ...432 SUPPLEMENTARY PRO man reset 1P 10A 250VAC frict 2 6 2T 3T 172 661 BLOCK stud connection 6 position 2 7 212 480 PANEL front 1 8 206 795 BOOT circuit breaker clear hex nut 4 9 601 836 NUT 250 20 50...

Page 68: ...a 125v 5 20r 2 GFCI 1 2 151 981 RECEPTACLE Str Dx Grd 2p3w 15 20a 125v 5 20r Gfi 2 32 CB2 CB3 093 996 SUPPLEMENTARY PRO man reset 1P 20A 250VAC frict 2 33 RC4 007 469 RECEPTACLE twlk grd 3P4W 30A 250V...

Page 69: ...polyp film 34uf 1 4 025 248 STAND OFF insul 250 20 x 1 2 2 5 179 276 BUSHING snap in nyl 1 000 1 6 175 140 BRACKET DI DT 1 7 181 197 GASKET DI DT rubber 1 8 L3 L4 175 482 COIL DI DT 2 9 109 056 CORE...

Page 70: ...USHING snap in nyl 750 ID 2 46 177 547 BUSHING snap in nyl ct mount 1 47 CT1 175 199 TRANSFORMER current 1 213 410 HARNESS wiring unit consisting of 1 RC26 147 663 CONNECTOR rect univ 084 15 p s 3 row...

Page 71: ...2 047 x 591 1 5 192 600 FAN rotor gen 1 6 212 957 STATOR generator 1 7 159 918 BAFFLE fan 1 8 193 515 ADAPTER engine 1 9 013 367 LABEL warning moving parts 2 10 170 861 STUD stl 375 16 x 17 375 4 11 2...

Page 72: ...Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual...

Page 73: ...TM 188 304 Page 2 Invision 354MP Notes...

Page 74: ...Notes Over 80 000 trained since 1930 400 Trade Square East Troy Ohio 45373 1 800 332 9448 www welding org Start Your Professional Welding Career Now...

Page 75: ...nduction Heating Coils and Blankets Cables and Non Electronic Controls APT SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers...

Page 76: ...retain with your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal...

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