Miller Electric PipePro 304 Owner's Manual
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Miller Electric PipePro 304 Owner's Manual

Miller electric owner's manual welding engine driven welding generator pipepro 304
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www.MillerWelds.com
PipePro 304
OM-492
190 603BF
2007−05
Processes
MIG (GMAW) and Pulsed MIG
(GMAW-P) Welding
Flux Cored (FCAW) Welding
Stick (SMAW) Welding
TIG (GTAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
Description
Engine Driven Welding Generator
File: Engine-Driven

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  • Page 1 Visit our website at www.MillerWelds.com PipePro 304 OM-492 190 603BF 2007−05 Processes MIG (GMAW) and Pulsed MIG (GMAW-P) Welding Flux Cored (FCAW) Welding Stick (SMAW) Welding TIG (GTAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging Description Engine Driven Welding Generator...
  • Page 2 ISO 9001:2000 Quality System Standard. 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1-1. Symbol Usage ............... . 1-2.
  • Page 4 TABLE OF CONTENTS SECTION 8 − MAINTENANCE AND TROUBLESHOOTING 8-1. Maintenance Label ..............8-2.

  • Page 5: Section 1 − Safety Precautions − Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
  • Page 6 FUMES AND GASES can be hazardous. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases.

  • Page 7: Engine Hazards

    1-3. Engine Hazards BATTERY EXPLOSION can BLIND. D Always wear a face shield, rubber gloves, and protective clothing when working on a battery. D Stop engine before disconnecting or connect- ing battery cables or servicing battery. D Do not allow tools to cause sparks when working on a battery. D Do not use welder to charge batteries or jump start vehicles.

  • Page 8: Additional Symbols For Installation, Operation, And Maintenance

    HOT METAL from air arc cutting and gouging can cause fire or explosion. D Do not cut or gouge near flammables. D Watch for fire; keep extinguisher nearby. HOT PARTS can cause burns and injury. D Do not touch hot compressor or air system parts.

  • Page 9: California Proposition 65 Warnings

    H.F. RADIATION can cause interference. D High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. D Have only qualified persons familiar with electronic equipment perform this installation. D The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.

  • Page 10: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 CONSIGNES DE SÉCURITÉ − LIRE AVANT − Se protéger, ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud. 2-1. Signification des symboles DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves.
  • Page 11 DES PIÈCES CHAUDES peuvent provoquer des brûlures graves. D Ne pas toucher à mains nues les parties chau- des. D Prévoir une période de refroidissement avant de travailler à l’équipement. D Ne pas toucher aux pièces chaudes, utiliser les outils recomman- dés et porter des gants de soudage et des vêtements épais pour éviter les brûlures.

  • Page 12: Dangers Existant En Relation Avec Le Moteur

    LES CHAMPS MAGNETIQUES peuv- ent affecter des implants médicaux. D Porteur de simulateur cardiaque ou autre im- plants médicaux, rester à distance. D Les porteurs d’implants doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de sou- dage par points, de gougeage, du coupage plasma ou de chauf- fage par induction.

  • Page 13: Dangers Liés À L'air Comprimé

    L’utilisation d’un groupe autonome à l’intérieur PEUT VOUS TUER EN QUELQUES MINUTES. D Les fumées d’un groupe autonome contient du monoxyde de carbone. C’est un poison invisi- ble et inodore. D JAMAIS utiliser dans une maison ou garage, même avec les portes et fenêtres ouvertes. D Uniquement utiliser à...
  • Page 14 LE SURCHAUFFEMENT peut endom- mager le moteur électrique. D Arrêter ou déconnecter l’équipement avant de démarrer ou d’arrêter le moteur. D Ne pas laisser tourner le moteur trop lentement sous risque d’en- dommager le moteur électrique à cause d’une tension et d’une fré- quence trop faibles.

  • Page 15: Proposition Californienne 65 Avertissements

    2-6. Proposition californienne 65 Avertissements Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des mal- formations congénitales et, dans certains cas, des cancers. (Code de santé...

  • Page 16: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Symbol Definitions Stop Engine Start Engine Engine Oil Engine MIG (GMAW), Wire Foot Control Positive Time Do not switch while welding Wire Feed SECTION 4 − SPECIFICATIONS 4-1. Weld, Power, And Engine Specifications Rated Maximum Welding Welding Open-Circuit...

  • Page 17: Dimensions, Weights, And Operating Angles

    4-2. Dimensions, Weights, and Operating Angles Dimensions Height 36 in (914 mm) Width 24 in (610 mm) Depth 59 in (1499 mm) 23-5/8 in (600 mm) 21-1/2 in (546 mm) 1 in (25 mm) 15-5/8 in (397 mm) 26-3/8 in (679 mm) 58-3/4 in (1492 mm) 13/32 in (10 mm) Dia.

  • Page 18: Volt-Ampere Curves

    4-4. Volt-Ampere Curves 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 ARC CONTROL B. CV Mode 178 652 / 178 653 OM-492 Page 14...

  • Page 19: Fuel Consumption

    4-5. Fuel Consumption 7.57 2.00 6.62 1.75 5.67 1.50 4.73 1.25 3.78 1.00 2.84 0.75 1.98 0.50 0.95 0.25 Notes 3600 RPM IDLE 100 150 200 250 300 350 400 450 500 DC WELD AMPERES AT 100% DUTY CYCLE 193 458 Work like a Pro! Pros weld and cut safely.

  • Page 20: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Installing Welding Generator Movement Do not lift unit from end. Location / Airflow Clearance 18 in (460 mm) 18 in (460 mm) 18 in 18 in (460 mm) (460 mm) Mounting Inadequate support. Do not use flexible mounts. Grounding GND/PE Electrically bond generator frame to...

  • Page 21: Engine Prestart Checks

    5-2. Engine Prestart Checks Full 1/2 in (13 mm) Full Diesel Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. Engine stops if oil pressure is too low or en- gine temperature is too high.

  • Page 22: Adding Coolant To Radiator

    5-3. Adding Coolant To Radiator 5-4. Connecting The Battery OM-492 Page 18 Stop engine and let cool. Check coolant level according Full to Section 5-2 before starting this procedure. If coolant level is below bottom of radiator filler neck, add coolant as Capacity follows: w/Overflow Tank...

  • Page 23: Installing Exhaust Pipe

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

  • Page 24: Connecting To Weld Output Terminals

    5-6. Connecting To Weld Output Terminals Stop engine. Positive (+) Weld Output Terminal Negative (−) Weld Output Terminal Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your machine. Weld Output Terminal Supplied Weld Output Terminal Nut Weld Cable Terminal Copper Bar Remove supplied nut from weld output termi-...

  • Page 25: Selecting Weld Cable Sizes

    5-7. Selecting Weld Cable Sizes* Welding Amperes Weld Output Weld Output Terminals Turn off power before connecting to weld connecting to weld output terminals. Do not use worn, damaged, under- sized, sized, poorly poorly spliced cables. This chart is a general guideline and may not suit all applications. If cable(s) overheat, use next size larger cable. **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.

  • Page 26: Guidelines For Installing Customer-Supplied Emergency Air Shutdown Valve

    5-9. Guidelines For Installing Customer-Supplied Emergency Air Shutdown Valve Mount on lower front panel OM-492 Page 22 A customer-supplied emergency air shutdown valve can be installed to stop the engine imme- diately in emergency situations. These guidelines show the typical installation of a Gator ESD 175-275-L3 air shutdown valve.

  • Page 27: Operating Engine Block Heater

    5-10. Operating Engine Block Heater Coolant Heater Specifications Watts Volts 10% Amps Notes Start Your Professional Welding Career Now! 400 Trade Square East, Troy, Ohio 45373 1-800-332-9448 www.welding.org Do not touch hot engine block. Engine block gets hot near heater. NOTICE −...

  • Page 28: Section 6 − Operating Welding Generator

    SECTION 6 − OPERATING WELDING GENERATOR 6-1. Controls (See Section 6-2) OM-492 Page 24 Ref. 213 263-B / 802 330-G...

  • Page 29: Description Of Controls (See Section 6-1)

    6-2. Description Of Controls (See Section 6-1) motor thermostatically controlled and only runs when cooling is needed. Engine Lights Engine Temperature Light Light goes on and engine stops if engine tem- perature is too high. NOTICE − Stop engine and fix trouble if En- gine Temperature light goes on.

  • Page 30: Meter Functions

    6-3. Meter Functions The meters display the actual weld output values for approximately three seconds after the arc is broken. Mode Scratch Start TIG Actual Volts (OCV) Lift-Arc TIG Actual Volts Preset Volts Pulsed Pulse Display Stick Actual Volts (OCV) V-Sense Feeder Flashes OCV And Preset...

  • Page 31: Lift-Arc Tig Procedure

    6-5. Lift-Arc TIG Procedure 6-6. Recommendations For Extreme Cold Weather Operation For more information on operating in cold weather, contact the nearest Factory Au- thorized Service Agent or Kubota Service Center. Fuel Use an arctic-grade diesel fuel and keep fuel tank at least half full to prevent fuel lines from draining back into tank.

  • Page 32: Section 7 − Operating Auxiliary Equipment

    SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. Generator Power Receptacles And Circuit Breakers Weld Current In Amperes If unit does not have GFCI recep- tacles, use GFCI-protected exten- sion cord. Generator power decreases as weld current increases. 240 V 50 A AC Receptacle RC1 RC1 supplies 60 Hz single-phase power at weld/power speed.

  • Page 33: Optional Gfci Receptacles And Circuit Breakers

    7-2. Optional GFCI Receptacles And Circuit Breakers 7-3. Wiring Instructions For Optional 240 Volt, 3-Phase Twistlock Plug (NEMA L15-30P) 240V 240V 240V If unit does not have GFCI receptacles, use GFCI-pro- tected extension cord. Generator power decreases as weld current increases. 120 V 20 A AC GFCI Duplex Receptacle GFCI-2 120 V 20 A AC GFCI Duplex...

  • Page 34: Wiring Instructions For Optional 240 Volt, Single-Phase Plug (Nema 14-50P)

    7-4. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P) Current Available in Amperes 240 V Each 120 V Duplex Receptacle* Receptacle V x A = Watts *One 240 V load or two 120 V loads. OM-492 Page 30 120V 120V 240V...

  • Page 35: Section 8 − Maintenance And Troubleshooting

    SECTION 8 − MAINTENANCE AND TROUBLESHOOTING 8-1. Maintenance Label OM-492 Page 31...

  • Page 36: Routine Maintenance

    8-2. Routine Maintenance n = Check Z = Change ........... . Every Hours n Coolant Level...

  • Page 37: Servicing Spark Arrestor

    8-3. Servicing Spark Arrestor Tools Needed: 1/4 in Stop engine and let cool. 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, briefly cover end of exhaust pipe with fire- proof material.

  • Page 38: Servicing Air Cleaner

    8-4. Servicing Air Cleaner Keep nozzle 2 in (51 mm) from element. Blow OM-492 Page 34 Inspect Stop engine. NOTICE − Do not run engine without air cleaner or with dirty element. Engine damage caused by using a damaged ele- ment is not covered by the warranty.

  • Page 39: Servicing Engine Lubrication And Fuel Systems

    8-5. Servicing Engine Lubrication And Fuel Systems Stop engine and let cool. Oil Filter Oil Drain Valve 1/2 ID x 12 in Hose Fuel Line Primary Fuel Filter Secondary Fuel Filter Petcock Fuel Tank Sludge Drain To change oil and filter: Pull oil drain hose through access hole in base.

  • Page 40: Servicing Engine Cooling System

    8-6. Servicing Engine Cooling System OM-492 Page 36 Stop engine and let cool. Radiator Draincock Radiator Cap 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.

  • Page 41: Replacing Throttle Solenoid Ts1

    8-7. Replacing Throttle Solenoid TS1 Stop engine, and let cool. Disconnect battery, negative (−) cable first. Remove right side engine panel. Plug PLG39/Receptacle RC39 Throttle Solenoid TS1 Shoulder Bolt And Nut Throttle Link Throttle Solenoid Plunger Rod Jam Nut Throttle Arm Throttle Arm Stop Screw Disconnect solenoid plug PLG39 from wiring harness receptacle...

  • Page 42: Adjusting Engine Speed

    8-8. Adjusting Engine Speed OM-492 Page 38 2500 rpm (41.6 Hz) 3750 Max (62.5 Hz) After tuning engine, check engine speeds with a tachometer (see table). If necessary, adjust speeds as follows: Start engine and run until warm. Turn V/A control to max. Adjusting Idle Speed Idle speed is factory set and normally does not not require adjustment unless...

  • Page 43: Overload Protection

    8-9. Overload Protection Tools Needed: 3/8 in Stop engine. When a supplementary protec- tor or circuit breaker opens, it usually indicates a more seri- ous problem exists. Contact Factory Authorized Service Agent. Supplementary Protector CB5 CB5 protects the 115 volt ac output to Remote 14 receptacle RC14.

  • Page 44: Voltmeter/Ammeter Help Displays

    8-10. Voltmeter/Ammeter Help Displays Use the voltmeter/ammeter help displays to help determine the cause of no weld output. When a help display is shown, the inverter module weld output has stopped but the en- gine continues to run. Correct the problem before resuming operation.

  • Page 45: Troubleshooting

    8-11. Troubleshooting A. Welding Trouble No weld output. Check control settings. Check weld connections. Disconnect equipment from generator power receptacles during start-up. If using remote control, be sure mode switch is in a position that provides output control at Remote 14 receptacle (see Sections 5-8 and 6-1).
  • Page 46 Trouble Remote contactor control does not Check and tighten connections to Remote 14 receptacle RC14 (see Section 5-8). activate contactor. Lack of high frequency; difficulty in Use proper size tungsten for welding amperage. establishing Gas Tungsten Arc Weld- ing arc. Reduce leakage of high frequency from torch or work cable (check grounding, remove excessive coils from weld cables, use shorter weld cables, etc.).
  • Page 47 C. Engine Trouble Engine will not crank. Reset circuit breaker CB8 (see Section 8-9). Check battery voltage. Check battery connections and tighten if necessary. Have Factory Authorized Service Agent check Engine Control switch S2. Engine cranks, but does not start. Check fuel level (see Section 5-2).
  • Page 48 Trouble Engine does not go to low (idle) speed Be sure Engine Control switch S2 is in Run/Idle position. with Engine Control switch in Run/Idle position. Remove all weld and generator power loads. Turn off remote device connected to Remote 14 receptacle RC14 (see Section 5-8). Check for obstructed movement of throttle solenoid linkage.
  • Page 49 Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual. OM-492 Page 45...

  • Page 50: Section 9 − Electrical Diagrams

    SECTION 9 − ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For Welding Generator OM-492 Page 46...
  • Page 51 212 633-F OM-492 Page 47...

  • Page 52: Section 10 − Run-In Procedure

    SECTION 10 − RUN-IN PROCEDURE 10-1. Wetstacking OM-492 Page 48 run_in4 2007−05 perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur. Welding Generator Run diesel engines near rated volt- age and current during run-in period to properly seat piston rings and prevent wetstacking.

  • Page 53: Run-In Procedure Using Load Bank

    10-2. Run-In Procedure Using Load Bank Stop engine. Do not touch hot exhaust pipe, engine parts, or load bank/grid. Keep exhaust and pipe away from flammables. NOTICE − Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur.

  • Page 54: Run-In Procedure Using Resistance Grid

    10-3. Run-In Procedure Using Resistance Grid OM-492 Page 50 Stop engine. Do not touch hot exhaust pipe, engine parts, or load bank/grid. Keep exhaust and pipe away from flammables. NOTICE − Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur.

  • Page 55: Section 11 − Generator Power Guidelines

    SECTION 11 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown. 11-1. Selecting Equipment 11-2. Grounding Generator To Truck Or Trailer Frame GND/PE Generator Power Receptacles −...

  • Page 56: Grounding When Supplying Building Systems

    11-3. Grounding When Supplying Building Systems 11-4. How Much Power Does Equipment Require? OM-492 Page 52 GND/PE VOLTS 115 AMPS Equipment Grounding Terminal Grounding Cable Use #10 AWG or larger insulated copper wire. Ground Device Use ground device as stated in electrical codes.
  • Page 57 11-5. Approximate Power Requirements For Industrial Motors Industrial Motors Split Phase Capacitor Start-Induction Run Capacitor Start-Capacitor Run Fan Duty 11-6. Approximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Stock Tank De-Icer Grain Cleaner Portable Conveyor Grain Elevator Milk Cooler Milker (Vacuum Pump) FARM DUTY MOTORS Std.
  • Page 58 11-7. Approximate Power Requirements For Contractor Equipment Contractor Hand Drill Circular Saw Table Saw Band Saw Bench Grinder Air Compressor Electric Chain Saw Electric Trimmer Electric Cultivator Elec. Hedge Trimmer Flood Lights Submersible Pump Centrifugal Pump Floor Polisher High Pressure Washer 55 gal Drum Mixer Wet &...
  • Page 59 11-8. Power Required To Start Motor Motor Start Code KVA/HP 11-9. How Much Power Can Generator Supply? Single-Phase Induction Motor Starting Requirements 10.0 AC MOTOR VOLTS AMPS CODE PHASE 11.2 12.5 Motor Start Code Running Amperage Motor HP Motor Voltage To find starting amperage: Step 1: Find code and use table to find kVA/HP.
  • Page 60 11-10. Typical Connections To Supply Standby Power Utility Electrical Transfer Switch Service Essential Loads OM-492 Page 56 Fused Welding Disconnect Generator Switch Output (If Required) Have only qualified persons perform these connections according to all applicable codes and safety practices. Properly install and ground this equipment according to its Owner’s Manual and na-...
  • Page 61 11-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord. Current Load (Watts) (Amperes) 1200 1800 2400 3000 3600 4200 4800 5400 6000 *Conductor size is based on maximum 2% voltage drop Cord Lengths for 240 Volt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord.

  • Page 62: Section 12 − Parts List

    SECTION 12 − PARTS LIST Hardware is common and not available unless listed. Fig. 12-3 1000 Fig. 12-2 Figure 12-1. Main Assembly OM-492 Page 58...

  • Page 63: Main Assembly

    30 Fig. 12-4 OM-492 Page 59 802 324-N...
  • Page 64 Item Dia. Part Mkgs. Figure 12-1. Main Assembly ... . +198 157 PANEL, generator left ..+198 873 PANEL, generator left stainless .
  • Page 65 Item Dia. Part Mkgs. Figure 12-1. Main Assembly (Continued) ... . 202 198 BASE, fuel filter ... *192 744 FILTER, fuel spin-on .
  • Page 66 Item Dia. Part Mkgs. Figure 12-1. Main Assembly (Continued) ....213 226 HARNESS, wiring ignition (consisting of) 96 CR1, CR2 173 069 ..
  • Page 67 Hardware is common and not available unless listed. Item Dia. Part Mkgs. Figure 12-2. Front Panel (Figure 12-1, Item 93) ... . . 198 049 UPRIGHT, base front ... . +191 737 PANEL, front louver .
  • Page 68 Item Dia. Part Mkgs. Figure 12-2. Front Panel (Continued) ... . 192 265 GAUGE, fuel elec switch w/o switchgage sensor ... . 145 247 METER, hour 12−24vdc 1.25 x 2.12 rect 206 879...
  • Page 69 Item Dia. Part Mkgs. Figure 12-3. Inverter Assembly (Figure 12-1, Item 103) ..196 148 CIRCUIT CARD ASSEMBLY, interconnecting C3,C4,C5 192 935 CAPACITOR, elctlt 2700uf 450 ..186 015 CAPACITOR, polyp film .34uf .
  • Page 70 Item Dia. Part Mkgs. Figure 12-3. Inverter Assembly (Continued) ... . 181 853 INSULATOR, screw ..189 567 TRANSDUCER, current 400A D1,D2 . . . 179 630 KIT, diode ultra-fast recovery 26 R1,C6,C7 175 194...
  • Page 71 Hardware is common and not available unless listed. Item Dia. Part Mkgs. Figure 12-4. Generator Assembly (Figure 12-1, Item 30) ... . . 217 046 ENDBELL (includes) ... . . 216 532 .
  • Page 72 Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual.
  • Page 73 Notes Invision 354MP TM-188 304 Page 2...
  • Page 74 Notes Start Your Professional Over 80,000 trained 400 Trade Square East, Troy, Ohio 45373 Welding Career Now! since 1930! 1-800-332-9448 www.welding.org...
  • Page 75 Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to 1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in for your local material and workmanship at the time it is shipped by Miller.

  • Page 76: Options And Accessories

    File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. 2007 Miller Electric Mfg. Co. 2007−01 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA...

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