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

Engine driven welding generator
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PipePro 304
OM-492
190 603BB
November 2003
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

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  • Page 1 November 2003 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  PipePro 304 Visit our website at www.MillerWelds.com...
  • Page 2 We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.

  • Page 3: Table Of Contents

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

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

    SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom _nd_8/03 Y Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.

  • Page 6: Engine Hazards

    WELDING can cause fire or explosion. HOT PARTS can cause severe burns. D Allow cooling period before maintaining. Welding on closed containers, such as tanks, drums, or D Wear protective gloves and clothing when working on pipes, can cause them to blow up. Sparks can fly off from the welding arc.

  • Page 7: Compressed Air Hazards

    STEAM AND HOT COOLANT can burn. BATTERY ACID can BURN SKIN and EYES. D Do not tip battery. D If possible, check coolant level when engine is cold to D Replace damaged battery. avoid scalding. D Always check coolant level at overflow tank, if pres- D Flush eyes and skin immediately with water.

  • Page 8: California Proposition 65 Warnings

    READ INSTRUCTIONS. ARC WELDING can cause interference. D Use only genuine MILLER/Hobart replacement D Electromagnetic energy can interfere with sensitive parts. electronic equipment such as microprocessors, D Perform engine and air compressor (if applicable) computers, and computer-driven equipment such as robots.

  • Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION rom_fre 8/03 Y Avertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions. 2-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure Ce groupe de symboles si- présente des risques de danger ! Ceux-ci sont identifiés par gnifie Mise en garde !

  • Page 10: Dangers Existant En Relation Avec Le Moteur

    Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et NFPA 51B LES ACCUMULATIONS DE GAZ ris- pour les travaux à chaud et avoir de la surveillance et un extincteur à proxi- quent de provoquer des blessures ou mité. même la mort. DES PARTICULES VOLANTES peuvent blesser les yeux.

  • Page 11: Dangers Liés À L'air Comprimé

    D Pour empêcher tout démarrage accidentel pendant les travaux d’entretien, L’EXPLOSION DE LA BATTERIE peut débrancher le câble négatif (−) de batterie de la borne. RENDRE AVEUGLE. D Ne pas approcher les mains, cheveux, vêtements lâches et outils des orga- nes mobiles.

  • Page 12: Principales Normes De Sécurité

    LE SURCHAUFFEMENT peut endom- LIRE LES INSTRUCTIONS. mager le moteur électrique. D Utiliser seulement les pièces de rechange d’origine. D Effectuer la maintenance du moteur et du compres- D Arrêter ou déconnecter l’équipement avant de dé- seur (si applicable) suivant ce manuel et le manuel du marrer ou d’arrêter le moteur.

  • Page 13: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Symbol Definitions Fast Fast/Slow Stop Engine Slow (Idle) (Run, Weld/Power) (Run/Idle) Start Engine Panel/Local Temperature Fuel Check Valve Engine Oil Battery (Engine) Clearance Read Operator’s Engine Amperes Volts Manual MIG (GMAW), Stick (SMAW) TIG (GTAW) Circuit Breaker Wire Touch Start...

  • Page 14: Dimensions, Weights, And Operating Angles

    4-2. Dimensions, Weights, and Operating Angles Dimensions Height 36 in (914 mm) Width 24 in (610 mm) Y Do not exceed tilt angles or engine could Y Do not exceed tilt angles or engine could Depth 59 in (1499 mm) be damaged or unit could tip.

  • Page 15: 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 Return To Table Of Contents OM-492 Page 11...

  • Page 16: Fuel Consumption

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

  • Page 17: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Installing Welding Generator Y Do not weld on base. Welding on base can cause fuel tank fire or explosion. Bolt unit down using holes provided in base. Movement Y Always securely fasten weld- Y Do not lift unit from end. ing generator onto transport vehicle or trailer and comply with all DOT and other applica-...

  • Page 18: Engine Prestart Checks

    5-2. Engine Prestart Checks Check radiator coolant level when fluid is low in recovery tank. Full Capacity w/Overflow Tank 6.4 qt (6 L) Full 1/2 in (13 mm) Full Diesel Full 802 330-G Check all fluids daily. Engine must be cold Keep radiator and air intake clean and free and on a level surface.

  • Page 19: Adding Coolant To Radiator

    5-3. Adding Coolant To Radiator Y 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 Radiator Air Bleed Screw 6.4 qt (6 L) Remove radiator air bleed screw.

  • Page 20: Installing Exhaust Pipe

    5-5. Installing Exhaust Pipe 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 5-6. Connecting To Weld Output Terminals Positive (+) Weld Output Terminal Negative (−) Weld Output Terminal...

  • Page 21: Selecting Weld Cable Sizes

    5-7. Selecting Weld Cable Sizes* Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding*** 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 100 ft (30 m) or Less (45 m) (60 m) (70 m) (90 m) (105 m)

  • Page 22: Guidelines For Installing Customer-Supplied Emergency Air Shutdown Valve

    5-9. Guidelines For Installing Customer-Supplied Emergency Air Shutdown Valve 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. Installation of other air shutdown valves may differ from that shown.

  • Page 23: Operating Engine Block Heater

    5-10. Operating Engine Block Heater Y Do not run engine while cool- ant heater is on. Y Do not touch hot engine block. Engine block gets hot near heater. Coolant Heater Heater Plug Use heater to maintain a constant engine coolant temperature. See table for heater specifications.

  • Page 24: Section 6 − Operating Welding Generator

    SECTION 6 − OPERATING WELDING GENERATOR 6-1. Controls (See Section 6-2) Ref. 213 263-B / 802 330-G Return To Table Of Contents OM-492 Page 20...

  • Page 25: Description Of Controls (See Section 6-1)

    6-2. Description Of Controls (See Section 6-1) mode switch. Inductance determines the Engine Starting Controls motor thermostatically “wetness” of the weld puddle. When set to- 12 Glow Plug Switch controlled and only runs when cooling is ward maximum, “wetness” (puddle fluidity) in- needed.

  • Page 26: Meter Functions

    6-3. Meter Functions NOTE The meters display the actual weld output values for approximately three seconds after the arc is broken. Mode Meter Reading At Idle Meter Reading While Welding Scratch 80.0 10.3 Start TIG Actual Volts (OCV) Preset Amps Actual Volts Actual Amps 10.3...

  • Page 27: Lift-Arc Tig Procedure

    6-5. Lift-Arc TIG Procedure With Mode Switch in the Lift-Arc TIG position, start an arc as follows: TIG Electrode Workpiece Touch tungsten electrode to work- piece at weld start point, hold electrode to workpiece for 1-2 seconds, and slowly lift electrode. An arc will form when electrode is lifted.

  • Page 28: Section 7 − Operating Auxiliary Equipment

    SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. Generator Power Receptacles And Circuit Breakers SIMULTANEOUS WELDING AND AUXILIARY POWER Weld Total 120 V Single-Phase Three-Phase Current Power Receptacle 240 V 240 V In Amperes In Watts Amperes Receptacle Receptacle Amperes Amperes 11900 −...

  • Page 29: Optional Gfci Receptacles And Circuit Breakers

    7-2. Optional GFCI Receptacles And Circuit Breakers Y 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 Receptacle GFCI-3 GFCI-2 and GFCI-3 supply 60 Hz single-phase power at weld/power...

  • Page 30: Wiring Instructions For Optional 240 Volt, 3-Phase Twistlock Plug (Nema L15-30P)

    7-4. Wiring Instructions For Optional 240 Volt, 3-Phase Twistlock Plug (NEMA L15-30P) 240 V AC Three-Phase, 30 A, 3P4W Twistlock Plug Load 1 (Brass) Terminal (X) Load 2 (Brass)Terminal (Y) Load 3 (Brass) Terminal (Z) Ground (Green) Terminal (G) Cord Grip Strip cord jacket back enough to sep- arate conductors.

  • Page 31: Section 8 − Maintenance And Troubleshooting

    SECTION 8 − MAINTENANCE AND TROUBLESHOOTING 8-1. Maintenance Label Return To Table Of Contents OM-492 Page 27...

  • Page 32: Routine Maintenance

    8-2. Routine Maintenance Note Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period. Y Stop engine before maintaining. See also Engine Manual and Maintenance Label. Recycle engine Service engine more often if used in severe condi- fluids.

  • Page 33: Servicing Spark Arrestor

    Every 500 h Replace fan belt. Flush radiator. FUEL Drain sludge from Repair or replace SLUDGE fuel tank. cracked cables. Every 800 h Check valve clearance.* Every 1000 h Blow Service welding generator vacuum inside. brushes and slip rings. Service During heavy more often in dirty conditions.* service, clean...

  • Page 34: Servicing Air Cleaner

    8-4. Servicing Air Cleaner Y Stop engine. Y Do not run engine without air cleaner or with dirty element. En- gine damage caused by using a damaged element is not covered by the warranty. The air cleaner primary element can be cleaned but the dirt holding capac- ity of the filter is reduced with each cleaning.

  • Page 35: Servicing Engine Lubrication And Fuel Systems

    8-5. Servicing Engine Lubrication And Fuel Systems FLOW Tools Needed: 9/16 in Ref. 213 263-B / 802 330-G / S-0842 Y Stop engine and let cool. To drain water from fuel system: To change coolant: Oil Filter Open secondary fuel filter petcock and Change coolant according to engine Oil Drain Valve drain water into metal container.

  • Page 36: Servicing Engine Cooling System

    8-6. Servicing Engine Cooling System Y 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. Loosen air bleed screw to remove air from cooling system.

  • Page 37: Replacing Throttle Solenoid Ts1

    8-7. Replacing Throttle Solenoid TS1 Y Stop engine, and let cool. Y 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 Disconnect solenoid plug PLG39 from wiring harness receptacle...

  • Page 38: Adjusting Engine Speed

    8-8. Adjusting Engine Speed After tuning engine, check engine speeds with a tachometer (see table). If necessary, adjust speeds as follows: 2500 rpm Start engine and run until warm. Turn V/A control to max. 3750 Max Adjusting Idle Speed Turn Engine Control switch to Run/ Idle position.

  • Page 39: Overload Protection

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

  • Page 40: Voltmeter/Ammeter Help Displays

    8-10. Voltmeter/Ammeter Help Displays HE.L P−0 HE.L P−5 HE.L P−1 HE.L P−6 HE.L P−2 HE.L P−7 HE.L P−3 HE.L P−8 HE.L P−4 HE.L P−9 802 174-G Use the voltmeter/ammeter help displays to Help 2 Display Help 6 Display help determine the cause of no weld output. Indicates that the input voltage is too low and When a help display is shown, the inverter Indicates a malfunction in the thermal protec-...

  • Page 41: Troubleshooting

    8-11. Troubleshooting A. Welding Trouble Remedy 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 42 Trouble Remedy 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 43 C. Engine Trouble Remedy 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 44 Trouble Remedy 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 45 Notes Return To Table Of Contents OM-492 Page 41...

  • Page 46: Section 9 − Electrical Diagrams

    SECTION 9 − ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For Welding Generator OM-492 Page 42 Return To Table Of Contents...
  • Page 47 212 633-C Return To Table Of Contents OM-492 Page 43...

  • Page 48: Section 10 − Run-In Procedure

    SECTION 10 − RUN-IN PROCEDURE run_in4 8/01 10-1. Wetstacking Y Do 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 49: Run-In Procedure Using Load Bank

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

  • Page 50: Run-In Procedure Using Resistance Grid

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

  • Page 51: Grounding Generator To Truck Or Trailer Frame

    SECTION 11 − GENERATOR POWER GUIDELINES NOTE 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 Generator Power Receptacles − Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double...

  • Page 52: Grounding When Supplying Building Systems

    11-3. Grounding When Supplying Building Systems Equipment Grounding Terminal Grounding Cable GND/PE Use #10 AWG or larger insulated copper wire. Ground Device Y Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. Use ground device as stated in electrical codes.
  • Page 53 11-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1/8 HP 1/6 HP 1225 1/4 HP 1600 1/3 HP 2100 1/2 HP 3175 Capacitor Start-Induction Run 1/3 HP 2020 1/2 HP 3075 3/4 HP 4500 1400 1 HP...
  • Page 54 11-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1/4 in 3/8 in 1/2 in Circular Saw 6-1/2 in 7-1/4 in 8-1/4 in 1400 1400 Table Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in...
  • Page 55 11-8. Power Required To Start Motor Motor Start Code AC MOTOR Running Amperage VOLTS AMPS Motor HP CODE Motor Voltage PHASE To find starting amperage: Step 1: Find code and use table to find kVA/HP. If code is not listed, multiply running amperage by six to find starting amperage.
  • Page 56 11-10. Typical Connections To Supply Standby Power Y Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes. Fused Utility Welding Disconnect Electrical Generator Transfer Switch Switch Service Output (If Required) Essential Loads Y Have only qualified persons perform Switch transfers the electrical load from Connect generator with temporary or perma-...
  • Page 57 11-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current Load (Watts) (Amperes) 350 (106) 225 (68)

  • Page 58: Section 12 − Parts List

    SECTION 12 − PARTS LIST Hardware is common and not available unless listed. 103 − Figure 12-3 93 − Figure 12-2 Figure 12-1. Main Assembly Return To Table Of Contents OM-492 Page 54...
  • Page 59 30 − Figure 12-4 802 324-H Return To Table Of Contents OM-492 Page 55...
  • Page 60 Item Dia. Part Mkgs. Description Quantity Figure 12-1. Main Assembly ... . +198 157 PANEL, generator left ..........♦+198 873 .
  • Page 61 Item Dia. Part Mkgs. Description Quantity Figure 12-1. Main Assembly (Continued) ... . 202 198 BASE, fuel filter ...........
  • Page 62 Item Dia. Part Mkgs. Description Quantity Figure 12-1. Main Assembly (Continued) ....213 226 HARNESS, wiring ignition (consisting of) ......96 CR1, CR2 173 069 .
  • Page 63 Hardware is common and not available unless listed. 802 327-C Figure 12-2. Front Panel Item Dia. Part Mkgs. Description Quantity Figure 12-2. Front Panel (Figure 12-1, Item 93) ... . . 198 049 UPRIGHT, base front .
  • Page 64 Item Dia. Part Mkgs. Description Quantity Figure 12-2. Front Panel (Continued) ... . 192 265 GAUGE, fuel elec switch w/o switchgage sensor ..... . .
  • Page 65 Hardware is common and not available unless listed. 802 326-A Figure 12-3. Inverter Assembly Item Dia. Part Mkgs. Description Quantity Figure 12-3. Inverter Assembly (Figure 12-1, Item 103) ..196 148 CIRCUIT CARD ASSEMBLY, interconnecting .
  • Page 66 Item Dia. Part Mkgs. Description Quantity Figure 12-3. Inverter Assembly (Continued) ... . 181 853 INSULATOR, screw ..........
  • Page 67 Hardware is common and not available unless listed. 802 338-A Figure 12-4. Generator Item Dia. Part Mkgs. Description Quantity Figure 12-4. Generator Assembly (Figure 12-1, Item 30) ... . . 217 046 ENDBELL (includes) .
  • Page 71 Effective January 1, 2003 (Equipment with a serial number preface of “LC” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. Call LIMITED WARRANTY − Subject to the terms and conditions Induction Heating Coils and Blankets below, Miller Electric Mfg.

  • Page 72: Options And Accessories

    Distributor Address City State For Service Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories...

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