Page 2 - To locate your nearest; Thank you; From Miller to You
Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local Miller distributor to receive the latest fullline catalog or individual specification sheets. To locate your nearest distributor or service agency call...
Page 3 - TABLE OF CONTENTS
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 5 - ELECTRIC SHOCK can kill.; SIGNIFICANT DC VOLTAGE exists in inverters after stop-; FUMES AND GASES can be hazardous.
OM-4433 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom _nd_3/05 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 adjoi...
Page 8 - ARC WELDING can cause interference.
OM-4433 Page 4 READ INSTRUCTIONS. Use only genuine MILLER/Hobart replacement parts. Perform engine and air compressor (if applicable) maintenance and service according to this manual and the engine/air compressor (if applicable) manu- als. H.F. RADIATION can cause interference. High-frequency (H.F.)...
Page 11 - LA CHUTE DE L’APPAREIL peut blesser.
OM-4433 Page 7 Si le moteur est chaud et que le liquide doit être vérifié, opérer comme suivant. Mettre des lunettes de sécurité et des gants, placer un torchon sur le bouchon du radiateur. Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant d’enle- ver le bouchon. LES ACCUMULATIONS...
Page 12 - Proposition californienne 65 Avertissements; Principales normes de sécurité; Information EMF
OM-4433 Page 8 LIRE LES INSTRUCTIONS. Utiliser seulement les pièces de rechange d’origine. Effectuer la maintenance du moteur et du compresseur (si applicable) suivant ce manuel et le manuel du moteur/ compresseur (si applicable). LE RAYONNEMENT HAUTE FRÉ- QUENCE (H.F.) risque de provoquer des inter...
Page 13 - Notes; Pros weld and cut
OM-4433 Page 9 SECTION 3 − DEFINITIONS 3-1. Warning Label Definitions 3/96 1 Remove unit from shipping crate. Remove Owner’s Manual from unit. Follow instructions to install muffler. 2 Read Owner’s Manual. Read labels on unit. 3 Use Diesel Fuel only, and fill fuel tank. Leave room for expansion. 4 W...
Page 15 - Some symbols are found only on CE products.; NOTE; Hz
OM-4433 Page 11 3-3. Symbols And Definitions Some symbols are found only on CE products. NOTE Stop Engine Fast (Run, Weld/ Power) Slow (Idle) Start Engine Starting Aid (Preheat) Battery (Engine) Engine Oil Pressure Engine Oil Check Injectors/ Pump Check Valve Clearance Fuel Protective Earth (Ground)...
Page 18 - DC WELD AMPERES AT 100% DUTY CYCLE; CC
OM-4433 Page 14 4-4. Fuel Consumption The curve shows typical fuel use under weld or power loads. 217 509 IDLE DC WELD AMPERES AT 100% DUTY CYCLE U.S. GAL/HR. 0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 0 50 100 150 200 250 300 350 400 Continuous Welding 4-5. Duty Cycle And Overheating Duty Cycle i...
Page 19 - AC AMPERES IN 120 V MODE; MATERIAL THICKNESS REFERENCE CHART
OM-4433 Page 15 4-6. AC Generator Power Curve 217 519 The ac power curve shows the gen- erator power in amperes available at the 120 and 240 volt receptacles. 0 40 80 120 160 0 20 40 60 80 AC AMPERES IN 120 V MODE AC AMPERES IN 240 V MODE 300 250200 150 100 50 0 150 125 100 75 50 25 0 AC VOL TS Note...
Page 25 - -7. Connecting To Weld Output Terminals
OM-4433 Page 21 5-7. Connecting To Weld Output Terminals 803 562 / 803 778-A Tools Needed: 3/4 in MIG and FCAW Welding For MIG and FCAW welding Direct Current Electrode Positive (DCEP) connect wire feed- er cable to CV (Wire) terminal on right and work cable to Work/Negative ( − ) terminal on left. ...
Page 27 - -9. Connecting To Remote 14 Receptacle RC14; REMOTE; OUTPUT
OM-4433 Page 23 5-9. Connecting To Remote 14 Receptacle RC14 Socket* Socket Information 24 VOLTS AC A 24 volts ac. Protected by sup- plementary protector CB8. 24 VOLTS AC B Contact closure to A completes 24 volt ac contactor control circuit. C Output to remote control:+10 volts dc in MIG mode; 0 to ...
Page 30 - Process/Contactor Switch Settings
OM-4433 Page 26 6-3. Process/Contactor Switch 1 Process/Contactor Switch Weld output terminals are ener- gized when Process/Contactor switch is in a Weld Terminals Al- ways On position and the engine is running. Use switch to select weld process and weld output on/off control (see table be- low).Pla...
Page 31 - Start Procedure
OM-4433 Page 27 6-4. Lift-Arc ™ Start Procedure Lift-Arc TIG With Lift-Arc TIG selected, start arc as follows:1 TIG Electrode 2 Workpiece Turn gas on. Touch tungsten electrode to workpiece at weld start point. Hold electrode to workpiece for 1-2 seconds , and slowly lift electrode. Arc is formed whe...
Page 37 - -4. Inspecting And Cleaning Optional Spark Arrestor Muffler
OM-4433 Page 33 8-4. Inspecting And Cleaning Optional Spark Arrestor Muffler 803 582 / Ref. 217 357-A Stop engine and let cool. 1 Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole.3 Exhaust Pipe Start engine and run at idle speed to blow out cleanout hole....
Page 40 - -8. Servicing Fuel And Lubrication Systems
OM-4433 Page 36 8-8. Servicing Fuel And Lubrication Systems 802 490 / Ref. 801 434 Stop engine and let cool. After servicing, start engine and check for fuel leaks. Stop engine, tighten connec- tions as necessary, and wipe up spilled fuel. 1 Oil Filter 2 Oil Drain Valve And Hose 3 Oil Fill Cap 4 Pri...
Page 44 - Note; Trouble
OM-4433 Page 40 8-12. Troubleshooting Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 8-11). Note A. Welding Trouble Remedy No weld output; generator power output okay at ac receptacles. Place Process/Contactor switch in a Weld Terminals Always On pos...
Page 48 - Figure 9-1. Circuit Diagram For Welding Generator
OM-4433 Page 44 SECTION 9 − ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For Welding Generator
Page 53 - GENERATOR POWER GUIDELINES; welding generators. Your unit may differ from those shown.; 1-2. Grounding Generator To Truck Or Trailer Frame
OM-4433 Page 49 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. NOTE 11-1. Selecting Equipment gen_pwr 11/02 − Ref. ST-159 730 / ST-800 577 1 Generator Power Receptacle...
Page 54 - 1-3. Grounding When Supplying Building Systems
OM-4433 Page 50 11-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding Terminal 2 Grounding Cable Use #10 AWG or larger insulated copper wire.3 Ground Device Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. GND/PE ...
Page 55 - 1-5. Approximate Power Requirements For Industrial Motors
OM-4433 Page 51 11-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 2100 700 1/2 HP 3175 875 Capacitor Start-Induction Run 1/3 HP 2020 720 1/2 HP 3075 975 3/4 HP 4500 1400 1...
Page 56 - 1-7. Approximate Power Requirements For Contractor Equipment
OM-4433 Page 52 11-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/2 in 500 500 7-1/4 in 900 900 8-1/4 in 1400 1400 Table Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 ...
Page 58 - 1-10. Typical Connections To Supply Standby Power
OM-4433 Page 54 11-10. Typical Connections To Supply Standby Power Have only qualified persons perform these connections according to all applicable codes and safety practic- es. Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes. Customer...
Page 60 - PARTS LIST
OM-4433 Page 56 SECTION 12 − PARTS LIST Hardware is common and notavailable unless listed. Wirng harnesses are listed at the end of parts section. 1 (Fig.12-3) 2 3 4 5 6 (Fig.12-5) 7 8 9 10 11 12 13 14 16 17 18 19 20 21 22 23 15 24 25 26 27 28 90 91 92 93 94 95 96 98 97 99 100 101 102 103 104 105 10...
Page 70 - associated wiring harness.; Wiring Harnesses
OM-4433 Page 66 Some wiring harness components (switches, relays, supplementary protectors) are also referenced elsewhere in this parts list. Purchase components separately or as part of the associated wiring harness. Note Description Part No. Dia. Mkgs. Item No. Wiring Harnesses Quantity 231122 Har...
Page 71 - (Equipment with a serial number preface of “LG” or newer)
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2006 − 01 Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding ...
Page 72 - Please complete and retain with your personal records.; Contact a DISTRIBUTOR or SERVICE AGENCY near you.; For Service
PRINTED IN USA © 2006 Miller Electric Mfg. Co. 2006 − 01 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters − USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 E...