Page 2 - 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 catalog sheets. To locate your nearestdistributor or service agency call 1-800-...
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-4411 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom _nd_10/02 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 adjo...
Page 8 - ARC WELDING can cause interference.
OM-4411 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 9 - Avertissement: Protégez vous et les autres des blessures; UN CHOC ÉLECTRIQUE peut tuer.
OM-4411 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION rom_fre 8/03 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 présente des risques de danger ...
Page 10 - LES CHAMPS MAGNÉTIQUES peuvent
OM-4411 Page 6 LES ACCUMULATIONS DE GAZ ris- quent de provoquer des blessures ou même la mort. Fermer l’alimentation du gaz protecteur en cas de non utilisation. Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi- rateur d’adduction d’air homologué. Le rayonnement de l’arc du...
Page 11 - maintenance
OM-4411 Page 7 L’EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE. Toujours porter une protection faciale, des gants en caoutchouc et vêtements de protection lors d’une in- tervention sur la batterie. Arrêter le moteur avant de débrancher ou de brancher les câbles de batterie. Eviter de provoquer des ét...
Page 12 - -7. Information sur les champs électromagnétiques
OM-4411 Page 8 LE SURCHAUFFEMENT peut endom- mager le moteur électrique. Arrêter ou déconnecter l’équipement avant de dé- marrer ou d’arrêter le moteur. Ne pas laisser tourner le moteur trop lentement sous risque d’endommager le moteur électrique à cause d’une tension et d’une fréquence trop faibles...
Page 13 - CC; Notes; Pros weld and cut
OM-4411 Page 9 SECTION 3 − DEFINITIONS 3-1. Symbol Definitions Stop Engine Fast (Run, Weld/Power) Fast/Slow (Run/Idle) Slow (Idle) Start Engine Panel/Local Temperature Fuel Engine Oil Engine Choke Check Valve Clearance Battery (Engine) Engine Read Operator’s Manual A Amperes V Volts MIG (GMAW), Wire...
Page 15 - -4. Fuel Consumption While Welding And Using Generator Power; DC WELD AMPERES AT 100% DUTY CYCLE
OM-4411 Page 11 4-4. Fuel Consumption While Welding And Using Generator Power 207 967 3000 RPM Weld 0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 0 100 150 200 250 300 DC WELD AMPERES AT 100% DUTY CYCLE U.S. GAL./HR. 1.98 0.95 2.84 3.78 5.67 4.73 6.62 7.57 LITERS/HR. 0.00 3600 RPM Weld Generator at 5...
Page 16 - WELD AMPERES
OM-4411 Page 12 Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating. Exceeding duty cycle can damage unit and void warranty. 100% Duty Cycle at 280 Amperes DC/CC Continuous Welding 4-6. Duty Cycle Ref. 207 925 0 10 20 30 40 50 60 100 70 80 90 150 175 200 2...
Page 17 - DC AMPERES
OM-4411 Page 13 207 970 / 207 971 The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of other settings fall between the curves shown. A. CC/DC Stick Mode B. CV/DC MIG Mode 4-7. Stick And MIG Mode Volt-Ampere Curves 3600 RPM 0...
Page 23 - -6. Connecting To Weld Output Terminals
OM-4411 Page 19 5-6. Connecting To Weld Output Terminals Stop engine. Do not connect to CC and CV terminals at the same time. 1 Negative ( − ) Weld Output Terminal 2 Stick/TIG (CC) Weld Output Terminal 3 Wire /CV Weld Output Terminal For MIG welding, connect work cable to Negative ( − ) terminal and...
Page 24 - NOTE; AMPERAGE
OM-4411 Page 20 5-8. Remote Receptacle Information Engine runs at weld speed (3000 or 3600 rpm) whenever a device connected tothe remote receptacle is running. NOTE Socket* Socket Information A J 24 VOLTS AC A 24 volts ac. Protected by circuit breaker CB5. A J B K I B Not used. C L N H D M G 115 VOL...
Page 28 - Process Switch Settings
OM-4411 Page 24 6-3. Process Switch 1 Process Switch Weld output terminals are ener- gized whenever the engine is run- ning. The unit will not return to idle speedwhen the remote contactor is on (clo-sure between pins A and B on remotereceptacle). Use switch to select weld process (see table below a...
Page 30 - -1. 60 Hz Generator Power Receptacles And Circuit Breakers
OM-4411 Page 26 SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. 60 Hz Generator Power Receptacles And Circuit Breakers Ref. 211 909 If unit does not have GFCI re- ceptacles, use GFCI-protected extension cord. Weld output and 60 Hz generatorpower output at receptacles RC1and RC2 are not available at t...
Page 32 - Receptacle
OM-4411 Page 28 7-3. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P) plug1 11/03 − 120 813-D The plug can be wired for a 240 V, 2-wire load or a 120/240V, 3-wire load. See circuit diagram.1 Plug Wired for 120/240 V, 3-Wire Load When wired for 120 V loads, each duplex recep...
Page 33 - Every 8 h; OIL
OM-4411 Page 29 SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Routine Maintenance Recycle engine fluids. Stop engine before maintaining. See Engine Manual and Maintenance Label for impor-tant start-up, service, and storage information. Servicemore often if used in severe conditions. * To be don...
Page 41 - Start Your Professional
OM-4411 Page 37 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 42 - Figure 9-1. Circuit Diagram For Welding Generator
OM-4411 Page 38 SECTION 9 − ELECTRICAL DIAGRAM Figure 9-1. Circuit Diagram For Welding Generator
Page 44 - 0-2. Grounding Generator To Truck Or Trailer Frame
OM-4411 Page 40 SECTION 10 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-drivenwelding generators. Your unit may differ from those shown. NOTE 10-1. Selecting Equipment gen_pwr 11/02 − Ref. ST-159 730 / ST-800 577 1 Generator Power Receptacles...
Page 45 - 0-3. Grounding When Supplying Building Systems
OM-4411 Page 41 10-3. 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 46 - 0-5. Approximate Power Requirements For Industrial Motors
OM-4411 Page 42 10-5. 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 47 - 0-7. Approximate Power Requirements For Contractor Equipment
OM-4411 Page 43 10-7. 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 49 - 0-10. Typical Connections To Supply Standby Power
OM-4411 Page 45 10-10. 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 51 - MATERIAL THICKNESS REFERENCE CHART
OM-4411 Page 47 Notes 16 Gauge (.063 in) 22 Gauge (.031 in) 24 Gauge (.025 in) 20 Gauge (.037 in)18 Gauge (.050 in) 14 Gauge (.078 in) 1/8 in (.125 in) 3/16 in (.188 in) 1/4 in (.25 in) 5/16 in (.313 in) 3/8 in (.375 in) 1/2 in (.5 in) MATERIAL THICKNESS REFERENCE CHART
Page 52 - PARTS LIST
OM-4411 Page 48 SECTION 11 − PARTS LIST 16 19 Fig.1 1-2 − 35 30 18 37 38 36 3 2 40 1 4 17 7 8 − Fig.1 1-3 7 9 11 27 25 20 21 23 24 22 10 26 6 5 12 14 13 15 28 29 33 32 31 34 41 − Fig.1 1-4 803 340 Figure 11-1. Main Assembly
Page 59 - (Equipment with a serial number preface of “LE” or newer)
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 3/04 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 quest...
Page 60 - Please complete and retain with your personal records.; For Service
PRINTED IN USA 2003 Miller Electric Mfg. Co. 1/03 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 Europe...