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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2...
Page 5 - DECLARATION OF CONFORMITY; declares that the; 000/14/EC Noise Level of Welding Generators; David A. Werba
DECLARATION OF CONFORMITY for European Community (CE marked) products. MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the product(s) identified in this declaration conform to the essential requirements and provisions ofthe stated Council Directive(s) and Stand...
Page 7 - ELECTRIC SHOCK can kill.; SIGNIFICANT DC VOLTAGE exists in inverter power; FLYING METAL or DIRT can injure eyes.
OM-4435 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2011 − 04 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will resu...
Page 9 - EXHAUST SPARKS can cause fire.; STEAM AND HOT COOLANT can burn.; Using a generator indoors CAN KILL; ENGINE HEAT can cause fire.
OM-4435 Page 3 1-3. Engine Hazards BATTERY EXPLOSION can injure. Always wear a face shield, rubber gloves, and protective clothing when working on a battery. Stop engine before disconnecting or connect- ing battery cables, battery charging cables (if applicable), or servicing battery. Do not allow t...
Page 10 - HOT PARTS AND FLUID can burn.; COMPRESSED AIR EQUIPMENT can
OM-4435 Page 4 1-4. Hydraulic Hazards HYDRAULIC EQUIPMENT can injure or kill. Incorrect installation or operation of this unit could result in equipment failure and personal injury. Only qualified persons should install, op- erate, and service this unit according to its Owner’s Manual, industry stan...
Page 11 - BREATHING COMPRESSED AIR can in-
OM-4435 Page 5 HOT METAL from air arc cutting and gouging can cause fire or explosion. Do not cut or gouge near flammables. Watch for fire; keep extinguisher nearby. COMPRESSED AIR can injure or kill. Before working on compressed air system, turn off and lockout/tagout unit, release pres- sure, and ...
Page 12 - WELDING WIRE can injure.; OVERUSE can cause OVERHEATING.; ARC WELDING can cause interference.
OM-4435 Page 6 WELDING WIRE can injure. Do not press gun trigger until instructed to do so. Do not point gun toward any part of the body, other people, or any metal when threading welding wire. OVERUSE can cause OVERHEATING. Allow cooling period; follow rated duty cycle. Reduce current or reduce dut...
Page 14 - UN CHOC ÉLECTRIQUE peut tuer.
OM-4435 Page 8 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_rom_2011 − 04 Pour écarter les risques de blessure pour vous − même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1. Signification des s...
Page 17 - Les ÉQUIPEMENTS HYDRAULIQUES
OM-4435 Page 11 LES ÉTINCELLES À L’ÉCHAPPEMENT peuvent provoquer un incendie. Empêcher les étincelles d’échappement du moteur de provoquer un incendie. Utiliser uniquement un pare-étincelles approuvé − voir codes en vigueur. LES PIÈCES CHAUDES peuvent provoquer des brûlures. Ne pas toucher des parti...
Page 19 - Les PIÈCES MOBILES peuvent causer
OM-4435 Page 13 Une PRESSION D’AIR RÉSIDUELLE ET DES FLEXIBLES QUI FOUETTENT risquent de provoquer des blessures. Détendre la pression pneumatique des outils et circuits avant d’entretenir, ajouter ou changer des accessoires et avant d’ouvrir le bouchon de vidange ou de remplissage d’huile du compre...
Page 20 - LIRE LES INSTRUCTIONS.; -7. Proposition californienne 65 Avertissements
OM-4435 Page 14 LES CHARGES ÉLECTROSTATI- QUES peuvent endommager les circuits imprimés. Établir la connexion avec la barrette de terre avant de manipuler des cartes ou des pièces. Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des cartes de circuits imprimes. ...
Page 22 - Notes; Pros weld and cut
OM-4435 Page 16 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 ...
Page 23 - Hz
OM-4435 Page 17 3-2. Symbols And Definitions Some symbols are found only on CE products. 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) Posi...
Page 26 - DC WELD AMPERES AT 100% DUTY CYCLE; CC
OM-4435 Page 20 4-5. Fuel Consumption The curve shows typical fuel use under weld or power loads. 237 471 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 IDLE 4-6. Duty Cycle And Overheating 1 100% Duty Cycle Duty Cycle is...
Page 27 - AC AMPERES IN 110V MODE; MATERIAL THICKNESS REFERENCE CHART
OM-4435 Page 21 4-7. AC Generator Power Curve 220 346 − B The AC power curve shows the generator power in amperes. AC AMPERES IN 110V MODE AC AMPERES IN 220V MODE AC VOL TS 0 20 40 60 80 100 120 140 0 10 20 30 40 50 60 70 0 20 40 60 80 100 120 0 40 80 120 160 200 240 Notes 16 Gauge (.063 in) 22 Gaug...
Page 28 - -1. Serial Number And Rating Label Location
OM-4435 Page 22 SECTION 5 − INSTALLATION 5-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the front. Use rating label to determine input power requirements and/or ratedoutput. For future reference, write serial number in space provi...
Page 30 - -4. Grounding Generator To Truck Or Trailer Frame
OM-4435 Page 24 ! Always ground generator frame to vehicle frame to pre- vent electric shock and static electricity hazards. ! Also see AWS Safety & Health Fact Sheet No. 29, Grounding of Portable And Vehicle Mounted Welding Generators. ! Bed liners, shipping skids, and some running gear insu- l...
Page 34 - -9. Connecting To Weld Output Terminals
OM-4435 Page 28 5-9. Connecting To Weld Output Terminals Tools Needed: 3/4 in. Ref.804 009-F / Ref. 287 125-A / 803 778-B 6 4 5 3 ! Stop engine. ! Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your machine. Do not place anything between weld cabletermin...
Page 35 - Selecting Weld Cable Sizes*
OM-4435 Page 29 5-10. Selecting Weld Cable Sizes* NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 f...
Page 36 - Connecting To Remote 14 Receptacle RC14; REMOTE
OM-4435 Page 30 5-11. Connecting To Remote 14 Receptacle RC14 OR Ref 804 009-F Socket* Socket Information 24 VOLTS AC A 24 volts AC. Protected by sup- plementary protector CB8. B Contact closure to A completes 24 volt AC contactor control circuit. REMOTE OUTPUT CONTROL C Output to remote control:+10...
Page 40 - Process/Contactor Switch Settings
OM-4435 Page 34 ! Weld output terminals are en- ergized when Process/Con- tactor switch is in a Weld Ter- minals Always On position and the engine is running. 1 Process/Contactor Switch 2 Weld Terminals Always On − TIG Lift Arc Position 3 Remote On/Off Switch Required − TIG HF Required Or Scratch St...
Page 41 - Arc Start With Lift-Arc; OR
OM-4435 Page 35 6-4. Lift-Arc t TIG With Crater-Out And Auto-Stop t WM Marketing Arc Start With Lift-Arc Arc End With Crater-Out Arc End With Auto-Stop 1 2 1 2 1 2 3 3 Arc Start With Lift-Arc TIG Lift-Arc is used for the DCEN GTAW process when HF Start method is not permitted.Select Lift-Arc at Proc...
Page 50 - -8. Adjusting Engine Speed On Standard Models
OM-4435 Page 44 8-8. Adjusting Engine Speed On Standard Models 803 563 3 1 2 RPM (Hz) Engine Speed (No Load) Weld/Power 1880 (61.7) Maximum ! Stop engine and let cool. Engine speed is factory set and should not require adjustment. Af- ter tuning engine, check engine speed with tachometer or frequen-...
Page 51 - -9. Servicing Fuel And Lubrication Systems
OM-4435 Page 45 8-9. Servicing Fuel And Lubrication Systems Ref 287 125-A / 804 009 − C ! 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 ...
Page 52 - Overload Protection
OM-4435 Page 46 8-10. Overload Protection Ref. 287 125-A / 803 566 / 804 009-F ! Stop engine. When a circuit breaker, supple-mentary protector, or fuse opens, it usually indicates a more serious problem exists. Contact Factory Authorized Service Agent. 1 Fuse F1 F1 protects the stator exciter wind- ...
Page 53 - Optional Voltmeter/Ammeter Help Displays
OM-4435 Page 47 8-11. Optional Voltmeter/Ammeter Help Displays Use the Voltmeter/Ammeter help displays to diagnose and correct fault conditions. When a help code is displayednormally weld output has stopped but generator power output may be okay. To reset help displays, stop unit and then restart. S...
Page 54 - Troubleshooting; Trouble
OM-4435 Page 48 8-12. Troubleshooting Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 8-11). A. Welding Trouble Remedy No weld output; generator power output okay at AC receptacles. Place Process/Contactor switch in a Weld Terminals Always On position...
Page 55 - B. Standard Generator Power
OM-4435 Page 49 B. Standard Generator Power Trouble Remedy No generator power output at AC recep- tacles; weld output okay. Reset receptacle supplementary protectors (see Section 7-1). No generator power or weld output. Disconnect equipment from generator power receptacles during start-up. Check fus...
Page 58 - Figure 9-1. Circuit Diagram For Welding Generator
OM-4435 Page 52 SECTION 9 − ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For Welding Generator
Page 63 - GENERATOR POWER GUIDELINES; 1-2. Grounding Generator To Truck Or Trailer Frame
OM-4435 Page 57 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 gen_pwr 2011 − 04 − ST-800 577 1 Generator Power Receptacles − Neutral Bonded ...
Page 64 - 1-3. Grounding When Supplying Building Systems
OM-4435 Page 58 11-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding Terminal 2 Grounding Cable Use #8 AWG or larger insulated copper wire.3 Ground Device Use ground device as stated inelectrical codes. ! Ground generator to system earth ground if supplying power to a p...
Page 65 - 1-5. Approximate Power Requirements For Industrial Motors
OM-4435 Page 59 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 66 - 1-7. Approximate Power Requirements For Contractor Equipment
OM-4435 Page 60 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 68 - 1-10. Typical Connections To Supply Standby Power
OM-4435 Page 62 11-10. Typical Connections To Supply Standby Power Transfer Switch Essential Loads Fused Disconnect Switch (If Required) Utility Electrical Service 1 2 3 4 5 Welding Generator Output ! Have only qualified persons perform these connections according to all applicable codes and safety ...
Page 70 - PARTS LIST
OM-4435 Page 64 SECTION 12 − PARTS LIST Hardware is common and notavailable unless listed. Wiring harnesses are listed at the end of parts section. 2 − Fig.12 − 3 3 7 4 − Fig.12 − 5 103 8 9 5 10 11 12 14 15 13 16 17 102 101 100 18 19 20 21 22 23 91 92 84 83 82 81 80 85 86 90 89 88 87 94 95 96 97 − F...
Page 80 - Wiring Harnesses
OM-4435 Page 74 Some wiring harness components (switches, relays, supplementary protectors) are also referenced elsewhere in this parts list. Purchase compo-nents separately or as part of the associated wiring harness. Description Part No. Dia. Mkgs. Item No. Wiring Harnesses Quantity 235012 Harness...
Page 81 - (Equipment with a serial number preface of MB or newer)
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2011 − 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 82 - Please complete and retain with your personal records.; Contact a DISTRIBUTOR or SERVICE AGENCY near you.; For Service
ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2011 Miller Electric Mfg. Co. 2011 − 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 Internati...