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-4417 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-4417 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 10 - -3. Dangers existant en relation avec le moteur
OM-4417 Page 6 Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des incen...
Page 11 - LA CHUTE DE L’APPAREIL peut blesser.
OM-4417 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-4417 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 16 - WELD AMPERES
OM-4417 Page 12 Continuous Welding 4-5. Duty Cycle 220 625 − A 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 80 Amperes CC/DC 20% Duty Cycle at 145 Amperes CC/DC % DUTY CYCLE...
Page 17 - -2. Grounding Generator To Truck Or Trailer Frame
OM-4417 Page 13 SECTION 5 − INSTALLATION 5-1. Installing Welding Generator Ref 151 556 / Ref. 800 652 / 803 594-B / S-0854 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) OR Movement Airflow Clearance Location Shown with optional running gear. Always securely fasten weldin...
Page 18 - -3. Grounding Generator When Supplying Building Systems; Standard Model
OM-4417 Page 14 5-3. Grounding Generator When Supplying Building Systems GND/PE 1 2 Use ground device as stated in electrical codes. 2 3 800 576-B 1 Equipment Grounding Terminal 2 Grounding Cable Use #10 AWG or larger insulated copper wire.3 Ground Device Ground generator to sys- tem earth ground if...
Page 19 - DX Model
OM-4417 Page 15 5-5. Engine Prestart Checks − DX Model 803 595-B Full Gasoline 1/2 in (13 mm) Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. 1 Fuel Valve Open valve. Close fuel valve before movingunit or carburetor may flood and make starti...
Page 20 - -7. Connecting To Weld Output Terminals
OM-4417 Page 16 5-7. Connecting To Weld Output Terminals 803 596 − B / 803 778-A 1 Positive (+) Weld Output Terminal 2 Negative ( − ) Weld Output Terminal For Direct Current Electrode Posi- tive (DCEP), connect work cable to Negative ( − ) terminal and electrode holder to Positive (+) terminal.For D...
Page 21 - Notes; MATERIAL THICKNESS REFERENCE CHART
OM-4417 Page 17 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 23 - Pros weld and cut
OM-4417 Page 19 6-2. Description Of Controls (Standard Models) (See Section 6-1) 1 Engine Switch Use switch to control ignition circuit. Turn switch to On position when starting engine. Turn switch to Off position to stop engine. En- gine cannot be started with switch in the Off position.Engine stop...
Page 27 - used for an extended period.; NOTE
OM-4417 Page 23 SECTION 8 − MAINTENANCE Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period. NOTE 8-1. Routine Maintenance Stop engine before maintaining. See Engine Manual and Maintenance Labelfor important start-up, service, and storage inf...
Page 33 - ELECTRICAL DIAGRAMS; Figure 10-1. Circuit Diagram For Standard Models
OM-4417 Page 29 SECTION 10 − ELECTRICAL DIAGRAMS 226 737-A Figure 10-1. Circuit Diagram For Standard Models
Page 34 - Figure 10-2. Circuit Diagram for DX Models
OM-4417 Page 30 226 738-A Figure 10-2. Circuit Diagram for DX Models
Page 35 - GENERATOR POWER GUIDELINES; welding generators. Your unit may differ from those shown.; 1-2. Grounding Generator To Truck Or Trailer Frame
OM-4417 Page 31 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 36 - 1-3. Grounding When Supplying Building Systems
OM-4417 Page 32 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 37 - 1-5. Approximate Power Requirements For Industrial Motors
OM-4417 Page 33 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 38 - 1-7. Approximate Power Requirements For Contractor Equipment
OM-4417 Page 34 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 40 - 1-10. Typical Connections To Supply Standby Power
OM-4417 Page 36 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 45 - 2-8. Conditions That Affect Weld Bead Shape; thickness of base metal.; multiple stringer beads work better.
OM-4417 Page 41 12-8. Conditions That Affect Weld Bead Shape Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal. NOTE S-0061 ELECTRODE ANGLE ARC LENGTH TRAVEL SPEED Slow Normal Fast 10 ° - 30 ° Drag Too Short Normal Too Long Spatter Angle Too Small ...
Page 47 - Porosity; Excessive Spatter
OM-4417 Page 43 12-13. Weld Test S-0057-B 1 Vise 2 Weld Joint 3 Hammer Strike weld joint in direction shown. A good weld bends over but does not break. 2 To 3 in 1/4 in 3 21 2 To 3 in 3 2 1 (51-76 mm) (6.4 mm) (51-76 mm) 12-14. Troubleshooting − Porosity Porosity − small cavities or holes resulting ...
Page 50 - PARTS LIST; Figure 13-1. Main Assembly Standard Model
OM-4417 Page 46 SECTION 13 − PARTS LIST 803 795 − B Hardware is common andnot available unless listed. 1 2 3 4 5 6 7 8 10 11 13 14 15 23 24 29 30 31 32 33 2 34 35 36 37 39 38 9 12 28 27 26 25 22 21 20 19 17 18 16 Figure 13-1. Main Assembly Standard Model
Page 55 - (Equipment with a serial number preface of “LF” or newer)
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 1/05 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 56 - Please complete and retain with your personal records.; Contact a DISTRIBUTOR or SERVICE AGENCY near you.; For Service
PRINTED IN USA © 2005 Miller Electric Mfg. Co. 10/05 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 Europ...
