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 - ELECTRIC SHOCK can kill.; HOT PARTS can cause severe burns.
OM-4415 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2007 − 04 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards...
Page 7 - Using a generator indoors CAN KILL; ENGINE HEAT can cause fire.
OM-4415 Page 3 1-3. Engine Hazards BATTERY EXPLOSION can BLIND. Always wear a face shield, rubber gloves, and protective clothing when working on a battery. Stop engine before disconnecting or connect- ing battery cables or servicing battery. Do not allow tools to cause sparks when working on a batt...
Page 10 - UN CHOC ÉLECTRIQUE peut tuer.
OM-4415 Page 6 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION rom_2007 − 04fre Se protéger, ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud. 2-1. Signification des symboles DANGER! − Indique une situation dangereuse qui si on l’évite pas ...
Page 12 - LE CARBURANT MOTEUR peut provo
OM-4415 Page 8 Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et NFPA 51B pour les travaux à chaud et avoir de la surveillance et un extincteur à proximité. LE BRUIT peut affecter l’ouïe. Le bruit des processus et des équipements peut affec l’ouïe. Porter des protections approuvés pour les ...
Page 15 - -6. Proposition californienne 65 Avertissements
OM-4415 Page 11 2-6. Proposition californienne 65 Avertissements Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des mal- formations congénitales et, dans certains cas, des cancers....
Page 16 - SECTION 3
. Complete Parts List available at www.MillerWelds.com OM-4415 Page 12 SECTION 3 − DEFINITIONS 3-1. Symbol Definitions Engine Choke Read Operator’s Manual A Amperes V Volts Engine Oil Fuel Battery (Engine) Engine Positive Negative Alternating Current (AC) Output h Hours s Seconds Time Protective Ear...
Page 17 - WELD AMPERES
. Complete Parts List available at www.MillerWelds.com OM-4415 Page 13 4-2. Dimensions, Weights, And Operating Angles Dimensions Height 22-3/4 in (578 mm) D Width 22-3/4 in (577 mm) D Depth 31-5/8 in (803 mm) Do not move or operate unit A 31-5/8 in (803 mm) B Do not move or operate unit where it cou...
Page 18 - VOL
. Complete Parts List available at www.MillerWelds.com OM-4415 Page 14 4-4. Volt-Ampere Curves The volt-ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the curves shown. VOL TS AMPERES 0 0 10 20 3...
Page 19 - A. Weld Output Standard
. Complete Parts List available at www.MillerWelds.com OM-4415 Page 15 4-5. Fuel Consumption Curves U.S. Gal./Hr . DC Weld Amperes At Rated Duty Cycle 0 25 50 75 100 125 150 175 200 0.00 0.20 0.40 0.60 0.80 1.00 U.S. Gal./Hr . Aux Power kW At 100% Duty Cycle 0 1 2 3 4 5 6 7 8 0.00 0.20 0.40 0.60 0.8...
Page 20 - A. Power Output Standard
. Complete Parts List available at www.MillerWelds.com OM-4415 Page 16 4-6. Generator Power Curves The ac generator power curves show the generator power available in amperes at the receptacles. VOL TS 0 50 100 150 200 250 300 AMPERES 0 10 20 30 40 50 60 70 80 240 VOLT 120 VOLT VOL TS AMPERES 0 0 10...
Page 21 - SECTION 5
. Complete Parts List available at www.MillerWelds.com OM-4415 Page 17 SECTION 5 − INSTALLATION 5-1. Installing Welding Generator Ref 151 556 / Ref. 800 652 / 803 597-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 Do not i...
Page 22 - -2. Grounding Generator When Supplying Building Systems; Standard Model
. Complete Parts List available at www.MillerWelds.com OM-4415 Page 18 5-2. Grounding Generator When Supplying Building Systems GND/PE 1 2 2 3 800 576-B 1 Equipment Grounding Terminal 2 Grounding Cable Use #10 AWG or larger insulated copper wire.3 Ground Device . Use ground device as statedin electr...
Page 23 - DX Model
. Complete Parts List available at www.MillerWelds.com OM-4415 Page 19 5-4. 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 valv...
Page 24 - -6. Connecting To Weld Output Terminals
. Complete Parts List available at www.MillerWelds.com OM-4415 Page 20 5-6. 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 ( − ) termi...
Page 25 - Notes
. Complete Parts List available at www.MillerWelds.com OM-4415 Page 21 Notes
Page 26 - SECTION 6
. Complete Parts List available at www.MillerWelds.com OM-4415 Page 22 SECTION 6 − OPERATING THE WELDING GENERATOR 6-1. Controls (Standard Models) (See Section 6-2) 803 597 − B / 218 611 − B 4 1 3 5 2
Page 27 - Pros weld and cut
. Complete Parts List available at www.MillerWelds.com OM-4415 Page 23 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...
Page 31 - SECTION 8
. Complete Parts List available at www.MillerWelds.com OM-4415 Page 27 SECTION 8 − MAINTENANCE Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period. 8-1. Routine Maintenance . See Engine Manual and Maintenance Labelfor important start-up, serv...
Page 35 - SECTION 9
. Complete Parts List available at www.MillerWelds.com OM-4415 Page 31 SECTION 9 − TROUBLESHOOTING 9-1. Troubleshooting A. Welding Trouble Remedy No weld output or generator power out- put at ac receptacles. Be sure all equipment is disconnected from receptacles when starting unit. Have Factory Auth...
Page 37 - PARTS LIST; Recommended Spare Parts
. Complete Parts List available at www.MillerWelds.com OM-4415 Page 33 SECTION 10 − PARTS LIST 10-1. Recommended Spare Parts Description Part No. Dia. Mkgs. Recommended Spare Parts Quantity 220305 Tune − up & Filter Kit, Honda (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 38 - ELECTRICAL DIAGRAMS; Figure 11-1. Circuit Diagram For Standard Models
OM-4415 Page 34 SECTION 11 − ELECTRICAL DIAGRAMS 226 737-A Figure 11-1. Circuit Diagram For Standard Models
Page 39 - Figure 11-2. Circuit Diagram for DX Models
OM-4415 Page 35 226 738-A Figure 11-2. Circuit Diagram for DX Models
Page 40 - GENERATOR POWER GUIDELINES; 2-2. Grounding Generator To Truck Or Trailer Frame
OM-4415 Page 36 SECTION 12 − 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. 12-1. Selecting Equipment gen_pwr 2007 − 04 − Ref. ST-159 730 / ST-800 577 1 Generator Power Receptacles...
Page 41 - 2-3. Grounding When Supplying Building Systems
OM-4415 Page 37 12-3. 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 Use ground device as stated inelectrical codes. Ground generator to system earth ground if supplying power to a pr...
Page 42 - 2-5. Approximate Power Requirements For Industrial Motors
OM-4415 Page 38 12-5. 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 43 - 2-7. Approximate Power Requirements For Contractor Equipment
OM-4415 Page 39 12-7. 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 45 - 2-10. Typical Connections To Supply Standby Power
OM-4415 Page 41 12-10. 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 pr...
Page 50 - 3-8. Conditions That Affect Weld Bead Shape
OM-4415 Page 46 13-8. Conditions That Affect Weld Bead Shape Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal. S-0061 ELECTRODE ANGLE ARC LENGTH TRAVEL SPEED Slow Normal Fast 10 ° - 30 ° Drag Too Short Normal Too Long Spatter Angle Too Small Angle...
Page 52 - Porosity; Excessive Spatter
OM-4415 Page 48 13-13. 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) 13-14. Troubleshooting − Porosity Porosity − small cavities or holes resulting ...
Page 55 - (Equipment with a serial number preface of “LH” or newer)
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007 − 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 56 - Please complete and retain with your personal records.; Contact a DISTRIBUTOR or SERVICE AGENCY near you.; For Service
PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007 − 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...
