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 distributorto receive the latest full line catalog orindividual catalog sheets. To locate your nearestdistributor or service agency call 1-800-4...
Page 3 - TABLE OF CONTENTS; WARNING
The following terms areused interchangeablythroughout this manual:MIG = GMAW, Wire WeldingTIG = GTAWStick = SMAW The engine exhaust fromthis product containschemicals known to theState of California tocause cancer, birthdefects, or otherreproductive harm. WARNING TABLE OF CONTENTS SECTION 1 – SAFETY...
Page 5 - SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING; Symbol Usage; Arc Welding Hazards; ELECTRIC SHOCK can kill.; FUMES AND GASES can be hazardous.
OM-486 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING rom _nd_11/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoining symbols. Marks a special safety message. Means “Note”; not safety related. This gro...
Page 6 - BUILDUP OF GAS can injure or kill.; CYLINDERS can explode if damaged.; Engine Hazards; FUEL can cause fire or explosion.; STEAM AND HOT COOLANT can burn.
OM-486 Page 2 Welding on closed containers, such as tanks,drums, or pipes, can cause them to blow up. Sparkscan fly off from the welding arc. The flying sparks, hotworkpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can causesparks, explosion, ove...
Page 7 - Additional Symbols For Installation, Operation, And Maintenance; TILTING OF TRAILER can cause injury.
OM-486 Page 3 MOVING PARTS can cause injury. Keep away from fans, belts, and rotors. Keep all doors, panels, covers, and guardsclosed and securely in place. Stop engine before installing or connecting unit. Have only qualified people remove guards or covers for maint-enance and troubleshooting as ne...
Page 8 - Principal Safety Standards
OM-486 Page 4 H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommunications equipment. Have only qualified persons familiar withelectronic equipment perform this installation. The user is responsible for having a qualif...
Page 9 - Signification des symboles; Dangers relatifs au soudage à l’arc; UN CHOC ÉLECTRIQUE peut tuer.
OM-486 Page 5 SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION rom _nd_fre 11/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédureprésente des risques de danger ! Ceux-ci sont identifiéspar des symboles adjacents aux directives. Identifie un message ...
Page 10 - LE BRUIT peut affecter l’ouïe.; Dangers existant en relation avec le moteur
OM-486 Page 6 Le soudage effectué sur des conteneurs fermés tels quedes réservoirs, tambours ou des conduites peut provoquerleur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et deséquipements chauds peut provoquer des incendies...
Page 11 - LIRE LES INSTRUCTIONS.
OM-486 Page 7 DES ORGANES MOBILES peuventprovoquer des blessures. Ne pas approcher les mains des ventilateurs, cour-roies et autres pièces en mouvement. Maintenir fermés et fixement en place les portes,panneaux, recouvrements et dispositifs deprotection. Arrêter le moteur avant d’installer ou branch...
Page 13 - SECTION 2 – DEFINITIONS; Symbol Definitions; SECTION 3 – SPECIFICATIONS
OM-486 Page 9 SECTION 2 – DEFINITIONS 2-1. Symbol Definitions Stop Engine Fast (Run, Weld/Power) Fast/Slow (Run/Idle) Slow (Idle) Start Engine Panel/Local Temperature Fuel Engine Oil On Check Valve Clearance Battery (Engine) Engine Read Operator’s Manual A Amperes V Volts MIG (GMAW), Wire Stick (SMA...
Page 14 - Dimensions, Weights, and Operating Angles; Fuel Consumption
OM-486 Page 10 3-2. Dimensions, Weights, and Operating Angles Dimensions A Height 33 in (838 mm) B C Width 18-3/4 in (476 mm) C Depth 45-1/2 in (1156 mm) D Do not exceed tilt angles or engine couldbe damaged or unit could tip. A 18 in (457 mm) G Do not move or operate unit where it couldtip. B 16-1/...
Page 15 - Auxiliary Power Curve; Duty Cycle
OM-486 Page 11 ST-189 268 The ac auxiliary power curveshows the auxiliary power availablein amperes at the receptacles. 3-4. Auxiliary Power Curve 0 20 40 60 80 100 120 140 160 0 20 40 60 80 100 120 140 0 120 80 40 200 160 280 240 AC POWER AMPERES AT 120V AC POWER AMPERES AT 240V 0 10 20 30 40 60 50...
Page 17 - SECTION 4 – INSTALLATION; Installing Welding Generator
OM-486 Page 13 SECTION 4 – INSTALLATION install1 12/99 – Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854 Do not weld on base. Weld-ing on base can cause fueltank fire or explosion. Boltunit down using holes pro-vided in base. Always ground generatorframe to vehicle frame to pre-vent elec...
Page 18 - Activating The Dry Charge Battery (If Applicable)
OM-486 Page 14 4-3. Activating The Dry Charge Battery (If Applicable) Remove battery from unit. 1 Eye Protection – SafetyGlasses Or Face Shield 2 Rubber Gloves 3 Vent Caps 4 Sulfuric Acid Electrolyte(1.265 Specific Gravity) 5 Well Fill each cell with electrolyte tobottom of well (maximum). Do not ov...
Page 20 - Selecting Weld Cable Sizes; Remote 14 Receptacle Information; NOTE
OM-486 Page 16 4-7. Selecting Weld Cable Sizes Total Cable (Copper) Length In Weld Circuit Not Exceeding Welding Amperes 100 ft (30 m) Or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft (105 m) 400 ft (120 m) Amperes 10 – 60% Duty Cycle 60 – 100% Duty Cycle 10 – 100% Duty Cycle 1...
Page 21 - Adjusting MIG Weld Puddle Consistency
OM-486 Page 17 4-9. Adjusting MIG Weld Puddle Consistency ST-801 944-C / Ref. ST-189 925-A Stop engine. Stabilizer DC-Z is factoryconnected to suit most MIG (WireWelding) applications. To change MIG weld puddle consis-tency, proceed as follows: Remove lower front panel and sidepanel. Starting from c...
Page 22 - SECTION 5 – OPERATING WELDING GENERATOR; Front Panel Controls
OM-486 Page 18 SECTION 5 – OPERATING WELDING GENERATOR 5-1. Front Panel Controls Ref. ST-189 925-A 1 DC Polarity/AC Switch Do not switch under load. Use switch to select AC weld output or polar-ity of DC weld output. 2 Process Select Switch Do not switch under load. Use switch to select output for w...
Page 23 - Remote Amperage/Voltage Control
OM-486 Page 19 5-2. Remote Amperage/Voltage Control 1 Remote 14 Receptacle RC1 Connect optional remote control toRC1 (see Section 4-8). 2 Remote Hand Control(Optional) 3 Remote Foot Control(Optional) Engine runs at weld/powerspeed whenever a device con-nected to the remote 14 recep-tacle is running....
Page 24 - SECTION 6 – OPERATING AUXILIARY EQUIPMENT; Auxiliary Power Receptacles And Circuit Breakers
OM-486 Page 20 SECTION 6 – OPERATING AUXILIARY EQUIPMENT 6-1. Auxiliary Power Receptacles And Circuit Breakers Ref. ST-189 925-A 1 4 2 5 3 If unit does not have GFCI re-ceptacles, use GFCI-protected extension cord. Auxiliary power decreases asweld current increases. 1 240 V 50 A AC ReceptacleRC1 RC1...
Page 25 - Optional Auxiliary Power Receptacles
OM-486 Page 21 6-2. Optional Auxiliary Power Receptacles If unit does not have GFCI re-ceptacles, use GFCI-protected extension cord. Auxiliary power decreases asweld current increases. Combined output of all receptacleslimited to 8 kVA/kW rating of thegenerator. GFCI Receptacle Option 1 120 V 15 A A...
Page 26 - SECTION 7 – MAINTENANCE AND TROUBLESHOOTING; Routine Maintenance
OM-486 Page 22 SECTION 7 – MAINTENANCE AND TROUBLESHOOTING 7-1. Routine Maintenance Recycle engine fluids. Stop engine before maintaining. See Engine Manual and Maintenance Label. Ser-vice more often if used in severe conditions. * To be done by Factory Authorized Service Agent. 8 h Wipe up spills. ...
Page 27 - Maintenance Label
OM-486 Page 23 7-2. Maintenance Label Follow the storage procedure in the engine owner ’s manual if the unit will not beused for an extended period. NOTE
Page 28 - Servicing Air Cleaner; Servicing Optional Spark Arrestor
OM-486 Page 24 7-3. Servicing Air Cleaner aircleaner3 1/97 – ST-156 852 / Ref. ST-185 095-A / S-0759 Stop engine. Do not run engine without aircleaner or with dirty element. 1 Wrapper (Foam Element) Wash wrapper with soap and watersolution. Allow wrapper to air drycompletely. Spread 1 tablespoon SAE...
Page 29 - Changing Engine Oil, Oil Filter, And Fuel Filter
OM-486 Page 25 7-5. Changing Engine Oil, Oil Filter, And Fuel Filter Ref. ST-801 942-C / ST-800 395-B / Ref. ST-189 925-A / S-0842 Stop engine and let cool. 1 Oil Drain Valve 2 1/2 ID x 12 in Hose 3 Oil Filter Change engine oil and filter accord-ing to engine manual. Close valve and valve capbefore ...
Page 30 - Adjusting Engine Speed
OM-486 Page 26 7-6. Adjusting Engine Speed Ref. ST-801 942-C / ST-800 397-A After tuning engine, check enginespeeds with a tachometer (seetable). If necessary, adjust speedsas follows: Start engine and run until warm.Turn A/V control to max. Idle Speed Adjustment 1 Throttle Solenoid 2 Mounting Screw...
Page 31 - Overload Protection
OM-486 Page 27 Stop engine. When a circuit breaker or fuseopens, it usually indicates amore serious problem exists.Contact a Factory AuthorizedService Agent. 1 Circuit Breaker CB5 CB5 protects the 24 volt ac outputto Remote 14 receptacle RC1. IfCB5 opens, 24 volt ac output toRC1 stops. 2 Circuit Bre...
Page 34 - SECTION 8 – ELECTRICAL DIAGRAM; Figure 8-1. Circuit Diagram For Welding Generator
OM-486 Page 30 SECTION 8 – ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram For Welding Generator
Page 36 - SECTION 9 – AUXILIARY POWER GUIDELINES; Selecting Equipment; Grounding Generator To Truck Or Trailer Frame; OR
OM-486 Page 32 SECTION 9 – AUXILIARY POWER GUIDELINES 9-1. Selecting Equipment aux_pwr 2/99 – Ref. ST-159 730 / ST-800 577 1 Auxiliary Power Receptacles– Neutral Bonded To Frame 2 3-Prong Plug From CaseGrounded Equipment 3 2-Prong Plug From DoubleInsulated Equipment OR 2 Be sure equipmenthas this sy...
Page 37 - Grounding When Supplying Building Systems; How Much Power Does Equipment Require?
OM-486 Page 33 9-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment GroundingTerminal 2 Grounding Cable Use #10 AWG or larger insulatedcopper wire. 3 Ground Device Ground generator to systemearth ground if supplyingpower to a premises (home,shop, farm) wiring system. GND/PE 1 2 Us...
Page 39 - Approximate Power Requirements For Contractor Equipment
OM-486 Page 35 9-7. 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 in...
Page 40 - Power Required To Start Motor; How Much Power Can Generator Supply?
OM-486 Page 36 9-8. Power Required To Start Motor S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor Voltage To find starting amperage: Step 1: Find code and use table tofind kVA/HP. If code is not listed,multiply running amperage by six tofind starting amperage. Step 2: Find Motor HP a...
Page 41 - -10. Typical Connections To Supply Standby Power
OM-486 Page 37 9-10. Typical Connections To Supply Standby Power S-0405-A 1 Power Company ServiceMeter 2 Main and Branch OvercurrentProtection 3 Double-Pole, Double-ThrowTransfer Switch Obtain and install correct switch.Switch rating must be same as orgreater than the branch overcurrentprotection. 4...
Page 43 - ARTS LIST; Figure
OM-486 Page 39 SECTION 10 – P ARTS LIST ST-802 048-D Hardware is common and n o t available unless listed. 1 2 3 4 5 6 7 8 9 11 12 13 14 15 16 17 18 19 10 20 21 22 23 24–Fig 10–3 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 42 43 44 45 46 47 48 49 50 47 51 46 45 53 54 – Fig. 10-2 52 55 41 Figure ...
Page 51 - (Equipment with a serial number preface of “LA” or newer)
Warranty Questions? Call1-800-4-A-MILLERfor your localMiller distributor. miller_warr 7/00 Your distributor also givesyou ... ServiceYou always get the fast,reliable response youneed. Most replacementparts can be in yourhands in 24 hours. SupportNeed fast answers to thetough welding questions?Contac...
Page 52 - Please complete and retain with your personal records.; For Service
PRINTED IN USA 2000 Miller Electric Mfg. Co. 6/00 Miller Electric Mfg. Co. An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 USA International Headquarters–USAUSA Phone: 920-735-4505 Auto-AttendedUSA & Canada FAX: 920-735-4134International FAX: 920-735-4125 European Head...
