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-4430 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-4430 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-4430 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 - -3. Dangers existant en relation avec le moteur; LE CARBURANT MOTEUR peut provo
OM-4430 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-4430 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; CC; Notes; Pros weld and cut
A complete Parts List is available at www.MillerWelds.com OM-4430 Page 12 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) Engin...
Page 17 - SECTION 4
A complete Parts List is available at www.MillerWelds.com OM-4430 Page 13 SECTION 4 − SPECIFICATIONS 4-1. Description This multiprocess engine-driven welder and AC generator provides low speed generator AC power and DC weld out-put for quiet, fuel-efficient operation. At 1800 rpm, this unit produces...
Page 18 - -4. Dimensions For Units With Optional Running Gear; -5. Fuel Consumption While Welding And Using Generator Power; DC WELD AMPERES AT 100% DUTY CYCLE
A complete Parts List is available at www.MillerWelds.com OM-4430 Page 14 4-4. Dimensions For Units With Optional Running Gear Dimensions Height All Running Gear Options: 42-1/2 in (1079 mm) (To Top Of Handle Assembly) C A Protective Cage Width: 26 in (660 mm) D C B Running Gear Width: 32 in (813 mm...
Page 19 - AC AMPERES
A complete Parts List is available at www.MillerWelds.com OM-4430 Page 15 222 553 The ac generator power curve shows the generator power avail- able in amperes at the receptacles. 4-6. Generator Power Curve AC AMPERES AC VOL TS 0 5 10 15 20 25 30 0 50 100 150 200 250 300 Notes BUTT BUTT BUTT BUTT T ...
Page 20 - WELD AMPERES
A complete Parts List is available at www.MillerWelds.com OM-4430 Page 16 Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating. NOTICE − Exceeding duty cycle can damage unit and void warranty. 100% Duty Cycle at 280 Amperes DC/CC Continuous Welding 4-7. Dut...
Page 21 - DC AMPERES
A complete Parts List is available at www.MillerWelds.com OM-4430 Page 17 222 555 / 222 556 / 222 557 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. ...
Page 22 - SECTION 5
A complete Parts List is available at www.MillerWelds.com OM-4430 Page 18 SECTION 5 − INSTALLATION install2 12/06 − Ref. 800 652 / Ref. 800 477-A / 803 274-A / 804 712 ! Do not weld on base. Welding on base can cause fuel tank fire or explosion. Bolt unit down using holes provided in base. ! Always ...
Page 24 - -3. Connecting Or Replacing The Battery
A complete Parts List is available at www.MillerWelds.com OM-4430 Page 20 5-3. Connecting Or Replacing The Battery + − ! Connect negative ( − ) cable last. 803 847 / 803 849 / Ref. S-0756-D Ref 216 172-D / Ref 803 983 − A 3/8, 1/2 in Tools Needed: Replacing The Battery + − + − Remove end panel to re...
Page 26 - -5. Connecting To Weld Output Terminals
A complete Parts List is available at www.MillerWelds.com OM-4430 Page 22 5-5. 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 ...
Page 28 - SECTION 6
A complete Parts List is available at www.MillerWelds.com OM-4430 Page 24 SECTION 6 − OPERATING WELDING GENERATOR 6-1. Front Panel Controls 2 1 4 3 Ref 216 172-D 7 5 6 8 9 1 Process Switch See Section 6-5 for Process switch informa- tion.2 Remote Receptacle Use receptacle to connect remote control.W...
Page 31 - Process Switch Settings
A complete Parts List is available at www.MillerWelds.com OM-4430 Page 27 1 Process Switch ! Weld output terminals are energized when Process switch is in an Elec- trode Hot position and the engine is running. The unit will not return to idle speedwhen Process switch is in a Wire or TIG position and...
Page 32 - Stick Start Procedure
A complete Parts List is available at www.MillerWelds.com OM-4430 Page 28 6-6. Stick Start Procedure − Scratch Start Technique With Stick selected, start arc as follows:1 Electrode 2 Workpiece 3 Arc Drag electrode across workpiece like striking a match; lift electrode slightly after touching work. I...
Page 37 - SECTION 8
A complete Parts List is available at www.MillerWelds.com OM-4430 Page 33 SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Routine Maintenance Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period. ! Stop engine before maintaining. See Engine...
Page 43 - B. 60 Hz Generator Power Receptacles RC1 And RC2
A complete Parts List is available at www.MillerWelds.com OM-4430 Page 39 Trouble Remedy Lack of high frequency; difficulty in establishing Gas Tungsten Arc Weld- ing arc. Use proper size tungsten for welding amperage. Reduce leakage of high frequency from torch or work cable (check grounding, remov...
Page 45 - SECTION 9; Recommended Spare Parts
A complete Parts List is available at www.MillerWelds.com OM-4430 Page 41 SECTION 9 − PARTS LIST 9-1. Recommended Spare Parts Description Part No. Dia. Mkgs. Recommended Spare Parts Quantity F6 021718 Fuse, Mintr Gl 30. Amp 32 Volt 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 46 - ELECTRICAL DIAGRAMS; Figure 10-1. Circuit Diagram For Welding Generator Models
OM-4430 Page 42 SECTION 10 − ELECTRICAL DIAGRAMS Figure 10-1. Circuit Diagram For Welding Generator Models
Page 48 - GENERATOR POWER GUIDELINES; 1-2. Grounding Generator To Truck Or Trailer Frame
OM-4430 Page 44 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 2007 − 04 − Ref. ST-159 730 / ST-800 577 1 Generator Power Receptacles...
Page 49 - 1-3. Grounding When Supplying Building Systems
OM-4430 Page 45 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 Use ground device as stated inelectrical codes. ! Ground generator to system earth ground if supplying power to a ...
Page 50 - 1-5. Approximate Power Requirements For Industrial Motors
OM-4430 Page 46 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 51 - 1-7. Approximate Power Requirements For Contractor Equipment
OM-4430 Page 47 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 53 - 1-10. Typical Connections To Supply Standby Power
OM-4430 Page 49 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 55 - SOCKET/WRENCH SELECTION TABLE
OM-4430 Page 51 Notes SOCKET/WRENCH SELECTION TABLE (U.S. STANDARD) SOCKET/WRENCH SELECTION TABLE (METRIC) Specifications Socket or Wrench Size Specifications Socket or Wrench Size Bolt Diameter Decimal Equivalent Bolt Nut Bolt Diameter U.S. Decimal Equivalent Bolt Nut 1/4 in .250 in 3/8 in 7/16 in ...
Page 56 - Welding Symbols
OM-4430 Page 52 Notes Welding Symbols Ref. AWS/ANSI A2.4
Page 59 - (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 60 - 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...
