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 distributor to receive the latest fullline catalog or individual catalog sheets. To locate your nearestdistributor or service agency call 1-800-...
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.; FUMES AND GASES can be hazardous.
OM-4407 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom _nd_10/02 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 adjo...
Page 9 - Avertissement: Protégez vous et les autres des blessures; UN CHOC ÉLECTRIQUE peut tuer.
OM-4407 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION rom_fre 8/03 Avertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions. 2-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ...
Page 10 - LES CHAMPS MAGNÉTIQUES peuvent
OM-4407 Page 6 LES ACCUMULATIONS DE GAZ ris- quent de provoquer des blessures ou même la mort. Fermer l’alimentation du gaz protecteur en cas de non utilisation. Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi- rateur d’adduction d’air homologué. Le rayonnement de l’arc du...
Page 11 - maintenance
OM-4407 Page 7 L’EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE. Toujours porter une protection faciale, des gants en caoutchouc et vêtements de protection lors d’une in- tervention sur la batterie. Arrêter le moteur avant de débrancher ou de brancher les câbles de batterie. Eviter de provoquer des ét...
Page 12 - -7. Information sur les champs électromagnétiques
OM-4407 Page 8 LE SURCHAUFFEMENT peut endom- mager le moteur électrique. Arrêter ou déconnecter l’équipement avant de dé- marrer ou d’arrêter le moteur. Ne pas laisser tourner le moteur trop lentement sous risque d’endommager le moteur électrique à cause d’une tension et d’une fréquence trop faibles...
Page 13 - CC; Notes; Pros weld and cut
OM-4407 Page 9 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) Engine Read Operator’s Manual A Amperes V Volts MIG (GMAW), Wire...
Page 15 - DC WELD AMPERES AT 100% DUT Y CYCLE; -4. Fuel Consumption While Using Generator Power; KW AT 100% DUTY CYCLE
OM-4407 Page 11 IDLE − KOHLER AND ROBIN ROBIN 4-3. Fuel Consumption While Welding 0 50 100 150 200 250 300 DC WELD AMPERES AT 100% DUT Y CYCLE KOHLER 0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 US GAL/HR. 0.00 0.95 1.89 2.84 3.79 4.73 5.68 6.62 7.57 LITERS/HR. 2.25 8.51 IDLE − KOHLER AND ROBIN ROBI...
Page 17 - AC AMPERES
OM-4407 Page 13 204 923 / 204 928 / 204 935 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. AC output is not available on allmodels. A. CC/AC Stick Mode B. CC/DC Stick Mode ...
Page 18 - DC AMPERES
OM-4407 Page 14 204 934 / 204 930 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. AC output is not available on allmodels. A. CC/AC TIG Mode B. CC/DC TIG Mode 4-8. TIG Mode ...
Page 24 - -7. Connecting To Weld Output Terminals
OM-4407 Page 20 5-7. Connecting To Weld Output Terminals Stop engine. Do not connect to CC and CV terminals at the same time. AC/DC Models: 1 Work Weld Output Terminal 2 Stick/TIG (CC) Weld Output Terminal 3 Wire /CV Weld Output Terminal For MIG welding, connect work cable to Work terminal and wire ...
Page 25 - NOTE
OM-4407 Page 21 5-8. Selecting Weld Cable Sizes* Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding*** 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) Weld Output Terminals Stop engine before connecting to weld ...
Page 28 - Process/Contactor Switch Settings
OM-4407 Page 24 6-2. Process/Contactor Switch On CC/CV Models 1 Process/Contactor Switch Weld output terminals are ener- gized when Process/Contactor switch is in an Electrode Hot posi- tion and the engine is running. The unit will not return to idle speedwhen Process/Contactor switch is ina Wire or...
Page 30 - -1. Generator Power Receptacles And Circuit Breakers
OM-4407 Page 26 SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. Generator Power Receptacles And Circuit Breakers Ref. 206 422 1 2 5 3 If unit does not have GFCI re- ceptacles, use GFCI- protected extension cord. Generator power decreases asweld current increases. 1 240 V 50 A AC Receptacle RC1 RC1 su...
Page 31 - -2. Optional Generator Power Receptacles
OM-4407 Page 27 7-2. Optional Generator Power Receptacles If unit does not have GFCI re- ceptacles, use GFCI- protected extension cord. Generator power decreases asweld current increases. Combined output of all receptacles limited to 8 kVA/kW rating of the generator. GFCI Receptacle Option 1 120 V 2...
Page 33 - SECTION 8
OM-4407 Page 29 SECTION 8 − MAINTENANCE (Robin EH64-POWERED UNITS) 8-1. Maintenance Label (Robin EH64-Powered Units)
Page 34 - Note; Every 8 h
OM-4407 Page 30 8-2. Routine Maintenance (Robin EH64-Powered Units) Follow the storage procedure in the engine owner ’s manual if the unit will not be used for anextended period. Note Recycle engine fluids. Stop engine before maintaining. See also Engine Manual and Maintenance Label for im-portant s...
Page 40 - SECTION 9
OM-4407 Page 36 SECTION 9 − MAINTENANCE (KOHLER-POWERED UNITS) 9-1. Routine Maintenance (Kohler-Powered Units) Recycle engine fluids. Stop engine before maintaining. See also Engine Manual and Maintenance Label for im-portant start-up, service, and storage information. Ser-vice engine more often if ...
Page 46 - TROUBLESHOOTING
OM-4407 Page 42 SECTION 10 − TROUBLESHOOTING 10-1. Welding Troubleshooting Trouble Remedy No weld output. Check control settings. Check weld connections. Disconnect equipment from generator power receptacles during start-up. Place V/A Adjust switch in Panel position, or move switch to Remote positio...
Page 50 - ELECTRICAL DIAGRAMS
OM-4407 Page 46 SECTION 11 − ELECTRICAL DIAGRAMS Figure 11-1. Circuit Diagram For Welding Generator Models With AC/DC Output
Page 54 - 2-2. Grounding Generator To Truck Or Trailer Frame
OM-4407 Page 50 SECTION 12 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-drivenwelding generators. Your unit may differ from those shown. NOTE 12-1. Selecting Equipment gen_pwr 11/02 − Ref. ST-159 730 / ST-800 577 1 Generator Power Receptacles...
Page 55 - 2-3. Grounding When Supplying Building Systems
OM-4407 Page 51 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 Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. GND/PE ...
Page 56 - 2-5. Approximate Power Requirements For Industrial Motors
OM-4407 Page 52 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 57 - 2-7. Approximate Power Requirements For Contractor Equipment
OM-4407 Page 53 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 59 - 2-10. Typical Connections To Supply Standby Power
OM-4407 Page 55 12-10. 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 62 - PARTS LIST
OM-4407 Page 58 SECTION 13 − PARTS LIST 802 951 Hardware is common andnot available unless listed. 1 2 3 4 5 6 7 8 9 11 14 16 17 10 28 27 26 25 29 30 31 34 36 18 37 40 56 57 − Fig.13-2 45 32 59 58 35 54 55 50 33 20 15 19 − Fig.13-3 22 21 23 38 41 42 44 43 46 47 48 49 51 52 53 24 60 Figure 13-1. Main...
Page 63 - Kohler
OM-4407 Page 59 Description Part No. Dia. Mkgs. Item No. Figure 13-1. Main Assembly Quantity 1 182367 Panel, Side Rh 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦ 185352 Panel, Side Rh Stainless Steel 1 ....
Page 71 - (Equipment with a serial number preface of “LE” or newer)
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 3/04 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 72 - Please complete and retain with your personal records.; For Service
PRINTED IN USA 2003 Miller Electric Mfg. Co. 1/03 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 Europe...
