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 orindividual catalog sheets. To locate your nearestdistributor or service agency call 1-800-4...
Page 3 - TABLE OF CONTENTS
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 5 - SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING; Symbol Usage; Arc Welding Hazards
OM-499 Page 1 Return To Table Of Contents SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom _nd_8/03 Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazardswith this procedure! The possible haza...
Page 6 - Engine Hazards
OM-499 Page 2 Return To Table Of Contents Welding on closed containers, such as tanks, drums, orpipes, can cause them to blow up. Sparks can fly off from thewelding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metalobjects can...
Page 7 - Compressed Air Hazards; Additional Symbols For Installation, Operation, And Maintenance
OM-499 Page 3 Return To Table Of Contents STEAM AND HOT COOLANT can burn. If possible, check coolant level when engine is cold toavoid scalding. Always check coolant level at overflow tank, if pres-ent on unit, instead of radiator (unless told otherwisein maintenance section or engine manual). If th...
Page 8 - California Proposition 65 Warnings; Principal Safety Standards
OM-499 Page 4 Return To Table Of Contents READ INSTRUCTIONS. Use only genuine MILLER/Hobart replacementparts. Perform engine and air compressor (if applicable)maintenance and service according to this manualand the engine/air compressor (if applicable) manu-als. H.F. RADIATION can cause interference...
Page 9 - SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT; Signification des symboles; Dangers relatifs au soudage à l’arc; UN CHOC ÉLECTRIQUE peut tuer.
OM-499 Page 5 Revenez à la table des matières 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 procédurep...
Page 10 - LE BRUIT peut affecter l’ouïe.; Dangers existant en relation avec le moteur
OM-499 Page 6 Revenez à la table des matières LES ACCUMULATIONS DE GAZ ris-quent de provoquer des blessures oumême la mort. Fermer l’alimentation du gaz protecteur en cas denon utilisation. Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi-rateur d’adduction d’air homologué....
Page 11 - Dangers liés à l’air comprimé; LIRE LES INSTRUCTIONS.
OM-499 Page 7 Revenez à la table des matières L’EXPLOSION DE LA BATTERIE peutRENDRE AVEUGLE. Toujours porter une protection faciale, des gants encaoutchouc et vêtements de protection lors d’une in-tervention sur la batterie. Arrêter le moteur avant de débrancher ou de brancher les câbles debatterie....
Page 12 - Principales normes de sécurité
OM-499 Page 8 Revenez à la table des matières 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 sousrisque d’endommager le moteur électrique à caused’une tension et d...
Page 13 - SECTION 3 − DEFINITIONS; Symbol Definitions; SECTION 4 − SPECIFICATIONS
OM-499 Page 9 Return To Table Of Contents 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 Earth (Ground) Circuit Breaker T...
Page 14 - Dimensions, Weights, And Operating Angles
OM-499 Page 10 Return To Table Of Contents 4-2. Dimensions, Weights, And Operating Angles Dimensions Height 20-3/4 in (527 mm) D Width 22-3/4 in (577 mm) D Depth 31-1/4 in (793 mm) B Do not exceed tilt angles or engine couldbe damaged or unit could tip. A 31-1/4 in (793 mm) B be damaged or unit coul...
Page 15 - Duty Cycle
OM-499 Page 11 Return To Table Of Contents 4-4. Fuel Consumption (Honda-Powered Units) 802 122 Continuous Welding 4-5. Duty Cycle 802 093 Duty cycle is the percentage of 10minutes that unit can weld at ratedload without overheating. Exceeding duty cycle candamage unit and voidwarranty. 100% Duty Cyc...
Page 16 - Generator Power Curves
OM-499 Page 12 Return To Table Of Contents 4-6. Generator Power Curves 198 570 The generator power curves showthe ac power available in amperesat the receptacles. A. 60 Hz Model B. 50 Hz Model 0 25 50 75 100 125 150 175 200 225 250 0 5 10 15 20 25 30 35 LOAD AMPS LOAD VOL TS 0 25 50 75 100 125 150 1...
Page 18 - SECTION 5 − INSTALLATION; Installing Welding Generator; Grounding Generator To Truck Or Trailer Frame
OM-499 Page 14 Return To Table Of Contents SECTION 5 − INSTALLATION 5-1. Installing Welding Generator install1 10/00*− 802 524-A / Ref. 151 556 / 158 936-A / 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 Always securely faste...
Page 19 - Grounding Generator When Supplying Building Systems
OM-499 Page 15 Return To Table Of Contents 5-3. Grounding Generator When Supplying Building Systems GND/PE 1 2 Use ground device asstated in electrical codes. 2 3 800 576-B 1 Equipment GroundingTerminal 2 Grounding Cable Use #10 AWG or larger insulatedcopper wire. 3 Ground Device Ground generator to...
Page 21 - Connecting To Weld Output Terminals
OM-499 Page 17 Return To Table Of Contents 5-7. Connecting To Weld Output Terminals 196 914 / 495 178 1 Positive (+) Weld OutputTerminal 2 Negative (−) Weld OutputTerminal For Direct Current Electrode Posi-tive (DCEP), connect work cable toNegative (−) terminal and electrodeholder to Positive (+) te...
Page 22 - SECTION 6 − OPERATING THE WELDING GENERATOR
OM-499 Page 18 Return To Table Of Contents SECTION 6 − OPERATING THE WELDING GENERATOR 6-1. Controls (Kohler-Powered Units) 802 511-A / 802 0511 / 495 178 6 7 60 Hz Weld and generator power output stops ifgenerator overheats or engine speed istoo low. 1 Engine Switch Use switch to open ignition circ...
Page 24 - Notes
OM-499 Page 20 Return To Table Of Contents 6-3. Description Of Controls (Honda-Powered Units) (See Section 6-2) Weld and generator power output stops ifgenerator overheats or engine speed istoo low. 1 Engine Switch On models with recoil-start, use switch toopen ignition circuit, and to stop engine.O...
Page 25 - SECTION 7 − OPERATING AUXILIARY EQUIPMENT
OM-499 Page 21 Return To Table Of Contents SECTION 7 − OPERATING AUXILIARY EQUIPMENT The welding generator provides power while welding and with the Current controlin any position. However, under these conditions equipment connected to thewelding generator may be subject to larger than normal voltag...
Page 26 - Optional Generator Power Panels
OM-499 Page 22 Return To Table Of Contents 7-2. Optional Generator Power Panels Ref. ST-802 124 / H-495 290 / H-495 283 / 495 277 Generator Power Panel 495 315 (USA) Generator Power Panel 495 278 (Canada−CSA) Generator Power Panel 495 253 (South Africa) Generator Power Panel 495 289 (Australia) If u...
Page 27 - Generator Power Panel Ratings; NOTE
OM-499 Page 23 Return To Table Of Contents 7-3. Generator Power Panel Ratings Unless otherwise stated, the rating of duplex outlets is the combined load of allreceptacles. NOTE Total power from generator NOT to exceed 5500 Watts (60 Hz) or 5000 Watts (50 Hz) Receptacle Protected By Panel 495 218 (US...
Page 28 - SECTION 8 − MAINTENANCE; Maintenance Label; ENGINE MAINTENANCE
OM-499 Page 24 Return To Table Of Contents 7-4. Wiring Instructions For Optional 120/240 Volt Twistlock Plug (NEMA L14-30P) plug3-11/99 − 802 527 1 Plug Wired For 120/240 V,3-Wire Load When wired for 120 V loads, each du-plex receptacle shares a load withone half of the 240 V receptacle. 2 Neutral (...
Page 29 - Routine Maintenance
OM-499 Page 25 Return To Table Of Contents 8-2. 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 20 h Wipe up spills. Check fluid...
Page 32 - SECTION 9 − TROUBLESHOOTING; Troubleshooting
OM-499 Page 28 Return To Table Of Contents SECTION 9 − TROUBLESHOOTING 9-1. Troubleshooting A. Welding Trouble Remedy No weld output. Check Amperage control setting. Check weld connections. Check engine speed, and adjust if necessary (see Section 8-4 or 8-5). Output stops if engine speed istoo low. ...
Page 34 - SECTION 10 − ELECTRICAL DIAGRAMS
OM-499 Page 30 Return To Table Of Contents SECTION 10 − ELECTRICAL DIAGRAMS 197 857-E Figure 10-1. Circuit Diagram For Welding Generator (1 Of 2)
Page 38 - SECTION 11 − GENERATOR POWER GUIDELINES; 1-2. Grounding Generator To Truck Or Trailer Frame
OM-499 Page 34 Return To Table Of Contents SECTION 11 − 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 11-1. Selecting Equipment gen_pwr 11/02 − Ref. ST-159 730 / ST-800 577 1 ...
Page 39 - 1-3. Grounding When Supplying Building Systems
OM-499 Page 35 Return To Table Of Contents 11-3. 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)...
Page 40 - 1-5. Approximate Power Requirements For Industrial Motors
OM-499 Page 36 Return To Table Of Contents 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 ...
Page 41 - 1-7. Approximate Power Requirements For Contractor Equipment
OM-499 Page 37 Return To Table Of Contents 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 1...
Page 43 - 1-10. Typical Connections To Supply Standby Power; Pros weld and cut
OM-499 Page 39 Return To Table Of Contents 11-10. Typical Connections To Supply Standby Power Have only qualified persons performthese connections according to allapplicable codes and safety practic-es. Properly install and ground thisequipment according to its Owner’sManual and national, state, and...
Page 45 - SECTION 12 − STICK WELDING (SMAW) GUIDELINES
OM-499 Page 41 Return To Table Of Contents SECTION 12 − STICK WELDING (SMAW) GUIDELINES 12-1. Stick Welding Procedure stick 12/96 − ST-151 593 Weld current starts whenelectrode touches work-piece. Weld current can damageelectronic parts in vehicles.Disconnect both batterycables before welding on ave...
Page 46 - 2-2. Electrode and Amperage Selection Chart
OM-499 Page 42 Return To Table Of Contents 12-2. Electrode and Amperage Selection Chart Ref. S-087 985-A 3/32 1/8 5/323/167/32 1/4 1/165/643/32 1/8 5/323/167/32 1/4 3/32 1/8 5/323/167/32 1/4 3/32 1/8 5/323/167/32 1/4 3/32 1/8 5/323/167/32 1/4 3/32 1/8 5/323/163/32 1/8 5/32 6010 & 6011 6013 7014 ...
Page 48 - 2-8. Conditions That Affect Weld Bead Shape
OM-499 Page 44 Return To Table Of Contents 12-8. Conditions That Affect Weld Bead Shape Weld bead shape is affected by electrode angle, arc length, travel speed, andthickness of base metal. NOTE S-0061 ELECTRODE ANGLE ARC LENGTH TRAVEL SPEED Slow Normal Fast 10 ° - 30 ° Drag Too Short Normal Too Lon...
Page 50 - 2-15. Troubleshooting − Excessive Spatter
OM-499 Page 46 Return To Table Of Contents 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 doesnot break. 2 To 3 in 1/4 in 3 2 1 2 To 3 in 3 2 1 (51-76 mm) (6.4 mm) (51-76 mm) 12-14. Troubleshooting − Porosity Porosity − small ca...
Page 51 - 2-16. Troubleshooting − Incomplete Fusion
OM-499 Page 47 Return To Table Of Contents 12-16. Troubleshooting − Incomplete Fusion Incomplete Fusion − failure of weld metal to fuse completely withbase metal or a preceeding weld bead. Possible Causes Corrective Actions Insufficient heat input. Increase amperage. Select larger electrode and incr...
Page 52 - 2-20. Troubleshooting − Waviness Of Bead
OM-499 Page 48 Return To Table Of Contents 12-19. Troubleshooting − Burn-Through Burn-Through − weld metal melting completely through base metal resultingin holes where no metal remains. Possible Causes Corrective Actions Excessive heat input. Select lower amperage. Use smaller electrode. Increase a...
Page 53 - SECTION 13 − PARTS LIST
OM-499 Page 49 Return To Table Of Contents SECTION 13 − PARTS LIST 802 509-A Hardware is common andnot available unless listed. 7 32 33 34 31 28 29 30 23 46 40 41 44 42 43 36 38 39 37 35 47 8 6 5 4 9 10 11 1 27 18 25 26 22 20 21 19 15 17 16 14 13 12 45 3 49 50 Figure 13-1. Main Assembly
Page 56 - Generator Power Panel 495 278 (Canada−CSA)
OM-499 Page 52 Return To Table Of Contents Hardware is common and not available unless listed. Generator Power Panel 495 315 (USA) Generator Power Panel 495 219 (USA) Generator Power Panel 495 278 (Canada−CSA) Generator Power Panel 495 253 (South Africa) Generator Power Panel 495 289 (Australia) Gen...
Page 57 - Generator Power Panel 495 253 (South Africa)
OM-499 Page 53 Return To Table Of Contents Description Part No. Dia. Mkgs. Item No. Figure 13-2. Generator Power Panels (Figure 13-1, Item 39) Quantity Generator Power Panel 495 218 (USA) 1 495 220 PANEL, generator power assembly 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 59 - (Equipment with a serial number preface of “LC” or newer)
Warranty Questions? Call1-800-4-A-MILLERfor your localMiller distributor. miller_warr 8/03 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 60 - Please complete and retain with your personal records.; For Service
PRINTED IN USA 2004 Miller Electric Mfg. Co. 1/04 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...
