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 - CALIFORNIA; TABLE OF CONTENTS; WARNING
The following terms areused interchangeablythroughout this manual: Stick = SMAWMIG = GMAW CALIFORNIA Proposition 65Warning Diesel engine exhaust andsome of its constituentsare known to the State ofCalifornia to causecancer, birth defects, andother reproductive harm. TABLE OF CONTENTS SECTION 1 – SAF...
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-481 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING rom _nd_4/02 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 grou...
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-481 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; OVERUSE can cause OVERHEATING.
OM-481 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-481 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-481 Page 5 SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION rom _nd_fre 4/02 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 d...
Page 10 - LE BRUIT peut affecter l’ouïe.; Dangers existant en relation avec le moteur
OM-481 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-481 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; Symbols And Definitions; SECTION 3 – SPECIFICATIONS
OM-481 Page 9 SECTION 2 – DEFINITIONS 2-1. Symbols And Definitions Stop Engine Fast (Run, Weld/ Power) Start Engine Engine Check engine belt Oil Pressure Battery Hourmeter (HM) Do Not Switch Under Load Read Operator’s Manual Certified/Trained Mechanic Engine Oil Check Injectors/ Pump Check Valve Cle...
Page 14 - Dimensions, Weights, And Operating Angles; Fuel Consumption
OM-481 Page 10 3-2. Dimensions, Weights, And Operating Angles Dimensions Height 58 (1473 mm) A C Width 32 (813 mm) A B C Depth 68 in (1727 mm) D Do not exceed operating angleswhile running or engine damage will A 1-1/16 in (27 mm) D E F while running or engine damage willoccur. B 29-7/8 in (759 mm) ...
Page 15 - Duty Cycle And Overheating; WELD AMPERES; AC Generator Power
OM-481 Page 11 3-4. Duty Cycle And Overheating sb1.1 8/93 SB-134 397-C Duty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithout overheating. Exceeding duty cycle candamage unit and voidwarranty. Continuous Welding 100% Duty Cycle At 600 Amperes 10 100 15 20 25 30 40 50 60 80 1...
Page 17 - SECTION 4 – INSTALLATION; Installing Welding Generator; Connecting The Battery
OM-481 Page 13 SECTION 4 – INSTALLATION 4-1. Installing Welding Generator install1 7/02 – Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854 Electrically bond generator frame tovehicle frame by metal-to-metalcontact. GND/PE 1 2 Always securely fastenwelding generator ontotransport vehicle o...
Page 18 - Installing Exhaust Pipe And Rain Cap; Engine Prestart Checks
OM-481 Page 14 4-3. Installing Exhaust Pipe And Rain Cap Stop engine, and let cool. 1 Exhaust Pipe 2 Muffler Pipe Install exhaust pipe over mufflerpipe. Secure exhaust pipe to topcover using supplied hardware. 3 Rain Cap Install so cap opens toward front ofunit. Do not blow exhaust towardair cleaner...
Page 20 - Remote 14 Receptacle RC3 Information
OM-481 Page 16 4-7. Remote 14 Receptacle RC3 Information Socket* Socket Information A J B K I A 24 volts ac. Protected by circuitbreaker CB4. B C L N H D M G E F B Contact closure to A completes 24volts ac contactor control circuit. I 115 volts ac. Protected by circuitbreaker CB3. J Contact closure ...
Page 21 - Terminal Strip 3T Connections
OM-481 Page 17 4-8. Terminal Strip 3T Connections Ref. ST-131 784-A / Ref. ST-121 578-D / Ref. S-184 781 Stop engine. If remote control plug does not fit inreceptacle RC3, wire cord directlyto terminal strip 3T. Do not connect to Remote 14receptacle RC3 and terminalstrip 3T at the same time. Useonly...
Page 22 - SECTION 5 – OPERATING THE WELDING GENERATOR; Front Panel Controls
OM-481 Page 18 SECTION 5 – OPERATING THE WELDING GENERATOR 5-1. Front Panel Controls ST-134 687-B 1 2 4 5 6 7 8 9 10 11 12 15 14 13 3 1 Voltmeter 2 Ammeter 3 Ampere Range Switch Do not switch under load. Use switch to select weld amperage range.For most welding applications, use lowestamperage range...
Page 23 - Example Of Remote Amperage Control; SECTION 6 – OPERATING AUXILIARY EQUIPMENT; 20 Volt Duplex GFCI Receptacles
OM-481 Page 19 5-2. Example Of Remote Amperage Control Set Switches Adjust Remote Control Set Percentage Min = 55 A DC/CC Percentage Of Range = 50% Max = 90 A DC/CC (50% of 55 to 125) In Example: S-0774 / S-0769 Set Range Min (55 A DC/CC) Max (90 A DC/CC) 2 3 SECTION 6 – OPERATING AUXILIARY EQUIPMEN...
Page 24 - SECTION 7 – MAINTENANCE & TROUBLESHOOTING; Routine Maintenance; Note
OM-481 Page 20 6-2. 240 Volt Duplex Receptacle (Optional) Ref. ST-174 733 / ST-174 757 If unit does not have GFCI recep-tacles, use GFCI-protected exten-sion cord. 1 240 V 15 A AC Duplex Receptacle RC1 Receptacle supplies 60 Hz single-phasepower at weld/power speed. Maximum out-put from this recepta...
Page 27 - Servicing Air Cleaner
OM-481 Page 23 7-3. Servicing Air Cleaner aircleaner1 2/01 – ST-153 929-B / ST-153 585 / Ref. S-0698-B Stop engine. Do not run engine without aircleaner or with dirty element. En-gine damage caused by using adamaged element is not coveredby the warranty. The air cleaner primary element canbe cleaned...
Page 28 - Servicing Fuel And Lubrication Systems
OM-481 Page 24 7-4. Servicing Fuel And Lubrication Systems Ref. ST-153 653-A / Ref. SD-131 784 Stop engine and let cool. 1 Oil Filter 2 Oil Drain Plug 3 Secondary Fuel Filter 4 Primary Fuel Filter/WaterSeparator 5 Petcock 6 Sludge Drain Plug To change oil and filter: See engine manual. To drain wate...
Page 29 - Adjusting Engine Speed; Overload Protection
OM-481 Page 25 7-5. Adjusting Engine Speed Stop engine. Engine speeds have been factoryset and should not require adjust-ment. After tuning engine, checkengine speeds with a tachometer.See table for proper no loadspeeds. If necessary, adjustspeeds as follows: 1 Speed Adjustment Screw 2 Locknut Loose...
Page 30 - Checking And Replacing Engine Belt; Servicing Optional Spark Arrestor
OM-481 Page 26 7-7. Checking And Replacing Engine Belt Ref. ST-134 730-B / SD-131 784-A Stop engine, and let cool. A V-belt drives the engine coolingfan and alternator. To check tight-ness of belt, proceed as follows: Remove rear panel. 1 Fan Pulley 2 Alternator Pulley 3 Engine Belt Place straight e...
Page 31 - Adjusting Overspeed Shutdown Valve
OM-481 Page 27 7-9. Adjusting Overspeed Shutdown Valve Drawing # Stop engine, and let cool. The overspeed shutdown valveprotects the engine from damagedue to high engine speed. If the en-gine stops, the valve may beclosed. Shutdown speed is between 1950and 2100 rpm. Use a tachometer tocheck shutdown...
Page 33 - B. Generator Power Trouble
OM-481 Page 29 B. Generator Power Trouble Trouble Remedy No output at 120 volt ac receptacles. Reset circuit breaker CB1 and/or CB2 (see Section 6-1). Check fuse F6, and replace if necessary (see Section 7-6). Have Factory Authorized Service Agent check brushes and slip rings. Low or high generator ...
Page 34 - SECTION 8 – ELECTRICAL DIAGRAM; Figure 8-1. Circuit Diagram For Welding Generator
OM-481 Page 30 SECTION 8 – ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram For Welding Generator
Page 36 - SECTION 9 – RUN-IN PROCEDURE; Wetstacking
OM-481 Page 32 SECTION 9 – RUN-IN PROCEDURE run_in1 8/01 9-1. Wetstacking Do not perform run-inprocedure at less than 20volts weld output and do notexceed duty cycle or equip-ment damage may occur. 1 Welding Generator Run diesel engines near rated volt-age and current during run-in periodto properly...
Page 37 - Run-In Procedure Using Load Bank
OM-481 Page 33 9-2. Run-In Procedure Using Load Bank S-0683 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep exhaust and pipe awayfrom flammables. Do not perform run-inprocedure at less than 20volts weld output and do notexceed duty cycle or equip-ment damage may occur...
Page 38 - Run-In Procedure Using Resistance Grid
OM-481 Page 34 9-3. Run-In Procedure Using Resistance Grid S-0684 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep exhaust and pipe awayfrom flammables. Do not perform run-inprocedure at less than 20volts weld output and do notexceed duty cycle or equip-ment damage may...
Page 39 - SECTION 10 – GENERATOR POWER GUIDELINES; -2. Grounding Generator To Truck Or Trailer Frame
OM-481 Page 35 SECTION 10 – GENERATOR POWER GUIDELINES 10-1. Selecting Equipment gen_pwr 6/02 – Ref. ST-159 730 / ST-800 577 1 Generator Power Receptacles– Neutral Bonded To Frame 2 3-Prong Plug From CaseGrounded Equipment 3 2-Prong Plug From DoubleInsulated Equipment Do not use 2-prong plug un-less...
Page 40 - 0-3. Grounding When Supplying Building Systems
OM-481 Page 36 10-3. 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 U...
Page 41 - 0-5. Approximate Power Requirements For Industrial Motors
OM-481 Page 37 10-5. 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 42 - 0-7. Approximate Power Requirements For Contractor Equipment
OM-481 Page 38 10-7. 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 i...
Page 44 - 0-10. Typical Connections To Supply Standby Power; Notes; Pros weld and cut
OM-481 Page 40 10-10. 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 localcodes. Customer-suppli...
Page 46 - SECTION 11 – PARTS LIST
OM-481 Page 42 SECTION 11 – PARTS LIST 1 2 3 4 5 6 8 9 10 11 12 13 14 15 16 17 18 19 21 22 65 93 65 66 69 70 71 65 66 72 73 72 77 5 78 80 82 73 67 66 83 84 85 87 88 89 90 92 Fig 11-2 Fig 11-4 Fig 11-3 7 20 68 79 81 5 74 64 75 76 94 95 96 97 65 98 99 Hardware is common andnot available unless listed....
Page 59 - (Equipment with a serial number preface of “LC” or newer)
Warranty Questions? Call1-800-4-A-MILLERfor your localMiller distributor. miller_warr 6/02 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 2002 Miller Electric Mfg. Co. 5/02 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...
