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; WARNING
The following terms areused interchangeablythroughout this manual:TIG = GTAWStick = SMAWMIG = GMAW The engine exhaust fromthis product containschemicals known to theState of California tocause cancer, birthdefects, or otherreproductive harm. WARNING TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS -...
Page 5 - SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING; Symbol Usage; Arc Welding Hazards; ELECTRIC SHOCK can kill.
OM-499 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.
OM-499 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
OM-499 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-499 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-499 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-499 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-499 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-499 Page 9 SECTION 2 – DEFINITIONS 2-1. 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 Temperature SECTION 3 – SPECI...
Page 14 - Dimensions, Weights, And Operating Angles
OM-499 Page 10 3-2. Dimensions, Weights, And Operating Angles Dimensions Height 20-3/4 in (527 mm) D Width 22-3/4 in (577 mm) Depth 31-1/4 in (793 mm) Do not exceed tilt angles or engine could A 31-1/4 in (793 mm) B be damaged or unit could tip. B 10-1/2 in (268 mm) Do not move or operate unit where...
Page 15 - Duty Cycle
OM-499 Page 11 3-4. Fuel Consumption (Honda-Powered Units) 802 122 Continuous Welding 3-5. 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 Cycle at 100 Amperes CC/DC
Page 16 - Generator Power Curves
OM-499 Page 12 3-6. 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 75 100 125 150 175 200 225 250 0 5 10 15 20 ...
Page 18 - SECTION 4 – INSTALLATION; Installing Welding Generator; Grounding Generator To Truck Or Trailer Frame
OM-499 Page 14 SECTION 4 – INSTALLATION 4-1. 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 fasten weldinggenerator onto tran...
Page 19 - Grounding Generator When Supplying Building Systems
OM-499 Page 15 4-3. 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 sys-tem earth ground if sup...
Page 22 - SECTION 5 – OPERATING THE WELDING GENERATOR
OM-499 Page 18 SECTION 5 – OPERATING THE WELDING GENERATOR 5-1. 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 circuit, and to stopengine. 2 Th...
Page 24 - Notes
OM-499 Page 20 5-3. Description Of Controls (Honda-Powered Units) (See Section 5-2) 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.On models with electric-start...
Page 26 - Optional Generator Power Panels
OM-499 Page 22 6-2. 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 unit does not have GFCI recep...
Page 27 - Generator Power Panel Ratings; NOTE
OM-499 Page 23 6-3. 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 (USA) Panel 495 315 (USA) Panel...
Page 28 - SECTION 7 – MAINTENANCE; Maintenance Label; ENGINE MAINTENANCE
OM-499 Page 24 6-4. 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 (Silver) Terminal 3 Load 1 (B...
Page 29 - Routine Maintenance
OM-499 Page 25 7-2. 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 fluidlevels. SeeSection 4-4or 4-5...
Page 32 - SECTION 8 – TROUBLESHOOTING; Troubleshooting
OM-499 Page 28 SECTION 8 – TROUBLESHOOTING 8-1. Troubleshooting A. Welding Trouble Remedy No weld output. Check Amperage control setting. Check weld connections. Check engine speed, and adjust if necessary (see Section 7-4 or 7-5). Output stops if engine speed istoo low. Be sure all equipment is dis...
Page 34 - SECTION 9 – ELECTRICAL DIAGRAMS
OM-499 Page 30 SECTION 9 – ELECTRICAL DIAGRAMS 197 857-E Figure 9-1. Circuit Diagram For Welding Generator (1 Of 2)
Page 36 - Figure 9-3. Wiring Diagram For Welding Generator
OM-499 Page 32 197 858-C Figure 9-3. Wiring Diagram For Welding Generator
Page 39 - SECTION 10 – GENERATOR POWER GUIDELINES; 0-2. Grounding Generator To Truck Or Trailer Frame
OM-499 Page 35 SECTION 10 – GENERATOR POWER GUIDELINES 10-1. Selecting Equipment gen_pwr 4/02 – 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 OR 2 Be sure equipmenthas this ...
Page 40 - 0-3. Grounding When Supplying Building Systems
OM-499 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-499 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-499 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
OM-499 Page 40 10-10. Typical Connections To Supply Standby Power S-0405-A Have only qualified personsperform these connectionsaccording to all applicablecodes and safety practices. Properly install and groundthis equipment according toits Owner’s Manual and na-tioanl, state, and local codes. 1 Powe...
Page 46 - SECTION 11 – STICK WELDING (SMAW) GUIDELINES
OM-499 Page 42 SECTION 11 – STICK WELDING (SMAW) GUIDELINES 11-1. 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 avehicle. Place work clamp ascl...
Page 49 - 1-8. Conditions That Affect Weld Bead Shape
OM-499 Page 45 11-8. 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 Long Spatter Angle Too Small An...
Page 51 - 1-15. Troubleshooting – Excessive Spatter
OM-499 Page 47 11-13. 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) 11-14. Troubleshooting – Porosity Porosity – small cavities or holes resulting fr...
Page 53 - 1-20. Troubleshooting – Waviness Of Bead
OM-499 Page 49 11-19. 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 and/or maintain steady travel...
Page 54 - SECTION 12 – PARTS LIST
OM-499 Page 50 SECTION 12 – PARTS LIST 802 509-A Hardware is common andnot available unless listed. 7 32 33 34 31 28 29 30 24 23 46 40 41 44 42 43 36 38 39 37 35 47 48 8 6 5 4 9 10 11 2 1 27 18 25 26 22 20 21 19 15 17 16 14 13 12 45 3 49 Figure 12-1. Main Assembly
Page 57 - Generator Power Panel 495 278 (Canada–CSA)
OM-499 Page 53 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) Generator Power Panel 495 218 (...
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...
