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-4434 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-4434 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-4434 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-4434 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-4434 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
A complete Parts List is available at www.MillerWelds.com OM-4434 Page 12 SECTION 3 − DEFINITIONS 3-1. Symbol Definitions Stop Engine Fast (Run, Weld/Power) Fast/Slow (Run/Idle) Slow (Idle) Start Engine Read Operator’s Manual A Amperes V Volts Engine Oil Fuel Battery (Engine) Engine Engine Choke Che...
Page 17 - -3. Dimensions For Units With Optional Running Gear
A complete Parts List is available at www.MillerWelds.com OM-4434 Page 13 4-2. Dimensions, Weights, and Operating Angles Dimensions A Height 33-1/2 in (851 mm) (To Top Of Exhaust) A B C Width 20 in (508 mm) C ! D d il l i ld Depth 45-3/8 in (1153 mm) D ! Do not exceed tilt angles or engine could be ...
Page 21 - SECTION 5
A complete Parts List is available at www.MillerWelds.com OM-4434 Page 17 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 - -5. Connecting Or Replacing the Battery
A complete Parts List is available at www.MillerWelds.com OM-4434 Page 20 5-4. Installing Exhaust Pipe 803 847 / Ref 801 681 / Ref. 228 199-A ! Engine backfire can cause se- vere burns or other injuries. Do not point exhaust pipe toward control panel. Keep away from exhaust outlet. ! Point exhaust p...
Page 25 - -6. Connecting to Weld Output Terminals
A complete Parts List is available at www.MillerWelds.com OM-4434 Page 21 ! Stop engine. 1 Work Weld Output Terminal 2 Electrode Weld Output Terminal Connect work cable to Work terminal.Connect electrode holder cable or electrode weld cable to Electrode ter- minal for Stick and MIG welding.Connect t...
Page 26 - Notes; Pros weld and cut
A complete Parts List is available at www.MillerWelds.com OM-4434 Page 22 5-7. 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) We...
Page 29 - Frequently; Choose Genuine Select to review spare parts requirements such
A complete Parts List is available at www.MillerWelds.com OM-4434 Page 25 6-2. Cold Weather Engine Operation Ref. 216 170 1 Engine Control Switch Carburetor Icing Carburetor icing causes the unit to drop below the normal idle speed and then stall. This condition occurs when the temperature is near f...
Page 30 - -3. Typical Stick Welding Connections And Control Settings
A complete Parts List is available at www.MillerWelds.com OM-4434 Page 26 ELECTRODE DC* AC POSITION PENETRA TION USAGE MIN. PREP, ROUGH HIGH SPATTER GENERAL SMOOTH, EASY, FAST LOW HYDROGEN, STRONG SMOOTH, EASY, FASTER CAST IRONSTAINLESS DEEPDEEP LOW MED LOW LOW LOWLOW ALLALLALL ALL ALL FLAT HORIZ FI...
Page 31 - -4. Typical MIG Welding Connections And Settings; A. Solid Wire Applications
A complete Parts List is available at www.MillerWelds.com OM-4434 Page 27 6-4. Typical MIG Welding Connections And Settings A. Solid Wire Applications 803 847-C / 802 766 / 228 199-A ! Stop engine. This section provides general guide-lines and may not suit all ap- plications. The control panel shows...
Page 32 - B. Self-Shielded Flux Core Wire Applications
A complete Parts List is available at www.MillerWelds.com OM-4434 Page 28 B. Self-Shielded Flux Core Wire Applications 803 847-C / 802 766 / 228 199-A ! Stop engine. This section provides generalguidelines and may not suit all applications. The control panel shows the typi-cal settings for welding w...
Page 34 - SECTION 7
A complete Parts List is available at www.MillerWelds.com OM-4434 Page 30 SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. Standard Receptacles 803 847-C / Ref. 228 199-A ! If unit does not have GFCI re- ceptacles, use GFCI-protected extension cord. Generator power decreases asweld current increases. ...
Page 35 - -2. Optional Generator Power Receptacles
A complete Parts List is available at www.MillerWelds.com OM-4434 Page 31 ! If unit does not have GFCI recep- tacles, use GFCI-protected exten- sion cord. Generator power decreases as weldcurrent increases. Set Fine Control R1 at 10 for full genera- tor power. Combined output of all receptacles limi...
Page 37 - SECTION 8
A complete Parts List is available at www.MillerWelds.com OM-4434 Page 33 SECTION 8 − MAINTENANCE (ROBIN-POWERED UNITS) 8-1. Maintenance Label (Robin-Powered Units)
Page 42 - MATERIAL THICKNESS REFERENCE CHART
A complete Parts List is available at www.MillerWelds.com OM-4434 Page 38 8-7. Overload Protection (Robin-Powered Units) 803 848-C ! Stop engine. Disconnect negative ( − ) battery cable. 1 Fuse F1 (See Section 11-1) F1 protects the weld excitation winding from overload. If F1 opens, weld output stop...
Page 43 - SECTION 9
A complete Parts List is available at www.MillerWelds.com OM-4434 Page 39 SECTION 9 − MAINTENANCE − (KOHLER-POWERED UNITS) 9-1. Maintenance Label (Kohler-Powered Units)
Page 49 - TROUBLESHOOTING
A complete Parts List is available at www.MillerWelds.com OM-4434 Page 45 SECTION 10 − TROUBLESHOOTING 10-1. Welding Troubleshooting Trouble Remedy Low or no weld output; generator pow- er output okay at ac receptacles. Check control settings. Check weld connections. Check fuse F1, and replace if op...
Page 51 - PARTS LIST; Recommended Spare Parts
A complete Parts List is available at www.MillerWelds.com OM-4434 Page 47 Trouble Remedy Battery Discharges between uses. Clean battery, terminals, and posts with baking soda and water solution; rinse with clear water. Periodically recharge battery (approximately every 3 months). Replace battery. Ch...
Page 52 - ELECTRICAL DIAGRAMS; Figure 12-1. Circuit Diagram For Welding Generator
OM-4434 Page 48 SECTION 12 − ELECTRICAL DIAGRAMS Figure 12-1. Circuit Diagram For Welding Generator
Page 54 - GENERATOR POWER GUIDELINES; 3-2. Grounding Generator To Truck Or Trailer Frame
OM-4434 Page 50 SECTION 13 − 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. 13-1. Selecting Equipment gen_pwr 2007 − 04 − Ref. ST-159 730 / ST-800 577 1 Generator Power Receptacles...
Page 55 - 3-3. Grounding When Supplying Building Systems
OM-4434 Page 51 13-3. 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 pr...
Page 56 - 3-5. Approximate Power Requirements For Industrial Motors
OM-4434 Page 52 13-5. 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 - 3-7. Approximate Power Requirements For Contractor Equipment
OM-4434 Page 53 13-7. 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 - 3-10. Typical Connections To Supply Standby Power
OM-4434 Page 55 13-10. 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 pr...
Page 64 - 4-8. Conditions That Affect Weld Bead Shape
OM-4434 Page 60 14-8. Conditions That Affect Weld Bead Shape Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal. S-0061 ELECTRODE ANGLE ARC LENGTH TRAVEL SPEED Slow Normal Fast 10 ° - 30 ° Drag Too Short Normal Too Long Spatter Angle Too Small Angle...
Page 66 - Porosity; Excessive Spatter
OM-4434 Page 62 14-13. Weld Test S-0057-B 1 Vise 2 Weld Joint 3 Hammer Strike weld joint in direction shown. A good weld bends over but does not break. 2 To 3 in 1/4 in 3 21 2 To 3 in 3 2 1 (51-76 mm) (6.4 mm) (51-76 mm) 14-14. Troubleshooting − Porosity Porosity − small cavities or holes resulting ...
Page 69 - 5-2. Holding And Positioning Welding Gun
OM-4434 Page 65 SECTION 15 − MIG WELDING (GMAW) GUIDELINES 15-1. Typical MIG Process Connections Using A Voltage-Sensing Wire Feeder ! Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible. ...
Page 70 - 5-3. Conditions That Affect Weld Bead Shape
OM-4434 Page 66 15-3. Conditions That Affect Weld Bead Shape Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed(weld current), and voltage. Short Normal Long Short Normal Long 10 ° 10 ° GUN ANGLES AND WELD...
Page 74 - Waviness Of Bead; Distortion
OM-4434 Page 70 15-13. Troubleshooting − Waviness Of Bead Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Corrective Actions Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) ...
Page 77 - (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 78 - 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...
