Page 2 - To locate your nearest; 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 distributorto receive the latest full line catalog orindividual catalog sheets. To locate your nearest distributor or service agency call 1-800-...
Page 3 - Table of Contents; Call; Processes
Description Features NEW! Warranty extended to 3 years (engine warranted by engine manufacturer) Versatile weld output for DC Stick and DC TIG welding Stepless amperage control for precise heat selection Arc force control ensures a forceful arc for tight fit-ups − prevents electrode sticking Built-i...
Page 5 - Symbol Usage; ELECTRIC SHOCK can kill.; FUMES AND GASES can be hazardous.
1 OM-402 1. Safety Precautions − Read Before Using 1.1 Symbol Usage OM-402B -4/97, safety_rom 4/97 Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Marks a special safety message. Means “Note”; not safety related. This...
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.
2 OM-402 Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, over...
Page 7 - Additional Symbols for Installation, Operation, and Maintenance; TILTING OF TRAILER can cause injury.
3 OM-402 MOVING PARTS can cause injury. Keep away from fans, belts, and rotors. Keep all doors, panels, covers, and guards closed 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 neces...
Page 8 - Principal Safety Standards
4 OM-402 H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. Have only qualified persons familiar with electronic equipment perform this installation. The user is responsible for having a qualifie...
Page 9 - Signification des symboles; Dangers relatifs au soudage à l’arc; UN CHOC ÉLECTRIQUE peut tuer.
5 OM-402 1. Consignes de sécurité − lire avant utilisation 1.1 Signification des symboles OM-402B - 4/97, safety_rom_fre 4/97 Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Identifie un mes...
Page 10 - LES CHAMPS MAGNÉTIQUES peuvent; Dangers existant en relation avec le moteur; LE CARBURANT MOTEUR peut pro-
6 OM-402 Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des incendies e...
Page 11 - et la maintenance
7 OM-402 DES ORGANES MOBILES peuvent provoquer 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 de protection. Arrêter le moteur avant d’installer ou branche...
Page 12 - Principales normes de sécurité
8 OM-402 LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés. Établir la connexion avec la barrette de terre avant de manipuler des cartes ou des pièces. Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des cartes de circuits imprimes. UNE REMOR...
Page 13 - Symbols and Definitions; min
9 OM-402 2. Definitions 2.1 Symbols and Definitions Stop Engine Fast (Run, Weld/Power) Fast/Slow (Run/Idle) Slow (Idle) Start Engine Glow Plug Temperature Fuel Engine Oil 14 Remote 14 Panel/Local On Check Injectors/ Pump Check Valve Clearance Battery (Engine) V Volts A Amperes Stick (SMAW) Arc Force...
Page 14 - General Precautionary Label
10 OM-402 3/96 2.2 General Precautionary Label 1 1.1 1.2 1.3 3 3.1 3.2 3.3 4 4.1 S-176 105-A + 2 2.1 2.2 + 5 + 7 7.1 7.2 2.3 + 6 6.1 6.2 6.3 + = A. Warning! Watch Out! There are possible hazards as shown by the symbols. B. Become trained and read the instructions before working on the machine or wel...
Page 16 - DIESEL
12 OM-402 2.5 Hot Muffler Label 3/96 1 Warning! Watch Out! There are possible hazards as shown by the symbols. 2 Hot muffler and exhaust pipes can cause severe burns. Do not touch hot muffler or pipes. 1 S-176 230 2 2.6 Diesel Fuel Label 3/96 1 Warning! Watch Out! There are possible hazards as shown...
Page 19 - Dimensions, Weights, and Operating Angles
15 OM-402 3. Specifications 3.1 Weld, Power, and Engine Specifications Rated Welding Output Amperage Range Maximum Open-Circuit Voltage DC Auxiliary Power Rating Engine Fuel Capacity Average Sound Level 280 A, 31 V DC, 60% Duty Cycle 250 A, 30 V DC, 100% Duty Cycle 20 − 280 61 (Average) Single-Phase...
Page 24 - Remote 14 Receptacle RC1 Information
20 OM-402 4.6 Remote 14 Receptacle RC1 Information Ref. ST-158 93 Socket* Socket Information A 24 volt ac with respect to socket G. Protected by circuit breaker CB5. B Contact closure to A completes 24 volt ac contactor control circuit. A J B K I G Circuit common for 24 volt ac circuit. B K I C L N ...
Page 25 - Operating the Welding Generator; Front Panel Controls
21 OM-402 5. Operating the Welding Generator 5.1 Front Panel Controls Ref. ST-175 918-C 9 Heavy loading during first 50 hours will damage engine. Keep load less than 225A (weld) or 7 kVA (power) for first 50 hours. 1 Engine Control Switch Use switch to operate glow plug (optional − see table), start...
Page 26 - Remote Amperage and Contactor Control
22 OM-402 5.2 Remote Amperage and Contactor Control Weld output terminals are energized when Output (Contactor) Control switch is On and engine is running. 1 Remote 14 Receptacle RC1 Connect optional remote control to RC1 (see Section 4.6). Place Engine Control switch inRun position for HF-start TIG...
Page 27 - Operating Auxiliary Equipment; Auxiliary Power Receptacles
23 OM-402 6. Operating Auxiliary Equipment 6.1 Auxiliary Power Receptacles Place Engine Control switch in Runposition to maintain weld/power speed under light auxiliary power loads. Press button to reset circuit breaker. If acircuit breaker continues to open, contact a Factory Authorized Service Age...
Page 28 - Routine Maintenance
24 OM-402 7. Maintenance & Troubleshooting 7.1 Routine Maintenance Recycle engine fluids. Stop engine before maintaining. See also Engine Manual and MaintenanceLabel. Service engine more often if used in severe conditions. 8 h Wipe up spills. Check fluid levels. See Section 4.3. 50 h Clean and t...
Page 29 - DEUTZ/RUGGERINI RD211 DIESEL ENGINE
25 OM-402 6-2. Maintenance Label S-157 812-E 20W 30 50 40 API CD-MIL L 2104D, SF/CD, CC/CD 2.4 qt (2.3 L) MILLER 066 702 Deutz 77-175-24 MILLER 066 113 11.8 gal (44.6 l ) 100 Hrs. + 12 V BCI 58430 A @ 0 ° F (-18 ° C) Deutz 77-656-19 72 ° F (20 ° C) 0.006 in (0.15 mm) Î Î Deutz 77-644-39 DIESEL DIN 5...
Page 30 - Changing Engine Oil and Oil Filter
26 OM-402 7.3 Changing Engine Oil and Oil Filter Ref. ST-159 219-D / Ref. ST-159 215-E / Ref. ST-175 918-C / Ref. S-0842 Tools Needed: Stop engine. See engine manual for oil/filter change procedure. Drain oil while engine is warm.1 Oil Fill Caps (Use Either Cap) 2 Oil Drain Valve Close oil drain val...
Page 32 - Adjusting Engine Speed
28 OM-402 7.6 Adjusting Engine Speed After tuning engine, check engine speeds with a tachometer (see table for no load speeds). If necessary, adjust speeds as follows:Start engine and run until warm. Idle Speed Adjustment Turn Engine Control switch to Run/ Idle position.1 Idle Speed Lock Nut 2 Idle ...
Page 33 - Overload Protection
29 OM-402 7.7 Overload Protection Stop engine. If checking fuse, disconnect battery negative ( − ) cable. Press button to reset circuitbreaker. If fuse or breaker continues to open, contact Factory Authorized Service Agent. Weld And Auxiliary Power Circuits 1 Fuse F2 F2 protects battery excitation c...
Page 34 - Servicing Optional Spark Arrestor; Welding Troubleshooting
30 OM-402 7.8 Servicing Optional Spark Arrestor ST-801 154-B / Ref. ST-175 918-C Stop engine and let cool. 1 Spark Arrestor 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole.3 Exhaust Pipe Start engine and run at idle speed to blow out cleanout hole. If nothing blows out of hole...
Page 37 - Notes
Page 38 - Electrical Diagram; Circuit Diagram for Welding Generator
34 OM-402 8. Electrical Diagram 8.1 Circuit Diagram for Welding Generator
Page 40 - Wetstacking
36 OM-402 9. Run-In Procedure 9.1 Wetstacking runin2 12/96 Heavy loading during first 50 hours will damage engine. Keep load less than 225A (weld) or 7 kVA (power) for first 50 hours. Do not idle engine longer thannecessary. Piston rings seat faster if engine runs at weld/ power rpm, and the welding...
Page 41 - Run-In Procedure Using Load Bank
37 OM-402 9.2 Run-In Procedure Using Load Bank S-0683 Stop engine. Do not touch hot exhaust pipe, engine parts, or load bank/grid. Keep exhaust and pipe away from flammables. 1 Load Bank Turn all load bank switches Off. If needed, connect load bank to 115 volts ac wall receptacle or genera- tor auxi...
Page 42 - Run-In Procedure Using Resistance Grid
38 OM-402 9.3 Run-In Procedure Using Resistance Grid S-0684 Stop engine. Do not touch hot exhaust pipe, engine parts, or load bank/ grid. Keep exhaust and pipe away from flammables. 1 Resistance Grid Use grid sized for generator rated output.Turn Off grid.2 Welding Generator Set Amperage control at ...
Page 43 - Auxiliary Power Guidelines; Selecting Equipment; Grounding Generator to Truck or Trailer Frame; OR
39 OM-402 10. Auxiliary Power Guidelines 10.1 Selecting Equipment aux_pwr 12/96 − Ref. ST-159 730 / ST-800 577 1 Auxiliary Power Receptacles − Neutral Bonded To Frame 2 3-Prong Plug From Case Grounded Equipment 3 2-Prong Plug From Double Insulated Equipment OR 2 Be sure equipment has this symbol and...
Page 44 - Grounding When Supplying Building Systems; How Much Power Does Equipment Require?
40 OM-402 10.3 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 1 2 Use...
Page 46 - Approximate Power Requirements for Contractor Equipment
42 OM-402 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 in 2500...
Page 47 - Power Required to Start Motor; How Much Power Can Generator Supply?
43 OM-402 10.8 Power Required to Start Motor S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor Voltage To find starting amperage: Step 1: Find code and use table to find kVA/HP. If code is not listed, multiply running amperage by six to find starting amperage. Step 2 : Find Motor HP an...
Page 48 - Typical Connections to Supply Standby Power
44 OM-402 10.10 Typical Connections to Supply Standby Power S-0405-A 1 Power Company Service Meter 2 Main and Branch Overcurrent Protection 3 Double-Pole, Double-Throw Transfer Switch Obtain and install correct switch. Switch rating must be same as or greater than the branch overcurrent protection.4...
Page 62 - Options and Accessories; HITCHES
58 OM-303 12. Options and Accessories 12.1 Metro 250D WELD METERS − DC AMP & VOLT (#042 947 Field ) Machine is prewired for easy installation of field kit. STARTING AID KITS (#043 139 Field ) Improve starting in cold weather by adding air intake manifold glow plug. Machine is prewired. SPARK ARR...
Page 63 - (Equipment with a serial number preface of “LA” or newer)
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 7/00 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 64 - Please complete and retain with your personal records.; For Service
PRINTED IN USA 2000 Miller Electric Mfg. Co. 6/00 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...
