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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 5 - ELECTRIC SHOCK can kill.; SIGNIFICANT DC VOLTAGE exists in inverters after stop-; HOT PARTS can cause severe burns.
OM-4409 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-4409 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 9 - ARC WELDING can cause interference.
OM-4409 Page 5 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 qu...
Page 10 - UN CHOC ÉLECTRIQUE peut tuer.
OM-4409 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 - LE CARBURANT MOTEUR peut provo
OM-4409 Page 8 LES CHAMPS MAGNETIQUES peuv- ent affecter des implants médicaux. Porteur de simulateur cardiaque ou autre im- plants médicaux, rester à distance. Les porteurs d’implants doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de sou- dage par poi...
Page 13 - LA CHUTE DE L’APPAREIL peut blesser.
OM-4409 Page 9 L’utilisation d’un groupe autonome à l’intérieur PEUT VOUS TUER EN QUELQUES MINUTES. Les fumées d’un groupe autonome contient du monoxyde de carbone. C’est un poison invisi- ble et inodore. JAMAIS utiliser dans une maison ou garage, même avec les portes et fenêtres ouvertes. Uniquemen...
Page 15 - -6. Proposition californienne 65 Avertissements
OM-4409 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 18 - Dimensions; Notes; Pros weld and cut
OM-4409 Page 14 4-4. Dimensions, Weights, And Operating Angles Dimensions Height 54-1/2 in (1384 mm) (to top of muffler) G Width 28-1/2 in (724 mm) (mtg. brackets turned in) 30-3/4 in (781 mm) (mtg. brackets turned out) G ! Do not exceed tilt angles or engine could be damaged or unit could tip. Dept...
Page 23 - AC AMPERES
OM-4409 Page 19 4-10. Optional 3-Phase Generator Power Curves 197 472 / 197 473 The ac power curves show the gen- erator power available in amperes at the single-phase 120/240 volt re- ceptacle or three-phase 240 volt terminals. A. 12 kVA/kW Single-Phase AC Output (No Weld Load) B. 20 kVA/kW Three-P...
Page 24 - -12. Optional Battery Charging Output Curve
OM-4409 Page 20 4-11. Air Compressor Output Curve 208 955 The air output curve shows the vol- ume and pressure of air available from the air compressor. 0 20 40 60 80 100 120 140 0 10 20 30 40 50 60 70 80 90 100 CUBIC FEET PER MINUTE (CFM) POUNDS PER SQUARE INCH (PSI) Idle 4-12. Optional Battery Cha...
Page 28 - -3. Installing Optional Spark Arrestor Muffler
OM-4409 Page 24 5-3. Installing Optional Spark Arrestor Muffler Tools Needed: 803 230 ! Stop engine and let cool. 1 Spark Arrestor Muffler 2 Double-Flanged Elbow 3 Nut 4 Flat Washer 5 Mount 6 Bracket 7 Screw 8 Single-Flanged Elbow 9 Rain Cap 10 ClampLoosely assemble components as shown. Mount the mu...
Page 30 - -6. Using The Optional Battery Disconnect Switch; Start Your Professional
OM-4409 Page 26 5-6. Using The Optional Battery Disconnect Switch 803 228 / Ref. 803 324 ! Stop engine. 1 Battery Disconnect Switch The battery disconnect switch dis- connects battery voltage from the circuit. When the switch is turned Off, the front panel controls do not work.To run unit, turn swit...
Page 32 - -8. Connecting To Weld Output Terminals
OM-4409 Page 28 5-8. Connecting To Weld Output Terminals 803 231 / 803 778-A Tools Needed: 3/4 in MIG And FCAW Welding For MIG welding Direct Current Electrode Positive (DCEP), connect wire feeder cable to Positive (+) terminal on left and work cable to Negative ( − ) terminal on right. Use Process/...
Page 34 - REMOTE
OM-4409 Page 30 5-10. Connecting To Remote 14 Receptacle RC14 Socket* Socket Information 24 VOLTS AC A 24 volts ac. Protected by sup- plementary protector CB5. 24 VOLTS AC B Contact closure to A completes 24 volt ac contactor control circuit. C Output to remote control:+10 volts dc in MIG or Stick m...
Page 38 - Process/Contactor Switch Settings
OM-4409 Page 34 6-3. Process/Contactor Switch 217 356-A 1 1 Process/Contactor Switch ! Weld output terminals are ener- gized when Process/Contactor switch is in a Weld Terminals Al- ways On position and the en- gine is running. ! DC voltage is still present at the weld terminals when Process/ Contac...
Page 41 - -2. Connecting To Optional AC Power Plant
OM-4409 Page 37 7-2. Connecting To Optional AC Power Plant Ref. 197 399 / 802 332-B Do not weld while using optional acpower plant. Place Process/Contactor switch inWeld Terminals Always On - Stick position when using optional ac power plant (see Section 6-3). Single-Phase Generator Power 1 120/240 ...
Page 42 - -3. Optional Generator Power Receptacles
OM-4409 Page 38 7-3. Optional Generator Power Receptacles 2 1 120 V 20 A AC GFCI Receptacle GFCI1 2 240 V 16 A AC European Receptacle RC1 3 240 V 15 A AC Australian Receptacle RC1 4 240 V 15 A AC South African Receptacle RC1 Receptacles supply 60 Hz single- phase power at weld/power speed.If a groun...
Page 43 - -2. Determining Battery Charging Current
OM-4409 Page 39 SECTION 8 − OPERATING OPTIONAL BATTERY CHARGER 8-1. Battery Charge Controls 1 Output Selector Switch NOTICE − Do not switch under load. Stop en- gine or set Process/Contactor switch to any Remote position before switching. Use switch to select weld or battery charge output. Output au...
Page 49 - MATERIAL THICKNESS REFERENCE CHART
OM-4409 Page 45 9-3. Checking Generator Brushes Ref. 206 467 ! Stop engine and let cool. 1 Generator Brush Remove brushes from brush holder.Replace brushes if damaged or if brush material is at or near minimum length. 1 Damaged Brushes New Length: 1-1/4 in (32 mm) Minimum Length: 5/8 in (16 mm) Repl...
Page 53 - -7. Servicing Engine Fuel And Lubrication Systems
OM-4409 Page 49 9-7. Servicing Engine Fuel And Lubrication Systems 803 228 ! Stop engine and let cool. ! After servicing, start engine and check for fuel leaks. Stop engine, tighten connections as necessary, and wipe up spilled fuel. 1 Oil Filter 2 Oil Drain Hose And Valve 3 Oil Fill Cap 4 Primary F...
Page 55 - AIR COMPRESSOR MAINTENANCE
OM-4409 Page 51 SECTION 10 − AIR COMPRESSOR MAINTENANCE Use only genuine Ingersoll Rand compressor oil and filters to maintain 3-year warranty on air compressor. The air compressor warranty will be reduced to 2 years if non-Ingersoll Rand oil and filters are used The air compressor normally requires...
Page 61 - TROUBLESHOOTING; Trouble
OM-4409 Page 57 SECTION 11 − TROUBLESHOOTING 11-1. Troubleshooting Tables A. Welding Trouble Remedy No weld output; generator power output okay at ac receptacles. Place Process/Contactor switch in a Weld Terminals Always On position, or place switch in a Remote On/Off Switch Required position and co...
Page 64 - F. Optional Battery Charging
OM-4409 Page 60 Trouble Remedy Engine does not run at idle speed. Turn Process/Contactor switch to any position but Remote On/Off Switch Required-TIG. Check for obstructed throttle solenoid. Allow circuit breaker CB14 to reset. Have Factory Authorized Service Agent check throttle solenoid TS1 and li...
Page 65 - AIR COMPRESSOR DIAGRAM; Figure 12-1. Circuit Diagram For Air Compressor
OM-4409 Page 61 SECTION 12 − AIR COMPRESSOR DIAGRAM 209 059-A Figure 12-1. Circuit Diagram For Air Compressor
Page 66 - CIRCUIT DIAGRAM; Figure 13-1. Circuit Diagram For Welding Generator
OM-4409 Page 62 SECTION 13 − CIRCUIT DIAGRAM Figure 13-1. Circuit Diagram For Welding Generator
Page 71 - AIR COMPRESSOR TABLES
OM-4409 Page 67 SECTION 15 − AIR COMPRESSOR TABLES 15-1. Flow Of Free Air (CFM) Through Orifices Of Various Diameters Gauge Pressure (psi) Orifice Diameter (in) And Free Air Flow (CFM) 1/64 1/32 3/64 1/16 3/32 1/8 3/16 1/4 1 0.027 0.107 0.242 0.430 0.97 1.72 3.86 6.85 2 0.038 0.153 0.342 0.607 1.36 ...
Page 73 - GENERATOR POWER GUIDELINES; 6-2. Grounding Generator To Truck Or Trailer Frame
OM-4409 Page 69 SECTION 16 − 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. 16-1. Selecting Equipment gen_pwr 2007 − 04 − Ref. ST-159 730 / ST-800 577 1 Generator Power Receptacles...
Page 74 - 6-3. Grounding When Supplying Building Systems
OM-4409 Page 70 16-3. 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 ...
Page 75 - 6-5. Approximate Power Requirements For Industrial Motors
OM-4409 Page 71 16-5. 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 76 - 6-7. Approximate Power Requirements For Contractor Equipment
OM-4409 Page 72 16-7. 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 78 - 6-10. Typical Connections To Supply Standby Power
OM-4409 Page 74 16-10. 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 ...
Page 80 - Wear Clean gloves To Prevent Contamination Of Tungsten
OM-4409 Page 76 SECTION 17 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING gtaw_Phase_2007 − 04 ! Whenever possible and practical, use DC weld output instead of AC weld output. 17-1. Selecting Tungsten Electrode ( Wear Clean gloves To Prevent Contamination Of Tungsten ) Amperage Range - Ga...
Page 83 - 8-3. Positioning Torch Tungsten For Various Weld Joints
OM-4409 Page 79 18-3. Positioning Torch Tungsten For Various Weld Joints ST-162 003 / S-0792 70 ° 70 ° 90 ° 20 ° 20 ° 10 ° 20 ° 70 ° 40 ° 30 ° 20 ° 70 ° 90 ° 20 ° Butt Weld And Stringer Bead “T” Joint Lap Joint Corner Joint
Page 84 - PARTS LIST
OM-4409 Page 80 SECTION 19 − PARTS LIST Hardware is common and notavailable unless listed. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 123 124 125 126 127 128 129 130 131 − Figure 19-2 132 133 15 134 135 136 137 138 139 140 141 142 143 144 − Figure 19-3 28 29 30 31 32 33 ...
Page 101 - (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 102 - 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...
