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 or individual catalog sheets. To locate your nearestdistributor or service agency call 1-800-...
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-; FUMES AND GASES can be hazardous.
OM-494 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom _nd_8/03 Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoin...
Page 8 - ARC WELDING can cause interference.
OM-494 Page 4 READ INSTRUCTIONS. Use only genuine MILLER/Hobart replacement parts. Perform engine and air compressor (if applicable) maintenance and service according to this manual and the engine/air compressor (if applicable) manu- als. H.F. RADIATION can cause interference. High-frequency (H.F.) ...
Page 9 - Avertissement: Protégez vous et les autres des blessures; UN CHOC ÉLECTRIQUE peut tuer.
OM-494 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION rom_fre 8/03 Avertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions. 2-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger !...
Page 10 - LES CHAMPS MAGNÉTIQUES peuvent
OM-494 Page 6 LES ACCUMULATIONS DE GAZ ris- quent de provoquer des blessures ou même la mort. Fermer l’alimentation du gaz protecteur en cas de non utilisation. Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi- rateur d’adduction d’air homologué. Le rayonnement de l’arc du ...
Page 11 - maintenance
OM-494 Page 7 L’EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE. Toujours porter une protection faciale, des gants en caoutchouc et vêtements de protection lors d’une in- tervention sur la batterie. Arrêter le moteur avant de débrancher ou de brancher les câbles de batterie. Eviter de provoquer des éti...
Page 12 - -7. Information sur les champs électromagnétiques
OM-494 Page 8 LE SURCHAUFFEMENT peut endom- mager le moteur électrique. Arrêter ou déconnecter l’équipement avant de dé- marrer ou d’arrêter le moteur. Ne pas laisser tourner le moteur trop lentement sous risque d’endommager le moteur électrique à cause d’une tension et d’une fréquence trop faibles....
Page 15 - AC AMPERES IN 240V MODE
OM-494 Page 11 4-4. Fuel Consumption The curve shows typical fuel use un- der the combined weld loads of both sides (Welder A and Welder B). 195 711 0 50 100 150 200 250 300 350 400 450 500 550 600 DC WELD AMPERES AT 40% DUTY CYCLE CV CC 0 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 0.40 0.21 0.62 0.83 ...
Page 16 - A or V
OM-494 Page 12 4-6. Duty Cycle And Overheating Ref. rduty1 5/95 − 194 313-A Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. Exceeding duty cycle can damage unit and void warranty. If a weld module overheats, the High Temperature light goes on and the th...
Page 17 - Single Mode
OM-494 Page 13 4-7. Volt-Ampere Curves 194 397 / 194 398 / 194 399 The volt-ampere curve shows the minimum, medium, and maximum voltage and amperage output capa- bilities of the welding generator. Curves of all other settings fall be- tween the curves shown. A. CC/DC − Single Mode B. CC/DC − Dual Mo...
Page 18 - When facing the front panel, the Welder B; NOTE; Notes; Pros weld and cut
OM-494 Page 14 SECTION 5 − INSTALLATION When facing the front panel, the Welder B controls and weld terminals are on the right and the Welder A controls and weld terminals are on the left. NOTE 5-1. Installing Welding Generator install1 11/02* − Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S...
Page 21 - Start Your Professional
OM-494 Page 17 5-5. Engine Prestart Checks Full 1/2 in (13 mm) Full Ref. 158 633-C / S-176 697 Diesel Check all fluids daily. Engine must be cold and on a level surface.Follow run-in procedure in engine manual. If unburned fuel and oil col- lect in exhaust pipe during run-in, see Section 10. Fuel Do...
Page 22 - -6. Safety Information For Connecting To Weld Output Terminals
OM-494 Page 18 5-6. Safety Information For Connecting To Weld Output Terminals UNEXPECTED WELD OUTPUT can cause injury or fire. Both weld outputs can be live (ON) when Welder Selector switch is in Welder A/Welder B position and engine is running. Disconnect or insulate any unused cables. Know where ...
Page 26 - -11. Making Dual Operator CV Weld Connections w/ Common Work Cable
OM-494 Page 22 5-11. Making Dual Operator CV Weld Connections w/ Common Work Cable Ref. 190 377 / 802 292-A Stop engine. Do not exceed machine duty cycle. For common work connection, workcable must be able to carry combinedweld output of both CC weld output ter-minals (see Section 5-15 for propercab...
Page 29 - -14. Making Single Operator CC Weld Connections
OM-494 Page 25 5-14. Making Single Operator CC Weld Connections 190 377 / 802 292-A Stop engine. Do not exceed machine duty cycle. Welder A (left) weld output terminalsare disabled in Single Operator mode.Connect only to Welder B (right) termi-nals for Single Operator mode opera-tion. Use Single Ope...
Page 36 - SECTION 8; Every 8 h
OM-494 Page 32 SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. 120 Volt And 240 Volt Duplex Receptacles 190 376 Be sure equipment connected to the 240 V receptacles is GFCI-pro- tected. Generator power is not affected byposition of Welder Selector switch. 4 kVA/kW generator power output isshared by a...
Page 41 - -6. Servicing Optional Ether Starting Aid
OM-494 Page 37 8-5. Adjusting Engine Speed Ref. 045 768-B Engine speed is factory set and should not require adjustment. Af- ter tuning engine, check engine speed with tachometer. See table for proper no load speed. If neces- sary, adjust speed as follows:1 High Speed Stop Screw 2 Lock Nut Loosen nu...
Page 42 - -7. Checking And Replacing Alternator Belt
OM-494 Page 38 8-7. Checking And Replacing Alternator Belt 158 632 / Ref. 190 377 Stop engine. To check belt tension: Remove rear panel.1 Alternator V-Belt 2 Crank Pulley 3 Alternator Pulley Place straight edge along top of pul- leys. Pull down belt as far as it will go, then measure distance from b...
Page 44 - -9. Inspecting And Cleaning Optional Spark Arrestor Muffler; MATERIAL THICKNESS REFERENCE CHART
OM-494 Page 40 8-9. Inspecting And Cleaning Optional Spark Arrestor Muffler Ref. 800 633-B / Ref. 190 377 Stop engine and let cool. 1 Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole.3 Exhaust Pipe Start engine and run several min- utes to blow out cleano...
Page 50 - Figure 9-1. Circuit Diagram For Welding Generator
OM-494 Page 46 SECTION 9 − ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For Welding Generator
Page 55 - 1-2. Grounding Generator To Truck Or Trailer Frame
OM-494 Page 51 SECTION 11 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-drivenwelding generators. Your unit may differ from those shown. NOTE 11-1. Selecting Equipment gen_pwr 11/02 − Ref. ST-159 730 / ST-800 577 1 Generator Power Receptacles ...
Page 56 - 1-3. Grounding When Supplying Building Systems
OM-494 Page 52 11-3. 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...
Page 57 - 1-5. Approximate Power Requirements For Industrial Motors
OM-494 Page 53 11-5. 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 58 - 1-7. Approximate Power Requirements For Contractor Equipment
OM-494 Page 54 11-7. 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 60 - 1-10. Typical Connections To Supply Standby Power
OM-494 Page 56 11-10. Typical Connections To Supply Standby Power Have only qualified persons perform these connections according to all applicable codes and safety practic- es. Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes. Customer-...
Page 62 - PARTS LIST
OM-494 Page 58 SECTION 12 − PARTS LIST Hardware is common andnot available unless listed. 12 11 10 8 7 96 − SEE FIG 12-2 95 94 92 91 90 93 89 88 87 97 98 99 100 101 4 1 3 2 9 102 103 10 13 5 6 34 86 84 85 83 3738 36 35 9 9 15 14 16 17 26 18 32 10 31 33 30 28 25 − SEE FIG 12-4 27 19 20 22 23 24 21 Fi...
Page 75 - (Equipment with a serial number preface of “LF” or newer)
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 1/05 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 76 - Please complete and retain with your personal records.; Contact a DISTRIBUTOR or SERVICE AGENCY near you.; For Service
PRINTED IN USA 2005 Miller Electric Mfg. Co. 1/05 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...
