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.; FUMES AND GASES can be hazardous.
OM-4422 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 adjoi...
Page 9 - Avertissement: Protégez vous et les autres des blessures; UN CHOC ÉLECTRIQUE peut tuer.
OM-4422 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-4422 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-4422 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 ét...
Page 12 - -7. Information sur les champs électromagnétiques
OM-4422 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 16 - Notes; Pros weld and cut
OM-4422 Page 12 3/96 1 Remove unit from shipping crate. Remove Owner’s Manual from unit. Follow instructions to install muffler. 2 Read Owner’s Manual. Read labels on unit. 3 Use Diesel Fuel only, and fill fuel tank. Leave room for expansion. 4 Warning! Watch Out! There are possible hazards as shown...
Page 18 - Some symbols are found only on CE products.; NOTE; Hz
OM-4422 Page 14 3-3. Symbols And Definitions Some symbols are found only on CE products. NOTE Stop Engine Fast (Run, Weld/ Power) Slow (Idle) Start Engine Starting Aid (Preheat) Battery (Engine) Engine Oil Pressure Engine Oil Check Injectors/ Pump Check Valve Clearance Fuel Protective Earth (Ground)...
Page 21 - DC WELD AMPERES AT 100% DUTY CYCLE; CC
OM-4422 Page 17 4-4. Fuel Consumption The curve shows typical fuel use under weld or power loads. 217 509 IDLE DC WELD AMPERES AT 100% DUTY CYCLE U.S. GAL/HR. 0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 0 50 100 150 200 250 300 350 400 Continuous Welding 4-5. Duty Cycle And Overheating Duty Cycle i...
Page 22 - AC AMPERES IN 120 V MODE; MATERIAL THICKNESS REFERENCE CHART
OM-4422 Page 18 4-6. AC Generator Power Curve 217 519 The ac power curve shows the gen- erator power in amperes available at the 120 and 240 volt receptacles. 0 40 80 120 160 0 20 40 60 80 AC AMPERES IN 120 V MODE AC AMPERES IN 240 V MODE 300 250200 150 100 50 0 150 125 100 75 50 25 0 AC VOL TS Note...
Page 29 - -7. Connecting To Weld Output Terminals
OM-4422 Page 25 5-7. Connecting To Weld Output Terminals Tools Needed: 3/4 in 1 2 Stop engine. 1 Work ( − ) Weld Output Terminal 2 CV (Wire) Weld Output Terminal 3 CC (Stick/TIG) Weld Output Terminal Stick and TIG Welding For Stick and TIG welding Direct Current Elec- trode Positive (DCEP), connect ...
Page 30 - -9. Connecting To Remote 14 Receptacle RC14
OM-4422 Page 26 5-9. Connecting To Remote 14 Receptacle RC14 Socket* Socket Information 24 VOLTS AC A 24 volts ac. Protected by circuit breaker CB8. 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 mode; 0 to +10 volts ...
Page 31 - Start Your Professional
OM-4422 Page 27 Notes Over 80,000 trained since 1930! 400 Trade Square East, Troy, Ohio 45373 1-800-332-9448 www.welding.org Start Your Professional Welding Career Now!
Page 34 - Process/Contactor Switch Settings
OM-4422 Page 30 6-3. Process/Contactor Switch On CC/CV Models 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 engine is running. Use switch to select weld process and weld output on/off control (see ta...
Page 35 - Start Procedure
OM-4422 Page 31 6-4. Lift-Arc Start Procedure Lift-Arc TIG With Lift-Arc TIG selected, start arc as follows:1 TIG Electrode 2 Workpiece Turn gas on. Touch tungsten electrode to workpiece at weld start point. Hold electrode to workpiece for 1-2 seconds , and slowly lift electrode. Arc is formed whe...
Page 38 - Every 8 h
OM-4422 Page 34 SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Routine Maintenance Follow the storage procedure in the engine owner’s manual if the unit will not be used for anextended period. Note Recycle engine fluids. Stop engine before maintaining. See Engine Manual and MaintenanceLabel for ...
Page 43 - -7. Adjusting Engine Speed On Standard Models
OM-4422 Page 39 8-7. Adjusting Engine Speed On Standard Models 803 563 3 1 2 RPM (Hz) Engine Speed (No Load) Weld/Power 1850 (61.7) Maximum Stop engine and let cool. Engine speed is factory set and should not require adjustment. Af- ter tuning engine, check engine speed with tachometer or frequen- c...
Page 45 - -9. Servicing Fuel And Lubrication Systems
OM-4422 Page 41 8-9. Servicing Fuel And Lubrication Systems 802 490 / Ref. 801 434 / 803 563 Stop engine and let cool. After servicing, start engine and check for fuel leaks. Stop engine, tighten connec- tions as necessary, and wipe up spilled fuel. 1 Oil Filter 2 Oil Drain Valve And Hose 3 Oil Fill...
Page 48 - Note; B. Standard Generator Power
OM-4422 Page 44 8-12. Troubleshooting Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (seeSection 8-11). Note A. Welding Trouble Remedy No weld output; generator power output okay at ac receptacles. Place Process/Contactor switch in a Weld Terminals Always On posi...
Page 52 - Figure 9-1. Circuit Diagram For Welding Generator
OM-4422 Page 48 SECTION 9 − ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For Welding Generator
Page 57 - 1-2. Grounding Generator To Truck Or Trailer Frame
OM-4422 Page 53 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 58 - 1-3. Grounding When Supplying Building Systems
OM-4422 Page 54 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 ...
Page 59 - 1-5. Approximate Power Requirements For Industrial Motors
OM-4422 Page 55 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 60 - 1-7. Approximate Power Requirements For Contractor Equipment
OM-4422 Page 56 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 ...
Page 62 - 1-10. Typical Connections To Supply Standby Power
OM-4422 Page 58 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 64 - PARTS LIST
OM-4422 Page 60 SECTION 12 − PARTS LIST Hardware is common and notavailable unless listed. Wirng harnesses are listed atthe end of parts section. 1 − Fig.15 − 3 2 7 3 − Fig.15 − 5 4 6 8 9 5 10 11 12 14 15 13 16 17 105 96 97 18 19 20 21 22 23 94 95 87 85 84 83 82 88 89 90 91 93 92 98 99 100 102 103 1...
Page 74 - Wiring Harnesses
OM-4422 Page 70 Some wiring harness components (switches, relays, circuit breakers) are also referencedelsewhere in this parts list. Purchase components separately or as part of the associatedwiring harness. Note Description Part No. Dia. Mkgs. Item No. Wiring Harnesses Quantity 219231 Harness, Engi...
Page 75 - (Equipment with a serial number preface of “LE” or newer)
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 6/04 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.; For Service
PRINTED IN USA 2004 Miller Electric Mfg. Co. 1/04 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...
