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-4422 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-4422 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-4422 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-4422 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-4422 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-4422 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-4422 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 - Notes; Pros weld and cut
OM-4422 Page 12 SECTION 3 − DEFINITIONS 3-1. Warning Label Definitions 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 ...
Page 18 - Hz
OM-4422 Page 14 3-3. Symbols And Definitions Some symbols are found only on CE products. 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) Posi...
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 4-5. Duty Cycle And Overheating 100% Duty Cycle At 250 Amperes ...
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 28 - -7. Connecting To Weld Output Terminals
OM-4422 Page 24 5-7. Connecting To Weld Output Terminals 803 562 / 803 778-A Tools Needed: 3/4 in MIG and FCAW Welding For MIG and FCAW welding Direct Current Electrode Positive (DCEP) connect wire feed- er cable to CV (Wire) terminal on right and work cable to Work/Negative ( − ) terminal on left. ...
Page 29 - Start Your Professional
OM-4422 Page 25 5-8. Selecting Weld Cable Sizes* Weld Output Terminals ! Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding*** ! Stop engine before connecting to weld output terminals. ! Do not use worn, damaged, under- sized, or poorly spliced cables. 100 ft (30 m) or L...
Page 30 - -9. Connecting To Remote 14 Receptacle RC14; REMOTE; OUTPUT
OM-4422 Page 26 5-9. Connecting To Remote 14 Receptacle RC14 Socket* Socket Information 24 VOLTS AC A 24 volts ac. Protected by sup- plementary protector 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 ...
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 ...
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 43 - -8. Adjusting Engine Speed On Standard Models
OM-4422 Page 39 8-8. Adjusting Engine Speed On Standard Models 803 563-E 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 freque...
Page 45 - -10. Servicing Fuel And Lubrication Systems
OM-4422 Page 41 8-10. 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...
Page 49 - B. Standard Generator Power; Trouble
OM-4422 Page 45 B. Standard Generator Power Trouble Remedy No generator power output at ac recep- tacles; weld output okay. Reset receptacle supplementary protector(s) (see Section 7-1). No generator power or weld output. Disconnect equipment from generator power receptacles during start-up. Check f...
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 - GENERATOR POWER GUIDELINES; 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-driven welding generators. Your unit may differ from those shown. 11-1. Selecting Equipment gen_pwr 2007 − 04 − 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 Use ground device as stated inelectrical codes. ! Ground generator to system earth ground if supplying power to a ...
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 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 64 - PARTS LIST
OM-4422 Page 60 SECTION 12 − PARTS LIST Hardware is common and notavailable unless listed. Wirng harnesses are listed at the end of parts section. 110 (Fig.12 − 3) 1 2 3 4 (Fig.12 − 5) 5 6 7 8 9 10 11 12 14 15 16 17 18 19 20 21 13 22 23 24 25 26 90 91 92 93 94 95 96 98 97 99 100 101 102 103 104 105 ...
Page 74 - Wiring Harnesses
OM-4422 Page 70 Some wiring harness components (switches, relays, supplementary protectors) are also referenced elsewhere in this parts list. Purchase compo-nents separately or as part of the associated wiring harness. Description Part No. Dia. Mkgs. Item No. Wiring Harnesses Quantity 231122 Harness...
Page 75 - (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 76 - 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...
