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 specification sheets. To locate your nearestdistributor 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2...
Page 5 - ELECTRIC SHOCK can kill.; HOT PARTS can cause severe burns.
OM-228 042 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 haza...
Page 7 - Using a generator indoors CAN KILL; ENGINE HEAT can cause fire.
OM-228 042 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 b...
Page 10 - UN CHOC ÉLECTRIQUE peut tuer.
OM-228 042 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 p...
Page 12 - LE CARBURANT MOTEUR peut provo
OM-228 042 Page 8 Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et NFPA 51B pour les travaux à chaud et avoir de la surveillance et un extincteur à proximité. LE BRUIT peut affecter l’ouïe. Le bruit des processus et des équipements peut affec l’ouïe. Porter des protections approuvés pour l...
Page 15 - -6. Proposition californienne 65 Avertissements
OM-228 042 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 cance...
Page 16 - SECTION 3
Complete Parts List available at www. MillerWelds.com OM-228 042 Page 12 SECTION 3 − DEFINITIONS 3-1. Symbol Definitions Engine Choke Read Operator’s Manual A Amperes V Volts Engine Oil Fuel Circuit Protector Engine Positive Negative Alternating Current (AC) Output h Hours Direct Current (DC) Time P...
Page 17 - DC Amperage; Wall Maximum
Complete Parts List available at www. MillerWelds.com OM-228 042 Page 13 4-3. Gun Specifications Air-Cooled Welding Guns For GMAW And FCAW Welding Using gasless flux cored wire reduces gun duty cycle. Ref. 800 797-D M-15 Feeds .023 To .045 in. (0.6 To 1.1 mm) Hard Or Flux Cored Wires .045 in. (1.1 m...
Page 18 - Auxiliary Power Kw At 100% Duty Cycle; A or V
Complete Parts List available at www. MillerWelds.com OM-228 042 Page 14 4-6. Fuel Consumption 233 244 Auxiliary Power Kw At 100% Duty Cycle US Gal./Hr . 0 1 2 3 4 5 6 0.00 0.20 0.40 0.60 0.80 1.00 4-7. Power Source Duty Cycle 230 343-A Duty cycle is the percentage of 10 minutes that unit can weld a...
Page 20 - SECTION 5
Complete Parts List available at www. MillerWelds.com OM-228 042 Page 16 SECTION 5 − INSTALLATION Always ground generator frame to vehicle frame to pre- vent electric shock and static electricity hazards. 1 Metal Vehicle Frame 2 Equipment Grounding Terminal 3 Grounding Cable Bed liners, shipping ski...
Page 21 - -2. Grounding Generator When Supplying Building Systems; Notes
Complete Parts List available at www. MillerWelds.com OM-228 042 Page 17 5-2. Grounding Generator When Supplying Building Systems GND/PE 1 2 2 3 800 576-B Ground generator to sys- tem earth ground if supply- ing power to a premises (home, shop, farm) wiring system. 1 Equipment Grounding Terminal 2 G...
Page 25 - Phase, 230 Volt AC Utility Input Power
Complete Parts List available at www. MillerWelds.com OM-228 042 Page 21 5-9. Connecting Single − Phase, 230 Volt AC Utility Input Power This unit can provide weld out-put using the engine to power the welding power source/wire feeder OR single − phase 230 volt ac utility power can be used to power ...
Page 26 - -11. Installing Wire Spool And Adjusting Hub Tension
Complete Parts List available at www. MillerWelds.com OM-228 042 Page 22 5-10. Electrical Service Guide 60 Hz Single Phase Input Voltage 230 Input Amperes At Rated Output 20 Max Recommended Standard Fuse Rating In Amperes Circuit Breaker 1 , Time-Delay 2 25 Normal Operating 3 30 Min Input Conductor ...
Page 30 - SECTION 6; Electric Start Models
Complete Parts List available at www. MillerWelds.com OM-228 042 Page 26 SECTION 6 − OPERATING THE WELDING GENERATOR 6-1. Controls (See Section 6-2) 229 573 / 804 971-B 4 1 6 3 5 2 7 8 9 Electric Start Models Recoil Start Models 1 2 4
Page 34 - SECTION 7
Complete Parts List available at www. MillerWelds.com OM-228 042 Page 30 SECTION 7 − OPERATING AUXILIARY EQUIPMENT If unit does not have GFCI recep- tacles, use GFCI-protected exten- sion cord. Generator power decreases as weld current increases. 1 240 V AC Receptacle RC1 RC1 supplies 60 Hz single-p...
Page 35 - SECTION 8
Complete Parts List available at www. MillerWelds.com OM-228 042 Page 31 SECTION 8 − MAINTENANCE 8-1. Power Source Routine Maintenance Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period. Stop engine before maintaining. See Engine Manual and ...
Page 36 - -4. Drive Motor Protection And Tip Saver/Short Circuit Protection; A. Drive Motor Protection
Complete Parts List available at www. MillerWelds.com OM-228 042 Page 32 8-2. Gun Routine Maintenance Stop engine and dis- connect gun before maintaining. = Check = Change = Clean = Replace Reference Every Spool Of Wire Section 8-7 Gun Casing Nozzle, Contact Tip Every 3 Months Section 8-7 Cracked Pa...
Page 37 - -5. Changing Drive Roll Or Wire Inlet Guide
Complete Parts List available at www. MillerWelds.com OM-228 042 Page 33 8-5. Changing Drive Roll Or Wire Inlet Guide 1 Inlet Wire Guide Remove guide by pressing on barbed area or cutting off one end near housing and pulling it out of hole. Push new guide into hole from rear until it snaps in place....
Page 42 - SECTION 9
Complete Parts List available at www. MillerWelds.com OM-228 042 Page 38 SECTION 9 − TROUBLESHOOTING 9-1. Troubleshooting A. Welding Trouble Remedy No weld output or generator power out- put at ac receptacles. Be sure all equipment is disconnected from receptacles when starting unit. AC receptacles ...
Page 44 - PARTS LIST; Description; Recommended Spare Parts; Quantity; Kohler; Air Filter Pre
Complete Parts List available at www. MillerWelds.com OM-228 042 Page 40 Trouble Remedy Engine will not start. Check fuel level (see Section 5-3). Move choke control to correct position (see Section 6-1). Open fuel valve (see Section 5-3). Close fuel valve before moving unit or carburetor may flood ...
Page 45 - ELECTRICAL DIAGRAMS; Figure 11-1. Circuit Diagram For Welding Generator
OM-217 454 Page 41 SECTION 11 − ELECTRICAL DIAGRAMS 235 289-A Figure 11-1. Circuit Diagram For Welding Generator
Page 47 - 2-2. Typical MIG Process Control Settings
OM-228 042 Page 43 12-2. Typical MIG Process Control Settings These settings are guidelines only. Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. Test welds to be surethey comply to specifications. These settings are guidelines only. Materialand wire type,...
Page 48 - 2-3. Holding And Positioning Welding Gun
OM-228 042 Page 44 12-3. Holding And Positioning Welding Gun Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger, be sure wire is no more than 1/2 in (13 mm)past end of nozzle, and tip of wire is positioned correctly on seam. S-0421-A Welding wire is en...
Page 49 - 2-4. Conditions That Affect Weld Bead Shape
OM-228 042 Page 45 12-4. Conditions That Affect Weld Bead Shape Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed(weld current), and voltage. S-0634-A Weld bead shape depends ongun angle, direction of tra...
Page 51 - Excessive Spatter; Porosity
OM-228 042 Page 47 12-8. Troubleshooting − Excessive Spatter Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead. S-0636 Possible Causes Corrective Actions Wire feed speed too high. Select lower wire feed speed. Voltage too high. Select lower voltage range...
Page 54 - Common MIG Shielding Gases
OM-228 042 Page 50 12-16. Common MIG Shielding Gases This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed over the years. The most commonly used shielding gases are listed in the following table. Application G...
Page 55 - GENERATOR POWER GUIDELINES; 3-2. Grounding Generator To Truck Or Trailer Frame
OM-228 042 Page 51 SECTION 13 − 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. 13-1. Selecting Equipment gen_pwr 2007 − 04 − Ref. ST-159 730 / ST-800 577 1 Generator Power Receptac...
Page 56 - 3-3. Grounding When Supplying Building Systems
OM-228 042 Page 52 13-3. 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 57 - 3-5. Approximate Power Requirements For Industrial Motors
OM-228 042 Page 53 13-5. 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 140...
Page 58 - 3-7. Approximate Power Requirements For Contractor Equipment
OM-228 042 Page 54 13-7. 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 ...
Page 60 - 3-10. Typical Connections To Supply Standby Power
OM-228 042 Page 56 13-10. 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 62 - SOCKET/WRENCH SELECTION TABLE
OM-228 042 Page 58 Notes SOCKET/WRENCH SELECTION TABLE (U.S. STANDARD) SOCKET/WRENCH SELECTION TABLE (METRIC) Specifications Socket or Wrench Size Specifications Socket or Wrench Size Bolt Diameter Decimal Equivalent Bolt Nut Bolt Diameter U.S. Decimal Equivalent Bolt Nut 1/4 in .250 in 3/8 in 7/16 ...
Page 63 - (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 64 - 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...
