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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2...
Page 5 - ELECTRIC SHOCK can kill.; HOT PARTS can cause severe burns.
OM-4426 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-4426 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 10 - UN CHOC ÉLECTRIQUE peut tuer.
OM-4426 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 - -3. Dangers existant en relation avec le moteur; LE CARBURANT MOTEUR peut provo
OM-4426 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 les ...
Page 15 - -6. Proposition californienne 65 Avertissements
OM-4426 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 - SECTION 3; CC; Notes; Pros weld and cut
A complete Parts List is available at www.MillerWelds.com OM-4426 Page 12 SECTION 3 − DEFINITIONS 3-1. Symbol Definitions Stop Engine Fast (Run, Weld/Power) Fast/Slow (Run/Idle) Slow (Idle) Start Engine Panel/Local Temperature Fuel Engine Oil Engine Choke Check Valve Clearance Battery (Engine) Engin...
Page 17 - SECTION 4
A complete Parts List is available at www.MillerWelds.com OM-4426 Page 13 SECTION 4 − SPECIFICATIONS 4-1. Weld, Power, And Engine Specifications Welding Mode Rated Welding Output Maximum Open-Circuit Voltage Weld Output Range Generator Power Rating Fuel Capacity Engine CC/DC 280 A, 25 V, 100% Duty C...
Page 18 - -3. Dimensions For Units With Optional Running Gear; DC WELD AMPERES AT 100% DUT Y CYCLE
A complete Parts List is available at www.MillerWelds.com OM-4426 Page 14 4-3. Dimensions For Units With Optional Running Gear Dimensions Height All Running Gear Options: 42-1/2 in (1079 mm) (To Top Of Handle Assembly) C A Protective Cage Width: 26 in (660 mm) D C B Running Gear Width: 32 in (813 mm...
Page 19 - VOL
A complete Parts List is available at www.MillerWelds.com OM-4426 Page 15 Ref. 220 807 − A The ac generator power curve shows the generator power avail- able in amperes at the receptacles.Tools and motors are designed to operate within 10% of 120/240 VAC. 4-5. Generator Power Curve AC AMPERES At 120...
Page 21 - DC
A complete Parts List is available at www.MillerWelds.com OM-4426 Page 17 220 312 − A / 220 311 − A The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of other settings fall between the curves shown. AC output is not availabl...
Page 22 - SECTION 5
A complete Parts List is available at www.MillerWelds.com OM-4426 Page 18 SECTION 5 − INSTALLATION Do not lift unit from end.Do not weld on base. Welding on base can cause fuel tank fire or explosion. Bolt unit down using holes provided in base.Always securely fasten weld- ing generator onto transpo...
Page 25 - -4. Connecting Or Replacing The Battery
A complete Parts List is available at www.MillerWelds.com OM-4426 Page 21 5-4. Connecting Or Replacing The Battery Ref. 803 − 573 − A / Ref. 803 752-C / Ref. 202 069-A / Ref. S-0756-D 1/2 in Tools Needed: + − ! Connect negative ( − ) battery cable last To connect battery, open right side engine acce...
Page 28 - -7. Connecting To Weld Output Terminals
A complete Parts List is available at www.MillerWelds.com OM-4426 Page 24 5-7. Connecting To Weld Output Terminals 803 778-A ! Stop engine. ! Failure to properly connect weld cables may cause ex- cessive heat and start a fire, or damage your machine. 1 Weld Output Terminal 2 Supplied Weld Output Ter...
Page 30 - SECTION 6
A complete Parts List is available at www.MillerWelds.com OM-4426 Page 26 SECTION 6 − OPERATING WELDING GENERATOR 6-1. Front Panel Controls (See Section 6-2) Ref. 216 170 / Ref. 227 723-A 4 2 1 3 5 9 7 8 6
Page 31 - Frequently
A complete Parts List is available at www.MillerWelds.com OM-4426 Page 27 6-2. Description Of Front Panel Controls (See Section 6-1) 1 Process/Contactor Switch See Section 6-4 for Process/Contactor switch information.2 Remote Receptacle Use receptacle to connect remote control or wire feeder.When a ...
Page 32 - Process/Contactor Switch Settings
A complete Parts List is available at www.MillerWelds.com OM-4426 Page 28 6-4. Process/Contactor Switch On AC/DC Models 1 Process/Contactor Switch ! Weld output terminals are energized when Process/Contactor switch is in an Electrode Hot position and the engine is running. The unit will not return t...
Page 33 - Stick Start Procedure
A complete Parts List is available at www.MillerWelds.com OM-4426 Page 29 6-5. Stick Start Procedure − Scratch Start Technique With Stick selected, start arc as follows:1 Electrode 2 Workpiece 3 Arc Drag electrode across workpiece like striking a match; lift electrode slightly after touching work. I...
Page 34 - TIG With Auto-Crater; OR
A complete Parts List is available at www.MillerWelds.com OM-4426 Page 30 6-6. Lift-Arc t TIG With Auto-Crater t And Auto-Stop t WM Marketing Arc Start With Lift-Arc Arc End With Auto-Crater Arc End With Auto-Stop 1 2 1 2 2 1 3 3 4 Arc Start With Lift-Arc TIG Lift-Arc is used for the DCEN GTAW proce...
Page 36 - SECTION 7; -1. Generator Power Receptacles And Supplementary Protectors
A complete Parts List is available at www.MillerWelds.com OM-4426 Page 32 SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. Generator Power Receptacles And Supplementary Protectors Ref. 216 170 4 ! If unit does not have GFCI recep- tacles, use GFCI-protected exten- sion cord. Generator power decreases ...
Page 38 - SECTION 8
A complete Parts List is available at www.MillerWelds.com OM-4426 Page 34 SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Maintenance Label
Page 40 - Robin
A complete Parts List is available at www.MillerWelds.com OM-4426 Page 36 8-3. Servicing Optional Spark Arrestor Ref. 803 572 − A / Ref. 183 175 − A ! Stop engine and let cool. 1 Spark Arrestor Screen Clean and inspect screen. Replace spark arrestor if screen wires are broken or missing. 1/4 in 1 To...
Page 49 - SECTION 9; Recommended Spare Parts
A complete Parts List is available at www.MillerWelds.com OM-4426 Page 45 SECTION 9 − PARTS LIST A complete Parts List is available on-line at www.MillerWelds.com. 9-1. Recommended Spare Parts Description Part No. Dia. Mkgs. Recommended Spare Parts Quantity F6 021718 Fuse, Mintr Gl 30. Amp 32 Volt 1...
Page 50 - ELECTRICAL DIAGRAMS
OM-4426 Page 46 SECTION 10 − ELECTRICAL DIAGRAMS Figure 10-1. Circuit Diagram For Welding Generator Models With AC/DC Output
Page 54 - GENERATOR POWER GUIDELINES; 1-2. Grounding Generator To Truck Or Trailer Frame
OM-4426 Page 50 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 55 - 1-3. Grounding When Supplying Building Systems
OM-4426 Page 51 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 56 - 1-5. Approximate Power Requirements For Industrial Motors
OM-4426 Page 52 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 57 - 1-7. Approximate Power Requirements For Contractor Equipment
OM-4426 Page 53 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 59 - 1-10. Typical Connections To Supply Standby Power
OM-4426 Page 55 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 61 - MATERIAL THICKNESS REFERENCE CHART
OM-4426 Page 57 Notes 16 Gauge (.063 in) 22 Gauge (.031 in) 24 Gauge (.025 in) 20 Gauge (.037 in)18 Gauge (.050 in) 14 Gauge (.078 in) 1/8 in (.125 in) 3/16 in (.188 in) 1/4 in (.25 in) 5/16 in (.313 in) 3/8 in (.375 in) 1/2 in (.5 in) MATERIAL THICKNESS REFERENCE CHART
Page 62 - Welding Symbols
OM-4426 Page 58 Notes Welding Symbols Ref. AWS/ANSI A2.4
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...