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-4410 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 8 - ARC WELDING can cause interference.
OM-4410 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-4410 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-4410 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-4410 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-4410 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 13 - CC
OM-4410 Page 9 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 Glow Plug Check Valve Clearance Battery (Engine) Engine High Temperature A Amperes V Volts MIG (GMAW), Wire Stick (S...
Page 15 - DC AMPERES
OM-4410 Page 11 207 918 / 207 919 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. A. CC/DC Stick Mode B. CV/DC MIG Mode 4-3. Stick And MIG Mode Volt-Ampere Curves 0 10 20 30...
Page 16 - AC AMPERES
OM-4410 Page 12 207 920 / 207 921 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. A. CC/AC TIG Mode B. CC/DC TIG Mode 4-4. TIG Mode Volt-Ampere Curves 0 10 20 30 40 50 60 0 ...
Page 17 - -6. Fuel Consumption While Using Generator Power
OM-4410 Page 13 4-5. Fuel Consumption While Welding 207 922 0 50 100 150 200 250 300 DC WELD AMPERES AT 100% DUTY CYCLE IDLE W E L D − 3 6 0 0 R P M 0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 US GAL/HR. 0.00 0.95 1.89 2.84 3.79 4.73 5.68 6.62 7.57 LITERS/HR. 207 923 4-6. Fuel Consumption While Usi...
Page 18 - WELD AMPERES
OM-4410 Page 14 Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating. Exceeding duty cycle can damage unit and void warranty. 100% Duty Cycle at 300 Amperes DC Continuous Welding 4-7. Duty Cycle 207 925 0 10 20 30 40 50 60 100 70 80 90 150 175 200 225 250 2...
Page 24 - -7. Connecting To Weld Output Terminals
OM-4410 Page 20 5-7. Connecting To Weld Output Terminals Stop engine. Do not connect to CC and CV terminals at the same time. 1 Work Weld Output Terminal 2 Stick/TIG (CC) Weld Output Terminal 3 Wire /CV Weld Output Terminal For MIG welding, connect work cable to Work terminal and wire feeder cable t...
Page 27 - Notes
Page 29 - Glow Plug Time
OM-4410 Page 25 1 Process/Contactor Switch See Section 6-3 for Process/Contactor switch information.2 Voltage/Amperage Adjust Switch And Remote Receptacle Use switch to select front panel or remote voltage/amperage control. For remote con- trol, place switch in Remote position and connect remote con...
Page 30 - Process/Contactor Switch Settings
OM-4410 Page 26 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 an Electrode Hot posi- tion and the engine is running. In MIG and TIG modes, the unit willnot return to idle speed when the re-mote conta...
Page 32 - -1. Generator Power Receptacles And Circuit Breakers
OM-4410 Page 28 SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. Generator Power Receptacles And Circuit Breakers Ref. 206 580 1 2 5 3 If unit does not have GFCI re- ceptacles, use GFCI- protected extension cord. Generator power decreases asweld current increases. 1 240 V 50 A AC Receptacle RC1 RC1 su...
Page 33 - Start Your Professional
OM-4410 Page 29 7-2. Optional GFCI Receptacles If unit does not have GFCI re- ceptacles, use GFCI- protected extension cord. Generator power decreases asweld current increases. Combined output of all receptacles limited to 9.5 kVA/kW rating of the generator. GFCI Receptacle Option 1 120 V 20 A AC GF...
Page 34 - Receptacle
OM-4410 Page 30 7-3. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P) plug1 11/03 − 120 813-D The plug can be wired for a 240 V, 2-wire load or a 120/240V, 3-wire load. See circuit diagram.1 Plug Wired for 120/240 V, 3-Wire Load When wired for 120 V loads, each duplex recep...
Page 36 - NOTE; Every 8 h
OM-4410 Page 32 8-2. Routine Maintenance Follow the storage procedure in the engine owner ’s manual if the unit will not beused for an extended period. NOTE Stop engine before maintaining. See Engine Manual and Maintenance Labelfor important start-up, service, and storageinformation. Service engine ...
Page 41 - A. Checking Fuel Solenoid
OM-4410 Page 37 8-6. Adjusting Engine Speed If the engine does not start and stop properly, verify the fuel solenoid is installedproperly before adjusting engine speed (see Section A following). If the engine does not stay at idle speed, verify the throttle solenoid is installed andadjusted properly...
Page 42 - B. Checking Throttle Solenoid
OM-4410 Page 38 B. Checking Throttle Solenoid Ref. 801 961 / 802 649 Stop engine. If the engine does not stay at idle speed, verify the the throttle sole- noid and linkage is installed proper- ly. Adjusting Throttle Solenoid 1 Throttle Solenoid 2 Jam Nut 3 Solenoid Link 4 Shoulder Bolt 5 Throttle Le...
Page 43 - C. Making Engine Speed Adjustments
OM-4410 Page 39 C. Making Engine Speed Adjustments Ref. 801 961 / 801 963 Before adjusting engine speed, verifythrottle solenoid is installed properly(see Section B on previous page). Check engine speeds with a tachometer (see table). If necessary, adjust speeds as follows:Start engine and run until...
Page 48 - MATERIAL THICKNESS REFERENCE CHART
OM-4410 Page 44 Trouble Remedy Engine does not remain at idle speed with Engine Control switch in Speed Lock position and Speed Lock switch in Idle position. Check for obstructed movement of solenoid linkage (see Section 8-6). Have Factory Authorized Service Agent check control relay CR2, Speed Lock...
Page 50 - ELECTRICAL DIAGRAM; Figure 10-1. Circuit Diagram For Welding Generator
OM-4410 Page 46 SECTION 10 − ELECTRICAL DIAGRAM Figure 10-1. Circuit Diagram For Welding Generator
Page 55 - 2-2. Grounding Generator To Truck Or Trailer Frame
OM-4410 Page 51 SECTION 12 − 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 12-1. Selecting Equipment gen_pwr 11/02 − Ref. ST-159 730 / ST-800 577 1 Generator Power Receptacles...
Page 56 - 2-3. Grounding When Supplying Building Systems
OM-4410 Page 52 12-3. 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 57 - 2-5. Approximate Power Requirements For Industrial Motors
OM-4410 Page 53 12-5. 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 - 2-7. Approximate Power Requirements For Contractor Equipment
OM-4410 Page 54 12-7. 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 60 - 2-10. Typical Connections To Supply Standby Power; Pros weld and cut
OM-4410 Page 56 12-10. 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-4410 Page 58 SECTION 13 − PARTS LIST 23 89 71 69 45 92 1 91 72 87 80 74 81 73 84 79 82 85 86 75 77 76 78 83 88 90 See Figure 13-2 2 3 4 6 5 7 8 10 9 12 11 13 14 15 16 22 21 17 18 19 20 93 Figure 13-1. Main Assembly
Page 67 - OHM’S LAW
OM-4410 Page 63 803 150-A Hardware is common andnot available unless listed. 1 5 6 7 8 10 11 12 13 21 23 27 26 24 28 30 31 36 39 14 29 3 2 25 35 4 18 19 37 38 34 33 32 20 22 15 17 9 16 Figure 13-2. Panel, Front w/Components Notes OHM’S LAW VOLTAGE = CURRENT X RESISTANCE CURRENT = VOLTAGE RESISTANCE ...
Page 71 - (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 72 - 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...
