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We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING rom _nd_4/02 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Y Marks a special safety message.
WELDING can cause fire or explosion. HOT PARTS can cause severe burns. D Allow cooling period before maintaining. Welding on closed containers, such as tanks, D Wear protective gloves and clothing when drums, or pipes, can cause them to blow up. Sparks working on a hot engine.
READ INSTRUCTIONS. stopping engine. D Do not let low voltage and frequency caused by D Use only genuine MILLER replacement parts. low engine speed damage electric motors. D Perform engine maintenance and service D Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle according to this manual and the engine where applicable.
H.F. RADIATION can cause interference. ARC WELDING can cause interference. D High-frequency (H.F.) can interfere with radio D Electromagnetic energy can interfere with navigation, safety services, computers, and sensitive electronic equipment such as communications equipment. computers and computer-driven equipment D Have only qualified persons familiar with such as robots.
SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION rom _nd_fre 11/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Y Identifie un message de sécurité...
LE SOUDAGE peut provoquer un in- DES PIÈCES CHAUDES peuvent cendie ou une explosion. provoquer des brûlures graves. D Prévoir une période de refroidissement avant d’effec- Le soudage effectué sur des conteneurs fermés tels que tuer des travaux d’entretien. des réservoirs, tambours ou des conduites peut provoquer D Porter des gants et des vêtements de protection pour leur éclatement.
DES ORGANES MOBILES peuvent L’ACIDE DE LA BATTERIE peut pro- provoquer des blessures. voquer des brûlures dans les YEUX et sur la PEAU. D Ne pas approcher les mains des ventilateurs, cour- roies et autres pièces en mouvement. D Ne pas renverser la batterie. D Maintenir fermés et fixement en place les portes, D Remplacer une batterie endommagée.
LE RAYONNEMENT HAUTE FRÉ- LE SOUDAGE À L’ARC risque de QUENCE (H.F.) risque de provoquer provoquer des interférences. des interférences. D L’énergie électromagnétique risque de provoquer des interférences pour l’équipement électronique D Le rayonnement haute fréquence (H.F.) peut sensible tel que les ordinateurs et l’équipement com- provoquer des interférences avec les équipements mandé...
3-2. Dimensions, Weights, and Operating Angles Dimensions Height 33-1/2 in (851 mm) Width 18-3/4 in (476 mm) Y Do not exceed tilt angles or engine could Depth 46 in (1164 mm) be damaged or unit could tip. Y Do not move or operate unit where it could 18 in (457 mm) tip.
3-6. Volt-Ampere Curves The volt-ampere curve shows the A. For CC/AC Mode minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the curves shown. B. For CC/DC Mode C. For CV/DC Mode 200 296 / 200 297 / 200 298 OM-4403 Page 12...
3-7. Duty Cycle Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating. Y Exceeding duty cycle can damage unit void warranty. Continuous Welding 100% Duty Cycle at 250 Amperes 200 293 SECTION 4 – INSTALLATION 4-1.
4-2. Engine Prestart Checks (Onan-Powered Units) Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. Full Follow run-in procedure in en- gine manual. This unit has a low oil pressure Gasoline shutdown switch.
4-3. Engine Prestart Checks (Kohler-Powered Units) Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. Full Follow run-in procedure in en- gine manual. This unit has a low oil pressure shutdown switch.
4-4. Activating The Dry Charge Battery (If Applicable) Remove battery from unit. Eye Protection – Safety Glasses Or Face Shield Rubber Gloves Vent Caps Sulfuric Acid Electrolyte (1.265 Specific Gravity) Well Fill each cell with electrolyte to bottom of well (maximum). Y Do not overfill battery cells.
4-5. Connecting the Battery Y Connect negative (–) cable last. – Tools Needed: 3/8, 1/2 in Ref. 800 394-C / Ref. 200 017 / Ref. S-0756-D 4-6. Installing Exhaust Pipe Y Engine backfire can cause se- vere burns or other injuries. Do not point exhaust pipe toward control panel.
4-7. Connecting to Weld Output Terminals See Section 5 for examples of typical weld connections and control settings. Work Weld Output Terminal Electrode Weld Output Terminal Connect work cable to Work terminal. Connect electrode holder cable or electrode weld cable to Electrode ter- minal for Stick and MIG welding.
SECTION 5 – OPERATING THE WELDING GENERATOR 5-1. Front Panel Controls Shown with optional receptacle covers. Ref. 200 017 Engine Control Switch position. For best arc starts and when using weld Use switch to start engine, select speed, and and generator power together, use a low Engine Hour Meter stop engine.
5-2. Typical Stick Welding Connections And Control Settings Y Stop engine. This section provides general guide- lines and may not suit all applications. The control panel shows the typical For best arc starts and best settings for welding with a 7018 (1/8 in) results using weld and generator electrode.
5-3. Typical MIG Welding Connections And Settings A. Solid Wire Applications Y Stop engine. This section provides general guide- lines and may not suit all ap- plications. Typical Control Settings For .035 (ER70S-3) Solid Wire – Short Circuit Transfer The control panel shows the typical settings for welding with .035 (ER70S-3) solid wire.
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B. Self-Shielded Flux Core Wire Applications Y Stop engine. This section provides general guidelines and may not suit all applications. Typical Control Settings For .045 (71T-11) Self-Shielded Flux Core Wire The control panel shows the typi- cal settings for welding with .045 (71T-11) self-shielded flux core Note Coarse Range, wire.
5-4. Typical MIG Connections And Settings Using Weld Control And Spoolgun Typical Settings For 4043 (.035) Tools Needed: Aluminum On 1/8 in Material: 3/4 in Note Coarse Range and Weld Process switch settings. Connect to unused Work contactor terminal. Plug and sensing lead not used in this application.
SECTION 6 – OPERATING AUXILIARY EQUIPMENT 6-1. Standard Receptacles Y If unit does not have GFCI re- ceptacles, use GFCI-protected extension cord. Generator power decreases as weld current increases. Set Fine Control R1 at 10 for full generator power. 240 V 50 A AC Receptacle RC1 RC1 supplies 60 Hz single-phase power at weld/power speed.
6-2. Optional Generator Power Receptacles Y If unit does not have GFCI recep- tacles, use GFCI-protected exten- sion cord. Generator power decreases as weld current increases. Set Fine Control R1 at 10 for full genera- tor power. Combined output of all receptacles limited to 10 kVA/kW rating of the generator.
6-3. Wiring Optional 240 Volt Plug The plug can be wired for a 240 V, 2-wire load or a 120/240V, 3-wire load. See circuit diagram. Plug Wired for 120/240 V, 3-Wire Load Current Available in Amperes When wired for 120 V loads, each 240 V Each 120 V Duplex duplex receptacle shares a load...
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50 h Clean tighten weld terminals. 100 h Change oil. See Clean cooling system. Section 7-5 and See Engine Manual. maintenance label. Service Clean cleaner element. tighten battery See Section 7-3. connections. 200 h Replace fuel Change oil filter. See filter.
7-3. Servicing Air Cleaner (Onan-Powered Units) Y Stop engine. Y Do not run engine without air cleaner or with dirty element. Wrapper (Foam Element) Wash wrapper with soap and water solution. Allow wrapper to air dry completely. Spread 1 tablespoon SAE 30 oil evenly into wrapper.
7-5. Changing Engine Oil, Oil Filter, and Fuel Filter (Onan-Powered Units) Y Stop engine and let cool. Oil Drain Valve 1/2 ID x 12 in Hose Oil Filter Change engine oil and filter accord- ing to engine owner’s manual. Y Close valve and valve cap before adding running engine.
7-6. Adjusting Engine Speed (Onan-Powered Units) After tuning engine, check engine speeds with a tachometer (see table). If necessary, adjust speeds as follows: ± 2200 100 rpm Start engine and run until warm. ± Remove wrapper to access speed 3700 50 rpm adjustments.
7-7. Servicing Optional Spark Arrestor (Onan-Powered Units) Y Stop engine and let cool. Spark Arrestor Screen Clean and inspect screen. Replace spark arrestor if screen wires are broken or missing. Tools Needed: 1/4 in Ref. 801 682-A / Ref. 183 175–A SECTION 8 –...
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100 h Change oil. See Section 8-4 Check air cleaner element. and maintenance label. See Section 8-3. Clean cooling system. See Clean and tighten battery Engine Manual. connections. 200 h Change oil filter. See Section Replace fuel filter. See 8-4 and maintenance label. Section 8-4.
8-2. Maintenance Label (Kohler-Powered Units) 8-3. Servicing Air Cleaner (Kohler-Powered Units) Y Stop engine. Y Do not run engine without air cleaner or with dirty element. Wrapper (Foam Element) Wash wrapper with soap and water solution. Allow wrapper to air dry completely.
8-4. Changing Engine Oil, Oil Filter, and Fuel Filter (Kohler-Powered Units) Y Stop engine and let cool. Oil Drain Valve 1/2 ID x 12 in Hose Oil Filter Change engine oil and filter accord- ing to engine owner’s manual. Y Close valve and valve cap before adding running engine.
8-5. Adjusting Engine Speed (Kohler-Powered Units) After tuning engine, check engine speeds with a tachometer (see table). If necessary, adjust speeds as follows: ± 2200 50 rpm Start engine and run until warm. Turn Fine Control to 10. ± 3700 50 rpm Remove top cover to access speed adjustments.
8-6. Overload Protection (Kohler-Powered Units) Y Stop engine. Disconnect negative (–) battery cable. Fuse F1 (See Parts List) F1 protects the weld excitation winding from overload. If F1 opens, weld output stops or is low. Fuse F2 (See Parts List) F2 protects the generator power excitation winding from overload.
SECTION 9 – TROUBLESHOOTING 9-1. Welding Troubleshooting Trouble Remedy Low or no weld output; generator pow- Check control settings. er output okay at ac receptacles. Check weld connections. Check fuse F1, and replace if open (see Section 7-4 or 8-6). Have Factory Authorized Service Agent check brushes, slip rings, and integrated rectifiers SR2 and SR3.
Trouble Remedy Low power output at ac receptacles. Check fuse F2, and replace if open (see Section 7-4 or 8-6). Increase Fine control R1 setting to max. High power output at ac receptacles. Check engine speed, and adjust if necessary (see Section 7-6 or 8-5). Erratic power output at ac receptacles.
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Trouble Remedy Unstable or sluggish engine speeds. Readjust throttle linkage if necessary. Check throttle solenoid TS1 for smooth operation. Tune-up engine according to engine manual. Engine does not return to idle speed. Remove weld and generator power loads. Check throttle linkage for smooth, non-binding operation. Have Factory Authorized Service Agent check idle module PC1, current transformer CT1, Engine Control switch S2, and throttle solenoid TS1.
SECTION 11 – GENERATOR POWER GUIDELINES 11-1. Selecting Equipment Generator Power Receptacles – Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment Be sure equipment has this symbol and/or wording. gen_pwr 4/02 – Ref. ST-159 730 / ST-800 577 11-2.
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11-3. Grounding When Supplying Building Systems Equipment Grounding Terminal Grounding Cable GND/PE Use #10 AWG or larger insulated copper wire. Ground Device Y Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. Use ground device as stated in electrical codes.
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11-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1/8 HP 1/6 HP 1225 1/4 HP 1600 1/3 HP 2100 1/2 HP 3175 Capacitor Start-Induction Run 1/3 HP 2020 1/2 HP 3075 3/4 HP 4500 1400 1 HP...
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11-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1/4 in 3/8 in 1/2 in Circular Saw 6-1/2 in 7-1/4 in 8-1/4 in 1400 1400 Table Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in...
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11-8. Power Required To Start Motor Motor Start Code AC MOTOR Running Amperage VOLTS AMPS Motor HP CODE Motor Voltage PHASE To find starting amperage: Step 1: Find code and use table to find kVA/HP. If code is not listed, multiply running amperage by six to find starting amperage.
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11-10. Typical Connections To Supply Standby Power Y Have only qualified persons perform these connections Customer-supplied equipment is required if according to all applicable generator is to supply standby power during codes and safety practices. emergencies or power outages. Y Properly install and ground this equipment according to its Owner’s Manual and na- tioanl, state, and local codes.
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11-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current Load (Watts) (Amperes) 350 (106) 225 (68)
SECTION 12 – STICK WELDING (SMAW) GUIDELINES 12-1. Stick Welding Procedure Y Weld current starts when electrode touches work- piece. Y Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible.
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12-2. Electrode and Amperage Selection Chart 3/32 6010 5/32 & 3/16 6011 7/32 6010 DEEP MIN. PREP, ROUGH 1/16 HIGH SPATTER 6011 DEEP 5/64 6013 EP,EN GENERAL 3/32 SMOOTH, EASY, 6013 7014 EP,EN FAST 5/32 3/16 LOW HYDROGEN, 7018 STRONG 7/32 FLAT SMOOTH, EASY,...
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12-5. Positioning Electrode Holder ° ° ° ° End View of Work Angle Side View of Electrode Angle GROOVE WELDS ° ° ° ° End View of Work Angle Side View of Electrode Angle FILLET WELDS S-0060 12-6. Poor Weld Bead Characteristics Large Spatter Deposits Rough, Uneven Bead Slight Crater During Welding...
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12-8. Conditions That Affect Weld Bead Shape NOTE Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal. Correct Angle ° - ° Angle Too Large Angle Too Small Drag ELECTRODE ANGLE Spatter Normal Too Long Too Short...
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12-10. Butt Joints Tack Welds Prevent edges of joint from drawing together ahead of electrode by tack welding the materials in position be- fore final weld. Square Groove Weld Good for materials up to 3/16 in (5 mm) thick. Single V-Groove Weld °...
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12-13. Weld Test Vise Weld Joint Hammer Strike weld joint in direction shown. A good weld bends over but does not break. 2 To 3 in (51-76 mm) 2 To 3 in (51-76 mm) 1/4 in (6.4 mm) S-0057-B 12-14. Troubleshooting – Porosity Porosity –...
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12-16. Troubleshooting – Incomplete Fusion Incomplete Fusion – failure of weld metal to fuse completely with base metal or a preceeding weld bead. Possible Causes Corrective Actions Insufficient heat input. Increase amperage. Select larger electrode and increase amperage. Improper welding technique. Place stringer bead in proper location(s) at joint during welding.
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12-19. Troubleshooting – Burn-Through Burn-Through – weld metal melting completely through base metal resulting in holes where no metal remains. Possible Causes Corrective Actions Excessive heat input. Select lower amperage. Use smaller electrode. Increase and/or maintain steady travel speed. 12-20. Troubleshooting – Waviness Of Bead Waviness Of Bead –...
SECTION 13 – MIG WELDING (GMAW) GUIDELINES 13-1. Typical MIG Process Connections Using A Voltage-Sensing Wire Feeder Y Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as Constant close to the weld as possible.
13-3. Typical MIG Process Control Settings NOTE These settings are guidelines only. Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. Test welds to be sure they comply to specifications. Material thickness determines weld parameters. 1/8 or Convert Material .125 in Thickness to...
13-4. Holding And Positioning Welding Gun NOTE 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. Hold Gun and Control Gun Trigger Workpiece...
13-5. Conditions That Affect Weld Bead Shape NOTE 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. ° Push ° Perpendicular Drag GUN ANGLES AND WELD BEAD PROFILES Short Normal Long...
13-6. Gun Movement During Welding NOTE Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads works better. Stringer Bead – Steady Movement Along Seam Weave Bead –...
13-9. 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. Electrode extension (stickout) too long.
13-12. Troubleshooting – Lack Of Penetration Lack Of Penetration – shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration S-0638 Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while maintaining proper welding wire extension and arc characteristics.
13-15. Troubleshooting – Waviness Of Bead Waviness Of Bead – weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Corrective Actions Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle. Unsteady hand.
13-17. 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.
SECTION 14 – PARTS LIST Hardware is common and not available unless listed. Figure 14-1. Main Assembly (Onan OHV Engine Shown) 802 920-D OM-4403 Page 68...
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Item Dia. Part Mkgs. Description Quantity Figure 14-1. Main Assembly ....181 881 Grommet, Neck Filler ..........
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Item Dia. Part Mkgs. Description Quantity Figure 14-1. Main Assembly (Continued) ....082 319 Cable, Cable, Bat Neg 17.750 (Battery To Engine Block) ......(Onan OHV &...
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ST-801 747-B Figure 14-3. Panel, Front w/Components Item Dia. Part Mkgs. Description Quantity Figure 14-3. Panel, Front w/Components (Figure 14-1 Item 42) ....198 700 Switch, Polarity 5 Position With Leads And Jumpers .
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Item Dia. Part Mkgs. Description Quantity Figure 14-3. Panel, Front w/Components (Figure 14-1 Item 42) (Continued) ....010 915 Washer, Flat .250 Id Brs .
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Effective January 1, 2001 (Equipment with a serial number preface of “LB” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. Call LIMITED WARRANTY – Subject to the terms and conditions APT, ZIPCUT &...
Distributor Address City State For Service Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories...
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