ISO 9001:2000 Quality System Standard. particular model are also provided. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets.
TABLE OF CONTENTS 8-5. Servicing Engine Cooling System 8-6. Adjusting Engine Speed On Standard Models 8-7. Adjusting Engine Speed On Models With Automatic Idle (Optional) 8-8. Servicing Fuel And Lubrication Systems 8-9. Overload Protection ..............8-10.
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING Y 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 adjoining symbols.
WELDING can cause fire or explosion. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire.
STEAM AND HOT COOLANT can burn. D If possible, check coolant level when engine is cold to avoid scalding. D Always check coolant level at overflow tank, if pres- ent on unit, instead of radiator (unless told otherwise in maintenance section or engine manual). D If the engine is warm, checking is needed, and there is no overflow tank, follow the next two statements.
READ INSTRUCTIONS. D Use only genuine MILLER/Hobart replacement parts. D 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. D High-frequency (H.F.) can interfere with radio naviga- tion, safety services, computers, and communica- tions equipment.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT 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 ! Ceux-ci sont identifiés par des symboles adjacents aux directives.
LE SOUDAGE peut provoquer un in- cendie ou une explosion. Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures.
D Si le moteur est chaud et que le liquide doit être vérifié, opérer comme suivant. D Mettre des lunettes de sécurité et des gants, placer un torchon sur le bouchon du radiateur. D Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant d’enle- ver le bouchon.
LIRE LES INSTRUCTIONS. D Utiliser seulement les pièces de rechange d’origine. D Effectuer la maintenance du moteur et du compresseur (si applicable) suivant ce manuel et le manuel du moteur/ compresseur (si applicable). LE RAYONNEMENT HAUTE FRÉ- QUENCE (H.F.) risque de provoquer des interférences.
SECTION 3 − DEFINITIONS 3-1. Warning Label Definitions 0 − 50 h Std. 50 h Std. Notes S-177 571 DIESEL 200A 0 − 200A API CD-MIL L 2104D, CD/SE, CD/SF Remove unit from shipping crate. Remove Owner’s Manual from unit. Follow instructions to install muffler.
3-3. Symbols And Definitions NOTE Some symbols are found only on CE products. Stop Engine Starting Aid (Preheat) Check Injectors/ Pump Positive Amperes Engine Stick (SMAW) Welding Time Three Phase Electrode Connection Duty Cycle Rated Idle Speed Contactor On Fast (Run, Weld/ Power) Battery (Engine) Check Valve...
4-3. Volt-Ampere Curves A. Stick Mode DC AMPERES B. MIG Mode DC AMPERES C. TIG Mode DC AMPERES The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the curves shown.
4-6. AC Generator Power Curve Notes AC AMPERES IN 240 V MODE AC AMPERES IN 120 V MODE MATERIAL THICKNESS REFERENCE CHART The ac power curve shows the gen- erator power in amperes available at the 120 and 240 volt receptacles. 217 519 24 Gauge (.025 in) 22 Gauge (.031 in)
5-2. Mounting Welding Generator Supporting The Unit Inadequate support. Y Do not use flexible mounts. Using Mounting Brackets Tools Needed: 9/16 in Welding Unit In Place Bolting Unit In Place Y Do not weld on base. Weld- ing on base can cause fuel tank fire or explosion.
5-3. Installing Exhaust Pipe Tools Needed: 1/2 in Notes OM-4433 Page 18 Y Stop engine and let cool. Point exhaust pipe in desired di- rection but always away from front panel and direction of travel. 803 582 / Ref. 217 357-A Work like a Pro! Pros weld and cut safely.
5-4. Activating The Dry Charge Battery (If Applicable) 5 A For 30 Minutes 30 A For 12 Minutes Tools Needed: 5-5. Connecting The Battery Tools Needed: 1/2 in − Y Always wear a face shield, rubber gloves and protective clothing when working on a battery.
5-6. Engine Prestart Checks Full Diesel Full Check all engine fluids daily. Engine must be cold and on a level surface. Unit is shipped with 20W break-in oil. Automatic shutdown system stops engine if oil pressure is too low or coolant tempera- ture is too high.
5-7. Connecting To Weld Output Terminals Y Stop engine. Work/Negative (−) Weld Output Terminal CV (wire) Weld Output Terminal CC (Stick/TIG) Weld Output Terminal Y Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your machine. Weld Output Terminal Supplied Weld Output Terminal Nut Weld Cable Terminal...
5-8. Selecting Weld Cable Sizes* Weld Output Terminals Y Stop engine before Welding connecting to weld out- Amperes put terminals. Y Do not use worn, dam- aged, undersized, or poorly spliced cables. This chart is a general guideline and may not suit all applications. If cables overheat, use next size larger cable. **Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
5-9. Connecting To Remote 14 Receptacle RC14 LDR-14 long distance remote (includes 120 V receptacle) *The remaining sockets are not used. Notes Socket* 24 volts ac. Protected by sup- plementary protector CB8. 24 VOLTS AC 24 VOLTS AC Contact closure to A completes 24 volt ac contactor control circuit.
6-2. Description Of Front Panel Controls (See Section 6-1) Engine Starting Controls Preheat Switch Use switch to energize starting aid for cold weather starting (see starting instructions fol- lowing). Engine Control Switch Use switch to start engine, select engine speed (if unit has auto idle option), and stop engine.
6-4. Lift-Arc Start Procedure Lift-Arc Start Method “Touch” Do NOT Strike Like A Match! Notes 1 − 2 Seconds Lift-Arc t TIG With Lift-Arct TIG selected, start arc as follows: TIG Electrode Workpiece Turn gas on. Touch tungsten electrode to workpiece at weld start point.
6-5. Remote Voltage/Amperage Control In Example: Min = 20 A DC Max = 205 A DC Connect Remote Control To Remote Receptacle RC14 Set TIG or STICK Process Connect Remote Control To Remote Receptacle RC14 Set WIRE Process OM-4433 Page 28 Remote 14 Receptacle RC14 Connect optional remote control to RC14 (see Section 5-9).
SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. Generator Power Receptacles 120 V 20 A AC (shown) Receptacle RC5 and/or GFCI1 120 V 20 A AC GFCI (shown) Receptacle RC6 and/or GFCI2 240 V 50 A AC Receptacle RC11 RC5 / 6 and GFCI1 / 2 supply 60 Hz single- phase power at weld/power speed.
SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Routine Maintenance n = Check Z = Change * To be done by Factory Authorized Service Agent Every Hours n Coolant Level n Fuel Level Every Hours ~ Air Cleaner Element ~ Weld Terminals Every Hours ~ Battery Terminals...
8-3. Servicing Air Cleaner Keep nozzle 2 in (51 mm) from element. Blow OM-4433 Page 32 Optional Inspect aircleaner1 2/01− ST-153 929-B / ST-153 585 / Ref. S-0698-B / Ref. 217 357-A Y Stop engine. Y Do not run engine without air cleaner or with dirty element.
8-4. Inspecting And Cleaning Optional Spark Arrestor Muffler Tools Needed: 3/8 in 8-5. Servicing Engine Cooling System Y Stop engine and let cool. Spark Arrestor Muffler Cleanout Plug Remove plug and remove any dirt covering cleanout hole. Exhaust Pipe Start engine and run at idle speed to blow out cleanout hole.
8-6. Adjusting Engine Speed On Standard Models Engine Speed RPM (Hz) (No Load) 1880 (61.7) Weld/Power Maximum OM-4433 Page 34 Y 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 frequen- cy meter.
8-7. Adjusting Engine Speed On Models With Automatic Idle (Optional) Engine Speed (No Load) 1880 rpm max (62.6 Hz) 1250 rpm (41.6 Hz) To prevent solenoid damage, be sure a 1/8 in (3 mm) gap exists be- tween the engine low speed screw throttle lever when the...
8-8. Servicing Fuel And Lubrication Systems OM-4433 Page 36 Y Stop engine and let cool. Y After servicing, start engine and check for fuel leaks. Stop engine, tighten connec- tions as necessary, and wipe up spilled fuel. Oil Filter Oil Drain Valve And Hose Oil Fill Cap Primary (Canister) Fuel Filter Secondary (In-Line) Fuel...
8-9. Overload Protection Y Stop engine. When a circuit breaker, supple- mentary protector, opens, it usually indicates a more serious problem exists. Contact Factory Service Agent. Fuse F1 F1 protects the stator exciter wind- ing from overload. If F1 opens, weld and generator power is low or stops entirely.
8-10. Checking Generator Brushes Notes OM-4433 Page 38 5/16 in. (8 mm) Minimum Length 9/16 in. (14.3 mm) New Length Replace Damaged Brushes MATERIAL THICKNESS REFERENCE CHART Y Stop engine and let cool. Generator Brush With Spring Mark and disconnect leads at brush hold- er cap.
8-11. Voltmeter/Ammeter Help Displays HL.P HL.P HL.P HL.P HL.P HL.P Use the Voltmeter/Ammeter help displays to diagnose and correct fault conditions. Indicates a failure of meter display module PC2, or the wiring between PC2 and main control module PC1. If this display is shown, have Facto- ry Authorized Service Agent check PC1, PC2, and the wiring between PC1 and PC2.
8-12. Troubleshooting Note Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 8-11). A. Welding Trouble No weld output; generator power output Place Process/Contactor switch in a Weld Terminals Always On position, or place switch in a Remote okay at ac receptacles.
B. Generator Power Trouble No generator power output at ac recep- Reset receptacle supplementary protector(s) (see Section 7-1). tacles; weld output okay. No generator power or weld output. Disconnect equipment from generator power receptacles during start-up. Check fuse F1, and replace if open (see Section 8-9). Have Factory Authorized Service Agent check vol- tage regulator module PC3.
Trouble Engine slowly stopped and cannot be Check fuel level. restarted. Check engine air and fuel filters (see Sections 8-3 and 8-8). See engine manual. Battery discharges between uses. Turn Engine Control switch off when unit is not running. Clean top of battery with baking soda and water solution; rinse with clear water. Recharge or replace battery if necessary.
SECTION 10 − RUN-IN PROCEDURE 10-1. Wetstacking OM-4433 Page 46 run_in1 8/01 Y Do perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur. Welding Generator Run diesel engines near rated volt- age and current during run-in period to properly seat piston rings and prevent wetstacking.
10-2. Run-In Procedure Using Load Bank Y Stop engine. Y Do not touch hot exhaust pipe, engine parts, or load bank/grid. Y Keep exhaust and pipe away from flammables. Y Do perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur.
10-3. Run-In Procedure Using Resistance Grid OM-4433 Page 48 Y Stop engine. Y Do not touch hot exhaust pipe, engine parts, or load bank/grid. Y Keep exhaust and pipe away from flammables. Y Do perform procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur.
SECTION 11 − GENERATOR POWER GUIDELINES NOTE 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 11-2. Grounding Generator To Truck Or Trailer Frame Electrically bond generator frame to vehicle frame by metal-to-metal contact.
11-3. Grounding When Supplying Building Systems 11-4. How Much Power Does Equipment Require? AMPERES x VOLTS = WATTS EXAMPLE 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power requirement in watts. The load applied by the drill is 520 watts. EXAMPLE 2: If three 200 watt flood lamps are used with the drill from Example 1, add the individual loads to calculate total load.
11-7. Approximate Power Requirements For Contractor Equipment Contractor Hand Drill Circular Saw Table Saw Band Saw Bench Grinder Air Compressor Electric Chain Saw Electric Trimmer Electric Cultivator Elec. Hedge Trimmer Flood Lights Submersible Pump Centrifugal Pump Floor Polisher High Pressure Washer 55 gal Drum Mixer Wet &...
11-8. Power Required To Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code KVA/HP kVA/HP x HP x 1000 VOLTS EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4 HP motor with a motor start code of M. Volts = 230 HP = 1/4 11.2 x 1/4 x 1000...
11-10. Typical Connections To Supply Standby Power Y Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes. Utility Electrical Service Y Have only qualified persons perform these connections according to all applicable codes and safety practic- Y Properly install and ground this equipment according to its Owner’s Manual and national, state, and local...
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. Current Load (Watts) (Amperes) 1200 1800 2400 3000 3600 4200 4800 5400 6000 *Conductor size is based on maximum 2% voltage drop Cord Lengths for 240 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord.
SECTION 12 − PARTS LIST Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. 6 (Fig.12-5) 1 (Fig.12-3) 108 (Fig.12-2) OM-4433 Page 56 Figure 12-1. Main Assembly 25 26...
Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. Item Dia. Part Mkgs. Figure 12-2. Panel, Front w/Components (Figure 12-1 Item 108) ....097926 .
Note Some wiring harness components (switches, relays, supplementary protectors) are also referenced elsewhere in this parts list. Purchase components separately or as part of the associated wiring harness. Item Dia. Part Mkgs..... 231122 .
Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to 1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in for your local material and workmanship at the time it is shipped by Miller.
File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. 2006 Miller Electric Mfg. Co. 2006−01 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA...