
ProcessesDescriptionTIG (GTAW) WeldingStick (SMAW) WeldingMIG (GMAW) WeldingFlux Cored (FCAW)Engine Driven Welding GeneratorOM-4402 199101JMay 2001Tra
OM-4402 Page 6Le soudage effectué sur des conteneurs fermés tels quedes réservoirs, tambours ou des conduites peut provoquerleur éclatement. Des étinc
OM-4402 Page 7DES ORGANES MOBILES peuventprovoquer des blessures. Ne pas approcher les mains des ventilateurs, cour-roies et autres pièces en mouveme
OM-4402 Page 8LE RAYONNEMENT HAUTE FRÉ-QUENCE (H.F.) risque de provoquerdes interférences. Le rayonnement haute fréquence (H.F.) peutprovoquer des in
OM-4402 Page 9SECTION 2 − DEFINITIONS2-1. Symbol DefinitionsStop EngineFast(Run, Weld/Power)Fast/Slow(Run/Idle)Slow (Idle)Start Engine Panel/Local Tem
OM-4402 Page 103-2. Dimensions, Weights, and Operating AnglesDimensionsAHeight 33 in (838 mm)ABCWidth 18-3/4 in (476 mm)C D t d tilt l i ldDe
OM-4402 Page 11201 5273-4. Fuel Consumption While Using Auxiliary Power0.000.250.500.751.001.251.501.752.00012345678US GAL/HR.IDLE − KOHLERIDLE − ONAN
OM-4402 Page 12189 280 / 189 282-A / 189 265The volt-ampere curves show theminimum and maximum voltageand amperage output capabilities ofthe welding g
OM-4402 Page 13Duty cycle is the percentage of 10minutes that unit can weld at ratedload without overheating. Exceeding duty cycle candamage unit and
OM-4402 Page 144-2. Engine Prestart Checks (Onan-Powered Units) Ref. 151 983 / 801 942-C / Ref. 800 3951/2 in(13 mm)FullGasolineFullCheck all fluids d
OM-4402 Page 154-3. Engine Prestart Checks (Kohler-Powered Units) 801 221 / 802 6921/2 in(13 mm)FullGasolineFullCheck all fluids daily. Engine must be
Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M
OM-4402 Page 164-4. Activating The Dry Charge Battery (If Applicable)Remove battery from unit.1 Eye Protection − SafetyGlasses Or Face Shield2 Rubber
OM-4402 Page 174-5. Connecting The BatteryRef. 800 394-C / Ref. 203 073 / Ref. S-0756-D+−3/8, 1/2 in Connect negative (−)cable last.Tools Needed:4-6.
OM-4402 Page 184-8. Selecting Weld Cable Sizes*Weld Cable Size** and Total Cable (Copper) Length in Weld CircuitNot Exceeding***100 ft (30 m) or Less1
OM-4402 Page 194-10. Adjusting MIG Weld Puddle Consistency801 944-C / Ref. 203 073 Stop engine.Stabilizer DC-Z is factoryconnected to suit most MIG (
OM-4402 Page 20SECTION 5 − OPERATING WELDING GENERATOR5-1. Front Panel ControlsRef. 203 0731 DC Polarity/AC Switch Do not switch under load.Use switc
OM-4402 Page 215-2. Remote Amperage/Voltage Control1 Remote 14 Receptacle RC1Connect optional remote control toRC1 (see Section 4-9).2 Remote Hand Con
OM-4402 Page 22SECTION 6 − OPERATING AUXILIARY EQUIPMENT6-1. Auxiliary Power Receptacles And Circuit BreakersRef. 203 073 If unit does not have GFCI
OM-4402 Page 236-2. Optional Auxiliary Power Receptacles If unit does not have GFCI re-ceptacles, use GFCI-protected extension cord. Auxiliary power
OM-4402 Page 24SECTION 7 − MAINTENANCE (ONAN-POWERED UNITS)7-1. Routine Maintenance (Onan-Powered Units)Recycleenginefluids. Stop engine before maint
OM-4402 Page 257-2. Maintenance Label (Onan-Powered Units)Follow the storage procedure in the engine owner’s manual if the unit will not beused for an
The following terms areused interchangeablythroughout this manual:MIG = GMAW, Wire WeldingTIG = GTAWStick = SMAWThe engine exhaust fromthis product co
OM-4402 Page 267-3. Servicing Air Cleaner (Onan-Powered Units) aircleaner3 1/97 − 156 852 / Ref. 185 095-A / S-0759 Stop engine. Do not run engine w
OM-4402 Page 277-5. Changing Engine Oil, Oil Filter, And Fuel Filter (Onan-Powered Units)Ref. 801 942-C / 800 395-B / Ref. 203 073 / S-0842 Stop engi
OM-4402 Page 287-6. Adjusting Engine Speed (Onan-Powered Units)Ref. 801 942-C / 800 397-AAfter tuning engine, check enginespeeds with a tachometer (se
OM-4402 Page 29 Stop engine. When a circuit breaker or fuseopens, it usually indicates amore serious problem exists.Contact a Factory AuthorizedServ
OM-4402 Page 30SECTION 8 − MAINTENANCE (KOHLER-POWERED UNITS)8-1. Routine Maintenance (Kohler-Powered Units)Recycleenginefluids. Stop engine before m
OM-4402 Page 318-2. Maintenance Label (Kohler-Powered Units)Follow the storage procedure in the engine owner’s manual if the unit will not beused for
OM-4402 Page 328-3. Servicing Air Cleaner (Kohler-Powered Units) aircleaner3 9/00 − 802 772 / Ref. 185 095-A / S-0759 Stop engine. Do not run engine
OM-4402 Page 338-5. Changing Engine Oil, Oil Filter, And Fuel Filter (Kohler-Powered Units)802 692 / S-0842 Stop engine and let cool.1 Oil Drain Valv
OM-4402 Page 348-6. Adjusting Engine Speed (Kohler-Powered Units)802 692 / ST-801 209-AAfter tuning engine, check enginespeeds with a tachometer (seet
OM-4402 Page 35 Stop engine. When a circuit breaker or fuseopens, it usually indicates amore serious problem exists.Contact a Factory AuthorizedServ
OM-4402 Page 36SECTION 9 − TROUBLESHOOTING9-1. Welding TroubleshootingTrouble RemedyNo weld output. Check control settings.Check weld connections.Disc
OM-4402 Page 37Trouble RemedyLack of high frequency; difficulty inestablishing Gas Tungsten Arc Weld-ing arc.Use proper size tungsten for welding ampe
OM-4402 Page 38Trouble RemedyEngine does not start. Check fuel level (see Section 4-2 or 4-3).Check battery and replace if necessary.Check engine char
OM-4402 Page 39Notes
OM-4402 Page 40SECTION 10 − ELECTRICAL DIAGRAMFigure 8-1. Circuit Diagram For Welding Generator
OM-4402 Page 41203 082
OM-4402 Page 42SECTION 11 − AUXILIARY POWER GUIDELINES11-1. Selecting Equipmentaux_pwr 4/01 − Ref. ST-159 730 / ST-800 5771 Auxiliary Power Receptacle
OM-4402 Page 4311-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse #10 AWG or larger insulate
OM-4402 Page 4411-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running WattsSplit Phase 1/8 HP 800 3
OM-4402 Page 4511-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHand Drill 1/4 in 350 3503/8
OM-4402 Page 1SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USINGrom _nd_11/981-1. Symbol UsageMeans Warning! Watch Out! There are possible hazardswit
OM-4402 Page 4611-8. Power Required To Start MotorS-06241 Motor Start Code2 Running Amperage3 Motor HP4 Motor VoltageTo find starting amperage:Step 1:
OM-4402 Page 4711-10. Typical Connections To Supply Standby PowerS-0405-A Have only qualified personsperform these connectionsaccording to all applic
OM-4402 Page 4811-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, u
OM-4402 Page 49Notes
OM-4402 Page 50SECTION 12 − PARTS LISTST-802 048-D Hardware is common andnot available unless listed.123456789111213141516171819102021222324−Fig 12-3
OM-4402 Page 51DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-1. Main AssemblyQuantity1 182 367 PANEL, right side 1. . . . . . . . . . . . . . . . . .
OM-4402 Page 52DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-1. Main Assembly (Continued)Quantity33 DC-Z 187 018 STABILIZER ASSEMBLY, (consisting of) 1.
OM-4402 Page 53ST-802 049-B Hardware is common andnot available unless listed.13456789101213141516171819202122232425262829303132333435361127Figure 12
OM-4402 Page 54DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-2. Panel, Front w/Components (Figure 12-1 Item 54)Quantity1 187 593 PANEL, front 1. . . .
OM-4402 Page 55DescriptionPartNo.ItemNo.Figure 12-3. Generator (Figure 12-1 Item 24)Quantity1 +186 238 STATOR 1. . . . . . . . . . . . . . . . . .
OM-4402 Page 2Welding on closed containers, such as tanks,drums, or pipes, can cause them to blow up. Sparkscan fly off from the welding arc. The flyi
OM-4402 Page 56Notes
Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 7/00Your distributor also givesyou ...ServiceYou always get the fa
PRINTED IN USA © 2001 Miller Electric Mfg. Co. 1/01Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US
OM-4402 Page 3MOVING PARTS can cause injury. Keep away from fans, belts, and rotors. Keep all doors, panels, covers, and guardsclosed and securely i
OM-4402 Page 4H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommuni
OM-4402 Page 5SECTION 1 − CONSIGNES DE SÉCURITÉ − LIRE AVANTUTILISATIONrom _nd_fre 11/981-1. Signification des symbolesSignifie Mise en garde ! Soyez
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