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Miller Electric 250 Bedienungsanleitung

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Das Wort kommt vom lateinischen „instructio”, d.h. ordnen. Demnach kann man in der Anleitung Miller Electric 250 die Beschreibung der Etappen der Vorgehensweisen finden. Das Ziel der Anleitung ist die Belehrung, Vereinfachung des Starts, der Nutzung des Geräts oder auch der Ausführung bestimmter Tätigkeiten. Die Anleitung ist eine Sammlung von Informationen über ein Gegenstand/eine Dienstleistung, ein Hinweis.

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Die Gebrauchsanleitung Miller Electric 250 sollte vor allem folgendes enthalten:
- Informationen über technische Daten des Geräts Miller Electric 250
- Den Namen des Produzenten und das Produktionsjahr des Geräts Miller Electric 250
- Grundsätze der Bedienung, Regulierung und Wartung des Geräts Miller Electric 250
- Sicherheitszeichen und Zertifikate, die die Übereinstimmung mit entsprechenden Normen bestätigen

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Der Grund dafür ist die fehlende Zeit und die Sicherheit, was die bestimmten Funktionen der gekauften Geräte angeht. Leider ist das Anschließen und Starten von Miller Electric 250 zu wenig. Eine Anleitung beinhaltet eine Reihe von Hinweisen bezüglich bestimmter Funktionen, Sicherheitsgrundsätze, Wartungsarten (sogar das, welche Mittel man benutzen sollte), eventueller Fehler von Miller Electric 250 und Lösungsarten für Probleme, die während der Nutzung auftreten könnten. Immerhin kann man in der Gebrauchsanleitung die Kontaktnummer zum Service Miller Electric finden, wenn die vorgeschlagenen Lösungen nicht wirksam sind. Aktuell erfreuen sich Anleitungen in Form von interessanten Animationen oder Videoanleitungen an Popularität, die den Nutzer besser ansprechen als eine Broschüre. Diese Art von Anleitung gibt garantiert, dass der Nutzer sich das ganze Video anschaut, ohne die spezifizierten und komplizierten technischen Beschreibungen von Miller Electric 250 zu überspringen, wie es bei der Papierform passiert.

Warum sollte man Gebrauchsanleitungen lesen?

In der Gebrauchsanleitung finden wir vor allem die Antwort über den Bau sowie die Möglichkeiten des Geräts Miller Electric 250, über die Nutzung bestimmter Accessoires und eine Reihe von Informationen, die erlauben, jegliche Funktionen und Bequemlichkeiten zu nutzen.

Nach dem gelungenen Kauf des Geräts, sollte man einige Zeit für das Kennenlernen jedes Teils der Anleitung von Miller Electric 250 widmen. Aktuell sind sie genau vorbereitet oder übersetzt, damit sie nicht nur verständlich für die Nutzer sind, aber auch ihre grundliegende Hilfs-Informations-Funktion erfüllen.

Inhaltsverzeichnis der Gebrauchsanleitungen

  • Seite 1

    Bob cat 250 Diesel Processes Description ™ Non-Critical TIG (GT A W) W elding Stick (SMAW ) Welding MIG (GMAW) Welding Flux Cored (FCA W ) W elding Engine Driven Welding Generator OM-217 455H 2007 − 05 − 21 File: Engine Drive V isit our website at www.MillerWelds.com[...]

  • Seite 2

    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. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .Mille[...]

  • Seite 3

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . . . . [...]

  • Seite 4

    T ABLE OF CONTENTS SECTION 10 − P ARTS LIST 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1. Recommended Spare Parts 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 1 1 − ELEC[...]

  • Seite 5

    OM-217 455 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 are shown in the adjoining symbols [...]

  • Seite 6

    OM-217 455 Page 2 W elding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. D If ventilation is poo[...]

  • Seite 7

    OM-217 455 Page 3 1-3. Engine Hazards BA TTER Y EXPLOSION can BLIND. D Always wear a face shield, rubber gloves, and protective clothing when working on a battery . D Stop engine before disconnecting or connect- ing battery cables or servicing battery . D Do not allow tools to cause sparks when working on a battery . D Do not use welder to charge b[...]

  • Seite 8

    OM-217 455 Page 4 HOT MET AL from air arc cutting and gouging can cause fire or explosion. D Do not cut or gouge near flammables. D W atch for fire; keep extinguisher nearby . HOT P ARTS can cause burns and injury . D Do not touch hot compressor or air system parts. D Let system cool down before touching or ser- vicing. READ INSTRUCTIONS. D Read Ow[...]

  • Seite 9

    OM-217 455 Page 5 H. F . RADIA TION can cause interference. D High-frequency (H.F .) can interfere with radio navigation, safety services, computers, and communications equipment. D Have only qualified persons familiar with electronic equipment perform this installation. D The user is responsible for having a qualified electrician promptly correct [...]

  • Seite 10

    OM-217 455 Page 6 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION 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 peut donner la mort ou des [...]

  • Seite 11

    OM-217 455 Page 7 Une tension DC importante subsiste à l’intérieur des onduleurs après avoir coupé l’alimentation. D Couper l’alimentation du poste et décharger les condensateurs d’entrée comme indiqué dans la Section Maintenance avant de toucher des composants. DES PIÈCES CHAUDES peuvent provoquer des brûlures graves. D Ne pas tou[...]

  • Seite 12

    OM-217 455 Page 8 D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et N FPA 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 affe c l’ouïe. D Porter des protections approuvés pour les or e les si le niveau sonore e[...]

  • Seite 13

    OM-217 455 Page 9 D Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant d’enlever le bouchon. L ’utilisation d’un groupe autonome à l’intérieur PEUT VOUS TUER EN QUELQUES MINUTES. D Le s fumées d’un groupe autonome contient du monoxyde de carbone. C’est un poison invisi- ble et inodore. D JAMAIS utiliser dans u[...]

  • Seite 14

    OM-217 455 Page 10 LE SURCHAUFFEMENT peut endom- mager le moteur électrique. D Arrêter ou déconnecter l’équipement avant d e démarrer ou d’a rrêter le moteur . D Ne pas laisser tourner le moteur trop lentement sous risque d’en - dommager l e moteur électrique à cause d’une tension et d’une fré - quence trop faibles. D N e pas bra[...]

  • Seite 15

    OM-217 455 Page 1 1 2-6. P r oposition californienne 65 A vertissements 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. (Code de santé et de sécurité [...]

  • Seite 16

    . A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 12 SECTION 3 − DEFINITIONS 3-1. Symbol Definitions Stop Engine Fast (Run, W eld/Power) Fast/Slow (Run/Idle) Slow (Idle) Start Engine Read Operator’s Manual A Amperes V V olts Engine Oil Fuel Battery (Engine) Engine T emperature Check V alve Clearance Do not switch whi[...]

  • Seite 17

    . A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 13 4-2. Dimensions, W eights, and Operating Angles Dimensions Height 35-1/2 in (902 mm) (T o T op Of Exhaust) A B Width 20 in (508 mm) B C ! D d il l i ld Depth 53 in (1346 mm) D ! D o not exceed tilt angles or engine could be damaged or unit could tip. A 20 in (508 mm) 4[...]

  • Seite 18

    . A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 14 SECTION 5 − INST ALLA TION install2 12/06 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712 ! 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 ont[...]

  • Seite 19

    . A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 15 5-2. Installing Exhaust Pipe 804 196-A / Ref. 228 647-A ! Stop engine and let cool. ! Do not blow exhaust toward right side of unit where air inlet is or air cleaner may require frequent service. Point ex- haust pipe in desired direction but always away from front pane[...]

  • Seite 20

    . A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 16 5-4. Overview And Engine Prestart Checks 1 Generator Power Receptacles (see Section 7) 2 W eld Output T erminals (see Section 5- 5) 3 Operator Controls (see Section 6) 4 Fuel Gauge/Maintenance Display 5 Fuel Filler Cap 6 Exhaust Pipe 7 Radiator Cap 8 Engine Maintenance[...]

  • Seite 21

    . A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 17 12 11 15 16 17 18 ! Engine shown with doors removed. Doors must be in place when engine is running. Engine Left Side Engine Right Side Engine must be cold and on a level sur- face. See maintenance label (Section 9- 2) for fluid specifications. Starting engine for the f[...]

  • Seite 22

    . A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 18 1 W ork Weld Output T erminal 2 Electrode W eld Output T erminal Connect work cable to W ork terminal. Connect electrode holder cable or electrode weld cable to Electrode ter- minal for Stick and MIG welding. Connect torch cable to Electrode ter- minal for TIG welding.[...]

  • Seite 23

    . A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 19 5-6. Selecting W eld Cable Sizes* W eld Output T erminals ! W eld Cable Size** and T otal Cable (Copper) Length in Weld Circuit Not Exceeding*** ! T ur n off power before connecting to weld output terminals. ! Do not use worn, damaged, under- sized, or poorly spliced c[...]

  • Seite 24

    . A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 20 SECTION 6 − OPERA TING THE WELDING GENERA TOR Ref. 228 647-A 1 4 6-1. Engine Control Switches NOTICE − Disconnect equipment from auxil- iary power receptacles during start − up and shutdown. Some equipment can be damaged by changes in frequency as engine rpms cha[...]

  • Seite 25

    . A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 21 13 6-2. W eld Output Controls 1 W eld Process Selector Switch NOTICE − Do not switch while welding. Use switch to select type of weld output. Wire (GMA W) Welding: Use a positive (+) position for Direct Current Electrode Positive (DCEP) and a negative ( − ) positio[...]

  • Seite 26

    . A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 22 6-3. T ypical Stick Welding Connections And Control Settings Ref. 804 249-A / Ref 228 647-A ! Stop engine. . This section provides general guidelines and may not suit all applications. T ypical Settings For 7018 (1/8 in) Electrode: > Set W eld Process Selector switc[...]

  • Seite 27

    . A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 23 6-4. T ypical MIG Welding Connections And Settings Ref. 804 249-A / Ref 228 647-A / Ref. 802 766-C ! Stop engine. . This section provides general guide- lines and may not suit all ap- plications. T ypical Control Settings For Short Circuit T ransfer Using .035 (ER70S-3[...]

  • Seite 28

    . A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 24 6-5. T ypical MIG Connections And Settings Using Weld Control And Spoolgun Ref. 804 249-A / Ref. 228 647-A / Ref. 802 750-A ! Stop engine. . This section provides general guide- lines and may not suit all applications. T ypical Settings For 4043 (.035) Aluminum On 1/8 [...]

  • Seite 29

    . A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 25 SECTION 7 − OPERA TING AUXILIAR Y EQUIPMENT 7-1. Generator Power Receptacles 803 750-B / Ref. 21 1 362-A ! If unit does not have GFCI recep- tacles, use GFCI-protected extension cord. NOTICE − Disconnect equipment from auxil- iary power receptacles during start −[...]

  • Seite 30

    . A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 26 7-2. Simultaneous W eld And Power W eld Current in Amperes T otal Power in Watts 120 V Full kV A Receptacle Amperes 240 V Full kV A Receptacle Amperes 250 2200 18 9 180 3500 29 14 125 5200 43 21 90 8000 66 33 0 10,500 (Peak) 88 44 7-3. Wiring Instructions For Optional [...]

  • Seite 31

    . A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 27 SECTION 8 − OPERA TING OPTIONAL BA TTER Y CHARGER 8-1. Battery Charge Controls ! Have only qualified persons charge batteries. ! Do not use battery charger for jump starting. NOTICE − D o not use generator power ac re - ceptacles while using optional battery charge[...]

  • Seite 32

    . A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 28 8-3. Battery Charge Cable Connections ! Stop engine. ! Do not charge a battery which has loose terminals or one showing damage such as a cracked case or cover . ! Have only qualified persons do bat- tery charging work. ! Keep cables away from moving parts. ! Do not use[...]

  • Seite 33

    . A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 29 8-4. Battery Charging Procedure Stop Engine. Connect Cables (Observe Correct Polarity). T urn Off Battery Charging Switch. Set Charge V oltage Switch T o V oltage Of Battery Being Charged (12, 24, Or 36 V olt). NOTICE − Do not switch under load. + − Start Engine. S[...]

  • Seite 34

    . A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 30 Notes Over 80,000 trained since 1930! 400 T rade Square East, T roy , Ohio 45373 1-800-332-9448 www.welding.org Star t Y our Professional W elding Career Now![...]

  • Seite 35

    . A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 31 SECTION 9 − MAINTENANCE AND TROUBLESHOOTING 9-1. Routine Maintenance ! Stop engine before maintaining. . S ee Engine Manual and Maintenance Label for important start-up, service, and storage information. Service engine more often if used in severe conditions. Recycle[...]

  • Seite 36

    . A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 32 9-2. Maintenance Label And Engine Maintenance Activities 4 3 3 1 8 2 7 6 5 7 ! Stop engine and let cool. Oil And Fuel 1 Oil Drain V alve 2 Oil Filter Change engine oil and filter according to en- gine manual. NOTICE − Close valve and valve cap before adding oil and r[...]

  • Seite 37

    . A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 33 804 197-A / Ref 803 1 1 1-A / 227 727[...]

  • Seite 38

    . A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 34 9-3. Servicing Air Cleaner aircleaner1 9/02 − ST -153 929-B / ST-153 585 / Ref. S-0698-B ! Stop engine. NOTICE − Do not run engine without air cleaner or with dirty element. Engine damage caused by using a damaged ele- ment is not covered by the warranty . . The ai[...]

  • Seite 39

    . A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 35 9-4. Adjusting Engine Speed . If the engine does not start and stop properly , verify the fuel solenoid is installed properly before adjusting engine speed (see Section A following). If the engine does not stay at idle speed, verify the throttle solenoid is installed a[...]

  • Seite 40

    . A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 36 B. Checking Throttle Solenoid Ref. 804 250-A / 802 649 ! Stop engine. If the engine does not stay at idle speed, verify the the throttle solenoid and linkage is installed properly . Adjusting Throttle Solenoid 1 Throttle Solenoid 2 Jam Nut 3 Solenoid Link 4 Shoulder Bo[...]

  • Seite 41

    . A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 37 C. Making Engine Speed Adjustments Ref. 804 250-A / 801 963 . Before adjusting engine speed, verify throttle solenoid is installed properly (see Section B on previous page). Check engine speeds with a tachometer (see table). If necessary , adjust speeds as follows: Sta[...]

  • Seite 42

    . A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 38 ! Stop engine. . When a circuit breaker or fuse opens, it usually indicates a more serious problem exists. Contact a Factory Authorized Service Agent. 1 Fuse F1 F1 protects the weld excitation winding from overload. If F3 opens, weld output stops or is low . 2 Fuse F2 [...]

  • Seite 43

    . A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 39 9-6. T roubleshooting T ables A. Welding T rouble Remedy Low or no weld output; generator pow- er output okay at ac receptacles. Check control settings. Check weld connections. Check fuse F1, and replace if open (see Section 9-5). Have Factory Authorized Service Agent [...]

  • Seite 44

    . A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 40 T rouble Remedy Low power output at ac receptacles. Increase Fine control R1 setting to max. Check fuse F2, and replace if open (see Section 9-5). High power output at ac receptacles. Check engine speed, and adjust if necessary (see Section 9 -4). Erratic power output [...]

  • Seite 45

    . A complete Parts List is available at www .MillerW elds.com OM-217 455 Page 41 T rouble Remedy Battery discharges between uses. Clean top of battery with baking soda and water solution; rinse with clear water . Periodically recharge battery (approximately every 3 months). Replace battery . Check voltage regulator according to engine manual. Engin[...]

  • Seite 46

    OM-217 455 Page 42 SECTION 1 1 − ELECTRICAL DIAGRAMS Figure 1 1-1. Circuit Diagram For Welding Generator[...]

  • Seite 47

    OM-217 455 Page 43 228 719-B[...]

  • Seite 48

    OM-217 455 Page 44 Figure 1 1-2. Circuit Diagram For Welding Generator With Battery Charging Option[...]

  • Seite 49

    OM-217 455 Page 45 231 607-B[...]

  • Seite 50

    OM-217 455 Page 46 SECTION 12 − RUN-IN AND WETST ACKING run_in_D722 9/05 12-1. Run-In And Wetstacking 1 W elding Generator Run-in procedures for this engine should not be required. Put unit into regular service. 2 Engine Exhaust Pipe W etstacking is unburned fuel and oi l in the exhaust pipe and occurs if the engine is run too long at light load [...]

  • Seite 51

    OM-217 455 Page 47 SECTION 13 − PERFORMANCE DA T A 13-1. Fuel Consumption Curves 226795-A / 226 796-A Auxiliary Power Fuel Consumption Weld Fuel Consumption DC WELD AMPERES A T 100% DUTY CYCLE US Gal./Hr . IDLE 0 50 100 150 200 250 300 350 400 0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 AUXILAR Y POWER KW A T 100% DUTY CYCLE US Gal./Hr . IDLE 0.[...]

  • Seite 52

    OM-217 455 Page 48 226 791-A The ac generator power curve shows the generator power avail- able in amperes at the receptacles. 13-2. Generator Power Curve AC Amperes At 240 V olts 0 AC V olts 0 20 40 60 80 100 120 50 100 150 200 250 300 0 40 80 120 160 200 240 AC Amperes At 120 V olts 0 25 50 75 100 125 150 Continuous Welding 13-3. Duty Cycle 200 2[...]

  • Seite 53

    OM-217 455 Page 49 226 792-A / 226 793-A The volt-ampere curves show the minimum and maximum voltage an d amperage output capabilities of the welding generator . Curves of other settings fall between the curves shown. A. CC/DC Stick Mode 13-4. Stick Mode V olt-Ampere Curves B. CC/AC STICK Mode DC Amps DC V olts 0 0 50 100 150 200 250 300 350 400 10[...]

  • Seite 54

    OM-217 455 Page 50 226 794-A The volt-ampere curves show the minimum and maximum voltage an d amperage output capabilities of the welding generator . Curves of other settings fall between the curves shown. 13-5. MIG Mode V olt-Ampere Curve DC Amps DC V olts 0 100 200 300 400 500 600 700 800 0 5 10 15 20 25 30 35 40 45[...]

  • Seite 55

    OM-217 455 Page 51 SECTION 14 − GENERA TOR POWER GUIDELINES . The views in this section are intended to be representative of all engine-driven welding generators. Y our unit may differ from those shown. 14-1. Selecting Equipment gen_pwr 2007 − 04 − Ref. ST -159 730 / ST-800 577 1 Generator Power Receptacles − Neutral Bonded T o Frame 2 3-Pr[...]

  • Seite 56

    OM-217 455 Page 52 14-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 AWG or larger insulated copper wire. 3 Ground Device . Us e ground device as stated in electrical codes. ! Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system[...]

  • Seite 57

    OM-217 455 Page 53 14-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Sta rting W atts Running W atts 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 HP 6100 1600 1-1/2 HP 8200 2200 2 HP 10550 [...]

  • Seite 58

    OM-217 455 Page 54 14-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running W atts 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 T able Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in 2500 1 100 Bench Grinder 6 in 1720 720 8 i[...]

  • Seite 59

    OM-217 455 Page 55 14-8. Power Required T o Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code G H J K L M N P KV A/HP 6.3 7.1 8.0 9.0 10.0 1 1.2 12.5 14.0 S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor V oltage T o find starting amperage: Step 1: Find code and use table to find kV A/HP . If code is not[...]

  • Seite 60

    OM-217 455 Page 56 14-10. T ypical Connections T o Supply Standby Power T ransfer Switch Essential Loads Fused Disconnect Switch (If Required) Utility Electrical Service 12 3 4 5 W elding Generator Output ! Have only qualified persons perform these connections according to all applicable codes and safety practices. ! Properly install and ground thi[...]

  • Seite 61

    OM-217 455 Page 57 14-1 1. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 V olt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (A WG)* Current (Amperes) Load (W atts) 4 6 8 10 12 14 5 600 350 (106) 225 (68) 137 (42) 100 (30) 7 84[...]

  • Seite 62

    OM-217 455 Page 58 SECTION 15 − STICK WELDING (SMA W) GUIDELINES 15-1. Stick W elding Procedure stick 2007 − 04 − ST-151 593 ! W eld current starts when electrode touches work- piece. ! W eld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Pla ce wor k c la mp a s close to the weld [...]

  • Seite 63

    OM-217 455 Page 59 15-2. Electrode and Amperage Selection Chart Ref. S-087 985-A 3/32 1/8 5/32 3/16 7/32 1/4 1/16 5/64 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 3/32 1/8 5/32 6010 & 601 1 6013 7014 7018 7024 Ni-Cl 308L 50 100 150 200 250 300 350 400 450 ELE[...]

  • Seite 64

    OM-217 455 Page 60 15-5. Positioning Electrode Holder S-0060 90 ° 90 ° 10 ° -30 ° 45 ° 45 ° GROOVE WELDS FILLET WELDS End V iew of Work Angle Sid e V iew of Electrode Angle End V iew of Work Angle S ide View of Electrode Angle 10 ° -30 ° 15-6. Poor Weld Bead Characteristics S-0053-A 1 Large Spatter Deposits 2 Rough, Uneven Bead 3 Slight Cra[...]

  • Seite 65

    OM-217 455 Page 61 15-8. Conditions That Affect Weld Bead Shape . W el d bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal. S-0061 ELECTRODE ANGLE ARC LENGTH TRA V EL SPEED Slow Normal Fast 10 ° - 30 ° Drag T oo Short Normal T oo Long Spatter Angle T oo Small Angle T oo Large Correct Angle 15-9. Elec[...]

  • Seite 66

    OM-217 455 Page 62 15-10. Butt Joints S-0662 1 T ack Welds Prevent ed ge s o f j oint from drawing together ahead of electrode by tack welding the materials in position be- fore final weld. 2 Square Groove W el d Good for materials up to 3/16 in (5 mm) thick. 3 Single V -Groove Weld Good for materials 3/16 − 3/4 in (5-19 mm) thick. Cut bevel with[...]

  • Seite 67

    OM-217 455 Page 63 15-13. W eld T est S-0057-B 1 V ise 2 W eld Joint 3 Hammer Strike weld joint in direction shown. A good weld bends over but does not break. 2 T o 3 in 1/4 in 3 2 1 2 T o 3 in 3 2 1 (51-76 mm) (6.4 mm) (51-76 mm) 15-14. T roubleshooting − Porosity Porosity − small cavities or holes resulting from gas pockets i n weld metal. Po[...]

  • Seite 68

    OM-217 455 Page 64 15-16. T roubleshooting − Incomplete Fusion Incomplete Fusion − failure of weld metal to fuse completely with base metal or a preceeding weld bead. Possible Causes Corrective Actions Insuf ficient heat input. Increase amperage. Select larger electrode and increase amperage. Improper welding technique. Place stringer bead in p[...]

  • Seite 69

    OM-217 455 Page 65 15-19. T roubleshooting − 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. 15-20. T roubleshooting − W av[...]

  • Seite 70

    Notes W or k l i ke a P r o ! Pros wel d and cut safel y . Read the safety rules at the beginni ng of this manual .[...]

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    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007 − 01 Y our distributor also gives you ... Service Y ou 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 questions? Contact your distributor . The expe[...]

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    PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007 − 01 Miller Elect ric Mfg. Co. An Illinois T ool Wo rks Comp any 1635 West S pencer S treet Applet on, WI 5 4914 US A International He adquarters − USA USA Phone: 920-735-4505 Aut o-At tended USA & Canada F A X: 920-735-4134 Int ernati onal F AX : 920-735-4125 European Headqua rters − U[...]