Miller Electric 250 manual From Miller to You

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Miller is the first welding equipment manufacturer in the U.S.A. to be registered to the ISO 9001:2000 Quality System Standard.

From Miller to You

Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. 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. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy.

Today, the people that build and sell Miller products continue the tradition. They’re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929.

This Owner’s Manual is designed to help you get the most out of your Miller products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite.

We’ve made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there’s a Troubleshooting section that will help you figure out what the problem is. The parts list will then help you to decide the exact part you may need to fix the problem. Warranty and service information for your 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. To locate your nearest distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web.

Mil_Thank 4/05

Working as hard as you do

−every power source from Miller is backed by the most hassle-free warranty in the business.

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Contents Visit our website at OM-217 455HFile Engine Drive 2007−05−21From Miller to You Table of Contents 13-4 13-213-3 13-5Electric Shock can kill Symbol UsageArc Welding Hazards HOT Parts can cause severe burnsARC Rays can burn eyes and skin Fumes and Gases can be hazardousBuildup of GAS can injure or kill Welding can cause fire or explosionEngine Hazards Compressed Air HazardsFire or Explosion hazard Welding Wire can cause injuryHOT Parts can cause burns and injury Falling Unit can cause injuryEMF Information Principal Safety StandardsCalifornia Proposition 65 Warnings Radiation can cause interferenceUN Choc Électrique peut tuer Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation Indique des instructions spécifiquesLE Soudage peut provoquer un in cendie ou une explosion DES Pièces Chaudes peuvent provoquer des brûlures gravesLES Fumées ET LES GAZ peuvent être dangereux DES Organes Mobiles peuvent pro voquer des blessures LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peu Risque D’INCENDIE OU D’EXPLO- Sion LA Chaleur DU Moteur peut pro- voquer un incendie’AIR Comprimé peut provoquer des blessures LES Fils DE Soudage peuvent provoquer des blessures LE Surchauffement peut endom- mager le moteur électriqueDES Organes Mobiles peuvent provoquer des blessures ’EMPLOI Excessif peutInformation EMF Proposition californienne 65 AvertissementsPrincipales normes de sécurité En ce qui concerne les implants médicauxWeld, Power, and Engine Specifications − SpecificationsSymbol Definitions − DefinitionsDimensions Dimensions, Weights, and Operating AnglesDimensions For Units With Optional Running Gear Vehicle frame. Always connect a ground wire − InstallationInstalling Welding Generator Mounting+ − Installing Exhaust PipeConnecting the Battery Stop engine and let coolOverview And Engine Prestart Checks Run-in period first 100 hours Engine Left Side Engine Right SideStarting engine for the first time Daily pre-start checksWork Weld Output Terminal Connecting to Weld Output TerminalsCorrect Installation Tools Needed Do not placeSelecting Weld Cable Sizes − Operating the Welding Generator Engine Control SwitchesPlace switch in Run position to operate most MIG equipment Do not use glow plugs longer than 20 secondsWeld Output Controls Stop engine Typical Stick Welding Connections And Control SettingsTypical Settings For 7018 1/8 Electrode Work Clamp Electrode HolderSet Weld Process Selector switch to Wire + position Typical MIG Welding Connections And SettingsSet Weld Process Selector switch to Wire + Dcep position Set Weld Process Selector switch to Wire − position DcenTools Needed 3/4 Work Not Used To Work Left Side View At least once a month, run engine at Generator Power Receptacles− Operating Auxiliary Equipment To verify Gfci is working properlySimultaneous Weld And Power Determining Battery Charging Current − Operating Optional Battery ChargerBattery Charge Controls Battery Charge Cable Connections Battery Charging Procedure MinutesStart Your Professional Welding Career Now − Maintenance and Troubleshooting Routine MaintenanceMaintenance Label And Engine Maintenance Activities Stop engine and let cool Oil And Fuel804 197-A / Ref 803 111-A / 227 Air cleaner primary element can Cleaner or with dirty element. EngineMent is not covered by the warranty Damage when determining whetherStop screw is factory-set and should not be adjusted Adjusting Engine SpeedAdjusting Fuel Solenoid Position Checking Fuel Solenoid16 mm Adjusting Throttle SolenoidChecking Throttle Solenoid Check for non-bindingAdjusting Weld/Power Speed Making Engine Speed AdjustmentsAdjusting Idle Speed Fuse F1 Overload ProtectionComponent Panel Stop engine Supplementary Protector CB8Welding Troubleshooting TablesGenerator Power Trouble RemedyMaintenance Display Action EngineRecommended Spare Parts − Parts ListRecommended Spare Parts Current transformer CT1, and throttle solenoid TS1− Electrical Diagrams Circuit Diagram For Welding Generator228 719-B OM-217 455 231 607-B − RUN-IN and Wetstacking Run-In And WetstackingUS Gal./Hr − Performance DataFuel Consumption Curves IdleVolts Generator Power CurveDuty Cycle AC Amperes At 120 VoltsAC Amps Stick Mode Volt-Ampere CurvesDC Amps CC/AC Stick Mode AC Volts MIG Mode Volt-Ampere Curve DC AmpsGrounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesSelecting Equipment Use ground device as stated in electrical codes Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Amperes x Volts = WattsIndustrial Motors Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsSingle-Phase Induction Motor Starting Requirements Power Required To Start MotorHow Much Power Can Generator Supply? KVA/HP x HP x 1000 / Volts = Starting AmperageTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible − Stick Welding Smaw Guidelines Stick Welding ProcedureWeld current starts when electrode touches work- piece Striking an Arc − Tapping Technique Electrode and Amperage Selection ChartStriking an Arc − Scratch Start Technique Positioning Electrode Holder Poor Weld Bead CharacteristicsGood Weld Bead Characteristics 10-30 9090 End View of Work AngleConditions That Affect Weld Bead Shape Electrode Movement During WeldingTee Joint Butt JointsLap Joint 16 in 30 1.6 mm Tack WeldsWeld Test Troubleshooting − PorosityTroubleshooting − Excessive Spatter Possible Causes Corrective ActionsTroubleshooting − Excessive Penetration Troubleshooting − Incomplete FusionTroubleshooting − Lack Of Penetration Troubleshooting − Distortion Troubleshooting − Burn-ThroughTroubleshooting − Waviness Of Bead Work like a Pro Support ServiceYour distributor also gives For assistance in filing or settling claims, contact To locate a Distributor or Service Agency visitMiller Electric Mfg. Co Your distributor and/or equipment manufacturer’s