Miller Electric 250 manual Start Your Professional Welding Career Now

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.A complete Parts List is available at www.MillerWelds.com

Notes

Start Your Professional Welding Career Now!

400 Trade Square East, Troy, Ohio 45373

1-800-332-9448 www.welding.org

Over 80,000 trained

since 1930!

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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 spécifiquesLES Fumées ET LES GAZ peuvent être dangereux DES Pièces Chaudes peuvent provoquer des brûlures gravesLE Soudage peut provoquer un in cendie ou une explosion ’EXPLOSION DE LA Batterie peu LE Bruit peut affecter l’ouïeDES Organes Mobiles peuvent pro voquer des blessures ’AIR Comprimé peut provoquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendieRisque D’INCENDIE OU D’EXPLO- Sion 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 For Units With Optional Running Gear Dimensions, Weights, and Operating AnglesDimensions 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 Battery Charge Controls − Operating Optional Battery ChargerDetermining Battery Charging Current 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 Idle Speed Making Engine Speed AdjustmentsAdjusting Weld/Power 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 VoltsDC Amps CC/AC Stick Mode AC Volts Stick Mode Volt-Ampere CurvesAC Amps MIG Mode Volt-Ampere Curve DC AmpsSelecting Equipment − Generator Power GuidelinesGrounding Generator To Truck Or Trailer Frame 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 Weld current starts when electrode touches work- piece Stick Welding Procedure− Stick Welding Smaw Guidelines Striking an Arc − Scratch Start Technique Electrode and Amperage Selection ChartStriking an Arc − Tapping 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 − Lack Of Penetration Troubleshooting − Incomplete FusionTroubleshooting − Excessive Penetration Troubleshooting − Waviness Of Bead Troubleshooting − Burn-ThroughTroubleshooting − Distortion Work like a Pro Your distributor also gives ServiceSupport 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