Table of Contents | Miller Electric 250 specs

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING		1
1-1.	Symbol Usage	1
1-2.	Arc Welding Hazards	1
1-3.	Engine Hazards	3
1-4.	Compressed Air Hazards	3
1-5. Additional Symbols For Installation, Operation, And Maintenance		4
1-6. California Proposition 65 Warnings		5
1-7.	Principal Safety Standards	5
1-8.	EMF Information	5

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION		6
2-1.	Signification des symboles	6
2-2. Dangers relatifs au soudage à l’arc		6
2-3. Dangers existant en relation avec le moteur		8
2-4. Dangers liés à l’air comprimé		9
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance		9
2-6. Proposition californienne 65 Avertissements		11
2-7. Principales normes de sécurité		11
2-8.	Information EMF	11
SECTION 3 − DEFINITIONS		12
SECTION 4 − SPECIFICATIONS		12
4-1. Weld, Power, and Engine Specifications		12
4-2. Dimensions, Weights, and Operating Angles		13
4-3. Dimensions For Units With Optional Running Gear		13
SECTION 5 − INSTALLATION		14
5-1.	Installing Welding Generator	14
5-2.	Installing Exhaust Pipe	15
5-3.	Connecting the Battery	15
5-4. Overview And Engine Prestart Checks		16
5-5. Connecting to Weld Output Terminals		18
5-6. Selecting Weld Cable Sizes*		19
SECTION 6 − OPERATING THE WELDING GENERATOR		20
6-1.	Engine Control Switches	20
6-2.	Weld Output Controls	21
6-3. Typical Stick Welding Connections And Control Settings		22
6-4. Typical MIG Welding Connections And Settings		23
6-5. Typical MIG Connections And Settings Using Weld Control And Spoolgun		24
SECTION 7 − OPERATING AUXILIARY EQUIPMENT		25
7-1.	Generator Power Receptacles	25
7-2. Simultaneous Weld And Power		26
7-3. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P)		26
SECTION 8 − OPERATING OPTIONAL BATTERY CHARGER		27
8-1.	Battery Charge Controls	27
8-2. Determining Battery Charging Current		27
8-3. Battery Charge Cable Connections		28
8-4.	Battery Charging Procedure	29
SECTION 9 − MAINTENANCE AND TROUBLESHOOTING		31
9-1.	Routine Maintenance	31
9-2. Maintenance Label And Engine Maintenance Activities		32
9-3.	Servicing Air Cleaner	34
9-4.	Adjusting Engine Speed	35
9-5.	Overload Protection	38
9-6.	Troubleshooting Tables	39

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Miller Electric 250 manual Table of Contents

Contents

2007−05−21 OM-217 455HFile Engine Drive Visit our website at From Miller to You Table of Contents 13-5 13-213-3 13-4 HOT Parts can cause severe burns Symbol UsageArc Welding Hazards Electric Shock can kill Welding can cause fire or explosion Fumes and Gases can be hazardousBuildup of GAS can injure or kill ARC Rays can burn eyes and skin Compressed Air Hazards Engine Hazards Falling Unit can cause injury Welding Wire can cause injuryHOT Parts can cause burns and injury Fire or Explosion hazard Radiation can cause interference Principal Safety StandardsCalifornia Proposition 65 Warnings EMF Information Indique des instructions spécifiques Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation UN Choc Électrique peut tuer DES Pièces Chaudes peuvent provoquer des brûlures graves LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un in cendie ou une explosion LE Bruit peut affecter l’ouïe ’EXPLOSION DE LA Batterie peuDES Organes Mobiles peuvent pro voquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessuresRisque D’INCENDIE OU D’EXPLO- Sion ’EMPLOI Excessif peut LE Surchauffement peut endom- mager le moteur électriqueDES Organes Mobiles peuvent provoquer des blessures LES Fils DE Soudage peuvent provoquer des blessures En ce qui concerne les implants médicaux Proposition californienne 65 AvertissementsPrincipales normes de sécurité Information EMF − Definitions − SpecificationsSymbol Definitions Weld, Power, and Engine Specifications Dimensions, Weights, and Operating Angles Dimensions For Units With Optional Running GearDimensions Mounting − InstallationInstalling Welding Generator Vehicle frame. Always connect a ground wire Stop engine and let cool Installing Exhaust PipeConnecting the Battery + − Overview And Engine Prestart Checks Daily pre-start checks Engine Left Side Engine Right SideStarting engine for the first time Run-in period first 100 hours Tools Needed Do not place Connecting to Weld Output TerminalsCorrect Installation Work Weld Output Terminal Selecting Weld Cable Sizes Do not use glow plugs longer than 20 seconds Engine Control SwitchesPlace switch in Run position to operate most MIG equipment − Operating the Welding Generator Weld Output Controls Work Clamp Electrode Holder Typical Stick Welding Connections And Control SettingsTypical Settings For 7018 1/8 Electrode Stop engine Set Weld Process Selector switch to Wire − position Dcen Typical MIG Welding Connections And SettingsSet Weld Process Selector switch to Wire + Dcep position Set Weld Process Selector switch to Wire + position Tools Needed 3/4 Work Not Used To Work Left Side View To verify Gfci is working properly Generator Power Receptacles− Operating Auxiliary Equipment At least once a month, run engine at Simultaneous Weld And Power − Operating Optional Battery Charger Battery Charge ControlsDetermining Battery Charging Current Battery Charge Cable Connections Minutes Battery Charging Procedure Start Your Professional Welding Career Now Routine Maintenance − Maintenance and Troubleshooting Stop engine and let cool Oil And Fuel Maintenance Label And Engine Maintenance Activities 804 197-A / Ref 803 111-A / 227 Damage when determining whether Cleaner or with dirty element. EngineMent is not covered by the warranty Air cleaner primary element can Checking Fuel Solenoid Adjusting Engine SpeedAdjusting Fuel Solenoid Position Stop screw is factory-set and should not be adjusted Check for non-binding Adjusting Throttle SolenoidChecking Throttle Solenoid 16 mm Making Engine Speed Adjustments Adjusting Idle SpeedAdjusting Weld/Power Speed Supplementary Protector CB8 Overload ProtectionComponent Panel Stop engine Fuse F1 Trouble Remedy Troubleshooting TablesGenerator Power Welding Engine Maintenance Display Action Current transformer CT1, and throttle solenoid TS1 − Parts ListRecommended Spare Parts Recommended Spare Parts Circuit Diagram For Welding Generator − Electrical Diagrams 228 719-B OM-217 455 231 607-B Run-In And Wetstacking − RUN-IN and Wetstacking Idle − Performance DataFuel Consumption Curves US Gal./Hr AC Amperes At 120 Volts Generator Power CurveDuty Cycle Volts Stick Mode Volt-Ampere Curves DC Amps CC/AC Stick Mode AC VoltsAC Amps DC Amps MIG Mode Volt-Ampere Curve − Generator Power Guidelines Selecting EquipmentGrounding Generator To Truck Or Trailer Frame Amperes x Volts = Watts Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Use ground device as stated in electrical codes Farm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Industrial Motors Rating Starting Watts Running Watts Contractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor Equipment KVA/HP x HP x 1000 / Volts = Starting Amperage Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting Requirements Typical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Stick Welding Procedure Weld current starts when electrode touches work- piece− Stick Welding Smaw Guidelines Electrode and Amperage Selection Chart Striking an Arc − Scratch Start TechniqueStriking an Arc − Tapping Technique 10-30 9090 End View of Work Angle Poor Weld Bead CharacteristicsGood Weld Bead Characteristics Positioning Electrode Holder Electrode Movement During Welding Conditions That Affect Weld Bead Shape 16 in 30 1.6 mm Tack Welds Butt JointsLap Joint Tee Joint Possible Causes Corrective Actions Troubleshooting − PorosityTroubleshooting − Excessive Spatter Weld Test Troubleshooting − Incomplete Fusion Troubleshooting − Lack Of PenetrationTroubleshooting − Excessive Penetration Troubleshooting − Burn-Through Troubleshooting − Waviness Of BeadTroubleshooting − Distortion Work like a Pro Service Your distributor also givesSupport Your distributor and/or equipment manufacturer’s To locate a Distributor or Service Agency visitMiller Electric Mfg. Co For assistance in filing or settling claims, contact