Start Your Professional Welding Career Now

.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!

OM-217 455 Page 30

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Miller Electric 250 manual Start Your Professional Welding Career Now

Contents

Visit our website at OM-217 455HFile Engine Drive 2007−05−21 From Miller to You Table of Contents 13-4 13-213-3 13-5 Electric Shock can kill Symbol UsageArc Welding Hazards HOT Parts can cause severe burns ARC Rays can burn eyes and skin Fumes and Gases can be hazardousBuildup of GAS can injure or kill Welding can cause fire or explosion Engine Hazards Compressed Air Hazards Fire or Explosion hazard Welding Wire can cause injuryHOT Parts can cause burns and injury Falling Unit can cause injury EMF Information Principal Safety StandardsCalifornia Proposition 65 Warnings Radiation can cause interference UN Choc Électrique peut tuer Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation Indique des instructions spécifiques LES 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 peut Information EMF Proposition californienne 65 AvertissementsPrincipales normes de sécurité En ce qui concerne les implants médicaux Weld, Power, and Engine Specifications − SpecificationsSymbol Definitions − Definitions Dimensions 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 cool Overview And Engine Prestart Checks Run-in period first 100 hours Engine Left Side Engine Right SideStarting engine for the first time Daily pre-start checks Work Weld Output Terminal Connecting to Weld Output TerminalsCorrect Installation Tools Needed Do not place Selecting 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 seconds Weld Output Controls Stop engine Typical Stick Welding Connections And Control SettingsTypical Settings For 7018 1/8 Electrode Work Clamp Electrode Holder Set 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 Dcen Tools 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 properly Simultaneous Weld And Power Battery Charge Controls − Operating Optional Battery ChargerDetermining Battery Charging Current Battery Charge Cable Connections Battery Charging Procedure Minutes Start Your Professional Welding Career Now − Maintenance and Troubleshooting Routine Maintenance Maintenance Label And Engine Maintenance Activities Stop engine and let cool Oil And Fuel 804 197-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 whether Stop screw is factory-set and should not be adjusted Adjusting Engine SpeedAdjusting Fuel Solenoid Position Checking Fuel Solenoid 16 mm Adjusting Throttle SolenoidChecking Throttle Solenoid Check for non-binding Adjusting Idle Speed Making Engine Speed AdjustmentsAdjusting Weld/Power Speed Fuse F1 Overload ProtectionComponent Panel Stop engine Supplementary Protector CB8 Welding Troubleshooting TablesGenerator Power Trouble Remedy Maintenance Display Action Engine Recommended Spare Parts − Parts ListRecommended Spare Parts Current transformer CT1, and throttle solenoid TS1 − Electrical Diagrams Circuit Diagram For Welding Generator 228 719-B OM-217 455 231 607-B − RUN-IN and Wetstacking Run-In And Wetstacking US Gal./Hr − Performance DataFuel Consumption Curves Idle Volts Generator Power CurveDuty Cycle AC Amperes At 120 Volts DC Amps CC/AC Stick Mode AC Volts Stick Mode Volt-Ampere CurvesAC Amps MIG Mode Volt-Ampere Curve DC Amps Selecting 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 = Watts Industrial 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 Watts Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Single-Phase Induction Motor Starting Requirements Power Required To Start MotorHow Much Power Can Generator Supply? KVA/HP x HP x 1000 / Volts = Starting Amperage Typical 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 Angle Conditions That Affect Weld Bead Shape Electrode Movement During Welding Tee Joint Butt JointsLap Joint 16 in 30 1.6 mm Tack Welds Weld Test Troubleshooting − PorosityTroubleshooting − Excessive Spatter Possible Causes Corrective Actions Troubleshooting − 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