Home

Miller Electric Big Blue 500 PT User's Manual

1. 56 Tist WVCISTACKING acer pU ee tato Sp raa 56 11 2 Run In Procedure Using Load 57 11 3 Run In Procedure Using Resistance Grid 58 SECTION 12 GENERATOR POWER GUIDELINES 59 SECTIONS PARTS LIST RS E Ed rE ee 66 WARRANTY 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 or explained in the text Indicates a hazardous situation which if not avoided could result in death or serious injury The possible hazards are shown in the adjoining symbols or ex plained in the text NOTICE Indicates statements not related to personal injury 1 2 Arc Welding Hazards A EG The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section
2. Optional When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 4429 Page 77 gt Hardware is common and not available unless listed Sa NS 803 650 Figure 13 5 Panel Front w Components CC CV Models Item Dia Part No Mkgs No Description Quantity Figure 13 5 Panel Front w Components CC CV Models Figure 13 1 Item 121 aaa 215158 PLATE SCREENED ident control when ordering this item the nameplate should also be ordered 1 To E NAMEPLATE screened order by model and serial number 1 uo mr EET 215 014 PANEL engine weld control 1 o E 220544 PANEL engine weld control ss 1 4 OS ossis 208278 SWITCH range changeover 1 ACT 1 193118 flat 1t 2w 1k ohm 1 56 193 234 SWITCH rotary 6 position gold contacts 1 197 527 GUARD circuit breaker S6 Not Included w Harness 1 ap DD is 011 609 SWITCH t
3. 1 039 047 TERMINAL pwr output red 1 196 073 LABEL do not switch while welding 1 021 385 BOOT toggle switch lever 1 190 323 BOOT circuit breaker clear hex nut 2 PL u aparka ta haah 170 391 CONN circ ms protective cap size 20 1 m ins 210 424 METER hour 12 24vdc snap in 1 49 FUEL 192265 GAUGE fuel elec switch w o sensor 1 secs cad usuri 193 228 METER Volt Dc 8 18 Scale 2 250 In Black Face 1 VE TRE 217 084 GAUGE Coolant Temp 0 300 Deg F Electric 1 gusta ud zr Actor 197 798 SENDER Coolant Temp 300 Deg M16 1 5 1 e AT ES ate 217 083 GAUGE Pressure Oil 0 100 Psi Electric 1 193 230 SENDER Pressure Oil 0 100 Psi 1 164 873 METER amp ac dc 0 500 0 600 dc scale 2 5 in 1 n 164 874 METER volt ac dc 0 100 scale 2 5 in 1 OM 4429 Page 79 oc 097 922 pointer 875 dia x 250 ID w set screws plstc 1 MR EP
4. 36 7 4 Remote Voltage Amperage Control On CC CV Models Optional 37 SECTION 8 OPERATING AUXILIARY EQUIPMENT 38 8 1 120 Volt And 240 Volt Receptacles 38 8 2 Connecting To Optional Three Phase Generator CC CV Models Only 39 8 3 Optional Generator Power Receptacles 40 SECTION 9 MAINTENANCE TROUBLESHOOTING 41 9 1 Maintenance Label re a atte e oen e ee ol ey o e 41 9 2 Routine Maintenances xx Sota u uka ea RE Ee whale ex Eu eS oe ew be ee 42 el e Ue EE SE ER 43 9 4 Inspecting And Cleaning Optional Spark Arrestor Muffler 44 9 5 Gheckirig Generator Brushes dures tutes ARE EE 44 9 6 Servicing Fuel And Lubrication Systems 45 9 7 Overload Proteci n te 46 9 65 WNOUDIGSHOOING ace feiss does hoe paw uuruuu Qu w 47 SECTION 10 ELECTRICAL DIAGRAMS erue hu nr 52 SECTION 11 RUN IN PROCEDURE ctt er xe ee
5. 7 r 100 5100 56 lt 3 OPTIONAL STANDARD 705 725 27 N CBI RECEPTACLE al 707 3 70 AUX fe V 7055 S 105 STATOR z BL 2 706 lt 706 v t DR E ECTS 240 108 STATOR CB1 TOPS g 510 N 26 9 gt GFCI1 120V CB2 ec 2 N wH PLG3 RC3 aux fe ZN 1 gt STATOR GND 42 TS a SZ 702 x 102 LEAD 89 NOT CONNECTED 4 gt ON CC MODEL in 707 49 gt gt 7 5 06 118 118 8 gt 102 1255 9 5125 Le 35 540 107 106 Si 65 909 63 PLG4 RC4 25 gt 2 2653556 205 522 2255 5 _ 26 gt 2 257 gt 52 59 gt 9 gt Ee ZI gt Z 575 7a gt 13 gt gt 4 gt AUTO IDLE OPTIONIAL CR4 722 PLG6 RC6 46 gt gt 56 3 gt 4 gt PLG7 RC7 103 gt 1 gt 103 2 gt LE 46 FUEL PUMP Figure 10 1 Circuit Diagram For CC Welding Generator OM 4429 Page 52 4 WARNING e Do not touch live electrical parts e Disconnect input power or stop engine before servicing e Do not operate with covers removed e Have only qualified persons install use or service this unit E EN MM POSITION Je ST POLARITY RECEPTACLE PACKAGE
6. s vec Exc rate ee eR SEA 14 SECTION 4 SPECIFICATIONS 23525 oa thane ea ace qd moa e ac m sm ooa e a mr kee 15 4 1 Weld Power And Engine Specifications 15 4 2 Dimensions Weights And Operating Angles 15 4 3 Volt Ampere Curves For CC Models 16 4 4 Volt Ampere Curves For CC CV Models 17 ES e ed e Era a rt 18 4 6 Duty Cycle And Overheating 4 4 18 4 7 AG Generator Power GUNE S uu avis OW eae ee ed eee ee eed 19 4 8 Optional Three Phase Generator Curves 19 SECTION 5 INSTALLATION __ _ __ ___ 20 5 1 Installing Welding Generator eios x ce x CY nee man pQ abei ee hae es 20 5 2 USing LINING EVE uuu ROGER a Dia ya de Sie ela PR Te dona n 21 9 3 Mounting Welding Generators sea u exe x pace Saba Seid ban 22 5 4 Tristalling Exhaust RIPE S su oie ence itt x pa e S erede Eq ee pdt eee Sub aded dent 23 5 5 Activating The Dry Charge Battery If
7. nm 4 209 220 STATOR weld assembly complete full KVA option f suu NS 225 120 LABEL warning moving parts can cause injury m uA 190 197 GUARD generator wire mesh oss Aet uela 172 674 SPRING ext 240 OD x 041 wire x 3 500 18 03920772 11 ROTOR 212 997 ROTOR Generator Segmented Assy Includes 4429 80 Item Dia Part No Mkgs No Description Quantity Figure 13 6 Generator Continued nasua kaq 210 446 ROTOR Generator Includes 1 Wu cr M 024 617 RING Rtng Ext 1 375 Shaft 050 Thk 1 sid wh Gaara e e daten 053 390 BEARING Sgl Row 1 370 X 2 830 X 6 1 RE HUB Drive Not Sold Separately 1 DER 210 447 FAN Rotor Assy Generator Segmented includes 1 2 0 532 vs PLATE Flex Hubmount 1 ind sas wa aa 206 242 FAN Rotor Segmented Assy Gen 4 Lar df ncc ku a ma 049 026 SCREW M10 1 5x 25 Hex Hd pln 8 8 Pin 10 TP 083 883 WASHER Lock 402idx0 7090dx 087t Stl SplitiOmm 10 Ero PMID 080 389 SCREW 312 18 1 00 Hexwhd 66d Sil Pl
8. 24 9 6 Connecing ss z et Saxo S RUE RAE RAT ag CER PLC EV PIC EE RIEN 24 5 7 Engine Pres ail GHOCKS s d ERROR URL AUR pukuy ee ee an Nos keeles 25 5 8 Connecting To Weld Output Terminals 26 5 9 Selecting Weld Cable 27 5 10 Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models 27 5 11 Connecting To Remote 14 Receptacle RC14 On CC CV Models 28 SECTION 6 OPERATING WELDING GENERATOR CC MODELS 30 6 1 Front Panel Controls For CC Models See Section 6 2 30 6 2 Description Of Front Panel Controls For CC Models See Section 6 1 31 6 3 Remote Amperage Control On CC Models Optional 32 6 4 Weld Control Arc Condition Information Label 32 TABLE OF CONTENTS SECTION 7 OPERATING WELDING GENERATOR CC CV MODELS 34 7 1 Front Panel Controls For CC CV Models See Section 7 2 34 7 2 Description Of Front Panel Controls For CC CV Models See Section 7 1 35 7 3 Process Contactor Switch On CC CV Models
9. 1 DEE Mesias oxy areas a 190 861 LABEL warning electric shock and moving parts etc 1 nod ee 197 399 LABEL warning ph generator power 1 PE c MENOR eee 209 056 COVER receptacle w gasket 2 rco ERROR 206 795 BOOT circuit breaker clear hex nut 1 ix dA eau m 9512 4195 925 SWITCH polarily aicist ta t Dec en re cde 1 inerti bi 12 220 491 SWITCH polarity AC COD Lada E dodi 201 125 PANEL mtg terminal pwr 1 PU Pr 199 303 PANEL mtg terminal pwr output SS 1 36 5 189 744 CIRCUIT CARD ASSEMBLY fiterhf 2 PC 039 046 TERMINAL pwr output black 1 180 735 WASHER output stud 2 Ti een eee 134 201 STAND OFF support 12 T 181 169 SPACER output stud 2 AU 186 621 BOOT generic output Stud 2 059 72 MANDLE SWIN eru ied rm 1 010 647 PIN spring cs 156 1 250
10. 4 2 Dimensions Weights And Operating Angles Dimensions 60 1524 Height to top of muffler 28 1 2 in 724 mm G mtg brackets turned in zs Width 30 3 4 781 mtg brackets turned out d u Depth 65 1 8 in 1654 mm Do not exceed tilt angles or engine could be damaged or unit could tip r Do not move operate unit where it could B 56 in 1422 mm tip C 46 1 2 1181 D 9 5 8 in 244 mm B C E 27 1 2 in 699 mm 1 in 25 mm 29 13 16 757 mm 9 16 in 14 mm Dia p n 4 Holes E 1 D With mounting brackets in center position Dimensions vary with location of mounting brackets Weight E w Perkins No fuel 1700 Ib 771 kg 802 161 A 404 22T w fuel 1875 Ib 850 kg Lifting Eye Weight Rating 2500 Ib 1134 kg Maximum OM 4429 Page 15 4 3 Volt Ampere Curves For CC Models The volt ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator Curves of all Ranges other settings fall between the 300 Max curves shown 185 425 125 320 85 190 55 90 2 gt O 100 200 300 400 500 600 700 800 900 DC 5 203 412 Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual 4429 Page 16 4 4 Volt Ampere Curves Models Th
11. 1 uya t W aii Wara Sa 215 345 Manifold Exhaust Muffler 1 Bracket Included With Item 37 Manifold Muffler 1 OM 4429 Page 68 Item Dia Part No Mkgs No Description Quantity Figure 13 1 Main Assembly Continued Uo NM 216 133 Engine Perkins Dsl Elec 404C 22T 1 Ur THE 214 931 Sender Coolant Temp amp 110c N o Switch 1 VETE 4215 094 lt Switch Oll Pressure DTP 023 562 Clamp Hose 312 875 Clp Dia 1 v 197899 uuu uz o tee Cl 192 744 Filter Fuel Spin on 1 TR 7197 997 Filler Fuel Secondaly c usa us sata 1 O y Linie a 214 658 Hose Radiator Upper 1 TU STET 218 273 Fan Engine Cooling 15 350 Blower 1 TE UE 197 9442 aiuti Eoo qe did seco 1 ioc LE run 202 01 7 ard Bell quus smi aci acne 1 44 220 280 Radiator W Shroud Includes 1 eee ee ere 220281 zas ohliroud Radiator 2 2 2 B mre e e ocu bike ee Rut ose
12. 12 spst 30a 15vdc 5pin flange mtg 1 7 Engine Controller 219 848 MODULE control governor 1 204 702 CORE torodial 187 id x 375 od x 125 thk 1 8 090104 RELAY 12vdc spst 30a 15vdc 5pin flange mtg 1 9 D10 C10 189 701 DIODE CAPACITOR BOARD 1 10 10 190374 CIRCUIT BREAKER Auto Reset 12vdc 40 Amp 1 E ERE S 201 O79 COVER control BOX eei nt Rr eme te ede Nc dettes 1 12 CR5 223710 RELAY encl 12vdc dpst no 25a 6pin flange 1 13 PC7 195 706 MODULE pull to idle two output 7 pin 1 14 SR1 035704 RECTIFIER integ 40A 800V 1 15 CR4 6113 247 RELAY 12vdc dpdt 20a 120vac flange mtg 1 16 PC9 192224 CIRCUIT CARD ASSY display 1 OM 4429 Page 74 Item Dia Part No Mkgs No Description Quantity Figure 13 3 Control Box Assembly CC CV Models Continued 2 AP 134 201 STAND OFF support pc card 3 Wu C9 087 110 CAPACITOR elctit 240uf 200VDC 1 Oc RU RR 177
13. 181572 5 25 BUSHING tank FUGI 2 hi as ears 1 ss trous 189 908 Valve Drain Fuel 180deg 1 OS PR ach TT 191 446 Extrusion Rubber W Adhesive 1 000 X 1 000 D Order By Ft 6ft ru rie 218 086 Bracket Hold Down Fuel Tank 1 POT 196 220 Bracket Hold Down Fuel Tank Rear 1 102 2 192 362 Bracket Mtg Nyl 1 2 1 191 897 Bracket Mtg Unit hee ess 4 TOA 1200 999 BASO Tu saam pus tes bee dns 1 7205 302 Base stet doo ete e ooo cte mare ne peer 1 DOS cre tuer d 224 266 Label Warning Do Not Weld On Base 2 190 179 Bracket Mtg Resistor 1 107 R3 189 699 Resistor Ww Tap 375w 10 Ohm W Mtg Bkt 1 108 R2 189 699 Resistor Ww Tap 375w 10 Ohm W Mtg 1 109 R4 191 292 Resistor Ww Fxd 375 W 50 Ohm W Mtg Bkt 1 191 446 Extrusion Rubber W Adhesive 1 000 X 1 000 D Order By Ft 6ft WAM oe Seana Figures 13 2 13 3 Control Box Assembly
14. 3ft La aa anat 189708 TOD 2 ten e ed eco ces om eim Bo e aeos 1 CEA 191307 Cover Plat 22 2 mai ERE SIE WU e 1 Kee apaga s od 189 763 Bracket Mtg Air Cleaner 1 steal eds 218 048 lt Hose Air Cleaner 2 eroe eme Cet Su 1 A me ne 218 047 Tube Air Intake 1 nr PC 218 046 Hose Air Cleaner 1 TET HIMEN 010 863 Clamp Hose 1 125 3 000 Dia 4 amata ti 220 091 Hose Sae 500 Id X 750 Od X 13 000 1 189 764 Air Cleaner Intake 1 192 938 Filter Air Element Primary 1 eet G 192 939 Filter Air Element Safety 1 AR aaa na aza 189 464 Seal Weather Lift Eye 1 173 909 Hose Sae 312 Id X 560 Od X 24 000 Order By Ft 2 201 658 Upright Center Assembly 1 191 819 312 Id X 560 Od X 14 000 Order Ft 2 AUS re 198 584 Hose Sae 312 Id X 560 Od X 5 000 Order
15. d Ventas A 214 884 Radiator W 14 Cap 4 Row Core 3 Pass 1 A 187 120 Cap Radiator Pressure 14 0 do o ee 20L 1495 64 apte Cu 1 E Ls E 4207 188 s s Lees dr aa aa headend 1 a ete 207 005 GrilliRear Panel SS xime ed es bein e dei dem main ss 108 081 Terminal Protector Battery Post 2 ET Ares u grade 190 206 Cable Bat Neg 42 In Lg No 2 Awg W Clamp And 375rng 1 ee pede 190 207 Cable Bat Pos 45 In Lg No 1 Awg W Clamp And 406rng 1 Bein nls as Me 203 430 Bracket Battery Holddown 1 SOO eae 190 897 Battery Stor 12v 650crk 110rsv Gp 24 1 EER E sdh 225 120 Label Warning Moving Parts Can Cause 2 2 168 385 Label Warning Battery Explosion Can Blind 1 201 183 Cover Battery Access 1 202 639 Cover Battery Access SS 1 OR 201 006 0 312 18 X 8500 Pld Remis 2 PDO SLR 225 120 Label Warning Moving Parts Can Cause 2 DD ha E 215 006 GUANO exu
16. 4429 45 9 7 Overload Protection Stop engine gt When a supplementary protector circuit breaker or fuse opens it usu ally indicates a more serious problem exists Contact Factory Authorized Service Agent 1 Fuse F1 2 Fuse F2 F1 and F2 protect the stator exciter wind ing from overload If F1 opens weld and generator power is low or stops entirely If F2 opens weld output is low or stops entirely 4 KVA kW generator power is still available 3 Circuit Breaker CB4 Not Shown 4 Supplementary Protector CB5 CC CV Models Only 5 Supplementary Protector CB6 CC CV Models Only 6 Circuit Breaker CB10 Not Shown 7 Supplementary Protector CB11 8 Supplementary Protector CB12 9 Supplementary Protector CB13 CBA protects the welding arc drive dig circuit If CB4 opens electrode may stick to the workpiece more frequently during low voltage short arc length conditions CB4 automatically resets when the fault is corrected CB5 protects the 24 volt ac output to re mote receptacle RC14 and 24 volt output to field current regulator board PC1 CC CV models only If CB5 opens weld out put and 24 volt output to RC14 stops On units with optional three phase genera tor generator power output at receptacle RC5 also stops if CB5 opens CB6 protects the 115 volt ac output to re mote receptacle RC14 CC CV models only If CB6 opens 115 volt output to RC14 stops CB10 protects the engine b
17. 4429 2216 138 2007 05 Miller DW Sick SMAW Welding TIG GTAW Welding MIG GMAW Welding NN p 4 a Flux Cored FCAW Welding Air Carbon Arc CAC A Cutting and Gouging Description 9 04 Engine Driven Welding Generator Big Blue 500 PT Big Blue 600 X Perkins Turbo Powered OWNER S MANUAL File Engine Drive dii Visit our website at www MillerWelds com 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 Ir BI E Her This Owner s Manual 15 designed to help you get the most out of your Miller products Please take time to read the Safety precautions They boleu Ie ete jue ere ex e every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most We ve m
18. OPE oae ebbe 1 197 496 Hose Radiator Lower 1 199 505 Hose Oil Drain Assy 32 In Consisting Of 1 DO Must i 165 271 Valve Oil Drain 3 8 18nptf 1 xo 176 529 Fitting Hose Brs Barbed Fem 1 2tbg X 3 8npt 1 113 854 Hose Sae 500 Id X 780 Od Xc Oil Order Ft Washer Oil Drain Available Through Engine Manufacturer 1 197 196 Fitting Adapter Oil Drain 12mm Male X 3 8 Female 1 197 448 Fitting Hose Brs Barbed Elbow 1 2 Tbg X 3 8 Npt 1 BE T 199 849 Screw 625 11 X 4 00hexhd Gr 5 4 071 731 Washer Flat 656 Id 2 250 Od X 187t Stl 4 Moo 197 489 Bracket MIRIT Ge e E 1 197489 5 Bracket WIG 1 ent 071890 Retainer Mount Eng Gen 4 Moo PED 071 730 Tubing Stl 875 Od X 12ga Wall X 2 500 4 SOO 083 476 Mount Eng Gen Nprn 875 Id X 2 500 Od X 2 000 4 TL PP 135 205 Nut 625 11 94hex 76h Stl Pld Elastic Stop Nut
19. DEOR ES 206 795 BOOT circuit breaker clear hex nut 1 Tro eer er ere 021 385 BOOT toggle switch lever 2 it OE ta 201 045 COVER receptacle twistlock 1 Eo o NONEM 193 228 METER Volt Dc 8 18 Scale 2 250 In Black Face 1 94 FUEL 192 265 GAUGE fuel elec switch w o sensor 1 Vs dd ere 210424 METER hour 12 24VDC 2 25dia 1 MON satay es Y 217 084 GAUGE Coolant Temp 0 300 Deg F Electric 1 COPIE EE 197 798 SENDER Coolant Temp 300 Deg M16 1 5 1 217 083 GAUGE Pressure Oil 0 100 Psi Electric 1 193 230 SENDER Pressure Oil 0 100 Psi 1 164 873 VOLT METER W Leads 1 164 874 AMMETER W Leads 1 DI p prc 189161 sz HANDLE SWIICDETATIQO x zu US RC c t ea ushpha etia ta ote aes 1 T 010 647 PIN spring CS 156 1 250 1 baud set Me Suyuta 019 602 IKNOB DOI coms Se i USE OC uec E RO Rad 1 CU d 024 103 BLANK snap in nyl 750 mtg hole black
20. Seu sas 188636 RELAY OCV control dried ira e RE n act ena ie dut 1 DEC 201077 CONTROL BOX ene Iris 1 TI T H6 141424 RESISTOR ww fxd w 25 ohm faston te 1 6 C12 191 944 CAPACITOR polyp met film 10 uf 250 vac 10 1 ie A uyu tu asha dium 201 078 CONTROL BOX Mirar et ees SR 1 8 CR8 197 325 RELAY 12vdc spst 70a flange mtg 1 9 CH1 090 104 RELAY 12vdc spst 30a 15vdc 5pin flange mtg 1 10 Engine Controller 219 848 MODULE control governor 1 204 702 CORE torodial 187 id x 375 od x 125 thk 1 11 090104 RELAY 12vdc spst 30a 15vdc 5pin flange mtg 1 12 D10 C10 189 701 DIODE CAPACITOR BOARD 1 13 CB10 190374 CIRCUIT BREAKER Auto Reset 12vdc 40 Amp 1 ten uapa aaa 201079 COVER Control DOX xx ee e aun u 1 15 CR5 223710 RELAY Encl 12vdc Dpst no 25 Flange 1 16 PC7 195 706 MODULE pull to idle two output 7 pin 1 17 SR1 SR2 035 704 RECTIFIER integ 40A 80
21. 726 5 gt RC2 PLG14 6 gt 718 82 41 3 PLce 18 PIN 22 gt gt 92 a Fz FS TUM 5 s gt 7 N J6 6 gt gt B1 Et E2 G2 V Z Z v yvy HOT OUTPUT 727 CONTACTOR Y Y 722 123 STANDARD 240V RECEPTACLE POSITION 10 4 G D2 D3 K2 F3 J2 B3 732 01 A2 P PLG6 RCE 725 LE gs Pe s gt 4 gt gt O m oo PLG10 RC10 Z gt gt i 136 136 20 gt 33 gt 4 gt 771 43 gt 5 gt 52 gt 2 ALL HOT 6 gt STICK RMT CRS MIG RMT TIG RMT 56 O 65 PLG13 44 139 2 gt 5 24 2 742 52 47 amp 7 40 40 5 42 2 61 8 CR1 AST 12 Jur 43 9 744 gt 10 GLOW PLUGS GAD 57 FUEL PUMP i 5 AUTO IDLE 42 42 42 42 42 42 p Figure 10 2 Circuit Diagram For CC CV Welding Generator OM 4429 Page 54 5 RECEPTACLE PACKAGE OPTIONS AUX OPTIONAL 4 See WELD METERS ENGINE CONTROLLER AUTO IDLE OPTIONIAL gt 67 42 57 57 67 67 67 Eu 6 1 6 1 46941 Le 4 3 4 3 BATTERY GAUGE OPTIONIAL COOLAN TEMP FUEL LEVEL SENDER 4 42 42 42 42 PCS RECTIFIER PROTECTION JO TS1 SHIELD X CLOSED TO A TERMINAL POSITIO
22. 4 4 ree are ate ere eee 190 992 Keeper Latch Engine Access Door 1 190 076 Channel Stiffener Engine Access 1 ue 202 635 Channel Stiffener Engine Access E coat 1 7 us gaa 199 592 Latch Paddle Series 20 Black 1 TE Mak in Shes At dat 220 539 Label Maintenance Big Blue Perkins Series 1 200 989 Door Engine 5 1 ADR Late 210 736 Door Engine ACCESS SS 9404 1 TO ue an 189 975 Hinge Door Access 180deg 2 OM 4429 Page 69 Item Dia Part No Mkgs No Description Quantity Figure 13 1 Main Assembly Continued 190 190 Tank Coolant Recovery 1 sean 2 rm 199 926 Panel BOCKSE eiaa aa asha ebrei eco 1 Co EE 199 298 Panel Rocker SS 1 OO DOES 189827 Gem ot eta IDEE Ex edi aliler Ete edu Reo e 1 199300 Panel Rh SS 1 Olive ka 191 626 Bumper Door Engine Access 2 ss de 197
23. Toutefois des tudes sont toujours en cours et les preuves continuent tre examin es En attendant que les conclusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn ti ques pendant le soudage ou le coupage Pour r duire les champs magn tiques sur le poste de travail appliquer les proc dures suivantes Pour les moteurs essence Les gaz d chappement des moteurs contiennent des duits chimiques dont l Etat de Californie reconna t qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Pour les moteurs diesel Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l Etat de Californie com me provoquant des cancers et des malformations cong nitales ou autres probl mes de procr ation LAW 5NS t l phone 800 463 6727 ou Toronto 416 747 4044 site Internet www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 de American National Standards Institute 11 West 43rd Street New York NY 10036 8002 t l phone 212 642 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 t l phone 617 770 3000 site Internet ww
24. eL DES ET OM 4429 Page 41 9 2 Routine Maintenance 59 Recycle engine Stop engine before maintaining gt See Engine Manual and Maintenance Label for important start up service and storage Injectors fluids I information Service engine more often if used in severe conditions D Check lt Change Clean Replace Reference To be done by Factory Authorized Service Agent Every Section 5 7 FUEL 3 WATER lt Ps Qc 9 6 Hours Fuel Water Separator Fuel Level Oil Level Oil Fuel Spills Coolant Level Every 50 Hours KT Weld Terminals Every Section 9 3 100 Hours Battery Terminals Air Cleaner Hoses Air Cleaner Element Every Engine 250 Manual Hours u Section 9 4 Unreadable Labels Fan Belt Tension Spark Arrestor Every Section 9 6 500 Hours z x Weld Cables Oil Oil Filter Every Section 5 7 1000 9 5 9 6 Hours and Engine Manual FuelFilter Drain Sludge Slip Rings Valve Clearance w Brushes Every 2000 Hours OM 4429 Page 42 9 3 Servicing Air Cleaner A Stop engine NOTICE Do not run engine without air 3 4 cleaner or with dirty element Engine damage caused by using a damaged ele ment is not covered the warranty Optional gt The air cleaner primary element WAWA
25. 50A 125 250W uuu eR A ceca Es 1 n TO bout des Qa 025 248 STAND OFF insul 250 20 X1 2 1 604 102 CONNECTOR clamp cable 1 000 1 PEE 197 527 GUARD circuit breaker 1 197 363 TERMINAL ring tng screw clamp 3 23 CB7 e214 926 SUPPLEMENTARY PROTECTOR man reset 1 215 347 PANEL generator power 1 pedes eia Meus 215 403 PANEL gen pwr export models only 1 MERE 215 406 PANEL generator power 1 a amsa 215 363 PANEL generator power full KVA option 1 214 927 BOOT circuit breaker 1 pole 1 TE P 197 508 PLUG DIOIGCIVO x2 utu bcr em rmt ce erbe recorre es 1 eor PE 077 440 BUSHING conduit 11 1 C 601 836 NUT 250 20 50hex 19h brs 3 mc ERES 209 056 COVER receptacle w gasket 1 083 030 STUD brs 250 20 1 750 w hex collar 1 HN De CT2 197 433 TRANSFORMER current sensing
26. Connect voltmeter and ammeter as shown if not provided on generator Start engine and run for several minutes Set grid switches and then ad just generator A V control so load equals rated voltage and current of the generator see nameplate rating label or the specifications section in this manual Check generator and meters after first five minutes then every fifteen minutes to be sure generator is loaded properly NOTICE Check oil level frequent ly during run in add oil if needed It is recommended to run the weld ing generator for two hours mini mum and up to four hours under load Place A V control in minimum position then shut down grid to remove load Run engine several minutes at no load A Stop engine and let cool 6 Engine Exhaust Pipe Repeat procedure if wetstacking is present S 0684 OM 4429 Page 58 SECTION 12 GENERATOR POWER GUIDELINES gt views this section are intended to be representative of all engine driven welding generators Your unit may differ from those shown 12 1 Selecting Equipment ayo AD G Generator Power Receptacles Neutral Bonded To Frame 3 Prong Plug From Case Grounded Equipment 2 Prong Plug From Double Insulated Equipment gt Be sure equipment has double insulated symbol and or word ing on it Do not use 2 prong plug un less equipment is double in sulated gen_pwr 2007 04 Ref ST 159
27. Use Starting Aid switch see Section 6 1 or 7 1 Keep battery in good condition Store battery in warm area Use fuel formulated for cold weather diesel fuel can gel in cold weather Contact local fuel supplier for fuel in formation Use correct grade oil for cold weather see Section 9 1 OM 4429 Page 25 5 8 Connecting To Weld Output Terminals Stick and TIG Welding For Stick and TIG welding Direct Current Elec trode Positive DCEP connect electrode holder cable to Positive terminal on left and work cable to Negative terminal on right For Direct Current Electrode Negative DCEN reverse cable connections If equipped with optional Polarity switch or op tional Polarity AC switch connect electrode holder cable to Electrode terminal on left and work cable to Work terminal on right MIG and FCAW Welding For MIG and FCAW welding Direct Current Electrode Positive DCEP on CC CV models connect wire feeder cable to Positive termi nal on left and work cable to Negative ter minal on right Use Process Contactor switch to select type of weld output see Section 7 3 For Direct Current Electrode Negative DCEN reverse cable connections If equipped with optional Polarity switch or op tional Polarity AC switch connect wire feeder cable to Electrode terminal on left and work cable to Work terminal on right Stop engine Positive Weld Output Terminal Negati
28. and prevent damage to base Mounting Surface 1 Cross Supports 2 Mounting Brackets Supplied Mount unit on flat surface or use cross supports to support base Secure unit with mounting brack ets 3 1 2 Bolt And Washer Minimum Not Supplied 4 3 8 16 x1 in Screws Supplied To Bolt Unit In Place Remove hardware securing the four mounting brackets to the base Reverse brackets and reattach to base with original hardware Mount unit to truck or trailer with 1 2 in 12 mm or larger hardware not supplied To Weld Unit In Place Weld unit to truck or trailer only at the four mounting brackets install3 2007 04 803 274 200 864 A 803 602 5 4 Installing Exhaust Pipe Stop engine and let cool gt Point exhaust pipe in desired di rection but always away from front panel and direction of travel Tools Needed 1 2 Ref 803 604 Ref 215 158 Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual OM 4429 Page 23 A Always wear a face shield rubber gloves and protective clothing when working on battery Remove battery from unit 5 Vent Caps 6 Sulfuric Acid Electrolyte 1 265 Specific Gravity 7 Well Fill each cell with electrolyte to bottom of well maximum A Do not overfill battery cells Wait ten minutes and check electro lyte level If necessary add electro lyte to raise to proper level R
29. une bouteille e Ne jamais souder une bouteille pressuris e risque d explosion e Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat e Ne pas tenir la t te en face de la sortie en ouvrant la soupape de la bouteille e Maintenirle chapeau de protection sur la soupape sauf en cas d utilisation ou de branchement de la bouteille e Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles e Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s curit moteur e Seules des personnes qualifi es sont autoris es enlever les por tes panneaux recouvrements ou dispositifs de protection pour effectuer s il y a lieu des travaux d entretien et de d pannage e Pour emp cher tout d marrage accidentel pendant les travaux d entretien d brancher le c ble n gatif de batterie de la borne e Ne pas approcher les mains cheveux v tements l ches et outils des organes mobiles e Remettre en place les panneaux ou les dispositifs de protection et fermer les portes la fin des travaux d entretien et avant de faire d marrer le moteur e Avant d inter
30. 1 7 Read and follow all Safety Standards Only qualified persons should install operate maintain and repair this unit During operation keep everybody especially children away ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equip ment is a hazard Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit Additional safety precautions are required when any of the follow ing electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when cramped positions such as sitting kneeling or lying or when ther
31. 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1 3 HP 2100 700 Elec Hedge Trimmer 18 in 400 400 Flood Lights HID 125 100 Metal Halide 313 250 Mercury 1000 Sodium 1400 Vapor 1250 1000 Submersible Pump 400 gph 600 200 Centrifugal Pump 900 gph 900 500 Floor Polisher 3 4 HP 16 in 4500 1400 1 HP 20 in 6100 1600 High Pressure Washer 1 2 HP 3150 950 3 4 HP 4500 1400 1 HP 6100 1600 55 gal Drum Mixer 1 4 HP 1900 700 Wet amp Dry Vac 1 7 HP 900 900 2 1 2 HP 1300 1300 OM 4429 Page 62 12 8 Power Required To Start Motor Single Phase Induction Motor Starting Requirements Motor Start G H J K L M N P Code KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0 Motor Start Code Running Amperage Motor HP Motor Voltage To find starting amperage Step 1 Find code and use table to find kVA HP If code is not listed multiply running amperage by six to find starting amperage Step 2 Find Motor HP and Volts Step 3 Determine starting amper age see example Welding generator amperage out put must be at least twice the motors running amperage kVA HP x HP x 1000 Volts Starting Amperage Example Calculate starting amper age required for a 230 V 1 4 HP mo tor with a motor start code of M Volts 230 HP 1 4 kVA HP 11 2 11 2 x 1 4 x 1000 230 12 2 Starting the motor requires 12 2
32. 14 receptacle RC14 see Section 5 11 Repair or replace remote control device Have Factory Authorized Service Agent check PC1 sensing leads 36 and 37 and connections Constant speed wire feeder does not Work Reset supplementary protector CB5 or CB6 see Section 9 7 OM 4429 Page 48 Trouble Remedy Check and secure connections to Remote 14 receptacle RC14 see Section 5 11 Repair or replace wire feeder Low CV weld output Set Ampere Range switch to highest range Increase Voltage Amperage Adjust Control setting Min or max CV weld output only Check position of Voltage Amperage Adjust control and Voltage Amperage Adjust switch Repair or replace remote control device Have Factory Authorized Service Agent check Amperage Voltage Adjust Control R1 and field current regulator board PC1 C Standard Generator Power Trouble Remedy No generator power output at ac recep tacles weld output okay Reset receptacle supplementary protectors Reset GFCI receptacle No generator power or weld output Disconnect equipment from generator power receptacles during start up Check fuses F1 and F2 and replace if open see Section 9 7 Have Factory Authorized Service Agent check integrated rectifier SR1 capacitor C9 diode capacitor board D1 C1 and the rotor Reset supplementary protector CB12 Have Factory Authorized Service Age
33. 189 161 HANDLE switch range 1 5 010 647 PIN spring CS 156 1 250 1 DB 097 924 pointer 1 625 dia x 250 ID w set scrws plstc 1 024 103 BLANK snap in 750 mtg hole blk 1 120 304 BLANK snap in nyl 250 mtg hole black 2 Optional When ordering component originally displaying precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor gt Hardware is common not available unless listed 21 804 291 A Figure 13 6 Generator Item Dia Part No Mkgs No Description Quantity Figure 13 6 Generator Figure 13 1 Item 88 7E 132 053 SCREW 375 16x1 50 hex hd pln gr5 pld 6 T 183 387 WASHER conical spring 406 ID x 875 OD pltd 6 gr 195 911 ENDBELL gen consisting of y P ipsa d 143 220 O RING 2 559 ID Xx 2139 9 E 201 099 STATOR exciter gen 208 287 STATOR weld assembly complete
34. 997 Filter Fuel Secondary 1 m rm Pump Fuel Available Through Engine Manufacturer 1 x o CS 173 909 Hose Sae 312 Id X 560 Od Order Ft 1 218 222 Bracket Mtg Fuel 1 No 225 120 Label Warning Moving Parts Can Cause 2 s O uya 095 636 Hose Sae 187 Id X 410 Od X 30 000 Order By Ft 1 DOG pudet Figure 13 6 2 Generator a su sss ete da AC E ea dta 1 Mio tr ne 218 087 Tank Fuel Consisting Of 1 124 253 res B usning Tank ee dec Mardi ens 4 084 173 Clamp Hose 460 545clp Dia Slfttng 2 O eed 189 912 Fitting Stl Barbed Elbow W 047 In Orf Zinc Pld 1 RR 189 909 Fitting Stand Pipe Hose 250 X 9 260 Lg 90deg Zinc 1 V Gu af dei et des 201 025 sap Kee HE 1 5 astaga 189 913 Fitting Stl Barbed Elbow Zinc Pld 1 190 142 Sender Fuel Gauge 9 7500 Deep Tank 1 Xo t 189 910 Fitting Stand Pipe Hose 3125 X 9 260 Lg 90deg Zinc 1
35. By Ft 1 MUR Pat 095 636 Hose Sae 187 Id X 41 Od X 30 000 Order By Ft 1 kay aa Sa 206 297 Base Fuel Filter W Fittings 1 192 744 Filter Fuel Spin on 1 ee 201 COVER yung 1 202 640 Cover 55 1 Rm 189 052 Grommet Plastic Neck Filler Fuel 1 190 198 Cap Tank Screw on 3 500 In W Vent 1 c EET 192 041 Label Use Diesel Fuel Only 1 Tos OSEE ONE 222513 Label Warning Falling Equipment Can Cause Serious 2 iei de xm lacked tt Res 224 265 Label Warning Hot Exhaust Parts Do Not Touch 1 cc MEC 105 734 Pipe Muffler Extension Elbow 1 750 Od 1 uo RE 201 851 Cover Radiator Access 1 EE 202 629 Cover Radiator Access Ss 1 EO adiu 191 354 SUDDOLL COVEI asaidie qt e dene det deco coe derit de ds res 1 Ul UMP 202 633 Support Cover E coat 1 LEE 010875 Clamp Muffler 2 000 Dia
36. H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation e The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation e notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference 1 6 California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling 1 7 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com Recommended Safe Practices for the Preparation for Welding and Cut ting of Co
37. Label Danger Using A Generator Indoors Can Kill You In Minutes Unit 1 Tr 190 058 Nut 250 20 U nut Multi thread 19 049 525 Nut 312 18 U nut Multi thread 32 tie PESE 216 136 Kit Label Includes Safety amp Informational Labels uya taa un 216 135 Kit Label Includes Safety amp Informational Labels 216 993 Kit Label Includes Safety amp Informational Labels CC Export Models aaa ates 216992 Kit Label Includes Safety amp Informational Labels CC CV Export Models When ordering a component originaly displaying a precautionary label the label should also be ordered Recommended Spare Parts CC models only CC CV models only Optional To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor CC Models 1 CC CV Models wk i 4 OM 4429 Page 71 803 845 D Figure 13 2 Control Box Assembly CC Models OM 4429 Page 72 Item Dia Part No Mkgs No Description Quantity Figure 13 2 Control Box Assembly CC Models Figure 13 1 Item 111 1 F1 F2 085 874 FUSE mintr cer slo blo 10 250V 2 Tn 046 432 HOLDER fuse mintr 250 x 1 250 2 2x
38. d chappement du moteur de provoquer un incendie e Utiliser uniquement un pare tincelles approuv voir codes en vigueur Le METAL CHAUD lors du coupage et gougeage plasma peut provoquer un in cendie ou une explosion e Ne pas couper ou gouger proximit de pro duits inflammables e Surveillez et garder un extincteur proximit DES PIECES CHAUDES peuvent provo quer des br lures et blessures e Ne pas toucher le compresseur ou d autres l ments du circuit air comprim chauds e Laisser l ensemble se refroidir avant de toucher ou d effectuer la maintenance LIRE LES INSTRUCTIONS e Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil e Arr ter le moteur et rel cher la pression avant d effectuer la maintenance e N tiliser que les pi ces de rechange recommand es par le constructeur 2 b Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Risque D INCENDIE OU D EXPLO SION e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Ne pas installer l appareil proximit de pro duits inflammables e Ne pas surcharger l installation lectrique s assurer que l ali mentation est correctement dimensionn e et prot g e avant de mettre l appareil en service BEBE LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage pour lever l appareil et les accessoires co
39. fuel tank Leave room for expansion Warning Watch Out There are possible hazards as shown by the symbols Read Owner s Manual Follow instructions to activate battery Check oil level Add oil if necessary S 177 571 During the first 50 hours of operation keep welding load above 200 amperes Do not weld below 200 amperes of output After the first 50 hours of operation change the oil and oil filter API CD MIL L 2104D CD SE CD SF OM 4429 Page 12 3 2 Manufacturer s Rating Labels CC Models x on wiran ss ue ore B a x on arsa Ug 64V 24 zw n 1800 min 1 1 60Hz 120 240V AKVA 20 17A Optional 500 CC 215 975 B CC CV Models AS peres e 20A 10 8V 400A 26V 35A 21 4V 410A 36 4V ML Lm V u mw LEV pem n 1800 1 120 240V 20 17 120 240V 12kVA 50 50A Optional 500 CV 215 974 B OM 4429 Page 13 3 3 Symbols And Definitions Some symbols are found only on CE products Stop Engine Fast Run Weld Power Slow Idle Start Engine Starting Aid Check Injectors Pump Stick SMAW Welding Time A Battery Engine Check Valve Clearance Air Temperature Or Engine Temperature Constant Current CO Hours Engine Oil Pres
40. load equals rated voltage and current of generator see name plate rating label or the specifi cations section in this manual Check generator and load bank meters after first five minutes then every fifteen minutes to be sure generator is loaded properly NOTICE Check oil level frequent ly during run in add oil if needed It is recommended to run the weld ing generator for two hours mini mum and up to four hours under load Place A V control in minimum position then turn off load bank to remove load Run engine several minutes at no load Stop engine and let cool 4 Engine Exhaust Pipe Repeat procedure if wetstacking is present S 0683 4429 Page 57 11 3 Run In Procedure Using Resistance Grid A Stop engine A Do not touch hot exhaust pipe engine parts or load bank grid Keep exhaust and pipe away from flammables NOTICE Do not perform run in procedure at less than 20 volts weld output and do not exceed duty cycle or equip ment damage may occur 1 Resistance Grid Use grid sized for generator rated output Turn Off grid 2 Welding Generator Place A V range switch in maxi mum position A V control in mini mum position and Output Selector switch if present in either DC position 3 Weld Cables Connect grid to generator weld output terminals using proper size weld cables with correct connec tors polarity is not important 4 Voltmeter 5 Clamp On Ammeter
41. nor mes de s curit e soudez pas si l air ambiant est charg de particules gaz ou peurs inflammables vapeur d essence par exemple e Brancherle c ble de masse sur la pi ce le plus pr s possible de la zone de soudage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provo quant des risques d lectrocution d tincelles et d incendie e Ne pas utiliser le poste de soudage pour d geler des conduites ge l es e Encas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact e Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans revers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos po ches telles qu un allumeur au butane ou des allumettes e Une fois le travail achev assurez vous qu il ne reste aucune tra ce d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Suivre les recommandations dans 1910 252 a 2 iv et NFPA 51B pour les travaux chaud et avoir de la surveillance et un extincteur proximit LE BRUIT peut affecter l ouie Le bruit des processus et des quipements peut affec l ouie e Porter des protections approuv s p
42. sant e Eloigner votre t te des fum es pas respirer les fum es l int rieur la zone et ou utiliser une ventilation forc e au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Sila ventilation est m diocre porter un respirateur anti vapeurs approuv e Lire et comprendre les sp cifications de s curit des mat riaux MSDS et les instructions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d graisseurs e Travailler dans un espace ferm seulement s il est bien ventil ou en portant un respirateur alimentation d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent d placer l air et abaisser le niveau d oxyg ne provoquant des blessures ou des accidents mortels S assurer que l air de respiration ne pr sente aucun danger e Ne pas souder dans des endroits situ s proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et for mer des gaz hautement toxiques et irritants e Ne pas souder des m taux munis d un rev tement tels que l acier galvanis plaqu en plomb ou au cadmium moins que le rev te ment n ait t enlev dans la zone de soudure que l endroit soit bien ventil et en portant un respirateur alimentation d air Les rev tements et t
43. structures m talliques au sol grillages et chafaudages dans des positions assises genoux et allong es ou quand il y a un risque important de contact accidentel avec la pi ce ou le sol Dans ces cas utiliser les appareils suivants dans l ordre de pr f rence 1 un poste souder DC semi automatique de type CV MIG MAG 2 un poste souder manuel lectrode enrob e DC 3 un poste souder OM 4429 Page 6 gt Indique des instructions sp cifiques Ce groupe de symboles veut dire Avertissement Attention DANGER DE CHOC ELECTRIQUE PIECES EN MOUVEMENT et PIECES CHAUDES Consulter les symboles et les instructions ci dessous y aff rant pour les actions n cessaires afin d viter le danger manuel AC avec tension vide r duite Dans la plupart des cas un poste courant continu de type CV est recommand Et ne pas tra vailler seul Couper l alimentation ou arr ter le moteur avant de proc der l installation la r paration ou l entretien de l appareil D verrouiller l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de s curit Installer et mettre la terre correctement cet appareil conform ment son manuel d utilisation et aux codes nationaux provinciaux et municipaux Toujours v rifier la terre du cordon d alimentation V rifier et s assurer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon es
44. 0 30 40 AC AMPERES IN 120V MODE 193 018 4 8 Optional Three Phase Generator Curves A 12 kVA kW Single Phase AC Output No Weld Load MEE power available at the single phase 120 240 volt ceptacle three phase 240 volt 140 280 terminals 135 270 130 260 125 250 120 240 115 230 110 220 105 210 100 200 95 190 90 180 AC VOLTS 100 O N O A O O O AC AMPERES B 20 kVA kW Three Phase AC Output No Weld Load 280 260 240 220 AC VOLTS 200 180 O O N O O D O O1 O O O N O AC AMPERES 197 472 197 473 OM 4429 Page 19 SECTION 5 INSTALLATION 5 1 Installing Welding Generator l JB H Always securely fasten weld ing generator onto transport a vehicle trailer comply with all DOT and other applica ble codes Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards If unit does not have re ceptacles use GFCI protected extension cord not install unit where air flow is restricted or engine may overheat gt See Section 4 2 for lifting eye rat ing gt See Section 5 3 for mounting in formation Grounding 1 Equipment Grounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Connect cable from equipment ground terminal to metal
45. 0V 2 18 CR4 6113 247 RELAY 12vdc dpdt 20a 120vac flange mtg 1 19 214928 TIMER delay on make break open 30 sec 12vdc 1 LO issus C9 087 110 CAPACITOR elctit 2404 200VDC 1 Su wau aa 177 186 2 GLANMP capacitor 1 975dla 21 L3 o EE eR 1 DUCI iw 189 701 DIODE CAPACITOR BOARD 4 527235 En coda eats 1 23 CB11 12 13 139 266 SUPPLEMENTARY PROTECTOR man reset 1P 15 250VAC 3 Optional Recommended Spare Parts To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 4429 Page 73 803 846 D Figure 13 3 Control Box Assembly CC CV Models Item Dia Part No Mkgs No Description Quantity Figure 13 3 Control Box Assembly CC CV Models Figure 13 1 Item 111 1 Fl F2 085 874 FUSE mintr cer slo blo 10A 250V 2 Ro FUR 046 432 HOLDER fuse mintr 250x 1 250 2 201 077 CONTROL 1 danse 201078 4 CONTROL BOX rh d nn sn ne Ce hu pce 1 5 CR8 197 325 RELAY 12vdc spst 70a flange mtg 1 6 090104 RELAY
46. 1 1i e 189 731 Firewall 2 2 ee e dee maine a A 1 res ete 173 352 Extrusion Rubber Clamp Bulb Order By Ft 3ft TTA uses iss Figure 13 7 Main Rectifier Assembly 1 115 207 397 Module Field Current Regulator 1 TIED tossed sa C 193 453 Bracket Mtg Box Fer 1 191 448 Top Cover Front Upright 1 182 199 305 Cover Front Upright Ss 1 Not Applicable LOO ae Le LL Mal apo ooo lie 1 202 637 Upright Front SS 1 120 same 233 953 Label Warning General Precautionary Csa 1 T2T Figures13 4 13 5 Panel Front W Components 1 XQ 173 216 Label Ce European Community Mark Export Models Only 1 202 130 Xfmr Current Sensing 1 4429 70 Item Dia Part No Mkgs No Description Quantity Figure 13 1 Main Assembly Continued E uo BH 212944 Label Weld Control Arc Condition Information Label 1 Lo CR 233 088
47. 136 CLAMP capacitor 1 375dia 1 20 01 1 189 701 DIODE CAPACITOR BOARD 1 21 TDi 214928 TIMER delay on make break open 30 sec 12vdC 1 22 CB11 12 13 139 266 SUPPLEMENTARY PROTECTOR man reset 1P 15A 250VAC 3 Optional Recommended Spare Parts To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 4429 Page 75 222 774 E ANA 2 y Hardware is common and not available unless listed _ w y EE 4 Panel Front w Components CC Models Figure 13 Part No Quantity Description Dia Mkgs Item No Figure 13 4 Panel Front w Components CC Models Figure 13 1 Item 121 PLATE SCREENED ident control rating when ordering this item the nameplate should also be ordered 215 070 NAMEPLATE screened order by model and serial number OM 4429 Page 76 Item Dia Part No Mkgs No Description Quantity Figure 13 4 Panel Front w Components CC Models Continued dat 215 014 PANEL engine weld control 1 217 883 PANEL engine weld control
48. 2 OPTIONS 7 REV PDLARITY POLARITY WITH THE POLARITY AR RC1 240V l TO THE POLARITY ee SWITCH RATHER OUTPUT Sra L Pi lil STUDS THE DUTPUT STUDS ARE LABELED 22 plete ELECTRODE AND WORK LEADS 17 amp 37 ARE pe HOOKED DIRECT FROM THE RANGE SWITCH TO IEISIAIB THE POLARITY SWITCH R S Il POSITIVE J ELECTRODE WORK E crc J WELD METERS OPTIONAL Ten x WITH THE POLARITY SWITCH OPTION 19 amp 30 GO TO THE POLARITY RATH THE OUTPUT STUDS THE OUTPUT STUDS ARE LABELED ELECTRODE AND WORK _ __ POSITIVE 27 ELECTRODE RECTIFIER PROTECTION 28 WORK MACHINE WIRE NUMBERS 10 39 z WELD SECONDARY gt gt 151 40 79 ENGINE CONTROLS 42 CHASSIS 80 99 AUX SECONDARY 100 149 EXCITER CONTROL gt SHIELD AUTO IDLE TERMINAL OPTIONIAL J pollent e ees nt J 725 61 15 12 42 DONNE S3 67 57 67 61 61 1 32 34 6 1 8 1 JE el Le 4 3 4 3 e e GAUGE OPTONAL FUEL L SENDER 42 42 2 2 223 525 B OM 4429 Page 53 WARNING e Do not touch live electrical parts 9 e Disconnect inpu
49. 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 4 0 120 2 ea 2 0 2 ea 2 0 250 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2x70 2x70 2 ea 2 0 2ea 3 0 2 ea 3 0 300 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2x70 2x95 2x95 2 ea 2 0 2ea 3 0 2ea 3 0 2 ea 4 0 350 1 0 60 2 0 70 3 0 95 4 0 120 2x70 2x95 2x95 2 120 2 ea 2 0 2ea 3 0 2ea 4 0 2 ea 4 0 400 1 0 60 2 0 70 3 0 95 4 0 120 2x70 2x95 2x120 2x120 2 ea 2 0 2 ea 3 0 2 ea 4 0 3 ea 3 0 3 ea 3 0 500 2 0 70 3 0 95 4 0 120 2x70 2x95 2x120 3x95 3x95 Chart is a general guideline and may not suit all applications If cables overheat use next size larger cable Weld cable size AWG is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere mm for metric use S 0007 F For distances longer than those shown in this guide call a factory applications representative at 920 735 4505 5 10 Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models 1 Remote Adjust Receptacle RC13 Connect optional remote control to RC13 see Section 6 3 Ref 154 862 A 048 720 K 803 602 OM 4429 Page 27 5 11 Connecting To Remote 14 Receptacle RC14 On CC CV Models REMOTE 4 Socket Information A 24 volts a
50. 36 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 web site www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 Keep cables close together by twisting or taping them or using a cable cover 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 Keep welding power source and cables as far away from operator as practical 5 Connect work clamp to workpiece as close to the weld as possible About Implanted Medical Devices Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding spot welding gouging plasma arc cutting or induction heating operations If cleared by your doctor then following the above procedures is recom mended OM 4429 Page 5 SECTION 2 CONSIGNES S CURIT LIRE AVANT UTILISATION rom_2007 04fre Se pro
51. 429 Page 83 1 ART u pa 150316 193234 TP NES 021467 shat SOO 011609 D1 C1 189701 abo SI 193183 196602 ta 196603 TH t kusa EU 141450 uka sap mu eee 093995 ER 211292 211293 abo RENS rS 201109 147632 GFCI1 151981 CB2 093996 bound 201053 GFCI1 151981 139266 CB2 093996 OM 4429 Page 84 215207 PLG6 114063 Riu 193184 A 147992 PLGS 158465 es 187654 DR ts 196602 ECT aa 215377 CB11 12 13 139266 035704 aie 148850 RC4 047483 158466 135133 Harness Unit Weld Control CV Includes Conn Rect Univ 084 4p S 1row Plug Cable Conn Rect Cinch 30 Pin Conn Rect Univ 039 10p S 2row Plug Cable Lkg Conn Rect Univ 084 12p S 3row Plug Cable Lkg Seal Wire Univ 12p S 3row Plug Cavity 18 30 Position Cinch Connector Harness Control Box CC CV Includes Supplementary Protector Man Reset 1p 15a 250 Rectifier Integ Bridge 40 Amp 800v Socket Relay 5 Pin Conn Rect Univ 084 15p S 3row Rcpt Cable Panel Conn Rect Univ 084 12p S Rept Cable Panel Conn Rect Univ 084 9p S 3row Rept Cable Panel Conn Rect Univ 039 5 3row Plug Cable Lkg Switch Rotary 6 Posn Gold Contacts S
52. 5 4125 European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 www MillerWelds com Miller
53. 50316 092670 158466 135133 Description Wiring Harnesses Harness Engine Includes Diode Capacitor Board Circuit Breaker Auto Reset 12vdc 40 Amp Nut 010 32 31hex 13h Stl Pld Sem Cone Wshr 38d Relay Encl 12vdc Spst 30a 15vdc 5pin Flange Mtg Harness Governor Control 404 22t Relay Encl 12vdc Spst 70a 4 Flange Mig Core Toroidal 187 Id X 375 Od X 125 Thk Harness Range Switch Includes Conn Rect Univ 084 4p S 1row Rcpt Cable Panel Lkg Service Kit Harness Wrg Brushholder Includes Conn Rect Univ 084 9p S 3row Plug Cable Lkg Service Kit Seal Wire Univ 9p S 3row Harness Unit Weld Control CC Includes Conn Rect Univ 084 12p S 3row Plug Cable Lkg Seal Wire Univ 12p S 3row Conn Rect Univ 084 4p S 1row Plug Cable Lkg Harness Control Box CC Includes Rectifier Integ Bridge 40 Amp 800v Diode Capacitor Board Conn Rect Univ 084 15p S 3row Rept Cable Panel Supplementary Protector Man Reset 1p 15 250vac Relay Ocv Control Socket Relay 5 Pin Switch Tgl 3pdt 15a 125vac On none on Spd Term owitch Tgl Spdt 15a 125vac On none on Spd Term Chr Conn Pack 4p 1row Female Conn Pack Terminal Position Assurance Lock owitch Tgl Spst 3a 250v Off none On Spd Term Conn Rect Univ 039 5 3row Plug Cable Lkg Conn Rect Univ 084 3p S 1row Plug Cable Lkg Conn Rect Univ 084 12p S 3row Rept Cable Panel Conn Rect Univ 084 9p S Rept Cable Panel Quantity OM 4
54. 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 2 voltage drop Cord Lengths for 240 Volt Loads If unit does not have GFCI receptacles use GFCI protected extension cord Maximum Allowable Cord Length in ft m for Conductor Size AWG Current Load Watts 4 6 8 10 12 14 Amperes 5 1200 700 213 450 137 225 84 200 61 7 1680 800 244 500 152 300 91 200 61 125 38 10 2400 800 244 550 168 350 107 225 69 125 38 100 31 15 3600 600 183 350 107 225 69 150 46 75 23 60 18 20 4800 450 137 275 84 175 53 100 31 60 18 25 6000 350 107 225 69 125 38 75 23 30 7000 300 91 175 53 100 31 75 23 35 8400 250 76 150 46 100 31 40 9600 225 69 125 38 75 23 45 10 800 200 61 125 38 50 12 000 175 53 100 31 Conductor size is based on maximum 2 voltage drop OM 4429 Page 65 SECTION 13 PARTS LIST Hardware is and notavallable unless listed 122 O 121 Fig 13 4 OR 13 5 Figure 13 1 Main Assembly OM 4429 Page 66 803 844 B OM 4429 Page 67 Item Dia Part No Mkgs No Description Quantity Figure 13 1 Main Assembly e 189 824 Panel Gen Lh 1 199 294 Panel GenLh SS 1 TE 200 865 Label CE Sound Power Lev
55. 7 and to the isolated neutral terminal and grounding termi nal as necessary Supplementary protector protects single phase receptacle and the load wires from overload If CB7 opens all gener ator output stops and the recep tacle does not work Reinstall generator power panel Ref 197 399 802 332 E 803 655 OM 4429 Page 39 8 3 Optional Generator Power Receptacles 1 120V 20 A AC GFCI Receptacle GFCI1 gt 2 240V 16A AC European European Receptacle Receptacle RC1 3 240V 15A AC Australian Receptacle RC1 4 240 V 15 A AC South African Receptacle RC1 Receptacles supply 60 Hz single phase power at weld power speed If a ground fault is detected the GFCI Reset button pops out and the receptacle does not work Check for faulty tools plugged in receptacle Press button to reset GFCI1 120V 20 15 60 240V 15 F At least once a month run en gine at weld power speed and press test button to verify GFCI is working properly Australian Receptacle 3 5 Supplementary Protector CB2 6 Supplementary Protector CB3 CB2 protects from overload If CB2 opens GFCl1 does not work Press button to reset CB3 protects RC1 from overload If CB3 opens RC1 does not work Press button to reset gt a supplementary protector continues to open contact Factory Authorized Service 120V 20A 1 V60HzZ 240 15 Agent Generator power i
56. 730 ST 800 577 2 3 Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards Also see AWS Safety amp Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Generators Equipment Grounding Terminal On Front Panel Grounding Cable Not Supplied Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insulated copper wire gt Electrically bond generator frame to vehicle frame by met al to metal contact Bed liners shipping skids and some running gear insu late the welding generator from the vehicle frame Al ways connect a ground wire from the generator equip ment grounding terminal to bare metal on the vehicle frame as shown If unit does not have re ceptacles use tected extension cord S 0854 OM 4429 Page 59 12 3 Grounding When Supplying Building Systems 1 Equipment Grounding Terminal 2 Grounding Cable Use 10 AWG or larger insulated copper wire 3 Ground Device Use ground device as stated in electrical codes Ground generator to system earth ground if supplying power to a premises home shop farm wiring system Also see AWS Safety amp Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Generators ST 800 576 B 1 Resistive Load A light bulb is a r
57. AL or DIRT can injure eyes e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet OM 4429 Page 1 FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instructions for metals consumables coatings cleaners and degreasers e Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe e Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases e Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and while wearing an air supplied respirator The coatings a
58. FLYING SPARKS can cause injury e Wear a face shield to protect eyes and face e Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face hand and body protection e Sparks can cause fires keep flammables away MOVING PARTS can cause injury e Keep away from moving parts e Keep away from pinch points such as drive rolls OM 4429 Page 4 WELDING WIRE can cause injury e Do not press gun trigger until instructed to do So e Do not point gun toward any part of the body other people or any metal when threading welding wire OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again Do not block or filter airflow to unit STATIC ESD can damage PC boards Put on grounded wrist strap BEFORE handling boards or parts Use proper static proof bags and boxes to store move or ship PC boards TILTING OF TRAILER can cause injury e Use tongue jack or blocks to support weight 0B e Properly install welding generator onto trailer according to instructions supplied with trailer READ INSTRUCTIONS e Read Owner s Manual before using or servic ing unit Use only genuine replacement parts from the manufacturer Perform engine and air compressor mainte nance and service according to this manual and the engine air compressor if applicable manuals
59. ICE Do not idle engine longer than necessary Piston rings seat faster if engine runs at weld power rpm and the welding generator is kept loaded during run in 2 Engine Exhaust Pipe Wetstacking is unburned fuel and oil in the exhaust pipe and occurs during run in if the engine is run too long at light load or idle rpm If exhaust pipe is coated with a wet black tar like substance dry the engine using one of the following run in procedures See the engine manual for addition al engine run in information OM 4429 Page 56 11 2 Run In Procedure Using Load Bank Stop engine Do not touch hot exhaust pipe engine parts or load bank grid Keep exhaust and pipe away from flammables NOTICE Do not perform run in procedure at less than 20 volts weld output and do not exceed duty cycle or equip ment damage may occur 1 LoadBank Turn all load bank switches Off If needed connect load bank to 115 volts ac wall receptacle or genera tor auxiliary power receptacle 2 Welding Generator Place A V range switch in maxi mum position A V control in mini mum position and Output Selector switch if present in either DC position 3 Weld Cables Connect load bank to generator weld output terminals using proper size weld cables with correct connectors Observe correct polarity D cT Start engine and run for several minutes Set load bank switches and then adjust generator A V control so
60. MBLY protection 1 INSULATOR heat sink 8 HEAT SINK rectifl er uu su tai tre boe e e 2 DIODE 275A 300V SP x leben dci tse doe aha ets 3 DIODE rect 275A 300V RP 3 performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 4429 Page 82 Some wiring harness components switches relays circuit breakers are also referenced elsewhere in this parts list Purchase components sepa rately or as part of the associated wiring harness Item No Dia Mkgs D10 C10 CB10 190374 1567234 CR7 Part No 221374 189701 090104 219886 Conn Deutsch Dtm 12p 2row Plug a Conn Deutsch Dtm Wedge Lock 12 Position Conn Deutsch 2p 1row Female Plug Conn Deutsch Wedge Lock 2 Position Core Toroidal 187 Id X 375 Od X 125 Thk Conn Deutsch Dtm 12p 2row Plug b Conn Deutsch Dtm Wedge Lock 12 Position Conn Deutsch 2p 1row Female Plug Conn Deutsch Wedge Lock 2 Position 197325 204702 192558 148439 190259 168071 187651 215013 158465 187654 114063 215054 035704 189701 047483 139266 188636 148850 011622 011609 211292 211293 021467 1
61. N ST POLARITY AC REV POLARITY POLARITY SWITCH OPTIONAL WITH THE POLARITY SWITCH OPTION 77 37 THE OUTPUT STUDS THE OUTPUT STUDS ARE LABELED ELECTRODE AND WORK LEADS 17 amp 37 ARE HOOKED DIRECT FROM THE RANGE SWITCH TO THE POLARITY SWITCH POSITIVE ELECTRODE NEGATIVE WORK POLARITY SWITCH OPTIONAL WITH THE POLARITY SWITCH OPTION 0 SWITCH RATHER THAN THE OUTPUT STUDS THE OUTPUT STUDS ARE LABELED 79 ELECTRODE WORK STR 512 O 1 L __ T 27 ELECTRODE Wis 1 5 S12 NEGATIVE us 270 WORK JO MACHINE WIRE NUMBERS 10 59 WELD SECONDARY 40 79 ENGINE CONTROLS EXCEPT 42 CHASSIS 80 99 AUX SECONDARY 100 149 EXCITER CONTROL 37 23 16 24 26 725 25 126 9 10 48 68 x x x x x 11 12 84 98 X X CONTACT CLOSED 223 524 B OM 4429 Page 55 SECTION 11 RUN IN PROCEDURE run_in1 2007 04 11 1 Wetstacking NOTICE Do not perform run in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur 1 Welding Generator Run diesel engines near rated volt age and current during run in period to properly seat piston rings and prevent wetstacking See name plate rating label or specifications section in this manual to find rated voltage and current NOT
62. NLY if required for the welding process If AC output is re quired use remote output control if present on unit NOTICE Do not switch under load Use Polarity AC switch to select AC or DC weld output and DC weld output polarity For Direct Current Electrode Negative DCEN turn switch to Negative position For Direct Current Electrode Positive DCEP turn switch to Positive position For weld pro cesses that require alternating current AC use AC position Weld Meters 14 AC DC Voltmeter Optional Voltmeter displays voltage at the weld output terminals but not necessarily the welding arc due to resistance of cable and connections 15 AC DC Ammeter Optional Ammeter displays amperage output of the unit OM 4429 Page 35 7 3 Process Contactor Switch On CC CV Models WIRE Voltage Sensing W Feeder CV de HF CV Feeder is Required Using 2 4 2 Or Remote Scratch Start se 2 REMOTE ON OFF SWITCH REQUIRED Process Contactor Switch Weld output terminals ener gized when Process Contactor switch is in an Weld Terminals Always On position and the en gine is running DC voltage is still present at the weld terminals when Process Contactor switch is in the Re mote On Off Switch Required Stick position and the engine is running Use switch to select weld process and weld output on off control see table be low and Section 7 4 Place switch in R
63. QA be cleaned but the dirt holding capac D of the filter is reduced with each Ay cleaning The chance of dirt reaching the clean side of the filter while clean ing and the possibility of filter damage makes cleaning a risk Consider the risk of unwarrantable equipment 5 damage when determining whether to clean or replace the primary ele ment If you decide to clean the primary ele ment we strongly recommend instal ling an optional safety element to pro vide additional engine protection Never clean a safety element Re place the safety element after servic ing the primary element three times Clean or replace primary element if dirty see note above before cleaning Re place primary element if damaged Re place primary element yearly or after six cleanings 1 Housin Keep nozzle u g 2 in 51 mm in 2 Safety Element Optional Cy lt 3 Primary Element DES 525422 52525252 525252521 4 Dust 52525252 52525252 Soseses 292222294 22 8595 5555221 5 Dust Eject 525252521 525252507 ust Ejector 52525252 52525252 QU X LR lt To clean air filter XX e A Q P X Wipe off housing Remove and dump out dust Remove element s Wipe dust from inside cap and housing with damp cloth Reinstall safety element Blow Inspect if present Reinstall cap NOTICE Do not clean housing with air h
64. ach range for TIG welding Use the highest range for MIG welding and for cutting and gouging CAC A For most welding applications use lowest amperage range possible to help prevent arc outages 10 Voltage AmperageAdjust Control With Process Contactor switch in any Stick or TIG setting use control to adjust amperage within range selected by Ampere Range switch With Process Contactor switch in any MIG position use control to adjust voltage With Voltage Amperage Adjust Switch in Re mote position control limits the remote am perage in TIG mode but has no effect in Stick and MIG modes Weld output would be about 250 A DC with controls set as shown 5096 of 110 to 390 A The numbers around the control reference only and do not represent an actual percentage value 11 Voltage Amperage Adjust Switch And Hemote 14 Receptacle Use switch to select front panel or remote voltage amperage control For remote con trol place switch in Remote position and con nect remote control to Remote 14 receptacle RC14 see Sections 5 11 and 7 4 12 Polarity Switch Optional NOTICE Do not switch under load Use Polarity switch to change weld output Select either DC Electrode Positive DCEP or DC Electrode Negative DCEN 13 Polarity AC Switch Optional A Electric shock can kill A Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output O
65. ade installation and operation quick Ios and easy With Miller you can count on years 00012000 of reliable service with proper maintenance And if for some reason the unit needs repair QUALITY SYSTEM there s a Troubleshooting section that will help you figure out what the problem is The Miller is the first welding parts list will then help you to decide the equipment manufacturer in exact part you may need to fix the problem the ISO 9001 2000 Quality Warranty and service information for your System Standard particular model are also provided Miller Electric manufactures full 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 Miller Mil_Thank 4 05 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ USING 1 Ts uru oe reek kan D AUD deen old ida A 1 125 Ate Welding Hazarde nux deed eu eM 1 1522 ENQINGHAZONS LR Gap kaha 3 1 4 Compressed Air 1 3 1 5 Additional Symbols F
66. afe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com National Electrical Code NFPA Standard 70 de National Fire Protec tion Association P O Box 9101 Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de Compressed Gas Association 4221 Walney Road 5th Floor Chan VA 20151 t l phone 703 788 2700 site Internet www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 de Canadian Standards Association 5060 Mississauga Ontario Canada 2 8 Information EMF Consid rations sur le soudage et les effets de basse fr quence et des champs magn tiques et lectriques Le courant de soudage pendant son passage dans les c bles de sou causera des champs lectromagn tiques a eu et a encore un certain souci propos de tels champs Cependant apr s avoir exa min plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban bleu du National Research Council a conclu L accumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lectriques haute fr quence repr sente un risque la sant humaine
67. amperes S 0624 12 9 How Much Power Can Generator Supply 1 Limit Load To 90 Of Generator Output Always start non resistive motor loads in order from largest to small est and add resistive loads last 2 5 Second Rule If motor does not start within 5 seconds turn off power to prevent motor damage Motor requires more power than generator can supply Ref ST 800 396 A S 0625 OM 4429 Page 63 12 10 Typical Connections To Supply Standby Power A Have only qualified persons perform these connections according to all applicable codes and safety practices Utility Di Fused Welding Properly install and ground Electrical Transfer Switch Caen Generator this equipment according to Output its Owner s Manual and na tional state and local codes Service If Required gt Customer supplied equipment is required if generator will sup ply standby power during emergencies or power out ages Essential 1 Utility Electrical Service Loads 2 Transfer Switch Double Throw Switch transfers the electrical load from electric utility service to the generator Transfer load back to electric utility when service is re stored Install correct switch customer supplied Switch rating must be same as or greater than the branch overcurrent protection 3 Fused Disconnect Switch Install correct switch customer supplied if required by electrical code 4 Welding Generator Output Generato
68. arc If this is not possible tightly cover them with approved covers Do not weld where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side OM 4429 Page 2 Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire haz ards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap Remove any combustibles such as a butane lighter or matches from your person before doing any welding After completion of work inspect area to ensure it is free of sparks glowing embers and flames Use only correct fuses or circuit breakers Do not over
69. attery circuit If CB10 opens the engine will not crank CB10 automatically resets when the fault is corrected CB11 protects the weld control circuit On CC models if CB11 opens the max OCV circuit does not work and open circuit voltage is variable at all times see max OCV note under Weld Controls in Section 6 2 If CB11 opens on CV models weld output stops generator power is still available CB12 protects the field flashing circuit If CB12 opens the generator may not ex cite at start up and weld and generator power output may not be available CB13 protects the engine control circuit If CB13 opens the engine does not crank Press button to reset 803 605 OM 4429 Page 46 9 8 Troubleshooting A Welding CC Models Trouble Remedy No weld output generator power output okay at ac receptacles Check position of Ampere Range switch Check position of optional Polarity switch Place Amperage Adjust switch in Panel position or place switch in Remote position and connect remote controlto Remote Amperage Adjust receptacle RC13 see Sections 5 10 and 6 1 Check and secure connections to Remote Amperage Adjust receptacle RC13 see Section 5 10 Check fuse F2 and replace if open see Section 9 7 Have Factory Authorized Service Agent check inte grated rectifier SR2 and the rotor Have Factory Authorized Service Agent check brushes and slip rings and weld excitation
70. board PC1 and PC1 voltage feedback circuit Erratic output at optional three phase generator receptacle RC5 Have Factory Authorized Service Agent check brushes and slip rings and field current regulator board Engine Trouble Remedy Engine will not crank Check battery and replace if necessary Check battery connections and tighten if necessary Circuit breaker CB10 may be open CB10 automatically resets when fault is corrected see Section 9 7 Have Factory Authorized Service Agent check engine wiring harness and components OM 4429 Page 49 Trouble Remedy Check engine wiring harness plug connections Have Factory Authorized Service Agent check control relay CR1 diode capacitor board D8 C8 and En gine Control switch S1 Engine cranks but does not start Check fuel level Check battery and replace if necessary Check engine charging system according to engine manual Have Factory Authorized Service Agent check engine wiring harness time delay relay TD1 control relay CR5 fuel pump fuel solenoid FS1 and diode capacitor board D10 C10 Air in fuel system See engine manual Engine starts but stops after 30 seconds Check oil and coolant levels Automatic shutdown system stops engine if oil pressure is too low or coolant temperatureis too high see Section 5 7 Automatic shutdown system is inhibited for 30 seconds afte
71. c Protected by sup plementary protector CB5 24 VOLTS OUTPUT B Contact closure to A completes CONTACTOR 24 volt ac contactor control circuit C Output to remote control 10 volts dc in MIG or Stick mode to 10 volts dc in TIG mode New LDR 14 long REMOTE D Remote control circuit common distance remote OUTPUT d CONTROL E DC input command signal 0 to 10 volts from min to max of remote control with Voltage Amperage Adjust control at max 115 volts 10 amperes 60 Hz Protected by supplementary 115 VOLTS AC protector CB6 OUTPUT CONTACTOR Contact closure to completes J 115 volt ac contactor control circuit GND K Chassis common Ref 803 602 NEUTRAL G Circuit common for 24 and 115 volt ac circuit The remaining sockets are not used Notes YE x HOBARI INSTITUT OF WELDING TECHNOLOGY Start Your Professional yy Trade Square East Troy Ohio 45373 Over 80 000 trained Welding Career Now 1 800 332 9448 www welding org since 1930 OM 4429 Page 28 Notes OM 4429 Page 29 SECTION 6 OPERATING WELDING GENERATOR CC MODELS 6 1 Front Panel Controls For CC Models See Section 6 2 215 663 803 602 4429 Page 30 6 2 Description Of Front Panel Controls For CC Models See Section 6 1 Engine Starting Controls 1 Starting Aid Switch Use switch to energize starting aid for cold weather starting see starting instructions fol lowing 2 Engine Control Switch U
72. c ble de retour de facon obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s possible de la soudure Isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique Une tension DC importante subsiste l int rieur des onduleurs apres avoir coup l alimentation Couper l alimentation du poste et d charger les condensateurs d entr e comme indiqu dans la Section Maintenance avant de toucher des composants DES PIECES CHAUDES peuvent provoquer des br lures graves e Ne pas toucher mains nues les parties chau des e Pr voir une p riode de refroidissement avant de travailler l quipement e Ne pas toucher aux pi ces chaudes utiliser les outils d s et porter des gants de soudage et des v tements pais pour viter les br lures DES 5 DE METAL ou DES SA E LETES peuvent provoquer des bles sures dans les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la p riode de refroidissement des soudures elles risquent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereux pour votre
73. cations Leave filler neck empty to allow room for ex pansion E N Do not run out of fuel or air will enter fuel sys tem and cause starting problems See en gine manual to bleed air from fuel system Oil After fueling check oil with unit on level sur face If oil is not up to full mark on dipstick add oil see maintenance label Coolant Check coolant level in radiator before start ing unit the first time If necessary add cool ant to radiator until coolant level is at bottom of filler neck Check coolant level in recovery tank daily If necessary add coolant to recovery tank until coolant level is between Cold Full and Hot Full levels If recovery tank coolant level was low also check coolant level in radiator Add coolant if level is below bottom of radia tor filler neck Unit is shipped with an engine coolant mix ture of water and ethylene glycol base anti freeze rated to 34 F 37 Add anti Check radiator coolant level when fluid is low in recovery tank Capacity 404 22 Engine 9 5 qt 9 01L Hot Full Cold Full 803 603 freeze to mixture if using the unit in tempera tures below 34 F 37 C Keep radiator and air intake clean and free of dirt NOTICE Incorrect engine temperature can damage engine Do not run engine with out a properly working thermostat and ra diator cap gt To improve cold weather starting
74. circuit No weld output or generator power out put at ac receptacles Disconnect equipment from generator power receptacles during start up Check fuses F1 and F2 and replace if open see Section 9 7 Have Factory Authorized Service Agent check integrated rectifier SR1 capacitor C9 integrated rectifier SR2 and the rotor Reset supplementary protector CB12 Have Factory Authorized Service Agent check diode D1 see Sec tion 9 7 Have Factory Authorized Service Agent check brushes and slip rings and field excitation circuit Erratic weld output Check and tighten connections inside and outside unit Be sure connection to work piece is clean and tight Use dry properly stored electrodes Remove excessive coils from weld cables Have Factory Authorized Service Agent check brushes and slip rings High weld output Check position of Ampere Range switch and Voltage Amperage Adjust control Check engine speed and have Factory Authorized Service Agent adjust if necessary Have Factory Authorized Service Agent check OCV control circuit Low weld output Check engine speed and have Factory Authorized Service Agent adjust if necessary Check fuses F1 and F2 and replace if open see Section 9 7 Have Factory Authorized Service Agent check integrated rectifier SR1 capacitor C9 integrated rectifier SR2 and the rotor Electrode sticks to the workpiece more frequently dur
75. d Slffmg Tap rw 8 ace PR ufa 197 2877 FLYWHEEL OCCORRE EN EARS NOR 1 221 916 SENSOR Speed Magnetic 5 8 18 1 Mao HERE ES 197 4667 2 ADAPTER ENGINE 42 dos dto hated Ew kid nude se is a Q 1 TEC TERN 083 883 WASHER Lock 402idx0 7090dx 087t Stl SplitiOmm 4 m 049 026 SCREW 10 1 5 25 Hex Hd pln 8 8 Pin 4 Tm T a a a 191 579 COVER starter hole Continental 2 195 560 GUARD starter hole deutz 912 202 c ii ue 083 883 WASHER Lock 402idx0 7090dx 087t Stl SplitiOmm 6 172 555 SCREW 10 1 5 50hexhd pln 8 8pld 6 NE TT ol eae 602 159 SCREW 312 18x 75 hexwhd 66d stl slffmg tap rw 6 iau Leu Eee ufa 601 961 SCREW 312 18 x 2 25hexhd pln gr 5pld 4 MNT TH T 602 211 WASHER lock 318 ID 0 586 6 dote Lenta n 139 341 uui aou rte me tet tede m e neis 4 190 823 BRUSFL CONIACL 5 ette rm rr EE 3 e oo 2060409 CLIP SOWING 5 die 3 rise ose 189 142 BRUSHHOLDER ASSEMBLY gen 1 Oa ewes 602 242 WASHER flat 3751D
76. ders Inverter Power Sources Unless Otherwise Stated Water Coolant Systems Integrated Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified Motor Driven Guns w exception of Spoolmate Spoolguns Positioners and Controllers Automatic Motion Devices RFCS Foot Controls nduction Heating Power Sources Coolers and Electronic Controls Recorders Water Coolant Systems Non Integrated Flowgauge and Flowmeter Regulators No Labor Units Grids Spot Welders Load Banks Arc Stud Power Sources amp Arc Stud Guns Racks Running Gear Trailers Plasma Cutting Torches except APT amp SAF Models Field Options NOTE Field options are covered under True Blue for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater Bernard Branded Mig Guns No Labor Weldcraft Branded TIG Torches No Labor Subarc Wire Drive Assemblies 4 6 Months Batteries 5 90 Days Parts Guns TIG Torches Subarc SAW Guns Induction Heating Coils and Blankets Cables and Non Electronic Controls amp SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Millers True Blue Limited Warranty shall not apply
77. e dig circuits are disabled and OCV changes when the control is adjusted 11 Amperage Adjust Switch And Remote Amperage Adjust Receptacle Connect optional remote control to RC13 See Section 5 10 Use switch to select front panel or remote amperage control For re mote control place switch in Remote position and connect remote control to Remote perage Adjust receptacle RC13 see Sec tions 5 10 and 6 3 12 Polarity Switch Optional NOTICE Do not switch under load Use switch to change weld output Select ei ther DC Electrode Positive DCEP or DC Electrode Negative DCEN Weld Meters 13 AC DC Voltmeter Optional Voltmeter displays voltage at the weld output terminals but not necessarily the welding arc due to resistance of cable and connections 14 AC DC Ammeter Optional Ammeter displays amperage output of the unit OM 4429 Page 31 6 3 Remote Amperage Control On CC Models Optional 1 Remote Amperage Adjust Receptacle RC13 Connect optional remote control to RC13 see Section 5 10 In Example Range 115 to 330 A DC Percentage Of Range 50 Max About 240 A DC 5096 of 150 to 330 Max 240 A DC rm Min 84 A DC Set Range a Set Control Adjust Optional Remote Control Ref 154 862 A Ref 181 711 A 803 602 gt Set weld controls as shown to achieve softer or stiffer arc condi tions for different applications SOFTER ARC A softer arc condition can be ach
78. e is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomatic DC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards Properly install and ground this equipment according to its Owners Manual and national state and local codes 5 Indicates special instructions TN zf This group of symbols means Warning Watch Out ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult sym bols and related instructions below for necessary actions to avoid the hazards Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet When making input connections attach proper grounding conduc tor first double check connections Keep cords dry free of oil and grease and protected from hot metal and sparks Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn o
79. e limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province miller_warr 2007 01 Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks To locate a Distributor or Service Agency visit www millerwelds com or call 1 800 4 A Miller Contact the Delivering Carrier to File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA C 2007 Miller Electric Mfg Co 2007 01 Miller Electric Mfg Co An Illinois Tool Works Company 1635 West Spencer Street Appleton WI 54914 USA International Headquarters USA USA Phone 920 735 4505 Auto Attended USA amp Canada FAX 920 735 4134 International FAX 920 73
80. e volt ampere curves show the A Stick Mode minimum and maximum voltage and amperage output capabilities of the welding generator Curves of all 100 Ranges other settings fall between the curves shown 275 Max 150 525 75 110 390 80 240 50 125 e 0 100 200 300 400 500 600 700 3800 900 1000 DC AMPERES B MIG Mode 100 80 2 60 ri O gt O 40 20 0 0 100 200 300 400 500 600 700 800 900 1000 DC 5 Mode Ranges 50 440 35 320 25 215 15 115 VOLTS 0 100 200 300 400 500 DC AMPERES 217 811 203 415 217 810 OM 4429 Page 17 4 5 Fuel Consumption The curve shows typical fuel use under weld or power loads as I lt O 2 D 0 50 100 150 200 250 300 350 400 450 500 550 600 WELD AMPERES 100 DUTY CYCLE 215 082 4 6 Duty Cycle And Overheating t 100 Duty Cycle At 400 Amperes Duty Cycle is percentage of 10 min utes that unit can weld at rated load without overheating NOTICE Exceeding duty cycle can damage unit and void warranty Un Qc gt lt DUTY CYCLE 202 356 OM 4429 Page 18 4 7 AC Generator Power Curve 150 300 The ac power curve shows the gen erator power in amperes available at the 120 and 240 volt receptacles 125 250 100 200 75 150 gt lt 50 100 50 5 10 15 20 AC AMPERES IN 240V MODE 2
81. eins tall vent caps 8 Battery Charger A Read and follow all instruc tions supplied with battery charger Charge battery for 12 minutes at 30 amperes or 30 minutes at 5 am peres Disconnect charging cables and install battery When electrolyte is low add only distilled water to cells to maintain proper level 5 A For 30 Minutes OR S Tools Needed 30 A For 12 Minutes amp p drybatt1 6 05 S 0886 Reinstall cover after connecting battery Tools Needed S 1 21 Ref 215 158 803 605 0756 OM 4429 Page 24 5 7 Engine Prestart Checks Diesel gt Check all engine fluids daily Engine must be cold and on a level surface Unit is shipped with 20W break in oil Automatic shutdown system stops engine if oil pressure is too low coolant temperature is too high or engine overspeeds This unit has a low oil pressure shut down switch However some condi tions may cause engine damage before the engine shuts down Check oil level often and do not use the oil pressure shutdown system to monitor oil level Follow run in procedure in engine manual If unburned fuel and oil collect in exhaust pipe during run in see Section 11 Fuel NOTICE Do not use gasoline Gasoline will damage engine The unit is shipped with enough fuel to pre vent air from entering fuel system Add fresh diesel fuel before starting see engine main tenance label for fuel specifi
82. el 98db Export Models Only 1 189 828 Panel Engine Side 1 ear OF nd Putte 199 301 Panel Engine Side 1 Z 251 45 61909395 HeacloL AC Cue zu AK ORS AR ek ORS Quinua ass 1 21 6 201 520 Reactor Ac Environmental 1 iu 206 352 Brace Front To Center Upright 2 CN 1T 038 621 Block Term 30a 4 Frict Term 51 1 page tun duce 038 620 Link Jumper Term 30a 2 MON a LE 081 499 Bracket Mtg Strip Terminal 1 203 260 Label Caution Do Not Use Ether 1 8 584 585 035 704 Rectifier Integ Bridge 40 Amp 800v 2 9 045061 Circuit Breaker Auto Reset 24vdc 7 1 x dee T1 201613 Transformer W Bracket 1 SEL POE T1 205636 Transformer W Bracket Environmental Coating 1 AUNT Rr ER 201 697 Pan Reactor And Rectifier 1 iu dot 173 352 Extrusion Rubber Clamp Bulb Order By Ft
83. emote On Off Switch Required positions to turn weld output on and off with a device connected to the remote 14 receptacle Place switch in Weld Terminals Always On positions for weld output to be on whenever the engine is running Use Stick position for air carbon arc CAC A cutting and gouging When switch is in a Stick position the arc drive dig circuit provides addition al amperage during low voltage short arc length conditions to prevent stick ing electrodes The arc drive dig circuit is disabled when switch is in MIG or TIG positions Place switch in Weld Terminals Al ways On Stick position when us ing optional three phase generator see Section 8 2 The engine auto idle option does not work in the Remote On Off Switch Required TIG mode Process Contactor Switch Settings Switch Setting Process Output On Off Control Engine Auto Idle Optional Remote On Off Switch Re GTAW With Unit Pulsing 2 Device Or Remote Control At Remote 14 Receptacle Not Active Stick SMAW With Remote On Off At Remote 14 Receptacle Active Remote On Off Switch Required CV Feeder MIG GMAW At Remote 14 Receptacle Active Using Remote x None MIG GMAW Electrode Hot Active Stick SMAW LES Mee d Carbon Arc CAC A Cutting Electrode Hot Active And Gouging TIG Scratch Start GTAW Electrode Hot Active 4429 Page 36 7 4 Remote Vol
84. es lectriques peut provoquer une lectrocution ou des blessures graves L lectrode et le circuit de soudage sont sous tension d s que l appareil est sur ON Le circuit d entr e et les circuits internes de l appareil sont galement sous tension ce moment l En soudage semi automatique ou automatique le fil le d vidoir le logement des galets d entrainement et les pi ces m talliques en contact avec le fil de soudage sont sous tension Des mat riels mal install s ou mal mis la terre pr sentent un danger Ne jamais toucher les pi ces lectriques sous tension Porter des gants et des v tements de protection secs ne compor tant pas de trous e S isoler de la pi ce et de la terre au moyen de tapis ou d autres moyens isolants suffisamment grands pour emp cher le contact physique ventuel avec la pi ce ou la terre e Ne pas servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou l on risque de tomber e Se servir d une source lectrique courant lectrique UNIQUE MENT si le proc d de soudage le demande e 51 l utilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip e Des pr cautions de s curit suppl mentaires sont requises dans des environnements risque comme les endroits humides ou lorsque l on porte des v tements mouill s sur des
85. esistive load and requires a constant amount of power 2 Non Resistive Load VOLTS 115 th AMPS 45 quipment with a motor is a non re 60 sistive load and requires approxi mately six times more power while Starting the motor than when running see Section 12 8 3 Rating Data Rating shows volts and amperes or watts required to run equipment Amperes x Volts Watts Example 1 If a drill uses 4 5 peres at 115 volts calculate its run ning power requirement in watts 4 5 Ax 115 V 2 520W The load applied by the drill is 520 watts Example 2 If three 200 watt flood lamps are used with the drill from Ex ample 1 add the individual loads to calculate total load 3 x 200W 520 W 1120 W The total load applied by the three flood lamps and drill is 1120 watts 4429 Page 60 12 5 Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts 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 2850 3 HP 15900 3900 5 HP 23300 6800 Capacitor Start Capacitor Run 1 1 2 HP 8100 2000 5 HP 23300 6000 7 1 2 HP 35000 8000 10 HP 46700 10700 Fan Duty 1 8 HP 1000 400 1 6 HP 1400 550 1 4 HP 1850 650 1 3 HP 2400 800 1 2 HP 3500 1100 12 6 Approximate Power Requiremen
86. et les poser aussi bas que possible ex par terre Veiller souder une distance de 100 m tres de tout quipe ment lectronique sensible Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi En cas d interf rences apr s avoir pris les mesures pr c den tes il incombe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de bles blind s l utilisation de filtres de ligne ou la pose de protec teurs dans la zone de travail 2 6 Proposition californienne 65 Avertissements Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l Etat de Californie reconnait qu ils provoquent des mal formations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants Les batteries les bornes et autres accessoires contiennent du plomb et des compos s base de plomb produits chimi ques dont l Etat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apr s manipu lation 2 7 Principales normes de s curit Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com Recommended S
87. ff all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable Do not touch electrode if you are in contact with the work ground or another electrode from a different machine Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present e Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical Insulate work clamp when not connected to workpiece to prevent contact with any metal object Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists in inverters after stop ping engine Stop engine on inverter and discharge input capacitors according to instructions in Maintenance Section before touching any parts HOT PARTS can cause severe burns e Do not touch hot parts bare handed e Allow cooling period before working on equip ment e Tohandle hot parts use proper tools and or wear heavy insu lated welding gloves and clothing to prevent burns FLYING MET
88. gl 15 125VAC spd term chr 1 202 209 2 SPACER NYOM Lea E 2 9 PC6 192995 CIRCUIT CARD ASSY connector receptacle 1 10 CB5 139266 SUPPLEMENTARY PROTECTOR man reset 1p 15 250vac frict 1 11 CB6 083 432 SUPPLEMENTARY PROTECTOR Man Reset 1p 10 250vac Frict 1 OM 4429 Page 78 Item Dia Part No Mkgs No Description Quantity Figure 13 5 Panel Front w Components CC CV Models Continued TN gt 52 021467 SWITCH tgl spst 250v off none spd term 1 dd bonia S1 212 436 SWITCH ignition 4posn w o 1 14 CB1 201 083 SUPPLEMENTARY PROTECTOR man reset 2P 20 A 250VAC 1 en eto 201 553 CLIP circuit breaker retaining 1 15 CB2 093 996 SUPPLEMENTARY PROTECTOR man reset 1P 20A 250VAC frict 1 15 139 266 SUPPLEMENTARY PROTECTOR man reset ETE E 1P 15A 250VAC export models only 1 16 GFCI1 151981 RECEPTACLE str dx grd 2P3W 15 20 125V 1 17 RC1 147 632 RECEPTACLE tw grd 2P3W 30A 250V L6 30R 1 17 176 355 RECEPTACLE str 2p3w 16a 220v flange mtg export models only 1 ww ACS 9192 954 9PAW
89. i ble et inodore e JAMAIS utiliser dans une maison ou garage m me avec les portes et fen tres ouvertes e Uniquementutiliser l EXTERIEUR loin des portes fen tres et bouches a ration L ACIDE DE LA BATTERIE peut pro voquer des br lures dans les YEUX et sur la PEAU e Ne pas renverser la batterie e Remplacer une batterie endommag e e Rincer imm diatement les yeux et la peau l eau 2 4 Dangers li s l air comprim RESPIRER L AIR COMPRIM peut pro voquer des blessures graves ou causer la mort e Ne pas utiliser l air comprim pour respirer e Utiliser l ai comprim seulement pour le cou page gougeage et les outils pneumatiques L AIR COMPRIM peut provoquer des blessures e Porter des lunettes de s curit approuv es e Ne pas diriger le jet d air vers d autres ou Soi m me L AIR COMPRIME EMMAGASINE ET DES TUYAUX SOUS PRESSION peuvent provo quer des blessures e Rel cher la pression d air de l outillage ou du syst me avant d effectuer la maintenance avant de changer ou de rajouter des l ments ou avant d ouvrir la purge ou le bouchon de remplissage d huile LA CHALEUR DU MOTEUR peut pro voquer un incendie e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Tenir distance les produits inflammables de l chappement LES TINCELLES L CHAPPEMENT peuvent provoquer un incendie e Emp cher les tincelles
90. ieved by selecting the lowest usable range for the electrode with a higher fine amperage setting preferably above 50 This improves 6010 for uphill pipe welding by reducing Arc outages Popouts and reduces spatter with 7018 STIFFER ARC A stiffer arc condition can be achieved by selecting the highest usable range for the electrode with a lower fine amperage setting preferably below 50 This improves 6010 for downhill stick welding and 7018 for out of position welding by increasing dig un 212 944 B OM 4429 Page 32 Notes OM 4429 Page 33 SECTION 7 OPERATING WELDING GENERATOR CC CV MODELS 7 1 Front Panel Controls For CC CV Models See Section 7 2 2 A 215 664 802 602 OM 4429 Page 34 7 2 Description Of Front Panel Controls For CC CV Models See Section 7 1 Engine Starting Controls 1 Starting Aid Switch Use switch to energize starting aid for cold weather starting see starting instructions fol lowing 2 Engine Control Switch Use switch to start engine select engine speed if unit has auto idle option and stop engine In Run position engine runs at weld power speed In Auto position optional engine runs at idle speed at no load and weld speed with load applied To Start NOTICE Do not use ether Using ether voids warranty If engine does not start let engine come to a complete stop before attempting re start Above 32 F 0 turn Engine Contro
91. ing low voltage short arc length conditions Circuit breaker CB4 may be open CB4 automatically resets when the fault is corrected see Section 9 7 Have Factory Authorized Service Agent check transformer T1 and integrated rectifiers SR4 and SR5 Low open circuit voltage Check engine speed and have Factory Authorized Service Agent adjust if necessary Place Stick TIG switch in Stick position Maximum weld output only in each ampere range with Stick TIG Selection switch in Stick position Have Factory Authorized Service Agent check control relay CR7 No remote fine amperage control Place Amperage Adjust switch in Remote position Check and secure connections to Remote Amperage Adjust receptacle RC13 see Section 5 10 Reset supplementary protector CB11 see Section 9 7 Have Factory Authorized Service Agent check control relay CR7 Repair or replace remote control device Have Factory Authorized Service Agent check OCV control circuit 4429 Page 47 B Welding CC CV Models Trouble Remedy No weld output generator power output okay at ac receptacles Place Process Contactor switch in a Weld Terminals Always On position or place switch in a Remote On Off Switch Required position and connect remote contactor to optional Remote 14 receptacle RC14 see Sections 5 11 and 7 1 Check position of Ampere Range switch Check position of optional Polarit
92. inse with clear water Recharge or replace battery if necessary Periodically recharge battery approximately every 3 months Engine does not run at weld power speed Have Factory Authorized Service Agent check engine controller throttle actuator TS1 and speed sensor Engine idles but does not come up to weld speed models with idle option only Check for obstructed throttle actuator TS1 Have Factory Authorized Service Agent check idle module PC7 current transformer CT1 throttle actua tor TS1 and engine controller Engine does not run at idle speed models with idle option only CC models place Stick TIG Selection switch in Stick position CC CV models place Process Contactor switch in any position but Remote On Off Switch Required TIG Check for obstructed throttle actuator Have Factory Authorized Service Agent check idle module PC7 control relay CR6 throttle actuator TS1 speed sensor and engine controller Engine uses oil during run in period wetstacking occurs Dry engine according to run in procedure see Section 11 OM 4429 Page 50 Notes E HOBART INSTITUT _ OF WELDING TECHNOLOGY Start Your Professional yy Trade Square East Troy Ohio 45373 Over 80 000 trained Welding Career Now 1 800 332 9448 www welding org since 1930 OM 4429 Page 51 SECTION 10 ELECTRICAL DIAGRAMS 95 STICK PLG1 RC1 ONG 4
93. isconsin or F O B at a Miller authorized service facility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived th
94. it correcte et sur les batteries e D brancher le c ble n gatif en premier lieu Le rebrancher dernier lieu LE CARBURANT MOTEUR peut provo quer un incendie ou une explosion e Arr ter le moteur avant de v rifier le niveau de carburant ou de faire le plein e Ne pas faire le plein en fumant ou proche d une source d tincelles ou d une flamme nue e Ne pas faire le plein de carburant ras bord pr voir de l espace pour son expansion e Faire attention de ne pas renverser de carburant Nettoyer toul carburant renvers avant de faire d marrer le moteur Jeter les chiffons dans un r cipient ignifuge Toujours garder le pistolet en contact avec le r servoir lors du remplissage DES ORGANES MOBILES peuvent pro voquer des blessures y e Ne pas approcher les mains des ventilateurs courroies et autres pi ces en mouvement e Maintenir ferm s et fixement en place les portes panneaux re couvrements et dispositifs de protection e Arr ter le moteur avant d installer ou brancher l appareil OM 4429 Page 8 Placer les bouteilles debout en les fixant dans un support station naire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e Tenir les bouteilles loign es des circuits de soudage ou autres circuits lectriques e Ne jamais placer une torche de soudage sur une bouteille gaz e Une lectrode de soudage ne doit jamais entrer en contact avec
95. l switch to Start Release Engine Control switch when engine starts Below 32 F 0 C push Starting Aid switch up for 20 seconds While still holding Starting Aid switch turn Engine Control switch to Start Release Engine Control switch and Starting Aid switch when engine starts To Stop turn Engine Control switch to Off position Engine Gauges And Meters 3 Engine Hour Meter Use hour meter to monitor engine run time to help schedule maintenance 4 Fuel Gauge Use gauge to check fuel level To check fuel level when engine is not run ning turn Engine Control switch to Run posi tion 5 Battery Voltmeter Optional Use gauge to check battery voltage and moni tor the engine charging system The meter should read about 14 volts dc when the en gine is running and about 12 volts dc when the engine is stopped 6 Engine Coolant Temperature Gauge Normal temperature is 180 203 F 82 95 C Engine stops if temperature exceeds 220 F 104 C 7 Engine Oil Pressure Gauge Normal pressure is 30 60 psi 207 414 kPa Engine stops if pressure is below 10 psi 69 kPa Weld Controls 8 Process Contactor Switch See Section 7 3 for Process Contactor switch information 9 Ampere Range Switch NOTICE Do not switch under load Use switch to select weld amperage range Use the lowest four ranges for Stick and TIG welding Read the upper set of numbers at each range for Stick welding and the lower set at e
96. l Fill Cap Fuel Line N Primary Fuel Filter Fuel Water Separator 6 Petcock 7 Secondary Fuel Filter 8 Fuel Tank Sludge Drain Valve To change oil and filter Route oil drain hose and valve through hole in base See engine manual and engine maintenance label for oil filter change in formation To drain water from fuel system Open primary fuel filter petcock and drain water into metal container Close petcock when water free fuel flows To replace primary fuel filter Turn filter counterclockwise Re move filter Fill new filter with fresh fuel Apply thin coat of fuel to gasket on new fil ter Install new filter and turn clock wise Bleed air from fuel system ac cording to engine manual Inspect fuel lines and replace if cracked or worn To replace secondary fuel filter See engine manual To drain sludge from fuel tank A Beware of fire Do not smoke and keep sparks and flames away from drained fuel Dis pose of drained fuel in an en vironmentally safe manner Do not leave unit unattended while draining fuel tank Properly lift unit and secure in a level position Use ade quate blocks or stands to support unit while draining fuel tank Attach 1 2 ID hose to drain valve Put metal container under drain and use screwdriver to open sludge drain valve Close valve when sludge has drained Remove hose Close door Tools Needed 802 490 Ref 801 434
97. l at overflow tank if present on unit instead of radiator unless told otherwise in maintenance section or engine manual e engine is warm checking is needed and there is no over flow tank follow the next two statements e Wear safety glasses and gloves and put a rag over radiator cap Turn cap slightly and let pressure escape slowly before completely removing cap 4 Using a generator indoors CAN KILL YOU IN MINUTES e Generator exhaust contains carbon monoxide This is a poison you cannot see or smell e NEVER use inside a home or garage EVEN IF doors and windows are open e Only use OUTSIDE and far away from windows doors and vents BATTERY ACID can BURN SKIN and EYES e Do not tip battery e Replace damaged battery e Flush eyes and skin immediately with water ENGINE HEAT can cause fire e Do not locate unit on over or near combustible surfaces or flammables e Keep exhaust and exhaust pipes way from flammables EXHAUST SPARKS can cause fire e Do not let engine exhaust sparks cause fire e Use approved engine exhaust spark arrestor in required areas see applicable codes TRAPPED AIR PRESSURE AND WHIPPING E HOSES can cause injury AY e Release air pressure from tools and system be fore servicing adding or changing attach ments or opening compressor oil drain or oil fill cap OM 4429 Page 3 HOT METAL from air arc cutting and gouging can cause fire or exp
98. lding or cutting To reduce magnetic fields in the workplace use the following procedures ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as micro processors computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagnetically compatible e Toreduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e lfinterference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area For Gasoline Engines Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive harm For Diesel Engines Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Ontario Canada L4W 5NS phone 800 463 6727 or in Toronto 416 747 4044 website www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 25 West 48rd Street New York NY 100
99. losion e Do not cut or gouge near flammables e Watch for fire keep extinguisher nearby HOT PARTS can cause burns and injury e Do not touch hot compressor or air system parts e Let system cool down before touching or ser vicing READ INSTRUCTIONS e Read Owner s Manual before using or servic ing unit Stop engine and release air pressure before servicing Use only genuine replacement parts from the manufacturer 1 5 Additional Symbols For Installation Operation And Maintenance FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do notinstall unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING UNIT can cause injury e Use lifting eye to lift unit and properly installed accessories only NOT gas cylinders Do not exceed maximum lift eye weight rating see Specifications e Lift and support unit only with proper equipment and correct procedures e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit OVERHEATING can damage motors e Turn off or unplug equipment before starting or stopping engine e Do not let low voltage and frequency caused by low engine speed damage electric motors e Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable gt
100. m DWE i UE E buc E d e das 1 lbs Die 215405 PANEL gen pwr SS a ee 1 DT ue ce 215 403 PANEL gen pwr export models only 1 on das 083 030 STUD brs 250 20 1 750 w hex collar 1 601 836 250 20 50hex 19h brs 3 mA D 196 073 LABEL do not switch while welding 1 512 259195925 SWITCH 3 bas nue Blache rtc rac 1 DKL E a cc 201 125 PANEL mtg terminal pwr 1 199 303 PANEL mtg terminal pwr output SS 1 p o m 039 046 TERMINAL pwr output black 1 MR EMEN 180 735 WASHER oulput 5104 ew xD 2 pd xcu Ei 181 169 SPACER OUIDUE eire E AER eo aa anni dae eel a 2 bo oe 186 621 BOOT generic output Stud 2 T 9059 773 HANDLE el mme 1 T asb Beb y Boh as 010 647 PIN spring cs 156 1 250 1 ide Lua PA 039 047 TERMINAL pwr output red 1 Auc REPE 209 056 COVER receptacle w gasket 2
101. n maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Use the right equipment correct procedures and sufficient num ber of persons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Engine Hazards BATTERY EXPLOSION can BLIND e Always wear a face shield rubber gloves and protective clothing when working on a battery e Stop engine before disconnecting or connect ing battery cables or servicing battery e Do not allow tools to cause sparks when working on a battery e Do not use welder to charge batteries or jump start vehicles e Observe correct polarity and on batteries e Disconnect negative cable first and connect it last FUEL can cause fire or explosion e Stop engine and let it cool off before checking or adding fuel e Do not add fuel while smoking or if unit is near any sparks or open flames e Do not overfill tank allow room for fuel to expand e Do noi spill fuel If fuel is spilled clean up before starting engine e Dispose of rags in a fireproof container e Always keep nozzle in contact with tank when fueling MOVING PARTS can cause injury e Keep away from fans belts and rotor
102. nd any metals containing these elements can give off toxic fumes if welded 4 BUILDUP OF GAS can or kill e Shut off shielding gas supply when not in use e Always ventilate confined spaces or use ap proved air supplied respirator ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld e Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet e Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc e Wear protective clothing made from durable flame resistant mate leather heavy cotton or wool and foot protection WIE WELDING can cause fire or explosion Welding on closed containers such as tanks drums Or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding e Remove all flammables within 35 ft 10 7 m of the welding
103. nt check diode D1 Have Factory Authorized Service Agent check brushes and slip rings and field excitation circuit High output at generator power ac re ceptacles Check engine speed and have Factory Authorized Service Agent adjust if necessary Have Factory Authorized Service Agent adjust generator power field current resistor R3 Low output at generator power ac receptacles Check engine speed and have Factory Authorized Service Agent adjust if necessary Check fuse F1 and replace if open see Section 9 7 Have Factory Authorized Service Agent check inte grated rectifier SR1 resistor R3 and capacitor C9 D Optional Three Phase Generator Power CC CV Models Only Trouble Remedy No or low output at optional three phase generator receptacle RC5 Place Process Contactor switch in Weld Terminals Always On Stick position see Section 7 3 Reset supplementary protector CB7 see Section 8 2 Reset supplementary protector CB5 see Section 9 7 Check engine weld power speed and have Factory Authorized Service Agent adjust if necessary Have Factory Authorized Service Agent check brushes slip rings and field current regulator board PC1 High output at optional three phase generator receptacle RC5 Check engine weld power speed and have Factory Authorized Service Agent adjust if necessary Have Factory Authorized Service Agent check field current regulator
104. ntainers and Piping American Welding Society Standard AWS F4 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 4221 Walney Road 5th Floor Chantilly VA 20151 phone 703 788 2700 website www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Mississauga 1 8 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when we
105. nts de coincement tels que des rouleaux de commande LES FILS DE SOUDAGE peuvent provoquer des blessures e Ne pas appuyer sur la g chette avant d en avoir recu l instruction Ne pas diriger le pistolet vers soi d autres per sonnes ou toute pi ce m canique en enga geant le fil de soudage 23 L EMPLOI EXCESSIF peut SURCHAUFFER L EQUIPEMENT e Laisser l quipement refroidir respecter le fac teur de marche nominal e R duire le courant ou le facteur de marche avant de poursuivre le soudage e Ne pas obstruer les passages d air du poste LES CHARGES LECTROSTATI QUES peuvent endommager les circuits imprim s e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des boites antistatiques pour stocker d placer ou exp dier des cartes de circuits imprimes OM 4429 Page 10 UNE REMORQUE QUI BASCULE peut entrainer des blessures e Utiliser les supports de la remorque ou des blocs pour soutenir le poids e Installer convenablement le poste sur la remor que comme indiqu dans le manuel s y rappor tant LIRE LES INSTRUCTIONS e Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil e N utiliser que les pi ces de rechange recom mand es par le constructeur e Effectuer la maintenance et le service du moteur et du compres seur d air suivant les instructions dans ce manuel ou le ma
106. nuel du moteur compresseur si applicable LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Le rayonnement haute fr quence H F peut provoquer des interf rences avec les quipe ments de radio navigation et de communica tion les services de s curit et les ordinateurs Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l instal lation L utilisateur est tenu de faire corriger rapidement par un lectri cien qualifi les interf rences r sultant de l installation Si le FCC signale des interf rences arr ter imm diatement l ap pareil Effectuer r guli rement le contr le et l entretien de l installation Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une dis tance correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique risque de provo quer des interf rences pour l quipement lec tronique sensible tel que les ordinateurs et l qQuipementcommand par ordinateur tel que les robots Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement Pour r duire la possibilit d interf rence maintenir les c bles de soudage aussi courts que possible les grouper
107. or Installation Operation And Maintenance 4 1 6 California Proposition 65 06 5 187 Prncmpal Satety Standards uu bete t nce Ge 5 1 9 2 5 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 6 251 Signification des Symboles 2 2 wee cals dea deett exe ws 6 2 2 Dangers relatifs au soudage l arc 6 2 3 Dangers existant en relation avec le moteur 8 2 4 Dangers lies a l air vs uus oue eme Pe S Ede e c ous E Rs 9 2 5 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 9 2 6 Proposition californienne 65 11 2 17 Principales normes de ades bes d a ai t 11 2 0 x oon rasant pite a Gant kusatam a Mo ssi BOR On 11 SECTION D FINITIONS u unie eens dee PEE 12 3 1 Warning Label Definitions For Wordless Labels 12 3 2 Manufacturers Rating Labels anses 13 3 3 Symbols And
108. ose Clean primary element with compressed air only Air pressure must not exceed 100 psi 690 kPa Use 1 8 in 3 mm nozzle and keep nozzle at least 2 in 51 mm from inside of element Replace primary ele ment if it has holes or damaged gaskets Reinstall primary element and cap dust ejector down aircleaner1 9 00 ST 153 929 B ST 153 585 Ref S 0698 B Ref 215 158 OM 4429 Page 43 9 4 Inspecting And Cleaning Optional Spark Arrestor Muffler Stop engine and let cool 1 Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole Start engine and run at idle speed to blow out cleanout hole If nothing blows out of hole briefly cover end of exhaust pipe with fireproof material Stop engine and let cool Reinstall cleanout plug Tools Needed 3 8 803 656 Ref 215 158 Stop engine and let cool 1 Generator Brush Remove brushes from brush holder Replace brushes if damaged or if brush RUN AUTO materialis at or near minimum length OFF N START Minimum Length 5 8 in 16 mm L 1 New Length 1 1 4 in 32 mm um Heplace Damaged Brushes Ref 215 664 OM 4429 Page 44 9 6 Servicing Fuel And Lubrication Systems Stop engine and let cool After servicing start engine and check for fuel leaks Stop engine tighten connec tions as necessary and wipe up spilled fuel Oil Filter Oil Drain Valve And Hose Oi
109. our les ore les si le niveau sonore est trop lev OM 4429 Page 7 LES CHAMPS MAGNETIQUES peuv ent affecter des implants m dicaux e Porteur de simulateur cardiaque ou autre im plants m dicaux rester distance e Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de sou dage par points de gougeage du coupage plasma ou de chauf fage par induction Si des BOUTEILLES sont endomma g es elles pourront exploser Des bouteilles de gaz protecteur contiennent du ga sous haute pression Si une bouteille est endomme g e elle peut exploser Du fait que les bouteilles de gaz for normalement partie du proc d de soudage les manipuler ave pr caution e Prot gerles bouteilles de gaz comprim d une chaleur excessive des chocs m caniques des dommages physiques du laitier des flammes ouvertes des tincelles et des arcs 2 3 Dangers existant en relation avec le L EXPLOSION DE LA BATTERIE peu RENDRE AVEUGLE e Toujours porter une protection faciale des gants en caoutchouc et v tements de protection lors d une intervention sur la batterie e Arr ter le moteur avant de d brancher ou de brancher les c bles de batterie e Eviter de provoquer des tincelles avec les outils en travaillant sur la batterie e Ne pas utiliser le poste de soudage pour charger les batteries ou des v hicules de d marrage rapide e Observer la polar
110. ous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage LES ACCUMULATIONS DE GAZ ris quent de provoquer des blessures ot m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confin s ou se servir d un respirateur d adduction d air homologu LES RAYONS DE L ARC peuvent pro voquer des br lures dans les yeux sur la peau Le rayonnement de l arc du proc d de g n re des rayons visibles et invisibles intense ultraviolets et infrarouges susceptibles de provoquer des br lure dans les yeux et sur la peau Des tincelles sont projet es pendant soudage e Porter un casque de soudage approuv muni de verres filtrants appropri pour prot ger visage et yeux pendant le soudage voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit e Porter des lunettes de s curit avec crans lat raux m me sous votre casque e Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les blouissements et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc e Porter des v tements confectionn s avec des mati res r sistan tes et ignifuges cuir coton lourd ou laine et des bottes de protection LE SOUDAGE peut provoquer un in a cendie ou une explosion Le soudage effec
111. pere Range switch and Voltage Amperage Adjust control Check engine speed and have Factory Authorized Service Agent adjust if necessary Have Factory Authorized Service Agent check field current regulator board PC1 and PC1 voltage feed back circuit Voltage Amperage control does not work when welding in Stick mode Place Ampere Range switch in lower range Voltage Amperage control does not work with Ampere Range switch in highest range Low weld output Check position of Ampere Range switch and Voltage Amperage Adjust control Check engine speed and have Factory Authorized Service Agent adjust if necessary Check fuses F1 and F2 and replace if open see Section 9 7 Have Factory Authorized Service Agent check integrated rectifier SR1 capacitor 9 field current regulator board PC1 and the rotor Electrode sticks to the workpiece more frequently during low voltage short arc length conditions Circuit breaker CB4 may be open CB4 automatically resets when the fault is corrected see Section 9 7 Have Factory Authorized Service Agent check transformer T1 and integrated rectifiers SR4 and SR5 Low open circuit voltage Check engine speed and have Factory Authorized Service Agent adjust if necessary Check position of Process Contactor switch No remote fine amperage or voltage control Place Voltage Amperage Adjust switch in Remote position Check and secure connections to Remote
112. r start up Check engine speed Overspeed shutdown automatically stops engine if speed is too high Turn engine off and restart to resume operation If unit continues to overspeed and shut down have unit checked by a Factory Authorized Service Agent Have Factory Authorized Service Agent check time delay relay TD1 and control relay CR5 Engine hard to start in cold weather Use starting aid switch see Section 6 1 or 7 1 Keep battery in good condition Store battery in warm area off cold surface Use fuel formulated for cold weather diesel fuel can gel in cold weather Contact local fuel supplier for fuel information Use correct grade oil for cold weather see Section 9 1 Have Factory Authorized Service Agent check starting aid switch and glow plugs Engine suddenly stops Check oil and coolant levels Automatic shutdown system stops engine if oil pressure is too low or coolant temperatureis too high see Section 5 7 Automatic shutdown system is inhibited for 30 seconds after start up See engine manual Have Factory Authorized Service Agent check engine speed sensor Engine slowly stopped and cannot be restarted Check fuel level Check engine air and fuel filters see Sections 9 3 and 9 6 See engine manual Battery discharges between uses Turn Engine Control switch off when unit is not running Clean top of battery with baking soda and water solution r
113. r faulty tools plugged in receptacle Press button to reset GFCI1 At least once a month run en gine at weld power speed and press test button to verify GFCI is working properly 3 Supplementary Protector CB1 4 Supplementary Protector CB2 CB1 protects RC1 and the genera tor winding from overload If CB1 opens RC1 and GFCI1 do not work Place switch in On position to reset CB2 protects GFCI1 from overload If CB2 opens GFCI1 does not work Press button to reset gt If a supplementary protector continues to open contact Factory Authorized Service Agent Generator power is not af fected by weld output Maximum output is 2 4 kVA kW from GFCI1 4 kVA kW from RC1 Maximum output from all re ceptacles is 4 kVA kW EXAMPLE If 13 A is drawn from RC1 only 7 A is available at GFCI1 240 V x 13 A 120 V x 7 A 4 0 kVA kW 191 624 A 8 2 Connecting To Optional Three Phase Generator CC CV Models Only IN WE Single Phase Power Connection 1 2 Three Phase Power Connection ere Uu cs ase ase Output Busy 27 Close panel opening if no connections are made to generator Frequency 60 Hz Engine Speed 1850 RPM Lead 42 connects to GROUND stud on front of unit Jumper 42 is connected to 90 at factory 7 2 8 Z ve plug before inserting leads Reinstall bushing 90 92 Rear Of Panel Close panel opening if no connections a
114. r output voltage and wir ing must be consistent with regular utility system voltage and wiring Connect generator with temporary or permanent wiring suitable for the installation Turn off or unplug all equipment connected to generator before starting or stopping engine When starting or stopping the engine has low speed which causes low volt age and frequency 5 Essential Loads Generator output may not meet the electrical requirements of the prem ises If generator does not produce enough output to meet all require ments connect only essential loads pumps freezers heaters etc See Section 12 4 OM 4429 Page 64 12 11 Selecting Extension Cord Use Shortest Cord Possible Lengths for 120 Volt Loads A If unit does not have GFCI receptacles use GFCl protected extension cord Current Maximum Allowable Cord Length in ft m for Conductor Size AWG Amperes Load Watts 4 6 8 10 12 14 5 600 350 106 225 68 137 42 100 30 7 840 400 122 250 76 150 46 100 30 62 19 10 1200 400 122 275 84 175 53 112 34 62 19 50 15 15 1800 300 91 175 53 112 34 75 23 37 11 30 9 20 2400 225 68 137 42 87 26 50 15 30 9 25 3000 175 53 112 34 62 19 37 11 30 3600 150 46 87 26 50 15 37 11 35 4200 125 38 75 23 50 15 40 4800 112 34
115. re made to generator Tools Needed gt Place Process Contactor switch in Weld Terminals Always On Stick position when using three phase generator see Section 7 3 Single Phase Generator Power 1 120 240 V 50 A Receptacle RC5 RC5 is connected to the optional three phase generator and supplies 60 Hz single phase power at weld power speed Maximum output from RC5 is 12 kVA kW Power available at RC5 is reduced when welding 2 Supplementary Protector Supplementary protector CB7 pro tects single phase receptacle RC5 and the load wires from overload If CB7 opens all generator output stops and the receptacle does not work Three Phase Generator Power Stop engine Power and weld outputs are live at the same time Discon nect or insulate unused cables Have qualified person install ac cording to circuit diagram and Generator Power Guidelines see Section 12 Remove generator power panel mounting screws Tilt panel forward 3 Lead 93 Lead 92 5 Lead 91 6 Lead 42 Circuit Grounding Lead 7 Lead 90 Neutral 8 Isolated Neutral Terminal 9 Jumper Lead 42 10 Grounding Terminal Jumper 42 is connected to lead 90 at factory Jumper 42 may be discon nected from neutral to meet applica ble electrical codes Lead 42 connects to front panel Ground stud 11 User Supplied Leads 12 Supplementary Protector CB7 User Terminals Connect user supplied leads to ter minals on CB
116. ressed or implied LIMITED WARRANTY Subject to the terms and conditions below Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Miller must be notified in writing within thirty 30 days of such defect or failure at which time Miller will provide instructions on the warranty claim procedures to be followed Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the delivery date of the equipment the original end user purchaser and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Process Controllers Semi Automatic and Automatic Wire Fee
117. rrectement install es seuls PAS les bouteilles de gaz Ne pas d passer le poids nominal maximal de l ceilleton voir les sp cifications e Ne lever et ne soutenir l appareil qu avec de l quipement appropri et en suivant les proc dures ad quates En utilisant des fourches de levage pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil OM 4429 Page 9 LE SURCHAUFFEMENT peut endom mager le moteur lectrique e Arr ter ou d connecter l quipement avant de d marrer ou d arr ter le moteur e Ne pas laisser tourner le moteur trop lentement sous risque d en dommager le moteur lectrique cause d une tension et d une fr quence trop faibles e Ne pas brancher de moteur de 50 ou de 60 Hz la prise de 100 Hz LES TINCELLES VOLANTES ris quent de provoquer des blessures o lt y gt e Porter facial pour prot ger le el les yeux e Aff ter l lectrode au tungst ne uniquement la meuleuse dot e de protecteurs Cette manceuv re est ex cuter dans un endroit s r lorsque l on porte l quipement homologu de protection du visage des mains et du corps e Les tincelles risquent de causer un incendie loigner toute sub stance inflammable N DES ORGANES MOBILES peuvent provoquer des blessures e Ne pas s approcher des organes mobiles e Ne pas s approcher des poi
118. s e Keep all doors panels covers and guards closed and securely in place e Stop engine before installing or connecting unit e Have only qualified people remove doors panels covers or guards for maintenance and troubleshooting as necessary e To prevent accidental starting during servicing disconnect negative battery cable from battery e Keep hands hair loose clothing and tools away from moving parts e Reinstall doors panels covers or guards when servicing is finished and before starting engine e Before working on generator remove spark plugs or injectors to keep engine from kicking back or starting e Block flywheel so that it will not turn while working on generator components HOT PARTS can cause severe burns Do not touch hot parts bare handed e Allow cooling period before working on equip ment e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns 1 4 Compressed Air Hazards BREATHING COMPRESSED AIR can 23 cause serious injury or death e Do not use compressed air for breathing e Use only for cutting gouging and tools COMPRESSED AIR can cause injury D e Wear approved safety goggles e Do not direct air stream toward self or others STEAM AND HOT COOLANT can burn e f possible check coolant level when engine is cold to avoid scalding e Always check coolant leve
119. s Am perage Adjust control H1 to maximum when the arc breaks When an arc is struck weld output control returns to the H1 front panel or combination front panel remote control setting The Amperage Adjust control adjusts amperage only when welding and does not adjust open circuit voltage The max OCV circuit is disabled when the Stick TIG Selection switch is in Scratch Start TIG position see item 10 8 Ampere Range Switch NOTICE Do not switch under load Use switch to select weld amperage range For most welding applications use lowest amperage range possible to help prevent arc outages 9 Amperage Adjust Control Control adjusts amperage within range se lected by Ampere Range switch Weld output would be about 180 A DC with controls set as shown 5096 of 150 to 330 A The numbers around the control are for reference only and do not represent an actual percentage value 10 Stick TIG Selection Switch Use switch to disable the max circuit and the arc drive dig circuit for scratch start TIG welding see max OCV note under Weld Controls When switch is in the Stick position the max OCV circuit resets Amperage Adjust Control R1 to maximum when the arc breaks Also in the Stick position the arc drive dig circuit provides additional amperage during low voltage short arc length conditions to prevent sticking electrodes When switch is in Scratch Start TIG position the max OCV and arc driv
120. s not af fected by weld output Maximum output is 2 4 kVA kW from GFCI1 4 kVA kW from RC1 Maximum output from all re ceptacles is 4 kVA kW EXAMPLE If 13 A is drawn from RC1 only 7 A is available at GFCI1 240 V x 13 A 120 V x 7 A 4 0 kVA kW South African Receptacle 5 120 V 20A 1 V 60 Hz 240 V 15A 191 624 OM 4429 Page 40 MAINTENANCE amp TROUBLESHOOTING SECTION 9 Maintenance Label 9 1 8 6259 Occ 0969076 289099 uospeuoq VV YATIIN L 061905051 266 261 YATIIN c u 8 000 Z 0 xo ul 000 Z 0 ul 4 27 0 02 08L90cSv e1souueu b s 6 1106 PIS 0001 vvecHd 1 0519 9071 Subl d 668 261 8 D 2 11 1901 ib 6 16 8 t 49 39 09 201601080 SuP448d vv6 261 YATIIN ul 2 1 pis 062 68790 XIM 89 cc8d 856 261 H3TIIIN 06797 XIM 69 28 Uosp euo 656 261 H3TIIIN reuondo ID EMEREIS gt L 4G V 4G 9008 4 AA a z q L L8 G 6 WLSV LV 698c Sg 4 0 9 8L V 069 109 109 IS NIG lt 2 1 2 26 195314 0981 082 gt Y 972
121. se switch to start and stop engine To Start NOTICE Do not use ether Using ether voids warranty gt If engine does not start let engine come to a complete stop before attempting re start Above 32 F 0 C turn Engine Control switch to Start Release Engine Control switch when engine starts Below 32 F 0 C push Starting Aid switch up for 20 seconds While still holding Starting Aid switch turn Engine Control switch to Start Release Engine Control switch and Starting Aid switch when engine starts To Stop turn Engine Control switch to Off position Engine Gauges And Meters 3 Engine Hour Meter Use hour meter to monitor engine run time to help schedule maintenance 4 Fuel Gauge Use gauge to check fuel level To check fuel level when engine is not run ning turn Engine Control switch to Run posi tion 5 Battery Voltmeter Optional Use gauge to check battery voltage and moni tor the engine charging system The meter should read about 14 volts dc when the en gine is running and about 12 volts dc when the engine is stopped 6 Engine Coolant Temperature Gauge Normal temperature is 180 203 F 82 95 C Engine stops if temperature exceeds 220 F 104 C 7 Engine Oil Pressure Gauge Normal pressure is 30 60 psi 207 414 kPa Engine stops if pressure is below 10 psi 69 kPa Weld Controls gt Max Control Circuit This unit has a max OCV control circuit that reset
122. size or by pass them Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby NOISE can damage hearing Noise from some processes or equipment can dam age hearing e Wear approved ear protection if noise level is high MAGNETIC FIELDS can affect Implanted Medical Devices e Wearers of Pacemakers and other Implanted Medical Devices should keep away Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding spot welding gouging plasma arc cutting or induction heating operations CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pres sure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks physical damage slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific applicatio
123. ss 1 TE de jo NE 208278 SWITCH range changeover 1 R1 188 635 RHEOSTAT WW 300W 34 1 T 202209 ea ab ee ai EE ira bag t 3 P cm o6 011 622 SWITCH tgl 15A 125VAC 1 TE qe S5 cuu 011 609 SWITCH tgl SPDT 15A 125VAC on none on spd term chr 1 9 1 032 897 RECEPTACLE twlk grd 2P3W 15 125V 1 es 91 212 436 SWITCH ignition 4 position w handle 1 S2 021467 SWITCH tgl spst 250v off none on spd term 1 201 553 CLIP circuit breaker retaining 12 CB1 201 083 SUPPLEMENTARY PROTECTOR man reset 2P 20 A 250VAC 1 13 CB2 093 996 SUPPLEMENTARY PROTECTOR man reset 1P 20A 250VAC frict 3 14 GFCI1 151981 RECEPTACLE str dx grd 2PSW 15 20 125V 1 15 147632 RECEPTACLE tw Ik grd 2PSW 30A 250V L6 30R 1 15 176 355 RECEPTACLE str 2p3w 16a 220v flange mtg export models only 1 Fei usata uns 190 861 LABEL warning electric shock and moving parts etc 1 219 347 PANEL Ge
124. sure Fuel Certified Trained Mechanic Panel Local MIG GMAW Welding Protective Earth Ground Welding Arc Alternating Current TIG GTAW Seconds 1 Ny Single Phase Do Not Switch gt e ere Read Operator s go NEC 3 Ny Three Phase Manual b Circuit Protector 4 i While Welding Engine Driven Electrode Three Phase Connection Work Connection A H Alternator With one Rectifier X Dutv Cvcle Rated No Load U Conventional Rated Load Voltage Average 2 Load Voltage n Speed n Rated Idle Rated No Load Rated Welding 1 Speed Speed 2 Current Contactor On OM 4429 Page 14 SECTION 4 SPECIFICATIONS 4 1 Weld Power And Engine Specifications Maximum Welding Weld Output Rated Welding Open Generator Power Enae Fuel Mode Range Output Circuit Rating g Capacity Voltage Standard d TRAN dE Single Phase 4 KVA KW 34 17 A CC DC 500 40 Volts DC I 20 600 100 Duty Cycle 120 240 V AC ZS Perkins CC CV Models 50 60 Hz e VORS DG Three Phase Generator Perkins 404C 22T 25 gal 9 uty Cycle Option Water Cooled 95 L CV DC 600 A Single Phase Three Phase Four Cylinder CC CV 30 Volts DC CC 12 20 kVA kW 50 48A 47 HP Turbocharged sched 14 40V 40 Duty Cycle 56 120 240 VAC 60 Hz Diesel Engine Only Addition To Standard 4 kVA kW Generator Power
125. t ger ainsi que toute autre personne travaillant sur les lieux contre les tincelles et le m tal chaud 2 1 Signification des symboles l vite pas peut donner la mort ou des blessures graves Les dangers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte DANGER Indique une situation dangereuse qui si on peut donner la mort ou des blessures graves Les dan gers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte Indique une situation dangereuse qui si on l vite pas NOTE Indique des d clarations pas en relation avec des blessures personnelles 2 2 Dangers relatifs au soudage l arc Les symboles pr sent s ci apr s sont utilis s tout au long du pr sent manuel pour attirer votre attention et identifier les ris ques de danger Lorsque vous voyez un symbole soyez vigilant et suivez les directives mentionn es afin d viter tout danger Les consignes de s curit pr sent es ci apr s ne font que r sumer l information contenue dans les normes de s curit num r es la section 2 7 Veuillez lire et respecter toutes ces normes de s curit L installation l utilisation l entretien et les r parations ne doivent tre confi s qu des personnes qualifi es Au cours de l utilisation tenir toute personne l cart et plus particulierementles enfants UN CHOC LECTRIQUE peut tuer 7 Un simple contact avec des pi c
126. t power or stop engine before servicing e Do not operate with covers removed Have only qualified persons install use or service this unit STICK PLG1 RC1 PLG14 TIG O MIG 100 100 md 1 EE TA 1 s6 1 OPTIONAL STANDARD gt 22 AOAN 27 101 S 727 120 T O PACKAGE 703 703 727 7 Z 4 STATOR 025 71255 T Hm 704 778 0565210 2256 1 120 CB2 wH ZN INQ Ka NM A e 722 272 AUX 709 6 5108 765 9 gt gt 9 yg s 138 AUX 138 gt STATOR 12 512 702 702 4 gt lt 107 106 5 gt 703 6 103 65 59 63 706 CR4 gt 7 726 725 g 05 108 9 gt 108 10 11 gt CONNECTION TO 177 125474 PLG4 RC4 42 SEES gt 22 1 44 ZZ CB5 TERMINAL W 240V RECEPTACLE OPTION MOVE LEAD 84 89 84 100 F1 A B AUX 85 2 225 556 707 2055525 7 8 505550 127 57 57 57 Jie 64 54 6922269 0542 118 Ba 133 2250 RC14 PC6 AUX H1 55 77 71 FILTER BOARD STATOR 11 gt K gt gt lt lt lt PC1 i 730 27512557 pm 2 gt J 8 lt ET FIELD CURRENT 5 gt REGULATOR 7 177 es Al PLGB 30 PIN
127. t raccord e une prise correctement mise la terre En effectuant les raccordements d entr e fixer d abord le conduc teur de mise la terre appropri et contre v rifier les connexions Les c bles doivent tre exempts d humidit d huile et de graisse prot gez les contre les tincelles et les pi ces m talliques chau des V rifier fr quemment le cordon d alimentation pour voir s il n est pas endommag ou d nud remplacer le cordon imm diatement s il est endommag un cable d nud peut provoquer une lectro cution Mettre l appareil hors tension quand on ne l utilise pas Ne pas utiliser des c bles us s endommag s de grosseur insuffi sante ou mal piss s Ne pas enrouler les c bles autour du corps Si la pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct ne pas utiliser le connecteur de pi ce ou le c ble de retour Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine Ne pas toucher des porte lectrodes connect s deux machines en m me temps cause de la pr sence d une tension vide dou bl e N utiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment ce manuel Porter un harnais de s curit quand on travaille en hauteur Maintenir solidement en place tous les panneaux et capots Fixer le
128. tage Amperage Control On CC CV Models Optional 1 Remote 14 Receptacle 14 Connect optional remote control to RC14 see Section 5 11 Example Combination Remote Amperage Control Stick 2 On Off Range 110 to 390 A DC Min 110A DC Max 390 A DC 410 399 PANEL EU V as Max 390 A DC pom REMOTE O REMOTE ON OFF SWITCH REQUIRED Min 1 1 0 A DC Set V A Set Remote U Adjust Switch Set Range 4 ud Adjust Optional Remote Control Stick Mode Example Combination Remote Amperage Control TIG In Example Process TIG Using Remote On Off Range 35 to 320 A DC Percentage Of Range 50 Min 35 DC so 38 Max About 178 A DC 50 of 35 to 320 Ve 24 Ve A 178 5 REMOTE ON OFF SWITCH REQUIRED Min 35 A DC Set V A Set Remote Set Range Set Control Adjust Optional Remote Control Adjust Switch Process 0774 Ref 215 664 Ref 803 602 4429 Page 37 SECTION 8 OPERATING AUXILIARY EQUIPMENT 8 1 120 Volt And 240 Volt Receptacles 4429 Page 38 120 V 20A 17 60 Hz 240 V 20A 1 120 V 20 A AC Receptacle GFCI1 2 240V 30 A AC Twistlock Receptacle RC1 Receptacles supply 60 Hz single phase power at weld power speed If a ground fault is detected GFCI Reset button pops out and receptacle does not work Check fo
129. to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Bobcat Trailblazer and Legend models 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Miller s option 1 repair or 2 replacement or where authorized in writing by Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Millers option of repair or replacement will be Factory at Appleton W
130. ts For Farm Home Equipment Farm Home Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 Milker Vacuum Pump 2 HP 10500 2800 FARM DUTY MOTORS 1 3 HP 1720 720 Std e g Conveyors 1 2 HP 2575 975 Feed Augers Air 3 4 4500 1400 Compressors 1 HP 6100 1600 1 1 2 HP 8200 2200 2 10550 2850 3 HP 15900 3900 5 HP 23300 6800 High Torque e g Barn 1 1 2 HP 8100 2000 Cleaners Silo Unloaders 5 HP 23300 6000 Silo Hoists Bunk Feeders 7 1 2 HP 35000 8000 10 HP 46700 10700 3 1 2 cu ft Mixer 1 2 HP 3300 1000 High Pressure 1 8 Gal Min 500 PSI 3150 950 Washer 2 gal min 550 PSI 4500 1400 2 gal min 700 PSI 6100 1600 Refrigerator or Freezer 3100 800 Shallow Well Pump 1 3 HP 2150 750 1 2 HP 3100 1000 Sump Pump 1 3 HP 2100 800 1 2 HP 3200 1050 OM 4429 Page 61 12 7 Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts 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 Table Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 2500 1100 Bench Grinder 6in 1720 720 8 in 3900 1400 10 in 5200 1600 Air Compressor 1 2 HP 3000 1000 1 HP 6000 1500 1 1 2 HP 8200 2200 2 HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in
131. tu sur des conteneurs ferm s tel que des r servoirs tambours ou des conduites pet provoquer leur clatement Des tincelles peuver tre projet es de l arc de soudure La projection d tincelles des pi ce chaudes et des quipements chauds peut provoquer des incendies des br lures Le contact accidentel de l lectrode avec des objet m talliques peut provoquer des tincelles une explosion un surchaui fement ou un incendie Avant de commencer le soudage v rifier c s assurer que l endroit ne pr sente pas de danger e D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneusementavec des protections homologu s e Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables e Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud e Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures e Surveiller tout d clenchement d incendie et tenir un extincteur proximit e Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t e Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient t pr par s correctement conform ment AWS F4 1 voir les
132. ve Weld Output Terminal 1 2 Failure to properly connect weld cables may cause excessive heat and start a fire or damage your machine 3 Weld Output Terminal 4 Supplied Weld Output Terminal Nut 5 Weld Cable Terminal 6 Copper Bar Remove supplied nut from weld output termi nal Slide weld cable terminal onto weld output terminal and secure with nut so that weld cable terminal is tight against copper bar Do not place anything between weld cable termi nal and copper bar Make sure that the sur faces of the weld cable terminal and cop per bar are clean Tools Needed 3 4 in Do not place anything between weld cable terminal and copper bar Incorrect Installation Correct Installation 803 602 803 778 A OM 4429 Page 26 5 9 Selecting Weld Cable Sizes F Weld Cable Size and Total Cable Copper Length in Weld Circuit Not Exceeding 100 ft 30 m or Less 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 45 m 60 70m 90m 105 120 m Weld Output Terminals Stop engine before 10 60 60 100 bs wela A 10 100 Duty Cycle outputterminals p Cycle Cycle Do not use worn dam aged undersized or poorly spliced cables 100 4 20 4 20 4 20 3 30 2 35 1 50 1 0 60 1 0 60 150 3 30 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 3 0 95 200
133. vehicle frame Use 10 AWG or larger insu lated copper wire gt Electrically bond generator frame to vehicle frame by met al to metal contact Bed liners shipping skids and some running gears insu late the welding generator from the vehicle frame Al ways connect a ground wire from the generator equipment grounding terminal to bare metal on the vehicle frame as shown Grounding installa 2007 04 Ref 800 652 Ref 800 477 A 803 274 804 712 OM 4429 Page 20 5 2 Using Lifting Eye 1 Lifting Eye 2 Nut 3 Carriage Bolt Raise lifting eye until it snaps in place Lower lifting eye when not needed To lock the lifting eye in the upright position insert a 3 8 16 x 1 1 2 in carriage bolt through slot in bracket and secure with nut bolt and nut not supplied Tools Needed 3 Ref 802 311 Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual OM 4429 Page 21 5 3 Mounting Welding Generator Supporting The Unit Using Mounting Brackets Welding Unit In Place Bolting Unit In Place Tools Needed J 9f46 in OM 4429 Page 22 Do not weld on base Weld ing on base can cause fuel tank fire or explosion Weld only on the four mounting brackets or bolt unit down NOTICE Do not mount unit by supporting the base only at the four mounting brackets Use cross supports to adequately support unit
134. venir d poser les bougies ou injecteurs pour viter la mise en route accidentelle du moteur e Bloquerle volant moteur pour viter sa rotation lors d une interven tion sur le g n rateur DES PI CES CHAUDES peuvent provoquer des br lures graves e Ne pas toucher mains nues les parties chau des e Pr voir une p riode de refroidissement avant de travailler l quipement e Ne pas toucher aux pi ces chaudes utiliser les outils d s et porter des gants de soudage et des v tements pais pour viter les br lures LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT CHAUD peuvent provoquer des br lures e est pr f rable de v rifier le liquide de refroi dissement une fois le moteur refroidi pour viter de se br ler e Toujours v rifier le niveau de liquide de refroidissement dans le vase d expansion si pr sent et non dans le radiateur sauf si pr cis autrement dans la section maintenance du manuel du moteur e Sile moteur est chaud et que le liquide doit tre v rifi op rer com me suivant e Mettre des lunettes de s curit et des gants placer un torchon sur le bouchon du radiateur e D visser le bouchon l g rement et laisser la vapeur s chapper avant d enlever le bouchon L utilisation d un groupe autonome l int rieur PEUT VOUS TUER EN QUELQUES MINUTES e Les fum es d un groupe autonome contient du monoxyde de carbone C est un poison invis
135. w nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de U S Government Printing Office Superin tendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 t l phone 1 866 512 1800 il y a 10 bureaux r gionaux le t l pho ne de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 1 Garder les c bles ensemble les torsader les scotcher ou les recouvrir d une housse 2 Disposer les c bles d un c t et distance de l op rateur 3 Ne pas courber pas et ne pas entourer pas les c bles autour de votre corps 4 Garder le poste de soudage et les c bles le plus loin possible de VOUS 5 Connecter la pince sur la pi ce aussi pr s que possible de la soudure En ce qui concerne les implants m dicaux Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de soudage par points de gougeage du coupage plasma ou de chauffage par induc tion Si le m decin approuve il est recommand de suivre les proc dures pr c dentes OM 4429 Page 11 SECTION 3 DEFINITIONS 3 1 Warning Label Definitions For Wordless Labels Remove unit from shipping crate Remove Owner s Manual from unit Follow instructions to install muffler Read Owner s Manual Read labels on unit Use Diesel Fuel only and fill
136. witch Spst 250v Off none Spd Term Switch Tgl Spdt 15a 125vac On none on Spd Term Chr Diode Capacitor Board Conn Rect Cinch 18 Pin Plug Cavity 18 30 Position Cinch Connector Seal Switch 6 Position Rotary 250 Shaft Conn Rect Metrmate 10skt 1row Plug Cable Lkg Circuit Breaker Man Reset 1p 15a 250vac Frict Conn Pack 4p 1row Female Conn Pack Terminal Position Assurance Lock Harness Receptacle Auxiliary Power Includes Rcpt Tw Lk Grd 2p3w 30a 250v L6 30r Rept Str Dx Grd 2p3w 15 20a 125v 5 20r Supplementary Protector Man Reset 1p 20a 250vac Frict Harness Receptacle Auxiliary Power Export Includes Rept Str Dx Grd 2p3w 15 20a 125v 5 20r Supplementary Protector Man Reset 1p 15a 250vac Frict Supplementary Protector Man Reset 1p 20a 250vac Warranty Questions Call 1 800 4 A MILLER for your local Miller distributor Your distributor also gives you Service You 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 expertise of the distributor and Miller is there to help you every step of the way Miller Effective January 1 2007 Equipment with a serial number preface of LH or newer This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties exp
137. x0 8750dx 083t stl pld 2 ARS Lu kha 602 211 WASHER Lock 318idx0 5860dx 078t Stl Pld Split 312 2 maa gas Bg 604 534 SCREW 312 18 1 25 hex hd pln gr5 pld 2 When ordering a component originally displaying a precautionary label the label should also be ordered Hecommended Spare Parts Optional To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 4429 Page 81 gt Hardware is common and not available unless listed Item Dia No Mkgs SR3 DU RE E e d deat ton audi 5 8 D3 05 07 9 02 04 06 maintain the factory origin Part No 188 135 2195 910 5 188 137 188 517 134 201 208 335 s ID TOO uon 188 136 188 493 208 334 al 802 279 A Figure 13 7 Main Rectifier Assembly Description Quantity Figure 13 7 Main Rectifier Assembly Figure 13 1 Item 114 RECTIFIER environmental consisting of 1 CONNECTION BOARD rectifier AC 1 BUS BAR connection board 3 ENCLOSURE rectifief 1 d e emo RC De ee C 2 s STANDOFF SUDDOLL Dre eren ebd as 3 CIRCUIT CARD ASSE
138. y switch or Polarity AC switch Reset supplementary protector CB11 see Section 9 7 Reset supplementary protector CB5 see Section 9 7 Check for faulty remote device connected to RC14 Check and secure connections to Remote 14 receptacle RC14 see Section 5 11 Have Factory Authorized Service Agent check connector board PC6 and connections Check fuse F2 and replace if open see Section 9 7 Have Factory Authorized Service Agent check brushes and slip rings weld excitation circuit field current regulator board PC1 and the rotor No weld output or generator power out put at ac receptacles Disconnect equipment from generator power receptacles during start up Check fuses F1 and F2 and replace if open see Section 9 7 Have Factory Authorized Service Agent check integrated rectifier SR1 capacitor 9 field current regulator board PC1 and the rotor Reset supplementary protector CB12 Have Factory Authorized Service Agent check diode D1 see Sec tion 9 7 Have Factory Authorized Service Agent check brushes and slip rings and field excitation circuit Erratic weld output Check and tighten connections inside and outside unit Be sure connection to work piece is clean and tight Use dry properly stored electrodes Remove excessive coils from weld cables Have Factory Authorized Service Agent check brushes and slip rings High weld output Check position of Am

Miller Electric Big Blue 500 PT User's Manual

Contents

Download Pdf Manuals

Related Search

Related Contents