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Miller Electric Big 40 WG Owner`s manual

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1. Weld Cable Size and Total Cable Copper Length in Weld Circuit Not Exceeding 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 100ft 30m orLess 45m 60m 70m 90m 105 m 120 m Weld Output Terminals A Stop engine before 10 60 60 10096 connecting to weld out Welding Duty Duty 10 100 Duty Cycle put terminals Amperes 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 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 2ea 2 0 250 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2x70 2x70 2ea 2 0 2ea 3 0 2ea 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 2ea 4 0 350 1 0 60 2 0 70 3 0 95 4 0 120 2x70 2x95 2x95 2x120 2 ea 2 0 2 3 0 2ea 4 0 2ea 4 0 400 1 0 60 2 0 70 3 0 95 4 0 120 2x70 2x95 2x120 2x120 2ea 2 0 2ea 3 0 2ea 4 0 3ea 3 0 3ea 3 0 500 2 0 70 3 0 95 4 0 120 2x70 2x95 2x120 3x95 3x95 This chart is a general guideline and may not suit all applications If cable overheating occurs normally you can smell it use next size larger cable Weld cable size AWG is base
2. 1 uc See dace ates Gea 2022232 BUS BAR idealized 43 aedes cuneate den 192 558 HARNESS range consisting of 1 ee re RC6 148439 HOUSING rect univ 084 4p s 1 row 1 OM 4405 Page 68 Dia Par No Mkgs No Description Quantity Figure 11 4 Panel Front w Components CC Models Continued X TR R1 188 635 RHEOSTAT WW 300W 34 202 209 4 PAGER AVON eb bandes Ps 011 622 SWITCH tgl 15A 125VAC included in control box harness TIL See FONS 1152 hadas te code el nana ane uas SERRE 011 609 SWITCH tgl SPDT 15A 125VAC on none on spd term chr included in U control box harness see Figure 11 2 9 RC13 032897 RECEPTACLE twlk grd 2P3W 15 125 10 S1 176606 SWITCH ignition 4posn w o handle 11 MS1 189698 SWITCH magnetic manual reset low current TX 201 553 CLIP circuit breaker retaining 12 CB1 201 083 CIRCUIT BREAKER man reset 2P 20 A 250VAC TUMORS 201 109 HARNESS auxiliary power consisting of 13 CB2 093996
3. 2 10 090 104 RELAY 12VDC SPST 15 0 1 REM S5 011 609 SWITCH tgl spdt 15a 125vac on none on spd term chr E located on front panel see Figure 11 4 1 T 56 011 622 SWITCH tgl 3pdt 15a 125 on none on spd term Pn located on front panel see Figure 11 4 1 nsque RC4 047483 CONNECTOR rect univ 084 15P S 3 row rcpt cable panel Ikg 1 TOT 158466 CONNECTOR rect univ 084 12P S row rcpt cable panel 1 RUM donee 135 133 CONNECTOR rect univ 084 9P S row rcpt cable panel lkg 1 TE 146 800 SOCKET relay xam m Re ead acetone ire TTE 177 859 CONN body 5 terminal to engine control switch S1 1 jede b ded ARA eC 150 316 CONN rect univ 039 6p s 3row plug cable 6 Tp 092 670 CONN rect univ 084 3p s 1row plug cable 1 11 CB11 12 13 139266 CIRCUIT BREAKER man reset 1P 15A 250VAC frict 9 190 260 HARNESS unit weld control consisting of 1 PLG3 158465 CONN rect univ 084 12p s 3row plug cable 1 187654 SEAL wire univ 12p s 3row 1 T
4. 1 bnt 201 089 STATOR weld assembly complete full KVA option 1 RE 013 367 LABEL warning moving parts 2 TTE mn 190 197 GUARD generator wire 1 uo gcc 172 674 SPRING ext 240 OD x 041 wire x 3 500pld 2 ena WO ss ates es a 0992075 BAFFLE AIN MWS 1 201 098 ROTOR gen consisting Of 1 HS 024 617 RING ext 1 375 shaft x 050thk 1 Mr DT 053 390 BEARING ball sgl row 1 370 x 2 830 x 6 1 Lika 1952547 MOLO GON ea bate uos et E apa ets 1 ii S eee 049 026 SCREW 10 1 5 x 25hexhd pln 8 8 6 083 883 WASHER lock 402 ID x 0 709 OD 10 eee eee eee 202 9D PLATE eX ss tad tne awardee mR ee ae end bands 1 usar WO aa ds ered dos 605 231 SCREW m10 1 5x 35 hex hd pln 8 8 4 orm 194 512 WASHER flat 1 250 od x 406id x 7ga thk stl pld 4 SPEO DIEN 183 387 WASHER cone 380idx 8600dx 109t stl 4000lbs 6 assa 198 631 NUT m10 hex
5. 1 iene Oe Reb hed seid Beane et 204 59 T cc STOR COON a tubae cat heen atid uten bat ete watt en RR i 2 DH 189826 lt PANEL TOCKE iiie ricus eed eae ccn can cec CR eec den 1 mi TU 191 626 BUMPER door engine access 2 dus dO taa 99502755 PANEL Oe Tiu to es odas deed au tb dod 1 tas DE edd 199 849 SCREW 625 11 x 4 00hexhd pln gr 5 pld 4 een 071 731 WASHER flat 656 ID x 2 250 OD x 187T stl pld 4 UD EE 200 985 BRACKET mtg engine Wis Con TM 20 2 PORE repone UM 071 890 RETAINER mount eng gen 4 E Ath 071 730 TUBING stl 875 OD x 12ga wall x 2 500 4 083 476 MOUNT eng gen 875 ID x 2 500 OD x 2 000 4 135 205 NUT 625 11 94hex 76H stl elastic stop nut 4 Si EE 190757 SOLENOID ASSY consisting of 1 de id Lab ek 118658 55 LINKAGE beg dead etc d ncn ero ae cese ECTS 115857 BRACKET mtg solenoid idle 1 DONA MU Aie 005373 SOLENOID 14vdc 84 pull type cont 1
6. 1 4 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 1 5 Principales normes de s curit 1 6 Information sur les champs lectromagn tiques SECTION DEFINITIONS 225 iii ME EI 2 1 Symbols And Definitions SECTION 3 SPECIFICATIONS 3 1 Weld Power And Engine Specifications 3 2 Dimensions Weights And Operating Angles 3 3 Volt Ampere Curves For CC Models 3 4 Volt Ampere Curves for CC CV Models 9 59 otiam a ctr t ede i a d brat 3 6 Duty Cycle And 3 7 Auxiliary Power Curve 3 8 Optional AC Power Plant Curves SECTION4 INSTALLATION ERE RR RES 4 1 Installing Welding Generator See Sections 4 2 And 4 3 2 2 sing ta bte RE Caio ttc SEQ ie 4 3 Mounting Welding Generator 4 4 Installing Exhau
7. RES s a eee ex 1 TP E 200 969 HOSE x ses ED eap o DER de 1 d Dna doter ca 189 464 SEAL weather lift eye 1 173 909 HOSE sae 312 id x 560 od x 24 000 order by ft 2 ee tee eee 201 658 UPRIGHT center 1 eh e 4200999 2 0 coe Sees eG Ges 1 TOU a ek ah So an ihe 196 220 BRACKET hold down fuel tank rear 1 EN PME 192 362 BRACKET mtg nyl 1 2 conduit 1 PT 2200995 GOVER aem e OU tuo DEDA 1 aan 189 052 GROMMET plastic neck filler fuel 1 ADO soe 190 198 CAP tank screw on 3 500 in w vent 1 exco Po 192 042 LABEL use gasoline fuel 1 Mao a God atra au on 108 487 LABEL warning falling equipment 2 th ed cantra 010 875 CLAMP muffler 2 000 dia 1 DEC MESES 105 740 PIPE muffler exhaust engine 1 925 inlet outlet 1 NUR o POI 201851 COVER radiator access 1 va dud 176 230 LABEL warning
8. Control Circuit This unit has a max OCV control circuit that resets Am perage Adjust control R1 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 oircuit is disabled when the Stick TIG Selection switch is in Scratch Start TIG position see item 15 13 Ampere Range Switch 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 14 Amperage Adjust Control Control adjusts amperage within range se lected by Ampere Range switch Weld output would be about 153 A DC with controls set as shown 50 of 100 to 205 A gt The numbers around the control are for reference only and do not represent an actual percentage value 15 Stick TIG Selection Switch Use switch to disable the max OCV 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
9. Service Welding Generator Brushes And Slip Rings Service More Often In Dirty Conditions Stop engine and let cool gt 1 Spark Arrestor Muffler OFF opt Tg oo 2 Cleanout Plug lt gt Remove plug and remove any dirt dads covering cleanout hole Qs Exhaust Pipe 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 8in 802 729 Ref 201 841 OM 4405 Page 35 8 4 Servicing Air Cleaner Stop engine Do not run engine without air cleaner or with dirty element En gine damage caused by using a damaged element is not covered by the warranty Y m RUN IDLE gt The air cleaner primary element be cleaned but the dirt holding capac RUN ity of the filter is reduced with each 7 cleaning The chance of dirt reaching odd the clean side of the filter while clean ing and the possibility of filter damage makes cleaning a risk Consider the 5 risk of unwarrantable equipment damage when determining whether to clean or replace the primary ele ment UAAAAAAA A 5 RN ANNA 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 sa
10. CIRCUIT BREAKER man reset 1P 20A 250VAC frict 14 GFCI1 151 981 RECEPTACLE str dx grd 2P3W 15 20A 125V GFCI 1 15 RC1 147 632 RECEPTACLE tw Ik 2P3W 30A 250V L6 30R 1 190 861 LABEL warning electric shock and moving parts 1 deerme gee 3201 1055 Qux OW cid ad Ka Rd bose da 1 083 030 STUD brs 250 20 x 1 750 w hex collar 1 601 836 250 20 50hex 19h brs 3 196 073 LABEL do not switch while welding 1 12 91958252 SWITCH DOIAN 2 ees 1 Le 201 125 PANEL mtg terminal pwr 1 039 046 TERMINAL pwr output black 1 TEMPE 190 735 WASHER output stud 2 2 181 169 SPAGER OUIDUL SIUO 424020 ivi oven 2 186 621 BOOT generic output Stud 2 26 PE 059 779 SWIIQIY ie sica msn Om af ER eae romance 1 ZT MEE 010 647 PIN spring cs 156 x 1 250 a ea na te ER oa C te EC m 1 PO vau 039 047 TERMINAL pwr output red 1 zi PEE 193 2
11. e Do not touch live electrical parts Wear dry hole free insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground e 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 e f AC output is required use remote output control if present on unit e 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 e Properly install and ground this equipment according to its Owner s Manual and national state and local codes e 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 e When making input connections attach proper grounding conduc tor first double check connections e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off 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
12. iis dtu dti 010937 PIN Spring Cs 093 629 eicere Eee d cese eed 11 ni UE 199 505 HOSE oil drain assy 32 in consisting of d anes 169 271 2 VALVE 282284 mti meme ae x 1 dos OOF seins atari 176 529 FITTING hose brs barbed fem 1 2tbg x 3 8NPT 1 phd OU Bk 113 854 HOSE SAE 500 ID x 780 OD xc oil order by ft ordi 197 448 FITTING hose brs barbed elbow 1 2 tbg x 3 8 npt 1 E awe eee 201 141 FITTING engine adapter oil drain 12 20 x 3 8 npt female 1 quies D a cia ec et 201 962 as WASHEROll 1 vix OT HOSTIE OENERATOR 1 191 697 s BRACKET MIOUN aA cs ico Im na ed M que Ee nh ac 4 191 512 BRACKET hold down fuel tank 1 190 250 LABEL warning do not weld on 2 RT Ot were eee 190 179 PANEL mtg components 1 ae Dia aad oe R2 189 699 RESISTOR WW tap 375W 10 ohm w mtg bkt 1 R3 189 699 RESISTOR WW tap 375W 10 ohm w mtg bkt 1 Figure T 2 Figure 11 3
13. 17 D8 C8 189 701 DIODE CAPACITOR BOARD 1 a2 CB10 190374 CIRCUIT BREAKER auto reset 12VDC 40A 1 Asie 149 990 s SOCKET Avs ean TRADER E Rh esr 9 A Ein Bick PLG4 114 062 CONNECTOR rect univ 084 15P S row plug cable 1 185 655 SEAL wire univ 15P S row 1 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 4405 Page 67 4 CAD SON v RNN A wd Hardware is common and i m not available unless listed L wy 40 39 38 Sn N 802 799 Figure 11 4 Panel Front w Components CC Models Dia Part No Mkgs No Description Quantity Figure 11 4 Panel Front w Components CC Models Figure 11 1 Item 104 TT wc 201 841 PLATE SCREENED ident control rating when ordering this item UE the nameplate should also be ordered 1 ee oa Rees NAMEPLATE screened order by model and serial number 1 PN REED 201 580 PANEL engine weld control 1 uada S3 189382 SWITCH range changeover
14. PARIS LIST 60 OPTIONS AND ACCESSORIES WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 Symbol Usage Means Warning Watch Out There are possible hazards with this procedure The possible hazards are shown in the adjoining symbols Marks special safety message gt Means Note not safety related 1 2 Arc Welding Hazards 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 1 5 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 equipment is a hazard
15. e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual rom nd 11 98 This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazards 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 e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists after stopping engine on inverters e Stop engine on inverter and discharge input capacitors according to instructions in Maintenance Section before touching any parts 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 a welding helmet fitted with a proper shade of filter 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 W
16. When switch is in Scratch Start TIG position the max OCV and arc drive dig circuits are disabled and OCV changes when the control is adjusted 16 Amperage Adjust Switch And Remote Amperage Adjust Receptacle Connect optional remote control to RC13 See Section 4 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 Am perage Adjust receptacle RC13 see Sec tions 4 10 and 5 3 17 Polarity Switch Optional 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 18 DC Voltmeter Optional Voltmeter displays voltage at the weld output terminals but not necessarily the welding arc due to resistance of cable and connections 19 DC Ammeter Optional Ammeter displays amperage output of the unit OM 4405 Page 23 5 3 Remote Amperage Control On CC Models Optional 1 Remote Amperage Adjust Receptacle RC13 Connect optional remote control to RC13 see Section 4 10 In Example Example Combination Remote Amperage Control Stick Range 100 to 205 A DC Percentage Of Range 5096 Max About 153 A DC 50 of 100 to 205 100 205 165 350 SA Max 153 A DC _ _ SCRATCH FR START 5 TIG 75 A DC Set Switches Set Range Ym Set Control Adjust Optional Remote Con
17. 197 527 GUARD circuit breaker 2 22 2 4 4 1 N 197 363 TERMINAL ring tng screw 3 22 CB7 196 780 CIRCUIT BREAKER man reset 1 201 106 PANEL auxiliary power 1 RE 201 107 PANEL auxiliary power full KVA option 1 EHE 196 781 BOOT circuit breaker 3 pole 1 PEL MEETS 9197 5085 PLUG DIOIGCIVO o bri dos debeo fec edel d Geer ee 1 077 440 BUSHING conduit 11 1 601 836 NUT 250 20 50hex 19h brs 3 s IDE 197 291 COVER receptacle w gasket 1 HA cath 083 030 STUD brs 250 20 x 1 750 w hex 1 CT2 197 433 TRANSFORMER current sensing 1 TN PET 190 861 LABEL warning electric shock and moving parts 1 WEE DoD 197 399 LABEL warning ph auxiliary 1 cow 193 260 COVER receptacle 2 250 dia lexan 1 193258 COVER receptacle REC SC CA rt Sees 1 scan e
18. PLG6 114063 CONN rect univ 084 4p s 1row plug cablelkg 1 METER 192309 CLIP snap in 630 bundle 250 hole 248 thk 2 no PU TUR 177136 GLEAMP capacitor 1 3 75 1 2 m roc rem RE rS 1 9 087 110 CAPACITOR elctit 240uf 200VDC 1 mo PX 141424 RESISTOR ww fxd 30 w 25 ohm faston te 1 15 PC7 195706 MODULE pull to idle two output 7 pin 1 16 CR4 113247 RELAY 12vdc 20a 120vac 8pin flange mtg 1 PEN CR6 090104 RELAY 12vdc spst 0 15 5pin flange mtg 1 18 CRI CR2 CR3 090 104 RELAY encl 12VDC SPST 30A 15VDC spin flange mtg 3 Sr 201 357 HARNESS engine control consisting of 1 zx 922 99 1989 701 lt gt DIODE CAPACITOR BOARD A iN 1 20 10 190 374 CIRCUIT BREAKER auto reset 12VDC 40A 1 148 850 SOCKET relay 29 TET PLG4 114 062 CONNECTOR rect univ 084 15P S row plug cable 1 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
19. S6 O 48 6 7 fx e gt 6 gt 9 10 48 68 STICK RMT 11 12 84 98 x x X CLOSED TO B MIG RMT X CONTACT CLOSED TERMINAL PLG13 42 eB z 225 1 40 n CR1 3 740 5 4 02 74 CR2 CR3 SL SW sw2 m E UE 7 BATTERY wee 46 i 5 ae E 12 VOLT S2 p 5 0 BAT O DA O L _ 151 3 57 42 LOCATED IN IGNITION CARBURETOR SYSTEM ALT START AID IS NOT USED ON 42 42 BIG 40 WG 42 60 08 Figure 9 2 Circuit Diagram For CC CV Welding Generator OM 4405 Page 50 INN NWN A 7 REMO AN D1 2 C3 02 D3 K2 F3 J2 B3 9 LED BOARD RC1 PLG13 68 WARNING e Do not touch live electrical parts Disconnect input power stop engine before servicing Do not operate with covers removed Have only qualified persons install use or service this unit RECEPTACLE PACKAGE OPTIONS 256 AUX POWER OPTIONAL OPTIONAL mem L O PROTECTION ES 1d PC7 IDLE MODULE 57 COOLANT TEMP SENDER FUEL LEVEL SENDER 42 ENGINE GAUGE 1 OPTON ENGINE GAUGE L OPTION J WITH THE ENGINE GAUGE OPTION THE COOLANT TEMP amp OIL PRESSURE SENDERS REPLACE SWITCHES S7 amp S8 WELD METERS a PC3 POLARITY SWITCH OPTIONAL THE POLARITY SWIT
20. 2 240V 16 AC European European Receptacle Receptacle RC1 3 240V 15 A AC Australian Receptacle RC1 4 240V15AAC 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 120 V 20A 1 60 Hz 240 V 15A gt At least once a month run en gine at weld power speed and press test button to verify GFCI is working properly 1 3 5 Circuit Breaker CB2 6 Circuit Breaker CB3 CB2 protects GFCI1 from overload If CB2 opens GFCI1 does not work Place button to reset breaker Australian Receptacle CB3 protects RC1 from overload If CB3 opens RC1 does not work Press button to reset breaker gt If a circuit breaker continues to open contact Factory Autho rized Service Agent 120 V 20A 1 60 Hz 240 V 15 A gt Auxiliary power is not affected by weld output South African Receptacle Maximum output is 2 4 from GFCI1 and 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 9 120 V 20A 1 V 60 Hz 240 V 15A 191 624 OM 4405 Page 32 SECTION 8 MAINTENANCE amp TROUBLESHOOTING 8 1 Maintenanc
21. 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 4405 Page 58 Notes OM 4405 Page 59 SECTION 11 PARTS LIST Hardware is common not available unless listed SS CC ONLY 96 104 FIG 11 4 OR 11 5 Figure 11 1 Main Assembly OM 4405 Page 60 C ASS M 802 789 OM 4405 Page 61 Dia Part No Mkgs No Description Quantity Figure 11 1 Main Assembly ee eee 1989 924 PANEL gen LH t en Ses tni 1 191 623 LABEL warning all panels must be in place while running 2 TUN CUR 189 828 PANEL engine Side 1 TT UT Z1 s 96202 151 REACTOR OC jer d cede n 1 Pre Z 1 2 9201 914 c REAG TOR moe de 1 zu D auri 1T 038621 BLOCK term 30A 4 pole frict term str 1 eee ee ux 038 620 LINK jumper term blk 30A 2 TE SERLO 081 499 BRACKET mtg strip t
22. 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 the 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 7 00 Owner s Record Please complete and retain with your personal records Model Name Purchase Date Distributor Address City State Serial Style Number Date which equipment was delivered to original customer For Service Call 1 800 4 A Miller or see our website at www MillerWelds com to locate a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for Contact the Delivering Carrier for For assistance in filing or settling clai
23. HEAT SINK rectifier al 1 25 isses mede e 2 20 03 95 97 037956 DIODE rect 275A 300V SP css unit 3 D2 06 037 957 lt DIODE rect 275A 300V RP ia ecu hm ERU Ime ERR UNI 3 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 4405 Page 74 Warranty Questions Call 1 800 4 A MILLER for your local Miller distributor Your distributor also gives 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 The Power of Blue Effective January 1 2000 Equipment with a serial number preface of LA or newer This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed 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 T
24. Voltage Sensing Wire Feeder CV arc drive dig circuit provides addi Wire Feeder CV Using Remote tional amperage during low voltage CQ short arc length conditions to pre vent sticking electrodes The arc drive dig circuit is disabled when switch is in MIG or TIG positions Place switch in Electrode Hot Stick position when using option al auxiliary power plant see Sec tion 7 2 gt The engine auto idle function does not work in the Remote TIG mode Process Contactor Switch Settings Switch Setting Process Output On Off Control Engine Auto Idle GTAW With HF Unit Pulsing Remote Device Or Remote Control At Remote 14 Receptacle Not Active Remote Stick Stick SMAW With Remote On Off At Remote 14 Receptacle Active Remote MIG MIG GMAW At Remote 14 Receptacle Active Electrode Hot MIG MIG GMAW Electrode Hot Active Stick GMAW Electrode Hot Stick Air Carbon Arc CAC A Cutting Electrode Hot Active And Gouging Scratch Start TIG GTAW Electrode Hot Active OM 4405 Page 28 6 4 Remote Voltage Amperage Control On CC CV Models Optional 1 Remote 14 Receptacle RC14 Connect optional remote control to RC14 see Section 4 11 Example Combination Remote Amperage Control Stick In Example Process Stick Using Remote On Off Range 110 to 315A DC Min 110 A DC Max 315 DC 50 335 Max 315 D
25. an uc 28 1085 3 5 108 LENT STATOR je CBE 56 83 A 297 Pr 2 Ti GFCI1 120V CB 26 gt 10 zm D E 85 wH PLG3 RC3 EN 138 138 Ino IN 1 STATOR up din Dike 42 85 4 022 32705 102545102 55 gt 107 5 403 106 5 gt 106 109 g gt 10 02555108 510 es 11 770 IM aas 113 PLG4 RC4 42 42 gt 1 44 44 CBS gt gt AUX 56 STATOR wes 96 2 3 58 Pdl P a ae 127 82 6560 3 10 49 100 Ou OF 705 108 FT 27 TE BS 7 34 REG 736 R 135 5 JM NA A RC2 PLG14 104 F21 ce A3 PC6 AUX FILTER BOARD STATUIS lt M 1 L FIELD CURRENT 117 REGULATOR 7 gt cs A1 PLGB 30 PIN 10 82 A1 F3 Pics 18 PIN 5757567 AS 69 569 RC14 ZI 1522 7 gt 87 gt 13 gt 14 gt 729 PANEL 5 7 2 RC2 PLG14 PLG6 RC6 125 26 126 6 26 gt gt gt 4 gt E E2 G2 OUTPUT CONTACTOR gt o 0 M Qo LES gt 74 135 135 SWITCH LEAD olo 5 222 42 NUMBERS NUMBERS F 1 2 ne zo x x x S4s xxx S 5 umo Em TIG RMT O
26. dans la Section Maintenance avant de toucher des compo sants LES RAYONS DE L ARC peuvent pro voquer des br lures dans les yeux et sur la peau Le rayonnement de l arc du proc d de soudage des rayons visibles et invisibles intenses ultraviolets et infrarouges susceptibles de provoquer des br lures dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage e Porter un casque de soudage muni d un cran de filtre appropri pour pro t ger votre visage et vos yeux pendant le soudage ou pour regarder voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit e Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev e Utiliser des crans ou des barri res pour prot ger des tiers de l clair et de l blouissement demander aux autres personnes de ne pas regarder l arc e Porter des v tements de protection constitu dans une mati re durable r sistant au feu laine ou cuir et une protection des pieds 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 sant e Eloigner votre t te des fum es Ne pas respirer les fum es e l interieur ventiler la zone et ou utiliser un chappement au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Sila ventilation est insuffisante utiliser un respirateur alimentation d air homolo
27. row rcpt cable panel CIRCUIT BREAKER man reset 1P 15A 250VAC SOCKET relay 5 pin SWITCH rotary 6 position gold contacts located on front panel see Figure 11 5 SWITCH tgl spdt 15a 125vac on none on spd term chr CONN rect univ 039 6p s 3row plug cable located on front panel see Figure 11 5 802 360 Quantity Dia Part No Mkgs No Description Quantity Figure 11 3 Control Box Assembly CC CV Models Continued E 177 859 CONN body 5 terminal to engine control switch S1 1 193 183 CONN epi we 196 602 PLUG cavity 18 30 position cinch connector 4 ALME 196 603 SEAL switch 6 position rotary 250 shaft d TUTTO 141 450 CONN rect metrmate 10skt 1row plug cable 1 dass 4 42 195706 MODULE pull to idle two output 7 pin 1 14 CR4 113247 RELAY 12vdc 20a 120vac 8pin flange 1 TN CR6 090104 RELAY 12 spst 30a 15vdc 5pin flange mtg 1 16 CRI CR2 CR3 090 104 RELAY encl 12VDC SPST 30A 15VDC spin flange mtg 3 E E en Scat neues 201 357 HARNESS engine control consisting of 1
28. 225152 fft M PBS 4 52 2255522 2056562 57 gt 7 gt 27 f gt 2259562 0s 9 gt Z2 751521 2757527 13 14 5 5 PLG6 RC6 LE 5128 Os 5126 6 3 gt PLG7 RC7 ia 103 1 gt 2 gt DE 718 OM 4405 Page 48 SECTION 9 ELECTRICAL DIAGRAMS 95 STICK me P 71 56 4 OPTIONAL M STANDARD 81 a Rd Al 27 aa RECEPTACLE m STATOR RCI 240 AUX pi 55 STATOR X JN ED m GFCI1 120V CB2 wH EX d aux STATOR GND 42 nam 1 LEAD 89 NOT CONNECTED ON CC MODEL 7 89 722 CR4 100 737 F1 AUX STATOR 707 104 l 1358 2 T X STATOR C1 D 1 CR7 0 C V CONTROL RC13 78 wo 2 R4 NOT USED ON CC MODEL 50 X CLOSED TO B TERMINAL 40 CB 10 44 40 40 CR1 43 56 AED CR2 CR3 12 VOLT ro t 74 cB 541 2 START MS1 12 VOLT ps G NC STARTER E LOCATED CARBURETOR UE 57 START AID IS 42 42 NOT USED ON 42 BIG 40 WG m D8 C8 Figure 9 1 Circuit Diagram For CC Welding Generator WARNING RECEPTACLE PACKAGE OPTIONS oc 0 0 RECTIFIER PROTECTION PC7 IDLE MODULE 71 iu 57
29. 45 lg No 1 awg w clamp and 406rng 1 Wade UE 203 430 BRACKET battery holddown 1 190 897 BATTERY stor 12V 650crk 110rsv gp 24 1 NM TE 201 006 BOLT j stl 312 18 8 500 2 EE 201 183 COVER battery access 1 pix De 168 385 LABEL warning battery explosion can blind 1 DO dash wd 201 996 LABEL warning do not operate with guard missing 2 oT EEEE 200 967 HOSE radiator lower Wis Con 20 1 meu ras 200 990 GUARD fan right side 1 oo tat de 190 992 KEEPER latch engine access door 1 190 076 CHANNEL stiffener engine access 1 TERE S e AEE E 199 592 LATCH paddle series 20 black 1 EDS dye del 201 031 LABEL gasoline engine maintenance Wis Con TM 20 1 pais 200 989 DOOR engine access 1 189 975 HINGE door access 1800 0 2 RET 190 190 TANK coolant recovery
30. 6 6 1 6 1 To eat Le 4 4 3 4 3 22 20 ENGINE GAUGE p OPTION S8 OIL 57 COOLANT PRESSURE TEMP SENDER SENDER 42 42 42 42 42 42 42 ENGINE GAUGE ENGINE GAUGE L OPTION L OPTION WITH THE ENGINE GAUGE OPTION THE COOLANT TEMP amp OIL PRESSURE SENDERS REPLACE SWITCHES 57 amp S8 e Do not touch live electrical parts e Disconnect input power or stop engine before servicing e Do not operate with covers removed Have only qualified persons install use or service this unit POLARITY SWITCH OPTIONAL x WITH THE POLARITY SWITCH OPTION LEADS 19 amp 30 GO TO THE POLARITY SWITCH RATHER THAN THE OUTPUT STUDS THE OUTPUT STUDS ARE LABELED 79 ELECTRODE AND WORK T STR 71 WELD METERS 222 224 OPTIONAL 0 POSITIVE 29 ELECTRODE NEGATIVE WORK MACHINE WIRE NUMBERS 10 59 WELD SECONDARY 40 79 ENGINE CONTROLS EXCEPT 42 CHASSIS 80 99 AUX SECONDARY 100 149 EXCITER CONTROL 6 1 s 42 42 201 991 4405 49 59 gt STICK PLG1 RC1 PLG14 TIG O MIG 2 100 100 n pd Fd s Y 1 OPTIONAL STANDARD pue P oum 8 87 Eua an EIE a RECEPTACLE 707 101 121s O 719 PACKAGE 1035 103 12 5 5 ee 4 4 STATOR gt 106 _ 706 179
31. Contactor switch in a Electrode Hot position or place switch in a Remote position and connect remote contactor to optional Remote 14 receptacle RC14 see Sections 4 11 and 6 1 Check position of Ampere Range switch Check position of optional polarity switch Reset circuit breaker CB11 see Section 8 9 Reset circuit breaker CB5 see Section 8 9 Check for faulty remote device connected to RC 14 Check and secure connections to Remote 14 receptacle RC14 see Section 4 11 Have Factory Authorized Service Agent check connector board PC6 and connections Check fuse F2 and replace if open see Section 8 9 Have Factory Authorized Service Agent check brushes and slip rings field excitation circuit field current regulator board PC1 and the rotor No weld output or auxiliary power output Disconnect equipment from auxiliary power receptacles during start up Check fuses F1 and F2 and replace if open see Section 8 9 Have Factory Authorized Service Agent check integrated rectifier SR1 capacitor C9 field current regulator board PC1 and the rotor 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 High weld output Chec
32. Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Water Coolant Systems Units Grids Maxstar 140 Spot Welders Load Banks Miller Cyclomatic Equipment 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 4 6 Months Batteries 5 90 Days Parts MIG Guns TIG Torches Induction Heating Coils and Blankets APT ZIPCUT amp PLAZCUT Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate 185 amp Spoolmate 250 Canvas Covers Millers True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear 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 sp
33. Engine Speed RPM He Engine speed is factory set and should not require adjustment Af Weld Power ter tuning engine check engine enn speed with tachometer or frequen cy meter See table for proper no load speed If necessary adjust speed as follows Start engine and run until warm On CC Models place Stick TIG switch in Stick position On CC CV models turn Process Contactor switch to Stick Elec trode Hot position 1 Socket Nut Governor Linkage Rod Lock Nut Socket Governor Arm Rod length should be 3 1 4 in 83 mm between lock nuts To adjust remove socket from arm and loos en lock nut Turn socket to adjust length Tighten nut and reattach socket to arm A If linkage binds loosen socket nuts and turn sockets until link age works smoothly Tighten nuts 6 Carburetor 7 Throttle Stop Plate 8 Throttle Stop Clearance between plate and stop should be 1 16 in 1 6 mm To ad just clearance proceed as follows 9 Linkage Pivot Arm 10 Linkage Socket 11 Lock Nut Remove socket at arm and loosen lock nut Turn socket to adjust clearance Reattach socket and tighten nut Start engine and run until warm Turn Engine Control switch to Run position 12 Governor Speed Screw 13 Lock Nut Loosen nut Turn screw until engine runs at weld power speed Stop engine Close door Tools Needed 3 lt 3 8 7 16 in NGF OM 4405 Page 37 8 6 EM i
34. LE LIQUIDE DE REFROIDISSEMENT CHAUD peuvent provoquer des br lures e est pr f rable de verifier le liquide de refroidissement 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 autre ment dans la section maintenance du manuel du moteur e Sile moteur est chaud et que le liquide doit tre v rifi op rer comme 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 DES ORGANES MOBILES peuvent provoquer des blessures AJ e Ne pas approcher les mains des ventilateurs cour roies et autres pieces en mouvement e Maintenir ferm s et fixement en place les portes panneaux recouvrements et dispositifs de protection e Arr ter le moteur avant d installer ou brancher l appareil Demander seulement un personnel qualifi d enlever les dispositifs de s curit ou les recouvrements 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 entre tien d brancher le cable n gatif de batterie de la borne e pas approcher les mains cheveux v tements laches et outils des or ganes mobiles e Remettre en place les pannea
35. STATIC ESD can damage PC boards e Puton grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards FLYING SPARKS can cause injury e Wear 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 TILTING OF TRAILER can cause injury e Use tongue jack or blocks to support weight e Properly install welding generator onto trailer according to instructions supplied with trailer 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 READ INSTRUCTIONS e Use only genuine MILLER replacement parts e Perform engine maintenance and service e Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable according to this manual and the engine manual OM 4405 Page 3 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 Theuseris responsible for having a qualified electrician prompt ly correct any interference problem resu
36. d viter tout danger Les consignes de s curit pr sent es ne font que r sumer l information contenue dans les normes de s cu rit num r es la section 1 5 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 particulierement les enfants e UN CHOC LECTRIQUE peut tuer Un simple contact avec des pi ces 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 comportant pas de trous e Sisoler de la pi ce et de la terre au moyen de tapis ou d autres moyens iso lants suffisamment grands pour emp cher le contact physique ventuel avec la pi ce ou la terre e Ne pas se servir de source lectrique acourant lectri
37. drained fuel in an environmentally safe manner Do not leave unit unattended while draining fuel tank Properly lift unit and secure in a level position Use adequate blocks or stands to support unit while drain ing fuel tank Attach 1 2 ID hose to drain valve Put metal container under drain and use screwdriver Tools Needed 5 gt 802 731 Ref 801 434 to open sludge drain valve Close valve when sludge has drained Remove hose Close door To replace fuel filter 5 Fuel Line 6 Fuel Filter Remove clamps and filter Install new filter and clamps Inspect fuel lines and replace if cracked or worn Wipe up any spilled fuel Start engine and check for leaks Stop engine tighten connections as necessary and wipe up Spilled fuel Close door 8 9 Overload Protection Stop engine gt When a circuit breaker or fuse opens it usually indicates a more serious problem exists Contact Factory Authorized Service Agent 1 Fuse F1 2 Fuse F2 F1 and F2 protect the stator exciter winding from overload If F1 opens weld and auxiliary power is low or stops entirely If F2 opens weld out put is low or stops entirely 4 kW auxiliary power is still available 3 Circuit Breaker CB4 Not Shown 4 Circuit Breaker CB5 CC CV Models Only 5 Circuit Breaker CB10 Not Shown 6 Circuit Breaker CB11 7 Circuit Breaker CB12 8 Circuit Breaker CB13 CB4 protec
38. hot 1 PE 19153945 SUPPORT COVOI ae ne dotem pd dodi 1 NOS CERTE RN 189 245 TANK fuel 23gal consisting of 1 TEX RESP PR 124 253 BUSHING tank f el es 4 T PPP 084 173 CLAMP hose 460 545clp dia 51 2 a AAE 189 912 FITTING stl barbed elbow w 047 in orf zinc pld 1 EAE 189 909 FITTING stand pipe hose 250 x 9 260 lg 90deg Zinc 1 NEL 2013025 CAP TUSIND ear uns de 1 HE eos 189 913 FITTING stl barbed elbow zinc pld 1 eae Ae ws aa 190 142 SENDER fuel gauge 9 7500 deep tank 1 WM op 189 910 FITTING stand pipe hose 3125 x 9 260 lg 90deg zinc 1 ER 189 908 VALVE drain fuel 1800 60 1 NUM 181 572 BUSHING IPIE a at chs 1 sin DT 191 446 EXTRUSION rubber w adhesive 1 000 x 1 000 D order by ft oft Trace 013 367 LABEL warning moving parts 2 200 984 ENGINE Wis Con gasoline TM 20 consisting of 1 025 474 SWITCH therm
39. in nyl 375 ID x 500 mtg hole 1 135 873 CLIP conduit convoluted 1 2 in 2 187 654 SEAL wire univ 12p s row 1 024 103 BLANK snap in 750 mtg hole blk 1 120 304 BLANK snap in nyl 250 mtg hole black 2 When ordering a component originally displaying a precautionary label the label should also be ordered Order label individually or as part of Label Kit 202 022 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 Hardware is common OM 4405 Page 72 not available unless listed 802 800 Figure 11 6 Generator Dia Part No Mkgs No Description Quantity Figure 11 6 Generator Figure 11 1 Item 91 PL ree 132 053 SCREW 375 16x1 50 hex hd pln gr5 pld 6 ro PEE 183 387 WASHER conical spring 406 ID x 875 OD plid 6 T T 195 911 ENDBELL gen consisting of a oon d at uni t jo EDI Ur EI 1 dei oies ue 143 220 s O RING 2 859 ID X 139CS nas at 1 A nd 201 099 STATOR exciter aux 1 UPC 201 110 STATOR weld assembly complete
40. le transport du courant sur une longue distance par des che mins inconnus ventuels en provoquant des risques d lectrocution et d incendie e Ne pas utiliser le poste de soudage pour d geler des conduites gel es e cas de non utilisation enlever la baguette d lectrode du porte lectro de 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 poches telles qu un allumeur au butane ou des allumettes DES PARTICULES VOLANTES j je peuvent blesser 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 vo lantes Pendant la p riode de refroidissement des soudures elles ris quent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial LES ACCUMULATIONS DE GAZ ris quent de provoquer des blessures ou 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 respi rateur d adduction d air homologu des r servoirs tambours ou des conduites peut provoquer DES PIECES CHAUDES peuvent provoquer des br lu
41. lock nut stl pld 4 JO A e 201 139 FLYWHEEL engine Wis Con 20 1 201 140 ADAPTER engine Wis Con 20 1 PER 191579 COVER starter hole 1 200 991 GUARD starter hole Wis Con TM 20 1 T E 191 580 x COVER Statterole Ae 1 TN 2 172 555 SCREW M10 1 5 x 50hexhd pln 8 8pld 6 VLL PR 602 159 SCREW 312 18 75 hexwhd 66d stl pld slffmg tap rw 6 i gee ee pug 601 950 SCREW 312 18 x 2 00 hexhd pln gr 5pld 4 o ERES 602 211 WASHER lock 318 ID 0 586 6 139 341 s WASHER dos e Exe code ds 4 5190823 BRUSH contact s osuere 3 C PEE 1967500 55 OERS OINO pte be e eee zac te 3 Toc 189 142 BRUSHHOLDER ASSEMBLY gen 1 orm 602 242 WASHER flat 3751Dx0 8750dx 083t stl 2 604 534 SCREW 312 18x1 25 hex hd pln gr5 pld 2 190 259 HARNESS brush consisting of d Tm PLG1 135 134 CONNECTOR rect un
42. parts from your local distributor OM 4405 Page 65 ltem Dia Part No Mkgs No 1 Fi F2 085 874 AU Me Se E 046 432 201 077 ree 201 078 201 079 134 201 T7 PC9 192 224 T 9 087 110 177 136 ten 201 495 10 SH1 035 704 11 5 090 104 RC4 047 483 TC RC3 158 466 RC1 135 133 12 CB11 12 13 139 266 prre 148 850 Vd RUNE o6 193 324 TP 5 011 609 Tm 150 316 OM 4405 Page 66 Figure 11 3 Control Box Assembly CC CV Models Description Figure 11 3 Control Box Assembly CC CV Models Figure 11 1 Item 98 FUSE mintr cer slo blo 10 250 HOLDER fuse mintr 250 x 1 250 S GON TROL BOX II iss v ee oet GONTROLE BOX Id iiia hti ri e terae eter ae COVER control DOX itaque bodes EIER eles EL STAND OFF support pc card CIRCUIT CARD ASSY display CAPACITOR elctit 240uf 200VDC GEAMP capacitor 1 3750ld ie ebbe REP Ee HARNESS control box cv weld control consisting of RECTIFIER integ 40A 800V RELAY 12VDC SPST CONNECTOR rect univ 084 15P S row rcpt cable panel CONNECTOR rect univ 084 12P S row rcpt cable panel CONNECTOR rect univ 084 9P S
43. see Sections 4 7 and 8 10 See engine manual Engine slowly stopped and cannot be restarted Check fuel level Check engine air and fuel filters see Section 8 8 Check engine wiring harness connections 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 rinse with clear water Recharge or replace battery if necessary Periodically recharge battery approximately every 3 months Engine idles but does not come up to weld speed Have Factory Authorized Service Agent check idle module PC7 current transformer CT1 and throttle solenoid TS1 Check for obstructed throttle solenoid and linkage Engine does not run at idle speed CC models place Stick TIG Selection switch in Stick position CC CV models place Process Contactor switch in any position but Remote TIG Check for obstructed throttle solenoid and linkage Have Factory Authorized Service Agent check idle module PC7 and control relays CR3 and CR6 OM 4405 Page 46 Notes OM 4405 Page 47 PLG1 RC1 100 5100 5105 207 3 102 702 106s 5106 704 TE gt gt 7 gt 1005 3 5108 gt 9 gt PLG3 RC3 Oy gt 82 PS gt 97 22 vL 2 12 ys 7275 5 gt las 100 7 gt 106 LE 3 E 25 9 725 1775105217 1265 7 126 12 gt _ PLG4 RC4
44. 1 Check voltage requirements of wire feeder 115 volt output not available through Remote 14 recep tacle see Section 4 11 Repair or replace wire feeder Low CV weld output Set Ampere Range switch to highest range 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 field current regulator board OM 4405 Page 44 C Standard Auxiliary Power Trouble Remedy No auxiliary power output weld output okay Reset receptacle circuit breakers No auxiliary power or weld output Disconnect equipment from auxiliary power receptacles during start up Check fuses F1 and F2 and replace if open see Section 8 9 Have Factory Authorized Service Agent check integrated rectifier SR1 capacitor C9 and the rotor Reset circuit breaker CB12 Have Factory Authorized Service Agent check diode D1 CC models or field current regulator board PC1 CC CV models see Section 8 9 Have Factory Authorized Service Agent check brushes and slip rings and field excitation circuit High output at receptacles auxiliary power Check engine speed and adjust if necessary Have Factory Authorized Service Agent adjust auxiliary power field current resistor R3 Low output receptacles auxiliary power Check
45. 100 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 4405 Page 55 10 8 Power Required To Start Motor Motor Start Code Running Amperage Motor HP Motor Voltage To find starting amperage AC MOTOR 60 PHASE 1 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 Single Phase Induction Motor Starting Requirements motor s running amperage Motor Start E S P kVA HP x HP x 1000 VOLTS EXAMPLE Calculate the starting amperage required for a 230 V 1 4 HP motor with a motor start code of M Volts 230 1 4 Using Table Code M results in KVA HP 11 2 STARTING AMPERAGE 11 2 x 1 4 x 1000 230 122A Starting the motor requires 12 2 amperes 10 9 How Much Power Can Generator Supply 1 LimitLoad To 90 Of
46. 140 OM 4405 Page 12 3 7 AC Auxiliary Power Curve The ac power curve shows the aux power in amperes available at 150 300 the 120 and 240 volt receptacles 125 250 100 200 75 150 ep ET O gt O lt 50 100 25 50 5 10 15 20 AC AMPERES IN 240V MODE 20 30 40 AC AMPERES IN 120V MODE 3 8 Optional AC Power Plant Curves u The ac power curves show the aux A 12 kVA kW Single Phase Auxiliary Power Plant No Weld Load iliary power available in amperes at the single phase 120 240 volt re 280 ceptacle or three phase 240 volt terminals 260 240 220 AC VOLTS 200 180 20 40 60 80 100 AC AMPERES B 15 kVA kW Three Phase Auxiliary Power Plant No Weld Load 280 260 240 220 AC VOLTS 200 AC AMPERES 198 868 98 869 OM 4405 Page 13 SECTION 4 INSTALLATION Installing Welding Generator See Sections 4 2 And 4 3 4 1 Airflow Clearance Grounding 2 3 Electrically bond generator frame to S uz vehicle frame by metal to metal contact 4 Location Always securely fasten welding generator onto transport vehicle or trailer and comply with all DOT and other applicable codes Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards Generator Base Metal Vehicle Frame Equipment Grounding Terminal Grounding Cable Use 10 AWG or larger insulated copper wire If uni
47. 3 Optional Auxiliary Power Receptacles O1 O1 Cl A R NN CO N ee 10 10 et eodd 11 detre fie 12 idee 12 13 13 Continued TABLE OF CONTENTS SECTION 8 MAINTENANCE amp TROUBLESHOOTING 33 Maintenance us ogee eee rte baste Sur ene tp eda die dita rdi 33 8 2 Poutine Maintenance ease oa uas pop oe le Bc a GIS a Date ak he EN 34 8 3 Inspecting And Cleaning Optional Spark Arrestor Muffler 35 9 4 Servieirig AIF GIGANER ast ae gate a accus eek dub 36 8 5 Adjusting Engine Weld Power Speed 37 8 6 Adjusting Engine Idle Speed eie etes tope eae od 38 8 7 Adjusting Governor SensitiVily is asc rares ER aide Ra Red Patate 39 8 9 Servicing Fuel And Lubrication Systems 40 6 10 Overload PIOIgelOEIcss IS p 41 8 11 Diagnosing Causes Of Engine Fault Shutdowns 42 8 12 TrOUBIeSOoODH pavet cert ade med 43 SECTION 9 ELECTRICAL DIAGRAMS 5 2 3 349 9 3 wx minimiser suite 48 SECTION 10 AUXILIARY POWER GUIDELINES 52 SECTION 11
48. 3126 National Electrical Code NFPA Standard 70 de la National Fire Protec tion Association Batterymarch Park Quincy MA 02269 LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique risque de provoquer des interf rences pour l quipement lectronique sensible tel que les ordinateurs et l quipement com mand par ordinateur tel que les robots e Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement e Pour r duire la possibilit d interf rence maintenir les c bles de souda ge aussi courts que possible les grouper et les poser aussi bas que pos sible ex par terre e Veiller souder une distance de 100 metres de tout quipement lec tronique sensible e Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi e En cas d interf rences apres avoir pris les mesures pr c dentes il in combe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de c bles blind s l utilisation de fil tres de ligne ou la pose de protecteurs dans la zone de travail Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de la Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 R gles de s curit en soudage coupage et proc d s connexes norme CSA W117 2 de l Association canadienne de no
49. 60 COVER receptacle 2 250 dia lexan 1 BO ind 193 258 COVER receptacle 555 ree Se C ates 1 190 323 BOOT circuit breaker clear hex nut 1 Oe 193 143 BOOT magnetic shutdown switch 1 eaten 200 9939 CONTROL seras ans eee Beak ee gie est 1 119014 ss LEVER Switch DIBOK odere ooo 1 35 ous PL1 191 241 LED red 12V 4 ind lights panel mtg round 1 36 FUEL 192 265 GAUGE fuel elec switch w o sensor 1 Of iussus HM 118 058 METER hour 12 24VDC 2 25 1 Sl MMC 189 161 HANDLE switch 1 ero Ma RCM 010 647 PIN spring CS 156 x 1 250 ioo sd assed dds ote eee diese bones 1 148 729 KNOB PONET Jerre dee eee See Gs 1 POTE 024 103 BLANK snap in nyl 750 mtg hole black d When ordering a component originally displaying a precautionary label the label should also be ordered Order label individually or as part of Label Kit 192 505 or Label Kit 202 022 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 distri
50. C VE 14 40V Min 110 A DC Set V A Set Remote Adjust Switch Proces Set Range ba um Adjust Optional Remote Control Stick Mode Example Combination Remote Amperage Control TIG In Example Process TIG Using Remote On Off Range 40 to 240 A DC Percentage Of Range 5096 Min 40 A DC DT Max About 140 A DC 50 of 40 to 240 Max 140 DC VE l ELECTRODE 3705 14 40 40 DC Set V A Set Remote Adjust Switch Set Range Set Control Adjust Optional Remote Control 0774 Ref 201 579 802 730 OM 4405 Page 29 SECTION 7 OPERATING AUXILIARY EQUIPMENT 7 1 120 Volt And 240 Volt Receptacles OM 4405 Page 30 120 V 20A 17 60 Hz 240 V 20A 1 120 V 20 GFCI 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 for faulty tools plugged receptacle Press button to reset gt At least once a month run en gine at weld power speed and press test button to verify is working properly 3 Circuit Breaker CB1 4 Circuit Breaker CB2 CB1 protects RC1 and the genera tor winding from overload If CB1 opens RC1 and GFCl1 do not work Place switch in On position to reset breaker CB2 p
51. CONTROL BOX ASSEMBLY 1 OM 4405 Page 63 No Mkgs No Description Quantity Figure 11 1 Main Assembly Continued UN cS erste tee eee FIREWALL JOWE 2282 ii PAG 1 WOO Ts Figure 11 7 MAIN RECTIFIER 1 WOW cent basin 191 448 TOP cover front upright 1 nd WO 201 750 UPRIGHT 1 sa TOG 182 761 LABEL warning general precautionary 1 104 Figure 11 4 Figure 11 5 PANEL front w components 1 st 105 uerunt REA 202130 XFMR current sensing 1 6193453 BRACKET MiG DOX hee x hd 1 107 6 189 143 MODULE field current 1 TE tun 147 923 LABEL warning moving parts can cause Serious injury 1 TR 190 058 NUT 250 20 u nut multi thread 19 049 525 NUT 312 18 u nut multi thread 32 TE 202 022 KIT label includes safety and informational labels 1 When ordering a component ori
52. Curves For CC Models DC VOLTS OM 4405 Page 10 400 DC AMPERES 500 The volt ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator Curves of all other settings fall between the curves shown 202 666 A 3 4 Volt Ampere Curves for CC CV Models A Stick Mode The volt ampere curves show the minimum and maximum voltage 100 and amperage output capabilities of Ranges the welding generator Curves of all M other settings fall between the curves shown 150 420 110 315 2 75 200 40 90 gt 500 900 DC AMPERES B MIG Mode 100 80 2 60 gt S 40 20 0 0 100 200 300 400 500 600 700 800 900 1000 DC AMPERES C TIG Mode 100 90 80 70 2 H 60 9 50 4 amp 404 30 0 50 100 150 200 250 300 350 400 450 500 DC AMPERES 202 655 202 656 202 654 OM 4405 Page 11 3 5 Fuel Consumption The curve shows typical fuel use under weld or power loads U S Gal Hr 50 100 150 200 250 300 350 WELD AMPERES 100 DUTY CYCLE 201 033 3 6 Duty Cycle And Overheating p 100 Duty Cycle At 300 Amperes Duty Cycle is percentage of 10 min utes that unit can weld at rated load without overheating Exceeding duty cycle can damage unit and void warranty N Lu B lt e _ 25 30 DUTY CYCLE 199
53. Generator Output Always start non resistive motor loads in order from largest to small est and add resistive loads last 2 5Second 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 4405 Page 56 10 10 Typical Connections To Supply Standby Power 7 Customer supplied equipment is required if generator is to supply standby power during emergencies or power outages 1 1 Power Company Service Meter 2 Main and Branch Overcurrent Protection 3 Double Pole Double Throw Transfer Switch Obtain and install correct switch Switch rating must be same as or greater than the branch overcurrent protection 4 Circuit Breakers or Fused Disconnect Switch 240 V Obtain and install correct switch TET 5 Extension Cord 60 Hz Select as shown Section 10 11 Three Wire m 120 V 6 Generator Connections Service Connect terminals or plug of ade quate amperage capacity to cord w Follow all applicable codes and 2 2 safety practices 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 Load age and frequency lt i 7 Load Connections 7 CB D TUM ltem 4 is not necessary if circuit or protectionis already present in weld
54. HIS 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 date that the equipment was delivered to the original retail purchaser or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers Inverters input and output rectifiers only 2 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Semi Automatic and Automatic Wire Feeders Inverter Power Supplies Intellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor DS 2Wire Feeder Motor Driven Guns w exception of Spoolmate 185 amp Spoolmate 250 Process Controllers Positioners and
55. I POSITIVE 229 ELECTRODE NEGATIVE unt 28 WORK MACHINE WIRE NUMBERS 10 39 WELD SECONDARY 40 79 ENGINE CONTROLS EXCEPT 42 CHASSIS 80 99 AUX SECONDARY 100 149 EXCITER CONTROL 427 201 992 4405 51 SECTION 10 AUXILIARY POWER GUIDELINES 10 1 Selecting Equipment Auxiliary Power Receptacles Neutral Bonded To Frame 3 Prong Plug From Case Grounded Equipment 2 Prong Plug From Double Insulated Equipment Be sure equipment has this symbol and or wording aux pwr 2 99 Ref ST 159 730 ST 800 577 10 2 Grounding Generator To Truck Or Trailer Frame Generator Base Metal Vehicle Frame Equipment Grounding Terminal 4 Grounding Cable Use 10 AWG or larger insulated copper wire lfunit does not have re ceptacles use GFCl pro tected extension cord OR 74 Electrically bond generator 2 frame to vehicle frame by metal to metalcontact OM 4405 Page 52 10 3 Grounding When Supplying Building Systems 1 Equipment Grounding Terminal 2 Grounding Cable Use 10 AWG or larger insulated copper wire 3 Ground Device GND PE Ground generator to system earth ground if supplying power to a premises home shop farm wiring system Use ground device as stated in electrical codes ST 800 576 B 10 4 How Much Power Does Equipment Require 1 Resistive Load A light bulb is
56. Idle Speed ex 1 my RUN IDLE Engine Speed lt No Load 7 RUN 1850 T stant 1250 rpm 41 6 Hz OM 4405 Page 38 Stop engine and let cool Engine idle speed is factory set and normally should not require adjust ment After tuning engine check engine speed with tachometer or frequency meter See table for proper no load speed If necessary adjust idle speed as follows Start engine and run until warm On CC Models place Stick TIG switch in Stick position On CC CV models turn Process Contactor switch to Stick Elec trode Hot position 1 Solenoid Bracket Screws 2 Throttle Arm 3 Speed Screw 4 Throttle Stop Loosen bracket screws and move arm so screw touches stop Do not release arm Turn idle soeed screw to obtain 550 rpm 5 1 Mixture Screw Turn mixture screw counterclock wise until engine falters then turn screw clockwise until engine runs smoothly Turn idle speed screw to obtain 1250 rpm 6 Solenoid 7 Plunger Slide solenoid inside bracket so plunger bottoms in solenoid If nec essary shim solenoid bracket to prevent linkage from binding Do not readjust idle soeed screw when adjusting solenoid Tighten bracket screws Release throttle arm Recheck idle speed and readjust if necessary Stop engine Close door Tools Needed 1 4 in 802 731 Ref 115 155 A 8 7 Adjusting Governor Sensitivity T
57. OM 4405 200 972A January 2001 Miller Stick SMAW Welding The Power of Blue TIG GTAW Welding FA P2 MIG GMAW Welding Flux Cored FCAW Welding Air Carbon Arc CAC A 9 Cutting and Gouging Description 44 20 Engine Driven Welding Generator Big 40 WG im i O OWNER S MANUAL Visit our website a MANUAL DEL OPERADOR cuando disponible sigue al manual en ingl s 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 Ir RU E BL El that meets the high standards of quality and value established in 1929 WARRANTY 9 This Owner s Manual is designed to help you get the most of your Working as hard as you do every power source from Miller products Please take time to read the Safety precautions They Miller is backed by the most will help you protect yoursel
58. OOT circuit breaker clear hex nut 1 170 391 CONN circ ms protective cap size 20 1 sr PL1 191241 LED red 12V 4 ind lights panel mtg round 1 51 FUEL 192 265 GAUGE fuel elec switch w o sensor 1 118 058 METER hour 12 24 2 25dia 1 4405 71 Item Dia No Mkgs T E EXCEPT EOM ee T PLG6 TRA PLG8 PLG13 PLG3 Part No Description Quantity Figure 11 5 Panel Front w Components CC CV Models Continued 097 922 KNOB pointer 875 dia x 250 ID w set screws plste 1 189 161 HANDLE switch 1 010 647 PIN SDMNG CS 2156 1 250 od Ep Ee 1 097 924 KNOB pointer 1 625 dia x 250 ID w set scrws plste 1 193 158 HARNESS unit weld control CV consisting of 1 114 063 CONNECTOR rect univ 084 4p s 1 row plug cable 1 193 184 CONNECTOR rect cinch 30 pin 1 147 992 CONNECTOR rect univ 039 10 5 2 row plug cable 1 158 465 CONNECTOR rect univ 084 12p s row plug cable 1 088 731 BUSHING snap
59. PDT 15A 125VAC on none on spd term chr included in EAT control box harness see Figure 11 3 1 TEN m 202 209 4 SPACER AVION 2 Pato eame REX Uneme qi wu mas 2 9 PC6 192 995 CIRCUIT CARD ASSY connector receptacle 1 10 CB5 139 266 CIRCUIT BREAKER man reset 1p 15a 250vac frict 1 TG S1 176606 SWITCH ignition 4posn w o handle 1 12 MS1 189698 SWITCH magnetic manual reset low current 1 13 CB1 201083 CIRCUIT BREAKER man reset 2P 20 A 250VAC 1 nist ile Dhan 201 553 CLIP circuit breaker retaining 1 201 109 HARNESS auxiliary power consisting of 1 14 CB2 093996 CIRCUIT BREAKER man reset 1P 20A 250VAC frict 1 15 151 981 RECEPTACLE str dx grd 2P3W 15 20 125V GFCI 1 16 RC1 147632 RECEPTACLE tw Ik grd 2P3W 30A 250V L6 30R 1 17 ROS 4182954 RCPT str 3P4W 50 125 250V 1 cus diuidi SS 025 248 STAND OFF insul 250 20 x 1 2 1 604 102 CONNECTOR clamp cable 1 000 1 eoo
60. SWITCH Y LOAD 65 120 4 STARTING AID 2 Q E v prd lo AMPERAGE 201 841 802 729 OM 4405 Page 22 5 2 Description Of Front Panel Controls For CC Models See Section 5 1 Engine Starting Controls 1 Magnetic Shutdown Switch Use switch during start up to bypass engine shutdown system System stops engine if oil pressure is too low or coolant temperature is too high 2 Starting Aid Engine Choke Control Use control to change engine air fuel mix 3 Engine Control Switch Use switch to start engine select engine speed and stop engine In Run position engine runs at weld power speed In Run Idle position engine runs at idle speed at no load and weld speed with load applied To Start gt If engine does not start let engine come to a complete stop before attempting re start Pull Choke control out Turn Engine Control switch to Start while pressing Shutdown switch Release Engine Control switch when engine starts Continue holding Shutdown switch until engine indicator lights go out Push Choke control in To Stop turn Engine Control switch to Off position Engine Indicator Lights 4 Battery Charging Light Light goes on if engine alternator is not charg ing battery Engine continues to run Stop engine and fix trouble if Battery Charging light goes on 5 Engine Temperature Light Light goes on and engine stops if engine tem perature i
61. Timing 18 BTDC at 1800 RPM WIS CON YF41A WIS CON 20 00505 WIS CON TM20M00213 WIS CON TM27M00243 Use only resistor spark plugs and wires 250 operating hours see Owner s Manual Optional 201 031 OM 4405 Page 33 8 2 Routine Maintenance Note Ea Follow the storage procedure in the engine owner s manual if the unit will not be used for an extended period a Stop engine before maintaining Recycle engine See also Engine Manual and Mainte fluids nance Label Service unit more often if used in severe conditions To be done by Factory Authorized Service Agent 8h Wipe Check Fluid Levels See Up Section 4 7 Spills 50h Clean Air Filter Check Belt Clean And Tension See Section 8 4 Tighten 2 Weld Terminals 100h Change Oil See UR ol Section 8 8 Melee Section 8 8 Replace fuel 2 aus ighten filter See Battery Section 8 8 Connections Check air cleaner hoses lc for cracks and loose clamps 250h Check And Check E Clean Spark Spark TE Arrestor See Plugs Section 8 3 Replace Unreadable Labels OM 4405 Page 34 Repair Or 2 Replace Damaged Clearance Cables 1000h Blow Out Or Drain Sludge Vacuum Inside From Fuel During Heavy Tank See Service Section 8 8 Clean Monthly 8 3 Inspecting And Cleaning Optional Spark Arrestor Muffler
62. a resistive load and VOLTS 115 AMPS 45 a constant amount of pow 60 2 Non Resistive Load Equipment with a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when run ning see Section 10 8 3 Rating Data Rating shows volts and amperes or watts required to run equipment AMPERES x VOLTS z WATTS EXAMPLE 1 If a drill uses 4 5 amperes at 115 volts calculate its running power requirementin watts 4 5Ax115V 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 Example 1 add the individual loads to calculate total load 200 W 200 W 200 W 520 W 1120 W The total load applied by the three flood lamps and drill is 1120 watts OM 4405 Page 53 10 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 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 10 6 Approximate Power Requirements For Farm Ho
63. actory Authorized Service Agent check engine wiring harness and components Check engine wiring harness plug connections Have Factory Authorized Service Agent check Engine Control switch S1 OM 4405 Page 45 Trouble Remedy Engine cranks but does not start Press Magnetic Shutdown switch 51 when starting engine Check fuel level Reset circuit breaker CB13 See Section 8 9 Have Factory Authorized Service Agent check engine wiring harness and components Check battery and replace if necessary Check engine charging system according to engine manual Have Factory Authorized Service Agent check control relay CR2 and fuel solenoid FS1 Engine starts but stops when Magnetic Shutdown switch is released When starting engine continue holding Magnetic Shutdown switch until after engine indicator lights go out Check oil and coolant levels Automatic shutdown system stops engine if oil pressure is too low or cool ant temperature is too high see Sections 4 7 and 8 10 Engine hard to start in cold weather Use starting Aid Engine Choke control see Section 5 1 Keep battery in good condition Store battery in warm area off cold surface Use correct grade oil for cold weather see Section 8 1 Engine suddenly stops Check fuel oil and coolant levels Automatic shutdown system stops engine if oil pressure is too low or coolant temperature is too high
64. ations Circuit Breaker Maximum Welding Weld Output Rated Welding Open A Fuel ger in Engin Mode Range Output Circuit Paling Pos Capacity Voltage Standard JT 07 CC DC 300 A 40 Volts DC Wis Con 15 500 120 240 V AC FA CC CV Models 100 Duty Cycle 50 60 Hz 400 A 40 Volts DC Wis Con TM 20 25 gal 60 Duty Cycle FUE Option Water Cooled 95 L CV DC eut Single Phase Three Phase Three Cylinder 500 A 30 Volts DC 12 15 kVA kW 50 36A 38 HP Gasoline CC CV 14 40 V 40 Duty Cycle 56 120 240 VAC 60 Hz Engine pins In Addition To Standard 4 KVA KW Auxiliary Power OM 4405 Page 9 3 2 Dimensions Weights And Operating Angles Dimensions Height 58 in 1473 mm to top of muffler Width 28 1 2 in 724 mm mtg brackets turned in 30 3 4 in 781 mm mtg brackets turned out Depth 64 7 16 in 1637 mm 64 7 16 in 1637 mm 55 7 8 in 1419 mm 46 3 8 in 1178 9 1 2 in 241 mm 27 1 2 in 699 mm 1 in 25 mm On mm OO x 29 1 2 in 743 mm 9 16 in 14 mm Dia 4 Holes Weight No fuel 1600 Ib 726 kg w fuel 1775 1 805 kg Front Panel End 802 161 A Do not exceed tilt angles or engine could be damaged or unit could tip Do not move or operate unit where it could tip 802 729 3 3 Volt Ampere
65. butor OM 4405 Page 69 Hardware is common and not available unless listed 55 54 53 Pee 3 802 732 Figure 11 5 Panel Front w Components CC CV Models Item Dia Par NO Mkgs NO Description Quantity Figure 11 5 Panel Front w Components CC CV Models Figure 11 1 Item 104 TP CRT 201 579 PLATE SCREENED ident control when ordering this item the nameplate should also be ordered 1 UR NAMEPLATE screened order by model serial number 1 201 580 PANEL engine weld control 1 THE S3 189382 SWITCH range changeover 1 42022232 es a ee 2 Tr TOT 192 558 HARNESS range consisting of 1 DENS RC6 148439 HOUSING rect univ 084 4p s 1 row 1 OM 4405 Page 70 Dia Part No Mkgs No Description Quantity Figure 11 5 Panel Front w Components CC CV Models Continued 193 118 cp flat 1t 2w 1k ohm linear 1 TM CDU S6 193234 SWITCH rotary 6 position gold contacts included in control box harness rS See FIQUIC TT durent xti 7 P qu DD uei 011 609 SWITCH tgl S
66. c engine shutdown Pre Start Diagnostic Checks Correct the cause of the shut down before operating the o welding generator _ pn This unit does not have a tery charging fault shutdown The engine continues to run if the Battery Charging Light goes on Turn Engine Control Switch To Run Idle Normal Condition Position While Pressing Magnetic Shut Oil Pressure Light On down Switch Battery Charging Fuel And Temperature Lights Off Oil Pressure Light Is Off See Factory Authorized Service Agent If Battery Charging Light Is On Have Factory Authorized Service Agent Check Alternator If Temperature Light Is On Correct Cause Of Overheating See Engine Manual If Engine Is Okay See Factory Authorized Service Agent If Fuel Light Is On Check Fuel Level If Fault Continues See Factory Authorized Service Agent J Diagnostic Checks While Running ie AUN IGLE 9 lt 205 7 RUN A IDLE Vs starr SIART Do Start Engine With No Load Applied Continue Pressing Shutdown Switch Normal Condition Until Engine Lights Go Off Engine Lights Go Off As Engine Reaches Normal Operating Condition Lights That Stay On After 20 Sec Indicate Fault Condition Stop Engine And Correct Fault See Above If Fault Continues See Factory Authorized Ser vice Agent Ref 201 841 OM 4405 Page 42 8 11 Troubleshooting A Welding CC Models Trouble R
67. ce des entr es d air dans les b ti ments LA CHALEUR DU MOTEUR peut pro voquer un incendie e 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 d chappement du moteur de provoquer un incendie e Utiliser uniquement un pare tincelles approuv voir codes en vigueur 1 4 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage uniquement pour soulever l appareil lui m me sans chariot de bouteilles de gaz remorque ou autres accessoires e Utiliser un quipement de levage de capacit suffi sante pour lever l appareil e 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 LES TINCELLES VOLANTES ris quent de provoquer des blessures e Porter un cran facial pour prot ger le visage et les yeux e Affuterr l lectrode au tungst ne uniquement la meuleuse dot e de pro tecteurs Cette manoeuvre 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 loi
68. celui du moteur OM 4405 Page 7 LE RAYONNEMENT HAUTE FRE QUENCE risque de provoquer des interf rences e Le rayonnement haute fr quence peut provoquer des interf rences avec les quipements de radio navigation et de communication les services de s curit et les ordinateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installation e L utilisateur est tenu de faire corriger rapidement par un lectricien quali fi les interf rences r sultant de l installation e Si le FCC signale des interf rences arr ter imm diatement l appareil e Effectuer r guli rement le contr le et l entretien de l installation e Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distance correcte et utiliser une terre et et un blindage pour r duire les interf rences ventuelles 1 5 Principales normes de s curit Safety in Welding and Cutting norme ANSI Z49 1 de l American Weld ing Society 550 N W Lejeune Rd Miami FL 33126 Safety and Health Sandards OSHA 29 CFR 1910 du Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practice for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances norme AWS F4 1 de l American Welding Society 550 N W Lejeune Rd Miami FL 3
69. centage value 16 Voltage Amperage Adjust Switch And Remote 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 4 11 and 6 4 17 Polarity Switch Optional 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 18 DC Voltmeter Optional Voltmeter displays voltage at the weld output terminals but not necessarily the welding arc due to resistance of cable and connections 19 DC Ammeter Optional Ammeter displays amperage output of the unit OM 4405 Page 27 6 3 Process Contactor Switch CC CV Models Process Contactor Switch Weld output terminals are en ergized when Process Con tactor switch is in an Electrode Hot position and the engine is running Use switch to select weld process and weld output on off control see table below and Section 6 4 SCRATCH START TIG Place switch in Remote positions to Q c turn weld output on and off with a de gt 2 vice connected the remote 14 ceptacle Place switch in Electrode Hot posi a STICK tions for weld output to be on whenev Using Renate er the engine is running ON OFF Use Stick position for air carbon arc CAC A cutting and gouging When switch is in a Stick position the
70. d 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 E For distances longer than those shown in this guide call a factory applications representative at 920 735 4505 OM 4405 Page 19 4 10 Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models 1 Remote Amperage Adjust Receptacle RC13 Connect optional remote control to RC13 see Section 5 3 Ref 154 862 A 048 720 K 802 729 OM 4405 Page 20 4 11 Connecting To Remote 14 Receptacle RC14 On CC CV Models New LDR 14 long distance remote includes 120 V receptacle 802 729 REMOTE 14 Socket Socket Information A 24 volts ac Protected by circuit breaker CB5 24 VOLTS AC OUTPUT B Contact closure to A completes CONTACTOR 24 volt ac contactor control Circuit Output to remote control 10 volts in MIG or Stick mode 0 to 10 volts dc in TIG mode D Remote control circuit common REMOTE OUTPUT CONTROL E DC input command signal 0 to 10 volts from min to max of remote control with Voltage Amperage Adjust control at max K Chassis common GND NEUTRAL G Circuit common for 24 volt ac Circuit The remaining sockets are not used OM 4405 Page 21 SECTION 5 OPERATING WELDING GENERATOR CC MODELS 5 1 Front Panel Controls For CC Models See Section 5 2 QA 100 205 DO NOT
71. e Label WIS CON TM 20 GASOLINE ENGINE See Engine Manual for complete engine care Give Engine Specification and Serial Number when ordering parts 15W 40 10W 30 10W 40 Check daily 11 5W 20 a Recommended Oil API Service Classification SE CD SF CD Oil Change amp Filter dirty conditions 50 hours or less normal conditions 100 hours max Oil Filter MILLER 114559 WIS CON TM27L00213 Fram PH43 Hastings LF196 Oil Capacity 5 0 qts 4 7L With filter change 5 5 qts 5 2L Fuel Capacity 24 75 Gal 93 7L Fuel Grade Regular or Unleaded 85 Octane min Fuel Filter MILLER 066113 Fram G2 Hastings GF2 Gasoline Air Filter Service 50 hours or less see Owner s Manual Air Filter Element MILLER 192938 Donaldson P822768 Wix 46489 Air Filter Safety Element Opt MILLER 192939 Donaldson P822769 Wix 46490 Coolant Capacity 9 qts 8 5L Thermostat 180 F 82 C WIS CON TM27K00429 Radiator Cap 7 Ib MILLER 605982 Gates 31327 Protect to lowest expected temperature with ethylene glycol based anti freeze Protect to at least 34 F 37 C for year round lubrication and antirust protection Battery BCI Group 24 Valve Clearance HOT Cranking Performance at 0 014 in 0 36mm 0 F 18 C 660 Amps Exhaust 0 018 in 0 46mm Engine RPM No Load Fan Belt MILLER 201142 WIS CON X27019434 Spark Plug Gap 0 032 in 8 mm Champion RN12YC Firing Order Ignition
72. e les champs lectromagn tiques dans l environnement de travail respecter les consignes suivantes 1 Garder les cables ensembles en les torsadant ou en les attachant avec du ruban adh sif 2 Mettre tous les c bles du c t oppos 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 cables le plus loin possible de vous 5 Relier la pince de masse le plus pr s possible de la zone de soudure Consignes relatives aux stimulateurs cardiaques Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur docteur Si vous tes d clar apte par votre docteur il est alors recommand de respecter les consignes ci dessus SECTION 2 DEFINITIONS 2 1 Symbols And Definitions Stop Engine Air Temperature Or Engine Temperature Fast Run Weld Power Battery Engine Check Valve Clearance Slow Idle Start Engine Engine Oil Pressure Engine Oil Protective Earth Ground Certified Trained Negative Mechanic Welding Arc Electrode Alternating Connection Work Connection Current Stick SMAW Constant Current MIG GMAW Welding Welding TIG GTAW CC om tal 3 Ny Three Ph Read Operator s Do Not Switch Manual While Welding reu Contactor On SECTION 3 SPECIFICATIONS 3 1 Weld Power And Engine Specific
73. ear approved safety glasses with side shields under your helmet e Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc e Wear protective clothing made from durable flame resistant mate rial wool and leather and foot protection 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 e lf inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator e Read the Material Safety Data Sheets MSDSs and the manufacturers 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 if necessary while wearing an air supplied resp
74. ecifications 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 Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin 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
75. ees 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 welding or cutting To reduce magnetic fields in the workplace use the following procedures OM 4405 Page 4 ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagnetically compatible e To reduce 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 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Boule
76. emedy No weld output auxiliary power output Okay 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 control to Remote Amperage Adjust receptacle RC13 see Sections 4 10 and 5 1 Check and secure connections to Remote Amperage Adjust receptacle RC13 see Section 4 10 Check fuse F2 and replace if open see Section 8 9 Have Factory Authorized Service Agent check inte grated rectifier SR2 and the rotor Have Factory Authorized Service Agent check brushes and slip rings and field excitation circuit No weld output or auxiliary power output Disconnect equipment from auxiliary power receptacles during start up Check fuses F1 and F2 and replace if open see Section 8 9 Have Factory Authorized Service Agent check integrated rectifier SR1 capacitor C9 integrated rectifier SR2 and the rotor Reset circuit breaker CB12 Have Factory Authorized Service Agent check diode D1 see Section 8 9 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 High weld output Check engine speed and adj
77. en engine is cold to avoid scalding e Always check coolant level at overflow tank if present on unit instead of radiator unless told otherwise in maintenance section or engine manual e Ifthe engine is warm checking is needed and there is no overflow tank follow the next two statements e Wear safety glasses and gloves and put a rag over radiator cap e Turn cap slightly and let pressure escape slowly before completely removing cap BATTERY ACID can BURN SKIN and MOVING PARTS can cause injury EYES Keep away from fans belts and rotors CLS Ny Keep all doors panels covers and guards closed and securely in place e Do not tip battery e Replace damaged battery e Flush eyes and skin immediately with water Stop engine before installing or connecting unit Have only qualified people remove guards or covers for maint enance 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 panels or guards and close doors when servicing is finished and before starting engine e Before working on generator remove spark plugs or injectors to e Use equipment outside in open well ventilated areas If used in a closed area vent engine exhaust outside and away from any building air intakes keep engine from kicking back or starti
78. engine speed and adjust if necessary Check fuse F1 and replace if open see Section 8 9 Have Factory Authorized Service Agent check inte grated rectifier SR1 resistor R3 and capacitor C9 D Optional Auxiliary Power Plant Trouble Remedy No or low output at optional auxiliary power plant receptacle RC5 CC CV models only Place Process Contactor switch in Electrode Hot Stick position see Section 6 3 Reset circuit breaker CB7 see Section 7 2 Reset circuit breaker CB5 see Section 8 9 Check engine weld power speed and adjust if necessary see Section 8 5 Have Factory Authorized Service Agent check brushes and slip rings and field current regulator board PC1 High output at optional auxiliary power plant receptacle RC5 CC CV models only Check engine weld power speed and adjust if necessary see Section 8 5 Have Factory Authorized Service Agent check field current regulator board PC1 Erratic output at optional auxiliary power plant receptacle RC5 CC CV models only Have Factory Authorized Service Agent check brushes and slip rings and field current regulator board PC1 E 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 8 9 Have F
79. erminal 1 vp RESERET 201 701 BRACE front to center 2 8 SR4 SR5 035 704 RECTIFIER integ bridge 40 amp 800v 2 9 CB4 045061 CIRCUIT BREAKER auto reset 24vdc 7 1 Re 201 697 PAN reactor and rectifier 1 sans dira nsi T1 201613 TRANSFORMER w bracket 1 nude dent 173 352 EXTRUSION rubber clamp bulb order by ft OPE o T NONE 189 70855 FIREWALL 10D ace decer eie eid 1 ons dedos cies T9307 a COVER PaE tuia dion genni Gen ack hg den sca iia Ge ecu tete uius 1 irae la ren maine 200 968 HOSE elbow air cleaner 1 l e es EET 010863 CLAMP hose 1 125 3 000 clp dia 4 an e 189 763 BRACKET mtg air 1 189764 AIRGLEANER bd Kee ob ie des 1 ene a th 5192 938 FILTER air element primary 1 DONORUM ESO e192939 FILTER air element safety 1 ESL 198 457 TUBE
80. f against potential hazards on the worksite A 88 warranty in the We ve made installation and operation quick and easy With Miller you can count on years of reliable service with proper maintenance And if for some reason the unit needs repair REGISTERED QUALITY SYSTEM there s a Troubleshooting section that will Miller is the first welding help you figure out what the problem is The equipment manufacturer in 2122 10 parts list will then help you to decide which the ISO 9001 Quality System exact part you may need to fix the problem Warranty and service information for your particular model are also provided Miller offers a Technical Manual which provides more detailed service and parts information for your unit To obtain a Technical Manual contact your local distributor Your distributor can also supply you with Welding Process Manuals such as SMAW GTAW GMAW GMAW P Miller Electric manufactures a full line of welders and welding related equipment For information on other quality Miller products contact your local Miller distributor to receive the latest full line catalog or individual catalog 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 The Power of Blue 4 WARNING This product when used for welding or cutting produces fumes or gases which contain chemicals know
81. fety 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 Keep nozzle 7 1 Housing 2in 51 mm f PE lt gt lt 2 Safety Element Optional ST TA p 3 Primary Element 5252525 25255555 5252525 525255 52525252 52525252 4 Dust Cap P 52525252 52525252 7 52525252 525252501 52525252 5252525 5 Dust Ejector QU e m XX LR WN CQ XX M WX v To clean air filter Wipe off cap and housing Remove cap 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 Do not clean housing with air hose 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 00 153 929 B 153 585 Ref S 0698 B OM 4405 Page 36 8 5 Adjusting Engine Weld Power Speed Stop engine and let cool Governor sensitivity may re quire adjustment if engine speed is adjusted see Section 8 7
82. ginally displaying a precautionary label the label should also be ordered Order label individually or as part of Label Kit 202 022 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 802 551 A Figure 11 2 Control Box Assembly CC Models OM 4405 Page 64 Dia Part No Mkgs No Description Quantity Figure 11 2 Control Box Assembly CC Models Figure 11 1 Item 98 1 F1 F2 085 874 FUSE mintr cer slo blo 10A 250 2 046 432 HOLDER fuse mintr 250 1 250 2 m 201077 z CONTROL BOXAIM XR Rag ae Ito d 1 ee 201078 GONTROL BOX PH ERE Ducem xA bok Suse decem SG gts 1 eir 201 079 COVER control box 1 6 C12 191944 CAPACITOR polyp met film 10 uf 250 vac 10 1 Ius 201 681 HARNESS control box weld control consisting of 1 sas i 199 99D 4 RELAY OOV COMMON 1 8 01 1 189 701 DIODE CAPACITOR BOARD 1 9 SR1 SR2 035 704 RECTIFIER integ 40A 800V
83. gner toute substance inflammable 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 endommager le moteur lectrique cause d une tension et d une fr quence trop faibles e pas brancher de moteur de 50 ou de 60 Hz la prise de 100 Hz s il y a lieu Lamm Dr ere 3 RO om L EMPLOI EXCESSIF peut SURCHAUFFER L EQUIPEMENT e Laisser l quipement refroidir respecter le facteur de marche nominal e R duire le courant ou le facteur de marche avant de poursuivre le soudage e pas obstruer les passages d air du poste LES CHARGES ELECTROSTATIQUES 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 bo tes antistatiques pour stocker d placer ou exp dier des cartes de circuits imprimes 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 remorque comme indiqu dans le manuel s y rapportant LIRE LES INSTRUCTIONS e Utiliser seulement les pi ces de rechange d origine e Effecteur la maintenance et la mise en service d apr s le manuel et
84. gu e Lire les sp cifications de s curit des mat riaux MSDSs et les instruc tions 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 por tant 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 former des gaz hautement toxiques et irritants e pas souder des m taux munis d un rev tement tels que l acier galvani S plaqu en plomb ou au cadmium moins que le rev tement n ait t enlev dans la zone de soudure que l endroit soit bien ventil et si n ces saire en portant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage OM 4405 Page 5 gt LE SOUDAGE peut provoquer un in FS cendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que leur clatement Des tincelles peuvent t
85. ing generator auxiliary power output circuit 6 240 V 120 240 Volt Single Phase Three Wire Generator Output Connection Ground 5 0405 4405 57 10 11 Selecting Extension Cord Use Shortest Cord Possible n Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles use GFCI protected extension Maximum Allowable Cord Length in ft m for Conductor Size AWG Load Watts 4 6 8 10 12 14 Amperes 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 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based maximum 2 voltage drop Cord Lengths for 240 Volt Loads A If unit does not have GFCI receptacles use GFCI protected extension cord Maximum Allowable Cord Length in ft m for Conductor Size AWG 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
86. ional Normal temperature is 180 203 F 82 95 C When equipped with gauge option engine stops if temperature exceeds 220 F 104 12 Engine Oil Pressure Gauge Optional Normal pressure is 30 80 psi 207 552 kPa When equipped with gauge option en gine stops if pressure is below 10 psi 69 kPa Weld Controls 13 Process Contactor Switch See Section 6 3 for Process Contactor switch information 14 Ampere Range Switch 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 each 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 15 Voltage Amperage Adjust 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 213 A DC with controls set as shown 50 of 110 to 315 A gt The numbers around the control are for reference only and do not represent an actual per
87. irator The coatings and any metals containing these elements can give off toxic fumes if welded OM 4405 Page 1 f 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 Protect yourself and others from flying sparks and hot metal e Do not weld where flying sparks can strike flammable material e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers e Be alert that welding sparks and hot materials from welding easily go through small cracks and openings to adjacent areas e Watch for fire and keep a fire extinguisher nearby e Beaware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side e 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 e 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 and fire hazards e Do not use welder to thaw frozen
88. iv 084 9P S row plug cable 1 187 651 SEAL wire univ 9P S 1 When ordering a component originally displaying a precautionary label the label should also be ordered Order label individually or as part of Label Kit 202 022 Recommended 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 4405 Page 73 Hardware is common not available unless listed 6 802 279 A Figure 11 7 Main Rectifier Assembly Dia Part No Mkgs No Description Quantity Figure 11 7 Main Rectifier Assembly Figure 11 1 Item 100 201 747 RECTIFIER corisisting OR 3452242 CER rae der ee 1 Dia lk 188 137 CONNECTION BOARD rectifier AC 1 T 188 517 BUS BAR connection board 3 URS CIRCE 188 135 ENCLOSURE rectifier 2 TIT qr 134 201 ssa STANDOFF SUPPO re ded bere dO eek 3 5 201449 CIRCUIT CARD ASSEMBLY protection 1 uL T 188 136 INSULATOR heat sink c os o enc mede acta tc des 8 D 188 493
89. k position of Ampere Range switch and Voltage Amperage Adjust control Check engine speed and adjust if necessary Have Factory Authorized Service Agent check field current regulator board 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 engine speed and adjust if necessary Check fuses F1 and F2 and replace if open see Section 8 9 Have Factory Authorized Service Agent check integrated rectifier SR1 capacitor C9 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 8 9 Have Factory Authorized Service Agent check transformer T1 and integrated rectifiers SR4 and SR5 Low open circuit voltage Check engine speed and adjust if necessary No remote fine amperage or voltage control Place Voltage Amperage Adjust switch in Remote position Check and secure connections to Remote 14 receptacle RC14 see Section 4 11 Repair or replace remote control device Constant speed wire feeder does not work Reset circuit breaker CB5 see Section 8 9 Check and secure connections to Remote 14 receptacle RC14 see Section 4 1
90. lk 190 323 BOOT circuit breaker clear hex nut 1 912 4549195925 SWITCH DOlallly deut E 1 201 125 PANEL mtg terminal pwr 1 96 4 5 189 744 CIRCUIT CARD ASSEMBLY filter 2 cio 039 046 TERMINAL pwr output black 1 160 795 WASHER Output SWIG 2 mn edm o e et use 2 Oreste 134 201 STAND OFF support 12 NIS DM 191 169 ow 2 pt OS issus 186 621 BOOT generic output Stud 2 En 059 773 2 HAND E and 1 9010647 PIN spring cs 156 x 1 250 etc borde vno 1 EPE e E EE 039 047 TERMINAL pwr output red 1 E bon re 196 073 LABEL do not switch while 0 1 ptu D then Sct 193 143 BOOT magnetic shutdown switch 1 iQ 200895 GONTROL DUSh OUI ie ac an en t Rn 1 spaces LEVER Alo d ananas oder 1 PNE 190 323 B
91. lting from the installa tion e f 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 5 Principal Safety Standards Safety in Welding and Cutting ANSI Standard Z49 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safety and Health Standards OSHA 29 CFR 1910 from Superinten dent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Batterymarch Park Quincy MA 02269 1 6 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 committ
92. me Equipment Farm Home Equipment Rating Starting Watts Running Watts Stock Tank 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 10500 2800 FARM DUTY MOTORS 1 3 HP 1720 720 Std e g Conveyors 1 2 HP 2575 975 Feed Augers Air 3 4 HP 4500 1400 Compressors 1 HP 6100 1600 1 1 2 HP 8200 2200 2 HP 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 4405 Page 54 10 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 in 2500 1100 Bench Grinder 6 in 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 1100 1100 2 HP 14 in 1
93. mmag s de grosseur insuffisante 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 e pas toucher l lectrode quand est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine rom nd fre 11 98 Ce groupe de symboles signifie Mise en garde Soyez vigilant a des risques de danger reli s aux CHOCS LECTRIQUES aux PIECES EN MOUVEMENT et aux PIECES CHAUDES Reportez vous aux symboles et aux directives ci dessous afin de connaitre les mesures prendre pour viter tout danger 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 e Porter un harnais de s curit quand on travaille en hauteur e Maintenir solidement en place tous les panneaux et capots e Fixer le cable de retour de fa on 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 e soler 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 e Couper l alimentation du poste et d charger les condensateurs d entr e comme indiqu
94. ms contact your distributor and or equipment manufacturers Transportation Department PRINTED IN USA 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 File a claim for loss or damage during shipment 2001 Miller Electric Mfg Co 1 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 920 735 4125 European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 www MillerWelds com Miller The Power of Blue
95. n To Stop turn Engine Control switch to Off position Engine Indicator Lights 4 Battery Charging Light Light goes on if engine alternator is not charg ing battery Engine continues to run Stop engine and fix trouble if Battery Charging light goes on 5 Engine Temperature Light Light goes on and engine stops if engine tem perature is above 230 F 110 C Stop engine and fix trouble if Engine Temperature light goes on 6 Engine Oil Pressure Light Light goes on and engine stops if oil pressure is below 5 psi 34 kPa Light goes on momen tarily during start up but goes out when en gine reaches normal oil pressure Stop engine and fix trouble if Engine Cil Pressure light stays on after start up 7 Fuel Light Fuel light is not active on this model 8 Engine Hour Meter Engine Gauges gt To read gauges and engine indicator lights with engine off turn Engine Control switch to Run Idle and press Magnetic Shutdown switch see Section 8 10 9 Fuel Gauge Use gauge to check fuel level To check fuel level when engine is not run ning turn Engine Control switch to Run Idle position and press Magnetic Shutdown switch 10 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 11 Engine Coolant Temperature Gauge Opt
96. n to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq WARNING 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 WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm The following terms are used interchangeably throughout this manual Stick SMAW TIG GTAW MIG GMAW TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING tae SYMOONUSAGR a vao acad ahah eb udi 1525 Are Welding Hazards aeta ahora sana 1 953 dde PASS tet hue 1 4 Additional Symbols For Installation Operation And Maintenance 1 5 Principal Safety Standards 126 EMP Infortaalor 55 3 uita ades oco Ca aca eae e RF ca et SECTION 1 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 11 Signification d s Symboles Less sien LIESS 1 2 Dangers relatifs au soudage l arc 1 3 Dangers existant en relation avec le moteur
97. ng e Block flywheel so that it will not turn while working on generator components 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 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 Do not allow tools to cause sparks when working on a battery Do not use welder to charge batteries or jump start vehicles Observe correct polarity and on batteries Disconnect negative cable first and connect it last 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 1 4 Additional Symbols For Installation Operation And Maintenance FALLING UNIT can cause injury OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit e Use lifting eye to lift unit only NOT running gear gas cylinders trailer or any other accessories e Use equipment of adequate capacity to lift and support unit e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit
98. no connections are rabies made to power plant KVA KW Frequency 5 Have qualified person install ac Engine Speed 1850 RPM cording to circuit diagram and Lead 42 connects to GROUND stud on Auxiliary Power Guidelines see front of unit Section 10 Jumper 42 is connected to 90 at factory Remove auxiliary power panel mounting screws Tilt panel forward 3 Lead 93 2 B plug 4 Lead 92 before inserting 5 Lead 91 tay 90 6 Lead 42 Circuit Grounding bushing Lead 92 7 Lead 90 Neutral 8 Isolated Neutral Terminal 9 Jumper Lead 42 10 Grounding Terminal Rear Of Panel 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 Circuit Breaker CB7 User Terminals Connect user supplied leads to ter minals on CB7 and to the isolated neutral terminal and grounding termi nal as necessary Close panel opening if no connections are made to power plant Circuit breaker CB7 protects single phase receptacle RC5 and the load wires from overload If opens all auxiliary power plant output stops and the recep a Tools Needed tacle does not work 3 Phase Reinstall auxiliary power panel Ref 197 399 802 332 E OM 4405 Page 31 7 3 Optional Auxiliary Power Receptacles 1 120V 20 GFCI Receptacle GFCI1
99. o temp 240 make 230 open 1 wo 025 473 SWITCH pressure oil 8 psi brake or make 1 doe dab RU UE 201 141 FTG adapter oil drain 1 2 20 male x 3 8 npt female 1 pH t cae 1201 142 2 BEL Talk ue ed wi wowed cha Mad ds OM 4405 Page 62 Dia Part No Mkgs No Description Quantity Figure 11 1 Main Assembly Continued TTE 172 725 BOOT starter eyelet terminal 1 aras ee MMA Soa REST OI eee a e p Etat UI aee hoe A ad tls 066 113 2 FILTER inline i siue dete Pe IR ede deese rts 1 od er ce 200 966 HOSE radiator upper Wis Con TM 20 1 pas dedu udi 202 052 GUARD fan left side 1 i TEET EEE 147 923 LABEL warning moving parts 2 D 201 982 RADIATOR w shroud 7lb cap row core 1 605 982 CAP radiator pressure 71 1 tees i 201 749 tom Sra a ee es 1 EES 190 206 CABLE bat neg 42 in 10 No 2 awg w clamp and 375rng 1 108 081 TERMINAL PROTECTOR battery post mtg 2 cr eee 190 207 CABLE bat pos
100. ools Needed JE 1 2 in Notes gt Governor sensitivity may re quire readjustment if weld speed is adjusted Weld speed must be readjusted if sensitivity is adjusted Be sure carburetor and link ages are adjusted properly be fore adjusting sensitivity Start engine Apply and remove load 1 Locking Nuts 2 Sensitivity Adjustment Screw 3 Governor Spring If engine is slow to pick up load or rpm drops under load adjust spring tension as follows Loosen top nut and tighten bottom nut to move screw down Tighten nuts If engine hunts with or without load adjust spring tension as follows Loosen bottom nut and tighten top nut to move screw up Tighten nuts Stop engine Close door 802 780 Ref 115 155 A OM 4405 Page 39 8 8 Servicing Fuel And Lubrication Systems 5 e RUN IDLE lt DE TN Stop engine and let cool A After servicing start engine and check for fuel leaks Stop engine tighten connections as necessary and wipe up spilled fuel Oil Filter Oil Drain Valve And Hose Oil Fill Cap Dipstick Fuel Tank Sludge Drain Valve WD To change oil and filter Route oil drain valve and hose through hole in base See engine manual and engine OM 4405 Page 40 maintenance label for oil filter change in formation To drain sludge from fuel tank Beware of fire Do not smoke and keep sparks and flames away from drained fuel Dispose of
101. pipes e Remove stick electrode from holder or cut off welding wire at contact tip when not in use e Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap e Remove any combustibles such as a butane lighter or matches from your person before doing any welding FLYING METAL can injure eyes 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 4 a BUILDUP OF GAS can injure or kill e Shut off shielding gas supply when not in use e Always ventilate confined spaces or use ap proved air supplied respirator 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 not spill fuel If fuel is spilled clean up before starting engine e Dispose of rags in a fireproof container OM 4405 Page 2 HOT PARTS can cause severe burns Allow cooling period before maintaining e Wear protective gloves and clothing when working on a hot engine e Do not touch hot engine parts or just welded parts bare handed NOISE can damage hearing Noise from some processes or equipment can damage hearing e Wear approved ea
102. pressure is too low or coolant tempera ture is too high gt This unit has 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 Fuel Add fresh fuel before starting engine the first OM 4405 Page 18 time see engine maintenance label for fuel specifications 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 Check radiator coolant level when fluid is low in recovery tank Capacity 9 qt 8 5L Hot Full 4 Cold Full 802 731 Engine coolant is a mixture of water and ethylene glycol base antifreeze Add anti freeze to mixture if using the unit in tempera tures below 34 37 Keep radiator and air intake clean and free of dirt Incorrect engine
103. que dans les zones humides dans les endroits confin s ou l ou on risque de tomber e Se servir d une source lectrique acourant lectrique UNIQUEMENT si le proc d de soudage le demande e GSil utilisation d une source lectrique acourant lectrique s av re n ces saire se servir de la fonction de t l commande si l appareil en est quip e 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 e Installer et mettre la terre correctement cet appareil conform ment a son manuel d utilisation et aux codes nationaux provinciaux et municipaux e 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 est raccord e une prise correctement mise la terre e effectuant les raccordements d entr e fixer d abord le conducteur de mise la terre appropri et contre v rifier les connexions e V rifier fr quemment le cordon d alimentation pour voir s il n est pas en dommag ou d nud remplacer le cordon imm diatement s il est endommag un cable d nud peut provoquer une lectrocution Mettre l appareil hors tension quand on ne l utilise pas Ne pas utiliser des c bles us s endo
104. r protection if noise level is high MAGNETIC FIELDS can affect pacemakers Pacemaker wearers keep away e Wearers should consult their doctor before going near arc welding gouging or spot welding operations CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully e Protect compressed gas cylinders from excessive heat mechani cal shocks slag open flames sparks and arcs e 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 application maintain them and associated parts in good condition e Turn face away from valve outlet when opening cylinder valve e Keep protective cap in place over valve except when cylinder is in use or connected for use e Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards STEAM AND HOT COOLANT can burn e f possible check coolant level wh
105. re projet es de l arc de soudure La projection d tincelles des pi ces chaudes et des quipements chauds peut provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un surchauffement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger e Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud e pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables e D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneusement avec des protections homologu s 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 pas effectuer le soudage sur des conteneurs ferm s tels que des r ser voirs tambours ou conduites moins qu ils n aient t pr par s correctement conform ment AWS F4 1 voir les normes de s curit e Brancher le cable sur la pi ce le plus pr s possible de la zone de soudage pour viter
106. res graves e Pr voir une p riode de refroidissement avant d effec tuer des travaux d entretien e Porter des gants et des v tements de protection pour travailler sur un moteur chaud e pas toucher mains nues les parties chaudes du moteur ni les pieces r cemment soud es LE BRUIT peut affecter l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques e Porteurs de stimulateur cardiaque restez distance Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de gougeage ou de soudage par points Si des BOUTEILLES sont endomma g es elles pourront exploser Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endommag e elle peut exploser Du fait que les bouteilles de gaz font normale ment partie du proc d de soudage les manipuler avec pr caution e Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques du laitier des flammes ouvertes des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e Tenir les bouteilles loign es des circuit
107. rmalisation vente de normes 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protec tion norme ANSI Z87 1 de l American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme NFPA 51B de la National Fire Protection Association Batterymarch Park Quincy MA 02269 1 6 Information sur les champs lectromagn tiques Donn es sur le soudage lectrique et sur les effets pour l organisme des champs magn tiques basse fr quence Le courant de soudage pendant son passage dans les c bles de sou dage causera des champs lectromagn tiques Il y a eu et il y a encore un certain souci propos de tels champs Cependant apr s avoir ex amin 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 Re search 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 Toutefois des tudes sont toujours en cours et les preuves continuent tre examin es En attendant que les con clusions 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 OM 4405 Page 8 Afin de r duir
108. rotects GFCI1 from overload If CB2 opens GFCI1 does not work Press button to reset breaker gt If a circuit breaker continues to open contact Factory Autho rized Service Agent gt Auxiliary power is not affected by weld output Maximum output is 2 4 from GFCI1 and 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 Vx 7 A 4 0 KVA KW 191 624 A 7 2 Connecting To Optional Auxiliary Power Plant CC CV Models Only L LZ Place Process Contactor switch in Electrode Hot Stick position when using auxiliary power plant see Section 6 3 Single Phase Power Connection 1 2 Single Phase Auxiliary Power 2 1 120 240 50 A Receptacle RC5 D RC5 is connected to the optional auxiliary power plant and supplies 60 Hz single phase power at weld pow speed Maximum output from RC5 is 12 kVA kW Power available at RC5 is reduced when welding 2 Circuit Breaker CB7 Circuit breaker CB7 protects single phase receptacle RC5 and the load wires from overload If CB7 opens all auxiliary power plant output stops and the receptacle does not work Three Phase Auxiliary Power Three Phase Power Connection ze Side Three Power and weld outputs are Close panel openin Een live at the same time Discon b nect or insulate unused if
109. s above 230 F 110 C Stop engine and fix trouble if Engine Temperature light goes on 6 Engine Oil Pressure Light Light goes on and engine stops if oil pressure is below 5 psi 34 kPa Light goes on momen tarily during start up but goes out when en gine reaches normal oil pressure Stop engine and fix trouble if Engine Oil Pressure light stays on after start up 7 Fuel Light Fuel light is not active on this model 8 Engine Hour Meter Engine Gauges gt To read gauges and engine indicator lights with engine off turn Engine Control switch to Run ldle and press Magnetic Shutdown switch see Section 8 10 9 Fuel Gauge Use gauge to check fuel level To check fuel level when engine is not run ning turn Engine Control switch to Run ldle position and press Magnetic Shutdown switch 10 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 11 Engine Coolant Temperature Gauge Optional Normal temperature is 180 203 F 82 95 C When equipped with gauge option engine stops if temperature exceeds 220 F 104 12 Engine Oil Pressure Gauge Optional Normal pressure is 30 80 psi 207 552 kPa When equipped with gauge option en gine stops if pressure is below 10 psi 69 kPa Weld Controls gt
110. s de soudage ou autres circuits lectriques e jamais placer une torche de soudage sur une bouteille a gaz e Une lectrode de soudage ne doit jamais entrer en contact avec une bou teille e Ne jamais souder une bouteille pressuris e risque d explosion 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 pas tenir la t te en face de la sortie en ouvrant la soupape de la bouteille Maintenir le chapeau de protection sur la soupape sauf en cas d utilisation ou de branchement de la bouteille e Lire et suivre les instructions concernant les bouteilles de gaz comprim les quipements associ s et les publication P 1 CGA num r es dans les normes de s curit 1 3 Dangers existant en relation avec le moteur LE CARBURANT MOTEUR peut pro voquer un incendie ou une explosion Arr ter le moteur avant de v rifier le niveau de carbu rant ou de faire le plein e Ne pas faire le plein en fumant ou proche d une sour ce d tincelles ou d une flamme nue e 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 tout carbu rant renvers avant de faire d marrer le moteur e Jeter les chiffons dans un r cipient ignifuge OM 4405 Page 6 LA VAPEUR ET
111. st FIDO sue ui ok acies 4 5 Activating The Dry Charge Battery If Applicable 4 6 Connecting The Bahe usc uisa ue ci ee nde ehe S eee d bd 4 7 Engine Prestart Checks y nk ma A 4 8 Connecting To Weld Output Terminals 4 9 Selecting Weld Cable 4 10 Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models 4 11 Connecting To Remote 14 Receptacle RC14 On CC CV Models SECTION 5 OPERATING WELDING GENERATOR CC MODELS 5 1 Front Panel Controls For CC Models See Section 5 2 5 2 Description Of Front Panel Controls For CC Models See Section 5 1 5 3 Remote Amperage Control On CC Models Optional SECTION 6 OPERATING WELDING GENERATOR CC CV MODELS 6 1 Front Panel Controls For CC CV Models See Section 6 2 6 2 Description Of Front Panel Controls For CC CV Models See Section 6 1 6 3 Process Contactor Switch On CC CV 5 6 4 Remote Voltage Amperage Control On CC CV Models Optional SECTION 7 OPERATING AUXILIARY EQUIPMENT 7 1 120 Volt And 240 Volt Duplex Receptacles 7 2 Connecting To Optional Auxiliary Power Plant CC CV Models Only 7
112. t does not have re ceptacles use GFCI protected extension cord install2 1 01 Ref 800 652 Ref 800 477 A 158 936 0854 4 2 Using Lifting Eye 1 2 3 Lifting Eye Nut Carriage Bolt Raise lifting eye until it snaps in place Lower lifting eye when not needed C7 To lock the lifting eye in the up OM 4405 Page 14 right 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 D o Ref 802 729 4 3 Mounting Welding Generator 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 Mounting Bracket 1 2 in Bolt And Washer Not Supplied 3 8 16 x 1 in Screws Supplied To Bolt Unit In Place Remove hardware securing the four mounting brackets to the base Welding Unit In Place Reverse brackets and reattach to base with original hardware Bolting Unit In Place Mount unit to truck or trailer with 1 2 in 12 mm hardware not supplied To Weld Unit In Place Weld unit to truck or trailer only at the four mounting brackets Tools Needed 9 16 in Ref 190 250 A Ref 802 730 4 4 Installing Exhaust Pipe Stop engine and let cool Engine backfire can cause se vere burns or other injuries Do not point exhaust pipe toward control panel Keep away from exhaust outlet lt 5 Point exha
113. temperature can damage engine Do not run engine without a properly working thermo stat and radiator cap gt To improve cold weather starting Keep battery in good condition Store battery in warm area off concrete sur face Use correct grade oil for cold weather see Section 8 1 4 8 Connecting To Weld Output Terminals Tools Needed Stop engine EE 1 Positive Weld Output Terminal 2 Negative Weld Output Terminal For Stick and TIG welding Direct Current Electrode Positive DCEP connect XT electrode holder cable to Positive ter NE minal on left and work cable to Negative e terminal on right RUN CO For Direct Current Electrode Negative 7 START DCEN reverse cable connections If equipped with optional polarity switch connect electrode holder cable to Elec trode terminal on left and work cable to Work terminal on right For MIG and FCAW welding Direct Cur rent Electrode Positive DCEP on CC CV models connect wire feeder cable to Positive terminal on left and work cable to Negative terminal on right Use Process Contactor switch to select type of weld output see Section 6 3 For Direct Current Electrode Negative DCEN reverse cable connections If equipped with optional polarity switch connect wire feeder cable to Electrode terminal on left and work cable to Work terminal on right 802 729 4 9 Selecting Weld Cable Sizes
114. trol 0774 Ref 154 862 A Ref 181 711 802 729 OM 4405 Page 24 Notes OM 4405 Page 25 SECTION 6 OPERATING WELDING GENERATOR CC CV MODELS 6 1 Front Panel Controls For CC CV Models See Section 6 2 RUN VI HOLD IN sms TO START gt ELECTRODE nor 13705 SCRATCH AN 2 ON OFF o o 2 E Y REMOTE 4 Using Remo 2 2 2 ON OFF o C Wire 201 579 802 729 4405 26 6 2 Description Of Front Panel Controls For CC CV Models See Section 6 1 Engine Starting Controls 1 Magnetic Shutdown Switch Use switch during start up to bypass engine shutdown system System stops engine if oil pressure 1 too low or engine temperature is too high 2 Starting Aid Engine Choke Control Use control to change engine air fuel mix 3 Engine Control Switch Use switch to start engine select engine speed and stop engine In Run position engine runs at weld power speed In Run Idle position engine runs at idle speed at no load and weld speed with load applied To Start gt If engine does not start let engine come to a complete stop before attempting re start Pull Choke control out Turn Engine Control switch to Start while pressing Shutdown switch Release Engine Control switch when engine starts Continue holding Shutdown switch until engine indicator lights go out Push Choke control i
115. ts the welding arc drive dig circuit If CB4 opens electro de may stick to the workpiece more frequently during low voltage short arc length conditions CB4 auto matically resets when the fault is corrected CB5 protects the 24 volt ac output to remote receptacle RC14 and 24 volt output to field current regulator board PC1 CC CV models only If CB5 opens weld output and 24 volt output to RC14 stops On units with optional auxiliary power plant aux power output at receptacle RC5 also stops if CB5 opens CB10 protects the engine battery circuit If CB10 opens the engine will not crank CB10 automatically resets when the fault is corrected CB11 protects the engine wiring harness 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 Sec tion 5 2 If CB11 opens on CV mod els weld output stops auxiliary power is still available CB12 protects the field flashing cir cuit If CB12 opens the generator may not excite at start up and weld and auxiliary power output may not be available CB13 protects the engine shut down circuit If CB13 opens the en gine cranks but does not start Press button to reset breaker 802 729 Ref 802 789 OM 4405 Page 41 8 10 Diagnosing Causes Of Engine Fault Shutdowns Use the front panel engine lights to help determine the cause of an au NU tomati
116. ust if necessary Have Factory Authorized Service Agent check OCV control circuit Low weld output Check engine speed and adjust if necessary Check fuses F1 and F2 and replace if open see Section 8 9 Have Factory Authorized Service Agent check integrated rectifier SR1 capacitor C9 integrated rectifier SR2 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 8 9 Have Factory Authorized Service Agent check transformer T1 and integrated rectifiers SR4 and SR5 Low open circuit voltage Check engine speed and adjust if necessary 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 correct position Check and secure connections to Remote Amperage Adjust receptacle RC13 see Section 4 10 Reset circuit breaker CB11 see Section 8 9 Have Factory Authorized Service Agent check control relay CR7 Repair or replace remote control device Have Factory Authorized Service Agent check OCV control circuit OM 4405 Page 43 B Welding CC CV Models Trouble Remedy No weld output auxiliary power output okay Place Process
117. ust pipe in desired di OFF LAN op rection but always away from front panel and direction of travel RUN Tools Needed IE 1 2 in Ref 802 730 Ref 201 841 OM 4405 Page 15 5 A For 30 Minutes OR 30 A For 12 Minutes OM 4405 Page 16 Remove battery from unit 1 Eye Protection Safety Glasses Or Face Shield 2 Rubber Gloves Vent Caps 4 Sulfuric Acid Electrolyte 1 265 Specific Gravity 5 Well Fill each cell with electrolyte to bottom of well maximum Do not overfill battery cells Wait ten minutes and check electro lyte level If necessary add electro lyte to raise to proper level Reins tall vent caps 6 Battery Charger 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 Tools Needed 5 rubber gloves glasses drybatt1 1 98 0886 4 6 Connecting The Battery RUN IDLE lt Tools Needed wm Notes 802 168 B Ref 201 841 802 313 S 0756 C OM 4405 Page 17 4 7 Engine Prestart Checks Gasoline 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
118. ux ou les dipositifs de protection et fermer les portes la fin des travaux d entretien et avant de faire d marrer le moteur e Avant d intervenir d poser les bougies ou injecteurs pour viter la mise en route accidentelle du moteur e Bloquer le volant moteur pour viter sa rotation lors d une intervention sur le g n rateur L EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE e Toujours porter une protection faciale des gants en caoutchouc et v tements de protection lors d une in tervention 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 Observer la polarit correcte et sur les batteries e D brancher le cable n gatif en premier lieu Le rebrancher en dernier lieu 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 LES GAZ D CHAPPEMENT DU MOTEUR peuvent provoquer des accidents mortels e Utiliser l quipement l ext rieur dans des zones ou vertes et bien ventil es e En cas d utilisation dans un endroit ferm vacuer les gaz d chappe ment du moteur vers l ext rieur distan
119. vard Rexdale Ontario Canada M9W 1HR3 Safe Practices For Occupation And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway New York NY 10018 Cutting And Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 1 Keepcables close together by twisting or taping them 2 Arrange cables to one side and away from the operator 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 possi ble About Pacemakers Pacemaker wearers consult your doctor first If cleared by your doctor then following the above procedures is recommended SECTION 1 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 1 1 Signification des symboles oignifie Mise en garde Soyez vigilant Cette proc dure pr sente des risques de danger Ceux ci sont identifi s par des symboles adjacents aux directives A ldentifie un message de s curit particulier Signifie NOTA n est pas relatif la s curit 1 2 Dangers relatifs au soudage l arc A 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

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