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Miller Electric Big 40 CX Owner`s manual

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1. 21 9 6 Connecing The Bale xac et Saxo S RUE RAE Min PLC EV PIC ERE RIEN 21 5 7 Engine Prestalt GHOCKS s ud ERROR URL CREE ee AUN ee ee sie n d an Nos keeles 22 5 8 Connecting Weld Output Terminals 23 5 9 Selecting Weld Cable 24 5 10 Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models 24 5 11 Connecting To Remote 14 Receptacle RC14 On Models 25 SECTION 6 OPERATING WELDING GENERATOR CC MODELS 26 6 1 Front Panel Controls For CC Models See Section 6 2 26 6 2 Description Of Front Panel Controls For CC Models See Section 6 1 27 6 3 Remote Amperage Control On CC Models Optional 28 6 4 Weld Control Arc Condition Information Label 28 TABLE 5 SECTION 7 OPERATING WELDING GENERATOR CC CV MODELS 30 7 1 Front Panel Controls For CC CV Models See Section 7 2 30 7 2 Description Of Front Panel Controls For CC CV Models See Section 7 1 31 7 3
2. 1 Ce NAMEPLATE screened order by model and serial number 1 TODO 215 014 PANEL engine weld control 1 Wo TE 220 544 PANEL engine weld control ss 1 4 S3 208 278 SWITCH range changeover 1 5 188 635 RHEOSTAT WW 300W 34 ohm 1 202 209 SPACER cete ioo anat Ae 3 56 011 622 SWITCH tgl DPDT 15A 125VAC 1 MS sr 011 609 SWITCH tgl SPDT 15 125 on none on spd term chr 1 9 RC13 032 897 RECEPTACLE twlk 2P3W 15A 125V 1 51 212 436 SWITCH ignition 4 position w handle 1 dois 52 021 467 SWITCH 1 spst 250v spd term 1 LEA MIAME de Mth a 201 553 CLIP circuit breaker retaining 1 gt 201 083 CIRCUIT BREAKER man reset 2P 20 250VAC 1 19 CB2 093 996 CIRCUIT man reset 1P 20A 250VAC frict 3 14 GFCl1 151 981 RECEPTACLE str dx grd 2P3W 15 20A 125V GFCI 1 15 147 632 RECEPTACLE tw Ik grd 2P3
3. 1 008 to 193 230 SENDER Pressure Oil 0 100 Psi 1 OM 4427 Page 75 Item Dia Part No Mkgs No Description Quantity Figure 13 4 Panel Front w Components CC Models Continued LO Litas at 9164873 VOLT METER W Leads 1 TIO D 164 874 AMMETER W Leads 1 Ca 189 161 HANDLE switch range 1 26201 dre 010 647 PIN spring CS 156 x 1 250 1 019 602 KNOB Sen uias 1 s 024 103 BLANK snap in 750 mtg hole black 1 Optional When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor 5 Hardware is common and not available unless listed SONS ND TI 803 650 Figure 13 5 Panel Front w Components Models OM 4427 Page 76 Item Dia Part No Mkgs No Description Figure 13 5 Panel Front w Components CC CV Models Figure 13 1 Item 125 Meu 215 158 PLATE SCREENED
4. 1 gta tas 180 735 WASHER OUIDUESIUG bos bonne hae o or ecol 20 Ge te 169 5 SPACER OUIDUL SIG ai Lab e Se dees 2 MR 186 621 BOOT generic output stud 2 To case 0059 773 HANDLE SWIIGII ete eee ete Reo ete 1 Toc PE 010 647 PIN Spring 5 156 15260 eet ette 1 039 047 TERMINAL pwr output red 1 Qc 209 056 COVER receptacle w gasket 2 OU 206 795 BOOT circuit breaker clear hex nut 1 ls se oh asia Bee 021 385 BOOT toggle switch lever 2 MOD rien 201 045 COVER receptacle twistlock 1 RC CHR RER 193 228 METER Volt Dc 8 18 Scale 2 250 In Black Face 1 34 FUEL 192 265 GAUGE fuel elec switch w o sensor 1 POO MS 210 424 METER hour 12 24VDC 2 25dia 1 7186 217 084 GAUGE Coolant Temp 0 300 Deg F Electric 1 lo eee 197 798 SENDER Coolant Temp 300 Deg F M16 X 1 5 1 se 217 083 GAUGE Pressure Oil 0 100 Psi Electric
5. 2 TO qp 046 432 HOLDER fuse mintr 250x 1 250 2 adum rond 201077 CONTROL BOX II Rick vs 1 a SRI etra eds 201 079 2 CONTROLBOX cie Cu dcn ima eo n oce Rees 1 5 090 104 RELAY 12VDC SPST 30A 15VDC spin flange mtg 1 6 CR8 197325 RELAY 12 spst 70a flange mtg 1 7 CR1 090104 RELAY Encl 12vdc Spst 30a 15vdc 5pin Flange Mtg 1 8 CR6 090 104 RELAY 12vdc spst 30a 15vdc 5pin flange mtg 1 9 D10 C10 011 11 189 701 DIODE CAPACITOR BOARD 2 10 10 190374 CIRCUIT BREAKER auto reset 12VDC 40A 1 11 CB14 205 927 CIRCUIT BREAKER auto reset 12vdc 12 1 12 CR5 223 710 RELAY 12vdc dpst no 25a 6pin flange 1 pn dete hc 201079 COVER control BOX Rt de Re TRE bes 1 14 PC7 195 706 MODULE pull to idle two output 7 pin 1 15 SAT 035704 RECTIFIER integ 40A 800 1 16 CR4 113247 RELAY 12vdc 20a 120vac flange mtg 1 17 PC9 192224 CIRCUIT CAR
6. 215 363 PANEL generator power full KVA option ds ee E 214 927 BOOT circuit breaker 1 pole 197 508 5 PLUG Hee Carine ees mor 077 440 BUSHING conduit 1 DD cess ies LU 601 836 NUT 250 20 50hex 19h brs ET 209 056 COVER receptacle w gasket POUR en mes 083 030 STUD brs 250 20 1 750 w hex collar m CT2 197 433 TRANSFORMER current sensing 190 861 LABEL warning electric shock and moving parts etc 197 399 LABEL warning ph generator power DER ser 209 056 COVER receptacle w gasket RC oe ee ee 206 795 BOOT circuit breaker clear hex nut SZ md 512 9195025 SWITCH polarity sien daw eka aaa dire OE S12 as SWITCH polanty AC peny oh SR Ee hie ip ET in 201 125 PANEL mtg terminal pwr sin o ei eru 199 303 PANEL mtg terminal pwr output ss
7. 96 5 189 744 CIRCUIT CARD ASSEMBLY filter 1 Mcr 039 046 TERMINAL pwr output black Mone LUIS Ain 100739 25 WASHER OUIDUE SIUG ue dnt cw ed DR ph Rd Quantity OM 4427 Page 77 Item Dia Part No Mkgs No Description Quantity Figure 13 5 Panel Front w Components CC CV Models Continued ac Diane 134201 SUDDOLIT i 25 ue do oo ce RUE C pes 12 Ec DI 1814469 SPACER 5 xdi din E A apres e aot s 2 D DTE 186 621 BOOT generic output stud 2 TI SRE Er 059 773 MANDLE SWICK esse Liane MA iront eder ue d 1 dev RU LE 010 647 PIN spring cs 156 1 250 1 039 047 TERMINAL pwr output 1 ie 196 073 LABEL do switch while welding 1 dep eae D 021 385 BOOT toggle switch lever 1 AO 2 190 323 BOOT circuit breaker clear hex nut 2 170 391 CONN circ ms protective cap size 20 1 dO etes HM 210424 METER hour 12 24 snap in 1 49 FUEL 192 265 GAUGE fuel e
8. and easy With Miller you can count on years 00012000 of reliable service with proper maintenance And if for some reason the unit needs repair QUALITY SYSTEM there s a Troubleshooting section that will help you figure out what the problem is The Miller is the first welding parts list will then help you to decide the equipment manufacturer in 252 exact part you may need to fix the problem the ISO 9001 2000 Quality Warranty and service information for your System Standard particular model are also provided Miller Electric manufactures 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 specification sheets To locate your nearest distributor or service agency call 1 800 4 A Miller or visit us at www MillerWelds com on the web 2 Miller Mil_Thank 4 05 TABLE 5 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 154 CSV oe reek oy ee eae ea ae eee deen AR denne A 1 125 Ate Welding Hazarde sees 1 153 ENQINGHAZONS EN aa 2 1 4 Compressed 3 1 5 Additional Symbols For Installa
9. 1 E NP ie 199 592 LATCH paddle series 20 black 1 TM o NEN RR PEE 190 076 CHANNEL stiffener engine access 1 202 635 CHANNEL stiffener engine access 1 Bet 190 992 KEEPER latch engine access door 1 C NC TE 220539 LABEL diesel engine maintenance required on rh door only 1 cec PROP 2 OP OOO 55 58 t eti oto nie a doni 1 Tul m 199 925 PANEL fend wae roe c e teda dee he 1 199298 PANEL rocker SS ue we ate ee ERO 1 ZT lt 66214972 REACTOR EIER x tt dd Ea tu ei 1 ice Holes Z1 692 15964 REACTOR Rn at o eae qam deae teh he ouo une oat 1 206 352 BRACE front to center upright 2 203 260 LABEL caution not use ether 1 pes lose 1T 038 621 BLOCK term 30A 4 pole frict term str 1 038 620 LINK jumper term 2 uc VEM TET RT 081 499 BRACKET mtg strip terminal 1 15 5 4 SR5 035 704 RECTIFIER integ bridge 40 amp 800v
10. 1 irat 55 011609 Switch Tgl Spdt 15a 125vac On none on Spd Term Chr 1 es heats D1 C1 189701 Diode Capacitor Board 1 aa eee 193183 Conn Rect Cinch 18 Pin 1 196602 Plug Cavity 18 30 Position Cinch Connector 4 RAA 196603 Seal Switch 6 Position Rotary 250 Shaft 1 PEE 141450 Conn Rect Metrmate 10skt 1row Plug Cable Lkg 1 ERAS 093995 Circuit Breaker Man Reset 1p 15a 250vac Frict 2 Duae TE 211292 Conn Pack 1row Female 1 211293 Terminal Position Assurance Lock 1 sn a 215013 Harness weld control includes 1 24 PLG3 158465 Conn Rect Univ 084 12 5 Plug Cable 1 187654 Seal Wire Univ 12p S 3rOW 1 PLG6 114063 Conn Rect Univ 084 4p S 1row Plug Cable 1 215207 Harness weld control CV includes 1 NP TT PLG6 114063 Conn Rect Univ 084 4 5 1row Plug Cable 1 ace gate
11. 45 SECTION 10 ELECTRICAL DIAGRAMS amas an en iEn r 50 SECTION 11 RUN IN PROCEDURE 5455 59 2 xmi EIE net nce n e 54 114 I cicer 54 11 2 Run In Procedure Using Load 55 11 3 Run In Procedure Using Resistance Grid 56 SECTION 12 GENERATOR POWER GUIDELINES 57 SECTION IS PARTS LIST exte e ute m exe omg ue S mE RE DE 64 WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING nd 3 05 Warning Protect yourself and others from injury read and follow these precautions 1 1 Symbol Usage 4 Marks a special safety message Means Warning Watch Out There are possible hazards with this procedure The possible hazards are shown in the adjoining symbols 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 Stan dards listed in Section 1 7 Read and follow all Safety Standards Only qualified per
12. OVERHEATING can damage motors e Turn off or unplug equipment before starting or stop ping engine e Do not let low voltage and frequency caused by low engine speed damage electric motors e Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable 2 Sparks can cause fires keep flammables away FLYING SPARKS can cause injury e Wear a face shield to protect eyes and face e Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face hand and body protection OVERUSE can cause OVERHEATING Allow cooling period follow rated duty cycle e Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit STATIC ESD can damage PC boards 79 5 gt a e Put on grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards TILTING OF TRAILER can cause injury SPD e Use tongue jack or blocks to support weight e Properly install welding generator onto trailer accord ing to instructions supplied with trailer OM 4427 Page 3 READ INSTRUCTIONS e Use only genuine MILLER Hobart replacement parts Perform engine and air compressor if applicable maintenance and service according to this manual and the engine air compressor if applicable manu als H F RADI
13. e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Tenir distance les produits inflammables de l chappement LES TINCELLES L CHAPPEMENT peuvent provoquer un incendie e Emp cher les tincelles d chappement du moteur de provoquer un incendie e Utiliser uniquement un pare tincelles approuv voir codes en vigueur Le METAL CHAUD lors du coupage et gougeage plasma peut provoquer un in cendie ou une explosion e Ne pas couper ou gouger proximit de produits in flammables e Surveillez et garder un extincteur proximit DES PIECES CHAUDES peuvent provo quer des br lures et blessures e Ne pas toucher le compresseur ou d autres l ments du circuit air comprim chauds e Laisser l ensemble se refroidir avant de toucher ou d effectuer la mainte nance LIRE LES INSTRUCTIONS e Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil e Arr ter le moteur et rel cher la pression avant d ef fectuer la maintenance e Utiliser uniquement des pi ces de rechange Miller Hobart Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance L EMPLOI EXCESSIF peut SURCHAUFFER L EQUIPEMENT Laisser l quipement refroidir respecter le facteur de marche nominal R duire le courant ou le facteur de marche avant de poursuivre le soudage e pas obstruer les passages d air du post
14. 4427 215 6221 2006 01 Miller DW Stick SMAW Welding TIG GTAW Welding MIG GMAW Welding p 2 4 a Flux Cored FCAW Welding Air Carbon Arc CAC A Cutting and Gouging Description 23 40 40 OWNER S MANUAL File Engine Drive Visit our website at www MillerWelds com From Miller to You Thank you and congratulations on choosing Miller Now you can get the job done and get it done right We know you don t have time to do it any other way That s why when Niels Miller first started building arc welders in 1929 he made sure his products offered long lasting value and superior quality Like you his customers couldn t afford anything less Miller products had to be more than the best they could be They had to be the best you could buy Today the people that build and sell Miller products continue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 y BL El Her This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They ete jue ere ex e every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most We ve made installation and operation quick
15. 1 Sor see 203 430 BRACKET battery holddown 1 be OO Wei 190 897 BATTERY stor 12V 650crk 110rsv gp 24 1 OO Lese des 168 385 LABEL warning battery explosion can blind 1 SI Sere Te en er 225 120 LABEL warning moving parts can cause injury 1 Po ee eee 201 183 COVER battery access 1 202 639 COVER battery access SS 1 201 006 BOLT j stl 312 18 x 8 500 pld redo oh Ete Rn Rr te esse 2 OO oa 219 0067 2 GUARD IAN SRE desi ae tere aed a ed 1 mm cu EP 197 496 HOSE radiator lower 1 pitch Chee 199 505 HOSE oil drain assy 32 in consisting of 1 165271 VALVE oll drain 3 B TONPTE 2 ENTER 1 176 529 FITTING hose brs barbed 1 2tbg 3 8 1 113 854 HOSE SAE 500 ID x 780 OD xc oil order by ft 197 448 FITTING hose brs barbed elbow m 1 2 tbg x 3 8 1 WASHER oil drain available through engine manufacturer
16. Do not use ether Using ether voids warranty gt If engine does not start let engine come to a complete stop before attempting re start Above 32 F 0 C turn Engine Control switch to Start Release Engine Control switch when engine starts Below 32 F 0 C push Starting Aid switch up for 60 seconds While still holding Starting Aid switch turn Engine Control switch to Start Release Engine Control switch and Starting Aid switch when engine starts To Stop turn Engine Control switch to Off position Engine Gauges And Meters 3 Engine Hour Meter Use hour meter to monitor engine run time to help schedule maintenance 4 Fuel Gauge Use gauge to check fuel level To check fuel level when engine is not run ning turn Engine Control switch to Run posi tion 5 Battery Voltmeter Optional Use gauge to check battery voltage and moni tor the engine charging system The meter should read about 14 volts dc when the en gine is running and about 12 volts dc when the engine is stopped 6 Engine Coolant Temperature Gauge Optional Normal temperature is 180 203 F 82 95 C Engine stops if temperature exceeds 220 F 104 C 7 Engine Oil Pressure Gauge Optional Normal pressure is 30 60 psi 207 414 kPa Engine stops if pressure is below 10 psi 69 kPa Weld Controls Control Circuit This unit has a max OCV control circuit that resets Am perage Adjust control H1
17. N START material is at or near minimum length Minimum Length 5 8 in 16 mm 1 New Length 1 1 4 in 32 mm um Replace Damaged Brushes Ref 215 158 Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual OM 4427 Page 39 9 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 9 9 be cleaned but the dirt holding capac ANNONA ity of the filter is reduced with each cleaning The chance of dirt reaching the clean side of the filter while clean ing and the possibility of filter damage makes cleaning a risk Consider the risk of unwarrantable equipment damage when determining whether to clean or replace the primary ele ment AKA The air cleaner primary element can RA 4 5 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 safety element Re place the safety element after servic ing the primary element three times Clean or replace primary element if dirty see note above before cleaning Re place primary element if damaged Re place primary element yearly or after six cleanings Keep nozzle lt lt 1 Housing 2 51
18. Use dry properly stored electrodes Remove excessive coils from weld cables Have Factory Authorized Service Agent check brushes and slip rings High weld output Check position of Ampere Range switch and Voltage Amperage Adjust control Check engine speed and have Factory Authorized Service Agent adjust if necessary Have Factory Authorized Service Agent check field current regulator board PC1 and PC1 voltage feed back circuit Voltage Amperage control does not work when welding in Stick mode Place Ampere Range switch in lower range Voltage Amperage control does not work with Ampere Range switch in highest range Low weld output Check position of Ampere Range switch and Voltage Amperage Adjust control Check engine speed and have Factory Authorized Service Agent adjust if necessary Check fuses F1 and 22 and replace if open see Section 9 8 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 9 8 Have Factory Authorized Service Agent check transformer and integrated rectifiers SR4 and 5 5 Low open circuit voltage Check engine speed and adjust if necessary Check position of Proces
19. 3 8in 803 656 Ref 215 158 4427 41 9 6 Adjusting Engine Speed On Models With Automatic Idle Optional See engine manual for engine models AS ree After tuning engine check engine 61 6 Hz speed with tachometer or frequency 1250 rpm meter See table for proper no load 41 6 Hz speed If necessary adjust speed as follows Start engine and run until warm On CC models place Stick TIG switch in Stick position On models turn Process Contactor switch to Stick Weld Terminals Always On position Idle Speed Adjustment 1 Throttle Rod Plunger 2 Locknut Loosen locknut Place Engine Con trol switch in Auto position Turn throttle rod and plunger until engine runs at idle speed Tighten locknut Be sure solenoid plunger pulls all the way in bottoms when energized F If necessary move linkage to other hole in bracket or move cotter pin to other hole in throttle arm to set idle speed correctly Stop engine Weld Power Speed Adjustment Weld power speed adjustment must be done by a Factory Authorized Service Agent SNNNNNNNNNNN d If necessary move linkage to other hole in bracket or move cotter pin to other hole in throttle arm to set idle speed correctly 22 803 606 4427 42 9 7 Servicing Fuel And Lubrication Systems Stop engine and let cool After servic
20. PLG8 193184 Conn Rect Cinch Pin 1 dee oak PLG13 147992 Conn Rect Univ 039 10 5 2row Plug Cable Lkg 1 PLG3 158465 Conn Rect Univ 084 12 5 Plug Cable 1 187654 Seal Wire Univ 12 5 3row 1 196602 Plug 18 30 Position Cinch Connector 6 OM 4427 Page 82 Item Dia No Mkgs DE uerus CB10 Part No 221376 189701 190374 090104 148850 114062 212116 212117 197325 192558 148389 201109 147632 093996 201053 cvs HOT 22 139266 093996 190259 135134 187651 Description Quantity Wiring Harnesses Continued Harness engine control includes 1 Diode Capacitor Board 2 Circuit Breaker Auto Reset 12vdc 40 Amp 1 Relay Encl 12vdc Spst 30a 15vdc 5pin Flange 1 RED eee Gu ese ees 1 Conn Rect Univ 084 15p S 3row Plug Cable Lkg 1 Conn Deutsch 2 1row Female Plug 3 Conn Deutsch Wedge Lock 2 Position 3 Rela
21. 1 tu D hu 197 196 FITTING adapter oil drain 12mm male x 3 8 npt female 1 HL 199 849 SCREW 625 11 x 4 00hexhd pln gr 5 pld 4 071 731 WASHER flat 656 ID x 2 250 OD x 187T stl pld 4 NL Sd 197 489 BRAOISET Ttg 2 edet re tour Bead orto 1 OR ee 197 488 BRACKET mtg LH eec ont E et OCC e tbe 1 Pl diese 071 890 RETAINER mount eng gen 4 HO ban 071 730 TUBING stl 875 OD 12ga wall x 2 500 4 Te 083 476 MOUNT nprn 875 ID x 2 500 OD x 2 000 4 as uot E 135 205 NUT 625 11 94hex 76H stl pld elastic stop nut 4 pi EIE 190 992 KEEPER latch engine access door 2 E E Prat 190 076 CHANNEL stiffener engine access 2 202 635 CHANNEL stiffener engine access 1 OM 4427 Page 67 Item Dia Part No Mkgs No Description Quantity Figure 13 1 Main Assembly Continued ee Oe ee ee 191 626 BUMPER door engine access 4 i Mesa bts ieee 199 592 LATCH paddle series 20 black 1
22. 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 4427 Page 58 12 5 Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1 8 HP 800 300 1 6 HP 1225 500 1 4 HP 1600 600 1 3 HP 2100 700 1 2 HP 3175 875 Capacitor Start Induction Run 1 3 HP 2020 720 1 2 HP 3075 975 3 4 HP 4500 1400 1 HP 6100 1600 1 1 2 HP 8200 2200 2 HP 10550 2850 3 HP 15900 3900 5 HP 23300 6800 Capacitor Start Capacitor Run 1 1 2 HP 8100 2000 5 HP 23300 6000 7 1 2 HP 35000 8000 10 HP 46700 10700 Fan Duty 1 8 HP 1000 400 1 6 HP 1400 550 1 4 HP 1850 650 1 3 HP 2400 800 1 2 HP 3500 1100 12 6 Approximate Power Requirements For Farm Home Equipment Farm Home Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 Milker Vacuum Pump 2 HP 10500 2800 FARM DUTY MOTORS 1 3 HP 1720 720 Std e g Conveyors 1 2 HP 2575 975 Feed Augers Air 3 4 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 H
23. 50 100 25 50 5 10 15 20 240 20 30 40 AC 120V 4 8 Optional Three Phase Generator 5 A 12 kVA kW Single Phase AC Output Weld Load 280 260 NO N O AC VOLTS D NO 10 20 30 40 50 60 70 80 90 100 AC AMPERES B 15 kVA kW Three Phase AC Output No Weld Load 260 AC VOLTS NO N O AC AMPERES OM 4427 Page 16 The ac power curve shows the gen erator power in amperes available at the 120 and 240 volt receptacles 193 018 The ac power curves show the gen erator power available in amperes at the single phase 120 240 volt re ceptacle or three phase 240 volt terminals 215 086 A 215 087 A SECTION 5 INSTALLATION 5 1 Installing Welding Generator JB D Always securely weld E ing generator onto transport SP IN vehicle or trailer and comply with all DOT and other applica ble codes A Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards A Ifunit does not have GFCI re ceptacles use GFCl protected OR extension cord See Section 4 2 for lifting eye rating gt See Section 5 3 for mounting I I I information Location Grounding 1 Equipment Grounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Ve
24. FILTER fuel Secondary its As soso sh dos drogues l HAS sera 214 658 HOSE radiator upper 1 POT 944 BELL fati 1 kf 217775 GUARD belt export models only 1 AT oui sates hla iene 202 O17 2 GUARD Del ep ee ee th nates es na 1 220 280 RADIATOR w shroud includes 1 220 281 oMROUD radiatot 235 oe Dea nee didis 214 884 RADIATOR w 14 4 row core pass 1 PANNE ete eae 187 120 radiator pressure 14 1 E EM DE 225 120 LABEL warning moving parts can cause injury 2 esu d date 201 749 UPRIGHIET A ets o ved e Seed une 1 SEU 207 188 5 UPRIGHT Tear SS 3 2549 d ea dee RN oit se e Rte dat 1 poU Sr 207 005 GRILL rear panel 55 1 ee 108 081 TERMINAL PROTECTOR battery post mtg 2 Les 190 206 CABLE bat neg 42 lg No 2 awg w clamp and 375rng 1 Dd Pastis Lacie 190 207 CABLE bat pos 45 in No 1 awg w clamp and 406rng
25. PC7 195 706 MODULE pull to idle two output 7 pin 1 17 581 SR2 035 704 RECTIFIER integ 40A 800V 2 18 113 247 RELAY 12vdc 20a 120vac flange mtg 1 19 TD1 214928 TIMER delay on make break open 30 sec 12vdC 1 OM 4427 Page 70 Item Dia Part No Mkgs No Description Quantity Figure 13 2 Control Box Assembly CC Models Continued 201 079 COVER control 1 C9 087 110 CAPACITOR elctit 240uf 200VDC 1 A ee ee 177 136 CLAMP capacitor 1 375dia 1 23 D1 C1 189 701 DIODE CAPACITOR BOARD 1 24 11 12 13 139 266 CIRCUIT BREAKER man reset 1P 15A 250VAC frict 3 Optional Recommended Spare Parts To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 4427 Page 71 803 648 Figure 13 3 Control Box Assembly CC CV Models Item Dia Part No Mkgs No Description Quantity Figure 13 3 Control Box Assembly CC CV Models Figure 13 1 Item 114 1 Fl F2 085 874 FUSE mintr slo blo 10A 250V
26. 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 10 Voltage AmperageAdjust Control With Process Contactor switch in any Stick or TIG setting use control to adjust amperage within range selected by Ampere Range switch With Process Contactor switch in any MIG position use control to adjust voltage With Voltage Amperage Adjust Switch in Re mote position control limits the remote am perage in TIG mode but has no effect in Stick and MIG modes Weld output would be about 218 A DC with controls set as shown 5096 of 115 to 320 A gt The numbers around the control are reference only and do not represent an actual percentage value 11 Voltage Amperage Adjust Switch And Hemote 14 Receptacle Use switch to select front panel or remote voltage amperage control For remote con trol place switch in Remote position and con nect remote control to Remote 14 receptacle RC14 see Sections 5 11 and 7 4 12 Polarity Switch Optional not switch under load Use Polarity switch to change weld output Select either DC Electrode Positive DCEP or DC Electrode Negative DCEN 13 Polarity AC Switch Optional Electric sho
27. Ifa circuit breaker continues to open contact Factory Autho rized Service Agent 120 V 20A 17 60 Hz 240 V 15 A 5 Generator power is not af fected by weld output South African Receptacle Maximum output is 2 4 kVA kW from and 4 kVA kW from RC1 Maximum output from all re ceptacles is 4 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 5 120 V 20A 1 V 60 Hz 240 V 15A 191 624 OM 4427 Page 36 bd Ue 061906061 289099 09 90t LEE 166 261 HATIIN 2 1 9 gt S 244 L 1Q 10008 a z d L 18 946 WLSV 2 LV 6982 58 RE LA 109 LS NIG ESS 8 LA 6 1 1766 47 201601080 19591 vv6 261 5 0002 82000 UA VU ut 2 1 ui DUK 08190297 18200 0 20 14 JEISOULIOY PIs 4 20 2 02 ab 6 1106 68797 XIM 89106284 866 261 H3TIIIN PP P P AP AP AP AP P PIS 0001 N S 20 81 099 vz 104 0619 07 52 668 61 H3TIIN 666 261 HATIIW jeuondo ra 08 ib 2 11 19001 j
28. es Properly install and ground this equipment according to its Owner s Manual and national state and local codes 5 Customer supplied equipment is re quired if generator will supply standby power during emergencies or power out ages 1 Utility Electrical Service 2 Transfer Switch Double Throw Notes Transfer Switch Fused Disconnect Switch If Required Essential Loads Switch transfers the electrical load from electric utility service to the generator Trans fer load back to electric utility when service is restored Install correct switch customer supplied Switch rating must be same as or greater than the branch overcurrent protection 3 Fused Disconnect Switch Install correct switch customer supplied if required by electrical code 4 Welding Generator Output Generator output voltage and wiring must be consistent with regular utility system volt age and wiring Welding Generator Output Connect generator with temporary or perma nent wiring suitable for the installation Turn off or unplug all equipment connected to generator before starting or stopping engine When starting or stopping the engine has low speed which causes low voltage and frequency 5 Essential Loads Generator output may not meet the electrical requirements of the premises If generator does not produce enough output to meet all requirements connect only essential loads pumps freezers heaters etc S
29. f kom elemani lt gt gt 2 Safety Element Optional 2 3 Primary Element 5252525 25252525 5252525 52525252 52525252 52525252 4 Dust Cap lt 2 lt 2 lt 240 55252525 55252525 52525252 525252521 5 Dust Ejector QU X LR n LR KQ 59 WY v To clean air filter X 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 ST 153 929 B ST 153 585 Ref S 0698 B Ref 215 158 OM 4427 Page 40 9 5 Inspecting And Cleaning Optional Spark Arrestor Muffler NAM gt gt Stop engine let cool 1 Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole Start engine and run at idle speed to blow out cleanout hole If nothing blows out of hole briefly cover end of exhaust pipe with fireproof material Stop engine and let cool Reinstall cleanout plug Tools Needed
30. okay at ac receptacles Place Process Contactor switch in a Weld Terminals Always On position or place switch in Remote On Off Switch Required position and connect remote contactor to optional Remote 14 receptacle RC14 see Sections 5 11 and 7 1 Check position of Ampere Range switch Check position of optional Polarity switch or Polarity AC switch Reset circuit breaker CB11 see Section 9 8 Reset circuit breaker 5 see Section 9 8 Check for faulty remote device connected to RC14 Check and secure connections to Remote 14 receptacle RC14 see Section 5 11 Have Factory Authorized Service Agent check connector board PC6 and connections Check fuse F2 and replace if open see Section 9 8 Have Factory Authorized Service Agent check brushes and slip rings weld excitation circuit field current regulator board PC1 and the rotor No weld output or generator power out put at ac receptacles Disconnect equipment from generator power receptacles during start up Check fuses F1 and F2 and replace if open see Section 9 8 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
31. tincelles et des particules m talliques volantes Pendant la p riode de re froidissement des soudures elles risquent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial DES PI CES CHAUDES peuvent provoquer des br lures graves e Ne pas toucher mains nues les parties chaudes e Pr voir une p riode de refroidissement avant de travailler l quipement e Ne pas toucher aux pi ces chaudes utiliser les outils recommand s et por ter des gants de soudage et des v tements pais pour viter les br lures LE BRUIT peut affecter l ouie Le bruit des processus et des quipements peut affecter des protections approuv s pour les oreilles si le veau sonore est trop lev LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques Porteurs de stimulateur cardiaque restez distance e Les porteurs stimulateur cardiaque doivent d abord consulter leur m decin avant de s approcher des tions de soudage de gougeage ou de soudage par points Si des BOUTEILLES sont 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 normalement partie du proc d de soudage les manipuler avec pr caution e Prot ger les bouteilles d
32. yi 220 686 LABEL diesel engine maintenance 1 200 989 DOOR engine access 1 210 736 engine ACCESS 5 5 1 aiebat 218002 LABEL CAT diesel power 4 000 x 4 000 2 RE Dee 189 975 HINGE door access 180deg 2 liu rua es 199 301 PANEL engine side ss 1 OQ Lea 190 190 2 FANIS CoOlant TeGOVOlV Voir eec e Rte c te e e st 1 Wr ML 189 826 PANEL rocker nim Sate tego Re nee nl 1 D 199 298 PANEL rocker SS 1 E PEE 2481548 02 2 OLOF GOO tet Dreier vet eae a ee ec E WAR Pd oi dite us 1 199 927 PANEEL stipe ecran E eto oa ree excede son Peor pa ER 1 21993002 PANEL gen HEIL 65 254 02 ue nee 1 HOT MNT 197 997 FILTER fuel secondary 1 45 173 909 HOSE sae 312 id x 560 od order by ft 1 fuel available through engine 1 218 222 BRACKET mtg fuel filter pump
33. 126 202 130 XFMR current sensing 1 189 828 PANEL engine side 40C Models 1 HOT ne 199 301 PANEL engine side ss 1 Re 190 058 NUT 250 20 u nut multi thread 19 LT 049 525 NUT 312 18 u nut multi thread 32 215 627 KIT label includes safety informational labels CC models 1 dd mp ada uera 215 629 KIT label includes safety amp informational labels CC CV models 216 985 KIT label includes safety amp informational labels CC export models 216 984 KIT label includes safety amp informational labels CC CV export erm When ordering a component displaying precautionary label the label should also ordered Recommended Spare Parts CC models only CC CV models only Optional To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 4427 Page 69 5 Hardware is common not available unless listed 803 647 E Figure 13 2 Control Box Assembly CC Models Item Dia Par No Mkgs No Description Quantity Figure 13 2 Con
34. 2 16 045061 CIRCUIT BREAKER auto reset 24vdc 7 amp 1 urn T1 201613 TRANSFORMER w bracket 1 NE ION T1 205636 TRANSFORMER w bracket environmental coating 1 pu li n e ie sse 173 352 EXTRUSION rubber clamp bulb order by ft Lui 189 7062 FIREWALL 10D eo E dedi 1 RE PIT 191 307 GOVER Plate aot edem e doe coe sedentem cde P 1 Roa 189 763 BRACKET mtg air cleaner 1 MRA foc Aik Bs ie Andes 189619 1 HOSE 81 Cleaner Re SUR 1 o TERRE RE 198 457 2 x aeo ear re ee Dol vi OR ede en ecce die ee 1 TRO 173036 HOSE elbow air cleaner 1 te 010 863 CLAMP hose 1 125 3 000 clo dia 4 Qd 189 764 AIR GLEANER ie SIA Eu dows 1 192 938 FILTER air element primary 1 mM EE 192 939 FILTER air element safety 1 re 189 464 SEAL weather lift eye 1 Dore AR EE 173 909 HOSE sae 312 i
35. 24 volt ac contactor control circuit Output to remote control 10 volts dc MIG or Stick mode to 10 volts in mode Remote control circuit common DC input command signal 0 to 10 volts from min to max of remote control with Voltage Amperage Adjust control at max 115 volts 10 amperes 60 Hz ac Protected by circuit breaker CB6 Contact closure to completes 115 volt ac contactor control circuit Chassis common 7 REMOTE 14 Socket A 24 VOLTS AC OUTPUT B CONTACTOR C REMOTE D OUTPUT CONTROL 115 VOLTS OUTPUT CONTACTOR J K Ref 803 602 GND NEUTRAL G Circuit common for 24 and 115 volt ac circuit The remaining sockets are not used Notes HOBARI INSTITUT OF WELDING TECHNOLOGY 400 Trade Square East Troy Ohio 45373 1 800 332 9448 www welding org Start Your Professional Welding Career Now Over 80 000 trained since 1930 OM 4427 Page 25 SECTION 6 OPERATING WELDING MODELS 6 1 Front Panel Controls For CC Models See Section 6 2 215 070 803 602 OM 4427 Page 26 6 2 Description Of Front Panel Controls For CC Models See Section 6 1 Engine Starting Controls 1 Starting Aid Switch Use switch to energize starting aid for cold weather starting see starting instructions fol lowing 2 Engine Control Switch Use switch to start and stop engine To Start
36. 4 FIREWALL JOWGM mcer Dd e Een Born itt e e edit 1 114 Figures 13 2 13 3 CONTROL BOX ASSEMBLY 1 115 189 699 RESISTOR WW tap 375W 10 ohm w mtg bkt 1 116 R2 189 699 RESISTOR WW tap 375W 10 ohm w mtg bkt 1 ls Figure 13 7 MAIN RECTIFIER ASSEMBLY 1 118 PC1 189 143 MODULE field current regulator 1 x E 19324593 ICT 3 337912 dom lien PE oo Sa satire 1 s T20 191 448 TOP cover front upright esitis ses bae d ott n Rr ite rt cn e 1 OM 4427 Page 68 Item Dia Part No Mkgs No Description Quantity Figure 13 1 Main Assembly Continued eee 199 305 TOP cover front upright ss 1 m gt RS 212944 LABEL weld control arc condition information label 1 Not Applicable 7102 2 5 201 75072 UPRIGAE AONE 4 40 1 gt 4202 697 gt UPRIG H TE SS bib be ee 1 223 379 LABEL warning general precautionary csa 1 is da Figures 13 4 13 5 PANEL front w components 1
37. 46 z 4 gt PLG10 RC10 236467 3 gt lt 6 gt PLG13 Le 22 gt 3 2A 22 P 28 226 STICK PLG14 TIG QWMIG 7 27 a E PME 7 22 56 Y 1 OPTIONAL STANDARD LR 2 77 X al 21 eB RECEPTACLE a gt 3 97719 2 119 5 7856 UT 240V 763 oF 9 Y O 2 875 n 120V CB2 23 wH AUX H2 gt 42 85 V 102 2 L 107 106 65 044 63 CR4 702 9 LED BOARD MOVE LEAD 84 CONNECTION TERMINAL W 240V 89 54 RECEPTACLE OPTION PF 22 CB5 x C9 T 707 2 gt PANEL REMOTE STANDARD 240V 735 55 RECEPTACLE POSTION T 128 T T 5 2 10 A AN CANN A A A RC2 PLG14 704 MT 78 43 Di A2 C3 02 03 K2 F3 J2 BS RC14 aai STATOR H1 225 FILTER BOARD 103 H 776 81 FIELD CURRENT 777 REGULATOR pe 75 lt 3 K3 PLGB 30 PIN 222 gt gt pM 95 lt 2 gt gt O RMT 5 128 56 5 22 F1 OUTP UT CONTACTOR 727 TIG RMT S6 68 52 49 2 9 ALL HOT CR5 STICK RMT MIG RMT O CB13
38. 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 0 120 250 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 15 2 300 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2 TY 2 2 2 2 ea 2 0 2 3 0 2 3 0 2 ea 4 0 350 1 0 60 2 0 70 3 0 95 4 0 120 2x1 2 2 ea 2 0 2 3 0 2ea 4 0 2 ea 4 0 400 1 0 60 2 0 70 3 0 95 4 0 120 20 ox xt 2 2 ea 2 0 2 ea 3 0 2ea 4 0 3ea 3 0 3 ea 3 0 900 2 0 70 3 0 95 4 0 120 2x70 2x95 2x120 3x95 3x95 Chart is a general guideline and may not suit all applications If cables overheat use next size larger cable Weld cable size is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere mm for metric use S 0007 F For distances longer than those shown in this guide call a factory applications representative at 920 735 4505 5 10 Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models 1 Remote Amperage Adjust Receptacle RC13 Connect optional remote control to RC13 see Section 6 3 Ref 154 862 A 048 720 K 803 602 OM 4427 Page 24 5 11 Remote 14 Receptacle 14 CC CV Models Socket Information 24 volts ac Protected by circuit breaker CB5 Contact closure to completes
39. AC switch connect electrode holder cable to Electrode terminal on left and work cable to Work terminal on right Do not place Tools Needed 6 3 4 in MIG FCAW Welding For welding Direct Current Electrode Positive DCEP on CC CV models connect wire feeder cable to Positive termi nal on left and work cable to Negative ter minal on right Use Process Contactor switch to select type of weld output see Section 7 3 For Direct Current Electrode Negative DCEN reverse cable connections If equipped with optional Polarity switch or op tional Polarity AC switch connect wire feeder cable to Electrode terminal on left and work cable to Work terminal on right Incorrect Installation 803 602 803 778 A OM 4427 Page 23 5 9 Selecting Weld Cable Sizes Weld Cable Size and Total Cable Copper Length Weld Circuit 0 Exceeding 100 ft 30 Less 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 45m 60m 70 90 105 120 Weld Output Terminals A Stop engine before 10 60 60 100 connectingto weld Welding Duty Duty 10 100 Duty Cycle put terminals Amperes Cycle Cycle Do not use worn dam aged undersized or poorly spliced cables 100 4 20 4 20 4 20 3 30 2 35 1 50 1 0 60 1 0 60 150 3 30 3 30 2 35 1 50 1 0 60 2 0
40. COVER starter hole Continental 1 ee 195 560 GUARD starter hole deutz 912 1 RE EE 083 883 WASHER Lock 402idx0 7090dx 087t Stl SplitiOmm 6 m 172 555 SCREW M10 1 5 x 50hexhd pln 8 8pld 6 Tro 602 159 SCREW 312 18x 75 hexwhd 66d stl pld slffmg tap rw 6 INN 601 961 SCREW 312 18 x 2 25hexhd pln gr 4 Odeur 6022112 WASHER lock 318 ID X 0 586 s 2 5 45124084 CL Re c 6 ODA since se 1598412 MASHER Deed rtr e aine e eas due 4 2301 cus D 190 823 c BRUSEFLCONAC GER Ea Mn 3 NC ere PPS 208 469 7 CHIP Men Bee net 3 CPR 189 142 BRUSHHOLDER ASSEMBLY gen 1 BEC MEN 602 242 WASHER flat 3751Dx0 8750dx 083t stl pld 2 602 211 WASHER Lock 318idx0 5860dx 078t Stl Pld Split 312 2 EG P masse 604 534 SCREW 312 18x1 25 hex hd pln gr5 pld 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 202 021 or Label Kit 201 061 export models only Recommended Spare Parts Optional To maintain th
41. Process Contactor Switch CC CV 5 32 7 4 Remote Voltage Amperage Control On CC CV Models Optional 33 SECTION 8 OPERATING AUXILIARY EQUIPMENT 34 8 1 120 Volt And 240 Volt Receptacles 34 8 2 Connecting To Optional Three Phase Generator CC CV Models Only 35 8 3 Optional Generator Power Receptacles 36 SECTION 9 MAINTENANCE TROUBLESHOOTING 37 9 1 Maintenance Label Rove rr das ev oen eee ol ev o e e 37 9 2 Routine Malntenarice s seeks hota dank EA 38 9 3 Checking Generator Brushes 1 39 9 4 Servicing Air Gleaner ciuis Re mus RARI ______________ 40 9 5 Inspecting And Cleaning Optional Spark Arrestor Muffler 41 9 6 Adjusting Engine Speed On Models With Automatic Idle Optional 42 9 7 Servicing Fuel And Lubrication Systems 43 9 3 Overload CDD ID 44 9 9 uon Dire board Gere ee Chae
42. close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards e Do not use welder to thaw frozen 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 cuf fless trousers high shoes and a cap e Remove any combustibles such as a butane lighter or matches from your person before doing any welding e Follow requirements in OSHA 1910 252 a 2 iv and NFPA 518 for hot work and have a fire watcher and extinguisher nearby FLYING METAL can injure eyes 2 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 1 3 Engine Hazards BATTERY EXPLOSION can BLIND e Always wear a face shield rubber gloves and protec tive clothing when working on a battery e Stop engine before disconnecting or connecting bat tery 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 FUEL can cause fire or explosion Stop engine and let it cool off before checking
43. 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 fittings de signed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Use the right equipment correct procedures and sufficient number of per sons to llift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards MOVING PARTS can cause injury e Keep away from fans belts and rotors Keep all doors panels covers guards closed and securely in place Stop engine before installing or connecting unit Have only qualified people remove doors panels covers or guards for maintenance and troubleshooting as necessary To prevent accidental starting during servicing disconnect negative battery cable from battery Keep hands hair loose clothing and tools away from moving parts Reinstall doors panels covers or guards when servicing is finished and before starting engine Before working on generator remove spark plugs or injectors to keep en
44. est chaud et que le liquide doit tre v rifi op rer comme suivant Mettre des lunettes de s curit et des gants placer un torchon sur le bouchon du radiateur D visser le bouchon l g rement et laisser la vapeur s chapper avant d enle ver le bouchon 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 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 imm diatement les yeux et la peau l eau 2 4 Dangers li s l air comprim RESPIRER L AIR COMPRIM peut pro voquer des blessures graves ou causer la mort e Ne pas utiliser l air comprim pour respirer e Utiliser l aii comprim seulement pour le coupage gou geage et les outils pneumatiques L AIR COMPRIM peut provoquer des blessures e Porter des lunettes de s curit approuv es e pas diriger le jet d air vers d autres ou soi m me IF 5 L AIR COMPRIME EMMAGASINE DES TUYAUX SOUS PRESSION peuvent quer des blessures e Relacher la pression d air de ou du syst me avant d effectuer la maintenance avant de chan ger ou de rajouter des l ments ou ava
45. le connecteur de pi ce ou le c ble de retour Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine Ne pas toucher des porte lectrodes connect s deux machines en m me temps cause de la pr sence d une tension vide doubl 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 Ce groupe de symboles signi fie Mise en garde Soyez vigi lant a des risques de dan ger reli s aux CHOCS LEC TRIQUES aux PI CES EN MOUVEMENT et aux PI CES CHAUDES Repor tez vous aux symboles et aux directives ci dessous afin de connaitre les mesu res prendre pour viter tout danger Porter un harnais de s curit quand on travaille en hauteur Maintenir solidement en place tous les panneaux et capots Fixer le c ble de retour de facon obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s possible de la soudure Isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique Une tension DC importante subsiste l int rieur des onduleurs apr s avoir coup l alimentation Couper l alimentation du poste et d charger les condensateurs d entr e com me indiqu dans la Section Maintenance avant de toucher des composants LES FUM ES ET LES GAZ peuvent tre dan
46. not start let engine come to a complete stop before attempting re start Above 32 F 0 C turn Engine Control switch to Start Release Engine Control switch when engine starts Below 32 F 0 C push Starting Aid switch up for 60 seconds While still holding Starting Aid switch turn Engine Control switch to Start Release Engine Control switch and Starting Aid switch when engine starts To Stop turn Engine Control switch to Off position Engine Gauges And Meters 3 Engine Hour Meter Use hour meter to monitor engine run time to help schedule maintenance 4 Fuel Gauge Use gauge to check fuel level To check fuel level when engine is not run ning turn Engine Control switch to Run posi tion 5 Battery Voltmeter Optional Use gauge to check battery voltage and moni tor the engine charging system The meter should read about 14 volts dc when the en gine is running and about 12 volts dc when the engine is stopped 6 Engine Coolant Temperature Gauge Optional Normal temperature is 180 208 F 82 95 C Engine stops if temperature exceeds 220 F 104 Engine Oil Pressure Gauge Optional Normal pressure is 30 60 psi 207 414 kPa Engine stops if pressure is below 10 psi 69 kPa Weld Controls 8 Process Contactor Switch See Section 7 3 for Process Contactor switch information 9 Ampere Range Switch not switch under load Use switch to select weld amperage range
47. or add ing fuel e Do not add fuel while smoking or if unit is near any sparks or open flames Do not overfill tank allow room for fuel to expand Do not spill fuel If fuel is spilled clean up before starting engine Dispose of rags in a fireproof container OM 4427 Page 2 Always keep nozzle in contact with tank when fueling HOT PARTS can cause severe burns e Do not touch hot parts bare handed Allow cooling period before working on equipment To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to pre vent burns NOISE can damage hearing Noise from some processes or equipment can damage hearing e Wear approved ear 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 opera tions 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 Protect compressed gas cylinders from excessive heat mechanical shocks physical damage slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other
48. 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 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 sta
49. running Use switch to select weld process and weld output on off control see table be low and Section 7 4 Place switch in Remote On Off Switch Required positions to turn weld output on and off with a device connected to the remote 14 receptacle Place switch in Weld Terminals Always On positions for weld output to be on whenever the engine is running Use Stick position for air carbon arc CAC A cutting and gouging When switch is in a Stick position the arc drive dig circuit provides addition al amperage during low voltage short arc length conditions to prevent stick ing electrodes The arc drive dig circuit is disabled when switch is in MIG or TIG positions gt Place switch Weld Terminals Al ways On Stick position when us ing optional three phase generator see Section 8 2 The engine auto idle option does not work in the Remote On Off Switch Required TIG mode Process Contactor Switch Settings Switch Setting Process Output On Off Control Engine Auto Idle Optional Remote On Off Switch Re GTAW With HF Unit Pulsing 2 Device Or Remote Control At Remote 14 Receptacle Not Active Stick SMAW With Remote On Off At Remote 14 Receptacle Active Remote On Off Switch Required CV Feeder MIG GMAW At Remote 14 Receptacle Active Using Remote None MIG GMAW Electrode Hot Active Stick SMAW Mee d Carbon Arc Cutt
50. to maximum when the arc breaks When an arc is struck weld output control returns to the H1 front panel or combination front panel remote control setting The Amperage Adjust control adjusts amperage only when welding and does not adjust open circuit voltage The max OCV circuit is disabled when the Stick TIG Selection switch is in Scratch Start TIG position see item 10 8 Ampere Range Switch not switch under load Use switch to select weld amperage range For most welding applications use lowest amperage range possible to help prevent arc outages 9 Amperage Adjust Control Control adjusts amperage within range se lected by Ampere Range switch Weld output would be about 168 A DC with controls set as shown 5096 of 110 to 225 A gt The numbers around the control are for reference only and do not represent an actual percentage value 10 Stick TIG Selection Switch Use switch to disable the max circuit and the arc drive dig circuit for scratch start TIG welding see max OCV note under Weld Controls When switch is in the Stick position the max OCV circuit resets Amperage Adjust Control R1 to maximum when the arc breaks Also in the Stick position the arc drive dig circuit provides additional amperage during low voltage short arc length conditions to prevent sticking electrodes When switch is in Scratch Start TIG position the max OCV and arc drive dig circuits are disab
51. your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 4427 Page 81 Some wiring harness components switches relays circuit breakers are also referenced elsewhere in this parts list Purchase components separately or as part of the associated wiring harness Item Dia Par No Mkgs No Description Quantity Wiring Harnesses CT 215054 Harness control box CC weld control includes 1 DH SR1 SR2 035704 Rectifier Integ Bridge 40 Amp 800v 2 D1 C1 189701 Diode Capacitor Board m 1 RC4 047483 Conn Rect Univ 084 15p S 3row Rept Cable Panel Lkg 1 CB11 CB12 CB13 139266 Circuit Breaker Man Reset 15a 250vac Frict 3 rar lt gt 188636 2 Relay Ocv ere Em atem etc otra te 1 SR 148850 SOCKEL Relay S TID Las Iis datos B 96 011622 Switch Tgl 3pdt 15a 125vac On none on Spd Term 1 55 011609 Switch Spdt 15 125vac Spd Term Chr 1 211292 Conn 4p 1 Female 1 211293 Conn Pack Terminal Position Assurance Loc
52. 1 es 198 624 IDLE SOLENOID ASSEMBLY consisting of 1 049 839 BRACKET adjustment solenoid 1 OT de a 080 517 SOLENOID 12 pull type tubular 1 203 716 BRACKET mtg solenoid 104 22 1 PT 605277 PIN Cotter 093 x 750 21 pld 852 00781 1 TERRENI 198 3710 232 26 mio E ot ate ache A 1 206 209 JOINT 1250 28 TAG 3 52 eC ahem nr 1 rn 198 609 ARM throttle 104 22 1 225 120 LABEL warning moving parts can cause injury 2 c EIguregl3s5 GENERATOR bw cht dank e roce dote 1 o METERS 218 087 TANK fuel 1 DE Bos 189 909 FITTING stand pipe hose 250 9 260 lg 90deg zinc 1 HO 095 636 HOSE sae 187 id x 410 od x 30 000 order by ft 1 201 025 5 CAE fuel NUNG AR hd ee ye 1 pU t trei 189 913 FITTING stl barbed elbow zinc pld 1 qe 190 142 SENDER fuel gauge
53. 12996 ROTOR Generator Segmented Assy Includes 1 210 824 ROTOR Generator 5 1 1e PPM 024 617 RING Rtng Ext 1 375 Shaft X 050 Thk 1 Dr 053 390 BEARING Sgl Row 1 370 X 2 830 X 6 1 pcr M MU oe M I HUB Drive Not Sold Separately 1 CORREO 210 447 FAN Rotor Assy Generator Segmented includes 1 RON EM 210332 PLATE Flex Hubmount aco 1 206 242 FAN Rotor Segmented Assy Gen 4 049 026 SCREW 10 1 5 25 Hex 8 8 Pin 10 NS Sai aes 083 883 WASHER Lock 402idx0 7090dx 087t 51 Spliti mm 10 c 080 389 SCREW 312 18 1 00 Hexwhd 66d Sil Pld Slffmg Tap rw 8 T 197 487 s FLYWHEEL a menta enu 1 OM 4427 Page 79 Item Dia Part No Mkgs No Description Quantity Figure 13 6 Generator Continued we 197 486 ADAPTER ENJING epe bate ehe ar ee 1 Mae Biola p SUN 083 883 WASHER Lock 402idx0 7090dx 087t Stl 4 049 026 SCREW 10 1 5 25 Hex 8 8 Pin 4 191 579
54. 2 Manufacturers Rating Labels EN unless siens 10 9 3 Symbols And Deflnillons s vec Exc RAE 11 SECTION 4 SPECIFICATIONS 52 eai ce od moa ooa eu E e Rea o a 12 4 1 Weld Power And Engine Specifications 12 4 2 Dimensions Weights And Operating Angles 12 4 3 Volt Ampere Curves For CC Models 13 4 4 Volt Ampere Curves For Models 14 4 55 ed e Era a rt 15 4 6 Duty Cycle And Overheating 15 4 7 AG Generator Power dace eee eee ed eee n CR a ee e 16 4 8 Optional Three Phase Generator Curves 16 5 INSTALLATION causes ane eee eter eee rekon e nune nico 17 5 1 Installing Welding Generator ccs eek ce x CY man Oo ee eee hae eed 17 5 2 Usmo LINING EVG sk eine ya de NN PR Te dona t 18 9 93 Mounting Welding Generators eet o pace aha Sed de peus 19 5 4 Tristalling Exhaust su eic hence 20 5 5 Activating The Dry Charge Battery If
55. 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 and receptacle does not work Check for faulty tools plugged in receptacle Press button to reset GFCI1 C7 At least once a month run en gine at weld power speed and press test button to verify GFCI is working properly 3 Circuit Breaker 4 Circuit Breaker CB2 CB1 protects RC1 and the genera tor winding from overload If CB1 opens RC1 and do not work Place switch in On position to reset breaker CB2 protects GFCI from overload If CB2 opens does not work Press button to reset breaker CF Ifa circuit breaker continues to open contact Factory Autho rized Service Agent 5 Generator power is not af fected by weld output Maximum output is 2 4 from 4 kVA kW from RC1 Maximum output from all re ceptacles is 4 EXAMPLE If 13 A is drawn from RC1 only 7 A is available at GFCI1 240 V x 13 A 120 V x 7 A 4 0 kVA kW 191 624 A 8 2 Connecting Optional Three Phase Generator CC CV Models Only a WE Single Phase Power Connection 1 2 Three Phase Power Connection Single Three Frequency 60 Hz Engine Speed 1850 RPM Lead 42 connects to GROUND stud on front of unit Jumper 42 is connected to 90 at factory Close panel
56. 44 TR 1 amp 10 r i 9 CRB 52 69 67 gt 14 42 52 CR1 AST 12 60 c 7 AA TD1 GLOW CAD Va EE AED PLUGS 46 69 57 LE 12 Var SARER d BATERY cm 2 Ye FUEL PUMP 22 011 57 58 2 5 e AUTO AUTO Iit 42 42 42 42 42 22 4 Figure 10 2 Circuit Diagram For Welding Generator OM 4427 Page 52 POSITION Je ST POLARITY 2e 7 REV POLARITY RECEPTACLE PACKAGE OPTIONS POLARITY SWITCH OPTIONAL WITH THE POLARITY 2 79 37 THE OUTPUT STUDS THE OUTPUT STUDS ARE LABELED ELECTRODE AND WORK LEADS 17 amp 37 ARE HOOKED DIRECT FROM THE RANGE SWITCH TO THE POLARITY SWITCH POSITIVE ee ELECTRODE 212202020220202 20020000 4 RC5 120 240V 14 Hf WORK K Ns lt 6 WELD STATOR 2 9 J AUX POLARITY SWITCH OPTIONAL OPTIONAL E puse LEADS 19 amp 30 GO 3 42 THE POLARITY GND gt SWITCH RATHER 5 THAN THE OUTPUT 76 77 STUDS THE OUTPUT e sex STUDS ARE LABELED 19 ELECTRODE AND WORK POSITIVE 279 ELECTRODE WEL
57. 63 2127 AUTO IDLE oF 27 LLL PLG4 RC4 22 22 AUX 25 tt 2 44 STATOR 56 3556 28 gt a SE 2255552 20 6540 F2 52 m STATOR gt gt 21 E mate 2125 CONTROL M13 214 gt gt 15 gt PLG6 RC6 Ei gt 4 gt PLG7 RC7 103 1 703 116 ALES 176 CR5 44 lan 67 67 77 cB14 5 40 40 GLOW PLUGS PA VOLT STARTE 45 FED 12 VOLT BATTERY FUEL PUMP 42 D11 nn AUTO IDLE OPTIONAL AUTO IDLE 42 OF PTION Figure 10 1 Circuit Diagram For Welding Generator OM 4427 Page 50 4 WARNING e Do not touch live electrical parts e Disconnect input power or stop engine before servicing e Do not operate with covers rem oved Have only qualified persons install use or service this unit POSITION Je ST POLARITY 296 7 REV POLARITY RECEPTACLE PACKAGE OPTIONS 17 30 79 37 POLARITY SWITCH OPTIONAL WITH THE POLARITY SWITCH OPTION LEADS 19 amp 30 GO TO THE POLARITY SWITCH RATHER THAN THE OUTPUT STUDS THE OUTPUT STUDS ARE LABELED ELECTRODE AND WORK ira A 5 7 ZN UE ELECTRODE RECTIFIER LI WELD esl OPTIONAL dd WOR
58. 69 125 38 100 31 15 3600 600 183 350 107 225 69 150 46 75 23 60 18 20 4800 450 137 275 84 175 53 100 31 60 18 25 6000 350 107 225 69 125 38 75 23 30 7000 300 91 175 53 100 31 75 23 35 8400 250 76 150 46 100 31 40 9600 225 69 125 38 75 23 45 10 800 200 61 125 38 50 12 000 175 53 100 31 Conductor size is based on maximum 2 voltage drop OM 4427 Page 63 SECTION 13 PARTS LIST Hardware is and not available unless listed V gt 116 CC ONLY 126 125 Fig 13 4 OR 13 5 Figure 13 1 Main Assembly Export Model Shown OM 4427 Page 64 93 803 646 0 4427 65 Item Dia Part Mkgs No Description Quantity Figure 13 1 Main Assembly M cen dhs Blt 199 924 5 Geb te 1 kx d A eae 199 294 4 EET SS 53 med aie ee et 1 ee ee 191 626 BUMPER door engine access 2 GOP eras SRE RET 189 975 HINGE door access 180deg 2 ig Qa PE 200 989 DOOR engine access 1 TL qu 210 736 DOOR engine access 55
59. 9 7500 deep tank 1 up crues 189 910 FITTING stand pipe hose 3125 x 9 260 Ig 90deg zinc 1 LOL sise 181 572 2422 BUSHING t nk fuel conta o acoso ate a pecca bees 1 ta 189 908 VALVE drain fuel 180469 1 i DOS uus 191 446 EXTRUSION rubber w adhesive 1 000 x 1 000 D order by ft eft 121048 PNE 124259 24a BUSHING tank fuel Ee Oe RR 4 084 173 CLAMP hose 460 545clp dia sifttng 2 189 912 FITTING stl barbed elbow w 047 in orf zinc pld 1 ue LOL 224 266 LABEL warning weld on base 2 XI PP 191 897 1BRACKET MI UNIT utter dote Retos cuo 4 y5 192 362 BRACKET mtg 1 2 conduit 1 196 220 BRACKET hold down fuel tank rear 1 zx LE RES 2200 999 5 BASE end abe lei Rte dal ad ni atn a sra Ree 1 ALI si 203 382 BASE e coat 1 CED 218 086 BRACKET hold down 1 dete We cases tas 173 352 EXTRUSION rubber clamp bulb order by ft thai 189 731
60. 900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov To reduce magnetic fields in the workplace use the following procedures 1 Keepcables close together by twisting or taping them 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 Keep welding power source and cables as far away from operator as practical 5 Connect work clamp to workpiece as close to the weld as possible About Pacemakers Pacemaker wearers consult your doctor before welding or going near welding operations If cleared by your doctor then following the above procedures is recommended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION rom fre 3 05 Avertissement Prot gez vous et les autres des blessures lisez et suivez ces pr cautions 2 1 A Signification des symboles Signifie Mise
61. AGE peut provoquer un in cendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer leur clatement Des tincelles peuvent tre projet es 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 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 Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables e prot ger et d autres personnes de la projection d tincelles et de m tal chaud e Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures e Surveiller tout d clenchement d incendie et tenir un extincteur proximit e Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t e Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r ser voirs tambours ou conduit
62. ATION can cause interference e High frequency H F can interfere with radio naviga tion safety services computers and communica tions equipment e Have only qualified persons familiar with electronic equipment perform this installation e The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation e lf notified by the FCC about interference stop using the equipment at once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference 1 6 California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling 1 7 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard 249 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers
63. D ASSY display 9 ir eb 1 TU LELTE bok EEEN 134 201 STAND OFF support pc card 3 C9 087 110 CAPACITOR elctit 2400 200VDC 1 4427 72 Item Dia Part No Mkgs No Description Quantity Figure 13 3 Control Box Assembly CC CV Models Continued ET th tea 127 136 CLAMP Capacitor 1 975dl 2 oe eee c 1 21 1 1 189701 DIODE CAPACITOR BOARD 1 22 TD1 214928 TIMER delay make break open 30 sec 12vdc 1 23 11 12 13 139 266 CIRCUIT BREAKER man reset 1P 15A 250VAC frict 3 Optional Recommended Spare Parts To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 4427 Page 73 Hardware is common and not available unless listed LE ER LR CR D 4 Panel Front w Components CC Models Figure 13 OM 4427 Page 74 Item Dia Part No Mkgs No Description Quantity Figure 13 4 Panel Front w Components CC Models Figure 13 1 Item 125 ux 215070 PLATE SCREENED ident control rating when ordering this item Sica ic he ates Bre the nameplate should also be ordered
64. D METERS NE OPTIONAL NEGATIVE D WORK pese MACHINE WIRE NUMBERS G 10 39 WELD SECONDARY 40 79 ENGINE CONTROLS 42 CHASSIS 80 99 AUX SECONDARY AUTO IDLE OPTIONIAL 100 149 EXCITER CONTROL SWITC LEAD 5 F4 NUNBERS NUMBERS tr 1 2 9 120 2 3 120 121 E 6 7 123 1724 x 9 10 48 68 11 12 84 08 ixi CLOSED TERMINAL X CONTACT CLOSED BATTERY GAUGE OPTIONIAL FUEL LEVEL SENDER 42 2 2 2 2 223 523 4427 53 SECTION 11 RUN IN PROCEDURE run_in1 11 05 11 1 Wetstacking Do not perform run in procedure at less than 20 volts weld output and do not exceed duty cycle or equip ment damage may occur 1 Welding Generator Run diesel engines near rated volt age and current during run in period to properly seat piston rings and prevent wetstacking See name plate rating label or specifications section in this manual to find rated voltage and current gt Do not idle engine longer than necessary Piston rings seat faster if engine runs at weld power rpm and the welding generator is kept loaded during run in 2 Engine Exhaust Pipe Wetstacking is unburned fuel and oil in the exhaust pipe and occurs during run in if the engine is run too long at light load or idle rpm If
65. K 2 MACHINE WIRE NUMBERS 10 39 WELD SECONDARY 40 79 ENGINE CONTROLS 42 CHASSIS 80 99 AUX SECONDARY 100 149 EXCITER CONTROL AUTO IDLE OPTIONIAL 42 42 5 67 67 67 pepe 6 1 e 1 ay TOHE 4 3 4 3 4 5 e CLOSED TO 70 BATTERY GAUGE TERMINAL OPTIONIAL COOLANT TEMP SENDER FUEL LEVEL SENDER 42 42 42 42 42 POLARITY SWITCH OPTIONAL WITH THE POLARITY SWITCH OPTION LEADS 19 amp 30 GO TO THE POLARITY SWITCH RATHER THAN THE OUTPUT BE THE OUTPUT S ARE LABELED ELECTRODE AND WORK LEADS 17 amp 57 ARE HOOKED DIRECT FROM THE RANGE SWITCH TO THE POLARITY SWITCH POSITIVE ELECTRODE NEGATIVE WORK 223 522 B OM 4427 Page 51 WARNING e 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 PLG1 RC1 102 5100 10759 5105 a 77304477 gt 5 gt lt 065 S 10 108 7 gt 108 PLG3 RC3 158 5 1 gt 138 42 27 42 gt 27 707 4 102 702 705 7 706 705 105 703 773 PLG4 RC4 42 42 44 44 Sse Sse T gt 62_ NA 64 225 55 5 205 25 45 89 569 22 o gt ZZ IZG SZ gt 14 gt 5 gt 2 3 4 5 6 7 8 PLG6 RC6 725 714567
66. Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 t l phone 703 412 0900 site Internet www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 de Canadian Standards Association Standards Sales 178 Rexdale 2 8 Information Consid rations sur le soudage et les effets de basse fr quence et des champs magn tiques et lectriques Le courant de soudage pendant son passage dans les c bles de souda causera des champs lectromagn tiques y a eu et il y a encore un certain souci propos de tels champs Cependant apr s avoir examin plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban bleu du National Research Council a conclu L accumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lec triques 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 conclusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn tiques pendant le soudage ou le coupage Pour r duire les cha
67. Sections 5 10 and 6 1 Check and secure connections to Remote Amperage Adjust receptacle RC13 see Section 5 10 Check fuse F2 and replace if open See Section 9 8 Have Factory Authorized Service Agent check inte grated rectifier SR2 and the rotor Have Factory Authorized Service Agent check brushes and slip rings and weld excitation circuit No weld output or generator power out put at ac receptacles Disconnect equipment from generator power receptacles during start up Check fuses F1 and F2 and replace if open see Section 9 8 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 9 8 Have Factory Authorized Service Agent check brushes and slip rings and field excitation circuit Erratic weld output Check and tighten connections inside and outside unit Be sure connection to work piece is clean and tight Use dry properly stored electrodes Remove excessive coils from weld cables Have Factory Authorized Service Agent check brushes and slip rings High weld output Check position of Ampere Range switch and Voltage Amperage Adjust control Check engine speed and have Factory Authorized Service Agent adjust if necessary Have Factory Authorized Service Agent check OCV control circuit Low we
68. To improve cold weather starting Use Starting Aid switch see Section 6 1 or 7 1 Keep battery in good condition Store battery in warm area Use fuel formulated for cold weather diesel fuel can gel in cold weather Contact local fuel supplier for fuel in formation Use correct grade oil for cold weather see Section 9 1 Stop engine Positive Weld Output Terminal Negative Weld Output Terminal gt Failure to properly connect weld cables may cause excessive heat and start a fire or damage your machine Weld Output Terminal Supplied Weld Output Terminal Nut Weld Cable Terminal Copper Bar Remove supplied nut from weld output termi nal Slide weld cable terminal onto weld output terminal and secure with nut so that weld cable terminal is tight against copper bar Do not place anything between weld cable termi nal and copper bar Make sure that the sur faces of the weld cable terminal and cop per bar are clean o anything between weld cable terminal and copper bar Correct Installation 5 8 Connecting To Weld Output Terminals Stick and TIG Welding For Stick and TIG welding Direct Current Elec trode Positive DCEP connect electrode holder cable to Positive terminal on left and work cable to Negative terminal on right For Direct Current Electrode Negative DCEN reverse cable connections If equipped with optional Polarity switch or op tional Polarity
69. W 30A 250V L6 30R 1 CB2 093 996 CIRCUIT BREAKER man reset 1P 20A 250VAC frict 1 9 us CB3 139266 CIRCUIT BREAKER man reset 1P 15A 250VAC 1 14 GFCl1 151981 RECEPTACLE str dx grd 2P3W 15 20A 125V GFCI 1 IGI 176 355 RECEPTACLE str 2p3w 16a 220v flange mtg export models only 1 WO eR 190 861 LABEL warning electric shock and moving parts etc 1 ek eh 219 947 5 PANEL GEN DWP ott be ed Dac uet ead 1 jc pP 01215405 PANEL gerr DWI SS 2 teat ar lara aed acai 1 TU nee ees 215 403 PANEL gen pwr export models only 1 dI cda Eris 083 030 STUD brs 250 20 x 1 750 w hex collar 1 NUT 601 836 NUT 250 20 50hex 19h brs 3 sce dba m 196 073 LABEL do not switch while welding 1 T M 512 2195 0925 22 SWITCH DOlarlby e head ed ete 1 512 220 491 SWITCH 1 201 125 PANEL mtg terminal pwr 1 199 303 PANEL mtg terminal pwr output SS 1 PRE EE 039 046 TERMINAL pwr output black
70. a 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 2 Miller
71. and Piping American Welding Society Standard AWS F4 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 phone 703 412 0900 website www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Bou 1 8 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to
72. ansformer CT1 Check for obstructed throttle solenoid Engine does not run at idle speed models with idle option only CC models place Stick TIG Selection switch in Stick position CC CV models place Process Contactor switch in any position but Remote On Off Switch Required TIG Check for obstructed throttle solenoid Have Factory Authorized Service Agent check idle module and control relays and Engine uses oil during run in period wetstacking occurs Dry engine according to run in procedure see Section 11 OM 4427 Page 48 Notes DECIMAL EQUIVALENTS 96 96 926 96 9 6 eu Oe 9 5 E 9 9 96 9 8 0660 s 9 5 2 e 2 92 6 6 i OM 4427 Page 49 SECTION 10 ELECTRICAL DIAGRAMS 98 STICK PLG1 RC1 ga EE zum CC M 700 700 OU d 502 pisa STANDARD 1055 5105 a RECEPTACLE 707 707 106 IOT y g Z 708 7 108 STATOR gt 8 gt 295 PLG3 RC3 STATOR c EE 1 gt 56 ME 5247 gt RC1 240V 027 5 2 LEAD 89 NOT CONNECTED gt 4 ON CC MODEL Bn 703 2 703 29 225622 1065 gt 106 116 102 8 gt Z 102 725 125 e 5 gt i10 gt 107 198 gt 11 gt 65 54
73. anvas 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 Exception brushes slip rings and relays are covered on Bobcat Trailblazer and Legend models 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipmentthat has been modified by any party other than Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Miller s option 1 repair or 2 replacement or where authorized in writing by Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Miller s option of
74. b 86 168 t 19 39 09 JVCOE LVO Maintenance Label SECTION 9 MAINTENANCE amp TROUBLESHOOTING 9 1 OM 4427 Page 37 9 2 Routine Maintenance 59 Recycle engine Stop engine before maintaining gt See Engine Manual and Maintenance Label for important start up service and storage Injectors WS fluids information Service engine more often if used in severe conditions D Check Change Clean Replace Reference To be done by Factory Authorized Service Agent Every Section 5 7 FUEL Hours Fuel Water Separator Fuel Level y Oil Level Oil Fuel Spills Every Section 9 4 50 227 Hours M Weld Terminals Every 100 Hours Air Cleaner Hoses Every Engine 250 Manual Hours pos Section 9 5 Unreadable Labels Fan Belt Tension Oil Oil Filter QSpark Arrestor Every 500 Hours AP Weld Cables Every Section 5 7 1000 9 7 9 3 and Hours Engine Manual FuelFilter Drain Sludge Slip Rings Valve Clearance w Brushes Every 2000 Hours OM 4427 Page 38 9 3 Checking Generator Brushes Stop engine and let cool 1 Generator Brush Mark and disconnect leads at brush hold er cap Remove brushes Replace brushes if damaged or if brush RUN AUTO OFF
75. check integrated rectifier SR1 capacitor C9 diode capacitor board D1 C1 and the rotor Reset circuit breaker CB12 Have Factory Authorized Service Agent check diode D1 Have Factory Authorized Service Agent check brushes and slip rings and field excitation circuit High output at generator power ac re ceptacles Check engine speed and have Factory Authorized Service Agent adjust if necessary Have Factory Authorized Service Agent adjust generator power field current resistor R3 Low output at generator power ac recep tacles Check engine speed and have Factory Authorized Service Agent adjust if necessary Check fuse F1 and replace if open See Section 9 8 Have Factory Authorized Service Agent check inte grated rectifier SR1 resistor R3 and capacitor C9 D Optional Three Phase Generator Power CC CV Models Only Trouble Remedy No or low output at optional three phase generator receptacle RCE Place Process Contactor switch in Weld Terminals Always On Stick position see Section 7 3 Reset circuit breaker CB7 see Section 8 2 Reset circuit breaker CB5 see Section 9 8 Check engine weld power speed and have Factory Authorized Service Agent adjust if necessary Have Factory Authorized Service Agent check brushes and slip rings and field current regulator board PC1 High output at optional three phase generator receptacle RC5 Check engine weld p
76. chments or open ing compressor oil drain or oil fill cap BATTERY ACID can BURN SKIN and EYES e Do not tip battery Replace damaged battery e Flush eyes and skin immediately with water ENGINE HEAT can cause fire e not locate unit on over or near combustible surfaces or flammables e Keep exhaust and exhaust pipes way from flam mables EXHAUST SPARKS can cause fire e Do notlet engine exhaust sparks cause fire e Use approved engine exhaust spark arrestor in re quired areas see applicable codes HOT METAL from air arc cutting and gouging can cause fire or explosion e Do not cut or gouge near flammables e Watch for fire keep extinguisher nearby HOT PARTS can cause burns and injury e Do not touch hot compressor or air system parts e Let system cool down before touching or servicing READ INSTRUCTIONS e Read Owner s Manual before using or servicing unit Stop engine and release air pressure before servicing e Use only genuine Miller Hobart replacement parts 1 5 Additional Symbols For Installation Operation And Maintenance FALLING UNIT can cause injury e Use lifting eye to lift unit and properly installed acces sories only Do not exceed maximum lift eye weight rating see Specifications e Lift and support unit only with proper equipment and correct procedures e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit
77. ck can kill Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process If AC output is re quired use remote output control if present on unit not switch under load Use Polarity AC switch to select AC or DC weld output and DC weld output polarity For Direct Current Electrode Negative DCEN turn switch to Negative position For Direct Current Electrode Positive DCEP turn switch to Positive position For weld pro cesses that require alternating current AC use AC position Weld Meters 14 AC DC Voltmeter Optional Voltmeter displays voltage at the weld output terminals but not necessarily the welding arc due to resistance of cable and connections 15 AC DC Ammeter Optional Ammeter displays amperage output of the unit OM 4427 Page 31 7 3 Process Contactor Switch CC CV Models WIRE Voltage Sensing W Feeder CV 2 HF CV Feeder Required Using Remote Scratch Start 2 REMOTE ON OFF SWITCH REQUIRED Process Contactor Switch Weld output terminals are gized when Process Contactor switch is in an Weld Terminals Always On position and the en gine is running DC voltage is still present at the weld terminals when Process Contactor switch is in the Re mote On Off Switch Required Stick position and the engine is
78. corps 4 Garder le poste de soudage et les c bles le plus loin possible de VOUS 5 Connecter la pince sur la pi ce aussi pr s que possible de la sou dure En ce qui concerne les stimulateurs cardiaques Les porteurs de stimulateur cardiaque doivent consulter leur m decin avant de souder ou d approcher des op rations de soudage Si le m decin approuve il est recommand de suivre les proc dures pr c dentes SECTION 3 DEFINITIONS 3 1 Warning Label Definitions For Wordiess Labels Remove unit from shipping crate Remove Owner s Manual from unit Follow instructions to install muffler Read Owner s Manual Read labels on unit Use Diesel Fuel only and fill fuel tank Leave room for expansion Warning Watch Out There are possible hazards as shown by the symbols Read Owner s Manual Follow instructions to activate battery Check oil level Add oil if S 177 571 necessary During the first 50 hours of operation keep welding load above 200 amperes Do not weld below 200 amperes of output After the first 50 hours of operation change the oil and oil filter CD MIL L 2104D CD SE CD SF Notes x HOBARI INSTIT WELDING TECHNOLOGY Start Your Professional Square East Troy Ohio 45373 Over 80 000 trained Welding Career Now 1 800 332 9448 www welding org since 1930 OM 4427 Page 9 3 2 Manufacturer s Rating Labels CC Models
79. d starting amperage AC MOTOR Step 1 Find code and use table to find 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 motors running amperage Motor Start E P ee IET x HP x 1000 VOLTS STARTING AMPERAGE EXAMPLE Calculate the starting amperage required for 230 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 11 2 x 1 4 x 1000 230 12 2A Starting the motor requires 12 2 amperes 12 9 How Much Power Can Generator Supply 1 Limit Load To 90 Of Generator Output Always start non resistive motor loads in order from largest to small est and add resistive loads last 2 5 Second Rule If motor does not start within 5 seconds turn off power to prevent motor damage Motor requires more power than generator can supply Ref ST 800 396 A S 0625 OM 4427 Page 61 12 10 Typical Connections To Supply Standby Power Properly install and ground this equipment according to its Owner s Manual and national state and local codes Utility Electrical Service Have only qualified persons perform these connections according to all applicable codes and safety practic
80. d use screwdriver to open sludge drain valve Close valve when sludge has drained Remove hose Close door Tools Needed FS 802 490 Ref 801 434 OM 4427 Page 43 9 8 4427 44 Stop engine 7 When a circuit breaker or fuse opens it usually indicates a more se rious problem exists Contact Facto ry Authorized Service Agent 1 FuseF1 2 Fuse F2 F1 and F2 protect the stator exciter wind ing from overload If F1 opens weld generator power is low or stops entirely If F2 opens weld output is low or stops entirely 4 generator power is still available 3 Circuit Breaker CB4 Not Shown 4 Circuit Breaker CB5 CC CV Models Only 5 Circuit Breaker CB6 CC CV Models Only 6 Circuit Breaker CB10 Not Shown 7 Circuit Breaker CB11 8 Circuit Breaker CB12 9 Circuit Breaker CB13 10 Circuit Breaker CB14 Not Shown CB4 protects the welding arc drive dig circuit If CB4 opens electrode may stick to the workpiece more frequently during low voltage short arc length conditions CB4 automatically resets when the fault is corrected CB5 protects the 24 volt ac output to re mote receptacle RC14 24 volt output to field current regulator board PC1 CC CV models only If CB5 opens weld out put and 24 volt output to RC14 stops On units with optional three phase genera tor generator power output at receptacle RC5 also s
81. d x 560 od x 24 000 order ft 2 n e EE 191819 HOSE sae 312 id x 560 x 14 000 order ft 2 198 584 HOSE 312 id x 560 od x 5 000 order ft 1 095 636 HOSE sae 187 id x 41 od x 30 000 order ft 1 ou m 206 297 BASE fuel filter w fittings 1 ee 192 741 BLOCK spacer mtg filter base 1 192 744 FILTER fuel spin on 1 201 658 UPRIGHT center assembly 1 iris noue 201 697 PAN reactor and rectifier 1 D id 1201 9843 GOVER JOD xtate etre eer 1 ee 4202 640 COVER TOD SS en pce m b Ux etate a 1 RR 189 052 GROMMET plastic neck filler fuel 1 MX 190 198 CAP tank screw on 3 500 in w vent 1 UC 192 041 LABEL use diesel fuel only 1 ic d eset aunt 222 513 LABEL warning falling equipment can cause serious 2 px backen lt Roa 224 265 LABEL warning hot exhaust parts do not touch 1 Uc DC 105 734 PIPE m
82. e LES CHARGES LECTROSTATI QUES peuvent endommager les circuits imprim s e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des boites antistatiques pour stocker d placer OU exp dier des cartes de circuits imprimes D 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 com me indiqu dans le manuel s y rapportant OM 4427 Page 7 LIRE LES INSTRUCTIONS e Utiliser seulement les pi ces de rechange d origine e Effectuer la maintenance du moteur et du compresseur si applicable suivant ce manuel et le manuel du moteur compresseur si applicable LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Lerayonnement haute fr quence H F 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 Sile FCC signale des interf rences arr ter imm diatement l appareil e Effectuer r guli rement le contr le et l ent
83. e 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 4427 Page 80 5 Hardware is common and not available unless listed 802 279 A Figure 13 7 Main Rectifier Assembly Item Dia Part Mkgs No Description Quantity Figure 13 7 Main Rectifier Assembly Figure 13 1 Item 117 RR x 19 909 2 RECTIFIER times e tm i P atte 1 Se SUUS SR3 RECTIFIER environmental consisting of 1 188 137 CONNECTION BOARD rectifier AC 1 TE PRICE 188 517 BUS BAR connection board 3 EON 188 135 52 ENGEOSURBE rectifier ere sop DDR Rhea pa bdo 2 TL AT 134 201 STAND OFF support 3 5 215755 CIRCUIT CARD ASSEMBLY protection 1 ES 188 136 INSULATOR heat sink e ete Rode e e Rr e 8 bu 188 493 HEAT SINK rectifier al 2 8 D3 D5 D7 037956 DIODE rect 275A 300V SP 3 9 D2 D4 D6 037 957 DIODE rect 275A 300V RP 3 To maintain the factory original performance of
84. e gaz comprim d une chaleur excessive des chocs m caniques des dommages physiques 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 Tenir les bouteilles loign es des circuits de soudage ou autres circuits lectri ques Ne jamais placer une torche de soudage sur une bouteille gaz Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille Ne jamais souder une bouteille pressuris e risque d explosion Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et rac cords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat Ne pas tenir la t te en face de la sortie en ouvrant la soupape de la bouteille e Maintenir le chapeau de protection sur la soupape sauf en cas d utilisation ou de branchement de la bouteille e Utiliser les quipements corrects les bonnes proc dures et suffisamment de personnes pour soulever et d placer les bouteilles e Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association men tionn dans les principales normes de s curit 2 3 Dangers existant en relation avec le moteur L EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE e Toujours porter u
85. ecommended to run the weld ing generator for two hours mini mum and up to four hours under load Place A V control in minimum position then turn off load bank to remove load Run engine several minutes at no load Stop engine and let cool 4 Engine Exhaust Pipe Repeat procedure if wetstacking is present 5 0683 4427 55 11 3 Run In Procedure Using Resistance Grid OM 4427 Page 56 Stop engine Do not touch hot exhaust pipe engine parts or load bank grid Keep exhaust and pipe away from flammables A Do not perform run in procedure at less than 20 volts weld output and do not exceed duty cycle or equip ment damage may occur 1 Resistance Grid Use grid sized for generator rated output Turn Off grid 2 Welding Generator Place A V range switch in maxi mum position A V control in mini mum position and Output Selector switch if present in either DC position 3 Weld Cables Connect grid to generator weld output terminals using proper size weld cables with correct connec tors polarity is not important 4 Voltmeter 5 Clamp On Ammeter Connect voltmeter and ammeter as shown if not provided on generator Start engine and run for several minutes Set grid switches and then ad just generator A V control so load equals rated voltage and current of the generator see nameplate rating label or the specifications section in this manual Check genera
86. ee i H 40A 21 6V to 375A 35V x 40 eo 100 EEEN NE _ 3754 3354 3004 mE Que w sa av 1800 min 1 60Hz 120 240V 4 20 17A Optional 400 40 CC 215 073 B CC Export Models ISO IEC 60974 1 55A 22V to 430A 37V 92V 55A 12V to 500A 30V 500A 400A 300A e 1800 21850 n 2 1235 eons 120240 mm 200 781 OM 4427 Page 10 CC CV Models mem e aw ay G HE E 2 4504 4004 CS H u 25A 21V to 375A 35V En pee AR ERN n 1800 min 1 Co Optional 400 40 CV 215 206 B CC CV Export Models 60974 1 20A 15V to 430A 36V x oom SES n 1800 min 1 LTEM T NN Optional 3 3 Symbols And Definitions NOTE 17 Stop Engine Fast Run Weld Power Slow Idle Start Engine Check Injectors Pump Starting Aid Stick SMAW Welding Time Battery Engine Check Valve Clearance Air Temperature Or Engine Temperature Constant Current CC Hours 210 Engine Oil Pres
87. ee Sec tion 12 4 Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual OM 4427 Page 62 12 11 Selecting Extension Use Shortest Possible Cord Lengths for 120 Loads unit does not receptacles use GFCI protected extension cord Maximum Allowable Cord Length in ft m for Conductor Size AWG Current Load Watts 4 6 8 10 12 14 Amperes 5 600 350 106 225 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 on maximum 2 voltage drop Cord Lengths for 240 Volt Loads If unit does not receptacles use GFCI protected extension Maximum Allowable Cord Length in ft m for Conductor Size AWG current Load Watts 4 6 8 10 12 14 Amperes 5 1200 700 213 450 137 225 84 200 61 7 1680 800 244 500 152 300 91 200 61 125 38 10 2400 800 244 550 168 350 107 225
88. electromagnetic fields when welding or cutting OM 4427 Page 4 ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as microprocessors computers and computer driven equipment such as robots e Besure all equipment in the welding area is electro magnetically compatible e Toreduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive electronic equipment e sure this welding machine is installed and grounded according to this manual e f interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area For Gasoline Engines Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm For Diesel Engines Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm levard Rexdale Ontario Canada M9W 1R3 phone 800 463 6727 or in Toronto 416 747 4044 website www csa international org Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 11 West 42nd Street New York NY 10036 8002 phone 212 642 4
89. emperature 15 too high see Section 5 7 Automatic shutdown system is inhibited for 30 seconds after start up Have Factory Authorized Service Agent check time delay relay TD1 and control relay CR5 Engine hard to start in cold weather Use starting aid switch see Section 6 1 or 7 1 Keep battery in good condition Store battery in warm area off cold surface Use fuel formulated for cold weather diesel fuel can gel in cold weather Contact local fuel supplier for fuel information Use correct grade oil for cold weather see Section 9 1 Engine suddenly stops Check oil and coolant levels Automatic shutdown system stops engine if oil pressure is too low or coolant temperatureis too high see Section 5 7 Automatic shutdown system is inhibited for 30 seconds after start up See engine manual Engine slowly stopped and cannot be restarted Check fuel level Check engine air and fuel filters see Sections 9 4 and 9 7 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 models with idle option only Have Factory Authorized Service Agent check idle module PC7 and current tr
90. en garde Soyez vigilant Cette proc dure pr sente des risques de danger Ceux ci sont identifi s par des symboles adjacents aux directives Identifie un message de s curit particulier gt Signifie NOTA n est pas relatif la s curit 2 2 Dangers relatifs au soudage l arc A gt gt ry 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 risques de danger Lorsque vous voyez un symbole soyez vigilant et suivez les directives mentionn es afin d viter tout danger Les consignes de s curit pr sent es ci apr s ne font que r sumer l information contenue dans les normes de s curit num r es la section 2 7 Veuillez lire et respecter toutes ces normes de s curit L installation l utilisation l entretien et les r parations ne doivent tre confi s qu des personnes qualifi es Au cours de l utilisation tenir toute personne l cart et plus particu lierement les enfants UN CHOC LECTRIQUE peut tuer Un simple contact avec des pi ces lectriques peut provo quer 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
91. erters input and output rectifiers only 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Semi Automatic and Automatic Wire Feeders Inverter Power Sources Unless Otherwise Stated Water Coolant Systems Integrated Maxstar 150 Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified DS 2Wire Feeder Motor Driven Guns w exception of Spoolmate Spoolguns Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources and Coolers Water Coolant Systems Non Integrated Flowgauge and Flowmeter Regulators No Labor Units Grids Maxstar 85 140 Spot Welders Load Banks Arc Stud Power Sources amp Arc Stud Guns Racks Running Gear Trailers Plasma Cutting Torches except APT amp SAF Models Field Options NOTE Field options are covered under True Blue for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater m Miller 4 6 Months Batteries 5 90 Days Parts MIG Guns TIG Torches Induction Heating Coils and Blankets APT amp SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns C
92. es moins qu ils n aient t pr par s correctement conform ment a 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 le transport du courant sur une longue distance par des chemins incon nus ventuels en provoquant des risques d lectrocution et d incendie e Brancher le c ble de masse sur la pi ce le plus pr s possible de la zone de soudage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provoquant des risques d lectrocution d tincelles et d incendie e pas utiliser le poste de soudage pour d geler des conduites gel es e cas de utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact e Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans revers des chaus sures hautes et un couvre chef e de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes e Suivre les recommandations dans 1910 252 a 2 iv et 518 pour les travaux chaud et avoir de la surveillance et un extincteur proximit DES PARTICULES VOLANTES 22127 peuvent blesser les yeux Le soudage l caillement le passage de la pi ce la bros se en fil de fer et le meulage g n rent des
93. 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 S isoler 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 Ne pas se servir de source lectrique courant lectrique dans les zones hu mides dans les endroits confin s ou l on risque de tomber Se servir d une source lectrique courant lectrique UNIQUEMENT si le proc d de soudage le demande Si l utilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip Des pr cautions de s curit suppl mentaires sont requises dans des envi ronnements risque comme les endroits humides ou lorsque l on porte des v tements mouill s sur des structures m talliques au sol grillages et cha faudages dans des positions assises genoux et allong es ou quand il y a un risque important de contact accidentel avec la pi ce ou le sol Dans ces cas utiliser les appareils suivants dans l ordre de pr f rence 1 un poste souder DC semi automatique de type CV MIG MAG 2 un poste souder manuel lectrode enrob e DC 3
94. exhaust pipe is coated with a wet black tar like substance dry the engine using one of the following run in procedures See the engine manual for addition al engine run in information OM 4427 Page 54 11 2 Run In Procedure Using Load Bank Stop engine Do not touch hot exhaust pipe engine parts or load bank grid Keep exhaust and pipe away from flammables A Do not perform run in procedure at less than 20 volts weld output and do not exceed duty cycle or equip ment damage may occur 1 Load Bank Turn all load bank switches Off If needed connect load bank to 115 volts ac wall receptacle or genera tor auxiliary power receptacle 2 Welding Generator Place A V range switch in maxi mum position A V control in mini mum position and Output Selector switch if present in either DC position 3 Weld Cables Connect load bank to generator weld output terminals using proper size weld cables with correct connectors Observe correct polarity Start engine and run for several minutes Set load bank switches and then adjust generator A V control so load equals rated voltage and current of generator see name plate rating label or the specifi cations section in this manual Check generator and load bank meters after first five minutes then every fifteen minutes to be sure generator is loaded properly gt Check oil level frequently dur ing run in add oil if needed It is r
95. gereux Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereux pour votre sant Eloigner votre t te des fum es Ne pas respirer les fum es A l int rieur ventiler la zone et ou utiliser une ventilation forc e au niveau de l arc pour l vacuation des fum es et des gaz de soudage Si la ventilation est m diocre porter un respirateur anti vapeurs approuv Lire et comprendre les sp cifications de s curit des mat riaux MSDS et les instructions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d graisseurs Travailler dans un espace ferm seulement s il est bien ventil ou en portant un respirateur alimentation d air Demander toujours un surveillant 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 dan ger Ne pas souder dans des endroits situ s proximit d op rations de d grais sage 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 Ne pas souder des m taux munis d un rev tement tels que l acier galvanis plaqu en plomb ou au cadmium moins que le rev tement n ait t enlev dans la zone de soudure que l endroit soit bien venti
96. gine from kicking back or starting Block flywheel so that it will not turn while working on generator compo nents HOT PARTS can cause severe burns Do not touch hot engine parts Allow cooling period before maintaining e Wear protective gloves and clothing when working on a hot engine STEAM COOLANT can burn e f possible check coolant level when engine is cold to avoid scalding e Always check coolant level at overflow tank if pres ent on unit instead of radiator unless told otherwise in maintenance section or engine manual e lf the engine is warm checking is needed and there is no overflow tank follow the next two statements Wear safety glasses and gloves and put a rag over radiator cap Turn cap slightly and let pressure escape slowly before completely re moving cap e Use equipment outside in open well ventilated ar eas e f used in a closed area vent engine exhaust outside and away from any building air intakes 1 4 Compressed Air Hazards BREATHING COMPRESSED AIR can cause serious injury or death e Do not use compressed air for breathing e Use only for cutting gouging and tools COMPRESSED AIR can cause injury e Wear approved safety goggles e Do not direct air stream toward self or others 9 TRAPPED AIR PRESSURE AND WHIPPING HOSES can cause injury 4r LY e Release air pressure from tools and system before servicing adding or changing atta
97. happement des moteurs diesel et certains de leurs compo sants sont reconnus par l Etat de Californie comme provoquant des cancers et des malformations cong nitales ou autres probl mes de pro cr ation Boulevard Rexdale Ontario Canada M9W 183 800 463 6727 ou Toronto 416 747 4044 site www csa international org telephone Internet Practice For Occupational And Educational Eye And Face Protection ANSI Standard 287 1 de American National Standards Institute 11 West 42nd Street New York NY 10036 8002 t l phone 212 642 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org OSHA Occupational Safety and Health Standards for General Industry Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de U S Government Printing Office Superintendent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux r gionaux le t l phone de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov proc dures suivantes 1 Maintenir les c bles ensemble en les tordant ou en les envelop pant 2 Disposer les c bles d un c t et distance de l op rateur 3 Ne pas courber pas et ne pas entourer pas les c bles autour de votre
98. heets MSDSs and the manufacturer s instructions for metals consumables coatings cleaners and degreasers e Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watchperson nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breathing air is safe e Do not weld in locations near degreasing cleaning or spraying operations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases e Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded BUILDUP OF GAS can injure or kill e Shut off shielding gas supply when in use e Always ventilate confined spaces or use approved air supplied respirator ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld e Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks when welding or watching see ANSI 249 1 and 287 1 listed in Safety Standards Wear approved safety gla
99. hicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insu lated copper wire Airflow Clearance 18 in 460 mm Grounding Electrically bond generator frame to vehicle frame by metal to metal contact Bed liners shipping skids and some running gears insulate the welding generator from the vehicle frame Always connect a ground wire from the generator equipment grounding termi nal to bare metal on the vehicle frame as shown install3 6 05 Ref 800 652 Ref 800 477 A 803 274 OM 4427 Page 17 5 2 Using Lifting Eye 1 Lifting Eye 2 Nut 3 Carriage Bolt Raise lifting eye until it snaps in place Lower lifting eye when not needed To lock the lifting eye in the upright position insert a 3 8 16 x 1 1 2 in carriage bolt through slot in bracket and secure with nut bolt and nut not supplied Tools Needed Ref 802 311 Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual OM 4427 Page 18 5 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 Do not mount unit by sup porting the base only at the four mounting brackets Use cross supports to ade quately support unit and pre vent damage to base Mounting Surface 1 Cross Supports 2 Mounti
100. ident control when ordering this item ord the nameplate should also ordered ee NAMEPLATE screened order by model and serial number TODO 215 014 PANEL engine weld control Wo TE 220 544 PANEL engine weld control ss 4 S3 208 278 SWITCH range changeover m MT 22 193118 POT cp flat 1t 2w 1k ohm linear m 56 193 234 SWITCH rotary 6 position gold contacts er 197527 Guard Circuit Breaker For S6 Not Included w Harness 2218 hind see SD re 011 609 SWITCH tgl SPDT 15A 125VAC on none on spd term chr MO 202 209 SPACER AVION a Ics ur de c seed ee Ie 9 PC6 192 995 CIRCUIT CARD ASSY connector receptacle 10 CB5 139 266 CIRCUIT BREAKER man reset 1p 15a 250 frict 11 CB6 083 432 CIRCUIT BREAKER Man Reset 1 10a 250vac Frict laisse S2 021 467 SWITCH 1 spst 250v spd term seas 51 212 436 SWITCH ignition 4posn w o 14 201 083 CIRCUIT BREAKER man reset 2P 20 250VAC pod ete 201 553 CLIP circuit brea
101. igh 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 4427 Page 59 12 7 Power Requirements For 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 4500 1500 10 in 6300 1800 Band Saw 14 2500 1100 Bench Grinder Gin 1720 720 8in 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 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1 3 HP 2100 700 Elec Hedge Trimmer 18 in 400 400 Flood Lights HID 125 100 Metal Halide 313 250 Mercury 1000 Sodium 1400 Vapor 1250 1000 Submersible Pump 400 gph 600 200 Centrifugal Pump 900 gph 900 500 Floor Polisher 3 4 HP 16 in 4500 1400 1 HP 20 in 6100 1600 High Pressure Washer 1 2 HP 3150 950 3 4 HP 4500 1400 1 HP 6100 1600 55 gal Drum Mixer 1 4 HP 1900 700 Wet amp Dry Vac 1 7 HP 900 900 2 1 2 HP 1300 1300 OM 4427 Page 60 12 8 Power Required To Start Motor Motor Start Code Running Amperage Motor HP To fin
102. ing start engine and check for fuel leaks Stop engine tighten connec tions as necessary and wipe up spilled fuel Oil Filter Oil Drain Valve And Hose Oil Fill Cap Fuel Line a A N Primary Fuel Filter Fuel Water Separator 6 7 Secondary Fuel Filter 8 Fuel Tank Sludge Drain Valve To change oil and filter Route oil drain hose and valve through hole in base See engine manual and engine maintenance label for oil filter change in formation To drain water from fuel system Open primary fuel filter petcock and drain water into metal container Close petcock when water free fuel flows To replace primary fuel filter Turn filter counterclockwise move filter Fill new filter with fresh fuel Apply thin coat of fuel to gasket on new fil ter Install new filter and turn clock wise Bleed air from fuel system ac cording to engine manual Inspect fuel lines and replace if cracked or worn To replace secondary fuel filter See engine manual To drain sludge from fuel tank Beware of fire Do not smoke and keep sparks and flames away from drained fuel Dis pose of drained fuel in an en vironmentally safe manner Do not leave unit unattended while draining fuel tank Properly lift unit and secure in a level position Use ade quate blocks or stands to support unit while draining fuel tank Attach 1 2 ID hose to drain valve Put metal container under drain an
103. ing Electrode Hot Active And Gouging TIG Scratch Start GTAW Electrode Hot Active OM 4427 Page 32 7 4 Remote Voltage Amperage Control CC CV Models Optional mE 1 Remote 14 Receptacle RC14 Connect optional remote control to RC14 see Section 5 11 Example Combination Remote Amperage Control Stick In Example Process Stick Using Remote On Off Range 115 to 320 A DC Min 115 A DC 320 A DC 415 320 PANEL STRESS 2 5 WIRE G 2 I D retire Max 320 A DC 3 4 REMOTE ON OFF SWITCH REQUIRED Min 1 1 5 A DC Set V A Set Remote Adjust Switch be en Set Range 4 um Adjust Optional Remote Contro Stick Mode Example Combination Remote Amperage Control TIG In Example Process TIG Using Remote On Off Range 35 to 250 A DC Percentage Of Range 5096 Min 35 A DC Max About 143 A DC 5096 of 35 to 250 Max 143 A DC CO REMOTE SWITCH REQUIRED 35 Set V A Set Remote Adjust Switch Process Set Range gt Set Control gt Adjust Optional Remote Control 0774 Ref 215 158 Ref 803 602 OM 4427 Page 33 SECTION 8 OPERATING AUXILIARY EQUIPMENT 8 1 120 Volt And 240 Volt Receptacles OM 4427 Page 34 120 V 20A 17 60 Hz 240 V 20A 1 120 V 20 A AC Receptacle GFCI1 2 240V
104. ition To Standard Models 4 KVA kW Generator Power Only 500 A 30 Volts DC 34 Volts DC CV 40 Duty Cycle 4 2 Dimensions Weights And Operating Angles Dimensions 60 in 1524 mm Height to top of muffler 28 1 2 in 724 mm G mtg brackets turned in Width 30 3 4 in 781 mm mtg brackets turned out y Depth 65 1 8 in 1654 mm not exceed tilt angles or engine could be damaged or unit could tip A 65 1 8 in 1654 mm Do not move or operate unit where it could B 56 in 1422 mm tip 46 1 2 1181 D 9 5 8 in 244 mm 27 1 2 699 mm 1 25 29 13 16 757 mm 9 16 14 mm Dia P 2 4 Holes 1 D With mounting brackets in center position Dimensions vary with location of mounting brackets E Weight E w Cat No fuel 1600 Ib 726 kg 802 161 A 3024C W fuel 1775 Ib 805 kg Lifting Eye Weight Rating 2500 Ib 1134 kg Maximum OM 4427 Page 12 4 3 Volt Ampere Curves For Models 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 Ranges 230 Max 170 365 110 225 70 130 55 85 2 gt 100 200 300 400 500 600 700 800 900 1000 215 081 Notes Wo
105. k 1 RT 164617 Clip Wiring Straight 9 REE EE S2 021467 Switch Tgl Spst 250v Off none On Spd Term 1 T 150316 Conn Rect Univ 039 6p S Plug Cable Lkg 5 TP RC3 158466 Conn Rect Univ 084 12p S 3row Rept Cable Panel Lkg 1 135133 Conn Rect Univ 084 9 5 3row Rept Cable Panel 1 EN 215377 Harness control box CV weld control includes 1 CB11 CB12 CB13 139266 Circuit Breaker Man Reset 15a 250vac Frict 3 Baines SR1 035704 Rectifier Integ Bridge 40 Amp 800 1 Re 148850 Socket Relay 5 Pin 1 ie RC4 047483 Conn Rect Univ 084 15p S 3row Rept Cable Panel Lkg 1 de RC3 158466 Conn Rect Univ 084 12p S 3row Rept Cable Panel Lkg 1 M RC1 135133 Conn Rect Univ 084 9p S 3row Rept Cable Panel 1 150316 Univ 039 5 Plug Cable Lkg 6 te 96 193234 Switch Rotary 6 Posn Gold Contacts 1 021467 Switch 250v Off none Spd Term
106. ker retaining CB2 093 996 CIRCUIT BREAKER man reset 1P 20 250VAC frict 16 GFCl1 151 981 RECEPTACLE str grd 2P3W 15 20 125V GFCI 17 147 632 RECEPTACLE tw Ik grd 2P3W 30A 250V L6 30R 2 093 996 CIRCUIT BREAKER man reset 1P 20 250VAC frict 139 266 CIRCUIT BREAKER man reset 1P 15A 250VAC 16 GFCl1 151 981 RECEPTACLE str grd 2P3W 15 20A 125V 17 1 176 355 RECEPTACLE str 2p3w 16a 220v flange mtg export models only 1 218 2 24 9182954 Str SOA 125 2D0V exo ERR ste See 025 248 STAND OFF insul 250 20 x 1 2 Re 604 102 CONNECTOR clamp cable 1 000 Ex 197 527 GUARD circuit breaker 197 363 TERMINAL ring tng screw clamp 23 7 214 926 CIRCUIT BREAKER reset 215 347 PANEL generator power 215 403 PANEL pwr export models only 215 406 PANEL generator power ss 28
107. kpiece or ground For these conditions use the following equipment in order present ed 1 a semiautomatic DC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit voltage In most situations use of a DC constant voltage wire welder is recommended And do not work alone 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 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 conductor 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 sep arate cable e Do not touch electrode if you are in contact with the work ground or anoth er electrode from a different machine e Use only well maintained e
108. l et en portant un respi rateur 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 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 utili sation e Veiller toujours bien a rer les espaces confin s ou se servir d un respira teur d adduction d air homologu 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 g n re des rayons visibles et invisibles intenses ultraviolets et infrarou ges susceptibles de provoquer des br lures dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage Porter un casque de soudage approuv muni de verres filtrants appropri pour prot ger visage et yeux pendant le soudage voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit Porter des lunettes de s curit avec crans lat raux m me sous votre cas que Avoir recours des crans protecteurs ou des rideaux pour prot ger les au tres contre les rayonnements les blouissements et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc Porter des v tements confectionn s avec des mati res r sistantes et ignifu ges cuir coton lourd ou laine et des bottes de protection OM 4427 Page 5 LE SOUD
109. l Kit 202 021 or Label Kit 201 061 export models only 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 4427 Page 78 5 Hardware is common not available unless listed Figure 13 6 Generator 802 552 B Item Dia Part No Mkgs No Description Quantity Figure 13 6 Generator Figure 13 1 Item 93 2 dus 132 053 SCREW 375 16x1 50 hex hd pln gr5 pld 6 T Pr 183 387 WASHER conical spring 406 ID x 875 OD pltd 6 cg ere ea ee ee 195 911 ENDBELL gen consisting of 1 y 149 220 2 2 O RING 2 859 ID X 13965 5109 e 1 T TTE 201 099 STATOR exciter gen 1 See pm 215 011 STATOR weld assembly complete 1 4216 318 STATOR weld assembly complete full KVA option 1 a rn 225 120 LABEL warning moving parts can cause injury 2 fe 190 197 GUARD generator wire mesh 1 D 172 674 SPRING ext 240 OD x 041 wire x 3 500 18 2 j WC EON 099 207 BAFFLE AF UE So a Be aes 1 11 ROTOR 2
110. ld output Check engine speed and have Factory Authorized Service Agent adjust if necessary Check fuses F1 and 22 and replace if open see Section 9 8 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 9 8 Have Factory Authorized Service Agent check transformer T1 and integrated rectifiers SR4 and 5 5 Low open circuit voltage Check engine speed and have Factory Authorized Service Agent adjust if necessary Place Stick TIG switch in Stick position Maximum weld output only in each ampere range with Stick TIG Selection switch in Stick position Have Factory Authorized Service Agent check control relay CR7 No remote fine amperage control Place Amperage Adjust switch in Remote position Check and secure connections to Remote Amperage Adjust receptacle RC13 see Section 5 10 Reset circuit breaker CB11 See Section 9 8 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 4427 Page 45 Welding CC CV Models Trouble Remedy No weld output generator power output
111. lec switch w o sensor 1 RDS 193 228 METER Volt Dc 8 18 Scale 2 250 In Black Face 1 217 084 GAUGE Coolant Temp 0 300 Deg F Electric 1 PEN 197 798 SENDER Coolant Temp 300 Deg F M16 1 5 1 217 083 GAUGE Pressure Oil 0 100 Psi Electric 1 193 230 SENDER Pressure Oil 0 100 Psi 1 164 873 METER amp ac dc 0 500 0 600 scale 2 5 1 o Ss eo 164 874 METER volt ac dc 0 100 scale 2 5 in 1 See 097 922 KNOB pointer 875 dia x 250 ID w set screws plste 1 DO ade Een 189 161 2 HANDLE Switch FANG acier Ee eee om ra ect Blazes rte dec 1 4 DE hte 010 647 PIN spring CS 156 x 1 250 1 mith DO eae ad ed 097 924 KNOB pointer 1 625 x 250 ID w set scrws plste 1 024 103 BLANK snap in 750 mtg hole bik 1 E 120 304 BLANK snap in 250 mtg hole black 2 Optional When ordering a component originally displaying a precautionary label the label should also be ordered Order label individually or as part of Labe
112. led and OCV changes when the control is adjusted 11 Amperage Adjust Switch And Remote Amperage Adjust Receptacle Connect optional remote control to RC13 See Section 5 10 Use switch to select front panel or remote amperage control For re mote control place switch in Remote position and connect remote control to Remote Am perage Adjust receptacle RC13 see Sec tions 5 10 and 6 3 12 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 13 AC DC Voltmeter Optional Voltmeter displays voltage at the weld output terminals but not necessarily the welding arc due to resistance of cable and connections 14 AC DC Ammeter Optional Ammeter displays amperage output of the unit OM 4427 Page 27 6 3 Remote Control On Models Optional 1 Remote Amperage Adjust Receptacle RC13 Connect optional remote control to RC13 see Section 5 10 Example Combination Remote Amperage Control Stick In Example Range 110 to 225 A DC Percentage Of Range 50 7 About 168 DC 50 110 to 225 168 90 Set Switches Set Range a Set Control Adjust Optional Remote Control Ref 154 862 A Ref 181 711 A 803 602 6 4 Weld Control Arc Condition Information Label gt Set weld controls as sho
113. mps magn tiques sur le poste de travail appliquer les OM 4427 Page 8 LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique risque de provoquer des in terf rences pour l quipement lectronique sensible tel que les ordinateurs et l quipement command par ordi nateur tel que les robots e Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement e Pourr 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 m tres 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 cas d interf rences apr s 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 Proposition californienne 65 Avertissements Pour les moteurs essence Les gaz d chappement des moteurs contiennent des produits chimi ques dont l Etat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Pour les moteurs diesel Lesgazd c
114. ne protection faciale des gants en caout chouc et v tements de protection lors d une intervention sur la batterie e Arr ter le moteur avant de d brancher ou de brancher les cables de batterie e Eviter de provoquer des tincelles avec les outils en travaillant sur la batterie e pas utiliser le poste de soudage pour charger les batteries ou des v hicu les de d marrage rapide e Observer la polarit correcte et sur les batteries e D brancher le c ble n gatif en premier lieu Le rebrancher en dernier lieu LE CARBURANT MOTEUR peut provo quer un incendie ou une explosion Arr ter le moteur avant de v rifier le niveau de carburant ou de faire le plein e Ne pas faire le plein en fumant ou proche d une source d tincelles ou d une flamme nue e Ne pas faire le plein de carburant ras bord pr voir de l espace pour son expansion e Faire attention de ne pas renverser de carburant Nettoyer tout carburant renvers avant de faire d marrer le moteur e Jeter les chiffons dans un r cipient ignifuge DES ORGANES MOBILES peuvent pro voquer des blessures e Ne pas approcher les mains des ventilateurs courroies et autres pi ces en mouvement e Maintenir ferm s et fixement en place les portes panneaux recouvre ments et dispositifs de protection OM 4427 Page 6 Arr ter le moteur avant d installer ou brancher l appareil e Seules des personnes qualifi es son
115. ng Brackets Supplied Mount unit on flat surface or use cross supports to support base Secure unit with mounting brack ets 3 1 2 in Bolt And Washer Minimum Not Supplied 4 3 8 16 x1 in Screws Supplied To Bolt Unit In Place Remove hardware securing the four mounting brackets to the base Reverse brackets and reattach to base with original hardware Mount unit to truck or trailer with 1 2 in 12 mm or larger hardware not supplied To Weld Unit In Place Weld unit to truck or trailer only at the four mounting brackets Using Mounting Brackets Welding Unit In Place Bolting Unit In Place Tools Needed 916 install3 6 05 803 274 200 864 A 803 602 OM 4427 Page 19 5 4 Installing Exhaust Pipe Stop engine and let cool 5 Point exhaust pipe in desired di rection but always away from front panel and direction of travel Tools Needed 1 2 Ref 803 604 Ref 215 158 Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual OM 4427 Page 20 Always wear face shield rubber gloves and protective clothing when working on a battery Remove battery from unit 5 Vent Caps 6 Sulfuric Acid Electrolyte 1 265 Specific Gravity 7 Well Fill each cell with electrolyte to bottom of well maximum Do not overfill battery cells Wait ten minutes and check electro lyte level If nece
116. nt d ouvrir la purge ou le bouchon de remplissage d huile 4r VY 2 5 LA CHUTE DE L APPAREIL peut blesser e Ultiliser un ceilleton de levage pour lever l appareil et les accessoires correctement install s Ne pas d passer le poids nominal maximal de l oeilleton voir les sp cifications e Nelever et ne soutenir l appareil qu avec de l quipement appropri et en suivant les proc dures ad quates 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 LE SURCHAUFFEMENT peut endom mager le moteur lectrique Arr ter ou d connecter l quipement avant de d marrer ou d arr ter le moteur e 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 LES TINCELLES VOLANTES risquent de provoquer des blessures e Porter un cran facial pour prot ger le visage et les yeux e Affdter l lectrode au tungst ne uniquement la meuleuse dot e protec teurs Cette man uvre est ex cuter dans un endroit s r lorsque l on porte l quipement homologu de protection du visage des mains et du corps e Les tincelles risquent de causer un incendie loigner toute substance in flammable
117. opening if no connections are made to generator 27 2 b 78 ve plug before inserting leads Reinstall bushing 90 92 Rear Of Panel Close panel opening if no connections are made to generator Tools Needed Place Process Contactor switch in Weld Terminals Always On Stick position when using three phase generator see Section 7 3 Single Phase Generator Power 1 120 240 V 50 Receptacle RC5 5 is connected to the optional three phase generator and supplies 60 Hz single phase power at weld power speed Maximum output from RC5 is 12 kVA kW Power available at RC5 is reduced when welding 2 Circuit Breaker CB7 Circuit breaker CB7 protects single phase receptacle RC5 and the load wires from overload If CB7 opens all generator output stops and the recep tacle does not work Three Phase Generator Power Stop engine Power and weld outputs are live at the same time Discon or insulate unused cables Have qualified person install ac cording to circuit diagram and Generator Power Guidelines see Section 12 Remove generator power panel mounting screws Tilt panel forward 3 Lead 93 4 Lead 92 5 Lead 91 6 Lead 42 Circuit Grounding Lead 7 Lead 90 Neutral 8 Isolated Neutral Terminal 9 Jumper Lead 42 10 Grounding Terminal Jumper 42 is connected to lead 90 at factory Jumper 42 may be discon nected from neutral to meet applica ble electrical code
118. ord Electrically bond generator H frame to vehicle frame by metal to metalcontact Bed liners shipping skids and some running gear insulate the welding generator from the ve hicle frame Always connect a ground wire from the generator equipment grounding terminal to bare metal on the vehicle frame as shown OM 4427 Page 57 12 3 Grounding When Supplying Building Systems 1 Equipment Grounding Terminal 2 Grounding Cable Use 10 AWG or larger insulated copper wire 3 Ground Device 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 12 4 How Much Power Does Equipment Require 1 Resistive Load A light bulb is a resistive load and VOLTS 115 AMPS 45 requires a constant amount of power 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 running see Section 12 8 3 Rating Data Rating shows volts and amperes or watts required to run equipment AMPERES x VOLTS WATTS EXAMPLE 1 If a drill uses 4 5 amperes at 115 volts calculate its running power requirement in watts 4 5 x 115 V 520 W 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
119. ower speed and have Factory Authorized Service Agent adjust if necessary Have Factory Authorized Service Agent check field current regulator board PC1 and PC1 voltage feedback circuit Erratic output at optional three phase generator receptacle RC5 Have Factory Authorized Service Agent check brushes and slip rings and field current regulator board PC1 OM 4427 Page 47 Engine Trouble Remedy Engine will not crank Check battery and replace if necessary Check battery connections and tighten if necessary Circuit breaker CB10 may be open CB10 automatically resets when fault is corrected see Section 9 8 Have Factory Authorized Service Agent check engine wiring harness and components Check engine wiring harness plug connections Have Factory Authorized Service Agent check control relay CR1 and Engine Control switch S1 Engine cranks but does not start Check fuel level Check battery and replace if necessary Check engine charging system according to engine manual Have Factory Authorized Service Agent check engine wiring harness time delay relay TD1 control relay CR5 fuel pump fuel solenoid FS1 and diode capacitor board D10 C10 Air in fuel system See engine manual Engine starts but stops when Engine Control switch is released Check oil and coolant levels Automatic shutdown system stops engine if oil pressure is too low or coolant t
120. quipment Repair or replace damaged parts at once Maintain unit according to manual 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 e Do not touch electrode holders connected to two welding machines at the same time since double open circuit voltage will be present 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 work table 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 in inverters after stop ping engine e Stop engine on inverter and discharge input capacitors according to instructions in Maintenance Section before touching any parts FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health e Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data S
121. retien 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 un blindage pour r duire les interf rences ventuelles 2 6 Les quipements de soudage et coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l Etat de Californie reconnait qu ils provoquent des malformations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants Les batteries les bornes et autres accessoires contiennent du plomb et des compos s base de plomb produits chimiques dont l Etat de Cali fornie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apres manipulation 2 7 Principales normes de s curit eafety in Welding Cutting and Allied Processes ANSI Standard Z49 1 de Global Engineering Documents t l phone 1 877 413 5184 site In ternet www global ihs com Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping American Welding Society Standard AWS F4 1 de Global Engineering Documents t l phone 1 877 413 5184 site In ternet www global ihs com National Electrical Code NFPA Standard 70 de National Fire Protection Association P O Box 9101 1 Battery March Park
122. rk like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual OM 4427 Page 13 4 4 Volt Ampere Curves For Models A Stick Mode 100 RANGES MAX 155 450 115 320 75 195 40 90 0 ar gt Q O 100 200 300 400 500 600 700 800 900 1000 DC AMPERES B MIG Mode 100 80 60 2 40 gt Q 20 0 Mew O 100 200 300 400 500 600 700 800 900 1000 DC AMPERES C TIG Mode 100 RANGES 60 365 80 35 250 25 155 15 75 0 gt Q 200 300 500 DC AMPERES OM 4427 Page 14 The volt ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator Curves of all other settings fall between the curves shown 215 080 A 215 083 A 215 079 A 4 5 Fuel Consumption The curve shows typical fuel use under weld or power loads I E 2 50 100 150 200 250 300 350 400 450 WELD 100 DUTY CYCLE 199 032 A 4 6 Duty Cycle And Overheating 100 Duty Cycle At 400 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 Y am gt lt DUTY CYCLE 215 084 A OM 4427 Page 15 4 7 Generator Power 150 300 125 250 100 200 75 150 cn O gt lt
123. s 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 gt Circuit breaker CB7 protects single phase receptacle 5 and the load wires from overload If CB7 opens all generator out put stops and the receptacle does not work Reinstall generator power panel Ref 197 399 802 332 E 803 655 OM 4427 Page 35 8 3 Optional Generator Power Receptacles 1 120V 20 A AC GFCI Receptacle GFCI1 Pw 2 240V 16A AC European European Receptacle Receptacle RC1 3 240V 15 AC Australian Receptacle RC1 4 240 V 15 A AC South African Receptacle RC1 Receptacles supply 60 Hz single phase power at weld power speed If a ground fault is detected the GFCI Reset button pops out and the receptacle does not work Check for faulty tools plugged in receptacle Press button to reset GFCI1 120V 20 15 60 240V 15 F At least once a month run en gine at weld power speed and press test button to verify GFCI is working properly 3 5 Circuit Breaker CB2 6 Circuit Breaker CB3 CB2 protects GFCI1 from overload If CB2 opens does not work Press button to reset breaker Australian Receptacle CB3 protects RC1 from overload If opens does not work Press button to reset breaker gt
124. s Contactor switch 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 5 11 Repair or replace remote control device Have Factory Authorized Service Agent check PC1 current sensing leads 86 and 37 and connections Constant speed wire feeder does not work Reset circuit breaker CB5 or CB6 see Section 9 8 Check and secure connections to Remote 14 receptacle RC14 see Section 5 11 Repair or replace wire feeder OM 4427 Page 46 Trouble Remedy Low CV weld output Set Ampere Range switch to highest range Increase Voltage Amperage Adjust Control setting Min or max CV weld output only Check position of Voltage Amperage Adjust control and Voltage Amperage Adjust switch Repair or replace remote control device Have Factory Authorized Service Agent check Amperage Voltage Adjust Control R1 and field current regulator board PC1 C Standard Generator Power Trouble Remedy No generator power output at ac recep tacles weld output okay Reset receptacle circuit breakers Reset GFCI receptacle No generator power or weld output Disconnect equipment from generator power receptacles during start up Check fuses F1 and F2 and replace if open see Section 9 8 Have Factory Authorized Service Agent
125. sons should install operate maintain and pair this unit During operation keep everybody especially children away ELECTRIC SHOCK can kill R 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 Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground e Donotuse AC output in damp areas if movement is confined or if there isa danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit Additional safety precautions are required when any of the following electri cally hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoidable or accidental contact with the wor
126. ssary add electro lyte to raise to proper level Reins tall vent caps 8 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 5 When electrolyte is low only distilled water to cells to maintain proper level 5 A For 30 Minutes OR S Tools Needed 30 A For 12 Minutes E s drybatti 6 05 5 0886 Reinstall cover after connecting battery Tools Needed 4 Ref 215 158 803 605 S 0756 C 4427 21 5 7 Engine Prestart Checks Diesel Check all engine fluids daily Engine must be cold and on a level surface Unit is shipped with 20W break in oil Automatic shutdown system stops engine if oil pressure is too low or coolant tempera ture is too high This unit has a low oil pressure shut down switch However some condi tions may cause engine damage before the engine shuts down Check oil level often and do not use the oil pressure shutdown system to monitor oil level Follow run in procedure in engine manual If unburned fuel and oil collect in exhaust pipe during run in see Section 11 Fuel Do not use gasoline Gasoline will damage engine The unit is shipped with enough fuel to pre vent air from entering fuel system Add fresh diesel fuel before starting see engine main
127. sses with side shields under your helmet Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc e Wear protective clothing made from durable flame resistant material leather heavy cotton or wool and foot protection OM 4427 Page 1 WIE WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Do not weld where flying sparks can strike flammable material e Protect yourself and others from flying sparks and hot metal e alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas e Watch for fire and keep a fire extinguisher nearby Be aware that welding 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
128. sure Certified Trained Mechanic i Panel Local MIG GMAW Welding Seconds ER 4 1 N Protective Earth Ground Welding Arc Alternating Current TIG GTAW Single Phase Do Not Switch Read Operator s pet 3 Ny Three Phase Manual 5 Circuit 4 While Welding Engine Driven Electrode Three Phase Work Connection Alternator With Z ere mmm Rectifier X Dutv Rated No Load U Conventional Rated Load ud Voltage Average 2 Load Voltage n Speed n Rated Idle n Rated No Load Rated Welding 1 Speed 2 Current Contactor On OM 4427 Page 11 SECTION 4 SPECIFICATIONS 4 1 Weld Power And Engine Specifications Maximum Welding Weld Output Rated Welding Open Generator Power Ename Fuel Mode Range Output Circuit Rating g Capacity Voltage Export Models 300 A 32 Volts DC 100 Dut d E a d CC DC 6096 Duty Cycle Single Phase CC CV Models 300 A 29 Volts DC 4 KVA KW 34 17 CV 10096 Duty Cycle 120 240 V AC 430 A 36 Volts DC 90 60 Hz CV 60 Duty Cycle Three Phase Generator 25 gal Option Caterpillar 3024C 95 L 2 Single Phase Three Phase Water Cooled 1 00 Duty Cycle i 12 15 kVA kW 50 36A Four Cylinder CV DC FERAE 120 240 VAC 60 Hz 32 6 HP Diesel Engine CC CV 14 40V s e 56 In Add
129. t autoris es enlever les portes pan neaux recouvrements ou dispositifs de protection pour effectuer s il y a lieu des travaux d entretien et de d pannage e Pour emp cher tout d marrage accidentel pendant les travaux d entretien d brancher le c ble n gatif de batterie de la borne e pas approcher les mains cheveux v tements l ches et outils des organes mobiles e Remettre en place les panneaux ou les dispositifs de protection et fermer les portes la fin des travaux d entretien et avant de faire d marrer le moteur e Avant d 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 DES PIECES CHAUDES peuvent provo quer des br lures et blessures e Ne pas toucher les parties chaudes du moteur e Laisser l ensemble se refroidir avant d effectuer la maintenance e Porter des gants et des v tements de protection pour travailler sur un moteur chaud LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT CHAUD peuvent provoquer des br lures est pr f rable de v rifier 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 expan sion si pr sent et non dans le radiateur sauf si pr cis autrement dans la section maintenance du manuel du moteur e Sile moteur
130. ted 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 1 05 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City otate Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Heplacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks To locate a Distributor or Service Agency visit www millerwelds com or call 1 800 4 A Miller Contact the Delivering Carrier to File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA C 2005 Miller Electric Mfg Co 10 05 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 Canad
131. tenance label for fuel specifications Leave filler neck empty to allow room for ex pansion OM 4427 Page 22 E N Do not run out of fuel or air will enter fuel sys tem and cause starting problems See en gine manual to bleed air from fuel system Oil After fueling check oil with unit on level sur face If oil is not up to full mark on dipstick add oil see maintenance label Coolant Check coolant level in radiator before start ing unit the first time If necessary add cool ant to radiator until coolant level is at bottom of filler neck Check coolant level in recovery tank daily If necessary add coolant to recovery tank until coolant level is between Cold Full and Hot Full levels recovery tank coolant level was low also check coolant level in radiator Add coolant if level is below bottom of radia tor filler neck Unit is shipped with an engine coolant mix ture of water and ethylene glycol base anti freeze rated to 34 F 37 C Add anti Check radiator coolant level when fluid is low in recovery tank 404 22 Engine 9 5 qt 9 01L Hot Full Cold Full 803 603 freeze to mixture if using the unit in tempera tures below 34 F 37 C Keep radiator and air intake clean and free of dirt Incorrect engine temperature can damage engine Do not run engine without a properly working thermo stat and radiator cap
132. tion Operation And Maintenance 3 1 6 California Proposition 65 06 4 187 Standards o siea rt neath eed oat dono ao Nos e D 4 1285 EMFInOMalON dac aio d D dt cie dn d AD 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 Signification des Symboles ax dau a ERES RO REED S Rd deett 5 2 2 Dangers relatifs au soudage l arc 1 5 2 3 Dangers existant en relation avec le moteur 6 2 4 Dangers lies a l air cssc atin eos oue em Pe S X Ede E Dc ous E Rs 7 2 5 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 7 2 6 Proposition californienne 65 5 8 2 7 Principales normes de ades bes tisque Veios d mah acid 8 2 0 EMF Dites a Gant Riche d MU 8 SECTION DEFINITIONS vei UI REPRE ERE EE EE 9 3 1 Warning Label Definitions For Wordless Labels 9 9
133. tops if CB5 opens CB6 protects the 115 volt ac output to re mote receptacle RC14 CC CV models only If CB6 opens 115 volt output to RC14 stops CB10 protects the engine battery circuit If CB10 opens the engine will not crank CB10 automatically resets when the fault is corrected CB11 protects the weld control circuit On CC models if CB11 opens the max OCV circuit does not work and open circuit voltage is variable at all times see max note under Weld Controls in Section 6 2 If CB11 opens on CV models weld output stops generator power is still available CB12 protects the field flashing circuit CB12 opens the generator may not ex cite at start up and weld and generator power output may not be available CB13 protects the engine control circuit If CB13 opens the engine does not crank CB14 protects throttle solenoid TS1 on units with auto idle option If CB14 opens the engine does not run at idle speed CB14 automatically resets when the fault is corrected Press button to reset breaker 803 605 9 9 Troubleshooting Welding Models Trouble Remedy No weld output generator power output okay at ac receptacles Check position of Ampere Range switch Check position of optional Polarity switch Place Amperage Adjust switch in Panel position or place switch in Remote position and connect remote control to Remote Amperage Adjust receptacle RC13 see
134. tor and meters after first five minutes then every fifteen minutes to be sure generator is loaded properly gt Check oil level frequently dur ing run in add oil if needed It is recommended to run the weld ing generator for two hours mini mum and up to four hours under load Place A V control in minimum position then shut down grid to remove load Run engine several minutes at no load Stop engine and let cool 6 Engine Exhaust Pipe Repeat procedure if wetstacking is present S 0684 SECTION 12 GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine driven welding generators Your unit may differ from those shown 12 1 Selecting Equipment Generator Power Receptacles Neutral Bonded To Frame 3 Prong Plug From Case Grounded Equipment 2 Prong Plug From Double Insulated Equipment Do not use 2 prong plug un less equipment is double in sulated Be sure equipment has this symbol and or wording gen_pwr 11 02 Ref ST 159 730 ST 800 577 A Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards Equipment Grounding Terminal On Front Panel Grounding Cable Not Supplied Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insulated copper wire A unit does have GFCI re ceptacles use GFCI pro tected extension c
135. trol Box Assembly CC Models Figure 13 1 Item 114 1 F1 F2 085 874 FUSE mintr slo blo 10A 250V 2 E es 046 432 HOLDER fuse mintr 250 x 1 250 2 Lux dan OAT O9 O9SO sc RELAY OOV CONTO ic rt 1 wth teresa 201 077 CONTROL BOX Ih 1 5 C12 191944 CAPACITOR polyp met film 10 uf 250 vac 10 1 ru R6 141424 RESISTOR ww fxd 30 w 25 ohm faston te 1 ide S doter duet rts 201 079 4 CONTROL BOX e ede Eb Ge es 1 TE TM 090104 RELAY 12VDC SPST 30A 15VDC spin flange mtg 1 9 CR8 197 325 RELAY 12vdc spst 70a flange mtg 1 10 CH1 090104 RELAY Encl 12vdc Spst 30a 15vdc 5pin Flange 1 11 CR6 090104 RELAY 12vdc spst 30a 15vdc 5pin flange mtg 1 12 D10 C10 D11 C11 189 701 DIODE CAPACITOR BOARD 2 13 CB10 190374 CIRCUIT BREAKER auto reset 12VDC 40A 1 14 CB14 205 927 CIRCUIT BREAKER auto reset 12vdc 12 1 15 CR5 223710 RELAY Encl 12vdc Dpst no 25a 6pin Flange 1 16
136. uffler extension elbow 1 750 1 do RE 201 851 COVER radiator access 1 OM 4427 Page 66 Item Dia Part No Mkgs No Description Quantity Figure 13 1 Main Assembly Continued d o ados Bt 202 629 COVER radiator access 55 1 PR 1919545 SUPPORT COVER dre ete oc cathe an ahaa en 1 meo METER 202 633 SUPPORT cover e coat 1 010 875 CLAMP muffler 2 000 dia 1 203 180 MANIFOLD exhaust muffler 1 203 179 BRACKET support muffler 2 TON D 213185 ENGINE cat dsl elec 3024c series 1 Sate SR TTE TOES 214931 coolant temp amp 110c switch 1 aede ee 5215094 SWITCH OI oe redes 1 rs 023 562 CLAMP hose 312 875 clp dia 1 RE 197 099 2 3 FILTER 0152 onis cni EMT Om E 11 519274432422 gt gt 1 197 997
137. un poste souder manuel AC avec tension vide r duite Dans la plupart des cas un poste courant continu de type CV est re command Et ne pas travailler seul Couper l alimentation ou arr ter le moteur avant de proc der l installation la r paration ou l entretien de l appareil D verrouiller l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de s curit Installer et mettre la terre correctement cet appareil conform ment son manuel d utilisation et aux codes nationaux provinciaux et municipaux Toujours v rifier la terre du cordon d alimentation V rifier et s assurer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre En effectuant les raccordements d entr e fixer d abord le conducteur de mise la terre appropri et contre v rifier les connexions V rifier fr quemment le cordon d alimentation pour voir s il n est pas endom mag ou d nud remplacer le cordon imm diatement s il est endommag un c ble 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 endommag 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 distinct ne pas utiliser
138. with a serial number preface of LF 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 THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Miller must be notified in writing within thirty 30 days of such defect or failure at which time Miller will provide instructions on the warranty claim procedures to be followed Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the 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 Inv
139. wn to achieve softer or stiffer arc condi tions for different applications SOFTER ARC A softer arc condition can be achieved by selecting the lowest usable range for the electrode with a higher fine amperage setting preferably above 50 This improves 6010 for uphill pipe welding by reducing Arc outages Popouts and reduces spatter with 7018 STIFFER ARC A stiffer arc condition can be achieved by selecting the highest usable range for the electrode with a lower fine amperage setting preferably below 50 This improves 6010 for downhill stick welding and 7018 for out of position welding by increasing dig OM 4427 Page 28 Notes OM 4427 Page 29 SECTION 7 OPERATING WELDING CC CV MODELS 7 1 Front Panel Controls For CC CV Models See Section 7 2 215 158 802 602 OM 4427 Page 30 7 2 Description Of Front Panel Controls For CC CV Models See Section 7 1 Engine Starting Controls 1 Starting Aid Switch Use switch to energize starting aid for cold weather starting see starting instructions fol lowing 2 Engine Control Switch Use switch to start engine select engine speed if unit has auto idle option and stop engine In Run position engine runs at weld power speed In Auto position optional engine runs at idle speed at no load and weld speed with load applied To Start Do not use ether Using ether voids warranty gt If engine does
140. y Encl 12vdc Spst 70a Flange 1 Harness range switch includes 1 Conn Rect Univ 084 4 5 1row Rept Cable Panel Lkg 1 Harness receptacle auxiliary power includes 1 Rept Tw Lk Grd 2p3w 30a 250v L6 30r 1 Rept Str Dx 2p3w 15 20a 125v 5 20r 1 Circuit Breaker Man Reset 1p 20a 250vac 1 Harness receptacle auxiliary power export models includes 1 Rept Str Dx Grd 2p3w 15 20a 125v 5 20r 1 Circuit Breaker Man Reset 1 15a 250vac 1 Circuit Breaker Man Reset 1p 20a 250vac 1 Harness brushholder includes 1 Conn Rect Univ 084 9p S Plug Cable Lkg 1 Seal Wire Uniy 9D S SIOW 52552 SEA ae ka OE B 1 OM 4427 Page 83 Warranty Questions Call 1 800 4 A MILLER for your local Miller distributor Your distributor also gives you Service You always get the fast reliable response you need Most replacement parts can be in your hands in 24 hours Support Need fast answers to the tough welding questions Contact your distributor The expertise of the distributor and Miller is there to help you every step of the way Effective January 1 2005 Equipment

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