Contents
OM-4428215 932K
Processes
Description
File Engine Drive
From Miller to You
Table of Contents
Troubleshooting
Symbol Usage
Arc Welding Hazards
Electric Shock can kill
HOT Parts can cause severe burns
Fumes and Gases can be hazardous
Buildup of GAS can injure or kill
ARC Rays can burn eyes and skin
Welding can cause fire or explosion
Engine Hazards
Compressed Air Hazards
Welding Wire can cause injury
HOT Parts can cause burns and injury
Fire or Explosion hazard
Falling Unit can cause injury
Principal Safety Standards
California Proposition 65 Warnings
EMF Information
Radiation can cause interference
Signification des symboles
− Consignes DE Sécurité − Lire Avant Utilisation
UN Choc Électrique peut tuer
Indique des instructions spécifiques
DES Pièces Chaudes peuvent provoquer des brûlures graves
LES Fumées ET LES GAZ peuvent être dangereux
LE Soudage peut provoquer un in cendie ou une explosion
LE Bruit peut affecter l’ouïe
’EXPLOSION DE LA Batterie peu
DES Organes Mobiles peuvent pro voquer des blessures
LA Chaleur DU Moteur peut pro- voquer un incendie
’AIR Comprimé peut provoquer des blessures
Risque D’INCENDIE OU D’EXPLO- Sion
LE Surchauffement peut endom- mager le moteur électrique
DES Organes Mobiles peuvent provoquer des blessures
LES Fils DE Soudage peuvent provoquer des blessures
’EMPLOI Excessif peut
Proposition californienne 65 Avertissements
Principales normes de sécurité
Information EMF
En ce qui concerne les implants médicaux
− Definitions
− 50 h Std
Std
Manufacturer’s Rating Labels
CC Models
Symbols And Definitions
Some symbols are found only on CE products
− Specifications
Weld, Power, And Engine Specifications
Dimensions, Weights, And Operating Angles
Lifting Eye Weight Rating
Volt-Ampere Curves For CC Models
Volts
Stick Mode
MIG Mode
TIG Mode
Volt-Ampere Curves For CC/CV Models
Curve shows typical fuel use under weld or power loads
Fuel Consumption
AC Generator Power Curve
Duty Cycle And Overheating
100% Duty Cycle At 500 Amperes
Optional Three-Phase Generator Curves
12 kVA/kW Single-Phase AC Output No Weld Load
20 kVA/kW Three-Phase AC Output No Weld Load
− Installation
Installing Welding Generator
Location/Airflow Clearance
Grounding1
Using Lifting Eye
Mounting Welding Generator
Installing Exhaust Pipe
After installing cylinder, wait at
Stop engine and let cool
Activating The Dry Charge Battery If Applicable
Connecting The Battery
Engine Prestart Checks
Deutz F4L2011 Engine
Deutz F3L912 Engine
Fuel
Connecting To Weld Output Terminals
Correct Installation
Stick and TIG Welding
MIG and Fcaw Welding
Connecting to Weld
Selecting Weld Cable Sizes
45 m 60 m 70 m 90 m 105 m 120 m
Output terminals
Connecting To Remote 14 Receptacle RC14 On CC/CV Models
Socket
− Operating Welding Generator − CC Models
Front Panel Controls For CC Models See Section
Engine Starting Controls
To Start
Engine Gauges And Meters
Weld Controls
Remote Amperage Control On CC Models Optional
Weld Control/Arc Condition Information Label
Example Combination Remote Amperage Control Stick
Work like a Pro
− Operating Welding Generator − CC/CV Models
Front Panel Controls For CC/CV Models See Section
Voltage/Amperage Adjust Switch And Remote 14 Receptacle
14 AC/DC Voltmeter Optional
Process/Contactor Switch On CC/CV Models
Process/Contactor Switch Settings
Remote Voltage/Amperage Control On CC/CV Models Optional
Example Combination Remote Amperage Control TIG
− Operating Auxiliary Equipment
Volt And 240 Volt Receptacles
At least once a month, run en
If a Supplementary
Rear Of Panel
Close
Connections
Are made Generator
Optional Generator Power Receptacles Standard Models
240 V 15 a AC South African Receptacle RC1
Supplementary Protector CB2 Supplementary Protector CB3
Generator Power Receptacles Export Models
Generator power is not affected by weld output
− Maintenance Deutz F4L2011−POWERED Units
Maintenance Label Deutz F4L2011-Powered Units
Routine Maintenance Deutz F4L2011-Powered Units
Checking Generator Brushes
Servicing Air Cleaner Deutz F4L2011-Powered Units
To clean air filter
Spark Arrestor Muffler Cleanout Plug
Covering cleanout hole
Blow out cleanout hole. If nothing
Reinstall cleanout plug Tools Needed 3/8
Adjusting Engine Speed Deutz F4L2011-Powered Units
Standard Models
Do not set engine speed higher than specified
Models With Automatic Idle Optional
To change oil and filter
To drain water from fuel system
To replace primary fuel filter
To replace secondary fuel filter
Overload Protection Deutz F4L2011-Powered Units
When a supplementary protector
− Maintenance Deutz F3L912−POWERED Units
Maintenance Label Deutz F3L912-Powered Units
Routine Maintenance Deutz F3L912-Powered Units
Checking Generator Brushes
Ment is not covered by the warranty
Clean or replace primary element if dirty
See note above before cleaning. Re
Cleanings
Spark Arrestor Muffler Cleanout Plug
Adjusting Engine Speed Deutz F3L912-Powered Units
To change oil and filter
Overload Protection Deutz F3L912-Powered Units
− Troubleshooting
Troubleshooting
Welding − CC Models
Welding − CC/CV Models
Standard Generator Power
Optional Three-Phase Generator Power CC/CV Models Only
Engine
− Electrical Diagrams
215 221-E
OM-4428
235 275-A
OM-4428
215 806-E
OM-4428
235 276-A
OM-4428
215 807-D
OM-4428
215 808-D
− RUN-IN Procedure
Wetstacking
Welding Generator
Run-In Procedure Using Load Bank
Keep exhaust and pipe away
From flammables
Run-In Procedure Using Resistance Grid
Specifications section in this
Just generator A/V control so
Manual
− Generator Power Guidelines
Selecting Equipment
Grounding Generator To Truck Or Trailer Frame
Electrically Bond Generator
Grounding When Supplying Building Systems
How Much Power Does Equipment Require?
Use ground device as stated in electrical codes
Amperes x Volts = Watts
Approximate Power Requirements For Industrial Motors
Approximate Power Requirements For Farm/Home Equipment
Industrial Motors Rating Starting Watts Running Watts
Farm/Home Equipment Rating Starting Watts Running Watts
Approximate Power Requirements For Contractor Equipment
Contractor Rating Starting Watts Running Watts
Power Required To Start Motor
How Much Power Can Generator Supply?
Single-Phase Induction Motor Starting Requirements
KVA/HP x HP x 1000 / Volts = Starting Amperage
Typical Connections To Supply Standby Power
Selecting Extension Cord Use Shortest Cord Possible
− Parts List
CC CC Models Only CV CC/CV Models Only
Deutz F4L2011 en
Dia Part Description Quantity
Dia Part Description Quantity Mkgs
CC191
Control Box Assembly − CC Models
PLG3
Control Box Assembly − CC/CV Models
193 SWITCH, rotary 6 position gold contacts
Panel, Front w/Components − CC Models
GFCI1
Temp
Panel, Front w/Components − CC/CV Models
Panel, Front w/Components − CC/CV Models -1Item
PC6 192
PC4, PC5 189
Hardware is common
2827
602 SCREW, .312−18x .75 hexwhd.66d stl pld slffmg tap−rw 601
Main Rectifier Assembly
Main Rectifier Assembly -1Item
Page
Service
Your distributor also gives
Support
To locate a Distributor or Service Agency visit
Miller Electric Mfg. Co
For assistance in filing or settling claims, contact
Your distributor and/or equipment manufacturer’s