Contents
OM-496
Processes
Description
From Miller to You
Table of Contents
11-1
11-2
11-3
Directives
Standards
Deccon1 11/02
Sound Level Information
Deccon1 5/98
Symbol Usage
Arc Welding Hazards
Engine Hazards
Compressed Air Hazards
EMF Information
Principal Safety Standards
California Proposition 65 Warnings
Radiation can cause interference
UN Choc Électrique peut tuer
Signification des symboles
− Consignes DE Sécurité − Lire Avant Utilisation
LES Fumées ET LES GAZ peuvent être dangereux
DES Pièces Chaudes peuvent provoquer des brûlures graves
LE Soudage peut provoquer un in- cendie ou une explosion
DES Particules Volantes peuvent blesser les yeux
LE Bruit peut affecter l’ouïe
LA Chaleur DU Moteur peut pro- voquer un incendie
’EXPLOSION DE LA Batterie peut
DES Organes Mobiles peuvent provoquer des blessures
’AIR Comprimé peut provoque r des blessures
Principales normes de sécurité
Information sur les champs électromagnétiques
− Definitions
+ −
Starting Instructions
Can cause severe burns. Do
Are possible hazards as
Hot muffler and exhaust pipes
Engine
Return To Table Of Contents
Std
Manufacturer’s Rating Labels For CE Products
− 50 h Std
CC Models CC/CV Models
Symbols And Definitions
− Specifications
Weld, Power, And Engine Specifications
Dimensions, Weights, And Operating Angles
Volt-Ampere Curves For CC Models
TIG Mode
Stick Mode
MIG Mode
Volt-Ampere Curves For CC/CV Models
Fuel Consumption
Duty Cycle And Overheating
12 kVA/kW Single-Phase AC Output No Weld Load
AC Generator Power Curve
Optional Three-Phase Generator Curves
15 kVA/kW Three-Phase AC Output No Weld Load
Location Grounding
− Installation
Installing Welding Generator See Sections 5-2And
Airflow Clearance
Using Lifting Eye
Work like a Pro
Mounting Surface
Mounting Welding Generator
Supporting The Unit
To Bolt Unit In Place
Installing Exhaust Pipe
Stop engine and let cool
Read and follow all instruc
Activating The Dry Charge Battery If Applicable
When electrolyte is low, add
Charger
Connecting The Battery
Reinstall cover after connecting battery
Connect Negative − Cable Last
Coolant Recovery Tank
Engine Prestart Checks
Connecting To Weld Output Terminals
Selecting Weld Cable Sizes
Ref 862-A / 048 720-K / 802
Connecting To Remote 14 Receptacle RC14 On CC/CV Models
Socket
− Operating Welding Generator − CC Models
Front Panel Controls For CC Models See Section
Do not switch under load
To Start Do not use ether. Using ether voids warranty
Engine Indicator Lights
Engine Starting Controls
Example Combination Remote Amperage Control Stick
Remote Amperage Control On CC Models Optional
Weld Control/Arc Condition Information Label
Set weld controls as shown to
Return To Table Of Contents
− Operating Welding Generator − CC/CV Models
Front Panel Controls For CC/CV Models See Section
Use switch to select weld amperage range
Voltage/Amperage Adjust Switch And Remote 14 Receptacle
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
At least once a month, run en
− Operating Auxiliary Equipment
Volt And 240 Volt Receptacles
Open, contact Factory Autho
Three-Phase Power Connection
Rear Of Panel
Close panel opening if no connections are made to generator
Optional Generator Power Receptacles
240 V 15 a AC South African Receptacle RC1
Circuit Breaker CB2 Circuit Breaker CB3
− Maintenance & Troubleshooting
Maintenance Labels
For Non-CE Products
Every 50 h
Routine Maintenance
Every 8 h
Every 100 h
Every 2000 h
Clean/Set Injectors
Every 1000 h
Change Fuel
To clean air filter
Servicing Air Cleaner
By the warranty
Do not clean housing with air hose
Inspecting And Cleaning Optional Spark Arrestor Muffler
Reinstall cleanout plug Tools Needed
Do not set engine speed higher than specified
Adjusting Engine Speed On Standard Models
Maximum
Close door Tools Needed 10 mm
Engine Speed No Load
Idle Speed Adjustment
Weld/Power Speed Adjustment
Rpm max 61.6 Hz 1250 rpm 41.6 Hz
Servicing Fuel And Lubrication Systems
Overload Protection
Correct the cause of the shut
Diagnosing Causes Of Engine Fault Shutdowns
Diagnostic Checks While Running
Down before operating
Troubleshooting
Welding − CC Models
Welding − CC/CV Models
Standard Generator Power
Optional Three-Phase Generator Power CC/CV Models Only
Engine
Temperature is too high see Sections 5-7and
Wiring harness and components
Shutdown switch is released Out
Air in fuel system. See engine manual
Return To Table Of Contents
− Electrical Diagrams
Circuit Diagram For CC Welding Generator
215 296-B
Circuit Diagram For CC/CV Welding Generator
215 297-B
− RUN-IN Procedure
Wetstacking
Ment damage may occur
Stop engine Do not touch hot exhaust
Run-In Procedure Using Load Bank
Procedure at less than
From flammables Do not Perform
From flammables
Run-In Procedure Using Resistance Grid
Bank/grid
Do not perform run-in
Selecting Equipment
− Generator Power Guidelines
Has this symbol
Grounding Generator To Truck Or Trailer Frame
Earth ground if supplying
Grounding When Supplying Building Systems
How Much Power Does Equipment Require?
Use ground device as stated in electrical codes
Industrial Motors Rating Starting Watts Running Watts
Approximate Power Requirements For Industrial Motors
Approximate Power Requirements For Farm/Home Equipment
Farm/Home Equipment Rating Starting Watts Running Watts
Approximate Power Requirements For Contractor Equipment
Contractor Rating Starting Watts Running Watts
Single-Phase Induction Motor Starting Requirements
Power Required To Start Motor
How Much Power Can Generator Supply?
KVA/HP x HP x
Typical Connections To Supply Standby Power
Selecting Extension Cord Use Shortest Cord Possible
Current Load Watts Amperes
− Parts List
109 111 -4 or
118
85 Fig
Dia Part Mkgs Description Quantity
209
Figures 13-2
Control Box Assembly − CC Models
PLG3
Control Box Assembly − CC/CV Models
PC7 195
Panel, Front w/Components − CC Models
RC13 032
Panel, Front w/Components − CC/CV Models
41 40
Panel, Front w/Components − CC/CV Models -1Item
PC4, PC5 189
Generator
Generator -1Item
602 SCREW, .312−18x .75 hexwhd.66d stl pld slffmg tap−rw 601
Main Rectifier Assembly
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Service
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Your distributor and/or equipment manufacturer’s
Miller Electric Mfg. Co
For assistance in filing or settling claims, contact
Transportation Department