Contents
OM-4421215 075N
Processes
Description
File Engine Drive
From Miller to You
Table of Contents
− Maintenance & Troubleshooting
Directives
Standards
Decrot9/06
Manufacturer European Contact Notified Body
Decrotsound6/05
Symbol Usage
Arc Welding Hazards
Engine Hazards
Compressed Air Hazards
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
LES Fumées ET LES GAZ peuvent être dangereux
LE Soudage peut provoquer un in- cendie ou une explosion
DES Particules Volantes peuvent blesser les yeux
DES Pièces Chaudes peuvent provoquer des brûlures graves
LE Bruit peut affecter l’ouïe
’AIR Comprimé peut provoquer des blessures
’EMPLOI Excessif peut
LE Surchauffement peut endom- mager le moteur électrique
LES Étincelles Volantes risquent de provoquer des blessures
LE Soudage À L’ARC risque de provoquer des interférences
Pour les moteurs à essence
Pour les moteurs diesel
Boulevard, Rexdale, Ontario, Canada M9W 1R3 téléphone
− Definitions
− 50 h Std
Std
Manufacturer’s Rating Labels
CC Models CC/CV Models CC Export Models
OM-4421
Symbols And Definitions
− Specifications
Weld, Power, And Engine Specifications
Dimensions, Weights, And Operating Angles
Volt-Ampere Curves For CC Models
Stick Mode
MIG Mode
TIG Mode
Volt-Ampere Curves For CC/CV Models
Curve shows typical fuel use under weld or power loads
Exceeding duty cycle can damage unit and void warranty
Fuel Consumption
Duty Cycle And Overheating
AC Generator Power Curve
Optional Three-Phase Generator Curves
12 kVA/kW Single-Phase AC Output No Weld Load
15 kVA/kW Three-Phase AC Output No Weld Load
− Installation
Installing Welding Generator
Location/Airflow Clearance
Grounding1
Using Lifting Eye
Mounting Welding Generator
Supporting The Unit
Mounting Surface
To Bolt Unit In Place
Installing Exhaust Pipe
Tools Needed 1/2
Stop engine and let cool
Activating The Dry Charge Battery If Applicable
Connecting The Battery
Do not overfill battery cells
For 30 Minutes
Coolant Recovery Tank
Engine Prestart Checks
Full Capacity Engine 9.5 qt 9.01L Diesel
Hot Full Cold Full
Connecting To Weld Output Terminals
Stick and TIG Welding
MIG and Fcaw Welding
Stop engine
Selecting Weld Cable Sizes
150 ft 200 ft 250 ft
350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m
Stop engine before
Connecting To Remote 14 Receptacle RC14 On CC/CV Models
Socket
− Operating Welding Generator − CC Models
Front Panel Controls For CC Models See Section
To Start Do not use ether. Using ether voids warranty
Do not switch under load
Engine Starting Controls
Engine Gauges And Meters
Remote Amperage Control On CC Models Optional
Weld Control/Arc Condition Information Label
Example Combination Remote Amperage Control Stick
OM-4421
− 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
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
Single-Phase Generator Power 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
Supplementary Protector CB2 Supplementary Protector CB3
− Maintenance & Troubleshooting
Maintenance Label
Routine Maintenance
Checking Generator Brushes
Servicing Air Cleaner
By the warranty
To clean air filter
Do not clean housing with air hose
Inspecting And Cleaning Optional Spark Arrestor Muffler
Stop engine and let cool. Reinstall cleanout plug
Tools Needed 3/8
Adjusting Engine Speed
Weld/Power Speed Adjustment
Engine Speed No Load
Standard Model Idle Speed Ad- justment
Servicing Fuel And Lubrication Systems
Overload Protection
Troubleshooting
Welding − CC Models
Welding − CC/CV Models
Standard Generator Power
Optional Three-Phase Generator Power CC/CV Models Only
Engine
OM-4421
− Electrical Diagrams
Circuit Diagram For CC Welding Generator
223 522-B
Circuit Diagram For CC/CV Welding Generator
223 523-B
− RUN-IN Procedure
Wetstacking
Welding Generator
Run-In Procedure Using Load Bank
Procedure at less than
Stop engine Do not touch hot exhaust
From flammables Do not Perform
Run-In Procedure Using Resistance Grid
Bank/grid
From flammables
Do not perform run-in
− Generator Power Guidelines
Selecting Equipment
Grounding Generator To Truck Or Trailer Frame
Grounding When Supplying Building Systems
How Much Power Does Equipment Require?
Earth ground if supplying
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 = Starting Amperage
Typical Connections To Supply Standby Power
Selecting Extension Cord Use Shortest Cord Possible
Current Load Watts Amperes
− Parts List
93 −6 105 104 100 101 102 103
Main Assembly
010
Figures 13-2
Figures 13-4
Control Box Assembly − CC Models
087
Control Box Assembly − CC/CV Models
Control Box Assembly − CC/CV Models -1Item
TD1 214
Panel, Front w/Components − CC Models
3634
Panel, Front w/Components − CC Models -1Item
Panel, Front w/Components − CC/CV Models
40 39
Panel, Front w/Components − CC/CV Models -1Item
170
Generator
Generator -1Item
602 SCREW, .312−18x .75 hexwhd.66d stl pld slffmg tap−rw 601
Main Rectifier Assembly
Wiring Harnesses
Harness, receptacle auxiliary power export models includes
PLG4
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