Description
OM-4428215 932K
Processes
File Engine Drive
From Miller to You
Table of Contents
Troubleshooting
Electric Shock can kill
Symbol Usage
Arc Welding Hazards
HOT Parts can cause severe burns
ARC Rays can burn eyes and skin
Fumes and Gases can be hazardous
Buildup of GAS can injure or kill
Welding can cause fire or explosion
Engine Hazards
Compressed Air Hazards
Fire or Explosion hazard
Welding Wire can cause injury
HOT Parts can cause burns and injury
Falling Unit can cause injury
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
Indique des instructions spécifiques
LE Soudage peut provoquer un in cendie ou une explosion
DES Pièces Chaudes peuvent provoquer des brûlures graves
LES Fumées ET LES GAZ peuvent être dangereux
LE Bruit peut affecter l’ouïe
’EXPLOSION DE LA Batterie peu
DES Organes Mobiles peuvent pro voquer des blessures
Risque D’INCENDIE OU D’EXPLO- Sion
LA Chaleur DU Moteur peut pro- voquer un incendie
’AIR Comprimé peut provoquer des blessures
LES Fils DE Soudage peuvent provoquer des blessures
LE Surchauffement peut endom- mager le moteur électrique
DES Organes Mobiles peuvent provoquer des blessures
’EMPLOI Excessif peut
Information EMF
Proposition californienne 65 Avertissements
Principales normes de sécurité
En ce qui concerne les implants médicaux
Std
− Definitions
− 50 h Std
Manufacturer’s Rating Labels
CC Models
Symbols And Definitions
Some symbols are found only on CE products
Dimensions, Weights, And Operating Angles
− Specifications
Weld, Power, And Engine Specifications
Lifting Eye Weight Rating
Volt-Ampere Curves For CC Models
Volts
TIG Mode
Stick Mode
MIG Mode
Volt-Ampere Curves For CC/CV Models
Curve shows typical fuel use under weld or power loads
Fuel Consumption
100% Duty Cycle At 500 Amperes
AC Generator Power Curve
Duty Cycle And Overheating
20 kVA/kW Three-Phase AC Output No Weld Load
Optional Three-Phase Generator Curves
12 kVA/kW Single-Phase AC Output No Weld Load
Location/Airflow Clearance
− Installation
Installing Welding Generator
Grounding1
Using Lifting Eye
Mounting Welding Generator
Stop engine and let cool
Installing Exhaust Pipe
After installing cylinder, wait at
Activating The Dry Charge Battery If Applicable
Connecting The Battery
Deutz F3L912 Engine
Engine Prestart Checks
Deutz F4L2011 Engine
Fuel
Stick and TIG Welding
Connecting To Weld Output Terminals
Correct Installation
MIG and Fcaw Welding
45 m 60 m 70 m 90 m 105 m 120 m
Connecting to Weld
Selecting Weld Cable Sizes
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 Gauges And Meters
Engine Starting Controls
To Start
Weld Controls
Example Combination Remote Amperage Control Stick
Remote Amperage Control On CC Models Optional
Weld Control/Arc Condition Information Label
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
At least once a month, run en
− Operating Auxiliary Equipment
Volt And 240 Volt Receptacles
If a Supplementary
Connections
Rear Of Panel
Close
Are made Generator
Supplementary Protector CB2 Supplementary Protector CB3
Optional Generator Power Receptacles Standard Models
240 V 15 a AC South African Receptacle RC1
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
Blow out cleanout hole. If nothing
Spark Arrestor Muffler Cleanout Plug
Covering cleanout hole
Reinstall cleanout plug Tools Needed 3/8
Do not set engine speed higher than specified
Adjusting Engine Speed Deutz F4L2011-Powered Units
Standard Models
Models With Automatic Idle Optional
To replace primary fuel filter
To change oil and filter
To drain water from fuel system
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
See note above before cleaning. Re
Ment is not covered by the warranty
Clean or replace primary element if dirty
Cleanings
Spark Arrestor Muffler Cleanout Plug
Adjusting Engine Speed Deutz F3L912-Powered Units
To change oil and filter
Overload Protection Deutz F3L912-Powered Units
Welding − CC Models
− Troubleshooting
Troubleshooting
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
Welding Generator
− RUN-IN Procedure
Wetstacking
From flammables
Run-In Procedure Using Load Bank
Keep exhaust and pipe away
Just generator A/V control so
Run-In Procedure Using Resistance Grid
Specifications section in this
Manual
Grounding Generator To Truck Or Trailer Frame
− Generator Power Guidelines
Selecting Equipment
Electrically Bond Generator
Use ground device as stated in electrical codes
Grounding When Supplying Building Systems
How Much Power Does Equipment Require?
Amperes x Volts = Watts
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 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
Support
Service
Your distributor also gives
For assistance in filing or settling claims, contact
To locate a Distributor or Service Agency visit
Miller Electric Mfg. Co
Your distributor and/or equipment manufacturer’s