Description
Processes
File Engine Drive
Visit our website at OM-44292216 138H 2007−05
From Miller to You
Table of Contents
− Maintenance & Troubleshooting
Arc Welding Hazards
Symbol Usage
Electric Shock can kill
HOT Parts can cause severe burns
Buildup of GAS can injure or kill
Fumes and Gases can be hazardous
ARC Rays can burn eyes and skin
Welding can cause fire or explosion
Compressed Air Hazards
Engine Hazards
HOT Parts can cause burns and injury
Welding Wire can cause injury
Fire or Explosion hazard
Falling Unit can cause injury
California Proposition 65 Warnings
Principal Safety Standards
EMF Information
Radiation can cause interference
− Consignes DE Sécurité − Lire Avant Utilisation
Signification des symboles
UN Choc Électrique peut tuer
Indique des instructions spécifiques
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
LE Bruit peut affecter l’ouïe
DES Organes Mobiles peuvent pro voquer des blessures
’EXPLOSION DE LA Batterie peu
’AIR Comprimé peut provoquer des blessures
LA Chaleur DU Moteur peut pro- voquer un incendie
Risque D’INCENDIE OU D’EXPLO- Sion
DES Organes Mobiles peuvent provoquer des blessures
LE Surchauffement peut endom- mager le moteur électrique
LES Fils DE Soudage peuvent provoquer des blessures
’EMPLOI Excessif peut
Principales normes de sécurité
Proposition californienne 65 Avertissements
Information EMF
En ce qui concerne les implants médicaux
− 50 h Std
− Definitions
Std
CC Models
Manufacturer’s Rating Labels
Some symbols are found only on CE products
Symbols And Definitions
Weld, Power, And Engine Specifications
− Specifications
Dimensions, Weights, And Operating Angles
Volts
Volt-Ampere Curves For CC Models
MIG Mode
Stick Mode
TIG Mode
Volt-Ampere Curves For CC/CV Models
Duty Cycle And Overheating
Fuel Consumption
100% Duty Cycle At 400 Amperes
Optional Three-Phase Generator Curves
AC Generator Power Curve
12 kVA/kW Single-Phase AC Output No Weld Load
20 kVA/kW Three-Phase AC Output No Weld Load
Installing Welding Generator
− Installation
Location/Airflow Clearance
Grounding1
Using Lifting Eye
Mounting Welding Generator
Stop engine and let cool
Installing Exhaust Pipe
Connecting The Battery
Activating The Dry Charge Battery If Applicable
Engine Prestart Checks
Coolant Recovery Tank
Fuel
Oil
Stick and TIG Welding
Connecting To Weld Output Terminals
MIG and Fcaw Welding
Stop engine
Selecting Weld Cable Sizes
Connecting to Weld
150 ft 200 ft 250 ft
350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m
Socket
Connecting To Remote 14 Receptacle RC14 On CC/CV Models
OM-4429
Front Panel Controls For CC Models See Section
− Operating Welding Generator − CC Models
To Start
Engine Starting Controls
Engine Gauges And Meters
Weld Controls
Weld Control/Arc Condition Information Label
Remote Amperage Control On CC Models Optional
Example Combination Remote Amperage Control Stick
OM-4429
Front Panel Controls For CC/CV Models See Section
− Operating Welding Generator − CC/CV Models
14 AC/DC Voltmeter Optional
Voltage/Amperage Adjust Switch And Remote 14 Receptacle
Process/Contactor Switch Settings
Process/Contactor Switch On CC/CV Models
Example Combination Remote Amperage Control TIG
Remote Voltage/Amperage Control On CC/CV Models Optional
Volt And 240 Volt Receptacles
− Operating Auxiliary Equipment
At least once a month, run en
If a Supplementary
Rear Of Panel
Three-Phase Power Connection
Close panel opening if no connections are made to generator
240 V 15 a AC South African Receptacle RC1
Optional Generator Power Receptacles
Supplementary Protector CB2 Supplementary Protector CB3
Maintenance Label
− Maintenance & Troubleshooting
Routine Maintenance
To clean air filter
Servicing Air Cleaner
Checking Generator Brushes
Inspecting And Cleaning Optional Spark Arrestor Muffler
To change oil and filter
Servicing Fuel And Lubrication Systems
To replace primary fuel filter
Overload Protection
Welding − CC Models
Troubleshooting
Welding − CC/CV Models
Optional Three-Phase Generator Power CC/CV Models Only
Standard Generator Power
Engine
Gine Control switch S1
Check engine wiring harness plug connections
Factory Authorized Service Agent
Engine cranks but does not start Check fuel level
Start Your Professional Welding Career Now
Circuit Diagram For CC Welding Generator
− Electrical Diagrams
223 525-B
Circuit Diagram For CC/CV Welding Generator
223 524-B
Wetstacking
− RUN-IN Procedure
Welding Generator
Keep exhaust and pipe away
Run-In Procedure Using Load Bank
From flammables
Specifications section in this
Run-In Procedure Using Resistance Grid
Just generator A/V control so
Manual
Selecting Equipment
− Generator Power Guidelines
Grounding Generator To Truck Or Trailer Frame
Electrically Bond Generator
How Much Power Does Equipment Require?
Grounding When Supplying Building Systems
Use ground device as stated in electrical codes
Amperes x Volts = Watts
Approximate Power Requirements For Farm/Home Equipment
Approximate Power Requirements For Industrial Motors
Industrial Motors Rating Starting Watts Running Watts
Farm/Home Equipment Rating Starting Watts Running Watts
Contractor Rating Starting Watts Running Watts
Approximate Power Requirements For Contractor Equipment
How Much Power Can Generator Supply?
Power Required To Start Motor
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
114 −7 115 CV
− Parts List
123 116 CV 112
2831 124 88 −6 6059 58
Dia Part Description Quantity
Dia Part Description Quantity Mkgs
111
Figures 13-2
123 212
Control Box Assembly − CC Models
Engine Controller
Control Box Assembly − CC Models -1Item
Control Box Assembly − CC/CV Models
134
3634
Panel, Front w/Components − CC Models
208278
Panel, Front w/Components − CC/CV Models -1Item
Panel, Front w/Components − CC/CV Models
CB1 201 Supplementary PROTECTOR, man reset 2P 20 A, 250VAC
32 31 30
Hardware is common
053 BEARING, Ball Rdl Sgl Row 1.370 X 2.830 X
Main Rectifier Assembly
Wiring Harnesses
215207
Your distributor also gives
Service
Support
Miller Electric Mfg. Co
To locate a Distributor or Service Agency visit
For assistance in filing or settling claims, contact
Your distributor and/or equipment manufacturer’s