Description
OM-4421215 075N
Processes
File Engine Drive
From Miller to You
Table of Contents
− Maintenance & Troubleshooting
Standards
Directives
Decrot9/06
Manufacturer European Contact Notified Body
Decrotsound6/05
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
LE Surchauffement peut endom- mager le moteur électrique
’AIR Comprimé peut provoquer des blessures
’EMPLOI Excessif peut
LES Étincelles Volantes risquent de provoquer des blessures
Pour les moteurs diesel
LE Soudage À L’ARC risque de provoquer des interférences
Pour les moteurs à essence
Boulevard, Rexdale, Ontario, Canada M9W 1R3 téléphone
− 50 h Std
− Definitions
Std
CC Models CC/CV Models CC Export Models
Manufacturer’s Rating Labels
OM-4421
Symbols And Definitions
Weld, Power, And Engine Specifications
− 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
Curve shows typical fuel use under weld or power loads
Exceeding duty cycle can damage unit and void warranty
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/Airflow Clearance
− Installation
Installing Welding Generator
Grounding1
Using Lifting Eye
Mounting Surface
Mounting Welding Generator
Supporting The Unit
To Bolt Unit In Place
Tools Needed 1/2
Installing Exhaust Pipe
Stop engine and let cool
Do not overfill battery cells
Activating The Dry Charge Battery If Applicable
Connecting The Battery
For 30 Minutes
Full Capacity Engine 9.5 qt 9.01L Diesel
Coolant Recovery Tank
Engine Prestart Checks
Hot Full Cold Full
MIG and Fcaw Welding
Connecting To Weld Output Terminals
Stick and TIG Welding
Stop engine
350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m
Selecting Weld Cable Sizes
150 ft 200 ft 250 ft
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
Engine Starting Controls
To Start Do not use ether. Using ether voids warranty
Do not switch under load
Engine Gauges And Meters
Weld Control/Arc Condition Information Label
Remote Amperage Control On CC Models Optional
Example Combination Remote Amperage Control Stick
OM-4421
− Operating Welding Generator − CC/CV Models
Front Panel Controls For CC/CV Models See Section
Voltage/Amperage Adjust Switch And Remote 14 Receptacle
Use switch to select weld amperage range
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
Rear Of Panel
Single-Phase Generator Power 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 & Troubleshooting
Maintenance Label
Routine Maintenance
Checking Generator Brushes
To clean air filter
Servicing Air Cleaner
By the warranty
Do not clean housing with air hose
Stop engine and let cool. Reinstall cleanout plug
Inspecting And Cleaning Optional Spark Arrestor Muffler
Tools Needed 3/8
Engine Speed No Load
Adjusting Engine Speed
Weld/Power Speed Adjustment
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
Wetstacking
− RUN-IN Procedure
Welding Generator
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
Grounding Generator To Truck Or Trailer Frame
Earth ground if supplying
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 = 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
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Support
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To locate a Distributor or Service Agency visit
Miller Electric Mfg. Co
Your distributor and/or equipment manufacturer’s