Page 2 - To locate your nearest; Thank you; From Miller to You
Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local Miller distributor to receive the latest fullline catalog or individual specification sheets. To locate your nearest distributor or service agency call...
Page 3 - TABLE OF CONTENTS
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 5 - Declaration of Conformity for; NOTE; Manufacturer; Managing Director; Directives; Arc Welding Equipment
dec_rot_1/07 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). NOTE Manufacturer : European Contact: Miller Electric Mg. Co. Mr. Danilo Fedolfi, 1635 W. Spencer St. Managing Director Appleton, WI 54...
Page 6 - European Contact Signature:; Sound Level Information
dec_rotsound_6/05 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). NOTE Manufacturer : European Contact: Notified Body: Miller Electric Mg. Co. Mr. Danilo Fedolfi, AV Technology Limited 1635 W. Spe...
Page 7 - ELECTRIC SHOCK can kill.; HOT PARTS can cause severe burns.
OM-4421 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2007 − 04 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards...
Page 9 - Using a generator indoors CAN KILL; ENGINE HEAT can cause fire.
OM-4421 Page 3 1-3. Engine Hazards BATTERY EXPLOSION can BLIND. Always wear a face shield, rubber gloves, and protective clothing when working on a battery. Stop engine before disconnecting or connect- ing battery cables or servicing battery. Do not allow tools to cause sparks when working on a batt...
Page 12 - UN CHOC ÉLECTRIQUE peut tuer.
OM-4421 Page 6 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION rom_2007 − 04fre Se protéger, ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud. 2-1. Signification des symboles DANGER! − Indique une situation dangereuse qui si on l’évite pas ...
Page 14 - LE CARBURANT MOTEUR peut provo
OM-4421 Page 8 LES CHAMPS MAGNETIQUES peuv- ent affecter des implants médicaux. Porteur de simulateur cardiaque ou autre im- plants médicaux, rester à distance. Les porteurs d’implants doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de sou- dage par poi...
Page 17 - -6. Proposition californienne 65 Avertissements
OM-4421 Page 11 2-6. Proposition californienne 65 Avertissements Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des mal- formations congénitales et, dans certains cas, des cancers....
Page 18 - Notes; Pros weld and cut
OM-4421 Page 12 SECTION 3 − DEFINITIONS 3-1. Warning Label Definitions (For Wordless Labels) 3/96 1 Remove unit from shipping crate. Remove Owner’s Manual from unit. Follow instructions to install muffler. 2 Read Owner’s Manual. Read labels on unit. 3 Use Diesel Fuel only, and fill fuel tank. Leave ...
Page 20 - Hz
OM-4421 Page 14 3-3. Symbols And Definitions Some symbols are found only on export products. Stop Engine Fast (Run, Weld/ Power) Slow (Idle) Start Engine Starting Aid Battery (Engine) Engine Oil Pressure Engine Oil Check Injectors/ Pump Check Valve Clearance Fuel Protective Earth (Ground) Positive N...
Page 22 - DC AMPERES
OM-4421 Page 16 4-3. Volt-Ampere Curves For CC Models 215 081-A The volt-ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the curves shown. DC AMPERES DC VOL TS 100 80 60 40 20 0 0 100 200 300 400 ...
Page 24 - DC WELD AMPERES AT 100% DUTY CYCLE
OM-4421 Page 18 4-5. Fuel Consumption The curve shows typical fuel use under weld or power loads. 199 032 − A DC WELD AMPERES AT 100% DUTY CYCLE US Gal./Hr . 0 50 100 150 200 250 300 350 400 450 500 0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 2.25 2.50 IDLE Continuous Welding 4-6. Duty Cycle And Ov...
Page 25 - AC AMPERES IN 240V MODE; AC AMPERES
OM-4421 Page 19 4-7. AC Generator Power Curve 193 018 The ac power curve shows the gen- erator power in amperes available at the 120 and 240 volt receptacles. 0 50 100 150 200 250 300 0 5 10 15 20 25 30 AC AMPERES IN 240V MODE AC VOL TS 0 25 50 75 100 150 125 0 10 20 30 40 50 60 AC AMPERES IN 120V M...
Page 32 - -8. Connecting To Weld Output Terminals
OM-4421 Page 26 5-8. Connecting To Weld Output Terminals 803 602 / 803 778-A Tools Needed: 2 3/4 in 1 MIG and FCAW Welding For MIG and FCAW welding Direct Current Electrode Positive (DCEP) on CC/CV models, connect wire feeder cable to Positive (+) termi- nal on left and work cable to Negative ( − ) ...
Page 34 - -11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models; Start Your Professional
OM-4421 Page 28 5-11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models Socket* Socket Information 24 VOLTS AC A 24 volts ac. Protected by sup- plementary protector CB5. 24 VOLTS AC B Contact closure to A completes 24 volt ac contactor control circuit. C Output to remote control:+10 volts dc i...
Page 42 - Process/Contactor Switch Settings
OM-4421 Page 36 7-3. Process/Contactor Switch On CC/CV Models 1 Process/Contactor Switch ! Weld output terminals are ener- gized when Process/Contactor switch is in an Weld Terminals Always On position and the en- gine is running. ! DC voltage is still present at the weld terminals when Process/ Con...
Page 51 - -5. Inspecting And Cleaning Optional Spark Arrestor Muffler
OM-4421 Page 45 9-5. Inspecting And Cleaning Optional Spark Arrestor Muffler 803 656 / Ref. 215 158 ! Stop engine and let cool. 1 Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole.Start engine and run at idle speed to blow out cleanout hole. If nothing blo...
Page 53 - -7. Servicing Fuel And Lubrication Systems
OM-4421 Page 47 9-7. Servicing Fuel And Lubrication Systems 802 490 / Ref. 801 434 ! Stop engine and let cool. ! After servicing, start engine and check for fuel leaks. Stop engine, tighten connec- tions as necessary, and wipe up spilled fuel. 1 Oil Filter 2 Oil Drain Valve And Hose 3 Oil Fill Cap 4...
Page 55 - CC Models
OM-4421 Page 49 9-9. Troubleshooting A. Welding − CC Models Trouble Remedy No weld output; generator power output okay at ac receptacles. Check position of Ampere Range switch. Check position of optional Polarity switch. Place Amperage Adjust switch in Panel position, or place switch in Remote posit...
Page 57 - C. Standard Generator Power
OM-4421 Page 51 Trouble Remedy No remote fine amperage or voltage control. Repair or replace remote control device. Have Factory Authorized Service Agent check PC1 sensing leads (36 and 37), and connections. Constant speed wire feeder does not work. Reset supplementary protector CB5 or CB6 (see Sect...
Page 59 - Welding Symbols
OM-4421 Page 53 Notes Welding Symbols Ref. AWS/ANSI A2.4
Page 60 - ELECTRICAL DIAGRAMS; Figure 10-1. Circuit Diagram For CC Welding Generator
OM-4421 Page 54 SECTION 10 − ELECTRICAL DIAGRAMS Figure 10-1. Circuit Diagram For CC Welding Generator
Page 67 - GENERATOR POWER GUIDELINES; 2-2. Grounding Generator To Truck Or Trailer Frame
OM-4421 Page 61 SECTION 12 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown. 12-1. Selecting Equipment gen_pwr 2007 − 04 − Ref. ST-159 730 / ST-800 577 1 Generator Power Receptacles...
Page 68 - 2-3. Grounding When Supplying Building Systems
OM-4421 Page 62 12-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding Terminal 2 Grounding Cable Use #10 AWG or larger insulated copper wire.3 Ground Device Use ground device as stated inelectrical codes. ! Ground generator to system earth ground if supplying power to a ...
Page 69 - 2-5. Approximate Power Requirements For Industrial Motors
OM-4421 Page 63 12-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 2100 700 1/2 HP 3175 875 Capacitor Start-Induction Run 1/3 HP 2020 720 1/2 HP 3075 975 3/4 HP 4500 1400 1...
Page 70 - 2-7. Approximate Power Requirements For Contractor Equipment
OM-4421 Page 64 12-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/2 in 500 500 7-1/4 in 900 900 8-1/4 in 1400 1400 Table Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 ...
Page 72 - 2-10. Typical Connections To Supply Standby Power
OM-4421 Page 66 12-10. Typical Connections To Supply Standby Power Transfer Switch Essential Loads Fused Disconnect Switch (If Required) Utility Electrical Service 1 2 3 4 5 Welding Generator Output ! Have only qualified persons perform these connections according to all applicable codes and safety ...
Page 74 - PARTS LIST
OM-4421 Page 68 SECTION 13 − PARTS LIST Hardware is common andnot available unless listed. 400 P Models Only 1 2 3 4 5 6 7 8 9 10 11 13 14 15 12 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 106 107 108 109 110 111 112 113 114 (Fig. 13-2 OR 13-3 115 116 (CC ONLY) 117 118 (CV) 119 (CV) 120 121 1...
Page 81 - CC Models Continued
OM-4421 Page 75 Description Part No. Dia. Mkgs. Item No. Figure 13-2. Control Box Assembly − CC Models Continued Quantity 20 201 079 COVER, control box 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 C9 087 110 CAPACI...
Page 92 - Wiring Harnesses
OM-4421 Page 86 Some wiring harness components (switches, relays, circuit breakers) are also referenced elsewhere in this parts list. Purchase components sepa-rately or as part of the associated wiring harnes s. Description Part No. Dia. Mkgs. Item No. Wiring Harnesses Quantity 215054 Harness, contr...
Page 95 - (Equipment with a serial number preface of “LH” or newer)
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007 − 01 Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding ...
Page 96 - Please complete and retain with your personal records.; Contact a DISTRIBUTOR or SERVICE AGENCY near you.; For Service
PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007 − 01 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters − USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 E...
