Page 2 - 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 catalog sheets. To locate your nearestdistributor or service agency call 1-800-...
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’s Address:; CAT; conforms to the following Directives and Standards:; Directives; Rotating Electrical Machines
dec_con1_11/02 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). NOTE Manufacturer’s Name: Miller Electric Mfg. Co. Manufacturer’s Address: 1635 W. Spencer Street Appleton, WI 54914 USA Declares tha...
Page 7 - SECTION 1; ELECTRIC SHOCK can kill.; FUMES AND GASES can be hazardous.
OM-4406 Page 1 Return To Table Of Contents SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom _nd_8/03 Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible ha...
Page 11 - SECTION 2; Avertissement: Protégez vous et les autres des blessures; UN CHOC ÉLECTRIQUE peut tuer.
OM-4406 Page 5 Revenez à la table des matières SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION rom_fre 8/03 Avertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions. 2-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure...
Page 12 - LES CHAMPS MAGNÉTIQUES peuvent
OM-4406 Page 6 Revenez à la table des matières LES ACCUMULATIONS DE GAZ ris- quent de provoquer des blessures ou même la mort. Fermer l’alimentation du gaz protecteur en cas de non utilisation. Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi- rateur d’adduction d’air homol...
Page 13 - maintenance
OM-4406 Page 7 Revenez à la table des matières L’EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE. Toujours porter une protection faciale, des gants en caoutchouc et vêtements de protection lors d’une in- tervention sur la batterie. Arrêter le moteur avant de débrancher ou de brancher les câbles de batt...
Page 14 - UNE REMORQUE QUI BASCULE peut; -7. Information sur les champs électromagnétiques
OM-4406 Page 8 Revenez à la table des matières LE SURCHAUFFEMENT peut endom- mager le moteur électrique. Arrêter ou déconnecter l’équipement avant de dé- marrer ou d’arrêter le moteur. Ne pas laisser tourner le moteur trop lentement sous risque d’endommager le moteur électrique à cause d’une tension...
Page 15 - SECTION 3
OM-4406 Page 9 Return To Table Of Contents SECTION 3 − DEFINITIONS 3-1. Warning Label Definitions 3/96 Warning! Watch Out! There are possible hazards as shown by the symbols. Become trained and read the instructions before working on the machine or welding.1 Electric shock from welding electrode or ...
Page 19 - -2. Manufacturer ’s Rating Labels For CE Products
OM-4406 Page 13 Return To Table Of Contents 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 room for expansion. 4 Warning! Watch Out! There a...
Page 20 - Some symbols are found only on CE products.; Hz
OM-4406 Page 14 Return To Table Of Contents 3-3. Symbols And Definitions Some symbols are found only on CE products. NOTE 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 Protect...
Page 21 - SECTION 4
OM-4406 Page 15 Return To Table Of Contents SECTION 4 − SPECIFICATIONS 4-1. Weld, Power, And Engine Specifications Welding Mode Weld Output Range Rated Welding Output Maximum Open- Circuit Voltage Generator Power Rating Engine Fuel Capacity CC/DC 45 − 500 A (CC Models) 15 − 500 A (CC/CV Models) 300 ...
Page 22 - DC AMPERES; Notes
OM-4406 Page 16 Return To Table Of Contents 0 20 40 60 80 100 0 100 200 300 400 500 600 700 4-3. Volt-Ampere Curves For CC Models 202 666-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...
Page 24 - DC WELD AMPERES AT 100% DUTY CYCLE; WELD
OM-4406 Page 18 Return To Table Of Contents 4-5. Fuel Consumption The curve shows typical fuel use under weld or power loads. 199 032 0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 0 50 100 150 200 250 300 350 400 DC WELD AMPERES AT 100% DUTY CYCLE US Gal./Hr . IDLE Continuous Welding 4-6. Duty Cycle ...
Page 25 - AC AMPERES IN 240V MODE; AC AMPERES
OM-4406 Page 19 Return To Table Of Contents 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 4...
Page 26 - Ranges
OM-4406 Page 20 Return To Table Of Contents 4-9. Volt-Ampere Curve For CC/CV Models In AC TIG Mode 207 045 AC output is only available onunits equipped with optional Polarity/AC switch. The volt-ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding genera...
Page 27 - SECTION 5
OM-4406 Page 21 Return To Table Of Contents SECTION 5 − INSTALLATION install3 6/03 − Ref. 800 652 / Ref. 800 477-A / 803 274 Always securely fasten weld- ing generator onto transport vehicle or trailer and comply with all DOT and other applica- ble codes. Always ground generator frame to vehicle fra...
Page 28 - Pros weld and cut
OM-4406 Page 22 Return To Table Of Contents 5-2. Using Lifting Eye Ref. 802 311 1 Lifting Eye 2 Nut 3 Carriage Bolt Raise lifting eye until it snaps in place. Lower lifting eye when not needed.To lock the lifting eye in the upright position, insert a 3/8-16 x 1-1/2 in carriage bolt through slot in b...
Page 34 - -8. Connecting To Weld Output Terminals
OM-4406 Page 28 Return To Table Of Contents 5-8. Connecting To Weld Output Terminals 802 311 Tools Needed: 3/4 in 1 2 Stop engine. 1 Positive (+) Weld Output Terminal 2 Negative ( − ) Weld Output Terminal Stick and TIG Welding For Stick and TIG welding Direct Current Elec- trode Positive (DCEP), con...
Page 35 - -11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models
OM-4406 Page 29 Return To Table Of Contents 5-10. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models Ref. 154 862-A / 048 720-K / 802 311 1 Remote Amperage Adjust Receptacle RC13 Connect optional remote control to RC13 (see Section 6-3). 1 5-11. Connecting To Remote 14 Receptacle RC14...
Page 36 - SECTION 6
OM-4406 Page 30 Return To Table Of Contents SECTION 6 − OPERATING WELDING GENERATOR − CC MODELS 6-1. Front Panel Controls For CC Models (See Section 6-2) 201 841 / 802 311 6 5 4 7 15 16 2 1 3 13 18 19 14 12 10 11 9 8
Page 40 - SECTION 7
OM-4406 Page 34 Return To Table Of Contents SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS 7-1. Front Panel Controls For CC/CV Models (See Section 7-2) 201 579 / 802 311-D 6 5 4 7 2 1 3 14 19 20 15 12 10 11 9 8 16 13 18 OR 17
Page 42 - Process/Contactor Switch Settings
OM-4406 Page 36 Return To Table Of Contents 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 Electrode Hot posi- tion and the engine is running. DC voltage is still present at the weld terminals when...
Page 44 - SECTION 8
OM-4406 Page 38 Return To Table Of Contents SECTION 8 − OPERATING AUXILIARY EQUIPMENT 8-1. 120 Volt And 240 Volt Receptacles 191 624-A 2 1 120 V 20 A AC GFCI Receptacle GFCI1 2 240 V 30 A AC Twistlock Receptacle RC1 Receptacles supply 60 Hz single- phase power at weld/power speed.If a ground fault i...
Page 47 - SECTION 9
OM-4406 Page 41 Return To Table Of Contents SECTION 9 − MAINTENANCE & TROUBLESHOOTING 9-1. Maintenance Label
Page 48 - Note; Every 8 h
OM-4406 Page 42 Return To Table Of Contents 9-2. Routine Maintenance Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period. Note Recycle engine fluids. Stop engine before maintaining. See Engine Manual and MaintenanceLabel for important start-u...
Page 51 - -5. Inspecting And Cleaning Optional Spark Arrestor Muffler
OM-4406 Page 45 Return To Table Of Contents 9-5. Inspecting And Cleaning Optional Spark Arrestor Muffler Ref. 802 311 / Ref. 802 160 / Ref. 201 841 Stop engine and let cool. 1 Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole.3 Exhaust Pipe Start engine an...
Page 53 - -7. Servicing Fuel And Lubrication Systems
OM-4406 Page 47 Return To Table Of Contents 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 A...
Page 55 - -9. Diagnosing Causes Of Engine Fault Shutdowns
OM-4406 Page 49 Return To Table Of Contents 9-9. Diagnosing Causes Of Engine Fault Shutdowns Ref. 201 841 Use the front panel engine lights to help determine the cause of an au- tomatic engine shutdown. Correct the cause of the shut-down before operating the welding generator. This unit does not hav...
Page 58 - C. Standard Generator Power
OM-4406 Page 52 Return To Table Of Contents Trouble Remedy Min or max CV weld output only. Check position of Voltage/Amperage Adjust control and Voltage/Amperage Adjust switch. Repair or replace remote control device. Have Factory Authorized Service Agent check field current regulator board PC1. C. ...
Page 60 - ELECTRICAL DIAGRAMS; Figure 10-1. Circuit Diagram For CC Welding Generator
OM-4406 Page 54 Return To Table Of Contents SECTION 10 − ELECTRICAL DIAGRAMS Figure 10-1. Circuit Diagram For CC Welding Generator
Page 67 - GENERATOR POWER GUIDELINES; welding generators. Your unit may differ from those shown.; 2-2. Grounding Generator To Truck Or Trailer Frame
OM-4406 Page 61 Return To Table Of Contents 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. NOTE 12-1. Selecting Equipment gen_pwr 11/02 − Ref. ST-159 730 / ST-800 577 ...
Page 68 - 2-3. Grounding When Supplying Building Systems
OM-4406 Page 62 Return To Table Of Contents 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 Ground generator to system earth ground if supplying power to a premises (home, shop, ...
Page 69 - 2-5. Approximate Power Requirements For Industrial Motors
OM-4406 Page 63 Return To Table Of Contents 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...
Page 70 - 2-7. Approximate Power Requirements For Contractor Equipment
OM-4406 Page 64 Return To Table Of Contents 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 ...
Page 72 - 2-10. Typical Connections To Supply Standby Power
OM-4406 Page 66 Return To Table Of Contents 12-10. Typical Connections To Supply Standby Power Have only qualified persons perform these connections according to all applicable codes and safety practic- es. Properly install and ground this equipment according to its Owner’s Manual and national, stat...
Page 74 - PARTS LIST
OM-4406 Page 68 Return To Table Of Contents SECTION 13 − PARTS LIST Hardware is common andnot available unless listed. 17 18 19 15 16 26 25 24 22 23 1 2 3 4 5 6 7 10 11 12 13 14 20 21 103 102 101 100 104 99 98 107 (CC ONLY) 108 106 (FIG 13-2 OR 13-3) 105 12 109 110 111 (FIG. 13-4 OR 13-5) 112 114 11...
Page 84 - Description
OM-4406 Page 78 Return To Table Of Contents Hardware is common andnot available unless listed. 802 332-F 1 2 3 4 5 6 7 9 48 50 51 52 53 59 60 61 62 13 18 19 20 21 22 23 24 25 26 27 30 28 29 15 16 34 33 32 17 35 42 43 41 40 39 38 37 36 44 47 14 10 49 11 8 31 45 46 12 54 55 56 57 58 63 Figure 13-5. Pa...
Page 91 - (Equipment with a serial number preface of “LC” or newer)
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 8/03 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 quest...
Page 92 - Please complete and retain with your personal records.; For Service
PRINTED IN USA 2004 Miller Electric Mfg. Co. 1/04 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 Europe...
