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 distributorto receive the latest full line catalog orindividual catalog sheets. To locate your nearestdistributor or service agency call 1-800-4...
Page 3 - TABLE OF CONTENTS; WARNING
TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards 1 ...
Page 5 - SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING; Symbol Usage; Arc Welding Hazards; ELECTRIC SHOCK can kill.; FUMES AND GASES can be hazardous.
OM-4405 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING rom _nd_11/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoining symbols. Marks a special safety message. Means “Note”; not safety related. This gr...
Page 6 - BUILDUP OF GAS can injure or kill.; CYLINDERS can explode if damaged.; Engine Hazards; FUEL can cause fire or explosion.; STEAM AND HOT COOLANT can burn.
OM-4405 Page 2 Welding on closed containers, such as tanks,drums, or pipes, can cause them to blow up. Sparkscan fly off from the welding arc. The flying sparks, hotworkpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can causesparks, explosion, ov...
Page 7 - Additional Symbols For Installation, Operation, And Maintenance; OVERUSE can cause OVERHEATING.
OM-4405 Page 3 MOVING PARTS can cause injury. Keep away from fans, belts, and rotors. Keep all doors, panels, covers, and guardsclosed and securely in place. Stop engine before installing or connecting unit. Have only qualified people remove guards or covers for maint-enance and troubleshooting as n...
Page 8 - Principal Safety Standards
OM-4405 Page 4 H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommunications equipment. Have only qualified persons familiar withelectronic equipment perform this installation. The user is responsible for having a quali...
Page 9 - Signification des symboles; Dangers relatifs au soudage à l’arc; UN CHOC ÉLECTRIQUE peut tuer.
OM-4405 Page 5 SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION rom _nd_fre 11/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédureprésente des risques de danger ! Ceux-ci sont identifiéspar des symboles adjacents aux directives. Identifie un message...
Page 10 - LE BRUIT peut affecter l’ouïe.; Dangers existant en relation avec le moteur
OM-4405 Page 6 Le soudage effectué sur des conteneurs fermés tels quedes réservoirs, tambours ou des conduites peut provoquerleur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et deséquipements chauds peut provoquer des incendie...
Page 11 - LIRE LES INSTRUCTIONS.
OM-4405 Page 7 DES ORGANES MOBILES peuventprovoquer des blessures. Ne pas approcher les mains des ventilateurs, cour-roies et autres pièces en mouvement. Maintenir fermés et fixement en place les portes,panneaux, recouvrements et dispositifs deprotection. Arrêter le moteur avant d’installer ou branc...
Page 13 - SECTION 2 – DEFINITIONS; Symbols And Definitions; Hz; SECTION 3 – SPECIFICATIONS; Wis
OM-4405 Page 9 SECTION 2 – DEFINITIONS 2-1. Symbols And Definitions Stop Engine Fast (Run, Weld/ Power) Slow (Idle) Start Engine Air Temperature Or Engine Temperature Battery (Engine) Engine Oil Pressure Engine Oil Engine Check Valve Clearance Fuel Protective Earth (Ground) Positive Negative Certifi...
Page 14 - Dimensions, Weights, And Operating Angles; Volt-Ampere Curves For CC Models; DC AMPERES
OM-4405 Page 10 3-2. Dimensions, Weights, And Operating Angles Dimensions Height 58 in (1473 mm) (to top of muffler) G Width 28-1/2 in (724 mm) (mtg. brackets turned in) 30-3/4 in (781 mm) (mtg. brackets turned out) Do not exceed tilt angles or engine couldbe damaged or unit could tip. Do not move o...
Page 16 - Fuel Consumption; D C W E L D A M P E R E S AT 1 0 0 % D U T Y C Y C L E; Duty Cycle And Overheating; WELD
OM-4405 Page 12 3-5. Fuel Consumption The curve shows typical fuel useunder weld or power loads. 201 033 0. 00 0. 25 0. 50 0. 75 1. 00 1. 25 1. 50 1. 75 2. 00 2. 25 2. 50 0 50 100 150 200 250 300 350 400 D C W E L D A M P E R E S AT 1 0 0 % D U T Y C Y C L E U .S. Ga l./H r. IDLE Continuous Welding ...
Page 17 - AC Auxiliary Power Curve; AC AMPERES IN 240V MODE; Optional AC Power Plant Curves; AC AMPERES
OM-4405 Page 13 3-7. AC Auxiliary Power Curve 193 018 The ac power curve shows the aux-iliary power in amperes available atthe 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 MOD...
Page 18 - SECTION 4 – INSTALLATION; Using Lifting Eye
OM-4405 Page 14 SECTION 4 – INSTALLATION 4-1. Installing Welding Generator (See Sections 4-2 And 4-3) install2 1/01 – Ref. 800 652 / Ref. 800 477-A / 158 936-A / 0854 1 2 Electrically bond generator frame tovehicle frame by metal-to-metalcontact. GND/PE 3 4 Always securely fastenwelding generator on...
Page 19 - Mounting Welding Generator; Installing Exhaust Pipe
OM-4405 Page 15 4-3. Mounting Welding Generator Ref. 190 250-A / Ref. 802 730 Do not weld on base. Weld-ing on base can cause fueltank fire or explosion. Weldonly on the four mountingbrackets or bolt unit down. 1 Mounting Bracket 2 1/2 in Bolt And Washer (NotSupplied) 3 3/8-16 x 1 in Screws(Supplied...
Page 20 - Activating The Dry Charge Battery (If Applicable)
OM-4405 Page 16 4-5. Activating The Dry Charge Battery (If Applicable) Remove battery from unit. 1 Eye Protection – SafetyGlasses Or Face Shield 2 Rubber Gloves 3 Vent Caps 4 Sulfuric Acid Electrolyte(1.265 Specific Gravity) 5 Well Fill each cell with electrolyte tobottom of well (maximum). Do not o...
Page 21 - Connecting The Battery; Notes
OM-4405 Page 17 4-6. Connecting The Battery 1/2 in – + Connect Negative (–) Cable Last. Tools Needed: 802 168-B / Ref. 201 841 / 802 313 / S-0756-C Notes
Page 22 - Engine Prestart Checks
OM-4405 Page 18 4-7. Engine Prestart Checks Check all engine fluids daily. Engine must be cold and on a level surface.Unit is shipped with 20W break-in oil. Automatic shutdown system stops engine ifoil pressure is too low, or coolant tempera-ture is too high. This unit has a low oil pressure shut-do...
Page 25 - -11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models
OM-4405 Page 21 4-11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models Socket* Socket Information 24 VOLTS AC A 24 volts ac. Protected by circuitbreaker CB5. 24 VOLTS AC B Contact closure to A completes24 volt ac contactor controlcircuit. New! LDR-14 long distance remote (includes 120 V recep...
Page 26 - SECTION 5 – OPERATING WELDING GENERATOR – CC MODELS
OM-4405 Page 22 SECTION 5 – OPERATING WELDING GENERATOR – CC MODELS 5-1. Front Panel Controls For CC Models (See Section 5-2) 17 201 841 / 802 729 15 16 2 1 3 13 18 19 14 12 10 11 9 8 6 5 4 7
Page 27 - Description Of Front Panel Controls For CC Models (See Section 5-1)
OM-4405 Page 23 5-2. Description Of Front Panel Controls For CC Models (See Section 5-1) Engine Starting Controls 1 Magnetic Shutdown Switch Use switch during start-up to bypass engineshutdown system. System stops engine if oilpressure is too low or coolant temperature istoo high. 2 Starting Aid (En...
Page 28 - Remote Amperage Control On CC Models (Optional)
OM-4405 Page 24 5-3. Remote Amperage Control On CC Models (Optional) 1 Remote Amperage AdjustReceptacle RC13 Connect optional remote control toRC13 (see Section 4-10). Example: Combination Remote Amperage Control (Stick) In Example: Range = 100 to 205 A DC Percentage Of Range = 50% Max = About 153 A...
Page 30 - SECTION 6 – OPERATING WELDING GENERATOR – CC/CV MODELS
OM-4405 Page 26 SECTION 6 – OPERATING WELDING GENERATOR – CC/CV MODELS 6-1. Front Panel Controls For CC/CV Models (See Section 6-2) 201 579 / 802 729 6 5 4 7 13 16 2 1 3 14 18 19 15 12 10 11 9 8 17
Page 32 - Process/Contactor Switch On CC/CV Models; Process/Contactor Switch Settings
OM-4405 Page 28 6-3. Process/Contactor Switch On CC/CV Models 1 1 Process/Contactor Switch Weld output terminals are en-ergized when Process/Con-tactor switch is in an ElectrodeHot position and the engine isrunning. Use switch to select weld processand weld output on/off control (seetable below and ...
Page 34 - SECTION 7 – OPERATING AUXILIARY EQUIPMENT
OM-4405 Page 30 SECTION 7 – OPERATING AUXILIARY EQUIPMENT 7-1. 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 TwistlockReceptacle RC1 Receptacles supply 60 Hz single-phase power at weld/power speed. If a ground fault is detected, GFCIReset button ...
Page 35 - Connecting To Optional Auxiliary Power Plant (CC/CV Models Only)
OM-4405 Page 31 7-2. Connecting To Optional Auxiliary Power Plant (CC/CV Models Only) Ref. 197 399 / 802 332-E Place Process/Contactor switchin Electrode Hot - Stick positionwhen using auxiliary power plant(see Section 6-3). Single-Phase Auxiliary Power 1 120/240 V 50 A ReceptacleRC5 RC5 is connecte...
Page 36 - Optional Auxiliary Power Receptacles
OM-4405 Page 32 7-3. Optional Auxiliary Power Receptacles 2 1 120 V 20 A AC GFCI Receptacle GFCI1 2 240 V 16 A AC EuropeanReceptacle RC1 3 240 V 15 A AC AustralianReceptacle RC1 4 240 V 15 A AC South AfricanReceptacle RC1 Receptacles supply 60 Hz single-phase power at weld/power speed. If a ground f...
Page 37 - SECTION 8 – MAINTENANCE & TROUBLESHOOTING; Maintenance Label
OM-4405 Page 33 SECTION 8 – MAINTENANCE & TROUBLESHOOTING 8-1. Maintenance Label
Page 38 - Routine Maintenance; Note
OM-4405 Page 34 8-2. Routine Maintenance Follow the storage procedure in the engine owner’s manual if the unit will not be used for anextended period. Note Recycle engine fluids. Stop engine before maintaining. See also Engine Manual and Mainte-nance Label. Service unit more often ifused in severe c...
Page 39 - Inspecting And Cleaning Optional Spark Arrestor Muffler
OM-4405 Page 35 500 h Repair Or Replace Damaged Cables. Check Valve Clearance.* 1000 h Blow Out Or Vacuum Inside. During Heavy Service, Clean Monthly. OR Drain Sludge From Fuel Tank. See Section 8-8. FUEL SLUDGE Service Welding Generator Brushes And Slip Rings. Service More Often In Dirty Conditions...
Page 40 - Servicing Air Cleaner
OM-4405 Page 36 8-4. Servicing Air Cleaner aircleaner1 9/00 – 153 929-B / 153 585 / Ref. S-0698-B Stop engine. Do not run engine without aircleaner or with dirty element. En-gine damage caused by using adamaged element is not coveredby the warranty. The air cleaner primary element canbe cleaned but ...
Page 41 - Adjusting Engine Weld/Power Speed
OM-4405 Page 37 8-5. Adjusting Engine Weld/Power Speed 802 731 / 802 780 / Ref. 801 179 / Ref. 800 161 Stop engine and let cool. Governor sensitivity may re-quire adjustment if enginespeed is adjusted (see Section8-7). Engine speed is factory set andshould not require adjustment. Af-ter tuning engin...
Page 42 - Adjusting Engine Idle Speed
OM-4405 Page 38 8-6. Adjusting Engine Idle Speed 802 731 / Ref. 115 155-A Stop engine and let cool. Engine idle speed is factory set andnormally should not require adjust-ment. After tuning engine, checkengine speed with tachometer orfrequency meter. See table forproper no load speed. If necessary,a...
Page 43 - Adjusting Governor Sensitivity
OM-4405 Page 39 8-7. Adjusting Governor Sensitivity 802 780 / Ref. 115 155-A Governor sensitivity may re-quire readjustment if weldspeed is adjusted. Weld speedmust be readjusted if sensitivityis adjusted. Be sure carburetor and link-ages are adjusted properly be-fore adjusting sensitivity. Start en...
Page 44 - Servicing Fuel And Lubrication Systems
OM-4405 Page 40 3 1 8-8. Servicing Fuel And Lubrication Systems 802 731 / Ref. 801 434 Stop engine and let cool. After servicing, start engine andcheck for fuel leaks. Stop engine,tighten connections as necessary,and wipe up spilled fuel. 1 Oil Filter 2 Oil Drain Valve And Hose 3 Oil Fill Cap/Dipsti...
Page 45 - Overload Protection
OM-4405 Page 41 8-9. Overload Protection Stop engine. When a circuit breaker or fuseopens, it usually indicates amore serious problem exists.Contact Factory AuthorizedService Agent. 1 Fuse F1 2 Fuse F2 F1 and F2 protect the stator exciterwinding from overload. If F1 opens,weld and auxiliary power is...
Page 46 - -10. Diagnosing Causes Of Engine Fault Shutdowns
OM-4405 Page 42 8-10. Diagnosing Causes Of Engine Fault Shutdowns Ref. 201 841 Use the front panel engine lights tohelp determine the cause of an au-tomatic engine shutdown. Correct the cause of the shut-down before operating thewelding generator. This unit does not have a bat-tery charging fault sh...
Page 47 - A. Welding – CC Models
OM-4405 Page 43 8-11. Troubleshooting A. Welding – CC Models Trouble Remedy No weld output; auxiliary power outputokay. Check position of Ampere Range switch. Check position of optional polarity switch. Place Amperage Adjust switch in Panel position, or place switch in Remote position and connect re...
Page 52 - SECTION 9 – ELECTRICAL DIAGRAMS; Figure 9-1. Circuit Diagram For CC Welding Generator
OM-4405 Page 48 SECTION 9 – ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For CC Welding Generator
Page 56 - SECTION 10 – AUXILIARY POWER GUIDELINES; 0-2. Grounding Generator To Truck Or Trailer Frame; OR
OM-4405 Page 52 SECTION 10 – AUXILIARY POWER GUIDELINES 10-1. Selecting Equipment aux_pwr 2/99 – Ref. ST-159 730 / ST-800 577 1 Auxiliary Power Receptacles– Neutral Bonded To Frame 2 3-Prong Plug From CaseGrounded Equipment 3 2-Prong Plug From DoubleInsulated Equipment OR 2 Be sure equipmenthas this...
Page 57 - 0-3. Grounding When Supplying Building Systems
OM-4405 Page 53 10-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment GroundingTerminal 2 Grounding Cable Use #10 AWG or larger insulatedcopper wire. 3 Ground Device Ground generator to systemearth ground if supplyingpower to a premises (home,shop, farm) wiring system. GND/PE 1 2 ...
Page 58 - 0-5. Approximate Power Requirements For Industrial Motors
OM-4405 Page 54 10-5. 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 59 - 0-7. Approximate Power Requirements For Contractor Equipment
OM-4405 Page 55 10-7. 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 61 - 0-10. Typical Connections To Supply Standby Power
OM-4405 Page 57 10-10. Typical Connections To Supply Standby Power S-0405-A 1 Power Company ServiceMeter 2 Main and Branch OvercurrentProtection 3 Double-Pole, Double-ThrowTransfer Switch Obtain and install correct switch.Switch rating must be same as orgreater than the branch overcurrentprotection....
Page 64 - SECTION 11 – PARTS LIST
OM-4405 Page 60 SECTION 11 – PARTS LIST Hardware is common andnot available unless listed. 1 2 3 4 5 6 7 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 92 93 94 95 96 (CC ONLY) 97 98 (FIG. 11–2 OR 11–3) 99 12 102 103 104 (FIG. 11–4 OR 11–5) 105 101 100 (Fig. 11–7) 106 107 46 9 8 Figure 11-1. Main A...
Page 68 - Figure 11-2. Control Box Assembly – CC Models
OM-4405 Page 64 Description Part No. Dia. Mkgs. Item No. Figure 11-1. Main Assembly (Continued) Quantity 99 189 731 FIREWALL, lower 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Figure 11-7 MAIN RECTIFIER ASSEM...
Page 79 - (Equipment with a serial number preface of “LA” or newer)
Warranty Questions? Call1-800-4-A-MILLERfor your localMiller distributor. miller_warr 7/00 Your distributor also givesyou ... ServiceYou always get the fast,reliable response youneed. Most replacementparts can be in yourhands in 24 hours. SupportNeed fast answers to thetough welding questions?Contac...
Page 80 - Please complete and retain with your personal records.; For Service
PRINTED IN USA 2001 Miller Electric Mfg. Co. 1/01 Miller Electric Mfg. Co. An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 USA International Headquarters–USAUSA Phone: 920-735-4505 Auto-AttendedUSA & Canada FAX: 920-735-4134International FAX: 920-735-4125 European Head...
