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 Name:; Big Blue; conforms to the following Directives and Standards:; Directives
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 StreetAppleton, WI 54914 USA Declares t...
Page 7 - SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING; Symbol Usage; Arc Welding Hazards; ELECTRIC SHOCK can kill.
OM-496 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 hazardswith this procedure! The possible haza...
Page 8 - Engine Hazards
OM-496 Page 2 Return To Table Of Contents Welding on closed containers, such as tanks, drums, orpipes, can cause them to blow up. Sparks can fly off from thewelding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metalobjects can...
Page 9 - STEAM AND HOT COOLANT can burn.; Compressed Air Hazards; HOT PARTS can cause burns and injury.; Additional Symbols For Installation, Operation, And Maintenance; OVERUSE can cause OVERHEATING.
OM-496 Page 3 Return To Table Of Contents STEAM AND HOT COOLANT can burn. If possible, check coolant level when engine is cold toavoid scalding. Always check coolant level at overflow tank, if pres-ent on unit, instead of radiator (unless told otherwisein maintenance section or engine manual). If th...
Page 10 - California Proposition 65 Warnings; Principal Safety Standards
OM-496 Page 4 Return To Table Of Contents READ INSTRUCTIONS. Use only genuine MILLER/Hobart replacementparts. Perform engine and air compressor (if applicable)maintenance and service according to this manualand the engine/air compressor (if applicable) manu-als. H.F. RADIATION can cause interference...
Page 11 - SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT; Signification des symboles; Dangers relatifs au soudage à l’arc; UN CHOC ÉLECTRIQUE peut tuer.
OM-496 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 procédurep...
Page 12 - LE BRUIT peut affecter l’ouïe.; Dangers existant en relation avec le moteur
OM-496 Page 6 Revenez à la table des matières LES ACCUMULATIONS DE GAZ ris-quent de provoquer des blessures oumême la mort. Fermer l’alimentation du gaz protecteur en cas denon utilisation. Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi-rateur d’adduction d’air homologué....
Page 13 - Dangers liés à l’air comprimé; LIRE LES INSTRUCTIONS.
OM-496 Page 7 Revenez à la table des matières L’EXPLOSION DE LA BATTERIE peutRENDRE AVEUGLE. Toujours porter une protection faciale, des gants encaoutchouc et vêtements de protection lors d’une in-tervention sur la batterie. Arrêter le moteur avant de débrancher ou de brancher les câbles debatterie....
Page 14 - Principales normes de sécurité
OM-496 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 sousrisque d’endommager le moteur électrique à caused’une tension et d...
Page 15 - SECTION 3 − DEFINITIONS; Warning Label Definitions (CE Models Only)
OM-496 Page 9 Return To Table Of Contents SECTION 3 − DEFINITIONS 3-1. Warning Label Definitions (CE Models Only) 3/96 Warning! Watch Out! There arepossible hazards as shown by thesymbols. Become trained and read theinstructions before working on themachine or welding. 1 Electric shock from weldinge...
Page 19 - Manufacturer ’s Rating Labels For CE Products
OM-496 Page 13 Return To Table Of Contents 3/96 1 Remove unit from shippingcrate. Remove Owner’sManual from unit. Followinstructions to install muffler. 2 Read Owner’s Manual. Readlabels on unit. 3 Use Diesel Fuel only, and fillfuel tank. Leave room forexpansion. 4 Warning! Watch Out! Thereare possi...
Page 20 - Symbols And Definitions; Some symbols are found only on CE products.; Hz
OM-496 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 Protecti...
Page 21 - SECTION 4 − SPECIFICATIONS; Dimensions, Weights, And Operating Angles
OM-496 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 A...
Page 22 - Volt-Ampere Curves For CC Models; DC AMPERES
OM-496 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 theminimum and maximum voltageand amperage output capabilities ofthe welding generator. Curves of allother settings fall between thec...
Page 24 - Fuel Consumption; DC WELD AMPERES AT 100% DUTY CYCLE; Duty Cycle And Overheating; WELD
OM-496 Page 18 Return To Table Of Contents 4-5. Fuel Consumption The curve shows typical fuel useunder 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 And ...
Page 25 - AC Generator Power Curve; AC AMPERES IN 240V MODE; Optional Three-Phase Generator Curves; AC AMPERES
OM-496 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 availableat 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 5...
Page 26 - SECTION 5 − INSTALLATION
OM-496 Page 20 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 transportvehicle or trailer and complywith all DOT and other applica-ble codes. Always ground generatorframe to vehicle frame to ...
Page 27 - Using Lifting Eye; Notes; Pros weld and cut
OM-496 Page 21 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 inplace. Lower lifting eye when notneeded. To lock the lifting eye in the uprightposition, insert a 3/8-16 x 1-1/2 incarriage bolt through slot in brack...
Page 28 - Mounting Welding Generator
OM-496 Page 22 Return To Table Of Contents 5-3. Mounting Welding Generator Tools Needed: 9/16 in 2 2 3 4 Welding Unit In Place Bolting Unit In Place Do not weld on base. Weld-ing on base can cause fueltank fire or explosion. Weldonly on the four mountingbrackets or bolt unit down. Do not mount unit ...
Page 29 - Installing Exhaust Pipe
OM-496 Page 23 Return To Table Of Contents 5-4. Installing Exhaust Pipe 1/2 in Tools Needed: Ref. 802 311 / Ref. 201 841 Stop engine and let cool. Point exhaust pipe in desired di-rection but always away from frontpanel and direction of travel. Notes Work like a Pro! Pros weld and cut safely. Read t...
Page 30 - Activating The Dry Charge Battery (If Applicable)
OM-496 Page 24 Return To Table Of Contents 5-5. 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 ...
Page 31 - Connecting The Battery
OM-496 Page 25 Return To Table Of Contents 5-6. Connecting The Battery 1/2 in − + Connect Negative (−) Cable Last. Tools Needed: 802 168-B / Ref. 201 841 / 802 313 / S-0756-C Reinstall cover after connecting battery. Notes
Page 32 - Engine Prestart Checks
OM-496 Page 26 Return To Table Of Contents 5-7. 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...
Page 33 - Connecting To Weld Output Terminals; Selecting Weld Cable Sizes*
OM-496 Page 27 Return To Table Of Contents 5-8. Connecting To Weld Output Terminals 802 311 Tools Needed: 2 3/4 in 1 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), connect...
Page 35 - -11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models; Start Your Professional
OM-496 Page 29 Return To Table Of Contents 5-11. 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. C Output to remote control:...
Page 36 - SECTION 6 − OPERATING WELDING GENERATOR − CC MODELS
OM-496 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) 17 201 841 / 802 311 6 5 4 7 15 16 2 1 3 13 18 19 14 12 10 11 9 8
Page 37 - Description Of Front Panel Controls For CC Models (See Section 6-1)
OM-496 Page 31 Return To Table Of Contents 6-2. Description Of Front Panel Controls For CC Models (See Section 6-1) 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 ist...
Page 38 - Remote Amperage Control On CC Models (Optional); Weld Control/Arc Condition Information Label
OM-496 Page 32 Return To Table Of Contents 6-3. Remote Amperage Control On CC Models (Optional) 1 Remote Amperage AdjustReceptacle RC13 Connect optional remote control toRC13 (see Section 5-10). Example: Combination Remote Amperage Control (Stick) Adjust Optional Remote Control Set Switches Set Rang...
Page 40 - SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS
OM-496 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 On CC/CV Models; Process/Contactor Switch Settings
OM-496 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/Contactorswitch is in an Electrode Hotposition and the engine is run-ning. DC voltage is still present at theweld terminals when Proce...
Page 44 - SECTION 8 − OPERATING AUXILIARY EQUIPMENT
OM-496 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 TwistlockReceptacle RC1 Receptacles supply 60 Hz single-phase power at weld/power speed. If a ground fault is ...
Page 46 - Optional Generator Power Receptacles
OM-496 Page 40 Return To Table Of Contents 8-3. Optional Generator 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...
Page 47 - SECTION 9 − MAINTENANCE & TROUBLESHOOTING; Maintenance Labels
OM-496 Page 41 Return To Table Of Contents SECTION 9 − MAINTENANCE & TROUBLESHOOTING 9-1. Maintenance Labels For Non-CE Products For CE Products Only
Page 48 - Routine Maintenance; Note; Every 8 h
OM-496 Page 42 Return To Table Of Contents 9-2. Routine Maintenance The engine oil/filter and fuel injector maintenance intervals are different for the Perkins404.22 and 3.152 engines (see maintenance schedule following). Note Follow the storage procedure in the engine owner’s manual if the unit wil...
Page 49 - MATERIAL THICKNESS REFERENCE CHART
OM-496 Page 43 Return To Table Of Contents Every 1000 h Blow Out Or Vacuum Inside. During Heavy Service, Clean Monthly. OR Drain Sludge From Fuel Tank. See Section 9-7. FUEL SLUDGE Service Welding Generator Brushes And Slip Rings. Service More Often In Dirty Conditions.* Change Fuel Filters. See Sec...
Page 50 - Servicing Air Cleaner
OM-496 Page 44 Return To Table Of Contents 9-3. Servicing Air Cleaner 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 the dirt holding capac-ity o...
Page 51 - Inspecting And Cleaning Optional Spark Arrestor Muffler
OM-496 Page 45 Return To Table Of Contents 9-4. 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 dirtcovering cleanout hole. 3 Exhaust Pipe Start engine and...
Page 52 - Adjusting Engine Speed On Standard Models
OM-496 Page 46 Return To Table Of Contents 9-5. Adjusting Engine Speed On Standard Models 802 490-D / 802 491 Stop engine and let cool. Engine speed is factory set andshould not require adjustment. Af-ter tuning engine, check enginespeed with tachometer or frequen-cy meter. See table for proper nolo...
Page 54 - Servicing Fuel And Lubrication Systems
OM-496 Page 48 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 engineand check for fuel leaks.Stop engine, tighten connec-tions as necessary, and wipeup spilled fuel. 1 Oil Filter 2 Oil Drain Valve And Ho...
Page 55 - Overload Protection
OM-496 Page 49 Return To Table Of Contents 9-8. Overload Protection 802 170-D / Ref. 802 311 2 1 9 8 7 4 Stop engine. When a circuit breaker or fuseopens, it usually indicates a moreserious problem exists. ContactFactory Authorized ServiceAgent. 1 Fuse F1 2 Fuse F2 F1 and F2 protect the stator excit...
Page 56 - Diagnosing Causes Of Engine Fault Shutdowns
OM-496 Page 50 Return To Table Of Contents 9-9. 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 ...
Page 57 - A. Welding − CC Models
OM-496 Page 51 Return To Table Of Contents 9-10. Troubleshooting A. Welding − CC Models Trouble Remedy No weld output; generator power outputokay at ac receptacles. Check position of Ampere Range switch. Check position of optional Polarity switch. Place Amperage Adjust switch in Panel position, or p...
Page 59 - C. Standard Generator Power
OM-496 Page 53 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. S...
Page 62 - SECTION 10 − ELECTRICAL DIAGRAMS; Figure 10-1. Circuit Diagram For CC Welding Generator
OM-496 Page 56 Return To Table Of Contents SECTION 10 − ELECTRICAL DIAGRAMS Figure 10-1. Circuit Diagram For CC Welding Generator
Page 66 - SECTION 11 − RUN-IN PROCEDURE
OM-496 Page 60 Return To Table Of Contents SECTION 11 − RUN-IN PROCEDURE run_in1 8/01 11-1. Wetstacking Do not perform run-inprocedure at less than 20volts weld output and do notexceed duty cycle or equip-ment damage may occur. 1 Welding Generator Run diesel engines near rated volt-age and current d...
Page 69 - SECTION 12 − GENERATOR POWER GUIDELINES; 2-2. Grounding Generator To Truck Or Trailer Frame
OM-496 Page 63 Return To Table Of Contents SECTION 12 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-drivenwelding generators. Your unit may differ from those shown. NOTE 12-1. Selecting Equipment gen_pwr 11/02 − Ref. ST-159 730 / ST-800 577 1 ...
Page 70 - 2-3. Grounding When Supplying Building Systems
OM-496 Page 64 Return To Table Of Contents 12-3. 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)...
Page 71 - 2-5. Approximate Power Requirements For Industrial Motors
OM-496 Page 65 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 72 - 2-7. Approximate Power Requirements For Contractor Equipment
OM-496 Page 66 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 1...
Page 74 - 2-10. Typical Connections To Supply Standby Power
OM-496 Page 68 Return To Table Of Contents 12-10. Typical Connections To Supply Standby Power Have only qualified persons performthese connections according to allapplicable codes and safety practic-es. Properly install and ground thisequipment according to its Owner’sManual and national, state, and...
Page 76 - SECTION 13 − PARTS LIST
OM-496 Page 70 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) 112 114 115...
Page 81 - Figure 13-2. Control Box Assembly − CC Models
OM-496 Page 75 Return To Table Of Contents Description Part No. Dia. Mkgs. Item No. Figure 13-1. Main Assembly (Continued) Quantity 119 212 944 LABEL, weld control/arc condition information label 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 058 NUT, .250-20 u-nut multi-t...
Page 87 - Description
OM-496 Page 81 Return To Table Of Contents Description Part No. Dia. Mkgs. Item No. Figure 13-4. Panel, Front w/Components − CC Models (Continued) Quantity 43 ♦ 194 345 VOLT METER, W/Leads 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 95 - (Equipment with a serial number preface of “LC” or newer)
Warranty Questions? Call1-800-4-A-MILLERfor your localMiller distributor. miller_warr 8/03 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 96 - 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 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...
