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 - SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING; Symbol Usage; Arc Welding Hazards; ELECTRIC SHOCK can kill.
OM-491 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 6 - Engine Hazards
OM-491 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 7 - 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-491 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 8 - California Proposition 65 Warnings; Principal Safety Standards
OM-491 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 9 - SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT; Signification des symboles; Dangers relatifs au soudage à l’arc; UN CHOC ÉLECTRIQUE peut tuer.
OM-491 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 10 - LE BRUIT peut affecter l’ouïe.; Dangers existant en relation avec le moteur
OM-491 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 11 - Dangers liés à l’air comprimé; LIRE LES INSTRUCTIONS.
OM-491 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 12 - Principales normes de sécurité
OM-491 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 13 - SECTION 3 − DEFINITIONS; Symbols And Definitions; SECTION 4 − SPECIFICATIONS
OM-491 Page 9 Return To Table Of Contents SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions 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...
Page 14 - Dimensions, Weights, And Operating Angles
OM-491 Page 10 Return To Table Of Contents 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 55 − 600 A (CC Models) 20 − 600 A (CC/CV Models) 400 A, 40 Volts DC, 100% Duty Cy...
Page 15 - Volt-Ampere Curves For CC Models; DC AMPERES
OM-491 Page 11 Return To Table Of Contents 4-3. Volt-Ampere Curves For CC Models 203 412 The volt-ampere curve shows theminimum and maximum voltageand amperage output capabilities ofthe welding generator. Curves of allother settings fall between thecurves shown. 0 20 40 60 80 100 0 100 200 300 400 5...
Page 17 - Fuel Consumption; DC WELD AMPERES AT 100% DUTY CYCLE; Duty Cycle And Overheating
OM-491 Page 13 Return To Table Of Contents 4-5. Fuel Consumption The curve shows typical fuel useunder weld or power loads. 193 093 0 50 100 150 200 250 300 350 400 450 500 DC WELD AMPERES AT 100% DUTY CYCLE 1800 RPM 0 IDLE Continuous Welding 4-6. Duty Cycle And Overheating Duty Cycle is percentage ...
Page 18 - AC Generator Power Curve; AC AMPERES IN 240V MODE; Optional Three-Phase Generator Curves; AC AMPERES
OM-491 Page 14 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 19 - SECTION 5 − INSTALLATION; Installing Welding Generator
OM-491 Page 15 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 20 - Mounting Welding Generator
OM-491 Page 16 Return To Table Of Contents 5-2. 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 21 - Using Lifting Eye; Installing Exhaust Pipe
OM-491 Page 17 Return To Table Of Contents 5-3. Using Lifting Eye Ref. 802 169-F 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 bra...
Page 22 - Activating The Dry Charge Battery (If Applicable)
OM-491 Page 18 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 23 - Connecting The Battery; Notes
OM-491 Page 19 Return To Table Of Contents 5-6. Connecting The Battery 1/2 in − + Connect Negative (−) Cable Last. Tools Needed: 802 168-E / Ref. 202 705 / 802 313 / S-0756-C Reinstall cover after connecting battery. Notes
Page 24 - Engine Prestart Checks
OM-491 Page 20 Return To Table Of Contents Ref. 802 168-E 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. The Automatic shutdown system stops en-gine if fuel level or oil pressure is too low, orcoolant tempe...
Page 25 - Connecting To Weld Output Terminals
OM-491 Page 21 Return To Table Of Contents 5-8. Connecting To Weld Output Terminals Ref. 802 169-E Stop engine. 1 Positive (+) Weld Output Terminal 2 Negative (−) Weld Output Terminal For Stick and TIG welding Direct Cur-rent Electrode Positive (DCEP), con-nect electrode holder cable to Positive(+) ...
Page 26 - -11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models
OM-491 Page 22 Return To Table Of Contents 5-10. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models Ref. 154 862-A / 048 720-K / 802 160-E 1 Remote Amperage AdjustReceptacle RC13 Connect optional remote control toRC13 (see Section 6-3). 1 5-11. Connecting To Remote 14 Receptacle RC14 ...
Page 27 - SECTION 6 − OPERATING WELDING GENERATOR − CC MODELS
OM-491 Page 23 Return To Table Of Contents SECTION 6 − OPERATING WELDING GENERATOR − CC MODELS 6-1. Front Panel Controls For CC Models (See Section 6-2) 17 202 705 / 802 169-F 15 16 2 1 3 13 18 19 14 12 10 11 9 8 6 5 4 7
Page 28 - Description Of Front Panel Controls For CC Models (See Section 6-1)
OM-491 Page 24 Return To Table Of Contents 6-2. Description Of Front Panel Controls For CC Models (See Section 6-1) Engine Starting Controls1 Magnetic Shutdown Switch Use switch during start-up to bypass engineshutdown system. System stops engine if oilpressure or fuel level is too low or coolant te...
Page 29 - Remote Amperage Control On CC Models (Optional); Weld Control/Arc Condition Information Label
OM-491 Page 25 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) In Example: Range = 125 to 320 A DC Percentage Of Ra...
Page 31 - SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS
OM-491 Page 27 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) 202 706 / 802 311-D 6 5 4 7 13 16 2 1 3 14 18 19 15 12 10 11 9 8 17
Page 33 - Process/Contactor Switch On CC/CV Models; Process/Contactor Switch Settings
OM-491 Page 29 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 35 - SECTION 8 − OPERATING AUXILIARY EQUIPMENT
OM-491 Page 31 Return To Table Of Contents SECTION 8 − OPERATING AUXILIARY EQUIPMENT 8-1. 120 Volt And 240 Volt Receptacles 191 624-A 2 1 3 4 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 fau...
Page 37 - Optional Generator Power Receptacles
OM-491 Page 33 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 38 - SECTION 9 − MAINTENANCE & TROUBLESHOOTING; Routine Maintenance; Note; Every 8 h; Continued on next page.
OM-491 Page 34 Return To Table Of Contents SECTION 9 − MAINTENANCE & TROUBLESHOOTING 9-1. 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 Engine Manua...
Page 40 - Maintenance Label
OM-491 Page 36 Return To Table Of Contents 9-2. Maintenance Label
Page 41 - Servicing Air Cleaner
OM-491 Page 37 Return To Table Of Contents 9-3. Servicing Air Cleaner aircleaner1 9/00 − ST-153 929-B / ST-153 585 / Ref. S-0698-B / Ref. 202 705 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. Th...
Page 42 - Inspecting And Cleaning Optional Spark Arrestor Muffler
OM-491 Page 38 Return To Table Of Contents 9-4. Inspecting And Cleaning Optional Spark Arrestor Muffler 802 160-E / Ref. 202 705 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 run at idle speed...
Page 43 - Adjusting Engine Speed
OM-491 Page 39 Return To Table Of Contents 9-5. Adjusting Engine Speed 802 168-C / 802 229-A / Ref. 202 705 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 noload...
Page 44 - Servicing Fuel And Lubrication Systems
OM-491 Page 40 Return To Table Of Contents 9-6. Servicing Fuel And Lubrication Systems 802 170-D / Ref. 802 168-B / 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...
Page 45 - Overload Protection
OM-491 Page 41 Return To Table Of Contents 9-7. Overload Protection 802 170-E 2 1 9 8 7 4 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 ...
Page 46 - Diagnosing Causes Of Engine Fault Shutdowns
OM-491 Page 42 Return To Table Of Contents 9-8. Diagnosing Causes Of Engine Fault Shutdowns Ref. 202 705 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 47 - Troubleshooting; A. Welding − CC Models
OM-491 Page 43 Return To Table Of Contents 9-9. 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 pl...
Page 49 - C. Standard Generator Power
OM-491 Page 45 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 52 - SECTION 10 − ELECTRICAL DIAGRAMS; Figure 10-1. Circuit Diagram For CC Welding Generator
OM-491 Page 48 Return To Table Of Contents SECTION 10 − ELECTRICAL DIAGRAMS Figure 10-1. Circuit Diagram For CC Welding Generator
Page 56 - SECTION 11 − RUN-IN PROCEDURE
OM-491 Page 52 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 59 - SECTION 12 − GENERATOR POWER GUIDELINES; 2-2. Grounding Generator To Truck Or Trailer Frame
OM-491 Page 55 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 60 - 2-3. Grounding When Supplying Building Systems
OM-491 Page 56 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 61 - 2-5. Approximate Power Requirements For Industrial Motors
OM-491 Page 57 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 62 - 2-7. Approximate Power Requirements For Contractor Equipment
OM-491 Page 58 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 64 - 2-10. Typical Connections To Supply Standby Power; Pros weld and cut
OM-491 Page 60 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 66 - SECTION 13 − PARTS LIST
OM-491 Page 62 Return To Table Of Contents SECTION 13 − PARTS LIST Hardware is common andnot available unless listed. 3 2 1 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 30 29 31 32 33 34 93 94 95 96 97 98 99 100 102 101 (CC ONLY) 104 FIG 13-2 OR 13-3) 105 21 106 107 108 (FIG ...
Page 71 - Figure 13-2. Control Box Assembly − CC Models
OM-491 Page 67 Return To Table Of Contents 802 551-E 2 1 11 8 6 3 7 14 20 13 16 12 5 22 15 10 9 18 17 4 21 19 Figure 13-2. Control Box Assembly − CC Models Description Part No. Dia. Mkgs. Item No. Figure13-2. Control Box Assembly − CC Models (Figure 13-1 Item 104) Quantity 1 F1, F2 *085 874 FUSE, mi...
Page 76 - Description
OM-491 Page 72 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. Pan...
Page 81 - (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 82 - Please complete and retain with your personal records.; For Service
PRINTED IN USA 2003 Miller Electric Mfg. Co. 1/03 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...
