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 - ELECTRIC SHOCK can kill.; SIGNIFICANT DC VOLTAGE exists in inverters after stop-; HOT PARTS can cause severe burns.
OM-4429 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 7 - Using a generator indoors CAN KILL; ENGINE HEAT can cause fire.
OM-4429 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 9 - ARC WELDING can cause interference.
OM-4429 Page 5 H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. Have only qualified persons familiar with electronic equipment perform this installation. The user is responsible for having a qu...
Page 10 - UN CHOC ÉLECTRIQUE peut tuer.
OM-4429 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 12 - LE CARBURANT MOTEUR peut provo
OM-4429 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 13 - LA CHUTE DE L’APPAREIL peut blesser.
OM-4429 Page 9 L’utilisation d’un groupe autonome à l’intérieur PEUT VOUS TUER EN QUELQUES MINUTES. Les fumées d’un groupe autonome contient du monoxyde de carbone. C’est un poison invisi- ble et inodore. JAMAIS utiliser dans une maison ou garage, même avec les portes et fenêtres ouvertes. Uniquemen...
Page 15 - -6. Proposition californienne 65 Avertissements
OM-4429 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 - Hz
OM-4429 Page 14 3-3. Symbols And Definitions Some symbols are found only on CE 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 Negat...
Page 20 - DC AMPERES; Notes; Pros weld and cut
OM-4429 Page 16 4-3. Volt-Ampere Curves For CC Models 203 412 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. 0 20 40 60 80 100 0 100 200 300 400 500 600 700 800 900 DC ...
Page 22 - IDLE
OM-4429 Page 18 4-5. Fuel Consumption The curve shows typical fuel use under weld or power loads. 215 082 − A IDLE DC WELD AMPERES AT 100% DUTY CYCLE U.S. GAL./HR. 0 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 2.25 2.50 0 50 100 150 200 250 300 350 400 450 500 550 600 Continuous Welding 4-6. Duty Cycle ...
Page 23 - AC AMPERES IN 240V MODE; AC AMPERES
OM-4429 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 30 - -8. Connecting To Weld Output Terminals
OM-4429 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 32 - -11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models; REMOTE; OUTPUT; Start Your Professional
OM-4429 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 40 - Process/Contactor Switch Settings
OM-4429 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 48 - -4. Inspecting And Cleaning Optional Spark Arrestor Muffler
OM-4429 Page 44 9-4. 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 49 - -6. Servicing Fuel And Lubrication Systems
OM-4429 Page 45 9-6. 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 51 - Trouble
OM-4429 Page 47 9-8. 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 53 - C. Standard Generator Power
OM-4429 Page 49 Trouble Remedy Check and secure connections to Remote 14 receptacle RC14 (see Section 5-11). Repair or replace wire feeder. Low CV weld output. Set Ampere Range switch to highest range. Increase Voltage/Amperage Adjust Control setting. Min or max CV weld output only. Check position o...
Page 56 - ELECTRICAL DIAGRAMS; Figure 10-1. Circuit Diagram For CC Welding Generator
OM-4429 Page 52 SECTION 10 − ELECTRICAL DIAGRAMS Figure 10-1. Circuit Diagram For CC Welding Generator
Page 63 - GENERATOR POWER GUIDELINES; 2-2. Grounding Generator To Truck Or Trailer Frame
OM-4429 Page 59 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 64 - 2-3. Grounding When Supplying Building Systems
OM-4429 Page 60 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 65 - 2-5. Approximate Power Requirements For Industrial Motors
OM-4429 Page 61 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 66 - 2-7. Approximate Power Requirements For Contractor Equipment
OM-4429 Page 62 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 68 - 2-10. Typical Connections To Supply Standby Power
OM-4429 Page 64 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 70 - PARTS LIST
OM-4429 Page 66 SECTION 13 − PARTS LIST Hardware is common andnot available unless listed. 1 2 3 4 5 7 6 8 9 10 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 101 102 103 104 105 100 106 107 108 (CC) 109 (CC) 110 111 (Fig. 13 − 2 112 113 114 (Fig.13 − 7) 115 (CV) 116 (CV) 117 118 119 120 121 (Fig.13 −...
Page 87 - Wiring Harnesses
OM-4429 Page 83 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 harness. Description Part No. Dia. Mkgs. Item No. Wiring Harnesses Quantity 221374 Harness, Engine...
Page 89 - (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 90 - 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...