ISO 9001:2000 Quality System Standard. particular model are also provided. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets.
TABLE OF CONTENTS SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS 7-1. Front Panel Controls For CC/CV Models (See Section 7-2) 7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1) 7-3. Process/Contactor Switch On CC/CV Models 7-4.
European Community (CE) Products NOTE This information is provided for units with CE certification (see rating label on unit). Manufacturer: Miller Electric Mg. Co. 1635 W. Spencer St. Appleton, WI 54914 USA Phone: (920) 734-9821 European Contact Signature: Big Blue 500 X...
Declaration of Conformity for European Community (CE) Products NOTE This information is provided for units with CE certification (see rating label on unit). Manufacturer: Miller Electric Mg. Co. 1635 W. Spencer St. Appleton, WI 54914 USA Phone: (920) 734-9821 European Contact Signature:...
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING Y 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 hazards are shown in the adjoining symbols.
WELDING can cause fire or explosion. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire.
STEAM AND HOT COOLANT can burn. D If possible, check coolant level when engine is cold to avoid scalding. D Always check coolant level at overflow tank, if pres- ent on unit, instead of radiator (unless told otherwise in maintenance section or engine manual). D If the engine is warm, checking is needed, and there is no overflow tank, follow the next two statements.
READ INSTRUCTIONS. D Use only genuine MILLER/Hobart replacement parts. D Perform engine and air compressor (if applicable) maintenance and service according to this manual and the engine/air compressor (if applicable) manu- als. H.F. RADIATION can cause interference. D High-frequency (H.F.) can interfere with radio naviga- tion, safety services, computers, and communica- tions equipment.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT 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 présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives.
LE SOUDAGE peut provoquer un in- cendie ou une explosion. Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures.
D Si le moteur est chaud et que le liquide doit être vérifié, opérer comme suivant. D Mettre des lunettes de sécurité et des gants, placer un torchon sur le bouchon du radiateur. D Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant d’enle- ver le bouchon.
LIRE LES INSTRUCTIONS. D Utiliser seulement les pièces de rechange d’origine. D Effectuer la maintenance du moteur et du compresseur (si applicable) suivant ce manuel et le manuel du moteur/ compresseur (si applicable). LE RAYONNEMENT HAUTE FRÉ- QUENCE (H.F.) risque de provoquer des interférences.
3-3. Symbols And Definitions NOTE Some symbols are found only on export products. Stop Engine Starting Aid Check Injectors/ Pump Positive Amperes Engine Stick (SMAW) Welding Time Three Phase Electrode Connection Duty Cycle Rated Idle Speed Contactor On Fast (Run, Weld/ Power) Battery (Engine) Check Valve...
4-3. Volt-Ampere Curves For CC Models Notes Ranges: 230 − Max 170 − 365 110 − 225 70 − 130 55 − 85 400 500 900 1000 DC AMPERES The volt-ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator.
4-7. AC Generator Power Curve AC AMPERES IN 240V MODE AC AMPERES IN 120V MODE 4-8. Optional Three-Phase Generator Curves A. 12 kVA/kW Single-Phase AC Output (No Weld Load) B. 15 kVA/kW Three-Phase AC Output (No Weld Load) OM-4421 Page 16 90 100 AC AMPERES AC AMPERES...
SECTION 5 − INSTALLATION 5-1. Installing Welding Generator Movement Location/Airflow Clearance 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) (460 mm) Grounding GND/PE 18 in (460 mm) 18 in Electrically bond generator frame to vehicle frame by metal-to-metal contact. Y Bed liners, shipping skids, and some running gears insulate the welding generator from the vehicle frame.
5-2. Using Lifting Eye Notes OM-4421 Page 18 Lifting Eye 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 bracket and secure with nut (bolt and nut not supplied).
5-3. Mounting Welding Generator Supporting The Unit Inadequate support. Y Do not use flexible mounts. Using Mounting Brackets Tools Needed: 9/16 in Welding Unit In Place Bolting Unit In Place Y Do not weld on base. Weld- ing on base can cause fuel tank fire or explosion.
5-4. Installing Exhaust Pipe Tools Needed: 1/2 in Notes OM-4421 Page 20 Y Stop engine and let cool. Point exhaust pipe in desired di- rection but always away from front panel and direction of travel. Ref. 803 604 / Ref. 215 158 Work like a Pro! Pros weld and cut safely.
5-5. Activating The Dry Charge Battery (If Applicable) 5 A For 30 Minutes 30 A For 12 Minutes Tools Needed: 5-6. Connecting The Battery Y Connect Negative (−) Cable Last. Tools Needed: 1/2 in − − Y Always wear a face shield, rubber gloves and protective clothing when working on a battery.
5-7. Engine Prestart Checks Full Diesel 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 if oil pressure is too low or coolant tempera- ture is too high.
5-9. Selecting Weld Cable Sizes* Weld Output Terminals Y Stop engine before Welding connecting to weld out- Amperes put terminals. Y Do not use worn, dam- aged, undersized, or poorly spliced cables. Chart is a general guideline and may not suit all applications. If cables overheat, use next size larger cable. **Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
5-11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models *The remaining sockets are not used. Notes Start Your Professional Welding Career Now! 24 VOLTS AC 24 VOLTS AC REMOTE OUTPUT OUTPUT CONTROL 115 VOLTS AC NEUTRAL Ref. 803 602 400 Trade Square East, Troy, Ohio 45373 1-800-332-9448 www.welding.org Socket*...
6-2. Description Of Front Panel Controls For CC Models (See Section 6-1) Engine Starting Controls Starting Aid Switch Use switch to energize starting aid for cold weather starting (see starting instructions fol- lowing). Engine Control Switch Use switch to start and stop engine. To Start: Y Do not use ether.
6-3. Remote Amperage Control On CC Models (Optional) Example: Combination Remote Amperage Control (Stick) Set Switches Set Range 6-4. Weld Control/Arc Condition Information Label OM-4421 Page 28 Remote Amperage Adjust Receptacle RC13 Connect optional remote control to RC13 (see Section 5-10). In Example: Range = 110 to 225 A DC Percentage Of Range = 50%...
7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1) Engine Starting Controls Starting Aid Switch Use switch to energize starting aid for cold weather starting (see starting instructions fol- lowing). Engine Control Switch Use switch to start engine, select engine speed ( if unit has auto idle option), and stop engine.
7-4. Remote Voltage/Amperage Control On CC/CV Models (Optional) Example: Combination Remote Amperage Control (Stick) Set Remote Set V/A Adjust Switch Process Example: Combination Remote Amperage Control (TIG) Set V/A Set Remote Process Adjust Switch Process = Stick (Using Remote On/Off) Set Range Control Not Used In Remote...
SECTION 8 − OPERATING AUXILIARY EQUIPMENT 8-1. 120 Volt And 240 Volt Receptacles OM-4421 Page 34 120 V 20 A AC GFCI Receptacle GFCI1 240 V 30 A AC Twistlock Receptacle RC1 Receptacles supply 60 Hz single- phase power at weld/power speed. If a ground fault is detected, GFCI Reset button...
8-2. Connecting To Optional Three-Phase Generator (CC/CV Models Only) Single-Phase Power Connection Three-Phase Power Connection Y Close panel opening if no connections are made to generator. Remove plug before inserting leads. Reinstall bushing. Rear Of Panel 120V 120V Single Phase Output Volts 120/240...
8-3. Optional Generator Power Receptacles European Receptacle Australian Receptacle South African Receptacle OM-4421 Page 36 120 V 20 A AC GFCI Receptacle GFCI1 240 V 16 A AC European Receptacle RC1 240 V 15 A AC Australian Receptacle RC1 240 V 15 A AC South African Receptacle RC1 Receptacles supply 60 Hz single- phase power at weld/power speed.
9-2. Routine Maintenance n = Check Z = Change * To be done by Factory Authorized Service Agent Every FUEL WATER Hours n Fuel/Water Separator n Fuel Level n Coolant Level Every Hours ~ Weld Terminals Every Hours ~ Battery Terminals n Air Cleaner Hoses Every Hours...
9-3. Checking Generator Brushes Notes Minimum Length: 5/8 in (16 mm) New Length: 1-1/4 in (32 mm) Replace Damaged Brushes Y Stop engine and let cool. Generator Brush Mark and disconnect leads at brush hold- er cap. Remove brushes. Replace brushes if damaged or if brush material is at or near minimum length.
9-4. Servicing Air Cleaner Keep nozzle 2 in (51 mm) from element. Blow OM-4421 Page 40 Optional Inspect aircleaner1 9/00 − ST-153 929-B / ST-153 585 / Ref. S-0698-B / Ref. 215 158 Y Stop engine. Y Do not run engine without air cleaner or with dirty element.
9-5. Inspecting And Cleaning Optional Spark Arrestor Muffler Tools Needed: 3/8 in Y Stop engine and let cool. Spark Arrestor Muffler Cleanout Plug Remove plug and remove any dirt covering cleanout hole. Start engine and run at idle speed to blow out cleanout hole.
9-6. Adjusting Engine Speed To prevent solenoid damage, be sure a 1/8 in (3 mm) gap exists between the engine low speed screw and throttle lever when the solenoid is held in the energized position. OM-4421 Page 42 Engine Speed (No Load) 1850 rpm max (61.6 Hz)
9-7. Servicing Fuel And Lubrication Systems Y Stop engine and let cool. Y After servicing, start engine and check for fuel leaks. Stop engine, tighten connec- tions as necessary, and wipe up spilled fuel. Oil Filter Oil Drain Valve And Hose Oil Fill Cap Fuel Line Primary Fuel Filter (Fuel/...
9-8. Overload Protection OM-4421 Page 44 Y Stop engine. When a supplementary protector, circuit breaker or fuse opens, it usu- ally indicates a more serious problem exists. Contact Factory Authorized Service Agent. Fuse F1 Fuse F2 F1 and F2 protect the stator exciter wind- ing from overload.
9-9. Troubleshooting A. Welding − CC Models Trouble No weld output; generator power output Check position of Ampere Range switch. okay at ac receptacles. Check position of optional Polarity switch. Place Amperage Adjust switch in Panel position, or place switch in Remote position and connect remote control to Remote Amperage Adjust receptacle RC13 (see Sections 5-10 and 6-1).
Trouble No remote fine amperage control. Repair or replace remote control device. Have Factory Authorized Service Agent check OCV control circuit. B. Welding − CC/CV Models Trouble No weld output; generator power output Place Process/Contactor switch in a Weld Terminals Always On position, or place switch in a Remote okay at ac receptacles.
Trouble No remote fine amperage or voltage Repair or replace remote control device. control. Have Factory Authorized Service Agent check PC1 sensing leads (36 and 37), and connections. Constant speed wire feeder does not Reset supplementary protector CB5 or CB6 (see Section 9-8). work.
E. Engine Trouble Engine will not crank. Check battery, and replace if necessary. Check battery connections and tighten if necessary. Circuit breaker CB10 may be open. CB10 automatically resets when fault is corrected (see Section 9-8). Have Factory Authorized Service Agent check engine wiring harness and components. Check engine wiring harness plug connections.
SECTION 11 − RUN-IN PROCEDURE 11-1. Wetstacking OM-4421 Page 54 run_in1 11/05 Y Do perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur. Welding Generator Run diesel engines near rated volt- age and current during run-in period to properly seat piston rings and prevent wetstacking.
11-2. Run-In Procedure Using Load Bank Y Stop engine. Y Do not touch hot exhaust pipe, engine parts, or load bank/grid. Y Keep exhaust and pipe away from flammables. Y Do perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur.
11-3. Run-In Procedure Using Resistance Grid OM-4421 Page 56 Y Stop engine. Y Do not touch hot exhaust pipe, engine parts, or load bank/grid. Y Keep exhaust and pipe away from flammables. Y Do perform procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur.
SECTION 12 − GENERATOR POWER GUIDELINES NOTE 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 12-2. Grounding Generator To Truck Or Trailer Frame Electrically bond generator frame to vehicle frame by metal-to-metal contact.
12-3. Grounding When Supplying Building Systems 12-4. How Much Power Does Equipment Require? AMPERES x VOLTS = WATTS EXAMPLE 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power requirement in watts. The load applied by the drill is 520 watts. EXAMPLE 2: If three 200 watt flood lamps are used with the drill from Example 1, add the individual loads to calculate total load.
12-7. Approximate Power Requirements For Contractor Equipment Contractor Hand Drill Circular Saw Table Saw Band Saw Bench Grinder Air Compressor Electric Chain Saw Electric Trimmer Electric Cultivator Elec. Hedge Trimmer Flood Lights Submersible Pump Centrifugal Pump Floor Polisher High Pressure Washer 55 gal Drum Mixer Wet &...
12-8. Power Required To Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code KVA/HP kVA/HP x HP x 1000 VOLTS EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4 HP motor with a motor start code of M. Volts = 230 HP = 1/4 11.2 x 1/4 x 1000...
12-10. Typical Connections To Supply Standby Power Y Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes. Utility Electrical Service Y Have only qualified persons perform these connections according to all applicable codes and safety practic- Y Properly install and ground this equipment according to its Owner’s Manual and national, state, and local...
12-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord. Current Load (Watts) (Amperes) 1200 1800 2400 3000 3600 4200 4800 5400 6000 *Conductor size is based on maximum 2% voltage drop Cord Lengths for 240 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord.
SECTION 13 − PARTS LIST 400 P Models Only 125 (Fig. 13-4 OR 13-5) Figure 13-1. Main Assembly (Export Model Shown) OM-4421 Page 64 118 (CV) 119 (CV) Fig. 13−7 114 (Fig. 13-2 OR 13-3 116 (CC ONLY) Hardware is common and not available unless listed.
Note Some wiring harness components (switches, relays, circuit breakers) are also referenced elsewhere in this parts list. Purchase components separately or as part of the associated wiring harness. Item Dia. Part Mkgs..... 215054 .
Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to 1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in for your local material and workmanship at the time it is shipped by Miller.
File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. 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...