Miller Big Blue 400P Owner's Manual
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Miller Big Blue 400P Owner's Manual

Miller Big Blue 400P Owner's Manual

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Big Blue 400P
Big Blue 500 X
(Perkins-Powered)
OM-4421
2012−07
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
Description
Engine Driven Welding Generator
R
R
CE
File: Engine Drive
215 075AE

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  • Page 1 Stick (SMAW) Welding TIG (GTAW) Welding MIG (GMAW) Welding Flux Cored (FCAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging Description Engine Driven Welding Generator Big Blue 400P Big Blue 500 X (Perkins-Powered) File: Engine Drive Visit our website at www.MillerWelds.com...
  • Page 2 We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING ....... . 1-1.
  • Page 4 TABLE OF CONTENTS SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS ......7-1. Front Panel Controls For CC/CV Models (See Section 7-2) .
  • Page 5 DECLARATION OF CONFORMITY for European Community (CE marked) products. MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(s) and Standard(s).

  • Page 7: Section 1 − Safety Precautions − Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2011−10 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury.
  • Page 8 D Do not weld on containers that have held combustibles, or on FUMES AND GASES can be hazardous. closed containers such as tanks, drums, or pipes unless they are properly prepared according to AWS F4.1 and AWS A6.0 (see Welding produces fumes and gases. Breathing these Safety Standards).

  • Page 9: Engine Hazards

    1-3. Engine Hazards EXHAUST SPARKS can cause fire. BATTERY EXPLOSION can injure. D Do not let engine exhaust sparks cause fire. D Always wear a face shield, rubber gloves, and protective clothing when working on a battery. D Use approved engine exhaust spark arrestor in required areas —...

  • Page 10: Additional Symbols For Installation, Operation, And Maintenance

    HOT METAL from air arc cutting and MOVING PARTS can injure. gouging can cause fire or explosion. D Keep away from moving parts such as fans, D Do not cut or gouge near flammables. belts and rotors. D Watch for fire; keep extinguisher nearby. D Keep all doors, panels, covers, and guards closed and securely in place.
  • Page 11 BATTERY CHARGING OUTPUT and BATTERY STATIC (ESD) can damage PC boards. EXPLOSION can injure. D Put on grounded wrist strap BEFORE handling Battery charging not present on all models. boards or parts. D Use proper static-proof bags and boxes to D Always wear a face shield, rubber gloves, and protective store, move, or ship PC boards.

  • Page 12: California Proposition 65 Warnings

    1-6. California Proposition 65 Warnings For Gasoline Engines: Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc- Health &...

  • Page 13: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 CONSIGNES DE SÉCURITÉ − LIRE AVANT − UTILISATION fre_rom_2011−10 Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
  • Page 14 Il reste une TENSION DC NON NÉGLIGEABLE dans les LES RAYONS DE L’ARC peuvent sources de soudage onduleur UNE FOIS le moteur coupé. provoquer des brûlures dans les yeux et sur la peau. D Couper l’alimentation du poste et décharger les condensateurs d’entrée comme indiqué...

  • Page 15: Dangers Existant En Relation Avec Le Moteur

    D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, LE BRUIT peut affecter l’ouïe. des chocs mécaniques, des dommages physiques, du laitier, des flammes ouvertes, des étincelles et des arcs. Le bruit des processus et des équipements peut D Placer les bouteilles debout en les fixant dans un support station- affecter l’ouïe.

  • Page 16: Dangers Liés À L'air Comprimé

    LA VAPEUR ET LE LIQUIDE DE L’ACIDE DE LA BATTERIE peut pro- REFROIDISSEMENT CHAUD peuvent voquer des brûlures dans les YEUX et provoquer des brûlures. sur la PEAU. D Il est préférable de vérifier le liquide de refroi- D Ne pas renverser la batterie. dissement une fois le moteur refroidi pour éviter D Remplacer une batterie endommagée.

  • Page 17: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    détendre la pression et s’assurer que le circuit d’air ne peut être L’INHALATION D’AIR COMPRIMÉ risque mis sous pression par inadvertance. de provoquer des blessures ou même D Demander seulement à un personnel qualifié d’enlever la mort. les dispositifs de sécurité ou les recouvrements pour effectuer, s’il y a lieu, des travaux d’entretien et de dépannage.
  • Page 18 LA SORTIE DE RECHARGE et L’EXPLO- LES CHARGES ÉLECTROSTATI- SION BATTERIE peuvent QUES peuvent endommager les provoquer des blessures. circuits imprimés. D Établir la connexion avec la barrette de terre La recharge de batterie n’existe pas sur tous les avant de manipuler des cartes ou des pièces. modèles.

  • Page 19: Proposition Californienne 65 Avertissements

    2-6. Proposition californienne 65 Avertissements Pour les moteurs à essence : Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques Les gaz d’échappement des moteurs contiennent des pro- dont l’État de Californie reconnaît qu’ils provoquent des mal- duits chimiques dont l’État de Californie reconnaît qu’ils formations congénitales et, dans certains cas, des cancers.

  • Page 20: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbols And Definitions Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. Safe2 2012−05 Protect yourself from electric shock by insulating yourself from work and ground.
  • Page 21 Do not work on unit if engine is running. Stop engine first. Safe21 2012−05 Do not smoke while fueling or if near fuel. Safe22 2012−05 Stop engine before fueling. Safe23 2012−05 Do not fuel a hot engine. Safe24 2012−05 Use lift eye to lift unit and properly installed accessories only, not gas cylinders. Do not exceed maximum lift eye rating (see Specifications).
  • Page 22 0 - 50 h std During the first 50 hours of operation keep welding load above 200 amperes. Do not weld below 200 amperes of output. Safe54 2012−05 50 h std After the first 50 hours of operation, change the engine oil and filter. Safe55 2012−05 Notes Work like a Pro!

  • Page 23: Miscellaneous Symbols And Definitions

    3-2. Miscellaneous Symbols And Definitions Some symbols are found only on export products. Fast (Run, Weld/ Stop Engine Slow (Idle) Start Engine Power) Engine Oil Starting Aid Battery (Engine) Engine Oil Pressure Check Injectors/ Check Valve Protective Earth Fuel Pump Clearance (Ground) Certified/Trained...

  • Page 24: Section 4 − Specifications

    SECTION 4 − SPECIFICATIONS 4-1. Important Information Regarding CE Products (Sold Within The EU) A. Information On Electromagnetic Fields (EMF) This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding. This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.

  • Page 25: Dimensions, Weights, And Operating Angles

    4-4. Dimensions, Weights, And Operating Angles Dimensions 60 in (1524 mm) Height (to top of muffler) 28-1/2 in (724 mm) (mtg. brackets turned in) Width 30-3/4 in (781 mm) (mtg. brackets turned out) Do not exceed tilt angles or engine could Depth 65-1/8 in (1654 mm) be damaged or unit could tip.

  • Page 26: Volt-Ampere Curves For Cc/Cv Models

    4-6. Volt-Ampere Curves For CC/CV Models C. Stick Mode The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all RANGES: other settings fall between the curves shown. 155 − 450 115 −...

  • Page 27: Fuel Consumption

    4-7. Fuel Consumption The curve shows typical fuel use under weld or power loads. 2.50 2.25 2.00 1.75 1.50 1.25 1.00 0.75 0.50 IDLE 0.25 0.00 DC WELD AMPERES AT 100% DUTY CYCLE 199 032−A 4-8. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- 100% Duty Cycle At 400 Amperes utes that unit can weld at rated load...

  • Page 28: Ac Generator Power Curve

    4-9. AC Generator Power Curve The ac power curve shows the gen- erator power in amperes available at the 120 and 240 volt receptacles. AC AMPERES IN 240V MODE AC AMPERES IN 120V MODE 193 018 4-10. Optional Three-Phase Generator Curves The ac power curves show the gen- A.

  • Page 29: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the front. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. 5-2.

  • Page 30: Mounting Welding Generator

    5-3. Mounting Welding Generator Do not weld on base. Weld- ing on base can cause fuel tank fire or explosion. Weld only on the four mounting brackets or bolt unit down. Supporting The Unit NOTICE − Do not mount unit by supporting the base only at the four mounting brackets.

  • Page 31: Grounding Generator To Truck Or Trailer Frame

    5-4. Grounding Generator To Truck Or Trailer Frame Always ground generator frame to vehicle frame to pre- vent electric shock and static electricity hazards. Also see AWS Safety & Health Fact Sheet No. 29, Grounding of Portable And Vehicle Mounted Welding Generators.

  • Page 32: Installing Exhaust Pipe

    5-6. Installing Exhaust Pipe Stop engine and let cool. Point exhaust pipe in desired di- rection but always away from front panel and direction of travel. Tools Needed: 1/2 in Exhaust1 2008−01 Ref. 803 604 / Ref. 236 972 5-7. Connecting The Battery Connect negative (−) battery cable last.

  • Page 33: Engine Prestart Checks

    5-8. Engine Prestart Checks Check radiator coolant level when fluid is low in recovery tank. Full NOTICE − Follow run-in pro- Capacity: cedure in engine manual. If 404.22 Engine: 9.5 qt (9.01L) unburned fuel and oil collect in exhaust pipe during run-in, see Section 11.

  • Page 34: Connecting To Weld Output Terminals

    5-9. Connecting To Weld Output Terminals Stick and TIG Welding MIG and FCAW Welding For Stick and TIG welding Direct Current Elec- For MIG and FCAW welding Direct Current trode Positive (DCEP), connect electrode Electrode Positive (DCEP) on CC/CV models, holder cable to Positive (+) terminal on left and connect wire feeder cable to Positive (+) termi- work cable to Negative (−) terminal on right.

  • Page 35: Selecting Weld Cable Sizes

    ( ) = mm for metric use ***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart). Ref. S-0007-J 2011−07 5-11. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models...

  • Page 36: Connecting To Remote 14 Receptacle Rc14 On Cc/Cv Models

    5-12. Connecting To Remote 14 Receptacle RC14 On CC/CV Models Socket* Socket Information 24 volts AC. Protected by sup- plementary protector CB5. 24 VOLTS AC Contact closure to A completes 24 volt AC contactor control circuit. Output to remote control:+10 volts DC in MIG or Stick mode;...
  • Page 37 Notes WELD POSITION: FLAT HORIZONTAL VERTICAL OVERHEAD BUTT BUTT WELD JOINT BUTT BUTT TYPES T−JOINT T−JOINT GROOVE T−JOINT FILLET T−JOINT Ref. 804 248-A Ref. AWS/ANSI D1.1 OM-4421 Page 31...

  • Page 38: Section 6 − Operating Welding Generator − Cc Models

    SECTION 6 − OPERATING WELDING GENERATOR − CC MODELS 6-1. Front Panel Controls For CC Models (See Section 6-2) 236 970 / 803 602 OM-4421 Page 32...

  • Page 39: Description Of Front Panel Controls For Cc Models (See Section 6-1)

    6-2. Description Of Front Panel Controls For CC Models (See Section 6-1) Engine Starting Controls (69 kPa). When switch is in the Stick position, the max OCV circuit resets Amperage Adjust Control Engine Coolant Temperature Gauge Starting Aid Switch R1 to maximum when the arc breaks. (Optional) Use switch to energize starting aid for cold Also in the Stick position, the arc drive (dig)

  • Page 40: Remote Amperage Control On Cc Models (Optional)

    6-3. Remote Amperage Control On CC Models (Optional) Remote Amperage Adjust Receptacle RC13 Connect optional remote control to RC13 (see Section 5-11). In Example: Example: Combination Remote Amperage Control (Stick) Range = 110 to 225 A DC Percentage Of Range = 50% Max = About 168 A DC (50% of 110 to 225) Max (168 A DC) Min (90 A DC)
  • Page 41 Notes OM-4421 Page 35...

  • Page 42: Section 7 − Operating Welding Generator − Cc/Cv Models

    SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS 7-1. Front Panel Controls For CC/CV Models (See Section 7-2) 236 971 / 803 602 OM-4421 Page 36...

  • Page 43: Description Of Front Panel Controls For Cc/Cv Models (See Section 7-1)

    7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1) Engine Starting Controls Engine Coolant Temperature Gauge Use switch to select front panel or remote (Optional) voltage/amperage control. For remote con- Starting Aid Switch trol, place switch in Remote position and con- Normal temperature is 180 - 203°...

  • Page 44: Process/Contactor Switch On Cc/Cv Models

    7-3. Process/Contactor Switch On CC/CV Models 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/ Contactor switch is in the Re- mote On/Off Switch Required −...

  • Page 45: Remote Voltage/Amperage Control On Cc/Cv Models (Optional)

    7-4. Remote Voltage/Amperage Control On CC/CV Models (Optional) Remote 14 Receptacle RC14 Connect optional remote control to RC14 (see Section 5-12). In Example: Example: Combination Remote Amperage Control (Stick) Process = Stick (Using Remote On/Off) Range = 115 to 320 A DC Min = 115 A DC Max = 320 A DC Max (320 A DC)

  • Page 46: Fuel/Hour Gauge Descriptions

    7-5. Fuel/Hour Gauge Descriptions OM-4421 Page 40...

  • Page 47: Optional Oil Pan Heater Operation

    7-6. Optional Oil Pan Heater Operation Oil Pan Heater Plug Use heater to maintain a constant engine oil temperature. To turn on heater, connect heater plug to 120 volts AC receptacle. Heater rated at 300 watts. Do not run engine while oil pan heater is on.

  • Page 48: Section 8 − Operating Auxiliary Equipment

    SECTION 8 − OPERATING AUXILIARY EQUIPMENT 8-1. Domestic Auxiliary Power Receptacles 191 624-A Use GFCI protection when operat- Test GFCI monthly. See Section 8-2 If a supplementary protector continues ing auxiliary equipment. If unit does for GFCI information and for reset- to open, contact Factory Authorized not have GFCI receptacles, use ting and testing procedures.

  • Page 49: Gfci Receptacle Information, Resetting And Testing

    8-2. GFCI Receptacle Information, Resetting And Testing Test and reset GFCI only at Run speed. RotGFCI1 2012−05 If a ground fault is detected, the GFCI Reset Check for damaged or wet tools, cords, Use GFCI protection when operat- button pops out, and the circuit opens to plugs, etc.

  • Page 50: Connecting To Optional Three-Phase Generator (Cc/Cv Models Only)

    8-3. Connecting To Optional Three-Phase Generator (CC/CV Models Only) Place Process/Contactor switch in Weld Terminals Always On - Stick position when using three- phase generator (see Section Single-Phase Power Connection 7-3). Single-Phase Generator Power 120/240 V 50 A Receptacle RC5 is connected to the optional three-phase generator and supplies 60 Hz single-phase power at weld/ power speed.

  • Page 51: Export Auxiliary Power Receptacles

    8-4. Export Auxiliary Power Receptacles European Receptacle Australian Receptacle South African Receptacle 238 127-A / 805 259-A and 4 kVa/kW from RC1. does not work. Place circuit breaker switch Use GFCI protection when operat- in the On position to reset breaker. ing auxiliary equipment.

  • Page 52: Section 9 − Maintenance & Troubleshooting

    SECTION 9 − MAINTENANCE & TROUBLESHOOTING 9-1. Maintenance Label Perkins Engine North American office: Perkins USA & Canada Office: Perkins Engines Inc. N4-AC6160, PO Box 610 Mossville, Illinois, 61552-0610 - Toll Free Number: 1-888-PERK-ENG - Telephone 1.309.578.7364 - Fax 1.309.578.7329 To find a service distributor, go to: http://www.perkins.com/distributor OM-4421 Page 46...

  • Page 53: Routine Maintenance

    9-2. Routine Maintenance Stop engine before maintaining. See Engine Manual and Maintenance Label Recycle engine for important start-up, service, and storage fluids. information. Service engine more often if used in severe conditions. n = Check Z = Change ~ = Clean l = Replace Reference * To be done by Factory Authorized Service Agent...

  • Page 54: Checking Generator Brushes

    9-3. Checking Generator Brushes Stop engine and let cool. Generator Brush Mark and disconnect leads at brush hold- er cap. Remove brushes. Minimum Length: Replace brushes if damaged or if brush 5/8 in. (16 mm) material is at or near minimum length. New Length: 1-1/4 in.

  • Page 55: Servicing Air Cleaner

    9-4. Servicing Air Cleaner Stop engine. NOTICE − Do not run engine without air cleaner or with dirty element. Engine damage caused by using a damaged ele- ment is not covered by the warranty. The air cleaner primary element can be cleaned but the dirt holding capac- ity of the filter is reduced with each cleaning.

  • Page 56: Inspecting/Cleaning Optional Spark Arrestor

    9-5. Inspecting/Cleaning Optional Spark Arrestor 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. If nothing blows out of hole, briefly cover end of exhaust pipe with fireproof ma- terial.

  • Page 57: Adjusting Engine Speed

    9-6. Adjusting Engine Speed Engine Speed Adjustment Engine Speed After tuning engine, check en- (No Load) gine speed with tachometer or frequency meter. See table for 1850 rpm max proper no load speed. If neces- (61.6 Hz) sary, adjust speed as follows: 1250 rpm Start engine and run until warm.

  • Page 58: Servicing Fuel And Lubrication Systems

    9-7. Servicing Fuel And Lubrication Systems 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. Oil Filter Oil Drain Valve And Hose Oil Fill Cap Fuel Line Primary Fuel Filter (Fuel/ Water Separator)

  • Page 59: Overload Protection

    9-8. Overload Protection 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.

  • Page 60: Troubleshooting

    9-9. Troubleshooting A. Welding − CC Models Trouble Remedy 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 5-11 and 6-1).
  • Page 61 Trouble Remedy 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 Remedy 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.
  • Page 62 Trouble Remedy 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.
  • Page 63 E. Engine Trouble Remedy 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.

  • Page 64: Section 10 − Electrical Diagrams

    SECTION 10 − ELECTRICAL DIAGRAMS Figure 10-1. Circuit Diagram For CC Welding Generator OM-4421 Page 58...
  • Page 65 240 152-B OM-4421 Page 59...
  • Page 66 Figure 10-2. Circuit Diagram For CC/CV Welding Generator OM-4421 Page 60...
  • Page 67 240 153-B OM-4421 Page 61...

  • Page 68: Section 11 − Run-In Procedure

    SECTION 11 − RUN-IN PROCEDURE run_in1 2007−04 11-1. Wetstacking NOTICE − Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment 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.

  • Page 69: Run-In Procedure Using Load Bank

    11-2. Run-In Procedure Using Load Bank Stop engine. Do not touch hot exhaust pipe, engine parts, or load bank/grid. Keep exhaust and pipe away from flammables. NOTICE − Do not perform run- in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur.

  • Page 70: Run-In Procedure Using Resistance Grid

    11-3. Run-In Procedure Using Resistance Grid Stop engine. Do not touch hot exhaust pipe, engine parts, or load bank/grid. Keep exhaust and pipe away from flammables. NOTICE − Do not perform run- in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur.

  • Page 71: Section 12 − Generator Power Guidelines

    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 Generator Power Receptacles − Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment...
  • Page 72 12-3. Grounding When Supplying Building Systems Equipment Grounding Terminal Grounding Cable Use #8 AWG or larger insulated copper wire. GND/PE Ground Device Use ground device as stated in electrical codes. Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system.
  • Page 73 12-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1/8 HP 1/6 HP 1225 1/4 HP 1600 1/3 HP 2100 1/2 HP 3175 Capacitor Start-Induction Run 1/3 HP 2020 1/2 HP 3075 3/4 HP 4500 1400 1 HP...
  • Page 74 12-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1/4 in 3/8 in 1/2 in Circular Saw 6-1/2 in 7-1/4 in 8-1/4 in 1400 1400 Table Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in...
  • Page 75 12-8. Power Required To Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code KVA/HP 10.0 11.2 12.5 14.0 Motor Start Code Running Amperage Motor HP Motor Voltage To find starting amperage: Step 1: Find code and use table to find kVA/HP.
  • Page 76 12-10. Typical Connections To Supply Standby Power Have only qualified persons perform these connections according to all applicable codes and safety practices. Properly install, ground, and operate this equipment ac- cording to its Owner’s Manu- Fused Welding Utility al and national, state, and lo- Disconnect Electrical Generator...
  • Page 77 12-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected exten- sion cord. Do not use GFCI receptacles to power life support equipment. Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current Load (Watts)

  • Page 78: Section 13 − Parts List

    SECTION 13 − PARTS LIST 118 (CV) 119 (CV) 117 (Fig. 13−8) 116 (CC ONLY) 125 (Fig. 13−4 OR 13−5) Figure 13-1. Main Assembly (Export Model Shown) OM-4421 Page 72...
  • Page 79 93 (Fig. 13−7) 803 646-J OM-4421 Page 73...
  • Page 80 Item Dia. Part Mkgs. Description Quantity Figure 13-1. Main Assembly ....189 824 PANEL, gen LH ..........♦199 294 .
  • Page 81 Item Dia. Part Mkgs. Description Quantity Figure 13-1. Main Assembly (Continued) ♦202 629 ....COVER, radiator access ss ........
  • Page 82 Item Dia. Part Mkgs. Description Quantity Figure 13-1. Main Assembly (Continued) ....191 626 BUMPER, door engine access ........
  • Page 83 Item Dia. Part Mkgs. Description Quantity Figure 13-1. Main Assembly (Continued) ♦199 305 ... TOP, cover front upright ss ........
  • Page 84 Hardware is common and not available unless listed. 803 647-G Figure 13-2. Control Box Assembly − CC Models Item Dia. Part Mkgs. Description Quantity Figure 13-2. Control Box Assembly − CC Models (Figure 13-1 Item 114) ..F1, F2 *085 874 FUSE, mintr cer slo-blo 10A 250V...
  • Page 85 Hardware is common and not available unless listed. 803 648-G Figure 13-3. Control Box Assembly − CC/CV Models Item Dia. Part Mkgs. Description Quantity Figure 13-3. Control Box Assembly − CC/CV Models (Figure 13-1 Item 114) ..F1, F2 *085 874 FUSE, mintr cer slo-blo 10A 250V...
  • Page 86 Hardware is common and not available unless listed. 803 649-D Figure 13-4. Panel, Front w/Components − CC Models Item Dia. Part Mkgs. Description Quantity Figure 13-4. Panel, Front w/Components − CC Models (Figure 13-1 Item 125) ......PLATE SCREENED, ident control rating (order by model and serial number) .
  • Page 87 Item Dia. Part Mkgs. Description Quantity Figure 13-4. Panel, Front w/Components − CC Models (Figure 13-1 Item 125) ....238 616 PANEL, engine/weld control ........
  • Page 88 Hardware is common and not available unless listed. 803 650-E Figure 13-5. Panel, Front w/Components − CC/CV Models Item Dia. Part Mkgs. Description Quantity Figure 13-5. Panel, Front w/Components − CC/CV Models (Figure 13-1 Item 125) ......PLATE SCREENED, ident control (order by model and serial number) .
  • Page 89 Item Dia. Part Mkgs. Description Quantity Figure 13-5. Panel, Front w/Components − CC/CV Models (Figure 13-1 Item 125) ....201 244 WASHER, tooth.728idx1.166odx.050t stl pld int.688 .
  • Page 90 805 259-A Figure 13-6. Auxiliary Power Group, Export Item Dia. Part Mkgs. Description Quantity Figure 13-6. Auxiliary Power Group, Export ....+223121 Panel, Aux Power (Export) .
  • Page 91 Hardware is common and not available unless listed. 802 552-B Figure 13-7. Generator Item Dia. Part Mkgs. Description Quantity Figure 13-7. Generator (Figure 13-1 Item 93) ....132 053 SCREW, .375−16x1.50 hex hd−pln gr5 pld .
  • Page 92 Item Dia. Part Mkgs. Description Quantity Figure 13-7. Generator (Figure 13-1 Item 93) (Continued) ....189 142 BRUSHHOLDER, generator ........
  • Page 93 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 harnes Item Dia. Part Mkgs. Description Quantity Wiring Harnesses ....238763 Harness, control box, CC weld control (includes) .
  • Page 94 ....212117 Conn, Deutsch Wedge Lock 2 Position ......
  • Page 95 Effective January 1, 2012 (Equipment with a serial number preface of MC or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions 90 Days —...
  • Page 96 Contact the Delivering Carrier to: 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. © ORIGINAL INSTRUCTIONS − PRINTED IN USA 2012 Miller Electric Mfg. Co. 2012−01...

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