Miller 907186 Owner'S Manual Download Page 34

Page: 34 / 80

Complete Parts List available at www.MillerWelds.com

OM-4421 Page 28

5-7. Connecting To Weld Output Terminals

803 602 / 803 778-B

Tools Needed:

3/4 in.

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 (

−

) ter-

minal on right. Use Process/Contactor switch

to select type of weld output (see Section 7-3).
For Direct Current Electrode Negative

(DCEN), reverse cable connections.
If equipped with optional Polarity switch or op-

tional Polarity/AC switch, connect wire feeder

cable to Electrode (+) terminal on left and

work cable to Work (

−

) terminal on right.

Stop engine.

Failure to properly connect weld

cables may cause excessive heat and

start a fire, or damage your machine.

Turn off power before connecting to

weld output terminals.

Do not use worn, damaged, under-

sized, or repaired cables.

Do not place anything between weld cable
terminal and copper bar. Make sure that

the surface of the weld cable terminal and

copper bar are both clean.

Correct Weld Cable Connection

Incorrect Weld Cable Connection

Weld Output Terminal

Supplied Weld Output Terminal Nut

Weld Cable Terminal

Copper Bar

Remove supplied nut from weld output termi-

nal. Slide weld cable terminal onto weld output

terminal and secure with nut so that weld cable

terminal is tight against copper bar.
7

Positive (+) Weld Output Terminal

Negative (

−

) Weld Output Terminal

Stick and TIG Welding

For Stick and TIG welding Direct Current Elec-

trode Positive (DCEP), connect electrode

holder cable to Positive (+) terminal on left and

work cable to Negative (

−

) terminal on right.

For Direct Current Electrode Negative

(DCEN), reverse cable connections.
If equipped with optional Polarity switch or op-

tional Polarity/AC switch, connect electrode

holder cable to Electrode (+) terminal on left

and work cable to Work (

−

) terminal on right.

Summary of Contents for 907186

Page 1: ...elding MIG GMAW Welding Engine Driven Welder Generator OM 4421 215 075AL 2015 04 Visit our website at www MillerWelds com Flux Cored FCAW Welding Air Carbon Arc CAC A Cutting and Gouging File Engine Drive Big Blue 400P Big Blue 500 X CE Perkins Powered ...

Page 2: ...ontinue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operati...

Page 3: ... 4 1 Serial Number And Rating Label Location 19 4 2 Weld Power And Engine Specifications 19 4 3 Dimensions Weights And Operating Angles 19 4 4 Environmental Specifications 20 4 5 Duty Cycle And Overheating 20 4 6 Volt Ampere Curves For CC CV Models 21 4 7 Volt Ampere Curves For CC Models 22 4 8 Fuel Consumption 22 4 9 AC Generator Power Curve 23 4 10 Optional Three Phase Generator Curves 23 SECTIO...

Page 4: ...Export Auxiliary Power Receptacles 42 8 4 GFCI Receptacle Information Resetting And Testing 43 SECTION 9 MAINTENANCE TROUBLESHOOTING 44 9 1 Maintenance Label 44 9 2 Routine Maintenance 45 9 3 Checking Generator Brushes 46 9 4 Servicing Air Cleaner 47 9 5 Inspecting Cleaning Optional Spark Arrestor 48 9 6 Battery Maintenance 48 9 7 Adjusting Engine Speed 49 9 8 Servicing Fuel And Lubrication System...

Page 5: ...nic equipment 2000 14 EC 2005 88 EC Outdoor Noise Notified Body AV Technology AVTECH House Arkle Avenue Stanley Green Trading Estate Hand forth Cheshire SK93RW United Kingdom Conformity Assessment Procedure Followed Annex VI 2000 14 EC Technical Document Holder Manufacturer Notified Body Evaluation Report No GB 1067 0956 07 Measured Sound Power level 97 dB L WA Guaranteed Sound Power Level 97 dB L...

Page 6: ......

Page 7: ...gh risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone Disconnect input power or stop ...

Page 8: ...g sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on containers that have held combustibles or on closed containers such as tanks drums or pipes unless they are properly prepared accor...

Page 9: ...e hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns STEAM AND HOT COOLANT can burn If possible check coolant level when engine is cold to avoid scalding Always check coolant level at overflow tank if present on unit instead of radiator unless told otherwise in maintenance section or engine manual If the engine is warm checking is needed and there i...

Page 10: ...PARTS can burn Do not touch hot compressor or air system parts Allow cooling period before working on equip ment To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns READ INSTRUCTIONS Read and follow all labels and the Owner s Manual carefully before installing operating or servicing unit Read the safety information at the beginning of the m...

Page 11: ... wire OVERUSE can cause OVERHEATING Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again Do not block or filter airflow to unit STATIC ESD can damage PC boards Put on grounded wrist strap BEFORE handling boards or parts Use proper static proof bags and boxes to store move or ship PC boards TILTING OF TRAILER can injure Use tongue jack or bl...

Page 12: ...r Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 25 West 43rd Street New York NY 10036 phone 212 642 4900 web site www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupati...

Page 13: ...ipé Des précautions de sécurité supplémentaires sont requises dans des environnements à risque comme les endroits humides ou lorsque l on porte des vêtements mouillés sur des structures mé talliques au sol grillages et échafaudages dans des positions assises à genoux et allongées ou quand il y a un risque important de contact accidentel avec la pièce ou le sol Dans ces cas utiliser les appareils s...

Page 14: ...es blessures ou même la mort Fermer l alimentation du gaz comprimé en cas de non utilisation Veiller toujours à bien aérer les espaces confinés ou se servir d un respirateur d adduction d air homologué LES RAYONS DE L ARC peuvent provoquer des brûlures dans les yeux et sur la peau Le rayonnement de l arc du procédé de soudage génère des rayons visibles et invisibles intenses ultraviolets et infrar...

Page 15: ...s de l ouverture de la vanne de la bouteille Ne pas se tenir devant ou derrière le régulateur lors de l ouverture de la vanne Maintenir le chapeau de protection sur la soupape sauf en cas d utilisationou de branchement de la bouteille Utiliser les équipements corrects les bonnes procédures et suffi samment de personnes pour soulever et déplacer les bouteilles Lire et suivre les instructions sur le...

Page 16: ...2 4 Dangers liés à l air comprimé Un ÉQUIPEMENT PNEUMATIQUE risque de provoquer des blessures ou même la mort Une installation ou une utilisation incorrecte de cet appareil pourrait conduire à des dégâts matériels ou corporels Seul un personnel qualifié est autorisé à installer utiliser et entretenir cet appareil conformément à son manuel d utilisation aux normes industrielles et aux codes nationa...

Page 17: ...isation ou l entretien de l appareil Lire les informations de sécurité au début du manuel et dans chaque section N utiliser que les pièces de rechange recommandées par le constructeur Effectuer l entretien en respectant les manuels d utilisation les normes industrielles et les codes nationaux d état et locaux 2 5 Dangers supplémentaires en relation avec l installation le fonctionnement et la maint...

Page 18: ...age L EMPLOI EXCESSIF peut SURCHAUFFER L ÉQUIPEMENT Laisser l équipement refroidir respecter le fac teur de marche nominal Réduire le courant ou le facteur de marche avant de poursuivre le soudage Ne pas obstruer les passages d air du poste LES CHARGES ÉLECTROSTATI QUES peuvent endommager les circuits imprimés Établir la connexion avec la barrette de terre avant de manipuler des cartes ou des pièc...

Page 19: ...Standards Sales 5060 Spectrum Way Suite 100 Ontario Canada L4W 5NS phone 800 463 6727 website www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 25 West 43rd Street New York NY 10036 phone 212 642 4900 web site www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot ...

Page 20: ...OM 4421 Page 14 ...

Page 21: ...Protect yourself from electric shock by insulating yourself from work and ground Safe3 2012 05 Keep your head out of the fumes Safe6 2012 05 Use forced ventilation or local exhaust to remove the fumes Safe8 2012 05 Use ventilating fan to remove fumes Safe10 2012 05 Keep flammables away from welding Do not weld near flammables Safe12 2012 05 Welding sparks can cause fires Have a fire extinguisher n...

Page 22: ...ignated collection facility Contact your local recycling office or your local distributor for further information Safe37 2012 05 Do not use ether or other starting fluids Using starting fluids voids warranty See engine Owner s Manual Safe89 2015 02 Wear hat and safety glasses Use ear protection and button shirt collar Use welding helmet with correct shade of filter Wear complete body protection Sa...

Page 23: ...e engine oil and filter Never use generator inside a home or garage even if doors and win dows are open Safe87 2012 07 Only use generator outside and far away from windows doors and vents Safe88 2012 07 3 2 Miscellaneous Symbols And Definitions Some symbols are found only on export products Read Operator s Manual Clock Time Switch A Amperage V Voltage Hz Hertz Seconds h Hours U0 Rated No Load Volt...

Page 24: ...l Remote Output Contractor On Do Not Switch While Welding Welding General Shielded Metal Arc Welding SMAW Gas Tungsten Arc Welding GTAW Tungsten Inert Gas TIG Welding Gas Metal Arc Welding GMAW Constant Current Electrode Connection Work Connection Engine Oil Engine Oil Pressure Fuel Battery Engine Engine Engine Engine RPM Engine Stop Engine Stop Glow Plug Slow Fast Engine Temperature Check Injecto...

Page 25: ... CV 40 Duty Cycle 95 Standard Single Phase 4 kVA kW 34 17 A 120 240 V AC 50 60 Hz Three Phase Generator Option Single Phase Three Phase 12 15 kVA kW 50 36A 120 240 VAC 60 Hz In Addition To Standard 4 kVA kW Generator Power Perkins 404D 22 Water Cooled Four Cylinder 32 6 HP Diesel Engine 25 gal 95 L CV DC CC CV Models Only 14 40 V 56 4 3 Dimensions Weights And Operating Angles Dimensions D B A F E ...

Page 26: ...ary equipment such as torches liquid cooling systems and arc striking and stabilizing devices as part of the welding circuit may not be a major contributor to the EMF See the Owner s Manuals for all components of the welding circuit for additional EMF exposure information The EMF assessment on this equipment was conducted at 0 5 meter At a distance of 1 meter the EMF exposure values were less than...

Page 27: ...lities of the welder generator Curves of all other settings fall between the curves shown A Stick Mode B MIG Mode C TIG Mode DC VOLTS DC AMPERES DC VOLTS DC AMPERES DC VOLTS DC AMPERES 100 80 60 40 20 0 0 100 200 300 400 500 600 700 800 900 1000 100 80 60 40 20 0 0 100 200 300 400 500 600 700 800 900 1000 MAX MIN 100 80 60 40 20 0 0 100 200 300 400 500 RANGES MAX 155 450 115 320 75 195 40 90 RANGE...

Page 28: ...pabilities of the welder generator Curves of all other settings fall between the curves shown DC AMPERES DC VOLTS 100 80 60 40 20 0 0 100 200 300 400 500 600 700 800 900 1000 Ranges 230 Max 170 365 110 225 70 130 55 85 4 8 Fuel Consumption The curve shows typical fuel use under weld or power loads 199 032 A DC WELD AMPERES AT 100 DUTY CYCLE US Gal Hr 0 50 100 150 200 250 300 350 400 450 500 0 00 0...

Page 29: ...0 150 125 0 10 20 30 40 50 60 AC AMPERES IN 120V MODE 4 10 Optional Three Phase Generator Curves 215 086 A 215 087 A The ac power curves show the gen erator power available in amperes at the single phase 120 240 volt re ceptacle or three phase 240 volt terminals A 12 kVA kW Single Phase AC Output No Weld Load B 15 kVA kW Three Phase AC Output No Weld Load AC VOLTS AC VOLTS AC AMPERES AC AMPERES 28...

Page 30: ...enerator onto transport vehicle or trailer and comply with all DOT and other applicable codes Do not weld on base Welding on base can cause fuel tank fire or ex plosion Weld only on the four mounting brackets or bolt unit down NOTICE Do not mount unit by supporting the base only at the four mounting brack ets Use cross supports to adequately support unit and prevent damage to base 1 Cross Supports...

Page 31: ...uip ment If unit does not have GFCI receptacles use GFCI protected extension cord Do not use GFCI receptacles to power life support equip ment 1 EquipmentGrounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 8 AWG or larger insu lated copper wire Electrically bond generator frame to vehicle fra...

Page 32: ...ast NOTICE Wait two minutes after engine shutdown before disconnecting battery or engine controller may be damaged Battery is most easily accessed through the rear panel Remove battery access panel from rear panel Connect battery negative cable last Reinstall battery ac cess panel Do not allow the battery cables to touch opposing terminals When con necting the battery cables attach the positive ca...

Page 33: ... radiator before start ing unit the first time If necessary add coolant to radiator until coolant level is at bottom of filler neck Check coolant level in recovery tank daily If necessary add coolant to recovery tank until coolant level is between Cold Full and Hot Full levels If recovery tank coolant level was low also check coolant level in radiator Add coolant if level is below bottom of radia ...

Page 34: ...ecting to weld output terminals Do not use worn damaged under sized or repaired cables Do not place anything between weld cable terminal and copper bar Make sure that the surface of the weld cable terminal and copper bar are both clean 1 Correct Weld Cable Connection 2 Incorrect Weld Cable Connection 3 Weld Output Terminal 4 Supplied Weld Output Terminal Nut 5 Weld Cable Terminal 6 Copper Bar Remo...

Page 35: ...120 4 0 120 250 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2x2 0 2x70 2x2 0 2x70 300 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2x2 0 2x70 2x3 0 2x95 2x3 0 2x95 350 1 0 60 2 0 70 3 0 95 4 0 120 2x2 0 2x70 2x3 0 2x95 2x3 0 2x95 2x4 0 2x120 400 1 0 60 2 0 70 3 0 95 4 0 120 2x2 0 2x70 2x3 0 2x95 2x4 0 2x120 2x4 0 2x120 500 2 0 70 3 0 95 4 0 120 2x2 0 2x70 2x3 0 2x95 2x4 0 2x120 3x3 0 3x95 3x3 0 3x95 This chart is...

Page 36: ... DC in MIG or Stick mode 0 to 10 volts DC in TIG mode D Remote control circuit common E DC input command signal 0 to 10 volts from min to max of remote control with Voltage Amperage Adjust control at max 115 VOLTS AC I 115 volts 10 amperes 60 Hz AC Protected by supplementa ry protector CB6 J Contact closure to I completes 115 volt AC contactor control circuit GND K Chassis common NEUTRAL G Circuit...

Page 37: ...e Parts List available at www MillerWelds com OM 4421 Page 31 SECTION 6 OPERATING WELDER GENERATOR CC MODELS 6 1 Front Panel Controls For CC Models See Section 6 2 12 236 970 803 602 11 2 1 8 9 7 6 4 5 3 10 13 ...

Page 38: ...ting The Amperage Adjust control adjusts amperage only when welding and does not adjust open circuit voltage The max OCV circuit is disabled when the Stick TIG Selection switch is in Scratch Start TIG position see item 8 6 Ampere Range Switch NOTICE Do not switch under load Use switch to select weld amperage range For most welding applications use lowest amperagerange possible to help prevent arc ...

Page 39: ...le Combination Remote Amperage Control Stick Adjust Optional Remote Control Set Switches Set Range Set Control Ref 154 862 A Ref 181 711 A 803 602 In Example 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 1 6 4 Weld Control Arc Condition Information Label Set weld controls as shown to achieve softer or stiffer arc condi tions for different...

Page 40: ...llerWelds com Complete Parts List available at www MillerWelds com OM 4421 Page 34 SECTION 7 OPERATING WELDER GENERATOR CC CV MODELS 7 1 Front Panel Controls For CC CV Models See Section 7 2 236 971 803 602 2 1 9 14 7 6 4 5 8 13 OR 12 3 10 11 ...

Page 41: ...G welding Read the upper set of numbers at each range for Stick welding and the lower set at each range for TIG welding Use the highest range for MIG welding and for cutting and gouging CAC A For most welding applications use lowest amperagerange possible to help prevent arc outages 8 Voltage AmperageAdjust Control With Process Contactor switch in any Stick or TIG setting use control to adjust amp...

Page 42: ...k position the arc drive dig circuit provides addition al amperage during low voltage short arc length conditions to prevent stick ing electrodes The arc drive dig circuit is disabled when switch is in MIG or TIG positions Place switch in Weld Terminals Al ways On Stick position when us ing optional three phase generator see Section 8 2 The engine auto idle option does not work in the Remote On Of...

Page 43: ... Control Set V A Adjust Switch Set Range Control Not Used In Remote Stick Mode Set Remote Process Example Combination Remote Amperage Control TIG Adjust Optional Remote Control Set V A Adjust Switch Set Range Set Control Set Remote Process 1 In Example Process Stick Using Remote On Off Range 115 to 320 A DC Min 115 A DC Max 320 A DC Max 320 A DC Min 115 A DC In Example Process TIG Using Remote On ...

Page 44: ... Complete Parts List available at www MillerWelds com Complete Parts List available at www MillerWelds com OM 4421 Page 38 7 5 Fuel Hour Gauge Descriptions ...

Page 45: ...r rated at 300 watts Do not run engine while oil pan heater is on NOTICE In extremely cold weath er heater should be connected to 120 volts AC power source when engine oil is warm to eliminate pos sibility of oil coking on heater Severe coking on heater element may cause damage to engine en gine oil and oil pan heater The area near the oil pan heater gets hot Disconnect plug to turn off heater 1 N...

Page 46: ...0 Hz single phase power at weld power speed Test GFCI monthly See Section 8 4 for GFCI information and for reset ting and testing procedures 3 Supplementary Protector CB1 4 Supplementary Protector CB2 CB1 protects RC1 and the generator wind ing from overload If CB1 opens RC1 and GFCI1 do not work Place switch in On position to reset CB2 protects GFCI1 from overload If CB2 opens GFCI1 does not work...

Page 47: ...ad 92 5 Lead 91 6 Lead 42 Circuit Grounding Lead 7 Lead 90 Neutral 8 Isolated Neutral Terminal 9 Jumper Lead 42 10 Grounding Terminal Jumper 42 is connected to lead 90 at factory Jumper 42 may be discon nected from neutral to meet applica ble electrical codes Lead 42 connects to front panel Ground stud 11 User Supplied Leads 12 Supplementary Protector CB7 User Terminals Connect user supplied leads...

Page 48: ... output of all recep tacles is 4 kVA kW EXAMPLE If 13 A is drawn from RC1 only 7 A is available at GFCI1 240 V x 13 A 120 V x 7 A 4 0 kVA kW 2 Circuit Breaker CB2 CB2 protects GFCI1 from overload If a cir cuit breaker opens the receptacle does not work Press CB2 to reset breaker 3 Earth Leakage Circuit Breaker ELCB1 ELCB1 protects RC1 from Earth leakage fault If circuit breaker opens the receptacl...

Page 49: ...g GFCI Receptacle Do not test or reset GFCI receptacles at idle speed low voltage or the GFCI will be damaged and not provide protection from electric shock caused by a ground fault If LED blinks stop using GFCI re ceptacle and have it replaced by a Factory Authorized Service Agent Extension cords with bad insulation or of extended length can allow enough leakage current to trip the GFCI circuit R...

Page 50: ... 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 ...

Page 51: ...8 Fuel Water Separator Fuel Level Oil Level Oil Fuel Spills Coolant Level Every 50 Hours Weld Terminals Every 100 Hours Section 9 4 Battery Terminals Air Cleaner Hoses Air Cleaner Element Every 250 Hours 1 2 in 13 mm Engine Manual Section 9 5 Unreadable Labels Fan Belt Tension Spark Arrestor Every 500 Hours NOTICE Change engine oil and filter after initial 50 to 75 hours of use Section 9 8 Weld Ca...

Page 52: ...Ref 190 823 Stop engine and let cool 1 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 1 Damaged Brushes New Length 1 1 4 in 32 mm Minimum Length 5 8 in 16 mm Replace Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual ...

Page 53: ...fety element Re place the safety element after servic ing the primary element three times Clean or replace primary element if dirty see note above before cleaning Re place primary element if damaged Re place primary element yearly or after six cleanings 1 Housing 2 Safety Element Optional 3 Primary Element 4 Dust Cap 5 Dust Ejector To clean air filter Wipe off cap and housing Remove cap and dump o...

Page 54: ... blow out cleanout hole If nothing blows out of hole briefly cover end of exhaust pipe with fireproof ma terial Stop engine and let cool Reinstall cleanout plug Tools Needed 3 8 in 1 2 9 6 Battery Maintenance Lead acid batteries discharge when stored in any temperature Units that are stored should have the battery recharged every three months and before being put into service To preserve optimum b...

Page 55: ...t engine speed when auto matic idle option is installed To prevent solenoid dam age be sure a 1 8 in 3 mm gap exists between the en gine low speed screw and throttle lever when the sole noid is held in the energized position Unhook rubber boot from the so lenoid housing but leave con nected to plunger Loosen lock nut Place Engine Control Switch in Auto position Turn throttle rod and plunger un til...

Page 56: ...al container Close petcock when water free fuel flows To replace primary fuel filter Turn filter counterclockwise Re move filter Fill new filter with fresh fuel Apply thin coat of fuel to gasket on new fil ter Install new filter and turn clock wise Bleed air from fuel system ac cording to engine manual Inspect fuel lines and replace if cracked or worn To replace secondary fuel filter See engine ma...

Page 57: ...te receptacle RC14 and 24 volt output to field current regulator board PC1 CC CV models only If CB5 opens weld out put and 24 volt output to RC14 stops On units with optional three phase genera tor generator power output at receptacle RC5 also stops if CB5 opens CB6 protects the 115 volt ac output to re mote receptacle RC14 CC CV models only If CB6 opens 115 volt output to RC14 stops CB10 protects...

Page 58: ...ve excessive coils from weld cables Have Factory Authorized Service Agent check brushes and slip rings High weld output Check position of Ampere Range switch and Voltage Amperage Adjust control Check engine speed and have engine manufacturer s factory authorized service agent adjust if neces sary See Section 9 7 for idle speed adjustment Have Factory Authorized Service Agent check OCV control circ...

Page 59: ...ure connection to work piece is clean and tight Use dry properly stored electrodes Remove excessive coils from weld cables Have Factory Authorized Service Agent check brushes and slip rings High weld output Check position of Ampere Range switch and Voltage Amperage Adjust control Check engine speed and have engine manufacturer s factory authorized service agent adjust if nec essary See Section 9 7...

Page 60: ...ield excitation circuit High output at generator power ac re ceptacles Check engine speed and have engine manufacturer s factory authorized service agent adjust if neces sary See Section 9 7 for idle speed adjustment Have Factory Authorized Service Agent adjust generator power field current resistor R3 Low output at generator power ac recep tacles Check engine speed and have engine manufacturer s ...

Page 61: ... Store battery in warm area off cold surface Use fuel formulated for cold weather diesel fuel can gel in cold weather Contact local fuel supplier for fuel information Use correct grade oil for cold weather see Section 9 1 Engine suddenly stops Check oil and coolant levels Automatic shutdown system stops engine if oil pressure is too low or coolant temperatureis too high see Section 5 6 Automatic s...

Page 62: ...iption Part No Dia Mkgs Quantity F1 F2 085874 Fuse Mintr Cer Slo blo 10 Amp 250 Volt 2 190823 Brush Contact Elect 250 X 500 X 1 250 Grd Ay 3 192939 Filter Air Element Safety 1 192938 Filter Air Element Primary 1 197997 Filter Fuel Secondary 1 192744 Filter Fuel Pri 1 197899 Oil Filter 1 197944 Belt Fan V groove 1 Battery Stor 12v 650 Crk 110 Rsv Gp 24 Maint Free 1 Optional Notes ...

Page 63: ... Complete Parts List available at www MillerWelds com OM 4421 Page 57 Notes ...

Page 64: ...OM 4421 Page 58 SECTION 11 ELECTRICAL DIAGRAMS Figure 11 1 Circuit Diagram For CC Welder Generator ...

Page 65: ...OM 4421 Page 59 240 152 B ...

Page 66: ...OM 4421 Page 60 Figure 11 2 Circuit Diagram For CC CV Welder Generator ...

Page 67: ...OM 4421 Page 61 240 153 B ...

Page 68: ...ge and current during run in period to properly seat piston rings and prevent wetstacking See name plate rating label or specifications section in this manual to find rated voltage and current NOTICE Do not idle engine longer than necessary Piston rings only seat correctly if engine runs at weld power rpm and the welder genera tor is kept loaded during run in 2 Engine Exhaust Pipe Wetstacking is u...

Page 69: ...n if not provided on generator Start engine and run for several minutes For Load Bank Set load bank switches and then adjust generator A V control so load equals rated voltage and current of generator see nameplate rating label or the specificationssection in this manual For Resistance Grid Set grid switches and then adjust gen erator A V control so load equals rated voltage and current of the gen...

Page 70: ...alth Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Gen erators 1 Equipment Grounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 8 AWG or larger insulated copper wire Electrically bond generator frame to ve hicle frame by metal to metal contact Bed liners shipping skids and...

Page 71: ...e load and requires a constant amount of power 2 Non Resistive Load Equipment with a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when running see Section 13 8 3 Rating Data Rating shows volts and amperes or watts required to run equipment Amperes x Volts Watts Example 1 If a drill uses 4 5 am peres at 115 volts calculate its run nin...

Page 72: ... Home Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 Milker Vacuum Pump 2 HP 10500 2800 FARM DUTY MOTORS 1 3 HP 1720 720 Std e g Conveyors 1 2 HP 2575 975 Feed Augers Air 3 4 HP 4500 1400 Compressors 1 HP 6100 1600 1 1 2 HP 8200 2200 2 HP 10550 2850 3 H...

Page 73: ...HP 6000 1500 1 1 2 HP 8200 2200 2 HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1 3 HP 2100 700 Elec Hedge Trimmer 18 in 400 400 Flood Lights HID 125 100 Metal Halide 313 250 Mercury 1000 Sodium 1400 Vapor 1250 1000 Submersible Pump 400 GPH 600 200 Centrifugal Pump 900 GPH 900 500 F...

Page 74: ...must be at least twice the motor s running amperage kVA HP x HP x 1000 Volts Starting Amperage Example Calculate starting amper age required for a 230 V 1 4 HP mo tor with a motor start code of M Volts 230 HP 1 4 kVA HP 11 2 11 2 x 1 4 x 1000 230 12 2A Starting the motor requires 12 2 amperes VOLTS AMPS HP 230 2 5 1 4 Hz PHASE CODE 60 1 M AC MOTOR 1 2 3 4 13 9 How Much Power Can Generator Supply R...

Page 75: ...d back to electric utility when service is re stored Install correct switch customer supplied Switch rating must be same as or greater than the branch overcurrent protection 3 Fused Disconnect Switch Install correct switch customer supplied if required by electrical code 4 Welder GeneratorOutput Generator output voltage and wir ing must be consistent with regular utility system voltage and wiring ...

Page 76: ...0 15 40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 2 voltage drop Cord Lengths for 240 Volt Loads Use GFCI protection when operating auxiliary equipment Do not use GFCI receptacles to power life support equipment Maximum Allowable Cord Length in ft m for Conductor Size AWG Current Amperes Load Watts 4 6 8 10 12 14 5 1200 700 213 450 137 225 ...

Page 77: ...OM 4421 Page 71 Notes ...

Page 78: ...OM 4421 Page 72 Notes ...

Page 79: ...uns and Subarc SAW Torches Remote Controls and RFCS RJ45 Replacement Parts No labor Roughneck Guns Spoolmate Spoolguns Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes relays work station table tops and welding curtains or parts that fail due to normal wear Exception brushes and relays are covered on all engine d...

Page 80: ...h your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering Carrier to ...

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