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Miller Electric Big 40 CX manual

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Table of contents for the manual

  • Page 1

    Processes Description TIG (GT A W) Welding Stick (SMAW ) Welding MIG (GMAW) Welding Engine Driven Welding Generator OM-4427 215 622L 2006 − 01 Visit our website at www.MillerWelds.com Flux Cored (FCA W ) Welding Air Carbon Arc (CAC-A) Cutting and Gouging File: Engine Drive Big 40 C Big 40 CX  [...]

  • Page 2

    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. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .Mille[...]

  • Page 3

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . [...]

  • Page 4

    T ABLE OF CONTENTS SECTION 7 − OPERA TING WELDING GENERA TOR − CC/CV MODELS 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Front Panel Controls For CC/CV Models (See Section 7-2) 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1) 3[...]

  • Page 5

    OM-4427 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom _nd_3/05  W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.  Marks a special saf[...]

  • Page 6

    OM-4427 Page 2 W elding 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. Check and be sure the are[...]

  • Page 7

    OM-4427 Page 3 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 pres- ent on unit, instead of radiator (unless told otherwise in maintenance section or engine manual).  If the engine is warm, checking is needed, and there is no overflow[...]

  • Page 8

    OM-4427 Page 4 READ INSTRUCTIONS.  Use only genuine MILLER/Hobart replacement parts.  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 . RADIA TION can cause interference.  High-frequency (H.F .) can interfere with radio naviga- [...]

  • Page 9

    OM-4427 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION rom_fre 3/05  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 [...]

  • Page 10

    OM-4427 Page 6 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. Le contact ac[...]

  • Page 11

    OM-4427 Page 7  Si le moteur est chaud et que le liquide doit être vérifié, opérer comme suivant.  Mettre des lunettes de sécurité et des gants, placer un torchon sur le bouchon du radiateur .  Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant d’enle- ver le bouchon. LES ACCUMULA TIONS DE GAZ ris- quent de [...]

  • Page 12

    OM-4427 Page 8 LIRE LES INSTRUCTIONS.  Utiliser seulement les pièces de rechange d’origine.  Ef fectuer la maintenance du moteur et du compresseur (s i applicable) suivant ce manuel et le manuel du moteur/ compresseur (si applicable). LE RA YONNEMENT HAUTE FRÉ- QUENCE (H.F .) risque de provoquer des interférences.  Le rayonnement haut[...]

  • Page 13

    OM-4427 Page 9 SECTION 3 − DEFINITIONS 3-1. W arning Label Definitions (For W ordless Labels) 3/96 1 Remove unit from shipping crate. Remove Owner’s Manual from unit. Follow instructions to install muf fler . 2 Read Owner ’s Manual. Read labels on unit. 3 Use Diesel Fuel only , and fill fuel tank. Leave room for expansion. 4 Warning! W atch O[...]

  • Page 14

    OM-4427 Page 10 3-2. Manufacturer ’ s Rating Labels CC Export Models CC/CV Models CC Models CC/CV Export Models[...]

  • Page 15

    OM-4427 Page 1 1 3-3. Symbols And Definitions Some symbols are found only on export products. NOTE Stop Engine Fast (Run, W eld/ Power) Slow (Idle) Start Engine Starting Aid Battery (Engine) Engine Oil Pressure Engine Oil Check Injectors/ Pump Check V alve Clearance Fuel Protective Earth (Ground) Positive Negative Certified/T rained Mechanic W eldi[...]

  • Page 16

    OM-4427 Page 12 SECTION 4 − SPECIFICA TIONS 4-1. W eld, Power , And Engine Specifications W elding Mode W eld Output Range Rated W elding Output Maximum Open- Circuit V oltage Generator Power Rating Engine Fuel Capacity CC/DC 55 − 500 A (CC Models) 15 − 500 A (CC/CV Models) Export Models : 300 A, 32 V olts DC, 100% Duty Cycle 430 A, 37 V olts[...]

  • Page 17

    OM-4427 Page 13 4-3. V olt-Ampere Curves For CC Models 215 081-A The volt-ampere curve shows the minimum and maximum voltage an d amperage output capabilities of th e welding generator . Curves of al l other settings fall between the curves shown. DC AMPERES DC VOL TS 100 80 60 40 20 0 0 100 200 300 400 500 600 700 800 900 1000 Ranges: 230 − Max [...]

  • Page 18

    OM-4427 Page 14 4-4. V olt-Ampere Curves For CC/CV Models 215 080-A / 215 083-A / 215 079-A The volt-ampere curves show the minimum and maximum voltage an d amperage output capabilities of th e welding generator . Curves of al l other settings fall between the curves shown. A. Stick Mode B. MIG Mode C. TIG Mode DC VOL TS DC AMPERES DC VOL TS DC AMP[...]

  • Page 19

    OM-4427 Page 15 4-5. Fuel Consumption The curve shows typical fuel use under weld or power loads. 199 032 − A DC WELD AMPERES A T 100% DUTY CYCLE US Gal./Hr . 0 50 100 150 200 250 300 350 400 450 500 0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 2.25 2.50 IDLE Continuous W elding 4-6. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- [...]

  • Page 20

    OM-4427 Page 16 4-7. AC Generator Power Curve 193 018 Th e 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 1 02 03 0 4 05 0 6 0 AC AMPERES IN 120V MODE 4-8. Optional Three-Phase Generator Curves[...]

  • Page 21

    OM-4427 Page 17 SECTION 5 − INST ALLA TION install3 6/05 − Ref. 800 652 / Ref. 800 477-A / 803 274  Always securely fasten weld- ing generator onto transport vehicle or trailer and comply with all DOT and other applica- ble codes.  Always ground generator frame to vehicle frame to pre- vent electric shock and static electricity hazards. ?[...]

  • Page 22

    OM-4427 Page 18 5-2. Using Lifting Eye Ref. 802 31 1 1 Lifting Eye 2 Nut 3 Carriage Bolt Raise lifting eye until it snaps in place. Lower lifting eye when not needed. T o lock the lifting eye in the upright position, insert a 3/8-16 x 1-1/2 in carriage bolt through slot in bracket a nd secure with nut (bolt and nut not supplied). T ools Needed: 2 1[...]

  • Page 23

    OM-4427 Page 19 5-3. Mounting Welding Generator T ools Needed: 9/16 in 2 2 4 W elding Unit In Place Bolting Unit In Place  Do not weld on base. W eld- ing on base can cause fuel tank fire or explosion. Weld only on the four mounting brackets or bolt unit down.  Do not mount unit by sup- porting the base only at the four mounting brackets. Use[...]

  • Page 24

    OM-4427 Page 20 5-4. Installing Exhaust Pipe 1/2 in T ools Needed: Ref. 803 604 / Ref. 215 158  Stop engine and let cool.  Point exhaust pipe in desired di- rection but always away from front panel and direction of travel. Notes W or k l i ke a P r o ! Pros wel d and cut safel y . R ead t he safety rules at the beginni ng of this manual .[...]

  • Page 25

    OM-4427 Page 21 5-5. Activating The Dry Charge Battery (If Applicable)  Always wear a face shield, rubber gloves and protective clothing when working on a battery . Remove battery from unit. 5 V ent Caps 6 Sulfuric Acid Electrolyte (1.265 Specific Gravity) 7 W ell Fill each cell with electrolyte to bottom of well (maximum).  Do not overfill b[...]

  • Page 26

    OM-4427 Page 22 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. Automatic shutdown system stops engine if oil pressure is too low or coolant tempera- ture is too high.  This unit has a low oil pressure shut- down switch. However , some condi- tions[...]

  • Page 27

    OM-4427 Page 23 5-8. Connecting T o Weld Output T erminals 803 602 / 803 778-A T ools Needed: 2 3/4 in 1 MIG and FCA W W elding For MIG and FCA W 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[...]

  • Page 28

    OM-4427 Page 24 5-9. Selecting W eld Cable Sizes* W eld Cable Size** and T otal Cable (Copper) Length in W eld Circuit Not Exceeding*** 100 ft (30 m) or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft (105 m) 400 ft (120 m) W eld Output T erminals  Stop engine before connecting t o weld out- put terminals.  Do not use worn[...]

  • Page 29

    OM-4427 Page 25 5-1 1. Connecting T o Remote 14 Receptacle RC14 On CC/CV Models Socket* Socket Information 24 VOL TS AC A 24 volts ac. Protected by circuit breaker CB5. 24 VOL TS AC B Contact closure to A completes 24 volt ac contactor control circuit. C Output to remote control:+10 volts dc in MIG or Stick mode; 0 to +10 volts dc in TIG mode. REMO[...]

  • Page 30

    OM-4427 Page 26 SECTION 6 − OPERA TING WELDING GENERA TOR − CC MODELS 6-1. Front Panel Controls For CC Models (See Section 6-2) 12 215 070 / 803 602 11 2 1 81 3 1 4 97 6 4 5 3 10[...]

  • Page 31

    OM-4427 Page 27 6-2. Description Of Front Panel Controls For CC Models (See Section 6-1 ) Engine Starting Controls 1 Starting Aid Switch Use switch to energize starting aid for cold weather starting (see starting instructions fol- lowing). 2 Engine Control Switch Use switch to start and stop engine. T o Start :  Do not use ether . Using ether vo[...]

  • Page 32

    OM-4427 Page 28 6-3. Remote Amperage Control On CC Models (Optional) 1 Remote Amperage Adjust Receptacle RC13 Connect optional remote control to RC13 (see Section 5-10 ). Example: Combination Remote Amperage Control (Stick) Adjust Optional Remote Control Set Switches Set Range Set Control Ref. 154 862-A / Ref. 181 71 1-A / 803 602 In Example: Range[...]

  • Page 33

    OM-4427 Page 29 Notes[...]

  • Page 34

    OM-4427 Page 30 SECTION 7 − OPERA TING WELDING GENERA TOR − CC/CV MODELS 7-1. Front Panel Controls For CC/CV Models (See Section 7-2) 215 158 / 802 602 2 1 91 4 1 5 10 7 6 4 5 11 8 13 OR 12 3[...]

  • Page 35

    OM-4427 Page 31 7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1 ) Engine Starting Controls 1 Starting Aid Switch Use switch to energize starting aid for cold weather starting (see starting instructions fol- lowing). 2 Engine Control Switch Use switch to start engine, select engine speed ( if unit has auto idle option), an[...]

  • Page 36

    OM-4427 Page 32 7-3. Process/Contactor Switch On CC/CV Models 1 Process/Contactor Switch  W eld output terminals are ener- gized when Process/Contactor switch is in an Weld T erminals 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 Swit[...]

  • Page 37

    OM-4427 Page 33 7-4. Remote V oltage/Amperage Control On CC/CV Models (Optional) 1 Remote 14 Receptacle RC14 Connect optional remote control to RC14 (see Section 5-1 1). 0774 / Ref. 215 158 / Ref. 803 602 Example: Combination Remote Amperage Control (Stick) Adjust Optional Remote Control Set V/A Adjust Switch Set Range Control Not Used In Remote St[...]

  • Page 38

    OM-4427 Page 34 SECTION 8 − OPERA TING AUXILIAR Y EQUIPMENT 8-1. 120 V olt And 240 V olt Receptacles 191 624-A 2 1 120 V 20 A AC GFCI Receptacle GFCI1 2 240 V 30 A AC T wistlock Receptacle RC1 Receptacles supply 60 Hz single- phase power at weld/power speed. If a ground fault is detected, GFCI Reset button pops out and receptacle does not work. C[...]

  • Page 39

    OM-4427 Page 35 8-2. Connecting T o Optional Three-Phase Generator (CC/CV Models Only) Ref. 197 399 / 802 332-E / 803 655  Place Process/Contactor switch in W eld T erminals Always On - Stick position when using three- phase generator (see Section 7-3 ). Single-Phase Generator Power 1 120/240 V 50 A Receptacle RC5 RC5 is connected to the optiona[...]

  • Page 40

    OM-4427 Page 36 8-3. Optional Generator Power Receptacles 2 1 120 V 20 A AC GFCI Receptacle GFCI1 2 240 V 16 A AC European Receptacle RC1 3 240 V 15 A AC Australian Receptacle RC1 4 240 V 15 A AC South African Receptacle RC1 Receptacles supply 60 Hz single- phase power at weld/power speed. If a ground fault is detected, the GFCI Reset button pops o[...]

  • Page 41

    OM-4427 Page 37 SECTION 9 − MAINTENANCE & TROUBLESHOOTING 9-1. Maintenance Label[...]

  • Page 42

    OM-4427 Page 38 9-2. Routine Maintenance  Stop engine before maintaining.  S ee Engine Manual and Maintenance Label for important start-up, service, and storage information. Service engine more often if used in severe conditions. Recycle engine fluids.  = Check  = Change  = Clean  = Replace * T o be done by Factory Authorized Serv[...]

  • Page 43

    OM-4427 Page 39 9-3. Checking Generator Brushes Ref 215 158  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 o r near minimum length. 1 Damaged Brushes New Length: 1-1/4 in (32 mm) Minimum Length: 5/8 in (16 mm) Replace Notes W or k[...]

  • Page 44

    OM-4427 Page 40 9-4. Servicing Air Cleaner  Stop engine.  Do not run engine without air cleaner or with dirty element. En- gine damage caused by using a damaged element 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. The chance of [...]

  • Page 45

    OM-4427 Page 41 9-5. 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 blows out of hole, briefly cover end of exhaust pi[...]

  • Page 46

    OM-4427 Page 42 9-6. Adjusting Engine Speed On Models With Automatic Idle (Optional) 803 606 1850 rpm max (61.6 Hz) 1250 rpm (41.6 Hz) Engine Speed (No Load)  See engine manual for engine speed adjustments on standard models. After tuning engine, check engine speed with tachometer or frequency meter . See table for proper no load speed. If neces[...]

  • Page 47

    OM-4427 Page 43 9-7. 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 V alve And Hose 3 Oil Fill Cap 4 Fuel Line 5 Primary Fuel Filter (Fuel/ W at[...]

  • Page 48

    OM-4427 Page 44 9-8. Overload Protection 803 605 21 9 8 7 4 5  Stop engine.  When a circuit breaker or fuse opens, it usually indicates a more se- rious problem exists. Contact Facto- ry Authorized Service Agent. 1 Fuse F1 2 Fuse F2 F1 and F2 protect the stator exciter wind- ing from overload. If F1 opens, weld a nd generator power is low or [...]

  • Page 49

    OM-4427 Page 45 9-9. T roubleshooting A. Welding − CC Models T rouble 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 position and connect remote control to Remote Amper[...]

  • Page 50

    OM-4427 Page 46 B. Welding − CC/CV Models T rouble Remedy No weld output; generator power output okay at ac receptacles. Place Process/Contactor switch in a Weld T erminals Always On position, or place switch in a Remote On/Of f Switch Required position and connect remote contactor to optional Remote 14 receptacle RC14 (see Sections 5-1 1 and 7-1[...]

  • Page 51

    OM-4427 Page 47 T rouble Remedy Low CV weld output. Set Ampere Range switch to highest range. Increase V oltage/Amperage Adjust Control setting. Min or max CV weld output only . Check position of V oltage/Amperage Adjust control and V oltage/Amperage Adjust switch. Repair or replace remote control device. Have Factory Authorized Service Agent check[...]

  • Page 52

    OM-4427 Page 48 E. Engine T rouble 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. Che[...]

  • Page 53

    OM-4427 Page 49 Notes[...]

  • Page 54

    OM-4427 Page 50 SECTION 10 − ELECTRICAL DIAGRAMS Figure 10-1. Circuit Diagram For CC Welding Generator[...]

  • Page 55

    OM-4427 Page 51 223 522-B[...]

  • Page 56

    OM-4427 Page 52 Figure 10-2. Circuit Diagram For CC/CV Welding Generator[...]

  • Page 57

    OM-4427 Page 53 223 523-B[...]

  • Page 58

    OM-4427 Page 54 SECTION 1 1 − RUN-IN PROCEDURE run_in1 1 1/05 1 1-1. Wetstacking  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 . 1 Welding Generator Ru n diesel engines near rated volt- ag e and current during run-in period to properly seat piston rings and preve[...]

  • Page 59

    OM-4427 Page 55 1 1-2. Run-In Procedure Using Load Bank S-0683  Stop engine.  Do not touch hot exhaust pipe, engine parts, or load bank/grid.  Keep exhaust and pipe away from flammables.  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 . 1 Load Bank T urn all[...]

  • Page 60

    OM-4427 Page 56 1 1-3. Run-In Procedure Using Resistance Grid S-0684  Stop engine.  Do not touch hot exhaust pipe, engine parts, or load bank/grid.  Keep exhaust and pipe away from flammables.  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 . 1 Resistance Gr[...]

  • Page 61

    OM-4427 Page 57 SECTION 12 − GENERA TOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding generators. Y our unit may differ from those shown. NOTE 12-1. Selecting Equipment gen_pwr 1 1/02 − Ref. ST -159 730 / ST-800 577 1 Generator Power Receptacles − Neutral Bonded T o Frame 2 3-Prong P[...]

  • Page 62

    OM-4427 Page 58 12-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 AWG or larger insulated copper wire. 3 Ground Device  Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. GND/PE 1 2 Us e ground device as stated in electric[...]

  • Page 63

    OM-4427 Page 59 12-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Star ting W atts Running W atts 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 HP 6100 1600 1-1/2 HP 8200 2200 2 HP 10550 285[...]

  • Page 64

    OM-4427 Page 60 12-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting W atts Running W atts 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 T able Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in 2500 1 100 Bench Grinder 6 in 1720 720 8 in [...]

  • Page 65

    OM-4427 Page 61 12-8. Power Required T o Start Motor S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor V oltage T o find starting amperage: Step 1: Find code and use table to find kV A/HP . If code is not listed, multiply running amperage by six to find starting amperage. Step 2 : Find Motor HP and V olts. Step 3: Determine starting a[...]

  • Page 66

    OM-4427 Page 62 12-10. T ypical Connections T o Supply Standby Power  Have only qualified persons perform these connections according to all applicable codes and safety practic- es.  Properly install and ground this equipment according to its Owner’ s Manual and national, state, and local codes.  Customer -supplied equipment is re- quire[...]

  • Page 67

    OM-4427 Page 63 12-1 1. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 V olt Loads  If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (A WG)* Current (Amperes) Load (W atts) 4 6 8 10 12 14 5 600 350 (106) 225 (68) 137 (42) 100 (30) 7 8[...]

  • Page 68

    OM-4427 Page 64 SECTION 13 − P ARTS LIST  Hardware is common and not available unless listed. 40C Models Only 1 2 3 4 5 6 7 8 9 10 11 13 14 15 12 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 106 107 108 109 11 0 111 11 2 11 3 1 14 (Fig. 13-2 OR 13-3 11 5 1 16 (CC ONLY) 1 17 1 18 (CV) 1 19 (CV) 120 121 122 123 124 125 (Fig. 13-4 OR 13-5) [...]

  • Page 69

    OM-4427 Page 65 803 646-D 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 85 84 86 87 88 89 90 91 93 (FIG. 13-6) 95 96 97 98 99 100 101 102 103 104 105 94 92 60[...]

  • Page 70

    OM-4427 Page 66 Description Part No. Dia. Mkgs. Item No. Figure 13-1. Main Assembly Quantity 1 189 824 P ANEL, gen LH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦ 199 294 P ANEL, gen LH ss 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 71

    OM-4427 Page 67 Description Part No. Dia. Mkgs. Item No. Figure 13-1. Main Assembly (Continued) Quantity 40 ♦ 202 629 COVER, radiator access ss 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 191 354 SUPPORT , cover 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 72

    OM-4427 Page 68 Description Part No. Dia. Mkgs. Item No. Figure 13-1. Main Assembly (Continued) Quantity 77 191 626 BUMPER, door engine access 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 199 592 LA TCH, paddle series 20 (black) 1 . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 73

    OM-4427 Page 69 Description Part No. Dia. Mkgs. Item No. Figure 13-1. Main Assembly (Continued) Quantity 120 ♦ 199 305 TOP , cover front upright ss 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 212 944 LABEL, weld control/arc condition information label 1 . . . . . . . . . . . . [...]

  • Page 74

    OM-4427 Page 70  Hardware is common and not available unless listed. 803 647-E 2 1 24 23 5 4 3 6 14 21 18 22 20 16 15 17 8 11 7 10 12 9 19 13 Figure 13-2. Control Box Assembly − CC Models Description Part No. Dia. Mkgs. Item No. Figure 13-2. Control Box Assembly − CC Models (Figure 13-1 Item 1 14) Quantity 1 F1, F2 *085 874 FUSE, mintr cer s[...]

  • Page 75

    OM-4427 Page 71 Description Part No. Dia. Mkgs. Item No. Figure 13-2. Control Box Assembly − CC Models Continued Quantity 20 201 079 COVER, control box 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 C9 087 1 10 CAP ACITOR, elctlt 240uf 200VDC 1 . . . . . . . . . .[...]

  • Page 76

    OM-4427 Page 72 803 648-E 23 1 2 3 16 20 18 19 17 15 14 5 11 8 4 7 9 6 12 22 21 10 13 Figure 13-3. Control Box Assembly − CC/CV Models Description Part No. Dia. Mkgs. Item No. Figure 13-3. Control Box Assembly − CC/CV Models (Figure 13-1 Item 1 14) Quantity 1 F1, F2 *085 874 FUSE, mintr cer slo-blo 10A 250V 2 . . . . . . . . . . . . . . . . . .[...]

  • Page 77

    OM-4427 Page 73 Description Part No. Dia. Mkgs. Item No. Figure 13-3. Control Box Assembly − CC/CV Models (Continued) Quantity 20 177 136 CLAMP , capacitor 1.375dia 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 D1/C1 189 701 DIODE/CAPACITOR BOARD 1 . . . . . . . . . . . . . [...]

  • Page 78

    OM-4427 Page 74  Hardware is common and not available unless listed. 803 649 1 2 3 4 5 6 7 8 9 11 10 12 13 14 15 16 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 34 33 35 36 37 38 39 40 41 42 17 Figure 13-4. Panel, Front w/Components − CC Models[...]

  • Page 79

    OM-4427 Page 75 Description Part No. Dia. Mkgs. Item No. Figure 13-4. Panel, Front w/Components − CC Models (Figure 13-1 Item 125 ) Quantity 1 215 070 PLA TE SCREENED, ident control rating; when ordering this item, . . . . . . . . . . . . . . . . . . the nameplate should also be ordered) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 80

    OM-4427 Page 76 Description Part No. Dia. Mkgs. Item No. Figure 13-4. Panel, Front w/Components − CC Models (Continued) Quantity 38 ♦ 164 873 VOL T METER, W/Leads 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 ♦ 164 874 AMMETER, W/Leads 1 . . . . . . . . . . . . . . . .[...]

  • Page 81

    OM-4427 Page 77 Description Part No. Dia. Mkgs. Item No. Figure 13-5. Panel, Front w/Components − CC/CV Models (Figure 13-1 Item 125) Quantity 1 215 158 PLA TE SCREENED, ident control; when ordering this item, . . . . . . . . . . . . . . . . . . the nameplate should also be ordered) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 82

    OM-4427 Page 78 Description Part No. Dia. Mkgs. Item No. Figure 13-5. Panel, Front w/Components − CC/CV Models (Continued) Quantity 38 134 201 ST AND-OFF , support 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 181 169 SP ACER, output stud 2 . . . . . . . . . . . .[...]

  • Page 83

    OM-4427 Page 79 802 552-B  Hardware is common and not available unless listed. 5 6 8 9 24 28 30 31 32 33 1 2 7 25 26 35 36 4 3 10 27 21 29 34 20 17 18 11 15 16 12 13 14 19 22 23 Figure 13-6. Generator Description Part No. Dia. Mkgs. Item No. Figure 13-6. Generator (Figure 13-1 Item 93) Quantity 1 132 053 SCREW, .375 − 16x1.50 hex hd − pln gr[...]

  • Page 84

    OM-4427 Page 80 Description Part No. Dia. Mkgs. Item No. Figure 13-6. Generator (Continued) Quantity 21 197 486 ADAPTER, Engine 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 083 883 WASHER, Lock .402idx0.709odx.087t Stl Split10mm 4 . . . . . . . . . . . . . . . .[...]

  • Page 85

    OM-4427 Page 81  Hardware is common and not available unless listed. 802 279-A 1 2 3 4 6 5 7 8 9 Figure 13-7. Main Rectifier Assembly Description Part No. Dia. Mkgs. Item No. Figure 13-7. Main Rectifier Assembly (Figure 13-1 Item 1 17) Quantity SR3 215 909 RECTIFIER (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 86

    OM-4427 Page 82 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. Note Description Part No. Dia. Mkgs. Item No. Wiring Harnesses Quantity 215054 Harness, control box, CC weld control (includes) 1 . . . . . [...]

  • Page 87

    OM-4427 Page 83 Description Part No. Dia. Mkgs. Item No. Wiring Harnesses (Continued) Quantity 221376 Harness, engine control (includes) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10/C10, D1 1/C1 1 189701 Diode/Capacitor Board, 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 88

    [...]

  • Page 89

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 1/05 Y our distributor also gives you ... Service Y ou 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 questions? Contact your distributor . The expertise o[...]

  • Page 90

    PRINTED IN USA © 2005 Miller Electric Mfg. Co. 10/05 Miller Elect ric Mfg. Co. An Illinois T ool W orks Compa ny 1635 West S pencer S treet Applet on, WI 5 4914 US A International He adquarters − US A USA Phone: 920-735-4505 Aut o-At tended USA & Canada F A X: 9 20-735-4134 Int ernati onal F AX : 920-735-4125 European Headqua rters − Unite[...]