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Miller Electric Big Blue 500 PT 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-4429 2216 138H 2007 − 05 Visit our website at www.MillerWelds.com Flux Cored (FCA W ) Welding Air Carbon Arc (CAC-A) Cutting and Gouging File: Engine Drive Big Blue 500 PT B i g B l u e 6 0 0 X   (Per kins T ur bo-Powere d)[...]

  • 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 near est distributor or service agency call 1-800-4-A-Miller , or visit us at www .Mill[...]

  • 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 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Front Panel Controls For CC/CV Models (See Section 7-2) 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1) 3[...]

  • Page 5

    OM-4429 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2007 − 04 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury . The possible hazards are shown in the adjoining symbols or [...]

  • Page 6

    OM-4429 Page 2 W elding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous.  Keep your head out of the fumes. Do not breathe the fumes.  If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases.  If ventilation is [...]

  • Page 7

    OM-4429 Page 3 1-3. Engine Hazards BA TTER Y EXPLOSION can BLIND.  Always wear a face shield, rubber gloves, and protective clothing when working on a battery .  Stop engine before disconnecting or connect- ing battery cables or servicing battery .  Do not allow tools to cause sparks when working on a battery .  Do not use welder to cha[...]

  • Page 8

    OM-4429 Page 4 HOT MET AL from air arc cutting and gouging can cause fire or explosion.  Do not cut or gouge near flammables.  W atch for fire; keep extinguisher nearby . HOT P ARTS can cause burns and injury .  Do not touch hot compressor or air system parts.  Let system cool down before touching or ser- vicing. READ INSTRUCTIONS.  [...]

  • Page 9

    OM-4429 Page 5 H. F . RADIA TION can cause interference.  High-frequency (H.F .) can interfere with radio navigation, safety services, computers, and communications equipment.  Have only qualified persons familiar with electronic equipment perform this installation.  The user is responsible for having a qualified electrician promptly corre[...]

  • Page 10

    OM-4429 Page 6 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION rom_2007 − 04fre Se protéger , ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud. 2-1. Signification des symboles DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des ble[...]

  • Page 11

    OM-4429 Page 7 DES PIÈCES CHAUDES peuvent provoquer des brûlures graves.  Ne pas toucher à mains nues les parties chau - des.  Prévoir une période de refroidissement avant d e travailler à l’équipement.  Ne pas toucher aux pièces chaudes, utiliser les outils recomman - dés et porter des gants de soudage et des vêtements épais [...]

  • Page 12

    OM-4429 Page 8 LES CHAMPS MAGNETIQUES peuv- ent affecter des implants médicaux.  Porteur de simulateur cardiaque ou autre im- plants médicaux, rester à distance.  Les porteurs d’implants doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de sou- dage par points, de gougeage, du coupage[...]

  • Page 13

    OM-4429 Page 9 L ’utilisation d’un groupe autonome à l’intérieur PEUT VOUS TUER EN QUELQUES MINUTES.  Le s fumées d’un groupe autonome contient du monoxyde de carbone. C’est un poison invisi- ble et inodore.  JAMAIS utiliser dans une maison ou garage, même avec les portes et fenêtres ouvertes.  Uniquement utiliser à l’EXT[...]

  • Page 14

    OM-4429 Page 10 LE SURCHAUFFEMENT peut endom- mager le moteur électrique.  Arrêter ou déconnecter l’équipement avant d e démarrer ou d ’a rrêter le moteur .  Ne pas laisser tourner le moteur trop lentement sous risque d’en - dommager l e moteur électrique à cause d’une tension et d’une fré - quence trop faibles.  N e pas[...]

  • Page 15

    OM-4429 Page 1 1 2-6. P r oposition californienne 65 A vertissem ents Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des mal- formations congénitales et, dans certains cas, des cancers. (Code de santé et de sécurité de[...]

  • Page 16

    OM-4429 Page 12 SECTION 3 − DEFINITIONS 3-1. W arning Label Definitions (For Wordless 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 17

    OM-4429 Page 13 3-2. Manufacturer ’ s Rating Labels CC Models CC/CV Models[...]

  • Page 18

    OM-4429 Page 14 3-3. Symbols And Definitions  Some symbols are found only on CE products. 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 elding Arc[...]

  • Page 19

    OM-4429 Page 15 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 65 − 600 A (CC Models) 20 − 600 A (CC/CV Models) 500 A, 40 V olts DC, 100% Duty Cycle 550 A, 42 V olts DC, 60% Duty Cy[...]

  • Page 20

    OM-4429 Page 16 4-3. V olt-Ampere Curves For CC Models 203 412 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. 0 20 40 60 80 100 0 100 200 300 400 500 600 700 800 900 DC AMPERES DC VOL TS Ranges 300 − Max 185 − [...]

  • Page 21

    OM-4429 Page 17 4-4. V olt-Ampere Curves For CC/CV Models 217 81 1 / 203 415 / 217 810 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 0 20 40 60 80 100 0 100 200 300 400 500 60[...]

  • Page 22

    OM-4429 Page 18 4-5. Fuel Consumption The curve shows typical fuel use under weld or power loads. 215 082 − A IDLE DC WELD AMPERES A T 100% DUTY CYCLE U.S. GAL./HR. 0 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 2.25 2.50 0 50 100 150 200 250 300 350 400 450 500 550 600 Continuous Welding 4-6. Duty Cycle And Overheating Duty Cycle is percentage of 10 [...]

  • Page 23

    OM-4429 Page 19 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 24

    OM-4429 Page 20 SECTION 5 − INST ALLA TION install3 2007 − 04 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712 ! 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 electrici[...]

  • Page 25

    OM-4429 Page 21 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 26

    OM-4429 Page 22 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. NOTICE − Do not mount unit by supporting the base only at the four mounting brackets. [...]

  • Page 27

    OM-4429 Page 23 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 . Read the safety rules at the beginni ng of this manual .[...]

  • Page 28

    OM-4429 Page 24 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 batte[...]

  • Page 29

    OM-4429 Page 25 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 , coolant temperature is too high, or engine overspeeds.  This unit has a low oil pressure shut- down switch. However [...]

  • Page 30

    OM-4429 Page 26 5-8. Connecting T o W eld Output T erminals 803 602 / 803 778-A T ools Needed: 2 3/4 in 1 MIG and FC A W Welding 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/Contacto[...]

  • Page 31

    OM-4429 Page 27 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 to weld output terminals. ! Do not use worn, dam- [...]

  • Page 32

    OM-4429 Page 28 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 sup- plementary protector 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 [...]

  • Page 33

    OM-4429 Page 29 Notes[...]

  • Page 34

    OM-4429 Page 30 SECTION 6 − OPERA TING WELDING GENERA TOR − CC MODELS 6-1. Front Panel Controls For CC Models (See Section 6-2) 12 215 663 / 803 602 11 2 1 81 3 1 4 97 6 4 5 3 10[...]

  • Page 35

    OM-4429 Page 31 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 : NOTICE − Do not use ether . Using e[...]

  • Page 36

    OM-4429 Page 32 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 Max (240 A DC) Mi[...]

  • Page 37

    OM-4429 Page 33 Notes[...]

  • Page 38

    OM-4429 Page 34 SECTION 7 − OPERA TING WELDING GENERA TOR − CC/CV MODELS 7-1. Front Panel Controls For CC/CV Models (See Section 7-2) 215 664 / 802 602 13 OR 12 2 1 91 4 1 5 10 7 6 4 5 8 3 11[...]

  • Page 39

    OM-4429 Page 35 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 40

    OM-4429 Page 36 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 Switch R[...]

  • Page 41

    OM-4429 Page 37 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. 215 664 / 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 42

    OM-4429 Page 38 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 43

    OM-4429 Page 39 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 44

    OM-4429 Page 40 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 45

    OM-4429 Page 41 SECTION 9 − MAINTENANCE & TROUBLESHOOTING 9-1. Maintenance Label[...]

  • Page 46

    OM-4429 Page 42 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 Servic[...]

  • Page 47

    OM-4429 Page 43 9-3. 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. The chanc[...]

  • Page 48

    OM-4429 Page 44 9-4. Inspecting And Cleaning Optional Spark Arrestor Muffler 803 656 / Ref. 215 158 ! Stop engine and let cool. 1 Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole. Start engine and run at idle speed to blow out cleanout hole. If nothing blows out of hole, briefly cover end of exhaust pipe[...]

  • Page 49

    OM-4429 Page 45 9-6. Servicing Fuel And Lubrication Systems 802 490 / Ref. 801 434 ! Stop engine and let cool. ! After servicing, start engine and check for fuel leaks. Stop engine, tighten connec- tions as necessary , and wipe up spilled fuel. 1 Oil Filter 2 Oil Drain V alve And Hose 3 Oil Fill Cap 4 Fuel Line 5 Primary Fuel Filter (Fuel/ W ater S[...]

  • Page 50

    OM-4429 Page 46 9-7. Overload Protection 803 605 21 9 8 7 4 ! 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. 1 Fuse F1 2 Fuse F2 F1 and F2 protect the stator exciter wind- ing from overload. If F1 opens, weld a nd genera[...]

  • Page 51

    OM-4429 Page 47 9-8. 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 52

    OM-4429 Page 48 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 53

    OM-4429 Page 49 T rouble Remedy Check and secure connections to Remote 14 receptacle RC14 (see Section 5-1 1). Repair or replace wire feeder . 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 olta[...]

  • Page 54

    OM-4429 Page 50 T rouble Remedy Check engine wiring harness plug connections. Have Factory Authorized Service Agent check control relay CR1, diode/capacitor board D8/C8, and En- gine Control switch S1. Engine cranks but does not start. Check fuel level. Check battery and replace if necessary . Check engine charging system according to engine manual[...]

  • Page 55

    OM-4429 Page 51 Notes Over 80,000 trained since 1930! 400 T rade Square East, T roy , Ohio 45373 1-800-332-9448 www.welding.org Star t Y our Pr ofessional W elding Career Now![...]

  • Page 56

    OM-4429 Page 52 SECTION 10 − ELECTRICAL DIAGRAMS Figure 10-1. Circuit Diagram For CC Welding Generator[...]

  • Page 57

    OM-4429 Page 53 223 525-B[...]

  • Page 58

    OM-4429 Page 54 Figure 10-2. Circuit Diagram For CC/CV Welding Generator[...]

  • Page 59

    OM-4429 Page 55 223 524-B[...]

  • Page 60

    OM-4429 Page 56 SECTION 1 1 − RUN-IN PROCEDURE run_in1 2007 − 04 1 1-1. Wetstacking 1 W elding Generator Ru n diesel engines near rated volt- ag e 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. NOTI[...]

  • Page 61

    OM-4429 Page 57 1 1-2. Run-In Procedure Using Load Bank S-0683 1 Load Bank T urn all load bank switches Of f. If needed, connect load bank to 1 15 volts ac wall receptacle or genera- tor auxiliary power receptacle. 2 Welding Generator Place A/V range switch in maxi- mum position, A/V control in mini- mum position, and Output Selector switch (if pre[...]

  • Page 62

    OM-4429 Page 58 1 1-3. Run-In Procedure Using Resistance Grid S-0684 1 Resistance Grid Use grid sized for generator rated output. Turn O f f grid. 2 Welding Generator Place A/V range switch in maxi- mum position, A/V control in mini- mum position, and Output Selector switch (if present) in either DC position. 3 Weld Cables Connect grid to generator[...]

  • Page 63

    OM-4429 Page 59 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. 12-1. Selecting Equipment gen_pwr 2007 − 04 − Ref. ST -159 730 / ST-800 577 1 Generator Power Receptacles − Neutral Bonded T o Frame 2 3-Pro[...]

  • Page 64

    OM-4429 Page 60 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  Us e 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 65

    OM-4429 Page 61 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 66

    OM-4429 Page 62 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 67

    OM-4429 Page 63 12-8. Power Required T o Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code G H J K L M N P KV A/HP 6.3 7.1 8.0 9.0 10.0 1 1.2 12.5 14.0 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 li[...]

  • Page 68

    OM-4429 Page 64 12-10. T ypical Connections T o Supply Standby Power T ransfer Switch Essential Loads Fused Disconnect Switch (If Required) Utility Electrical Service 12 3 4 5 W elding Generator Output ! Have only qualified persons perform these connections according to all applicable codes and safety practices. ! Properly install and ground this e[...]

  • Page 69

    OM-4429 Page 65 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) 7 840 4[...]

  • Page 70

    OM-4429 Page 66 SECTION 13 − P ARTS LIST  Hardware is common and not available unless listed. 1 2 3 4 5 7 6 8 9 10 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 101 102 103 104 105 100 106 107 108 (CC) 109 (CC) 11 0 1 1 1 (Fig. 13 − 2 11 2 11 3 1 14 (Fig.13 − 7) 1 15 (CV) 1 16 (CV) 11 7 11 8 11 9 120 121 (Fig.13 − 4 OR 13 − 5) 122 123 O[...]

  • Page 71

    OM-4429 Page 67 803 844-B 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 88 (Fig.13 − 6) 89 90 91 92 87 93 94 95 96 97 98 99 55 124[...]

  • Page 72

    OM-4429 Page 68 Description Part No. Dia. Mkgs. Item No. Figure 13-1. Main Assembly Quantity 1 189 824 Panel, Gen Lh 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦ 199 294 Panel, Gen Lh Ss 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 73

    OM-4429 Page 69 Description Part No. Dia. Mkgs. Item No. Figure 13-1. Main Assembly (Continued) Quantity 39 216 133 Engine, Perkins Dsl Elec 404C − 22T 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . *214 931 Sender , Coolant T emp & 1 10c N.o. Switch 1 . . . . . . . . . . . . . . . . . . . [...]

  • Page 74

    OM-4429 Page 70 Description Part No. Dia. Mkgs. Item No. Figure 13-1. Main Assembly (Continued) Quantity 77 190 190 T ank, Coolant Recovery 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 208 141 Stop, Door 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 75

    OM-4429 Page 71 Description Part No. Dia. Mkgs. Item No. Figure 13-1. Main Assembly (Continued) Quantity 123 212 944 Label, Weld Control/Arc Condition Information Label 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 233 088 Label, Danger Using A Generator Indoors Can Kill Y ou In Minutes (Unit) 1 . . . . . . . . . . . . . .[...]

  • Page 76

    OM-4429 Page 72 803 845-D 2 1 23 5 4 3 6 20 18 21 16 15 17 8 11 7 12 19 13 9 10 14 22 Figure 13-2. Control Box Assembly − CC Models[...]

  • Page 77

    OM-4429 Page 73 Description Part No. Dia. Mkgs. Item No. Figure 13-2. Control Box Assembly − CC Models (Figure 13-1 Item 1 1 1) Quantity 1 F1, F2 *085 874 FUSE, mintr cer slo-blo 10A 250V 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 046 432 HOLDER, fuse mintr .250 x 1.250 2 . . . . . . . . . . . . . . [...]

  • Page 78

    OM-4429 Page 74 803 846-D 22 1 2 3 15 19 17 18 16 14 13 8 4 9 12 21 20 10 5 6 7 11 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 1 1) Quantity 1 F1, F2 *085 874 FUSE, mintr cer slo-blo 10A 250V 2 . . . . . . . . . . . . . . . . . . .[...]

  • Page 79

    OM-4429 Page 75 Description Part No. Dia. Mkgs. Item No. Figure 13-3. Control Box Assembly − CC/CV Models (Continued) Quantity 17 134 201 ST AND-OFF , support pc card 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 C9 087 1 10 CAP ACITOR, elctlt 240uf 200VDC 1 . . . . . . . . . . [...]

  • Page 80

    OM-4429 Page 76  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 Description Part No. Dia. Mkgs. Item No. Figure 13-4. Panel, Front w/Components − CC Models (Figur[...]

  • Page 81

    OM-4429 Page 77 Description Part No. Dia. Mkgs. Item No. Figure 13-4. Panel, Front w/Components − CC Models (Continued) Quantity 3 215 014 P ANEL, engine/weld control 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ♦ 217 883 P ANEL, engine/weld control ss 1 . . . . . . . . . . [...]

  • Page 82

    OM-4429 Page 78  Hardware is common and not available unless listed. 803 650 11 31 14 30 27 54 42 53 52 51 50 46 47 49 48 44 39 40 41 38 37 36 35 43 34 29 28 33 2 56 55 57 58 1 7 6 8 10 9 3 5 4 19 24 20 25 26 22 23 21 17 16 15 18 13 12 32 45 Figure 13-5. Panel, Front w/Components − CC/CV Models Description Part No. Dia. Mkgs. Item No. Figure 1[...]

  • Page 83

    OM-4429 Page 79 Description Part No. Dia. Mkgs. Item No. Figure 13-5. Panel, Front w/Components − CC/CV Models (Continued) Quantity 12 S2 021 467 SWITCH, tgl spst 3a 250v off − none − (on) spd term 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 S1 212 436 SWITCH, ignition 4posn w/o handle 1 . . . . . . . . . . . . . . [...]

  • Page 84

    OM-4429 Page 80 55 097 922 KNOB, pointer .875 dia x .250 ID w/set screws plstc 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 189 161 HANDLE, switch range 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 010 647 PIN, spring CS .156 x 1.250 1 . [...]

  • Page 85

    OM-4429 Page 81 Description Part No. Dia. Mkgs. Item No. Figure 13-6. Generator (Continued) Quantity 12 210 446 ROTOR, Generator (Includes) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 024 617 RING, Rtng Ext 1.375 Shaft X .050 Thk 1 . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 86

    OM-4429 Page 82  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 14) Quantity SR3 215 910 RECTIFIER, environmental (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 87

    OM-4429 Page 83  Some wiring harness components (switches, relays, circuit breakers) are also referenced elsewhere in this parts list. Purchase components sepa- rately or as part of the associated wiring harness. Description Part No. Dia. Mkgs. Item No. Wiring Harnesses Quantity 221374 Harness, Engine (Includes) 1 . . . . . . . . . . . . . . . .[...]

  • Page 88

    OM-4429 Page 84 215207 Harness, Unit Weld Control CV (Includes) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG6 1 14063 Conn, Rect Univ 084 4p/S 1row Plug Cable Lkg 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193184 Conn, Rect Cinch 30 Pin 1 . . . . . . . . . . . . .[...]

  • Page 89

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007 − 01 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 expe[...]

  • Page 90

    PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007 − 01 Miller Elect ric Mfg. Co. An Illinois T ool Wo rks 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 −[...]