Miller KG195898 Owner's manual

Miller
Brand
Miller
Model
KG195898
Category
Welding System
Type
Owner's manual

This manual is also suitable for

Miller
December1996
Form:
OM-2801E
Effective
With
Serial
No.
KG195898
OWNERS
MANUAL
~
~IETh~
~!r'
CV-3
Constant
Voltage
Module
For
GMAW
And
FCAW
Welding
Model
Rated
Weld
Output
Voltage
Range
CVIDC
Open-Circuit
Voltage
CVIDC
Big
30A
Diesel
200A
@
28VCV/DC,
100%
Duty
Cycle
1440
40
Big
40G,
Big
40
Diesel,
Big
50
Diesel
300
A
At
32
V
CV/DC,
100%
Duty
Cycle
1440
40
cover_om
4/95
'
1996
MILLER
Electnc
Mfg.
Co.
PRINTED
IN
USA
a
I
L
MILLERS
TRUE
BLUEfi
LIMITED
WARRANTY
Effective
February
7,
1996
(Equipment
with
a
serial
number
preface
of
lCD
or
newer)
This
limited
wsnanty
supersedes
all
previous
MILLER
wsrranties
snd
is
esclusive
with
no
other
gusrsntees
or
wsrranties
expressed
or
implied.
UMITED
WARRANTY
Subjectto
the
terms
snd
conditions
below,
MILLER
Electric
Mfg.
Co.,
Appleton,
Wisconsin,
wsrrsnts
to
its
originst
retail
purchaser
thst
new
MILLER
equipment
sold
after
the
effective
dste
ot
this
limited
warranty
is
tree
of
de
tects
in
msterfsl
and
workmanship
at
the
time
it
is
shipped
by
MILLER.
ThIS
WAR
RANTY
IS
EXPRESSLY
IN
LIEU
OF
ALL
OThER
WARRANTIES,
EXPRESS
OR
IMPUED,
INCLUDING
THE
WARRAN11ES OF
MERCHANTABILITY
AND
FIT
NESS.
Within
the
warranty
periods
listed
below,
MILLER
will
repair
or
replace
any
war
ranted
parts
orcomponenta
that
fail
due
to
such
defects
in
material
orworknienship.
MILLER
must
be
notified
in
writing
within
thirty
(30)
days
of
such
defect
or
failure,
at
which
time
MILLER
will
provide
instructions
on
the
warranty
claim
procedures
to
be
followed.
MILLER
shall
honor
warranty
claims
on
warranted
equipment
listed
below
in
the
event
of
such
e
failure
within
the
warranty
time
periods.
All
warranty
time
periods
start
on
the
date
that
the
equipment
was
delivered
to
the
original
retail
purchaser,
or
one
year
after
the
equipment
is
sent
to
a
North
American
distributor
or
eighteen
months
after
the
equipment
is
sent
to
an
Intemational
distributor.
1.
BYearsParta3YearsLabor
Original
main
power
rectiflere
Inverters
(input
and
output
rectifiers
only)
2.
3
Years
Parts
and
Labor
*
Transformer/Rectifier
Power
Sources
Plasma
Arc
Cutting
Power
Sources
*
Semi-Automatic
and
Autometic
Wire
Feeders
*
Inverter
Power
Supplies
*
Irrlellitig
Robots
(1
year
labor)
3.
2
Years
Parts
and
Labor
Engine
Driven
Welding
Generators
(NOTE:
Engines
are
warranted
separately
by
the
engine
manufacturer.)
Air
Compressors
4.
1
Year
Parts
and
Labor
Motor
Driven
Guns
Process
Controllers
IHPSPowerSources
*
Water
Coolant
Systems
HFUnita
Grids
Spot
Welders
Load
Banka
*
SDX
Transformers
*
Miller
Cyclomatic
Equipment
Running
Gear/Trsilers
Plasma
Cutting
Torches
(except
APT,
ZIPCUT
&
PLAZCUT
Models)
*
Tecumaeh
Engines
*
Deutz
Engines
(outside
North
America)
*
Field
Options
(NOTE:
Field
options
are
covered
under
True
Bluefi
for
the
remaining
warranty
period
of
the
product
they
are
installed
in,
or
for
a
minimum
of
one
year
whichever
is
greeter.)
5.
6
Months
Batteries
6.
90
Days
Parts
and
Labor
*
MIG
GunsITlG
Torches
*
APT,
ZIPCUT
&
PLAZCUT
Model
Plasma
Cutting
Torches
Remote
Controla
Acceasory
Kits
*
Replacement
Parts
MILLERS
True
Bluefi
Limited
Warranty
shall
not
apply
to:
1.
Items
fumiahed
by
MILLER,
but
manufactured
by
othere,
such
as
engines
or
trsde
accaaaories.
These
itsms
are
covered
by
the
manufacturers
warranty,
if
any.
2.
Consumable
components;
such
as
contact
tips,
cutting
nozzles,
contactors
and
relays
or
parts
that
fail
due
to
normal
wear.
3.
Equipment
that
has
been
modified
by
any
party
other
than
MILLER,
or
equip
ment
that
has
bean
improperiy
installed,
improperly
operated
or
misused
based
upon
industry
standards,
or
equipment
which
has
not
had
reasonable
and
necessary
maintenance,
or
equipment
which
has
been
used
for
operation
outside
of
the
specifications
for
the
equipment.
MILLER
PRODUCTSARE
INTENDED
FOR
PURCHASEAND
USE
BYCOMMER
CIAL/INDUSTRIAL
USERS
AND PERSONS
TRAINED
AND
EXPERIENCED
IN
ThE
USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT
In
the
event
of
a
warranty
claim
covered
by
this
warranty,
the
exclusive
remedies
shall
be,
at
MILLERS
option:
(1)
repair;
or
(2)
replacement;
or,
where
authorized
in
writing
by
MILLER
in
appropriate
cases,
(3)
the
reasonable
coat
of
repairor
replace
ment
at
an
authorized
MILLER
service
station;
or
(4)
payment
of
orcredit
forthe
pur
chase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
retum
of
the
goods
at
customers
risk
and
expense.
MILLERS
option
of
repair
or
replacement
will
be
FOB.,
Factory
at
Appleton,
Wisconsin,
or
FOB.
at
a
MILLER
authorized
ser
vice
facility
as
determined
by
MILLER.
Therefore
no
compenastion
or
reimburse
ment
for
transportation
coats
of
any
kind
will
be
allowed.
TO
ThE
EXTENT
PERMITTED
BY
LAW,
THE
REMEDIES
PROVIDED
HEREIN
ARE
ThE
SOLE
AND
EXCLUSIVE
REMEDIES.
IN
NO
EVENT
SHALL
MILLER
BE
LiABLE
FOR
DIRECT,
INDIRECT,
SPECIAL
INCIDENTALOR
CONSEQUENTIAL
DAMAGES
(INCLUDING
LOSS
OF
PROFIT),
WHETHER
BASED
ON
CON
TRACT,
TORT
OR
ANY
OTHER
LEGAL
THEORY.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPLIED
WAR
RANTY,
GUARANTY
OR
REPRESENTA11ON
ASTO
PERFORMANCE,
AND
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
TORT
OR
ANY
OThER
LEGAL
ThEORY
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLiCATION,
OPERA11ON
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEAUNG,
IN
CLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
FITNESS
FOR
PARTICULAR
PURPOSE,
WITh
RESPECTTO
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
Some
statse
in
the
U.S.A.
do
not
ailow
limitations
of
how
long
an
implied
warranty
lasts,
or
the
exclusion
of
incidental,
indirect,
special
or
consequential
damages,
so
the
above
limitation
or
exclusion
may
nut
apply
to
you.
This
warranty
provides
ape
cific
legal
rights,
and
other
rights
may
be
available,
but
may
vary
from
state
to
state.
In
Canada,
legislation
in
some
provincea
provides
for
certain
additional
warranties
or
remedies
other
than
as
stated
herein,
and
to
the
extent
that
they
may
not
be
waived,
the
limitations
and
exclusions
set
out
above
may
not
apply.
This
Limited
Warranty
provides
specific
legal
rights,
and
other
rights
may
be
available,
but
may
vary
from
province
to
province.
WHO
DO
I
CONTACT?
For
help,
contact
your
distributor
For
additional
information,
such
as
Technical
Manuals
(SerVice
And
Parts)
Engine
Manuals
Circuit
And
Wiring
Diagrams
Process
Handbooks
To
file
a
claim
for
loss
or
damage
during
shipment,
contact
the
deliVering
carrier
For
assistance
in
filing
or
settling
claims,
contact
your
distributor
and/or
equipment
manufacturers
Transportation
Department
&j3jjj~
IT~T1
Miller
Electric
Mfg.
Co.
CALL:
414-735-4505
FAX:
800-637-2348
(in
USA),
or
414-735-4136
(outside
USA)
Users
Guides
Distributor
Directories
contact
your
distributor
r
I
WRITE:
Miller
Electric
Mfg.
Co.
P0.
BOX
1079
Appleton,
WI
54912
USA
Always
provide
Model
Name
and
Serial
or
Style
Number
.
I
1
I
I
milleLwarl
3/96
TABLE
OF
CONTENTS
SECTION
1
SAFETY
PRECAUTIONS
FOR
ARC
WELDING
1
1-1.
Symbol
Usage
1
1-2.
Arc
Welding
Hazards
1
1-3.
Engine
Hazards
2
1-4.
Additional
Installation,
Operation,
And
Maintenance
Hazards
3
1-5.
Principal
Safety
Standards
3
1-6.
EMF
Information
3
SECTION
2INSTALLATION
4
2-1.
Installing
CV-3
And
Remote
Control
4
2-2.
Installing
CV-3
In
Unit
Equipped
With
Remote
Control
12
SECTION
3OPERATION
14
3-1.
Front
Panel
Controls
14
3-2.
Remote
14
Receptacle
Information
And
Connections
14
3-3.
Terminal
Strip
3T
Connections
15
3-4.
Volt-Ampere
Curves
16
3-5.
Typical
Process
Connections
17
3-6.
Overload
Protection
17
3-7.
Maintenance
18
3-8.
Troubleshooting
18
SECTION
4-
ELECTRICAL
DIAGRAMS
19
SECTION
5
PARTS
LIST
24
OM-2801
E
12196
.
SECTION
1
-
SAFETY
PRECAUTIONS
FOR
ARC
WELDING
safety_romi
4/95
1-1.
Symbol
Usage
AA
Means
Warning!
Watch
Out?
There
are
possible
hazards
with
this
A
Marks
a
special
safety
message.
procedure!
The
possible
hazards
are
shown
in
the
adjoining
symbols.
~
Means
NOTE;
not
safety
related.
~
This
group
of
symbols
means
Warning!
Watch
Out!
possible
ELECTRIC
SHOCK,
MOVING
PARTS,
and
HOT
PARTS
hazards.
Consult
symbols
and
related
instructions
below
for
necessary
actions
to
avoid
the
hazards.
1
I
~
I
1
-2.
Arc
Welding
Hazards
A~
WARNING
The
symbols
shown
below
are
used
throughout
this
manual
to
call
attention
to
and
identify
possible
hazards.
When
you
see
the
symbol,
watch
out,
and
follow
the
related
instructions
to
avoid
the
hazard.
The
safety
information
given
below
is
only
a
summary
of
the
more
complete
safety
information
found
in
the
Safety
Standards
listed
in
Section
1-5.
Read
and
follow
all
Safety
Standards.
Only
qualified
persons
should
install,
operate,
maintain,
and
repair
this
unit.
During
operation,
keep
everybody,
especially
children,
away.
__________
ELECTRIC
SHOCK
can
kill.
Touching
live
electrical
parts
can
cause
fatal
shocks
or
severe
burns.
The
electrode
and
work
circuit
is
electrically
live
whenever
the
output
is
on.
The
input
power
circuit
and
machine
internal
circuits
are
also
live
when
power
is
on.
In
semiautomatic
or
automatic
wire
welding,
the
wire,
wire
reel,
drive
roll
housing,
and
all
metal
parts
touching
the
welding
wire
are
electrically
live.
Incorrectly
installed
or
improperly
grounded
equipment
is
a
hazard.
1.
Do
not
touch
live
electrical
parts.
2.
Wear
dry,
hole-free
insulating
gloves
and
body
protection.
3.
Insulate
yourself
from
work
and
ground
using
dry
insulating
mats
or
covers
big
enough
to
prevent
any
physical
contact
with
the
work
or
ground.
4.
Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment.
Lockout/tagout
input
power
according
to
OSHA
29
CFR
191
0.147
(see
Safety
Standards).
5.
Properly
install
and
ground
this
equipment
according
to
its
Owners
Manual
and
national,
state,
and
local
codes.
6.
Always
verify
the
supply
ground
check
and
be
sure
that
input
cower
cord
around
wire
is
DroDeriv
connected
to
around
terminal
in
disconnect
box
or
that
cord
plug
is
connected
to
a
properly
grounded
receptacle
outlet.
7.
When
making
input
connections,
attach
proper
grounding
conductor
first
double-check
connections.
8.
Frequently
inspect
input
power
cord
for
damage
or
bare
wiring
replace
cord
immediately
if
damaged
bare
wiring
can
kill.
Turn
off
all
equipment
when
not
in
use.
Do
not
use
worn,
damaged,
undersized,
or
poorly
spliced
cables.
11.
Do
not
drape
cables
over
your
body.
12.
If
earth
grounding
of
the
workpiece
is
required,
ground
it
directly
with
a
separate
cable
do
not
use
work
clamp
or
work
cable.
13.
Do
not
touch
electrode
if
you
are
in
contact
with
the
work,
ground,
or
another
electrode
from
a
different
machine.
14.
Use
only
well-maintained
equipment.
Repair
or
replace
damaged
parts
at
once.
Maintain
unit
according
to
manual.
15.
Wear
a
safety
hamess
if
working
above
floor
level.
16.
Keep
all
panels
and
covers
securely
in
place.
17.
Clamp
work
cable
with
good
metal-to-metal
contact
to
workciece
or
worktable
as near
the
weld
as
oractical.
9.
10.
ARC
RAYS
can
burn
eyes
and
skin;
ARC
RAYS
NOISE
can
damage
hearing;
FLYING
~
SLAG
OR
SPARKS
can
injure
eyes.
2.
Wear
a
welding
helmet
fitted
with
a
proper
shade
of
filter
to
protect
yourface
and
eyes
when
welding
or
watching
(see
ANSI
Arc
rays
from
the
welding
process
produce
intense
Z49.1
and
Z87.1
listed
in
Safety
Standards).
-
visible
and
invisible
(ultraviolet
and
infrared)
rays
that
can
bum
eyes
and
skin.
Noise
from
some
3.
Wear
approved
safety
glasses
with
side
shields.
processes
can
damage
hearing.
Chipping,
grinding,
and
welds
cooling
throw
off
pieces
of
4.
Use
protective
screens
or
barriers
to
protect
others
from
flash
metal
or
slag.
and
glare;
warn
others
not
to
watch
the
arc.
NOISE
5.
Wear
protective
clothing
made
from
durable,
flame-resistant
1.
Use
approved
ear
plugs
or
ear
muffs
if
noise
level
is
high.
material
(wool
and
leather)
and
foot
protection.
to
your
health.
wearing
an
air-supplied
respirator.
Always
have
a
trained
~J
FUMES
AND
GASES
can
be
hazardous
5.
Work
in
a
confined
space
only
if
it
is
well
ventilated,
or
while
~
Welding
produces
fumes
and
gases.
Breathing
watchperson
nearby.
Welding
fumes
and
gases
can
displace
air
these
fumes
and
gases
can
be
hazardous
to
your
and
lower
the
oxygen
level
causing
injury
or
death.
Be
sure
the
health.
breathing
air
is
safe.
6.
Do
not
weld
in
locations
near
degreasing,
cleaning,
or
spraying
1.
Keep
your
head
out
of
the
fumes.
Do
not
breathe
the
fumes.
operations.
The
heat
and
rays
of
the
arc
can
react
with
vapors
to
form
highly
toxic
and
irritating
gases.
2.
If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
remove
welding
fumes
and
gases.
7.
Do
not
weld
on
coated
metals,
such
as
galvanized,
lead,
or
3.
If
ventilation
is
pcor,
use
an
approved
air-supplied
respirator.
cadmium
plated
steel,
unless
the
coating
is
removed
from
the
4.
Read
the
Material
Safety
Data
Sheets
(MSDS5)
and
the
weld
area,
the
area
is
well
ventilated,
and
if
necessary,
while
manufacturer~s
instruction
for
metals,
consumables,
coatings,
wearing
an
air-supplied
respirator.
The
coatings
and
any
metals
cleaners,
and
degreasers.
containing
these
elements
can
give
oft
toxic
fumes
if
welded.
OM-2801
Page
1
CYLINDERS
can
explode
if
damaged.
Shielding
gas
cylinders
contain
gas
under
high
pressure.
If
damaged,
a
cylinder
can
explode.
Since
gas
cylinders
are
normally
partof
the
welding
process,
be
sure
to
treat
them
carefully.
1.
Protect
compressed
gas
cylinders
from
excessive
heat,
mechanical
shocks,
slag,
open
flames,
sparks,
and
arcs.
2.
Install
cylinders
in
an
upright
position
by
securing
to
a
stationary
support
or
cylinder
rack
to
prevent
falling
or
tipping.
3.
Keep
cylinders
away
from
any
welding
or
other
electrical
circuits.
4.
Never
drape
a
welding
torch
over a
gas
cylinder.
5.
Never
allow
a
welding
electrode
to
touch
any
cylinder.
6.
Never
weld
on a
pressurized
cylinder
explosion
will
result.
7.
Use
only
correct
shielding
gas
cylinders,
regulators,
hoses,
and
fittings
designed
for
the
specific
application;
maintain
them
and
associated
parts
in
good
condition.
8.
Turn
face
away
from
valve
outlet
when
opening
cylinder
valve.
9.
Keep
protective
cap
in
place
over
valve
except
when
cylinder
is
in
use
or
connected
for
use.
10.
Read
and
follow
instructions
on
compressed
gas
cylinders,
associated
equipment,
and
CGA
publication
P-i
listed
in
Safety
Standards.
WELDING
can
cause
fire
or
explosion.
Welding
on
closed
containers,
such
as
tanks,
drums,
or
pipes,
can
cause
them
to
blow
up.
Sparks
can
fly
off
from
the
welding
arc.
The
flying
sparks,
hot
workpiece,
and
hot
equipment
can
cause
fires
and
bums.
Accidental
contact
of
electrode
to
metal
objects
can
cause
sparks,
explosion,
overheating,
or
fire.
Check
and
be
sure
the
area
is
safe
before
doing
any
welding.
Protect
yourself
and
others
from
flying
sparks
and
hot
metal.
Do
not
weld
where
flying
sparks
can
strike
flammable
material.
Remove
all
flammables
within
35
ft
(10.7
m)
of
the
welding
arc.
If
this
is
not
possible,
tightly
cover
them
with
approved
covers.
4.
Be
alert
that
welding
sparks
and
hot
materials
from
welding
can
easily
go
through
small
cracks
and
openings
to
adjacent
areas.
5.
Watch
for
fire,
and
keep
a
fire
extinguisher
nearby.
6.
Be
aware
that
welding
on a
ceiling,
floor,
bulkhead,
or
partition
can
cause
fire
on
the
hidden
side.
7.
Do
not
weld
on
closed
containers
such
as
tanks,
drums,
or
pipes,
unless
they
are
properiy
prepared
according
to
AWS
F4.1
(see
Safety
Standards).
8.
Connect
work
cable
to
the
work
as
close
to
the
welding
area
as
-
practical
to
prevent
welding
current
from
traveling
long,
possibly
unknown
paths
and
causing
electric
shock
and
fire
hazards.
9.
Do
not
use
welder
to
thaw
frozen
pipes.
10.
Remove
stick
electrode
from
holder
or
cut
off
welding
wire
at
contact
tip
when
not
in
use.
11.
Wear
oil-free
protective
garments
such
as
leather
gloves,
heavy
shirt,
cuffless
trousers,
high
shoes,
and
a
cap.
12.
Remove
any
combustibles,
such
as
a
butane
lighter
or
matches,
from
your
person
before
doing
any
welding.
1-3.
Engine
Hazards
1.
If
the
engine
is
warm
and
checking
is
needed,
follow
steps
2
and
3.
2.
Wear
safety
glasses
and
gloves
and
put
a
rag
over
cap.
3.
Turn
cap
slightly
and
let
pressure
escape
slowly
before
completely
removing
cap.
1.
2.
3.
a
WARNING
ENGINE
EXHAUST
GASES
can
kill.
1.
Use
equipment
outside
in
open,
well-ventilated
areas.
Engines
produce
harmful
exhaust
gases.
2.
If
used
in
a
closed
area,
vent
engine
exhaust
outside
and
away
from
any
building
air
intakes.
.
.
.
I~
A,
~
~
ENGINE
FUEL
can
cause
explosion,
Engine
fuel
is
highly
flammable.
fire
or
2.
3.
Do
not
add
fuel
while
smoking
or
if
unit
is
near
any
s
open
flames.
Do
not
overfill
tank
allow
room
for
fuel
to
expand.
parks
or
1.
Stop
engine
and
let
it
cool
off
before
checking
or
a
dding
fuel.
4.
Do
not
spill
fuel.
If
fuel
is
spilled,
clean
up
before
engine.
starting
MOVING
PARTS
can
cause
injury.
3.
Have
only
qualified
people
remove
guards
or
covers
for
Moving
parts,
such
as
fans,
rotors,
and
belts
can
cut
fingers
and
hands
and
catch
loose
clothing.
4.
5.
maintenance
and
troubleshooting
as
necessary.
To
prevent
accidental
starting
during
servicing,
disconnect
negative
()
battery
cable
from
battery.
Keep
hands,
hair,
loose
clothing,
and
tools
away
from
moving
1.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
parts.
securely
in
place.
6.
Reinstall
panels
or
guards
and
close
doors
when
servicing
is
2.
Stop
engine
before
installing
or
connecting
unit.
finished
and
before
starting
engine.
SPARKS
can
cause
BATTERY
GASES
TO
EXPLODE;
BATTERY
ACID
can
burn
eyes
and
skin,
Batteries
contain
acid
and
generate
explosive
gases.
1.
2.
3.
4.
5.
Always
wear
a
face
shield
when
working
on
a
battery.
Stop
engine
before
disconnecting
or
connecting
battery
cables.
Do
not
allow
tools
to
cause
sparks
when
working
on a
battery.
Do
not
use
welder
to
charge
batteries
or
jump
start
vehicles.
Observe
correct
polarity
(+
and
)
on
batteries.
STEAM
AND
PRESSURIZED
HOT
COOLANT
can
burn
face,
eyes,
and
skin.
It
is
best
to
check
coolant
level
when
engine
is
cold
to
avoid
scalding.
OM-2801
Page
2
1-4.
Additional
Installation,
Operation,
And
Maintenance
Hazards
a
WARNING
MOVING
PARTS
can
cause
injury.
Before
working
of
generator,
remove
spark
plugs
or
injectors
to
keep
engine
from
kicking
back
or
starting.
Block
flywheel
so
that
it
will
not
turn
while
working
on
generator
components.
FLYING
PIECES
OF
METAL
or
DIRT
can
injure
eyes.
1.
Wear
safety
glasses
with
side
shields
or
face
shield.
STATIC
ELECTRICITY
can
damage
parts
on
circuit
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.
MAGNETIC
FIELDS
FROM
HIGH
CURRENTS
can
affect
pacemaker
operation.
1.
Pacemaker
wearers
keep
away.
2.
Wearers
should
consult
their
doctor
before
going
near
arc
welding,
gouging,
or
spot
welding
operations.
HOT
PARTS
can
cause
severe
burns.
1.
Allow
cooling
period
before
maintaining.
2.
Wear
protective
gloves
and
clothing
when
working
on a
hot
engine.
FALLING
EQUIPMENT
can
cause
serious
personal
injury
and
equipment
damage.
1.
Use
lifting
eye
to
lift
unit
only,
NOT
running
gear,
gas
cylinders,
or
any
other
accessories.
Use
equipment
of
adequate
capacity
to
lift
unit.
READ
INSTRUCTIONS.
1.
Use
only
genuine
MILLER
replacement
parts.
2.
Reinstall
injectors
and
bleed
air
from
fuel
system
according
to
engine
manual.
DO
NOT
LET
ENGINE
EXHAUST
SPARKS
CAUSE
FIRE.
1.
Use
approved
engine
exhaust
spark
arrestor
in
required
areas
see
applicable
codes.
LOW
VOLTAGE
AND
FREQUENCY
CAN
DAMAGE
electrical
equipment
such
as
MOTORS.
1.
Turn
off
or
unplug
equipment
before
starting
or
stopping
engine.
I
I
I
OVERUSE
can
cause
OVERHEATED
EQUIPMENT.
1.
Allow
cooling
period.
2.
Reduce
current
or
reduce
duty
cycle
before
starting
to
weld
again.
3.
Follow
rated
duty
cycle.
TILTING
OF
TRAILER
can
cause
injury.
1.
Use
tongue
jack
or
blocks
to
support
weight.
2.
Properly
install
welding
generaior
onto
trailer
according
to
instructions
supplied
with
trailer.
1-5.
Principal
Safety
Standards
BATIERY
ACID
can
BURN
SKIN
AND
EYES.
1.
Donottip.
2.
Replace
damaged
battery.
3.
Flush
eyes
and
skin
immediately
with
water
Safety
in
Welding
and
Cutting,
ANSI
Standard
Z49.1,from
American
Safe
Handllng
of
Compressed
Gases
in
Cylinders,
CGA
Pamphlet
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami
FL
33126
P-i,
from
Compressed
Gas
Association,
1235
Jefferson
Davis
Safety
and
Health
Standards,
OSHA
29
CFR
1910,
from
Highway,
Suite
501,
Arlington,
VA
22202.
Supenntendent
of
Documents,
U.S.
Government
Printing
Office,
Code
forSafety
in
Welding
and
Cutting,
CSA
Standard
Wi
17.2,
from
Washington,
D.C.
20402.
Canadian
Standards
Association,
Standards
Sales,
178
Rexdale
Recommended
Safe
Practices
for
the
Preparation
for
Welding
and
Boulevard,
Rexdale,
Ontario,
Canada
M9W
i
R3.
Cutting
of
Containers
That
Have
Held
Hazardous
Substances,
Safe
Practices
For
Occupation
And
Educational
Eye
And
Face
American
Welding
Society
Standard
AWS
F4.i,
from
American
Protection,
ANSI
Standard
Z87.1
from
American
National
Standards
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami,
FL
33126
Institute,
1430
Broadway,
New
York,
NY
10018.
National
Electrical
Code,
NFPA
Standard
70,
from
National
Fire
Cutting
And
Welding
Processes,
NFPA
Standard
51
B,
from
National
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
1-6.
EMF
Information
Considerations
About
Welding
And
The
Effects
Of
Low
Frequency
To
reduce
magnetic
fields
in
the
workplace,
use
the
following
Electric
And
Magnetic
Fields
procedures:
.
The
following
is
a
quotation
from
the
General
Conclusions
Section
of
1.
Keep
cables
close
together
by
twisting
or
taping
them.
the
U.S.
Congress,
Office
of
Technology
Assessment,
Biological
Effects
of
Power
Frequency
Electnc
&
Magnetic
Fields
Background
2.
Arrange
cables
to
one
side
and
away
from
the
operator.
Paper,
OTA-BP-E-53
(Washington,
DC:
U.S.
Government
Printing
Office,
May
1989):
~..
.
there
is
now
a
very
large
volume
of
scientific
3.
Do
not
coil
or
drape
cables
around
the
body.
findings
based
on
experiments
at
the
cellular
level
and
from
studies
4.
Keep
welding
power
source
and
cables
as
far
away
as
with
animals
and
people
which
clearly
establish
that
low
frequency
practical.
magnetic
fields
can
interact
with,
and
produce
changes
in,
biological
systems.
While
most
of
this
work
is
of
very
high
quality,
the
results
are
5.
Connect
work
clamp
to
workpiece
as
close
to
the
weld
as
complex.
Current
scientific
understanding
does
not
yet
allow
us
to
possible.
interpret
the
evidence
in
a
single
coherent
framework.
Even
more
frustrating,
it
does
not
yet
allow
us
to
draw
definite
conclusions
about
About
Pacemakers:
questions
of
possible
risk
or
to
offer
clear
science-based
advice
on
The
above
procedures
are
also
recommended
for
pacemaker
strategies
to
minimize
or
avoid
potential
risks.
wearers.
Consult
your
doctor
for
complete
information.
OM-280i
Page
3
B.
Installing
Circuit
Board
PC6
2
Mark
And
Dnll
2
Holes
A
Follow
safety
precautions
at
beginning
of
this
section.
A
Cover
parts
before
drilling.
Clean
unit
before
using.
If
necessary,
mark
holes
as
shown.
Drill
two
5/32
in
(4
mm)
holes
as
1-1/4
in
marked.
(32
mm)
1
6-32x3/8inScrew
2
Stand-Off
1
in
(25
mm)
3
Circuit
Board
PC6
4
Self-Locking
Nut
Install
PC6
as
shown.
Go
To
Section
C.
Tools
Needed:
5/32
in
EIIII~~JlJ
1/4,5/l6in
Ref.
ST-i
57
511-A
OM-2801
Page
5
C.
Connecting
To
Circuit
Board
PC6
Parts
And
Location
A
Follow
safety
precautions
at
beginning
of
this
section.
1
Circuit
Breaker
CB1
2
Receptacle
RC1
3
Receptacle
RC2
4
Ground
Stud
5
Circuit
Breaker
CB2
Make
connections
as
shown
below.
Go
To
Section
D.
Wiring
Connections
Connections
for
Big
40G
models
prior
to
Serial
No.
KB064495,
and
Big
40,
Big
50,
and
Big
30A
Diesel
models
prior
to
Serial
No.
KB058480.
(~I~
Cut
off
piggyback
connector
and
strip
insulation
from
end
of
supplied
leads
101
and
102.
GROUND
Terminal
Connections
for
Big
40G
models
with
Serial
No.
KB064496
and
fol
lowing,
and
Big
40,
Big
50,
and
Big
30A
Diesel
models
With
Serial
No.
KB058481
and
following.
Ref.
ST-i
56
194-C
/
S-0761
.
Tools
Needed:
~
5
4
RC2
Lead
120
RC1
Lead
110
GROUND
Terminal
CB2
Lead
101
OM-2801
Page
6
D.
Installing
Mounting
Bracket
And
Terminal
Strip
3T
A
Follow
safety
precautions
at
beginning
of
this
section.
For
Big
30A
Diesel
models
only:
1
Right
Front
Upright
2
Base
If
necessary,
drill
two
7/32
in
(5.6
mm)
holes
as
shown.
For
all
other
models:
3
Right
Front
Upright
4
Existing
Hole
5
Base
If
necessary,
drill
one
7/32
in
(5.6
mm)
hole
above
existing
top
hole
as
shown.
6
Mounting
Bracket
7
3TLabeI
8
Terminal
Strip
3T
9
No.
10
Mounting
Hardware
10
Insulation
Panel
Install
label,
strip,
and
panel
on
bracket.
11
Mounting
Bracket
Hardware
Attach
bracket
on
upright,
and
se
cure
with
1/4-20
x
1/2
in
screws.
12
Plug
PLG8
(Free-Hanging
From
3T)
Connect
PLG8
to
receptacle
RC3
on
PC5.
Go
to
Section
E.
Ref.
ST-156
200-A/Rot.
ST-156
195-A/S-0802
1/4,3/8in
OM-2801
Page
7
E.
Installing
Resistor
Board
R2
And
CV
Board
PC2
A
Follow
safety
precautions
at
beginning
of
this
section.
Use
front
panel
as
guide
to
make
holes
in
nameplate
for
parts
shown.
1
AmperageNoltage
Control
Switch
S4
2
Output
(Contactor)
Switch
S5
3
Constant
Voltage/Constant
Current
Switch
S9
4
Remote
14
Receptacle
RC3
5
6-32
x
3/8
Self-Tapping
Screw
6
Receptacle
Cover
7
Plug
PLG7
Connect
PLG7
to
receptacle
RC2
on
PC5.
8
Circuit
Breaker
CB3
9
Circuit
Breaker
CB4
Go
to
Section
G.
.
.
8
2
A
Follow
safety
precautions
at
beginning
of
this
section.
4
~
1
Retaining
Screw
2
Component
Box
Cover
Remove
screw
and
open
cover.
3
Resistor
Board
R2
4
Mounting
Holes
5
6-32
x
3/8
Screw
6
Lock
Washer
And
Nut
Install
R2
as
shown.
7
CV
Board
PC2
8
Stand-Off
Support
Install
PC2
with
receptacle
RC1
up.
Connect
plug
PLG2
(in
component
box)
to
RC1.
Go
to
Section
F.
Ref.
ST-156
866-A
Tools
Needed:
F.
Component
Installation
9
Tools
Needed:
~r
5/8,9116in
Ref.
ST-156
866-A
OM-2801
Page
8
G.
Circuit
Breakers
CB3
And
CB4
Wiring
Connections
CB3
i
E
SuppiledLead11O~
RC2
A
Follow
safety
precautions
at
beginning
of
this
section.
1
Terminal
Strip
iT
2
Circuit
Breaker
CB3
3
Circuit
Breaker
CB4
4
Circuit
Breaker
CB2
5
Duplex
Receptacle
RC2
Make
connections
shown
below.
Go
to
Section
H.
Tools
Needed:
Connections
for
Big
40G
models
prior
to
Serial
No.
KB064495,
and
all
other
models
prior
to
Serial
No.
KB058480.
CB3
L~1
~
Supplied
Lead
110
iT
ee
ee
ee
ge
ee
00
c~c14-
~
CB2
Lead
I
(Pigtail
In
Harness)
~
Connections
for
Big
40G
models
effective
with
Serial
No.
KB064495
and
following.
Connections
for
all
other
models
effective
with
Serial
No.
KB058480
and
following.
4
Parts
And
Location
Wiring
Connections
Lead
110
N
P
For
all
models.
Lead
130
=1/
Sijoo!ipdL~ad
120
T
Ii
ST.156
866-A
/
Ref.
S-0744-A
OM-2801
Page
9
H.
Supplied
Wiring
Harness
Connections
Lead
47
~
_~
Follow
safety
precautions
at
beginning
of
this
section.
Supplied
Wiring
Harness
Resistor
Board
R2
Terminal
Strip
2T
(Located
On
Back
Of
Component
Box)
4
Terminal
Strip
iT
5
Circuit
Breaker
CB3
6
Circuit
Breaker
CB4
Connect
wiring
harness
to
leads
and
components
as
shown
below.
Go
to
Section
I.
S
.
Parts
And
Location
Tools
Needed:
Wiring
Connections
Lead
18
Qc1
,
Existing
Lead
~L~ea~
CB3
~.Li3L
Connect
to
either
bottom
terminal
CB4
Lead
131
ST-156
866-A/
Ref.
SA-155
737-B
/
S-0745-B
OM-2801
Page
10
I.
Switches
S4,
S5,
And
S9
Wiring
Connections
A
Follow
safety
precautions
2
~
~
at
I~eginning
of
this
section.
1
Switch
S4
2
Switch
S5
3
Switch
S9
4
Component
Box
5
Idle
Module
(Not
Visible)
Make
connections
to
switches
as
shown
below.
All
loose leads
are
located
in
component
box.
Install
panel
guard.
Close
door(s)
and
component
box
cover.
Tools
Needed:
~
3/8
in
Parts
And
Location
Wiring
Connections
ST-i
56
866-A
I
S-0747
OM-2801
Page
11
2-2.
Installing
CV-3
In
Unit
Equipped
With
Remote
Control
NOTE
~
This
Reid
Kit
includes
optional
Remote
Control
components
fresistor
board
R2,
Remote
14
receptacle
RC3,
AmperageNoltage
Control
switch
S4,
Output
(Contactor)
switch
S5,
and
circuit
breakers
CB3
and
CB4).
These
components
do
not
have
to
be
installed
if
welding
generator
already
contains
the
Remote
Control
option.
Retain
parts
for
use
as
spares,
or
discard.
A.
CV-3
Component
Installation
A
Follow
safety
precautions
at
beginning
of
this
section.
Open
doors.
1
Panel
Guard
Remove
guard.
2
Retaining
Screw
3
Component
Box
Cover
Remove
screw
and
open
cover.
4
CV
Board
PC2
5
Stand-Off
Supports
Install
PC2
with
receptacle
RC1
up.
Insert
plug
PLG2
(in
component
box)
in
receptacle
RC1.
6
Constant
Voltage/Constant
Current
Switch
S9
Use
front
panel
as
template
to
mark
hole
for
Constant
Voltage/
Constant
Current
switch
S9
on
nameplate.
Punch
or
drill
hole
where
marked.
Install
S9
so
switch
positions
match
nameplate
labeling
Go
to
Section
B.
Tools
Needed:
.
ST-156
455-A
~
-~
3/8,9/l6in
C
OM-2801
Page
12
B.
Switch
S9
Wiring
Connections
Wiring
Connections
A
Follow
safety
precautions
at
beginning
of
this
section.
1
AmperageNoltage
Control
Switch
S4
2
Output
(Contactor)
Switch
S5
3
Constant
Voltage/Constant
Current
Switch
S9
4
Component
Box
5
Idle
Module
(Not
Visible)
6
Label
Make
connections
to
switches
as
shown.
All
loose leads
are
located
in
component
box.
Install
panel
guard.
Close
door(s)
and
component
box
cover.
Tools
Needed:
~r
3/8
in
/
sT-i
56
866-A
/
S-0748-A
Parts
And
Location
Supplied
Lead
65
Lead
98
Loose
Lead
65
Supplied
Lead
65
Idle
Module
Suppiled
Lead 65
OM-2801
Page
13
3-1.
Front
Panel
Controls
SECTION
3-
OPERATION
.
3-2.
Remote
14
Receptacle
Information
And
Connections
*The
remaining
sockets
are
not
used.
1
2.
4
3~
Ref.
ST-181
711
1
AmperageNoltage
Switch
S4
in
Remote
14
position
and
connect
remote
ensure
wire
feeder
reliability
and
im
To
use
front
panel
control,
place
switch
in
Panel
position.
To
use
remote
control,
place
switch
in
Remote
14
position
and
connect
remote
control
to
Remote
14
receptacle
RC3
or
terminal
strip
3T.
2
Output
(Contactor)
Switch
S5
control
to
Remote
14
receptacle
RC3
or
terminal
strip
3T.
3
Constant
Current/Constant
Voltage
Switch
S9
Place
switch
in
CC
position
for
welding
pro-
cesses
requiring
constant
current
output
(SMAW
and
GTAW).
Place
switch
in
CV
p0-
prove
arc
starting,
unit
does
not
run
at
idle
speed
when
operated
in
CV
mode.
~
When
using
CV
mode,
place
Ampere
Ranges
switch
on
welding
generator
in
the
maximum
amperage
range.
~
AmperageNoltage
Control
Ri
To
use
front
panel
control,
place
switch
in
On
position.
To
use
remote
control,
place
switch
sition
for
welding
processes
requiring
con-
stant
voltage
output
(GMAW
and
FCAW).
To
See
welding
generator
owners
manual
for
control
information.
REMOTE
14
Socket*
Socket
Information
A
24
volts
ac.
Protected
by
circuit
breaker
CB4.
B
Contact
closure
to
A
completes
24
.
volts
ac
contactor
control
circuit.
I
115
volts
ac.
Protected
by
circuit
breaker
CB3.
J
Contact
closure
to
I
completes
115
volts
ac
contactor
control
circuit.
G
Circuit
common
for
24 and
115
volts
ac
circuits.
C
AN
0
to
+10
volts
dc
output
to
remote
con
trol
from
mm
to
max
of
AmperageNolt
age
control
Ri.
Ref.
ST-154
862-A
D
Remote
control
circuit
common.
E
0
to
+10
volts
dc
input
command
signal
from
remote
control.
K
Chassis
common.
OM-2801
Page
14
3-3.
Terminal
Strip
3T
Connections
A
Follow
safety
precautions
at
beginning
of
this
section.
1
Terminal
Strip
3T
2
Terminal
Strip
3T
Cover
Make
connections
to
terminal
strip
31
if
the
plug
supplied
on
the
re
mote
control
cord
does
not
connect
to
Remote
14
receptacle
RC3.
A
Do
not
connect
to
Remote
14
receptacle
RC3
and
ter
minal
strip
3T
at
the
same
time.
Terminal
strip
3T
is
used
to
connect
any
of
the
following
equipment
to
the
welding
generator
control
circuitry:
a
Remote
Contactor
b
Remote
Amperage
or
Voltage
Control
c
Wire
feeder
which
pro
vides
contactor
control
to
the
welding
generator
3
Remote
Control
Cord
To
make
connections,
remove
ex
isting
plug
from
remote
control
cord.
Connect
cord
leads
to
3T
us
ing
terminal
information
from
3T
cover
and
Section
3-2.
Sockets
and
terminals
with
the
same
letter
have
identical
functions.
Route
remote
control
cord
out
just
above
base
rail.
Close
and
secure
side
door.
LINCOLN
cON~ECTION
~J4DER
A
MILLER
3
T
CONNECTION
NU~ER
B
H
F
G
C
D
V
2
Tools
Needed:
cL~1J~
5T-156
865-Al
5T-155
758-A
OM-2801
Page
15
3-4.
Volt-Ampere
Curves
B.
Big
40
Diesel
And
Big
40G
Models
60
va_curvel
4/95
SB-ill
680-B
I
SB-ill
679-A
/
SB-ill
678-A
A.
Big
30A
Diesel
Models
60
40
~30
10
0
.
Volt-ampere
curves
show
mini
mum
and
maximum
voltage
and
amperage
output
capabilities
of
unit.
Curves
of
other
settings
fall
between
curves
shown.
C.
Big
50
Diesel
Models
150
200
250
300
350
DC
AMPERES
60
40
40
~30
~20
10
0
~30
20
0
0
100
200
300
400
600
600
700
DC AMPERES
OM-2801
Page
16
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Miller KG195898 Owner's manual

Miller
Brand
Miller
Model
KG195898
Category
Welding System
Type
Owner's manual
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