Miller
December
1994
Form:
OM-2801C
Effective
With
Serial
No.
KC289996
OWNERS
MANUAL
CV-3
Control
Read
and
follow
these
instructions
and
all
safety
blocks
carefully.
Have
only
trained
and
qualified
persons
install,
operate,
or
service
this
unit.
Call
your
distributor
if
you
do
not
understand
the
directions.
Constant
Voltage
Control
For
Big
30A,
40,
And
50
Diesels,
And
Big
4oG
Models
With
Serial
No.
JK728391
And
Following
For
GMAW
And
FCAW
Welding
100%
Duty
Cycle
At
Welding
Generator
Rated
Load
Give
this
manual
to
the
operator.
For
help,
call
your
distributor
or:
MILLER
Electric
Mfg.
Co.,
P.O.
Box
1079,
Appleton,
WI
54912
414-734-9821
cover
5194
'
1994
MILLER
Electflc
MIg.
Co.
PRINTED
IN
USA
u-f
MILLERS
TRUE
BLUETM
LIMITED
WARRANTY
Effective
January
1,
1995
(Equipment
with
a
serial
number
preface
of
KC
or
newer)
This
limited
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
1~I
LIMITED
WARRANTY
Subject
to
the
terms
and
conditions
below,
MILLER
Electric
Mt
g.
Co.,
Appleton,
Wisconsin,
warrants
to
its
original
retail
purchaser
that
new
MILLER
equipment
sold
alter
the
effective
date
ot
this
limited
warranty
is
tree
ot
de
fects
in
material
and
workmanship
at
the
time
it
is
shipped
by
MILLER.
THIS
WAR
RANTY
IS
EXPRESSLY
IN
LIEU
OF
ALL
OTHER
WARRANTIES,
EXPRESS
OR
IMPLIED,
INCLUDING
THE
WARRANTIES
OF
MERCHANTABILITY
AND
FIT
NESS.
Within
the
warranty
periods
listed
below,
MILLER
will
repair
or
replace
any
war
ranted
parts
or
components
that
tail
due
to
such
detects
in
material
or
workmanship.
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
a
failure
within
the
warranty
time
periods.
All
warranty
time
periods
start
on
the
date
that
the
equipment
was
delivered
to
the
onginal
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
tntemational
distributor.
1,
5YearsParts3YearsLabor
Original
main
power
rectifiers
2.
3
Years
Parts
and
Labor
Transformer/Rectifier
Power
Sources
Plasma
Arc
Cutting
Power
Sources
SemI-Automatic
and
Automatic
Wire
Feeders
Robots
3.
2
Years
Parts
and
Labor
Engine
Driven
Welding
Generators
(NOTE:
Engines
are
warranted
separately
by
the
engine
manufacturer
for
a
period
of
Iwo
years.)
Air
Compressors
4.
1
Year
Parts
and
Labor
Motor
Driven
Guns
Process
Controlters
Water
Coolant
Systems
HF
Units
Grids
Spot
Welders
Load
Banks
SDX
Translormers
Running
Gear/Trailers
Plasma
Cutting
Torches
(except
APT,
ZIPCUT
&
PLAZCUT
Models)
Field
Options
(NOTE:
Field
options
are
covered
under
True
BIueTM
for
the
remaining
warranty
period
of
the
product
they
are
installed
in.
or
for
a
minimum
of
one
year
whichever
is
greater.)
6
Months
Batteries
90
Days
Parts
and
Labor
MIG
Guns/TIG
Torches
APT,
ZIPCUT
&
PLAZCUT
Model
Plasma
Cutting
Torches
u-I
Remote
Controls
Accessory
Kits
Replacement
Parts
MILLERS
True
BlueTM
Umited
Warranty
shall
not
apply
to:
1.
Items
furnished
by
MILLER,
but
manufactured
by
others.
such
as
engines
or
trade
accessories.
These
it
ems
are
covered
by
the
manufacturers
warranty,
if
any.
2.
Consumable
components;
such
as
contact
lips,
cutting
nozzles.
contactors
and
relays
or
parts
that
fatl
due
10
normat
wear.
3.
Equipmenl
that
has
been
modified
by
any
party
other
than
MILLER.
or
equip
ment
Ihat
has
been
improperly
installed,
improperly
operaled
or
misused
based
upon
industry
standards,
or
equipment
which
has
not
had
reasonabte
and
necessary
maintenance,
or
equipment
which
has
been
used
for
operation
outside
01
the
specifications
for
the
equipment.
MILLER
PRODUCTS
ARE
INTENDED
FOR
PURCHASE
AND
USE
BY
COMMER
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
MILLERS
option:
(1)
repair:
or
(2)
replacement:
or,
where
authorized
in
writing
by
MILLER
in
appropriate
cases,
(3)
the
reasonable
cost
of
repair
or
replace
ment
at
an
authorized
MILLER
service
station;
or
(4)
payment
of
or
credit
br
the
pur
chase
price
(less
reasonable
deprecialion
based
upon
actual
use)
upon
return
ol
the
goods
at
customers
risk
and
expense.
MILLERS
option
01
repair
or
replacement
will
be
FOB.,
Factory
at
Appleton,
Wisconsin,
or
FOB.
at
a
MILLER
authorized
ser
vice
lacility
as
determined
by
MILLER.
Therefore
no
compensation
or
reimburse
ment
br
transportation
costs
of
any
kind
wilt
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,
INCIDENTAL
OR
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
REPRESENTATION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
TORT
OR
ANY
OTHER
LEGAL
THEORY
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
IN
CLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
Some
states
in
the
U.S.A.
do
not
allow
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
not
apply
to
you.
This
warranty
provides
spe
cific
legal
rights,
and
other
rights
may
be
available,
but
may
vary
from
state
10
state.
In
Canada,
legislation
in
some
provinces
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.
5.
6.
Ii
RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
damage
that
may
have
occurred
during
shipment.
File
any
claims
for
loss
or
damage
with
the
delivering
carrier,
Assistance
for
filing
or
settling
claims
may
be
obtained
from
distributor
and/or
equipment
manufacturers
Transportation
Department.
When
requesting
information
about
this
equipment,
always
provide
Model
Designation
and
Serial
or
Style
Number.
Use
the
following
spaces
to
record
Model
Designation
and
Serial
or
Style
Number
of
your
unit.
The
information
is
located
on
the
rating
label
or
nameplate.
Model
_________
Serial
or
Style
No.
Date
of
Purchase
miller
11/94
ERRATA
SHEET
March
21,
1995
FORM:
OM-2801C
Use
above
FORM
number
when
ordering
extra
manuals.
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manuaL
CHANGES
TO
SECTION
3INSTALLATION
Replace
Figure
3-1.
Installing
Circuit
Board
PC5
Open
and
secure
right
side
door.
On
a
Big
30A
Diesel
model,
open
and
secure
left
side
door
also.
1
Panel
Guard
Remove
panel
guard.
2
Reference
Hole
Mark
hole
location
shown.
(Holes
are
pre-drilled
on
models
with
Seri
al
No.
KC289996
and
following.)
3
Circuit
Board
PC5
Use
PC5
as
template
to
locate
and
mark
remaining
two
holes.
Drill
three
5/32
in
(4
mm)
holes
at
marked
locations.
1
4
6-32
x
3/8
in
Screw
5
Stand-Off
Insert
supplied
screws
through
holes
in
front
panel,
and
secure
stand-offs
to
screws.
2-1/2
in
6
Self-Locking
Nut
(62
mm)
Install
PC5
as
shown.
7
Ground
Terminal
Stud
8
Male
Friction
Ground
Termi
nalA
9
Ground
Lead
42
Connect
female
friction
end
of
supplied
ground
lead
to
male
fric
tion
terminal
A.
Connect
ring
termi
nal
end
of
lead
to
rear
of
ground
ter
minal
stud.
10
Ground
Strap
M~rl~A~i09~rill
Secure
ground
strap
to
stand-off
when
installing
circuit
board.
Go
to
Section
B.
9
E~ZJ~fl
1/4,5/16
in
Ref.
ST-134
108/Ref.
ST-156
194-C
Tools
Needed:
5/32
in
Install
PC5
~iiiii~~
1/2
in
Figure
3-1.
Installing
Circuit
Board
PC5
Replace
Figure
3-7.
Circuit
Breaker
CB3
And
CB4
Wiring
Connections
E~J~j
E~Jp
E~Jc
E~J~
E~JT
E~Ju
CHANGES
TO
SECTION
7-
PARTS
LIST
Connections
for
all
other
models
effective
with
Serial
No.
KB058480
and
following.
Change
Parts
Lists
as
follows:
Description
Quantity
25-8
....
039
885
....
170
391
..
CONNECTOR,
circ
protective
cap
1
**First
digit
represents
page
no
digits
following
dash
represent
item
no.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
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:
Parts
And
Location
Wiring
Connections
CB3
DTh
CB3
CB2
____
Supplied
Lead
lD~~
~
Lead
IC
(
Harness
11
Lead
130
Suoolied
Lead
130
RC2
Connections
for
Big
40G
models
prior
to
Serial
No.
KB064495,
and
all
other
models
prior
to
Serial
No.
KB058480.
Connections
for
Big
40G
models
effective
with
Serial
No.
KB064495
and
following.
For
all
models.
CB4
Figure
3-7.
Circuit
Breaker
CB3
and
CB4
Wiring
connections
ST-156
866-B
/
Ref.
S-0744-A
**
Part
No.
Replaced
With
OM-2801C
Page
2
ARC
WELDING
SAFETY
PRECAUTIONS
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
livewhen
powerison.
In
semlautomaticorautomatic
wire
welding,
the
wire,
wire
reel,
drive
roll
housing,
and
all
metal
parts
touchin9
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.
Lockoutitagout
input
power
according
to
OSHA
29
CFR
1910.147
(see
Safety
Standards).
5.
Properly
install
and
ground
this
equipment
according
to
its
Owners
Manual and
national,
state,
and
local
codes.
6.
Always
verify
the
supply
ground
check
and
be
sure
that
input
cower
cord
around
wire
is
orołerlv
connected
to
around
ARC
RAYS
can
burn
eyes
and
skin;
NOISE
can
damage
hearing;
FLYING
SLAG
OR
SPARKS
can
injure
eyes.
Arc
rays
from
the
welding
process
produce
intense
visible
and
invisible
(ultraviolet
and
infrared)
rays
that
can
burn
eyes
and
skin.
Noise
from
some
processes
can
damage
hearing.
Chipping,
grinding,
and
welds
cooling
throw
off
pieces
of
metal
or
slag.
1.
Use
approved
ear
plugs
or
ear
muffs
if
noise
level
is
high
FUMES
AND
GASES
can
be
hazardous
to
your
health.
Welding
produces
fumes
and
gases.
Breathing
these
fumes
and
gases
can
be
hazardous
to
your
health.
1.
Keep
your
head
out
of
the
fumes.
Do
not
breathe
the
fumes.
2.
If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
remove
welding
fumes
and
gases.
3.
If
ventilation
is
poor,
use an
approved
air-supplied
respirator.
4.
Read
the
Material
Safety
Data
Sheets
(MSDSS)
and
the
manufacturers
instruction
for
metals,
consumables,
coatings,
and
degreasers.
CYLINDERS
can
explode
if
damaged.
Shielding
gas
cylinders
contain
gas
under
high
pressure.
If
damaged,
a
cylinder
can
explode.
Since
gas
cylinders
are
normally
part
of
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.
ARC
RAYS
2.
Wear
a
welding
helmet
fitted
with
a
proper
shade
of
filter
to
protect
your
face
and
eyes
when
welding
or
watching
(see
ANSI
Z49.1
and
Z87.1
listed
in
Safety
Standards).
3.
Wear
approved
safety
glasses
with side
shields.
4.
Use
protective
screens
or
barriers
to
protect
others
from
flash
and
glare;
warn
others
not
to
watch
the
arc.
5.
Wear
protective
clothing
made
from
durable,
flame-resistant
material
(wool
and
leather)
and
foot
protection.
5.
Work
in
a
confined
space
only
if
it
is
well
ventilated,
or
while
wearing
an
air-supplied
respirator.
Always
have
a
trained
watchperson
nearby.
Welding
fumes
and
gases
can
displace
air
and
lower
the
oxygen
level
causing
injury
or
death.
Be
sure
the
breathing
air
is
safe.
6.
Do
not
weld
in
locations
near
degreasing,
cleaning,
or
spraying
operations.
The
heat
and
rays
of
the
arc
can
react
with
vapors
to
form
highly
toxic
and
irritating
gases.
7.
Do
not
weld
on
coated
metals,
such
as
galvanized,
lead,
or
cadmium
plated
steel,
unless
the
coating
is
removed
from
the
weld
area,
the
area
is
well
ventilated,
and
if
necessary,
while
wearing
an
air-supplied
respirator.
The
coatings
and
any
metals
containing
these
elements
can
give
off
toxic
fumes
if
welded.
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.
_________________________
4A
WARNING
ARC
WELDING
can
be
hazardous.
PROTECT
YOURSELF
AND
OTHERS
FROM
POSSIBLE
SERIOUS
INJURY
OR
DEATH.
KEEP
CHILDREN
AWAY.
PACEMAKER
WEARERS
KEEP
AWAY
UNTIL
CONSULTING
YOUR
DOCTOR.
Inwelding,
as
in
most
jobs,
exposure
to
certain
hazards
occurs.
Welding
is
safe
when
precautions
are
taken.
The
safety
information
given
below
is
only
a
summary
of
the
more
complete
safety
information
that
will
be
found
in
the
Safety
Standards
listed
on
the
next
page.
Read
and
follow
all
Safety
Standards.
HAVE
ALL
INSTALLATION,
OPERATION,
MAINTENANCE,
AND
REPAIR
WORK
PERFORMED
ONLY
BY
QUALIFIED
PEOPLE.
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.
9.
Turn
off
all
equipment
when
not
in
use.
10.
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
harness
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
workoiece
or
worktable
as
near
the
weld
as
cractical.
NOISE
511.1.1
2/94
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
burns.
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.
1.
Protect
yourself
and
others
from
flying
sparks
and
hot
metal.
2.
Do
not
weld
where
flying
sparks
can
strike
flammable
material.
3.
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
pip~s,
unless
they
are
properly
prepared
according
t0AWS
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.
Wearoil-freeprotectivegarmentssuchasleathergloves,
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.
ENGINE
EXHAUST
GASES
can
kill.
Engines
produce
harmful
exhaust
gases.
ENGINE
FUEL
can
cause
fire
or
explosion.
Engine
fuel
is
highly
flammable.
1.
Stop
engine
and
let
it
cool
off
before
checking
or
adding
fuel.
2.
Do
not
add
fuel
while
smoking
or
if
unit
is
near
any
sparks
or
open
flames.
MOVING
PARTS
can
cause
injury.
Moving
parts,
such
as
fans,
rotors,
and
belts
can
cut
fingers
and hands and
catch
loose
clothing.
1.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.
2.
Stop
eng
ne
before
installing
or
connecting
unit
SPARKS
can
cause
BATTERY
GASES
TO
EXPLODE;
BATTERY
ACID
can
burn
eyes
and
skin.
Batteries
contain
acid
and
generate
explosive
~ases.
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.
ENGINES
can
be
hazardous.
1.
Use
equipment
outside
in
open,
well-ventilated
areas.
2.
If
used
in
a
closed
area,
vent
engine
exhaust
outside
and
away
from
any
building
air
intakes.
3.
Have
only
qualified
people
remove
guards
or
covers
for
maintenance
and
troubleshooting
as
necessary.
4.
To
prevent
accidental
starting
during
servicing,
disconnect
negative
()
battery
cable
from
battery.
5.
Keep
hands,
hair,
loose
clothing,
and
tools
away
from
moving
parts.
6.
Reinstall
panels
or
guards
and
close
doors
when
servicing
is
finished
and
before
starting
engine.
Always
wear
a
face
shield
when
working
on
a
battery.
Stop
engine
before
disconnecting
or
connecting
battery
cables.
3.
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.
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.
PRINCIPAL
SAFETY
STANDARDS
Safety
in
Welding
and
Cutting,
ANSI
Standard
Z49.
1,
from
American
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami
FL
33126
Safety
and
Health
Standards,
OSHA
29
CFR
1910,
from
Superinten
dent
of
Documents,
U.S.
Government
Printing
Office,
Washington,
D.C.
20402.
Recommended
Safe
Practices
for
the
Preparation
for
Welding
and
Cutting
of
Containers
That
Have
Held
Haza
rdous
Substances,
Ameri
can
Welding
Society
Standard
AWS
F4.
1,
from
American
Welding
So
ciety,
550
N.W.
LeJeune
Rd. Miami,
FL
33126
National
Electrical
Code,
NFPA
Standard
70,
from
National
Fire
Pro
tection
Association,
Batterymarch
Park.
Quincy,
MA
02269.
Safe
Handling
of
Compressed
Gases
in
Cylinders.
CGA
Pamphlet
P-i,
from
Compressed
Gas
Association,
1235
Jefferson
Davis
High
way,
Suite
501,
Arlington,
VA
22202.
Code
for
Safety
in
Welding
and
Cutting,
CSA
Standard
Wi
17.2,
from
Canadian
Standards
Association,
Standards
Sales,
178
Rexdale
Bou
levard,
Rexdale,
Ontario,
Canada
M9W
1
R3.
Safe
Practices
For
Occupation
And
Educational
Eye
And
Face
Protec
tion,
ANSI
Standard
Z87.1,
from
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
Cutting
And
Welding
Processes,
NFPA
Standard
516,
from
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
AA
WARNING
3.
Do
not
overfill
tank
allow
room
for
fuel
to
expand.
4.
Do
not
spill
fuel.
If
fuel
is
spilled,
clean
up
before
starting
engine.
1.
2.
4.
5.
srl.l.1
2/94
EMF
INFORMATION
NOTE
~
Considerations
About
Welding
And
The
Effects
Of
Low
Frequency
Electric
And
___________________
Magnetic
Fields
The
following
is
a
quotation
from
the
General
Conclusions
Section
To
reduce
magnetic
fields
in
the
workplace,
use
the
following
of
the
U.S.
Congress,
Office
of
Technology
Assessment,
Biological
procedures:
Effects
of
Power
Frequency
Electric
&
Magnetic
Fields
1.
Keep
cables
close
together
by
twisting
or
taping
them.
Background
Papel
OTA-BP-E-53
(Washington,
DC:
U.S.
Government
Printing
Office,
May
1989):.
.
.
there
is
now
a
very
2.
Arrange
cables
to
one
side
and
away
from
the
operator.
large
volume
of
scientific
findings
based
on
experiments
at
the
3.
Do
not
coil
or
drape
cables
around
the
body.
cellular
level
and
from
studies
with
animals
and
people
which
clearly
4.
Keep
welding
power
source
and
cables
as
far
away
as
establish
that
low
frequency
magnetic
fields
can
interact
with,
and
nractjcal
produce
changes
in,
biological
systems.
While
most
of
this
work
is
of
very
high
quality,
the
results
are
complex.
Current
scientific
5.
Connect
work
clamp
to
workpiece
as
close
to
the
weld
as
understanding
does
not
yet
allow
us
to
interpret
the
evidence
in
a
possible.
single
coherent
framework.
Even
more
frustrating,
it
does
not
yet
About
Pacemakers:
allow
us
to
draw
definite
conclusions
about
questions
of
possible
The
above
procedures
are
among
those
also
normally
risk
or
to
offer
clear
science-based
advice
on
strategies
to
minimize
recommended
for
pacemaker
wearers.
Consult
your
doctor
for
or
avoid
potential
risks.
complete
information.
modlO.1
4~93
TABLE
OF
CONTENTS
SECTION
1
-
SAFETY
INFORMATION
1
SECTION
2
SPECIFICATIONS
1
2-1.
Volt-Ampere
Curves
2
SECTION
3
INSTALLATION
2
3-1.
Installing
CV-3
And
Remote
Control
3
3-2.
Installing
CV-3
In
Unit
Equipped
With
Remote
Control
11
3-3.
Remote
14
Receptacle
Information
And
Connections
13
3-4.
Terminal
Strip
3T
Wiring
Connections
14
3-5.
Typical
Process
Connections
15
SECTION
4-OPERATION
16
SECTION
5
MAINTENANCE
&
TROUBLESHOOTING
18
5-1.
Routine
Maintenance
18
5-2.
Overload
Protection
18
5-3.
Troubleshooting
19
SECTION
6
ELECTRICAL
DIAGRAMS
20
SECTION
7
PARTS
LIST
24
Figure
7-1.
CV-3
Module
24
oM-28o1c
-
12194
SECTION
1
-
SAFETY
INFORMATION
modl.1
2/93
_______
:1~lI~eU
3
ELECTRIC
SHOCK
can
kiII.d~
Do
not
toucl~
five
electrical
parts.
Disconnect
input
power
before
4
installing
or
servicing.
1
Safety
Alert
Symbol
2
Signal
Word
WARNING
means
possible
death
or
serious
injury
can
happen.
CAUTION
means
possible
minor
injury
or
equipment
damage
can
happen.
3
Statement
Of
Hazard
And
Result
4
Safety
Instructions
To
Avoid
Hazard
5
Hazard
Symbol
(It
Available)
6
Safety
Banner
Read
safety
blocks
for
each
sym.
bol
shown.
7
NOTE
Special
instructions
for
best
oper
ation
not
related
to
safety.
Figure
1-1.
Safety
Information
SECTION
2-
SPECIFICATIONS
Table
2-1.
For
Welding
Generators
In
CV
Mode*
Specification
Description
Big
30A
Diesel
Big
40
Diesel
&
Big
40G
Big
50
DIesel
Rated
Weld
Output
At
100%
Duty
Cycle
Load
Voltage
Range
Max.
Open-Circuit
Voltage*
200A
At
28V
10.35
40
Volts
DC
300A
At
32V
10-35
40
Volts
DC
300A
At
32V
1
0~35
40
Volts
DC
See
Owners
Manual
for
specifications
in
CC
mode.
Read
all
safety
messages
throughout
this
manual.
Obey
all
safety
messages
to
avoid
injury.
Learn
the
meaning
of
WARNING
and
CAUTION.
1
2
2
\.
A~
CAUTION
/
5
MOVING
PARTS
can
Injure.
~
l(eep
away
from
moving
pans.
S
Keep
all
panels
and
covers
closed
when
operating.
6
a
WARNING
READ
SAFETY
BLOCKS
at
start
of
Section
3-1
before
proceeding.
7~~j
NOTE
Ei
Turn
Off
switch
when
using
high
frequency.
OM-2801
Page
1
2-1.
Volt-Ampere
Curves
Figure
2-1.
Volt-Ampere
Curves
SECTION
3-INSTALLATION
a
WARNING
ELECTRIC
SHOCK
can
kill
Do
not
touch
live
electncal
parts.
Stop
engine
and
disconnect
negative
()
battery
cable
from
battery
before
beginning
this
nstallation.
MOVING
PARTS
can
cause
injury.
Keep
away
from
moving
parts
such
as
fans,
belts,
and
rotors.
SPARKS
can
cause
BATTERY
GASES
TO
EXPLODE;
BATTERY
ACID
can
burn
eyes
and
skin.
Always
wear
a
face
shield
and
proper
protective
clothing
when
working
on
a
battery.
Do
not
allow
tools
to
cause
sparks
when
working
on
a
battery.
HOT
PARTS
can
cause
severe
burns.
Allow
cooling
period
before
touching.
Wear
protective
gloves
and
clothing
when
working
on
a
hot
engine.
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.
FILINGS
AND
TOOLS
HITTING
INSIDE
PARTS
can
damage
unit.
Cover
parts.
1%
I
Clean
unit
and
remove
covers
before
operating.
Have
only
qualified
persons
familiar
with
and
following
standard
safety
practices
install
this
kit.
~
~
A.
Big
30A
Diesel
Models
Volt-ampere
curves
show
minimum
and
maximum
voltage
and
amper
age
output
capabilities
of
the
weld
ing
generator.
Curves
of
other
set
tings
fall
between
the
curves
shown.
C.
Big
50
Diesel
Models
50
40
30
0
>
g2o
10
0
B.
Big
40
Diesel
And
Big
40G
Models
50
40
30
~20
10
0
DC
AMPERES
50
40
30
X20
10
0
~OX
~EO8ThT
0
100
200
300
400
500
DC
AMPERES
600
100
200
300
400
500
600
700
DC
AMPERES
Ssbl.l
10/91
SB-ill
680-B/SB-ill
679-A(SB~111
678-A
OM-2801
Page
2
NOTE
The
CV-3
control
cannot
be
installed
on
models
prior
to
Serial
No.
JK728391.
If
installing
CV-3
and
optional
Remote
Control,
go
to
Section
3-1.
If
installing
CV-3
in
a
unit
with
optional
Remote
Control,
go
to
Section
3-2.
If
CV-3
was
factory
installed,
go
to
Section
3-3.
A
Big
40
Diesel
model
is
shown
throughout
Section
3.
3-1.
Installing
CV-3
And
Remote
Control
READ
SAFETY
BLOCKS
at
start
of
Section
3
before
proceeding.
Figure
3-1.
Installing
Circuit
Board
PC5
Open
and
secure
right
side
door.
On
a
Big
30A
Diesel
model,
open
and
secure
left
side
door
also.
1
Panel
Guard
Remove
panel
guard.
2
Reference
Hole
Mark
hole
location
shown.
(Holes
are
pre-drilled
on
models
with
Seri
al
No.
KC289996
and
following.)
3
Circuit
Board
PC5
Use
PC5
as
template
to
locate
and
mark
remaining
two
holes.
Drill
three
5/32
in
(4
mm)
holes
at
marked
locations.
4
6-32
x
3/8
in
Screw
5
Stand-Off
Insert
supplied
screws
through
holes
in
front
panel,
and
secure
stand-offs
to
screws.
6
Self-Locking
Nut
Install
P05
as
shown.
7
Ground
Terminal
Stud
8
Male
Friction
Ground
Termi
nal
A
9
Ground
Lead
42
Connect
female
friction
end
of
supplied
ground
lead
to
male
fric
tion
terminal
A.
Connect
ring
termi
nal
end
of
lead
to
rear
of
ground
ter
minal
stud.
10
Ground
Lead
Secure
ground
lead
to
stand-off
when
installing
circuit
board.
Go
to
Section
B.
A.
Installing
Circuit
Board
PC5
2-1/2
in
(62
mm)
Mark
And
Drill
Hole
7
Mark
And
Drill
Two
Holes
9
Tools
Needed:
5/32
in
Install
PC5
c:::::=J=:cI
1/4,5/l6in
1/2in
Ret.
ST-134
108/
Ret.
ST-156
194-8
OM-2801
Page
3
Mark
And
Drill
2
Holes
Mark
location
of
holes
as
shown.
(Holes
are
pre-drilled
on
models
with
Serial
No.
KC289996
and
following.)
Drill
two
5/32
in
(4
mm)
holes
at
marked
locations.
1
6-32
x
3/8
in
Screw
2
Stand-Off
Insert
supplied
screws
through
holes
in
front
panel,
and
secure
stand-offs
to
screws.
3
Self-Locking
Nut
Install
PC6
as
shown.
Go
To
Section
C.
Tools
Needed:
5/32
in
CT~z]==~u
1/4,5/16
in
Figure
3-2.
Installing
Circuit
Board
PC6
ST-157
511
B.
Installing
Circuit
Board
PC6
PC6
5-1/2
in
(140
mm)
1-1/4
in
~
(32
mm)
1
in
(25
m)
2
Install
PC6
OM-2801
Page
4
C.
Connecting
To
Circuit
Board
PC6
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.
Rear
Of
RC1
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.
Figure
3-3.
Connecting
To
Circuit
Board
PC6
Tools
Needed:
1
Circuit
Breaker
CB1
2
Receptacle
RC1
3
Receptacle
RC2
4
Circuit
Breaker
CB2
5
Ground
Terminal
Stud
Make
connections
as
shown
below.
Go
To
Section
0.
2
3
4
5
Parts
And
Location
Wiring
Connections
Rear
Of
RC2
Lead
120C
I
It,
r
-l
OPTIONAL
CBI
~-cc-~-
~-
<
>
<
12
>
,
<
r)7
PCI
120V.
>
<
r)~
PC2
240V.
-,'
GROUND
Terminal
r
I
20V/240V1
1E409
C~)
A
OPTI~1
c526
I
Cr
RC
I
II~.)
~
I
(240V.)
L
CB2
Lead
101
Supplied
Lead
101
O
0 0
PC6
Lead
102
~
CB1
Supplied
Lead
102
Supplied
Lead
42
GROUND
Terminal
Ref.
ST-iSO
194-Al
S-0761
/
Ref.
50-136
915/
Ref.
SD-155
077
OM-2801
Page
5
D.
Installing
Mounting
Bracket
And
Terminal
Strip
3T
Hole
layout
for
Big
30A
Diesel
models
only.
(Holes
are
pre
drilled
on
models
with
Serial
No.
KC289996
and
following.)
1
Right
Front
Upright
2
Base
Drill
two
7/32
in
(5.6
mm)
bracket
mounting
holes
at
locations
shown.
Hole
layout
for
all
other
applica
ble
models.
(Holes
are
pre
drilled
on
models
with
Serial
No.
KC289996
and
following.)
3
Right
Front
Upright
4
Existing
Hole
5
Base
Use
top
existing
hole
for
lower
mounting
bracket
hole.
Drill
one
7/32
in
(5.6
mm)
bracket
mounting
hole
above
top
existing
hole
at
location
shown.
6
Mounting
Bracket
7
3T
Label
Install
supplied
label
to
bracket.
8
Terminal
Strip
31
9
Terminal
Strip
Mounting
Hardware
10
Insulation
Panel
Install
terminal
strip
and
panel
to
bracket
as
shown,
and
secure
with
no.
10
hardware.
11
Mounting
Bracket
Hardware
Install
bracket
to
upright,
and
se
cure
with
1/4-20
x
1/2
in
screws
as
shown.
12
Plug
PLG8
(Free-Hanging
From
31)
Connect
PLG8
into
receptacle
RC3
located
on
PC5.
Go
to
Section
E.
Tools
Needed:
7/32
in
Ref.
ST-156
200-A
I
Ref.
ST-156
i951
S-0802
Figure
3-4.
InstallIng
Mounting
Bracket
And
Terminal
Strip
3T
1/4,3/8in
OM-2801
Page
6
E.
Installing
Resistor
Board
R2
And
CV
Board
PC2
Figure
3-5.
Installing
Resistor
Board
R2
And
CV
Board
PC2
F.
Component
Installation
Tools
Needed:
_______~
5/8,9/161n
Locate
holes
in
front
panel
(behind
name-
Install
switches
onto
front
panel
with
termi-
7
Plug
PLG7
plate)
for
components
numbered
1
through
nals
positioned
vertically,
so
switch
posi
4,
and
8
and
9
below.
Use
rear
of
front
panel
tions
match
nameplate
labeling
(see
Section
Connect
PLG7
into
receptacle
RC2
located
as a
template,
and
mark
component
mount-
4).
Secure
switches
with
supplied
nut,
wash-
on
PC5.
ing
holes
onto
nameplate
by
applying
pres-
er,
and
switch
lever
boot.
sure
from
rear
with
a
sharp
tool.
8
Circuit
Breaker
CB3
4
Remote
14
Receptacle
RC3
Punch,
cut,
or
drill
correct
diameter
holes
at
9
Circuit
Breaker
CB4
marked
locations.
5
Screw
1
AmperageNoltage
Control
Switch
S4
6
Receptacle
Cover
Install
supplied
circuit
breakers
onto
front
panel
at
labeled
locations,
and
secure
with
2
Output
(Contactor)
Switch
S5
Install
RC3
and
receptacle
cover
onto
front
supplied
nuts
and
washers
as
shown.
3
Constant
Voltage/Constant
Current
panel,
and
secure
with
6-32
x
3/8
in
self
.tap.
Switch
S9
ping
screws
as
shown.
Go
to
SectIon
G.
3
2
1
Front
Panel
2
Component
Box
Cover
3
Retaining
Screw
Remove
retaining
screw,
and
open
component
box
cover.
4
Resistor
Board
R2
5
Resistor
Board
R2
Mounting
Holes
6
Hardware
For
Installing
Re
sistor
Board
R2
Insert
6-32
x
3/Bin
screws
through
mounting
holes
from
inside
com
ponent
box.
Install
R2
onto
screws
outside
component
box,
and
secure
with
supplied
lock
washers
and
6-32
nuts.
On
Big
30A
Diesel
models,
it
is
easiest
to
install
R2
from
left
side
of
unit.
7
CV
Board
PC2
8
Stand-Off
Support
Install
PC2
onto
stand-offs
inside
component
box
with
receptacle
Tools
Needed:
RC1
up.
Insert
plug
PLG2
(unconnected
plug
in
component
box)
into
recep
_______
tacle
RCI
on
PC2.
~3/8in
Go
to
Section
F.
Ref.
ST-156
868
9
Ref.
ST-156 866~B
Figure
3-6.
Component
Installation
OM-2801
Page
7
CB3
~
Supplied
Lead
110
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.
Connections
for
Big
40G
models
prior
to
Serial
No.
KB064495,
and
all
other
models
prior
to
Serial
No.
KB058480.
CB3
CB2
Lead
1
Connections
for
Big
40G
models
effective
with
Serial
No.
KB064495
and
following.
Connections
for
all
other
models
effective
with
Serial
No.
KB058480
and
following.
For
all
models.
5T-158
868-B
I
Ref.
S-0744-A
G.
Circuit
Breakers
CB3
And
CB4
Wiring
Connections
Parts
And
Location
Wiring
Connections
Tools
Needed:
RC2
Figure
3-7.
Circuit
Breaker
CB3
And
CB4
Wiring
Connections
OM-2801
Page
8
H.
Supplied
Wiring
Harness
Connections
6
1
Supplied
Wiring
Harness
Wiring
harness
consists
of
the
fol
lowing:
plug
PLG6,
and
leads
3,
18,
47, 55, 56,
58,
130,
131,
and
132.
2
Resistor
Board
R2
3
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.
Tools
Needed:
Wiring
Connections
iT
00
00
00
00
00
00
00
00
r
C
R
S
1
U
Figure
3-8.
Supplied
Wiring
Harness
Connections
Parts
And
Location
B
Lead
47
~
Lead 55
~
~
2T
00
00
00
00
00
00
00
00
00
Existing
Lead
&J~3
C
0
E
F
G
Connect
to
either
bottom
terminal
CB3
Lead
132
CB4
Lead
131
ST-i
56
866-B
I
Ref.
SAl
55
737-B!
S-0745-B
OM.2801
Page
9
I.
Switches
S4, S5,
And
S9
Wiring
Connections
1
Switch
S4
2
Switch
S5
3
Switch
S9
4
Component
Box
5
Idle
Module
(Not
Visible)
Idle
module
is
located
in
upper
left
corner
of
component
box.
Make
connections
to
switches
as
shown
below.
All
loose
leads
are
located
in
component
box.
Install
panel
guard,
close
and
se
cure
door(s)
and
component
box
cover.
Tools
Needed:
-
~
3/8
in
Parts
And
Location
Wiring
Connections
ST-I
56
866-8
/
S-0747
FIgure
3-9.
Switches
S4,
S5,
And
S9
Wiring
Connections
OM-2801
Page
10
3-2.
Installing
CV-3
In
Unit
Equipped
With
Remote
Control
~
_
7~
READ
SAFETY
BLOCKS
at
start
4
1
~
~Z
~
~-~VJ
of
Section
3
before
proceeding
N
OTE
~
This
Field
Kit
includes
optional
Remote
Control
components
(resistor
board
R2,
_____________________
Remote
14
receptacle
RC3,
Amperage/Voltage
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
Open
and
secure
right
side
door.
On
a
Big
30A
Diesel
model,
open
and
secure
left
side
door
also.
1
Panel
Guard
Remove
guard.
2
Front
Panel
3
Component
Box
Cover
4
Retaining
Screw
Hole
Remove
retaining
screw,
and
open
component
box
cover.
5
CV
Board
PC2
6
Stand-Off
Supports
Install
PC2
onto
stand-offs
inside
component
box
with
receptacle
RC1
towards
top
of
welding
generator.
Insert
plug
PLG2
(unconnected
plug
in
component
box)
into
receptacle
RC2
on
CV
board
PC2.
7
Constant
Voltage/Constant
Current
Switch
S9
Locate
hole
in
front
panel
(behind
nameplate)
for
Constant
Voltage/
Constant
Current
switch
59.
Use
rear
of front
panel
as
a
template,
and
mark
hole
onto
nameplate
by
apply
ing
pressure
from
rear
with
a
sharp
tool.
Punch,
cut,
or
drill
correct
diameter
hole.
Install
S9
onto
front
panel
with
switch
terminals
positioned
vertically
so
switch
positions
match
nameplate
labeling
(see
Figure
4-4).
Go
to
Section
8.
Tools
Needed:
ST-158
455
FIgure
3-10.
CV-3
Component
Installation
3/8,
9/16
in
OM-2801
Page
11
B.
Switch
S9
Wiring
Connections
Wiring
Connections
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)
Idle
module
is
located
in
upper
left
corner
of
component
box.
Make
connections
to
switches
as
shown
below.
All
loose
leads
are
located
in
component
box.
Install
panel
guard,
close
and
se
cure
door(s),
and
component
box
cover.
Tools
Needed:
~
3/8
in
J
Figure
3-11.
Switch
S9
Wiring
Connections
ST-I
56
866-B
I
S.0748-A
Parts
And
Location
Lead
98
S9
Loose
Lead
65
Supplied
Lead45...~,~
idle
Module
Suooli&d
Lead
65
OM-2801
Page
12
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