Miller KH360783 Owner's manual

Brand: Miller

Model: KH360783

Category: Welding System

Type: Owner's manual

This manual is also suitable for

CV-3

CV-3 Constant Voltage

Module

Processes

Description

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

For Engine Driven Welding Generators

OM-2801 131 759J

July 2000

Visit our website at

www.MillerWelds.com

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 catalog sheets. To locate your nearest

distributor or service agency call 1-800-4-A-Miller,

or visit us at www.MillerWelds.com on the web.

Thank you and congratulations on choosing Miller. Now

you can get the job done and get it done right. We know

you don’t have time to do it any other way.

That’s why when Niels Miller first started building arc

welders in 1929, he made sure his products offered

long-lasting value and superior quality. Like you, his

customers couldn’t afford anything less. Miller products

had to be more than the best they could be. They had to

be the best you could buy.

Today, the people that build and sell Miller products continue the

tradition. They’re just as committed to providing equipment and service

that meets the high standards of quality and value established in 1929.

This Owner’s Manual is designed to help you get the most out of your

Miller products. Please take time to read the Safety precautions. They will

help you protect yourself against potential hazards on the worksite. We’ve

made installation and operation quick and easy.

With Miller you can count on years of reliable

service with proper maintenance. And if for

some reason the unit needs repair, there’s a

Troubleshooting section that will help you

figure out what the problem is. The parts list

will then help you to decide which exact part

you may need to fix the problem. Warranty and

service information for your particular model

are also provided.

Miller is the first welding

equipment manufacturer in

the U.S.A. to be registered to

the ISO 9001 Quality System

Standard.

Working as hard as you do

– every power source from

Miller is backed by the most

hassle-free warranty in the

business.

From Miller to You

Miller offers a Technical

Manual which provides

more detailed service and

parts information for your

unit. To obtain a Technical

Manual, contact your local

distributor. Your distributor

can also supply you with

Welding Process Manuals

such as SMAW, GTAW,

GMAW, and GMAW-P.

TABLE OF CONTENTS

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Arc Welding Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Engine Hazards 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. Additional Symbols For Installation, Operation, And Maintenance 3. . . . . . . . . . . . . . . . . . . . .

1-5. Principal Safety Standards 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 – SPECIFICATIONS 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 – INSTALLATION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Installing CV-3 And Remote Control 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Installing CV-3 In Unit Equipped With Remote Control 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 – OPERATION 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Front Panel Controls 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Remote 14 Receptacle Information And Connections 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Terminal Strip 3T Connections 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Volt-Ampere Curves 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Typical Process Connections 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Overload Protection 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Maintenance 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. Troubleshooting 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 – ELECTRICAL DIAGRAMS 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 – PARTS LIST 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

WARNING

This product, when used

for welding or cutting,

produces fumes or

gases which contain

chemicals known to the

State of California to

cause birth defects and,

in some cases, cancer.

(California Health &

Safety Code Section

25249.5 et seq.)

CALIFORNIA

Proposition 65

Warning

Diesel engine exhaust and

some of its constituents

are known to the State of

California to cause

cancer, birth defects, and

other reproductive harm.

WARNING

Battery posts, terminals

and related accessories

contain lead and lead

compounds, chemicals

known to the State of

California to cause

cancer and birth defects

or other reproductive

harm. Wash hands after

handling.

OM-2801 Page 1

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING

rom _nd_11/98

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards

with this procedure! The possible hazards are shown in

the adjoining symbols.

Y Marks a special safety message.

. 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.

1-2. Arc Welding Hazards

Y 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.

Y Only qualified persons should install, operate, maintain, and

repair this unit.

Y 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.

D Do not touch live electrical parts.

D Wear dry, hole-free insulating gloves and body protection.

D Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work

or ground.

D Do not use AC output in damp areas, if movement is confined, or if

there is a danger of falling.

D Use AC output ONLY if required for the welding process.

D If AC output is required, use remote output control if present on

unit.

D Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according to

OSHA 29 CFR 1910.147 (see Safety Standards).

D Properly install and ground this equipment according to its

Owner’s Manual and national, state, and local codes.

D Always verify the supply ground – check and be sure that input

power cord ground wire is properly connected to ground terminal in

disconnect box or that cord plug is connected to a properly

grounded receptacle outlet.

D When making input connections, attach proper grounding conduc-

tor first – double-check connections.

D Frequently inspect input power cord for damage or bare wiring –

replace cord immediately if damaged – bare wiring can kill.

D Turn off all equipment when not in use.

D Do not use worn, damaged, undersized, or poorly spliced cables.

D Do not drape cables over your body.

D If earth grounding of the workpiece is required, ground it directly

with a separate cable.

D Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

D Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

D Wear a safety harness if working above floor level.

D Keep all panels and covers securely in place.

D Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

D Do not connect more than one electrode or work cable to any

single weld output terminal.

SIGNIFICANT DC VOLTAGE exists after stopping

engine on inverters.

D Stop engine on inverter and discharge input capacitors according

to instructions in Maintenance Section before touching any parts.

Arc rays from the welding process produce intense

visible and invisible (ultraviolet and infrared) rays

that can burn eyes and skin. Sparks fly off from the

weld.

ARC RAYS can burn eyes and skin.

D Wear a welding helmet fitted with a proper shade of filter to protect

your face and eyes from arc rays and sparks when welding or

watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards).

D Wear approved safety glasses with side shields under your

helmet.

D Use protective screens or barriers to protect others from flash and

glare; warn others not to watch the arc.

D Wear protective clothing made from durable, flame-resistant mate-

rial (wool and leather) and foot protection.

Welding produces fumes and gases. Breathing

these fumes and gases can be hazardous to your

health.

FUMES AND GASES can be hazardous.

D Keep your head out of the fumes. Do not breathe the fumes.

D If inside, ventilate the area and/or use exhaust at the arc to remove

welding fumes and gases.

D If ventilation is poor, use an approved air-supplied respirator.

D Read the Material Safety Data Sheets (MSDSs) and the

manufacturer’s instructions for metals, consumables, coatings,

cleaners, and degreasers.

D Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watch-

person nearby. Welding fumes and gases can displace air and

lower the oxygen level causing injury or death. Be sure the breath-

ing air is safe.

D Do not weld in locations near degreasing, cleaning, or spraying op-

erations. The heat and rays of the arc can react with vapors to form

highly toxic and irritating gases.

D 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.

OM-2801 Page 2

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.

WELDING can cause fire or explosion.

D Protect yourself and others from flying sparks and hot metal.

D Do not weld where flying sparks can strike flammable material.

D Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

D Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

D Watch for fire, and keep a fire extinguisher nearby.

D Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

D Do not weld on closed containers such as tanks, drums, or pipes,

unless they are properly prepared according to AWS F4.1 (see

Safety Standards).

D 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.

D Do not use welder to thaw frozen pipes.

D Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

D Wear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap.

D Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

FLYING METAL can injure eyes.

D Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool,

they can throw off slag.

D Wear approved safety glasses with side

shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

D Shut off shielding gas supply when not in use.

D Always ventilate confined spaces or use ap-

proved air-supplied respirator.

HOT PARTS can cause severe burns.

D Allow cooling period before maintaining.

D Wear protective gloves and clothing when

working on a hot engine.

D Do not touch hot engine parts or just-welded

parts bare-handed.

NOISE can damage hearing.

Noise from some processes or equipment can

damage hearing.

D Wear approved ear protection if noise level is

high.

MAGNETIC FIELDS can affect pacemakers.

D Pacemaker wearers keep away.

D Wearers should consult their doctor before

going near arc welding, gouging, or spot

welding operations.

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.

CYLINDERS can explode if damaged.

D Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, slag, open flames, sparks, and arcs.

D Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

D Keep cylinders away from any welding or other electrical circuits.

D Never drape a welding torch over a gas cylinder.

D Never allow a welding electrode to touch any cylinder.

D Never weld on a pressurized cylinder – explosion will result.

D Use only correct shielding gas cylinders, regulators, hoses, and fit-

tings designed for the specific application; maintain them and

associated parts in good condition.

D Turn face away from valve outlet when opening cylinder valve.

D Keep protective cap in place over valve except when cylinder is in

use or connected for use.

D Read and follow instructions on compressed gas cylinders,

associated equipment, and CGA publication P-1 listed in Safety

Standards.

1-3. Engine Hazards

FUEL can cause fire or explosion.

D Stop engine and let it cool off before checking or

adding fuel.

D Do not add fuel while smoking or if unit is near

any sparks or open flames.

D Do not overfill tank – allow room for fuel to expand.

D Do not spill fuel. If fuel is spilled, clean up before starting engine.

D Dispose of rags in a fireproof container.

STEAM AND HOT COOLANT can burn.

D If possible, check coolant level when engine is

cold to avoid scalding.

D Always check coolant level at overflow tank, if

present on unit, instead of radiator (unless told

otherwise in maintenance section or engine

manual).

D If the engine is warm, checking is needed, and

there is no overflow tank, follow the next two

statements.

D Wear safety glasses and gloves and put a rag over radiator cap.

D Turn cap slightly and let pressure escape slowly before completely

removing cap.

OM-2801 Page 3

MOVING PARTS can cause injury.

D Keep away from fans, belts, and rotors.

D Keep all doors, panels, covers, and guards

closed and securely in place.

D Stop engine before installing or connecting unit.

D Have only qualified people remove guards or covers for maint-

enance and troubleshooting as necessary.

D To prevent accidental starting during servicing, disconnect

negative (–) battery cable from battery.

D Keep hands, hair, loose clothing, and tools away from moving

parts.

D Reinstall panels or guards and close doors when servicing is

finished and before starting engine.

D Before working on generator, remove spark plugs or injectors to

keep engine from kicking back or starting.

D Block flywheel so that it will not turn while working on generator

components.

BATTERY EXPLOSION can BLIND.

D Always wear a face shield, rubber gloves, and

protective clothing when working on a battery.

D Stop engine before disconnecting or connect-

ing battery cables or servicing battery.

D Do not allow tools to cause sparks when working on a battery.

D Do not use welder to charge batteries or jump start vehicles.

D Observe correct polarity (+ and –) on batteries.

D Disconnect negative (–) cable first and connect it last.

BATTERY ACID can BURN SKIN and EYES.

D Do not tip battery.

D Replace damaged battery.

D Flush eyes and skin immediately with water.

ENGINE EXHAUST GASES can kill.

D Use equipment outside in open, well-ventilated

areas.

D If used in a closed area, vent engine exhaust

outside and away from any building air intakes.

ENGINE HEAT can cause fire.

D Do not locate unit on, over, or near combustible

surfaces or flammables.

D Keep exhaust and exhaust pipes way from

flammables.

EXHAUST SPARKS can cause fire.

D Do not let engine exhaust sparks cause fire.

D Use approved engine exhaust spark arrestor in

required areas – see applicable codes.

1-4. Additional Symbols For Installation, Operation, And Maintenance

FALLING UNIT can cause injury.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, trailer, or any other

accessories.

D Use equipment of adequate capacity to lift and

support unit.

D If using lift forks to move unit, be sure forks are long enough to

extend beyond opposite side of unit.

FLYING SPARKS can cause injury.

D Wear a face shield to protect eyes and face.

D Shape tungsten electrode only on grinder with

proper guards in a safe location wearing proper

face, hand, and body protection.

D Sparks can cause fires — keep flammables away.

OVERHEATING can damage motors.

D Turn off or unplug equipment before starting or

stopping engine.

D Do not let low voltage and frequency caused by

low engine speed damage electric motors.

D Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle

where applicable.

OVERUSE can cause OVERHEATING.

D Allow cooling period; follow rated duty cycle.

D Reduce current or reduce duty cycle before

starting to weld again.

D Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

TILTING OF TRAILER can cause injury.

D Use tongue jack or blocks to support weight.

D Properly install welding generator onto trailer

according to instructions supplied with trailer.

READ INSTRUCTIONS.

D Use only genuine MILLER replacement parts.

D Perform engine maintenance and service

according to this manual and the engine

manual.

OM-2801 Page 4

H.F. RADIATION can cause interference.

D High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and

communications equipment.

D Have only qualified persons familiar with

electronic equipment perform this installation.

D The user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installa-

tion.

D If notified by the FCC about interference, stop using the

equipment at once.

D Have the installation regularly checked and maintained.

D Keep high-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding to

minimize the possibility of interference.

ARC WELDING can cause interference.

D Electromagnetic energy can interfere with

sensitive electronic equipment such as

computers and computer-driven equipment

such as robots.

D Be sure all equipment in the welding area is

electromagnetically compatible.

D To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

D Be sure this welding machine is installed and grounded

according to this manual.

D If interference still occurs, the user must take extra measures

such as moving the welding machine, using shielded cables,

using line filters, or shielding the work area.

1-5. 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 Cut-

ting of Containers That Have Held Hazardous Substances, American

Welding Society Standard AWS F4.1, from American Welding Society,

550 N.W. LeJeune Rd, Miami, FL 33126

National Electrical Code, NFPA Standard 70, from National Fire Protec-

tion Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

from Compressed Gas Association, 1235 Jefferson Davis Highway,

Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from

Canadian Standards Association, Standards Sales, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices For Occupation And Educational Eye And Face

Protection, ANSI Standard Z87.1, from American National Standards

Institute, 1430 Broadway, New York, NY 10018.

Cutting And Welding Processes, NFPA Standard 51B, from National

Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

1-6. EMF Information

Considerations About Welding And The Effects Of Low Frequency

Electric And Magnetic Fields

Welding current, as it flows through welding cables, will cause electro-

magnetic fields. There has been and still is some concern about such

fields. However, after examining more than 500 studies spanning 17

years of research, a special blue ribbon committee of the National

Research Council concluded that: “The body of evidence, in the

committee’s judgment, has not demonstrated that exposure to power-

frequency electric and magnetic fields is a human-health hazard.”

However, studies are still going forth and evidence continues to be

examined. Until the final conclusions of the research are reached, you

may wish to minimize your exposure to electromagnetic fields when

welding or cutting.

To reduce magnetic fields in the workplace, use the following

procedures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep welding power source and cables as far away from

operator as practical.

5. Connect work clamp to workpiece as close to the weld as possi-

ble.

About Pacemakers:

Pacemaker wearers consult your doctor first. If cleared by your doctor,

then following the above procedures is recommended.

SECTION 2 – SPECIFICATIONS

Model Rated Weld Output Voltage Range CV/DC Open-Circuit Voltage CV/DC

Big 30A Diesel

200 A @ 28 V CV/DC, 100%

Duty Cycle

14 – 40 40

Big 40G, Big 40 Diesel

300 A At 32 V CV/DC, 100%

Duty Cycle

14 – 38 40

Big 50 Diesel

350 A At 34 V CV/DC, 100%

Duty Cycle

14 – 38 40

OM-2801 Page 5

SECTION 3 – INSTALLATION

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 4.

A Big 40 Diesel model is shown throughout Section 3.

NOTE

3-1. Installing CV-3 And Remote Control

A. Installing Circuit Board PC5

Ref. ST-157 511-A / Ref. ST-156 194-C

Y Cover parts before drilling.

Clean unit before using.

1 Panel Guard

Open doors. Remove panel guard.

2 Reference Hole

3 Circuit Board PC5

If necessary, use reference hole to

mark location of first hole. Use PC5

as template to mark remaining two

holes. Drill three 5/32 in (4 mm)

holes as marked.

4 6-32 x 3/8 in Screw

5 Stand-Off

6 Self-Locking Nut

7 Ground Strap

Install PC5 as shown. Secure

ground strap to stand-off.

8 Ground Lead 42

9 Ground Stud

10 Ground Terminal A

Connect lead 42 ring terminal to

rear of ground stud. Connect other

end of lead to terminal A.

Go to Section B.

Tools Needed:

5/32 in

1/4, 5/16 in

1/2 in

Mark And Drill

Two Holes

Mark And Drill Hole

2-1/2 in

(62 mm)

Location Of PC5

Installation

Remove Paint around stand-off

mounting hole to ensure good

ground connection.

OM-2801 Page 6

B. Installing Circuit Board PC6

Ref. ST-157 511-A

Y Follow safety precautions at

beginning of this section.

Y Cover parts before drilling.

Clean unit before using.

If necessary, mark holes as shown.

Drill two 5/32 in (4 mm) holes as

marked.

1 6-32 x 3/8 in Screw

2 Stand-Off

3 Circuit Board PC6

4 Self-Locking Nut

Install PC6 as shown.

Go To Section C.

Tools Needed:

1-1/4 in

(32 mm)

5-1/2 in

(140 mm)

1 in

(25 mm)

Mark And Drill 2 Holes

1/4, 5/16 in

5/32 in

OM-2801 Page 7

C. Connecting To Circuit Board PC6

Ref. ST-156 194-C / S-0761

Y 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.

Tools Needed:

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.

COM

Supplied Lead 42

PC6

Cut off piggyback connector

and strip insulation from end of

supplied leads 101 and 102.

1 23

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.

Parts And Location

Wiring Connections

5/8 in

Lead 120

Lead 110

Supplied Lead 101

Supplied Lead 102

Supplied Lead 42

GROUND

Terminal

com

PC6

CB2

Lead 101

Supplied Lead 101

Lead 102

Supplied Lead 102

CB1

GROUND

Terminal

RC1RC2

OM-2801 Page 8

D. Installing Mounting Bracket And Terminal Strip 3T

Ref. ST-156 200-A / Ref. ST-156 195-A / S-0802

Y 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 3T Label

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.

Tools Needed:

7/32 in

1/4, 3/8 in

131

132

1/2 in (12 mm)

5-5/8 in

(143 mm)

5-5/8 in

(143 mm)

1-1/8 in (29 mm)

Big 30A Model

All Other Models

OM-2801 Page 9

E. Installing Resistor Board R2 And CV Board PC2

Ref. ST-156 866-B

Y Follow safety precautions at

beginning of this section.

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.

Tools Needed:

3/8 in

F. Component Installation

Ref. ST-156 866-C

Y Follow safety precautions at

beginning of this section.

Use front panel as guide to make

holes in nameplate for parts shown.

1 Amperage/Voltage Adjust

Switch S4

2 Output (Electrode) Switch S5

3 Process 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.

Tools Needed:

5/8, 9/16 in

OM-2801 Page 10

G. Circuit Breakers CB3 And CB4 Wiring Connections

ST-156 866-C / Ref. S-0744-A

Y Follow safety precautions at

beginning of this section.

1 Terminal Strip 1T

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.

Connections for Big 40G models ef-

fective with Serial No. KB064495

and following.

Connections for all other models ef-

fective with Serial No. KB058480

and following.

Parts And Location

Wiring Connections

CB3

Supplied Lead 110 Lead 110

RC2

CB3

Supplied Lead 110

Lead 1 (Pigtail In Harness)

CB2

OM-2801 Page 11

H. Supplied Wiring Harness Connections

Y Follow safety precautions at

beginning of this section.

1 Supplied Wiring Harness

2 Resistor Board R2

3 Terminal Strip 2T (Located On

Back Of Component Box)

4 Terminal Strip 1T

5 Circuit Breaker CB3

6 Circuit Breaker CB4

Connect wiring harness to leads

and components as shown below.

Go to Section I or J.

Connect to either

bottom terminal

Tools Needed:

Parts And Location

Wiring Connections

Connect to either

top terminal

Lead 18

Lead 47

Lead 55

Lead 56

Lead 58

Existing Lead

Lead 3

Lead 132

Lead 131

CB3

CB4

ST-156 866-C / Ref. SA-155 737-B / S-0745-B

Existing Lead

Lead 130

OM-2801 Page 12

I. Switches S4, S5, And S9 Wiring Connections Prior to Serial No. KH360783

ST-156 866-C / S-0747

Y Follow safety precautions at

beginning 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 lo-

cated in component box.

Install panel guard. Close door(s)

and component box cover.

Tools Needed:

3/8 in

Lead 98 Lead 47

Lead 130 Lead 57

DGB

Lead 48

1 234 5

Parts And Location

Wiring Connections

Loose Lead 55

Loose Lead 47

Supplied Lead 47

Loose Lead 56

Loose Lead 66

Lead 98

Loose Lead 65

Supplied Lead 65

Supplied Lead 68

Supplied Lead 48

Lead 130

Supplied Lead 57

Supplied Lead 65

Supplied Lead 68

Idle Module

Supplied Lead 65

OM-2801 Page 13

J. Switches S4, S5, And S9 Wiring Connections Effective With Serial No. KH360783

ST-156 866-C / Ref. S-0747

Y Follow safety precautions at

beginning 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 lo-

cated in component box.

Install panel guard. Close door(s)

and component box cover.

Tools Needed:

3/8 in

1 234 5

Parts And Location

Wiring Connections

Lead 59

Lead 47

Lead 130 Lead 57

DGB

Lead 48

Loose Lead 55

Loose Lead 47

Supplied Lead 47

Loose Lead 56

Loose Lead 66

Lead 98

Supplied Lead 68

Supplied Lead 48

Lead 130

Supplied Lead 57

Existing Lead 59

Supplied Lead 68

Idle Module

Existing Lead 59 (From PLG9-2)

Lead 60 (From PLG9-1)

Lead 59 (From PLG2)

Lead 98 (from PC1)Lead 98 (from PLG9)

Insulate and tie off.

Insulate

and

tie off.

OM-2801 Page 14

3-2. Installing CV-3 In Unit Equipped With Remote Control

This Field Kit includes optional Remote Control components (resistor board R2,

Remote 14 receptacle RC3, Amperage/Voltage Adjust switch S4, Output

(Electrode) 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.

NOTE

A. CV-3 Component Installation

ST-156 455-C

Y Follow safety precautions at

beginning of this section.

Open doors.

1 Retaining Screw

2 Component Box Cover

Remove screw and open cover.

3 CV Board PC2

4 Stand-Off Supports

Install PC2 with receptacle RC1 up.

Insert plug PLG2 (in component

box) in receptacle RC1.

5 Constant Voltage/Constant

Current Switch S9

Use front panel as template to mark

hole for Process switch S9 on

nameplate. Punch or drill hole

where marked.

Install S9 so switch positions match

nameplate labeling

Go to Section B or C.

Tools Needed:

3/8, 9/16 in

3 4

OM-2801 Page 15

B. Switch S9 Wiring Connections Prior to Serial No. KH360783

ST-156 866-C / S-0748-A

Y Follow safety precautions at

beginning of this section.

1 Amperage/Voltage Adjust

Switch S4

2 Output (Electrode) Switch S5

3 Process 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:

3/8 in

12345

DGB

Lead 48

Parts And Location

Wiring Connections

Supplied Lead 65

Lead 98

Loose Lead 66

Lead 98

Loose Lead 65

Supplied Lead 65

Supplied Lead 48

Supplied Lead 68

Idle Module

Supplied Lead 65

OM-2801 Page 16

C. Switch S9 Wiring Connections Effective With Serial No. KH360783

ST-156 866-B / Ref. S-0748-A

Y Follow safety precautions at

beginning of this section.

1 Amperage/Voltage Adjust

Switch S4

2 Output (Electrode) Switch S5

3 Process 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:

3/8 in

12345

DGB

Lead 48

Parts And Location

Wiring Connections

Existing Lead 59

Loose Lead 66

Lead 98

Supplied Lead 48

Supplied Lead 68

Idle Module

Existing Lead 59 (From PLG9-2)

Lead 60

From PLG 9-1

Lead 59 (From PLG2)

Lead 98 (from PC1)Lead 98 (from PLG9)

Insulate and

tie off.

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Miller KH360783 Owner's manual

Brand: Miller

Model: KH360783

Category: Welding System

Type: Owner's manual

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Miller KH360783 Owner's manual

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Miller KH360783 Owner's manual

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