Documentos de Académico
Documentos de Profesional
Documentos de Cultura
April 2002
175 611T
Processes
Stick (SMAW) Welding MIG (GMAW) Welding Flux Cored (FCAW) Welding Non-Critical TIG (GTAW) Welding
Description
Bobcat 225D
www.MillerWelds.com
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.
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 orindividual 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.
TABLE OF CONTENTS
SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . 1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 1 CONSIGNES DE SCURIT LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . 1-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Dangers relatifs au soudage larc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. Principales normes de scurit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6. Information sur les champs lectromagntiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 2 DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 3 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Weld, Power, and Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Dimensions, Weights, and Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3. Auxiliary Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5. Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3. Activating The Dry Charge Battery (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 5 OPERATING WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 6 OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. Standard Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2. CSA Receptacle Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3. GFCI, South African, And Australian Auxiliary Power Receptacle Options . . . . . . . . . . . . . . 6-4. Wiring Optional 120/240 Volt Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 7 MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3. Inspecting And Cleaning Optional Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4. Changing Engine Oil, Oil Filter, And Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 8 ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 9 GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 10 RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 11 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPTIONS AND ACCESSORIES WARRANTY 1 1 1 2 3 4 4 5 5 5 6 7 8 8 9 9 9 9 10 10 10 11 11 12 12 13 14 15 15 16 17 17 18 18 19 20 21 22 22 24 25 26 27 27 29 31 32 39 39 40 41 42
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.)
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.
The following terms are used interchangeably throughout this manual: TIG = GTAW Stick = SMAW
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.
D D D D
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.
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 fittings 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.
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. OM-404 Page 2
READ INSTRUCTIONS.
D Use only genuine MILLER replacement parts. D Perform engine maintenance and service according to this manual and the engine manual. OM-404 Page 3
D D D D
D D D D
OM-404 Page 4
. Signifie NOTA ; nest pas relatif la scurit. 1-2. Dangers relatifs au soudage larc
Y Les symboles prsents ci-aprs sont utiliss tout au long du prsent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez vigilant et suivez les directives mentionnes afin dviter tout danger. Les consignes de scurit prsentes ci-aprs ne font que rsumer linformation contenue dans les normes de scurit numres la section 1-5. Veuillez lire et respecter toutes ces normes de scurit. Y Linstallation, lutilisation, lentretien et les rparations ne doivent tre confis qu des personnes qualifies. Y Au cours de lutilisation, tenir toute personne lcart et plus particulirement les enfants.
D D D D D
Nutiliser quun matriel en bon tat. Rparer ou remplacer sur-le-champ les pices endommages. Entretenir lappareil conformment ce manuel. Porter un harnais de scurit quand on travaille en hauteur. Maintenir solidement en place tous les panneaux et capots. Fixer le cble de retour de faon obtenir un bon contact mtal-mtal avec la pice souder ou la table de travail, le plus prs possible de la soudure. Isoler la pince de masse quand pas mis la pice pour viter le contact avec tout objet mtallique.
Une tension DC importante subsiste lintrieur des onduleurs aprs avoir coup lalimentation.
D Couper lalimentation du poste et dcharger les condensateurs dentre comme indiqu dans la Section Maintenance avant de toucher des composants.
LES RAYONS DE LARC peuvent provoquer des brlures dans les yeux et sur la peau.
Le rayonnement de larc du procd de soudage gnre des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brlures dans les yeux et sur la peau. Des tincelles sont projetes pendant le soudage. D D D D Porter un casque de soudage muni dun cran de filtre appropri pour protger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.1 numr dans les normes de scurit). Porter des protections approuvs pour les oreilles si le niveau sondre est trop lev. Utiliser des crans ou des barrires pour protger des tiers de lclair et de lblouissement; demander aux autres personnes de ne pas regarder larc. Porter des vtements de protection constitu dans une matire durable, rsistant au feu (laine ou cuir) et une protection des pieds.
D D D D D D D
OM-404 Page 5
D D D D
D D D D D
D D D
D D D D
D D D
OM-404 Page 6
LACIDE DE LA BATTERIE peut provoquer des brlures dans les YEUX et sur la PEAU.
D D D Ne pas renverser la batterie. Remplacer une batterie endommage. Rincer immdiatement les yeux et la peau leau.
D D D D D D D
D D D D D
En utilisant des fourches de levage pour dplacer lunit, sassurer que les fourches sont suffisamment longues pour dpasser du ct oppos de lappareil.
Affuterr llectrode au tungstne uniquement la meuleuse dote de protecteurs. Cette manoeuvre est excuter dans un endroit sr lorsque lon porte lquipement homologu de protection du visage, des mains et du corps. Les tincelles risquent de causer un incendie loigner toute substance inflammable.
OM-404 Page 7
D D D D D
D D D D D
Consignes relatives aux stimulateurs cardiaques : Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur docteur. Si vous tes dclar apte par votre docteur, il est alors recommand de respecter les consignes cidessus.
OM-404 Page 8
SECTION 2 DEFINITIONS
2-1. Symbol Definitions
Stop Engine Fast (Run, Weld/Power) Fast/Slow (Run/Idle) Slow (Idle)
Start Engine
Glow Plug
Temperature
Fuel
Engine Oil
Battery (Engine)
Engine
Amperes
Volts
Circuit Breaker
Positive
Negative
Output
Time
Hours
Seconds
Work Connection
SECTION 3 SPECIFICATIONS
3-1. Weld, Power, and Engine Specifications
Welding Mode Weld Output Range Rated Welding Output 225 A, 25 V, 100% Duty Cycle Maximum Open Circuit Voltage 80 Peak: 8.5 kW/kVA CC/DC 50 210 A 210 A, 25 V, 100% Duty Cycle 72 Continuous: 8 kVA/kW, Single-Phase, 70/35 A, 120/240 V AC, 50/60 Hz, (while not welding) 10 gal (38 L) Tank Deutz/Ruggerini MD-151 Air-Cooled, Two-Cylinder, Diesel Engine Generator Power Rating Fuel Capacity Engine
CC/AC
50 225 A
CV/DC
17 28 V
33
OM-404 Page 9
A B C Y Do not exceed tilt angles or engine could be damaged or unit could tip. G 4 Holes Y Do not move or operate unit where it could tip.
25 25 25 25
182 719
SB-145 981
OM-404 Page 10
Continuous Welding 100% Duty Cycle at 225 Amperes CC/AC, 210 Amperes CC/DC, 200 Amperes CV/DC
SB-119 454-A
OM-404 Page 11
SECTION 4 INSTALLATION
4-1. Installing Welding Generator
Y Do not weld on base. Welding on base can cause fuel tank fire or explosion. Bolt unit down using holes provided in base. 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) Y Always securely fasten welding generator onto transport vehicle or trailer and comply with all DOT and other applicable codes. Y Always ground generator frame to vehicle frame to prevent electric shock and static electricity hazards. 1 2 3 4 Generator Base Metal Vehicle Frame Equipment Grounding Terminal Grounding Cable
Airflow Clearance
OR
18 in (460 mm)
1
GND/PE
3 4
Use #10 AWG or larger insulated copper wire. OR OR Y If unit does not have GFCI receptacles, use GFCIprotected extension cord.
install1 10/00 Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854
Notes
OM-404 Page 12
Diesel
Y Do not use gasoline. Gasoline will damage engine. Add fresh diesel fuel before starting engine the first time (see maintenance label for specifications). Fill fuel tank to bottom of filler neck to allow room for expansion. Do not run out of fuel or air enters fuel system and causes starting problems. See engine manual to bleed air from fuel system. Oil After fueling, check oil with unit on level surface. If oil is not up to full mark on dipstick, add oil (see maintenance label).
. To
Full
improve starting:
cold
weather
Keep battery in good condition. Store battery in warm area off concrete surface. Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier for fuel information. Use correct grade oil for cold weather.
OM-404 Page 13
4 1 3
Fill each cell with electrolyte to bottom of well (maximum). Y Do not overfill battery cells. Wait ten minutes and check electrolyte level. If necessary, add electrolyte to raise to proper level. Reinstall vent caps. 6 Battery Charger Y Read and follow all instructions supplied with battery charger. Charge battery for 12 minutes at 30 amperes or 30 minutes at 5 amperes. Disconnect charging cables and install battery.
. When electrolyte
5 A For 30 Minutes
OR
+
30 A For 12 Minutes Tools Needed:
OM-404 Page 14
Connect work cable to Work terminal. Connect electrode holder cable or electrode weld cable to Electrode terminal for Stick and MIG welding. Connect torch cable to Electrode terminal for TIG welding. Use Process Selector switch to select type of weld output (see Section 5-1).
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150 ft (45 m)
200 ft (60 m)
250 ft (70 m)
300 ft (90 m)
Welding Amperes
1 (50) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95)
1/0 (60) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 3/0 (2x95)
1/0 (60) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 4/0 (2x120)
300
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
350
* This
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
chart is a general guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), use next size larger cable. **Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. ( ) = mm2 for metric use
S-0007-E
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.
Notes
OM-404 Page 16
t
0s 10 s 20 s 70F (21C) 32F (0C) 4F (20C) 1 Engine Control Switch
Right Side
. Place switch in Run position to operate . If the engine does not start, let engine
most GMAW equipment. 2 Glow Plug Switch (Optional) If necessary, push switch up before start-up (see table). 3 Idle Lock Switch Use switch to lock engine in idle speed during start-up. In Start position and Engine Control switch in Run or Run/Idle, engine is locked in idle speed. In Run/Idle position and Engine Control switch in Run/Idle, engine runs at idle speed at no load and weld/power speed under load.
Use switch to start engine, select speed, and stop engine. In Run/Idle position, engine runs at idle speed at no load, and weld/power speed under load. In Run position, engine runs at weld/power speed.
In Run/Idle position and Engine Control switch in Run, engine runs at weld/power speed. To start: move idle lock switch and engine control switch to Start. Release engine control switch when engine starts. come to a complete stop before attempting restart.
5 Coarse Adjust Switch Use switch to select weld amperage range when Weld Process Selector switch is in Stick/Tig position, or voltage range when switch is in Wire position.
Move idle lock switch to Run/Idle after engine warms. To stop: move engine control switch to Off. 4 Weld Process Selector Switch Use switch to select type of weld output. Use a positive (+) position for Direct Current Electrode Positive (DCEP) and a negative () position for Direct Current Electrode Negative. Use AC position for alternating current.
6 Fine Adjust Control Use control to select weld amperage (Stick/ Tig) or voltage (Wire) within the range selected by the Coarse Adjust switch. Control may be adjusted while welding. Weld output would be 110 amps DC with control settings as shown (50% of 70 to 150). Scale is for reference only. 7 Engine Hour Meter 8 Manual Shutoff Lever Turn lever counterclockwise to stop engine if engine control switch does not work. OM-404 Page 17
. Generator
6 4 5 1 2
power decreases as weld current increases. Set Fine Adjust control R1 at 10 for full generator power. 120 V 20 A AC Duplex Receptacle RC3 120 V 20 A AC Duplex Receptacle RC2
2 3 1
RC3 and RC2 supply 60 Hz singlephase power at weld/power speed. Maximum output from RC3 or RC2 is 2.4 kVA/kW (CSA: 1.8 kVA/kW). 3 120/240 V 50 A AC Receptacle RC1
RC1 supplies 60 Hz single-phase power at weld/power speed. Maximum output is 8.5 kVA/kW. 4 5 6 Circuit Breaker CB3 Circuit Breaker CB4 Circuit Breakers CB1 And CB2
CB3 protects RC2 and CB4 protects RC3 from overload. If a circuit breaker opens, the receptacle does not work. Press button to reset breaker. 7 CB1 and CB2 protect RC1 from overload. If CB1 or CB2 opens, RC1 and one of the 120 volt receptacles does not work. 120 volts may still be present at RC1. Y Power is still present at the 240 volt receptacle when only one circuit breaker trips. Unplug power cord before attempting to service accessories or tools. Combined output of all receptacles limited to 8.5 kVA/kW rating of the generator. EXAMPLE: If 20 A is drawn from each 120 V duplex receptacle, only 15 A is available at the 240V receptacle: 2 x (120 V x 20 A) + (240 V x 15 A) = 8.4 kVA/kW 7 Generator Power While Welding Chart (For Reference Only)
SIMULTANEOUS WELDING AND POWER WITH FINE ADJUST SET AT 10 Weld Current In Amperes 210 140 90 Total Power In Watts 1000 4300 6000 120V Receptacle Amperes 8 36 50 240V Receptacle Amperes 4 18 25
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RC1 supplies 60 Hz single-phase power at weld/power speed. Maximum output is 10 kVA/kW. 1 5 2 6 3 2 3 120 V 20 A AC Duplex Receptacle RC2 120 V 20 A AC Duplex Receptacle RC3
RC2 and RC3 supply 60 Hz singlephase power at weld/power speed. Maximum output from RC2 or RC3 is 2.4 kVA/kW. 4 Circuit Breaker CB1 CB1 protects the ac receptacles from overload. If CB1 opens, the ac receptacles do not work.
. Move
5 6
CB1 toggle switch to On position to reset circuit breaker. If breaker continues to open, contact Factory Authorized Service Agent. Circuit Breaker CB2 Circuit Breaker CB3
CB2 protects RC2 and CB3 protects RC3 from overload. If a circuit breaker opens, the receptacle does not work. 4
. Press
7
button to reset circuit breaker. If breaker continues to open, contact Factory Authorized Service Agent. Combined output of all receptacles limited to 8.5 kVA/kW rating of the generator. EXAMPLE: If 20 A is drawn from each 120 V duplex receptacle, only 15 A is available at the 240V receptacle: 2 x (120 V x 20 A) + (240 V x 15 A) = 8.4 kVA/kW 7 Generator Power While Welding Label
SIMULTANEOUS WELDING AND POWER WITH FINE ADJUST SET AT 10 Weld Current In Amperes 210 140 90 Total Power In Watts 1000 4300 6000 120V Receptacle Amperes 8 36 50 240V Receptacle Amperes 4 18 25
203 683
OM-404 Page 19
6-3. GFCI, South African, And Australian Generator Power Receptacle Options
Y If unit does not have GFCI receptacles, use GFCIprotected extension cord.
GFCI2 and GFCI3 supply 60 Hz single-phase power at weld/power speed. Maximum output from GFCI2 or GFCI3 is 2.4 kVA/kW. Circuit breaker protection is the same as standard receptacles. If a ground fault is detected, the GFCI Reset button pops out and the circuit opens to disconnect the faulty equipment. Check for damaged tools, cords, plugs, etc. connected to the receptacle. Press button to reset receptacle and resume operation.
. At
least once a month, run engine at weld/power speed and press Test button to verify GFCI is working properly.
South African And Australian Receptacle Options 2 240 V 16 A AC South African Receptacles RC1, RC2, And RC3 240 V 15 A AC Australian Receptacles RC1, RC2, And RC3
3 2
Receptacles supply 60 Hz singlephase power at weld/power speed. Maximum output from each receptacle is 3.6 kVA/kW. 4 4 Circuit Breakers CB1, CB2, CB3
CB1, CB2, and CB3 protect RC1, RC2, and RC3 from overload. If a circuit breaker opens, the receptacle does not work. Press button to reset breaker. 5 Circuit Breaker CB4 CB4 protects all the receptacles from overload. If CB4 opens, none of the receptacles work.
OM-404 Page 20
When wired for 120 V loads, each duplex receptacle shares a load with one half of 240 V receptacle. 2 5 3 4 5 6 7 Plug Wired For 240 V, 2-Wire Load Neutral (Silver) Terminal Load 1 (Brass)Terminal Load 2 (Brass) Terminal Ground (Green) Terminal Amperes Available Using 120/240 V Plug
240V 6
5 Tools Needed:
120 813-D
Notes
OM-404 Page 21
Note
Follow the storage procedure in the engine owners manual if the unit will not be used for an extended period.
8h
Check Fluid Levels. See Section 4-2. Service Air Filter.
Wipe Up Spills.
50 h
Clean And Tighten Weld Terminals. Service Air Filter Element.
100 h
Clean Cooling System. See Engine Manual. Clean And Tighten Battery Connections.
200 h
Change Oil. See Section 7-4 And Maintenance Label. Change Oil Filter. See Section 7-4.
250 h
Check And Clean Spark Arrestor. See Section 7-3. OM-404 Page 22
500 h
Service Welding Generator Brushes And Slip Rings. Service More Often In Dirty Conditions.* Repair Or Replace Cracked Cables And Cords. Clean/Set Injectors.*
1000 h
Blow Out Or Vacuum Inside.
Notes
OM-404 Page 23
40
C +40
50
SAE 15W-40
+32
10W
SAE 10W-30
20W
OM-404 Page 24 Air Filter Service . . . . . . . 50 hours or less see Owners Manual 12 Volt Battery . . BCI Group 58 + Cranking Performance at 0F (-18C) . . . . . . . . 430 Amps
See Engine Manual for complete engine care. Give Engine Specification and Serial Number when ordering parts.
To Drain Oil:
F +104
+68 +59 Engine RPM No Load Weld/Power . . . . 3750 Idle . . . . . . . . . . . 2000
Valve Clearance Cold Intake . . . 0.006 in (0.15 mm) Exhaust . 0.006 in (0.15 mm)
Engine Cooling Avoid recirculation of air from hot air exit to blower intake.
Injectors . . . . . . . . . . . . . . MILLER 066 852, Deutz 77-644-56 Have only trained technician maintain injection pump and injectors. AIR, WATER, or GASOLINE will harm the injection system.
+20 Recommended +10 Oil . . . . . . . . . . . . . . API Service Classification CD, SF/CD, CC/CD or better 0 Oil Change . . . . . . 200 hours or less -10 Oil Filter Change . . normal conditions - 200 hours -20 or less Oil Filter . . . . . . . . . MILLER 066 702, Deutz 77-175-24 MultiOil Capacity . . . . . . 1.9 qt (1.8 L) or Viscosity Oils 2 qt (1.9 L) with filter change
Fuel Grade . . . . . . . . . . . 1-D or 2-D Cetane No. 40 min. (.5% max. Sulfur content) Primary Fuel Filter . . . . . MILLER 066 113 Secondary Fuel Filter . . . MILLER 066 893, Deutz 77-175-19
Diesel
Spark Arrestor Inspection And Service . . . . . . . . . . 250 operating hours see Owners Manual Optional
S-173 094-B
Fill filter with clean fuel before installing read instructions on filter.
Remove plug and remove dirt covering cleanout hole. 3 Exhaust Pipe Start engine and run at idle speed to blow out cleanout hole. If nothing blows out of hole, briefly cover end of exhaust pipe with fireproof material. Y Stop engine and let cool. Reinstall cleanout plug.
Tools Needed:
5/16 in
Ref. 801 331-G / 800 497 -A / Ref. 192 785
OM-404 Page 25
Change engine oil and filter according to engine Owners Manual. Oil may be added at either oil fill. 6 7 Fuel Line Primary Fuel Filter
4 3 4
Replace line if cracked or worn. Install new filter. Wipe up any spilled fuel. 8 Secondary Fuel Filter Remove filter and install new filter element according to engine Owners Manual. Replace fuel line if cracked or worn. Wipe up spilled fuel. 9 Hand Primer Push lever 10 to 12 times to prime injector system. Start engine and check for fuel leaks. Y Stop engine, tighten connections as necessary, and wipe up spilled fuel. Tools Needed:
2 8
OM-404 Page 26
Start engine and run at idle speed. Loosen screw and adjust cable until engine runs at correct idle speed. Do not allow slack in cable. Tighten screw. Weld/Power Speed Adjustment: Run engine at weld/power speed. 3 4 Weld/Power Speed Screw Weld/Power Speed Jam Nut
Loosen jam nut. Turn screw clockwise to decrease speed and counterclockwise to increase speed. 2 Tighten jam nut. Y Stop engine.
Tools Needed:
Right Side
Internal time delay relay CB7 and the fusible link protect the optional glow plug system from overheating. If glow plugs overheat, CB7 automatically stops the heating process. Wait one minute for CB7 to automatically reset before using glow plugs. If the engine is hard to start in cold weather, check the fusible link and replace if open.
NOTE
When a circuit breaker or fuse opens, it usually indicates a more serious problem exists. Contact a Factory Authorized Service Agent.
OM-404 Page 27
CB8 protects the idle solenoid. If CB8 opens, engine drops to idle speed. Check throttle solenoid and cable for obstructions and throttle linkage for proper adjustment. Press button to reset circuit breaker.
C. Fuse F1
Y Stop engine and disconnect battery negative () cable. Remove top cover. 1 1 Fuse F1 (See Parts List For Rating)
F1 protects the exciter stator from overload. Replace F1 if open. Reinstall top cover before operating unit.
indicates a more serious problem exists. Contact a Factory Authorized Service Agent.
Tools Needed:
3/8, 1/2 in
Ref. 801 477-C
OM-404 Page 28
7-7. Troubleshooting
A. Welding
Trouble
No weld output. Check control settings (see Section 5-1). Check weld connections. Check fuse F1 and replace if open (see Section 7-6). Be sure all equipment is disconnected from receptacles when starting unit. Have Factory Authorized Service Agent check brushes, slip rings, and integrated rectifier SR2. Low weld output. Check control settings (see Section 5-1). Check fuse F1 and replace if open (see Section 7-6). Check and adjust engine speed (see Section 7-5). Service air cleaner according to engine manual. Have Factory Authorized Service Agent check brushes and slip rings. High weld output. Check control settings (see Section 5-1). Check and adjust engine speed (see Section 7-5). Erratic weld output. Check control settings (see Section 5-1). Tighten and clean connections to electrode and workpiece. Use dry, properly-stored electrodes for SMAW and GTAW. Remove excessive coils from weld cables. Tighten and clean connections both inside and outside welding generator. Check and adjust engine speed (see Section 7-5). Have Factory Authorized Service Agent check brushes and slip rings.
Remedy
B. Generator Power
Trouble
No output at generator power receptacles.
Remedy
Reset circuit breakers (see Sections 6-1 and 6-3). Press optional GFCI receptacle Reset button (see Section 6-3). Check fuse F1 and replace if open (see Section 7-6). Have Factory Authorized Service Agent check brushes, slip rings, and integrated rectifier SR2.
Check and adjust engine speed (see Section 7-5). Increase Fine Adjust control R1 setting. Check fuse F1 and replace if open (see Section 7-6).
Check fuel level (see Section 4-2). Check and adjust engine speed (see Section 7-5). Check receptacle wiring and connections. Have Factory Authorized Service Agent check brushes and slip rings. OM-404 Page 29
C. Engine
Trouble
Engine will not crank.
Remedy
Check plug PLG4 connection and plug PLG8 connection. Check battery voltage. Check battery connections, and tighten if necessary. Have Factory Authorized Service Agent check continuity and connections of Engine Control switch S2, and replace if necessary.
Check fuel level (see Section 4-2). Check battery and engine charging system. Check oil level. Check low oil pressure shutdown switch (see Section 4-2). Wait one minute for optional glow plug system time delay relay CB7 to reset (see Section 7-6). Have Factory Authorized Service Agent check optional glow plug system fusible link and relay CR2, and replace if necessary (see Section 7-6). Have Factory Authorized Service Agent check Engine Control switch S2, and replace if necessary. See engine manual.
Engine starts, but stops when Engine Control switch returns to Run position.
Check oil level. Check low oil pressure shutdown switch S4 (see Section 4-2). Have Factory Authorized Service Agent check Engine Control switch S2 and fuel solenoid, and replace if necessary.
Clean battery terminals and posts with baking soda solution; rinse with clear water. Periodically recharge battery (approximately every three months). Have Factory Authorized Service Agent check voltage regulator. Replace battery.
Check fuel level (see Section 4-2). Readjust throttle linkage if necessary (see Section 7-5). Tune engine according to engine manual.
Check fuel level (see Section 4-2). Check oil level. Check low oil pressure shutdown switch (see Section 4-2). Have Factory Authorized Service Agent check Engine Control switch S2 and fuel solenoid, and replace if necessary.
Check and reset circuit breaker CB8 (see Section 7-6). Check solenoid linkage for obstructions. Move Idle Lock switch to Run/Idle position (see Section 5-1). Have Factory Authorized Service Agent check Engine Control switch S2, and replace if necessary. Have Factory Authorized Service Agent check control relay CR1, current transformer CT1, throttle solenoid TS1, throttle linkage, and idle module PC1.
Engine uses oil during run-in period; Dry engine (see Section 10 and engine manual). wetstacking occurs. Engine will not stop. Stop engine using manual shut off lever. Have Factory Authorized Service Agent check unit.
OM-404 Page 30
SC-182 630-B
Use #10 AWG or larger insulated copper wire. Y If unit does not have GFCI receptacles, use GFCI-protected extension cord. 1
GND/PE
OR
S-0854
OM-404 Page 32
Use #10 AWG or larger insulated copper wire. 3 Ground Device Y Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system.
ST-800 576-B
EXAMPLE 2: If three 200 watt flood lamps are used with the drill from Example 1, add the individual loads to calculate total load. (200 W + 200 W + 200 W) + 520 W = 1120 W The total load applied by the three flood lamps and drill is 1120 watts.
S-0623
OM-404 Page 33
Fan Duty
1/4 HP 1/2 HP 3/4 HP 2 HP 1/3 HP 1/2 HP 3/4 HP 1 HP 1-1/2 HP 2 HP 3 HP 5 HP 1-1/2 HP 5 HP 7-1/2 HP 10 HP 1/2 HP 500 PSI 550 PSI 700 PSI 1/3 HP 1/2 HP 1/3 HP 1/2 HP
High Torque (e.g. Barn Cleaners, Silo Unloaders, Silo Hoists, Bunk Feeders) 3-1/2 cu. ft. Mixer High Pressure 1.8 Gal/Min Washer 2 gal/min 2 gal/min Refrigerator or Freezer Shallow Well Pump Sump Pump
OM-404 Page 34
Circular Saw
Air Compressor
Electric Chain Saw Electric Trimmer Electric Cultivator Elec. Hedge Trimmer Flood Lights
1000 200 500 1400 1600 950 1400 1600 700 900 1300
OM-404 Page 35
To find starting amperage: Step 1: Find code and use table to find kVA/HP. If code is not listed, multiply running amperage by six to find starting amperage. Step 2: Find Motor HP and Volts. Step 3: Determine starting amperage (see example). Welding generator amperage output must be at least twice the motors running amperage. N 12.5 P 14.0
Single-Phase Induction Motor Starting Requirements Motor Start Code KVA/HP G 6.3 H 7.1 J 8.0 K 9.0 L 10.0 M 11.2
= STARTING AMPERAGE
EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4 HP motor with a motor start code of M. Volts = 230 HP = 1/4 Using Table, Code M results in kVA/HP = 11.2
11.2 x 1/4 x 1000 = 12.2 A Starting the motor requires 12.2 amperes. 230
S-0624
Always start non-resistive (motor) loads in order from largest to smallest, and add resistive loads last. 1 2 5 Second Rule If motor does not start within 5 seconds, turn off power to prevent motor damage. Motor requires more power than generator can supply.
OM-404 Page 36
Obtain and install correct switch. Switch rating must be same as or greater than the branch overcurrent protection. 4 120 V 120 V Neutral Circuit Breakers or Fused Disconnect Switch
Obtain and install correct circuit breakers or switch. 5 3 6 Extension Cord Generator Connections Select as shown in Section 9-11. Connect terminals or plug of adequate amperage capacity to cord. Follow all applicable codes and safety practices. Turn off or unplug all equipment connected to generator before starting or stopping engine. When starting or stopping, the engine has low speed which causes low voltage and frequency. 7 CB or F1 Item 4 is not necessary if circuit protection is already present in generator power circuit. Load Connections
2 240 V
4 7
6 240 V 120/240 Volt Single-Phase Three-Wire Generator Output Connection 120 V 120 V Ground
S-0405-A
OM-404 Page 37
Cord Lengths for 120 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current (Amperes) 5 7 10 15 20 25 30 35 40 45 50 Load (Watts) 600 840 1200 1800 2400 3000 3600 4200 4800 5400 6000 400 (122) 300 (91) 225 (68) 175 (53) 150 (46) 125 (38) 112 (34) 100 (30) 87 (26) 400 (122) 275 (84) 175 (53) 137 (42) 112 (34) 87 (26) 75 (23) 62 (19) 62 (19) 50 (15) 4 6 8 350 (106) 250 (76) 175 (53) 112 (34) 87 (26) 62 (19) 50 (15) 50 (15) 37 (11) 10 225 (68) 150 (46) 112 (34) 75 (23) 50 (15) 37 (11) 37 (11) 12 137 (42) 100 (30) 62 (19) 37 (11) 30 (9) 14 100 (30) 62 (19) 50 (15) 30 (9)
Cord Lengths for 240 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current (Amperes) 5 7 10 15 20 25 30 35 40 45 50 Load (Watts) 1200 1680 2400 3600 4800 6000 7000 8400 9600 10,800 12,000 800 (244) 600 (183) 450 (137) 350 (107) 300 (91) 250 (76) 225 (69) 200 (61) 175 (53) 800 (244) 550 (168) 350 (107) 275 (84) 225 (69) 175 (53) 150 (46) 125 (38) 125 (38) 100 (31) 4 6 8 700 (213) 500 (152) 350 (107) 225 (69) 175 (53) 125 (38) 100 (31) 100 (31) 75 (23) 10 450 (137) 300 (91) 225 (69) 150 (46) 100 (31) 75 (23) 75 (23) 12 225 (84) 200 (61) 125 (38) 75 (23) 60 (18) 14 200 (61) 125 (38) 100 (31) 60 (18)
OM-404 Page 38
10-1. Wetstacking
Y Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur. 1 2 Welding Generator Run diesel engines near rated voltage and current during run-in period to properly seat piston rings and prevent wetstacking. See nameplate, rating label, or specifications section in this manual to find rated voltage and current.
1 2
Do not idle engine longer than necessary. Piston rings seat faster if engine runs at weld/ power rpm, and the welding generator is kept loaded during run-in. Engine Exhaust Pipe
Wetstacking is unburned fuel and oil in the exhaust pipe and occurs during run-in if the engine is run too long at light load or idle rpm. If exhaust pipe is coated with a wet, black, tar-like substance, dry the engine using one of the following run-in procedures. See the engine manual for additional engine run-in information.
OM-404 Page 39
. Check oil level frequently during run-in; add oil if needed. After one hour (minimum) place A/V control in minimum position, then turn off load bank to remove load. Run engine several minutes at no load. Y Stop engine and let cool. 4 Engine Exhaust Pipe Repeat procedure if wetstacking is present.
S-0683
OM-404 Page 40
. Check oil level frequently during run-in; add oil if needed. After one hour (minimum), place A/V control in minimum position, then shut down grid to remove load. Run engine several minutes at no load. Y Stop engine and let cool. 6 Engine Exhaust Pipe Repeat procedure if wetstacking is present.
S-0684
OM-404 Page 41
ST-801 516-K
65
Item No.
Dia. Mkgs.
Part No.
Quantity
. . . 1 . . . . . . . . . . . . . . . . . . 192 041 . . . LABEL, use diesel fuel only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 2 . . . . . . . . . . . . . . . . . . 181 881 . . . GROMMET, filler neck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 3 . . . . . . . . . . . . . . . . . . 147 601 . . . CAP, tank screw-on w/vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 4 . . . . . . . . . . . . . . . . . . 200 795 . . . LABEL,warning gen. precautionary csa . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 5 . . . . . . . . . . . . . . . . . +205 763 . . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 6 . . . . . . . . . . . . . . . . . . 169 329 . . . PANEL, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 7 . . . . . . . . . . . . . . . . . . 205 736 . . . UPRIGHT, base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 8 . . . . . . . . . . . . . . . . . . 205 734 . . . SEAL, weather lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 9 . . . . . . . . . . . . . . . . . . 194 253 . . . PANEL, rear lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 10 . . . . . . . . . . . . . . . . . . Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 . . . . . . . . . . . . . . . . . . 191 427 . . . TANK, fuel 10 gal (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . . . . . 124 253 . . . . BUSHING, tank fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . . . . . . . . . . . . 187 502 . . . . FITTING, stand pipe hose .250 x 7.325 lg 90 . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . . . . . 182 922 . . . . BUSHING, tank fuel 1.210 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . . . . . 182 925 . . . . GAUGE, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . . . . . 172 681 . . . . FITTING, hose stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL, return line (see engine parts list) . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . . . . . 107 816 . . . HOSE, SAE .250 ID x .500 OD (order by ft) . . . . . . . . . . . . . . . . . . . . 1ft . . . 12 . . . . . . . . . . . . . . . . . . 172 707 . . . SEAL, fuel hose fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 13 . . . . . . . . . . . . . . . . . . 066 113 . . . FILTER, fuel in-line .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 14 . . . . . . . . . . . . . . . . . . Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 . . . . . . . . . . . . . . . . . . 141 975 . . . WASHER, flat copper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 16 . . . . . . . . . . . . . . . . . . 177 123 . . . SWITCH, pressure oil 4PSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 17 . . . . . . . . . . . . . . . . . . 142 118 . . . FITTING, pipe brs adapter 1/8NPT x 8m16G . . . . . . . . . . . . . . . . . 1 . . . 18 . . . . . . . . . . . . . . . . . +172 635 . . . ENGINE, diesel elec start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 19 . . . . . . . . . . . . . . . . . . 142 322 . . . BRACKET, mtg fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BASE, fuel filter (see engine parts list) . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 21 . . . . . . . . . . . . . . . . . . 066 893 . . . ELEMENT, fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 22 . . . . . . . . . . . . . . . . . . 165 271 . . . VALVE, oil drain 3/8-18NPTF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 23 . . . . . . . . . . . . . . . . . . 172 634 . . . FITTING, adapter oil drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 24 . . . . . . . . . . . . . . . . . . 149 610 . . . STOP, cable throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 25 . . . . . . . . . . . . . . . . . . 150 203 . . . SPRING, cprsn .372 OD x .051 wire x 1.500 . . . . . . . . . . . . . . . . . . . . 1 . . . 26 . . . . . . . . . . . . . . . . . . 176 897 . . . ARM, throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 27 . . . . . . . . . . . . . . . . . . 172 668 . . . CONTROL, push/pull . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 28 . . . . . . . TS1 . . . . . . 179 385 . . . SOLENOID, 12VDC 44A pull/hold w/o spring . . . . . . . . . . . . . . . . . . . 1 . . . 29 . . . . . . . . . . . . . . . . . . 174 803 . . . BRACKET, mtg solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 30 . . . . . . . . . . . . . . . . . . 066 702 . . . OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 31 . . . . . . . . . . . . . . . . . . Fig 11-3 . . . GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 32 . . . . . . . . . . . . . . . . . . Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 . . . . . . . . . . . . . . . . . . 082 319 . . . CABLE, bat neg 17.750 (battery to engine block) . . . . . . . . . . . . . . . . 1 . . . 33 . . . . . . . . . . . . . . . . . . 172 669 . . . CABLE, bat neg 11.000 (engine block to case) . . . . . . . . . . . . . . . . . . 1 . . . 34 . . . . . . . . . . . . . . . . . . 182 935 . . . HOLD DOWN, battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 35 . . . . . . . . . . . . . . . . . . 186 896 . . . BRACKET, battery tray support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 36 . . . . . . . . . . . . . . . . . . 168 385 . . . LABEL, warning battery explosion can blind . . . . . . . . . . . . . . . . . . . . 1 . . . 37 . . . . . . . . . . . . . . . . . +201 174 . . . DOOR, access battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 38 . . . . . . . . . . . . . . . . . . 173 921 . . . CABLE, bat pos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 39 . . . . . . . . . . . . . . . . . . 167 677 . . . BATTERY, stor 12V 430crk 75rsv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 40 . . . . . . . . . . . . . . . . . +201 280 . . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 41 . . . . . . . . . . . . . . . . . . 173 094 . . . LABEL, engine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 42 . . . . . . . . . . . . . . . . . . 181 057 . . . COVER, base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 43 . . . . . . . . . . . . . . . . . . 183 771 . . . STAB/REACTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 44 . . . . . . AC-Z . . . . . . 176 301 . . . . REACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 45 . . . . . . DC-Z . . . . . . 183 179 . . . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . . . . . 164 920 . . . . BRACKET, mtg stab/reactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 46 . . . . . . . . . . . . . . . . . . 188 434 . . . BRACKET, mtg generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 47 . . . . . . . . . . . . . . . . . . 166 094 . . . MOUNT, engine vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OM-404 Page 43
Item No.
Dia. Mkgs.
Part No.
Quantity
. . . 48 . . . . . . . . . . . . . . . . . . 172 714 . . . . . . 49 . . . . . . . . . . . . . . . . . . 172 719 . . . . . . 50 . . . . . . . . . . . . . . . . . . 127 854 . . . . . . 51 . . . . . . . . . . . . . . . . . . 172 720 . . . . . . 52 . . . . . . . . . . . . . . . . . . 172 625 . . . . . . 53 . . . . . . . 1T . . . . . . . 172 661 . . . . . . 54 . . . . . . . . . . . . . . . . . . 173 734 . . . . . . 55 . . . . . . . SR1 . . . . . . 192 682 . . . . . . 56 . . . . . . . . . . . . . . . . . . 180 628 . . . . . . 57 . . . . . . . . . . . . . . . . . . Fig 11-2 . . . . . . 58 . . . . . . . CT1 . . . . . . 179 494 . . . . . . 59 . . . . . . . . . . . . . . . . . . 177 136 . . . . . . 60 . . . . . . . C1 . . . . . . . 176 719 . . . . . . 61 . . . . . . . . . . . . . . . . . . 172 731 . . . . . . 62 . . . . . . . F1 . . . . . . *169 296 . . . . . . 63 . . . . . . SR2,3 . . . . . 200 759 . . . . . . 64 . . . . . . . R2 . . . . . . . 184 278 . . . . . . . . . . . . . . . RC4 . . . . . . 116 045 . . . . . . . . . . . . . . . PLG6 . . . . . 136 810 . . . . . . . . . . . . . . . PLG4 . . . . . 135 556 . . . . . . . . . . . . . . . RC6 . . . . . . 168 844 . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 503 . . . . . . 65 . . . . . . . . . . . . . . . . . . 197 930 . . .
BRACKET, engine mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRACKET, mtg engine lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLAMP, stl cush 1.312dia x .343mtg hole . . . . . . . . . . . . . . . . . . . . . . BRACKET, mtg engine upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRACKET, mtg rectifier/components . . . . . . . . . . . . . . . . . . . . . . . . . . . BLOCK, stud connection 6 position . . . . . . . . . . . . . . . . . . . . . . . . . . . . LINK, jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RECTIFIER, si 1 ph 240A 400PIV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, front lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSFORMER, current sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLAMP, capacitor 2.500dia clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAPACITOR, elctlt 1000uf 75VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOLDER, fuse mintr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUSE, mintr gl 25A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RECTIFIER, integ 35A 600V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RESISTOR, WW adj 225W 5 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR, rect 4 pin/skt rcpt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KIT, label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL, warning do not weld on base . . . . . . . . . . . . . . . . . . . . . . . . . .
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 2
OPTIONAL +When ordering a component originally displaying a precautionary label, the label should also be ordered. *Recommended Spare Parts. To maintain the factory original performance of your equipment, use only Manufacturers Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. Item No. Dia. Mkgs. Part No. Description Figure 11-2. Panel, Front w/Components (Fig 11-1 Item 57) . . . 1 . . . . . . . S1 . . . . . . . 184 754 . . . ... 2 ............................. . . . 3 . . . . . . . . . . . . . . . . . . 207 845 . . . . . . 3 . . . . . . . . . . . . . . . . 183 171 . . . . . . 3 . . . . . . . . . . . . . . . . 185 161 . . . . . . 3 . . . . . . . . . . . . . . . . 203 681 . . . . . . 4 . . . . . . . . . . . . . . . . . . 186 058 . . . . . . 5 . . . . . . . S3 . . . . . . . 183 148 . . . . . . 6 . . . . . . . R1 . . . . . . . 117 243 . . . . . . 7 . . . . . . . PC1 . . . . . . 186 224 . . . . . . 8 . . . . . . CR1 . . . . . . 173 069 . . . . . . 9 . . . . . . . S2 . . . . . . . 176 606 . . . . . . 10 . . . . . . RC2,3 . . . . . 141 432 . . . . . . 10 . . . . . GFCI2,3 . . 151 981 . . . . . . 11 . . . . . . CB1,2 . . . . . 195 955 . . . . . . 11 . . . . . . . CB1 . . . . 200 929 . . . . . . . . . . . . . . . . . . . . . . . . . 202 631 . . . . . . . . . . . . . . . . . . . . . . . . . 202 630 . . . . . . 12 . . . . . . CB3,4 . . . . . 093 996 . . . . . . 12 . . . . . . CB3,4 . . . 093 995 . . . . . . 13 . . . . . . . S5 . . . . . . . 011 609 . . . . . . . . . . . . . . . . . . . . . . . . . . . 021 385 . . . . . . 14 . . . . . . . CB8 . . . . . . 083 432 . . . . . . 15 . . . . . . . HM . . . . . . 145 247 . . .
OM-404 Page 44
Quantity
SWITCH, polarity 5 position (Weld Process) . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, front (w/battery charger option) . . . . . . . . . . . . . . . . . . . . . . . . PANEL, front (w/Australian or South African receptacle option) . . . . PANEL, front (w/CSA receptacle option) . . . . . . . . . . . . . . . . . . . . . . . . COVER, dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWITCH, selector 4 position (Coarse Adjustment) . . . . . . . . . . . . . . . RHEOSTAT, WW 100W 10 ohm (Fine Adjustment) . . . . . . . . . . . . . . MODULE, weld/power 7 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RELAY, encl 12VDC SPDT 15A 125VDC . . . . . . . . . . . . . . . . . . . . . . . SWITCH, ignition 4 position w/out handle (Engine) . . . . . . . . . . . . . . . RECEPTACLE, str dx grd 2P3W 20A 125V . . . . . . . . . . . . . . . . . . . . . RECEPTACLE, str dx grd 2P3W 15/20A 125VAC GFI . . . . . . . . . . . CIRCUIT BREAKER, man reset 1P 50A 125VAC . . . . . . . . . . . . . . . . CIRCUIT BREAKER, man reset 2p 50a 240vac screw90 (CSA) . . COVER, circuit breaker (CSA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRKT, mtg ckt breaker cover (CSA) . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT BREAKER, man reset 1P 20A 250VAC . . . . . . . . . . . . . . . . CIRCUIT BREAKER, man reset 1P 15A 250VAC . . . . . . . . . . . . . . . . SWITCH, tgl SPDT 15A 125VDC (Idle Lock) . . . . . . . . . . . . . . . . . . . . BOOT, tgl switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT BREAKER, man reset 1P 10A 250VDC . . . . . . . . . . . . . . . METER, hour 12-24VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 1 1 1 1 1 2 1 1 1 1 1 2 2 2 1 1 1 2 2 1 1 1 1
Item No.
Dia. Mkgs.
Part No.
Description Figure 11-2. Panel, Front w/Components (Fig 11-1 Item 57) (Continued)
Quantity
119 014 . . . 046 819 . . . 099 255 . . . 083 030 . . . 010 915 . . . 601 836 . . . 159 921 . . . 147 195 . . . 182 954 . . . 119 172 . . . 148 956 . . . 097 924 . . . 200 532 . . .
LEVER, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SUPPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TERMINAL, pwr output neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STUD, brs .250-20 x 1.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WASHER, flat .250 ID brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NUT, .250-20 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEZEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NUT, .375-27 nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RECEPTACLE, str 3P4W 50A 125/250V . . . . . . . . . . . . . . . . . . . . . . . PLUG, str 50A 125/250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL, warning CSA circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 1 2 1 3 3 1 5 1 1 2 1 1
1 5 2 3 4 6 7 8 9 10 11 12 13 14 26 25
27
15 24 23
19 20 21 17
16
22
18
18
ST-801 517-C
Figure 11-2. Panel, Front w/Components OPTIONAL To maintain the factory original performance of your equipment, use only Manufacturers Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-404 Page 45
Item No.
Part No.
Quantity
... ... ... ... ... ... ... ... ... ... ... ... ...
1 2 3 4 5 6 7 8 9 10 11 12 13
. . . . . +205 901 . . . . . . 183 419 . . . . . . 079 624 . . . . . . 013 367 . . . . . . 179 647 . . . . . . 189 974 . . . . . . 178 527 . . . . . . 174 828 . . . . . . 189 743 . . . . . . 181 134 . . . . . . 181 143 . . . . . . 180 556 . . . . . . 142 156
. . HOUSING, generator front assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ORING, 1.984 id x .139 cs 70 duro viton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCREW, .37516 x 2.25 hex hdpln stl pld full thlkg pa . . . . . . . . . . . . . . . . . . . . . . LABEL, warning moving parts can cause serious injury . . . . . . . . . . . . . . . . . . . . . . . . STUD, stl .31218+24 x 18.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADAPTER, housing generator rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOUSING, generator rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCREW, M 81.2X 45 hex hdpln 8.8 pln . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ROTOR, generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAN, rotor gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEARING, ball rdl sgl row .984 x 2.047 x .591 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOLDER, brush elec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCREW, .375-16 x 1.75 hexwhd .81d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
1 1 1 1 1 1 1 4 1 1 1 1 4
6 5
4 1 8 2 11 10 9
12
13
Ref. 173 092-G
Figure 11-3. Generator +When ordering a component originally displaying a precautionary label, the label should also be ordered. *Recommended Spare Parts. To maintain the factory original performance of your equipment, use only Manufacturers Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-404 Page 46
* * * * * *
APT, ZIPCUT & PLAZCUT Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts (No labor) Spoolmate Spoolguns Canvas Covers
Millers True Blue Limited Warranty shall not apply to: 1. Consumable components; such as contact tips, cutting nozzles, contactors, brushes, slip rings, relays or parts that fail due to normal wear. Items furnished by Miller, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturers warranty, if any. Equipment that has been modified by any party other than Miller, or equipment that has been improperly 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.
2.
3.
* *
2.
Original main power rectifiers Inverters (input and output rectifiers only) Transformer/Rectifier Power Sources Plasma Arc Cutting Power Sources Semi-Automatic and Automatic Wire Feeders Inverter Power Supplies Intellitig Engine Driven Welding Generators (NOTE: Engines are warranted separately by the engine manufacturer.) DS-2 Wire Feeder Motor Driven Guns (w/exception of Spoolmate Spoolguns) Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Water Coolant Systems HF Units Grids Maxstar 140 Spot Welders Load Banks Miller Cyclomatic Equipment Running Gear/Trailers Plasma Cutting Torches (except APT & SAF Models) Field Options (NOTE: Field options are covered under True Blue for the remaining warranty period of the product they are installed in, or for a minimum of one year whichever is greater.)
* * * * * *
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/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 replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customers risk and expense. Millers option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility as determined by Miller. Therefore no compensation or reimbursement for transportation costs 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, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY. ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, 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, INCLUDING 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 specific legal rights, and other rights may be available, but may vary from state to 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.
miller_warr 10/01
3.
* * * * * * * * * * * * * * * * *
4. 5.
* *
Owners Record
Please complete and retain with your personal records.
Model Name Purchase Date Distributor Address City State Zip Serial/Style Number
(Date which equipment was delivered to original customer.)
For Service
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you.
PRINTED IN USA
1/02