Miller Electric Big Blue 300 P Owner'S Manual Download

Page: 68 / 76

OM-4433 Page 64

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 12-1. Main Assembly (Continued)

Quantity

172071

Clamp, Hose .520

−

.605 Clp Dia Slfttng Black

. . . . . . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . .

211961

Hose, Sae .312 Id X .560 Od X 16.000

. . . . . . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

213804

Hose, Sae .312 Id X .560 Od X 2.500

. . . . . . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

191819

Hose, Sae .312 Id X .560 Od X 15.000

. . . . . . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

145054

Hose, Sae .187 Id X .410 Od X 26.000

. . . . . . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

213465

Bolt, J Stl .312

−

18 X 7.250 Pld

. . .

. . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213466

Bracket, Battery Holddown

. . .

. . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BATT

146237

Battery, Stor 12v 585 Crk 95 Rsv Gp 55 Maint Free

. . .

. . . .

. .

. . . . . . . . . . . . . . . . .

190207

Cable, Bat Pos 45 In Lg No 1 Awg W/Clamp & .406 Rng

. . .

. . . . . . . . . . . . . .

. .

. . . . . . . . . . . . .

213668

Bracket, Mtg Unit

. . .

. . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213458

Base 1

. . .

. . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213483

Support, Engine Rh Cat

. . .

. . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

190206

Cable, Bat Neg 42 In Lg 2 Awg W/Clamp & .375 Rng

. . .

. . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . .

224266

Label, Warning Do Not Weld On Base

. . .

. . . . . . . . . . . . . .

. .

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213462

Pad, Mtg Generator

. . .

. . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213670

Screw, 500

−

13x2.25 Hex Flange

−

hd Gr8 Pln Chem/Phys

. . . . . . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . .

071731

Washer, Flat .656idx2.250odx.187t Stl Pld

. . . . . . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . .

100

213463

Spacer/Snubber, Generator Mtg

. .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

101

213485

Support, Engine Lh

. .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

102

213459

Crossmember, Engine

. .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

103

213460

Crossmember, Generator

. .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213600

Screw, 500

−

13x3.00 Hex Flange

−

hd Gr8 Pln

. . . . . . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . .

071731

Washer, Flat .656idx2.250odx.187t Stl Pld

. . . . . . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . .

213464

Bracket, Battery Locator (In Base

−

Not Shown)

. . . . . . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . .

213506

Bracket, Hold

−

Down Fuel Tank (Not Shown)

. . . . . . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . .

104

+226104

Upright, Front

. .

. . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

105

233953

Label, Warning General Precautionary CSA

. .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . .

106

216347

Label, Rating Card Code 133 (Provide Serial No. When Ordering)

. .

. . . . . . . . . . . . .

. .

. . . . .

107

220955

Panel, Front Access

. .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

108

Figure 12-2

Front Panel Assembly

. .

. . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

109

♦

105370

Xfmr, Current

. .

. . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

110

Figure 12-3

Control Panel

. .

. . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

111

213504

Tray, Reactor&Rectifier

. .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213491

Insulator, Capacitor Bank (Applies To Reactor /Redtifier Tray)

. . . . . . . . . . . . . . . . . . . .

. .

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215328

Kit, Label (Includes Safety And Informational Labels)

. . . . . . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . .

When ordering a component originally displaying a precautionary label, the label should also be ordered.

Recommended Spare Parts.

♦

Optional

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested

Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Summary of Contents for Big Blue 300 P

Page 1: ...07 11 Processes Description Air Carbon Arc CAC A Cutting and Gouging Stick SMAW Welding Engine Driven Welding Generator TIG GTAW Welding MIG GMAW Welding Flux Cored FCAW Welding Visit our website at www MillerWelds com File Engine Drive ...

Page 2: ...ntinue 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 operatio...

Page 3: ...FICATIONS 15 4 1 Weld Power And Engine Specifications 15 4 2 Dimensions Weights And Operating Angles 15 4 3 Volt Ampere Curves 16 4 4 Fuel Consumption 17 4 5 Duty Cycle And Overheating 17 4 6 AC Generator Power Curve 18 SECTION 5 INSTALLATION 19 5 1 Installing Welding Generator 19 5 2 Mounting Welding Generator 20 5 3 Installing Exhaust Pipe 21 5 4 Activating The Dry Charge Battery If Applicable 2...

Page 4: ...d Lubrication Systems 40 8 9 Overload Protection 41 8 10 Checking Generator Brushes 42 8 11 Voltmeter Ammeter Help Displays 43 8 12 Troubleshooting 44 SECTION 9 ELECTRICAL DIAGRAMS 48 SECTION 10 RUN IN PROCEDURE 50 10 1 Wetstacking 50 10 2 Run In Procedure Using Load Bank 51 10 3 Run In Procedure Using Resistance Grid 52 SECTION 11 GENERATOR POWER GUIDELINES 53 SECTION 12 PARTS LIST 60 WARRANTY ...

Page 5: ...h risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone Disconnect input power or stop e...

Page 6: ...ding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side 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 Do not weld where the atmosphere may conta...

Page 7: ...ts bare handed Allow cooling period before working on equip ment To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns STEAM AND HOT COOLANT can burn If possible check coolant level when engine is cold to avoid scalding Always check coolant level at overflow tank if present on unit instead of radiator unless told otherwise in maintenance sect...

Page 8: ...age and frequency caused by low engine speed damage electric motors Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable FLYING SPARKS can cause injury Wear a face shield to protect eyes and face Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face hand and body protection Sparks can cause fires keep flammables away MOVING ...

Page 9: ...c tion Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 4221 Walney Road 5th Floor Chantilly VA 20151 phone 703 788 2700 website www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from CanadianStandards Association Standards ...

Page 10: ...est équipé Des précautions de sécurité supplémentaires sont requises dans des environnements à risque comme les endroits humides ou lorsque l on porte des vêtements mouillés sur des structures mé talliques au sol grillages et échafaudages dans des positions assises à genoux et allongées ou quand il y a un risque important de contact accidentel avec la pièce ou le sol Dans ces cas utiliser les appa...

Page 11: ... Porter des lunettes de sécurité avec écrans latéraux même sous votre casque Avoir recours à des écrans protecteurs ou à des rideaux pour protéger les autres contre les rayonnements les éblouissements et les étincelles prévenir toute personne sur les lieux de ne pas regarder l arc Porter des vêtements confectionnés avec des matières résistan tes et ignifuges cuir coton lourd ou laine et des bottes...

Page 12: ... les batteries Débrancher le câble négatif en premier lieu Le rebrancher en dernier lieu LE CARBURANT MOTEUR peut provo quer un incendie ou une explosion Arrêter le moteur avant de vérifier le niveau de carburant ou de faire le plein Ne pas faire le plein en fumant ou proche d une source d étincelles ou d une flamme nue Ne pas faire le plein de carburant à ras bord prévoir de l espace pour son exp...

Page 13: ...t de changer ou de rajouter des éléments ou avant d ouvrir la purge ou le bouchon de remplissage d huile Le METAL CHAUD lors du coupage et gougeage plasma peut provoquer un in cendie ou une explosion Ne pas couper ou gouger à proximité de pro duits inflammables Surveillez et garder un extincteur à proximité DES PIECES CHAUDES peuvent provo quer des brûlures et blessures Ne pas toucher le compresse...

Page 14: ...IONS Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil N utiliser que les pièces de rechange recom mandées par le constructeur Effectuer la maintenance et le service du moteur et du compres seur d air suivant les instructions dans ce manuel ou le manuel du moteur compresseur si applicable LE RAYONNEMENT HAUTE FRÉ QUENCE H F risque de provoquer des interférences Le ...

Page 15: ...tandards Institute 11 West 43rd Street New York NY 10036 8002 téléphone 212 642 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 téléphone 617 770 3000 site Internet www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 2...

Page 16: ... possible hazards as shown by the symbols Read Owner s Manual Follow instructions to activate battery 5 Check oil level Add oil if necessary 6 During the first 50 hours of operation keep welding load above 200 amperes Do not weld below 200 amperes of output 7 After the first 50 hours of operation change the oil and oil filter 2 1 4 DIESEL API CD MIL L 2104D CD SE CD SF 3 S 177 571 0 50 h Std 0 200...

Page 17: ...OM 4433 Page 13 3 2 Manufacturer s Rating Label 228 417 B 803 562 F ...

Page 18: ...te Engine Air Temperature Or Engine Temperature Output Alternating Current Stick SMAW Welding Constant Current CC MIG GMAW Welding TIG GTAW Time h Hours s Seconds 1 Single Phase 3 Three Phase Read Operator s Manual Circuit Protector Do Not Switch While Welding Electrode Connection Work Connection 3 G Engine Driven Three Phase Alternator With Rectifier Hz Hertz X Duty Cycle U0 Rated No Load Voltage...

Page 19: ...uty cycle 65 10 kVA kW 84 42 A 120 240 V AC 60 Hz Water Cooled Three Cylinder 21 7 HP Diesel Engine 11 5 gal 43 5 L 4 2 Dimensions Weights And Operating Angles Dimensions Height 32 in 813 mm 35 3 4 in 908 mm to top of lift eye G Width 26 1 4 in 667 mm mtg brackets turned in 28 3 4 in 730 mm mtg brackets turned out Do not exceed tilt angles or engine could be damaged or unit could tip Do not move o...

Page 20: ...abilities of the welding generator Curves of all other settings fall between the curves shown A Stick Mode B MIG Mode C TIG Mode DC VOLTS DC AMPERES 0 100 200 300 400 500 100 90 80 70 60 50 40 30 20 10 0 MIN MAX 300 0 100 200 300 400 500 100 80 60 40 20 0 DC VOLTS DC AMPERES DC VOLTS DC AMPERES 0 100 200 300 400 500 100 80 60 40 20 0 MIN MAX 300 ...

Page 21: ...0 100 150 200 250 300 350 400 4 5 Duty Cycle And Overheating 1 100 Duty Cycle Duty Cycle is percentage of 10 min utes that unit can weld at rated load without overheating This unit is rated for welding at 250 amperes continuously NOTICE Exceeding duty cycle can damage unit and void warranty 217 515 10 15 20 25 30 40 50 60 80 100 CC CV 1000 800 600 500 400 300 250 200 150 100 WELD AMPERES DUTY CYCL...

Page 22: ... 0 40 80 120 160 0 20 40 60 80 AC AMPERES IN 120 V MODE AC AMPERES IN 240 V MODE 300 250 200 150 100 50 0 150 125 100 75 50 25 0 AC VOLTS Notes 16 Gauge 063 in 22 Gauge 031 in 24 Gauge 025 in 20 Gauge 037 in 18 Gauge 050 in 14 Gauge 078 in 1 8 in 125 in 3 16 in 188 in 1 4 in 25 in 5 16 in 313 in 3 8 in 375 in 1 2 in 5 in MATERIAL THICKNESS REFERENCE CHART ...

Page 23: ...e Section 5 2 for mounting information Grounding 1 Equipment Grounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Electrically bond generator frame to vehicle frame by met al to metalcontact Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insu lated copper wire Bed liners shipping skids and some running gears insu late the ...

Page 24: ...rackets Supplied Mount unit on flat surface or use cross supports to support base Secure unit with mounting brack ets 3 1 2 in Bolt And Washer Minimum Not Supplied 4 3 8 16 x 1 in Screws Supplied To Bolt Unit In Place Remove hardware securing the four mounting brackets to the base Reverse brackets and reattach to base with original hardware Mount unit to truck or trailer with 1 2 in 12 mm or large...

Page 25: ...ls Needed 803 582 Ref 217 357 A Stop engine and let cool Point exhaust pipe in desired di rection but always away from front panel and direction of travel Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual ...

Page 26: ...l If necessary add electro lyte to raise to proper level Reins tall vent caps 8 Battery Charger Read and follow all instruc tions supplied with battery charger Charge battery for 12 minutes at 30 amperes or 30 minutes at 5 am peres Disconnect charging cables and install battery When electrolyte is low add only distilled water to cells to maintainproper level 1 Tools Needed 2 4 30 A For 12 Minutes ...

Page 27: ...add oil see maintenance label Coolant Check coolant level in radiator before start ing unit the first time If necessary add cool ant to radiator until coolant level is at bottom of filler neck Check coolant level in recovery tank daily If necessary add coolant to recovery tank until coolant level is between Cold Full and Hot Full levels If recovery tank coolant level was low also check coolant lev...

Page 28: ...to properly connect weld cables may cause excessive heat and start a fire or damage your machine 4 Weld Output Terminal 5 Supplied Weld Output Terminal Nut 6 Weld Cable Terminal 7 Copper Bar Remove supplied nut from weld output termi nal Slide weld cable terminal onto weld output terminaland secure with nut so that weld cable terminal is tight against copper bar Do not place anything between weld ...

Page 29: ... 50 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 2 0 2x70 300 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 3 0 2x95 350 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 3 0 2x95 2 ea 4 0 2x120 400 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 4 0 2x120 2 ea 4 0 2x120 500 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 4 0 2x120 3 ea 3 0 ...

Page 30: ... receptacle OUTPUT CONTROL E DC input command signal 0 to 10 volts from min to max of remote control with Voltage Amperage Adjust control at max p 115 VOLTS AC I 115 volts 10 amperes 60 Hz ac Protected by supplementary protector CB7 OR J Contact closure to I completes 115 volt ac contactor control circuit OR F Current feedback 1 volt per 100 amperes H Voltage feedback 1 volt per 10 arc volts 803 5...

Page 31: ...OM 4433 Page 27 Notes Welding Symbols Ref AWS ANSI A2 4 ...

Page 32: ...OM 4433 Page 28 SECTION 6 OPERATING WELDING GENERATOR 6 1 Front Panel Controls See Section 6 2 217 357 B 803 563 1 2 5 4 6 7 8 9 10 3 ...

Page 33: ...e control is connected to the Remote receptacle the Auto Sense Remote feature automatically switches voltage am perage control to the remote control see Sec tion 5 9 With remote control connected weld output is determined by a combination of front panel and remote control voltage amperage set tings If no remote control is connected to the Re mote receptacle the front panel Voltage Am perage contro...

Page 34: ...ntrol from A to D to increase arc drive dig from min to max Use the Lift Arc TIG mode for TIG GTAW welding using the Lift Arc TIG starting procedure see Section 6 4 1 803 562 217 357 Process Contactor Switch Settings Switch Setting Process Output On Off Control Engine Auto Idle Optional Switch Setting Process Output On Off Control Engine Auto Idle Optional Remote On Off Switch Re quired TIG HF Req...

Page 35: ...rode touches workpiece only a low sensing voltage is present between electrode and workpiece The solid state output contactor does not energize until after electrode is touching workpiece This allows electrode to touch workpiece without overheating sticking or be ing contaminated Application Lift Arc is used for the DCEN GTAW process when HF Start method is not permitted or to replace the scratch ...

Page 36: ...ocess Contactor switch 0774 Ref 217 357 B 803 562 Adjust Optional Remote Control to 100 Set V A Control To Desired Maximum Weld Output Using Weld Meters Set TIG or STICK Process In Example Min 20 A DC Max 205 A DC Max 205 A DC Min 20 A DC Connect Remote Control To Remote Receptacle RC14 1 Adjust Optional Remote Control to desired weld output Weld meters will always show the combined main and remot...

Page 37: ...roperly RC11 supplies 60 Hz single phase power at weld power speed Maximum output from RC11 is 10 kVA kW 4 Supplementary Protector CB4 5 Supplementary Protector CB6 6 Supplementary Protector CB5 CB4 protects RC6 GFCI2 and CB6 pro tects RC5 GFCI1 from overload If a sup plementaryprotector opens the receptacle does not work Press button to reset Supplementary protector CB5 protects re ceptacles and ...

Page 38: ...ry 8 Hours Section 5 6 8 8 Coolant Level Fuel Level Oil Level Oil Fuel Spills Every 50 Hours Weld Terminals Every 100 Hours Section 8 3 Battery Terminals Air Cleaner Hoses Air Cleaner Element Every 250 Hours 1 2 in 13 mm Engine Manual Section 8 4 Unreadable Labels Fan Belt Tension Oil Oil Filter Spark Arrestor Every 500 Hours Weld Cables Fuel Filter Inline Fuel Filter Radiator Thermostat Every 100...

Page 39: ...OM 4433 Page 35 8 2 Maintenance Label ...

Page 40: ...fety element after servic ing the primary element three times Clean or replace primary element if dirty see note above before cleaning Re place primary element if damaged Re place primary element yearly or after six cleanings 1 Housing 2 Safety Element Optional 3 Primary Element 4 Dust Cap 5 Dust Ejector To clean air filter Wipe off cap and housing Remove cap and dump out dust Remove element s Wip...

Page 41: ...briefly cover end of exhaust pipe with fireproof material Stop engine and let cool Reinstall cleanout plug Tools Needed 3 8 in 1 2 3 8 5 Servicing Engine Cooling System 803 563 Stop engine and let cool 1 Radiator Draincock 2 Radiator Cap Cover Change coolant according to engine manual Add coolant according to Sec tion 5 6 Run engine until engine reaches normal operating temperature Check coolant l...

Page 42: ...ter or frequen cy meter See table for proper no load speed If necessary adjust speed as follows Start engine and run until warm Turn Process Contactor switch to Weld Terminals Always On Stick position 1 Lock Nut 2 Adjustment Screw Loosen nut Turn screw until engine runs at weld power speed Tighten nut Do not set engine speed higher than specified Tampering with adjustments other than shown may aff...

Page 43: ...hrottle Rod Plunger 2 Lock Nut 3 Rubber Boot 4 Adjustment Screw Adjustment screw is not used to adjust engine speed when auto matic idle option is installed However it must be at least 1 8 in 3 mm away from the throttle arm when engine is running at idle rpm Unhook rubber boot from the so lenoid housing but leave con nected to plunger Loosen lock nut Place Engine Control Switch in Auto position Tu...

Page 44: ... new filter and turn clock wise Inspect fuel lines and replace if cracked or worn To drain water from fuel system See engine manual To replace secondary in line fuel filter Note direction of fuel flow as indi cated by arrow on side of filter Re move fuel line clamps and discon nect fuel lines from fuel filter Re place filter reconnect fuel lines and reinstall clamps To drain sludge from fuel tank ...

Page 45: ...ects the engine battery cir cuit If CB1 opens the engine will not crank CB1 automatically resets when the fault is corrected CB2 protects the engine wiring har ness If CB2 opens the engine will not crank CB3 protects part of the weld control wiring harness If CB3 opens weld and generator power output stops CB7 protects the 115 volt ac output to remote receptacle RC14 If CB7 opens 115 volt output t...

Page 46: ...rushes Replace brushes if damaged or if brush material is at or near minimum length 1 5 16 in 8 mm Minimum Length 9 16 in 14 3 mm New Length Replace Damaged Brushes Notes 16 Gauge 063 in 22 Gauge 031 in 24 Gauge 025 in 20 Gauge 037 in 18 Gauge 050 in 14 Gauge 078 in 1 8 in 125 in 3 16 in 188 in 1 4 in 25 in 5 16 in 313 in 3 8 in 375 in 1 2 in 5 in MATERIAL THICKNESS REFERENCE CHART ...

Page 47: ...d or reduce duty cycle Keep en gine access door closed when run ning to maintain proper cooling air flow past rectifier Allow unit to cool before restarting If problem contin ues have Factory Authorized Ser vice Agent check unit 4 Help 23 Display Indicates one of the rectifier output SCR s has failed If this display is shown have Factory Authorized Service Agent check the rectifier SCR s 5 Help 24...

Page 48: ...r help displays see Section 8 11 Have Factory Authorized Service Agent check brushes and slip rings voltage regulator module PC3 and field excitation circuit Erratic weld output Check and tighten connections inside and outside unit Be sure connection to work piece is clean and tight Use dry properly stored electrodes Remove excessive coils from weld cables Have Factory Authorized Service Agent che...

Page 49: ...B2 see Section 8 9 Check engine wiring harness plug connections Have Factory Authorized Service Agent check Engine Control switch S1 and control relay CR2 Engine cranks but does not start Check fuel level Check battery and replace if necessary Check engine charging system according to engine manual Have Factory Authorized Service Agent check control relay CR1 fuel solenoid FS1 and the fuel pump Ai...

Page 50: ...tely every 3 months Engine idles but does not come up to weld speed units with idle option only Have Factory Authorized Service Agent check idle module PC5 and current transformer CT1 Check for obstructed throttle solenoid Engine does not run at idle speed units with idle option only Check for obstructed throttle solenoid Circuit breaker CB9 may be open CB9 automatically resets when fault is corre...

Page 51: ...otes 16 Gauge 063 in 22 Gauge 031 in 24 Gauge 025 in 20 Gauge 037 in 18 Gauge 050 in 14 Gauge 078 in 1 8 in 125 in 3 16 in 188 in 1 4 in 25 in 5 16 in 313 in 3 8 in 375 in 1 2 in 5 in MATERIAL THICKNESS REFERENCE CHART ...

Page 52: ...OM 4433 Page 48 SECTION 9 ELECTRICAL DIAGRAMS Figure 9 1 Circuit Diagram For Welding Generator ...

Page 53: ...OM 4433 Page 49 219 228 E ...

Page 54: ...ngs seat faster if engine runs at weld power rpm and the welding generator is kept loaded during run in 2 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...

Page 55: ...nerator weld output terminals using proper size weld cables with correct connectors Observe correct polarity Start engine and run for several minutes Set load bank switches and then adjust generator A V control so load equals rated voltage and current of generator see name plate rating label or the specifi cations section in this manual Check generator and load bank meters after first five minutes...

Page 56: ...tors polarity is not important 4 Voltmeter 5 Clamp On Ammeter Connect voltmeter and ammeter as shown if not provided on generator Start engine and run for several minutes Set grid switches and then ad just generator A V control so load equals rated voltage and current of the generator see nameplate rating label or the specifications section in this manual Check generator and meters after first fiv...

Page 57: ...ectric shock and static electricity hazards Also see AWS Safety Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Generators 1 EquipmentGrounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insulated copper wire Electrically bond generator frame to vehic...

Page 58: ...e load and requires a constant amount of power 2 Non Resistive Load Equipment with a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when running see Section 11 8 3 Rating Data Rating shows volts and amperes or watts required to run equipment Amperes x Volts Watts Example 1 If a drill uses 4 5 am peres at 115 volts calculate its run nin...

Page 59: ... Home Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 Milker Vacuum Pump 2 HP 10500 2800 FARM DUTY MOTORS 1 3 HP 1720 720 Std e g Conveyors 1 2 HP 2575 975 Feed Augers Air 3 4 HP 4500 1400 Compressors 1 HP 6100 1600 1 1 2 HP 8200 2200 2 HP 10550 2850 3 H...

Page 60: ...HP 6000 1500 1 1 2 HP 8200 2200 2 HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1 3 HP 2100 700 Elec Hedge Trimmer 18 in 400 400 Flood Lights HID 125 100 Metal Halide 313 250 Mercury 1000 Sodium 1400 Vapor 1250 1000 Submersible Pump 400 gph 600 200 Centrifugal Pump 900 gph 900 500 F...

Page 61: ... must be at least twice the motor s running amperage kVA HP x HP x 1000 Volts Starting Amperage Example Calculate starting amper age required for a 230 V 1 4 HP mo tor with a motor start code of M Volts 230 HP 1 4 kVA HP 11 2 11 2 x 1 4 x 1000 230 12 2A Starting the motor requires 12 2 amperes VOLTS AMPS HP 230 2 5 1 4 Hz PHASE CODE 60 1 M AC MOTOR 1 2 3 4 11 9 How Much Power Can Generator Supply ...

Page 62: ... to electric utility when service is re stored Install correct switch customer supplied Switch rating must be same as or greater than the branch overcurrent protection 3 Fused Disconnect Switch Install correct switch customer supplied if required by electrical code 4 Welding Generator Output Generator output voltage and wir ing must be consistent with regular utility system voltage and wiring Conn...

Page 63: ...0 15 40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 2 voltage drop Cord Lengths for 240 Volt Loads 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 Load Watts 4 6 8 10 12 14 5 1200 700 213 450 137 225 84 200 61 7 1680 800 244 500 152 300 91 20...

Page 64: ...ble unless listed Wirng harnesses are listed at the end of parts section 110 Fig 12 3 1 2 3 4 Fig 12 5 5 6 7 8 9 10 11 12 14 15 16 17 18 19 20 21 13 22 23 24 25 26 90 91 92 93 94 95 96 98 97 99 100 101 102 103 104 105 106 107 108 Fig 12 2 109 111 Figure 12 1 Main Assembly ...

Page 65: ...e 61 803 683 F 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 68 67 69 70 73 71 72 74 75 76 77 78 79 80 Fig 12 4 81 82 84 85 86 87 88 89 44 43 83 27 45 ...

Page 66: ...el Spin on 1 20 207721 Pump Fuel 1 21 213858 Filter Fuel In line 5 16x5 16 Mic 125 175 1 22 212621 Pipe Exhaust Flexible Inlet Cat 3013 1 23 183314 Clamp Muffler 1 625 Dia U Pld 3 24 212604 Baffle Air Lower Radiator 1 25 201528 Muffler Exhaust Engine 1 26 212605 Pipe Exhaust Blue Fuel 1 27 233088 Label Danger Using A Generator Indoors Can Kill You In Minutes 1 28 213470 Cover Top 1 049525 Nut 312 ...

Page 67: ...er 1 68 212612 Ftg Adapter Oil Drain Cat 3013 1 199505 Hose Assy Oil Drain 32 000 Lg Includes 1 69 165271 Valve Oil Drain 3 8 18 Nptf 1 70 176529 Ftg Hose Brs Barbed Fem 1 2 Tbg X 3 8 Npt 1 71 113854 Hose Sae 500 Id X 780 Od Xcoil 2 6 Ft 72 197448 Ftg Hose Brs Barbed Elbow M 1 2 Tbg X 3 8 Npt 1 73 212614 Hose Radiator Lower Cat 3013 1 74 217686 Belt Alternator 1 75 217651 Engine Perkins Includes 1...

Page 68: ...or Mtg 1 101 213485 Support Engine Lh 1 102 213459 Crossmember Engine 1 103 213460 Crossmember Generator 1 213600 Screw 500 13x3 00 Hex Flange hd Gr8 Pln 1 071731 Washer Flat 656idx2 250odx 187t Stl Pld 2 213464 Bracket Battery Locator In Base Not Shown 1 213506 Bracket Hold Down Fuel Tank Not Shown 1 104 226104 Upright Front 1 105 233953 Label Warning General Precautionary CSA 1 106 216347 Label ...

Page 69: ...ront w Components Figure 12 1 Item 108 Quantity 1 097926 Knob Pointer 2 375 Dia X 250 Id W Set Screwsplstc 1 2 072590 Lock Shaft Pot 375 32 X 250 Dia Shaft Tall 1 3 170391 Conn Circ Ms Protective Cap Size 20 Nylon 1 4 190323 Boot Circuit Breaker Clear Hex Nut 2 5 097922 Knob Pointer 875 Dia X 250 Id W Set Screwsplstc 1 6 Nameplate Control Order By Model Serial No 1 7 PC6 229949 Circuit Card Assy C...

Page 70: ... 125v 5 20r Order By Model Serial No 24 GFCI1 2 151981 Rcpt Str Dx Grd 2p3w 15 20a 125v 5 20r Gfi Order By Model Serial No 25 C11 C12 217054 Capacitor Cer Disc 0047 Uf 3000 Vdc W Terms 2 26 CB4 CB6 093996 Supplementary Pro Man Reset 1p 20a 250vac Frict 2 27 CB5 203026 Supplementary Protector Man Reset 2p 50a 240vac 1 28 GRD 083030 Stud Brs 250 20 X 1 750 W Hex Collar 1 29 010915 Washer Flat 257idx...

Page 71: ...anel Mtg 1 7 F1 085874 Fuse Mintr Cer Slo blo 10 Amp 250 Volt 1 8 R4 217335 Resistor Board 1 9 CR4 090104 Relay Encl 12vdc Spst 30a 15vdc 5pin Flange Mtg 1 10 CR3 197325 Relay Encl 12vdc Spst 70a 4pin Flange Mtg 1 11 SR3 035704 Rectifier Integ Bridge 40 Amp 800v 1 12 SR1 SR2 035704 Rectifier Integ Bridge 40 Amp 800v 2 13 PC5 214761 Module Pull To Idle 1 14 CB2 CB3 083432 Supplementary Pro Man Rese...

Page 72: ...t Stl Pld Split 312 6 9 192686 Screw M 8 1 25x 25 Hex Hd pln 8 8 Pld Din933 6 10 212641 Stud Stl 375 16 1 625x 19 000 4 11 STATOR 212470 Stator Generator 4 Pole 1 12 160943 Endbell 1 13 167788 Nut 375 16 56hex 34h Stl Pld Sem Cone Wshr 88d 4 14 218552 Brush Assembly 2 Pole Includes 1 15 047879 Bar Retaining Brushholder 2 Brushes 1 16 161306 Cap Brushholder 2 17 126984 Brush w Spring 2 18 005614 Ho...

Page 73: ... Module SCR 3 3 MOD4 5 6 218292 Kit Module SCR 3 4 212602 Bus Bar Rectifier 1 5 212639 Bus Bar Rectifier 3 6 212601 Insulator Rectifier 1 7 TH1 213930 Thermistor Ntc 30k Ohm 25 Deg C 8 5in Lead 1 8 C1 6 215611 Capacitor Assy 3 9 C7 8 9 048420 Capacitor Cer Disc 01 Uf 1000 Vdc W Terms 3 10 217085 Bus Bar Rectifier 1 181853 Insulator Screw For Mounting Rectifier 4 To maintain the factory original pe...

Page 74: ...Pack 4p 1row Female 1 For S1 211293 Conn Pack Terminal Position Assurance Lock 1 129524 Term Frict 250x032 Uninsul Male 130 Stud Mtg 3pr 2 217002 Harness Weld Control Includes 1 PLG2 150316 Conn Rect Univ 039 6p S 3row Plug Cable Lkg 1 PLG9 214951 Conn Rect Univ 039 6p S 3row Plug Cable Lkg Seal 1 214933 Seal Wire Univ 039 3 214934 Seal Plug Univ 039 3 PLG8 147992 Conn Rect Univ 039 10p S 2row Plu...

Page 75: ...Induction Heating Coils and Blankets Cables and Non Electronic Controls APT SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s 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 Exceptio...

Page 76: ...d retain with your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering...

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