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Miller Big Blue 300 D Owner'S Manual Download Page 66

OM-236 949 Page 62

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 12-1. Main Assembly (Continued)

Quantity

89

213465

Bolt,  J Stl .312

−

18 X 7.250 Pld 

2

. . . 

. . . . . . . . . . . . . . 

. . 

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

90

213466

Bracket, Battery Holddown 

1

. . . 

. . . . . . . . . . . . . . 

. . 

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

91

BATT

146237

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

1

. . . 

. . . . 

. . . . 

. . 

. . . . . . . . . . . . . . . . . 

92

190207

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

1

. . . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . 

93

213668

Bracket, Mtg Unit 

4

. . . 

. . . . . . . . . . . . . . 

. . 

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

94

213458

Base 1

. . . 

. . . . . . . . . . . . . . 

. . 

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

95

213483

Support, Engine Rh 

1

. . . 

. . . . . . . . . . . . . . 

. . 

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

96

190206

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

1

. . . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . 

97

224266

Label, Warning Do Not Weld On Base

2

. . . 

. . . . . . . . . . . . . . 

. . 

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

98

213462

Pad, Mtg Generator 

1

. . . 

. . . . . . . . . . . . . . 

. . 

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

213670

Screw, 500

−

13x2.25 Hex Flange

−

hd Gr8 Pln Chem/Phys 

2

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

. . 

. . . . . . . . . . . . 

071731

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

2

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

. . 

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

99

213463

Spacer/Snubber,  Generator Mtg 

1

. . . 

. . . . . . . . . . . . . . 

. . 

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

100

213485

Support,  Engine Lh 

1

. . 

. . . . . . . . . . . . . 

. . 

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

101

228237

Crossmember, Engine 

1

. . 

. . . . . . . . . . . . . 

. . 

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

102

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

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

. . 

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

103

+226104

Upright, Front 

1

. . 

. . . . . . . . . . . . 

. . 

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

104

233953

Label, Warning General Precautionary CSA

1

. . 

. . . . . . . . . . . . . 

. . 

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

105

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

1

. . 

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

. . . . . . . . . . . . . . . 

106

220955

Panel, Front Access 

1

. . 

. . . . . . . . . . . . . 

. . 

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

107

Figure 12-2

Front Panel Assembly

1

. . 

. . . . . . . . . 

. . 

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

108

♦

105370

Xfmr, Current 

1

. . 

. . . . . . . . . . . 

. . 

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

109

Figure 12-3

Control Panel

1

. . 

. . . . . . . . . 

. . 

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

110

213504

Tray, Reactor&Rectifier 

1

. . 

. . . . . . . . . . . . . 

. . 

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

213491

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

1

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

. . 

. . . . . . . . . . 

+

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 D

Page 1: ...2013 09 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: ...tinue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operation...

Page 3: ...nd Engine Specifications 14 4 2 Dimensions Weights And Operating Angles 14 4 3 Volt Ampere Curves 15 4 4 Fuel Consumption 16 4 5 Duty Cycle And Overheating 16 4 6 AC Generator Power Curve 17 SECTION 5 INSTALLATION 18 5 1 Installing Welding Generator 18 5 2 Mounting Welding Generator 19 5 4 Rating Label Location 20 5 5 Installing Exhaust Pipe 21 5 6 Activating The Dry Charge Battery If Applicable 2...

Page 4: ...8 Checking Generator Brushes 41 8 9 Adjusting Engine Speed 41 8 10 Voltmeter Ammeter Help Displays 42 8 11 Troubleshooting 43 SECTION 9 ELECTRICAL DIAGRAMS 46 SECTION 10 RUN IN PROCEDURE 48 10 1 Wetstacking 48 10 2 Run In Procedure Using Load Bank 49 10 3 Run In Procedure Using Resistance Grid 50 SECTION 11 GENERATOR POWER GUIDELINES 51 SECTION 12 PARTS LIST 58 OPTIONS AND ACCESSORIES WARRANTY ...

Page 5: ...igh 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...

Page 6: ...lding 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 cont...

Page 7: ...arts 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 se...

Page 8: ...tage 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: ...ec 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: ...n 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 ap...

Page 11: ...rter 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 de...

Page 12: ...sur les batteries Débrancher le câble négatif en premier lieu Le rebrancher en dernier lieu LE CARBURANT MOTEUR peut pro voquer 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 étincel les ou d une flamme nue Ne pas faire le plein de carburant à ras bord prévoir de l espace pour son...

Page 13: ...nt 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 compress...

Page 14: ...CTIONS 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 L...

Page 15: ... Standards 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...

Page 16: ...e 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 20...

Page 17: ...ote 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 Voltag...

Page 18: ... DC 100 Duty cycle 60 10 kVA kW 91 45 A 120 240 V AC 60 Hz Four Cylinder 24 2 HP Diesel Engine 11 gal 41 6 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 or opera...

Page 19: ...the welding generator Curves of all other settings fall between the curves shown A Stick Mode B MIG Mode C TIG Mode 0 100 200 300 400 500 0 10 20 30 40 50 60 70 80 90 100 DC Volts DC Amperes Min Max 0 100 200 300 400 500 0 10 20 30 40 50 60 70 80 90 100 DC Volts DC Amperes Min Max 0 100 200 300 400 500 0 10 20 30 40 50 60 70 80 90 100 DC Volts DC Amperes Min Max ...

Page 20: ...00 150 200 250 300 350 400 Idle 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 CY...

Page 21: ...0 0 150 125 100 75 50 25 0 AC VOLTS The ac power curve shows the gen erator power in amperes available at the 120 and 240 volt receptacles 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 22: ...and other applica ble codes NOTICE Do not install unit where air flow is restricted or engine may overheat See Section 4 2 for lifting eye rat ing See Section 5 2 for mounting information install3 2008 01 Ref 800 652 Ref 800 477 A 803 274 804 712 18 in 460 mm 18 in 460 mm 18 in 460 mm 18 in 460 mm 18 in 460 mm Movement 5 1 Installing Welding Generator OR OR OR Location AirflowClearance OR ...

Page 23: ...ss Supports 2 Mounting Brackets 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 wi...

Page 24: ...e GFCI re ceptacles use GFCI pro tected extension cord 1 Equipment Grounding 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 vehicle frame by met al to metal contact 5 3 Grounding Generator To Truck Or Trailer Frame rot_grn...

Page 25: ...ools 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: ...If necessary add electro lyte to raise to proper level Reins tall vent caps 4 Battery Charger Read and follow all instruc tions supplied with battery charger 5 5 Amperes For 30 Minutes Charge Time 6 30 Amperes For 12 Minutes Charge Time Charge battery Disconnect charg ing cables and install battery When electrolyte is low add only distilled water to cells to maintainproper level 1 Tools Needed 2 4...

Page 27: ...e 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 level in radiator Add coolant if level is below bottom of radia tor filler nec...

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: ... 1 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 ...

Page 30: ... V 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...

Page 31: ...OM 236 949 Page 27 Notes Welding Symbols Ref AWS ANSI A2 4 ...

Page 32: ...OM 236 949 Page 28 SECTION 6 OPERATING WELDING GENERATOR 6 1 Front Panel Controls See Section 6 2 217 357 D 803 563 1 2 5 4 6 7 8 9 3 ...

Page 33: ...automatically switches voltage am perage control to the remote control see Sec tion 5 11 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 control adjusts voltage and amper age If a remote device connected to Remote Recept...

Page 34: ...control 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 R...

Page 35: ... to workpiece at weld start point Slowly lift electrode Arc is started when electrode is lifted Maintain shielding gas coverage and eliminate tungsten and work piece contamination by using Auto Crater or Auto Stop to end the arc Arc End With Crater Out Momentary contact switch re quired to start crater out 1 While welding 2 Close momentary contact switch to start Crater out end current is reduced ...

Page 36: ...Process 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 rem...

Page 37: ...OM 236 949 Page 33 6 6 Fuel Hour Gauge Descriptions ...

Page 38: ...properly 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 39: ...very 8 Hours Section 5 8 8 6 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 1...

Page 40: ...OM 236 949 Page 36 8 2 Maintenance Label ...

Page 41: ...safety 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 W...

Page 42: ... 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 805 177 A 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 8 Run engine until engine reaches normal operating temperature Check coolan...

Page 43: ...Install 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 fue...

Page 44: ...or CB3 5 Supplementary Protector CB7 6 Supplementary Protector CB8 CB1 protects 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 ...

Page 45: ... 5 16 in 8 mm Minimum Length 9 16 in 14 3 mm New Length Replace Damaged Brushes 8 9 Adjusting Engine Speed NOTICE Engine speed adjustment must be done by an engine Factory Authorized Service Agent Tampering with adjustments may affect engine warranty 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 ...

Page 46: ...stem and 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 Can indicate a complete loss of generator excitation auxiliary pow er output and weld output or a fail ure of one of the rectifier output SRCs If ...

Page 47: ... 10 Have Factory Authorized Service Agent check brushes and slip rings 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 check brushes and slip rings High weld output Have Factory Au...

Page 48: ...onents Reset supplementary protector CB2 see Section 8 7 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 ...

Page 49: ...ar water Recharge or replace battery if necessary Periodically recharge battery approximately every 3 months Engine idles but does not come up to weld speed units with idle option only Have Factory Authorized Service Agent check fuel hour gauge and current transformer CT1 Engine does not run at idle speed units with idle option only Have Factory Authorized Service Agent check fuel hour gauge and c...

Page 50: ...OM 236 949 Page 46 SECTION 9 ELECTRICAL DIAGRAMS Figure 9 1 Circuit Diagram For Welding Generator ...

Page 51: ...OM 236 949 Page 47 236 892 A ...

Page 52: ...ings 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 engin...

Page 53: ...enerator 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 minute...

Page 54: ...c 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 f...

Page 55: ...hock 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 vehicle frame...

Page 56: ...ive 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 n...

Page 57: ...m 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 ...

Page 58: ...1 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...

Page 59: ...t 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 60: ...ck 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 Co...

Page 61: ...50 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 2...

Page 62: ...lable unless listed Wirng harnesses are listed at the end of parts section 109 Fig 15 2 1 2 3 4 Fig 15 5 5 6 7 8 9 10 11 12 14 15 16 20 19 13 22 23 24 25 26 89 90 91 92 93 94 95 97 96 98 99 100 101 102 103 104 105 106 107 Fig 15 2 108 110 17 18 21 Figure 12 1 Main Assembly ...

Page 63: ...Page 59 805 178 A 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 46 47 48 50 51 52 53 54 55 56 57 58 59 61 60 62 63 71 64 65 72 74 73 83 84 85 86 87 88 44 43 82 27 45 49 66 67 68 69 70 75 76 77 78 79 Fig 12 4 80 81 ...

Page 64: ...M 5 16 Tbg X 1 4 Npt 2 19 213858 Filter Fuel In line 5 16x5 16 Mic 125 175 1 20 228779 Filter Fuel Spin on 1 21 237666 Ftg Hose Brs Splice 5 32 Tbg X 1 4 Tbg 1 22 227687 Pipe Exhaust Flexible Inlet 1 23 183314 Clamp Muffler 1 625 Dia U Pld 3 24 212604 Baffle Air Lower Radiator 1 25 226018 Muffler Exhaust Engine 1 26 212605 Pipe Exhaust Blue Fuel 1 27 233088 Label Danger Using A Generator Indoors C...

Page 65: ...65 197448 Ftg Hose Brs Barbed Elbow M 1 2 Tbg X 3 8 Npt 1 66 228778 Filter Oil 1 67 213266 Mount Engine Generator Flange Mtg 2 68 237218 Bracket Mtg Engine 2 69 083883 Washer Lock 402idx0 709odx 087t Stl Split10mm 2 70 049026 Screw M10 1 5x 25 Hex Hd pln 8 8 Pln 2 71 227961 Hose Radiator Lower 1 72 227693 Hose Radiator Upper 1 73 228780 Belt Alternator 1 74 237007 Engine Deutz 2008 Includes 1 2287...

Page 66: ...02 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 1 103 226104 Upright Front 1 104 233953 Label Warning General Precautionary CSA 1 105 Label Rating Card Provide Serial No When Ordering 1 106 220955 Panel Front Access 1 10...

Page 67: ... Front 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...

Page 68: ...a 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 257id...

Page 69: ...ay Encl 12vdc Dpst no 25a 6pin Flange 1 6 046432 Holder Fuse Mintr 250 X 1 250 Panel Mtg 1 7 F1 085874 Fuse Mintr Cer Slo blo 10 Amp 250 Volt 1 8 CR4 090104 Relay Encl 12vdc Spst 30a 15vdc 5pin Flange Mtg 1 9 CR3 197325 Relay Encl 12vdc Spst 70a 4pin Flange Mtg 1 10 SR1 2 4 5 035704 Rectifier Integ Bridge 40 Amp 800v 4 11 CB2 CB3 083432 Supplementary Pro Man Reset 1p 10a 250vac Frict 2 Optional Wh...

Page 70: ...tl 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 235013 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 Holde...

Page 71: ...it 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 ...

Page 72: ...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 Plug Cable Lkg 1 PLG6 193184 Conn Rect Cinch 30 Pin 1 PLG7 193183 Conn Rect Cinch 18 Pin 1 PLG9 215261 Conn Deutsch 12p 2row Fe...

Page 73: ...OM 236 949 Page 69 Notes 400 Trade Square East Troy Ohio 45373 1 800 332 9448 www welding org Over 80 000 trained since 1930 Start Your Professional Welding Career Now ...

Page 74: ...2362 in 10 mm 10 mm 5 16 in 3125 in 1 2 in 9 16 in 8 mm 3150 in 14 mm 14 mm 3 8 in 375 in 9 16 in 5 8 in 10 mm 3937 in 17 mm 17 mm 7 16 in 4375 in 5 8 in 3 4 in 12 mm 4724 in 19 mm 19 mm 1 2 in 500 in 3 4 in 13 16 in 14 mm 5512 in 22 mm 22 mm 9 16 in 5625 in 7 8 in 7 8 in 16 mm 6299 in 24 mm 24 mm 5 8 in 625 in 15 16 in 1 in 18 mm 7087 in 27 mm 27 mm 3 4 in 750 in 1 1 8 in 1 1 8 in 22 mm 8661 in 3...

Page 75: ...uns and Subarc SAW Guns 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...

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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