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OM-477 Page 54

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 10-4. Control Box w/Components (Fig 10-3 Item 12)

Quantity

CR1

044 588

RELAY, encl 12VDC 3PDT

. . .

. . . . .

. . . . . . .

. . .

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♦

130 515

RESISTOR, board

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. . . . . .

. . .

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

189 701

DIODE/CAPACITOR BOARD

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. . . . . .

. . . . . . . .

. . .

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116 005

BLOCK, term 10A 7P

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. . . . . .

. . . . . . . .

. . .

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129 939

BLOCK, term 10A 19P

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. . . . . .

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. . .

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130 608

MOUNTING BOX, components

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

. . .

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

603 107

HOSE, nprn slit back .156 ID x .343 OD (order by ft)

1ft

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

. . .

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

134 201

STAND-OFF SUPPORT, PC card

. . .

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

. . .

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

PC1

♦

166 205

CIRCUIT CARD, field current regulator

. . .

. . . . .

. . .

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

PLG1

135 275

CONNECTOR PLUG & SOCKETS

. . . . . . . . . .

. . . . . . .

. . .

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

PC2

114 832

CIRCUIT CARD, voltage regulator

. . .

. . . . .

. . . . . . .

. . .

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

CR99

090 104

RELAY, encl 12VDC SPST

. . .

. . . .

. . . . . . .

. . .

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

SR2

097 353

DIODE/SCR, bridge integ 2scr 3 diodes

. . .

. . . . .

. . . . . . .

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

SR1

035 704

RECTIFIER, integ 40A 800V

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Idle Mod

189 742

MODULE, pull to idle 5 pin

. . .

. . . . . .

. . .

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

ST-109 773-C

PC1

PC2

Hardware is common and
not available unless listed.

Figure 10-4. Control Box w/Components

♦

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.

Содержание Big 40G

Страница 1: ...Processes Description Air Carbon Arc CAC A Cutting and Gouging TIG GTAW Welding Stick SMAW Welding Engine Driven Welding Generator With Optional Equipment MIG GMAW Welding Flux Cored FCAW Welding Vis...

Страница 2: ...alue 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 agains...

Страница 3: ...4 6 Selecting Weld Cable Sizes 16 4 7 Remote 14 Receptacle RC3 Information Optional See Section 4 8 17 4 8 Terminal Strip 3T Connections Optional 17 SECTION 5 OPERATING WELDING GENERATOR 18 5 1 Front...

Страница 4: ......

Страница 5: ...n not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable Do...

Страница 6: ...ch hot engine parts or just welded parts bare handed NOISE can damage hearing Noise from some processes or equipment can damage hearing Wear approved ear protection if noise level is high MAGNETIC FIE...

Страница 7: ...mmables Keep exhaust and exhaust pipes way from flammables EXHAUST SPARKS can cause fire Do not let engine exhaust sparks cause fire Use approved engine exhaust spark arrestor in required areas see ap...

Страница 8: ...une Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet...

Страница 9: ...quer une lectrocution Mettre l appareil hors tension quand on ne l utilise pas Ne pas utiliser des c bles us s endommag s de grosseur insuffisante ou mal piss s Ne pas enrouler les c bles autour du co...

Страница 10: ...pour travailler sur un moteur chaud Ne pas toucher mains nues les parties chaudes du moteur ni les pi ces r cemment soud es LE BRUIT peut affecter l ou e Le bruit des processus et des quipements peut...

Страница 11: ...nir distance les produits inflammables de l chappement LES TINCELLES L CHAPPEMENT peuvent provoquer un incendie Emp cher les tincelles d chappement du moteur de provoquer un incendie Utiliser uniqueme...

Страница 12: ...Lejeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 de la National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pa...

Страница 13: ...rent Time h Hours s Seconds Stick Welding SMAW Constant Current CC MIG Welding GMAW Constant Voltage CV Do Not Switch While Welding 1 Single Phase 3 Three Phase SECTION 3 SPECIFICATIONS 3 1 Weld Power...

Страница 14: ...ld tip B 59 1 8 in 1502 mm Do not move or operate unit where it could C 46 1 4 in 1175 mm tip D 34 3 4 in 883 mm B E 26 15 16 in 684 mm A C F 9 1 2 in 241 mm C 33 G 2 7 8 in 73 mm D E 33 H 7 8 in 22 m...

Страница 15: ...rcentage of 10 min utes that unit can weld at rated load without overheating Exceeding duty cycle can damage unit and void warranty 60 Duty Cycle At 350 Amperes 100 Duty Cycle At 300 Amperes 3 5 AC Au...

Страница 16: ...120 240 volt or three phase 240 volt terminals rsb13 1 12 94 ST 111 118 D ST 112 449 B A 8 5 KVA KW Single Phase Auxiliary Power Plant No Weld Load B 12 5 KVA KW Three Phase Auxiliary Power Plant No W...

Страница 17: ...ngs fall between the curves shown rsb13 1 12 94 ST 184 477 A ST 184 475 A ST 184 480 A A CC DC Standard B CC AC Models with Optional Polarity AC Selector Switch C CV DC Models with Optional CV 3 Modul...

Страница 18: ...nt Grounding Terminal 4 Grounding Cable Use 10 AWG or larger insulated copper wire If unit does not have GFCI receptacles use GFCI protected extension cord 2 OR 18 in 460 mm 18 in 460 mm 18 in 460 mm...

Страница 19: ...ance label for specifications Fill fuel tank up to 1 2 in 13 mm from top to allow room for expansion Open fuel shut off valve Check fuel level on a cold engine before use each day 4 Oil After fueling...

Страница 20: ...Left Side 2 1 3 4 in 4 5 Connecting To Weld Output Terminals 4 6 Selecting Weld Cable Sizes Total Cable Copper Length In Weld Circuit Not Exceeding Welding Amperes 100 ft 30 m Or Less 150 ft 45 m 200...

Страница 21: ...remote control D Remote control circuit common A V E 0 to 10 volts dc input command signal from remote control Ref ST 159 730 A K Chassis common The remaining sockets are not used 4 8 Terminal Strip...

Страница 22: ...OM 477 Page 18 SECTION 5 OPERATING WELDING GENERATOR 5 1 Front Panel Controls See Section 5 2 Ref ST 159 730 A Ref ST 191 898 1 2 16 17 6 7 8 15 3 4 5 12 14 13 9 10 11...

Страница 23: ...terminals when remote con tactor switch is closed 5 Process Switch Optional Use switch to select Stick or MIG CV weld output Use Stick for Stick SMAW welding Use MIG CV for wire feed processes MIG FC...

Страница 24: ...s On Hot and engine is running 1 Remote 14 Receptacle RC3 Connect optional remote control to RC3 see Section 4 7 Example Combination remote amperage control In Example Range 85 to 210 A DC Min 85 A DC...

Страница 25: ...ot work Press but ton to reset circuit breaker If a circuit breaker continues to open contact a Factory Authorized Service Agent If a ground fault is detected the GFCI Reset button pops out and the ci...

Страница 26: ...B2 protect the recep tacles from overload If CB1 or CB2 opens the 240 V receptacle and half of the 120 V receptacle does not work 120 volts may still be present at the 240 V receptacle Press button to...

Страница 27: ...Circuit Grounding Lead Jumper 42 is connected to lead 90 at factory Jumper 42 may be discon nected from neutral to meet applica ble electrical codes Lead 42 connects to front panel Ground stud 9 User...

Страница 28: ...ection 4 4 OIL Full 50 h Clean air filter See Section 7 3 Clean and tighten weld terminals 100 h Change oil See Section 7 5 Change oil filter See Section 7 5 Check air cleaner hoses for cracks and loo...

Страница 29: ...OM 477 Page 25 7 2 Maintenance Label...

Страница 30: ...t Max air pressure 100 psi 690 kPa Do not remove plastic fins Replace ele ment if it has holes or damaged gaskets Reinstall element and cap cap arrows pointing up Blow Inspect 1 2 3 5 4 7 4 Overload P...

Страница 31: ...Remote Oil Filter 3 Optional Remote Oil Filter Hoses And Adapter 4 Oil Drain Plug 5 Oil Fill Cap Change filter according to engine manual Install optional remote oil filter if lo cation makes it diffi...

Страница 32: ...Stop engine tighten connec tions as necessary and wipe up spilled fuel Close door Tools Needed 1 3 2 2 7 7 Inspecting And Cleaning Optional Spark Arrestor Muffler ST 800 722 Ref ST 191 898 Stop engine...

Страница 33: ...n lock nuts To adjust remove socket from arm and loos en lock nut Turn socket to adjust length Tighten nut and reattach socket to arm 6 Carburetor 7 Throttle Stop Plate 8 Throttle Stop Clearance betwe...

Страница 34: ...Tighten bracket screws Release throttle arm Recheck idle speed and readjust if necessary Stop engine Close door Tools Needed 1 2 3 4 5 6 7 Right Side 1 4 in 1250 rpm 7 10 Adjusting Governor Sensitivit...

Страница 35: ...12 Troubleshooting A Welding Trouble Remedy No weld output Check control settings Place optional Output Electrode Control switch in On Hot position or move switch to Remote posi tion and connect remot...

Страница 36: ...mperage Voltage Adjust switch in correct position Check connections to Remote 14 receptacle RC3 and terminal strip 3T see Sections 4 7 and 4 8 Repair or replace remote control device Have Factory Auth...

Страница 37: ...f necessary Check Magnetic Shutdown switch MS1 fuse F and replace if open see Section 7 4 See engine manual Have Factory Authorized Service Agent check engine charging system Battery discharges betwee...

Страница 38: ...OM 477 Page 34 Notes...

Страница 39: ...OM 477 Page 35 SECTION 8 ELECTRICAL DIAGRAMS 193 965 A Figure 8 1 Circuit Diagram For Welding Generator For Standard Models...

Страница 40: ...OM 477 Page 36 Figure 8 2 Circuit Diagram For Welding Generator With Welders And Deluxe Package Options...

Страница 41: ...OM 477 Page 37 193 967 A...

Страница 42: ...e Insulated Equipment OR 2 Be sure equipment has this symbol and or wording 3 1 9 2 Grounding Generator To Truck Or Trailer Frame S 0854 1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grounding Te...

Страница 43: ...istive Load Equipmentwith a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when run ning see Section 9 8 3 Rating Data Rating shows volts...

Страница 44: ...me 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 Mil...

Страница 45: ...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 H...

Страница 46: ...Starting Requirements Motor Start Code G H J K L M N P KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0 EXAMPLE Calculate the starting amperage required for a 230 V 1 4 HP motor with a motor start code of...

Страница 47: ...e 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 en...

Страница 48: ...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...

Страница 49: ...OM 477 Page 45 Notes...

Страница 50: ...is common and not available unless listed 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 49 67 66 65 68 69 70 71 72 73 74 91 92 93 94 95 96 99 98 97 103 102 Fig 10 3 115 116 114 113 111 110 109 108 107...

Страница 51: ...OM 477 Page 47 ST 115 004 P 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 19 35 36 37 38 40 41 42 43 39 44 45 46 47 50 51 52 53 54 55 56 57 58 59 60 25 61 Fig 10 2 64 63 62 48 Includes Item 49...

Страница 52: ...rb 1 24 000 272 CLAMP air cleaner 1 25 031 868 BRACKET mtg air cleaner 1 26 010 875 CLAMP muffler 2 000dia 1 27 105 740 MUFFLER exhaust engine 1 28 035 968 WASHER flat rbr 3 625 ID x 5 875 OD 1 195 86...

Страница 53: ...R fuse box 1 77 185 000 LABEL warning auxiliary power 1 78 026 947 STAND OFF insulated 2 50 20 x 1 000 lg 1 79 134 903 FUSE box 1 80 149 541 HOLDER fuse crtg 60A 250V 3 fuses 1 81 F1 3 012 625 FUSE cr...

Страница 54: ...30A 4P 1 038 620 LINK jumper term blk 30A 2 115 053 967 INSULATION rectifier 1 116 089 517 STRAP fuel tank 2 010 021 CLAMP stl cush 562dia 2 136 310 KIT label 1 Recommended Spare Parts When ordering a...

Страница 55: ...E air gen 1 16 201 198 ROTOR gen consisting of 1 17 024 617 RING retaining external 1 18 053 390 BEARING ball 1 19 089 737 FAN rotor 1 035 776 KEY 375 x 375 x 2 000 1 20 044 374 STATOR excitor 1 21 17...

Страница 56: ...UTDOWN consisting of 1 110 958 SWITCH automatic shutdown consisting of 1 6 MS1 011 072 SWITCH magnetic consisting of 1 7 F 048 317 FUSE mintr gl 14A 32V 1 D8 087 970 DIODE 1 8 131 999 PANEL front uppe...

Страница 57: ...ng of 1 20 072 590 LOCK shaft pot 375 32 x 250dia shaft 1 21 022 289 TUBING stl 312 OD x 187 ID x 437 2 22 097 926 KNOB pointer 1 23 021 385 BOOT tgl switch lever 2 24 170 663 HINGE panel front 1 25 0...

Страница 58: ...ARD field current regulator 1 PLG1 135 275 CONNECTOR PLUG SOCKETS 1 10 PC2 114 832 CIRCUIT CARD voltage regulator 1 11 CR99 090 104 RELAY encl 12VDC SPST 1 12 SR2 097 353 DIODE SCR bridge integ 2scr 3...

Страница 59: ...ting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate 185 Spoolmate 250 Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as...

Страница 60: ...complete and retain with your personal records Always provide Model Name and Serial Style Number Call 1 800 4 A Miller or see our website at www MillerWelds com to locate a DISTRIBUTOR or SERVICE AGEN...

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