Professional Documents
Culture Documents
197 760AG
June 2002
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
Description
www.MillerWelds.com
TABLE OF CONTENTS
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.
CALIFORNIA
Proposition 65
Warning
Diesel engine exhaust and
some of its constituents
are known to the State of
California to cause
cancer, birth defects, and
other reproductive harm.
The following terms are
used interchangeably
throughout this manual:
Stick = SMAW
TIG = GTAW
MIG = GMAW
1
1
1
2
3
4
4
1
1
1
2
3
4
4
SECTION 2 DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Warning Label Definitions (For Wordless Labels) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Manufacturers Rating Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
5
9
10
SECTION 3 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Volt-Ampere Curves For CC Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Volt-Ampere Curves For CC/CV Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Standard AC Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Optional Three-Phase Generator Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
11
11
12
13
14
14
15
15
SECTION 4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Installing Welding Generator (See Sections 4-2 And 4-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Using Lifting Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Mounting Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Activating The Dry Charge Battery (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models . . . . . . . . . . . . .
4-11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models . . . . . . . . . . . . . . . . . . . . . .
16
16
17
18
19
20
21
22
23
23
24
25
26
26
27
28
30
30
31
32
33
34
34
35
36
(Continued)
TABLE OF CONTENTS
SECTION 8 MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Maintenance Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Inspecting And Cleaning Optional Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-7. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-8. Diagnosing Causes Of Engine Fault Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-9. Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37
37
38
40
41
42
43
44
45
46
50
54
54
55
56
57
64
Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
READ INSTRUCTIONS.
Use only genuine MILLER replacement parts.
Perform engine maintenance and service
according to this manual and the engine
manual.
OM-497 Page 3
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: The body of evidence, in the
committees judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-497 Page 4
LES RAYONS DE LARC peuvent provoquer des brlures dans les yeux et
sur la peau.
Sisoler de la pice et de la terre au moyen de tapis ou dautres moyens isolants suffisamment grands pour empcher le contact physique ventuel
avec la pice ou la terre.
Si lutilisation dune source lectrique courant lectrique savre ncessaire, se servir de la fonction de tlcommande si lappareil en est quip.
Vrifier frquemment le cordon dalimentation pour voir sil nest pas endommag ou dnud remplacer le cordon immdiatement sil est
endommag un cble dnud peut provoquer une lectrocution.
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.
OM-497 Page 1
Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille.
LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT CHAUD peuvent
provoquer des brlures.
OM-497 Page 2
Ne pas approcher les mains des ventilateurs, courroies et autres pices en mouvement.
Maintenir ferms et fixement en place les portes,
panneaux, recouvrements et dispositifs de
protection.
Arrter le moteur avant dinstaller ou brancher lappareil.
Demander seulement un personnel qualifi denlever les dispositifs de
scurit ou les recouvrements pour effectuer, sil y a lieu, des travaux
dentretien et de dpannage.
Pour empcher tout dmarrage accidentel pendant les travaux dentretien, dbrancher le cble ngatif () de batterie de la borne.
Ne pas approcher les mains, cheveux, vtements lches et outils des organes mobiles.
Remettre en place les panneaux ou les dipositifs de protection et fermer
les portes la fin des travaux dentretien et avant de faire dmarrer le
moteur.
Avant dintervenir, dposer les bougies ou injecteurs pour viter la mise
en route accidentelle du moteur.
Bloquer le volant moteur pour viter sa rotation lors dune intervention
sur le gnrateur.
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-497 Page 3
Le courant de soudage, pendant son passage dans les cbles de soudage, causera des champs lectromagntiques. Il y a eu et il y a encore
un certain souci propos de tels champs. Cependant, aprs avoir examin plus de 500 tudes qui ont t faites pendant une priode de
recherche de 17 ans, un comit spcial ruban bleu du National Research Council a conclu: Laccumulation de preuves, suivant le
jugement du comit, na pas dmontr que lexposition aux champs
magntiques et champs lectriques haute frquence reprsente un
risque la sant humaine. Toutefois, des tudes sont toujours en cours
et les preuves continuent tre examines. En attendant que les conclusions finales de la recherche soient tablies, il vous serait
souhaitable de rduire votre exposition aux champs lectromagntiques pendant le soudage ou le coupage.
OM-497 Page 4
2
3
4
5
SECTION 2 DEFINITIONS
2-1. Warning Label Definitions (For Wordless Labels)
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
Become trained and read the
instructions before working on the
machine or welding.
1
1.1
1.2
1.3
2
2.1
2.2
2.3
3
3.1
3.2
3.3
4
4.1
5
6
6.1
6.2
6.3
7
7.1
7.2
3/96
OM-497 Page 5
10
11
+
+
S-176 108
12
3/96
S-176 106
OM-497 Page 6
S-176 230
3/96
4
5
6
3/96
2
3
S-176 104
3/96
OM-497 Page 7
1
1
3
4
5
2
3
OM-497 Page 8
S-177 571
2
3
+
3
DIESEL
5
0 50 h Std.
200A
0 200A
50 h Std.
CC/CV Models
OM-497 Page 9
Slow (Idle)
Start Engine
Starting Aid
Battery (Engine)
Engine Oil
Pressure
Engine Oil
Check Injectors/
Pump
Check Valve
Clearance
Fuel
Protective Earth
(Ground)
Positive
Negative
Certified/Trained
Mechanic
Welding Arc
Volts
Panel/Local
Remote
Engine
Air Temperature Or
Engine
Temperature
Output
Alternating
Current
Stick (SMAW)
Welding
Constant Current
(CC)
MIG (GMAW)
Welding
TIG (GTAW)
Time
Hours
Seconds
Amperes
Three Phase
Read Operators
Manual
Electrode
Connection
Work Connection
s
G
Engine-Driven,
Three-Phase
Alternator With
Rectifier
Duty Cycle
U0
Rated No Load
Voltage (Average)
U2
Conventional
Load Voltage
n1
Rated Idle
Speed
n0
Rated No Load
Speed
Current
OM-497 Page 10
Single Phase
Do Not Switch
While Welding
Circuit Breaker
Contactor On
Hz
n
I2
Hertz
Rated Load
Speed
Rated Welding
Current
SECTION 3 SPECIFICATIONS
3-1. Weld, Power, And Engine Specifications
Welding
Mode
CC/DC
Weld Output
Range
Rated Welding
Output
45 500 A
(CC Models)
15 500 A
(CC/CV Models)
Maximum
OpenCircuit
Voltage
Generator Power
Rating
95
Standard:
Single-Phase,
4 kVA/kW, 34/17 A,
120/240 V AC,
50/60 Hz
CV/DC
(CC/CV
Models
Only)
14 40 V
Three-Phase Generator
Option:*
Single-Phase/Three-Phase,
12/15 kVA/kW, 50/36A,
120/240 VAC, 60 Hz
56
Fuel
Capacity
Engine
DEUTZ
Deutz F3L1011
Air/Oil-Cooled, Three
Cylinder, 33 HP Diesel
Engine
25 gal
(95 L)
60 in (1524 mm)
(to top of muffler)
Width
30-3/4 in (781 mm)
(mtg. brackets turned out)
Depth
B*
56 in (1422 mm)
C*
46-1/2 in (1181)
D*
1 in (25 mm)
A
B
30
H
20
D
30
20
Weight
w/ Deutz
F3L1011
802 161-A
OM-497 Page 11
100
Ranges
210 Max
165 350
100 250
65 120
45 85
DC VOLTS
80
60
40
20
0
0
100
200
300
400
500
600
700
DC AMPERES
202 666-A
OM-497 Page 12
100
Ranges
Max
150 420
110 315
75 200
40 90
DC VOLTS
80
60
40
20
0
0
100
200
300
400
500
600
700
800
900
DC AMPERES
B. MIG Mode
100
DC VOLTS
80
60
MAX
40
20
MIN
0
0
100
200
300
400
500
600
700
800
900
1000
450
500
DC AMPERES
C. TIG Mode
100
90
Ranges
50 335
40 240
25 150
15 75
80
DC VOLTS
70
60
50
40
30
20
10
0
0
50
100
150
200
250
300
DC AMPERES
350
400
OM-497 Page 13
2.00
1.75
US Gal./Hr.
1.50
1.25
1.00
0.75
0.50
0.25
IDLE
0.00
0
50
100
150
200
250
300
350
400
199 032
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
Exceeding duty cycle can
damage unit and void
warranty.
WELD AMPERES
Continuous Welding
% DUTY CYCLE
199 140
OM-497 Page 14
150 300
AC VOLTS
125 250
100 200
75 150
50 100
25
50
0
0
10
15
20
AC AMPERES IN 240V MODE
25
30
10
20
30
40
AC AMPERES IN 120V MODE
50
60
193 018
AC VOLTS
260
240
220
200
180
0
20
40
60
80
100
AC AMPERES
B. 15 kVA/kW Three-Phase AC Output (No Weld Load)
280
AC VOLTS
260
240
220
200
180
0
10
20
30
40
AC AMPERES
50
60
70
198 868 / 198 869
OM-497 Page 15
SECTION 4 INSTALLATION
-1. Installing Welding Generator (See Sections 4-2 And 4-3)
Always securely fasten welding generator onto transport
vehicle or trailer and comply
with all DOT and other applicable codes.
Movement
OR
OR
Grounding:
1
Location
2
3
OR
Grounding
1
GND/PE
Airflow Clearance
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
install3 5/02 Ref. 800 652 / Ref. 800 477-A / 803 274
OM-497 Page 16
Lifting Eye
Nut
Carriage Bolt
802 311
Notes
OM-497 Page 17
Mounting Surface:
1
2
OR
Cross-Supports
Mounting Brackets (Supplied)
Inadequate support.
4
Do not use flexible mounts.
Tools Needed:
9/16 in
install3 5/02 803 274 / 190 250-A / 803 231
OM-497 Page 18
Tools Needed:
1/2 in
Notes
OM-497 Page 19
4
1
2
3
4
5
Battery Charger
When electrolyte
is low, add
only distilled water to cells to
maintain proper level.
5 A For 30 Minutes
Tools Needed:
OR
rubber gloves
30 A For 12 Minutes
glasses
drybatt1 1/98 0886
OM-497 Page 20
Tools Needed:
1/2 in
Notes
OM-497 Page 21
Full
Diesel
Full
down switch. However, some conditions may cause engine damage before
the engine shuts down. Check oil level
often and do not use the oil pressure
shutdown system to monitor oil level.
Follow run-in procedure in engine manual.
If unburned fuel and oil collect in exhaust
pipe during run-in, see Section 10.
OM-497 Page 22
802 489-D
Fuel
Do not use gasoline. Gasoline will
damage engine.
Add fresh diesel fuel before starting to prevent air from entering the fuel system (see
engine maintenance label for fuel specifications). Leave filler neck empty to allow room
for expansion.
Do not run out of fuel or air may enter fuel
system and cause 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).
Tools Needed:
2
3/4 in
802 311
If equipped with optional Polarity switch or optional Polarity/AC switch, connect wire feeder cable
to Electrode (+) terminal on left and work cable
to Work () terminal on right.
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
400 ft
(105 m) (120 m)
Weld Output
Terminals
Stop engine before
connecting to weld output terminals.
Welding
Amperes
10 60%
Duty
Cycle
60 100%
Duty
Cycle
100
4 (20)
4 (20)
4 (20)
3 (30)
2 (35)
1 (50)
1/0 (60)
1/0 (60)
150
3 (30)
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
200
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
4/0 (120)
250
2 (35)
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. 3/0
(3x95)
3 ea. 3/0
(3x95)
* This
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.
OM-497 Page 23
OM-497 Page 24
Socket*
Socket Information
Chassis common.
24 VOLTS AC
REMOTE
OUTPUT
CONTROL
OR
GND
802 311
NEUTRAL
OM-497 Page 25
13
14
18
19
10 11
12
15
16
17
OM-497 Page 26
5-2. Description Of Front Panel Controls For CC Models (See Section 5-1)
Light goes on if engine alternator is not charging battery. Engine continues to run.
Stop engine and fix trouble if Battery
Charging light goes on.
To
a max OCV control circuit that resets Amperage Adjust control R1 to maximum
when the arc breaks. When an arc is
struck, weld output control returns to the
R1 front panel or combination front panel/
remote control setting. The Amperage
Adjust control adjusts amperage only
when welding and does not adjust opencircuit voltage.
The max OCV circuit is disabled when
the Stick/TIG Selection switch is in
Scratch Start TIG position (see item 15).
OM-497 Page 27
In Example:
Range = 100 to 205 A DC
Percentage Of Range = 50%
Max = About 153 A DC (50% of 100 to 205)
Set Range
Set Control
OM-497 Page 28
Notes
OM-497 Page 29
14
15
19
20
10 11
12
13
16
17
18
OR
OM-497 Page 30
6-2. Description Of Front Panel Controls For CC/CV Models (See Section 6-1)
Fuel Light
Engine Gauges
To
Fuel Gauge
Light goes on if engine alternator is not charging battery. Engine continues to run.
Stop engine and fix trouble if Battery
Charging light goes on.
5
switch
in
AC
19 DC Voltmeter (Optional)
Voltmeter displays voltage at the weld output
terminals, but not necessarily the welding arc
due to resistance of cable and connections.
20 DC Ammeter (Optional)
Ammeter displays amperage output of the
unit.
OM-497 Page 31
Process/Contactor Switch
Place
Process
Remote TIG
At Remote 14 Receptacle
Not Active
Remote Stick
At Remote 14 Receptacle
Active
Remote MIG
MIG (GMAW)
At Remote 14 Receptacle
Active
MIG (GMAW)
Electrode Hot
Active
Stick (SMAW),
Air Carbon Arc (CAC-A) Cutting
And Gouging
Electrode Hot
Active
Electrode Hot
Active
OM-497 Page 32
In Example:
Process = Stick (Using Remote On/Off)
Range = 110 to 315 A DC
Min = 110 A DC
Max = 315 A DC
Set Remote
Process
Set Range
Control Not
Used In Remote
Stick Mode
In Example:
Process = TIG (Using Remote On/Off)
Range = 40 to 240 A DC
Percentage Of Range = 50%
Min = 40 A DC
Max = About 140 A DC (50% of 40 to 240)
Set Remote
Process
Set Range
Set Control
OM-497 Page 33
120 V 20 A AC GFCI
Receptacle GFCI1
240 V 30 A AC Twistlock
Receptacle RC1
1
3
CB1 protects RC1 and the generator winding from overload. If CB1
opens, RC1 and GFCI1 do not
work. Place switch in On position to
reset breaker.
CB2 protects GFCI1 from overload.
If CB2 opens, GFCI1 does not
work. Press button to reset breaker.
Generator
191 624-A
OM-497 Page 34
120/240 V 50 A Receptacle
RC5
Circuit breaker CB7 protects singlephase receptacle RC5 and the load
wires from overload. If CB7 opens, all
generator output stops and the receptacle does not work.
Three-Phase Generator Power
Three-Phase Power Connection
Volts
Single
Phase
1
120/240
Three
Phase
3
240
Amps
50
36
KVA/KW
12
15
AC
Output
Frequency
Engine Speed
Rear Of Panel
92
93
93
Lead 93
91
Lead 92
Lead 91
90
92
Lead 90 (Neutral)
Jumper Lead 42
5
91
60 Hz
1850 RPM
Remove plug
before inserting
leads. Reinstall
bushing.
Stop engine.
10 Grounding Terminal
6
2
12
7
10
11 User-Supplied Leads
12 Circuit Breaker CB7 User
Terminals
11
Close
panel
opening if no
connections
are made to
power plant.
240V
120V
1-Phase
120V
Tools Needed:
240V
3-Phase
240V
Circuit
240V
OM-497 Page 35
120 V 20 A AC GFCI
Receptacle GFCI1
240 V 16 A AC European
Receptacle RC1
240 V 15 A AC Australian
Receptacle RC1
European Receptacle
5
Australian Receptacle
5
Generator
(240 V x 13 A) + (120 V x 7 A) =
4.0 kVA/kW
191 624
OM-497 Page 36
OM-497 Page 37
Note
Follow the storage procedure in the engine owners manual if the unit will not be used for an
extended period.
Stop engine before maintaining.
Recycle
engine
fluids.
8h
Check Fluid
Levels. See
Section 4-7.
Wipe Up
Spills.
FUEL
WATER
Drain Water
From Fuel
System. See
Section 8-6.
50 h
Clean And
Tighten Weld
Terminals.
100 h
Clean And
Tighten
Battery
Connections.
Clean
Cooling
System.
250 h
Replace
Unreadable
Labels.
1/2 in.
(13 mm)
Check And
Clean Spark
Arrestor. See
Section 8-4.
500 h
Repair Or
Replace
Cracked
Cables.
OM-497 Page 38
Check
Belt
Tension.
1000 h
FUEL
SLUDGE
Change Fuel
Filters. See
Section 8-6.
Service Welding
Generator Brushes
And Slip Rings.
Service More Often
In Dirty Conditions.*
Drain Sludge
From Fuel
Tank. See
Section 8-6.
Check
Valve
Clearance.*
Blow Out Or
Vacuum Inside.
During Heavy
Service,
Clean Monthly.
OR
3000 h
Clean/Set
Injectors.*
OM-497 Page 39
be cleaned but the dirt holding capacity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while cleaning and the possibility of filter damage
makes cleaning a risk. Consider the
risk of unwarrantable equipment
damage when determining whether
to clean or replace the primary element.
Optional
5
If you decide to clean the primary element, we strongly recommend installing an optional safety element to provide additional engine protection.
Never clean a safety element. Replace the safety element after servicing the primary element three times.
Clean or replace primary element if dirty
(see note above before cleaning). Replace primary element if damaged. Replace primary element yearly or after six
cleanings.
Keep nozzle
2 in (51 mm)
from element.
Housing
Primary Element
Dust Cap
Dust Ejector
Blow
Inspect
aircleaner1 9/00 ST-153 929-B / ST-153 585 / Ref. S-0698-B / Ref. 201 841
OM-497 Page 40
Cleanout Plug
Exhaust Pipe
3
2
Tools Needed:
3/8 in
Ref. 802 311 / Ref. 802 160 / Ref. 201 841
OM-497 Page 41
Locking Nut
Standard Models
Throttle Rod
Locknut
Throttle Lever
2
1
Locknut
than specified.
Stop engine.
Close door.
5
6
7
8
Tools Needed:
3/8, 7/16 in
OM-497 Page 42
2
1
7
Oil Filter
Petcock
OM-497 Page 43
1
2
Fuse F1
Fuse F2
3
4
8
7
6
OM-497 Page 44
Normal Condition:
Oil Pressure Light On;
Battery Charging And Temperature Lights Off.
If Oil Pressure Light Is Off, See Factory Authorized Service Agent.
If Battery Charging Light Is On, Have Factory Authorized Service
Agent Check Alternator.
If Temperature Light Is On, Correct Cause Of Overheating
(See Engine Manual).
If Engine Is Okay, See Factory Authorized Service Agent.
If Fault Continues, See Factory Authorized Service Agent.
20s
Normal Condition:
Engine Lights Go Off As Engine Reaches
Normal Operating Condition.
Lights That Stay On After 20 Sec. Indicate Fault
Condition.
Stop Engine And Correct Fault (See Above) If Fault
Continues, See Factory Authorized Service Agent.
OM-497 Page 45
A. Welding CC Models
Trouble
Remedy
No weld output; generator power output Check position of Ampere Range switch.
okay at ac receptacles.
Check position of optional Polarity switch.
Place Amperage Adjust switch in Panel position, or place switch in Remote position and connect remote
control to Remote Amperage Adjust receptacle RC13 (see Sections 4-10 and 5-1).
Check and secure connections to Remote Amperage Adjust receptacle RC13 (see Section 4-10).
Check fuse F2, and replace if open (see Section 8-7). Have Factory Authorized Service Agent check integrated rectifier SR2 and the rotor.
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
No weld output or generator power out- Disconnect equipment from generator power receptacles during start-up.
put at ac receptacles.
Check fuses F1 and F2, and replace if open (see Section 8-7). Have Factory Authorized Service Agent
check integrated rectifier SR1, capacitor C9, integrated rectifier SR2, and the rotor.
Reset circuit breaker CB12. Have Factory Authorized Service Agent check diode D1 (see Section 8-7).
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
Erratic weld output.
Check engine weld/power speed, and adjust if necessary (see Section 8-5).
Have Factory Authorized Service Agent check OCV control circuit.
Check engine weld/power speed, and adjust if necessary (see Section 8-5).
Check fuses F1 and F2, and replace if open (see Section 8-7). Have Factory Authorized Service Agent
check integrated rectifier SR1, capacitor C9, integrated rectifier SR2, and the rotor.
Electrode sticks to the workpiece more Circuit breaker CB4 may be open. CB4 automatically resets when the fault is corrected (see Section 8-7).
frequently during low voltage (short arc Have Factory Authorized Service Agent check transformer T1 and integrated rectifiers SR4 and SR5.
length) conditions.
Low open-circuit voltage.
Check engine weld/power speed, and adjust if necessary (see Section 8-5).
Maximum weld output only in each Have Factory Authorized Service Agent check control relay CR7.
ampere range (with Stick/TIG Selection
switch in Stick position).
No remote fine amperage control.
OM-497 Page 46
Trouble
Remedy
No weld output; generator power output Place Process/Contactor switch in a Electrode Hot position, or place switch in a Remote position and
okay at ac receptacles.
connect remote contactor to optional Remote 14 receptacle RC14 (see Sections 4-11 and 8-7).
Check position of Ampere Range switch.
Check position of optional Polarity switch or Polarity/AC switch.
Reset circuit breaker CB11 (see Section 8-7).
Reset circuit breaker CB5 (see Section 8-7). Check for faulty remote device connected to RC14.
Check and secure connections to Remote 14 receptacle RC14 (see Section 4-11).
Have Factory Authorized Service Agent check connector board PC6 and connections.
Check fuse F2, and replace if open (see Section 8-7). Have Factory Authorized Service Agent check
brushes and slip rings, field excitation circuit, field current regulator board PC1, and the rotor.
No weld output or generator power out- Disconnect equipment from generator power receptacles during start-up.
put at ac receptacles.
Check fuses F1 and F2, and replace if open (see Section 8-7). Have Factory Authorized Service Agent
check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor.
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
Erratic weld output.
Voltage/Amperage control does not Place Ampere Range switch in lower range. Voltage/Amperage control does not work with Ampere
work when welding in Stick mode.
Range switch in highest range.
Low weld output.
Check engine weld/power speed, and adjust if necessary (see Section 8-5).
Check fuses F1 and F2, and replace if open (see Section 8-7). Have Factory Authorized Service Agent
check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor.
Electrode sticks to the workpiece more Circuit breaker CB4 may be open. CB4 automatically resets when the fault is corrected (see Section 8-7).
frequently during low voltage (short arc Have Factory Authorized Service Agent check transformer T1 and integrated rectifiers SR4 and SR5.
length) conditions.
Low open-circuit voltage.
No remote fine amperage or voltage Place Voltage/Amperage Adjust switch in Remote position.
control.
Check and secure connections to Remote 14 receptacle RC14 (see Section 4-11).
Repair or replace remote control device.
Constant speed wire feeder does not Reset circuit breaker CB5 (see Section 8-7).
work.
Check and secure connections to Remote 14 receptacle RC14 (see Section 4-11).
Check voltage requirements of wire feeder. 115 volt output not available through Remote 14 receptacle (see Section 4-11).
Repair or replace wire feeder.
Low CV weld output.
Remedy
High output at generator power ac re- Check engine weld/power speed, and adjust if necessary (see Section 8-5).
ceptacles.
Have Factory Authorized Service Agent adjust generator power field current resistor R3.
Low output at generator power ac recep- Check engine weld/power speed, and adjust if necessary (see Section 8-5).
tacles.
Check fuse F1, and replace if open (see Section 8-7). Have Factory Authorized Service Agent check
integrated rectifier SR1, resistor R3, and capacitor C9.
Trouble
No or low output at optional threephase generator/receptacle RC5.
Remedy
Place Process/Contactor switch in Electrode Hot - Stick position (see Section 6-3).
Reset circuit breaker CB7(see Section 8-7).
Reset circuit breaker CB5 (see Section 8-7).
Check engine weld/power speed, and adjust if necessary (see Section 8-5).
Have Factory Authorized Service Agent check brushes and slip rings, and field current regulator board
PC1.
Check engine weld/power speed, and adjust if necessary (see Section 8-5).
Have Factory Authorized Service Agent check field current regulator board PC1.
Erratic output at optional three-phase Have Factory Authorized Service Agent check brushes and slip rings, and field current regulator board
generator/receptacle RC5.
PC1.
E. Engine
Trouble
Engine will not crank.
Remedy
Check battery, and replace if necessary.
Check battery connections and tighten if necessary.
Circuit breaker CB10 may be open. CB10 automatically resets when fault is corrected (see Section 8-7).
Have Factory Authorized Service Agent check engine wiring harness and components.
Check engine wiring harness plug connections.
Have Factory Authorized Service Agent check Engine Control switch S1.
OM-497 Page 48
Trouble
Remedy
Have Factory Authorized Service Agent check control relay CR2, and fuel solenoid FS1.
Air in fuel system. See engine manual.
Engine starts, but stops when Magnetic When starting engine, continue holding Magnetic Shutdown switch until after engine indicator lights go
Shutdown switch is released.
out.
Check oil level. Automatic shutdown system stops engine if oil pressure is too low or engine temperature
is too high (see Sections 4-7 and 8-8).
Engine hard to start in cold weather.
Engine uses oil during run-in period; Dry engine (see Section 10).
wetstacking occurs.
OM-497 Page 49
205 959
OM-497 Page 51
205 960
OM-497 Page 53
10-1. Wetstacking
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
OM-497 Page 54
4
2
1
S-0683
OM-497 Page 55
1 Resistance Grid
Use grid sized for generator rated
output.
1
Voltmeter
5 Clamp-On Ammeter
Connect voltmeter and ammeter as
shown, if not provided on generator.
3
S-0684
OM-497 Page 56
3
Be sure equipment
has this symbol
and/or wording.
OR
Equipment Grounding
Terminal (On Front Panel)
Grounding Cable (Not
Supplied)
Metal Vehicle Frame
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
GND/PE
S-0854
OM-497 Page 57
GND/PE
Equipment Grounding
Terminal
Grounding Cable
Ground Device
ST-800 576-B
VOLTS 115
AMPS 4.5
Hz
60
Resistive Load
Non-Resistive Load
Equipment with a motor is a non-resistive load and requires approximately six times more power while
starting the motor than when running (see Section 11-8).
3
Rating Data
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-497 Page 58
Fan Duty
Rating
Starting Watts
Running Watts
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 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
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
800
1225
1600
2100
3175
2020
3075
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
1000
1400
1850
2400
3500
300
500
600
700
875
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
400
550
650
800
1100
Rating
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
Starting Watts
Running Watts
1000
1650
3400
4400
2900
10500
1720
2575
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
3300
3150
4500
6100
3100
2150
3100
2100
3200
1000
650
1000
1400
1100
2800
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
1000
950
1400
1600
800
750
1000
800
1050
OM-497 Page 59
Circular Saw
Table Saw
Band Saw
Bench Grinder
Air Compressor
Submersible Pump
Centrifugal Pump
Floor Polisher
High Pressure Washer
OM-497 Page 60
Rating
Starting Watts
Running Watts
1/4 in
3/8 in
1/2 in
6-1/2 in
7-1/4 in
8-1/4 in
9 in
10 in
14 in
6 in
8 in
10 in
1/2 HP
1 HP
1-1/2 HP
2 HP
1-1/2 HP, 12 in
2 HP, 14 in
Standard 9 in
Heavy Duty 12 in
1/3 HP
18 in
HID
Metal Halide
Mercury
Sodium
Vapor
400 gph
900 gph
3/4 HP, 16 in
1 HP, 20 in
1/2 HP
3/4 HP
1 HP
1/4 HP
1.7 HP
2-1/2 HP
350
400
600
500
900
1400
4500
6300
2500
1720
3900
5200
3000
6000
8200
10500
1100
1100
350
500
2100
400
125
313
1000
1400
1250
600
900
4500
6100
3150
4500
6100
1900
900
1300
350
400
600
500
900
1400
1500
1800
1100
720
1400
1600
1000
1500
2200
2800
1100
1100
350
500
700
400
100
250
1000
200
500
1400
1600
950
1400
1600
700
900
1300
AC MOTOR
VOLTS 230
AMPS 2.5
CODE M
Hz
60
HP
1/4
PHASE 1
1
2
3
4
KVA/HP
6.3
7.1
8.0
9.0
10.0
11.2
12.5
14.0
kVA/HP x HP x 1000
VOLTS
= STARTING AMPERAGE
HP = 1/4
S-0624
5 Second Rule
OM-497 Page 61
1
240 V
120/240 Volt
60 Hz
Three-Wire
Service
1
2
120 V
120 V
5
Neutral
Obtain and install the correct switchable circuit breakers or fused switch.
5
240 V
120 V
Load
120 V
Extension Cord
Generator Connections
Load Connections
7
240 V
120/240 Volt
Single-Phase
Three-Wire
Generator Output
Connection
120 V
120 V
Ground
S-0405-A
OM-497 Page 62
Load (Watts)
600
840
10
1200
15
10
12
14
350 (106)
225 (68)
137 (42)
100 (30)
400 (122)
250 (76)
150 (46)
100 (30)
62 (19)
400 (122)
275 (84)
175 (53)
112 (34)
62 (19)
50 (15)
1800
300 (91)
175 (53)
112 (34)
75 (23)
37 (11)
30 (9)
20
2400
225 (68)
137 (42)
87 (26)
50 (15)
30 (9)
25
3000
175 (53)
112 (34)
62 (19)
37 (11)
30
3600
150 (46)
87 (26)
50 (15)
37 (11)
35
4200
125 (38)
75 (23)
50 (15)
40
4800
112 (34)
62 (19)
37 (11)
45
5400
100 (30)
62 (19)
50
6000
87 (26)
50 (15)
Load (Watts)
1200
1680
10
2400
15
10
12
14
700 (213)
450 (137)
225 (84)
200 (61)
800 (244)
500 (152)
300 (91)
200 (61)
125 (38)
800 (244)
550 (168)
350 (107)
225 (69)
125 (38)
100 (31)
3600
600 (183)
350 (107)
225 (69)
150 (46)
75 (23)
60 (18)
20
4800
450 (137)
275 (84)
175 (53)
100 (31)
60 (18)
25
6000
350 (107)
225 (69)
125 (38)
75 (23)
30
7000
300 (91)
175 (53)
100 (31)
75 (23)
35
8400
250 (76)
150 (46)
100 (31)
40
9600
225 (69)
125 (38)
75 (23)
45
10,800
200 (61)
125 (38)
50
12,000
175 (53)
100 (31)
OM-497 Page 63
15
14
16
17
13
12
18
11
5 6
19
9
10
8
7
109 (CV)
108 (CV)
12
21
20
103
95
101
22
93
107
96
98 (CC ONLY)
105
104
97
CC CC Models Only
CV CC/CV Models Only
94
47
29
46
44
30
25
24
28
27
26
45
48
23
43
50
51
110
42
49
41
31
32
40
39
38
37
56
36
35
58
34
54
33 (Fig. 126)
66
67
71 70
69
59
55
60
68
61
62
63
64
77
65
75 76
87
84
74
88
85
52
53
57
89
72
86
73
78
90
83
79
91
92
93
82
81
80
802 559-E
OM-497 Page 65
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
OM-497 Page 66
. . PANEL, gen LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, gen LH ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning all panels must be in place while running . . . . . . . . . . . . .
. . PANEL, engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANLE, engine side ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . REACTOR, ac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . REACTOR, ac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BLOCK, term 30A 4 pole frict term str . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LINK, jumper term blk 30A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, mtg strip terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACE, front to center upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RECTIFIER, integ bridge 40. amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT BREAKER, auto reset 24vdc 7 amp . . . . . . . . . . . . . . . . . . . . . . .
. . PAN, reactor and rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSFORMER w/bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSFORMER w/bracket (environmental coating) . . . . . . . . . . . . . . . . .
. . EXTRUSION, rubber clamp/bulb (order by ft) . . . . . . . . . . . . . . . . . . . . . . .
. . FIREWALL, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COVER, plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOSE, air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, mtg air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . AIR CLEANER, intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FILTER, air element primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FILTER, air element safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SEAL, weather lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOSE, sae .312 id x .560 od x 24.000 (order by ft) . . . . . . . . . . . . . . . . . .
. . UPRIGHT, center assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BASE e-coat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, hold down fuel tank rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, mtg nyl 1/2 conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COVER, top ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . GROMMET, plastic neck filler fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CAP, tank screw-on 3.500 in w/vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, use diesel fuel only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, use diesel fuel only (Wordless Label) . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning falling equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning falling equipment (Wordless Label) . . . . . . . . . . . . . . . . . .
. . LABEL, warning hot exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PIPE, muffler extension elbow 1.875 OD . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PIPE, exhaust (CE rated)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COVER, radiator access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SUPPORT, cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SUPPORT, cover e-coat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . MANIFOLD, exhaust muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . MANIFOLD, exhaust muffler (CE rated) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, muffler 2.000 dia u pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning moving parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning moving parts (Wordless Label) . . . . . . . . . . . . . . . . . . . . .
. . GUARD, starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, mtg engine LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . EDGE TRIM, styel tl750-b2 x 1/16 black w/clips 1.625 . . . . . . . . . . . . . . .
. . BAFFLE, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
1
1
1
1
1
2
1
2
2
1
1
1
1
3ft
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
OM-497 Page 67
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
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-497 Page 68
14
18
6
3
17
8
7
2
21
20
1
22
15
11
10
19
9
16
13
12
802 551-D
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-2. Control Box Assembly CC Models (Figure 12-1 Item 100)
. . . 1 . . . F1, F2 . . *085 874 . . FUSE, mintr cer slo-blo 10A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . . 046 432 . . HOLDER, fuse mintr .250 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . . . . 201 077 . . CONTROL BOX, lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . . . . . . . . . 201 078 . . CONTROL BOX, rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . . . . . . . . . 201 079 . . COVER, control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . C12 . . . 191 944 . . CAPACITOR, polyp met film 10. uf 250 vac 10% . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 204 812 . . HARNESS, control box, weld control (consisting of) . . . . . . . . . . . . . . . . .
. . . 7 . . . . CR7 . . . 188 636 . . . . RELAY, OCV control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . D1/C1 . . 189 701 . . . . DIODE/CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . SR1, SR2 . 035 704 . . . . RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 10 . . . . CR5 . . . 090 104 . . . . RELAY, encl 12VDC SPST 30A/15VDC . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . S5 . . . . . 011 609 . . . . SWITCH, tgl spdt 15a 125vac onnoneon spd term chr
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (located on front panel, see Figure 12-4) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . S6 . . . . . 011 622 . . . . SWITCH, tgl 3pdt 15a 125vac onnoneon spd term
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (located on front panel, see Figure 12-4) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . RC4 . . . 047 483 . . . . CONNECTOR, rect univ 084 15P/S 3 row rcpt cable/panel lkg . . . . . . .
. . . . . . . . . . RC3 . . . 158 466 . . . . CONNECTOR, rect univ 084 12P/S 3 row rcpt cable/panel lkg . . . . . . .
. . . . . . . . . . RC1 . . . 135 133 . . . . CONNECTOR, rect univ 084 9P/S 3 row rcpt cable/panel lkg . . . . . . . .
. . . . . . . . . . . . . . . . . . . 148 850 . . . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 177 859 . . . . CONN, body 5 terminal (to engine control switch S1) . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 150 316 . . . . CONN, rect univ 039 6p/s 3row plug cable lkg . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 092 670 . . . . CONN, rect univ 084 3p/s 1row plug cable lkg . . . . . . . . . . . . . . . . . . . . .
. . . 11 CB11, 12, 13 139 266 . . . . CIRCUIT BREAKER, man reset 1P 15A 250VAC frict . . . . . . . . . . . . . .
2
2
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
6
1
3
OM-497 Page 69
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
1
1
1
1
2
1
1
1
1
1
1
3
1
1
1
3
1
1
1
1
Optional
*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.
4
16
3
15
17
11
19
1
18
20
12
5
13
10
14
6
8
9
802 360
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-3. Control Box Assembly CC/CV Models (Figure 12-1 Item 100)
. . . 1 . . . F1, F2 . . *085 874 . . FUSE, mintr cer slo-blo 10A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . . 046 432 . . HOLDER, fuse mintr .250 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . . . . 201 077 . . CONTROL BOX, lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . . . . . . . . . 201 078 . . CONTROL BOX, rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . . . . . . . . . 201 079 . . COVER, control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . . . . . . . . . 134 201 . . STAND-OFF, support pc card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . PC9 . . . 192 224 . . CIRCUIT CARD ASSY, display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . . . C9 . . . . . 087 110 . . CAPACITOR, elctlt 240uf 200VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . . . . . . . . . . 177 136 . . CLAMP, capacitor 1.375dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 204 811 . . HARNESS, control box, cv weld control (consisting of) . . . . . . . . . . . . . . .
. . . 10 . . . . SR1 . . . 035 704 . . . . RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . CR5 . . . 090 104 . . . . RELAY, encl 12VDC SPST 30A/15VDC . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . RC4 . . . 047 483 . . . . CONNECTOR, rect univ 084 15P/S 3 row rcpt cable/panel lkg . . . . . . .
. . . . . . . . . . RC3 . . . 158 466 . . . . CONNECTOR, rect univ 084 12P/S 3 row rcpt cable/panel lkg . . . . . . .
. . . . . . . . . . RC1 . . . 135 133 . . . . CONNECTOR, rect univ 084 9P/S 3 row rcpt cable/panel lkg . . . . . . . .
. . . 12 CB11, 12, 13 139 266 . . . . CIRCUIT BREAKER, man reset 1P 15A 250VAC frict . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 148 850 . . . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . S6 . . . . 193 324 . . . . SWITCH, rotary 6 position gold contacts
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (located on front panel, see Figure 12-5) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . S5 . . . . . 011 609 . . . . SWITCH,tgl spdt 15a 125vac onnoneon spd term chr
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (located on front panel, see Figure 12-5) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 150 316 . . . . CONN, rect univ 039 6p/s 3row plug cable lkg . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 177 859 . . . . CONN, body 5 terminal (to engine control switch S1) . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 193 183 . . . . CONN, rect cinch 18 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 196 602 . . . . PLUG, cavity 18,30 position cinch connector . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 196 603 . . . . SEAL, switch 6 position rotary .250 shaft . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 141 450 . . . . CONN, rect metrmate 10skt 1row plug cable lkg . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . PC7 . . 195 706 . . MODULE, pull to idle, two output, 7 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 14 . . . . CR4 . . 113 247 . . RELAY, encl 12vdc dpdt 20a/120vac 8pin flange mtg . . . . . . . . . . . . . . . .
. . . 15 . . . . CR6 . . 090104 . . RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg . . . . . . . . . . . . . . . . . .
. . . 16 CR1, CR2, CR3 090 104 . . RELAY, encl 12VDC SPST 30A/15VDC spin flange mtg . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 206 024 . . HARNESS, engine control (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . D8/C8 . . 189 701 . . . . DIODE/CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 18 . . . . CB10 . . . 190 374 . . . . CIRCUIT BREAKER, auto reset 12VDC 40A . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 148 850 . . . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . PLG4 . . . . 114 062 . . . . CONNECTOR, rect univ 084 15P/S 3 row plug cable lkg . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 185 655 . . . . SEAL, wire univ 15P/S 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 19 . . . . CB14 . . 205 927 . . CIRCUIT BREAKER, auto reset 12vdc 12 amp . . . . . . . . . . . . . . . . . . . . . .
. . . 20 . . . . CR8 . . 155 309 . . CONTACTOR, solenoid 12VDC cont 400A inrush . . . . . . . . . . . . . . . . . . . .
2
2
1
1
1
3
1
1
1
1
1
1
1
1
1
3
1
1
1
6
1
1
4
1
1
1
1
1
3
1
1
1
3
1
1
1
1
Optional
*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-497 Page 71
3
5
2
1
6
7
8
9
10
41
11
40
39
12
13
14
15
16
36
35
17
34
37
33
38
18
32
31
30
29
19
20
22
21
23
28
27
26
25
24
802 266-D
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-4. Panel, Front w/Components CC Models (Figure 12-1 Item 106)
. . . 1 . . . . . . . . . . . . . 201 841 . .
..............................
... 2 ........................
. . . 3 . . . . . . . . . . . . . 201 580 . .
. . . 3 . . . . . . . . . . . . 202 642 . .
. . . 4 . . . . . S3 . . . . 189 382 . .
. . . . . . . . . . . . . . . . . . . 202 223 . .
OM-497 Page 72
1
1
1
1
1
2
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
1
1
1
3
1
1
1
1
1
1
1
1
1
3
1
1
1
1
1
1
3
1
1
1
1
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Optional
+
When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 192 505 or Label Kit 201 062 (Wordless Labels).
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-497 Page 73
3
5
2
1
6
7
8
9
10
11
57
56
12
13
14
55
15
54
16
17
18
19
20
21
34
51
52 50
49
53
48
31
33
47
22
30
23
24
46
32
26
29
44
25
28
45
27
35
36
43
37
42
41
40
39
38
802 332-F
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-5. Panel, Front w/Components CC/CV Models (Figure 12-1 Item 106)
. . . 1 . . . . . . . . . . . . . 201 579 . .
..............................
... 2 ........................
. . . 3 . . . . . . . . . . . . . 201 580 . .
. . . 3 . . . . . . . . . . . . 202 642 . .
. . . 4 . . . . . S3 . . . . 189 382 . .
. . . . . . . . . . . . . . . . . . 202 223 . .
OM-497 Page 74
1
1
1
1
1
2
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
2
Optional
+
When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 192 505 or Label Kit 201 062 (Wordless Labels).
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.
18
16
17
11
15
14
10
12
19
20
13
21
9
22
23
8
7
6
5
3
2
17
24
25
1
29
30
31
27
28
26
32
33
28
802 552-A
34
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
6
6
1
1
1
1
1
2
2
1
2
1
1
1
1
1
1
6
10
1
1
4
4
6
4
1
1
6
6
4
6
4
3
3
1
2
2
1
1
1
When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 192 505 or Label Kit 201 062 (Wordless Labels).
*Recommended Spare Parts.
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-497 Page 77
4
3
2
1
5
802 279-A
Dia.
Mkgs.
Part
No.
Description
Quantity
1
1
1
3
2
3
1
8
2
3
3
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-497 Page 78
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
*
*
2.
*
*
*
*
*
*
3.
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
4.
6 Months Batteries
5.
90 Days Parts
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2.
3.
Owners Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
Distributor
Address
City
State
Zip
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.
Replacement Parts
Training (Schools, Videos, Books)
International HeadquartersUSA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
European Headquarters
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
www.MillerWelds.com
PRINTED IN USA
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