Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
081 902AD
December 1998
Processes
Stick (SMAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
With Optional Equipment:
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
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.)
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.
1
1
1
2
3
4
4
5
5
5
6
7
8
8
9
9
9
10
10
11
11
12
13
14
15
15
15
16
16
17
17
18
18
19
19
20
20
21
22
23
24
24
25
26
27
27
28
29
30
31
31
32
33
34
34
35
37
40
40
41
42
43
50
READ INSTRUCTIONS.
Use only genuine MILLER replacement parts.
Perform engine maintenance and service
according to this manual and the engine
manual.
OM-463 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-463 Page 4
Downloaded from www.Manualslib.com manuals search engine
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.
Ne pas se servir de source lectrique courant lectrique dans les zones
humides, dans les endroits confins ou l o on risque de tomber.
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-463 Page 5
Downloaded from www.Manualslib.com manuals search engine
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-463 Page 6
Downloaded from www.Manualslib.com manuals search engine
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.
LES
CHARGES
LECTROSTATIQUES
peuvent
endommager les circuits imprims.
OM-463 Page 7
Downloaded from www.Manualslib.com manuals search engine
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-463 Page 8
Downloaded from www.Manualslib.com manuals search engine
2
3
4
5
SECTION 2 DEFINITIONS
2-1. Symbols And Definitions
Stop Engine
Start Engine
Engine
Do Not Switch
While Welding
Battery (Engine)
Circuit Breaker
Engine Oil
Check Injectors/
Pump
Check Valve
Clearance
Fuel
Protective Earth
(Ground)
Positive
Negative
Certified/Trained
Mechanic
Welding Arc
Volts
Panel/Local
On
Temperature
Output
Alternating
Current
Stick (SMAW)
Welding
Constant Current
(CC)
MIG (GMAW)
Welding
Constant Voltage
(CV)
Amperes
Time
Hours
Seconds
14
Remote
Single Phase
Read Operators
Manual
Three Phase
SECTION 3 SPECIFICATIONS
3-1. Weld, Power, And Engine Specifications
Welding
Mode
Weld
Output
Range
Rated Welding
Output
45 500 A
Maximum
OpenCircuit
Voltage
Auxiliary Power
Rating
Engine
Fuel Capacity
Single-Phase,
3 kVA/kW, 25 A,
120 V AC, 60 Hz
Deutz F3L-912
Air-Cooled,
Three-Cylinder,
41.5 HP Diesel Engine
95
CC/DC
CV/DC
(Optional)
14 38 V
(88 in CC
mode on units
with CV)
48
OM-463 Page 9
Downloaded from www.Manualslib.com manuals search engine
Width
Depth
C
D
B
17.5
E
F
20
Do not exceed operating angles while running or engine damage will occur.
Engine End
20
Weight
17.5
angles_1 3/96
ST-158 699
OM-463 Page 10
Downloaded from www.Manualslib.com manuals search engine
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.
Continuous Welding
OM-463 Page 11
Downloaded from www.Manualslib.com manuals search engine
A. CC/DC (Standard)
OM-463 Page 12
Downloaded from www.Manualslib.com manuals search engine
OM-463 Page 13
Downloaded from www.Manualslib.com manuals search engine
OM-463 Page 14
Downloaded from www.Manualslib.com manuals search engine
SECTION 4 INSTALLATION
4-1. Installing Welding Generator
Movement
Airflow Clearance
Location
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
OR
OR
18 in
(460 mm)
18 in
(460 mm)
Grounding
1
2
3
GND/PE
OR
Generator Base
Metal Vehicle Frame
Equipment Grounding
Terminal
Grounding Cable
install1 3/96 Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854
OM-463 Page 15
Downloaded from www.Manualslib.com manuals search engine
Top View
Tools Needed:
1/2 in
1/2 in
(13 mm)
1
Full
Fuel
Diesel
Oil
To
improve
starting:
cold
weather
Valve Open
Ref. ST-158 633-C
OM-463 Page 16
Downloaded from www.Manualslib.com manuals search engine
Bracket
Left Side
Close door.
Tools Needed:
3/4 in
ST-158 700
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
(105 m)
400 ft
(120 m)
10 60%
Duty Cycle
60 100%
Duty Cycle
100
1/0
1/0
150
1/0
2/0
3/0
3/0
200
1/0
2/0
3/0
4/0
4/0
250
1/0
2/0
3/0
4/0
2-2/0
2-2/0
300
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
350
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
2-4/0
400
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
2-4/0
500
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3-3/0
*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. Contact your
distributor for the mm2 equivalent weld cable sizes.
S-0007-E
OM-463 Page 17
Downloaded from www.Manualslib.com manuals search engine
Ether Cylinder
Nozzle
3
4
5
Clamp
Fitting
Cap
Valve
OR
OM-463 Page 18
Downloaded from www.Manualslib.com manuals search engine
Chassis common.
H
C L N
D M
G
E F
OR
A/V
Socket Information
Cover
Terminal Strip 2T
Tools Needed:
OM-463 Page 19
Downloaded from www.Manualslib.com manuals search engine
10
11
12
OM-463 Page 20
Downloaded from www.Manualslib.com manuals search engine
that resets the Amperage/Voltage Control to maximum when the arc breaks.
When an arc is struck, weld output control returns to the front panel or remote
control setting. The Amperage/voltage
Control adjusts amperage only when
welding and does not adjust open-circuit
voltage.
DC Ammeter (Optional)
DC Voltmeter (Optional)
Amperage/Voltage Control
Control adjusts amperage within range selected by Ampere Range switch. Weld output
In Example:
Range = 125 to 320 A
Percentage Of Range = 50%
Max = 223 A DC (50% of 125 to 320)
Set Switches
Set Range
Set Percentage
OM-463 Page 21
Downloaded from www.Manualslib.com manuals search engine
10
11
12
13
14
ST-158 630-B / Ref. ST-158 631 / Ref. ST-185 762-B / S-185 440
OM-463 Page 22
Downloaded from www.Manualslib.com manuals search engine
5-4. Description Of Controls For Models With CV Option (See Section 5-3)
13 Output/Contactor Switch
DC Ammeter (Optional)
DC Voltmeter (Optional)
Weld output would be 223 A DC with amperage controls set as shown (50% of 125 to 320
A).
3
Use switch to control remote contactor connected to Remote 14 receptacle RC3 or terminal strip 2T.
Amperage/Voltage Control
With CC/CV switch in CC position, use control to adjust amperage within range selected
by Ampere Ranges switch. With switch in CV
position, use control to adjust voltage.
For weld output, place switch in the On position. Open-circuit voltage is present at the
weld output terminals whenever engine is
running.
For remote output control, place switch in Remote position. Open-circuit voltage is present
at the weld output terminals when remote
contactor switch is closed.
14 Amperage/Voltage Control Switch
Use switch to select front panel or remote amperage and voltage adjustment.
For front panel control, place switch in Panel
position. For remote control, place switch in
Remote position and connect remote control
to Remote 14 receptacle RC3 or terminal strip
2T.
In Example:
Mode = CC
Range = 125 to 320 A DC
Percentage Of Range = 50%
Min = 125 A DC
Max = 223 A DC
(50% of 140 to 325)
Max
(223 A DC)
Min
(125 A DC)
Set Switches
Set Range
Set Percentage
OM-463 Page 23
Downloaded from www.Manualslib.com manuals search engine
120 V 15 A AC Receptacle
RC2
240 V 15 A AC Receptacle
RC1
OM-463 Page 24
Downloaded from www.Manualslib.com manuals search engine
1
2
4
120 V 15 A AC GFCI
Receptacle GFCI1
3
4
OM-463 Page 25
Downloaded from www.Manualslib.com manuals search engine
on
units with CV option is 10/15
kVA/kw (see table below).
10
11
Lead 93
Lead 92
Lead 91
Lead 90 (Neutral)
2
F3
240V
3
F2
240V
240V
240V
F1
120V
120V
Grounding Terminal
Jumper Lead 42
4
88
77
User-Supplied Leads
10 Load Terminals
Connect leads to terminals.
Set
For Standard (CC) Models
AC
Output
Single
Phase
1
Three
Phase
3
AC
Output
Single
Phase
1
Three
Phase
3
Volts
120/240
240
Volts
120/240
240
Amps
31
24
Amps
42
36
KVA/KW
7.5
10
KVA/KW
10
15
Frequency
60 Hz
Engine Speed
1850 RPM
35 Amperes
Frequency
60 Hz
Engine Speed
1850 RPM
45 Amperes
93
91
90
92
Tools Needed:
OM-463 Page 26
Downloaded from www.Manualslib.com manuals search engine
8h
Wipe
Up
Spills.
Check Fluid
Levels. See
Section 4-4.
OIL
Full
FUEL
WATER
Drain Water
From Fuel
System.
50 h
Clean And
Tighten
Weld
Terminals.
100 h
Clean And
Tighten
Battery
Connections.
Change Oil
Filter. See
Section 7-4.
200 h
250 h
Check And
Clean Spark
Arrestor. See
Section 7-9.
Replace
Unreadable
Labels.
500 h
Repair Or
Replace
Cracked
Cables.
1000 h
OR
Blow Out Or
Vacuum Inside.
During Heavy
Service,
Clean Monthly.
Change Fuel
Filters. See
Section 7-4.
Service Welding
Generator Brushes
And Slip Rings.
Service More Often
In Dirty Conditions.*
1/2 in.
(13 mm)
Check Belt
Tension. See
Section 7-7.
FUEL
SLUDGE
Drain Sludge
From Fuel
Tank. See
Section 7-4.
Check
Valve
Clearance.*
OM-463 Page 27
Downloaded from www.Manualslib.com manuals search engine
20
40
20W/20
10
15W/40
15W/30
10
10W/40
30
20
10W
Check
daily.
30 C
10W/30
77
68
59
50
41
32
23
14
5
4
13
22
31
40
5W/30 (Synthetic)
F 86
30
40
Diesel
Have only trained technician maintain injection pump and injectors. AIR,
WATER, or GASOLINE will harm the injection system. If engine has run
out of fuel or fuel filter is changed, bleeding of air may be required.
Check engine manual for proper procedure.
Injectors should be checked annually.
OM-463 Page 28
Downloaded from www.Manualslib.com manuals search engine
Dust Cap
Baffle
Element
Plastic Fins
Housing
Blow
Inspect
aircleaner1 4/96 ST-153 929-B / ST-153 585 / Ref. ST-180 933-B / Ref. S-0698-B
OM-463 Page 29
Downloaded from www.Manualslib.com manuals search engine
Oil Filter
Oil Drain Plug
Oil Drain Hose (Optional)
Oil Fill Cap
Petcock
Fuel Line
10
3
Valve Open
Tools Needed:
3/8, 7/16, 3/4 in
Ref. ST-158 633-C / Ref. ST-180 933-B
OM-463 Page 30
Downloaded from www.Manualslib.com manuals search engine
Engine
Speed
(No Load)
Weld/Power
RPM
1850
Plastic Cap
Lock Nut
Linkage
Lock Nuts
Stop engine.
6
Right Side
Tools Needed:
3/8 in
ST-045 768-B
Ether Cylinder
Valve
Scale
33 oz
(935 g)
15 oz
(425 g)
Full
Empty
2
OM-463 Page 31
Downloaded from www.Manualslib.com manuals search engine
Alternator V-Belt
Crank Pulley
Alternator Pulley
Place straight edge along top of pulleys. Pull down belt as far as it will
go, then measure distance from
belt to straight edge.
If measurement is less than 1/2 in
(13 mm), belt is okay. If not okay,
adjust belt tension.
To adjust belt tension:
4
Alternator Bracket
if
damaged
or
To replace belt:
Loosen hex nuts and pivot alternator clockwise. Remove belt.
Install new belt, pivot alternator until
belt is tight, and tighten nuts. Recheck tightness of belt after running
engine 15 minutes.
4
1/2 in
(13 mm)
Max
Tools Needed:
1/2, 11/16 in
ST-158 632 / Ref. ST-180 933-B
OM-463 Page 32
Downloaded from www.Manualslib.com manuals search engine
Rod
Stop
Bracket
Handle
Pull handle towards front of unit until stop snaps in position behind
bracket.
Close door.
1
5
Right Side
2
Pull Handle To
Reset Shutdown
Tools Needed:
3/8 in
OM-463 Page 33
Downloaded from www.Manualslib.com manuals search engine
Cleanout Plug
Exhaust Pipe
3
2
Tools Needed:
3/8 in
Press
1
OM-463 Page 34
Downloaded from www.Manualslib.com manuals search engine
7-11. Troubleshooting
A. Welding
Trouble
No weld output.
Remedy
Check position of Ampere Range switch.
Check position of optional polarity switch.
Disconnect equipment from auxiliary power receptacles during start-up.
Place A/V Control switch in Panel position, or place switch in Remote position and connect remote control
to Remote A/V Control receptacle RC3 (see Sections 4-8 and 5-1).
Check and secure connections to Remote A/V Control receptacle RC3 (see Section 4-8).
Place optional Output/Contactor Control switch in On position, or place switch in Remote position and
connect remote contactor to optional Remote 14 receptacle RC3 or terminal strip 2T (see Sections 4-9
and 4-10).
Have Factory Authorized Service Agent check brushes and slip rings, field excitation circuit, and optional
field current regulator board PC1.
Maximum weld output only in each Have Factory Authorized Service Agent check Amperage/Voltage control R1, capacitor C8, diode D8,
ampere range.
integrated rectifier SR4, control relay CR2, and optional CV regulator board PC2.
Wire feeder does not work (models with Reset circuit breaker CB3 and/or CB4 (see Section 7-10).
CV option only).
Check connections to optional Remote 14 receptacle RC3 and terminal strip 2T (see Sections 4-9 and
4-10).
Repair or replace wire feeder.
No amperage control (or voltage control Place A/V Control switch in correct position.
on models with CV option).
Check connections to optional Remote 14 receptacle RC3 and terminal strip 2T (see Sections 4-9 and
4-10).
Repair or replace remote control device.
Have Factory Authorized Service Agent check optional CV regulator board PC2.
No CV weld output (units with CV option Check and secure connections to optional Remote 14 receptacle RC3 or terminal strip 2T (see Section
only).
4-9 or 4-10).
Repair or replace remote control device.
Have Factory Authorized Service Agent check CV regulator board PC2 and connector board PC3 and
connections, and replace if necessary.
Low CV weld output (models with CV op- Set Ampere Range switch to highest range.
tion only).
OM-463 Page 35
Downloaded from www.Manualslib.com manuals search engine
Trouble
Remedy
Min or max CV weld output only (models Check position of Amperage/voltage control and Amperage/Voltage Control switch.
with CV option only).
Repair or replace remote control device.
Have Factory Authorized Service Agent check optional CV regulator board PC2.
B. Auxiliary Power
Trouble
No output
receptacles.
at
auxiliary
Remedy
power Reset receptacle circuit breakers.
Have Factory Authorized Service Agent check brushes and slip rings, and optional field current regulator
board PC1.
High or low output at auxiliary power Check engine speed, and adjust if necessary (see Section 7-5).
receptacles.
No or low output at optional auxiliary Check connections to auxiliary power plant (see Section 6-3).
power plant.
Check engine speed, and adjust if necessary (see Section 7-5).
Place A/V Control switch in Panel position, or place switch in Remote position and connect remote control
to Remote A/V Control receptacle RC3 (see Sections 4-8 and 5-1).
Check fuses F1, F2, and F3 and replace as necessary (see Section 6-3).
Place optional Output/Contactor Control switch in On position, or place switch in Remote position and
connect remote contactor to optional Remote 14 receptacle RC3 or terminal strip 2T (see Sections 4-9
and 4-10).
Place optional CC/CV switch in CC position (see Section 5-4).
Have Factory Authorized Service Agent check brushes and slip rings, and optional field current regulator
board PC1.
High output at optional auxiliary power
plant.
C. Engine
Trouble
Engine does not start.
Remedy
Check fuel level (see Section 4-4).
Open fuel valve (see Section 4-4).
Check battery and replace if necessary.
Check blower fan V-belt according to engine manual. Safety shutdown stops engine if belt is broken or
loose (see Section 7-8).
Check engine Start button and replace if necessary.
Check engine charging system according to engine manual.
See engine manual.
Check blower fan V-belt according to engine manual. Safety shutdown stops engine if belt is broken or
loose (see Section 7-8).
See engine manual.
Clean top of battery with baking soda and water solution; rinse with clear water.
Recharge or replace battery if necessary.
Periodically recharge battery (approximately every 3 months).
Engine uses oil during run-in period; Dry engine (see Section 9).
wetstacking occurs.
OM-463 Page 36
Downloaded from www.Manualslib.com manuals search engine
SC-180 941
Figure 8-2. Circuit Diagram For Welding Generator (Models With CV Option)
OM-463 Page 38
Downloaded from www.Manualslib.com manuals search engine
ST-184 954-B
OM-463 Page 39
Downloaded from www.Manualslib.com manuals search engine
9-1. Wetstacking
1
Welding Generator
Run diesel engines near rated output during run-in period to properly
seat piston rings and prevent wetstacking. See nameplate or rating
label to find rated output.
2
OM-463 Page 40
Downloaded from www.Manualslib.com manuals search engine
3 Weld Cables
Connect load bank to generator
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 generator output (see
nameplate).
Check generator and load bank
meters after first five minutes then
every fifteen minutes to be sure
generator is loaded properly.
S-0683
OM-463 Page 41
Downloaded from www.Manualslib.com manuals search engine
2 Welding Generator
Place A/V range switch in maximum position, A/V control in minimum position, and Output Selector
switch (if present) in either DC
position.
3 Weld Cables
Connect grid to generator weld
output terminals using proper size
weld cables with correct connectors (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.
S-0684
OM-463 Page 42
Downloaded from www.Manualslib.com manuals search engine
3
Be sure equipment
has this symbol
and/or wording.
OR
Generator Base
Metal Vehicle Frame
Equipment Grounding
Terminal
Grounding Cable
GND/PE
OR
S-0854
OM-463 Page 43
Downloaded from www.Manualslib.com manuals search engine
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 10-8).
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-463 Page 44
Downloaded from www.Manualslib.com manuals search engine
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-463 Page 45
Downloaded from www.Manualslib.com manuals search engine
Circular Saw
Table Saw
Band Saw
Bench Grinder
Air Compressor
Submersible Pump
Centrifugal Pump
Floor Polisher
High Pressure Washer
OM-463 Page 46
Downloaded from www.Manualslib.com manuals search engine
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-463 Page 47
Downloaded from www.Manualslib.com manuals search engine
4
1
240 V
Neutral
120 V
Extension Cord
120 V
Generator Connections
240 V
120 V
Load
120/240 Volt
60 Hz
Three-Wire
Service
120 V
Load Connections
4
7
CB
or
F1
5
6
240 V
120/240 Volt
Single-Phase
Three-Wire
Generator Output
Connection
120 V
120 V
Ground
S-0405-A
OM-463 Page 48
Downloaded from www.Manualslib.com manuals search engine
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-463 Page 49
Downloaded from www.Manualslib.com manuals search engine
18
19
4
5
2
17
16
20
21
22
15
13
9
10
101
100
23
14
7
6
12
7
6
6
7
99
Fig 11-2
10
24
25
11
26
98
94
70
95
69
66
97
65
96
64
93
74
92
75
91
90
89
76
77
85 84 83
88
87
Fig 116
& Fig 11-7
81
86
Fig 11-5
OM-463 Page 50
Downloaded from www.Manualslib.com manuals search engine
78
82
80
79
38
37
36
35
34
33
28
27
29
39
32
40
41
42
31
30
43
44
73
51
72
52
71
46
70
69
47
48
53
55
49
45
50
54
56
57
58
68
Fig 11-3
67
66 65 64
63
59
62
61
60
102
ST-048 455-AA
OM-463 Page 51
Downloaded from www.Manualslib.com manuals search engine
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
4
1
1
1
1
6
6ft
2
1
2
1
1
1
1
1
1
3
2
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
2
1
1
1
1
1
1
2
1
1
6
2
2
1
1
1
1
1
2
1
1
1
1
1
1
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Fig 11-4
4
22
5
6
21
20
7
19
18
17
16
9
10
15
14
13
12
11
ST-048 457-N
OM-463 Page 54
Downloaded from www.Manualslib.com manuals search engine
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
2
2
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-463 Page 55
Downloaded from www.Manualslib.com manuals search engine
29
28
27
26
25
11
10
12
13
24
23
14
22
15
21
16
14
18 19
17
20
OM-463 Page 56
Downloaded from www.Manualslib.com manuals search engine
SD-048 456-E
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . INSULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BUS BAR, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . DIODE ASSEMBLY, reverse polarity (consisting of) . . . . . . . . . . . . . . . . . . .
. . . . CAPACITOR, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . DIODE, rect 275A 300V RP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . INSULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BAFFLE, air rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, mtg brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BAFFLE, air diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRUSH SET, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BRUSH, contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . HOLDER, brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CAP, brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning moving parts can cause serious injury . . . . . . . . . . . . . . . .
. . STATOR, gen (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STATOR, gen (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BAFFLE, air gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ROTOR, gen (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . RING, retaining external . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BEARING, ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . FAN, rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STATOR, excitor (CC model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STATOR, excitor (CC/CV model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ENDBELL, gen (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . O-RING, 2.859 ID x .139CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BARREL, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . DIODE ASSEMBLY, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CAPACITOR, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . INSULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . DIODE, rect 275A 300V SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SUPPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
2
1
2
1
3
2
1
1
1
3
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
3
1
OM-463 Page 57
Downloaded from www.Manualslib.com manuals search engine
Item
No.
Dia.
Mkgs.
Part
No.
171 878
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
1 ..........
2 ..........
3 ..........
4 . . . S10 . .
5 ..........
6 ..........
7 ..........
8 ..........
9 ..........
10 . . . . . . . . .
11 . . . . . . . . .
12 . . . . . . . . .
13 . . . . . . . . .
14 . . . . . . . . .
15 . . . . . . . . .
16 . . . . . . . . .
17 . . . . . . . . .
18 . . . . . . . . .
19 . . . . . . . . .
20 . . . . . . . . .
114 235
010 671
017 428
172 245
170 677
171 854
172 701
011 025
011 010
011 009
171 856
011 007
011 018
172 702
011 018
171 856
011 095
011 019
011 012
011 013
Description
Quantity
1
1
1
1
1
1
3
1
2
2
1
1
9
6
2
1
2
2
6
3
10
7
9
1
10
12
11
4
2
Includes
Item 8
5
13
15
16
15
8
ST-145 878-A
14
20
19 18
17
ST-145 879-B
OM-463 Page 58
Downloaded from www.Manualslib.com manuals search engine
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-5. Control Box CC/CV (Figure 11-1 Item 86) (Optional)
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
1 ..........
2 . . . S6 . . .
3 . . S8,9 . .
4 ..........
5 ..........
6 ..........
7 ..........
8 . . RC20 .
9 . . RC21 .
10 . RC22 .
11 . . SR2 . .
12 . . PC1 . .
13 . RC1 . .
14 . PLG1 .
15 . . . . . . . . .
16 . . PC2 . .
17 . RC1 . .
18 . . PC3 . .
19 . . . . . . . . .
20 PLG3-5 .
21 . CB3,4 .
22 . RC3 . .
23 . . . . . . . . .
24 . . . . . . . . .
25 . . . . . . . . .
605 321
011 611
011 609
601 836
010 915
083 030
185 778
147 663
168 071
158 466
097 353
185 746
114 064
135 275
134 201
185 747
115 092
150 415
185 761
165 668
083 432
143 976
039 885
147 195
021 385
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
3
1
2
3
3
1
1
1
1
1
1
1
1
1
11
1
1
1
1
3
2
1
1
2
3
8
9
4
5
10
11
12
2
1
13
3
14
15
21
16
17
25
18
22
24
5
4
23
19
20
5
4
ST-801 850
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
1 . . . R2 . . .
2 . . SR1,4 .
3 . . . D8 . . .
4 . . . R3 . . .
5 ..........
6 ..........
7 ..........
8 . . . 3T . . .
9 ..........
10 . . . . . . . . .
11 . . 1T . . .
12 . . . . . . . . .
13 . . D1 . . .
14 . . C8 . . .
15 . . R6 . . .
16 . . . . . . . . .
17 . CR1,2 .
185 748
035 704
192 307
128 862
601 836
134 201
185 187
185 189
083 030
010 913
038 639
164 617
128 299
170 674
030 844
605 741
044 588
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
RESISTOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KIT, diode w/washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESISTOR, WW adj 375W 50 ohm w/mtg bkt . . . . . . . . . . . . . . . . . . . . . . . . . . .
NUT, brs 250-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STAND-OFF SUPPORT, PC card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL, mtg components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BLOCK, terminal 15A 3P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STUD, brs .250-20 x 1.750 hex collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WASHER, flat brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BLOCK, terminal 30A 6P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLIP, wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIODE BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESISTOR, WW fxd 25W 25 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLIP, mtg resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RELAY, encl 12VDC 3PDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
1
1
2
3
1
1
1
1
1
2
1
1
1
2
2
17
16
12
15
13
12
14
10
11
ST-801 851
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
170 672
030 844
605 741
128 862
035 704
038 621
044 588
128 299
034 502
170 673
170 674
..
..
..
..
..
..
..
..
..
..
..
1
1
2
1
3
1
1
1
1
1
1
10
6
5
7
ST-801 852
OM-463 Page 61
Downloaded from www.Manualslib.com manuals search engine
Notes
2.
3.
Intellitig
Process Controllers
Robots
HF Units
Grids
Spot Welders
Load Banks
SDX Transformers
Running Gear/Trailers
Field Options
(NOTE: Field options are covered under True Blue
for the remaining warranty period of the product they
are installed in, or for a minimum of one year
whichever is greater.)
4.
6 Months Batteries
5.
Remote Controls
Accessory Kits
Spoolmate 185
2.
3.
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
miller_warr 1/98
Owners Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
Distributor
Address
City
State
Zip
Resources Available
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
To locate distributor nearest you call
1-800-4-A-Miller.
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
9/98