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Miller Electric PRO 300 manual

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  • Page 1

    P R O 3 0 0 (CA T -Powered) OM -4422 215 177Q 2007 − 11 Pro cesses Descrip tio n Air Carbon Arc (CAC-A) Cutting and Gouging Stick (SMAW ) W elding Engine Driven Welding Generator TIG (GT A W ) W elding MIG (GMAW) W elding Flux Cored (FCA W ) W elding Visit our website at www.MillerWelds.com File: Engine Drive[...]

  • Page 2

    Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .Mille[...]

  • Page 3

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . [...]

  • Page 4

    T ABLE OF CONTENTS 8-5. Servicing Air Cleaner 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6. Inspecting And Cleaning Optional Spark Arrestor Muf fler 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7. Servicing Engine Cooling Sy[...]

  • Page 5

    OM-4422 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2007 − 04 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury . The possible hazards are shown in the adjoining symbols or [...]

  • Page 6

    OM-4422 Page 2 W elding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous.  Keep your head out of the fumes. Do not breathe the fumes.  If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases.  If ventilation is [...]

  • Page 7

    OM-4422 Page 3 1-3. Engine Hazards BA TTER Y EXPLOSION can BLIND.  Always wear a face shield, rubber gloves, and protective clothing when working on a battery .  Stop engine before disconnecting or connect- ing battery cables or servicing battery .  Do not allow tools to cause sparks when working on a battery .  Do not use welder to cha[...]

  • Page 8

    OM-4422 Page 4 HOT MET AL from air arc cutting and gouging can cause fire or explosion.  Do not cut or gouge near flammables.  W atch for fire; keep extinguisher nearby . HOT P ARTS can cause burns and injury .  Do not touch hot compressor or air system parts.  Let system cool down before touching or ser- vicing. READ INSTRUCTIONS.  [...]

  • Page 9

    OM-4422 Page 5 H. F . RADIA TION can cause interference.  High-frequency (H.F .) can interfere with radio navigation, safety services, computers, and communications equipment.  Have only qualified persons familiar with electronic equipment perform this installation.  The user is responsible for having a qualified electrician promptly corre[...]

  • Page 10

    OM-4422 Page 6 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION rom_2007 − 04fre Se protéger , ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud. 2-1. Signification des symboles DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des ble[...]

  • Page 11

    OM-4422 Page 7 DES PIÈCES CHAUDES peuvent provoquer des brûlures graves.  Ne pas toucher à mains nues les parties chau - des.  Prévoir une période de refroidissement avant d e travailler à l’équipement.  Ne pas toucher aux pièces chaudes, utiliser les outils recomman - dés et porter des gants de soudage et des vêtements épais [...]

  • Page 12

    OM-4422 Page 8 LES CHAMPS MAGNETIQUES peuv- ent affecter des implants médicaux.  Porteur de simulateur cardiaque ou autre im- plants médicaux, rester à distance.  Les porteurs d’implants doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de sou- dage par points, de gougeage, du coupage[...]

  • Page 13

    OM-4422 Page 9 L ’utilisation d’un groupe autonome à l’intérieur PEUT VOUS TUER EN QUELQUES MINUTES.  Le s fumées d’un groupe autonome contient du monoxyde de carbone. C’est un poison invisi- ble et inodore.  JAMAIS utiliser dans une maison ou garage, même avec les portes et fenêtres ouvertes.  Uniquement utiliser à l’EXT[...]

  • Page 14

    OM-4422 Page 10 LE SURCHAUFFEMENT peut endom- mager le moteur électrique.  Arrêter ou déconnecter l’équipement avant d e démarrer ou d’a rrêter le moteur .  Ne pas laisser tourner le moteur trop lentement sous risque d’en - dommager le moteur électrique à cause d’une tension et d’une fré - quence trop faibles.  N e pas b[...]

  • Page 15

    OM-4422 Page 1 1 2-6. P r oposition californienne 65 A vertissements Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des mal- formations congénitales et, dans certains cas, des cancers. (Code de santé et de sécurité de [...]

  • Page 16

    OM-4422 Page 12 SECTION 3 − DEFINITIONS 3-1. W arning Label Definitions 3/96 1 Remove unit from shipping crate. Remove Owner’s Manual from unit. Follow instructions to install muf fler . 2 Read Owner ’s Manual. Read labels on unit. 3 Use Diesel Fuel only , and fill fuel tank. Leave room for expansion. 4 Warning! W atch Out! There are possible[...]

  • Page 17

    OM-4422 Page 13 3-2. Manufacturer ’ s Rating Label 226 156-B / 803 562-F[...]

  • Page 18

    OM-4422 Page 14 3-3. Symbols And Definitions  Some symbols are found only on CE products. Stop Engine Fast (Run, W eld/ Power) Slow (Idle) Start Engine Starting Aid (Preheat) Battery (Engine) Engine Oil Pressure Engine Oil Check Injectors/ Pump Check V alve Clearance Fuel Protective Earth (Ground) Positive Negative Certified/T rained Mechanic W [...]

  • Page 19

    OM-4422 Page 15 SECTION 4 − SPECIFICA TIONS 4-1. W eld, Power , And Engine Specifications W elding Mode W eld Output Range Rated W elding Output Maximum Open- Circuit V oltage Generator Power Rating Engine Fuel Capacity CC/DC 20 − 410 A 400 A, 23 V olts DC, 40% Duty Cycle 300 A, 32 V olts DC CC/DC 20 410 A 300 A , 32 V olts DC 60% Duty Cycle 25[...]

  • Page 20

    OM-4422 Page 16 4-3. V olt-Ampere Curves 217 517 / 217 516 / 217 518 The volt-ampere curves show the minimum and maximum voltage an d amperage output capabilities of th e welding generator . Curves of al l other settings fall between the curves shown. A. Stick Mode B. MIG Mode C. TIG Mode DC VOL TS DC AMPERES 0 100 200 300 400 500 100 90 80 70 60 5[...]

  • Page 21

    OM-4422 Page 17 4-4. Fuel Consumption The curve shows typical fuel use under weld or power loads. 217 509 ID L E DC WELD AMPERES A T 100% DUTY CYCLE U.S. GAL/HR. 0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 0 50 100 150 200 250 300 350 400 4-5. Duty Cycle And Overheating 100% Duty Cycle At 250 Amperes Continuous W elding Duty Cycle is percentage of[...]

  • Page 22

    OM-4422 Page 18 4-6. AC Generator Power Curve 217 519 Th e ac power curve shows the gen- erator power in amperes available at the 120 and 240 volt receptacles. 0 40 80 120 160 0 2 04 0 6 08 0 AC AMPERES IN 120 V MODE AC AMPERES IN 240 V MODE 300 250 200 150 100 50 0 150 125 100 75 50 25 0 AC VOL TS Notes 16 Gauge (.063 in) 22 Gauge (.031 in) 24 Gau[...]

  • Page 23

    OM-4422 Page 19 SECTION 5 − INST ALLA TION install3 2007 − 04 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712 ! Always securely fasten weld- ing generator onto transport vehicle or trailer and comply with all DOT and other applica- ble codes. ! Always ground generator frame to vehicle frame to pre- vent electric shock and static electrici[...]

  • Page 24

    OM-4422 Page 20 5-2. Mounting W elding Generator T ools Needed: 9/16 in 2 2 4 W elding Unit In Place Bolting Unit In Place ! Do not weld on base. W eld- ing on base can cause fuel tank fire or explosion. Weld only on the four mounting brackets or bolt unit down. NOTICE − Do not mount unit by supporting the base only at the four mounting brackets.[...]

  • Page 25

    OM-4422 Page 21 5-3. Installing Exhaust Pipe 1/2 in T ools Needed: 803 582 / Ref. 214 778-B ! Stop engine and let cool.  Point exhaust pipe in desired di- rection but always away from front panel and direction of travel. Notes W o r k l i k e a P r o ! Pros wel d and cut safel y . Read the safety rules at the beginni ng of this manual .[...]

  • Page 26

    OM-4422 Page 22 5-4. Activating The Dry Charge Battery (If Applicable) ! Always wear a face shield, rubber gloves and protective clothing when working on a battery . Remove battery from unit. 5 V ent Caps 6 Sulfuric Acid Electrolyte (1.265 Specific Gravity) 7 W ell Fill each cell with electrolyte to bottom of well (maximum). ! Do not overfill batte[...]

  • Page 27

    OM-4422 Page 23 5-6. Engine Prestart Checks  Check all engine fluids daily . Engine must be cold and on a level surface. Unit is shipped with 20W break-in oil. Automatic shutdown system stops engine if oil pressure is too low or coolant tempera- ture is too high.  This unit has a low oil pressure shut- down switch. However , some condi- tions[...]

  • Page 28

    OM-4422 Page 24 5-7. Connecting T o W eld Output T erminals 803 562 / 803 778-A T ools Needed: 3/4 in MIG and FC A W W elding For MIG and FCA W welding Direct Current Electrode Positive (DCEP) connect wire feed- er cable to CV (Wire) terminal on right and work cable to W ork/Negative ( − ) terminal on left. Use Process/Contactor switch to select [...]

  • Page 29

    OM-4422 Page 25 5-8. Selecting W eld Cable Sizes* W eld Output T erminals ! W eld Cable Size** and T otal Cable (Copper) Length in Weld Circuit Not Exceeding*** ! Stop engine before connecting to weld output terminals. ! Do not use worn, damaged, under- sized, or poorly spliced cables. 100 ft (30 m) or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m)[...]

  • Page 30

    OM-4422 Page 26 5-9. Connecting T o Remote 14 Receptacle RC14 Socket* Socket Information 24 VOL TS AC A 24 volts ac. Protected by sup- plementary protector CB8. 24 VOL TS AC B Contact closure to A completes 24 volt ac contactor control circuit. C Output to remote control:+10 volts dc in MIG mode; 0 to +10 volts dc in Stick or TIG mode. REMOTE OUTPU[...]

  • Page 31

    OM-4422 Page 27 Notes BUTT BUTT BUTT BUTT T − JOINT T − JOINT T − JOINT T − JOINT FILLET GROOVE FLA T VERTICAL HORIZONT AL OVERHEAD WELD POSITION: WELD JOINT TYPES Ref. AWS/ANSI D1.1 1G 1F 2G 2F 3G 3F 4G 4F Ref. 804 248-A[...]

  • Page 32

    OM-4422 Page 28 SECTION 6 − OPERA TING WELDING GENERA TOR 6-1. Front Panel Controls (See Section 6-2) 214 778-D / 803 563 1 25 4 67 8 9 1 0 3[...]

  • Page 33

    OM-4422 Page 29 6-2. Description Of Front Panel Controls (See Section 6-1 ) Engine Starting Controls 1 Preheat Switch Use switch to energize starting aid for cold weather starting (see starting instructions fol- lowing). 2 Engine Control Switch Use switch to start engine, select engine speed (if unit has auto idle option), and stop engine. In Run p[...]

  • Page 34

    OM-4422 Page 30 6-3. Process/Contactor Switch On CC/CV Models 1 Process/Contactor Switch ! W eld output terminals are ener- gized when Process/Contactor switch is in a Weld T erminals Al- ways On position and the engine is running. Use switch to select weld process and weld output on/off control (see table be- low). Place switch in Remote On/Off Sw[...]

  • Page 35

    OM-4422 Page 31 6-4. Lift-Arc ™ Start Procedure Lift-Arc  TIG With Lift-Arc  TIG selected, start arc as follows: 1 TIG Electrode 2 W orkpiece T urn gas on. T ouch tungsten electrode to workpiece at weld start point. Hold electrode to workpiece for 1-2 seconds , and slowly lift electrode. Arc is formed when electrode is lifted. Normal open-c[...]

  • Page 36

    OM-4422 Page 32 6-5. Remote V oltage/Amperage Control 1 Remote 14 Receptacle RC14 Connect optional remote control to RC14 (see Section 5-9).  When a remote control is connected to the Remote receptacle, the Auto Sense Re- mote feature automatically switches volt- age/amperage control to the remote con- trol. When a device is connected to the R e[...]

  • Page 37

    OM-4422 Page 33 SECTION 7 − OPERA TING AUXILIAR Y EQUIPMENT 7-1. 120 V olt And 240 V olt Receptacles 214 778-D 1 120 V 20 A AC (shown) Receptacle RC5 and/or GFCI1 2 120 V 20 A AC GFCI (shown) Receptacle RC6 and/or GFCI2 3 240 V 50 A AC Receptacle RC1 1 RC 5 / 6 and GFCI1 / 2 supply 60 Hz single- phase power at weld/power speed. Recep- tacle confi[...]

  • Page 38

    OM-4422 Page 34 SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Maintenance Label[...]

  • Page 39

    OM-4422 Page 35 8-2. Routine Maintenance ! Stop engine before maintaining.  S ee Engine Manual and Maintenance Label for important start-up, service, and storage information. Service engine more often if used in severe conditions. Recycle engine fluids.  = Check  = Change  = Clean  = Replace * T o be done by Factory Authorized Servic[...]

  • Page 40

    OM-4422 Page 36 8-3. Caterpillar Customer Assistance Service When a problem arises concerning the op- eration or service of the engine, the prob- le m will normally be managed by the dealer in your area. Y our satisfaction is a primary concern to Caterpillar and to Caterpillar dealers. If you have a problem that has not been handled to your complet[...]

  • Page 41

    OM-4422 Page 37 8-5. Servicing Air Cleaner ! Stop engine. NOTICE − Do not run engine without air cleaner or with dirty element. Engine damage caused by using a damaged ele- ment is not covered by the warranty .  The air cleaner primary element can be cleaned but the dirt holding capac- ity of the filter is reduced with each cleaning. The chanc[...]

  • Page 42

    OM-4422 Page 38 8-6. Inspecting And Cleaning Optional Spark Arrestor Muffler 803 582 / Ref. 214 778-B ! Stop engine and let cool. 1 Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole. 3 Exhaust Pipe Start engine and run at idle speed to blow out cleanout hole. If nothing blows out of hole, briefly cover en[...]

  • Page 43

    OM-4422 Page 39 8-8. Adjusting Engine Speed On Standard Models 803 563-E 3 1 2 RPM (Hz) Engine Speed (No Load) W eld/Power 1850 (61.7) Maximum ! Stop engine and let cool. Engine speed is factory set and should not require adjustment. Af- ter tuning engine, check engine speed with tachometer or frequen- cy meter . See table for proper no load speed.[...]

  • Page 44

    OM-4422 Page 40 8-9. Adjusting Engine Speed On Models With Automatic Idle (Optional) 803 563-G Engine Speed Adjustment After tuning engine, check engine speed with tachometer or frequen- cy meter . See table for proper no load speed. If necessary , adjust speed as follows: Start engine and run until warm. T urn Process/Contactor switch to Stick −[...]

  • Page 45

    OM-4422 Page 41 8-10. Servicing Fuel And Lubrication Systems 802 490 / Ref. 801 434 / 803 563 ! Stop engine and let cool. ! After servicing, start engine and check for fuel leaks. Stop engine, tighten connec- tions as necessary , and wipe up spilled fuel. 1 Oil Filter 2 Oil Drain V alve And Hose 3 Oil Fill Cap 4 Primary (Canister) Fuel Filter 5 Sec[...]

  • Page 46

    OM-4422 Page 42 8-1 1. Overload Protection 803 562 / Ref. 803 566-F 1 5 ! Stop engine.  When a circuit breaker , supple- mentary protector , or fuse opens, it usually indicates a more serious problem exists. Contact Factory Authorized Service Agent. 1 Fuse F1 F1 protects the stator exciter wind- ing from overload. If F1 opens, weld and generator[...]

  • Page 47

    OM-4422 Page 43 8-12. V oltmeter/Ammeter Help Displays Use the V oltmeter/Ammeter help displays to diagnose and correct fault conditions.  When a help code is displayed normally weld output has stopped but generator power output may be okay .  T o reset help displays, stop unit and then restart. See item 6 below to reset Help 25 dis- play . 1[...]

  • Page 48

    OM-4422 Page 44 8-13. T roubleshooting  Also see V oltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 8-12 ). A. Welding T rouble Remedy No weld output; generator power output okay at ac receptacles. Place Process/Contactor switch in a Weld T erminals Always On position, or place switch in a Remote On/Of f Swi[...]

  • Page 49

    OM-4422 Page 45 B. Standard Generator Power T rouble Remedy No generator power output at ac recep- tacles; weld output okay . Reset receptacle supplementary protector(s) (see Section 7-1). No generator power or weld output. Disconnect equipment from generator power receptacles during start-up. Check fuse F1, and replace if open (see Section 8-1 1).[...]

  • Page 50

    OM-4422 Page 46 T rouble Remedy Engine slowly stopped and cannot be restarted. Check fuel level. Check engine air and fuel filters (see Sections 8-5 and 8-10 ). See engine manual. Battery discharges between uses. T urn Engine Control switch off when unit is not running. Clean top of battery with baking soda and water solution; rinse with clear wate[...]

  • Page 51

    OM-4422 Page 47 Notes 400 T rade Square East, T roy , Ohio 45373 1-800-332-9448 www.welding.org Over 80,000 trained since 1930! Start Y our Professional W elding Car eer Now![...]

  • Page 52

    OM-4422 Page 48 SECTION 9 − ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For Welding Generator[...]

  • Page 53

    OM-4422 Page 49 219 228 − E[...]

  • Page 54

    OM-4422 Page 50 SECTION 10 − RUN-IN PROCEDURE run_in1 2007 − 04 10-1. W etstacking 1 W elding Generator Ru n diesel engines near rated volt- ag e and current during run-in period to properly seat piston rings and prevent wetstacking. See name- plate, rating label, or specifications section in this manual to find rated voltage and current. NOTIC[...]

  • Page 55

    OM-4422 Page 51 10-2. Run-In Procedure Using Load Bank S-0683 ! Stop engine. ! Do not touch hot exhaust pipe, engine parts, or load bank/grid. ! Keep exhaust and pipe away from flammables. NOTICE − 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 Load Bank T urn all l[...]

  • Page 56

    OM-4422 Page 52 10-3. Run-In Procedure Using Resistance Grid S-0684 ! Stop engine. ! Do not touch hot exhaust pipe, engine parts, or load bank/grid. ! Keep exhaust and pipe away from flammables. NOTICE − 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 Resistance Grid[...]

  • Page 57

    OM-4422 Page 53 SECTION 1 1 − GENERA TOR POWER GUIDELINES  The views in this section are intended to be representative of all engine-driven welding generators. Y our unit may differ from those shown. 1 1-1. Selecting Equipment gen_pwr 2007 − 04 − Ref. ST -159 730 / ST-800 577 1 Generator Power Receptacles − Neutral Bonded T o Frame 2 3-P[...]

  • Page 58

    OM-4422 Page 54 1 1-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 AWG or larger insulated copper wire. 3 Ground Device  Us e ground device as stated in electrical codes. ! Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system[...]

  • Page 59

    OM-4422 Page 55 1 1-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starti ng W atts Running W atts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 2100 700 1/2 HP 3175 875 Capacitor Start-Induction Run 1/3 HP 2020 720 1/2 HP 3075 975 3/4 HP 4500 1400 1 HP 6100 1600 1-1/2 HP 8200 2200 2 HP 10550 28[...]

  • Page 60

    OM-4422 Page 56 1 1-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting W atts Running W atts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/2 in 500 500 7-1/4 in 900 900 8-1/4 in 1400 1400 T able Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in 2500 1 100 Bench Grinder 6 in 1720 720 8 in[...]

  • Page 61

    OM-4422 Page 57 1 1-8. Power Required T o Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code G H J K L M N P KV A/HP 6.3 7.1 8.0 9.0 10.0 1 1.2 12.5 14.0 S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor V oltage T o find starting amperage: Step 1: Find code and use table to find kV A/HP . If code is not l[...]

  • Page 62

    OM-4422 Page 58 1 1-10. T ypical Connections T o Supply Standby Power T ransfer Switch Essential Loads Fused Disconnect Switch (If Required) Utility Electrical Service 12 3 4 5 W elding Generator Output ! Have only qualified persons perform these connections according to all applicable codes and safety practices. ! Properly install and ground this [...]

  • Page 63

    OM-4422 Page 59 1 1-1 1. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 V olt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (A WG)* Current (Amperes) Load (W atts) 4 6 8 10 12 14 5 600 350 (106) 225 (68) 137 (42) 100 (30) 7 840 [...]

  • Page 64

    OM-4422 Page 60 SECTION 12 − P ARTS LIST  Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. 1 10 (Fig.12 − 3) 1 2 3 4 (Fig.12 − 5) 5 6 7 8 9 10 11 12 14 15 16 17 18 19 20 21 13 22 23 24 25 26 90 91 92 93 94 95 96 98 97 99 100 101 102 103 104 105 106 107 108 (Fig.12 − 2) 109 111 Fi[...]

  • Page 65

    OM-4422 Page 61 803 683-F 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 68 67 69 70 73 71 72 74 75 76 77 78 79 80(Fig.12 − 4) 81 82 84 85 86 87 88 89 44 43 83 27 45[...]

  • Page 66

    OM-4422 Page 62 Description Part No. Dia. Mkgs. Item No. Figure 12-1. Main Assembly Quantity 1 HD1 168829 T ransducer , Current 1000a Module Max Open Loop 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 R3 213027 Resistor , WW T ap 300 W 40 Ohm 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 67

    OM-4422 Page 63 Description Part No. Dia. Mkgs. Item No. Figure 12-1. Main Assembly (Continued) Quantity 49 199592 Latch, Paddle Series 20 (Black) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 +213487 Door , Engine Access 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 68

    OM-4422 Page 64 Description Part No. Dia. Mkgs. Item No. Figure 12-1. Main Assembly (Continued) Quantity 172071 Clamp, Hose .520 − .605 Clp Dia Slfttng Black 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 1961 Hose, Sae .312 Id X .560 Od X 16.000 2 . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 69

    OM-4422 Page 65  Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. 803 684-A 1 2 3 4 5 6 37 36 7 8 9 10 11 12 13 14 15 16 17 18 19 31 32 33 34 35 20 21 22 23 24 25 26 27 28 29 30 24 Figure 12-2. Panel, Front w/Components Description Part No. Dia. Mkgs. Item No. Figure 12-2. Panel, Front w[...]

  • Page 70

    OM-4422 Page 66 Description Part No. Dia. Mkgs. Item No. Figure 12-2. Panel, Front w/Components (Continued) Quantity 10 214543 Enclosure, Circuit Card Assy 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 134201 Stand − of f Support, Pc Card .312/.375w/Post&lock .43 4 . . . [...]

  • Page 71

    OM-4422 Page 67  Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. 803 689-D 1 2 3 4 5 6 7 8 9 10 13 12 11 14 15 Figure 12-3. Control Panel Description Part No. Dia. Mkgs. Item No. Figure 12-3. Control Panel (Figure 12-1 Item 1 10) Quantity 1 220981 Bracket, Mtg Components 1 . . . . . . .[...]

  • Page 72

    OM-4422 Page 68 803 686-B  Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. 2 3 1 4 5 6 7 8 9 10 11 12 14 19 20 18 15 17 16 13 Figure 12-4. Generator Description Part No. Dia. Mkgs. Item No. Figure 12-4. Generator (Figure 12-1 Item 80) Quantity 1 ROTOR 212474 Rotor , Generator 4 Pole (In[...]

  • Page 73

    OM-4422 Page 69 803 685-A  Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. 1 2 3 6 4 5 9 8 10 7 Figure 12-5. Rectifier Assembly Description Part No. Dia. Mkgs. Item No. Figure 12-5. Rectifier Assembly (Figure 12-1 Item 4) Quantity 217081 Rectifier , Assembly (Includes) 1 . . . . . . . .[...]

  • Page 74

    OM-4422 Page 70  Some wiring harness components (switches, relays, supplementary protectors) are also referenced elsewhere in this parts list. Purchase compo- nents separately or as part of the associated wiring harness. Description Part No. Dia. Mkgs. Item No. Wiring Harnesses Quantity 231 122 Harness, Engine Cat 3013c (Includes) 1 . . . . . . [...]

  • Page 75

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007 − 01 Y o ur distributor also gives you ... Service Y ou 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 exp[...]

  • Page 76

    PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007 − 01 Miller Elect ric Mfg. Co. An Illinois T ool W orks Compan y 1635 West S pencer Street Applet on, WI 54914 USA International He adquarters − USA USA Phone: 9 20-735-4505 Auto-A tt ended USA & C anada F AX : 920-735-4134 Int ernati onal F A X: 9 20-735-4125 European Headqua rters − U[...]