Miller Electric Metro 300DX Specifications

Miller
August
1995
Form:
OM-1 56 368B
Effective With Serial No. KF941 356
OWNERS
MANUAL
~_' _I_
CE
Metro 300DX
CC/DC
Welding
Generator For SMAW And GTAW
Welding
Maximum
Rated
Welding
Output
280 A, 31
35% Duty
Amperage
Range
VDC,
3-Phase,
72 AMS
20280
225 A, 29 V DC,
Duty Cycle
cover_om 4/95
-
Auxiiiary
Rating
Engine
Power
Fuel
Sound
Capacity
Power
11.8 US
98 Lwa
iP
Rating
Single-Phasel
Cycle
250 A, 30 V DC,
60% Duty Cycle
100%
OpenCircuit
Voltage DC
Ref. ST-158 934-B
(65 Average)
7/10 kVA/kW,
32/15 A.
220/380 V AC,
50Hz
'
Ruggenni
RD211
Air-Cooled,
Two-Cylinder, 20
HP Diesel Engine
1995 MILLER Electric
Mfg. Co.
gal
(44.6 L)
23
PRINTED IN USA
UI
L~
MILLERS
TRUE BLUEfi LIMITED WARRANTY
(Equipment
This limited warranty
supersedes
all
Effective January 1, 1995
serial number preface of KD
with
previous MILLER
warranties and is exclusive with
LIMITED WARRANTY Subject to the terms and conditions below, MILLER Electric
Mt g. Co., Appleton. Wisconsin, warrants to its original retail purchaser that new
MILLER equipment sold after the effective date of this limited warranly is free of de
tects In material and workmanship at the time it is shipped by MILLER. THIS WAR
RANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES. EXPRESS OR
IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FIT
no
6 Months
6.
90
or warranties
Days
-
APT. ZIPCUT & PLAZCU1
*
Remote Controls
*
Accessory Kits
Replacement Pans
MILLERS
followed.
1.
or
Implied.
Parts end Labor
MIG Guns/TIG Torches
-
expressed
Batteries
*
listed below, MILLER will repair or replace any war
ranted pans or components thaI fall due to such defects In material orworlcmanship.
MILLER must be notified in writing within thIrty (30) days of such delect or failure, at
which time MILLER will provide instructions on the warranty claim procedures to be
periods
newer)
other guarantees
5.
NESS.
Within the warranty
or
a
True Bluefi Limited
items furnished
Model Plasma
Warranty
by MILLER,
Cutting
apply
shall not
Torches
to:
but manufactured
trade accessories. These items
are covered
by others, such as engines or
by the manufacturers warranty, if
any.
MILLER shall honor warranty claims
on warranted equipment listed below in the
warranty time periods. All warranty lime periods
equipment was delivered 10 the original retail purchaser, or
one year after the equipment is sent to a North American distributor or eighteen
months after the equipment is sent to an International distributor.
event of auch a failure within the
1.
and
main power rectifiers
Inverters
Cutting
Power Sources
Inverter Power
Supplies
Robots
2YearsPartsendLabor
4.
Parts end Labor
Motor Driven Guns
-
Process Controllers
-
IHPS Power Sources
Water Coolant
-
HF Units
*
Grids
-
Spot Welders
Systems
SDX Transformers
-
Running GeardTrsiters
Plasma Cutting Torches (except APt
Some states In the U.S.A. do not allow limitations of how long an Implied warranty
lasts, or Ihe exclusion of incidental, indirect, special or consequential damages, so
the above limitation or exclusion may not apply to you. This warranty provides spe
cific legal rights, and other rights may be available, but may vary from state to state.
ZIPCUT & PLAZCUT Models)
Tecumseh
Engines
Deutz Engines (outside
Options
(NOTE: Field options
North
America)
In
or
are covered
warranty period of the product they
year
Canada, legislation
whichever is
under True Bluefi for the remaining
are
installed in.
or
for
a
in some
provinces provides for certain additional warranties
as stated herein, and to the extent that they may not be
waived, the limitations and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may be available, but may
vary from province to province.
Field
one
costs of any kind will be allowed.
transportation
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, IN
CLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS
FOR PARTICULAR PURPOSE, W~-l RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.
Load Banks
-
a
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WAR
RANTY, GUARANTY OR REPRESENTATiON AS TO PERFORMANCE. AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL
THEORY WHICH. BUT FOR THIS PROVISION, MIGNTARISE BY IMPLICATION,
-
-
contactors
TO THE EXTENT PERMflTED BY LAW, THE REMEDIES PROVIDED HEREIN
ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE
LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL
DAMAGES (INCLUDING LOSS OF PROFIT). WHETHER BASED ON CON
TRACT. TORT OR ANY OTHER LEGAL THEORY.
Compressors
1 Year
-
ment for
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the engine manufacturer.)
Air
tips, cutting nozzles,
shall be, at MILLERS
Intellitig
-
contact
as
to normal wear.
warranty claim covered by this warranty, the exclusive remedies
option: (1) repair~ or (2) replacement; or, where authorized in
writing by MILLER in appropriate cases, (3) the reasonable cost of repair or replace
mental an authorized MILLER service station; or (4) payment of or credit for the pur
chase price (less reasonable depreciation based upon actual use) upon retum of the
goods at customers risk and expense. MILLERS option of repair or replecement
will be FOB.. Factory at Appleton, Wisconsin, or F.O.B. at a MILLER authorized ser
vice facility as determined by MILLER. Therefore no compensation or reimburse
In the event of
Semi-Automatic and Automatic Wire Feeders
3.
pans that tall due
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMER
CIAL/iNDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN
THE USE AND MAINTENANCE OF WELDING EQUIPMENT.
Transformer/Rectifier Power Sources
Plasma Arc
*
or
(input and output rectifiers only)
3YearsPartsandLabor
*
relays
Equipment that has been modified by any party other than MILLER. or eqwp
ment that has been improperly installed, improperly operated or misused
based upon industry standards, or equipment which has nof had reasonable
and necessary maintenance, or equipment which has been used for operation
outside of the specifications for the equipment.
3.
5YearsPafls-3YearsLabor
Original
2.
Consumable components; such
2.
start on the date that the
minimum of
greater.)
remedies other than
WHO DO I CONTACT?
For
To file
help,
U
For
additional information, such
Technical Manuals
Engine
claim for loss
Wiring Diagrams
contact the
as
(Sen/ice And Parts)
Manuals
Circuit And
a
or
damage during
Miller Electric
shipment,
contaCt your distributor
Mfg.
Co.
CALL:
deliVering
For assistance In
carrier
~
settling claims,
contact your distributor and/or equipment
manufacturers Transportation
Department
filing
or
{TE~T]
FAX:
(in USA), or
(outside USA)
800-637-2348
414-735-4136
Process Handbooks
Users
Guides
a
I
Distributor Directories
I
WRITE:
Miller Electric
Mfg. Co.
P.0. Box 1079
contact your distributor
Appleton,
Always provide
Model Name and Serial
or
WI 54912 USA
Style Number
mIller_wan
6/95
EI~RATA SHEET
December 1, 1995
FORM: OM-156 368B
Use above FORM number when
After this manual
appearing
was
printed,
Replace Figure
6-1. Circuit
Parts List
as
exceptions
to data
ELECTRICAL DIAGRAM
2 and 3
on
this Errata
Sheet)
PARTS LIST
follows:
Dia.
Part
No
Mkgs.
Replaced
Description
With
Added
178 913
..
31-54
.
.
TS1
....
176 625
178 903
...
31-72
...
FS1
....
176 626
178 902
.
31.
occurred. This sheet lists
Diagram For Welding Generator (see Pages
CHANGES TO SECTION 8
**
equipment design
extra manuals.
later in this manual.
CHANGES TO SECTION 6
Change
refinements in
ordering
.
.
.
SOLENOID, module control (Eff w/KG020121)
SOLENOID, throttle and timing module
(Effw/KG020121)
SOLENOID, fuel (Eff w/KG020121)
digit represents page no digits following dash represent item no.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
**First
Quantity
....
1
1
1
I
OLE
OQ~TRU
CT
12
13
~L1
2
lxxx
3
x
4
xx
5
I
XQ0$E0 TO
r~
8
ri
~
I
I
I
TEF~1IJAL
87>A)~
I
85>B>-~
3o>c>.~L
I
I
2ZIV
3tJ>C>~
I
L~~>
>J~
r~i
~
~
~,
I
85>B>~3O>C>-~ I
~ I
L~~>
>~.
~
I
24/4EV
RC5
r~i
>~
~-~2>~ I~i~&~
~ >~
RO9/PLC~
P108/ROE
~ >~
~
~
~5 >~ ~32 >~ ~2 >~
~6 >~ –L~3 >–~ ~ >~
~Z !L~4>–L
~-~8>~
-~9 >~-~ >~-
~JLLll:~1
-~ ~-~-~Q >-
~
RO5/RG8
!4~ >~ -~i ~:i
~7 >~ ~2 I>~
~8 >~L ~3 ~
~49 >~ ~-~4~J
~TO~AL
TO LOWER FELD 0.~NT
~OVE LEAD 31 TO iT-A
TO RA~ FEW 0~ENT
~GVE LEAD 3~ TO iT-A
210
1
~
0
0
0
67
62
63
B
0
33
.12
37
30
44
44
35
0
A6C~p~F
310
0
77
0
72
&7
~7
73
04
41
40
40
42
42
42
Figure
OM-156 368E
Page
2
6-1. Circuit
Diagram
For
Welding
Generator
t
RC7/I&G7
>-
>2 >>3>
SD-178 904
OM-156 368B
Page
3
C
1~
S
Declaration of
Manufacturers
Spencer Street
Appleton, WI 54914 USA
1635 W.
Manufacturers Address:
Declares that the
Mfg. Co.
Miller Electric
Name:
Conformity
Ni ET R 0 300 DX
product:
(product name)
conforms to the
following
Directives and Standards:
Directives
Low
Machinery
Voltage
Directive: 73/23/EEC
Directives: 89/392/EEC,91 /368/EEC, 93/C 133/04, .93/68/EEC
Noise Emission Directive: 79/113/EEC
Noise level of
Welding Generators: 84/535/EEC
Standards
Safety Requirements
Rotating
Rotating
for Arc
Electrical Machines
Welding Equipment Part
Part 1
Part 1.:
Mr. Roberto Moletto
MILLER
Europe S.P.A.
Via Privata lseo
20098 San Giuliano
Milanese, Italy
Fax:
dec_coni 7/95
and Pertormance: IEC 34-1:1994
by
equipment within low-voltage systems:
Principles, requirements and test: lEG 664-1: 1992
Insulation coordination for
Telephone:
Rating
Part 5: Classification of degrees of protection provided
electrical machines (IP code): lEG 34-5: 1991
Electrical Machines
European Contact:
:
1: EN 60974-1: 1990
39(02)98290-1
39(02)98281-552
enclosure of
rotating
TABLE OF CONTENTS
SECTION 1
1-1.
SAFETY PRECAUTIONS FOR ARC WELDING
1-3.
Symbol Usage
Arc Welding Hazards
Engine Hazards
1-4.
Additional Installation,
1-2.
1-5.
Principal Safety
EMF Information
SECTION 2
2-1.
2-2.
2-3.
2-4.
2-5.
2-6.
2-7.
2-8.
1
1
2
Operation,
3
Installing Welding
Dimensions, Weights, And Operating Angles
Fuel Consumption
Rating Label
Connecting Battery And Installing Muffler Pipe
Engine Prestart Checks
Weld Output Terminals And Selecting Cable Sizes
Remote 14 Receptacle RC1 Information
THE WELDING GENERATOR
And Definitions
3-1.
Symbols
3-2.
Front Panel Controls
3-3.
Duty Cycle And Overheating
Remote Amperage Control
4-1.
Auxiliary
SECTION 5
Power
Routine Maintenance
5-6.
5-7.
Overload Protection
5-8.
Inspecting And Cleaning Optional Spark
Troubleshooting
5-5.
5-9.
SECTION 6
ELECTRICAL DIAGRAM
SECTION 7- PARTS LIST
Figure
Figure
Figure
Figure
7-1. Main
7-4.
Assembly
Component
7
7
8
8
11
11
12
12
13
14
15
15
16
17
Arrestor
18
18
22
24
7-2. Generator
7-3. Panel, Front
5
6
10
Oil And Filter
Changing Engine
Changing Fuel Filters
Servicing Air Cleaner
Adjusting Engine Speed
5-4.
5
10
MAINTENANCE & TROUBLESHOOTING
Maintenance Label
4
8
Receptacles
5-2.
4
9
AUXILIARY EQUIPMENT
5-1.
5-3.
4
Generator
SECTION 4OPERATING
3
3
INSTALLATION
SECTION 3OPERATING
3-4.
And Maintenance Hazards
Standards
1-6.
1
24
29
w/Components
30
Box
31
OM-156 388B -8195
SECTION 1
-
SAFETY PRECAUTIONS FOR ARC WELDING
sately_roml 4/95
1-1.
Symbol Usage
a
Warning! Watch Out! There
procedure! The possible hazards are
Means
~1!~~d~
1-2.
Arc
Welding
possible
hazards with this
shown in the
adjoining symbols.
are
Marks
A
a
special safety message.
~ Means NOTE; not
safety
1
related.
This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING
PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary
actions to avoid the hazards.
Hazards
WARNING
a
The symbols shown below are used throughout this manual to call attention to and identify possible hazards.
When you see the symbol, watch out, and follow the related Instructions to avoid the hazard. The safety
Information given below Is only a summary of the more complete safety Information found in the Safety
Standards listed in Section 1-5. Read and follow all Safety Standards.
Only qualified
persons should install, operate, maintain, and repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK
Touching
can
kill.
terminal in disconnect box
electrical parts can cause fatal
shocks or severe bums. The electrode and work
circuit is electrically live whenever the output is on.
The input power circuit and machine internal
circuits are also live when power is on. In
semiautomatic or automatic wire welding, the wire,
wire reel, drive roll housing, and all metal parts
touching the welding wire are electrically live.
Incorrectly installed or improperly grounded
equipment is a hazard.
1.
Do not touch live electrical parts.
dry, hole-free insulating gloves and
Wear
3.
yourself from work and
big enough to prevent any physical contactwith
the work or ground.
Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according
to OSHA 29 CFR 191 0.147 (see Safety Standards).
Properly install and ground this equipment according to its
insulate
mats or covers
4.
5.
6.
Always verify the supply ground
nnwer
~nrd
nrniinrl
wire
is
check and be
ornnerhi
When
sure
ennne~tad
a
attach proper
grounding
double-check connections.
9.
Turn off all
10. Do not
cables.
equipment
use
worn,
when not in
use.
damaged, undersized,
drape cables
over
your
or
poorly spliced
body.
12. If earth
with
a
grounding of the workpiece is required, ground it directly
separate cable do not use work clamp or work cable.
13. Do not touch electrode if you are in contact with the work,
ground, or another electrode from a different machine.
14. Use
only well-maintained equipment. Repair or replace
damaged parts at once. Maintain unit according to manual.
15. Wear
a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable
workpiece
or
with
worktable
good
as near
metal-to-metal
the weld
as
contact
to
practical.
ARC RAYS
2.
Wear
a
welding
helmet fitted with
a
proper shade of filter to
protect your face and eyes when welding or watching (see ANSI
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can bum eyes and skin. Noise from some
3.
Chipping,
pieces of
4.
can
damage hearing.
processes
grinding, and welds cooling throw off
metal or slag.
connected to
Frequently inspect input power cord for damage or bare wiring
replace cord immediately if damaged bare wiring can kill.
nrntind
ARC RAYS can burn eyes and skin;
NOISE can damage hearing; FLYING
SLAG OR SPARKS can injure eyes.
plug Is
outlet.
8.
that input
tn
that cord
making input connections,
conductor first
16.
Manual and national, state, and local codes.
Owners
7.
11. Do not
body protection.
ground using dry insulating
2.
or
properly grounded receptacle
live
Z49.1 and Z87.1 listed in
Wear
Use
and
Safety Standards).
approved safety glasses
with side shields.
protective screens or barriers to protect
glare; warn others not to watch the arc.
others from flash
NOISE
5.
1.
Use
approved
ear
plugs
or ear
muffs if noise level is
FUMES AND GASES can be hazardous
to your health.
Welding produces fumes
these fumes and gases
health.
1.
2.
4.
welding
a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained
watchperson nearby. Welding fumes and gases can displace air
and lower the oxygen level causing injury or death. Be sure the
breathing air is safe.
6.
Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to
form highly toxic and irritating gases.
and gases. Breathing
be hazardous to your
can
fumes and gases.
protective clothing made from durable, flame-resistant
(wool and leather) and foot protection.
5.
Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use exhaust at the arc to
remove
3.
Wear
material
high.
7.
Work in
Do not weld
on
coated metals, such
as
galvanized, lead,
or
if ventilation is poor, use an approved air-supplied respirator.
Read the Material Safety Data Sheets (MSDSs) and the
manufacturers instruction for metals, consumables, coatings,
cadmium plated steel, unless the coating is removed from the
weld area, the area Is well ventilated, and If necessary, while
wearing an air-supplied respirator. The coatings and any metals
cleaners, and degreasers.
containing
these elements can
give
off toxic fumes If welded.
OM-156 368
Page
1
CYLINDERS
1.
2.
3.
can
if
explode
damaged.
drape
compressed gas cylinders from excessive heat,
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.
Keep cylinders away from any welding or other electrical
8.
mechanical shocks,
9.
circuits.
10. Read and follow instructions on compressed gas cylinders,
assOciated equipment, and CGA publication P-i listed in Safety
Standards.
fire
can cause
explosion.
or
closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks,
hot workpiece, and hot equipment can cause fires
and bums. Accidental contact of electrode to metal
objects
can cause
sparks, explosion, overheating,
fire. Check and be
doing any welding.
sure
the
7.
in
6.
1.
Protect
Do not weld where
3.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
4.
Be alert that
and others from
flying sparks
flying sparks
can
and hot metal.
strike flammable material.
welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
Watch for fire, and keep a fire extinguisher nearby.
use or
Be
a
connected for
aware
that
can cause
welding
fire
Do not weld
7.
on a
ceiling, floor, bulkhead,
closed containers such
tanks, drums,
or
8.
Connectwork cable to the work
9.
Do not
as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
welder to thaw frozen
use
pipes.
10. Remove stick electrode from holder
contact
tip when
or
cut off
welding
wire at
not in use.
11. Wear oil-free
protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
12. Remove any combustibles, such
from your person before
doing
as a
any
butane lighter or matches,
welding.
__
ENGINE EXHAUST GASES
Engines produce
ENGINE
can
kill.
1.
2.
harmful exhaust gases.
FUEL
can
cause
fire
or
2.
in open, well-ventilated areas.
closed area, vent engine exhaust outside and
away from any building air intakes.
Use
equipment outside
If used in
a
Do not add fuel while
smoking
or
if unit is near any
Engine fuel is highly flammable.
Do
~ot overfill tank
allow
room
for fuel to
A
4.
Stop engine and
let it cool off before
MOVING PARTS
checking
or
can cause
adding fuel.
Injury.
Moving parts, such as fans, rotors, and belts can
cut fingers and hands and catch loose clothing.
Keep all doors, panels,
securely in place.
2.
Stop engine
before
covers,
installing
and
guards closed
connecting
spill
fuel. If fuel is
4.
To
unit.
1.
2.
Do not
gases.
5.
Observe correct
STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and
skin.
1.
engine Is
for
cables.
Do not allow tools to
It Is best to check coolant level when
cold to avoid scalding.
covers
Always wear a face shield when working on a battery.
Stop engine before disconnecting or connecting battery
4.
generate explosive
starting
prevent accidental starting during servicing, disconnect
negative () battery cable from battery.
Keep hands, hair, loose clothing, and tools away from moving
parts.
Reinstall panels or guards and close doors when servicing is
finished and before starting engine.
3.
Batteries contain acid and
spilled,
expand.
clean up before
Have only qualified people remove guards or
maintenance and troubleshooting as necessary.
6.
or
Do not
3.
and
SPARKS can cause BATTERY GASES
TO EXPLODE; BATTERY ACID can
burn eyes and skin,
2
or
engine.
5.
1.
sparks
open flames.
explosion,
Page
as
WARNING
a
OM-156 368
partition
Hazards
____
1.
or
the hidden side.
on
on
use.
pipes, unless they are properly prepared according to AWS F4. 1
(see Safety Standards).
is safe before
area
2.
Engine
6.
on
or
yourself
Never allow
a
Protect
Welding
1-3.
Never
5.
WELDING
5.
welding torch over a gas cylinder.
welding electrode to touch any cylinder.
Never weld on a pressurized cylinder explosion will result.
Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is
4.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode.
Since gas cylinders are normally part of the welding
process, be sure to treat them carefully.
If the
use
cause
sparks when working on a battery.
charge batteries or jump start vehicles.
polarity (+ and ) on batteries.
welder to
engine
is
warm
and
checking
is needed, follow steps 2
and 3.
and gloves and put a rag over cap.
slightly and let pressure escape slowly before
completely removing cap.
safety glasses
2.
Wear
3.
Turn cap
1-4.
Additional Installation,
And Maintenance Hazards
WARNING
a
MOVING PARTS
1.
Operation,
READ INSTRUCTIONS.
injury.
can cause
Before
working of generator, remove spark plugs
or injectors to keep engine from kicking back or
starting.
Block flywheel so that it will not turn while working
on generator components.
FLYING PIECES OF METAL
or
DIRT
can
Use proper
static-proof bags
ship PC boards.
MAGNETIC
CURRENTS
or
face
handling
and boxes to store,
1.
Pacemaker
2.
Wearers should consult their doctor before
wearers
keep away.
welding, gouging,
operations.
near
arc
HOT PARTS
1.
2.
L
1.
or
can cause severe
going
I
~
I
I
1-5.
or unplug equipment before starting
stopping engine.
1.
Allow
2.
Reduce current
3.
spot welding
~I
burns.
.Allow
cooling period before maintaining.
Wear protective gloves and clothing when working
on a hot engine.
Use
Turn off
In
to weld
Follow rated
2.
Use
OVERHEATED
cause
or
reduce
duty cycle before
again.
duty cycle.
TILTING OF TRAILER
1.
or
cooling period.
starting
tongue jack
or
Injury.
can cause
blocks to
support weight.
Properly install welding generator
onto
trailer
according to_instructions_supplied with_trailer.
BATTERY
EYES.
FALLING EQUIPMENT can cause serIous
personal Injury and equipment damage.
1.
Use approved engine exhaust spark arrestor
required areas see applicable codes.
OVERUSE
can
EQUIPMENT.
FIELDS
FROM
HIGH
affect
can
pacemaker
operation.
injectors and bleed air from fuel system
according to engine manual.
LOW VOLTAGE AND FREQUENCY CAN
DAMAGE electrical equipment such as
MOTORS.
damage parts
Put on grounded wrist strap BEFORE
boards or parts.
move, or
Reinstall
1.
Wear safety glasses with side shields
shield.
STATIC ELECTRICITY
on circuit boards.
1.
Use
DO NOT LET ENGINE EXHAUST SPARKS
CAUSE FIRE.
can
Injure eyes.
1.
only genuine MILLER replacement parts.
1.
2.
eye to lift unit only, NOT running gear,
gas cylinders, or any other accessories.
Use equipment of adequate capacity to lift unit.
lifting
ACID
BURN
can
1.
Donottip.
2.
Replace damaged baftery.
3.
Flush eyes and skin
SKIN AND
immediately
with water.
Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.i ,from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safe Handling of Compressed Gases In Cylinders, CGA Pamphlet
P-i, from Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, ArlIngton, VA 22202.
Safety and Health Standards, OSHA 29 CFR 1910. from
Superintendent of Documents, US.- Government Printing ~Office, --fiode for Safetyin Welding and Cutting, CSA Standard Wi 17.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Washington, D.C. 20402.
Recommended Safe Practices for the
Cutting
Preparation for Welding and
Substances,
of Containers That Have Held Hazardous
Welding Society Standard AWS F4.i
Welding Society, 550 N.W. LeJeune Ad, Miami, FL
American
from American
33126
Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
National Electrical
1-6.
Boulevard, Rexdale, Ontario, Canada M9W 1 R3.
Safe Practices For Occupation And Educational Eye And Face
Protection, ANSI Standard Z87.1,from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51 B, from National
Batterymarch Park, Quincy, MA 02269.
Fire Protection Association,
EMF Information
Considerations About Welding And The Effects Of Low
Electric And Magnetic Fields
Frequency
following is a quotation from the General Conclusions Section of
the U.S. Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric& Magnetic Fields Background
Paper, OTA-BP-E-53 (Washington, DC: U.S. Government Printing
there is now a very large volume of scientific
Office, May 1989):.
findings based on experiments at the cellular level and from studies
with animals and people which cleariy establish that low frequency
magnetic fields can interact with, and produce changes In, biological
systems. While most of this work is of very high quality, the results are
complex. Current scientific understanding does not yet allow us to
Interpret the evidence in a single coherent framework. Even more
frustrating, it does not yet allow us to draw definite conclusions about
questions of possible risk or to offer clear science-based advice on
strategies to minimize or avoid potential risks.
To reduce
in the
workplace,
1.
Keep
2.
Arrange
3.
Do not coil
4.
Keep welding
practical.
5.
Connect work clamp to workpiece
The
.
magnetic fields
use
the
following
procedures:
cables close
cables to
or
together by twisting
one
drape
or
taping
side and away from the
cables around the
them.
operator.
body.
.
power
source
and cables
as
as
far away
as
close to the weld
as
possible.
About Pacemakers:
The
above
wearers.
procedures
are
also
Consult your doctor for
recommended
for pacemaker
complete informatIon.
OM-156 368
Page
3
SECTION 2-INSTALLATION
2-1.
2-2.
Installing Welding
Generator
Dimensions, Weights;And Operating Angles
Dimensions
Height
41 in
(1041 mm)
A
Do not exceed
running
Width
Depth
30 in
54-1/2 in
29 in
B
36-3/4 in
(1384 mm)
(737 mm)
9/l6in(l4mm)Dia.
Net
960 lb
Ship
1070 lb
(435 kg)
4 Holes
Sr-158 938
OM-1 56 368
Page
4
25
(933 mm)
Weight
C
operating angles while
engine damage will occur.
(762 mm)
A
C
or
(485 kg)
150
25
2-3.
Fuel
Consumption
Q.
~
-J
4.73
1,04
1.25
3.78
0.84
1.00
ITT I I IILII
~
7tt+- ; ~
-
,~,,
2.84
063
0.75
1.89
0.42
0.50
~
~
~
y__
0.95
0.21
025
0.00
0.00
0.00
~OLEJ
Rating
cc
I
I
I
I
I I I I II I
I
I
I
I
I
I
I
I
25
~)
75 1~ 125 150 175 20] 225 2~Q 275 30)
DC WELD AWERES AT 630% DUTY CYCLE
I
O
~
~
~
I
o
2-4.
POW~
A
I
I
I
I
I
~I
I
I
4
7
2
3
5
8
6
9
13
POWER KVA AT 130% DUTY CYCLE
I
I
11
12
I
I
I
SA-175 807
Label
Rating
EN 60974-1
U0
=
label shown includes op
receptacle in
tional 48 volt dinse
formation.
20A121 V
280A/31 V
20A/11V
280A121V
65V
35OHz
380V
1OkVA
1
50 Hz
220V
7kVA
1
50 Hz
48V
2.5kVA
50A
OM-156 368
Page
5
2-5.
Connecting Battery
OM-1 56 368
Page
6
And
Installing
Muffler
Pipe
2-6.
Engine
Prestart Checks
Check all fluids daily. Engine must
be cold and on a level surface.
Engine stops
if oil pressure is low.
A Heavy loading during first
50 hours will damage en
gine. Keep load less than
225A (weld) or 7 kVA (power)
for first 50 hours.
Ref. ST-159 219-D
2-7.
Weld
Output
Terminals And
Selecting
Cable Sizes
Total Cable
100 ft
(30 m)
1060%
Weld cable size
(AWG)
is based
on
either
a
Or Less
60
(Copper) Length
in Weld Circuit Not
150ft
200ft
(45 m)
(60 m)
r
Exceeding
250ft
300ft
350ft
400ft
(70 m)
(90 m)
(105 m)
(120 m)
100%
10100%
Duty
Cycle
Duty
Cycle
4
4
4
3
2
1
1/0
1/0
3
3
2
1
1/0
2/0
3/0
3/0
3
2
1
1/0
2/0
3/0
4/0
4/0
2
1
1/0
2/0
3/0
4/0
2-2/0
2-2/0
1
1/0
210
3/0
4/0
2-2/0
2-3/0
2-3/0
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
2-410
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
2-4/0
4 volts or less
drop
or a
current
density
Duty Cycle
of at least 300 circular mils per ampere.
S-0007-D
OM-156 366
Page
7
2-8.
Remote 14
Receptacle RC1 Information
REMOTE 14
Sockete
Socket Information
to socket G.
A
24 volts ac with
B
Contact closure to A completes 24 volts
respect
ac
contactor control
circuit.
A
~for 24 volts AC circuit.
G
Circuit
C
+10 volts dc
D
Remote control circuit
E
0 to +10 volts dc input command
respect to socket D.
K
Chassis
common
output
to remote control with
respect
to socket D.
common.
signal from
remote control with
common.
ST-Isa 934-B
*The
remaining
sockets
are
not used.
SECTION 3-OPERATING THE WELDING GENERATOR
3-1.
Symbols
OM-156 368 Page 8
And Definitions
3-2.
Front Panel Controls
8
9
1
2
7
Using
idle Lock Switch
2100 rpm (No Load)
3200 rpm (Load)
3200 rpm
Ret. ST-175 920-A
A Heavy loading during first 50 hours
will damage engine. Keep load less
than 225A (weld) or 7 kVA (power)
for first 50 hours.
1
Engine Control Switch Si
Use switch to operate glow plug (optional
see table), start engine, select speed, and
stop engine.
In Run/Idle
position, engine runs at idle
speed at no load, and weld/power speed
under load. In Run position, engine runs at
weld/power speed.
2
Idle Lock Switch S8
engine in idle speed dur
ing start-up (see table). Do not use ac re
ceptacles with switch in Idle position.
Use switch to lock
To Start: move Idle Lock switch to Idle posi
tion and Engine Control switch to Start posi
tion. Release. Engine Control. switch .when
engine starts. Do not crank engine while fly
wheel is turning. Move Idle Lock switch to
Run/Idle position after engine warms.
in arc starts, and reduce the chance of the
electrode freezing in the puddle. Set at
minimum for Tig welding.
To
Stop:
position.
turn
Engine
Control switch to
Hour Meter HM
3
Engine
4
Fuel
5
Engine Oil Pressure Light PL1
Gauge
Amperage
8
Voltmeter Vi
(Optional)
9
Ammeter Al
(Optional)
10
Remote
Amperage Control Switch S7
Use switch to select front panel
amperage control.
FG
Engine stops and light goes
sure
Stop
Control R4
7
on
If oil pres-
is too low,
11
Remote
or
remote
Output (Contactor) Switch S6
Use switch to control remote contactor if
connected to remote 14 receptacle RC1
-
6
(Dig) Control
Arc Force
Use control to
perage
as arc
R5
automatically increase am
length is decreased, to assist
A
Weld
output terminals
when switch S6 Is On
energized
and engine Is
are
running.
OM-l 56368
Page
9
3-3.
Duty Cycle
And
Overheating
4~fl
Duty Cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.
Exceeding duty cycle
damage unit and void
A
~.
ranty.
:
;
can
war
.
~-.
~-
2cXJ
40
3
50
8)
70
80
8)
fi)
Z DUTY CYCLE
35%
3-1/2 Minutes
Duty Cycle
Welding
At 280
Amperes
60%
6-1/2 Minutes
6 Minutes
Resting
100%
Duty Cycle
At 225
Continuous
3-4.
Remote
Duty Cycle At
250
Amperes
4 Minutes
Welding
Resting
Amperes
Welding
dutyl 5/95/SB-176
134
Amperage Control
r!1~
Weld output terminals
A
energized
when
are
Remote
switch is
Output (Contactor)
On and engine is running.
Remote 14
1
Receptacle RC1
Connect optional remote control to
RC1 (see Section 2-8).
1
I
0
1?
Mm
Max
A
Set Switches
....................~
Set Control
-*
(20
A
DC)
(100ADC)C ~
Adjust
Remote Control
Ref. ST-158 934-B / Ref. 5T-175 920-A
OM-156 368
Page
10
SECTION 4- OPERATING AUXILIARY EQUIPMENT
4-1.
Auxiliary
Power
Receptacles
6
4
5
35OHz
1-~50Hz
380V
220V
Ref. SC-175 913
(IJ~ Auxiliary power available at ac recep
tacles decreases as weld amperage in
creases.
1
380 V 15 A AC
2
220 V 16 A
3
220 V 16 A
Receptacle RC1
AC Receptacle RC2
AC Receptacle RC3
RC1 supplies 50 Hz three-phase power at
weld/power speed. Maximum output is 10
kVA/kW.
RC2 and RC3 supply 50 Hz single-phase
power at weld/power speed. Maximum
output from each receptacle is 3.3 kVA/kW.
Combined output of receptacles is limited to
10 kVA/kW output of generator. If maximum
output is exceeded, auxiliary equipment will
stop or not run properly.
Circuit Breakers CB1, CB2, And CB3
4
CB1 thru CB3 protect RC1 from overload. If
a circuit breaker opens, power is lost on one
phase and RC1 output drops. Voltage may
still be present at RC1. If all circuit breakers
open, RC1 output stops.
CB1 also protects RC2 from overload. If
CB1 opens, RC2 output stops.
5
Circuit Breaker CB1O
CB1O protects RC3 from overload. If CB1O
opens, RC3 output stops.
6
Ground Fault Circuit
GFCI1
Interrupter
GFCI1
provides ground fault protection for
RCI, RC2, and RC3.
7
48 V 50 A AC Dinse
And RC5
Receptacles RC4
(Optional)
RC4 and RC5 supply 50 Hz single-phase
power at weld/power speed. Maximum
output is 2.5 kVAIkW.
Connect
equipment neutral cable to E
(RC5) receptacle and equipment load cable
to U+ (RC4) receptacle.
8
Circuit Breaker CB4 (Optional)
CB4 protects RC4 from overload.
9
AuxIliary Power
While
Welding Table
OM-156 368
Page
11
SECTION 5- MAINTENANCE & TROUBLESHOOTING
5-1.
Routine Maintenance
A Stop engine
Recycle engine
before
OJ~ See also
nance
fluids.
.during
8 Hours
50 Hours
fi
100 Hours
Clean And Tighten
Battery Connections.
See Section 2-5
P
200 Hours
300 Hours
fi
4
500 Hours
Repair Or Repiace
Cracked Cabies
Blow Out Or Vacuum
inside.
During Heavy Service,
Clean Monthly
OM-156 368
Page
12
maintaining.
Engine Manual and Mainte
LabeL Se,vice engine more often
severe conditions.
UI VU
a,
p.
a,
C., CD
r a, 0
CD
std.
std.
h
h
250
300
std.
std.
h
h
100
200
ENGINE
DIES L
std.
h
8
std.
h
50
RD21
RUGEIN
0
cn0) C.) 0) 0) -u Co C
C.)
5-2.
Changing Engine Oil And Oil
Filter
Stop engine.
See engine manual for oiVfilter
change procedure.
Oil Fill
Caps (Use Either Cap)
Oil Drain Valve
Close oil drain valve and cap
before adding oIl and run
ning engine.
Oil Filter
Dipstick
Tools Needed:
~IIIIIII~
Ret. ST-159 219-D I Ref. ST-159 215-B! Ref. 5T-175 920A / Ref. S-0842
OM-156 368
Page
14
5-3.
Changing
Fuel Filters
5-4.
Servicing
Air Cleaner
Stop engine.
A Do not run engine without air
cleaner or with dirty element.
A
-
Use
only high pulsation-type
replacement filter listed on
maintenance label or engine
damage may occur.
Cap
1
Dust
2
Element
3
Housing
4
Dust Valve
To Clean air filter:
Wipe off cap and housing. Remove
cap and dump out dust. Remove
element and reinstall cap.
A
Do not clean
hose.
housing with
air
Clean element with compressed air
only. Keep nozzle
at least 1 In (25
from inside of element. Max.
air pressure: 30 psi (207 kPa). Do
~mm)
-ED
Blow
inspect
not remove plastic fins. Replace
element and valve if damaged.
Replace element yearly
cleanings.
or
after six
Reinstall element and cap
arrows
(cap
pointing up).
Ref. ST.175 92O~A / Ref. ST.159 219-D / Ref. S.0698.B
OM-156 368
Page
15
5-5.
Adjusting Engine Speed
tuning engine, check engine
speeds with a tachometer (see
table for no load speeds). If neces
saw, adjust speeds as follows:
After
Start
engine
and
run
until
warm.
Turn engine control switch to Run/
Idle position.
2
Idle
Speed
Screw
Loosen nut. Turn
runs
at idle
Turn
engine
position.
3
screw
until
speed. lighten
engine
nut.
control switch to Run
Swivel
Loosen nut and turn swivel until
engine
runs
at run
speed. Tighten
nut.
4
Shutdown Lever
5
Shutdown Lever Screw
Shutdown lever screw normally
does not require adjustment unless
tampered with.
Loosen nuts. Adjust screw so lever
hits screw and stops engine when
engine control switch is turned to
Stop position.
A
Do not loosen screw so much
that lever hits Internal stop or
engine damage may
Tools Needed:
OM-156 368
Page
16
occur.
5-6.
Overload Protection
fl~ If fuse
or
breaker continues to
open, contact Factory Autho
rized Seivice Agent.
Fuses
1
2
FuseF2
F2 protects
circuit.
2
battery
excitation
Fuse F3
F3 protects
circuit.
generator excitation
Replace any open fuses. Reinstall
panel before operating unit.
Circuit Breakers
3
Circuit Breaker CB5
CB5 .protects 24 volt ac output to
Remote 14 receptacle RC1.
4
Circuit Breaker CB6
CB6 protects fuel solenoid circuit.
5
Circuit Breaker CB7
CB7
protects
throttle
solenoid
circuit.
6
Circuit Breaker CB8
CB8 protects
Engine Control
switch and wiring harness.
7
Optional
Circuit Breaker CB9
CB9 protects optional
glow plug
system.
Press button to reset breaker.
Tools Needed:
-~
318,1/2in
Ret. 5T-159 215-B / ST-158 934-B
OM-156 368
Page
17
5-7.
Inspecting And Cleaning Optional Spark
Arrestor
Stop engine and allow
1
Spark Arrestor
2
Cleanout
Remove
to cool.
Plug
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 end
of exhaust pipe with fireproof
material.
2
I
Stop engine
and allow to cool.
Reinstall cleanout
plug.
Tools Needed:
~
3/8in
ST-8O1 154-B I Ref. ST-175 920-A
5-8.
A.
Troubleshooting
Welding
~$
Trouble
Remedy
Check fuses F2 and F3, and
No weld output.
Have
Factory
replace
Authorized Service
if necessary
Agent
(see Section 5-6).
check main rectifier and
capacitor C5.
Check and secure connectionsto Remote 14 Receptacle RC1.
Place Remote Output (Contactor) switch S6 in On position, or place switch in Remote 14
and connect remote contactor to Remote 14 receptacle RC1 (See Section 3-2).
Have
Low weld
Factory
Authorized Service
Check fuses F2 and F3, and
output.
Check and
Tune
Agent
replace if
check brushes and
open
adjust engine speed (see Section 5-5).
engine according
to
engine
~
Have Factory Authorized Service
fier SR3, and capacitor C5.
manual.
Check and adjust engine
Agent
position, or place
receptacle RC1.
check brushes and
slip rings,
speed (see Section 5-5).
~
Have
OM-156 368 Page 18
and circuit board PCi.
(see Section 5-6).
Place Remote Amperage Control switch S7 in Panel
and connect remote amperage control to Remote 14
High weld output.
slip rings,
position
Factory Authorized Service Agent check
main rectifier.
switch in Remote 14
main rectifier,
position
integrated
recti
Remedy
Clean and tighten weld output connections inside and outside unit.
Use
Be
dry, properly-stored
sure
Have
electrodes.
connection to work
Factory
piece is clean
Authorized Service
and
tight.
Agent check brushes, slip rings, main rectifier, integrated
rectifier
SR3, and capacitor C5.
at Remote 14
re-
Place Remote
Output (Contactor)
switch S6 in Remote 14
position (see Section 3-2).
.
Reset circuit breaker CB5
(see Section 5-6).
Power
Remedy
power
Reset
ground
fault circuit
Reset circuit breakers
Check
interrupter GFCI1 (see Section 4).
(see Section 4).
receptacles for continuity
Check fuses F2 and F3, and
Disconnect
Have
receptacles.
Factory
Authorized Service
Check and adjust
receptacles.
Factory
Check and
(see Section 5-6).
Agent check brushes, slip rings, relay CR5, and relay CR6.
replace
engine
to
Authorized Service
if necessary
(see Section 5-6).
manual.
Agent
check brushes,
rings,
and
integrated
rectifier SR3.
slip rings,
and
integrated
rectifier SR3.
slip
adjust engine speed.
Check receptacle
Have
if necessary
if necessary.
engine speed (see Section 5-5).
Tune-up engine according
receptacles.
replace
Replace receptacle(s)
equipment from receptacles.
Check fuses F2 and F3, and
Have
and proper connections.
Factory
wiring and
connections.
Authorized Service
Agent
check brushes,
.
~i~d*~.
Trouble
Engine
does not crank.
Remedy
Reset circuit breaker CBS
(see Section 5-6).
Check battery, and replace if necessary.
Check Engine Control switch Si and replace if necessary.
Check engine charging and starting systems
Engine
cranks but does not start.
~
Check fuel level
according
to
engine
service manual.
(see Section 2-6).
Reset circuit breaker CB6
(see Section 5-6).
I
Check oil level.
Engine stops
if oil pressure
gets
too low
(see
Section
2-6).
I
If
equipped with glow plug (optional),
Check
Engine
reset circuit breaker CB9
(see Section 5-6).
Control switch Si, and replace if necessary.
OM-156 368
Page
19
Trouble
Remedy
See
High Or
Low
engine
manual.
Check and adjust engine speed (see Section 5-5).
Engine Speed.
Engine
does not return to idle
Engine
idles but does not reach weld
speed.
Have Factory Authorized Service
control module.
Agent
check throttle solenoid TS1,
relay CR3, relay CR4,
and idle
relay CR3, relay CR4,
and idle
Reset circuit breaker CB7 (see Section 5-6).
speed.
Have Factory Authorized Service
control module.
.
Engine uses oil during run-in period;
wetstacking occurs.
Dry engine according
Battery discharges
Clean
between
uses.
to
engine
Agent
check throttle solenoid TS1
manual run-in
procedure.
~
battery, terminals,
and posts with
baking soda
~
Periodically recharge battery (approximately every
3
and water solution; rinse with clear water.
months).
Check engine charging system according to engine service manual.
Check Engine Control switch Si, and replace if necessary.
Replace battery.
Engine stopped
and cannot be
re-
Check fuel level
(see Section 2-6).
started.
Check circuit breaker CB8 (see Section 5-6).
Check oil level.
See
OM-156 368
Page
20
engine
Engine stops
manual.
if oil pressure gets too low
(see Section 2-6).
NOTES
OM-156 368
Page
21
SECTION 6- ELECTRICAL DIAGRAM
cQ~
CT
12
L3
360V1
~
Si
I
XXX
X
2
XXX
8
3
X
4
XX
x~cuxco TO ~B
r~n~
I
I
I
TERMNAL
1~~5
87>A)
85>8>~ I
32>c>~- I
2X8V
85>8>~-
L!.~>t
1~5~ ~
I 87>A>~
~
I
I
I
L_~>
65>O~4~
I
I
xi>c>~
>~
>~
)
>2
r ~
I
>~
L~i>
I
I
220V
8
5
24 48V
~ ~ j
~2>~ L~!i~i
2!.~3 ~
PLca/Fc8
~ ~1>~L
~5>~ ~2>~
~8>~ –L~3>~
Q~7>QT ~L~4>~L
~8>~ ~5>~
~~9>2
~5>~
4~ >~~7 >~
~8 >~L
~ ~~39>~
-~Q>-
I~6/~
~i
~2l>~- I
~
I
~
~TO~
TO LOWER FELD 0~NT
TO RASE FEW C~~NT
ICVE LEAD 31 TO TI-A
kC)VE LEAD 35 10 iT-A
ZTO
7
A~-~O
A
3T0
8
C
0
0
77
72
0
~p-~
C
0
~
d~~b
40
40
0
0
57
~
63
W~O
I~
I
0
~7
~7
73
01
41
0
5l~)
O~
vaTAIX
~TT,G
dV~b
42
42
42
~42
Figure
OM-156 368 Page 22
6-1. Circuit
Diagram
For
Welding
Generator
RcrnLcl
>;
>2
>3
rc7/P~.r7
>4
>6
>7
Icl~
I
N
N
C
A
r~
p
N
N
6
K
C
LAA__t~~_A__t..
9
K
A
PC2
C~PACfl~ 96AJ~)
N
I
~2~G22~I
A]
SD.172 300-0
OM-156 368
Page
23
SECTION 7- PARTS LIST
81
*Included
w/engine
Figure
OM-156 368 Page 24
7-1. Main
Assembly
0
-
\
\
\
\
\
\
\
-JO)
0) 01
CD
0)0)
-J C.)
0) -J
/
/
0) CD
/
/
/
/
/
/
/
/
/
/
/
-.1
0
UI0) C.)0) CD
0 CD 0
1%) 01
Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure
1
+163828
2
164507
3
+163958
171 053
176 104
165 839
167 340
107816
...7
172 295
172 297
172 296
...8....3T.. 172 661
173 734
166215
004214
...10....R2.. 128 862
11
166214
...12
165 840
162451
...13..
Shunt. 030 080
109 830
15... PC6.. 132 495
162 636
157026
172 133
19
172 134
20
168 037
108081
082316
114 923
...22
032 453
...23
164871
172 373
172 371
...24
124 253
BUSHING,tankfuel
HOSE ASSEMBLY, fuel tank
CLAMP, hose .375-.450 slifing green
CLAMP, hose .460-.545 slfttng
BRACKET, brace back RH
PAN, fuel splash
LABEL, use diesel fuel only
GROMMET, rbr neck filler
084 173
165 355
165 354
176 103
...27
107 343
...28
015603
166 723
166 638
164 552
176 109
166 634
144 802
010875
142 065
162 448
...36
164 318
176 230
...38
109 591
...39
173 931
603 767
OM-1 56368
Page
26
PANEL, side LH
PANEL, side LH rear
SPRING, latch w/knob
COVER, generator
LABEL, warning falling equipment
HINGE, concealed
COVER, engine
HOSE, SAE .250 ID x .500 OD (order by ft)
GAS, spring
BRACKET, flat mtg spring
BALL GAS SPRING, stud
BLOCK, stud connection
LINK, jumper
COVER, stabilizer
BUSHING, snap-in nyl 1.625 ID x 2.000mtg hole
RESISTOR, WW adj 375W 50 ohm
COVER, rectifier
FIREWALL, bottom
FIREWALL, top
SHUNT, meter
STAND-OFF, No. 8-32 x .250
CIRCUIT CARD, shunt
UPRIGHT, base center
GASKET, lift eye
HOLDDOWN, battery
BOLT, J stl .250-20 x 9.500
BATTERY, stor 12V 43Ocrk 75RSV
TERMINAL PROTECTORS, battery post
CABLE, bat pos
BOOT, insulator term post red
CABLE, bat neg
TANK, fuel l2gal (consisting of)
SENDER, fuel gauge
FITTING, stand pipe hose .250 x 8.875 Ig
FITTING,-hose-stI-barbed-M-1I4tbg
089 120
...32
Assembly
172 372
171 348
...25
7-1. Main
Quantity
CAP, tank fuel
ENCLOSURE, sides lower manifold
ENCLOSURE, sides upper manifold
BRACKET, brace back LH
LABEL, caution using either
DUCT, hotair
PIPE, exhaust flexible
CLAMP, muffler 2.000
MUFFLER, exhaust
UPRIGHT, base rear
PANEL, rear
LABEL, hot exhaust parts do not touch
CLAMP, muffler 1.750
PIPE, exhaust elbow
CAP, weather No. 3
1
1
2
1
1
2
1
2ff
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
2
1
2
1
1
1
1
1
1
:
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Item
No.
Dia.
Part
No.
Mkgs.
Description
Figure
167313
166 722
...43..
CR2,3. 090 104
173 366
...45....4T.. 174 901
.043138
46... CB9.. 147658
GP1
CR7
.
164938
.
155309
47... CB8..
115427
CB6,7.
083 432
48..
50
175897
170438
172375
52
127648
53
175895
...54... TS1.. 176625
172374
...56
Fig7-2
58
099542
176166
165271
60
176244
62
107816
63
*066113
..64
176541
*065 604
...66
...67
...68
.
010862
176467
010863
154 639
150 706
166 094
...72...
166 093
FS1.. 176 626
166 724
175 893
126 388
7-1. Main
Quantity
Assembly (Continued)
LATCH, elastic draw
BAFFLE, rear panel
RELAY, end 12VDC.SPST
PANEL, mtg components
BLOCK, term 30A 6P
2
1
2
1
1
COLD WEATHER DIESEL STARTING, (consisting
CIRCUIT BREAKER, man reset 1 P 30A 25OVAC
GENERATOR
HOSE, oil drain (included w/engine)
CLAMP, hose .583-.688c1p dia
FITTING, hose brs barbed fern 3/8tbg
+163074
176106
83
176105
176100
176006
...84
Fig7-4
...85... PCi.. 173421
1
2
2
1
1
1
1
1
ift
1
1
AIR ELEMENT
1
CLAMP, hose 1 .562-2.500cIp dia
HOSE, air cleaner
CLAMP, hose 1.1 25-3.000cIp dia
HOUSING, blower
ENGINE, Deutz elec Ruggerini
MOUNT, engine vibration
3
BRACKETmtgengine
1
SOLENOID, fuel
BRACKET, mtg solenoid
LINKAGE, spherical rod end 1/4-28 LH female
1
LABEL,
PANEL,
LABEL,
LABEL,
warning battery explosion
LABEL,
LABEL,
LABEL,
LABEL,
engine maintenance
warning general precautionary
rating (standard)
rating (48V optional receptacle)
173830
+162429 ..BASE
157797
1
VALVE, oil drain 3/8-18NPTF
SPRING CLIP, oil drain hose
HOSE, SAE .250 ID x .500 OD (order by ft)
FILTER, fuel inline
AIR CLEANER, intake (consisting of)
BATTERYBOX
82
1
3/8NPT
+166 952
176108
1
2
1
x
81
166635
1
1
1
*066 893
166 726
1
1
80
175 894
1
....GLOWPLUG,12V65A
CONTACTOR, solenoid 12VDC
CIRCUIT BREAKER, man reset 1P 25A 25OVAC
CIRCUIT BREAKER, man reset 1P 1OA25OVAC
LEVER, shutdown
SCREW, spot weld .250-20 x 3.000
LEVER, throttle
CLEVIS, throttle
LINKAGE, spherical rod end 1/4-28
SOLENOID, throttle & timing module
BRACKET, mtg throttle solenoid
NUT, .250-28 LH
LINKAGE, engine auto shutdown
LINKAGE, spherical rod end 10-32 female w/stud
BRACKET, mtg fuel filter
ENCLOSURE, muffler
FILTER, fuel element
172 392
of)
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
side RH
1
warning moving parts
2
EEC sound power level
2
1
1
1
1
1
CONTROL BOX w/COMPONENTS
CIRCUIT CARD, control main
1
1
OM-156 368
Page
27
Item
Dia.
No.
Mkgs.
Part
No
Figure
C1,3
C2,4
D1-3
STABILIZER
1
1
161 058
PANEL, front w/components
TRIM, panelfront bottom
PANEL, front lower
CIRCUIT CARD, filter HF
GROMMET, scr No. 8/10 panel hole
UPRIGHT, base front
HARNESS, wiring unit
HARNESS, engine
HARNESS, receptacle
KIT, label
137180
CLAMP, stl cushion .875dia
037957
SCR1,2 162516
028 388
...89
Fig7-3
164126
167658
92... PC5.. 148608
141 690
93
162447
172804
173654
172802
+When
ordering
a
1
163608
.
88
Assembly (Continued)
162442
.
048420
106641
.
7-1. Main
RECTIFIER, si diode (consisting of)
CAPACITOR, cer disc .Oluf 1000VDC
CAPACITOR, cer disc .01 uf 500VDC
DIODE,rect275A300VRP
THYRISTOR, SCR 300A 300V
CLAMP, thyristor
PANEL, air duct
162515
86
Quantity
Description
component originally displaying
a
precautionary label,
2
2
3
2
2
1
1
1
1
2
1
1
1
1
1
1
the label should also be ordered.
OPTIONAL
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-156 368
Page
28
Item
No.
Part
No.
Description
Figure
7-2. Generator
(Fig
7-1 Item
1
166770
STUD, stl .375-16
2
160943
ENDBELL
3
166727
4
053390
5
160566
+172462
172656
ROTOR, generator (consisting of)
BEARING, ball sgl row
FAN, rotor gen
STATOR, generator
GUARD, generator wire mesh
SPRING, ext
ADAPTER, engine
LABEL, warning moving parts
STUD, sti .375-16 x 17.375
HOLDER, brush elect
HOLDER, brush
6
7
8
9
...10
172674
165850
176106
170861
12
13
125548
005614
14
*126984
161306
16
047879
x
Quantity
56)
19.750
1
1
1
.
1
1
1
1
2
1
2
4
1
2
BRUSH w/SPRING
2
CAP, brushholder
BAR, retaining brushholder
2
1
9
7
10
11
>
14
ST-801 289
Figure
+When
ordering
*Recommended
a
component originally displaying
Spare
a
7-2. Generator
precautionary label,
the label should also be ordered.
Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-156 368
Page
29
Item
No.
Part
No.
Dia.
Mkgs.
Description
Figure
1
R4,5
2
Si
3
5
6
7
8
9
....
RC2,3
....
....
RC4,5
....
CB4
CB1-3,10
..
GFCI1
RC1
10
ii
....
12
PC2
CB5
13
14
16
18
19
20
PL1
...22
FG
...23
...24
...25
...26
HM
27
POTENTIOMETER, CP plain md lIT 2W 1K linear
SWITCH, ignition 5posn
169299
PANEL, front
SWITCH, tgl SPOT 15A 125VAC
RECEPTACLE, str 2P3W 1 6A 220V
RECEPTACLE, 48V dinse (consisting of)
RECEPTACLE, twlk fern Dinse 25 series
CIRCUIT BREAKER, man reset 1 P 50A 25OVAC
PANEL, receptacle European
PLATE, receptacle (order by model and serial number)
CIRCUIT BREAKER, man reset 1P 15A 25OVAC
176355
,043254
087640
141267
175915
...
....
Panel, Front w/Components (FIg 7-1 Item 89)
072623
172070
011609
S6-8
4
7-3.
139 266
Quantity
2
1
1
3
2
1
2
1
1
1
4
SENSOR, GFCI Test & Reset 50A 240V
RECEPTACLE, str 5P5W 16A 380V
COVER, receptacle GFCI
CIRCUIT CARD, connector/receptacle
CIRCUIT BREAKER, man reset 1 P 1 OA 25OVAC
NAMEPLATE, (order by model and serial number)
170391
CONNECTOR, circ protective cap size 20
021385.. BOOT, tgl switch lever
129525
RECEPTACLE, twlk fern Dinse 50170 series
082788
HOLDER, light md
*048 155
BULB, incand mm 14V
082789
LENS, light md red
118066
GAUGE, fuel elec 12V
119014
LEVER, switch black
097922
KNOB, pointer
097924
KNOB, pointer
072590
LOCK, shaft pot
172072
156830
154022
147554
083432
145247
1
1
1
1
1
1
1
3
2
1
1
1
1
1
1
1
2
METER, hour 12-24VDC
1
1
2
9
3
14
15
22
ST801 287
21
15
Figure
7-3.
Panel, Front w/Components
OPTIONAL
*Recommended Spare Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-156 368
Page
30
Item
No.
Dia.
Part
No.
Mkgs.
Quantity
DescEiption
Figure
7-4.
Component
Box
(Fig
7-1 Item
84)
135 184
DIODE BOARD
2
038 889
13
13
010494
STUD, pri board brs .250-20 x 1.750
WASHER, flat brs .257 ID x .640 OD
NUT, brs .250-20
TRANSFORMER, control 42/36V
RECTIFIER, integ 40A 800V
GROMMET, scr No. 8/10 panel hole
BUSHING, snap-in nyl 1.375 ID x 1 .75Omtg hole
026947
174 596
STAND-OFF, insul .250-20 x 1.000 Ig
RELAY, end 11OVDC DPST
173 069
RELAY,
...io
ii
171 345
TERMINAL BOARD, stator
MODULE, idle
12
098376
*073426
*142751
087111
010915
601 836
Ti
156 583
035 704
083 147
...5
...7
8....CR5,6....
9....CR1,4....
166719
F2
F3
15
...16
Cl
iT
087110
038772
601 219
end
Spare
1
2
5
1
4
2
12VDC SPDT
2
1
hook-up
1
HOLDER, fuse mintr
1
FUSE, mintr gI slo-blo 5A 125V
FUSE, mintr cer slo-blo 30A 125V
CLAMP, capacitor
1
CAPACITOR, elctlt 240uf 200VDC
BLOCK, term 20A 6P
LINK, jumper 20A
1
Figure
*Recommended
13
7-4.
Component
1
1
1
2
Box
Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-156 368
Page
31