Miller MILLER LEGEND Owner's Manual

 x September 1992 Form: OM-428G
| ег. Effective With Serial No. KC220664
OWNER'S
MANUAL
MILLER LEGEND"
CC, AC/DC Welding Generator
For SMAW,; With Accessory Equipment, GTAW And GMAW
225 A At 25 VAC Or 200 A At 25 VDC At 100% Duty Cycle
5 KVA/KW AC 60 Hz Auxiliary Power With Overload Protection
1 KVA/KW AC 100 Hz Auxiliary Power
Onan P218, Air-Cooled, Gasoline Engine
14-Pin Remote Control Receptacle
E Read and follow these instructions and all E E Give this manual to the operator.
safety blocks carefully. > A
E Have only trained and qualified persons
install, operate, or service this unit. B For help, call your distributor
® or: MILLER ELECTRIC Mfg. Co., P.O. Box
1079, Appleton, Wi 54912 414-734-9821
cover 8/92 — ST-140 091-A PRINTED IN USA
w Call your distributor if you do not understand
the directions.
®
MILLER’S TRUE BLUE™ LIMITED WARRANTY
Effective January 1, 1992
(Equipment with a serial number preface of “KC” or newer)
This limited warranty supersedes all previous MILLER warranties and is exclusive with no other guarantees or warranties expressed or implied.
LIMITED WARRANTY — Subjact to the terms and conditions below, MILLER Electric
Mig. Co., Appleton. Wisconsin, warrants to its original retail purchaser that new
MILLER equipment sold after the effective date of this limited warranty is free of de-
{ects in material and workmanship at the time it is shipped by MILLER. THIS WAR-
RANTY 15 EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FIT-
NESS.
Within the warranty periods listed below, MILLER will repair or replace any war-
ranted parts or components that fall due to such defects in material or workmanship,
MILLER must be notified in writing within thirty (30) days of such defect or failure, at
which time MILLER will provide instructions on the warranty claim procedures to be
followed.
MILLER shall honor warranty claims on warranted equipment listed below in the
event of such a failure within the warranty time periods. All warranty time periods
start on the date that the equipment was delivered to the original retail purchaser,
" Accessory Kits
* Replacement Parts
MILLER'S True Blue Limited Warranty shall not apply to:
1. ltems furnished by MILLER, but manufactured by others. such as engines or
trade accessories. These items are covered by the manufacturer's warranty, i
any.
2. Consumable components; such as contact tips, cutting nozzles, contactors
and relays.
3. Equipment that has been modified by any party other than MILLER, ar equip-
ment that has been improper'y installed, improperly operated or misused
based upon industry standards. or equipment which has not had reasonable
and necessary maintenance, or equipment which has been used for operation
and are as tollows: outside of the specifications for the equipment.
MILLER PRODUCTS ARE INTENDED FCR PURCHASE AND USE BY COMMER-
CIAL/INDUSTRIAL USEAS AND PERSONS TRAINED AND EXPERIENCED IN
THE USE AND MAINTENANCE OF WELDING EQUIPMENT.
1. 5 Years Parts - 3 Years Labor
* Qriginal main power rectifiers
2. 3 Years — Parts and Labor
* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources
* Semi-Automatic and Automatic Wire Feeders
* Robots
In the event of a warranty claim covered by this warranty, the exclusive remedies
shall be, at MILLER'S option; (1) repair; or (2) replacement; or, where authorized in
writing by MILLER inn appropriate cases, (3) the reasonable cost of repair or replace-
ment at an authorized MILLER service station; or (4) payment of or credit for the pur-
chase price (less reasonable depreciation based upon actual use) upon return of the
goods at customer's risk and expense. MILLER'S options of repair or replacement
wilbeF0.5,, Factory at Appleton, Wisconsin, or F.Q.B. ata MILLER authorized ser-
vice facility as determined by MILLER. Therefore no compensation or reimburse-
ment for transportation costs of any kind will be allowed.
3. 2 Years — Parts and Labor
* Engine Criven Welding Generators
(NOTE: Engines are warranted separately by the engine manufacturer)
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES FAOVIDED HEREIN
ARE THE SQLE AND EXCLUSIVE REMEDIES. IN NQ EVENT SHALL MILLER BE
LIABLE FOR SIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL
DAMAGES (INCLUDING LOSS QF PROFIT), WHETHER BASED ON CON-
TRACT. TORT QR ANY OTHER LEGAL THEORY.
4 1 Year — Paris anc Labor
+ Motor Driven Guns
* Process Controllars
* Water Coolant Systems
* HF Units ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WAR-
* Grids RANTY. GUARANTY OR AEPRESENTATION AS TO PERFORMANCE, AND ANY
+ Spot Welders REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL
* Load Banks THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, IN-
CLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS
FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.
»
SOX Transformers
* RAunning 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.)
Some states in the U.S.A. do not allow limitations of how long an implied warranty
lasts, or the exclusion of incidental, indirect, special or consequential damages, so
the above imitation or exclusion may not apply to you. This warranty provides spe-
5. 6 Months — Batteries cific Tegal rights, and other rights may be available, but may vary from state to state.
In Canada, legislation in some provinces provides for cerlain additional warranties
or remedies other than 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 De available, but may
vary from province to province.
o
6. 90 Days — Parts and Labor
+ MIG Guns/TIG Terches
* Plasma Cutting Torches
* Hemote Controls
RECEIVING-HANDLING
Before unpacking equipment, check carton for any damage that may have occurred during shipment. File any claims for loss or damage
with the delivering carrier. Assistance for filing or settling claims may be obtained from distributor and/or equipment manufacturer's
Transportation Department.
When requesting information about this equipment, always provide Model Designation and Serial or Style Number.
Use the following spaces to record Model Designation and Serial or Style Number of your unit. The information is located on the rating label
or nameplate.
Model
Serial or Style No.
Date of Purchase
miller 5/92
ERRATA SHEET January 8, 1993 FORM: OM-428G
Use above FORM number when ordering extra manuals.
After this manual was printed, refinements in equipment design occurred. This sheet lists exceptions
to data appearing later in this manual.
CHANGES TO SECTION 7 — ELECTRICAL DIAGRAMS |
Replace Figure 7-1. Circuit Diagram For Models Without Optional Features (see Page 2 on this Errata Sheet)
Replace Figure 7-2. Circuit Diagram For Models With Optional Features (see Page 3 on this Errata Sheet)
Replace Figure 7-3. Wiring Diagram For Models Without Optional Features (see Pages 4 and 5 on this Errata Sheet)
CHANGES TO SECTION 10 — PARTS LIST
Change Parts List as follows:
Dia. Part Replaced |
ne Mkgs. No. With Description Quantity
DB aaa Added ... 013367 .. LABEL, warmingmovingparts ..................... 1
. 39-7 . PC5,RC1,2 . 086022 . ++156025 .. CIRCUIT CARD, connector/receptacie
(Eff w/kKD344394) ............ e s0rerecere. 1
.39-8 ... C7-11....097749 .... Deleted.. Effw/KD344394
39-27 .... PC4 .... 115109 ... 148021 .. CIRCUIT CARD, filter HF (Eff w/KD344394) aria 1
C39 112 1200 Added ... 073756 .. STAND-OFF, No. 6-32 (Eff w/KD344394) ............ 2
. 39-.... PLG2..... Added . ++153 501 .. HOUSING PLUG & SOCKETS, (Eff w/KD344394)
(consistingof) .......... aa 11 Aa a aa ee 1
LL LL LL LL A LL a a Ra a a» 147 995 .... CONNECTOR, rect skt 22-18ga (Eff w/KD344394} ... 6
‚ 90-1 200000000000 011 198 .... Deleted
*First digit represents page no — digits following dash represent item no.
++Part of Remote Option.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
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OM-428G Page 3
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Figure 7-3. Wiring Diagram For Models Without Optional Features Effective With Serial No. KD344394
OM-428G Page 4
33H [GND)
DC
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OM-428G Page 5
ARC WELDING SAFETY PRECAUTIONS
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.
In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The
safety information given below is only a summary of the more complete safety information that will be found in the
Safety Standards listed on the next page. Read and foliow all Safety Standards.
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
QUALIFIED PEOPLE.
ARC WELDING can be hazardous.
Chipping and grinding cause flying metal. As welds
cool, they can throw off slag.
ELECTRIC SHOCK can kill. 5. Properly install and ground this equipment according to its
Touching live electrical parts can cause fatal shocks Owner's Manual and national, state, and local codes.
— or severe burns. The electrode and work circuit is 6. When making input connections, attach proper grounding
efectrically live whenever the output is on. The input conductor first. |
Pe when powar is an. Insemiautomatic orautomatie 7- Tum of all equipment when not in use.
wire welding, the wire, wire reel, drive roll housing, 8. Do not use worn, damaged, undersized, or poorly spliced
and all metal parts touching the welding wire are cables.
electrically Ive. Incorrectly installed or improperly в. Do notwrap cables around your body.
1 Do not touch live electrical parts. 10. Ground the workpiece to a good electrical (earth) ground.
2. Wear dry, hole-free insulating gloves and body protection. 11. Do not touch electrode f in contact with the work or ground.
3. Insulate yourself from work and ground using dry insulating . 12. Use only well-maintained equipment. Repair or replace
mats or covers. damaged parts at once.
4. Disconnect input power or stop engine before installing or 13. Wear a safety harness if working above floor level.
servicing this equipment. 14. Keep all panels and covers securely in place.
ARC BAYS can burn eyes and skin; ARC RAYS
> NOISE can damage hearing. 2. Wear a welding helmet fitted with a proper shade of filter (see
La В ANSI 249.1 listed in Safety Standards) to protect your face and
27 >| heateno svongurevabrmy ma con cumayes | Que When welding or watching
a and skin. Noi o from some processes can damage 3. Wear approved safety glasses. Side shields recommended.
hearing. 4. Use protective screens or barriers to protect others from flash
NOISE and glare; warn others not to watch the arc.
5. Wear protective clothing made from durable, flame-resistant
1. Use approved ear plugs or ear muffs if noise level is high. material (wool and leather) and foot protection.
FUMES AND GASES can be hazardous 5. Work in a confined space only if it is well ventilated, or while
to your health. wearing an air-supplied respirator. Shielding gases used for
Welding produces fumes and gases. Breathing welding can displace air causing injury or death. Be sure the
these fumes and gases can be hazardous to your breathing air is safe.
health. 6. Do notweld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to
1. Keep your head out of the fumes. Do not breathe the fumes. form highly toxic and irritating gases.
2. It inside, ventilate the area and/or use exhaust at the arc to
remove welding fumes and gases. 7. Do not weld on coated metals, such as galvanized, lead, or
3. If ventilation is poor, use an approved air-supplied respirator. cadmium plated steel, unless the coating is removed from the
4. Read the Material Safety Data Sheets (MSDSs) and the weld area, the area is well ventilated, and if necessary, while
manufacturer's instruction for metals, consumables, coatings, wearing anair-supplied respirator, The coatings and any metals
and cleaners. containing these elements can give off toxic fumes if welded.
WELDING can cause fire or explosion. 5. Watch for fire, and keep a fire extinguisher nearby.
AL Sparks and spatter fiy off from the welding arc. The 6. Be aware that welding on a ceiling, floor, bulkhead, or partition
PN flying sparks and hot metal, weld spatter, hot can cause fire on the hidden side.
workpiece, and hot equipment can cause fires and 7. Donotweld on closed containers such as tanks or drums.
pens. metal objects can cayo esparks. overheatines 8. Connect work cable to the work as close to the welding areaas
or fire. practical to prevent welding current from traveling long,
possibly unknown paths and causing electric shock and fire
1. Protect yourself and others from flying sparks and hot metal. hazards.
2. Do notweld where flying sparks can strike flammable material. 9. Da not use welder to thaw frozen pipes.
3. Remove all flammables within 35 ft (10.7 m) of the welding arc. 10. Remove stick electrode from holder or cut off welding wire at
If this is not possible, tightly cover them with approved covers. contact tip when nol in use.
4. Be alert that welding sparks and hot materials from welding can 11. Wear oil-free protective garments such as leather gloves,
easily go through small cracks and openings to adjacent areas. heavy shirt, cuffless trousers, high shoes, and a cap.
в FLYING SPARKS AND HOT METAL can 1. Wear approved face shield or safety goggles. Side shields
cause injury. recommended.
2. Wear proper body protection to protect skin.
sri 9/97
CYLINDERS can explode if damaged.
_| Shielding gas cylinders contain gas under high
pressure, If damaged, a cylinder can explode. Since
"Il gas cylinders are normally part of the welding
process, be sure to treat them carefully,
1. Protect compressed gas cylinders from excessive heat,
mechanical shocks, and ares.
2. Install and secure cylinders in an upright position by chaining
them to a stationary support or equipment cylinder rack to
prevent falling or tipping.
3. Keep cylinders away from any welding or other electrical
circuits.
4. Never allow a welding electrode to touch any cylinder.
5. Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
6. Turn face away from valve outlet when opening cylinder valve.
7. Keep protective cap in place over valve except when cylinder is
in use or connected for use.
8. Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
A WARNING
ENGINES can be hazardous.
bi. | ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
Use equipment outside in open, well-ventilated areas.
2. If used in a closed area, vent engine exhaust outside and
away from any building air intakes.
ENGINE FUEL can cause fire or
explosion.
Engine fuel is highly flammable.
ama
Stop engine before checking or adding fuel.
2. Do not add fuel while smoking or if unit is near any sparks or
open flames. .
3. Allow engine to cool before fueling. If possible, check and add
fuel to cold engine before beginning job.
4. Donotoverfill tank — allow room for fuel to expand.
5. Do not spill fuel. If fuel is spilled, clean up before starting
engine.
MOVING PARTS can cause injury.
Maving parts, such as fans, rotors, and beits can
Co cut fingers and hands and catch loose clothing.
1. Keep all doors, panels, covers, and guards closed and
securely in place.
2. Stop engine before installing or connecting unit.
3. Have only qualified people remove guards or covers for
maintenance and troubleshooting as necessary.
4. To prevent accidental starting during servicing, disconnect
negative {-) battery cable from battery.
5. Keep hands, hair, loose clothing, and tools away from moving
parts.
6. Reinstall panels or quards and close doors when servicing is
finished and before starting engine.
SPARKS can cause BATTERY GASES
TO EXPLODE; BATTERY ACID can
burn eyes and skin.
Batteries coniain acid and generate explosive
gases.
1. Always wear a face shield when working on a battery.
2. Stop engine before disconnecting or connecting battery
cables.
3. Do not allow tools to cause sparks when working on a battery.
4. Do not use welder to charge batteries or jump start vehicles.
5. Observe correct polarity (+ and =) on batteries.
STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and
skin.
The coolant in the radiator can be very hot and
under pressure.
1. Do not remove radiator cap when engine is hot. Allow engine
to cool.
2. Wear gloves and put a rag over cap area when removing cap.
3. Allow pressure to escape before completely removing cap.
PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-
dent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, Amefri-
can Welding Society Standard AWS F4.1, from American Welding So-
ciety, 550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire Pro-
tection Association, Batterymarch Park, Quincy, MA 02269.
sri 9/92
Safe Handling of Compressed Gases in Cylinders, CGA Pamphiet
P-1, from Compressed Gas Association, 1235 Jefferson Davis Migh-
way, Suite 501, Addington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale Bou-
levard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, from American National Standards
institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 516, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02268.
TABLE OF CONTENTS
SECTION 1 — SAFETY INFORMATION Li eones eyarearn, 1
SECTION 2 — SPECIFICATIONS |
2-1. VoltAmpere Curves .............—....0s9mrrrrireeeeaooeorenoerrarnarerai.
2
2-2. Duty Cycle ............e.es0e0oreea.daeracaronreracveraverarceredenrere naaa 2
2-3. Fuel Consumption ............. i... Le LL Le 4 4e 4 4e a 1e a ea era a 004 0 3
2-4. AC Auxiliary Power ......222000 2244 04e ea ae 4 RR KR a a a Lau 1 aa 0 3
SECTION 3 — INSTALLATION
3-1. Selecting A Location And Moving Welding Generator ...........e sere... rerero 4
3-2. Connecting The Battery RK tte ete eee eae 0 5
3-3. Engine Prestart Checks ...... iii i ee eee 6
3-4. Grounding The Welding Generator ........ noreeoo 6
3-5. Selecting And Preparing Weld Qutput Cables ............ ii... 7
3-6. Connecting ToWeld Output Terminals ......... iii ee. 8
3-7. Remote 14 Receptacle information And Connections (Optional) .................... 8
SECTION 4 — OPERATING THE WELDING GENERATOR ................................ 9
SECTION 5 - OPERATING AUXILIARY EQUIPMENT (60 Hz) ............................. 13
SECTION 6 — MAINTENANCE & TROUBLESHOOTING
6-1. Routine Maintenance ....... i ee eae eee 15
6-2. Servicing Air Cleaner oo. ean RAA 17
6-3. Replacing Fuel Filler .....1220004 0000440404 ed a a a ee 4 a a ee 4 0 ee a ee aa a a a a 0 0 17
6-4. Adjusting Engine Speed .....................00r0rrearaaecoaemanaearraronaroo 18
6-5. Replacing Battery Or Checking Battery Voltage .............22222000 044 a a neue 19
6-6. €6verload Protection ...........e.-ee.-.reerrorarararanecoarecroconrercarmerena 20
6-7. Troubleshooting ............e__.e-.eneorerareacaroadxranevinrvarierrerares 21
SECTION 7 — ELECTRICAL DIAGRAMS ...............e00m0oerereroneoaaoowrerare cara, 24
SECTION 8 — TUNGSTEN ELECTRODE
8-1. Selecting Tungsten Electrode . .. o.oo eee еоениоее 28
8-2. pPreparing Tungsten oo. eee eee n n 29
SECTION 9 ~ AUXILIARY POWER GUIDELINES
9-1. How Much Power Does Equipment Require? ........._—._eeerrasorerare re remar, 30
9-2. How Much Power Can Generator Supply? ..........e_eomcecesecsnrrerea,rereavena 32
9-3. Typical Connections To Supply Standby Power . ....... cc iii. . 33
9-4. Selecting Extension Cord «oe eee a a a a a a eee 34
SECTION 10 — PARTS LIST |
Figure 10-1. Main Assembly .............eeerredrecorecarareerorermaunecorodroaero 36
Figure 10-2. Panel, Front w/Components ............e0eXeemer0esederera enero neranranoo 38
Figure 10-3. Generator... .............. AA a 4 a 4 a a a a a ere ee ee 40
Figure 10-4. Switch, Selector .. 1.122044 00 4444 eee ea a 4 ea ee 48 0 ea a ea 8e ieee 41
Figure 10-5. Control Panel, w/Components ........12022000 00404 644 0 aa 4 a ee aa eens 42
Fiqure 10-6. Remote Control, Option .......212002002000 0000444 a 4 ee ee ieee 43
OM-428G — 9/92
SECTION 1 — SAFETY INFORMATION
mod{.! 6/92
a.
E Read all safety messages throughout this manual.
E Obey all safety messages to avoid injury.
B Learn the meaning of WARNING and CAUTION.
e Do not touch live electrical parts.
> * Disconnect input power
A |
installing or serviging.
Jr
1 Safety Alert Symbol
2 Signal Word
WARNING means possible death
or serious injury can happen.
CAUTION means possible minor
ZA | MOVING PARTS can injure. infury or equipment damage can
® Keep away from moving parts. happen.
<> ® Keep all panels and covers closed 3 Statement Of Hazard And
when operating. Result
4 Safety Instructions To Avoid
Hazard
5 Hazard Symbol (If Available)
READ SAFETY BLOCKS at start of
Section 3-1 before proceeding.
6 Safety Banner
Read safety blocks for each sym-
bol show.
7 NOTE
-— NOTE (7
Turn OFF switch when using high frequency.
Special instructions for best oper-
ation — not related to safety.
Fiqure 1-1. Safety Information
SECTION 2 — SPECIFICATIONS
Table 2-1. Welding Generator
Specification
Description
Type Of Output
Output Current
Rated Weld Qutput
Amperage Range
Max. Open-Circuit Violtage
Welding Processes
Auxiliary Power While Welding
Maximum 60 Hz Auxiliary Power
Engine
Engine Speed
Fuel Tank Capacity
Overall Dimensions
Weight
Options
Constant Current (CC)
Alternating Current (AC) Or Rectified Direct Current (DC)
225 Amperes At 25 Volts AC; 200 Amperes At 25 Volts DC At 100% Duty Cycle
(See Section 2-2)
35-225 À AC; 25-200 À DC
80 Volts AC: 72 Volts DC
{Maximum OCV may not be actual running values as shown on V-A curves.)
Shielded Metal Arc Welding (SMAW); With Accessory Equipment, Gas Tungsten
Arc Welding (GTAW) And Gas Metal Arc Welding (GMAW)
Single-Phase, 1 kVA, 115 Volts AC, 9 Amperes, 100 Hz
Single-Phase, 5 kVA, 120/240 Volts AC, 42/21 Amperes, 60 Hz
(4 kVA, 115/230 Volts AC, 34/17 Amperes For 50 Hz models)
Onan P218 Air-Cooled, Two-Cylinder Gasoline Engine (See Engine Manual)
Weld Speed: 3000 rpm; Power/idle Speed: 1860 rom (1650 rpm For 50 Hz Models)
7.5U.S5. gal {26 L}
See Fiqure 3-2
Net: 575 lbs (261 kg); Ship: 600 165 (272 Кб)
See Rear Cover
OM-428 Page 1
2-1. Volt-Ampere Curves
AC VOLTS
DC VOLTS
42 F
RANGES
— A = MIN-40
B 40-55
CL - 55-75
0 - 72-105
Е - 90-135
Е - 115-165
С - 140-MAX
=
“
N - -
x F
‘ `
E \
\ \
i x
T I | 1 | 1 I
180 200 240 280
AC AMPERES
RANGES
A = HIN-£40
В - 19-55
с = 55-75
D - 70-105
Е - 90-135
For 115-165
E — 14С-МАХ
o so Но 195 200 one sos Bo 400 450 500
DC AMPERES
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities
ofthe welding generator. Curves of
other settings fall between the
curves shown.
rsb1.1 10/91 — SB-115 529-А / 58-115 §28-A
Figure 2-1. Voit-Ampere Curves
2-2. Duty Cycle
WELD AMPERES
RATED OUTPUT =
10 15 20 = 30 40 50 60 70 80 99 100
x DUTY CYCLE
Duty cycle is how long the unit can
operate within a ten minute period
without causing overheating or
damage.
This unit is rated at 100% duty
cycle allowing continuous opera-
tion.
sb1.1 2/92 — 55-115 570
OM-428 Page 2
Figure 2-2. Duty Cycie Chart
2-3. Fuel Consumption
in LITERS/HR.
m IMP.GAL,/HR.
The fuel consumption curve shows
o U.S. GAL. /HR.
na
DC WELD 3000 RPM
60 HZ POWER 1860 RPM
0.50
0.25
0 25 50 75 100 125 150 175 200 225 250
OC WELD AMPERES AT 100% DUTY CYCLE
| i i I
|
2 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0
POWER KVA AT 100% DUTY CYCLE
typical fuel use under weld or pow-
er loads.
reb2,1 10/91 — SB-115 572
Figure 2-3. Fuel Consumption Curve
2-4, AC Auxiliary Power
AC POWER VOLTS
260
240
220
200
[ 20
The ac power curve shows the aux-
liary power in amperes available at
the 120 and 240 volt receptacles.
120
HOF
L 1 L | | Е |
100
О
10 20 30 40 50 60 70 80
AC POWER AMPERES AT 120V.
= 10 15 20 25 30 35 40
AC POWER AMPERES AT 240V,
r553.1 2/92 — 58-115 571
Figure 2-4. AC Power Curve For 120 And 240 Volt Receptacles
OM-428 Page 3
SECTION 3 — INSTALLATION
3-1. Selecting A Location And Moving Welding Generator
ENGINE EXHAUST GASES can kiil.
e Do not breathe exhaust fumes.
HOT ENGINE EXHAUST AND EXHAUST
PIPE can cause fires.
A WARNING
3
e Use in open, well-ventilated areas, or vent exhaust + Keep exhaust and pipe away from flammables.
outside and away from building air intakes.
FALLING EQUIPMENT can cause
serious personal injury and equipment
damage.
e Useliftingeyetoliftunitoniy, NOT running gear, gas
cylinders, trailer, or any other heavy options,
accessories, or devices.
e Use equipment of adequate capacity to lift the unit.
ENGINE EXHAUST SPARKS can cause
fire.
e Useonly U.S. Forestry Department approved spark
arrestor and comply with all local, state, and federal
laws.
s A spark arrestoris mandatory inall National Forests
and in grass, brush, or forest covered lands in
California, Oregon, and Washington. Check with
state and local authorities in other areas.
8 Properly maintain the spark arrestor.
e Stop engine and allow exhaust system to cool down
before servicing spark arrestor,
e Service spark arrestor away from flammables.
TILTING OF TRAILER can result in
personal injury or equipment damage.
e [nstall unit properly on trailer {if applicable)
according to trailer manual.
marnt.1 12/91
1 18in. (457 mm) Open Space
On All Sides
2 Lifting Eve
Use lifting eye to move unit.
3 Exhaust Pipe
4 Lifting Forks
if using lifting forks, extend forks
out opposite side of base.
Ref, 57-152 263
Figure 3-1. Location And Movement Of Welding Generator
F
| Inches |Millimeters
E —
| A 31-5/8 803
B 18 457
C 45 1143
D Engine
End D 16-1/2 419
E 32-3/4 1143
El F 1316 21
OM-428 Page 4
Fiqure 3-2. Overall Dimensions And Base Mounting Hole Layout
© OC Engine
о © ~~ End
25° PS AR ‘ e |
=
25 PSN
1 Trailer Hitch
Install unit onto trailer according to
trailer manual.
5-0024-5
Figure 3-3. Maximum Welding Generator Tilt Angles And Trailer Mounting
3-2. Connecting The Battery
A WARNING
* Stop engine before disconnecting or connecting battery cables.
* Always wear a face shield and proper protective clothing when working on a battery.
« Do not allow tools to cause sparks when working on a battery.
SPARKS can cause BATTERY GASES TO EXPLODE; BATTERY ACID can burn eyes and skin.
rearn2.1 9/91
OFF
RUN
RUN/IDLE
| E
o
Tools Needed:
Ie 38in., 1/2 in.
57-144 B39-B / Ref. ST-136 883-À / Ве!. 5-0756-В
1 Engine Control Switch
Place switch in the OFF position.
2 Bolt
3 Rear Panel
Remove bolts, and pull out rear
panel.
4 Positive (+) Battery Terminal
5 Positive (+) Battery Cable
Connect positive cable first.
6 Negative (-) Battery Terminal
7 Negative (-) Battery Cable
Connect negative cable last.
Reinstall rear panel.
If engine will not crank, check bat-
tery voltage according to Section
6-5.
Figure 3-4. Connecting The Battery
MAMAR Paña E
3-3. Engine Prestart Checks
4 WARNING
ENGINE FUEL can cause fire or
explosion.
e Stop engine before fueling.
e Do not fuel while smoking or near sparks or flames.
® Do not overfill tank; clean up any spitled fuel.
REMOVE FUEL CAP SLOWLY; FUEL
SPRAY may cause injury; FUEL may be
under pressure.
* Rotate fuel cap slowly and wait until hissing stops
before removing cap.
rwarm3.1 4/51
\
1 Oii Dipstick
Check oil level after fueling with
unit on level surface. If oil is not up
to full mark on dipstick, add oil (see
Figure 6-1). Engine stops if oil
pressure gets too low (see
Table 6-4).
2 Fuel Tank Cap
Add fresh fuel before starting en-
gine the first time (see Figure 6-1).
Fill fuel tank within 1/2 in. (13 mm)
from top. Check fuel level on à cold
engine before use each day.
rsb4.1* 4/92A — ST-151 983
Fiqure 3-5. Fuel And Oil Checks
3-4. Grounding The Welding Generator
~~]
115V 9A 100HZ AC
WHILE WELDING
|| | TOOLS
AND
LIGHTS
ONLY
0
CAUTION: REFER
TO OWNERS MANUAL
— GROUND
=
N ————
Tools Needed:
I—— 1/2 п.
1 Equipment Grounding Termi-
nal
Generator neutral connected to
frame. Connect equipment
grounding terminal to proper earth
ground. Meet National Electrical
Code and all other code require-
ments.
rsb5.1 10/91 - Ref. ST-136 883-A
Figure 3-6. Equipment Grounding Connection
OM-428 Page 6
3-5. Selecting And Preparing Weld Output Cables
1 Weld Output Cable
Determine total cable length in
weld circuit and maximum welding
amperes. Use Table 3-1 to select
proper cable size.
Use shortest cables possible.
Do not use damaged cables.
2 Terminal Lug
Use lugs of proper amperage
capacity and hole size for connect-
ing to work clamp, wire feeder or
electrode holder, and weld output
terminals.
3 Wire Feeder
4 Insulated Electrode Holder
5 GTAW Torch
Install according to manufacturer's
instructions.
6 Work Clamp
Install onto work cable.
10 ft. (3 m) >
el For Example,
Total Cable
Length in Weld
Circuit = 20 ft, (6 m)
16 ft. (3 m)
Tools Needed:
Tt or DD
SbE.5 8/92 — S-0752
Figure 3-7. Selecting And Preparing Weld Output Cables
Table 3-1. Weld Cable Size*
Total Cable (Copper) Length In Weld Circuit Not Exceeding*
150 ft. 200 ft. 250 ft. 300 ft. 350 ft. 400 ft.
100 ft. (30 m) Or Less (45 m) (60 m) (70 m) (90m) | (105m) | (120 m)
ans | tore Tare os тт ок вау бу
100 4 4 4 3 2 1 1/0 | 1/0
150 3 3 2 : 1/0 2/0 3/0 3/0
200 3 2 1 1/0 2/0 30 4/0 4/0
250 2 : 1/0 2/0 3/0 4/0 2.2/0 2.2/0
300 ; 1/0 2/0 3/0 ajo 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
“Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of not more than 300 circular mils per ampere. Use weld cable with
insulation rating equal to or greater than the open-circuit voltage of the unit. 5-0007-B
OM-428 Page 7
3-6. Connecting To Weld Output Terminals
4 WARNING
ELECTRIC SHOCK can kill.
es Do not use both AC and DC output terminals at the same time.
Disconnect weld cables from set of output terminals not in use.
Always wear dry insulating gloves.
Do not touch live electrical parts.
Stop engine before making any weld output connections.
Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling.
Use AC output ONLY if required for the welding process.
If AC output is required, use remote output control if present on unit.
Read Safety Precautions at beginning of this manual. rwarnd 1 10/91
Ig
1 AC Work Weld Output Termi-
nal
2 AC Electrode Weld Quiput
Terminal
3 DC Negative (-) Weld Output
Terminal
4 DC Positive (+) Weld Output
Terminal
For Direct Current Electrode Posi-
tive (DCEP), connect work cable to
DC— terminal and electrode holder
cable to DC+ terminal.
. For Direct Current Electrode Nega-
A Use ONLY one set of terminals at a time. tive (DCEN), reverse cable con-
Tools Needed: nections.
de Main,
Ref. ST-136 883-A
Figure 3-8. Weld Output Connections
3-7. Remote 14 Receptacie Information And Connections (Optional)
+ Remote 14 Receptacle RC7
2 Keyway
3 Plu
yf g
4 Threaded Coltar
2 To connect to receptacle, align key-
way, insert plug, and tighten
threaded collar.
Socket information:
Ч Remote Contactor
AB Caontact closure completes the 24 volts ac contactor
control circuit.
Remote Amperage Control
Co Command reference; +10 volts de.
D Control circuit common.
E Input command signal (potentiometer wiper 0-10 volts
de source); 0 to +10 volts de.
The remaining sockets are not used.
sb7.1* 4/92 — Ref. ST-136 883-A / Ref. 5-0004-A / S-0628
Figure 3-9. Remote 14 Connections
OM-428 Page 8
SECTION 4 — OPERATING THE WELDING GENERATOR
A WARNING
+
ELECTRIC SHOCK can kill.
e Do not touch live electrical parts.
Always wear dry insulating gloves.
Insulate yourself from work and ground.
Stop engine before installing or servicing.
Keep all panels and covers securely in place.
ENGINE EXHAUST GASES can kill.
® Do not breathe exhaust fumes.
* Usein open, well-ventilated areas, or vent exhaust
outside and away from any building air intakes.
WELDING can cause fire or explosion.
Do not weld near flammable material.
Watch for fire; keep extinguisher nearby.
Do not locate unit over combustible surfaces.
Do not weld on closed containers. |
Allow work and equipment to cool before handling.
++ + + ©
ENGINE FUEL can cause fire or explo-
sion.
e Stop engine before fueling.
® Do not fuel while smoking or near sparks or flames.
® Do not overfitl tank; clean up any spilled fuel.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
e Wear welding helmet with correct shade of filter.
e Wear correct eye, ear, and body protection.
MOVING PARTS can cause injury.
# Keep away from moving parts such as fans, belts,
and rotors.
a Keep all doors, panels, covers, and guards closed
and securely in place.
FUMES AND GASES can be hazardous.
e Keep your head out of the fumes.
e Ventilate area, or use breathing device.
e Read Material Safety Data Sheets (MSDSs) and
manufacturers instructions for material used.
MAGNETIC FIELDS FROM HIGH CUR-
RENTS can affect pacemaker operation.
e Pacemaker wearers keep away.
e Wearers should consult their doctor before going
near any welding operations.
See Safety Precautions at beginning of manual for ba-
sic welding safety information. rwam5.1 10/91
1 2
\
«a
7
©
©
S
За
añ
a
a 9 © ©
o
|
a
NARA
м
7
©
© © ©
&
—
1
=
3
Ampere Ranges Switch
Fine Amperage Control
Engine Hour Meter (Optional)
Idle Lock Switch
Engine Control Switch
Choke Control
Circuit Breaker CB3
115V 9 A100 Hz AC Recep-
tacle
Remote Control Switch (Op-
tional)
O 4 © NU hb & N —=
=
=
co
NAN NN
57-140 092-A
Figure 4-1, Controls
OM-428 Page 9
1 Insulating Gloves
2 Safety Glasses With Side
Shields
3 Welding Helmet
Wear dry insulating gloves, safety
glasses with side shields, and aweld-
ing helmet with a correct shade of fil-
ter (see ANSI 249.1).
sb3.1 10/91
Figure 4-2. Safety Equipment
1 Tools Needed:
=
1 Work Clamp
Use wire brush or sandpaper to clean
metal at weld joint area. Use chipping
hammer to remove slag after welding.
Connect work clamp to a clean,
paint-free location on workpiece, as
close to weld area as possible.
sb4.1 5/92
Figure 4-3. Work Clamp
ARCING can damage switch.
# Do not change AMPERE RANGES switch position while welding.
Arcing inside switch can damage contacts, causing switch to fail. mam6.1 9/91
,2 1 Ampere Ranges Switch
в Use switch to select weld amperage
50 range.
40 60
/ 7 2 Fine Amperage Control
au 70 Use control to adjust amperage with-
in. range selected by AMPERE
80 RANGES switch. Numbers around
control are for reference only.
90
о __ А 100
FINE AMPERAGE,
Ref. ST-136 883-A
ELECTRIC SHOCK can Kill.
® Do not touch live electrical parts.
* [Do not touch weld output terminals when engine is running.
® [Do not touch electrode and work clamp at the same time.
mem7.1 9/91
1 Remote Control Switch
Use switch to select way of control-
ling unit output.
For front panel control, place switch
in PANEL/ON position,
For remote control, place switch in
REMOTE 14 position (see Section
3-7).
Figure 4-5. Remote Control (Optional)
OM-428 Page 10
==
NENA À
E
READ SAFETY BLOCKS at start of Sections
4 and 5 before using IDLE LOCK switch.
IDLE LOCK
9
UNLOCK LOCK
OFF
©
RUN/IDLE
1 Idle Lock Switch
To keep engine at powersidie
speed, place switch in LOCK posi-
tion.
In the UNLOCK position, the En-
gine Control switch and optional
Remote Control switch determine
engine speed.
2 Engine Control Switch
Use switch to start engine, select
engine speed, and stop engine.
To start, rotate switch to START po-
sition and release as soon as en-
gine starts. Do not engage starter
while flywheel is rotating.
In RUN/IDLE position, engine runs
at powerfidle speed with no load
applied, and weld speed with a load
applied.
In RUN position, engine runs at
weld speed all the time.
To stop engine, rotate switch to
OFF position.
3 Choke Control
Use control to vary fuel-air mixture
to engine. Pull fully out before start-
ing engine. As engine warms up,
slowly push in.
Figure 4-6. Engine Controls
4 WARNING
a > BUILDUP OF SHIELDING GAS can harm health or Kill.
® Shut off shielding gas supply when not in use.
wamt.1 9/91
OR
Shielding Gas Cylinder
Valve
o MN —
Gun Trigger
4 Foot Control
Open valve on cylinder just before
welding.
Gun trigger or foot control tums
weld output and gas flow on and
off.
Close valve an cylinder when fin-
ished welding.
505.2 2/92 — 5-0621-C
Figure 4-7. Shielding Gas
OM-428 Page 11
á CAUTION
IMPROPER FREQUENCY can damage auxiliary equipment.
® Do not operate equipment designed for 50/60 Hz or 60 Hz from this receptacle.
и
HSY SA TCOHZ AC
WHILE WELDING
0 | | mas
ONLY
0
CAUTION: REFER
TO OWNERS MANUAL
GROUND
==
1 115V 9 A 100 Hz AC Recep-
tacle
This receptacle supplies single-
phase power at weld speed (see
Figure 5-3). Total output available
IS 1 KVA/kKW.
2 Circuit Breaker CB3
CB3 protects receptacle from over-
load. If CB3 opens, output to this
receptacle stops. Press button to
reset.
Figure 4-8, 100 Hz Auxiliary Power Receptacle
e
|
XX
offollollo ol
1 Engine Hour Meter
Use meter to check total operating
hours (see Section 6-1). This meter
operates only when engine is run-
ning.
rsb6.1 2/92
Fiqure 4-9. Engine Hour Meter (Optional}
Install & Install & Prepare Put On
Connect Wire Feeding Personal Say) Set Controls
Equipment System Equipment
Turn On
Auxiliary
Equipment
Wire Feeder
Turn On
Begin Welding
Turn On
Shielding Gas Start Engine
rsb7,1 4/92
Figure 4-10. Sequence Of Gas Metal Arc Welding (GMAW)
Install & Select
Connect Electrode
Equipment
Put On Turn On
Personal Safety Set Controls Start Engine Auxiliary
Equipment Equipment
Insert
Electrode Begin Welding
Into Holder
rsbg.1 4/92
Figure 4-11. Sequence Of Shielded Metal Arc Welding (SMAW)
OM-428 Page 12
Install & Install & Connect Select Insert Put On
; Connect High-Frequency Tungsten Tungsten Personal Safety Set Controls
Equipment Unit (See Section 8) Into Torch Equipment
Turn On Turn On Turn On
Shielding Gas Start Engine Auxiliary High-Frequency Begin Welding
Equipment Unit
Figure 4-12. Sequence Of Gas Tungsten Arc Welding (GTAW)
rsb9,1 4/95
SECTION 5 — OPERATING AUXILIARY EQUIPMENT (60 Hz)
A WARNING
ELECTRIC SHOCK can kill, | ELECTRIC SPARKS can cause fire.
® Do not touch live electrical parts. ® If using auxiliary power only and not welding,
e Siop engine before making internal inspection or disconnect both welding cables to prevent live
electrode from causing electric shock and fire
hazards.
* Watch for fire.
e Keep a fire extinguisher nearby, and know how to
use it.
The weld output terminals are electrically energized
when the engine is running and the contactor, if
applicable, is energized.
LOW VOLTAGE AND FREQUENCY can
damage electrical equipment.
reconnection.
> e Ground generator according to all applicable
national, state, and local codes.
* (Connect equipment grounding terminal to a proper
earth ground.
e
+
® Do not connect to any electrical distribution system
normally supplied by utility power unless a proper
transfer switch and grounding procedure are
employed (see Section 9).
MOVING PARTS can cause serious
injury. e Turn off or unplug all electrical equipment
e Keep away from moving parts such as fans, belts, connected to auxiliary power receptacles before
and rotors. starting or stopping the engine.
e Keep all doors, panels, covers, and guards closed When starting or stopping, the engine has low speed
and securely in place. which causes low voltage and frequency. ayamaı 9/91
NOTE [7 For 50 Hz units, each duplex receptacle (Figure 5-1, Item 1) supplies 115 volts ac,
17 amperes of single-phase power, and the twistlock receptacle (3) supplies 230
volts ac, 17 amperes of single-phase power.
2 1 120 V 21 A AC Duplex Re-
ceptacles RC1 And RC2
A
a
; 2 Circuit Breaker CB1 And CB2
A
A 1
€
5 3 240 Y 21 A AC Twistlock Re-
1 | ceptacle RC3
$ 5
57-140 D92-A
Figure 5-1, Auxiliary Power Receptacle And Circuit Breaker Location
CM-428 Page 13
3
|
| POWER OVERLOAD RESET
| = (© © =
fo NEUTRAL BONDED Y
AN 2
7
S e а 7 AN e ©
„ет
Ч ‚Ах У = WATTS om Loa ooo ro POWER USE EXPLANATION. J
}
|
4
1 120 \ 21 A AC Duplex Receptacles RC1 And RC2 3 Circuit Breakers CB1 And CB2
CB1 and CBZ protect the receptacles from overload. 1f CBA
or CB2 open, not all receptacles will work. Press button to
reset breaker.
4 Total Auxiliary Power Qutput
These receptacles supply 60 Hz single-phase power at
power/idle speed (see Figure 5-3). Maximum output from
each receptacle is 2.5 kVA/KW.
. Combined output of receptacles limited to 5 kVA/KW output
2 240 V 21 A AC Twistlock Receptacle RC3 of the generator.
This receptacle supplies 60 Hz single-phase power at pow- EXAMPLE: if 21 Ais drawn from a 120 V receptacle, only
er/idle speed (see Figure 5-3). Maximum output is 5.0 kVA/ 10 À is available at 24G V receptacle:
kW. (120 V x 21 A) + (240 V x 10 A) = 5.0 KVA/KW Ref. ST-136 883-A
Figure 5-2. 60 Hz Auxiliary Power Receptacles And Circuit Breakers
p 5 1 60 Hz Auxiliary Power Receptacies supply power when
^^
a -
8 6 = | these controls are set as follows:
When Welding | When hat
1 A = 3
| O 4 2 Idle/Lock Switch Position g y
LOCK UNLOCK
— 5
5 E с Switch RUN/IDLE RUN/IDLE
3 Engine Control Switc
ama mm 7 x — Position NS NS
ee ee ©) © © ©
НОНО ООВ НйНйы NM 7
4 Fine Amperage Control - — any
© © < © roster DAS Рен
7 \
0 100
PANEL PANEL
5 Remote Cantrol Switch
(Optional) Position | ON | ON
57-140 ©92-А
Figure 5-3. Auxiliary Power Control Settings
See Section 9 Install & Place IDLE LOCK\ \ If Applicable, Place Place Engine
Auxiliary Power Connect Switch In pt. Remote Switch Start Engine Control Switch In >
Guidelines Equipment LOCK Position In PANEL/ON RUN/DLE Position
Turn On
Auxiliary Begin Operation
Equipment
rsb11.1* 4/02
Figure 5-4. Sequence Of Auxiliary Equipment Operation
OM-428 Page 14
SECTION 6 — MAINTENANCE & TROUBLESHOOTING
A WARNING
—
ELECTRIC SHOCK can kill.
® Do not touch live electrical parts.
Always wear dry insulating gloves.
ENGINE FUEL can cause fire or explo-
sion.
e Stop engine before fueling.
* Do not fuel white smoking or near sparks or flames.
® Do not overfill tank; clean up any spilled fuel.
MOVING PARTS can cause injury.
* Keep away from moving parts such as fans, belts,
and rotors.
* Keep all doors, panels, covers, and guards closed
and securely in place.
Insulate yourself from work and ground.
Stop engine before installing or servicing.
Keep all panels and covers securely in place.
ENGINE EXHAUST GASES can kill.
* Do not breathe exhaust fumes.
# Usein open, well-ventilated areas, or vent exhaust
outside and away from any building air intakes.
HOT PARTS can cause severe burns.
e Allow cooling period before servicing.
* Wear protective gloves and clothing when working
on a hot engine.
Maintenance to be performed only by qualified
Persons. rwarm9.1 10/91
6-1. Routine Maintenance
IMPORTANT
ONAN P218
Recommended Oil-API Service Classification SF, SF/CC, SF/CD or better.
Below 0°F 0° to 40°F 40° to 100°F Above 100°F
—18°C) —18° to 4°C) (4° to 38°C) (38°C)
SAE 5W-30 SAE 10W SAE 30 SAE 30
Check oil level daily
Qil and Filter Change- Dirty conditions 25 hours or less
à Normal conditions 100 hours
Oil Filter Element. - - . Onan 122-0645
Miller 065 251
Oil Capacity = = = » « - 1.75 U.S. Qs. (1.6 L) with filter change
See Engine Manual For Additional Information
Fuel Capacity
12 Volt Battery 7.5 U.S. Gals (28.401)
BCI Group Size 24 Vented tank cap
Cranking performance @ Fuel Filter — Onan 149-2206-01
0 F (-18 C) 500 Amps Fram G10E1
Minimum Miller 666 113
Fuel Grade
Air Filter Service
100 hours or less—
See Engine Manual
“Regular”, “Unleaded”
at least 85 octane
(RON + MON)/2
Valve Clearance {Cold)
In. —.005" (0.13 mm)
Ex. —.013" (0.33 mm)
Engine RPM 3000
Power — 1650 180 На
1860 (60 Hz
Air filter element
Onan 140-2522
Fram CA 140PL
Miller 064 617
E
Air Filter Wrapper
Onan 140-1496
Miller 065 653 Weld — 3000
Spark plug gap- - - - ------ -025” (6 mm)
Spark Plug === = = = = = = = a Champion: RS-14YC*
Ignition timing- - - = = = = = = - Engine Stopped 20 BTDC
Capacitor, ignition = = = - - --- nan 312-0256
Miller 065 673
*Resistor Spark Plugs Mandatory
If equipped with a spark arrestor supplied by the
generator manufacturer, inspect and service every 250
operating hours.
See Owner's Manual.
i equipped with spark arrestor supplied by others, refer to
that manufacturers instructions for service and inspection
procedures.
5-134 092-A
Figure 6-1. Maintenance Label
OM-428 Page 15
A Stop engine before maintaining.
0) 8 HOURS
Check
Fluid
OIL Levels
3-3 full
С) 25 HOURS
Clean
And
Check
Air
Cleaner
O) 50 HOURS
A And
vil
Clean
3-6
Tighten
Weld
Terminals
©) 200 HOURS
Replace
Unreadable
Labels
Replace
Fuel
Change
Oil
3-3
Change
Oil
manual
Filter
O) soo Hours
С) 100 HOURS
ZZ
Tape Or
Replace
Cracked
Clean And
Tighten
Battery
Connections
Clean
Cooling
engine
manual
System
Cables
= =
@) 1000 HOURS
Blow Qut
Or
Vacuum
Inside
OM-428 Page 16
Figure 6-2. Maintenance Schedule
6-2. Servicing Air Cleaner
4 CAUTION
DIRTY AIR can damage engine.
® Do not run engine without air clear element in place or with dirty element.
Stop engine.
1 Nut
2 Cover
3 Spacer
4 Element Cover
5 Precleaner
6 Element
Base
Remove precleaner.
8 Washing Precleaner
Use soap and water solution. Allow
element to air dry completely.
9 ODiling Precleaner
Spread 1 tablespoon SAE 30 oil
evenly into precleaner. Squeeze
out excess oil.
10 Inspecting Element
Squeeze Air Dry | Replace if dirty or oily.
| Reinstall parts.
Squeeze Inspect |
9 10 rsb18.2 8/92 — ST-156 852 / 5-0759
Fiqure 6-3. Air Cleaner Service
6-3. Replacing Fuel Filter
Á WARNING Ml READ SAFETY BLOCKS at start of
Section 6 before proceeding.
Stop engine, and allow to cool.
1 Fuel Filter
See Figure 6-1 for replacement.
2 Hose Clamp
Remove clamps and filter.
3 Fuel Line
Inspect and replace line if cracked.
Reinstall hose clamps with new fil-
ter. Wipe up any spilled fuel,
Start engine, and check for fuel
leaks.
Tools Needed:
o Stop engine, tighten connections
e Ls] as necessary, and wipe up fuel.
ST-144 840-B
Figure 6-4. Fuel Filter Components
OM-428 Page 17
6-4. Adjusting Engine Speed
Section 6 before proceeding.
Engine speeds have been factory
set and should not require adjust-
ment. After tuning engine, check
engine speeds with a tachometer.
See table for proper no load
speeds. If necessary, adjust
NANI a READ SAFETY BLOCKS at start of
MN
Engine Speed RPM
Power/ldle 1860 (1650 for 50 Hz Models)
Weld 3000
e
Rear View
Top View
Tools Needed:
=r
S———2 3/8in., 8 mm, 11 mm
speeds as follows:
Start engine, and rotate FINE AM-
PERAGE control to 100.
1 Throttle Solenoid
2 Power/ldle Speed Rad
3 Locking Nut
Loosen nut,
4 Nut
Rotate until engine runs at power/
idle speed. Tighten locking nut.
5 Carburetor
6 Power/ldle Mixture Screw
If engine surges, rotate screw.
Place Engine Control switch in
RUN position.
7 Jam Nut
Loosen nut.
8 Hex Swivel
Rotate until engine runs at weld
speed, Tighten nut.
9 Weld Speed Governor Spring
10 Power/ldle Speed Governor
Spring
If a spring becomes loose or dis-
connected, reattach as shown.
ST-116 049-C
Figure 6-5. Engine Speed Adjustments
OM-428 Page 18
6-5. Replacing Battery Or Checking Battery Voltage
A WARNING
SPARKS can cause BATTERY GASES ¢ Do notallow tools to cause sparks when working on
TO EXPLODE; BATTERY ACID can burn a battery.
eyes and skin. > » Donotuse welder to charge batteries or jump start
e Stop engine before disconnecting or connecting | vehicles.
battery cables. hE e (Qbserve correct polarity (+ and —) on batteries.
e Always wear a face shield and proper protective
clothing when working on a battery. ; rwarn10.1 9/91
If engine will not crank, check bat-
tery voitage as follows:
1 1 Engine Control Switch
Place Engine Control switch in the
RUN/IDLE OFF position.
ee 2 Bolt
3 Battery
4 Rear Panel
Remove bolts, and pull out rear
panel.
5 Negative (—) Battery Cable
6 Positive (+) Battery Cable
7 Voltmeter
Remove terminal covers from bat-
tery.
If battery voltage is less than 12.4
volts, charge battery following bat-
tery charger’s instructions.
To replace batiery, proceed as fol-
lows:
Disconnect battery cables, nega-
tive cable first.
8 Hold Down
Remove hold down and battery.
When reconnecting battery, con-
nect negative (-) cable last. Rein-
stall terminal covers and rear pan-
el.
Tools Needed:
dE 3/8in., 12 in.
ST-144 B39-A / Het. ST-136 683-A
Figure 6-6. Checking And Replacing Battery
OM-428 Page 19
6-6. Overload Protection
Section 6 before proceeding.
áh WARNING À we READ SAFETY BLOCKS at start of
A. Throttle Solenoid Circuit Breaker CB4
Circuit breaker CB4 protects the unit from overload due to an obstructed throttle solenoid. CB4 is located within the unit,
and does not require manual resetting. If CB4 opens, engine speed drops to power/idle rpm for approximately 10 sec-
onds before automatically resetting.
If CB4 opens repeatedly, check throttle solenoid for obstructions and weld speed throttle link for proper adjustment (see
Section 6-4). If CB4 continues to open, contact the nearest Factory Authorized Service Station.
В. Fuse Fi
Stop engine.
1 Fuse Holder With Fuse F1
{see Parts List for rating)
2 Mounting Bracket
F1 protects the exciter excitation
winding from overioad. If weld and
auxiliary power output stops, F1
may be open.
Remove right side panel, check
and replace F1, and reinstall panel
before operating unit.
If fuse continues to open, contact
Factory Authorized Service Sta-
tion.
Tools Needed:
JO 38 in.
ST-152 264
Figure 6-7. Fuse F1 Replacement
OM-428 Page 20
6-7. Troubleshooting
`& WARNING
—e |:
ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Always wear dry insulating gloves.
Insulate yourself from work and ground,
Stop engine before installing or servicing.
Keep all panels and covers securely in place.
sion.
# Stop engine before fueling.
ENGINE FUEL can cause fire or explo-
e Do not fuel while smoking or near sparks or flames.
* Do not overfill tank; clean up any spilled fuel.
ENGINE EXHAUST GASES can kill.
* Do not breathe exhaust fumes.
* [sein open, well-ventilated areas, or vent exhaust
outside and away from any building air intakes.
and rotors.
and securely in place.
on a hot engine.
HOT PARTS can cause severe burns.
a Allow cooling period before servicing.
* Wear protective gloves and clothing when working
MOVING PARTS can cause injury.
e Keep away from moving parts such as fans, belts,
* Keep all doors, panels, covers, and guards closed
persons,
Troubleshooting to be performed only by qualified
rwarni1.1 11/91
Table 6-1. Welding Trouble
Trouble
No weld output.
— —y
No or erratic weld output.
Low or high weld output.
Lack of high frequency; difficulty in es-
tablishing an arc.
Remedy
Check and replace fuse F1.
——-
Have Factory Authorized Service Station check brushes and slip
rings, and Voltage Regulator Board PC2.
er cme fin
Check internal and external connections to weld output terminals;
check connections at stabilizer DC-Z.
Tighten any loose connections at Selector switch 55; check and
replace 55 if contacts are worn and/or pitted.
Be sure S5 is not set between positions.
- — = Check and adjust engine speed.
— — =;
Be sure that torch and work cables are not near any grounded met-
al.
Section
6-6
Check cables and torch for cracked or deteriorated insulation or
bad connections. Repair or replace necessary parts.
Use proper size tungsten for welding amperage.
Wandering arc — poor control of arc di:
rection.
—
Use proper size tungsten.
Properly prepare tungsten.
Reduce gas flow rate.
Tungsten electrode oxidizing and not re-
maining bright after conclusion of weld.
— —o наб
Water in torch. Refer to torch parts list for part(s) requiring replace-
ment, and repair torch as necessary.
Check and tighten all gas fittings.
Increase postilow time.
Shield weld zone from drafts.
OM-428 Page 21
Table 6-2. 60 Hz Auxiliary Power Troubleshooting
Trouble
No auxiliary power output at power/idle
speed (1860 rpm, 60 Hz: 1650 rpm, 50
Hz); low weld output available.
—— i
Low or high auxiliary power output.
— — —
Remedy
Reset circuit breakers CB1 and CRE.
——-
Check receptacles RC1, RC2, RC3 for continuity and proper con-
nections. Replace receptacle(s} if necessary.
Have Factory Authorized Service Station check Voltage Regulator
board PC2.
No or low output at 120 volts duplex re-
ceptacles, 240 volts twistlock recep-
tacle, or terminal strip 1T.
— — —№
Check RC1, RC2, RC3 for continuity and proper connections. Re-
place receptacie(s) if necessary.
—— ==
Section
Figure 5-2
Check connections to terminal strip 1T. ——. ——
Have Factory Authorized Service Station check Auto Idle Module |— — » -—
PC1 and Voltage Regulater board PC2.
Table 6-3. 100 Hz Auxiliary Power Trouble
Trouble Remedy Section
No output at 115 Y 9 A 100 Hz AC re- [— — -»| Reset circuit breaker CB3. ———| Figure 4-8
ceptacle.
Check receptacle RC4 for continuity and proper connections. Re- [—— -> --
place receptacle if necessary.
OM-428 Page 22
Table 6-4. Engine Trouble
Trouble
Engine will not start.
Engine starts but stops as soon as En-
gine Control switch S2 returns to RUN
position,
Remedy
Check battery and engine charging system according to engine
manual.
Check Engine Control switch 52, and replace if necessary.
See engine manual.
Check oil level. Check low oil pressure shutdown switch S3 (see
engine parts manual for location).
Check and refill crankcase with proper viscosity oil for operating
temperature, if necessary.
Engine stepped during normal opera-
tion.
Battery discharges between uses.
Check oil level. Check low oil pressure shutdown switch S3 (see
engine parts manual for location). S3 should close while engine is
running.
Check Engine Control switch S2, and replace if necessary.
— arf
Clean battery, terminals and posts with baking soda solution; rinse
with clear water.
Periodically recharge battery {approximately every 3 months).
Check Voltage Regulator according to engine manual.
Replace battery.
Section
— = lle — —
— wi ——
—— 33
—— 3-3
——. 3-3
— — —
Engine idles, but does not come up to |-- — =
weld speed.
Unstable or sluggish engine speeds. I~ — -
Check Engine Control switch S2, and replace if necessary.
Wait 10 seconds for throttle solenoid circuit breaker CB4 to reset.
Check resistance at throttle solenoid TS1 terminals. With plunger
out, resistance is less than 1 ohm. With plunger bottomed, resis-
tance is 17 ohms =10%.
Have Factory Authorized Service Station check Auto Idle Module
PCT.
Readjust throttle linkage if necessary.
Tune-up engine according to engine manual.
— fi
— fi
— — >
6-4
ОМ-428 Реде 23
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OM-428 Page 25
+
ВК (ВАТТ. САВЦЕ?
VOLTAGE
REGULATOR
AC B+ AC
E
CED (BATT. CABLE)
© O
12V
BATTERY
SED rent TION
BLK | CONTROL
ALTERNATOR
STATOR
(MOUNTED BEHIND
BLOWER WHEEL)
OM-428 Page 26
EXCITER
STATOR
WELD
STATOR
Figure 7-3. Wiring Diagram For Models Without Optional Features
SA(DC POS!
Ty
1501 POS)
7A
DC-Z
50-136 655-В
OM-428 Page 27
SECTION 8 —- TUNGSTEN ELECTRODE
mod2.1 9/92
NOTE C7
For additional information, see your distributor for a handbook on the Gas Tungsten
Arc Welding (GTAW) process.
8-1. Selecting Tungsten Electrode
Table 8-1. Tungsten Size
Amperage Range - Gas Type4 - Polarity
‘Electrode Diameter
DC — Argon - Electrode
Negative/Straight Polarity
DC - Argon - Electrode
Positive/Reverse Polarity
AC - Argon - Using
High Frequency
AC - Argon — Balanced
Wave Using High Freq.
Pure Tungsten
{Green Band)
0107 Up to 15 * Upto 15 Un to 10
0207 5-20 * 5-20 10-20
040” 15-80 * 10-60 20-30
1/16” 70-150 10-20 50-100 30-80
3/32" 125-225 15-30 100-160 60-130
1/8” 225-360 25-40 150-210 100-180
5/32" 360-450 40-55 200-275 160-240
3/16" 450-720 55-80 250-350 190-300
1/4” 720-950 80-125 325-450 250-400
2% Thorium Alloyed
Tungsten {Red Band)
010° Up to 25 * Up to 20 Upto 15
020” 15-40 * 15-35 5-20
040” 25-85 * 20-80 20-60
1/16” 50-160 10-20 50-150 60-120
3/32" 135-235 15-30 130-250 100-180
1/8” 250-400 25-40 225-360 160-250
5/32" 400-500 40-55 300-450 200-320
3/16" 500-750 55-80 400-500 290-390
1/4” 750-1000 80-125 600-800 340-525
Zirconium Alloyed
Tungsten (Brown Band)
010” * * Up to 20 Up to 15
020" * * 15-35 5-20
040" * * 20-80 20-50
1/16" * * 50-150 60-120
3/32" * * 130-250 100-180
1/8" * * 225-360 160-250
5/32" * * 300-450 200-320
3/16" * * 400-550 290-380
1/4" * * 600-800 340-525
* Typical argon shielding gas flow rates are 15 to 35 cfh (cubic feet per hour).
*Not Recommended.
The figures listed are intended as a guide ard are a composite of recommendations from American Welding Society (AWS) and electrode
manufacturers,
OM-428 Page 28
5-0008
8-2. Preparing Tungsten
1 Tungsten Electrode
1 2 Balled End
Ball end of tungsten before welding
by applying either an ac amperage
! slightly higher than what is recom-
2 D 1-1/2 Times mendedforagi lectrode diam-
§ given electrode diam
Electrode Diameter eter (see Table 8-1), or a dc elec-
trode positive amperage.
Ref. 5-0161
T
|
Figure 8-1. Preparing Tungsten For AC Or DC Electrode Positive (DCEP) Welding
A CAUTION |
Bh | FLYING SPARKS AND HOT METAL can cause injury and start fires.
e Shapetungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection.
= e Keep flammables away.
AT Р у warn2.* 9/91
1 Tungsien Electrode
1
2 2 Tapered End
Grind end of tungsten on fine grit,
hard abrasive wheel before welgd-
ing. Do not use wheel for other jobs
or tungsten can become contami-
nated causing lower weld quality.
| | |
2-1/2 Times
Electrode Diameter
Ref, 5-0161
7 1 Stabile Arc
2 Flat
Diameter of this flat determines
— amperage capacity.
3 Grinding Wheel
4 Straight Ground
Ideal Tungsten Preparation — Stable Arc Ref. 5-0162
4 1 Arc Wander
T7 2 Point
4
LPC Radial Ground
> К Æ 3
Wrong Tungsten Preparation — Wandering Arc Ref. 5-0162
Figure 8-2. Preparing Tungsten For DC Electrode Negative (DCEN) Welding
M-4298 Pana 29
SECTION 9 — AUXILIARY POWER GUIDELINES
mad 3,1 9/92
A WARNING
ELECTRIC SHOCK can kill.
* Disconnect both welding cables when using auxiliary power.
e Use all code-required methods for shack and overcurrent protection.
¢ Have only qualified persons make electrical connections.
a # Install and ground generator according to all applicable codes, such as OSHA and National Electrical Code.
9-1. How Much Power Does Equipment Require?
3 4 9 VOLTS 115
AMPS 45
Hz 50
EN
\
1 Resistive Load
A light bulb is a resistive load and
requires a constant amount of
power.
2 Non-Resistive Load
Equipment with a motor, such as
a drill, is a non-resistive load and
requires more power while start-
ing the motor than when running
(see Figure 9-3).
3 Rating Data
Volts and amperes, or walls re-
quired to run equipment. Deter-
mine power required as shawn in
Figure 9-2.
S-0623
Fiqure 9-1. Power Required By Different Types Of Equipment (Loads)
VOLTS x AMPERES = WATTS
resistive loads.
115 V x 4.5 A = 520 W
Therefore, the individual load applied by the drifl is 520 watts.
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
This equation provides an actual power requirement for resistive loads, or an approximate running requirement for non-
EXAMPLE 1: If a drill requires 4.5 amperes at 115 volts, calculate its running power requirement in watts.
EXAMPLE 2: If a flood lamp is rated at 200 watts, the individual load applied by the lamp is 200 watts. If three 200 watt flood
Therefore, the total load applied by the three flood lamps and drill is 1120 watts.
Figure 9-2. Calculating Power Required Te Run Equipment
OM-428 Page 30
Table 9-1. Approximate Power Requirements For Typical Equipment*
Industrial Motors Rating | Starting | Running Farm Equipment Rating | Staring | Running
Split Phase 1/8 HP 800 300 Stock Tank De-lcer 1000 1000
1/6 HP 1225 500 Grain Cleaner 1/4 HF 1650 650
1/4 HP 1600 500 Portable Conveyor 1/2 HP 3400 1000
1/3 HP 2100 700 Grain Elevator 3/4 HP 4400 1400
1/2 HP 3175 875 Milk Cooler 2300 1100
| Milker (Vacuum Pump) 2 HP 10500 2800
Capacitor Start- 1/3 HP 2020 720 FARM DUTY MOTORS 1/3 HP 1720 720
Induction Run 1/2 HP 3075 975 Std. (e.g. Conveyors, 172 HP 2575 975
3/4 HP 4500 1800 Feed Augers, Air 3/4 HP 4500 1400
1HP 6190 1600 Compressors) 1 HP 6100 1600
1-1/2 HP B200 2200 1-1/2 HP 8200 2200
2 HP 10550 2850 2 HP 10550 2950
3 HP 15900 3900 3 HP 15900 3900
5 HP 23300 6800 5 HP 23300 6800
Capacitor Start- 1-1/2 HP 8100 2000 High Torque (e.g. Barn 1-1/2 HP 8100 2000
Capacitar Run 5 HP 23200 5000 Cleaners, Silo Unicaders, 5 HP 23300 6000
7-1/2 HP 35000 8000 Sito Hoists, Bunk Feeders) 7-1/2 HP 35000 8000
10 НР 46700 10700 10 HP 46700 10700
Fan Duty 1/8 HP 1000 400 3-1/2 Cu. Ft. Mixer 1/2 HP 3300 1000
1/6 НР 1400 550 High Pressure 1.8 Gal/Min 500 PSI 3150 950
1/4 HP 1850 550 Washer 2 GalfMin 550 PSI 4500 1400
13 HP 2400 800 2 Gal/Min 700 PSI 6100 1500
1/2 HP 3500 1300
Contractor Rating pb Rane Residential Rating Starting Running
Hand Drill 1/47 350 350 Coffee Maker 1750 1750 Typ.
3/6" 400 400 Elec. Range 6" Element 1500 1500
1/27 600 600 8* Element 2100 2100
Circular Saw 6-1/2" 500 500 Oven 6000 6000
7-1/4" 900 900 Microwave 625W 2800 2000
B-1/4" 1400 1400 Television (Solid-State) B&W 100 100
Table Saw 9° 4500 1500 Color 300 300
10" 6300 1800 Radio 50-200 50-200
Band Saw 14" 2500 1109 Refrig. Or Freezer 3100 800
Bench Grinder E" 1720 720 Shallow Well Pump 1/3 HP 2150 750
8” 3900 1400 1/2 HP 3100 1000
10” 5200 1600 Sump Pump 1/3 HP 2100 806
Air Compressor 1/2 HF 3000 1000 1/2 HP 3200 1050
1 HP 5000 1500 Dishwasher {Cool Dry} 2100 700
1.1/2 НР B200 2200 (Hot Dry) 2850 1350
2 HP 10500 2800 Clothes Cryer Gas 2500 700
Electric Chain Saw 1-1/2 HP, 17" 1100 1190 Electric 7550 5750
2 HF, 14” 1100 1100 Automatic Washer 3450 1150
Electric Trimmer Standard 9° 350 350 Gas Or Fuel Oil 1/8 HP 300 300
Heavy Duty 12" 500 500 Fumace Blower 1/6 HP 1250 500
Electric Cuitivator 1/3 HP 2100 700 1/4 HP 1600 600
Elec. Hedge Trimmer 18" 400 400 1/3 HP 2100 700
Flood Lights HID 125 100 1/2 НР 3225 875
Metal Halide 313 250 Central Air Conditioner 10,000 BTU 3700 1500
Mercury 1000 20,000 BTU 5800 2500
Sodium 1400 24,000 BT 8750 3800
Vapor 1250 1900 32.000 BTU 11500 5000
Submersible Pump 400 GPH 500 200 40,000 8TU 13800 ° 6200
Centrifugal Pump 900 GPH 800 500 Garage Door Opener 1/4 HP 1650 550
Floor Polisher 3/4 HP, 16" 4500 1400 1/3 HP 2125 725
1 HP 20" 5100 1600 Electric Blanket Portable 400 400
High Pressure Washer 1/2 HP 3150 950 Dehumidifier 1450 650
3/4 HP 4500 1400 Vacuum Cleaner Standard 800 800
1 HP 6100 1600 Deluxe 1100 1100
55 Gal, Drum Mixer 1/4 HP 1900 700 Lights As Indicated On Bulb
Wet & Dry Vac 1.7 HP 900 300 Toaster 2 Slice 1050 1050
2-12 HP 1300 1300 4 Slice 1650 1650
Hair Dryer 300-1200 300-1200
Iron 1200 1200
*Motors require up to two or three times their starting wattage when starting under load.
OM-428 Page 31
Table 9-2. Single-Phase Induction Motor Starting Requirements
Motor Start Code
ос
Н
J
K
L
M
KVA/HP
6.3
7.1
8.0
3.0
10.0
11.2
12.5
14.0
i Motor Rating Label
2 Motor Start Code
3 Determine power required to start
motor using Table 9-2. Determine
starting amperage required as
shown in Figure 9-4.
AC
AM 2.5
Hz 60
PHASE 1
В
3 Running Amperage Require-
ment
If code is not present, multiply
running requirement by six. Gener-
ator amperage output must be at
least twice the motor's running
amperage requirement.
5-0624
Figure 9-3. Power Required To Start Motor
kVA/HP x HP x 1000
= STARTING AMPERAGE
VOLTS
EXAMPLE 3: Calculate the starting amperage required for a 230 V, 1/4 HP motor with a motor start code of M.
Volts = 230 HP =1/4 Using Table 9-2, Code M results in kVA/HP = 11.2
11.2 x 1/4 x 1000
= 12.2 А
230
Therefore, starting the motor requires 12.2 amperes.
Figure 9-4. Calculating Amperage Required To Start A Motor
9-2. How Much Power Can Generator Supply?
1 Limit Load To 90% Of Gener-
ator Output
Always start non-resistive (motor)
loads in order from largest to small-
est, and add resistive loads last.
2 5 Second Rule
If motor does not start within 5
seconds, turn off power to prevent
motor damage. Motor requires
more power than generator can
supply.
Ref. SB-140 092.4 / 5-0625
Figure 9-5. Limits Of Generator
OM-428 Page 32
9-3. Typical Connections To Supply Standby Power
Section 9 before proceeding.
A WARNING READ SAFETY BLOCKS at start of
Customer-supplied equipment is required if generator is to supply standby power during emergencies or power out-
ages. Locate the power company service meter (Figure 9-6, [tem 1), and main and branch overcurrent protection (2),
and install equipment as shown in Figure 9-6.
1
\ 240 V |
120/240 Volt — = ] !
60 Hz OGO y 120V Neutral
Three-Wire rio A
Service 120 V
— J
2
240 V \
U U Y =
3 — y 120V
Ä > Load
y 120 Y ]
OO ï cz
7
CB
Don
4 or
- MF
5
6 NY
\ 240 V
— Y
120/240 Volt y 120V
Single-Phase x
Three-Wire -— y 120V
Generator Output X
Connection Ground _
— =
Power Company Service Meter 4 (Circuit Breakers Or Fused Disconnect Connect terminals or plug of adequate
; _ Switch amperage capacity onto cord. Follow alf
2 Main And Branch Overcurrent Protec applicable codes and safety practices.
Obtain and install correct switch. Turn off or unplug all equipment connected
3 Double-Pole, Double-Throw Transfer , -
Switch 5 Extension Cord to generator before starting or stopping
engine. When starting or stopping, the
Obtain and install correct switch. Select as shown in Section 9-4. engine nas ow speed which causes low
Switch rating must be same as or greater 9 quency.
than the branch overcurrent protection. 6 Connections To Generator 7 Connections To Load
5-0405-A
Figure 9-6. Standby Power Equipment And Connections
OM-428 Pane 33
9-4. Selecting Extension Cord
Use Table 9-3 and Table 9-4 to select extension cords. Use shortest cords possible because long cords may reduce
output or cause unit overload.
Table 9-3. Cord Lengths For 120 Volt Loads
Maximum Allowable Cord Length in Feet (Meters)
For Conductor Size (AWG)*
Current Load In Watts 4 6 8 10 12 14
In Amperes
> 600 350 (106) 225 (68) 137 (42) 100 (30)
7 840 400 (122) 250 (76) 150 (46) 100 (30) 62 (19)
10 1200 400 (122) 275 (84) 175 (53) 112 (34) 62 (19) 50 (15)
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)
*Conductor size is based on maximum 2% voltage drop
Table 9-4. Cord Lengths For 240 Voit Loads
Maximum Allowable Cord Length In Feet (Meters)
For Conductor Size (AWG)*
Current Load In Watts 4 6 8 10 12 14
In Amperes
5 1200 700 (213) 450 (137) 225 (84) 200 (61)
7 1680 800 (244) 500 (152) 300 (91) 200 (61) 125 (38)
10 2400 800 (244) 550 (168) 350 (107) 225 (69) 125 (38) 100 (31)
15 3600 600 (183) 350 (197) 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-428 Page 34
*Conductor size is based on maximum 2% voltage drop
NOTES
OM-428 Page 35
SECTION 10 -- PARTS LIST
57-115 941-J
28 29 30 31 32 |
Figure 10-1. Main Assembly
OM-428 Page 36
tem Dia Part
No. Mkgs. No. Description Quantity
Figure 10-1. Main Assembly
Т.е... +042 383 .. REMOTE CONTROL, (Fig 10-8) .......... iii sian. 1
Dre Fig 10-5 .. CONTROL PANEL, w/components 0. KR 1
E к... 136 057 .. UPRIGHT, Базе 01001144 a ea ae ne a a ea ana a L 1
‚ 4 ......... 107 342 .. ЗЕАЮ, № еуе .............. RR RR 1
Ba. 113303 .. PANEL, Side 0.000 r0eeeedaaacamearaaaanonaanonancandoo 2
6 ........ +114 557 COVER, 10D... oe c—iecworereneararneraroo 1
Cee 143 397 .. BLANK, snap-innyl 312mtghole ...................... reee. E
A 108 487 .. LABEL, warning falling equipmentetc . .......... cL. 1
A 136059 .. PANEL, rear lower «ee LL ana aa LL 1
I * 095 970 .. STRIP, nprn ws! eng firewall 18 in ............. 2. ii... 2
.10......... 088 731 .. BUSHING, snap-in nyl .375 1D . . 0 LL LL ALL LL LL 1
11..PLGS ........... HOUSING, (part of engine wiring harness) ............10001114 11141100 1
12 ......... 133 056 .. TANK, fuel 7.5gal (consisting of) ...............0. LL 1
18 ......... 147 601 .... CAP tank screw-on w/Vent . ............ 4 a a a aa LL aa aa aa 1
14......... 126 239 .... SCREEN, fuellinepickup5/16thg . .. ......... 1
15......... 124 334 .... TUBING, urethane ester .250 ID x .312 OD (order by) .............. 1ft
16......... 124253 .... BUSHING, tank fuel ............ a a LL A LL LL 1
17... is 124 252 ....FITTING, hose stl elb 1/4tbg .............. i, 1
18 ........, 084 173 ....CLAMP, hose .460-.545cip dia ................0... 00 "e... 2
‚19 ......... 107 816 .... HOSE, nprn SAE .250 1D (order by ft) ................... ift
.20......... Fig 10-3 .. GENERATOR ... RR 1
‚ 21 ......... 135 627 .. ENGINE, gas elect start (consisting of) ...................0 2..." 1
. 22.122220. 113 251 .. FITTING, pipe brs cap .375NPT.......... eee aa a nana 1
‚ 28 ......... 113250 .... FITTING, pipe galv nipple L .375NPT ......... in... 1
‚Mk 066 113 .... FILTER, fuelin-Iine .250 ...................rrererecrecaCc)cenae 1
‚ 25 ......... 107 816 .... HOSE, SAE .250 10 (order by #) ......... ui... 1ft
‚ 26 ......... 084 173 .... CLAMP, hose .460-.545clp dia ..........010100000 tata Lana 2
C27 anna 107 297 .... MUFFLER, exhaustengine .............. 0... 1
‚ 28 ......... 106 977 .... SOLENOCID, 12VDC 20A ..............e0reoeiari e aneorarerer—ero 1
‚ 29 ......... 128 534 .... BRACKET, mtg solenoid ...........e ee eeeeeereoo0eorarereneoaena, 1
„30......... 128 431 .. SWIVEL, in-line .250-28 eneooranaanadea 1
Nueno. 128 533 . LINK, throttle «Le a a a ea aa LL LL 1
‚ 38 ......... 064 646 ... . SPRING, high Speed iii eee, 1
„33......... 115 511 .. BRACKET, support cover ie ee ee 2
‚ 34 aaa. 023641 .. CABLE, batneg (consisting of) ......... ii, 1
Cee eee 071 971 ‚... COVER, cable bat post BIK .............. III 1
‚ 85 ......... 108 081 .. TERMINAL PROTECTOR, batterypostmtg .......................... 2
Ce eee 020 279 .. CLAMP, stl cushion .750diax .281mtghole.. .......................... 2
. 36 .......,. 107 270 .. DOOR, access hat . ........ LL LL LL Re La a aa a aan 1
C37 088 577 .. CABLE, batpos (consistingof) ........................ ............ 1
Cee eee 071 970 .... COVER, cable bat post red ..........._ee_weecrereorererao.reriemoa 1
- 38... BAT . 071 678 .. BATTERY, stor 12V «oo. RR 1
. 39 ......... 146 697 .. HOLDDOWN, bat... RER aa à 1
. 40 ......... 146710 .. BASE ......e..earrariecienrereronvroanenerarneonanerrieroreoo. 1
O 134 792 .. LABEL, warning general precautionary engine etc ..................... 1
AD enano. 057 360 .. BLANK, snap-in nyi 1.375mtg hole ............. ii. 1
.43.. DC-Z . 113450 .. STABILIZER ......... 0 0 aa ea a aa ae a LL LL LA Aa aa na i
. 44... AC-Z . 113451 .. REACTOR ...... RR ncoranemerrar 1
45... 8R1 . 1425603 .. RECTIFIER, si 1ph 300A . oe eee 1
. 46. R3,VR1 046819 .. SUPPRESSOR ......... aaa ano amoo ALL 1
AT nano 126 072 .. BRACKET, mig resistor ............eseee0errarareaai ao eaaoocao ra 1
‚ 48 ......... 114544 .. PANEL, front lower ........... e. ees00rac.neaoñr.xoreaeose nana 1
‚ 49 ......... Fig 10-2 .. PANEL, front w/components 222202200440 4 ae na aa LL 4 da ea ea aa 1
‚ 50 ......... 012571 .. HOLDER, fuse mintr 250 x 1.250 ......... ities, 1
.851........ *083 596 .. FUSE, mintr cer 12A 250V oii ee ee ee уе. 1
‚. 52... R2,4 . 008951 .. RESISTOR, WW adj 189W 12 OhM .. 11211000 a aa ane ie, 2
.53...HRC5 . 116045 .. HOUSING PLUG & PINS, (consisting of) ...........—.ocerercoaararen. 1
eae 113633 .... TERMINAL, male 1 pin .‚084dia 20-14 Wir£ ......................... ©
54... CT1 . 105370 .. TRANSFORMER, Current . . . ei 1
Ce eae 135475 .. KIT, label
* OPTIONAL
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-428 Page 37
SC-115 943-D
Figure 10-2. Panel, Front w/Components
OM-428 Page 38
Нет Dia. Part
No. Mkgs. No. Description Quantity
Figure 10-2. Panel, Front w/Components (Fig 10-1 Item 49)
1 RC1,2 ... 604176 .. RECEPTACLE, str dx grd 2P3W 15A 125V ......... aa LL 2 2
Ce eee aaa 073 690 .. PLUG, str grd armd 2P3W 15A 125V P&S 5266 DF
Bde 143383 .. PANEL, front er RR ALL 1
. 3.... 85 .. Q05563 .. SWITCH, selector (Fig 10-4) ..... 2.2.0. aerea 1
. 4 ....CB1,2... 115427 .. CIRCUIT BREAKER, manreset ТР 25А 250\М ..................... 2
‚ 5 .... А1 .... 081712 .. RHEOSTAT, WW 100W 30ohm «ooo i, 1
. E... 54 .. ++011611 .. SWITCH, tgl DPDT 15A 125 000000 ee ee eee 1
‚ТФ... RCG7 .. ++086 022 .. RECEPTACLE, 14skt MS-3102A-20-27S ........ oii. 1
Cr eee aa 109766 .. PLUG, 14 pin Amphenol 97-4106A-20-27P
Ce eee 109770 .. TERMINAL, male 1 pin sz 45 16-22 wire
Cer eae 039734 .. CLAMP, cable Amphenol AN-3057-12
8 ...C7-11 . +4097 749 .. CAPACITOR ER 5
9 . 51 . 011611 .. SWITCH, tgl DPDT 154 125V ....... aaa LL LL LR 1
. 10.... $2 .... 1494641 .. SWITCH, ignition ..............2.20.. rene eoconecareo 1
. 11... CB3.... 083432 .. CIRCUIT BREAKER, man reset 1P 10A 250V ........ e... 1
12... ... ee... 601 836 .. NUT, brs hex jam hvy .250-20 ..............ee0r000roíreaeanerana, 3
13 ............ 010 915 .. WASHER, flat brs .250 ID x .625 OD .......... cnn. 2
14 ............ 083 030 .. STUD, brs grd .250-20 x 1.750 ............. 0... a da aa nn 1
¡PD +042 130 .. METER KIT, (consisting of) ..............eeeeer0aradeaoaoaoaaD 1
aa Le HM , 145 247 .... METER, hour 10-32VDC 121011111111 2 ea ana aa 1112 À
16... RC3 . 129067 .. RECEPTACLE, twlk grd 3P4W 30A 125/250V .......... e..." e... 1
Ce ee aa e 088 898 .. PLUG, twik grd 3P4W 30A 125/250V
17... RC4 . 034 952 .. RECEPTACLE, str 3P3W 154 125V ............ a LL La dedo 1
Cea 073690 .. PLUG, str grd armd 2P3W 15A 125V P&S 5266 DF
18. a. NAMEPLATE, {order by model and serial number) .................. 1
19... POS .... 039047 .. TERMINAL, pwr output red (consisting of ........................ 1
. 20... NEG . 039046 .. TERMINAL, pwr output black {consistingof) ....................... 1
E 099 255 .. TERMINAL, pwr output neutral (consisting of) ..................... 2
C22 Le caen 601976 .... SCREW, capstlhex hd 5500-13 x 1.500 ........................ 1
23... 033049 .... TERMINALBOARD, red ........ ci iin. 1
Xx E 0393 045 .... TERMINAL BOARD, black ............eoeeece0maooaaeoaranaaa 1
> AS 039 040 .... TERMINAL BOARD, neutral cui. 1
. 4111111112 601 880 .... NUT, st! hex jam ‚500-413 . LL LL LA ALL LL LL 1
S25 a. 039044 .... BUS BAR, term ba i к ке. 1
26 ............ 601879 .... NUT, stl hex full fnsh 500-13 ....... eee 1
27.... C6 . 115109 .. CAPACITOR RER 1
‚ 28 ............ 116813 .. CONTROL, push-pull ea 1
‚ 29 ............ 119014... LEVER, switch .........._eecereveaoaonareó,,vroreneaerceraaao 1
‚ 30 .......... ++109 993 .. CAP, dust connector 9760-20 .............. e síerecirero 1
E 2 0e 097 924 .. KNOB, pointer ......11200 00004021 LL ee A ae ea ae a a a a a aa aan 1
C82 ES 010647 .. PIN, spring CS 156 x 1.250 ....... iii, 1
„33.......... ++021 385 .. BOOT, tgl switch lever _ ee ALL 1
‚ 34 1 11e 115 493 .. HANDLE, switch range .......2222 22222 a a a a aa aa ra a a a aa aa a 1
++Part of Remote Control Option
+OPTIONAL
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-428 Page 39
item Dia. Part :
No. Mkgs. No. Description Quantity
Figure 10-3. Generator (Fig 10-1 Item 20)
Lo a 011198 .. LABEL, warning fan ......20222 0004444444 4 48 a a ee a 4 a ea ea a a ea 2 2 2
SHE 109 994 .. LABEL, warningenginefuelcanetc ........... LL. 1
E: кк.... 134 092 .. LABEL, engine maintenance Onan P218 ..........—.ee_remeerereros 1
2. 4 пе... +113 410 .. GUARD, fan gen .............. RR RR na. 1
1.05 ..22..2222000 153 297 .. ENDBELL, gen (consisting of} ........2120020 0044 2 aa a 4e a ea 0 a ea 0 1
2. 6 2........... 143 220 .... О-НИ№С, 2.859 16 х .139С5 ........ ia... 1
AO 113452 .. STATOR, gen 60HZ ...........—..esxeerverare _eavaaearenranenen 1
E AT 113454 .. STATOR, gen b0Hz ....... carecer are. 1
Bosse 013367 .. LABEL, warning moving parts ......0000 00000448 440 a 4 a a 4 a ea ae 0 2
‚ 9 ............ 017 702 .. АВОАРТЕН, епо!пе ........ ee ieee, 1
Ona. 134 981 .. ADAPTER, fan rotor ........... eee .enereararar:enoreeveraroa 1
RPG LES 008 917 .. WASHER, flat st! 343 ID x 2 (part of engine) ............... enana 1
AP 049 286 .. ROTOR ASSEMBLY, gen (consistingof) ....000 акк к лв вавее. 1
LAB 017 624 .... FAN, r0t0r QBN Le a a ee 4 a a a a ea a a ee ea 1
E 053 390 .... BEARING, ball rdl sgl row 1.37 .............. 2.2... у, 1
E 1- 024 617 .... RING, retaining ext 1.272 shaft ................. .............. 1
RAS 602 348 .... KEY stl|.250 x.250x.750 .......121 11111211 aa aa aa L 11 À
.. 16... SR2.... 035704 .. RECTIFIER, integ 40A 800V .........eee e. .eanceedaraneaaredecnos 1
AT 00 007 250 .. BRACKET, mtg brushholder ........2002 4000044004 e ea aa ae ea 0e» 1
e AB anarianonoa 047 878 .. BAR, retaining brushholder ............. ii iii a a ea 12e 0 1
19 ............ 047 885 .. CAP, brushhoider ......2000 004 448 11144 4 4 a 4 4 4 4 a 0 a a ee a a ea 0 3
1 ........... *126 984 .. BRUSH w/SPRING ........—.emoearererrrsvecerareraerarararen 3
21 ..ннн.нк..,. 005 614 .. HOLDER, brush _..... ii ieee 3
50-115 942-E
Figure 10-3. Generator
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-428 Page 40
No. No. Description Quantity
005563 Figure 10-4. Switch, Selector (Fig 10-2 item 3)
na 1..... 005562 .. BRACKET, mtg switch ...............e.eeesovereroaerearerenrerarera |
.…... 2... 005561 .. SHAFT, rotor ...........ee..ee.nearaaemaCeroaaerorrerereeaerana naa 1
Cee 3..... 005564 .. INSULATOR, screw switch... .. iii 1
2... 4..... 605276 .. SCREW, cap stl hex hd .250-20 x 1.250 .............— 7
e. 5..... 005559 .. CONTACT BOARD, movable switch ...........-.-...0000riarecaaa À
неее. 6..... 005560 .. CONTACT, switch movable ...... ..... ina |
Cee 7..... 008485 .. SPACER, contact switch ......... iii 7
Cee 8..... 005566 .. CONTACT BOARD, stationary switch ...........e.eeeecccrreiore 0 A:
Cee 9..... 011644 .. CONTACT, stationary switch .............. ci iii Y
‚... 10 .... 062405 .. SPRING, pressure contactswitch ............ cin... 1
Cee 11 .... 052404 .. CONTACT, movableswitch ........... cc. i
12 .... 005557 .. BUSBAR,switchrange . ............ ie ai. 1
13 .... 005558 .. SPRING, selector switch . ..... oi es ie eeu 1
56-097 264-A
Figure 10-4. Switch, Selector
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-428 Page 41
ltem Dia. Part
No. Mkgs. No. Description Quantity
Figure 10-5. Control Panel, w/Components (Fig 10-1 Item 2)
1 .... 1T .... 130648... BLOCK, term 30A 10P ..........eerararerararreano0naddanrecrverna 1
A 130 649 .. BRACKET, mtg components ............_—_———e_ecerevdrre redee. 1
3... PC1.... 142725 .. MODULE, pull to weld/power delay ..........02020000 404 00e ua en ee 00 1
ed 083147 .. GROMMET, scr No.8/10 ... ee ee eee eae eee 4
. 5... PC2.... 049404 .. CIRCUIT CARD ASSEMBLY, reguiator 115V ...................... 1
6... CR4.... 113247 .. RELAY. encl 12VD CG DPD T . . oii iti esta ite ae ieee 1
7 ... CR3.... 044588 .. RELAY, encl 12VDC SPDT RK кк,. 1
8... CR2.... 115693 .. RELAY, encl 12VDC SPDT .... iii iii a aa es 0 es 00 6 1
.. 9... CB4.... 045061 .. CIRCUIT BREAKER, autoreset24VDC 7A .......... cit. 1
.. 10... D45.... 059389 .. DIODE, rect BA 1000V SP 1.122042 4 00111114 a a a ea 1112000 6 2
11... TY .... 035759 .. TRANSFORMER, control mintr #15/36VCT ....................... +
E 038620 .. LINK, jumper term bik 30A .........e..--reseveeeracoeearearen_s 1
aa DE .... 117566... DIODE, rect 64 600V ... aa een en 6 1
56-114 309
Figure 10-5. Control Panel, w Components
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-428 Page 42
Item Dia. Part
No. Mkgs. No. | Description Quantity
Figure 10-6. Remote Control Option (Fig 10-1 Нет 1)
e 1... PC3.... 135246 .. CIRCUIT CARD ASSEMBLY, remote control ...................... 1
2 DB 2.112220 ee 110375 .. STAND-OFF SUPPORT, PCcard .........0 viii. 4
2 $ Век... 125 873 .. BRACKET, mtgremote control ..........cci ivi... 1
.. 4... CR5.... 052603 .. RELAY, encl 110YVDC DPDT ......... e... eet ee ee ee ee eee as 1
105 ....10012000 007 532 .. CLAMP, capacitor1.000dia .......... citi inn 1
.. 6 ....C5 .... 059887 .. CAPACITOR, polyp MF 10uUf220V .... ooo eee eee LL 1
ear 2 .... 116005 .. BLOCK, term 10A7P ........ enredado ererereneno. 1
2. В 2........... 108 023 .. LINK, jumper term blk 10A ....... 5..5... вс ква квн вовне, 4
.. 9... PLG6 ... 115091 .. HOUSING PLUG & SOCKETS, (consistingof} ..................... 1
Ce eee 113746 .... TERMINAL, female 1skt18-24W ............. ci ii... 10
58-116 028
Figure 10-6. Remote Control, Option
+See Figure 10-3 for additional parts not listed.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-428 Page 43
OPTIONS AND ACCESSORIES
RUNNING HOUR METER
(#042 130 Factory)
(#042 131 Field)
Furnishes an accurate record of
engine running time. Recommended
for efficient service.
LP GAS CONVERSION KIT
(#042 774 Factory)
(#042 584 Field)
Liquid withdrawal with vaporizer and
regulator. Does not include tank,
brackets, or hose from tank
to regulator.
FA-7.5 FLAME ARRESTOR FUEL
CAP — Gasoline Red
(4042 632 Field only)
Lockable for added protection.
FUEL GAUGE
(#042 590 Field only)
Handy and convenient accessory
designed for the 7.5 gal. (28.4 L)
fuel tank.
SPARK ARRESTOR MUFFLER
(#041 747 Field only)
Mandatory when operating on
California grasslands, brush, or
forest-covered land, and all
National Forests. For other areas,
check your state and local laws.
NO. 2WA WELDING
ACCESSORY PACKAGE
(#040 039)
Consists of 35 ft. {10.7 m) No. 2
electrode cable with insulated
electrode holder and lug, 30 ft. (9.1 m)
No. 2 work cable with work clamp
and lug, welding helmet, and wire
scratch brush.
CC-1 SERIES CANVAS COVERS
CC-1A {#040 252) Blue
CC-1C (4042 360) Gray
Attractive, waterproof canvas covers
resist stains and mildew, and protects
the finish of your welder. Blue cover
has Miller logo and name across side
HIGH ALTITUDE MODIFICATION
Not available from Miller Electric.
Please contact your local Onan
Dealer or Distributor who has the
parts and expertise to perform the
modification.
ONAN SERVICE LOCATOR
To locate the Onan Dealer in your
area, please call the Onan toll-free
Dealer HOTLINE: 800-888-ONAN.
GROUND FAULT CIRCUIT
INTERRUPTERS
Handy, convenient add-on devices
which reduce shock hazard.
OUTDOOR MOISTUREPROOF
GFCI PLUG
(#042 602)
User-attachable GFCI plug rated 15
Amps at 120 Volts AC. Permanently
attaches to power tool cords. Can
connect cords from 18 AWG to 12
AWG.
OUTDOOR RAINPROOF
ADAPTER
(#042 600)
8 in. (203 mm) Outdoor GFCI rated
15 Amps at 120 Volts AC. Handy
plug and receptacle adapter is
rugged, compact, and low cost. For
14/3 SJTW electrical cords.
PORTABLE GROUND FAULT
CIRCUIT INTERRUPTER BOX
{#042 601)
Two duplex, straight blade, three-
wire receptacles rated 15 Amps at
120 Volts AC mounted on box with
6 ft. (1.8 m) cord. Perfect when
many tools are used.
REMOTE CONTROLS AND
SWITCHES
REMOTE CONTROL FACILITIES
(#042 383 Factory)
(#042 384 Field)
Consists of 14-pin Amphenol
receptacle and switch for current
control and contactor control.
Remote controls and switches
required for use listed below.
*RHC-14 HAND CONTROL
(#129 340)
Miniature hand current and
contactor/exciter control. 20 ft. (6 m)
cord and 14-pin Amphenol plug.
*RFC-14 FOOT CONTROL
(#129 339)
Foot current and contactor/exciter
control. 20 ft. {6 m) cord and 14-pin
Amphenol plug.
*FTC-14 REMOTE CONTACTOR
AND CURRENT CONTROL
(#129 338)
Fastens to electrode holder or
GTAW torch. Includes 28 ft. (8.5 m)
cord and 14-pin Amphenol plug.
*RMLS-14 SWITCH
(#129 337)
Momentary- and maintained-contact
rocker switch for contactor/exciter” :
control. Push forward for maintained
contact and push back for
momentary contact. 20 ft. (6 m)
cord and 14-pin Amphenol plug.
*Remote control facilities must be
installed in order to use the remote
controls and switches indicated.
EXTENSION CORDS FOR
14-PIN REMOTE CONTROLS .
(#122972) 10 ft. (3 m)
(#122 973) 25 ft. (7.6 m)
(#122 974) 50 ft. (15.2 m)
(#122 975) 75 ft. (23m)
GTAW (TIG) WELDING
HF-251D-1 HIGH-FREQUENCY
ARC STARTER/STABILIZER
(#042 388)
À portable,115 Volt, 250 Amp high-
frequency arc starter and stabilizer
for 50/60/1400 Hz input. (Remote
control facilities recommended.)
RADIATOR 1A (100 Hz)
(4042 494)
Special cooling system designed to
operate from the 1 KW, 115 VAC,
100 Hz receptacle on the
Miller Legend™ front panel.
Perfect for GTAW (TIG) welding.
GMAW (MIG) WELDING
S-32 SERIES WIRE FEEDERS
Listed by Model and Catalog Sheet
Index Number.
S-32P M/6.25
5-325 M/6.21
Semiautomatic voltage sensing wire
feeders for use with self-shielding
gasless wire and Gas Metal Arc
Welding (MIG} with hard and flux-
cored wires.
OPTIONS AND ACCESSORIES
SPOOLMATIC®30A
(#130 831)
200 Amp, 100% duty cycle, air-
cooled 1 Ib. spool gun with 30 ft.
(9.1 m) cable assembly.
WC-115A WELD CONTROL
(4137 546)
Designed for use with the
Spoolmatic 30A spool gun anda
DC power source having oniy
115 VAC available.
EDT 1000-2 TWO-WHEEL
TRAILER
(4041 777)
A 1000 Ib. (454 kg) capacity trailer
with welded structural steel frame,
heavy-duty axle with roller bearing
hubs and leaf spring suspension.
Mounting holes for all small Miller
engine driven generators are pre-
punched. Hardware for mounting is
provided. Also included are a jack
stand for raising and lowering the
tongue, safety chains, and universal
tongue mounting for optional hitches.
An optional fender and light kit is
required when trailer is used on the
highway. Note: Hitch must be
ordered separately.
Specifications:
GVWR: 1200 ibs. (544 kg)
Trailer weight: 186 Ibs. (84 kg)
Trailer capacity: 1000 lbs. (454 kg)
Total width (without optional fender
kit): 55 in. (1.4 m)
Total length (without optional hitch):
72 in. (1.8 m)
Width of bed: 36 in. (914 mm)
Track width: 49-1/2 in. (1257 mm)
Height of bed: 18 in. (457 mm)
Tire size: 4.80-12
Shipping weight: 186 Ibs. (84 kg)
NOTES: When equipped with fender and
light kit and 2 In. (51 mm) ball hitch, this
trailer conforms to all applicable U.S.
Federal motor vehicle safety standards
in effect on date of manufacture.
When ordering trailers without the
fender and light kit and ball hitch, the
purchase order must include the
statement, “For off-the-road use only.”
FENDER AND LIGHT KIT
(#041 778)
Includes fenders, lights, wiring
harness, and mounting hardware.
Shipping weight: 37 Ibs. (17 kg)
HITCHES
2 in. (51 mm) BALL
(#042 705)
Shipping weight: 5 lbs. (2 kg)
CLEVIS (Not for highway use)
(#042 707)
Shipping weight: 11 Ibs.(5 kg)
2-1/2 in. (64 mm) LUNETTE EYE
(#042 706)
Shipping weight: 9 Ibs. (4 kg)
NO. 48 RUNNING GEAR
(#041 930)
Two rear wheels with 480/400x8
pneumatic tires. Two 8 in. (203 mm)
solid rubber tired front wheels and
30 in. (762 mm) towing handle.
CR-4B CYLINDER RACK
(#041 968)
For use with No. 4B running gear.
NO. 25 HAND RUNNING GEAR
(#042 503)
Constructed of lightweight tubular
steel and large, 480/400x8 pneumatic
tires, this running gear is designed
for manueverability and convenience.
The weld cables can be wrapped
around the handles. Protective cover
can be used with this running gear.
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