OM-4433 218 314K 2006−11 Processes Stick (SMAW) Welding TIG (GTAW) Welding MIG (GMAW) Welding Flux Cored (FCAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging Description Engine Driven Welding Generator Big Blue 300 P ® File: Engine Drive Visit our website at www.MillerWelds.
From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy.
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Engine Hazards . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS 8-5. Servicing Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6. Adjusting Engine Speed On Standard Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7. Adjusting Engine Speed On Models With Automatic Idle (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . .
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom _nd_3/05 Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Marks a special safety message. Means “Note”; not safety related. This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
WELDING can cause fire or explosion. HOT PARTS can cause severe burns. Welding on 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 burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding. Remove all flammables within 35 ft (10.
STEAM AND HOT COOLANT can burn. If possible, check coolant level when engine is cold to avoid scalding. Always check coolant level at overflow tank, if present on unit, instead of radiator (unless told otherwise in maintenance section or engine manual). If the engine is warm, checking is needed, and there is no overflow tank, follow the next two statements. Wear safety glasses and gloves and put a rag over radiator cap.
READ INSTRUCTIONS. Use only genuine MILLER/Hobart replacement parts. Perform engine and air compressor (if applicable) maintenance and service according to this manual and the engine/air compressor (if applicable) manuals. H.F. RADIATION can cause interference. ARC WELDING can cause interference. High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION rom_fre 3/05 Avertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions. 2-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Identifie un message de sécurité particulier. Signifie NOTA ; n’est pas relatif à la sécurité.
LE SOUDAGE peut provoquer un incendie ou une explosion. Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des objets métalliques peut provoquer des étincelles, une explosion, un surchauffement ou un incendie.
Si le moteur est chaud et que le liquide doit être vérifié, opérer comme suivant. Mettre des lunettes de sécurité et des gants, placer un torchon sur le bouchon du radiateur. Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant d’enlever le bouchon. LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort. LA CHALEUR DU MOTEUR peut provoquer un incendie. LES ÉTINCELLES À L’ÉCHAPPEMENT peuvent provoquer un incendie.
LIRE LES INSTRUCTIONS. LE SOUDAGE À L’ARC risque de provoquer des interférences. Utiliser seulement les pièces de rechange d’origine. Effectuer la maintenance du moteur et du compresseur (si applicable) suivant ce manuel et le manuel du moteur/ compresseur (si applicable). LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer des interférences. Le rayonnement haute fréquence (H.F.
SECTION 3 − DEFINITIONS 3-1. Warning Label Definitions S-177 571 1 + 2 2 3 + 3 1 4 DIESEL 5 4 6 5 7 0 − 50 h Std. 200A Remove unit from shipping crate. Remove Owner’s Manual from unit. Follow instructions to install muffler. Read Owner’s Manual. Read labels on unit. Use Diesel Fuel only, and fill fuel tank. Leave room for expansion. Warning! Watch Out! There are possible hazards as shown by the symbols. Read Owner’s Manual. Follow instructions to activate battery. Check oil level.
3-2. Manufacturer’s Rating Label Ref.
3-3. Symbols And Definitions NOTE A Some symbols are found only on CE products.
SECTION 4 − SPECIFICATIONS 4-1.
4-3. Volt-Ampere Curves A. Stick Mode DC VOLTS 100 90 80 70 60 50 40 30 20 10 0 The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the curves shown. MIN 0 300 100 200 300 MAX 400 500 400 500 DC AMPERES B. MIG Mode 100 DC VOLTS 80 60 40 20 0 0 100 200 300 DC AMPERES C.
4-4. Fuel Consumption The curve shows typical fuel use under weld or power loads. 2.00 U.S. GAL/HR. 1.75 1.50 1.25 1.00 0.75 0.50 0.25 0.00 IDLE 0 50 100 150 200 250 300 350 400 DC WELD AMPERES AT 100% DUTY CYCLE 217 509 4-5. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. 100% Duty Cycle At 250 Amperes Exceeding duty cycle can damage unit and void warranty.
4-6. AC Generator Power Curve The ac power curve shows the generator power in amperes available at the 120 and 240 volt receptacles. 150 300 AC VOLTS 125 250 100 200 75 150 50 100 25 50 0 0 0 20 40 60 80 AC AMPERES IN 240 V MODE 0 40 80 120 160 AC AMPERES IN 120 V MODE 217 519 Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge (.025 in) 22 Gauge (.031 in) 20 Gauge (.037 in) 18 Gauge (.050 in) 16 Gauge (.063 in) 14 Gauge (.078 in) 1/8 in (.125 in) 3/16 in (.188 in) 1/4 in (.
SECTION 5 − INSTALLATION 5-1. Installing Welding Generator Always securely fasten welding generator onto transport vehicle or trailer and comply with all DOT and other applicable codes. Movement Always ground generator frame to vehicle frame to prevent electric shock and static electricity hazards. If unit does not have GFCI receptacles, use GFCI-protected extension cord. OR Do not install unit where air flow is restricted or engine may overheat. See Section 4-2 for lifting eye rating.
5-2. Mounting Welding Generator Do not weld on base. Welding on base can cause fuel tank fire or explosion. Weld only on the four mounting brackets or bolt unit down. Supporting The Unit Do not mount unit by supporting the base only at the four mounting brackets. Use cross-supports to adequately support unit and prevent damage to base. 2 Mounting Surface: 1 2 OR Cross-Supports Mounting Brackets (Supplied) Mount unit on flat surface or use cross-supports to support base.
5-3. Installing Exhaust Pipe Stop engine and let cool. Point exhaust pipe in desired di- rection but always away from front panel and direction of travel. Tools Needed: 1/2 in 803 582 / Ref. 217 357-A Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual.
5-4. Activating The Dry Charge Battery (If Applicable) Always wear a face shield, rubber gloves and protective clothing when working on a battery. 3 Remove battery from unit. 5 6 2 Vent Caps Sulfuric Acid Electrolyte (1.265 Specific Gravity) Well 7 1 Fill each cell with electrolyte to bottom of well (maximum). Do not overfill battery cells. Wait ten minutes and check electrolyte level. If necessary, add electrolyte to raise to proper level. Reinstall vent caps.
5-6. Engine Prestart Checks Check radiator coolant level when fluid is low in recovery tank. Full Full Diesel Capacity: 6 qt (5.7 L) Coolant Recovery Tank Hot Full Cold Full Full 803 563 Check all engine fluids daily. Engine must be cold and on a level surface. Unit is shipped with 20W break-in oil. Automatic shutdown system stops engine if oil pressure is too low or coolant temperature is too high. This unit has a low oil pressure shut- down switch.
5-7. Connecting To Weld Output Terminals Stick and TIG Welding For Stick and TIG welding Direct Current Electrode Positive (DCEP), connect electrode holder cable to CC (Stick/TIG) terminal on right and work cable to Work/Negative (−) terminal on left. For Direct Current Electrode Negative (DCEN), reverse cable connections. Use Process/Contactor switch to select type of weld output (see Section 6-3).
5-8. Selecting Weld Cable Sizes* Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding*** 100 ft (30 m) or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft 400 ft (105 m) (120 m) Weld Output Terminals Stop engine before connecting to weld output terminals.
5-9. Connecting To Remote 14 Receptacle RC14 Socket* A 24 volts ac. Protected by supplementary protector CB8. B Contact closure to A completes 24 volt ac contactor control circuit. C Output to remote control:+10 volts dc in MIG mode; 0 to +10 volts dc in Stick or TIG mode. D Remote control circuit common. E DC input command signal: 0 to +10 volts from min. to max. of remote control with Voltage/ Amperage Adjust control at max.
SECTION 6 − OPERATING WELDING GENERATOR 6-1.
6-2. Description Of Front Panel Controls (See Section 6-1) Engine Starting Controls Engine Gauges, Meters, And Lights 7 1 4 See Section 6-3 for Process/Contactor switch information. Preheat Switch Use switch to energize starting aid for cold weather starting (see starting instructions following). 2 Engine Control Switch Use switch to start engine, select engine speed (if unit has auto idle option), and stop engine. In Run position, engine runs at weld/power speed.
6-3. Process/Contactor Switch 1 1 Process/Contactor Switch Weld output terminals are energized when Process/Contactor switch is in a Weld Terminals Always On position and the engine is running. Use switch to select weld process and weld output on/off control (see table below). Place switch in Remote On/Off Switch Required positions to turn weld output on and off with a device connected to the Remote 14 receptacle.
6-4. Lift-Arc™ Start Procedure Lift-Arc TIG With Lift-Arc TIG selected, start arc as follows: Lift-Arc Start Method 1 “Touch” 1−2 Seconds 2 1 TIG Electrode 2 Workpiece Turn gas on. Touch tungsten electrode to workpiece at weld start point. Hold electrode to workpiece for 1-2 seconds, and slowly lift electrode. Arc is formed when electrode is lifted.
6-5. Remote Voltage/Amperage Control 1 Remote 14 Receptacle RC14 Connect optional remote control to RC14 (see Section 5-9). When a remote control is connected to the Remote receptacle, the Auto Sense Remote feature automatically switches voltage/amperage control to the remote control. When a device is connected to the Remote receptacle, remote voltage/amperage control is always available regardless of the position of the Process/Contactor switch.
SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. Generator Power Receptacles 1 3 2 4 5 6 217 357-A 1 120 V 20 A AC (shown) Receptacle RC5 and/or GFCI1 2 120 V 20 A AC GFCI (shown) Receptacle RC6 and/or GFCI2 3 240 V 50 A AC Receptacle RC11 RC5 / 6 and GFCI1 / 2 supply 60 Hz singlephase power at weld/power speed. Receptacle configuration varies depending on machine model and serial number. Maximum output from these receptacles is 2.4 kVA/kW.
SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Routine Maintenance Stop engine before maintaining. See Engine Manual and Maintenance Label Recycle engine for important start-up, service, and storage fluids. information. Service engine more often if used in severe conditions.
8-2.
8-3. Servicing Air Cleaner Stop engine. 1 2 3 Do not run engine without air cleaner or with dirty element. Engine damage caused by using a damaged element is not covered by the warranty. 4 The air cleaner primary element can be cleaned but the dirt holding capacity of the filter is reduced with each cleaning. The chance of dirt reaching the clean side of the filter while cleaning and the possibility of filter damage makes cleaning a risk.
8-4. Inspecting And Cleaning Optional Spark Arrestor Muffler Stop engine and let cool. 1 Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole. 3 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. Stop engine and let cool. 1 Reinstall cleanout plug. 2 Tools Needed: 3/8 in 803 582 / Ref. 217 357-A 8-5.
8-6. Adjusting Engine Speed On Standard Models Stop engine and let cool. Engine Speed (No Load) RPM (Hz) Weld/Power 1880 (61.7) Maximum Engine speed is factory set and should not require adjustment. After tuning engine, check engine speed with tachometer or frequency meter. See table for proper no load speed. If necessary, adjust speed as follows: Start engine and run until warm. Turn Process/Contactor switch to Weld Terminals Always On − Stick position. 1 Lock Nut 2 Adjustment Screw 3 Loosen nut.
8-7. Adjusting Engine Speed On Models With Automatic Idle (Optional) Engine Speed (No Load) 1880 rpm max (62.6 Hz) 1250 rpm (41.6 Hz) Engine Speed Adjustment After tuning engine, check engine speed with tachometer or frequency meter. See table for proper no load speed. If necessary, adjust speed as follows: Start engine and run until warm. Turn Process/Contactor switch to Stick − Weld Terminals Always On position.
8-8. Servicing Fuel And Lubrication Systems Stop engine and let cool. After servicing, start engine and check for fuel leaks. Stop engine, tighten connections as necessary, and wipe up spilled fuel. 1 2 3 Oil Filter Oil Drain Valve And Hose Oil Fill Cap 4 Primary (Canister) Fuel Filter 5 Secondary (In-Line) Fuel Filter 6 Fuel Tank Sludge Drain Valve To change oil and filter: Route oil drain hose and valve through hole in base.
8-9. Overload Protection Stop engine. When a circuit breaker, supplementary protector, or fuse opens, it usually indicates a more serious problem exists. Contact Factory Authorized Service Agent. 1 Fuse F1 F1 protects the stator exciter winding from overload. If F1 opens, weld and generator power is low or stops entirely.
8-10. Checking Generator Brushes Stop engine and let cool. 1 Generator Brush With Spring Mark and disconnect leads at brush holder cap. Remove brushes. Replace brushes if damaged or if brush material is at or near minimum length. 5/16 in. (8 mm) Minimum Length 9/16 in. (14.3 mm) New Length Replace Damaged Brushes 1 Ref 2114 778−D / S−0233−A Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge (.025 in) 22 Gauge (.031 in) 20 Gauge (.037 in) 18 Gauge (.050 in) 16 Gauge (.063 in) 14 Gauge (.
8-11. Voltmeter/Ammeter Help Displays Use the Voltmeter/Ammeter help displays to diagnose and correct fault conditions. 1 HL.P 20 When a help code is displayed normally weld output has stopped but generator power output may be okay. To 2 HL.P 21 reset help displays, stop unit and then restart. See item 6 below to reset Help 25 display. 1 Help 20 Display 4 Indicates a failure of meter display module PC2, or the wiring between PC2 and main control module PC1.
8-12. Troubleshooting Note Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 8-11). A. Welding Trouble Remedy No weld output; generator power output Place Process/Contactor switch in a Weld Terminals Always On position, or place switch in a Remote okay at ac receptacles. On/Off Switch Required position and turn remote contactor on (see Section 5-9). Reset supplementary protector CB7 or CB8 (see Section 8-9).
B. Generator Power Trouble Remedy No generator power output at ac recep- Reset receptacle supplementary protector(s) (see Section 7-1). tacles; weld output okay. No generator power or weld output. Disconnect equipment from generator power receptacles during start-up. Check fuse F1, and replace if open (see Section 8-9). Have Factory Authorized Service Agent check voltage regulator module PC3. Reset supplementary protector CB3 (see Section 8-9). Check Voltmeter/Ammeter help displays (see Section 8-11).
Trouble Engine slowly stopped and cannot be restarted. Remedy Check fuel level. Check engine air and fuel filters (see Sections 8-3 and 8-8). See engine manual. Battery discharges between uses. Turn Engine Control switch off when unit is not running. Clean top of battery with baking soda and water solution; rinse with clear water. Recharge or replace battery if necessary. Periodically recharge battery (approximately every 3 months).
Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge (.025 in) 22 Gauge (.031 in) 20 Gauge (.037 in) 18 Gauge (.050 in) 16 Gauge (.063 in) 14 Gauge (.078 in) 1/8 in (.125 in) 3/16 in (.188 in) 1/4 in (.25 in) 5/16 in (.313 in) 3/8 in (.375 in) 1/2 in (.
SECTION 9 − ELECTRICAL DIAGRAMS Figure 9-1.
219 228−D OM-4433 Page 45
SECTION 10 − RUN-IN PROCEDURE run_in1 8/01 10-1. Wetstacking Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur. 1 2 Welding Generator Run diesel engines near rated voltage and current during run-in period to properly seat piston rings and prevent wetstacking. See nameplate, rating label, or specifications section in this manual to find rated voltage and current. Do not idle engine longer than necessary.
10-2. Run-In Procedure Using Load Bank Stop engine. Do not touch hot exhaust pipe, engine parts, or load bank/grid. Keep exhaust and pipe away from flammables. 4 2 1 Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur. 1 Load Bank Turn all load bank switches Off. If needed, connect load bank to 115 volts ac wall receptacle or generator auxiliary power receptacle.
10-3. Run-In Procedure Using Resistance Grid Stop engine. Do not touch hot exhaust pipe, engine parts, or load bank/grid. Keep exhaust and pipe away from flammables. 6 Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur. 2 1 Resistance Grid Use grid sized for generator rated output. 1 Turn Off grid. 2 Welding Generator Place V/A control in minimum position, and Output Selector switch (if present) in either DC position.
SECTION 11 − GENERATOR POWER GUIDELINES NOTE The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown. 11-1. Selecting Equipment 1 2 3 Generator Power Receptacles − Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment Do not use 2-prong plug unless equipment is double insulated. 1 2 3 Be sure equipment has this symbol and/or wording. OR gen_pwr 11/02 − Ref.
11-3. Grounding When Supplying Building Systems 1 1 2 Equipment Grounding Terminal Grounding Cable 2 GND/PE Use #10 AWG or larger insulated copper wire. 3 Ground Device Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. 2 Use ground device as stated in electrical codes. 3 ST-800 576-B 11-4. How Much Power Does Equipment Require? 1 3 2 1 VOLTS 115 AMPS 4.
11-5.
11-7. Approximate Power Requirements For Contractor Equipment Contractor Hand Drill Circular Saw Table Saw Band Saw Bench Grinder Air Compressor Electric Chain Saw Electric Trimmer Electric Cultivator Elec.
11-8. Power Required To Start Motor 4 1 3 AC MOTOR VOLTS 230 AMPS 2.5 CODE M Hz 60 HP 1/4 PHASE 1 1 2 3 4 2 Motor Start Code Running Amperage Motor HP Motor Voltage To find starting amperage: Step 1: Find code and use table to find kVA/HP. If code is not listed, multiply running amperage by six to find starting amperage. Step 2: Find Motor HP and Volts. Step 3: Determine starting amperage (see example). Welding generator amperage output must be at least twice the motor’s running amperage.
11-10. Typical Connections To Supply Standby Power Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes. 1 2 Utility Electrical Service 3 Transfer Switch 4 Fused Disconnect Switch (If Required) Welding Generator Output 5 Essential Loads Have only qualified persons perform these connections according to all applicable codes and safety practices. Switch transfers the electrical load from electric utility service to the generator.
11-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord.
SECTION 12 − PARTS LIST Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. 8 9 10 17 18 19 20 11 12 21 13 7 14 23 16 24 15 6 (Fig.12-5) 5 4 3 28 22 27 25 26 2 101 102 103 1 (Fig.12-3) 109 97 98 96 95 94 93 92 100 99 108 (Fig.12-2) 90 104 106 105 107 Figure 12-1.
34 33 31 30 35 44 32 43 29 36 38 45 42 37 41 40 79 39 78 46 77 76 75 80 73 88 81 (Fig.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 12-1. Main Assembly . . . 1 . . . . . . . . . . Figure 12−3 . . Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . . 213504 . . Tray, Reactor & Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213491 . . Insulator, Capacitor Bank (Applies To Reactor/Rectifier Tray) .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 12-1. Main Assembly (Continued) . . . 46 . . . . . . . . . . . . . . 220295 . . Bracket, Stiffener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 47 . . . . . . . . . . . . . . 190190 . . Tank, Coolant Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 48 . . . . . . . . . . . . . . 213502 . . Guard, Fan . . . . . . . . . . . . . . . . . . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 12-1. Main Assembly (Continued) . . . 83 . . . . . . . . . . . . . . 213266 . . Mount, Engine/Generator Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . 212623 . . Tank, Fuel (Includes Fuel Cap And Items Below) . . . . . . . . . . . . . . . . . . . . 1 . . . 84 . . . . . . . . . . . . . . 189908 . . . . Valve, Drain Fuel 180 Deg Zinc Pld . . . . . . . . . . . . . . . . . . . . . . . .
Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. 11 10 12 8 9 13 7 14 15 6 16 5 25 4 2 1 23 17 3 24 22 18 19 37 36 24 26 27 20 21 35 28 30 29 31 34 32 33 803 684-B Figure 12-2. Panel, Front w/Components Item No. Dia. Mkgs. Part No. Description Quantity Figure 12-2. Panel, Front w/Components (Figure 12-1 Item 108) ... ... ... ... ... ... ... ... ... 1 2 3 4 5 6 7 8 9 . . . . . . . . . . . . . . 097926 . . . . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 12-2. Panel, Front w/Components (Continued) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 24 25 26 27 28 29 30 31 32 33 34 35 36 37 . . . . . . . . . . . . . . 214543 . . . . . . . . . . . . . . . . 134201 . . . . . . PC2 . . . . 214660 . . . . . . . R1 . . . . . 214760 . . . . . . . R2 . . . . . 193118 . . . . . . . S4 . . . . .
Hardware is common and not 5 available unless listed. 4 Wirng harnesses are listed at the end of parts section. 3 2 6 7 8 1 9 10 11 12 13 14 803 689-D 15 Figure 12-3. Control Panel Item No. Dia. Mkgs. Part No. Description Quantity Figure 12-3. Control Panel (Figure 12-1 Item 1) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 . . . . . . . . . . . . . . 220981 . . . . . . . . . . . . . . 129524 . . . . CR2 . . . . 214876 . . . . CB1 . . .
Hardware is common and not 5 available unless listed. 4 Wirng harnesses are listed at the end of parts section. 1 6 7 3 2 8 9 10 11 12 13 14 20 19 18 17 16 803 686-A 15 Figure 12-4. Generator Item No. Dia. Mkgs. Part No. Description Quantity Figure 12-4. Generator (Figure 12-1 Item 81) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 . . . ROTOR . . . .............. .............. .............. .........
Hardware is common and not 6 available unless listed. 1 Wirng harnesses are listed at the end of parts section. 3 2 7 10 8 5 4 9 803 685-A Figure 12-5. Rectifier Assembly Item No. Dia. Mkgs. Part No. Description Quantity Figure 12-5. Rectifier Assembly (Figure 12-1 Item 6) .................... ... 1 .............. . . . 2 . . MOD1,2,3 . . . . . 3 . . MOD4,5,6 . . ... 4 .............. ... 5 .............. ... 6 .............. . . . 7 . . . . TH1 . . . . . . . 8 . . . . C1−6 . . . . . . . 9 . .
Note Item No. Some wiring harness components (switches, relays, supplementary protectors) are also referenced elsewhere in this parts list. Purchase components separately or as part of the associated wiring harness. Dia. Mkgs. Part No. Description Quantity Wiring Harnesses .................... . . . . . . . . . . . S4 . . . . . . . . . . . . . SR1, SR2 . . . . . . . . . . . . CB1 . . . . . . . . . . . . CB2, CB3 . . . . . . . . . . . . CR3 . . . . . . . . . . . . . . CR2 . . . . . . . . . . . . . . .
Effective January 1, 2006 (Equipment with a serial number preface of “LG” or newer) Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor. The expertise of the distributor and Miller is there to help you, every step of the way.
Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Miller Electric Mfg. Co.