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Miller Electric Belt/Hydraulic-Driven Generator manual

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Table of contents for the manual

  • Page 1

    Description Belt/Hydraulic-Driven Generator For W elding Power Sources OM-4414 209 141H 2006 − 07 Belt-Drive Generator Hydraulic-Drive Generator V isit our website at www.MillerWelds.com[...]

  • Page 2

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

  • Page 3

    OM-4414 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom _nd_8/03  W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.  Marks a special saf[...]

  • Page 4

    OM-4414 Page 2 W elding 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 are[...]

  • Page 5

    OM-4414 Page 3 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 pres- ent 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[...]

  • Page 6

    OM-4414 Page 4 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) manu- als. H. F . RADIA TION can cause interference.  High-frequency (H.F .) can interfere with radio naviga- [...]

  • Page 7

    OM-4414 Page 5 SECTION 2 − DEFINITIONS 2-1. Symbol Definitions Circuit Breaker Read Operator ’s Manual A Amperes V V olts Positive Negative Alternating Current (AC) Output T ime h Hours T emperature Protective Earth (Ground) W elding Arc (Electrode) W ork Connection V oltage Input SECTION 3 − SPECIFICA TIONS 3-1. Description This belt or hydr[...]

  • Page 8

    OM-4414 Page 6 3-3. Generator Dimensions And Weight Dimensions A 20-1/2 in (521 mm) B 9 in (229 mm) C 13 in (330 mm) C W eight A 1 10 lb (50 kg) B 1 10 lb ( 5 0 k g ) 803 233  A belt-driven model is shown. 3-4. Controller Dimensions And W eight Dimensions A 1 1-1/2 in (292 mm) B 9-1/2 in (241 mm) C 4-1/2 in (1 14 mm ) C W eight B A 10 lb (5 kg) [...]

  • Page 9

    OM-4414 Page 7 3-5. AC Power Curve 209 397 / 209 398 The ac power curve shows the power in amperes available from the generator . A. 6 kV A/Kw Single-Phase Output B. 7.5 kV A/kW Three-Phase Output 0 50 100 150 200 250 300 0 5 10 15 20 25 30 35 40 45 50 AC AMPERES AC VOL TS 0 50 100 150 200 250 300 0 5 10 15 20 25 30 35 40 AC AMPERES AC VOL TS[...]

  • Page 10

    OM-4414 Page 8 SECTION 4 − MAINTENANCE AND TROUBLESHOOTING 4-1. Maintenance Schedule  Stop engine before maintaining.  Service more often if used in severe conditions. * T o be done by Factory Authorized Service Agent. Every 250 h 1/2 in. (13 mm) Check Belt T ension (Belt-Driven Models Only) Replace Unreadable Labels. Every 500 h Blow Out I[...]

  • Page 11

    OM-4414 Page 9 4-3. T roubleshooting T rouble Remedy No generator output at platform receptacles. Be sure generator control switch is turned on at platform. Check and secure electrical connections at platform, generator , and control box. Be sure all equipment is turned off when starting unit. Reset circuit breaker CB1 (see Section 4-2). Check conn[...]

  • Page 12

    OM-4414 Page 10 SECTION 5 − ELECTRICAL DIAGRAM 210 193-C Figure 5-1. Circuit Diagram For Generator And Controller[...]

  • Page 13

    OM-4414 Page 1 1 SECTION 6 − GENERA TOR POWER GUIDELINES 6-1. Selecting Equipment gen_pwr 1 1/02* − Ref. ST-159 730 / ST -800 577 1 Generator Power Receptacles − Neutral Bonded T o Frame 2 3-Prong Plug From Case Grounded Equipment 3 2-Prong Plug From Double Insulated Equipment  Do not use 2-prong plug un- less equipment is double in- sulat[...]

  • Page 14

    OM-4414 Page 12 6-3. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starti ng W atts Running W atts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 2100 700 1/2 HP 3175 875 Capacitor Start-Induction Run 1/3 HP 2020 720 1/2 HP 3075 975 3/4 HP 4500 1400 1 HP 6100 1600 1-1/2 HP 8200 2200 2 HP 10550 2850[...]

  • Page 15

    OM-4414 Page 13 6-5. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running W atts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/2 in 500 500 7-1/4 in 900 900 8-1/4 in 1400 1400 T able Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in 2500 1 100 Bench Grinder 6 in 1720 720 8 in 39[...]

  • Page 16

    OM-4414 Page 14 6-6. Power Required T o Start Motor S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor V oltage T o find starting amperage: Step 1: Find code and use table to find kV A/HP . If code is not listed, multiply running amperage by six to find starting amperage. Step 2 : Find Motor HP and V olts. Step 3: Determine starting am[...]

  • Page 17

    OM-4414 Page 15 6-8. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 V olt Loads  If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (A WG)* Current (Amperes) Load (W atts) 4 6 8 10 12 14 5 600 350 (106) 225 (68) 137 (42) 100 (30) 7 840 [...]

  • Page 18

    OM-4414 Page 16 SECTION 7 − P ARTS LIST 803 235 − C  Hardware is common and not available unless listed. Actual parts may vary from illustration. 1 25 26 2 4 3 27 5 7 8 6 23 9 22 21 20 10 11 12 14 15 17 18 24 19 13 28 16 Figure 7-1. Generator Assembly Description Part No. Dia. Mkgs. Item No. Figure 7-1. Generator Assembly Quantity Generator [...]

  • Page 19

    OM-4414 Page 17 Description Part No. Dia. Mkgs. Item No. Figure 7-1. Generator Assembly (Continued) Quantity 9 +Stator, Generator Belt-Drive, Cat (T urbo) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Endbell, Gen Brush Block 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 20

    OM-4414 Page 18  Hardware is common and not available unless listed. Ref. 803 236 3 4 5 1 2 Figure 7-2. Controller Assembly Description Part No. Dia. Mkgs. Item No. Figure 7-2. Controller Assembly Quantity Control Box, Assy 60 Hz (includes) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 21

    OM-4414 Page 19 Notes[...]

  • Page 22

    OM-4414 Page 20 Notes 16 Gauge (.063 in) 22 Gauge (.031 in) 24 Gauge (.025 in) 20 Gauge (.037 in) 18 Gauge (.050 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 (.5 in) MA TERIAL THICKNESS REFERENCE CHART[...]

  • Page 23

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  • Page 24

    PRINTED IN USA © 2004 Miller Electric Mfg. Co. 1/03 Miller Elect ric Mfg. Co. An Ill inois T ool Works Company 1635 West S pencer S treet Applet on, WI 54914 US A International He adquarters − USA USA Phone: 920-735-4505 Aut o-At tended USA & Canada F A X: 9 20-735-4134 Int ernati onal F AX : 920-735-4125 European Headqua rters − United K [...]