OM-4414
209 141H
2006−07
Description
Belt/Hydraulic-Driven Generator For
Welding Power Sources
Belt-Drive Generator
Hydraulic-Drive Generator
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SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
rom _nd_8/03
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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.
This group of symbols means Warning! Watch Out! possible
Y
Marks a special safety message.
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
.
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.
1-2. Arc Welding Hazards
D
Use only well-maintained equipment. Repair or replace damaged parts at
once. Maintain unit according to manual.
Y
The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see the
symbol, watch out, and follow the related instructions to avoid the
hazard. The safety information given below is only a summary of
the more complete safety information found in the Safety Stan-
D
D
D
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece or work-
table as near the weld as practical.
Y
Y
Only qualified persons should install, operate, maintain, and re-
pair this unit.
D
D
Insulate work clamp when not connected to workpiece to prevent contact
with any metal object.
Do not connect more than one electrode or work cable to any single weld
output terminal.
During operation, keep everybody, especially children, away.
SIGNIFICANT DC VOLTAGE exists in inverters after stop-
ping engine.
ELECTRIC SHOCK can kill.
D
Stop engine on inverter and discharge input capacitors according to
instructions in Maintenance Section before touching any parts.
Touching live electrical parts can cause fatal shocks or
severe burns. The electrode and work circuit is electrically
live whenever the output is on. The input power circuit and
machine internal circuits are also live when power is on. In semiautomatic or
automatic wire welding, the wire, wire reel, drive roll housing, and all metal
parts touching the welding wire are electrically live. Incorrectly installed or
improperly grounded equipment is a hazard.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing these fumes
and gases can be hazardous to your health.
D
D
D
Do not touch live electrical parts.
D
D
Keep your head out of the fumes. Do not breathe the fumes.
Wear dry, hole-free insulating gloves and body protection.
If inside, ventilate the area and/or use exhaust at the arc to remove welding
fumes and gases.
Insulate yourself from work and ground using dry insulating mats or covers
big enough to prevent any physical contact with the work or ground.
D
D
If ventilation is poor, use an approved air-supplied respirator.
Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s
instructions for metals, consumables, coatings, cleaners, and degreasers.
D
Do not use AC output in damp areas, if movement is confined, or if there is a
danger of falling.
D
D
D
Use AC output ONLY if required for the welding process.
D
Work in a confined space only if it is well ventilated, or while wearing an air-
supplied respirator. Always have a trained watchperson nearby. Welding
fumes and gases can displace air and lower the oxygen level causing injury
or death. Be sure the breathing air is safe.
If AC output is required, use remote output control if present on unit.
Additionalsafety precautions are required when any of the following electri-
cally hazardous conditions are present: in damp locations or while wearing
wet clothing; on metal structures such as floors, gratings, or scaffolds;
when in cramped positions such as sitting, kneeling, or lying; or when there
is a high risk of unavoidable or accidental contact with the workpiece or
ground. For these conditions, use the following equipment in order present-
ed: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most
situations, use of a DC, constant voltage wire welder is recommended.
And, do not work alone!
D
D
Do not weld in locations near degreasing, cleaning, or spraying operations.
The heat and rays of the arc can react with vapors to form highly toxic and
irritating gases.
Do not weld on coated metals, such as galvanized, lead, or cadmium plated
steel, unless the coating is removed from the weld area, the area is well
ventilated, and if necessary, while wearing an air-supplied respirator. The
coatings and any metals containing these elements can give off toxic fumes
if welded.
D
Disconnect input power or stop engine before installing or servicing this
equipment. Lockout/tagout input power according to OSHA 29 CFR
1910.147 (see Safety Standards).
BUILDUP OF GAS can injure or kill.
D
D
Shut off shielding gas supply when not in use.
Always ventilate confined spaces or use approved
air-supplied respirator.
D
D
Properly install and ground this equipment according to its Owner’s Manual
and national, state, and local codes.
Always verify the supply ground — check and be sure that input power cord
ground wire is properly connected to ground terminal in disconnect box or
that cord plug is connected to a properly grounded receptacle outlet.
ARC RAYS can burn eyes and skin.
D
D
When making input connections, attach proper grounding conductor first −
double-check connections.
Arc rays from the welding process produce intense visible
and invisible (ultraviolet and infrared) rays that can burn eyes
and skin. Sparks fly off from the weld.
Frequently inspect input power cord for damage or bare wiring — replace
cord immediately if damaged — bare wiring can kill.
D
D
D
D
Turn off all equipment when not in use.
D
Wear a welding helmet fitted with a proper shade of filter to protect your face
and eyes from arc rays and sparks when welding or watching (see ANSI
Z49.1 and Z87.1 listed in Safety Standards).
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
D
D
Wear approved safety glasses with side shields under your helmet.
If earth grounding of the workpiece is required, ground it directly with a sep-
arate cable.
Use protective screens or barriers to protect others from flash and glare;
warn others not to watch the arc.
D
Do not touch electrode if you are in contact with the work, ground, or anoth-
er electrode from a different machine.
D
Wear protective clothing made from durable, flame-resistant material (wool
and leather) and foot protection.
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WELDING can cause fire or explosion.
HOT PARTS can cause severe burns.
D
D
Allow cooling period before maintaining.
Wear protective gloves and clothing when working on
a hot engine.
Do not touch hot engine parts or just-welded parts
bare-handed.
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.
D
D
D
D
Protect yourself and others from flying sparks and hot metal.
Do not weld where flying sparks can strike flammable material.
NOISE can damage hearing.
Noise from some processes or equipment can damage
hearing.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not
possible, tightly cover them with approved covers.
D
Wear approved ear protection if noise level is high.
D
Be alert that welding sparks and hot materials from welding can easily go
through small cracks and openings to adjacent areas.
MAGNETIC FIELDS can affect pacemakers.
D
D
Watch for fire, and keep a fire extinguisher nearby.
D
D
Pacemaker wearers keep away.
Be aware that welding on a ceiling, floor, bulkhead, or partition can cause
fire on the hidden side.
Wearers should consult their doctor before going
near arc welding, gouging, or spot welding opera-
tions.
D
D
Do not weld on closed containers such as tanks, drums, or pipes, unless
they are properly prepared according to AWS F4.1 (see Safety Standards).
Connect work cable to the work as close to the welding area as practical to
prevent welding current from traveling long, possibly unknown paths and
causing electric shock and fire hazards.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high pressure. If
damaged, a cylinder can explode. Since gas cylinders are
normally part of the welding process, be sure to treat them
carefully.
D
D
Do not use welder to thaw frozen pipes.
Remove stick electrode from holder or cut off welding wire at contact tip
when not in use.
D
D
Protect compressed gas cylinders from excessive heat, mechanical
shocks, slag, open flames, sparks, and arcs.
D
D
D
Wear oil-free protective garments such as leather gloves, heavy shirt, cuf-
fless trousers, high shoes, and a cap.
Install cylinders in an upright position by securing to a stationary support or
cylinder rack to prevent falling or tipping.
Remove any combustibles, such as a butane lighter or matches, from your
person before doing any welding.
D
D
D
D
D
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot
work and have a fire watcher and extinguisher nearby.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder — explosion will result.
Use only correct shielding gas cylinders, regulators, hoses, and fittings de-
signed for the specific application; maintain them and associated parts in
good condition.
FLYING METAL can injure eyes.
D
Welding, chipping, wire brushing, and grinding cause
sparks and flying metal. As welds cool, they can
throw off slag.
D
D
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is in use or
connected for use.
D
Wear approved safety glasses with side shields even
under your welding helmet.
D
Read and follow instructions on compressed gas cylinders, associated
equipment, and CGA publication P-1 listed in Safety Standards.
1-3. Engine Hazards
MOVING PARTS can cause injury.
BATTERY EXPLOSION can BLIND.
D
D
Keep away from fans, belts, and rotors.
Keep all doors, panels, covers, and guards closed
and securely in place.
D
Always wear a face shield, rubber gloves, and protec-
tive clothing when working on a battery.
D
Stop engine before disconnecting or connecting bat-
tery cables or servicing battery.
D
Stop engine before installing or connecting unit.
D
D
D
D
Do not allow tools to cause sparks when working on a battery.
Do not use welder to charge batteries or jump start vehicles.
Observe correct polarity (+ and −) on batteries.
D
Have only qualified people remove guards or covers for maintenance
and troubleshooting as necessary.
D
To prevent accidental starting during servicing, disconnect negative (−)
battery cable from battery.
Disconnect negative (−) cable first and connect it last.
D
D
Keep hands, hair, loose clothing, and tools away from moving parts.
Reinstall panels or guards and close doors when servicing is finished
and before starting engine.
FUEL can cause fire or explosion.
D
D
Before working on generator, remove spark plugs or injectors to keep
engine from kicking back or starting.
D
Stop engine and let it cool off before checking or add-
ing fuel.
D
Do not add fuel while smoking or if unit is near any
sparks or open flames.
Block flywheel so that it will not turn while working on generator compo-
nents.
D
D
D
D
Do not overfill tank — allow room for fuel to expand.
Do not spill fuel. If fuel is spilled, clean up before starting engine.
Dispose of rags in a fireproof container.
Always keep nozzle in contact with tank when fueling.
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BATTERY ACID can BURN SKIN and EYES.
STEAM AND HOT COOLANT can burn.
D
D
D
Do not tip battery.
Replace damaged battery.
D
If possible, check coolant level when engine is cold to
avoid scalding.
D
Always check coolant level at overflow tank, if pres-
ent on unit, instead of radiator (unless told otherwise
in maintenance section or engine manual).
Flush eyes and skin immediately with water.
D
If the engine is warm, checking is needed, and there is no overflow tank,
follow the next two statements.
ENGINE HEAT can cause fire.
D
D
Wear safety glasses and gloves and put a rag over radiator cap.
D
Do not locate unit on, over, or near combustible
surfaces or flammables.
Turn cap slightly and let pressure escape slowly before completely re-
moving cap.
D
Keep exhaust and exhaust pipes way from flam-
mables.
ENGINE EXHAUST GASES can kill.
EXHAUST SPARKS can cause fire.
D
Use equipment outside in open, well-ventilated ar-
eas.
D
D
Do not let engine exhaust sparks cause fire.
Use approved engine exhaust spark arrestor in re-
quired areas — see applicable codes.
D
If used in a closed area, vent engine exhaust outside
and away from any building air intakes.
1-4. Compressed Air Hazards
BREATHING COMPRESSED AIR can
cause serious injury or death.
HOT METAL from air arc cutting and
gouging can cause fire or explosion.
D
D
Do not use compressed air for breathing.
Use only for cutting, gouging, and tools.
D
D
Do not cut or gouge near flammables.
Watch for fire; keep extinguisher nearby.
HOT PARTS can cause burns and injury.
COMPRESSED AIR can cause injury.
D
D
Do not touch hot compressor or air system parts.
Let system cool down before touching or servicing.
D
D
Wear approved safety goggles.
Do not direct air stream toward self or others.
TRAPPED AIR PRESSURE AND WHIPPING
HOSES can cause injury.
READ INSTRUCTIONS.
D
D
Read Owner’s Manual before using or servicing unit.
Stop engine and release air pressure before
servicing.
D
Release air pressure from tools and system before
servicing, adding or changing attachments, or open-
ing compressor oil drain or oil fill cap.
1-5. Additional Symbols For Installation, Operation, And Maintenance
OVERUSE can cause OVERHEATING.
FALLING UNIT can cause injury.
D
D
Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before starting
to weld again.
D
D
D
Use lifting eye to lift unit only, NOT running gear, gas
cylinders, trailer, or any other accessories.
Use equipment of adequate capacity to lift and
support unit.
If using lift forks to move unit, be sure forks are long
enough to extend beyond opposite side of unit.
D
Do not block or filter airflow to unit.
OVERHEATING can damage motors.
STATIC (ESD) can damage PC boards.
D
Turn off or unplug equipment before starting or stop-
ping engine.
Do not let low voltage and frequency caused by low
engine speed damage electric motors.
D
Put on grounded wrist strap BEFORE handling
boards or parts.
D
D
Use proper static-proof bags and boxes to store,
move, or ship PC boards.
D
Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where
applicable.
FLYING SPARKS can cause injury.
TILTING OF TRAILER can cause injury.
D
D
Wear a face shield to protect eyes and face.
Shape tungsten electrode only on grinder with proper
guards in a safe location wearing proper face, hand,
and body protection.
D
D
Use tongue jack or blocks to support weight.
Properly install welding generator onto trailer accord-
ing to instructions supplied with trailer.
D
Sparks can cause fires — keep flammables away.
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READ INSTRUCTIONS.
ARC WELDING can cause interference.
D
Use only genuine MILLER/Hobart replacement
parts.
D
Electromagnetic energy can interfere with sensitive
electronic equipment such as microprocessors,
computers, and computer-driven equipment such as
robots.
Be sure all equipment in the welding area is electro-
magnetically compatible.
D
Perform engine and air compressor (if applicable)
maintenance and service according to this manual
and the engine/air compressor (if applicable) manu-
als.
D
D
D
D
D
To reduce possible interference, keep weld cables as short as possible,
close together, and down low, such as on the floor.
H.F. RADIATION can cause interference.
Locate welding operation 100 meters from any sensitive electronic
equipment.
D
High-frequency (H.F.) can interfere with radio naviga-
tion, safety services, computers, and communica-
tions equipment.
Be sure this welding machine is installed and grounded according to this
manual.
D
Have only qualified persons familiar with electronic
equipment perform this installation.
If interference still occurs, the user must take extra measures such as
moving the welding machine, using shielded cables, using line filters, or
shielding the work area.
D
D
The user is responsible for having
a
qualified electrician
promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the equipment at
once.
D
D
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep spark
gaps at correct setting, and use grounding and shielding to minimize the
possibility of interference.
1-6. California Proposition 65 Warnings
Y
Welding or cutting equipment produces fumes or gases which
contain chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)
For Gasoline Engines:
Y
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
For Diesel Engines:
Y
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductiveharm. Wash hands after handling.
Y
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
1-7. Principal Safety Standards
Safety inWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(phone: 305-443-9353, website: www.aws.org).
RecommendedSafe Practices for the Preparation for Welding and Cut-
ting of Containers and Piping, American Welding Society Standard
AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Mi-
ami, FL 33126 (phone: 305-443-9353, website: www.aws.org).
levard, Rexdale, Ontario, Canada M9W 1R3 (phone: 800-463-6727 or
in Toronto 416-747-4044, website: www.csa-international.org).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036–8002 (phone: 212-642-4900,
website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (phone:
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202-4102 (phone: 703-412-0900, website:
www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
CanadianStandards Association, Standards Sales, 178 Rexdale Bou-
OSHA, Occupational Safety and Health Standards for General Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Offices—phone for Region 5, Chicago, is
312-353-2220,website: www.osha.gov).
1-8. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from
operator as practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
Welding current, as it flows through welding cables, will cause electro-
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined.Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
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SECTION 2 − DEFINITIONS
2-1. Symbol Definitions
Read Operator’s
Amperes
Circuit Breaker
Volts
A
Manual
V
Alternating Current
(AC)
Positive
Time
Negative
Output
Protective Earth
(Ground)
Hours
Temperature
h
Welding Arc
(Electrode)
Work Connection
Voltage Input
SECTION 3 − SPECIFICATIONS
3-1. Description
This belt or hydraulically-driven generator supplies ac power to the platform to run tools through an ac receptacle,
and also operate lights, and cutting and welding equipment. All power regulation components are located in a water-
tight box that is connected by cable to the generator. The generator supplies power when running at the specified
speed with the Power switch on (switch is located on platform). A 3-pole, 30 Amp circuit breaker protects the generator
from overload.
803 233
3-2. Specifications
Drive-Type
Output
Generator Speed
Single-Phase, 6 kVA/kW, 25 A, 120/240 V,
50/60 Hz
Belt-Drive/Pulley
1.0 Power Factor
100% Duty Cycle
3000 rpm (50 Hz)
3600 rpm (60 Hz)
Three-Phase 7.5 kVA/kW, 18 A,
240 V, 50/60 Hz,
1.0 Power Factor
Hydraulic
100% Duty Cycle
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3-3. Generator Dimensions And Weight
Dimensions
A
B
C
20-1/2 in (521 mm)
9 in (229 mm)
13 in (330 mm)
Weight
C
A
B
110 lb (50 kg)
.
A
b
e
l
t
-
d
r
i
v
e
n
m
o
d
e
l
i
s
s
h
o
w
n
.
803 233
3-4. Controller Dimensions And Weight
Dimensions
A
B
C
11-1/2 in (292 mm)
9-1/2 in (241 mm)
4-1/2 in (114 mm)
Weight
C
B
A
10 lb (5 kg)
803 233
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3-5. AC Power Curve
The ac power curve shows the
power in amperes available from
the generator.
A. 6 kVA/Kw Single-Phase Output
300
250
200
150
100
50
0
0
5
10
15
20
25
30
35
40
45
50
AC AMPERES
B. 7.5 kVA/kW Three-Phase Output
300
250
200
150
100
50
0
0
5
10
15
20
25
30
35
40
AC AMPERES
209 397 / 209 398
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SECTION 4 − MAINTENANCE AND TROUBLESHOOTING
4-1. Maintenance Schedule
Y
Stop engine before maintaining.
.
S
e
r
v
i
c
e
m
o
r
e
o
f
t
e
n
i
f
u
s
e
d
i
n
s
e
v
e
r
e
c
o
n
d
i
t
i
o
n
s
.
*
To be done by Factory Authorized Service Agent.
Every 250 h
Check Belt
Tension
(Belt-Driven
Models Only)
1/2 in.
(13 mm)
Replace
Unreadable
Labels.
Every 500 h
Blow Out Inside Of
Generator.
During Heavy Service,
Clean Monthly.
Service Welding Generator
Brushes And Slip Rings. Service
More Often In Dirty Conditions.*
4-2. Overload Protection
Y
Stop engine.
. When a circuit breaker opens,
it usually indicates a more seri-
ous problem exists. Contact
Factory Authorized Service
Agent.
Open cover to access generator.
1
Circuit Breaker CB1
CB1 protects the generator wind-
ings from overload. If CB1 opens,
generator output stops.
Close covers before operating unit.
1
803 233
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4-3. Troubleshooting
Trouble
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.
Check connections at receptacle RC3.
Be sure +12 volts dc input voltage is being supplied to control box.
Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.
Verify generator is running at 3600 rpm.
Low generator output at platform
receptacles.
Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.
Check control settings on welding equipment.
High generator output at platform
receptacles.
Verify generator is running at 3600 rpm.
Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.
Check and secure electrical connections at platform, generator, and control box.
Erratic generator output at platform
receptacles.
Verify generator is running at 3600 rpm.
Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
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SECTION 6 − GENERATOR POWER GUIDELINES
6-1. Selecting Equipment
1
Generator Power Receptacles
− Neutral Bonded To Frame
2
3-Prong Plug From Case
Grounded Equipment
3
2-Prong Plug From Double
Insulated Equipment
Y
Do not use 2-prong plug un-
less equipment is double in-
sulated.
1
2
3
Be sure equipment
has this symbol
and/or wording.
OR
gen_pwr 11/02* − Ref. ST-159 730 / ST-800 577
6-2. How Much Power Does Equipment Require?
1
Resistive Load
3
A light bulb is a resistive load and
requires a constant amount of power.
VOLTS 115
AMPS 4.5
Hz 60
2
2
Non-Resistive Load
1
Equipment with a motor is a non-re-
sistive load and requires approxi-
mately six times more power while
starting the motor than when running
3
Rating Data
3
Rating shows volts and amperes, or
watts required to run equipment.
AMPERES x VOLTS = WATTS
EXAMPLE 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power
requirementin watts.
4.5 A x 115 V = 520 W
The load applied by the drill is 520 watts.
EXAMPLE 2: If three 200 watt flood 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
The total load applied by the three flood lamps and drill is 1120 watts.
S-0623
OM-4414 Page 11
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6-3. Approximate Power Requirements For Industrial Motors
Industrial Motors
Rating
Starting Watts
Running Watts
Split Phase
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
800
1225
1600
2100
3175
2020
3075
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
1000
1400
1850
2400
3500
300
500
600
700
875
Capacitor Start-Induction Run
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
400
1-1/2 HP
2 HP
3 HP
5 HP
Capacitor Start-Capacitor Run
Fan Duty
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
550
650
800
1100
6-4. Approximate Power Requirements For Farm/Home Equipment
Farm/HomeEquipment
Stock Tank De-Icer
Rating
Starting Watts
Running Watts
1000
1650
3400
4400
2900
10500
1720
2575
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
3300
3150
4500
6100
3100
2150
3100
2100
3200
1000
650
Grain Cleaner
1/4 HP
1/2 HP
3/4 HP
Portable Conveyor
Grain Elevator
1000
1400
1100
2800
720
Milk Cooler
Milker (Vacuum Pump)
FARM DUTY MOTORS
Std. (e.g. Conveyors,
Feed Augers, Air
Compressors)
2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
1000
950
1-1/2 HP
2 HP
3 HP
5 HP
High Torque (e.g. Barn
1-1/2 HP
5 HP
Cleaners, Silo Unloaders,
Silo Hoists, Bunk Feeders)
7-1/2 HP
10 HP
1/2 HP
500 PSI
550 PSI
700 PSI
3-1/2 cu. ft. Mixer
High Pressure 1.8 Gal/Min
Washer 2 gal/min
2 gal/min
1400
1600
800
Refrigerator or Freezer
Shallow Well Pump
1/3 HP
1/2 HP
1/3 HP
1/2 HP
750
1000
800
Sump Pump
1050
OM-4414 Page 12
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6-5. Approximate Power Requirements For Contractor Equipment
Contractor
Rating
Starting Watts
Running Watts
Hand Drill
1/4 in
3/8 in
350
400
350
400
1/2 in
600
600
Circular Saw
Table Saw
6-1/2 in
7-1/4 in
8-1/4 in
9 in
500
500
900
900
1400
4500
6300
2500
1720
3900
5200
3000
6000
8200
10500
1100
1100
350
1400
1500
1800
1100
720
10 in
Band Saw
14 in
Bench Grinder
6 in
8 in
1400
1600
1000
1500
2200
2800
1100
1100
350
10 in
Air Compressor
1/2 HP
1 HP
1-1/2 HP
2 HP
Electric Chain Saw
Electric Trimmer
Electric Cultivator
1-1/2 HP, 12 in
2 HP, 14 in
Standard 9 in
Heavy Duty 12 in
1/3 HP
500
500
2100
400
700
Elec. Hedge Trimmer
Flood Lights
18 in
400
HID
125
100
Metal Halide
Mercury
Sodium
Vapor
313
250
1000
1400
1250
600
1000
200
Submersible Pump
Centrifugal Pump
Floor Polisher
400 gph
900 gph
3/4 HP, 16 in
1 HP, 20 in
1/2 HP
900
500
4500
6100
3150
4500
6100
1900
900
1400
1600
950
High Pressure Washer
3/4 HP
1400
1600
700
1 HP
55 gal Drum Mixer
Wet & Dry Vac
1/4 HP
1.7 HP
900
2-1/2 HP
1300
1300
OM-4414 Page 13
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6-6. Power Required To Start Motor
1
2
3
4
Motor Start Code
Running Amperage
Motor HP
4
AC MOTOR
VOLTS 230 AMPS 2.5
Hz 60
PHASE 1
2
1
3
CODE
HP
M
1/4
Motor Voltage
To find starting amperage:
Step 1: Find code and use table to
find kVA/HP. If code is not listed,
multiplyrunning amperage by six to
find starting amperage.
Step 2: Find Motor HP and Volts.
Step 3: Determine starting amper-
age (see example).
Welding generator amperage out-
put must be at least twice the
motor’s running amperage.
Single-Phase Induction Motor Starting Requirements
Motor Start
Code
G
H
J
K
L
M
N
P
KVA/HP
6.3
7.1
8.0
9.0
10.0
11.2
12.5
14.0
kVA/HP x HP x 1000
VOLTS
= STARTING AMPERAGE
EXAMPLE: 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, Code M results in kVA/HP = 11.2
11.2 x 1/4 x 1000
= 12.2 A
Starting the motor requires 12.2 amperes.
230
S-0624
6-7. How Much Power Can Generator Supply?
1
Limit Load To 90% Of
Generator Output
Always start non-resistive (motor)
loads in order from largest to small-
est, and add resistive loads last.
2
5 Second Rule
1
If motor does not start within 5
seconds, turn off power to prevent
motor damage. Motor requires
more power than generator can
supply.
2
Ref. ST-800 396-A / S-0625
OM-4414 Page 14
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6-8. Selecting Extension Cord (Use Shortest Cord Possible)
Cord Lengths for 120 Volt Loads
Y
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)
Load (Watts)
4
6
8
10
12
14
5
600
350 (106)
250 (76)
175 (53)
112 (34)
87 (26)
62 (19)
50 (15)
50 (15)
37 (11)
225 (68)
150 (46)
112 (34)
75 (23)
50 (15)
37 (11)
37 (11)
137 (42)
100 (30)
62 (19)
37 (11)
30 (9)
100 (30)
62 (19)
50 (15)
30 (9)
7
840
400 (122)
275 (84)
175 (53)
137 (42)
112 (34)
87 (26)
10
15
20
25
30
35
40
45
50
1200
1800
2400
3000
3600
4200
4800
5400
6000
400 (122)
300 (91)
225 (68)
175 (53)
150 (46)
125 (38)
112 (34)
100 (30)
87 (26)
75 (23)
62 (19)
62 (19)
50 (15)
*Conductor size is based on maximum 2% voltage drop
Cord Lengths for 240 Volt Loads
Y
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)
Load (Watts)
4
6
8
10
12
14
5
1200
1680
2400
3600
4800
6000
7000
8400
9600
10,800
12,000
700 (213)
500 (152)
350 (107)
225 (69)
175 (53)
125 (38)
100 (31)
100 (31)
75 (23)
450 (137)
300 (91)
225 (69)
150 (46)
100 (31)
75 (23)
225 (84)
200 (61)
125 (38)
75 (23)
200 (61)
125 (38)
100 (31)
60 (18)
7
800 (244)
550 (168)
350 (107)
275 (84)
225 (69)
175 (53)
150 (46)
125 (38)
125 (38)
100 (31)
10
15
20
25
30
35
40
45
50
800 (244)
600 (183)
450 (137)
350 (107)
300 (91)
250 (76)
225 (69)
200 (61)
175 (53)
60 (18)
75 (23)
*Conductor size is based on maximum 2% voltage drop
OM-4414 Page 15
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SECTION 7 − PARTS LIST
.
H
a
r
d
w
a
r
e
i
s
c
o
m
m
o
n
a
n
d
not available unless listed.
Actual parts may vary from
illustration.
17
15
16
14
13
12
11
23
10
18
9
24
19
6
8
28
5
7
27
20
4
2
26
21
22
25
1
803 235−C
3
Figure 7-1. Generator Assembly
Description
Item
No.
Dia.
Mkgs.
Part
No.
Quantity
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . 1 . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . . . .
. . . 4 . . . . . . . . . . . . .
. . . 5 . . . . . . . . . . . . .
. . . 5 . . . . . . . . . . . . .
. . . 5 . . . . . . . . . . . . .
. . . 6 . . . . . . . . . . . . .
. . . 7 . . . . . . . . . . . . .
. . . 8 . . . . . . . . . . . . .
. . . 9 . . . . . . . . . . .
. . Generator Assy, Belt-Drive, Cat (Mitsubishi) (includes) . . . . . . . . . . . . . 1
. . Generator Assy, Belt-Drive, Deutz, Ford, Cat (Perkins) (includes) . . . . 1
. . Generator Assy, Hydraulic-Drive (includes) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Generator Assy, Belt-Drive, Cat (Turbo) (includes) . . . . . . . . . . . . . . . . . . 1
. . . . Key, Stl .250 X .250 X 1.750 (Belt-Drive Only) . . . . . . . . . . . . . . . . . . . . . 1
. . . . Ring, Rtng Int 2.000 Groove Dia X .064 Thk . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Ring, Rtng Ext 1.000 Shaft X .042 Thk . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Bearing, Ball Rdl Sgl Row .984 X 2.047 X .591 . . . . . . . . . . . . . . . . . . . . 1
. . . . Endbell, Gen Belt-Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Endbell, Gen Belt-Drive, Cat (Turbo) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Endbell, Gen Hydraulic-Drive Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Rotor, Generator (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . Fan, Rotor Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . Bearing, Ball Radial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . +Stator, Generator Belt-Drive, Cat (Mitsubishi) . . . . . . . . . . . . . . . . . . . 1
. . . . +Stator, Generator Belt-Drive Deutz, Ford, Cat (Perkins) . . . . . . . . . . 1
. . . . +Stator, Generator Hydraulic-Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . .
. . . 9 . . . . . . . . . . .
OM-4414 Page 16
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-1. Generator Assembly (Continued)
. . . 9 . . . . . . . . . . .
. . . 10 . . . . . . . . . . . . .
. . . 11 . . . . . . . . . . . . .
. . . 12 . . . . . . . . . . . . .
. . . . +Stator, Generator Belt-Drive, Cat (Turbo) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Endbell, Gen Brush Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Brushholder Assy, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Clamp, Nyl .750 Clamp Dia X.500 Wide .203 Mtg Hole
Belt/Hydraulic-Drive Deutz, Ford, Cat (Perkins) (Turbo) . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . .
. . . . Shroud Assy, Endbell
Belt/Hydraulic-Drive Deutz, Ford, Cat (Perkins) (Turbo) . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . .
. . . 14 . . . . TE1 . . .
. . . 15 . . . . CB1 . . .
. . . 16 . . . . . . . . . . . . .
. . . 17 . . . . . . . . . . . . .
. . . . . . . . . . RC4 . . .
. . . 18 . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . .
. . . 21 . . . . . . . . . . . . .
. . . 22 . . . . . . . . . . . . .
. . . 23 . . . . . . . . . . . . .
. . . 23 . . . . . . . . . . . . .
. . . 23 . . . . . . . . . . . . .
. . . . Shroud Assy, Endbell Belt-Drive Cat (Mitsubishi) . . . . . . . . . . . . . . . . . 1
. . . . Block, Stud Connection 6 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Circuit Breaker, Man Reset 3p 30a 250vac . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Boot, Circuit Breaker 3 Pole W/Bezel And Hardware . . . . . . . . . . . . . . . 1
. . . . Connector, W/Leads (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . Conn, Rect Univ 084 6p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . 1
. . . . Conn, Clamp Cable 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Panel, End Shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Panel, End Shroud Belt-Drive Cat (Mitsubishi) . . . . . . . . . . . . . . . . . . . 1
. . . . Nut, 250−20 .50hex .39h Stl Pld Elastic Stop Nut . . . . . . . . . . . . . . . . . 4
. . . . Stud, Stl .250−20 X 12.875 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . Label, Warning Moving Parts Can Cause Serious Injury . . . . . . . . . . . . 1
. . . . Pulley, Drive 1.694 In Bore, 4 Bolt Pat (Belt-Drive Only) Deutz . . . . . . 1
. . . . Pulley, Drive 1.688 In Bore, 3 Bolt Pat (Belt-Drive Only) Cat/Perkins
1
. . . . Pulley, Drive 1.688 In Bore, 4 Bolt Pat
(Belt-Drive Only) Mitsubishi, Turbo . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Label, Label,Term Mkg Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . *Bushing, Stl .938 Id X 1.625 Od X 1.000 Lg (Belt-Drive Only) . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . .
. . . 25 . . . . . . . . . . . .
. . . 26 . . . . . . . . . . . .
. . *Pulley, Generator 4.88 Dia (60 Hz Belt-Drive Only)
Deutz, Mitsubishi, Turbo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . .
. . . 26 . . . . . . . . . . . .
. . . 27 . . . . . . . . . . . .
. . . 28 . . . . . . . . . . . . .
. . *Pulley, Generator 5.63 Dia (50 Hz Belt-Drive Only) Deutz . . . . . . . . . . . 1
. . *Pulley, Generator 3.00 Pitch Dia (50 Hz Belt-Drive Only) Ford . . . . . . . 1
. . *Tensioner, Belt W/Pully (Belt-Drive Only) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Protector, Lead Mylar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
*
Not included in generator assembly.
+
When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-4414 Page 17
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3
.
H
a
r
d
w
a
r
e
i
s
c
o
m
m
o
n
a
n
d
not available unless listed.
1
2
5
4
Ref. 803 236
Figure 7-2. Controller Assembly
Description
Item
No.
Dia.
Mkgs.
Part
No.
Quantity
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . 1 . . . . PC1 . . .
. . . 2 . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . .
. . Control Box, Assy 60 Hz (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Control Box, Assy 50 Hz (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Circuit Card Assy, Gen Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Label, 60 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Label, 50 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Control Box, Belt/Hydraulic-Driven Generator . . . . . . . . . . . . . . . . . . . . . 1
. . . . Stand−off Support, PC Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . 8
. . . . Circuit Card Assy, Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Panel, Mtg PC Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Harness, Wrg Control Box (Not Shown) (includes) . . . . . . . . . . . . . . . . . 1
. . . . . . Conn, Rect Univ 084 9p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . 2
. . . . . . Conn, Circ 6 Skt Rcpt Pushin Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . Conn, Circ 3 Skt Rcpt Pushin Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . Conn, Push 4 Wire 12−16strnd 12−18sld 16−22tinstrnd . . . . . . . . . . . 2
. . . . . . Gasket, Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . Gasket (Seal), Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Harness, Wrg Inter Gen/Control (Belt-Drive Only) (includes) . . . . . . . . . . 1
. . . . Conn, Rect Univ 084 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1
. . . . Seal, Wire Univ 6p/S 3row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Conn, Circ 6 Skt Plug Pushin Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Seal, Interface Univ 6p/3Row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Harness, Wrg Inter Gen/Control (Hydraulic-Drive Only) (includes) . . . . 1
. . . . Conn, Rect Univ 084 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1
. . . . Seal, Wire Univ 6p/S 3row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Conn, Circ 6 Skt Plug Pushin Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Seal, Interface Univ 6p/3Row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . .
. . . 4 . . . . PC2 . . .
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . . . . . RC1, RC14
. . . . . . . . . . RC2 . . .
. . . . . . . . . . RC3 . . .
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . . . . . . . . .
. . . . . . . . . . PLG4 . . .
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . PLG2 . . .
. . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . . . . . . . . .
. . . . . . . . . . PLG4 . . .
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . PLG2 . . .
. . . . . . . . . . . . . . . . . . .
+
When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-4414 Page 18
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Notes
OM-4414 Page 19
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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 (.5 in)
OM-4414 Page 20
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Owner’s Record
Please complete and retain with your personal records.
Model Name
Purchase Date
Distributor
Address
Serial/Style Number
(Date which equipment was delivered to original customer.)
City
State
Zip
For Generator Service
Call 1−877−554−5438 to contact JLG Service.
Always provide Model Name and Serial/Style Number.
Contact your Miller Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Circuit Diagrams
Welding Process Handbooks
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA
© 2004 Miller Electric Mfg. Co. 1/03
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