Miller Electric 300, 225 manual Main Assembly

Page 43

 

Item

Dia.

 

Part

Description

Quantity

 

No.

Mkgs.

No.

 

 

 

 

 

Figure 9-1. Main Assembly

 

 

 

 

 

 

 

 

. .

1 .

. . . . . . .

.

. . 134 464

. . LABEL, warning general precautionary static&wire fe

. . 1

. .

1 .

. . . . . . .

.

. . 217 732

. . LABEL, warning general precautionary (EN/FR) vert

. . 1

. .

2 .

. . . . . . .

.

. . 210 309

. . +WRAPPER

. . 1

. .

3 .

. . . S2

. . . 190 079

. . SWITCH, secondary 2-position (AC 225 model) & (AC 300 model)

. . 1

. .

3 .

. . . S2

. . . 190 080

. . SWITCH, secondary 4-position (AC/DC 225 model) & (AC/DC 300 model)

. . 1

. .

4 .

. . . . . . .

.

. . 190 977

. . BUS BAR, jumper (AC/DC 225 model) & (AC/DC 300 model)

. . 2

. .

5 .

. . . . . . .

.

. . 190 978

. . BUS BAR, jumper (AC/DC 225 model) & (AC/DC 300 model)

. . 1

. .

6 .

. . . . . . .

.

. . 191 122

. . BRACKET, base reinforcing

. . 2

. .

7 .

. . . T1

. . . 190 170

. . TRANSFORMER & SHUNT, (230V 225A model) (consisting of)

. . 1

. .

7 .

. . . T1

. . . 192 467

. . TRANSFORMER & SHUNT, (460V 225A model) (consisting of)

. . 1

. .

7 .

. . . T1

. . . 192 468

. . TRANSFORMER & SHUNT, (115/230V 225A model) (consisting of)

. . 1

. .

7 .

. . . T1

. . . 192 179

. . TRANSFORMER & SHUNT, (220V 300A AC/DC model) (consisting of) . . . . 1

. .

7 .

. . . T1

. . . 192 317

. . TRANSFORMER & SHUNT, (220V 300A AC model) (consisting of)

. . 1

. .

7 .

. . . T1

. . . 192 326

. . TRANSFORMER & SHUNT, (230/400V 300A model) (consisting of)

. . 1

. .

7 .

. . . T1

. . . 192 469

. . TRANSFORMER & SHUNT, (460V 300A model) (consisting of)

. . 1

. .

8 .

. . . . . . .

.

. . 190 242

. . . SCREW, lead shunt

. . 1

. .

9 .

. . . . . . .

.

. . 190 150

. . . SHUNT

. . 1

. . 10

. . . . . . .

.

. . 147 907

. . . SCREW, 5/16-18 x 1.75 w/loctite

. . 4

. . 11

. . . . . . .

.

. . 080 522

. . . BLOCK, anti-noise shunt

. . 4

. . 12

. . . Z1

. . . 190 145

. . STABILIZER, (AC/DC 225A model)

. . 1

. . 12

. . . Z1

. . . 192 177

. . STABILIZER, (AC/DC 300A model)

. . 1

. . 13

. . SR1

 

. . 190 303

. . RECTIFIER, (AC/DC 225A model)

. . 1

. . 13

. . SR1

 

. . 190 965

. . RECTIFIER, (AC/DC 300A model)

. . 1

. . 14

. . . S1

. . . 124 511

. . SWITCH, (all 225A models)

. . 1

. . 14

. . . S1

. . . 045 834

. . SWITCH, (all 300A models)

. . 1

. . 15

. . . . . . .

.

. . 190 086

. . CASE SECTION

. . 1

. . 16

. PLG1

. . 088 297

. . CORD SET (230V 225A model)

. . 1

. . 16

. . . . . . .

.

. . 071 906

. . CABLE (460V 225A model) & (115/230V 225A model)

. . 1

. . 16

. . . . . . .

.

. . 204 141

. . CABLE (all 300A models)

. . 1

. . 17

. . . . . . .

.

. . 111 443

. . BUSHING, strain relief (230V 225A model)

. . 1

. . 17

. . . . . . .

.

. . 604 102

. . CONNECTOR (all 300A models), (460V 225A model) & (115/230V model) . 1

. . 18

. . . . . . .

.

. . 185 759

. . LABEL, warning electric shock & input power

. . 1

. . 18

. . . . . . .

.

. . 217 733

. . LABEL, warning electric shock & input power (EN/FR)

. . 1

. . 19

. . . FM . . . 190 234

. . MOTOR, fan (all models except 115/230V)

. . 1

. . 19

. . . FM . . . 191 864

. . MOTOR, fan (115/230V models)

. . 1

. . 20

. . . . . . .

.

. . 005 656

. . BLADE, fan

. . 1

. . 21

. . . . . . .

.

. . 190 599

. . LABEL, control/output ac 225 amp

. . 1

. . 21

. . . . . . .

.

. . 190 600

. . LABEL, control/output ac/dc 225/150 amp

. . 1

. . 21

. . . . . . .

.

. . 192 119

. . LABEL, control/output ac 300 amp

. . 1

. . 21

. . . . . . .

.

. . 192 120

. . LABEL, control/output ac/dc 300/200 amp

. . 1

. . 21

. . . . . . .

.

. . 218 237

. . LABEL, control/output ac 225 amp (EN/FR)

. . 1

. . 21

. . . . . . .

.

. . 217 857

. . LABEL, control/output ac/dc 225/150 amp (EN/FR)

. . 1

. . 22

. . . . . . .

.

. . 190 296

. . GEAR, pinion

. . 1

. . 23

. . . . . . .

.

. . 190 295

. . GEAR, pointer

. . 1

. . 24

. . . . . . .

.

. . 190 241

. . HANDLE, control current

. . 1

. . 25

. . . . . . .

.

. . 190 538

. . LEAD LIST

. . 1

. . 26

. . . . . . .

.

. . 190 584

. . KIT, electrode holder & gnd clamp

. . 1

. . 27

. . . . . . .

.

. . 191 635

. . LABEL, brand identity Thunderbolt XL

. . 1

. . 27

. . . . . . .

.

. . 217 964

. . LABEL, brand identity Thunderbolt XL (EN/FR)

. . 1

. . 28

. . . . . . .

.

. . 207 074

. . HANDLE, switch

. . 1

. . 29

. . . . . . .

.

. . 190 243

. . CLAMP, weld cable

. . 2

. . 30

. . . . . . .

.

. . 494 907

. . SCREW, K50 x 20 pan hd-trx stl pld thread forming

. . 1

. . 31

. . . . . . .

.

. . 216 361

. . LABEL, electrode/amperage selector (not included w/EN/FR models) . . . .

. . 1

+When ordering a component originally displaying a precautionary label, the label should also be ordered. Note: “225A model” and “300A model” refers to the AC output rating of the AC/DC and the AC only machines.

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-316 Page 39

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Contents Stick Smaw Welding ProcessesDescription Visit our website at OM-316087 083Q AugustFrom Miller to You Table of Contents Page Electric Shock can kill Symbol UsageMarks a special safety message Arc Welding HazardsBuildup of GAS can injure or kill ARC Rays can burn eyes and skinWelding can cause fire or explosion Flying Metal can injure eyesCalifornia Proposition 65 Warnings EMF Information Principal Safety StandardsAbout Pacemakers LES Fumées ET LES GAZ peuvent être dangereux Signification des symboles− Consignes DE Sécurité − À Lire Avant Utilisation LES Décharges Électriques peuvent être mortellesLE Bruit peut affecter l’ouïe LE Soudage peut causer un incen- die ou une explosionLES Particules Projetées peu- vent blesser les yeux LES Pièces Chaudes peuvent cau- ser des brûlures gravesLES Pièces Mobiles peuvent cau- ser des blessures Risque D’INCENDIE OU D’EXPLOLA Chute DE L’APPAREIL peut blesser ’EMPLOI Excessif peut FaireConsignes relatives aux stimulateurs cardiaques Principales normes de sécuritéInformation sur les champs électromagnétiques Rexdale, Rexdale Ontario Canada M9W 1R3 téléphone− Definitions Symbols And DefinitionsManufacturer’s Rating Labels AC Models − InstallationSpecifications AC/DC ModelsFor AC Models Duty Cycle ChartsVoid warranty For AC/DC ModelsFor 115/230, 230 And 460 Volt Models 225/150 Amperes Volt-Ampere CurvesFor 220, 230/400, And 460 Volt Models 300/200 Amperes For 220 Volt Model For 230/400 Volt Model Amperes For 115/230 And 230 Volt Models 225 AmperesAC Amperes 18 in 457 mm for airflow Selecting a LocationWeld Output Cables Installing Electrode Holder And Work ClampInstalling Electrode Cable and Barrel onto Electrode Holder Installing Work Cable onto Work Clamp150 Electrical Service Guide115 220 230 400 460 47.5Wrapper Remove wrapper Jumper Leads Turn Off unit and disconnect input power10 115 V Input Power Cord White Lead Tools Needed 16, 3/8 Cut tie wrapsConnected For 400 Volts Connected For 230 Volts Connecting Input Power For DC Weld Output − OperationControls Controls For AC/DC ModelsControls For AC Models Months − Maintenance & TroubleshootingRoutine Maintenance Lubricating Shunt Block And Anti-Noise AdjustmentWrapper Remove wrapper from unit Crank Handle Shunt Shaft Reinstalling Amperage Adjustment IndicatorTorx Trouble Remedy TroubleshootingCircuit Diagram For AC/DC 230 Volts Models − Electrical DiagramsCircuit Diagram For AC/DC 115/230 Volts Models Circuit Diagram For 300/200 AC/DC 230/400 Volts Models Circuit Diagram For 225 230 Volts Models Circuit Diagram For 300 220 Volts Models Welding Methods Shielded Metal Arc Welding Smaw Procedure − Welding Methods & TroubleshootingElectrode And Amperage Selection Chart Positioning The Electrode Holder Striking An Arc10−30 Arc Length Weld Bead CharacteristicsConditions That Affect Weld Bead Shape Electrode AngleTack Welds Electrode Movement During WeldingButt Joints Do not let weave widthPorosity Welding TroubleshootingLap Joints Tee Joints Incomplete Fusion Excessive Spatter Lack Of Penetration Distortion Excessive PenetrationBurn-Through Waviness Of BeadMain Assembly AC/DC model illustrated − Parts ListMain Assembly Page Work like a Pro TM-188 304 Invision 354MP Your distributor also gives ServiceSupport Transportation Department Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s
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