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Summary of Contents for Miller Electric OM-494
- Page 1 Visit our website at www.MillerWelds.com Miller DU-OP OM-494 191 862P January 2005 Processes Stick (SMAW) Welding MIG (GMAW) Welding Flux Cored (FCAW) Welding TIG (GTAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging Description Dual-Operator Engine Driven Welding Generator...
- Page 2 ISO 9001:2000 Quality System Standard. particular model are also provided. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets.
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Page 3: Table Of Contents
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1-1. Symbol Usage ............... . 1-2. - Page 4 TABLE OF CONTENTS SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Routine Maintenance ..............8-2.
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Page 5: Section 1 − Safety Precautions − Read Before Using
D Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc. D Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection. rom _nd_8/03 OM-494 Page 1... -
Page 6: Engine Hazards
D Do not spill fuel. If fuel is spilled, clean up before starting engine. D Dispose of rags in a fireproof container. D Always keep nozzle in contact with tank when fueling. OM-494 Page 2 HOT PARTS can cause severe burns. D Allow cooling period before maintaining. -
Page 7: Compressed Air Hazards
D Use proper static-proof bags and boxes to store, move, or ship PC boards. TILTING OF TRAILER can cause injury. D Use tongue jack or blocks to support weight. D Properly install welding generator onto trailer accord- ing to instructions supplied with trailer. OM-494 Page 3... -
Page 8: California Proposition 65 Warnings
Until the final conclusions of the research are reached, you may wish to minimize your exposure to electromagnetic fields when welding or cutting. OM-494 Page 4 ARC WELDING can cause interference. D Electromagnetic energy can interfere with sensitive electronic equipment such as microprocessors, computers, and computer-driven equipment such as robots. -
Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation
éléments peuvent dégager des fumées toxiques en cas de soudage. rom_fre 8/03 Ce groupe de symboles si- gnifie Mise en garde ! Soyez vigilant ! Il y a des risques de danger reliés OM-494 Page 5... -
Page 10: Dangers Existant En Relation Avec Le Moteur
D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi- rateur d’adduction d’air homologué. OM-494 Page 6 Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et NFPA 51B pour les travaux à chaud et avoir de la surveillance et un extincteur à proxi- mité. -
Page 11: Dangers Liés À L'air Comprimé
D Laisser l’ensemble se refroidir avant de toucher ou d’effectuer la maintenance. LIRE LES INSTRUCTIONS. D Lisez le manuel d’instructions avant l’utilisation ou la maintenance de l’appareil. D Arrêter le moteur et relâcher la pression avant d’effectuer la maintenance. OM-494 Page 7... -
Page 12: Principales Normes De Sécurité
électromagnétiques pendant le soudage ou le coupage. OM-494 Page 8 LIRE LES INSTRUCTIONS. D Utiliser seulement les pièces de rechange d’origine. D Effectuer la maintenance du moteur et du compres- seur (si applicable) suivant ce manuel et le manuel du moteur/compresseur (si applicable). -
Page 13: Section 3 − Definitions
Check Valve Fuel Clearance Certified/Trained Negative Mechanic Volts Panel/Local Temperature Output (Contactor) TIG (GTAW) MIG (GMAW) Welding Welding Hours Seconds Read Operator’s Manual Engine Engine Oil Protective Earth (Ground) Welding Arc Remote Alternating Current Three Phase Single Phase OM-494 Page 9... -
Page 14: Section 4 − Specifications
10-1/2 in (267 mm) 6-1/2 in (165 mm) 2-7/8 in (73 mm) 29-7/8 in (759 mm) 11/16 in (24 mm) 21/32 in (17 mm) Dia. 16 Holes Weight 2005 lb (909 kg) OM-494 Page 10 Max. Weld Rated Open- Output Welding Circuit Range... -
Page 15: Fuel Consumption
The curve shows typical fuel use un- der the combined weld loads of both sides (Welder A and Welder B). 195 711 The ac power curve shows the gen- erator power in amperes available at the 120 and 240 volt receptacles. 193 018 OM-494 Page 11... -
Page 16: Duty Cycle And Overheating
Dual Operator Mode − 40% Duty Cycle At 275 Amperes From Each Side Single Operator Mode − 40% Duty Cycle At 550 Amperes From Welder B side (Right) 4 Minutes Welding Overheating OM-494 Page 12 6 Minutes Resting A or V Reduce Duty Cycle... -
Page 17: Volt-Ampere Curves
The volt-ampere curve shows the minimum, medium, and maximum voltage and amperage output capa- bilities of the welding generator. Curves of all other settings fall be- tween the curves shown. 194 397 / 194 398 / 194 399 OM-494 Page 13... -
Page 18: Section 5 − Installation
Always connect a ground wire from the generator equipment grounding termi- nal to bare metal on the vehicle frame as shown. Notes OM-494 Page 14 Airflow Clearance 18 in (460 mm) 18 in... -
Page 19: Activating The Dry Charge Battery
Charge battery for 12 minutes at 30 amperes or 30 minutes at 5 am- peres. Disconnect charging cables and install battery. When electrolyte is low, add only distilled water to cells to maintain proper level. Tools Needed: drybatt1 2/96 − S-0886 OM-494 Page 15... -
Page 20: Connecting The Battery
5-3. Connecting The Battery 5-4. Installing Exhaust Pipe Tools Needed: 1/2 in OM-494 Page 16 Y Connect (−) Cable Last. − Top View 190 377 Y Stop engine and let cool. Y Do not blow exhaust toward air cleaner or air intake. -
Page 21: Engine Prestart Checks
Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier fuel formation. Use correct grade oil for cold weather. Ref. 158 633-C / S-176 697 Over 80,000 trained since 1930! OM-494 Page 17... -
Page 22: Safety Information For Connecting To Weld Output Terminals
Y Stop engine. Negative (−) Weld Output Terminal CV Weld Output Terminal CC Weld Output Terminal OM-494 Page 18 Dinse Weld Receptacles (Only On Units With Polarity Switch Option) See Sections 5-8 thru 5-13 for dual operator output connections for CC and CV welding. -
Page 23: Making Dual Operator Cc Weld Connections W/ Separate Work Cables
Negative (−) terminals. If unit has the Polarity switch option, con- nect work cables to Work receptacles and electrode holder cables to Electrode recep- tacles. Be sure Process Selector switches are set correctly. See Section 6-3. OM-494 Page 19... -
Page 24: Making Dual Operator Mode Cc Weld Connections W/ Common Work Cable
Use Dual Operator mode for CC and CV welding (see Section 6-1). Strain Relief Route cables through strain reliefs. Electrode Holder Cables Work Jumper Cable OM-494 Page 20 Direct Current Electrode Positive (DCEP) connections are shown. Note position of Process Selector switches. -
Page 25: Making Dual Operator Cv Weld Connections W/ Separate Work Cables
Place optional Polarity switches in Re- verse position when using CV weld re- ceptacles. There is no CV weld output when switch is in Straight position. Be sure Process Selector and Polarity switches are set correctly. See Section 6-3. OM-494 Page 21... -
Page 26: Making Dual Operator Cv Weld Connections W/ Common Work Cable
Use Dual Operator mode for CC and CV welding (see Section 6-1). Strain Relief Route cables through strain reliefs. Wire Feeder Cables Work Jumper Cable OM-494 Page 22 Direct Current Electrode Positive (DCEP) connections are shown. Note position of Process Selector switches. -
Page 27: Making Dual Operator Cc And Cv Weld Connections W/ Separate Work Cables
Place optional Polarity switches in Re- verse position when using CV weld re- ceptacles. There is no CV weld output when switch is in Straight position. Be sure Process Selector and Polarity switches are set correctly. See Section 6-3. OM-494 Page 23... -
Page 28: Making Dual Operator Cc And Cv Weld Connections W/ Common Work Cable
(see Section 6-1). Strain Reliefs Route cables through strain reliefs. Electrode Holder Cable Wire Feeder Cable Work Jumper Cable Common Work Cable OM-494 Page 24 Direct Current Electrode Positive (DCEP) connections are shown. Note position of Process Selector switches. -
Page 29: Making Single Operator Cc Weld Connections
Neg- ative (−) receptacle. If unit has the Polarity switch option, con- nect work cable to Work terminal and elec- trode holder cable to Electrode receptacle. Be sure Process Selector switch is set correctly. See Section 6-3. OM-494 Page 25... -
Page 30: Selecting Weld Cable Sizes
( ) = mm for metric use ***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505. OM-494 Page 26 Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding*** 150 ft... -
Page 31: Installing Ether Cylinder (Optional Ether Starting Aid)
After installing cylinder, wait at least 10 minutes before using to let ether particles settle and prevent atomizer plugging. Put cap on fitting when cylinder is removed. ether1 7/96 − 153 382-A / 190 377 / 802 291-A Socket Information OM-494 Page 27... -
Page 32: Remote 14 Receptacle Connections
5-18. Remote 14 Receptacle Connections Dual Operator Operation C L N C L N Single Operator Operation C L N 60 0 AM Ref. 802 291-A OM-494 Page 28... -
Page 33: Section 6 − Operating The Welding Generator
To Stop: Pull control out and hold. Release control when engine stops. Battery Charging Warning Light Light goes on when battery is not charging. Y If light goes on, stop engine and check engine belt. Engine Hour Meter OM-494 Page 29... -
Page 34: Weld Controls (See Section 6-3)
6-2. Weld Controls (See Section 6-3) 300 AMPS 300 AMPS WELDER A Welder B 600 AMPS Welder B 60 0 AM Ref. 191 848 OM-494 Page 30... -
Page 35: Weld Control Descriptions (See Section 6-2)
Use switch to change polarity of weld output (see Sections 5-7 thru 5-14). Place optional Polarity switch in Reverse position when using CV weld receptacle. There is no CV weld output when switch is in Straight position. OM-494 Page 31... -
Page 36: Section 7 − Operating Auxiliary Equipment
8-1. Routine Maintenance Wipe Spills. Clean Air Filter. See Section 8-3. OM-494 Page 32 faulty equipment and the GFCI Reset but- ton pops out. Check for damaged tools, cords, plugs, etc. connected to the recep- tacle. Press button to reset receptacle and resume operation. - Page 37 Service Welding Generator Brushes And Slip Rings. Service More Often In Dirty Conditions.* Check Belt 1/2 in. Tension. See Section 8-7. Change Oil Filter. See Section 8-4. FUEL Drain Sludge SLUDGE From Fuel Tank.* Check Valve Clearance.* OM-494 Page 33...
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Page 38: Maintenance Label
8-2. Maintenance Label OM-494 Page 34... -
Page 39: Servicing Air Cleaner
2 in (51 mm) from inside of element. Replace primary ele- ment if it has holes or damaged gaskets. Reinstall primary element and cap (dust ejector down). aircleaner1 2/01 − ST-153 929-B / ST-153 585 / Ref. S-0698-B OM-494 Page 35... -
Page 40: Servicing Fuel And Lubrication Systems
8-4. Servicing Fuel And Lubrication Systems Under Left Side Of Fuel Tank Behind Control Panel Tools Needed: 3/8, 7/16, 3/4 in OM-494 Page 36 Valve Open Y Stop engine and let cool. Oil Filter Oil Drain Plug Oil Drain Hose (Optional) -
Page 41: Adjusting Engine Speed
Scale Weigh cylinder to see if it is empty. Be sure atomizer is not plugged and valve fitting is clean. Replace cylinder according to Section 5-16. ether2 7/96 − 153 382-A / Ref. 190 377 / S-0692 OM-494 Page 37... -
Page 42: Checking And Replacing Alternator Belt
8-7. Checking And Replacing Alternator Belt Tools Needed: 1/2, 11/16 in OM-494 Page 38 1/2 in (13 mm) Y Stop engine. To check belt tension: Remove rear panel. Alternator V-Belt Crank Pulley Alternator Pulley Place straight edge along top of pul- leys. -
Page 43: Resetting Fan Belt Safety Shutdown
Stop Bracket Handle Pull handle towards front of unit un- til stop snaps in position behind bracket. Close door. Pull Handle To Reset Shutdown 158 715 / Ref. 158 632 / Ref. 190 377 OM-494 Page 39... -
Page 44: Inspecting And Cleaning Optional Spark Arrestor Muffler
8-9. Inspecting And Cleaning Optional Spark Arrestor Muffler Tools Needed: 3/8 in Notes OM-494 Page 40 Y Stop engine and let cool. Spark Arrestor Muffler Cleanout Plug Remove plug and remove any dirt covering cleanout hole. Exhaust Pipe Start engine and run several min- utes to blow out cleanout hole. -
Page 45: Circuit Protection
TP3 or TP4 opens, Welder A (left) or Welder B (right) weld output stops and the High Temp. Shutdown light goes on. Wait fifteen minutes for module to cool and thermostat to automatically reset. Reduce amperage, voltage, or duty cycle before welding. OM-494 Page 41... -
Page 46: Troubleshooting
Check fuses F11, F12, and F13, and replace if open. If fuse(s) are open, have Factory Authorized Service Agent check main rectifier SR3. Have Factory Authorized Service Agent check main rectifier SR3, synchronization transformers T8, T9 and T10, and control board PC5. OM-494 Page 42 Remedy... - Page 47 Place optional Polarity switches in Reverse position. There is no CV weld output when Polarity switch is in Straight position. Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit. Repair or replace wire feeder. Remedy OM-494 Page 43...
- Page 48 Clean battery, terminals, and posts with baking soda and water solution; rinse with clear water. Periodically recharge battery (approximately every 3 months). Replace battery. Check voltage regulator and connections according to engine manual. Engine uses oil during run-in period; Dry engine (see Section 10). wetstacking occurs. OM-494 Page 44 Remedy Remedy...
- Page 49 Notes OM-494 Page 45...
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Page 50: Section 9 − Electrical Diagrams
SECTION 9 − ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For Welding Generator OM-494 Page 46... - Page 51 210 657-A OM-494 Page 47...
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Page 52: Section 10 − Run-In Procedure
SECTION 10 − RUN-IN PROCEDURE 10-1. Wetstacking OM-494 Page 48 run_in3 8/01 Y Do perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur. Welding Generator Run diesel engines near rated volt-... -
Page 53: Run-In Procedure Using Load Bank
Run engine several minutes at no load. Y Stop engine and let cool. Engine Exhaust Pipe Repeat procedure if wetstacking is present. perform run-in S-0683 OM-494 Page 49... -
Page 54: Run-In Procedure Using Resistance Grid
10-3. Run-In Procedure Using Resistance Grid OM-494 Page 50 Y Stop engine. Y Do not touch hot exhaust pipe, engine parts, or load bank/grid. Y Keep exhaust and pipe away from flammables. Y Do perform procedure at less than 20... -
Page 55: Section 11 − Generator Power Guidelines
Supplied) Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame. Use #10 AWG or larger insulated copper wire. Y If unit does not have GFCI re- ceptacles, use GFCI-pro- tected extension cord. OM-494 Page 51 S-0854... -
Page 56: Grounding When Supplying Building Systems
(200 W + 200 W + 200 W) + 520 W = 1120 W The total load applied by the three flood lamps and drill is 1120 watts. OM-494 Page 52 GND/PE Use ground device as stated in electrical codes. - Page 57 1/2 HP 3200 Running Watts 1400 1600 2200 2850 3900 6800 2000 6000 8000 10700 1100 Running Watts 1000 1000 1400 1100 2800 1400 1600 2200 2850 3900 6800 2000 6000 8000 10700 1000 1400 1600 1000 1050 OM-494 Page 53...
- Page 58 Elec. Hedge Trimmer Flood Lights Submersible Pump Centrifugal Pump Floor Polisher High Pressure Washer 55 gal Drum Mixer Wet & Dry Vac OM-494 Page 54 Rating Starting Watts 1/4 in 3/8 in 1/2 in 6-1/2 in 7-1/4 in 8-1/4 in...
- Page 59 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. ST-800 396-A / S-0625 OM-494 Page 55 S-0624...
- Page 60 Customer-supplied equipment is re- quired if generator will supply standby power during emergencies or power out- ages. 1 Utility Electrical Service 2 Transfer Switch (Double-Throw) Notes OM-494 Page 56 Fused Disconnect Transfer Switch Switch (If Required) Essential Loads Switch transfers the electrical load from electric utility service to the generator.
- Page 61 30 (9) 37 (11) 37 (11) 450 (137) 225 (84) 200 (61) 300 (91) 200 (61) 125 (38) 225 (69) 125 (38) 100 (31) 150 (46) 75 (23) 60 (18) 100 (31) 60 (18) 75 (23) 75 (23) OM-494 Page 57...
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Page 62: Section 12 − Parts List
SECTION 12 − PARTS LIST Hardware is common and not available unless listed. 96−SEE FIG 12-2 OM-494 Page 58 Figure 12-1. Main Assembly 25−SEE FIG 12-4... - Page 63 57−SEE FIG 12-3 78−SEE FIG 12-4 802 317-D OM-494 Page 59...
- Page 64 010 863 CLAMP, hose 2.062 − 3.000 clp slftg OM-494 Page 60 Description ........
- Page 65 ..........OM-494 Page 61 Quantity 2.1ft...
- Page 66 *Recommended Spare Parts. OPTIONAL 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-494 Page 62 Description Figure 12-2. Front Panel Quantity .
- Page 67 ........OM-494 Page 63 Quantity...
- Page 68 Figure 12-3. Side Control Panels − Welder B (Right) Side Shown OM-494 Page 64 Hardware is common and not available unless listed. 802 320-A...
- Page 69 ..........OM-494 Page 65...
- Page 70 OPTIONAL 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-494 Page 66 Description TERMINAL BOARD, black ........
- Page 71 ..........OM-494 Page 67...
- Page 72 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-494 Page 68 Description ........
- Page 73 Notes OM-494 Page 69...
- Page 75 Warranty Questions? Call LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to 1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after for your local the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.
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Page 76: Options And Accessories
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. 2005 Miller Electric Mfg. Co. 1/05 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA...