Miller Electric OM-494 manual Item Dia Part Description Quantity Mkgs

Page 64

 

Item Dia.

Part

Description

Quantity

 

No.

Mkgs.

No.

 

 

 

 

Figure 12-1. Main Assembly

 

 

 

 

 

 

 

. .

1 .

. . . . . . . . .

. . . 605 288

. . FITTING, pipe galv plug sqhd .250NPT

. . . 1

. .

2 .

. . . . . . . . .

. . . 070 010

. . BOLT, J stl .250-20 x 2.750 pld

. . . 2

. .

3 .

. . . . . . . . .

. . . 088 696

. . STRAP, hold down fuel tank

. . . 2

. .

4 .

. . . . . . . . .

. . . 134 771

. . PLUG, protective .640sq

. . . 2

. .

5 .

. . . . . . . . .

. . . 184 675

. . TANK, fuel 22.3gal (consisting of)

. . . 1

. .

6 .

. . . . . . . . .

. . . 182 022

. . . . CAP, fuel

. . . 1

. .

7 .

. . . . . . . . .

. . . 020 185

. . FITTING, pipe brs elbow st 1/8NPT

. . . 1

. .

8 .

. . . . . . . . .

. . . 053 525

. . FITTING, hose brs barbed M 5/16tbg x 1/8NPT

. . . 1

. .

9 .

. . . . . . . . .

. . . 172 071

. . CLAMP, hose .520-.605clp dia slfng

. . . 6

. . 10

. . . . . . . . .

. . . 134 835

. . HOSE, SAE .312 ID x .560 OD (order by ft)

. . . 9ft

. . 11

. . . . . . . . .

. . . 097 507

. . STRIP, rbr adh back .125 x 1.000 x 20.500 60 duro

. . . 2

. . 12

. . . . . . . . .

. . . 175 432

. . VALVE, shut-off fuel

. . . 1

. . 13

. . . . . . . . .

. . . 039 599

. . FITTING, brs barbed M 5/16 tbg x 1/4 NPT

. . . 1

. . 14

. . . . . . . . .

. . +048 227

. . UPRIGHT, base front

. . . 1

. . 15

. . . . . . . . .

. . . 170 689

. . FRAME, mtg reactor and fuel tank

. . . 1

. . 16

. . . . . . . . .

. . +170 617

. . UPRIGHT, base center

. . . 1

. . 17

. . . . . . . . .

. . . 017 479

. . SEAL, weather lift eye

. . . 1

. . 18

. R3, R5

. . . 097 459

. . RESISTOR, WW fxd 375W 20 ohm

. . . 2

. . 19

. . . . . . . . .

. . . 108 081

. . TERMINAL PROTECTOR, battery post mtg

. . . 2

. . 20

. . . . . . . . .

. . . 182 276

. . CABLE, bat pos

. . . 1

. . 21

. . . . . . . . .

. . . 208 353

. . HOLD DOWN, battery

. . . 1

. . 22

. . . . . . . . .

. . . 032 453

. . CABLE, bat neg

. . . 1

. . 23

. . . . . . . . .

. . . 190 896

. . BATTERY, stor 12v 660 crk 110 rsv gp 24 low

. . . 1

. . 24

. . . . . . . . .

. . . 010 460

. . STUD, stl .312-18 x 10.000

. . . 1

. . 25

SR2, SR3 Figure 12-5

. . RECTIFIER ASSEMBLY

. . . 1

. . 26

. . . . . . . . .

. . . 176 697

. . LABEL, fuel shut-off

. . . 1

. . 27

. . . . . . . . .

. . . 145 282

. . FITTING, hose brs barbed elbow M 5/16tbg x 1/4NPT

. . . 2

. . 28

. . . . . . . . .

. . . 083 859

. . BRACKET, mtg fuel filter

. . . 1

. . 29

. . . . . . . . .

. . . Deleted

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .

. . 30

. . . . . . . . .

. . . 202 242

. . BASE, fuel filter assy

. . . 1

. . 31

. . . . . . . . .

. . . 192 744

. . SEPARATOR, fuel filter & water

. . . 1

. . 32

. . . . . . . . .

. . . 135 205

. . NUT, 625-11 .94 hex .76H stl pld

. . . 8

. . 33

. . . . . . . . .

. . . 116 707

. . SUPPORT, front engine

. . . 1

. . 34

. . . . . . . . .

. . . 119 849

. . SCREW, 625-11 x 4.00 hexhd pln gr 5 pld

. . . 4

. . 35

. . . . . . . . .

. . . 071 731

. . WASHER, flat stl .656 ID x 2.250 OD x .187thk

. . . 4

. . 36

. . . . . . . . .

. . . 071 890

. . RETAINER, mount eng/gen

. . . 4

. . 37

. . . . . . . . .

. . . 071 730

. . TUBING, stl .875 OD x 12ga wall x 2.500

. . . 4

. . 38

. . . . . . . . .

. . . 072 848

. . MOUNT, eng/gen nprn .875 ID x 2.500 OD x 2.000 50 dur

. . . 2

. . 39

. . . . . . . . .

. . . 010 875

. . CLAMP, muffler 2.000 dia

. . . 1

. . 40

. . . . . . . . .

. . . 105 734

. . PIPE, muffler extension elbow 1.875 OD

. . . 1

. . 41

. . . . . . . . .

. . . 176 232

. . BAFFLE, air muffler exhaust

. . . 1

. . 42

. . . . . . . . .

. . . 048 216

. . BRACKET, mtg breather

. . . 1

. . 43

. . . . . . . . .

. . +105 909

. . COVER, top

. . . 1

. . 44

. . . . . . . . .

. . . 107 990

. . LABEL, use diesel fuel only

. . . 1

. . 45

. . . . . . . . .

. . . 035 968

. . WASHER, flat rbr 3.625 ID x 5.875 OD x .062thk

. . . 1

. . 46

. . . . . . . . .

. . . 158 610

. . LABEL, warning electric shock

. . . 2

. . 47

. . . . . . . . .

. . . 168 385

. . LABEL, warning battery explosion

. . . 1

. . 48

. . . . . . . . .

. . +192 313

. . DOOR, side LH

. . . 1

. . 49

. . . . . . . . .

. . . 108 487

. . LABEL, warning falling equipment

. . . 2

. . 50

. . . . . . . . .

. . . 117 257

. . PANEL, end engine

. . . 1

. . 51

. . . . . . . . .

. . +192 314

. . DOOR, side RH

. . . 1

. . 52

. . . . . . . . .

. . . 181 642

. . LABEL, diesel engine maintenance

. . . 1

. . 53

. . . . . . . . .

. . . 004 130

. . BRACKET, support door

. . . 2

. . 54

. . . . . . . . .

. . . 087 341

. . BUMPER, door 1.000 OD x .750 high

. . . 4

. . 55

. . . . . . . . .

. . . 087 336

. . LATCH

. . . 2

. . 56

. . . . . . . . .

. . . 027 434

. . LABEL, welder will not start by applying power to terminals

. . . 2

. . 57

. . . . . . . . .

Figure 12-3

. . SIDE CONTROL PANELS

. . . 2

. . 58

. . . . . . . . .

. . . 023 313

. . CLAMP, hose 3.250-3.000 clp dia slftg

. . . 1

. . 59

. . . . . . . . .

. . . 201 547

. . HOSE, air cleaner w/spring

. . . 1

. . 60

. . . . . . . . .

. . . 010 863

. . CLAMP, hose 2.062 − 3.000 clp slftg

. . . 1

OM-494 Page 60

Page 63 Page 65
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Page 63 Page 65
Contents Processes DescriptionVisit our website at OM-494191 862P January Dual-Operator Engine Driven Welding GeneratorFrom Miller to You Table of Contents Options and Accessories Warranty Symbol Usage Arc Welding HazardsEngine Hazards Compressed Air Hazards Principal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interferenceSignification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un in- cendie ou une explosion DES Particules Volantes peuvent blesser les yeuxDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peut DES Organes Mobiles peuvent provoquer des blessuresLA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessuresPrincipales normes de sécurité Information sur les champs électromagnétiquesSymbols And Definitions − Definitions− Specifications Weld, Power, And Engine SpecificationsDimensions, Weights, And Operating Angles DescriptionAC Generator Power Fuel ConsumptionExceeding duty cycle can damage unit and void warranty Duty Cycle And OverheatingOverheating Reduce Duty Cycle MinutesCC/DC − Single Mode CC/DC − Dual ModeCV/DC Mode Volt-Ampere Curves− Installation Installing Welding GeneratorActivating The Dry Charge Battery Do not overfill battery cellsRead and follow all instruc ChargerConnecting The Battery Installing Exhaust PipeConnect − Cable Last Top View Tools Needed 1/2Fuel Do not use gasoline. Gaso Line will damage engine Engine Prestart ChecksOil Safety Information For Connecting To Weld Output Terminals Weld Output TerminalsUnexpected Weld Output can cause injury or fire Welder a Left Side Welder B Right SideWelder a Left Side Do not exceed machine duty cycleStop engine Do not exceed machine duty cycle Connect electrode holder cables to Elec- trode receptaclesPlace optional Polarity switches in Re Verse position when using CV weld reWhen switch is in Straight position Switches are set correctly. See SectionConnect wire feeder cables to Negative − terminals Connect wire feeder cables to CV recep- taclesBe sure Process Selector switches are Place optional Polarity switch in Re Making Single Operator CC Weld Connections Selecting Weld Cable Sizes 150 ft 200 ft 250 ft350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Put terminalsInstalling Ether Cylinder Optional Ether Starting Aid After installing cylinder, wait atRemote 14 Receptacle Information Socket InformationRemote 14 Receptacle Connections Dual Operator Operation− Operating the Welding Generator Engine ControlsSee -3for weld control descriptions If light goes on, stop engine and check engine beltWeld Controls See Section Do not switch under load or with out- put on Do not switch under loadWeld Control Descriptions See Section CV weld output for MIG is only available− Maintenance & Troubleshooting − Operating Auxiliary EquipmentEvery 100 h Every 200 hEvery 250 h Every 500 hMaintenance Label Servicing Air Cleaner By the warrantyTo clean air filter Do not clean housing with air hoseServicing Fuel And Lubrication Systems Adjusting Engine Speed Weld/Power 1850Servicing Optional Ether Starting Aid CylinderTo adjust belt tension Checking And Replacing Alternator BeltMax Tools Needed 11/16 Stop engine To check belt tensionResetting Fan Belt Safety Shutdown Inspecting And Cleaning Optional Spark Arrestor Muffler Reinstall cleanout plug Tools Needed 3/8Circuit Protection Thermostats TP3 And TP4 Internal − Not ShownTroubleshooting WeldingFactory Authorized Service Agent check main rectifier SR2 Factory Authorized Service Agent check main rectifier SR3Repair or replace wire feeder Formers T5 thru T10, and control board PC1 or PC5Generator Power EngineOM-494 − Electrical Diagrams Circuit Diagram For Welding Generator210 657-A Wetstacking − RUN-IN ProcedureMent damage may occur Run-In Procedure Using Load Bank 4exceed duty cycle or equip- ment damage may occurCheck oil level frequently dur Ing run-in add oil if neededRun-In Procedure Using Resistance Grid Procedure at less thanBank/grid From flammables− Generator Power Guidelines Has this symbolSelecting Equipment Grounding Generator To Truck Or Trailer FrameGrounding When Supplying Building Systems How Much Power Does Equipment Require?Earth ground if supplying Use ground device as stated Electrical codesApproximate Power Requirements For Industrial Motors Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsPower Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 = Starting AmperageTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Current Load Watts Amperes− Parts List 311 103 96−SEE -2 101 25−SEE FIG 9104748 57−SEE FIG 78−SEE FIG Item Dia Part Description Quantity Mkgs 189 Front Panel Front Panel -1Item Side Control Panels − Welder B Right Side Shown Side Control Panels -1Item Side Control Panels Generator Rectifier Assembly OM-494 Page Your distributor also gives ServiceSupport To locate a Distributor or Service Agency visit Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s
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