Miller Electric OM-494 manual 189

Page 65

 

Item Dia.

Part

Description

Quantity

 

No.

Mkgs.

No.

 

 

 

 

Figure 12-1. Main Assembly (Continued)

 

 

 

 

 

 

. . 61

. . . . . . . . .

. . . 189 764

. . AIR CLEANER, intake

. . . 1

. .

. . . .

. . . . . . . . .

. . *192 938

. . FILTER, air element primary

. . . 1

. .

. . . .

. . . . . . . . .

. *♦192 939

. . FILTER, air element safety

. . . 1

. .

. . . .

. . . . . . . . .

. . . 203 462

. . BRACKET, mtg air cleaner

. . . 1

. . 62

. . . . . . . . .

. . . 165 785

. . HOSE, air cleaner 2.437 ID

. . . 1

. . 63

. . . . . . . . .

. . . 048 213

. . BAFFLE, air intake

. . . 1

. .

. . . .

. . . . . . . . .

. . . 194 467

. . WASHER, flat (for baffle) 6.25 ID x 11.50 OD x .62 T buna

. . . 1

. . 64

. . . . . . . . .

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

. . LEVER, trip shutdown (included w/engine − see engine parts list) . . . .

. . . 1

. . 65

. . . . . . . . .

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

. . SPRING (included w/engine − see engine parts list)

. . . 1

. . 66

. . . . . . . . .

. . . 181 634

. . ENGINE, dsl electric (consisting of)

. . . 1

. . 67

. . . . . . . . .

. . . 087 371

. . . . ROD, shutdown

. . . 1

. .

. . . .

. . . . . . . . .

. . *064 677

. . FILTER, oil

. . . 1

. .

. . . .

. . . . . . . . .

. . *062 342

. . FILTER, fuel primary

. . . 1

. .

. . . .

. . . . . . . . .

. . *064 686

. . FILTER, fuel secondary

. . . 1

. .

. . . .

. . . . . . . . .

. . *064 690

. . BELT, blower

. . . 1

. . 68

. . . . . . . . .

. . . 070 661

. . ROD, speed control

. . . 1

. . 69

. . . . . . . . .

. . . 151 969

. . SWITCH, pressure 4PSI N/O

. . . 1

. . 70

. . . . . . . . .

. ♦047 361

. . FITTING, banjo

. . . 1

. . 71

. . . . . . . . .

. ♦089 351

. . FITTING, pipe brs plug hexhd 1/2NPT

. . . 1

. . 72

. . . . . . . . .

. ♦192 197

. . BRACKET, mounting

. . . 1

. . 73

. . . . . . . . .

. . ♦008 114

. . HOSE, oil w/fittings 17.500 lg

. . . 1

. . 74

. . . . . . . . .

. ♦047 234

. . BOLT, banjo

. . . 1

. .

. . . .

. . . . . . . . .

. ♦047 235

. . WASHER, oil seal copper

. . . 2

. . 75

. . . . . . . . .

. . . 127 994

. . BALL JOINT, .250-28

. . . 1

. . 76

. . . . . . . . .

. . . 162 740

. . STUD, stl .250-28 x 45.000

. . . 1

. . 77

. . . . . . . . .

. . . 083 476

. . MOUNT, eng/gen nprn .875 ID x 2.500 OD x 2.000 60 dur

. . . 2

. . 78

. . . . . . . . .

Figure 12-4

. . GENERATOR

. . . 1

. . 79

. . . . . . . . .

. . . 013 367

. . LABEL, warning moving parts

. . . 2

. . 80

. . . . . . . . .

. . . 176 236

. . BAFFLE, air outlet

. . . 1

. . 81

. . . . . . . . .

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

. . CLAMP, muffler (included with engine)

. . . 1

. . 82

. . . . . . . . .

. . . 105 733

. . PIPE, muffler extension elbow 1.875 OD

. . . 1

. . 83

. . . . . . . . .

. . . 165 739

. . BASE

. . . 1

. . 84

. . . . . . . . .

. . . 191 446

. . EXTRUSION, rubber w/adhesive 1.000 x 1.000 D (order by ft)

. . 2.1ft

. . 85

. . . . . . . . .

. . . 173 352

. . EXTRUSION, rubber clamp/bulb (order by ft)

. . 2.4ft

. . 86

. . . . . . . . .

. . . 192 305

. . TRAY, base

. . . 1

. . 87

. . . . . . . . .

. . . 176 167

. . NUT, 250-20 acorn nylon

. . . 6

. . 88

. . . . . . . . .

. . . 192 303

. . ANGLE, mtg stabilizer

. . . 4

. . 89

. Z1, Z2

. . . 192 296

. . STABILIZER

. . . 2

. . 90

. . . . . . . . .

. . . 205 791

. . BRACKET, mtg fuse assembly (consisting of)

. . . 1

. . 91

. . . . . . . . .

. . . 204 965

. . . . STRIP, insulation

. . . 6

. . 92

. . . . . . . . .

. . . . 026947

. . . . STAND-OFF, insul .250-20 x 1.0

. . . 12

. . 93 F11-13,F21-23 . 027 267

. . FUSE, link 300 A 250 volt

. . . 6

. . 94

. . . . . . . . .

. . . 192 304

. . PANEL, front lower

. . . 1

. . 95

. . . . . . . . .

. . . 134 792

. . LABEL, warning general precautionary

. . . 1

. . 96

. . . . . . . . .

Figure 12-2

. . FRONT PANEL

. . . 1

. . 97

. . . . . . . . .

. . . 175 256

. . INSULATOR, side rh

. . . 1

. . 98

. . . . . . . . .

. . . 192 300

. . SHROUD, generator LH

. . . 1

. . 99

. T2, T4

. . . 192 371

. . TRANSFORMER, 115V pri 24VCT 8A w/leads

. . . 2

.

100

. . . . . . . . .

. . . 192 301

. . SHROUD, generator RH

. . . 1

.

101

. . . . . . . . .

. . . 168 829

. . TRANSDUCER, current 1000A module max open loop

. . . 2

.

102

. . . . . . . . .

. . . 192 299

. . SHROUD, generator center

. . . 1

.

103

. . . . . . . . .

. . . 194 021

. . CAPACITOR ASSEMBLY, (consisting of)

. . . 2

. .

. . . .

. . . . . . . . .

. . . 162 817

. . . . BUS BAR, capacitor

. . . 2

. .

. . . .

C15, C20

. . 163 535

. . . . CAPACITOR, elctlt

. . . 6

. .

. . . .

. R4, R6

. . . 140 002

. . . . RESISTOR, WW fxd 10W

. . . 1

. .

. . . .

. . . . . . . . .

. . . 162 799

. . . . BRACKET, mtg capacitors

. . . 2

OM-494 Page 61

Page 64 Page 66
Image 65
Page 64 Page 66
Contents Description ProcessesVisit our website at OM-494191 862P January Dual-Operator Engine Driven Welding GeneratorFrom Miller to You Table of Contents Options and Accessories Warranty Arc Welding Hazards Symbol UsageEngine Hazards Compressed Air Hazards California Proposition 65 Warnings Principal Safety StandardsEMF Information Radiation can cause interference− Consignes DE Sécurité − Lire Avant Utilisation Signification des symbolesUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereuxDES Particules Volantes peuvent blesser les yeux LE Soudage peut provoquer un in- cendie ou une explosionDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut affecter l’ouïeDES Organes Mobiles peuvent provoquer des blessures ’EXPLOSION DE LA Batterie peutLA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessuresInformation sur les champs électromagnétiques Principales normes de sécurité− Definitions Symbols And DefinitionsWeld, Power, And Engine Specifications − SpecificationsDimensions, Weights, And Operating Angles DescriptionFuel Consumption AC Generator PowerDuty Cycle And Overheating Exceeding duty cycle can damage unit and void warrantyOverheating Reduce Duty Cycle MinutesCC/DC − Dual Mode CC/DC − Single ModeCV/DC Mode Volt-Ampere CurvesInstalling Welding Generator − InstallationDo not overfill battery cells Activating The Dry Charge BatteryRead and follow all instruc ChargerInstalling Exhaust Pipe Connecting The BatteryConnect − Cable Last Top View Tools Needed 1/2Oil Engine Prestart ChecksFuel Do not use gasoline. Gaso Line will damage engine Weld Output Terminals Safety Information For Connecting To Weld Output TerminalsUnexpected Weld Output can cause injury or fire Welder a Left Side Welder B Right SideDo not exceed machine duty cycle Welder a Left SideConnect electrode holder cables to Elec- trode receptacles Stop engine Do not exceed machine duty cycleVerse position when using CV weld re Place optional Polarity switches in ReWhen switch is in Straight position Switches are set correctly. See SectionConnect wire feeder cables to CV recep- tacles Connect wire feeder cables to Negative − terminalsBe sure Process Selector switches are Place optional Polarity switch in Re Making Single Operator CC Weld Connections 150 ft 200 ft 250 ft Selecting Weld Cable Sizes350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Put terminalsAfter installing cylinder, wait at Installing Ether Cylinder Optional Ether Starting AidRemote 14 Receptacle Information Socket InformationDual Operator Operation Remote 14 Receptacle ConnectionsEngine Controls − Operating the Welding GeneratorSee -3for weld control descriptions If light goes on, stop engine and check engine beltWeld Controls See Section Do not switch under load Do not switch under load or with out- put onWeld Control Descriptions See Section CV weld output for MIG is only available− Operating Auxiliary Equipment − Maintenance & TroubleshootingEvery 200 h Every 100 hEvery 250 h Every 500 hMaintenance Label By the warranty Servicing Air CleanerTo clean air filter Do not clean housing with air hoseServicing Fuel And Lubrication Systems Weld/Power 1850 Adjusting Engine SpeedServicing Optional Ether Starting Aid CylinderChecking And Replacing Alternator Belt To adjust belt tensionMax Tools Needed 11/16 Stop engine To check belt tensionResetting Fan Belt Safety Shutdown Reinstall cleanout plug Tools Needed 3/8 Inspecting And Cleaning Optional Spark Arrestor MufflerThermostats TP3 And TP4 Internal − Not Shown Circuit ProtectionWelding TroubleshootingFactory Authorized Service Agent check main rectifier SR3 Factory Authorized Service Agent check main rectifier SR2Repair or replace wire feeder Formers T5 thru T10, and control board PC1 or PC5Engine Generator PowerOM-494 Circuit Diagram For Welding Generator − Electrical Diagrams210 657-A Ment damage may occur − RUN-IN ProcedureWetstacking 4exceed duty cycle or equip- ment damage may occur Run-In Procedure Using Load BankCheck oil level frequently dur Ing run-in add oil if neededProcedure at less than Run-In Procedure Using Resistance GridBank/grid From flammablesHas this symbol − Generator Power GuidelinesSelecting Equipment Grounding Generator To Truck Or Trailer FrameHow Much Power Does Equipment Require? Grounding When Supplying Building SystemsEarth ground if supplying Use ground device as stated Electrical codesApproximate Power Requirements For Farm/Home Equipment Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentHow Much Power Can Generator Supply? Power Required To Start MotorSingle-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 = Starting AmperageTypical Connections To Supply Standby Power Current Load Watts Amperes Selecting Extension Cord Use Shortest Cord Possible311 103 96−SEE -2 101 25−SEE FIG 910 − Parts List4748 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 Support ServiceYour distributor also gives Miller Electric Mfg. Co To locate a Distributor or Service Agency visitFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s
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