Miller Electric 500DX R, OM-129 manual Table of Contents

Page 3

WARNING

This product, when used for welding or cutting, 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.)

WARNING

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 reproductive harm. Wash hands after handling.

CALIFORNIA

Proposition 65

Warning

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

The following terms are used interchangeably throughout this manual:

Stick = SMAW

MIG = GMAW

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

1

1-1.

Symbol Usage

1

1-2.

Arc Welding Hazards

1

1-3.

Engine Hazards

2

1-4. Additional Symbols For Installation, Operation, And Maintenance

3

1-5.

Principal Safety Standards

4

1-6.

EMF Information

4

SECTION 1 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION

5

1-1.

Signification des symboles

5

1-2. Dangers relatifs au soudage à l’arc

5

1-3. Dangers existant en relation avec le moteur

6

1-4.

Dangers supplémentaires en relation avec l’installation, le fonctionnement

 

 

et la maintenance

7

1-5.

Principales normes de sécurité

8

1-6.

Information sur les champs électromagnétiques

8

SECTION 2 − DEFINITIONS

9

2-1.

Symbols And Definitions

9

SECTION 3 − SPECIFICATIONS

9

3-1.

Specifications

9

3-2.

Dimensions, Weights, And Operating Angles

10

3-3.

Fuel Consumption

10

3-4. Duty Cycle And Overheating

11

3-5.

AC Auxiliary Power

11

3-6.

Volt-Ampere Curves

12

3-7.

Optional AC Power Plant Curves

13

SECTION 4 − INSTALLATION

14

4-1.

Installing Welding Generator

14

4-2.

Installing Exhaust Pipe

14

4-3.

Activating The Dry Charge Battery

15

4-4.

Connecting The Battery

16

4-5.

Engine Prestart Checks

16

4-6.

Connecting To Weld Output Terminals

17

4-7.

Selecting Weld Cable Sizes

17

4-8.

Installing Ether Cylinder (Optional Ether Starting Aid)

18

4-9.

Remote A/V Control Receptacle RC3

18

4-10.

Remote 14 Receptacle RC3 Information (Optional)

19

4-11.

Terminal Strip 2T Connections (Optional)

19

SECTION 5 − OPERATING THE WELDING GENERATOR

20

5-1.

Standard Controls (See Section 5-2)

20

5-2.

Description Of Standard Controls (See Section 5-1)

21

5-3.

Controls For Models With CV Option (See Section 5-4)

22

5-4.

Description Of Controls For Models With CV Option (See Section 5-3)

23

SECTION 6 − OPERATING AUXILIARY EQUIPMENT

24

6-1.

120 Volt And 240 Volt Duplex Receptacles

24

6-2.

Optional Auxiliary Power Receptacles

25

6-3.

Connecting Optional Auxiliary Power Plant

26

SECTION 7 − MAINTENANCE & TROUBLESHOOTING

27

7-1.

Routine Maintenance

27

7-2.

Maintenance Label

28

7-3.

Servicing Air Cleaner

29

7-4.

Servicing Fuel And Lubrication Systems

30

7-5.

Adjusting Engine Speed

31

7-6.

Servicing Optional Ether Starting Aid

31

7-7.

Checking And Replacing Alternator Belt

32

7-8.

Resetting Fan Belt Safety Shutdown

33

7-9.

Inspecting And Cleaning Optional Spark Arrestor Muffler

34

7-10.

Overload Protection For Models With CV Option

34

7-11.

Troubleshooting

35

SECTION 8 − ELECTRICAL DIAGRAMS

37

SECTION 9 − RUN-IN PROCEDURE

40

9-1.

Wetstacking

40

9-2.

Run-In Procedure Using Load Bank

41

9-3.

Run-In Procedure Using Resistance Grid

42

SECTION 10 − AUXILIARY POWER GUIDELINES

43

SECTION 10 − PARTS LIST

50

WARRANTY

 

Page 2 Page 4
Image 3
Page 2 Page 4
Contents OM-129 647W ProcessesDescription From Miller to You Table of Contents Page ARC Rays can burn eyes and skin Symbol UsageArc Welding Hazards Electric Shock can killEngine Hazards Engine Heat can cause fire Battery Explosion can BlindMoving Parts can cause injury Engine Exhaust Gases can killARC Welding can cause interference Principal Safety StandardsEMF Information Radiation can cause interferenceLES Fumées ET LES GAZ peuvent être dangereux Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation UN Choc Électrique peut tuerLE Bruit peut affecter l’ouïe LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux DES Pièces Chaudes peuvent provoquer des brûlures gravesLA Chute DE L’APPAREIL peut blesser DES Organes Mobiles peuvent provoquer des blessures’EXPLOSION DE LA Batterie peut LA Chaleur DU Moteur peut pro- voquer un incendieConsignes relatives aux stimulateurs cardiaques Principales normes de sécuritéInformation sur les champs électromagnétiques LE Soudage À L’ARC risque de provoquer des interférences− Definitions − SpecificationsSymbols And Definitions Weld, Power, And Engine Specifications1898 lb 861 kg Engine End Dimensions, Weights, And Operating AnglesCurve shows typical fuel use under weld or power loads Fuel Consumption60% Duty Cycle At 500 Amperes Duty Cycle is Percentage AC Auxiliary PowerWarranty Minutes Welding Minutes Resting Duty Cycle And OverheatingCC/DC Standard CV/DC Models With CV Option Volt-Ampere CurvesOptional AC Power Plant Curves Location − InstallationInstalling Welding Generator Do Not Lift Unit From End Airflow ClearanceMaintain proper level Activating The Dry Charge BatteryWhen electrolyte is low, add ChargerTools Needed 1/2 Connecting The BatteryEngine Prestart Checks Connect Negative − Cable LastSelecting Weld Cable Sizes Connecting To Weld Output TerminalsInstalling Ether Cylinder Optional Ether Starting Aid After installing cylinder, wait atRemote A/V Control Receptacle RC3 Stop engine Remote 14 Receptacle RC3 Information OptionalTerminal Strip 2T Connections Optional SocketStandard Controls See Section − Operating the Welding GeneratorIf light goes on, stop engine and check engine belt Do not switch under loadDescription Of Standard Controls See Section If light goes off, stop engine and check oil levelControls For Models With CV Option See Section This unit has a max OCV control circuit 120 V 15 a AC Receptacle RC2 240 V 15 a AC Receptacle RC1 Auxiliary power is not affected by weld output− Operating Auxiliary Equipment Volt And 240 Volt Duplex ReceptaclesBritish Receptacle Option Optional Auxiliary Power ReceptaclesGfci Receptacle Option Australian And South African Receptacle OptionsLoad Terminals Connecting Optional Auxiliary Power PlantSet Engine Control switch to Run when using auxiliary power 1011− Maintenance & Troubleshooting Deutz F3L912 Diesel Engine Maintenance LabelServicing Air Cleaner To clean air filterHose Servicing Fuel And Lubrication Systems Adjusting Engine Speed Servicing Optional Ether Starting Aid1850 Stop engine To check belt tension To adjust belt tensionChecking And Replacing Alternator Belt 13 mm Max Tools Needed 11/16Resetting Fan Belt Safety Shutdown Stop engine and let cool Inspecting And Cleaning Optional Spark Arrestor MufflerStop engine and let cool. Reinstall cleanout plug Overload Protection For Models With CV OptionWelding TroubleshootingEngine Auxiliary PowerTrouble Remedy OM-129 647 Circuit Diagram For Welding Generator Standard Models − Electrical DiagramsCircuit Diagram For Welding Generator Models With CV Option 184 954-C Wetstacking − RUN-IN ProcedureLoad Bank Run-In Procedure Using Load BankFrom flammables Run-In Procedure Using Resistance GridDo not touch hot exhaust Bank/grid− Auxiliary Power Guidelines Selecting EquipmentGrounding Generator To Truck Or Trailer Frame Use ground device as stated in electrical codes Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Earth ground if supplyingFarm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Industrial Motors Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentKVA/HP x HP x 1000 = Starting Amperage Volts Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsCustomer-supplied equipment is required if Generator is to supply standby power duringEmergencies or power outages Welding Generator Auxiliary Power output circuitSelecting Extension Cord Use Shortest Cord Possible 101 100 − Parts List66 65 102 Dia Part Description Quantity Mkgs Optional Panel, Front w/Components CC Model Illustrated Panel, Front w/Components -1 Item 6 5 GeneratorGenerator -1 Item 171 Hardware is common Not available unless listedIncludes Control Box CC/CV -1 Item 86 Optional Panel, Mtg Components CC/CV Model Panel, Mtg Components CC Model Page Service Your distributor also givesSupport Miller Electric Mfg. Co To locate distributor nearest you call 1-800-4-A-MillerFor assistance in filing or settling claims
Top Page Image Contents