Miller Electric 500DX R, OM-129 manual Optional

Page 59

 

Item

Dia.

Part

Description

Quantity

 

No.

Mkgs.

No.

 

 

 

 

Figure 11-1. Main Assembly (Continued)

 

 

 

 

 

 

 

. .

53 . .

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

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

. . . 1

. .

54 . .

. . . . . . . . . .

181 634 . .

ENGINE, diesel electric (consisting of)

. . . 1

. .

55 . .

. . . . . . . . . .

087 371 . .

. . ROD, shutdown

. . . 1

. .

56 . .

. . . . . . . . . .

070 661 . .

ROD, speed control

. . . 1

. .

. . . . . .

. . . . . . . . . .

604 393 . .

NUT, speed push-on type .187

. . . 1

. .

57 . .

. . S5 . . . .

151 969 . .

SWITCH, pressure oil 4psi NO

. . . 1

. .

58 . .

. . . . . . . . .

♦047 361 . .

FITTING, banjo

. . . 1

. .

59 . .

. . . . . . . . .

♦089 351 . .

FITTING, pipe brs plug hexhd 1/2NPT

. . . 1

. .

60 . .

. . . . . . . . .

♦008 114 . .

HOSE, oil w/fittings 17.500 lg

. . . 1

. .

61 . .

. . . . . . . . .

♦047 234 . .

BOLT, banjo

. . . 1

. .

. . . . . .

. . . . . . . . .

♦047 235 . .

WASHER, oil seal copper

. . . 2

. .

62 . .

. . . . . . . . . .

127 994 . .

BALL JOINT, .250-28

. . . 1

. .

63 . .

. . . . . . . . . .

162 740 . .

STUD, stl .250-28 x 45.000

. . . 1

. .

. . . . . .

. . . . . . . . . .

032 878 . .

CLAMP, stl cush .500dia x .406mtg hole (used on wiring harness) . . . .

. . . 1

. .

64 . .

. . . . . . . . . .

083 476 . .

TUBING, nprn .875 ID x 2.500 OD x 2.000

. . . 2

. .

65 . .

. . . . . . . . . .

071 730 . .

TUBING, stl .875 OD x 12ga wall x 2.375

. . . 4

. .

66 . .

. . . . . . . . . .

071 890 . .

RETAINER, mount engine/generator

. . . 4

. .

67 .

SHUNT . .

030 084 . .

SHUNT, meter 500MV 600A

. . . 1

. .

68 . .

. . . . . . . . . .

. Fig 11-3 . .

GENERATOR

. . . 1

. .

69 . .

. . . . . . . . . .

071 731 . .

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

. . . 4

. .

70 . .

. . . . . . . . . .

601 945 . .

SCREW, cap stl hexhd .625-18 x 4.000

. . . 4

. .

71 . .

. . . . . . . . . .

176 236 . .

BAFFLE, air outlet

. . . 1

. .

72 . .

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

CLAMP, muffler (included w/engine − see engine parts list)

. . . 1

. .

73 . .

. . . . . . . . . .

105 733 . .

PIPE, muffler extension elb

. . . 1

. .

74 . .

. . . . . . . . . .

165 739 . .

BASE

. . . 1

. .

75 . .

. . R2 . . . .

030 060 . .

RESISTOR, WW adj 375W 20 ohm (CC model)

. . . 1

. .

76 . .

. . . . . . . . . .

170 681 . .

STRIP, mtg resistor

. . . 1

. .

77 . .

. . R3 . . . .

128 862 . .

RESISTOR, WW adj 375W 50 ohm (CC model)

. . . 1

. .

78 . .

. . . . . . . . .

♦186 008 . .

INSULATION, terminal strip

. . . 1

. .

79 . .

. . 2T . . . ♦038 601 . .

BLOCK, term 30A 9P

. . . 1

. .

80 . .

. . . . . . . . .

♦184 499 . .

BRACKET, mtg terminal strip

. . . 1

. .

. . . . . .

PLG21 . .

♦168 071 . .

CONNECTOR & SOCKETS

. . . 1

. .

81 . .

. . . . . . . . . .

603 107 . .

HOSE, nprn slit bk .156 ID x .343 OD (order by ft)

. . . 1ft

. .

82 . .

. . . . . . . . . .

053 967 . .

INSULATION, rectifier

. . . 1

. . 83 . TE1/TE4 . .

038 621 . .

BLOCK, term 30A 4P

. . . 1

. .

. . . . . .

. . . . . . . . . .

038 620 . .

LINK, jumper

. . . 2

. .

84 . .

. . . . . . . . . .

081 499 . .

BRACKET, mtg

. . . 1

. .

85 . .

. . . . . . . . . .

010 146 . .

CLAMP, nyl .625clp dia

. . . 1

. .

86 . .

. . . . . . . . . .

. Fig 11-5 . .

CV-3 CONTROL BOX

. . . 1

. .

87 . .

. . . . . . . . . .

. Fig 11-6 . .

PANEL, mtg components (CC/CV model)

. . . 1

. .

87 . .

. . . . . . . . . .

. Fig 11-7 . .

PANEL, mtg components (CC model)

. . . 1

. .

88 . .

. . . . . . . . .

+182 171 . .

PANEL, front lower (CC model)

. . . 1

. .

88 . .

. . . . . . . . +♦185 826 . .

PANEL, front lower (CC/CV model)

. . . 1

. .

89 . .

. . Z1 . . . .

169 424 . .

REACTOR

. . . 1

. .

90 . .

. . . . . . . . . .

134 792 . .

LABEL, warning general precautionary

. . . 1

. .

91 . .

. . . . . . . . . .

083 030 . .

STUD, brs .250-20 x 1.750 grounding

. . . 1

. .

92 . .

. . . . . . . . . .

601 836 . .

NUT, brs hex .250-20 jam hvy grounding

. . . 3

. .

93 . .

. . . . . . . . . .

019 603 . .

KNOB, ball

. . . 1

. .

94 . .

. . . . . . . . . .

. Fig 11-2 . .

PANEL, front w/components

. . . 1

. .

95 . .

. . . . . . . . . .

108 127 . .

BRACKET, mtg terminal pwr output

. . . 1

. .

95 . .

. . . . . . . . .

♦088 951 . .

BRACKET, mtg components

. . . 1

. .

96 . .

. Pos . . . .

039 047 . .

TERMINAL, pwr output red

. . . 1

. .

97 . .

. Neg . . . .

039 046 . .

TERMINAL, pwr output black

. . . 1

. .

98 . .

. . . . . . . . .

♦091 067 . .

SWITCH, polarity

. . . 1

. .

. . . . . .

. . . . . . . . .

♦059 773 . .

HANDLE, switch

. . . 1

. .

99 . .

. . . . . . . . . .

605 288 . .

FITTING, pipe galv plug sq hd .250NPT

. . . 1

. . 100 .

. . . . . . . . . .

070 010 . .

BOLT, J stl .250-20 x 2.750

. . . 2

. . 101 .

. . . . . . . . . .

088 696 . .

STRAP, hold down fuel tank

. . . 2

. .

. . . . . .

. . . . . . . . . .

045 161 . .

KIT, label

. . . 1

. . 102 .

. . . . . . . . .

♦192 197 . .

BRACKET, mounting

. . . 1

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

*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-129 647 Page 55

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Page 58 Page 60
Contents Description OM-129 647WProcesses 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 TerminalsRemote A/V Control Receptacle RC3 Installing Ether Cylinder Optional Ether Starting AidAfter installing cylinder, wait at 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 LabelHose Servicing Air CleanerTo clean air filter Servicing Fuel And Lubrication Systems 1850 Adjusting Engine SpeedServicing Optional Ether Starting Aid 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/gridGrounding Generator To Truck Or Trailer Frame − Auxiliary Power GuidelinesSelecting Equipment 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 Includes 171Hardware is common Not available unless listed Control Box CC/CV -1 Item 86 Optional Panel, Mtg Components CC/CV Model Panel, Mtg Components CC Model Page Support ServiceYour distributor also gives For assistance in filing or settling claims Miller Electric Mfg. CoTo locate distributor nearest you call 1-800-4-A-Miller
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