Maintenance & Troubleshooting | Miller Electric Miller DU-OP

SECTION 8 − MAINTENANCE & TROUBLESHOOTING

8-1. Routine Maintenance

Y Stop engine before maintaining.

. See Engine Manual and Maintenance Label

Recycle engine for important start-up, service, and storage

fluids. information. Service engine more often if

used in severe conditions.

n = Check	Z = Change	~ = Clean	l = Replace	Reference
* To be done by Factory Authorized Service Agent

Every	FUEL				Section 5-5,
8	FUEL				8-4
8	WATER				8-4
Hours	WATER
Hours
	n Fuel/Water Separator	n Fuel Level	n Oil Level	~ Oil, Fuel Spills
Every					Section 8-3
50
Hours
	~ Air Cleaner Element	~ Weld Terminals
Every
100
Hours
	~ Battery Terminals	n Air Cleaner Hoses	Z Oil Z Oil Filter
Every					Engine
250					Manual,
Hours					Section 8-9
	l Unreadable Labels	n~Spark Arrestor
Every
500
Hours
	nl Weld Cables
Every				FUEL	Section 8-4,
1000	1/2 in.	OR		FUEL	8-10and
Hours	(13 mm)	OR		SLUDGE	Engine
Hours				SLUDGE	Engine
					Manual
	n Fan Belt Tension	~ Inside Unit	Z FuelFilter	~ Drain Sludge
	n~ Slip Rings*	nValve Clearance*
	nl Brushes*

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Miller Electric Miller DU-OP manual Maintenance & Troubleshooting, Routine Maintenance

Contents

Description ProcessesFile Engine Drive Visit our website at OM-494191 862Q September From Miller to You Table of Contents − Operating Auxiliary Equipment Arc Welding Hazards Symbol Usage Engine 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 dangereux DES 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’ouïe ’AIR Comprimé peut provoquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendie’EMPLOI Excessif peut LE Surchauffement peut endom- mager le moteur électrique Pour les moteurs à essence LE Soudage À L’ARC risque de provoquer des interférencesPour les moteurs diesel Boulevard, Rexdale, Ontario, Canada M9W 1R3 téléphone − Definitions Symbols And Definitions Weld, Power, And Engine Specifications − SpecificationsDimensions, Weights, And Operating Angles Description Fuel Consumption AC Generator Power Duty Cycle And Overheating Exceeding duty cycle can damage unit and void warrantyOverheating Reduce Duty Cycle Minutes CC/DC − Dual Mode CC/DC − Single ModeCV/DC Mode Volt-Ampere Curves Installing Welding Generator − Installation Connecting The Battery Activating The Dry Charge Battery If ApplicableDo not overfill battery cells For 30 Minutes Engine Prestart Checks Installing Exhaust PipeStop engine and let cool Fuel 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 Side Do not exceed machine duty cycle Welder a Left Side Connect electrode holder cables to Elec- trode receptacles Stop engine Do not exceed machine duty cycle Verse position when using CV weld re Place optional Polarity switches in ReWhen switch is in Straight position Switches are set correctly. See Section Connect wire feeder cables to CV recep- tacles Connect wire feeder cables to Negative − terminals Be sure Process Selector switches are Place optional Polarity switch in Re Making Single Operator CC Weld Connections OM-494 150 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 terminals After installing cylinder, wait at Installing Ether Cylinder Optional Ether Starting AidRemote 14 Receptacle Information Socket Information Dual Operator Operation Remote 14 Receptacle Connections Engine Controls − Operating the Welding GeneratorSee -3for weld control descriptions If light goes on, stop engine and check engine belt Weld 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 Generator power is not affected by weld outputVolt And 240 Volt Duplex Receptacles At least once a month, run engine at Routine Maintenance − Maintenance & Troubleshooting Maintenance Label By the warranty Servicing Air CleanerTo clean air filter Do not clean housing with air hose Servicing Fuel And Lubrication Systems Weld/Power Adjusting Engine SpeedServicing Optional Ether Starting Aid Cylinder Checking And Replacing Alternator Belt To adjust belt tensionMax Tools Needed 11/16 Stop engine To check belt tension Resetting Fan Belt Safety Shutdown Stop engine and let cool. Reinstall cleanout plug Inspecting And Cleaning Optional Spark Arrestor MufflerChecking Generator Brushes Thermostats TP3 And TP4 Internal − Not Shown Circuit Protection Welding Troubleshooting Factory 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 PC5 Engine Generator Power OM-494 Circuit Diagram For Welding Generator − Electrical Diagrams 210 657-A Wetstacking − RUN-IN ProcedureMent damage may occur 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 needed Procedure at less than Run-In Procedure Using Resistance GridBank/grid From flammables Has this symbol − Generator Power GuidelinesSelecting Equipment Grounding Generator To Truck Or Trailer Frame How Much Power Does Equipment Require? Grounding When Supplying Building SystemsEarth ground if supplying Use ground device as stated Electrical codes Approximate 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 Watts Contractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor Equipment How Much Power Can Generator Supply? Power Required To Start MotorSingle-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 = Starting Amperage Typical Connections To Supply Standby Power Current Load Watts Amperes Selecting Extension Cord Use Shortest Cord Possible 96−SEE FIG 92 91 103 102 101 100 25−SEE FIG 910 − Parts List 4748 57−SEE FIG 78−SEE FIG 76 75 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 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

SECTION 8 − MAINTENANCE & TROUBLESHOOTING

8-1. Routine Maintenance

Y Stop engine before maintaining.

WATER

SLUDGE

OM-494 Page 33