Manuals / Miller Electric / Power Tools / Welding System

Miller Electric manual Processes, Description, Visit our website at OM-494191 862P January

Models: OM-494

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OM-494191 862P

January 2005

Processes

Stick (SMAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

TIG (GTAW) Welding

Air Carbon Arc (CAC-A)

Cutting and Gouging

Description

Dual-Operator Engine Driven Welding

Generator

Miller DU-OP

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Miller Electric manual Processes, Description, Visit our website at OM-494191 862P January

Contents

Description ProcessesVisit our website at OM-494191 862P January Dual-Operator Engine Driven Welding Generator From Miller to You Table of Contents Options and Accessories Warranty 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 DES Organes Mobiles peuvent provoquer des blessures ’EXPLOSION DE LA Batterie peutLA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessures Information sur les champs électromagnétiques Principales normes de sécurité − 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 Do not overfill battery cells Activating The Dry Charge BatteryRead and follow all instruc Charger Installing Exhaust Pipe Connecting The BatteryConnect − Cable Last Top View Tools Needed 1/2 Fuel Do not use gasoline. Gaso Line will damage engine Engine Prestart ChecksOil 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 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 − Maintenance & Troubleshooting Every 200 h Every 100 hEvery 250 h Every 500 h 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 1850 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 Reinstall cleanout plug Tools Needed 3/8 Inspecting And Cleaning Optional Spark Arrestor Muffler 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 311 103 96−SEE -2 101 25−SEE FIG 910 − Parts List 4748 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 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