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Miller Electric OM-494 manual

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Table of contents for the manual

  • Page 1

    Miller DU-OP Processes Description Dual-Operator Engine Driven W elding Generator OM-494 191 862P January 2005 Air Carbon Arc (CAC-A) Cutting and Gouging TIG (GT A W) W elding Stick (SMAW ) W elding MIG (GMAW) W elding Flux Cored (FCA W ) W elding Visit our website at www.MillerWelds.com [...]

  • Page 2

    Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .MillerW eld[...]

  • Page 3

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . [...]

  • Page 4

    T ABLE OF CONTENTS SECTION 8 − MAINTENANCE & TROUBLESHOOTING 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. Routine Maintenance 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2. Maintenance Label 34 . . . . [...]

  • Page 5

    OM-494 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom _nd_8/03  W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.  Marks a special safe[...]

  • Page 6

    OM-494 Page 2 W elding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area[...]

  • Page 7

    OM-494 Page 3 STEAM AND HOT COOLANT can burn.  If possible, check coolant level when engine is cold to avoid scalding.  Always check coolant level at overflow tank, if pres- ent on unit, instead of radiator (unless told otherwise in maintenance section or engine manual).  If the engine is warm, checking is needed, and there is no overflow [...]

  • Page 8

    OM-494 Page 4 READ INSTRUCTIONS.  Use only genuine MILLER/Hobart replacement parts.  Perform engine and air compressor (if applicable) maintenance and service according to this manual and the engine/air compressor (if applicable) manu- als. H. F . RADIA TION can cause interference.  High-frequency (H.F .) can interfere with radio naviga- t[...]

  • Page 9

    OM-494 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION rom_fre 8/03  A vertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions. 2-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par [...]

  • Page 10

    OM-494 Page 6 LES ACCUMULA TIONS DE GAZ ris- quent de provoquer des blessures ou même la mort.  Fermer l’alimentation du gaz protecteur en cas de non utilisation.  V eiller toujours à bien aérer les espaces confinés ou se servir d’un respi- rateur d’adduction d’air homologué. Le rayonnement de l’arc du procédé de soudage gén[...]

  • Page 11

    OM-494 Page 7 L ’EXPLOSION D E LA BA TTERIE peut RENDRE A VEUGLE.  T oujours porter une protection faciale, des gants en caoutchouc et vêtements de protection lors d’une in- tervention sur la batterie.  Arrêter le moteur avant de débrancher ou de brancher les câbles de batterie.  Eviter de provoquer des étincelles avec les outils [...]

  • Page 12

    OM-494 Page 8 LE SURCHAUFFEMENT peut endom- mager le moteur électrique.  Arrêter ou déconnecter l’équipement avant de dé- marrer ou d’arrêter le moteur .  Ne pas laisser tourner le moteur trop lentement sous risque d’endommager le moteur électrique à cause d’une tension et d’une fréquence trop faibles.  Ne pas brancher d[...]

  • Page 13

    OM-494 Page 9 SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions Stop Engine Start Engine Ether Starting Aid Engine Do Not Switch While W elding Or Under Load Battery (Engine) Circuit Breaker Engine Oil Check Injectors/ Pump Check V alve Clearance Fuel Protective Earth (Ground) Positive Negative Certified/T rained Mechanic W elding Arc A Ampere[...]

  • Page 14

    OM-494 Page 10 SECTION 4 − SPECIFICA TIONS 4-1. Description This unit has two CC/CV modules with separate weld controls for applications where two welding arcs are needed. A Welder Selector switch controls whether one or both sets of weld output terminals are active (see Section 6-2 ). When the unit is operated in the dual operator mode, each wel[...]

  • Page 15

    OM-494 Page 1 1 4-4. Fuel Consumption The curve shows typical fuel use u n - der the combined weld loads of both sides (Welder A and Welder B). 195 71 1 0 50 100 150 200 250 300 350 400 450 500 550 600 DC WELD AMPERES A T 40% DUTY CYCLE CV CC 0 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 0.40 0.21 0.62 0.83 1.25 1.04 1.46 1.70 1.98 0.95 2.84 3.78 5.67 [...]

  • Page 16

    OM-494 Page 12 4-6. Duty Cycle And Overheating Ref. rduty1 5/95 − 194 313-A Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating.  Exceeding duty cycle can damage unit and void warranty . If a weld module overheats, the High T emperature light goes on and the thermostat opens to stop weld output to that[...]

  • Page 17

    OM-494 Page 13 4-7. V olt-Ampere Curves 194 397 / 194 398 / 194 399 The volt-ampere curve shows the minimum, medium, and maximum voltage and amperage output capa- bilities of the welding generator . Curves of all other settings fall be- tween the curves shown. A. CC/DC − Single Mode B. CC/DC − Dual Mode C. CV/DC Mode 0 20 40 60 80 100 0 100 200[...]

  • Page 18

    OM-494 Page 14 SECTION 5 − INST ALLA TION When facing the front panel, the Welder B controls and weld terminals are on the right and the Welder A controls and weld terminals are on the left. NOTE 5-1. Installing Welding Generator install1 1 1/02* − Ref. ST -800 652 / Ref. ST -800 477-A / ST-158 936-A / S-0854 Electrically bond generator frame t[...]

  • Page 19

    OM-494 Page 15 5-2. Activating The Dry Charge Battery Remove battery from unit. 1 Eye Protection − Safety Glasses Or Face Shield 2 Rubber Gloves 3 V ent Caps 4 Sulfuric Acid Electrolyte (1.265 Specific Gravity) 5 W ell Fill each cell with electrolyte to bottom of well (maximum).  Do not overfill battery cells. Wai t ten minutes and check elect[...]

  • Page 20

    OM-494 Page 16 5-3. Connecting The Battery − +  Connect ( − ) Cable Last. 190 377 5-4. Installing Exhaust Pipe  Stop engine and let cool. 1/2 in T ools Needed: exh_pipe2 4/96 − 154 089-A / 154 61 1 / 190 377  Do not blow exhaust toward air cleaner or air intake. T op View[...]

  • Page 21

    OM-494 Page 17 5-5. Engine Prestart Checks Full 1/2 in (13 mm) Full Ref. 158 633-C / S-176 697 Diesel Check all fluids daily . Engine must be cold and on a level surface. Follow run-in procedure in engine manual. If unburned fuel and oil col- lect in exhaust pipe during run-in, see Section 10. Fuel  Do not use gasoline. Gaso- line will damage en[...]

  • Page 22

    OM-494 Page 18 5-6. Safety Information For Connecting T o Weld Output T erminals  UNEXPECTED WELD OUTPUT can cause injury or fire.  Both weld outputs can be live (ON) when Welder Selector switch is in W elder A/W elder B position and engine is running.  Disconnect or insulate any unused cables.  Know where cables are located BEFORE star[...]

  • Page 23

    OM-494 Page 19 5-8. Making Dual Operator CC W eld Connections w/ Separate W ork Cables Ref. 190 377 / 802 292-A  Stop engine.  Do not exceed machine duty cycle.  Use Dual Operator mode for CC and CV welding (see Section 6-1). See Section 5-15 for proper cable size. 1 Strain Reliefs Route cables through strain reliefs. 2 Electrode Holder Ca[...]

  • Page 24

    OM-494 Page 20 5-9. Making Dual Operator Mode CC W eld Connections w/ Common Work Cable Ref. 190 377 / 802 292-A  Stop engine.  Do not exceed machine duty cycle.  For common work connection, work cable must be able to carry combined weld output of both CC weld output ter- minals (see Section 5-15 for proper cable size).  Use Dual Operat[...]

  • Page 25

    OM-494 Page 21 5-10. Making Dual Operator CV W eld Connections w/ Separate Work Cables Ref. 190 377 / 802 292-A  Stop engine.  Do not exceed machine duty cycle.  Use Dual Operator mode for CC and CV welding (see Section 6-1). See Section 5-15 for proper cable size. 1 Strain Reliefs Route cables through strain reliefs. 2 Wire Feeder Cables [...]

  • Page 26

    OM-494 Page 22 5-1 1. Making Dual Operator CV W eld Connections w/ Common W ork Cable Ref. 190 377 / 802 292-A  Stop engine.  Do not exceed machine duty cycle.  For common work connection, work cable must be able to carry combined weld output of both CC weld output ter- minals (see Section 5-15 for proper cable size).  Use Dual Operator[...]

  • Page 27

    OM-494 Page 23 5-12. Making Dual Operator CC And CV W eld Connections w/ Separate W ork Cables Ref. 190 377 / 802 292-A  Stop engine.  Do not exceed machine duty cycle.  Use Dual Operator mode for CC and CV welding (see Section 6-1). See Section 5-15 for proper cable size. 1 Strain Reliefs Route cables through strain reliefs. 2 Electrode H[...]

  • Page 28

    OM-494 Page 24 5-13. Making Dual Operator CC And CV W eld Connections w/ Common W ork Cable Ref. 190 377 / 802 292-A  Stop engine.  Do not exceed machine duty cycle.  For common work connection, work cable must be able to carry combined weld output of both CC weld output ter- minals (see Section 5-15 for proper cable size).  U se Dual O[...]

  • Page 29

    OM-494 Page 25 5-14. Making Single Operator CC W eld Connections 190 377 / 802 292-A  Stop engine.  Do not exceed machine duty cycle.  W elder A (left) weld output terminals are disabled in Single Operator mode. Connect only to Welder B (right) termi- nals for Single Operator mode opera- tion.  Us e Single Operator mode for CC weld- ing[...]

  • Page 30

    OM-494 Page 26 5-15. Selecting Weld Cable Sizes* W eld Cable Size** and T otal Cable (Copper) Length in Weld Circuit Not Exceeding*** 100 ft (30 m) or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft (105 m) 400 ft (120 m) W eld Output T erminals  T urn off power before connecting to weld out- put terminals.  Do not use wor[...]

  • Page 31

    OM-494 Page 27 ether1 7/96 − 153 382-A / 190 377 / 802 291-A  Stop engine.  Improper handling or expo- sure to ether can harm your health. Follow manufactur- er’s safety instructions on cylinder .  Do not use Ether Starting Aid while engine is running. Open right side door . 1 Ether Cylinder 2 Nozzle Remove cover and clean cylinder noz[...]

  • Page 32

    OM-494 Page 28 5-18. Remote 14 Receptacle Connections Single Operator Operation Dual Operator Operation OR OR OR AJ B K I C L NH D M G E F 60 0 AM PS AJ B K I C L NH D M G E F AJ B K I C L NH D M G E F Ref. 802 291-A[...]

  • Page 33

    OM-494 Page 29 SECTION 6 − OPERA TING THE WELDING GENERA TOR When facing the front panel, the W elder B controls and weld terminals are on the right and the Welder A side controls and weld terminals are on the left. NOTE 6-1. Engine Controls  See Section 6-3 for weld control descriptions. 1 Engine Start Button 2 Manual Stop Control 3 Ether Sta[...]

  • Page 34

    OM-494 Page 30 6-2. W eld Controls (See Section 6-3 ) Ref. 191 848 8 97 5 6 34 2 60 0 AM PS 300 AMPS 300 AMPS 600 AMPS WELDER A Welder B Welder B 1 10[...]

  • Page 35

    OM-494 Page 31 6-3. W eld Control Descriptions (See Section 6-2 ) 1 W elder Selector Switch Use switch to select Dual Operator or Single Operator welding mode. Place switch in W elder A/W elder B (dual oper- ator) position for CC and CV output from W e ld- er A (left) and W elder B (right) weld output ter- minals. Control the weld output from the t[...]

  • Page 36

    OM-494 Page 32 SECTION 7 − OPERA TING AUXILIAR Y EQUIPMENT 7-1. 120 V olt And 240 V olt Duplex Receptacles 190 376  Be sure equipment connected to the 240 V receptacles is GFCI-pro- tected.  Generator power is not affected by position of W elder Selector switch.  4 kV A/kW generator power output is shared by all receptacles. 1 240 V 20 A[...]

  • Page 37

    OM-494 Page 33 Every 100 h Clean And T ighten Battery Connections. Change Oil. See Section 8-4. Change Oil Filter . See Section 8-4. Check air cleaner hoses for cracks and loose clamps. Every 200 h Replace Unreadable Labels. Every 250 h Check An d Clean Spark Arrestor . See Section 8-9. Every 500 h Repair Or Replace Cracked Cables. Every 1000 h Blo[...]

  • Page 38

    OM-494 Page 34 8-2. Maintenance Label[...]

  • Page 39

    OM-494 Page 35 8-3. Servicing Air Cleaner aircleaner1 2/01 − ST -153 929-B / ST -153 585 / Ref. S-0698-B  Stop engine.  Do not run engine without air cleaner or wit h dirt y elem ent. En - gine damage caused by using a damaged element is not covered by the warranty .  The air cleaner primary element can be cleaned but the dirt holding ca[...]

  • Page 40

    OM-494 Page 36 8-4. Servicing Fuel And Lubrication Systems Ref. 158 633-C / Ref. 190 377 / Ref. S-176 697  Stop engine and let cool. 1 Oil Filter 2 Oil Drain Plug 3 Oil Drain Hose (Optional) 4 Oil Fill Cap 5 Primary Fuel Filter (Fuel/ W ater Separator) 6 Petcock 7 Secondary Fuel Filter 8 Fuel Shutof f V alve Lever 9 Sludge Drain Plug T o change [...]

  • Page 41

    OM-494 Page 37 8-5. Adjusting Engine Speed Ref. 045 768-B Engine speed is factory set and should not require adjustment. Af- ter tuning engine, check engine speed with tachometer . See table for proper no load speed. If neces- sary , adjust speed as follows: 1 High Speed Stop Screw 2 Lock Nut Loosen nut. T urn screw out (toward front of engine) sev[...]

  • Page 42

    OM-494 Page 38 8-7. Checking And Replacing Alternator Belt 158 632 / Ref. 190 377  Stop engine. T o check belt tension: Remove rear panel. 1 Alternator V -Belt 2 Crank Pulley 3 Alternator Pulley Place straight edge along top of pul- leys. Pull down belt as far as it will go, then measure distance from belt to straight edge. If measurement is les[...]

  • Page 43

    OM-494 Page 39 8-8. Resetting Fan Belt Safety Shutdown 158 715 / Ref. 158 632 / Ref. 190 377  Stop engine. 1 Cooling Fan V -Belt See engine manual to replace or tighten belt. If belt breaks or becomes loose, safety shutdown stops engine. Correct problem, then reset safety shutdown as follows: 2 Rod 3 Stop 4 Bracket 5 Handle Pull handle towards f[...]

  • Page 44

    OM-494 Page 40 8-9. Inspecting And Cleaning Optional Spark Arrestor Muffler Ref. 800 633-B / Ref. 190 377  Stop engine and let cool. 1 Spark Arrestor Muf fler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole. 3 Exhaust Pipe Start engine and run several min- utes to blow out cleanout hole. If nothing blows out of hole, brief[...]

  • Page 45

    OM-494 Page 41 8-10. Circuit Protection Ref. 802 300 / Ref. 802 292-A  Stop engine.  When a circuit breaker or fuse opens, it usually indicates a more serious problem exists. Contact Factory Au- thorized Service Agent. 1 Fuse F1 2 Fuse F2 3 Fuse F3 4 Fuse F4 Open front panel. Fuse F1 protects the exciter excitation winding. If F1 opens, there[...]

  • Page 46

    OM-494 Page 42 8-1 1. T roubleshooting A. Welding T rouble Remedy No weld output on either side; generator power output okay at ac receptacles. Place Output (Contactor) switches in On (Hot) position, or place switches in Remote position and connect remote contactors to remote receptacles RC8 and RC9 (see Section 6-3). Unit overheated (High T emp. S[...]

  • Page 47

    OM-494 Page 43 T rouble Remedy Low weld output on both sides. Check engine speed, and adjust if necessary (see Section 8-5). Check position of Process Selector switch(s) (see Section 6-3). Increase Amperage/V oltage controls settings. Have Factory Authorized Service Agent check field current regulator board PC4. High weld output on both sides. Have[...]

  • Page 48

    OM-494 Page 44 B. Generator Power T rouble Remedy No output at generator power ac recep- tacles. Reset receptacle circuit breakers (see Section 7-1). Press GFCI reset button on 120 volt GFCI receptacles (see Section 7-1). Check fuse F1, and replace if open (see Section 8-10 ). Check receptacle(s) for continuity and proper connections. Replace recep[...]

  • Page 49

    OM-494 Page 45 Notes[...]

  • Page 50

    OM-494 Page 46 SECTION 9 − ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For Welding Generator[...]

  • Page 51

    OM-494 Page 47 210 657-A[...]

  • Page 52

    OM-494 Page 48 SECTION 10 − RUN-IN PROCEDURE run_in3 8/01 10-1. W etstacking 2 1  Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur . 1 W elding Generator Ru n diesel engines near rated volt- ag e and current during run-in period to properly seat piston rings and prev[...]

  • Page 53

    OM-494 Page 49 10-2. Run-In Procedure Using Load Bank S-0683  Stop engine.  Do not touch hot exhaust pipe, engine parts, or load bank/grid.  Keep exhaust and pipe away from flammables.  Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur . 1 Load Bank T urn all l[...]

  • Page 54

    OM-494 Page 50 10-3. Run-In Procedure Using Resistance Grid S-0684  Stop engine.  Do not touch hot exhaust pipe, engine parts, or load bank/grid.  Keep exhaust and pipe away from flammables.  Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur . 1 Resistance Grid[...]

  • Page 55

    OM-494 Page 51 SECTION 1 1 − GENERA TOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding generators. Y our unit may differ from those shown. NOTE 1 1-1. Selecting Equipment gen_pwr 1 1/02 − Ref. ST-159 730 / ST -800 577 1 Generator Power Receptacles − Neutral Bonded T o Frame 2 3-Prong [...]

  • Page 56

    OM-494 Page 52 1 1-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 A WG or larger insulated copper wire. 3 Ground Device  Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. GND/PE 1 2 Us e ground device as stated in electri[...]

  • Page 57

    OM-494 Page 53 1 1-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Sta rting W atts Running W atts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 2100 700 1/2 HP 3175 875 Capacitor Start-Induction Run 1/3 HP 2020 720 1/2 HP 3075 975 3/4 HP 4500 1400 1 HP 6100 1600 1-1/2 HP 8200 2200 2 HP 10550 285[...]

  • Page 58

    OM-494 Page 54 1 1-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting W atts Running W atts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/2 in 500 500 7-1/4 in 900 900 8-1/4 in 1400 1400 T able Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in 2500 1 100 Bench Grinder 6 in 1720 720 8 in [...]

  • Page 59

    OM-494 Page 55 1 1-8. Power Required T o Start Motor S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor V oltage T o find starting amperage: Step 1: Find code and use table to find kV A/HP . If code is not listed, multiply running amperage by six to find starting amperage. Step 2 : Find Motor HP and V olts. Step 3: Determine starting a[...]

  • Page 60

    OM-494 Page 56 1 1-10. T ypical Connections T o Supply Standby Power  Have only qualified persons perform these connections according to all applicable codes and safety practic- es.  Properly install and ground this equipment according to its Owner ’ s Manual and national, state, and local codes.  Customer -supplied equipment is re- quir[...]

  • Page 61

    OM-494 Page 57 1 1-1 1. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 V olt Loads  If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (A WG)* Current (Amperes) Load (W atts) 4 6 8 10 12 14 5 600 350 (106) 225 (68) 137 (42) 100 (30) 7 8[...]

  • Page 62

    OM-494 Page 58 SECTION 12 − P ARTS LIST  Hardware is common and not available unless listed. 12 11 10 8 7 96 − SEE FIG 12-2 95 94 92 91 90 93 89 88 87 97 98 99 100 101 4 1 3 2 9 102 103 10 13 5 6 34 86 84 85 83 37 38 36 35 9 9 15 14 16 17 26 18 32 10 31 33 30 28 25 − SEE FIG 12-4 27 19 20 22 23 24 21 Figure 12-1. Main Assembly[...]

  • Page 63

    OM-494 Page 59 802 317-D 39 40 41 42 43 44 45 46 47 48 49 51 52 53 54 46 55 56 57 − SEE FIG 12-3 58 59 60 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 37 36 78 − SEE FIG 12-4 35 34 79 80 81 82 50 61 62[...]

  • Page 64

    OM-494 Page 60 Description Part No. Dia. Mkgs. Item No. Figure 12-1. Main Assembly Quantity 1 605 288 FITTING, pipe galv plug sqhd .250NPT 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 070 010 BOL T , J stl .250-20 x 2.750 pld 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 65

    OM-494 Page 61 Description Part No. Dia. Mkgs. Item No. Figure 12-1. Main Assembly (Continued) Quantity 61 189 764 AIR CLEANER, intake 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . *192 938 FIL TER, air element primary 1 . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 66

    OM-494 Page 62 Description Part No. Dia. Mkgs. Item No. Figure 12-1. Main Assembly (Continued) Quantity 193 501 KIT , label (includes safety and informational labels) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +When ordering a component originally displaying a precautionary label, the label should also be orde[...]

  • Page 67

    OM-494 Page 63 Description Part No. Dia. Mkgs. Item No. Figure 12-2. Front Panel (Figure 12-1 Item 96) Quantity 1 209056 COVER, receptacle w/gasket 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 190 323 BOOT , circuit breaker 6 . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 68

    OM-494 Page 64  Hardware is common and not available unless listed. 802 320-A 25 26 24 23 22 29 27 28 32 31 30 6 12 18 19 20 21 3 4 5 16 17 15 14 13 11 10 9 34 33 2 1 7 8 35 36 Figure 12-3. Side Control Panels − Welder B (Right) Side Shown[...]

  • Page 69

    OM-494 Page 65 Description Part No. Dia. Mkgs. Item No. Figure 12-3. Side Control Panels (Figure 12-1 Item 57) Quantity 1 +192 330 P ANEL, side output RH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +192 325 P ANEL, side output LH 1 . . . . . . . . . . . . . . . . . . . . [...]

  • Page 70

    OM-494 Page 66 Description Part No. Dia. Mkgs. Item No. Figure 12-3. Side Control Panels (Continued) Quantity 24 039 046 TERMINAL, pwr output black (consisting of) 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 039 045 TERMINAL BOARD, black 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 71

    OM-494 Page 67 Ref. 048 456-E 1 3 4 5 7 6 9 10 11 8 12 13 15 14  Hardware is common and not available unless listed. 2 Figure 12-4. Generator Description Part No. Dia. Mkgs. Item No. Figure 12-4. Generator (Figure 12-1 Item 78) Quantity 1 *151 299 BRUSH, contact elect clrg .375 x .750 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 72

    OM-494 Page 68 Description Part No. Dia. Mkgs. Item No. Figure 12-4. Generator (Continued) Quantity 13 195 704 ST A TOR, exciter aux pwr 120/240 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 173 068 ENDBELL, generator (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 73

    OM-494 Page 69 Notes[...]

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    [...]

  • Page 75

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 1/05 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor . The expertise o[...]

  • Page 76

    PRINTED IN USA  2005 Miller Electric Mfg. Co. 1/05 Miller Elect ric Mfg. Co. An Illinois T ool Wo rks Compan y 1635 W est S pencer Street Applet on, WI 5 4914 USA International He adquarte rs − US A USA Phone: 920-735-4505 Aut o-Att ended USA & Canada F AX : 9 20-735-4134 Int ernational F AX: 920-735-4125 European Headqua rters − United [...]