Miller Electric OM-494 Owner's Manual

Miller DU-OPProcessesDescriptionDual-Operator Engine Driven WeldingGeneratorOM-494 191 862PJanuary 2005Air Carbon Arc (CAC-A)Cutting and GougingTIG (G

OM-494 Page 6LES ACCUMULATIONS DE GAZ ris-quent de provoquer des blessures oumême la mort. Fermer l’alimentation du gaz protecteur en cas denon utili

OM-494 Page 7L’EXPLOSION DE LA BATTERIE peutRENDRE AVEUGLE. Toujours porter une protection faciale, des gants encaoutchouc et vêtements de protection

OM-494 Page 8LE SURCHAUFFEMENT peut endom-mager le moteur électrique. Arrêter ou déconnecter l’équipement avant de dé-marrer ou d’arrêter le moteur.

OM-494 Page 9SECTION 3 − DEFINITIONS3-1. Symbols And DefinitionsStop Engine Start Engine Ether Starting Aid EngineDo Not SwitchWhile WeldingOr Under L

OM-494 Page 10SECTION 4 − SPECIFICATIONS4-1. DescriptionThis unit has two CC/CV modules with separate weld controls for applications where two welding

OM-494 Page 114-4. Fuel ConsumptionThe curve shows typical fuel use un-der the combined weld loads of bothsides (Welder A and Welder B).195 7110 50 10

OM-494 Page 124-6. Duty Cycle And OverheatingRef. rduty1 5/95 − 194 313-ADuty Cycle is percentage of 10 min-utes that unit can weld at rated loadwitho

OM-494 Page 134-7. Volt-Ampere Curves194 397 / 194 398 / 194 399The volt-ampere curve shows theminimum, medium, and maximumvoltage and amperage output

OM-494 Page 14SECTION 5 − INSTALLATIONWhen facing the front panel, the Welder B controls and weld terminals are on theright and the Welder A controls

OM-494 Page 155-2. Activating The Dry Charge BatteryRemove battery from unit.1 Eye Protection − SafetyGlasses Or Face Shield2 Rubber Gloves3 Vent Caps

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

OM-494 Page 165-3. Connecting The Battery−+ Connect (−) Cable Last.190 3775-4. Installing Exhaust Pipe Stop engine and let cool.1/2 inTools Needed:e

OM-494 Page 175-5. Engine Prestart ChecksFull1/2 in(13 mm)FullRef. 158 633-C / S-176 697DieselCheck all fluids daily. Engine mustbe cold and on a leve

OM-494 Page 185-6. Safety Information For Connecting To Weld Output Terminals UNEXPECTED WELD OUTPUT can cause injury or fire. Both weld outputs can

OM-494 Page 195-8. Making Dual Operator CC Weld Connections w/ Separate Work Cables Ref. 190 377 / 802 292-A Stop engine. Do not exceed machine duty

OM-494 Page 205-9. Making Dual Operator Mode CC Weld Connections w/ Common Work Cable Ref. 190 377 / 802 292-A Stop engine. Do not exceed machine du

OM-494 Page 215-10. Making Dual Operator CV Weld Connections w/ Separate Work Cables Ref. 190 377 / 802 292-A Stop engine. Do not exceed machine dut

OM-494 Page 225-11. Making Dual Operator CV Weld Connections w/ Common Work Cable Ref. 190 377 / 802 292-A Stop engine. Do not exceed machine duty c

OM-494 Page 235-12. Making Dual Operator CC And CV Weld Connections w/ Separate Work Cables Ref. 190 377 / 802 292-A Stop engine. Do not exceed mach

OM-494 Page 245-13. Making Dual Operator CC And CV Weld Connections w/ Common Work Cable Ref. 190 377 / 802 292-A Stop engine. Do not exceed machine

OM-494 Page 255-14. Making Single Operator CC Weld Connections 190 377 / 802 292-A Stop engine. Do not exceed machine duty cycle. Welder A (left) w

TABLE OF CONTENTSSECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol

OM-494 Page 265-15. Selecting Weld Cable Sizes*Weld Cable Size** and Total Cable (Copper) Length in Weld CircuitNot Exceeding***100 ft (30 m) or Less1

OM-494 Page 27ether1 7/96 − 153 382-A / 190 377 / 802 291-A Stop engine. Improper handling or expo-sure to ether can harm yourhealth. Follow manufac

OM-494 Page 285-18. Remote 14 Receptacle ConnectionsSingle Operator OperationDual Operator OperationORORORAJBKICLNHDMGEF600 AMPSAJBKICLNHDMGEFAJBKICLN

OM-494 Page 29SECTION 6 − OPERATING THE WELDING GENERATORWhen facing the front panel, the Welder B controls and weld terminals are on theright and th

OM-494 Page 306-2. Weld Controls (See Section 6-3)Ref. 191 84889756342600 AMPS300 AMPS 300 AMPS600 AMPSWELDER A Welder BWelder B110

OM-494 Page 316-3. Weld Control Descriptions (See Section 6-2)1 Welder Selector SwitchUse switch to select Dual Operator or SingleOperator welding mod

OM-494 Page 32SECTION 7 − OPERATING AUXILIARY EQUIPMENT7-1. 120 Volt And 240 Volt Duplex Receptacles190 376 Be sure equipment connected to the240 V r

OM-494 Page 33Every 100 hClean AndTightenBatteryConnections.Change Oil. SeeSection 8-4.Change OilFilter. SeeSection 8-4.Check air cleanerhoses for cra

OM-494 Page 348-2. Maintenance Label

OM-494 Page 358-3. Servicing Air Cleaneraircleaner1 2/01 − ST-153 929-B / ST-153 585 / Ref. S-0698-B Stop engine. Do not run engine without airclean

TABLE OF CONTENTSSECTION 8 − MAINTENANCE & TROUBLESHOOTING 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-494 Page 368-4. Servicing Fuel And Lubrication SystemsRef. 158 633-C / Ref. 190 377 / Ref. S-176 697 Stop engine and let cool.1 Oil Filter2 Oil Dr

OM-494 Page 378-5. Adjusting Engine SpeedRef. 045 768-BEngine speed is factory set andshould not require adjustment. Af-ter tuning engine, check engin

OM-494 Page 388-7. Checking And Replacing Alternator Belt158 632 / Ref. 190 377 Stop engine.To check belt tension:Remove rear panel.1 Alternator V-Be

OM-494 Page 398-8. Resetting Fan Belt Safety Shutdown158 715 / Ref. 158 632 / Ref. 190 377 Stop engine.1 Cooling Fan V-BeltSee engine manual to repla

OM-494 Page 408-9. Inspecting And Cleaning Optional Spark Arrestor MufflerRef. 800 633-B / Ref. 190 377 Stop engine and let cool.1 Spark Arrestor Muf

OM-494 Page 418-10. Circuit ProtectionRef. 802 300 / Ref. 802 292-A Stop engine. When a circuit breaker or fuse opens,it usually indicates a more s

OM-494 Page 428-11. TroubleshootingA. WeldingTrouble RemedyNo weld output on either side; generatorpower output okay at ac receptacles.Place Output (C

OM-494 Page 43Trouble RemedyLow weld output on both sides. Check engine speed, and adjust if necessary (see Section 8-5).Check position of Process Sel

OM-494 Page 44B. Generator PowerTrouble RemedyNo output at generator power ac recep-tacles.Reset receptacle circuit breakers (see Section 7-1).Press

OM-494 Page 45Notes

OM-494 Page 1SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USINGrom _nd_8/03 Warning: Protect yourself and others from injury — read and follow these

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

OM-494 Page 47210 657-A

OM-494 Page 48SECTION 10 − RUN-IN PROCEDURErun_in3 8/0110-1. Wetstacking21 Do not perform run-inprocedure at less than 20volts weld output and do not

OM-494 Page 4910-2. Run-In Procedure Using Load BankS-0683 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep exhaust

OM-494 Page 5010-3. Run-In Procedure Using Resistance GridS-0684 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep ex

OM-494 Page 51SECTION 11 − GENERATOR POWER GUIDELINESThe views in this section are intended to be representative of all engine-drivenwelding generator

OM-494 Page 5211-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse #10 AWG or larger insulated

OM-494 Page 5311-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running WattsSplit Phase 1/8 HP 800 30

OM-494 Page 5411-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHand Drill 1/4 in 350 3503/8

OM-494 Page 5511-8. Power Required To Start MotorS-06241 Motor Start Code2 Running Amperage3 Motor HP4 Motor VoltageTo find starting amperage:Step 1:

OM-494 Page 2Welding on closed containers, such as tanks, drums, orpipes, can cause them to blow up. Sparks can fly off from thewelding arc. The flyin

OM-494 Page 5611-10. Typical Connections To Supply Standby Power Have only qualified persons performthese connections according to allapplicable code

OM-494 Page 5711-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, us

OM-494 Page 58SECTION 12 − PARTS LIST Hardware is common andnot available unless listed.1211108796−SEE FIG 12-295949291909389888797989910010141329102

OM-494 Page 59802 317-D39404142434445464748495152535446555657−SEE FIG 12-3585960636465666768697071727374757677373678−SEE FIG 12-4353479808182506162

OM-494 Page 60DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-1. Main AssemblyQuantity1 605 288 FITTING, pipe galv plug sqhd .250NPT 1. . . . . . . . . .

OM-494 Page 61DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-1. Main Assembly (Continued)Quantity61 189 764 AIR CLEANER, intake 1. . . . . . . . . . . .

OM-494 Page 62DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-1. Main Assembly (Continued)Quantity193 501 KIT, label (includes safety and informational la

OM-494 Page 63DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-2. Front Panel (Figure 12-1 Item 96)Quantity1 209056 COVER, receptacle w/gasket 4. . . . .

OM-494 Page 64 Hardware is common andnot available unless listed.802 320-A252624232229272832313061218192021345161715141311109343321783536Figure 12-3.

OM-494 Page 65DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-3. Side Control Panels (Figure 12-1 Item 57)Quantity1 +192 330 PANEL, side output RH 1. . .

OM-494 Page 3STEAM AND HOT COOLANT can burn. If possible, check coolant level when engine is cold toavoid scalding. Always check coolant level at ov

OM-494 Page 66DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-3. Side Control Panels (Continued)Quantity24 039 046 TERMINAL, pwr output black (consisting

OM-494 Page 67Ref. 048 456-E13457691011812131514 Hardware is common andnot available unless listed.2Figure 12-4. GeneratorDescriptionPartNo.Dia.Mkgs.

OM-494 Page 68DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-4. Generator (Continued)Quantity13 195 704 STATOR, exciter aux pwr 120/240 1. . . . . . . .

OM-494 Page 69Notes

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 1/05Your distributor also givesyou ...ServiceYou always get the fa

PRINTED IN USA  2005 Miller Electric Mfg. Co. 1/05Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US

OM-494 Page 4READ INSTRUCTIONS. Use only genuine MILLER/Hobart replacementparts. Perform engine and air compressor (if applicable)maintenance and se

OM-494 Page 5SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANTUTILISATIONrom_fre 8/03 Avertissement: Protégez vous et les autres des blessures − lisez