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Miller Electric Big Blue 502D manual

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Table of contents for the manual

  • Page 1

    Big Blue 402D, 502D, 602D  OM-495 192 774AR October 2003 Processes Description Air Carbon Arc (CAC-A) Cutting and Gouging Stick (SMAW ) W elding Engine Driven Welding Generator TIG (GT A W ) W elding MIG (GMAW) W elding Flux Cored (FCA W ) W elding Visit our website at www.MillerWelds.com And Non-CE Models[...]

  • 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 7 − OPERA TING WELDING GENERA TOR − CC/CV MODELS 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Front Panel Controls For CC/CV Models (See Section 7-2) 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1) 3[...]

  • Page 5

    dec_con1 _1 1/02 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). NOTE Manufacturer ’s Name: Miller Electric Mfg. Co. Manufacturer ’s Address: 1635 W . Spencer Street Appleton, WI 54914 USA Declares that the product: Big Blue  602D (Deutz F[...]

  • Page 6

    dec_con1 5/98 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). NOTE Manufacturer ’s Name: Miller Electric Mfg. Co. Manufacturer ’s Address: 1635 W . Spencer Street Appleton, WI 54914 USA Declares that the product: Big Blue  602D (Deutz F4L1[...]

  • Page 7

    OM-495 Page 1 Return T o T a ble Of Co ntents SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom _nd_10/02  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 [...]

  • Page 8

    OM-495 Page 2 Return T o T a ble Of Co ntents 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 [...]

  • Page 9

    OM-495 Page 3 Return T o T a ble Of Co ntents 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 n[...]

  • Page 10

    OM-495 Page 4 Return T o T a ble Of Co ntents 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 .) ca[...]

  • Page 11

    OM-495 Page 5 Return T o T able Of Contents 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 ![...]

  • Page 12

    OM-495 Page 6 Return T o T a ble Of Co ntents 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’[...]

  • Page 13

    OM-495 Page 7 Return T o T a ble Of Co ntents L ’EXPLOSION DE 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 d[...]

  • Page 14

    OM-495 Page 8 Return T o T able Of Contents 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 [...]

  • Page 15

    OM-495 Page 9 Return T o T able Of Contents SECTION 3 − DEFINITIONS 3-1. W arning Label Definitions (For W ordless Labels) 3/96 W arning! W atch Out! There are possible hazards as shown by the symbols. Become trained and read the instructions before working on the machine or we l ding. 1 Electric shock from welding electrode or wiring can kill. 1[...]

  • Page 16

    OM-495 Page 10 Return T o T a ble Of Co ntents 3/96 1 Warning! W atch Out! There are possible hazards as shown by the symbols. 2 Do not smoke and keep matches and flames away from battery . 3 Sparks can cause battery gases to explode. Battery explosion can blind and injure. W ear a face shield. 4 Battery acid can burn skin. Do not spill acid. 5 Rea[...]

  • Page 17

    OM-495 Page 1 1 Return T o T able Of Contents 3/96 1 Warning! W atch Out! There are possible hazards as shown by the symbols. 2 Hot muf fler and exhaust pipes can cause severe burns. Do not touch hot muf fler or pipes. 1 S-176 230 2 3/96 1 Warning! W atch Out! There are possible hazards as shown by the symbols. 2 Engine fuel plus flames or sparks c[...]

  • Page 18

    OM-495 Page 12 Return T o T a ble Of Co ntents 1 Warning! W atch Out! There are possible hazards as shown by the symbols. 2 Fire hazard from leaking engine fuel. Fire can result from welding on base at non-designated areas causing a possible fuel leak. 3 Fuel tank is located inside base. 4 Do not weld on base of unit. 5 Wel d only on supplied brack[...]

  • Page 19

    OM-495 Page 13 Return T o T a ble Of Co ntents 3/96 1 Remove unit from shipping crate. Remove Owner’s Manual from unit. Follow instructions to install muf fler . 2 Read Owner ’ s Manual. Read labels on unit. 3 Use Diesel Fuel only , and fill fuel tank. Leave room for expansion. 4 Warning! W atch Out! There are possible hazards as shown by the s[...]

  • Page 20

    OM-495 Page 14 Return T o T able Of Contents 3-3. Manufacturer ’ s Rating Labels For CE Products CC Models CC/CV Models Notes 16 Gauge (.063 in) 22 Gauge (.031 in) 24 Gauge (.025 in) 20 Gauge (.037 in) 18 Gauge (.050 in) 14 Gauge (.078 in) 1/8 in (.125 in) 3/16 in (.188 in) 1/4 in (.25 in) 5/16 in (.313 in) 3/8 in (.375 in) 1/2 in (.5 in) MA TERI[...]

  • Page 21

    OM-495 Page 15 Return T o T a ble Of Co ntents 3-4. Symbols And Definitions Stop Engine Fast (Run, Weld/ Power) Slow (Idle) Start Engine Starting Aid Battery (Engine) Engine Oil Pressure Engine Oil Check Injectors/ Pump Check V alve Clearance Fuel Protective Earth (Ground) Positive Negative Certified/T rained Mechanic W elding Arc A Amperes V V olt[...]

  • Page 22

    OM-495 Page 16 Return T o T able Of Contents SECTION 4 − SPECIFICA TIONS 4-1. W eld, Power , And Engine Specifications W elding Mode W eld Output Range Rated W elding Output Maximum Open-Circuit V oltage Generator Power Rating Engine Fuel Capacity CC/DC 55 − 600 A (CC Models) 20 − 600 A (CC/CV Models) Deutz F4L201 1-Powered Units: 400 A, 40 V[...]

  • Page 23

    OM-495 Page 17 Return T o T a ble Of Co ntents 4-3. V olt-Ampere Curves For CC Models 203 412 The volt-ampere curves show the minimum and maximum voltage an d amperage output capabilities of th e welding generator . Curves of all other settings fall between the curves shown. 0 20 40 60 80 100 0 100 200 300 400 500 600 700 800 900 DC AMPERES DC VOL [...]

  • Page 24

    OM-495 Page 18 Return T o T a ble Of Co ntents 4-4. V olt-Ampere Curves For CC/CV Models 203 414 / 203 415 / 203 413 The volt-ampere curves show the minimum and maximum voltage an d amperage output capabilities of th e welding generator . Curves of all other settings fall between the curves shown. A. Stick Mode B. MIG Mode C. TIG Mode 0 20 40 60 80[...]

  • Page 25

    OM-495 Page 19 Return T o T a ble Of Co ntents 4-5. Fuel Consumption The curve shows typical fuel use under weld or power loads. 193 093 0 50 100 150 200 250 300 350 400 450 500 DC WELD AMPERES A T 100% DUTY CYCLE 1800 RPM 0 IDLE Notes[...]

  • Page 26

    OM-495 Page 20 Return T o T a ble Of Co ntents Continuous W elding 4-6. Duty Cycle And Overheating 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 . 100% Duty Cycle At 400 Amperes 089 697-D / 202 356 A. Deutz F4L-101 1-Powered Units B. Deutz F3[...]

  • Page 27

    OM-495 Page 21 Return T o T able Of Contents 4-7. AC Generator Power Curve 193 018 Th e ac power curve shows the gen- erator power in amperes available at the 120 and 240 volt receptacles. 0 50 100 150 200 250 300 0 5 10 15 20 25 30 AC AMPERES IN 240V MODE AC VOL TS 0 25 50 75 100 150 125 0 1 0 2 03 0 4 05 0 6 0 AC AMPERES IN 120V MODE Notes[...]

  • Page 28

    OM-495 Page 22 Return T o T a ble Of Co ntents 4-8. Optional Three-Phase Generator Curves 197 472 / 197 473 Th e ac power curves show the gen- erator power available in amperes at the single-phase 120/240 volt re - ceptacle or three-phase 240 volt terminals. A. 12 kV A/kW Single-Phase AC Output (No Weld Load) B. 20 kV A/kW Three-Phase AC Output (No[...]

  • Page 29

    OM-495 Page 23 Return T o T a ble Of Co ntents Notes Over 80,000 trained since 1930! 400 T rade Square East, T roy , Ohio 45373 1-800-332-9448 www.welding.org Star t Y our Pr ofessional W elding Car eer Now![...]

  • Page 30

    OM-495 Page 24 Return T o T a ble Of Co ntents SECTION 5 − INST ALLA TION install3 6/03 − Ref. 800 652 / Ref. 800 477-A / 803 274  Always securely fasten weld- ing generator onto transport vehicle or trailer and comply with all DOT and other applica- ble codes.  Always ground generator frame to vehicle frame to pre- vent electric shock an[...]

  • Page 31

    OM-495 Page 25 Return T o T a ble Of Co ntents 5-2. Using Lifting Eye Ref. 802 169-B / 802 31 1 1 Lifting Eye 2 Nut 3 Carriage Bolt Raise lifting eye until it snaps in place. Lower lifting eye when not needed. T o lock the lifting eye in the upright position, insert a 3/8-16 x 1-1/2 in carriage bolt through slot in bracket a nd secure with nut (bol[...]

  • Page 32

    OM-495 Page 26 Return T o T a ble Of Co ntents 5-3. Mounting W elding Generator T ools Needed: 9/16 in 2 2 3 4 W elding Unit In Place Bolting Unit In Place  Do not weld on base. W eld- ing on base can cause fuel tank fire or explosion. Weld only on the four mounting brackets or bolt unit down.  Do not mount unit by sup- porting the base only [...]

  • Page 33

    OM-495 Page 27 Return T o T a ble Of Co ntents 5-4. Installing Exhaust Pipe 1/2 in T ools Needed: Ref. 802 169-E / Ref. 202 705  Stop engine and let cool.  Point exhaust pipe in desired di- rection but always away from front panel and direction of travel. 5-5. Installing Engine Side Baffle (CE Models Only) Ref. 803 353 / 803 372  Stop engi[...]

  • Page 34

    OM-495 Page 28 Return T o T able Of Contents 5-6. Activating The Dry Charge Battery (If Applicable) 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 ba[...]

  • Page 35

    OM-495 Page 29 Return T o T a ble Of Co ntents 5-7. Connecting The Battery 1/2 in − +  Connect Negative ( − ) Cable Last. T ools Needed: 802 168-E / Ref. 202 705 / 802 313 / S-0756-C  Reinstall cover after connecting battery . ether1 7/96 − 153 382-A / Ref. 202 705  Stop engine.  Improper handling or expo- sure to ether can harm y[...]

  • Page 36

    OM-495 Page 30 Return T o T a ble Of Co ntents 5-9. Engine Prestart Checks  Check all engine fluids daily . Engine must be cold and on a level surface. Unit is shipped with 20W break-in oil. The Automatic shutdown system stops engine if oil pressure is too low or coolant tempera- ture is too high.  This unit has a low oil pressure shut- down [...]

  • Page 37

    OM-495 Page 31 Return T o T able Of Contents 5-10. Connecting T o Weld Output T erminals 802 31 1-A T ools Needed: 3/4 in 2 1  Stop engine. 1 Positive (+) Weld Output T erminal 2 Negative ( − ) Weld Output T erminal For Stick and TIG welding Direct Current Electrode Positive (DCEP), connect elec- trode holder cable to Positive (+) terminal on [...]

  • Page 38

    OM-495 Page 32 Return T o T able Of Contents 5-12. Connecting T o Remote Amperage Adjust Receptacle RC13 On CC Models Ref. 154 862-A / 048 720-K / 802 31 1 1 Remote Amperage Adjust Receptacle RC13 Connect optional remote control to RC13 (see Section 6-3). 1 5-13. Connecting T o Remote 14 Receptacle RC14 On CC/CV Models Socket* Socket Information 24[...]

  • Page 39

    OM-495 Page 33 Return T o T able Of Contents Notes[...]

  • Page 40

    OM-495 Page 34 Return T o T able Of Contents SECTION 6 − OPERA TING WELDING GENERA TOR − CC MODELS 6-1. Front Panel Controls For CC Models (See Section 6-2) 17 202 705 / 802 31 1-A 15 16 2 1 3 13 18 19 14 12 10 1 1 9 8 6 5 47[...]

  • Page 41

    OM-495 Page 35 Return T o T able Of Conte nts 6-2. Description Of Front Panel Controls For CC Models (See Section 6-1) Engine Starting Controls 1 Magnetic Shutdown Switch Use switch during start-up to bypass engine shutdown system. System stops engine if oil pressure is too low or engine temperature is too high. 2 Starting Aid Switch (Optional) Use[...]

  • Page 42

    OM-495 Page 36 Return T o T able Of Conte nts 6-3. Remote Amperage Control On CC Models (Optional) 1 Remote Amperage Adjust Receptacle RC13 Connect optional remote control to RC13 (see Section 5-12 ). 0774 / Ref. 154 862-A / Ref. 181 71 1-A / 802 31 1-A Example: Combination Remote Amperage Control (Stick) In Example: Range = 125 to 320 A DC Percent[...]

  • Page 43

    OM-495 Page 37 Return T o T able Of Conte nts Notes[...]

  • Page 44

    OM-495 Page 38 Return T o T able Of Contents SECTION 7 − OPERA TING WELDING GENERA TOR − CC/CV MODELS 7-1. Front Panel Controls For CC/CV Models (See Section 7-2) 202 706 / 802 31 1-D 6 5 47 13 16 2 1 3 14 18 19 15 12 10 1 1 9 8 17[...]

  • Page 45

    OM-495 Page 39 Return T o T able Of Conte nts 7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1) Engine Starting Controls 1 Magnetic Shutdown Switch Use switch during start-up to bypass engine shutdown system. System stops engine if oil pressure is too low or engine temperature is too high. 2 Starting Aid Switch (Optional) [...]

  • Page 46

    OM-495 Page 40 Return T o T able Of Conte nts 7-3. Process/Contactor Switch On CC/CV Models 1 Process/Contactor Switch  W eld output terminals are ener- gized when Process/Contactor switch is in an Electrode Hot posi- tion and the engine is running.  DC voltage is still present at the weld terminals when Process/ Contactor switch is in the Re[...]

  • Page 47

    OM-495 Page 41 Return T o T able Of Contents 7-4. Remote V oltage/Amperage Control On CC/CV Models (Optional) 1 Remote 14 Receptacle RC14 Connect optional remote control to RC14 (see Section 5-13 ). 0774 / Ref. 192 895-A / 802 31 1-A Example: Combination Remote Amperage Control (Stick) In Example: Process = Stick (Using Remote On/Off) Range = 125 t[...]

  • Page 48

    OM-495 Page 42 Return T o T able Of Contents SECTION 8 − OPERA TING AUXILIAR Y EQUIPMENT 8-1. Generator Power Receptacles (Standard Models) 2 1 191 624 3 4 1 120 V 20 A AC GFCI Receptacle GFCI1 2 240 V 30 A AC T wistlock Receptacle RC1 Receptacles supply 60 Hz single- phase power at weld/power speed. If a ground fault is detected, GFCI Reset butt[...]

  • Page 49

    OM-495 Page 43 Return T o T able Of Contents 8-2. Connecting T o Optional Three-Phase Generator (CC/CV Standard Models Only) Ref. 197 399 / 802 332-B  Place Process/Contactor switch in Electrode Hot - Stick position when using three-phase genera- tor (see Section 7-3). Single-Phase Generator Power 1 120/240 V 50 A Receptacle RC5 RC5 is connected[...]

  • Page 50

    OM-495 Page 44 Return T o T able Of Contents 8-3. Optional Generator Power Receptacles (Standard Models) 2 1 120 V 20 A AC GFCI Receptacle GFCI1 2 240 V 16 A AC European Receptacle RC1 3 240 V 15 A AC Australian Receptacle RC1 4 240 V 15 A AC South African Receptacle RC1 Receptacles supply 60 Hz single- phase power at weld/power speed. If a ground [...]

  • Page 51

    OM-495 Page 45 Return T o T able Of Contents 8-4. Generator Power Receptacles (CE Models)  Generator power is not affected by weld output. 1 130 V 32 A AC Receptacle RC1 2 220 V olt 16 A AC Receptacle RC2 3 130 V olt 16 A AC Receptacle RC3 Receptacles supply 60 Hz single-phase power at weld/power speed. 4 Circuit Breaker CB1 5 Circuit Breakers C[...]

  • Page 52

    OM-495 Page 46 Return T o T able Of Conte nts SECTION 9 − MAINTENANCE (DEUTZ F4L201 1 − POWERED UNITS) The oil/filter maintenance intervals are different for the Deutz F4L201 1 and F3L912 engines (see maintenance schedules following). Note Follow the storage procedure in the engine owner ’s manual if the unit will not be used for an extended [...]

  • Page 53

    OM-495 Page 47 Return T o T able Of Contents Every 1000 h Change Oil Filter . See Section 9-6. Service more often in dirty conditions. Change Oil. See Section 9-6. Service W elding Generator Brushes And Slip Rings. Service More Often In Dirty Conditions.* Change Fuel Filters. See Section 9-6. Drain Sludge From Fuel T ank. See Section 9-6. Check V a[...]

  • Page 54

    OM-495 Page 48 Return T o T able Of Conte nts 9-2. Maintenance Label[...]

  • Page 55

    OM-495 Page 49 Return T o T able Of Conte nts 9-3. Servicing Air Cleaner (Deutz F4L201 1-Powered Units) aircleaner1 9/00 − ST -153 929-B / ST-153 585 / Ref. S-0698-B  Stop engine.  Do not run engine without air cleaner or with dirty element. En- gine damage caused by using a damaged element is not covered by the warranty .  The air clean[...]

  • Page 56

    OM-495 Page 50 Return T o T able Of Contents 9-4. Inspecting/Cleaning Optional Spark Arrestor (Deutz F4L201 1-Powered Units) 802 170-A / Ref. 202 705 / Ref. 802 31 1-A / Ref. 802 160-B  Stop engine and let cool. 1 Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole. 3 Exhaust Pipe Start engine and run at[...]

  • Page 57

    OM-495 Page 51 Return T o T able Of Contents 9-5. Adjusting Engine Speed (Deutz F4L201 1-Powered Units) 802 313-A  Stop engine and let cool. Engine speed is factory set and should not require adjustment. Af- ter tuning engine, check engine no load speed with a tachometer or fre- quency meter (see table for no load speeds). If necessary , adjust [...]

  • Page 58

    OM-495 Page 52 Return T o T able Of Contents 9-6. Servicing Fuel And Lubrication Systems (Deutz F4L201 1-Powered Units) Ref. 800 159-E / Ref. 802 170 / 802 313-A  Stop engine and let cool.  After servicing, start engine and check for fuel leaks. Stop engine, tighten connections as necessary , and wipe up spilled fuel. 1 Oil Filter 2 Oil Drain[...]

  • Page 59

    OM-495 Page 53 Return T o T able Of Contents 9-7. Overload Protection (Deutz F4L201 1-Powered Units)  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 F1 and F2 protect the stator exciter wind- ing from overload. If F1 opens,[...]

  • Page 60

    OM-495 Page 54 Return T o T able Of Conte nts SECTION 10 − MAINTENANCE (DEUTZ F3L912 − POWERED UNITS) Follow the storage procedure in the engine owner ’s manual if the unit will not be used for an extended period. Note 10-1. Routine Maintenance (Deutz F3L912-Powered Units) Recycle engine fluids.  Stop engine before maintaining.  See Eng[...]

  • Page 61

    OM-495 Page 55 Return T o T able Of Contents Every 500 h Change Oil Filter . See Section 10-7 . Service more often in dirty conditions. Change Oil. See Section 10-7 . Repair Or Replace Cracked Cables. Check V alve Clearance.* Every 1000 h Service W elding Generator Brushes And Slip Rings. Service More Often In Dirty Conditions.* Change Fuel Filters[...]

  • Page 62

    OM-495 Page 56 Return T o T able Of Conte nts 10-2. Maintenance Label[...]

  • Page 63

    OM-495 Page 57 Return T o T able Of Conte nts 10-3. Servicing Air Cleaner (Deutz F3L912-Powered Units) aircleaner1 9/00 − ST -153 929-B / ST-153 585 / Ref. S-0698-B  Stop engine.  Do not run engine without air cleaner or with dirty element. En- gine damage caused by using a damaged element is not covered by the warranty .  The air cleane[...]

  • Page 64

    OM-495 Page 58 Return T o T able Of Contents 10-4. Inspecting/Cleaning Optional Spark Arrestor (Deutz F3L912-Powered Units) 802 170-A / Ref. 202 705 / Ref. 802 31 1-A / Ref. 802 160-B  Stop engine and let cool. 1 Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole. 3 Exhaust Pipe Start engine and run at [...]

  • Page 65

    OM-495 Page 59 Return T o T able Of Contents 10-5. Adjusting Engine Speed (Deutz F3L912-Powered Units) 802 398 / 134 730-C  Stop engine. Engine speeds have been factory set and should not require adjust- ment. After tuning engine, check engine speeds with a tachometer . Se e table for proper no load speed. If necessary , adjust speed as fol- low[...]

  • Page 66

    OM-495 Page 60 Return T o T able Of Contents 10-7. Servicing Fuel And Lubrication Systems (Deutz F3L912-Powered Units) Ref. 800 159-E / Ref. 802 170 / 802 398  Stop engine and let cool.  After servicing, start engine and check for fuel leaks. Stop engine, tighten connections as necessary , and wipe up spilled fuel. 1 Oil Filter 2 Oil Drain V [...]

  • Page 67

    OM-495 Page 61 Return T o T able Of Contents 10-8. Overload Protection (Deutz F3L912-Powered Units) Ref. 802 313-A 21 9 8 7 4  Stop engine.  When a circuit breaker or fuse opens, it usually indicates a more se- rious problem exists. Contact Facto- ry Authorized Service Agent. 1 Fuse F1 2 Fuse F2 F1 and F2 protect the stator exciter wind- ing [...]

  • Page 68

    OM-495 Page 62 Return T o T able Of Contents SECTION 1 1 − TROUBLESHOOTING 1 1-1. Diagnosing Causes Of Engine Fault Shutdowns Ref. 202 705 Use the front panel engine lights to help determine the cause of an au- tomatic engine shutdown.  Correct the cause of the shut- down before operating the welding generator .  This unit does not have a b[...]

  • Page 69

    OM-495 Page 63 Return T o T able Of Contents 1 1-2. T roubleshooting T ables A. Welding − CC Models T rouble Remedy No weld output; generator power output okay at ac receptacles. Check position of Ampere Range switch. Check position of optional polarity switch. Place Amperage Adjust switch in Panel position, or place switch in Remote position and[...]

  • Page 70

    OM-495 Page 64 Return T o T able Of Contents B. Welding − CC/CV Models T rouble Remedy No weld output; generator power output okay at ac receptacles. Place Process/Contactor switch in a Electrode Hot position, or place switch in a Remote position and connect remote contactor to optional Remote 14 receptacle RC14 (see Sections 5-13 and 7- 1 ) . Ch[...]

  • Page 71

    OM-495 Page 65 Return T o T able Of Contents C. Standard Generator Power T rouble Remedy No generator power output at ac recep- tacles; weld output okay . Reset receptacle circuit breakers. No generator power or weld output. Disconnect equipment from generator power receptacles during start-up. Check fuses F1 and F2, and replace if open (see Sectio[...]

  • Page 72

    OM-495 Page 66 Return T o T able Of Conte nts T rouble Remedy Engine cranks but does not start. Press Magnetic Shutdown switch MS1 when starting engine. Check fuel level. Reset circuit breaker CB13 (see Section 9-7 o r 10-8 ). Have Factory Authorized Service Agent check en- gine wiring harness and components. Check battery and replace if necessary [...]

  • Page 73

    OM-495 Page 67 Return T o T able Of Contents Notes 16 Gauge (.063 in) 22 Gauge (.031 in) 24 Gauge (.025 in) 20 Gauge (.037 in) 18 Gauge (.050 in) 14 Gauge (.078 in) 1/8 in (.125 in) 3/16 in (.188 in) 1/4 in (.25 in) 5/16 in (.313 in) 3/8 in (.375 in) 1/2 in (.5 in) MA TERIAL THICKNESS REFERENCE CHART[...]

  • Page 74

    OM-495 Page 68 Return T o T able Of Conte nts SECTION 12 − ELECTRICAL DIAGRAMS Figure 12-1. Circuit Diagram For CC W elding Generator (Non-CE Deutz F4L201 1-Powered Units)[...]

  • Page 75

    OM-495 Page 69 Return T o T able Of Conte nts 215 302-A[...]

  • Page 76

    OM-495 Page 70 Return T o T able Of Conte nts Figure 12-2. Circuit Diagram For CC W elding Generator (CE Compliant Deutz F4L201 1-Powered Units)[...]

  • Page 77

    OM-495 Page 71 Return T o T able Of Conte nts 216 530-A[...]

  • Page 78

    OM-495 Page 72 Return T o T able Of Conte nts Figure 12-3. Circuit Diagram For CC/CV W elding Generator (Non-CE Deutz F4L201 1-Powered Units)[...]

  • Page 79

    OM-495 Page 73 Return T o T able Of Conte nts 215 303-A[...]

  • Page 80

    OM-495 Page 74 Return T o T able Of Conte nts Figure 12-4. Circuit Diagram For CC/CV W elding Generator (CE Compliant Deutz F4L201 1-Powered Units)[...]

  • Page 81

    OM-495 Page 75 Return T o T able Of Conte nts 216 531-A[...]

  • Page 82

    OM-495 Page 76 Return T o T able Of Conte nts Figure 12-5. Circuit Diagram For CC W elding Generator (Deutz F3L912-Powered Units)[...]

  • Page 83

    OM-495 Page 77 Return T o T able Of Conte nts 215 298-A[...]

  • Page 84

    OM-495 Page 78 Return T o T able Of Conte nts Figure 12-6. Circuit Diagram For CC/CV W elding Generator (Deutz F3L912-Powered Units)[...]

  • Page 85

    OM-495 Page 79 Return T o T able Of Conte nts 215 299-A[...]

  • Page 86

    OM-495 Page 80 Return T o T able Of Conte nts SECTION 13 − RUN-IN PROCEDURE 13-1. W etstacking  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 Welding Generator Ru n diesel engines near rated volt- ag e and current during run-in period to properly seat piston r[...]

  • Page 87

    OM-495 Page 81 Return T o T able Of Contents 13-2. 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 o[...]

  • Page 88

    OM-495 Page 82 Return T o T able Of Conte nts 13-3. 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 damag[...]

  • Page 89

    OM-495 Page 83 Return T o T able Of Conte nts SECTION 14 − GENERA TOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown. NOTE 14-1. Selecting Equipment gen_pwr 1 1/02 − Ref. ST -159 730 / ST-800 577 1 Generator Power Receptacles − Neutral[...]

  • Page 90

    OM-495 Page 84 Return T o T able Of Contents 14-3. 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 groun[...]

  • Page 91

    OM-495 Page 85 Return T o T able Of Contents 14-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Star ting 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/[...]

  • Page 92

    OM-495 Page 86 Return T o T able Of Contents 14-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts 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[...]

  • Page 93

    OM-495 Page 87 Return T o T able Of Contents 14-8. 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.[...]

  • Page 94

    OM-495 Page 88 Return T o T able Of Conte nts 14-10. 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 -s[...]

  • Page 95

    OM-495 Page 89 Return T o T able Of Conte nts 14-1 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) [...]

  • Page 96

    OM-495 Page 90 Return T o T able Of Contents SECTION 15 − P ARTS LIST  Hardware is common and not available unless listed.  A Deutz F4L201 1 engine-pow- ered unit is shown below . See insert for parts specific to a Deutz F3L912-powered unit. Parts not related to the engines are the same in both units. CC CC Models Only CV CC/CV Models Only [...]

  • Page 97

    OM-495 Page 91 Return T o T able Of Conte nts 802 331-F Deutz F3L912 Engine  A Deutz F4L201 1 en- gine-powered unit is shown below . See in- sert for parts specific to a Deutz F3L912-pow- ered unit. Parts not re- lated to the engines are the same in both units. 32 33 34 (Fig. 15-6) 35 36 37 38 39 40 41 55 56 57 58 59 60 61 62 63 64 65 66 67 68 9[...]

  • Page 98

    OM-495 Page 92 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 15-1. Main Assembly Quantity 1 189 824 P ANEL, gen LH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦ 199 294 P ANEL, gen LH ss 1 . . . . . . . . . . . . . . . . .[...]

  • Page 99

    OM-495 Page 93 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 15-1. Main Assembly (Continued) Quantity 40 213 877 ENGINE, Deutz dsl elec F4L201 1 (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . *067 265 FIL TER, oil (engine) (Deutz F4L201 1 engine) 1 . . . . . . . . . . [...]

  • Page 100

    OM-495 Page 94 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 15-1. Main Assembly (Continued) Quantity 80 199 298 P ANEL, rocker ss 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 189 827 P ANEL, gen RH 1 . . . . . . . . . . . . . .[...]

  • Page 101

    OM-495 Page 95 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 15-1. Main Assembly (Continued) Quantity 125 195 560 GUARD, starter hole (Deutz F3L912 engine) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 194 467 W ASHER, flat 6.25idx1 1.50odx.062t buna n 1 . . . . . . . . . . . . .[...]

  • Page 102

    OM-495 Page 96 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 15-2. Control Box Assembly − CC Models (Continued) Quantity 201 681 HARNESS, control box, weld control (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 CR7 188 636 RELA Y , OCV control 1 . . . . . . . . . . .[...]

  • Page 103

    OM-495 Page 97 Return T o T able Of Conte nts 802 360 12 1 2 3 18 14 9 6 8 7 10 13 5 21 16 17 20 11 15 4 19 Figure 15-3. Control Box Assembly − CC/CV Models Description Part No. Dia. Mkgs. Item No. Figure 15-3. Control Box Assembly − CC/CV Models (Figure 15-1 Item 100) Quantity 1 F1, F2 *085 874 FUSE, mintr cer slo-blo 10A 250V 2 . . . . . . . [...]

  • Page 104

    OM-495 Page 98 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 15-3. Control Box Assembly − CC/CV Models (Continued) Quantity 196 602 PLUG, cavity 18,30 position cinch connector 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 603 SEAL, switch 6 position rotary .250 shaf[...]

  • Page 105

    OM-495 Page 99 Return T o T able Of Conte nts  Hardware is common and not available unless listed. 802 266-D 1 3 4 5 12 15 18 23 24 26 29 32 35 36 37 38 39 40 41 17 25 30 31 16 20 2 22 27 28 13 19 14 6 7 8 9 10 21 34 33 11 Figure 15-4. Panel, Front w/Components − CC Models Description Part No. Dia. Mkgs. Item No. Figure 15-4. Panel, Front w/Co[...]

  • Page 106

    OM-495 Page 100 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 15-4. Panel, Front w/Components − CC Models (Continued) Quantity 192 558 HARNESS, range (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RC6 148 439 HOUSING, rect univ 084 4p/[...]

  • Page 107

    OM-495 Page 101 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 15-4. Panel, Front w/Components − CC Models (Continued) Quantity 32 190 323 BOOT , circuit breaker clear hex nut 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 193 143 BOOT , magnetic shutdown swi[...]

  • Page 108

    OM-495 Page 102 Return T o T able Of Conte nts  Hardware is common and not available unless listed. 802 332-F 1 2 3 4 5 6 7 9 48 50 51 52 53 54 55 56 57 13 18 19 20 21 22 23 24 25 26 27 30 28 29 15 16 34 33 32 17 35 42 43 41 40 39 38 37 36 44 47 14 10 49 11 8 31 45 46 12 58 Figure 15-5. Panel, Front w/Components − CC/CV Models Description Part[...]

  • Page 109

    OM-495 Page 103 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 15-5. Panel, Front w/Components − CC/CV Models (Continued) Quantity 6 S6 193 234 SWITCH, rotary 6 position gold contacts (included in control box harness, . . . . . . . . . . . . . . see Figure 15-3) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 110

    OM-495 Page 104 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 15-5. Panel, Front w/Components − CC/CV Models (Continued) Quantity 37 PC4, PC5 189 744 CIRCUIT CARD ASSEMBL Y , filter hf 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 039 046 TERMINAL, pwr output black 1 . . . . . .[...]

  • Page 111

    OM-495 Page 105 Return T o T able Of Conte nts 802 404-C  Hardware is common and not available unless listed. 5 6 8 9 22 27 28 29 30 31 7 24 25 10 26 34 33 32 1 2 4 3 23 17 18 11 13 14 12 15 19 20 21 16 Figure 15-6. Generator Description Part No. Dia. Mkgs. Item No. Figure 15-6. Generator (Figure 15-1 Item 34) Quantity 1 132 053 SCREW, 375-16 x [...]

  • Page 112

    OM-495 Page 106 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 15-6. Generator (Continued) Quantity 21 049 026 SCREW, M10 − 1.5x 25 Hex Hd − pln 8.8 Pln 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 191 579 COVER, starter hole Perkins/Continental 1 . . . . . . . . . . .[...]

  • Page 113

    OM-495 Page 107 Return T o T able Of Conte nts  Hardware is common and not available unless listed. 802 279-A 1 2 3 4 6 5 7 8 9 Figure 15-7. Main Rectifier Assembly Description Part No. Dia. Mkgs. Item No. Figure 15-7. Main Rectifier Assembly (Figure 15-1 Item 102) Quantity SR3 201 747 RECTIFIER (consisting of) 1 . . . . . . . . . . . . . . . . [...]

  • Page 114

    [...]

  • Page 115

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 8/03 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 116

    PRINTED IN USA  2003 Miller Electric Mfg. Co. 1/03 Miller Elect ric Mfg. Co. An Illinois T ool Wor k s Comp any 1635 W es t Spencer St reet Applet on, WI 5 4914 USA International He adquarters − US A USA Phone: 920-735-4505 Aut o-Att ended USA & Canada F AX : 920-735-4134 Int ernational F A X: 920-735-4125 European Headqua rters − United[...]