Miller Electric Big Blue 402D Owner's Manual
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Miller Electric Big Blue 402D Owner's Manual

Miller Electric Big Blue 402D Owner's Manual

Miller electric owner's manual welding engine driven welding generator big blue 402d, big blue 502d, big blue 602dr
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Visit our website at
www.MillerWelds.com
Big Blue 402D, 502D, 602D
R
OM-495
192 774AR
October 2003
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
Description
Engine Driven Welding Generator
And Non-CE Models

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Summary of Contents for Miller Electric Big Blue 402D

  • Page 1 Big Blue 402D, 502D, 602D Visit our website at www.MillerWelds.com OM-495 October 2003 Processes Stick (SMAW) Welding TIG (GTAW) Welding MIG (GMAW) Welding Flux Cored (FCAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging Description Engine Driven Welding Generator And Non-CE Models...
  • Page 2 ISO 9001:2000 Quality System Standard. particular model are also provided. 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1-1. Symbol Usage ............... . 1-2.
  • Page 4 TABLE OF CONTENTS SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS 7-1. Front Panel Controls For CC/CV Models (See Section 7-2) 7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1) 7-3. Process/Contactor Switch On CC/CV Models 7-4.
  • Page 5 Declaration of Conformity for European Community (CE) Products NOTE This information is provided for units with CE certification (see rating label on unit). Miller Electric Mfg. Co. Manufacturer’s Name: 1635 W. Spencer Street Manufacturer’s Address: Appleton, WI 54914 USA Big Blue 602D...
  • Page 6 Declaration of Conformity for European Community (CE) Products NOTE This information is provided for units with CE certification (see rating label on unit). Miller Electric Mfg. Co. Manufacturer’s Name: 1635 W. Spencer Street Manufacturer’s Address: Appleton, WI 54914 USA Big Blue 602D...

  • Page 7: Section 1 − Safety Precautions − Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING Y Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.

  • Page 8: Engine Hazards

    WELDING can cause fire or explosion. Welding 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.

  • Page 9: Compressed Air Hazards

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

  • Page 10: California Proposition 65 Warnings

    READ INSTRUCTIONS. D Use only genuine MILLER/Hobart replacement parts. D 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. RADIATION can cause interference. D High-frequency (H.F.) can interfere with radio naviga- tion, safety services, computers, and communica- tions equipment.

  • Page 11: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT Y Avertissement: 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 des symboles adjacents aux directives.

  • Page 12: Dangers Existant En Relation Avec Le Moteur

    LES ACCUMULATIONS DE GAZ ris- quent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz protecteur en cas de non utilisation. D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi- rateur d’adduction d’air homologué. LES RAYONS DE L’ARC peuvent pro- voquer des brûlures dans les yeux et sur la peau.

  • Page 13: Dangers Liés À L'air Comprimé

    L’EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE. D Toujours porter une protection faciale, des gants en caoutchouc et vêtements de protection lors d’une in- tervention sur la batterie. D Arrêter le moteur avant de débrancher ou de brancher les câbles de batterie.

  • Page 14: Principales Normes De Sécurité

    LE SURCHAUFFEMENT peut endom- mager le moteur électrique. D Arrêter ou déconnecter l’équipement avant de dé- marrer ou d’arrêter le moteur. D 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. D Ne pas brancher de moteur de 50 ou de 60 Hz à...

  • Page 15: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Warning Label Definitions (For Wordless Labels) Return To Table Of Contents Warning! Watch Out! There are possible hazards as shown by the symbols. Become trained and read the instructions before working on the machine or welding. Electric shock from welding electrode or wiring can kill.
  • Page 16 − − OM-495 Page 10 − − S-176 106 Return To Table Of Contents Warning! Watch Out! There are possible hazards as shown by the symbols. Do not smoke and keep matches and flames away from battery. Sparks can cause battery gases to explode.
  • Page 17 S-176 230 Return To Table Of Contents Warning! Watch Out! There are possible hazards as shown by the symbols. Hot muffler and exhaust pipes can cause severe burns. Do not touch hot muffler or pipes. Warning! Watch Out! There are possible hazards as shown by the symbols.
  • Page 18 OM-495 Page 12 Return To Table Of Contents Warning! Watch Out! There are possible hazards as shown by the symbols. Fire hazard from leaking engine fuel. Fire can result from welding base non-designated areas causing a possible fuel leak. Fuel tank is located inside base.

  • Page 19: Manufacturer's Rating Labels For Non-Ce Products

    0 − 50 h Std. 50 h Std. 3-2. Manufacturer’s Rating Labels For Non-CE Products CC Models S-177 571 DIESEL 200A 0 − 200A API CD-MIL L 2104D, CD/SE, CD/SF Return To Table Of Contents Remove unit from shipping crate. Remove Owner’s Manual from unit.

  • Page 20: Manufacturer's Rating Labels For Ce Products

    3-3. Manufacturer’s Rating Labels For CE Products CC Models Notes OM-495 Page 14 MATERIAL THICKNESS REFERENCE CHART Return To Table Of Contents CC/CV Models 24 Gauge (.025 in) 22 Gauge (.031 in) 20 Gauge (.037 in) 18 Gauge (.050 in) 16 Gauge (.063 in) 14 Gauge (.078 in) 1/8 in (.125 in)

  • Page 21: Symbols And Definitions

    3-4. Symbols And Definitions Stop Engine Starting Aid Check Injectors/ Pump Positive Amperes Engine Stick (SMAW) Welding Time Three Phase Electrode Connection Duty Cycle Rated Idle Speed Contactor On Fast (Run, Weld/ Power) Battery (Engine) Check Valve Clearance Negative Volts Air Temperature Or Engine Temperature...

  • Page 22: Section 4 − Specifications

    SECTION 4 − SPECIFICATIONS 4-1. Weld, Power, And Engine Specifications Weld Welding Rated Welding Output Mode Output Range Deutz F4L2011-Powered 55 − 600 A Units: (CC Models) 400 A, 40 Volts DC, CC/DC 20 − 600 A 100% Duty Cycle (CC/CV 500 A, 40 volts DC, Models)

  • Page 23: Volt-Ampere Curves For Cc Models

    4-3. Volt-Ampere Curves For CC Models Notes Ranges 300−Max 185−425 125−320 85−190 55−90 DC AMPERES Return To Table Of Contents The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the curves shown.

  • Page 24: Volt-Ampere Curves For Cc/Cv Models

    4-4. Volt-Ampere Curves For CC/CV Models A. Stick Mode DC AMPERES B. MIG Mode 100 200 300 400 500 600 700 800 900 1000 C. TIG Mode 100 150 200 250 300 350 400 450 500 DC AMPERES OM-495 Page 18 Ranges 300−Max 185−425...

  • Page 25: Fuel Consumption

    4-5. Fuel Consumption 1800 RPM IDLE DC WELD AMPERES AT 100% DUTY CYCLE Notes 100 150 200 250 300 350 400 450 500 Return To Table Of Contents The curve shows typical fuel use under weld or power loads. 193 093 OM-495 Page 19...

  • Page 26: Duty Cycle And Overheating

    4-6. Duty Cycle And Overheating A. Deutz F4L-1011-Powered Units B. Deutz F3L912-Powered Units OM-495 Page 20 100% Duty Cycle At 400 Amperes Continuous Welding 100% Duty Cycle At 500 Amperes Continuous Welding Return To Table Of Contents Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating.

  • Page 27: Ac Generator Power Curve

    4-7. AC Generator Power Curve AC AMPERES IN 240V MODE AC AMPERES IN 120V MODE Notes Return To Table Of Contents The ac power curve shows the gen- erator power in amperes available at the 120 and 240 volt receptacles. 193 018 OM-495 Page 21...

  • Page 28: Optional Three-Phase Generator Curves

    4-8. Optional Three-Phase Generator Curves A. 12 kVA/kW Single-Phase AC Output (No Weld Load) B. 20 kVA/kW Three-Phase AC Output (No Weld Load) OM-495 Page 22 AC AMPERES AC AMPERES Return To Table Of Contents The 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...
  • Page 29 Notes Start Your Professional Over 80,000 trained 400 Trade Square East, Troy, Ohio 45373 Welding Career Now! since 1930! 1-800-332-9448 www.welding.org Return To Table Of Contents OM-495 Page 23...

  • Page 30: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Installing Welding Generator (See Sections 5-2 And 5-3) Movement Location Grounding GND/PE Airflow Clearance 18 in (460 mm) 18 in (460 mm) OM-495 Page 24 Electrically bond generator frame to vehicle frame by metal-to-metal contact. Y Bed liners, shipping skids, and some running gears insulate the welding generator from the vehicle frame.

  • Page 31: Using Lifting Eye

    5-2. Using Lifting Eye Notes Return To Table Of Contents Lifting Eye Carriage Bolt Raise lifting eye until it snaps in place. Lower lifting eye when not needed. To lock the lifting eye in the upright position, insert a 3/8-16 x 1-1/2 in carriage bolt through slot in bracket and secure with nut (bolt and nut not supplied).

  • Page 32: Mounting Welding Generator

    5-3. Mounting Welding Generator Supporting The Unit Inadequate support. Y Do not use flexible mounts. Using Mounting Brackets Tools Needed: 9/16 in OM-495 Page 26 Welding Unit In Place Bolting Unit In Place Return To Table Of Contents Y Do not weld on base. Weld- ing on base can cause fuel tank fire or explosion.

  • Page 33: Installing Exhaust Pipe

    5-4. Installing Exhaust Pipe Tools Needed: 1/2 in 5-5. Installing Engine Side Baffle (CE Models Only) Loosen upper and lower panel mounting screws. Return To Table Of Contents Y Stop engine and let cool. Point exhaust pipe in desired di- rection but always away from front panel and direction of travel.

  • Page 34: Activating The Dry Charge Battery (If Applicable)

    5-6. Activating The Dry Charge Battery (If Applicable) 5 A For 30 Minutes 30 A For 12 Minutes OM-495 Page 28 − Return To Table Of Contents Remove battery from unit. Eye Protection − Safety Glasses Or Face Shield Rubber Gloves Vent Caps Sulfuric Acid Electrolyte (1.265 Specific Gravity)

  • Page 35: Connecting The Battery

    5-7. Connecting The Battery Y Connect Negative (−) Cable Last. Tools Needed: 1/2 in 5-8. Installing Optional Ether Cylinder (Deutz F3L912 Engine Only) − Return To Table Of Contents Reinstall cover after connecting battery. 802 168-E / Ref. 202 705 / 802 313 / S-0756-C Y Stop engine.

  • Page 36: Engine Prestart Checks

    5-9. Engine Prestart Checks Full Diesel Deutz F4L2011 Engine Full Diesel Deutz F3L912 Engine 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.

  • Page 37: Connecting To Weld Output Terminals

    5-10. Connecting To Weld Output Terminals 5-11. Selecting Weld Cable Sizes* Weld Output Terminals Y Stop engine before Welding connecting to weld out- Amperes put terminals. Y Do not use worn, dam- aged, undersized, or poorly spliced cables. This chart is a general guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), use next size larger cable.

  • Page 38: Connecting To Remote Amperage Adjust Receptacle Rc13 On Cc Models

    5-12. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models 5-13. Connecting To Remote 14 Receptacle RC14 On CC/CV Models New! LDR-14 long distance remote distance remote (includes 120 V receptacle) *The remaining sockets are not used. OM-495 Page 32 Socket* 24 VOLTS AC 24 VOLTS AC...
  • Page 39 Notes Return To Table Of Contents OM-495 Page 33...

  • Page 40: Section 6 − Operating Welding Generator − Cc Models

    SECTION 6 − OPERATING WELDING GENERATOR − CC MODELS 6-1. Front Panel Controls For CC Models (See Section 6-2) 10 11 202 705 / 802 311-A Return To Table Of Contents OM-495 Page 34...

  • Page 41: Description Of Front Panel Controls For Cc Models (See Section 6-1)

    6-2. Description Of Front Panel Controls For CC Models (See Section 6-1) Engine Starting Controls 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.

  • Page 42: Remote Amperage Control On Cc Models (Optional)

    6-3. Remote Amperage Control On CC Models (Optional) Example: Combination Remote Amperage Control (Stick) Set Switches Set Range 6-4. Weld Control/Arc Condition Information Label OM-495 Page 36 Max = About 223 A DC (50% of 125 to 320) Set Control Return To Table Of Contents Remote Amperage Adjust Receptacle RC13...
  • Page 43 Notes Return To Table Of Contents OM-495 Page 37...

  • Page 44: Section 7 − Operating Welding Generator − Cc/Cv Models

    SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS 7-1. Front Panel Controls For CC/CV Models (See Section 7-2) 10 11 202 706 / 802 311-D Return To Table Of Contents OM-495 Page 38...

  • Page 45: Description Of Front Panel Controls For Cc/Cv Models (See Section 7-1)

    7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1) Engine Starting Controls 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.

  • Page 46: Process/Contactor Switch On Cc/Cv Models

    7-3. Process/Contactor Switch On CC/CV Models Switch Setting Switch Setting GTAW With HF Unit, Pulsing Remote − TIG Device, Or Remote Control Remote − Stick Stick (SMAW) With Remote On/Off Remote − MIG MIG (GMAW) Electrode Hot − MIG MIG (GMAW) Stick (SMAW), Electrode Hot −...

  • Page 47: Remote Voltage/Amperage Control On Cc/Cv Models (Optional)

    7-4. Remote Voltage/Amperage Control On CC/CV Models (Optional) Example: Combination Remote Amperage Control (Stick) Set Remote Set V/A Adjust Switch Process Example: Combination Remote Amperage Control (TIG) Set V/A Set Remote Process Adjust Switch Process = Stick (Using Remote On/Off) Set Range Control Not Used In Remote...

  • Page 48: Section 8 − Operating Auxiliary Equipment

    SECTION 8 − OPERATING AUXILIARY EQUIPMENT 8-1. Generator Power Receptacles (Standard Models) OM-495 Page 42 Return To Table Of Contents 120 V 20 A AC GFCI Receptacle GFCI1 240 V 30 A AC Twistlock Receptacle RC1 Receptacles supply 60 Hz single- phase power at weld/power speed.

  • Page 49: Connecting To Optional Three-Phase Generator (Cc/Cv Standard Models Only)

    8-2. Connecting To Optional Three-Phase Generator (CC/CV Standard Models Only) Single-Phase Power Connection Three-Phase Power Connection Y Close panel opening if no connections are made to generator. Remove plug before inserting leads. Reinstall bushing. Rear Of Panel 120V 120V Single Phase Output Volts...

  • Page 50: Optional Generator Power Receptacles (Standard Models)

    8-3. Optional Generator Power Receptacles (Standard Models) European Receptacle Australian Receptacle South African Receptacle OM-495 Page 44 Return To Table Of Contents 120 V 20 A AC GFCI Receptacle GFCI1 240 V 16 A AC European Receptacle RC1 240 V 15 A AC Australian Receptacle RC1 240 V 15 A AC South African Receptacle RC1...

  • Page 51: Generator Power Receptacles (Ce Models)

    8-4. Generator Power Receptacles (CE Models) Generator power is not affected by weld output. 130 V 32 A AC Receptacle RC1 220 Volt 16 A AC Receptacle RC2 130 Volt 16 A AC Receptacle RC3 Receptacles supply 60 Hz single-phase power at weld/power speed.

  • Page 52: Section 9 − Maintenance (Deutz F4L2011−Powered Units)

    SECTION 9 − MAINTENANCE (DEUTZ F4L2011−POWERED UNITS) Note The oil/filter maintenance intervals are different for the Deutz F4L2011 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 period.
  • Page 53 FUEL SLUDGE Notes Every 1000 h Change Oil. See Section 9-6. Change Fuel Filters. See Section 9-6. Drain Sludge From Fuel Tank. See Section 9-6. Blow Out Or Vacuum Inside. During Heavy Service, Clean Monthly. Every 3000 h Clean/Set Injectors.* Return To Table Of Contents Change Oil Filter.

  • Page 54: Maintenance Label

    9-2. Maintenance Label Return To Table Of Contents OM-495 Page 48...

  • Page 55: Servicing Air Cleaner (Deutz F4L2011-Powered Units)

    9-3. Servicing Air Cleaner (Deutz F4L2011-Powered Units) Keep nozzle 2 in (51 mm) from element. Blow Optional Inspect Return To Table Of Contents Y Stop engine. Y 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.

  • Page 56: Inspecting/Cleaning Optional Spark Arrestor (Deutz F4L2011-Powered Units)

    9-4. Inspecting/Cleaning Optional Spark Arrestor (Deutz F4L2011-Powered Units) Tools Needed: 3/8 in Notes OM-495 Page 50 802 170-A / Ref. 202 705 / Ref. 802 311-A / Ref. 802 160-B Return To Table Of Contents Y Stop engine and let cool. Spark Arrestor Muffler Cleanout Plug Remove plug and remove any dirt...

  • Page 57: Adjusting Engine Speed (Deutz F4L2011-Powered Units)

    9-5. Adjusting Engine Speed (Deutz F4L2011-Powered Units) Models With Automatic Idle (Optional) Tools Needed: 3/8, 7/16 in 1850 rpm Max. (61.6 Hz) 1250 rpm (41.5 Hz) Standard Models Return To Table Of Contents Y Stop engine and let cool. Engine speed is factory set and should not require adjustment.

  • Page 58: Servicing Fuel And Lubrication Systems (Deutz F4L2011-Powered Units)

    9-6. Servicing Fuel And Lubrication Systems (Deutz F4L2011-Powered Units) Y Stop engine and let cool. Y After servicing, start engine and check for fuel leaks. Stop engine, tighten connections as necessary, and wipe up spilled fuel. Oil Filter Oil Drain Valve And Hose Oil Fill Cap Primary Fuel Filter (Fuel/Water Sepa- rator)

  • Page 59: Overload Protection (Deutz F4L2011-Powered Units)

    9-7. Overload Protection (Deutz F4L2011-Powered Units) Return To Table Of Contents Y Stop engine. When a circuit breaker or fuse opens, it usually indicates a more serious problem exists. Contact Factory Au- thorized Service Agent. Fuse F1 Fuse F2 F1 and F2 protect the stator exciter wind- ing from overload.

  • Page 60: Section 10 − Maintenance (Deutz F3L912−Powered Units)

    SECTION 10 − MAINTENANCE (DEUTZ F3L912−POWERED UNITS) Note Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period. 10-1. Routine Maintenance (Deutz F3L912-Powered Units) Wipe Up Spills. Check air cleaner hoses for cracks and loose clamps.
  • Page 61 Change Oil. See Section 10-7. Clearance.* FUEL SLUDGE Notes Every 500 h Check Valve Every 1000 h Change Fuel Filters. See Section 10-7. Drain Sludge From Fuel Tank. See Section 10-7. Every 3000 h Clean/Set Injectors.* Return To Table Of Contents Change Oil Filter.

  • Page 62: Maintenance Label

    10-2. Maintenance Label Return To Table Of Contents OM-495 Page 56...

  • Page 63: Servicing Air Cleaner (Deutz F3L912-Powered Units)

    10-3. Servicing Air Cleaner (Deutz F3L912-Powered Units) Keep nozzle 2 in (51 mm) from element. Blow Optional Inspect Return To Table Of Contents Y Stop engine. Y 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.

  • Page 64: Inspecting/Cleaning Optional Spark Arrestor (Deutz F3L912-Powered Units)

    10-4. Inspecting/Cleaning Optional Spark Arrestor (Deutz F3L912-Powered Units) Tools Needed: 3/8 in Notes OM-495 Page 58 802 170-A / Ref. 202 705 / Ref. 802 311-A / Ref. 802 160-B Return To Table Of Contents Y Stop engine and let cool. Spark Arrestor Muffler Cleanout Plug Remove plug and remove any dirt...

  • Page 65: Adjusting Engine Speed (Deutz F3L912-Powered Units)

    10-5. Adjusting Engine Speed (Deutz F3L912-Powered Units) 10-6. Servicing Optional Ether Starting Aid (Deutz F3L912-Powered Units) 33 oz (935 g) Full Empty Engine Speed (No Load) Weld/Power 15 oz (425 g) Return To Table Of Contents Y Stop engine. Engine speeds have been factory set and should not require adjust- ment.

  • Page 66: Servicing Fuel And Lubrication Systems (Deutz F3L912-Powered Units)

    10-7. Servicing Fuel And Lubrication Systems (Deutz F3L912-Powered Units) Y Stop engine and let cool. Y After servicing, start engine and check for fuel leaks. Stop engine, tighten connections as necessary, and wipe up spilled fuel. Oil Filter Oil Drain Valve And Hose Oil Fill Cap Primary Fuel Filter (Fuel/Water Sepa- rator)

  • Page 67: Overload Protection (Deutz F3L912-Powered Units)

    10-8. Overload Protection (Deutz F3L912-Powered Units) Return To Table Of Contents Y Stop engine. When a circuit breaker or fuse opens, it usually indicates a more se- rious problem exists. Contact Facto- ry Authorized Service Agent. Fuse F1 Fuse F2 F1 and F2 protect the stator exciter wind- ing from overload.

  • Page 68: Section 11 − Troubleshooting

    SECTION 11 − TROUBLESHOOTING 11-1. Diagnosing Causes Of Engine Fault Shutdowns Pre-Start Diagnostic Checks Turn Engine Control Switch To Run/Idle Position While Pressing Magnetic Shutdown Switch. Diagnostic Checks While Running Start Engine (With No Load Applied). OM-495 Page 62 Normal Condition: Oil Pressure Light On;...

  • Page 69: Troubleshooting Tables

    11-2. Troubleshooting Tables A. Welding − CC Models Trouble No weld output; generator power output Check position of Ampere Range switch. okay at ac receptacles. Check position of optional polarity switch. Place Amperage Adjust switch in Panel position, or place switch in Remote position and connect remote control to Remote Amperage Adjust receptacle RC13 (see Sections 5-12 and 6-1).
  • Page 70 B. Welding − CC/CV Models Trouble No weld output; generator power output Place Process/Contactor switch in a Electrode Hot position, or place switch in a Remote position and okay at ac receptacles. connect remote contactor to optional Remote 14 receptacle RC14 (see Sections 5-13 and 7-1). Check position of Ampere Range switch.
  • Page 71 C. Standard Generator Power Trouble No generator power output at ac recep- Reset receptacle circuit breakers. tacles; weld output okay. 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 Section 9-7 or 10-8). Have Factory Authorized Service Agent check integrated rectifier SR1, capacitor C9, and the rotor.
  • Page 72 Trouble 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 or 10-8). Have Factory Authorized Service Agent check en- gine wiring harness and components. Check battery and replace if necessary. Check engine charging system according to engine manual. On Deutz F3L912-powered units, allow circuit breaker CB14 to reset.
  • Page 73 Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge (.025 in) 22 Gauge (.031 in) 20 Gauge (.037 in) 18 Gauge (.050 in) 16 Gauge (.063 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)

  • Page 74: Section 12 − Electrical Diagrams

    SECTION 12 − ELECTRICAL DIAGRAMS Figure 12-1. Circuit Diagram For CC Welding Generator (Non-CE Deutz F4L2011-Powered Units) Return To Table Of Contents OM-495 Page 68...
  • Page 75 215 302-A Return To Table Of Contents OM-495 Page 69...
  • Page 76 Figure 12-2. Circuit Diagram For CC Welding Generator (CE Compliant Deutz F4L2011-Powered Units) Return To Table Of Contents OM-495 Page 70...
  • Page 77 216 530-A Return To Table Of Contents OM-495 Page 71...
  • Page 78 Figure 12-3. Circuit Diagram For CC/CV Welding Generator (Non-CE Deutz F4L2011-Powered Units) Return To Table Of Contents OM-495 Page 72...
  • Page 79 215 303-A Return To Table Of Contents OM-495 Page 73...
  • Page 80 Figure 12-4. Circuit Diagram For CC/CV Welding Generator (CE Compliant Deutz F4L2011-Powered Units) Return To Table Of Contents OM-495 Page 74...
  • Page 81 216 531-A Return To Table Of Contents OM-495 Page 75...
  • Page 82 Figure 12-5. Circuit Diagram For CC Welding Generator (Deutz F3L912-Powered Units) Return To Table Of Contents OM-495 Page 76...
  • Page 83 215 298-A Return To Table Of Contents OM-495 Page 77...
  • Page 84 Figure 12-6. Circuit Diagram For CC/CV Welding Generator (Deutz F3L912-Powered Units) Return To Table Of Contents OM-495 Page 78...
  • Page 85 215 299-A Return To Table Of Contents OM-495 Page 79...

  • Page 86: Section 13 − Run-In Procedure

    SECTION 13 − RUN-IN PROCEDURE 13-1. Wetstacking OM-495 Page 80 Return To Table Of Contents Y Do perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur. Welding Generator Run diesel engines near rated volt- age and current during run-in period to properly seat piston rings and...

  • Page 87: Run-In Procedure Using Load Bank

    13-2. Run-In Procedure Using Load Bank Return To Table Of Contents Y Stop engine. Y Do not touch hot exhaust pipe, engine parts, or load bank/grid. Y Keep exhaust and pipe away from flammables. Y Do perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur.

  • Page 88: Run-In Procedure Using Resistance Grid

    13-3. Run-In Procedure Using Resistance Grid OM-495 Page 82 Return To Table Of Contents Y Stop engine. Y Do not touch hot exhaust pipe, engine parts, or load bank/grid. Y Keep exhaust and pipe away from flammables. Y Do perform procedure at less than 20 volts weld output and do not exceed duty cycle or equip-...

  • Page 89: Section 14 − Generator Power Guidelines

    SECTION 14 − GENERATOR POWER GUIDELINES NOTE The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown. 14-1. Selecting Equipment 14-2. Grounding Generator To Truck Or Trailer Frame Electrically bond generator frame to vehicle frame by metal-to-metal contact.

  • Page 90: Grounding When Supplying Building Systems

    14-3. Grounding When Supplying Building Systems 14-4. How Much Power Does Equipment Require? AMPERES x VOLTS = WATTS EXAMPLE 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power requirement in watts. The load applied by the drill is 520 watts. EXAMPLE 2: If three 200 watt flood lamps are used with the drill from Example 1, add the individual loads to calculate total load.
  • Page 91 14-5. Approximate Power Requirements For Industrial Motors Industrial Motors Split Phase Capacitor Start-Induction Run Capacitor Start-Capacitor Run Fan Duty 14-6. Approximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Stock Tank De-Icer Grain Cleaner Portable Conveyor Grain Elevator Milk Cooler Milker (Vacuum Pump) FARM DUTY MOTORS Std.
  • Page 92 14-7. Approximate Power Requirements For Contractor Equipment Contractor Hand Drill Circular Saw Table Saw Band Saw Bench Grinder Air Compressor Electric Chain Saw Electric Trimmer Electric Cultivator Elec. Hedge Trimmer Flood Lights Submersible Pump Centrifugal Pump Floor Polisher High Pressure Washer 55 gal Drum Mixer Wet &...
  • Page 93 14-8. Power Required To Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code KVA/HP kVA/HP x HP x 1000 VOLTS EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4 HP motor with a motor start code of M. Volts = 230 HP = 1/4 11.2 x 1/4 x 1000...
  • Page 94 14-10. Typical Connections To Supply Standby Power Y Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes. Utility Electrical Service Y Have only qualified persons perform these connections according to all applicable codes and safety practic- Y Properly install and ground this equipment according to its Owner’s Manual and national, state, and local...
  • Page 95 14-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord. Current Load (Watts) (Amperes) 1200 1800 2400 3000 3600 4200 4800 5400 6000 *Conductor size is based on maximum 2% voltage drop Cord Lengths for 240 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord.

  • Page 96: Section 15 − Parts List

    SECTION 15 − PARTS LIST Hardware is common and not available unless listed. A Deutz F4L2011 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. 109(CV) 108(CV) 106 (FIG.
  • Page 97 A Deutz F4L2011 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. 26 27 34 (Fig. 15-6) Deutz F3L912 Engine 34 (Fig.
  • Page 98 Item Dia. Part Mkgs....189 824 ....199 294 ..
  • Page 99 Item Dia. Part Mkgs....213 877 ....*067 265 .
  • Page 100 Item Dia. Part Mkgs....199 298 ....189 827 .
  • Page 101 Item Dia. Part Mkgs... . . 195 560 ... . 194 467 ... . 212 944 When ordering a component originally displaying a precautionary label, the label should also be ordered.
  • Page 102 Item Dia. Part Mkgs. Figure 15-2. Control Box Assembly − CC Models (Continued) ....201 681 ..
  • Page 103 Figure 15-3. Control Box Assembly − CC/CV Models Item Dia. Part Mkgs. Figure 15-3. Control Box Assembly − CC/CV Models (Figure 15-1 Item 100) ..F1, F2 *085 874 ....046 432 .
  • Page 104 Item Dia. Part Mkgs. Figure 15-3. Control Box Assembly − CC/CV Models (Continued) ....196 602 ..... . . 196 603 .
  • Page 105 Hardware is common and not available unless listed. Figure 15-4. Panel, Front w/Components − CC Models Item Dia. Part Mkgs. Figure 15-4. Panel, Front w/Components − CC Models (Figure 15-1 Item 106) ....202 705 .
  • Page 106 Item Dia. Part Mkgs. Figure 15-4. Panel, Front w/Components − CC Models (Continued) ....192 558 ...
  • Page 107 Item Dia. Part Mkgs. Figure 15-4. Panel, Front w/Components − CC Models (Continued) ....190 323 ....193 143 .
  • Page 108 Hardware is common and not available unless listed. Figure 15-5. Panel, Front w/Components − CC/CV Models Item Dia. Part Mkgs. Figure 15-5. Panel, Front w/Components − CC/CV Models (Figure 15-1 Item 106) ....202 706 .
  • Page 109 Item Dia. Part Mkgs. Figure 15-5. Panel, Front w/Components − CC/CV Models (Continued) ... . 193 234 .......
  • Page 110 Item Dia. Part Mkgs. Figure 15-5. Panel, Front w/Components − CC/CV Models (Continued) . . . PC4, PC5 189 744 ....039 046 ....180 735 .
  • Page 111 Hardware is common and not available unless listed. Item Dia. Part Mkgs....132 053 ....183 387 .
  • Page 112 Item Dia. Part Mkgs....049 026 ....191 579 .
  • Page 113 Hardware is common and not available unless listed. Item Dia. Part Mkgs....201 747 ..203 381 ..
  • Page 115 Warranty Questions? Call LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants 1-800-4-A-MILLER to its original retail purchaser that new Miller equipment sold for your local after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.

  • Page 116: Options And Accessories

    File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. 2003 Miller Electric Mfg. Co. 1/03 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA...

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