Miller Electric 500DX R Manuel du propriétaire

Big Blue 400DBig Blue 500 XOM-4425 215 234FJuly 2004Visit our website atwww.MillerWelds.comProcessesDescriptionAir Carbon Arc (CAC-A)Cutting and Goug

OM-4425 Page 6LES ACCUMULATIONS DE GAZ ris-quent de provoquer des blessures oumême la mort. Fermer l’alimentation du gaz protecteur en cas denon util

OM-4425 Page 7L’EXPLOSION DE LA BATTERIE peutRENDRE AVEUGLE. Toujours porter une protection faciale, des gants encaoutchouc et vêtements de protectio

OM-4425 Page 8LE SURCHAUFFEMENT peut endom-mager le moteur électrique. Arrêter ou déconnecter l’équipement avant de dé-marrer ou d’arrêter le moteur.

OM-4425 Page 9SECTION 3 − DEFINITIONS3-1. Warning Label Definitions (For Wordless Labels)3/96Warning! Watch Out! There arepossible hazards as shown by

OM-4425 Page 103/961 Warning! Watch Out! Thereare possible hazards asshown by the symbols.2 Do not smoke and keepmatches and flames away frombattery.3

OM-4425 Page 113/961 Warning! Watch Out! Thereare possible hazards asshown by the symbols.2 Hot muffler and exhaust pipescan cause severe burns. Donot

OM-4425 Page 121 Warning! Watch Out! Thereare possible hazards asshown by the symbols.2 Fire hazard from leakingengine fuel. Fire can result fromweldi

OM-4425 Page 133/961 Remove unit from shippingcrate. Remove Owner’sManual from unit. Followinstructions to install muffler.2 Read Owner’s Manual. Read

OM-4425 Page 143-3. Symbols And DefinitionsSome symbols are found only on CE products.NOTEStop EngineFast (Run, Weld/Power)Slow (Idle) Start EngineSta

OM-4425 Page 15SECTION 4 − SPECIFICATIONS4-1. Weld, Power, And Engine SpecificationsWeldingModeWeld OutputRangeRated WeldingOutputMaximumOpen-CircuitV

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

OM-4425 Page 164-3. Volt-Ampere Curves For CC Models215 081-AThe volt-ampere curve shows theminimum and maximum voltageand amperage output capabilitie

OM-4425 Page 174-4. Volt-Ampere Curves For CC/CV Models215 080-A / 215 083-A / 215 079-AThe volt-ampere curves show theminimum and maximum voltageand

OM-4425 Page 184-5. Fuel ConsumptionThe curve shows typical fuel useunder weld or power loads.199 0320.000.250.500.751.001.251.501.752.000 50 100 150

OM-4425 Page 194-7. AC Generator Power Curve193 018The ac power curve shows the gen-erator power in amperes availableat the 120 and 240 volt receptacl

OM-4425 Page 20SECTION 5 − INSTALLATIONinstall3 6/04 − Ref. 800 652 / Ref. 800 477-A / 803 274 Always securely fasten weld-ing generator onto transpo

OM-4425 Page 215-2. Using Lifting EyeRef. 802 3111 Lifting Eye2 Nut3 Carriage BoltRaise lifting eye until it snaps inplace. Lower lifting eye when not

OM-4425 Page 225-3. Mounting Welding GeneratorTools Needed:9/16 in2234Welding Unit In PlaceBolting Unit In Place Do not weld on base. Weld-ing on bas

OM-4425 Page 235-4. Installing Exhaust Pipe1/2 inTools Needed:Ref. 803 604 / Ref. 215 158 Stop engine and let cool. Point exhaust pipe in desired di

OM-4425 Page 245-5. Activating The Dry Charge Battery (If Applicable)Remove battery from unit.1 Eye Protection − SafetyGlasses Or Face Shield2 Rubber

OM-4425 Page 255-6. Connecting The Battery1/2 in−+ Connect Negative (−) Cable Last.Tools Needed:Ref. 215 158 / 803 605 / S-0756-C Reinstall cover af

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

OM-4425 Page 265-7. Engine Prestart Checks Check all engine fluids daily.Engine must be cold and on a level surface.Unit is shipped with 20W break-in

OM-4425 Page 275-8. Connecting To Weld Output Terminals803 602Tools Needed:23/4 in1 Stop engine.1 Positive (+) Weld Output Terminal2 Negative (−) Wel

OM-4425 Page 285-10. Connecting To Remote Amperage Adjust Receptacle RC13 On CC ModelsRef. 154 862-A / 048 720-K / 803 6021 Remote Amperage AdjustRece

OM-4425 Page 295-11. Connecting To Remote 14 Receptacle RC14 On CC/CV ModelsSocket* Socket Information24 VOLTS ACA 24 volts ac. Protected by circuitbr

OM-4425 Page 30SECTION 6 − OPERATING WELDING GENERATOR − CC MODELS6-1. Front Panel Controls For CC Models (See Section 6-2)12215 070 / 803 60211218131

OM-4425 Page 316-2. Description Of Front Panel Controls For CC Models (See Section 6-1)Engine Starting Controls1 Starting Aid SwitchUse switch to ener

OM-4425 Page 326-3. Remote Amperage Control On CC Models (Optional)1 Remote Amperage AdjustReceptacle RC13Connect optional remote control toRC13 (see

OM-4425 Page 33Notes

OM-4425 Page 34SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS7-1. Front Panel Controls For CC/CV Models (See Section 7-2)215 158 / 802 6022191

OM-4425 Page 357-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1)Engine Starting Controls1 Starting Aid SwitchUse switch to e

TABLE OF CONTENTSSECTION 8 − OPERATING AUXILIARY EQUIPMENT 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-4425 Page 367-3. Process/Contactor Switch On CC/CV Models1 Process/Contactor Switch Weld output terminals are ener-gized when Process/Contactorswi

OM-4425 Page 377-4. Remote Voltage/Amperage Control On CC/CV Models (Optional)1 Remote 14 Receptacle RC14Connect optional remote control toRC14 (see S

OM-4425 Page 38SECTION 8 − OPERATING AUXILIARY EQUIPMENT8-1. 120 Volt And 240 Volt Receptacles191 624-A21 120 V 20 A AC GFCI Receptacle GFCI12 240 V 3

OM-4425 Page 398-2. Connecting To Optional Three-Phase Generator (CC/CV Models Only)Ref. 197 399 / 802 332-E / 803 655 Place Process/Contactor switch

OM-4425 Page 408-3. Optional Generator Power Receptacles21 120 V 20 A AC GFCI Receptacle GFCI12 240 V 16 A AC EuropeanReceptacle RC13 240 V 15 A AC Au

OM-4425 Page 41SECTION 9 − MAINTENANCE & TROUBLESHOOTING9-1. Maintenance Label

OM-4425 Page 429-2. Routine Maintenance Follow the storage procedure in the engine owner’s manual if the unit will not be used for anextended period.N

OM-4425 Page 43Every 1000 hChange Oil Filter.See Section 9-6.Service more oftenin dirty conditions.Change Oil. SeeSection 9-6.Service WeldingGenerator

OM-4425 Page 449-3. Servicing Air Cleaner Stop engine. Do not run engine without aircleaner or with dirty element. En-gine damage caused by using ad

OM-4425 Page 459-4. Inspecting And Cleaning Optional Spark Arrestor Muffler803 656 / Ref. 215 158 Stop engine and let cool.1 Spark Arrestor Muffler2

OM-4425 Page 1SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USINGrom _nd_8/03 Warning: Protect yourself and others from injury — read and follow these

OM-4425 Page 469-5. Adjusting Engine Speed803 644 / Ref. 800 159 Stop engine and let cool.Engine speed is factory set andshould not require adjustmen

OM-4425 Page 479-6. Servicing Fuel And Lubrication Systems 803 644 / Ref. 800 159 Stop engine and let cool. After servicing, start engine andcheck

OM-4425 Page 489-7. Overload Protection803 605219874 Stop engine. When a circuit breaker or fuse opens,it usually indicates a more seriousproblem ex

OM-4425 Page 499-8. TroubleshootingA. Welding − CC ModelsTrouble RemedyNo weld output; generator power outputokay at ac receptacles.Check position of

OM-4425 Page 50B. Welding − CC/CV ModelsTrouble RemedyNo weld output; generator power outputokay at ac receptacles.Place Process/Contactor switch in a

OM-4425 Page 51Trouble RemedyLow CV weld output. Set Ampere Range switch to highest range.Increase Voltage/Amperage Adjust Control setting.Min or max

OM-4425 Page 52E. EngineTrouble RemedyEngine will not crank. Check battery, and replace if necessary.Check battery connections and tighten if necessar

OM-4425 Page 53Notes16 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 i

OM-4425 Page 54SECTION 10 − ELECTRICAL DIAGRAMSFigure 10-1. Circuit Diagram For CC Welding Generator

OM-4425 Page 55215 221-D

OM-4425 Page 2Welding on closed containers, such as tanks, drums, orpipes, can cause them to blow up. Sparks can fly off from thewelding arc. The flyi

OM-4425 Page 56Figure 10-2. Circuit Diagram For CC/CV Welding Generator

OM-4425 Page 57215 243-E

OM-4425 Page 58SECTION 11 − RUN-IN PROCEDURErun_in1 8/0111-1. Wetstacking Do not perform run-inprocedure at less than 20volts weld output and do note

OM-4425 Page 5911-2. Run-In Procedure Using Load BankS-0683 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep exhaust

OM-4425 Page 6011-3. Run-In Procedure Using Resistance GridS-0684 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep e

OM-4425 Page 61SECTION 12 − GENERATOR POWER GUIDELINESThe views in this section are intended to be representative of all engine-drivenwelding generato

OM-4425 Page 6212-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse #10 AWG or larger insulate

OM-4425 Page 6312-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running WattsSplit Phase 1/8 HP 800 3

OM-4425 Page 6412-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHand Drill 1/4 in 350 3503/8

OM-4425 Page 6512-8. Power Required To Start MotorS-06241 Motor Start Code2 Running Amperage3 Motor HP4 Motor VoltageTo find starting amperage:Step 1:

OM-4425 Page 3STEAM AND HOT COOLANT can burn. If possible, check coolant level when engine is cold toavoid scalding. Always check coolant level at o

OM-4425 Page 6612-10. Typical Connections To Supply Standby Power Have only qualified persons performthese connections according to allapplicable cod

OM-4425 Page 6712-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, u

OM-4425 Page 68SECTION 13 − PARTS LIST Hardware is common and notavailable unless listed.CC CC Models OnlyCV CC/CV Models Only98 (CC ONLY)104106 (FIG

OM-4425 Page 69803 651-A939291848885868790897233 (Fig. 13−6)343571708182838079647473657675775859606261636768696678233136383739403225242928262730435642

OM-4425 Page 70DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-1. Main AssemblyQuantity1 189 824 PANEL, gen LH 1. . . . . . . . . . . . . . . . . . . .

OM-4425 Page 71DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-1. Main Assembly (Continued)Quantity39 213 878 ENGINE, Deutz dsl elec F3L2011 (includes man

OM-4425 Page 72DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-1. Main Assembly (Continued)Quantity80 208 141 STOP, door 2. . . . . . . . . . . . . . . .

OM-4425 Page 73803 652-A211119637142213161251592018178421232410Figure 13-2. Control Box Assembly − CC ModelsDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 1

OM-4425 Page 74DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-2. Control Box Assembly − CC Models (Continued)Quantity190 260 HARNESS, unit weld control (

OM-4425 Page 75DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-3. Control Box Assembly − CC/CV Models (Figure 13-1 Item 100)Quantity1 F1, F2 *085 874 FUSE

OM-4425 Page 4READ INSTRUCTIONS. Use only genuine MILLER/Hobart replacementparts. Perform engine and air compressor (if applicable)maintenance and s

OM-4425 Page 76 Hardware is common andnot available unless listed.803 654-A11109872213123937363834353220212527262423283018191516171424041421635429313

OM-4425 Page 77DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-4. Panel, Front w/Components − CC Models (Continued)Quantity192 558 HARNESS, range (consist

OM-4425 Page 78 Hardware is common andnot available unless listed.803 655-A11544253525146474944394041383736354334256555758176810935412134548503114302

OM-4425 Page 79DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-5. Panel, Front w/Components − CC/CV Models (Continued)Quantity192 558 HARNESS, range (cons

OM-4425 Page 80DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-5. Panel, Front w/Components − CC/CV Models (Continued)Quantity51 217 084 GAUGE, Coolant Te

OM-4425 Page 81DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-6. Generator (Figure 13-1 Item 33)Quantity1 132 053 SCREW, .375−16x1.50 hex hd−pln gr5 pld

OM-4425 Page 82 Hardware is common andnot available unless listed.802 279-A123465789Figure 13-7. Main Rectifier AssemblyDescriptionPartNo.Dia.Mkgs.It

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 6/04Your distributor also givesyou ...ServiceYou always get the fa

PRINTED IN USA  2004 Miller Electric Mfg. Co. 1/04Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US

OM-4425 Page 5SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANTUTILISATIONrom_fre 8/03 Avertissement: Protégez vous et les autres des blessures − lisez