Miller Electric 500DX R Manuel du propriétaire

Big Blue 402D And 502DBig Blue 602DOM-495 192 774ANMarch 2003ProcessesDescriptionAir Carbon Arc (CAC-A)Cutting and GougingStick (SMAW) WeldingEngine

OM-495 Page 4FLYING SPARKS can cause injury. Wear a face shield to protect eyes and face. Shape tungsten electrode only on grinder withproper guards

OM-495 Page 94DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 14-1. Main Assembly (Continued)Quantity80 199 298 PANEL, rocker ss 1. . . . . . . . . . . . .

OM-495 Page 95DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 14-1. Main Assembly (Continued)Quantity125 195 560 GUARD, starter hole (Deutz F3L912 engine) 1

OM-495 Page 96DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 14-2. Control Box Assembly – CC Models (Continued)Quantity201 681 HARNESS, control box, weld co

OM-495 Page 97802 3601253124161517181013147896201119Figure 14-3. Control Box Assembly – CC/CV ModelsDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 14-3. Con

OM-495 Page 98DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 14-3. Control Box Assembly – CC/CV Models (Continued)Quantity196 602 PLUG, cavity 18,30 positio

OM-495 Page 99 Hardware is common andnot available unless listed.802 266-D1345121518232426293235363738394041172530311620222272813191467891021343311Fi

OM-495 Page 100DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 14-4. Panel, Front w/Components – CC Models (Continued)Quantity192 558 HARNESS, range (consist

OM-495 Page 101DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 14-4. Panel, Front w/Components – CC Models (Continued)Quantity32 190 323 BOOT, circuit breake

OM-495 Page 102 Hardware is common andnot available unless listed.802 332-F12345679485051525354555657131819202122232425262730282915163433321735424341

OM-495 Page 103DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 14-5. Panel, Front w/Components – CC/CV Models (Continued)Quantity6 S6 193 234 SWITCH, rotary

OM-495 Page 5SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANTUTILISATIONrom_10_02fre Avertissement: Protégez vous et les autres des blessures – lisez

OM-495 Page 104DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 14-5. Panel, Front w/Components – CC/CV Models (Continued)Quantity37 PC4, PC5 189 744 CIRCUIT

OM-495 Page 105802 404-C Hardware is common andnot available unless listed.56892227282930317242510263433321243231718111314121519202116Figure 14-6. Ge

OM-495 Page 106DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 14-6. Generator (Continued)Quantity21 049 026 SCREW, M10–1.5x 25 Hex Hd–pln 8.8 Pln 4. . . .

OM-495 Page 107 Hardware is common andnot available unless listed.802 279-A123465789Figure 14-7. Main Rectifier AssemblyDescriptionPartNo.Dia.Mkgs.It

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 6/02Your distributor also givesyou ...ServiceYou always get the fa

PRINTED IN USA  2003 Miller Electric Mfg. Co. 1/03Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US

OM-495 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-495 Page 7L’EXPLOSION DE LA BATTERIE peutRENDRE AVEUGLE. Toujours porter une protection faciale, des gants encaoutchouc et vêtements de protection

OM-495 Page 8LE SURCHAUFFEMENT peut endom-mager le moteur électrique. Arrêter ou déconnecter l’équipement avant de dé-marrer ou d’arrêter le moteur.

OM-495 Page 9SECTION 2 – DEFINITIONS2-1. Warning Label Definitions (For Wordless Labels)3/96Warning! Watch Out! There arepossible hazards as shown by

OM-495 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-495 Page 113/961 Warning! Watch Out! Thereare possible hazards asshown by the symbols.2 Hot muffler and exhaust pipescan cause severe burns. Donot

OM-495 Page 121 Warning! Watch Out! Thereare possible hazards asshown by the symbols.2 Fire hazard from leakingengine fuel. Fire can result fromweldin

OM-495 Page 133/961 Remove unit from shippingcrate. Remove Owner’sManual from unit. Followinstructions to install muffler.2 Read Owner’s Manual. Readl

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

OM-495 Page 142-3. Manufacturer’s Rating Labels For CE ProductsCC ModelsCC/CV ModelsNotes16 Gauge (.063 in)22 Gauge (.031 in)24 Gauge (.025 in)20 Gaug

OM-495 Page 152-4. Symbols And DefinitionsStop EngineFast (Run, Weld/Power)Slow (Idle) Start EngineStarting Aid Battery (Engine)Engine OilPressureEngi

OM-495 Page 16SECTION 3 – SPECIFICATIONS3-1. Weld, Power, And Engine SpecificationsWeldingModeWeldOutputRangeRated WeldingOutputMaximumOpen-CircuitVol

OM-495 Page 173-3. Volt-Ampere Curves For CC Models203 412The volt-ampere curves show theminimum and maximum voltageand amperage output capabilities o

OM-495 Page 183-4. Volt-Ampere Curves For CC/CV Models203 414 / 203 415 / 203 413The volt-ampere curves show theminimum and maximum voltageand amperag

OM-495 Page 193-5. Fuel ConsumptionThe curve shows typical fuel useunder weld or power loads.193 0930 50 100 150 200 250 300 350 400 450 500DC WELD AM

OM-495 Page 20Continuous Welding3-6. Duty Cycle And OverheatingDuty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithout overhea

OM-495 Page 213-7. AC Generator Power Curve193 018The ac power curve shows the gen-erator power in amperes availableat the 120 and 240 volt receptacle

OM-495 Page 223-8. Optional Three-Phase Generator Curves197 472 / 197 473The ac power curves show the gen-erator power available in amperesat the sing

OM-495 Page 23NotesOver 80,000 trainedsince 1930!400 Trade Square East, Troy, Ohio 453731-800-332-9448 www.welding.orgStart Your ProfessionalWelding C

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

OM-495 Page 24SECTION 4 – INSTALLATIONinstall3 11/02 – Ref. 800 652 / Ref. 800 477-A / 803 274 Always securely fasten weld-ing generator onto transpo

OM-495 Page 254-2. Using Lifting EyeRef. 802 169-B / 802 3111 Lifting Eye2 Nut3 Carriage BoltRaise lifting eye until it snaps inplace. Lower lifting e

OM-495 Page 264-3. Mounting Welding GeneratorTools Needed:9/16 in2234Welding Unit In PlaceBolting Unit In Place Do not weld on base. Weld-ing on base

OM-495 Page 274-4. Installing Exhaust Pipe1/2 inTools Needed:Ref. 802 169-E / Ref. 202 705 Stop engine and let cool. Point exhaust pipe in desired

OM-495 Page 284-6. Activating The Dry Charge Battery (If Applicable)Remove battery from unit.1 Eye Protection – SafetyGlasses Or Face Shield2 Rubber G

OM-495 Page 294-7. Connecting The Battery1/2 in–+ Connect Negative (–) Cable Last.Tools Needed:802 168-E / Ref. 202 705 / 802 313 / S-0756-C Reinsta

OM-495 Page 304-9. Engine Prestart Checks Check all engine fluids daily.Engine must be cold and on a level surface.Unit is shipped with 20W break-in

OM-495 Page 314-10. Connecting To Weld Output Terminals802 311-ATools Needed:3/4 in21 Stop engine.1 Positive (+) Weld Output Terminal2 Negative (–) W

OM-495 Page 324-12. Connecting To Remote Amperage Adjust Receptacle RC13 On CC ModelsRef. 154 862-A / 048 720-K / 802 3111 Remote Amperage AdjustRecep

OM-495 Page 33Notes

TABLE OF CONTENTSSECTION 6 – OPERATING WELDING GENERATOR – CC/CV MODELS 38. . . . . . . . . . . . . . . . . . . . . . 6-1. Front Panel Controls For CC

OM-495 Page 34SECTION 5 – OPERATING WELDING GENERATOR – CC MODELS5-1. Front Panel Controls For CC Models (See Section 5-2)17202 705 / 802 311-A15 1621

OM-495 Page 355-2. Description Of Front Panel Controls For CC Models (See Section 5-1)Engine Starting Controls1 Magnetic Shutdown SwitchUse switch dur

OM-495 Page 365-3. Remote Amperage Control On CC Models (Optional)1 Remote Amperage AdjustReceptacle RC13Connect optional remote control toRC13 (see S

OM-495 Page 37Notes

OM-495 Page 38SECTION 6 – OPERATING WELDING GENERATOR – CC/CV MODELS6-1. Front Panel Controls For CC/CV Models (See Section 6-2)202 706 / 802 311-D654

OM-495 Page 396-2. Description Of Front Panel Controls For CC/CV Models (See Section 6-1)Engine Starting Controls1 Magnetic Shutdown SwitchUse switch

OM-495 Page 406-3. Process/Contactor Switch On CC/CV Models1 Process/Contactor Switch Weld output terminals are ener-gized when Process/Contactorswit

OM-495 Page 416-4. Remote Voltage/Amperage Control On CC/CV Models (Optional)1 Remote 14 Receptacle RC14Connect optional remote control toRC14 (see Se

OM-495 Page 42SECTION 7 – OPERATING AUXILIARY EQUIPMENT7-1. Generator Power Receptacles (Standard Models)21191 624341 120 V 20 A AC GFCI Receptacle GF

OM-495 Page 437-2. Connecting To Optional Three-Phase Generator (CC/CV Standard Models Only)Ref. 197 399 / 802 332-B Place Process/Contactor switchin

dec_con1 _11/02Declaration of Conformity forEuropean Community (CE) ProductsThis information is provided for units with CE certification (see rating l

OM-495 Page 447-3. Optional Generator Power Receptacles (Standard Models)21 120 V 20 A AC GFCI Receptacle GFCI12 240 V 16 A AC EuropeanReceptacle RC13

OM-495 Page 457-4. Generator Power Receptacles (CE Models) Generator power is not affected by weldoutput.1 130 V 32 A AC Receptacle RC12 220 Volt 16

OM-495 Page 46SECTION 8 – MAINTENANCE (DEUTZ F4L1011–POWERED UNITS)The oil/filter maintenance intervals are different for the Deutz F4L1011 and F3L912

OM-495 Page 47Every 1000 hChange Oil Filter.See Section 8-6.Service more oftenin dirty conditions.Change Oil. SeeSection 8-6.Service WeldingGenerator

OM-495 Page 488-2. Maintenance Labels

OM-495 Page 498-3. Servicing Air Cleaner (Deutz F4L1011-Powered Units)aircleaner1 9/00 – ST-153 929-B / ST-153 585 / Ref. S-0698-B Stop engine. Do n

OM-495 Page 508-4. Inspecting/Cleaning Optional Spark Arrestor (Deutz F4L1011-Powered Units)802 170-A / Ref. 202 705 / Ref. 802 311-A / Ref. 802 160-B

OM-495 Page 518-5. Adjusting Engine Speed (Deutz F4L1011-Powered Units)802 313-A Stop engine and let cool.Engine speed is factory set andshould not r

OM-495 Page 528-6. Servicing Fuel And Lubrication Systems (Deutz F4L1011-Powered Units) Ref. 800 159-E / Ref. 802 170 / 802 313-A Stop engine and let

OM-495 Page 538-7. Overload Protection (Deutz F4L1011-Powered Units) Stop engine. When a circuit breaker or fuse opens,it usually indicates a more s

dec_con1 5/98Declaration of Conformity forEuropean Community (CE) ProductsThis information is provided for units with CE certification (see rating lab

OM-495 Page 54SECTION 9 – MAINTENANCE (DEUTZ F3L912–POWERED UNITS) Follow the storage procedure in the engine owner’s manual if the unit will not be u

OM-495 Page 55Every 500 hChange Oil Filter.See Section 9-7.Service more oftenin dirty conditions.Change Oil. SeeSection 9-7.Repair OrReplaceCrackedCab

OM-495 Page 569-2. Maintenance Label

OM-495 Page 579-3. Servicing Air Cleaner (Deutz F3L912-Powered Units)aircleaner1 9/00 – ST-153 929-B / ST-153 585 / Ref. S-0698-B Stop engine. Do no

OM-495 Page 589-4. Inspecting/Cleaning Optional Spark Arrestor (Deutz F3L912-Powered Units)802 170-A / Ref. 202 705 / Ref. 802 311-A / Ref. 802 160-B

OM-495 Page 599-5. Adjusting Engine Speed (Deutz F3L912-Powered Units)802 398 / 134 730-C Stop engine.Engine speeds have been factoryset and should n

OM-495 Page 609-7. Servicing Fuel And Lubrication Systems (Deutz F3L912-Powered Units) Ref. 800 159-E / Ref. 802 170 / 802 398 Stop engine and let co

OM-495 Page 619-8. Overload Protection (Deutz F3L912-Powered Units)Ref. 802 313-A219874 Stop engine. When a circuit breaker or fuseopens, it usually

OM-495 Page 62SECTION 10 – TROUBLESHOOTING10-1. Diagnosing Causes Of Engine Fault ShutdownsRef. 202 705Use the front panel engine lights tohelp determ

OM-495 Page 6310-2. Troubleshooting TablesA. Welding – CC ModelsTrouble RemedyNo weld output; generator power outputokay at ac receptacles.Check posit

OM-495 Page 1SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USINGrom _nd_10/02 Warning: Protect yourself and others from injury — read and follow these

OM-495 Page 64B. Welding – CC/CV ModelsTrouble RemedyNo weld output; generator power outputokay at ac receptacles.Place Process/Contactor switch in a

OM-495 Page 65C. Standard Generator PowerTrouble RemedyNo generator power output at ac recep-tacles; weld output okay.Reset receptacle circuit breaker

OM-495 Page 66Trouble RemedyEngine cranks but does not start. Press Magnetic Shutdown switch MS1 when starting engine.Check fuel level.Reset circuit b

OM-495 Page 67Notes16 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

OM-495 Page 68SECTION 11 – ELECTRICAL DIAGRAMS Figure 11-1. Circuit Diagram For CC Welding Generator (Non-CE Deutz F4L1011-Powered Units)

OM-495 Page 69205 958-A

OM-495 Page 70 Figure 11-2. Circuit Diagram For CC Welding Generator (CE Compliant Deutz F4L1011-Powered Units)

OM-495 Page 71213 567-A

OM-495 Page 72 Figure 11-3. Circuit Diagram For CC/CV Welding Generator (Non-CE Deutz F4L1011-Powered Units)

OM-495 Page 73210 329-A

OM-495 Page 2BUILDUP OF GAS can injure or kill. Shut off shielding gas supply when not in use. Always ventilate confined spaces or useapproved air-s

OM-495 Page 74 Figure 11-4. Circuit Diagram For CC/CV Welding Generator (CE CompliantDeutz F4L1011-Powered Units)

OM-495 Page 75213 566-A

OM-495 Page 76 Figure 11-5. Circuit Diagram For CC Welding Generator (Deutz F3L912-Powered Units)

OM-495 Page 77205 932

OM-495 Page 78 Figure 11-6. Circuit Diagram For CC/CV Welding Generator (Deutz F3L912-Powered Units)

OM-495 Page 79210 330-B

OM-495 Page 80SECTION 12 – RUN-IN PROCEDURErun_in1 8/0112-1. Wetstacking Do not perform run-inprocedure at less than 20volts weld output and do notex

OM-495 Page 8112-2. Run-In Procedure Using Load BankS-0683 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep exhaust

OM-495 Page 8212-3. Run-In Procedure Using Resistance GridS-0684 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep ex

OM-495 Page 83SECTION 13 – GENERATOR POWER GUIDELINESThe views in this section are intended to be representative of all engine-drivenwelding generator

OM-495 Page 3MOVING PARTS can cause injury. Keep away from fans, belts, and rotors. Keep all doors, panels, covers, and guardsclosed and securely in

OM-495 Page 8413-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse #10 AWG or larger insulated

OM-495 Page 8513-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running WattsSplit Phase 1/8 HP 800 30

OM-495 Page 8613-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHand Drill 1/4 in 350 3503/8

OM-495 Page 8713-8. Power Required To Start MotorS-06241 Motor Start Code2 Running Amperage3 Motor HP4 Motor VoltageTo find starting amperage:Step 1:

OM-495 Page 8813-10. Typical Connections To Supply Standby Power Have only qualified persons performthese connections according to allapplicable code

OM-495 Page 8913-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, us

OM-495 Page 90SECTION 14 – PARTS LIST Hardware is common and notavailable unless listed. A Deutz F4L1011 engine-pow-ered unit is shown below. Seeins

OM-495 Page 91802 331-FDeutz F3L912 Engine A Deutz F4L1011 en-gine-powered unit isshown below. See in-sert for parts specific toa Deutz F3L912-pow-er

OM-495 Page 92DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 14-1. Main AssemblyQuantity1 189 824 PANEL, gen LH 1. . . . . . . . . . . . . . . . . . . .

OM-495 Page 93DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 14-1. Main Assembly (Continued)Quantity40 191 828 ENGINE, Deutz dsl elec F4L1011 (consisting of