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OM-495 Page 94

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Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 15-1. Main Assembly (Continued)

Quantity

199 298

PANEL, rocker ss

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

189 827

PANEL, gen RH

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

199 300

PANEL, gen RH ss

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

191 626

BUMPER, door engine access

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

189 245

TANK, fuel 23gal (consisting of)

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

124 253

BUSHING, tank fuel

. . .

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084 173

CLAMP, hose .460

−

.545clp dia slfttng

. . . . . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

189 912

FITTING, stl barbed elbow w/.047 in orf zinc pld

. . .

. . . . . . . . . . . . .

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189 909

FITTING, stand pipe hose .250 x 9.260 lg 90deg zinc

. . .

. . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . .

189 913

FITTING, stl barbed elbow zinc pld

. . .

. . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

190 142

SENDER, fuel gauge 9.7500 deep tank

. . .

. . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

189 910

FITTING, stand pipe hose .3125 x 9.260 lg 90deg zinc

. . .

. . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . .

189 908

VALVE, drain fuel 180deg

. . .

. . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

181 572

BUSHING, tank fuel

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. . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

191 446

EXTRUSION, rubber w/adhesive 1.000 x 1.000 D (order by ft)

6ft

. . .

. . . . . . . . . . . . .

. .

. . . . . . . .

191 897

BRACKET, mtg unit

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

191 512

BRACKET, hold down fuel tank

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

190 250

LABEL, warning do not weld on base

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

200 864

LABEL, warning do not weld on base (Wordless Label)

. . .

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. .

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190 179

PANEL, mtg components

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

191 292

RESISTOR, WW fxd 375W 50 ohm w/mtg bkt

. . .

. . . . .

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189 699

RESISTOR, WW tap 375W 10 ohm w/mtg bkt

. . .

. . . . .

. . . .

. .

. . . . . . . . . . . . . . . . . . . . . .

189 699

RESISTOR, WW tap 375W 10 ohm w/mtg bkt

. . .

. . . . .

. . .

. .

. . . . . . . . . . . . . . . . . . . . . .

100

Figure 15-2, Figure 15-3

CONTROL BOX ASSEMBLY

. .

. . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

101

189 731

FIREWALL, lower

. .

. . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

102

Figure 15-7

MAIN RECTIFIER ASSEMBLY

. .

. . . . . . . . .

. .

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103

191 448

TOP, cover front upright

. .

. . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

103

♦

199 305

TOP, cover front upright ss

. .

. . . . . . . . . . .

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104

+201 750

UPRIGHT, front

. .

. . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

104

♦

+202 637

UPRIGHT, front ss

. .

. . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

105

134 792

LABEL, warning general precautionary

. .

. . . . . . . . . . . .

. .

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105

176 105

LABEL, warning general precautionary (Wordless Label)

. .

. . . . . . . . . . . .

. .

. . . . . . . . . . . . . .

106

Figure 15-4, Figure 15-5

PANEL, front w/components

. .

. . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

107

♦

202130

XFMR, current sensing

. .

. . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

108

193 453

BRACKET, mtg box fcr

. .

. . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

109

PC1

189 143

MODULE, field current regulator

. .

. . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

190 058

NUT, .250-20 u-nut multi-thread

. . . . . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

049 525

NUT, 312-18 u-nut multi-thread

. . . . . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

202 031

KIT, label (includes safety and informational labels)

. . . . . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . .

201 062

KIT, label (includes safety and informational labels) (Wordless Labels)

. . . . . . . . . . . . . . . . . . .

. .

110

199 063

ENGINE, Deutz dsl elec F3L912 d0392

−

166/00 1

. .

. . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . .

111

*064 677

FILTER, oil (Deutz F3L912 engine)

. .

. . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

112

*066 271

BELT, blower (Deutz F3L912 engine)

. .

. . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

113

*195 745

SWITCH, pressure oil 1.5 bar nc cont

. .

. . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

114

*195 746

SENDER, coolant temp & 130 degee C switch

. .

. . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . .

115

194 135

BACKPLATE, Deutz F3L912 engine

. .

. . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

116

194 572

SUPPORT, front engine (Deutz F3L912 engine)

. .

. . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . .

117

FS1

141 346

SHUTDOWN KIT, engine (Deutz F3L912 engine)

. .

. . .

. .

. . . . . . . . . . . . . . . . . . . .

118

118 452

FTG, adapter oil drain (Deutz F3L912 engine)

. .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . .

119

193 313

MANIFOLD, exhaust muffler (Deutz F3L912 engine)

. .

. . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . .

120

194 496

BAFFLE, lower air outlet (Deutz F3L912 engine)

. .

. . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . .

121

194 497

BAFFLE, upper air outlet (Deutz F3L912 engine)

. .

. . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . .

122

194 500

BAFFLE, air intake (Deutz F3L912 engine)

. .

. . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . .

123

194 485

HOSE, air cleaner (Deutz F3L912 engine)

. .

. . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . .

124

+201 714

BOX, air intake (Deutz F3L912 engine)

. .

. . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Summary of Contents for Big Blue 402D

Page 1: ...ctober 2003 Processes Description Air Carbon Arc CAC A Cutting and Gouging Stick SMAW Welding Engine Driven Welding Generator TIG GTAW Welding MIG GMAW Welding Flux Cored FCAW Welding Visit our websit...

Page 2: ...ue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get the...

Page 3: ...cifications 16 4 2 Dimensions Weights And Operating Angles 16 4 3 Volt Ampere Curves For CC Models 17 4 4 Volt Ampere Curves For CC CV Models 18 4 5 Fuel Consumption 19 4 6 Duty Cycle And Overheating...

Page 4: ...ine Speed Deutz F4L2011 Powered Units 51 9 6 Servicing Fuel And Lubrication Systems Deutz F4L2011 Powered Units 52 9 7 Overload Protection Deutz F4L2011 Powered Units 53 SECTION 10 MAINTENANCE DEUTZ F...

Page 5: ...netic compatibility Directives 89 336 EEC 92 31 EEC Standards Safety Requirements for Arc Welding Equipment IEC 60974 1 1998 09 Rotating Electrical Machines Part 1 Rating and Performance IEC 34 1 1994...

Page 6: ...ing Generators 2000 14 EC Sound Level Information Measured Sound Power Level 98 dB Guaranteed Sound Power Level 98 dB This equipment conforms to requirements brought forth by 2000 14 EC Noise conformi...

Page 7: ...x or that cord plug is connected to a properly grounded receptacle outlet When making input connections attach proper grounding conductor first double check connections Frequently inspect input power...

Page 8: ...hielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully CYLINDERS can expl...

Page 9: ...fill cap HOT METAL from air arc cutting and gouging can cause fire or explosion Do not cut or gouge near flammables Watch for fire keep extinguisher nearby HOT PARTS can cause burns and injury Do not...

Page 10: ...American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Mi ami FL 33126 phone 305 443 9353 website www aws org National Electrical Code NFPA Standard 70 from Nation...

Page 11: ...der l installation la r paration ou l entretien de l appareil D verrouiller l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de s curit Installer et mettre la terre correctement cet app...

Page 12: ...antalons sans revers des chaussures hautes et un couvre chef Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes Suivre les recommandati...

Page 13: ...issement dans le vase d ex pansion si pr sent et non dans le radiateur sauf si pr cis autrement dans la section maintenance du manuel du moteur Si le moteur est chaud et que le liquide doit tre v rifi...

Page 14: ...ntaires telles que le d placement du poste l utilisation de c bles blind s l utilisation de fil tres de ligne ou la pose de protecteurs dans la zone de travail 2 6 Principales normes de s curit Safety...

Page 15: ...of the fumes 2 2 Use forced ventilation or local exhaust to remove the fumes 2 3 Use ventilating fan to remove fumes 3 Welding sparks can cause explosion or fire 3 1 Keep flammables away from welding...

Page 16: ...arity and make connections in numbered sequence shown 12 Once dead battery is charged disconnect cables in sequence shown 1 S 176 108 1 4 2 3 4 1 3 2 2 3 4 5 6 10 11 7 8 9 12 S 176 106 3 96 1 Warning...

Page 17: ...fuel plus flames or sparks can cause fire 3 Do not smoke while fueling or if near fuel 4 Stop engine before fueling 5 Do not fuel a hot engine 6 Use Diesel Fuel only 1 2 4 3 5 6 S 176 104 3 96 1 Warn...

Page 18: ...signatedareas causing a possible fuel leak 3 Fuel tank is located inside base 4 Do not weld on base of unit 5 Weld only on supplied brackets or bolt unit down 1 5 3 4 2 1 Warning Watch Out There are p...

Page 19: ...possible hazards as shown by the symbols Read Owner s Manual Follow instructions to activate battery 5 Check oil level Add oil if necessary 6 During the first 50 hours of operation keep welding load a...

Page 20: ...g 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...

Page 21: ...mote Engine Air Temperature Or Engine Temperature Output Alternating Current Stick SMAW Welding Constant Current CC MIG GMAW Welding TIG GTAW Time h Hours s Seconds 1 Single Phase 3 Three Phase Read O...

Page 22: ...Addition To Standard 4 kVA kW Generator Power Cylinder 44 HP Diesel Engine or Deutz F3L912 Air Cooled Three Cylinder 41 5 HP Diesel Engine 95 L 4 2 Dimensions Weights And Operating Angles Dimensions H...

Page 23: ...t 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 0 20 40 60 80 100 0 100 200 30...

Page 24: ...ator Curves of all other settings fall between the curves shown A Stick Mode B MIG Mode C TIG Mode 0 20 40 60 80 100 0 100 200 300 400 500 600 700 800 900 DC AMPERES DC VOLTS Ranges 300 Max 185 425 12...

Page 25: ...Return To Table Of Contents 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 AT 100 DUTY CYCLE 1800 RPM...

Page 26: ...ycle 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 F4...

Page 27: ...Curve 193 018 The 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 VOLTS 0 25 5...

Page 28: ...peres at the single phase 120 240 volt re ceptacle or three phase 240 volt terminals A 12 kVA kW Single Phase AC Output No Weld Load B 20 kVA kW Three Phase AC Output No Weld Load 180 190 200 210 220...

Page 29: ...OM 495 Page 23 Return To Table Of Contents Notes Over 80 000 trained since 1930 400 Trade Square East Troy Ohio 45373 1 800 332 9448 www welding org Start Your Professional Welding Career Now...

Page 30: ...ding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insu lated copper wire Electr...

Page 31: ...e 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 an...

Page 32: ...s 2 Mounting Brackets Supplied Mount unit on flat surface or use cross supports to support base Secure unit with mounting brack ets 3 1 2 in Bolt And Washer Minimum Not Supplied 4 3 8 16 x 1 in Screws...

Page 33: ...pe 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 engine and let cool 1 Engine Side Baffle Par...

Page 34: ...battery cells Wait ten minutes and check electro lyte level If necessary add electro lyte to raise to proper level Reins tall vent caps 6 Battery Charger Read and follow all instruc tions supplied wit...

Page 35: ...ions on cylinder Do not use Ether Starting Aid while engine is running Remove rubber access plug from cover 1 Ether Cylinder 2 Nozzle Remove cover and clean cylinder nozzle 3 Clamp 4 Fitting 5 Cap 6 V...

Page 36: ...Add fresh diesel fuel before starting to pre vent air from entering the fuel system see engine maintenance label for fuel specifica tions Leave filler neck empty to allow room for expansion Do not run...

Page 37: ...n Weld Circuit Not Exceeding 100 ft 30 m or Less 150 ft 45 m 200 ft 60 m 250 ft 70 m 300 ft 90 m 350 ft 105 m 400 ft 120 m Weld Output Terminals Stop engine before connectingto weld out put terminals...

Page 38: ...ac contactor control circuit C Output to remote control 10 volts dc in MIG or Stick mode 0 to 10 volts dc in TIG mode New LDR 14 long distance remote REMOTE OUTPUT D Remote control circuit common dis...

Page 39: ...OM 495 Page 33 Return To Table Of Contents Notes...

Page 40: ...Page 34 Return To Table Of Contents SECTION 6 OPERATING WELDING GENERATOR CC MODELS 6 1 Front Panel Controls For CC Models See Section 6 2 17 202 705 802 311 A 15 16 2 1 3 13 18 19 14 12 10 11 9 8 6...

Page 41: ...Idle and press Magnetic Shutdown switch see Section 11 1 9 Fuel Gauge Use gauge to check fuel level To check fuel level when engine is not run ning turn Engine Control switch to Run Idle position and...

Page 42: ...181 711 A 802 311 A Example Combination Remote Amperage Control Stick In Example Range 125 to 320 A DC Percentage Of Range 50 Max About 223 A DC 50 of 125 to 320 Adjust Optional Remote Control Set Sw...

Page 43: ...OM 495 Page 37 Return To Table Of Contents Notes...

Page 44: ...ge 38 Return To Table Of Contents SECTION 7 OPERATING WELDING GENERATOR CC CV MODELS 7 1 Front Panel Controls For CC CV Models See Section 7 2 202 706 802 311 D 6 5 4 7 13 16 2 1 3 14 18 19 15 12 10 1...

Page 45: ...rmal oil pressure Stop engine and fix trouble if Engine Oil Pressure light stays on after start up 7 Fuel Light Fuel light is not active on this model 8 Engine Hour Meter Engine Gauges To read gauges...

Page 46: ...drive dig circuit provides additional am perage during low voltage short arc length conditions to prevent sticking electrodes The arc drive dig circuit is disabled when switch is in MIG or TIG positio...

Page 47: ...On Off Range 125 to 320 A DC Min 125 A DC Max 320 A DC Adjust Optional Remote Control Set V A Adjust Switch Set Range Control Not Used In Remote Stick Mode Max 320 A DC Min 125 A DC Set Remote Proces...

Page 48: ...power speed and press test button to verify GFCI is working properly 3 Circuit Breaker CB1 4 Circuit Breaker CB2 CB1 protects RC1 and the genera tor winding from overload If CB1 opens RC1 and GFCI1 do...

Page 49: ...ead 42 Circuit Grounding Lead 7 Lead 90 Neutral 8 Isolated Neutral Terminal 9 Jumper Lead 42 10 Grounding Terminal Jumper 42 is connected to lead 90 at factory Jumper 42 may be discon nected from neut...

Page 50: ...power speed and press test button to verify GFCI is working properly 5 Circuit Breaker CB2 6 Circuit Breaker CB3 CB2 protects GFCI1 from overload If CB2 opens GFCI1 does not work Press button to rese...

Page 51: ...reset breaker CB2 protects RC2 and CB3 protects RC3 from overload If a circuit breaker opens the receptacle does not work Place switch in On position to reset breaker If a circuit breaker continues t...

Page 52: ...and Maintenance Label for important start up service and storage informa tion Service engine more frequently if used in se vere conditions To be done by Factory Authorized Service Agent Every 8 h Wipe...

Page 53: ...hange Oil See Section 9 6 Service Welding Generator Brushes And Slip Rings Service More Often In Dirty Conditions Change Fuel Filters See Section 9 6 Drain Sludge From Fuel Tank See Section 9 6 Check...

Page 54: ...OM 495 Page 48 Return To Table Of Contents 9 2 Maintenance Label...

Page 55: ...nt to pro vide additional engine protection Never clean a safety element Re place the safety element after servic ing the primary element three times Clean or replace primary element if dirty see note...

Page 56: ...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 idle speed to blow out cleanout hole I...

Page 57: ...dels 1 Engine Speed Adjustment Screw 2 Locking Nut Loosen nut Turn screw until engine runs at weld power speed Tighten nut Do not set engine speed higher than specified Models With Automatic Idle Opti...

Page 58: ...se petcock when water free fuel flows To replace primary fuel filter Turn filter counterclockwise Remove filter Apply thin coat of fuel to gasket on new filter Fill filter with fuel Install filter and...

Page 59: ...gulator board PC1 CC CV models only If CB5 opens weld out put and 24 volt output to RC14 stops On units with optional three phase genera tor generator power output at receptacle RC5 also stops if CB5...

Page 60: ...service and storage informa tion Service engine more frequently if used in se vere conditions To be done by Factory Authorized Service Agent Every 8 h Wipe Up Spills Check Fluid Levels See Section 5 9...

Page 61: ...7 Repair Or Replace Cracked Cables Check Valve Clearance Every 1000 h Service Welding Generator Brushes And Slip Rings Service More Often In Dirty Conditions Change Fuel Filters See Section 10 7 Drain...

Page 62: ...OM 495 Page 56 Return To Table Of Contents 10 2 Maintenance Label...

Page 63: ...nt to pro vide additional engine protection Never clean a safety element Re place the safety element after servic ing the primary element three times Clean or replace primary element if dirty see note...

Page 64: ...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 idle speed to blow out cleanout hole I...

Page 65: ...d higher than specified Stop engine Close side door RPM 1850 Engine Speed No Load Weld Power Tools Needed 9 16 7 8 in 1 2 10 6 Servicing Optional Ether Starting Aid Deutz F3L912 Powered Units ether2 7...

Page 66: ...e petcock when water free fuel flows To replace primary fuel filter Turn filter counterclockwise Remove filter Apply thin coat of fuel to gasket on new filter Fill filter with fuel Install filter and...

Page 67: ...ceptacle RC14 and 24 volt output to field current regulator board PC1 CC CV models only If CB5 opens weld out put and 24 volt output to RC14 stops On units with optional three phase genera tor power o...

Page 68: ...ce Agent If Battery Charging Light Is On Have Factory Authorized Service Agent Check Alternator If Temperature Light Is On Correct Cause Of Overheating See Engine Manual If Engine Is Okay See Factory...

Page 69: ...Use dry properly stored electrodes Remove excessive coils from weld cables Have Factory Authorized Service Agent check brushes and slip rings High weld output Check engine weld power speed and adjust...

Page 70: ...e Range switch and Voltage Amperage Adjust control Check engine weld power speed and adjust if necessary see Section 9 5 or 10 5 Have Factory Authorized Service Agent check field current regulator boa...

Page 71: ...ectifier SR1 resistor R3 and capacitor C9 D Optional Three Phase Generator Power CC CV Models Only Trouble Remedy No or low output at optional three phase generator receptacle RC5 Place Process Contac...

Page 72: ...information Use correct grade oil for cold weather see Section 9 2 or 10 2 Engine suddenly stops Check fuel level Check oil level Automatic shutdown system stops engine if oil pressure is too low or...

Page 73: ...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 MAT...

Page 74: ...OM 495 Page 68 Return To Table Of Contents SECTION 12 ELECTRICAL DIAGRAMS Figure 12 1 Circuit Diagram For CC Welding Generator Non CE Deutz F4L2011 Powered Units...

Page 75: ...OM 495 Page 69 Return To Table Of Contents 215 302 A...

Page 76: ...OM 495 Page 70 Return To Table Of Contents Figure 12 2 Circuit Diagram For CC Welding Generator CE Compliant Deutz F4L2011 Powered Units...

Page 77: ...OM 495 Page 71 Return To Table Of Contents 216 530 A...

Page 78: ...OM 495 Page 72 Return To Table Of Contents Figure 12 3 Circuit Diagram For CC CV Welding Generator Non CE Deutz F4L2011 Powered Units...

Page 79: ...OM 495 Page 73 Return To Table Of Contents 215 303 A...

Page 80: ...OM 495 Page 74 Return To Table Of Contents Figure 12 4 Circuit Diagram For CC CV Welding Generator CE Compliant Deutz F4L2011 Powered Units...

Page 81: ...OM 495 Page 75 Return To Table Of Contents 216 531 A...

Page 82: ...OM 495 Page 76 Return To Table Of Contents Figure 12 5 Circuit Diagram For CC Welding Generator Deutz F3L912 Powered Units...

Page 83: ...OM 495 Page 77 Return To Table Of Contents 215 298 A...

Page 84: ...OM 495 Page 78 Return To Table Of Contents Figure 12 6 Circuit Diagram For CC CV Welding Generator Deutz F3L912 Powered Units...

Page 85: ...OM 495 Page 79 Return To Table Of Contents 215 299 A...

Page 86: ...abel or specifications section in this manual to find rated voltage and current Do not idle engine longer than necessary Piston rings seat faster if engine runs at weld power rpm and the welding gener...

Page 87: ...ther DC position 3 Weld Cables Connect load bank to generator weld output terminals using proper size weld cables with correct connectors Observe correct polarity Start engine and run for several minu...

Page 88: ...ls using proper size weld cables with correct connec tors polarity is not important 4 Voltmeter 5 Clamp On Ammeter Connect voltmeter and ammeter as shown if not provided on generator Start engine and...

Page 89: ...2 Grounding Generator To Truck Or Trailer Frame S 0854 Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards 1 Equipment Grounding Terminal On Front...

Page 90: ...ower 2 Non Resistive Load Equipment with a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when running see Section 14 8 3 Rating Data Rat...

Page 91: ...uipment Farm Home Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Coole...

Page 92: ...3000 1000 1 HP 6000 1500 1 1 2 HP 8200 2200 2 HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric C...

Page 93: ...nduction Motor Starting Requirements Motor Start Code G H J K L M N P KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0 EXAMPLE Calculate the starting amperage required for a 230 V 1 4 HP motor with a motor...

Page 94: ...mer supplied if required by electrical code 4 Welding Generator Output Generator output voltage and wiring must be consistent with regular utility system volt age and wiring Connect generator with tem...

Page 95: ...5 38 75 23 50 15 40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 2 voltage drop Cord Lengths for 240 Volt Loads If unit does not have GFCI recept...

Page 96: ...nsert 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 99 CC ONLY 104 106 FIG 15 4 OR 15 5 105 96 10...

Page 97: ...d 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 92 91 90 83 87 84 85 86 89 88 80 81 82 79 78 73 75 74 76 77 23 31 25 24 29...

Page 98: ...nt primary 1 192 939 FILTER air element safety 1 18 189 464 SEAL weather lift eye 1 173 909 HOSE sae 312 id x 560 od x 24 000 order by ft 2 19 201 658 UPRIGHT center assembly 1 20 200 999 BASE 1 20 20...

Page 99: ...jury 3 55 199 849 SCREW 625 11 x 4 00hexhd pln gr 5 pld 4 56 071 731 WASHER flat 656 ID x 2 250 OD x 187T stl pld 4 57 191 812 BRACKET mtg engine RH Deutz F4L2011 engine 1 58 071 890 RETAINER mount en...

Page 100: ...AIN RECTIFIER ASSEMBLY 1 103 191 448 TOP cover front upright 1 103 199 305 TOP cover front upright ss 1 104 201 750 UPRIGHT front 1 104 202 637 UPRIGHT front ss 1 105 134 792 LABEL warning general pre...

Page 101: ...C C CC models only C V CC CV models only optional To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required wh...

Page 102: ...250 hole 248 thk 2 12 177 136 CLAMP capacitor 1 375dia 1 13 C9 087 110 CAPACITOR elctlt 240uf 200VDC 1 14 R6 141 424 RESISTOR ww fxd 30 w 25 ohm faston te 1 15 PC7 195 706 MODULE pull to idle two out...

Page 103: ...201 495 HARNESS control box cv weld control consisting of 1 10 SR1 035 704 RECTIFIER integ 40A 800V 1 11 CR5 090 104 RELAY encl 12VDC SPST 30A 15VDC 1 RC4 047 483 CONNECTOR rect univ 084 15P S 3 row r...

Page 104: ...10 pole 1 19 CR1 214 876 RELAY encl 6vdc spst 35a 14vdc 5 pin 1 20 CB14 205 927 CIRCUIT BREAKER auto reset 12vdc 12 amp 1 205 931 HARNESS engine control Deutz F3L912 engine consisting of 1 17 R8 214...

Page 105: ...omponents CC Models Description Part No Dia Mkgs Item No Figure 15 4 Panel Front w Components CC Models Figure 15 1 Item 106 Quantity 1 202 705 PLATE SCREENED ident control rating when ordering this i...

Page 106: ...power European Receptacle consisting of 1 14 CB2 093 996 CIRCUIT BREAKER man reset 1P 20A 250VAC frict 1 14 CB3 139 266 CIRCUIT BREAKER man reset 1P 15A 250VAC 1 15 GFCI1 151 981 RECEPTACLE str dx gr...

Page 107: ...5dia 1 39 189 161 HANDLE switch range 1 40 010 647 PIN spring CS 156 x 1 250 1 41 019 602 KNOB pointer 1 024 103 BLANK snap in nyl 750 mtg hole black 1 Optional When ordering a component originally di...

Page 108: ...Dia Mkgs Item No Figure 15 5 Panel Front w Components CC CV Models Figure 15 1 Item 106 Quantity 1 202 706 PLATE SCREENED ident control when ordering this item the nameplate should also be ordered 1...

Page 109: ...981 RECEPTACLE str dx grd 2P3W 15 20A 125V GFCI 1 213 577 HARNESS generator power CE Rated 1 189 549 BLOCK term assy standard 1 038 620 LINK jumper term block 1 17 RC1 176 355 RECEPTACLE str 2p3w 16a...

Page 110: ...screws plstc 1 55 189 161 HANDLE switch range 1 56 010 647 PIN spring CS 156 x 1 250 1 57 097 924 KNOB pointer 1 625 dia x 250 ID w set scrws plstc 1 58 CB6 083 432 CIRCUIT BREAKER Man Reset 1p 10a 2...

Page 111: ...mbly complete full kVA option 1 7 013 367 LABEL warning moving parts 2 7 176 106 LABEL warning moving parts Wordless Label 2 8 190 197 GUARD generator wire mesh 1 9 172 674 SPRING ext 240 OD x 041 wir...

Page 112: ...189 142 BRUSHHOLDER ASSEMBLY gen 1 32 602 242 WASHER flat 375IDx0 875odx 083t stl pld 2 33 602 211 WASHER Lock 318idx0 586odx 078t Stl Pld Split 312 2 34 604 534 SCREW 312 18x1 25 hex hd pln gr5 pld 2...

Page 113: ...of 1 1 188 137 CONNECTION BOARD rectifier AC 1 2 188 517 BUS BAR connection board 3 3 188 135 ENCLOSURE rectifier 2 4 134 201 STAND OFF support 3 5 PC3 201 449 CIRCUIT CARD ASSEMBLY protection 1 6 188...

Page 114: ......

Page 115: ...rols Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles con...

Page 116: ...complete and retain with your personal records Always provide Model Name and Serial Style Number Call 1 800 4 A Miller or see our website at www MillerWelds com to locate a DISTRIBUTOR or SERVICE AGEN...

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Miller Electric Big Blue 402D, Owner'S Manual

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