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Processes

Description

TIG (GTAW) Welding

Stick (SMAW) Welding

MIG (GMAW) Welding

Engine Driven Welding Generator

OM-4428

215 932K

2007

−

Visit our website at

www.MillerWelds.com

Flux Cored (FCAW) Welding

Air Carbon Arc (CAC-A)

Cutting and Gouging

File: Engine Drive

Big Blue 500D

Big Blue 600 X

(Deutz-Powered)

Содержание 600 X

Страница 1: ...Welding MIG GMAW Welding Engine Driven Welding Generator OM 4428 215 932K 2007 10 Visit our website at www MillerWelds com Flux Cored FCAW Welding Air Carbon Arc CAC A Cutting and Gouging File Engine...

Страница 2: ...tinue 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...

Страница 3: ...r And Engine Specifications 15 4 2 Dimensions Weights And Operating Angles 15 4 3 Volt Ampere Curves For CC Models 16 4 4 Volt Ampere Curves For CC CV Models 17 4 5 Fuel Consumption 18 4 6 Duty Cycle...

Страница 4: ...Powered Units 46 9 6 Adjusting Engine Speed Deutz F4L2011 Powered Units 47 9 7 Servicing Fuel And Lubrication Systems Deutz F4L2011 Powered Units 48 9 8 Overload Protection Deutz F4L2011 Powered Units...

Страница 5: ...risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC constant voltage wire welder 2 a DC man...

Страница 6: ...ing can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire o...

Страница 7: ...s bare handed Allow cooling period before working on equip ment To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns STEAM AND HOT COOLANT can...

Страница 8: ...ge and frequency caused by low engine speed damage electric motors Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable FLYING SPARKS can cause injury Wear a face shield t...

Страница 9: ...tion Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Assoc...

Страница 10: ...l appareil en est quip Des pr cautions de s curit suppl mentaires sont requises dans des environnements risque comme les endroits humides ou lorsque l on porte des v tements mouill s sur des structure...

Страница 11: ...Porter des lunettes de s curit avec crans lat raux m me sous votre casque Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les blouissements et les t...

Страница 12: ...r les batteries D brancher le c ble n gatif en premier lieu Le rebrancher en dernier lieu LE CARBURANT MOTEUR peut provo quer un incendie ou une explosion Arr ter le moteur avant de v rifier le niveau...

Страница 13: ...e changer ou de rajouter des l ments ou avant d ouvrir la purge ou le bouchon de remplissage d huile Le METAL CHAUD lors du coupage et gougeage plasma peut provoquer un in cendie ou une explosion Ne p...

Страница 14: ...INSTRUCTIONS Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil N utiliser que les pi ces de rechange recom mand es par le constructeur Effectuer la maintenance et le s...

Страница 15: ...onal Standards Institute 11 West 43rd Street New York NY 10036 8002 t l phone 212 642 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standa...

Страница 16: ...d 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 above 200 amperes Do not weld below 200 amper...

Страница 17: ...OM 4428 Page 13 3 2 Manufacturer s Rating Labels CC Models CC CV Models...

Страница 18: ...cal Remote 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...

Страница 19: ...led Three Cylinder 41 5 HP Diesel Engine 95 L 4 2 Dimensions Weights And Operating Angles Dimensions Height 50 in 1270 mm to top of muffler Width 28 1 2 in 724 mm mtg brackets turned in 30 3 4 in 781...

Страница 20: ...rage output capabilities of the welding generator Curves of all other settings fall between the curves shown 0 20 40 60 80 100 0 100 200 300 400 500 600 700 800 900 DC AMPERES DC VOLTS Ranges 300 Max...

Страница 21: ...ves 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 275 Max 150 525 110 390 80...

Страница 22: ...OM 4428 Page 18 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 0 IDLE Notes...

Страница 23: ...ding duty cycle can damage unit and void warranty 100 Duty Cycle At 500 Amperes 202 356 4 7 AC Generator Power Curve 193 018 The ac power curve shows the gen erator power in amperes available at the 1...

Страница 24: ...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 180 190 200 210 220 230 240 250 2...

Страница 25: ...ection 5 3 for mounting in formation Grounding 1 Equipment Grounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Connect cable from equipment ground terminal to metal...

Страница 26: ...n 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...

Страница 27: ...Supports 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...

Страница 28: ...structions 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 C...

Страница 29: ...If necessary add electro lyte to raise to proper level Reins tall vent caps 4 Battery Charger Read and follow all instruc tions supplied with battery charger Charge battery for 12 minutes at 30 ampere...

Страница 30: ...h 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 out of...

Страница 31: ...ive Weld Output Terminal Failure to properly connect weld cables may cause excessive heat and start a fire or damage your machine 3 Weld Output Terminal 4 Supplied Weld Output Terminal Nut 5 Weld Cabl...

Страница 32: ...ea 2 0 2x70 2 ea 3 0 2x95 2 ea 3 0 2x95 350 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 3 0 2x95 2 ea 4 0 2x120 400 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 4 0...

Страница 33: ...ommon distance remote includes 120 V receptacle OUTPUT CONTROL E DC input command signal 0 to 10 volts from min to max of remote control with Voltage Amperage Adjust control at max OR 115 VOLTS AC I 1...

Страница 34: ...OM 4428 Page 30 SECTION 6 OPERATING WELDING GENERATOR CC MODELS 6 1 Front Panel Controls For CC Models See Section 6 2 12 215 663 803 602 11 2 1 8 13 14 9 7 6 4 5 3 10...

Страница 35: ...st control adjusts amperage only when welding and does not adjust open circuit voltage The max OCV circuit is disabled when the Stick TIG Selection switch is in Scratch Start TIG position see item 10...

Страница 36: ...rage Control Stick Adjust Optional Remote Control Set Switches Set Range Set Control Ref 154 862 A Ref 215 663 803 602 In Example Range 115 to 330 A DC Percentage Of Range 50 Max About 240 A DC 50 of...

Страница 37: ...OM 4428 Page 33 Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual...

Страница 38: ...OM 4428 Page 34 SECTION 7 OPERATING WELDING GENERATOR CC CV MODELS 7 1 Front Panel Controls For CC CV Models See Section 7 2 215 664 802 602 2 1 9 14 15 10 7 6 4 5 11 8 13 OR 12 3...

Страница 39: ...welding Read the upper set of numbers at each range for Stick welding and the lower set at each range for TIG welding Use the highest range for MIG welding and for cutting and gouging CAC A For most...

Страница 40: ...t arc length conditions to prevent stick ing electrodes The arc drive dig circuit is disabled when switch is in MIG or TIG positions Place switch in Weld Terminals Al ways On Stick position when us in...

Страница 41: ...ch Set Range Control Not Used In Remote Stick Mode Set Remote Process Example Combination Remote Amperage Control TIG Adjust Optional Remote Control Set V A Adjust Switch Set Range Set Control Set Rem...

Страница 42: ...button to verify GFCI is working properly 3 Supplementary Protector CB1 4 Supplementary Protector CB2 CB1 protects RC1 and the genera tor winding from overload If CB1 opens RC1 and GFCI1 do not work P...

Страница 43: ...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 neutral to meet ap...

Страница 44: ...press test button to verify GFCI is working properly 5 Supplementary Protector CB2 6 Supplementary Protector CB3 CB2 protects GFCI1 from overload If CB2 opens GFCI1 does not work Press button to reset...

Страница 45: ...set CB2 protects RC2 and CB3 protects RC3 from overload If a supplementary protector opens the receptacle does not work Place switch in On position to reset If a supplementary protector continues to o...

Страница 46: ...OM 4428 Page 42 SECTION 9 MAINTENANCE DEUTZ F4L2011 POWERED UNITS 9 1 Maintenance Label Deutz F4L2011 Powered Units...

Страница 47: ...TER Section 5 8 Fuel Water Separator Fuel Level Oil Level Oil Fuel Spills Every 50 Hours Weld Terminals Every 100 Hours Section 9 4 Battery Terminals Air Cleaner Hoses L l ment du filtre air Every 250...

Страница 48: ...engine and let cool 1 Generator Brush Mark and disconnect leads at brush hold er cap Remove brushes Replace brushes if damaged or if brush material is at or near minimum length 1 Damaged Brushes New...

Страница 49: ...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 above before...

Страница 50: ...let cool 1 Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole Start engine and run at idle speed to blow out cleanout hole If nothing blows out of hole brie...

Страница 51: ...peed 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 Optional 3 Throttle...

Страница 52: ...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 turn clock wise Blee...

Страница 53: ...e RC14 and 24 volt out put to field current regulator board PC1 CC CV models only If CB5 opens weld output and 24 volt output to RC14 stops On units with optional three phase generator generator power...

Страница 54: ...OM 4428 Page 50 SECTION 10 MAINTENANCE DEUTZ F3L912 POWERED UNITS 10 1 Maintenance Label Deutz F3L912 Powered Units...

Страница 55: ...UEL WATER Section 5 8 Fuel Water Separator Fuel Level Oil Level Oil Fuel Spills Every 50 Hours Weld Terminals Every 100 Hours Section 10 4 Battery Terminals Air Cleaner Hoses Air Cleaner Element Every...

Страница 56: ...engine and let cool 1 Generator Brush Mark and disconnect leads at brush hold er cap Remove brushes Replace brushes if damaged or if brush material is at or near minimum length 1 Damaged Brushes New...

Страница 57: ...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 above before...

Страница 58: ...let cool 1 Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole Start engine and run at idle speed to blow out cleanout hole If nothing blows out of hole brie...

Страница 59: ...fied Stop engine Close side door RPM Hz 1850 Engine Speed No Load Weld Power Tools Needed 9 16 7 8 in 1 2 61 6 Hz 10 7 Servicing Optional Ether Starting Aid Deutz F3L912 Powered Units ether2 7 96 ST 1...

Страница 60: ...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 turn clock wise Blee...

Страница 61: ...output to remote receptacle RC14 and 24 volt output to field current regulator board PC1 CC CV mod els only If CB5 opens weld output and 24 volt output to RC14 stops On units with op tional three pha...

Страница 62: ...ons inside and outside unit Be sure connection to work piece is clean and tight Use dry properly stored electrodes Remove excessive coils from weld cables Have Factory Authorized Service Agent check b...

Страница 63: ...d cables Have Factory Authorized Service Agent check brushes and slip rings High weld output Check position of Ampere Range switch and Voltage Amperage Adjust control Check engine speed and adjust if...

Страница 64: ...d and adjust if necessary Have Factory Authorized Service Agent adjust generator power field current resistor R3 Low output at generator power ac recep tacles Check engine speed and adjust if necessar...

Страница 65: ...ulated for cold weather diesel fuel can gel in cold weather Contact local fuel supplier for fuel information Use correct grade oil for cold weather see Section 9 1 or 10 1 Engine suddenly stops Check...

Страница 66: ...OM 4428 Page 62 SECTION 12 ELECTRICAL DIAGRAMS Figure 12 1 Circuit Diagram For CC Welding Generator Deutz F4L2011 Powered Units...

Страница 67: ...OM 4428 Page 63 215 221 E...

Страница 68: ...OM 4428 Page 64 Figure 12 2 Circuit Diagram For CC Welding Generator Deutz F4L2011 Powered Units Export Models...

Страница 69: ...OM 4428 Page 65 235 275 A...

Страница 70: ...OM 4428 Page 66 Figure 12 3 Circuit Diagram For CC CV Welding Generator Deutz F4L2011 Powered Units...

Страница 71: ...OM 4428 Page 67 215 806 E...

Страница 72: ...OM 4428 Page 68 Figure 12 4 Circuit Diagram For CC CV Welding Generator Deutz F4L2011 Powered Units Export Models...

Страница 73: ...OM 4428 Page 69 235 276 A...

Страница 74: ...OM 4428 Page 70 Figure 12 5 Circuit Diagram For CC Welding Generator Deutz F3L912 Powered Units...

Страница 75: ...OM 4428 Page 71 215 807 D...

Страница 76: ...OM 4428 Page 72 Figure 12 6 Circuit Diagram For CC CV Welding Generator Deutz F3L912 Powered Units...

Страница 77: ...OM 4428 Page 73 215 808 D...

Страница 78: ...gs seat faster if engine runs at weld power rpm and the welding generator is kept loaded during run in 2 Engine Exhaust Pipe Wetstacking is unburned fuel and oil in the exhaust pipe and occurs during...

Страница 79: ...t of generator see name plate rating label or the specifi cations section in this manual Check generator and load bank meters after first five minutes then every fifteen minutes to be sure generator i...

Страница 80: ...voltage and current of the generator see nameplate rating label or the specifications section in this manual Check generator and meters after first five minutes then every fifteen minutes to be sure g...

Страница 81: ...ctric shock and static electricity hazards Also see AWS Safety Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Generators 1 EquipmentGrounding Terminal On Front Panel 2 Groun...

Страница 82: ...load and requires a constant amount of power 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 r...

Страница 83: ...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 Cooler 2900 1100 M...

Страница 84: ...P 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 Cultivator 1 3...

Страница 85: ...must be at least twice the motor s running amperage kVA HP x HP x 1000 Volts Starting Amperage Example Calculate starting amper age required for a 230 V 1 4 HP mo tor with a motor start code of M Volt...

Страница 86: ...to electric utility when service is re stored Install correct switch customer supplied Switch rating must be same as or greater than the branch overcurrent protection 3 Fused Disconnect Switch Install...

Страница 87: ...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 receptacles use GFC...

Страница 88: ...s 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 107 95 CC ONLY 100 Fig 15 7 97 CC ONLY 104 FIG 15 4 OR 15 5...

Страница 89: ...gines are the same in both units 50 53 88 90 89 84 81 82 83 85 86 87 35 Fig 15 6 54 64 66 63 65 57 59 58 61 62 60 56 55 23 32 38 2 36 37 33 24 29 28 27 26 25 43 41 39 40 34 42 2 49 31 4446 45 2 51 48...

Страница 90: ...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 20 203 382 BASE e coat 1 21 196 220 BRACKET hold down fuel tank rear 1 22 192 362 B...

Страница 91: ...brs barbed fem 1 2tbg x 3 8NPT 1 62 113 854 HOSE SAE 500 ID x 780 OD xc oil order by ft 2ft 63 176 528 FITTING hose brs barbed elbow fem 1 2 tbg x 1 2 NPT 1 64 173 336 FITTING adapter oil drain 1 65...

Страница 92: ...xport models Deutz F4L2011 engine 1 216 991 KIT label includes safety informational labels CC export models Deutz F3L912 engine 1 216 990 KIT label includes safety informational labels CC CV export mo...

Страница 93: ...CITOR BOARD 1 9 SR1 SR2 035 704 RECTIFIER integ 40A 800V 2 10 CR5 223 710 RELAY Encl 12vdc Dpst no 25a 6pin Flange 1 S5 011 609 SWITCH tgl spdt 15a 125vac on none on spd term chr located on front pane...

Страница 94: ...T relay 5 pin 2 PLG4 114 062 CONNECTOR rect univ 084 15P S 3 row plug cable lkg 1 173 916 HOUSING contact 10 pole 1 21 CR1 214 876 RELAY encl 6vdc spst 35a 14vdc 5 pin 1 22 CB14 205 927 CIRCUIT BREAKE...

Страница 95: ...35a 14vdc 5 pin 1 8 CR6 090104 RELAY encl 12vdc spst 30a 15vdc 5pin flange mtg 1 9 D8 C8 189 701 DIODE CAPACITOR BOARD 1 10 CB14 205 927 CIRCUIT BREAKER auto reset 12vdc 12 amp 1 11 CB10 190 374 CIRCU...

Страница 96: ...6 177 859 CONN body 5 terminal to engine control switch S1 1 193 183 CONN rect cinch 18 pin 1 196 602 PLUG cavity 18 30 position cinch connector 4 196 603 SEAL switch 6 position rotary 250 shaft 1 14...

Страница 97: ...Components CC Models Description Part No Dia Mkgs Item No Figure 15 4 Panel Front w Components CC Models Figure 15 1 Item 104 Quantity 1 215 663 PLATE SCREENED ident control rating when ordering this...

Страница 98: ...PROTECTOR man reset 1p 15a 250vac 1 14 GFCI1 151 981 RECEPTACLE str dx grd 2P3W 15 20A 125V GFCI 1 213 577 HARNESS generator power export models 1 189 549 BLOCK term assy standard 1 038 620 LINK jump...

Страница 99: ...874 VOLT METER W Leads 1 39 A1 164 873 AMMETER W Leads 1 40 189 161 HANDLE switch range 1 41 010 647 PIN spring CS 156 x 1 250 1 42 019 602 KNOB pointer 1 024 103 BLANK snap in nyl 750 mtg hole black...

Страница 100: ...Dia Mkgs Item No Figure 15 5 Panel Front w Components CC CV Models Figure 15 1 Item 104 Quantity 1 215 664 PLATE SCREENED ident control when ordering this item the nameplate should also be ordered 1...

Страница 101: ...ROTECTOR Man Reset 1p 15a 250vac 1 16 GFCI1 151 981 RECEPTACLE str dx grd 2P3W 15 20A 125V GFCI 1 213 577 HARNESS generator power export models 1 189 549 BLOCK term assy standard 1 038 620 LINK jumper...

Страница 102: ...l 0 100 Psi 1 194 403 ADAPTER oil pressure sender Deutz F4L2011 1 53 A1 164 873 AMMETER W Leads 1 54 V1 164 874 VOLT METER W Leads 1 55 097 922 KNOB pointer 875 dia x 250 ID w set screws plstc 1 56 18...

Страница 103: ...ld assembly complete full kVA option 1 7 225 120 LABEL warning moving parts can cause injury 2 8 190 197 GUARD generator wire mesh 1 9 172 674 SPRING ext 240 OD x 041 wire x 3 500pld 2 10 039 207 BAFF...

Страница 104: ...act 3 30 208 469 CLIP spring 3 31 189 142 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 SCRE...

Страница 105: ...ectifier 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 215 755 CIRCUIT CARD ASSEMBLY protection 1 6 188 136 INSULATOR heat sink 8 7 188...

Страница 106: ......

Страница 107: ...nduction Heating Coils and Blankets Cables and Non Electronic Controls APT SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers...

Страница 108: ...retain with your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal...

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