Instruction/ maintenance manual of the product 500D Miller Electric
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Processes Description TIG (GT A W) Welding Stick (SMAW ) Welding MIG (GMAW) Welding Engine Driven Welding Generator OM-4428 215 932K 2007 − 10 Visit our website at www.
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 specification sheets. T o locate your near est distributor or service agency call 1-800-4-A-Miller , or visit us at www .
T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T ABLE OF CONTENTS SECTION 7 − OPERA TING WELDING GENERA TOR − CC/CV MODELS 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Front Panel Controls For CC/CV Models (See Section 7-2) 34 . . . . . . . . . . . . . . . . . . . . . . . .
OM-4428 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2007 − 04 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury .
OM-4428 Page 2 W elding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous. Keep your head out of the fumes. Do not breathe the fumes. If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases.
OM-4428 Page 3 1-3. Engine Hazards BA TTER Y EXPLOSION can BLIND. Always wear a face shield, rubber gloves, and protective clothing when working on a battery . Stop engine before disconnecting or connect- ing battery cables or servicing battery .
OM-4428 Page 4 HOT MET AL from air arc cutting and gouging can cause fire or explosion. Do not cut or gouge near flammables. W atch for fire; keep extinguisher nearby . HOT P ARTS can cause burns and injury . Do not touch hot compressor or air system parts.
OM-4428 Page 5 H. F . RADIA TION can cause interference. High-frequency (H.F .) can interfere with radio navigation, safety services, computers, and communications equipment. Have only qualified persons familiar with electronic equipment perform this installation.
OM-4428 Page 6 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION rom_2007 − 04fre Se protéger , ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud.
OM-4428 Page 7 DES PIÈCES CHAUDES peuvent provoquer des brûlures graves. Ne pas toucher à mains nues les parties chau - des. Prévoir une période de refroidissement avant d e travailler à l’équipement.
OM-4428 Page 8 LES CHAMPS MAGNETIQUES peuv- ent affecter des implants médicaux. Porteur de simulateur cardiaque ou autre im- plants médicaux, rester à distance.
OM-4428 Page 9 L ’utilisation d’un groupe autonome à l’intérieur PEUT VOUS TUER EN QUELQUES MINUTES. Le s fumées d’un groupe autonome contient du monoxyde de carbone. C’est un poison invisi- ble et inodore. JAMAIS utiliser dans une maison ou garage, même avec les portes et fenêtres ouvertes.
OM-4428 Page 10 LE SURCHAUFFEMENT peut endom- mager le moteur électrique. Arrêter ou déconnecter l’équipement avant d e démarrer ou d ’a rrêter le moteur . Ne pas laisser tourner le moteur trop lentement sous risque d’en - dommager l e moteur électrique à cause d’une tension et d’une fré - quence trop faibles.
OM-4428 Page 1 1 2-6. P r oposition californienne 65 A vertissem ents Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des mal- formations congénitales et, dans certains cas, des cancers.
OM-4428 Page 12 SECTION 3 − DEFINITIONS 3-1. W arning Label Definitions (For Wordless Labels) 3/96 1 Remove unit from shipping crate. Remove Owner’s Manual from unit. Follow instructions to install muf fler . 2 Read Owner ’s Manual. Read labels on unit.
OM-4428 Page 13 3-2. Manufacturer ’ s Rating Labels CC Models CC/CV Models.
OM-4428 Page 14 3-3. Symbols And Definitions Some symbols are found only on CE products. Stop Engine Fast (Run, W eld/ Power) Slow (Idle) Start Engine Starting Aid Battery (Engine) Engine Oil Pres.
OM-4428 Page 15 SECTION 4 − SPECIFICA TIONS 4-1. W eld, Power , And Engine Specifications W elding Mode W eld Output Range Rated W elding Output Maximum Open-Circuit V oltage Generator Power Rating .
OM-4428 Page 16 4-3. V olt-Ampere Curves For CC Models 203 412 The volt-ampere curve shows the minimum and maximum voltage an d amperage output capabilities of th e welding generator .
OM-4428 Page 17 4-4. V olt-Ampere Curves For CC/CV Models 217 81 1 / 203 415 / 217 810 The volt-ampere curves show the minimum and maximum voltage an d amperage output capabilities of th e welding generator . Curves of al l other settings fall between the curves shown.
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 A T 100% DUTY CYCLE 1800 RPM 0 IDLE N.
OM-4428 Page 19 Continuous Welding 4-6. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. NOTICE − Exceeding duty cycle ca n damage unit and void warranty . 100% Duty Cycle At 500 Amperes 202 356 4-7.
OM-4428 Page 20 4-8. Optional Three-Phase Generator Curves 197 472 / 197 473 Th e 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 terminals. A. 12 kV A/kW Single-Phase AC Output (No Weld Load) B.
OM-4428 Page 21 SECTION 5 − INST ALLA TION install3 2007 − 04 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712 ! Always securely fasten weld- ing generator onto transport vehicle or trailer and comply with all DOT and other applica- ble codes.
OM-4428 Page 22 5-2. Using Lifting Eye Ref. 802 31 1 1 Lifting Eye 2 Nut 3 Carriage Bolt Raise lifting eye until it snaps in place. Lower lifting eye when not needed. T o lock the lifting eye in the upright position, insert a 3/8-16 x 1-1/2 in carriage bolt through slot in bracket a nd secure with nut (bolt and nut not supplied).
OM-4428 Page 23 5-3. Mounting Welding Generator T ools Needed: 9/16 in 2 2 4 W elding Unit In Place Bolting Unit In Place ! Do not weld on base. W eld- ing on base can cause fuel tank fire or explosion. Weld only on the four mounting brackets or bolt unit down.
OM-4428 Page 24 5-4. Installing Exhaust Pipe 1/2 in T ools Needed: Ref. 803 604 / Ref. 215 664 ! Stop engine and let cool. Point exhaust pipe in desired di- rection but always away from front panel and direction of travel. ether1 7/96 − 153 382-A / Ref.
OM-4428 Page 25 5-6. Activating The Dry Charge Battery (If Applicable) ! Always wear a face shield, rubber gloves and protective clothing when working on a battery . Remove battery from unit. 1 V ent Caps 2 Sulfuric Acid Electrolyte (1.265 Specific Gravity) 3 W ell Fill each cell with electrolyte to bottom of well (maximum).
OM-4428 Page 26 5-8. Engine Prestart Checks 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.
OM-4428 Page 27 5-9. Connecting T o Weld Output T erminals 803 602 / 803 778-A T ools Needed: 2 3/4 in 1 MIG and FC A W Welding For MIG and FCA W welding Direct Current Electrode Positive (DCEP) on CC/CV models, connect wire feeder cable to Positive (+) termi- nal on left and work cable to Negative ( − ) ter- minal on right.
OM-4428 Page 28 5-10. Selecting W eld Cable Sizes* W eld Cable Size** and T otal Cable (Copper) Length in W eld 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) W eld Output T erminals ! Stop engine before connecting to weld output terminals.
OM-4428 Page 29 5-12. Connecting T o Remote 14 Receptacle RC14 On CC/CV Models Socket* Socket Information 24 VOL TS AC A 24 volts ac. Protected by sup- plementary protector CB5. 24 VOL TS AC B Contact closure to A completes 24 volt ac contactor control circuit.
OM-4428 Page 30 SECTION 6 − OPERA TING WELDING GENERA TOR − CC MODELS 6-1. Front Panel Controls For CC Models (See Section 6-2) 12 215 663 / 803 602 11 2 1 81 3 1 4 97 6 4 5 3 10.
OM-4428 Page 31 6-2. Description Of Front Panel Controls For CC Models (See Section 6-1 ) Engine Starting Controls 1 Starting Aid Switch Use switch to energize starting aid for cold weather starting (see starting instructions fol- lowing). 2 Engine Control Switch Use switch to start and stop engine.
OM-4428 Page 32 6-3. Remote Amperage Control On CC Models (Optional) 1 Remote Amperage Adjust Receptacle RC13 Connect optional remote control to RC13 (see Section 5-1 1). Example: Combination Remote Amperage Control (Stick) Adjust Optional Remote Control Set Switches Set Range Set Control Ref.
OM-4428 Page 33 Notes W or k l i ke a P r o ! Pros wel d and cut safel y . Read the safety rules at the beginni ng of this manual ..
OM-4428 Page 34 SECTION 7 − OPERA TING WELDING GENERA TOR − CC/CV MODELS 7-1. Front Panel Controls For CC/CV Models (See Section 7-2) 215 664 / 802 602 2 1 91 4 1 5 10 7 6 4 5 11 8 13 OR 12 3.
OM-4428 Page 35 7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1 ) Engine Starting Controls 1 Starting Aid Switch Use switch to energize starting aid for cold weather starting (see starting instructions fol- lowing).
OM-4428 Page 36 7-3. Process/Contactor Switch On CC/CV Models 1 Process/Contactor Switch ! W eld output terminals are ener- gized when Process/Contactor switch is in an Weld T erminals Always On position and the en- gine is running.
OM-4428 Page 37 7-4. Remote V oltage/Amperage Control On CC/CV Models (Optional) 1 Remote 14 Receptacle RC14 Connect optional remote control to RC14 (see Section 5-12 ).
OM-4428 Page 38 SECTION 8 − OPERA TING AUXILIAR Y EQUIPMENT 8-1. 120 V olt And 240 V olt Receptacles 191 624-A 2 1 120 V 20 A AC GFCI Receptacle GFCI1 2 240 V 30 A AC T wistlock Receptacle RC1 Receptacles supply 60 Hz single- phase power at weld/power speed.
OM-4428 Page 39 8-2. Connecting T o Optional Three-Phase Generator (CC/CV Models Only) Ref. 197 399 / 802 332-B / 803 655 Place Process/Contactor switch in Electrode Hot - Stick position when using three-phase genera- tor (see Section 7-3).
OM-4428 Page 40 8-3. Optional Generator Power Receptacles (Standard Models) 2 1 120 V 20 A AC GFCI Receptacle GFCI1 2 240 V 16 A AC European Receptacle RC1 3 240 V 15 A AC Australian Receptacle RC1 4 240 V 15 A AC South African Receptacle RC1 Receptacles supply 60 Hz single- phase power at weld/power speed.
OM-4428 Page 41 8-4. Generator Power Receptacles (Export Models) Generator power is not affected by weld output. 1 130 V 32 A AC Receptacle RC1 2 220 V olt 16 A AC Receptacle RC2 3 130 V olt 16 A AC Receptacle RC3 Receptacles supply 60 Hz single-phase power at weld/power speed.
OM-4428 Page 42 SECTION 9 − MAINTENANCE (DEUTZ F4L201 1 − POWERED UNITS) 9-1. Maintenance Label (Deutz F4L201 1-Powered Units).
OM-4428 Page 43 9-2. Routine Maintenance (Deutz F4L201 1-Powered Units) ! Stop engine before maintaining. S ee Engine Manual and Maintenance Label for important start-up, service, and storage information. Service engine more often if used in severe conditions.
OM-4428 Page 44 9-3. Checking Generator Brushes Ref 215 158 ! Stop engine and let cool. 1 Generator Brush Mark and disconnect leads at brush hold- er cap.
OM-4428 Page 45 9-4. Servicing Air Cleaner (Deutz F4L201 1-Powered Units) aircleaner1 9/00 − ST -153 929-B / ST-153 585 / Ref. S-0698-B ! Stop engine. NOTICE − Do not run engine without air cleaner or with dirty element. Engine damage caused by using a damaged ele- ment is not covered by the warranty .
OM-4428 Page 46 9-5. Inspecting/Cleaning Optional Spark Arrestor (Deutz F4L201 1-Powered Units) 803 656 / Ref. 215 664 ! Stop engine and 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.
OM-4428 Page 47 9-6. Adjusting Engine Speed (Deutz F4L201 1-Powered Units) 803 657 ! Stop engine and let cool. Engine speed is factory set and should not require adjustment. Af- ter tuning engine, check engine no load speed with a tachometer or fre- quency meter (see table for no load speeds).
OM-4428 Page 48 9-7. Servicing Fuel And Lubrication Systems (Deutz F4L201 1-Powered Units) 803 657 ! Stop engine and let cool. ! After servicing, start engine and check for fuel leaks. Stop engine, tighten connections as necessary , and wipe up spilled fuel.
OM-4428 Page 49 9-8. Overload Protection (Deutz F4L201 1-Powered Units) Ref. 803 657 2 1 9 8 7 4 ! Stop engine. When a supplementary protector , circuit breaker or fuse opens, it usu- ally indicates a more serious prob- lem exists. Contact Factory Autho- rized Service Agent.
OM-4428 Page 50 SECTION 10 − MAINTENANCE (DEUTZ F3L912 − POWERED UNITS) 10-1. Maintenance Label (Deutz F3L912-Powered Units).
OM-4428 Page 51 10-2. Routine Maintenance (Deutz F3L912-Powered Units) ! Stop engine before maintaining. S ee Engine Manual and Maintenance Label for important start-up, service, and storage information. Service engine more often if used in severe conditions.
OM-4428 Page 52 10-3. Checking Generator Brushes Ref 215 158 ! Stop engine and let cool. 1 Generator Brush Mark and disconnect leads at brush hold- er cap.
OM-4428 Page 53 10-4. Servicing Air Cleaner (Deutz F3L912-Powered Units) aircleaner1 9/00 − ST -153 929-B / ST-153 585 / Ref. S-0698-B ! Stop engine. NOTICE − Do not run engine without air cleaner or with dirty element. Engine damage caused by using a damaged ele- ment is not covered by the warranty .
OM-4428 Page 54 10-5. Inspecting/Cleaning Optional Spark Arrestor (Deutz F3L912-Powered Units) 803 656 / Ref. 215 664 ! Stop engine and 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.
OM-4428 Page 55 10-6. Adjusting Engine Speed (Deutz F3L912-Powered Units) 803 658 / 134 730-C ! Stop engine. Engine speeds have been factory set and should not require adjust- ment. After tuning engine, check engine speeds with a tachometer . Se e table for proper no load speed.
OM-4428 Page 56 10-8. Servicing Fuel And Lubrication Systems (Deutz F3L912-Powered Units) 803 658 ! Stop engine and let cool. ! After servicing, start engine and check for fuel leaks. Stop engine, tighten connections as necessary , and wipe up spilled fuel.
OM-4428 Page 57 10-9. Overload Protection (Deutz F3L912-Powered Units) Ref. 803 658 2 1 9 8 7 4 ! Stop engine. When a supplementary protector , cir- cuit breaker or fuse opens, it usually in- dicates a mo re serious problem exists. Contact Factory Authorized Service Agent.
OM-4428 Page 58 SECTION 1 1 − TROUBLESHOOTING 1 1-1. T roubleshooting A. Welding − CC Models T rouble Remedy No weld output; generator power output okay at ac receptacles. Check position of Ampere Range switch. Check position of optional Polarity switch.
OM-4428 Page 59 B. Welding − CC/CV Models T rouble Remedy No weld output; generator power output okay at ac receptacles. Place Process/Contactor switch in a Weld T erminals Always On position, or pl.
OM-4428 Page 60 T rouble Remedy Low CV weld output. Set Ampere Range switch to highest range. Increase V oltage/Amperage Adjust Control setting. Min or max CV weld output only . Check position of V oltage/Amperage Adjust control and V oltage/Amperage Adjust switch.
OM-4428 Page 61 E. Engine T rouble Remedy Engine will not crank. Check battery , and replace if necessary . Check battery connections and tighten if necessary . Circuit breaker CB10 may be open. CB10 automatically resets when fault is corrected (see Section 9- 8 or 10-9 ).
OM-4428 Page 62 SECTION 12 − ELECTRICAL DIAGRAMS Figure 12-1. Circuit Diagram For CC Welding Generator (Deutz F4L201 1-Powered Units).
OM-4428 Page 63 215 221-E.
OM-4428 Page 64 Figure 12-2. Circuit Diagram For CC Welding Generator (Deutz F4L201 1-Powered Units) (Export Models).
OM-4428 Page 65 235 275-A.
OM-4428 Page 66 Figure 12-3. Circuit Diagram For CC/CV Welding Generator (Deutz F4L201 1-Powered Units).
OM-4428 Page 67 215 806-E.
OM-4428 Page 68 Figure 12-4. Circuit Diagram For CC/CV Welding Generator (Deutz F4L201 1-Powered Units) (Export Models).
OM-4428 Page 69 235 276-A.
OM-4428 Page 70 Figure 12-5. Circuit Diagram For CC Welding Generator (Deutz F3L912-Powered Units).
OM-4428 Page 71 215 807-D.
OM-4428 Page 72 Figure 12-6. Circuit Diagram For CC/CV Welding Generator (Deutz F3L912-Powered Units).
OM-4428 Page 73 215 808-D.
OM-4428 Page 74 SECTION 13 − RUN-IN PROCEDURE run_in1 2007 − 04 13-1. W etstacking 1 W elding Generator Ru n diesel engines near rated volt- ag e and current during run-in period to properly seat piston rings and prevent wetstacking. See name- plate, rating label, or specifications section in this manual to find rated voltage and current.
OM-4428 Page 75 13-2. Run-In Procedure Using Load Bank S-0683 1 Load Bank T urn all load bank switches Of f. If needed, connect load bank to 1 15 volts ac wall receptacle or genera- tor auxiliary power receptacle.
OM-4428 Page 76 13-3. Run-In Procedure Using Resistance Grid S-0684 1 Resistance Grid Use grid sized for generator rated output. Turn O f f grid. 2 Welding Generator Place A/V range switch in maxi- mum position, A/V control in mini- mum position, and Output Selector switch (if present) in either DC position.
OM-4428 Page 77 SECTION 14 − GENERA TOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding generators. Y our unit may differ from those shown. 14-1. Selecting Equipment gen_pwr 2007 − 04 − Ref.
OM-4428 Page 78 14-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 AWG or larger insulated copper wire. 3 Ground Device Us e ground device as stated in electrical codes. ! Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system.
OM-4428 Page 79 14-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Star ting W atts Running W atts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 21.
OM-4428 Page 80 14-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting W atts Running W atts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/.
OM-4428 Page 81 14-8. Power Required T o Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code G H J K L M N P KV A/HP 6.3 7.1 8.0 9.0 10.0 1 1.2 12.5 14.0 S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor V oltage T o find starting amperage: Step 1: Find code and use table to find kV A/HP .
OM-4428 Page 82 14-10. T ypical Connections T o Supply Standby Power T ransfer Switch Essential Loads Fused Disconnect Switch (If Required) Utility Electrical Service 12 3 4 5 W elding Generator Output ! Have only qualified persons perform these connections according to all applicable codes and safety practices.
OM-4428 Page 83 14-1 1. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 V olt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord.
OM-4428 Page 84 SECTION 15 − P ARTS LIST Hardware is common and not available unless listed. A Deutz F4L201 1 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.
OM-4428 Page 85 803 659 / 803 665 Deutz F3L912 Engine A Deutz F4L201 1 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. 50 53 88 90 89 84 81 82 83 85 86 87 35 (Fig.
OM-4428 Page 86 Description Part No. Dia. Mkgs. Item No. Figure 15-1. Main Assembly Quantity 1 189 824 P ANEL, gen LH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-4428 Page 87 Description Part No. Dia. Mkgs. Item No. Figure 15-1. Main Assembly (Continued) Quantity ♦ 174 064 IDLE, solenoid assy 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-4428 Page 88 Description Part No. Dia. Mkgs. Item No. Figure 15-1. Main Assembly (Continued) Quantity 88 189 908 V AL VE, drain fuel 180deg 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-4428 Page 89 803 660-C 2 1 11 19 6 3 7 14 22 13 16 12 5 15 9 20 18 17 8 4 21 23 24 10 25 26 Figure 15-2. Control Box Assembly − CC Models Description Part No. Dia. Mkgs. Item No. Figure 15-2. Control Box Assembly − CC Models (Figure 15-1 Item 98) Quantity 1 F1, F2 *085 874 FUSE, mintr cer slo-blo 10A 250V 2 .
OM-4428 Page 90 Description Part No. Dia. Mkgs. Item No. Figure 15-2. Control Box Assembly − CC Models (Continued) Quantity 215 013 HARNESS, unit weld control (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-4428 Page 91 803 661-C 23 1 2 3 11 16 21 18 20 17 14 13 15 5 9 10 8 4 7 6 12 19 22 25 24 Figure 15-3. Control Box Assembly − CC/CV Models Description Part No. Dia. Mkgs. Item No. Figure 15-3. Control Box Assembly − CC/CV Models (Figure 15-1 Item 98) Quantity 1 F1, F2 *085 874 FUSE, mintr cer slo-blo 10A 250V 2 .
OM-4428 Page 92 Description Part No. Dia. Mkgs. Item No. Figure 15-3. Control Box Assembly − CC/CV Models (Continued) Quantity 23 CB1 1, 12, 13 139 266 SUPPLEMENTAR Y PROTECT OR, man reset 1p 15a 250vac 3 . . . . . . . . . . . . . . 24 CR9 090 104 RELA Y , encl 12vdc spst 30a/15vdc 5pin flange mtg 1 .
OM-4428 Page 93 Hardware is common and not available unless listed. 803 662 11 10 9 8 7 22 13 12 39 37 36 38 34 35 32 20 21 25 27 26 24 23 28 30 18 19 15 16 17 14 2 40 41 42 1 6 3 5 4 29 31 33 Figure 15-4. Panel, Front w/Components − CC Models Description Part No.
OM-4428 Page 94 Description Part No. Dia. Mkgs. Item No. Figure 15-4. Panel, Front w/Components − CC Models (Continued) Quantity 192 558 HARNESS, range (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-4428 Page 95 Description Part No. Dia. Mkgs. Item No. Figure 15-4. Panel, Front w/Components − CC Models (Continued) Quantity 35 HM 210 424 METER, hour 12-24VDC 2.25dia 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-4428 Page 96 Hardware is common and not available unless listed. 803 663 11 54 53 52 51 46 47 49 2 56 55 57 58 1 7 6 8 10 9 3 5 4 12 13 45 48 50 42 44 39 40 41 38 37 36 35 43 34 31 14 30 27 29 28 33 19 24 20 25 26 22 23 21 17 16 15 18 32 Figure 15-5.
OM-4428 Page 97 Description Part No. Dia. Mkgs. Item No. Figure 15-5. Panel, Front w/Components − CC/CV Models (Continued) Quantity 6 S6 193 234 SWITCH, rotary 6 position gold contacts (included in control box harness, . . . . . . . . . . . . . . see Figure 15-3) 1 .
OM-4428 Page 98 Description Part No. Dia. Mkgs. Item No. Figure 15-5. Panel, Front w/Components − CC/CV Models (Continued) Quantity 36 PC4, PC5 189 744 CIRCUIT CARD ASSEMBL Y , filter hf 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-4428 Page 99 802 404-C Hardware is common and not available unless listed. 5 6 8 9 22 27 28 29 30 31 7 24 25 10 26 34 33 32 1 2 4 3 23 17 18 11 13 14 12 15 19 20 21 16 Figure 15-6. Generator Description Part No. Dia. Mkgs. Item No. Figure 15-6.
OM-4428 Page 100 Description Part No. Dia. Mkgs. Item No. Figure 15-6. Generator (Continued) Quantity 21 049 026 SCREW, M10 − 1.5x 25 Hex Hd − pln 8.8 Pln 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 191 579 COVER, starter hole Perkins/Continental 1 .
OM-4428 Page 101 Hardware is common and not available unless listed. 802 279-A 1 2 3 4 6 5 7 8 9 Figure 15-7. Main Rectifier Assembly Description Part No. Dia. Mkgs. Item No. Figure 15-7. Main Rectifier Assembly (Figure 15-1 Item 100) Quantity SR3 215 910 RECTIFIER, environmental (consisting of) 1 .
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Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007 − 01 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.
PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007 − 01 Miller Elect ric Mfg. Co. An Illinois T ool Wo rks Compa ny 1635 West S pencer S treet Applet on, WI 5 4914 US A International He adquarters.
An important point after buying a device Miller Electric 500D (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Miller Electric 500D yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Miller Electric 500D - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Miller Electric 500D you will learn all the available features of the product, as well as information on its operation. The information that you get Miller Electric 500D will certainly help you make a decision on the purchase.
If you already are a holder of Miller Electric 500D, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Miller Electric 500D.
However, one of the most important roles played by the user manual is to help in solving problems with Miller Electric 500D. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Miller Electric 500D along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
