Instruction/ maintenance manual of the product Big Blue 502D Miller Electric
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Big Blue 402D, 502D, 602D OM-495 192 774AR October 2003 Processes Description Air Carbon Arc (CAC-A) Cutting and Gouging Stick (SMAW ) W elding Engine Driven Welding Generator TIG (GT A W ) W elding MIG (GMAW) W elding Flux Cored (FCA W ) W elding 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 catalog sheets. T o locate your nearest 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 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Front Panel Controls For CC/CV Models (See Section 7-2) 38 . . . . . . . . . . . . . . . . . . . . . . . .
dec_con1 _1 1/02 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). NOTE Manufacturer ’s Name: Miller Electric Mfg. Co. Manufacturer ’s Address: 1635 W .
dec_con1 5/98 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). NOTE Manufacturer ’s Name: Miller Electric Mfg. Co. Manufacturer ’s Address: 1635 W .
OM-495 Page 1 Return T o T a ble Of Co ntents SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom _nd_10/02 W arning: Protect yourself and others from injury — read and follow these precautions.
OM-495 Page 2 Return T o T a ble Of Co ntents W elding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns.
OM-495 Page 3 Return T o T a ble Of Co ntents STEAM AND HOT COOLANT can burn. If possible, check coolant level when engine is cold to avoid scalding. Always check coolant level at overflow tank, if pres- ent on unit, instead of radiator (unless told otherwise in maintenance section or engine manual).
OM-495 Page 4 Return T o T a ble Of Co ntents READ INSTRUCTIONS. Use only genuine MILLER/Hobart replacement parts. Perform engine and air compressor (if applicable) maintenance and service according to this manual and the engine/air compressor (if applicable) manu- als.
OM-495 Page 5 Return T o T able Of Contents SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION rom_fre 8/03 A vertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions.
OM-495 Page 6 Return T o T a ble Of Co ntents LES ACCUMULA TIONS DE GAZ ris- quent de provoquer des blessures ou même la mort. Fermer l’alimentation du gaz protecteur en cas de non utilisation. V eiller toujours à bien aérer les espaces confinés ou se servir d’un respi- rateur d’adduction d’air homologué.
OM-495 Page 7 Return T o T a ble Of Co ntents L ’EXPLOSION DE LA BA TTERIE peut RENDRE A VEUGLE. T oujours porter une protection faciale, des gants en caoutchouc et vêtements de protection lors d’une in- tervention sur la batterie. Arrêter le moteur avant de débrancher ou de brancher les câbles de batterie.
OM-495 Page 8 Return T o T able Of Contents LE SURCHAUFFEMENT peut endom- mager le moteur électrique. Arrêter ou déconnecter l’équipement avant de dé- marrer ou d’arrêter le moteur .
OM-495 Page 9 Return T o T able Of Contents SECTION 3 − DEFINITIONS 3-1. W arning Label Definitions (For W ordless Labels) 3/96 W arning! W atch Out! There are possible hazards as shown by the symbols. Become trained and read the instructions before working on the machine or we l ding.
OM-495 Page 10 Return T o T a ble Of Co ntents 3/96 1 Warning! W atch Out! There are possible hazards as shown by the symbols. 2 Do not smoke and keep matches and flames away from battery . 3 Sparks can cause battery gases to explode. Battery explosion can blind and injure.
OM-495 Page 1 1 Return T o T able Of Contents 3/96 1 Warning! W atch Out! There are possible hazards as shown by the symbols. 2 Hot muf fler and exhaust pipes can cause severe burns. Do not touch hot muf fler or pipes. 1 S-176 230 2 3/96 1 Warning! W atch Out! There are possible hazards as shown by the symbols.
OM-495 Page 12 Return T o T a ble Of Co ntents 1 Warning! W atch Out! There are possible hazards as shown by the symbols. 2 Fire hazard from leaking engine fuel. Fire can result from welding on base at non-designated areas causing a possible fuel leak.
OM-495 Page 13 Return T o T a ble Of Co ntents 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. 3 Use Diesel Fuel only , and fill fuel tank.
OM-495 Page 14 Return T o T able Of Contents 3-3. Manufacturer ’ s Rating 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 (.
OM-495 Page 15 Return T o T a ble Of Co ntents 3-4. Symbols And Definitions Stop Engine Fast (Run, Weld/ Power) Slow (Idle) Start Engine Starting Aid Battery (Engine) Engine Oil Pressure Engine Oil Ch.
OM-495 Page 16 Return T o T able Of Contents 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 o.
OM-495 Page 17 Return T o T a ble Of Co ntents 4-3. V olt-Ampere Curves For CC Models 203 412 The volt-ampere curves show the minimum and maximum voltage an d amperage output capabilities of th e welding generator . Curves of all other settings fall between the curves shown.
OM-495 Page 18 Return T o T a ble Of Co ntents 4-4. V olt-Ampere Curves For CC/CV Models 203 414 / 203 415 / 203 413 The volt-ampere curves show the minimum and maximum voltage an d amperage output capabilities of th e welding generator . Curves of all other settings fall between the curves shown.
OM-495 Page 19 Return T o T a ble Of Co ntents 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 10.
OM-495 Page 20 Return T o T a ble Of Co ntents Continuous W elding 4-6. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. Exceeding duty cycle can damage unit and void warranty .
OM-495 Page 21 Return T o T able Of Contents 4-7. AC Generator Power Curve 193 018 Th e ac power curve shows the gen- erator power in amperes available at the 120 and 240 volt receptacles.
OM-495 Page 22 Return T o T a ble Of Co ntents 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.
OM-495 Page 23 Return T o T a ble Of Co ntents Notes Over 80,000 trained since 1930! 400 T rade Square East, T roy , Ohio 45373 1-800-332-9448 www.welding.
OM-495 Page 24 Return T o T a ble Of Co ntents SECTION 5 − INST ALLA TION install3 6/03 − Ref. 800 652 / Ref. 800 477-A / 803 274 Always securely fasten weld- ing generator onto transport vehicle or trailer and comply with all DOT and other applica- ble codes.
OM-495 Page 25 Return T o T a ble Of Co ntents 5-2. Using Lifting Eye Ref. 802 169-B / 802 31 1 1 Lifting Eye 2 Nut 3 Carriage Bolt Raise lifting eye until it snaps in place.
OM-495 Page 26 Return T o T a ble Of Co ntents 5-3. Mounting W elding Generator T ools Needed: 9/16 in 2 2 3 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-495 Page 27 Return T o T a ble Of Co ntents 5-4. Installing Exhaust Pipe 1/2 in T ools Needed: Ref. 802 169-E / Ref. 202 705 Stop engine and let cool. Point exhaust pipe in desired di- rection but always away from front panel and direction of travel.
OM-495 Page 28 Return T o T able Of Contents 5-6. Activating The Dry Charge Battery (If Applicable) Remove battery from unit. 1 Eye Protection − Safety Glasses Or Face Shield 2 Rubber Gloves 3 V ent Caps 4 Sulfuric Acid Electrolyte (1.265 Specific Gravity) 5 W ell Fill each cell with electrolyte to bottom of well (maximum).
OM-495 Page 29 Return T o T a ble Of Co ntents 5-7. Connecting The Battery 1/2 in − + Connect Negative ( − ) Cable Last. T ools Needed: 802 168-E / Ref. 202 705 / 802 313 / S-0756-C Reinstall cover after connecting battery . ether1 7/96 − 153 382-A / Ref.
OM-495 Page 30 Return T o T a ble Of Co ntents 5-9. Engine Prestart Checks Check all engine fluids daily . Engine must be cold and on a level surface. Unit is shipped with 20W break-in oil. The Automatic shutdown system stops engine if oil pressure is too low or coolant tempera- ture is too high.
OM-495 Page 31 Return T o T able Of Contents 5-10. Connecting T o Weld Output T erminals 802 31 1-A T ools Needed: 3/4 in 2 1 Stop engine. 1 Positive (+) Weld Output T erminal 2 Negative ( − ) W.
OM-495 Page 32 Return T o T able Of Contents 5-12. Connecting T o Remote Amperage Adjust Receptacle RC13 On CC Models Ref. 154 862-A / 048 720-K / 802 31 1 1 Remote Amperage Adjust Receptacle RC13 Connect optional remote control to RC13 (see Section 6-3).
OM-495 Page 33 Return T o T able Of Contents Notes.
OM-495 Page 34 Return T o T able Of Contents SECTION 6 − OPERA TING WELDING GENERA TOR − CC MODELS 6-1. Front Panel Controls For CC Models (See Section 6-2) 17 202 705 / 802 31 1-A 15 16 2 1 3 13 .
OM-495 Page 35 Return T o T able Of Conte nts 6-2. Description Of Front Panel Controls For CC Models (See Section 6-1) Engine Starting Controls 1 Magnetic Shutdown Switch Use switch during start-up to bypass engine shutdown system. System stops engine if oil pressure is too low or engine temperature is too high.
OM-495 Page 36 Return T o T able Of Conte nts 6-3. Remote Amperage Control On CC Models (Optional) 1 Remote Amperage Adjust Receptacle RC13 Connect optional remote control to RC13 (see Section 5-12 ).
OM-495 Page 37 Return T o T able Of Conte nts Notes.
OM-495 Page 38 Return T o T able Of Contents SECTION 7 − OPERA TING WELDING GENERA TOR − CC/CV MODELS 7-1. Front Panel Controls For CC/CV Models (See Section 7-2) 202 706 / 802 31 1-D 6 5 47 13 16.
OM-495 Page 39 Return T o T able Of Conte nts 7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1) Engine Starting Controls 1 Magnetic Shutdown Switch Use switch during start-up to bypass engine shutdown system. System stops engine if oil pressure is too low or engine temperature is too high.
OM-495 Page 40 Return T o T able Of Conte nts 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 Electrode Hot posi- tion and the engine is running.
OM-495 Page 41 Return T o T able Of Contents 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 5-13 ).
OM-495 Page 42 Return T o T able Of Contents SECTION 8 − OPERA TING AUXILIAR Y EQUIPMENT 8-1. Generator Power Receptacles (Standard Models) 2 1 191 624 3 4 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-495 Page 43 Return T o T able Of Contents 8-2. Connecting T o Optional Three-Phase Generator (CC/CV Standard Models Only) Ref. 197 399 / 802 332-B Place Process/Contactor switch in Electrode Hot - Stick position when using three-phase genera- tor (see Section 7-3).
OM-495 Page 44 Return T o T able Of Contents 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-495 Page 45 Return T o T able Of Contents 8-4. Generator Power Receptacles (CE 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-495 Page 46 Return T o T able Of Conte nts SECTION 9 − MAINTENANCE (DEUTZ F4L201 1 − POWERED UNITS) The oil/filter maintenance intervals are different for the Deutz F4L201 1 and F3L912 engines (see maintenance schedules following).
OM-495 Page 47 Return T o T able Of Contents Every 1000 h Change Oil Filter . See Section 9-6. Service more often in dirty conditions. Change Oil. See Section 9-6. Service W elding Generator Brushes And Slip Rings. Service More Often In Dirty Conditions.
OM-495 Page 48 Return T o T able Of Conte nts 9-2. Maintenance Label.
OM-495 Page 49 Return T o T able Of Conte nts 9-3. Servicing Air Cleaner (Deutz F4L201 1-Powered Units) aircleaner1 9/00 − ST -153 929-B / ST-153 585 / Ref. S-0698-B Stop engine. Do not run engine without air cleaner or with dirty element. En- gine damage caused by using a damaged element is not covered by the warranty .
OM-495 Page 50 Return T o T able Of Contents 9-4. Inspecting/Cleaning Optional Spark Arrestor (Deutz F4L201 1-Powered Units) 802 170-A / Ref. 202 705 / Ref. 802 31 1-A / Ref. 802 160-B Stop engine and let cool. 1 Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole.
OM-495 Page 51 Return T o T able Of Contents 9-5. Adjusting Engine Speed (Deutz F4L201 1-Powered Units) 802 313-A 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-495 Page 52 Return T o T able Of Contents 9-6. Servicing Fuel And Lubrication Systems (Deutz F4L201 1-Powered Units) Ref. 800 159-E / Ref. 802 170 / 802 313-A Stop engine and let cool. After servicing, start engine and check for fuel leaks.
OM-495 Page 53 Return T o T able Of Contents 9-7. Overload Protection (Deutz F4L201 1-Powered Units) Stop engine. When a circuit breaker or fuse opens, it usually indicates a more serious problem exists. Contact Factory Au- thorized Service Agent.
OM-495 Page 54 Return T o T able Of Conte nts SECTION 10 − MAINTENANCE (DEUTZ F3L912 − POWERED UNITS) Follow the storage procedure in the engine owner ’s manual if the unit will not be used for an extended period. Note 10-1. Routine Maintenance (Deutz F3L912-Powered Units) Recycle engine fluids.
OM-495 Page 55 Return T o T able Of Contents Every 500 h Change Oil Filter . See Section 10-7 . Service more often in dirty conditions. Change Oil. See Section 10-7 . Repair Or Replace Cracked Cables. Check V alve Clearance.* Every 1000 h Service W elding Generator Brushes And Slip Rings.
OM-495 Page 56 Return T o T able Of Conte nts 10-2. Maintenance Label.
OM-495 Page 57 Return T o T able Of Conte nts 10-3. Servicing Air Cleaner (Deutz F3L912-Powered Units) aircleaner1 9/00 − ST -153 929-B / ST-153 585 / Ref. S-0698-B Stop engine. Do not run engine without air cleaner or with dirty element. En- gine damage caused by using a damaged element is not covered by the warranty .
OM-495 Page 58 Return T o T able Of Contents 10-4. Inspecting/Cleaning Optional Spark Arrestor (Deutz F3L912-Powered Units) 802 170-A / Ref. 202 705 / Ref. 802 31 1-A / Ref. 802 160-B Stop engine and let cool. 1 Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole.
OM-495 Page 59 Return T o T able Of Contents 10-5. Adjusting Engine Speed (Deutz F3L912-Powered Units) 802 398 / 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 .
OM-495 Page 60 Return T o T able Of Contents 10-7. Servicing Fuel And Lubrication Systems (Deutz F3L912-Powered Units) Ref. 800 159-E / Ref. 802 170 / 802 398 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-495 Page 61 Return T o T able Of Contents 10-8. Overload Protection (Deutz F3L912-Powered Units) Ref. 802 313-A 21 9 8 7 4 Stop engine. When a circuit breaker or fuse opens, it usually indicates a more se- rious problem exists. Contact Facto- ry Authorized Service Agent.
OM-495 Page 62 Return T o T able Of Contents SECTION 1 1 − TROUBLESHOOTING 1 1-1. Diagnosing Causes Of Engine Fault Shutdowns Ref. 202 705 Use the front panel engine lights to help determine the cause of an au- tomatic engine shutdown. Correct the cause of the shut- down before operating the welding generator .
OM-495 Page 63 Return T o T able Of Contents 1 1-2. T roubleshooting T ables 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-495 Page 64 Return T o T able Of Contents B. Welding − CC/CV Models T rouble Remedy No weld output; generator power output okay at ac receptacles. Place Process/Contactor switch in a Electrode Hot position, or place switch in a Remote position and connect remote contactor to optional Remote 14 receptacle RC14 (see Sections 5-13 and 7- 1 ) .
OM-495 Page 65 Return T o T able Of Contents C. Standard Generator Power T rouble Remedy No generator power output at ac recep- tacles; weld output okay . Reset receptacle circuit breakers. No generator power or weld output. Disconnect equipment from generator power receptacles during start-up.
OM-495 Page 66 Return T o T able Of Conte nts T rouble Remedy Engine cranks but does not start. Press Magnetic Shutdown switch MS1 when starting engine. Check fuel level. Reset circuit breaker CB13 (see Section 9-7 o r 10-8 ). Have Factory Authorized Service Agent check en- gine wiring harness and components.
OM-495 Page 67 Return T o T able 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 (.
OM-495 Page 68 Return T o T able Of Conte nts SECTION 12 − ELECTRICAL DIAGRAMS Figure 12-1. Circuit Diagram For CC W elding Generator (Non-CE Deutz F4L201 1-Powered Units).
OM-495 Page 69 Return T o T able Of Conte nts 215 302-A.
OM-495 Page 70 Return T o T able Of Conte nts Figure 12-2. Circuit Diagram For CC W elding Generator (CE Compliant Deutz F4L201 1-Powered Units).
OM-495 Page 71 Return T o T able Of Conte nts 216 530-A.
OM-495 Page 72 Return T o T able Of Conte nts Figure 12-3. Circuit Diagram For CC/CV W elding Generator (Non-CE Deutz F4L201 1-Powered Units).
OM-495 Page 73 Return T o T able Of Conte nts 215 303-A.
OM-495 Page 74 Return T o T able Of Conte nts Figure 12-4. Circuit Diagram For CC/CV W elding Generator (CE Compliant Deutz F4L201 1-Powered Units).
OM-495 Page 75 Return T o T able Of Conte nts 216 531-A.
OM-495 Page 76 Return T o T able Of Conte nts Figure 12-5. Circuit Diagram For CC W elding Generator (Deutz F3L912-Powered Units).
OM-495 Page 77 Return T o T able Of Conte nts 215 298-A.
OM-495 Page 78 Return T o T able Of Conte nts Figure 12-6. Circuit Diagram For CC/CV W elding Generator (Deutz F3L912-Powered Units).
OM-495 Page 79 Return T o T able Of Conte nts 215 299-A.
OM-495 Page 80 Return T o T able Of Conte nts SECTION 13 − RUN-IN PROCEDURE 13-1. W etstacking Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur .
OM-495 Page 81 Return T o T able Of Contents 13-2. Run-In Procedure Using Load Bank S-0683 Stop engine. Do not touch hot exhaust pipe, engine parts, or load bank/grid.
OM-495 Page 82 Return T o T able Of Conte nts 13-3. Run-In Procedure Using Resistance Grid S-0684 Stop engine. Do not touch hot exhaust pipe, engine parts, or load bank/grid.
OM-495 Page 83 Return T o T able Of Conte nts SECTION 14 − GENERA TOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown. NOTE 14-1. Selecting Equipment gen_pwr 1 1/02 − Ref.
OM-495 Page 84 Return T o T able Of Contents 14-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 A WG or larger insulated copper wire. 3 Ground Device Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system.
OM-495 Page 85 Return T o T able Of Contents 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 .
OM-495 Page 86 Return T o T able Of Contents 14-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running W atts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 .
OM-495 Page 87 Return T o T able Of Contents 14-8. Power Required T o Start Motor 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 . If code is not listed, multiply running amperage by six to find starting amperage.
OM-495 Page 88 Return T o T able Of Conte nts 14-10. T ypical Connections T o Supply Standby Power Have only qualified persons perform these connections according to all applicable codes and safety practic- es. Properly install and ground this equipment according to its Owner’ s Manual and national, state, and local codes.
OM-495 Page 89 Return T o T able Of Conte nts 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-495 Page 90 Return T o T able Of Contents 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-495 Page 91 Return T o T able Of Conte nts 802 331-F 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.
OM-495 Page 92 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 15-1. Main Assembly Quantity 1 189 824 P ANEL, gen LH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-495 Page 93 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 15-1. Main Assembly (Continued) Quantity 40 213 877 ENGINE, Deutz dsl elec F4L201 1 (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-495 Page 94 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 15-1. Main Assembly (Continued) Quantity 80 199 298 P ANEL, rocker ss 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-495 Page 95 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 15-1. Main Assembly (Continued) Quantity 125 195 560 GUARD, starter hole (Deutz F3L912 engine) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-495 Page 96 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 15-2. Control Box Assembly − CC Models (Continued) Quantity 201 681 HARNESS, control box, weld control (consisting of) 1 . . . . . . . . . . . . . . . . . .
OM-495 Page 97 Return T o T able Of Conte nts 802 360 12 1 2 3 18 14 9 6 8 7 10 13 5 21 16 17 20 11 15 4 19 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 100) Quantity 1 F1, F2 *085 874 FUSE, mintr cer slo-blo 10A 250V 2 .
OM-495 Page 98 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 15-3. Control Box Assembly − CC/CV Models (Continued) Quantity 196 602 PLUG, cavity 18,30 position cinch connector 4 . . . . . . . . . . . . . . . . . . . .
OM-495 Page 99 Return T o T able Of Conte nts Hardware is common and not available unless listed. 802 266-D 1 3 4 5 12 15 18 23 24 26 29 32 35 36 37 38 39 40 41 17 25 30 31 16 20 2 22 27 28 13 19 14 6 7 8 9 10 21 34 33 11 Figure 15-4. Panel, Front w/Components − CC Models Description Part No.
OM-495 Page 100 Return T o T able Of Contents 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-495 Page 101 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 15-4. Panel, Front w/Components − CC Models (Continued) Quantity 32 190 323 BOOT , circuit breaker clear hex nut 1 . . . . . . . . . . . . . . . . . . . . .
OM-495 Page 102 Return T o T able Of Conte nts Hardware is common and not available unless listed. 802 332-F 1 2 3 4 5 6 7 9 48 50 51 52 53 54 55 56 57 13 18 19 20 21 22 23 24 25 26 27 30 28 29 15 16 34 33 32 17 35 42 43 41 40 39 38 37 36 44 47 14 10 49 11 8 31 45 46 12 58 Figure 15-5.
OM-495 Page 103 Return T o T able Of Contents 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, .
OM-495 Page 104 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 15-5. Panel, Front w/Components − CC/CV Models (Continued) Quantity 37 PC4, PC5 189 744 CIRCUIT CARD ASSEMBL Y , filter hf 2 . . . . . . . . . . . . . . . .
OM-495 Page 105 Return T o T able Of Conte nts 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.
OM-495 Page 106 Return T o T able Of Contents 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-495 Page 107 Return T o T able Of Conte nts 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 102) Quantity SR3 201 747 RECTIFIER (consisting of) 1 .
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Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 8/03 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. Support Need fast answers to the tough welding questions? Contact your distributor .
PRINTED IN USA 2003 Miller Electric Mfg. Co. 1/03 Miller Elect ric Mfg. Co. An Illinois T ool Wor k s Comp any 1635 W es t Spencer St reet Applet on, WI 5 4914 USA International He adquarters − .
An important point after buying a device Miller Electric Big Blue 502D (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 Big Blue 502D 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 Big Blue 502D - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Miller Electric Big Blue 502D you will learn all the available features of the product, as well as information on its operation. The information that you get Miller Electric Big Blue 502D will certainly help you make a decision on the purchase.
If you already are a holder of Miller Electric Big Blue 502D, 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 Big Blue 502D.
However, one of the most important roles played by the user manual is to help in solving problems with Miller Electric Big Blue 502D. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Miller Electric Big Blue 502D 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
