Miller Electric Big Blue 500 PT, Big Blue 600 X manual Dia Part Description Quantity

Page 72

Item

Dia.

 

Part

Description

 

Quantity

 

No.

 

Mkgs.

 

No.

 

 

 

 

 

 

 

Figure 13-1. Main Assembly

 

 

 

 

 

 

 

 

 

 

 

. . .

1

. . . .

. . . . . .

. . .

189 824 . .

Panel, Gen Lh

. . . 1

. . .

1

. . . .

. . . . . .

. . ♦199 294 . .

Panel, Gen Lh Ss

. . . 1

. . .

2

. . . .

. . . . . .

. . .

200 865 . .

Label, CE Sound Power Level 98db (Export Models Only)

. . . 1

. . .

3

. . . .

. . . . . .

. .

+189 828 . .

Panel, Engine Side

. . . 1

. . .

3

. . . .

. . . . . .

. ♦+199 301 . .

Panel, Engine Side Ss

. . . 1

. . . 4 . . . . . Z1 .

. . CC189 395 . .

Reactor, Ac

. . . 1

. . . 4 . . . . . Z1 .

. . CV201 520 . .

Reactor, Ac Environmental

. . . 1

. . .

5

. . . .

. . . . . .

. . .

206 352 . .

Brace, Front To Center Upright

. . . 2

. . .

6

. . . . . 1T .

. . .

038 621 . .

Block, Term 30a 4 Pole Frict Term Str

. . . 1

. . .

. . .

. . . .

. . . . . .

. . .

038 620 . .

Link, Jumper Term Blk 30a

. . . 2

. . .

7

. . . .

. . . . . .

. . .

081 499 . .

Bracket, Mtg Strip Terminal

. . . 1

. . .

. . .

. . . .

. . . . . .

. . .

203 260 . .

Label, Caution Do Not Use Ether

. . . 1

. . .

8

. . SR4, SR5 .

035 704 . .

Rectifier, Integ Bridge 40. Amp 800v

. . . 2

. . . 9 . . . . CB4

. . .

045 061 . .

Circuit Breaker, Auto Reset 24vdc 7 Amp

. . . 1

. . . 10

. . . .

. T1 .

. . .

201 613 . .

Transformer W/Bracket

. . . 1

. . . 10

. . . .

. T1 .

. . ♦205 636 . .

Transformer W/Bracket (Environmental Coating)

. . . 1

. . . 11

. . . .

. . . . . .

. . .

201 697 . .

Pan, Reactor And Rectifier

. . . 1

. . . 12

. . . .

. . . . . .

. . .

173 352 . .

Extrusion, Rubber Clamp/Bulb (Order By Ft)

. . . 3ft

. . . 13

. . . .

. . . . . .

. . .

189 708 . .

Firewall, Top

. . . 1

. . . 14

. . . .

. . . . . .

. . .

191 307 . .

Cover, Plate

. . . 1

. . . 15

. . . .

. . . . . .

. . .

189 763 . .

Bracket, Mtg Air Cleaner

. . . 1

. . . 16

. . . .

. . . . . .

. . .

218 048 . .

Hose, Air Cleaner

. . . 1

. . . 17

. . . .

. . . . . .

. . .

218 047 . .

Tube, Air Intake

. . . 1

. . . 18

. . . .

. . . . . .

. . .

218 046 . .

Hose, Air Cleaner

. . . 1

. . .

. . .

. . . .

. . . . . .

. . .

010 863 . .

Clamp, Hose 1.125 − 3.000 Clp Dia

. . . 4

. . . 19

. . . .

. . . . . .

. . .

220 091 . .

Hose, Sae .500 Id X .750 Od X 13.000

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

. . . 1

. . . 20

. . . .

. . . . . .

. . .

189 764 . .

Air Cleaner, Intake

. . . 1

. . .

. . .

. . . .

. . . . . .

. . .

*192 938 . .

Filter, Air Element Primary

. . . 1

. . .

. . .

. . . .

. . . . . .

. *♦192 939 . .

Filter, Air Element Safety

. . . 1

. . . 21

. . . .

. . . . . .

. . .

189 464 . .

Seal, Weather Lift Eye

. . . 1

. . .

. . .

. . . .

. . . . . .

. . .

173 909 . .

Hose, Sae .312 Id X .560 Od X 24.000

(Order By Ft)

. . . 2

. . . 22

. . . .

. . . . . .

. . .

201 658 . .

Upright, Center Assembly

. . . 1

. . . 23

. . . .

. . . . . .

. . .

191 819 . .

Hose, Sae .312 Id X .560 Od X 14.000

(Order By Ft)

. . . 2

. . .

. . .

. . . .

. . . . . .

. . .

198 584 . .

Hose, Sae .312 Id X .560 Od X 5.000 (Order By Ft)

. . . 1

. . . 24

. . . .

. . . . . .

. . .

095 636 . .

Hose, Sae .187 Id X .41 Od X 30.000

(Order By Ft)

. . . 1

. . . 25

. . . .

. . . . . .

. . .

206 297 . .

Base, Fuel Filter W/Fittings

. . . 1

. . . 26

. . . .

. . . . . .

. . .

*192 744 . .

Filter, Fuel Spin−on

. . . 1

. . . 27

. . . .

. . . . . .

. .

+201 934 . .

Cover, Top

. . . 1

. . . 27

. . . .

. . . . . .

. ♦+202 640 . .

Cover, Top Ss

. . . 1

. . . 28

. . . .

. . . . . .

. . .

189 052 . .

Grommet, Plastic Neck Filler Fuel

. . . 1

. . . 29

. . . .

. . . . . .

. . .

190 198 . . .

. Cap, Tank Screw−on 3.500 In W/Vent

. . . 1

. . . 30

. . . .

. . . . . .

. . .

192 041 . .

Label, Use Diesel Fuel Only

. . . 1

. . . 31

. . . .

. . . . . .

. . .

222 513 . .

Label, Warning Falling Equipment Can Cause Serious

. . . 2

. . . 32

. . . .

. . . . . .

. . .

224 265 . .

Label, Warning Hot Exhaust Parts Do Not Touch

. . . 1

. . . 33

. . . .

. . . . . .

. . .

105 734 . .

Pipe, Muffler Extension Elbow 1.750 Od

. . . 1

. . . 34

. . . .

. . . . . .

. . .

201 851 . .

Cover, Radiator Access

. . . 1

. . . 34

. . . .

. . . . . .

. . ♦202 629 . .

Cover, Radiator Access Ss

. . . 1

. . . 35

. . . .

. . . . . .

. . .

191 354 . .

Support, Cover

. . . 1

. . . 35

. . . .

. . . . . .

. . ♦202 633 . .

Support, Cover E−coat

. . . 1

. . . 36

. . . .

. . . . . .

. . .

010 875 . .

Clamp, Muffler 2.000 Dia

. . . 1

. . . 37

. . . .

. . . . . .

. . .

215 345 . .

Manifold, Exhaust Muffler

. . . 1

. . . 38

. . . .

. . . . . .

. . .

. . . . . . . . . . .

Bracket (Included With Item 37 − Manifold Muffler)

. . . 1

OM-4429 Page 68

Page 71 Page 73
Image 72
Page 71 Page 73
Contents Processes DescriptionFile Engine Drive Visit our website at OM-44292216 138H 2007−05From Miller to You Table of Contents − Maintenance & Troubleshooting Symbol Usage Arc Welding HazardsElectric Shock can kill HOT Parts can cause severe burnsFumes and Gases can be hazardous Buildup of GAS can injure or killARC Rays can burn eyes and skin Welding can cause fire or explosionEngine Hazards Compressed Air HazardsWelding Wire can cause injury HOT Parts can cause burns and injuryFire or Explosion hazard Falling Unit can cause injuryPrincipal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interferenceSignification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer Indique des instructions spécifiquesDES Pièces Chaudes peuvent provoquer des brûlures graves LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un in cendie ou une explosion LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peu DES Organes Mobiles peuvent pro voquer des blessuresLA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessuresRisque D’INCENDIE OU D’EXPLO- Sion LE Surchauffement peut endom- mager le moteur électrique DES Organes Mobiles peuvent provoquer des blessuresLES Fils DE Soudage peuvent provoquer des blessures ’EMPLOI Excessif peutProposition californienne 65 Avertissements Principales normes de sécuritéInformation EMF En ce qui concerne les implants médicaux− Definitions − 50 h StdStd Manufacturer’s Rating Labels CC ModelsSymbols And Definitions Some symbols are found only on CE products− Specifications Weld, Power, And Engine SpecificationsDimensions, Weights, And Operating Angles Volt-Ampere Curves For CC Models VoltsStick Mode MIG ModeTIG Mode Volt-Ampere Curves For CC/CV ModelsFuel Consumption Duty Cycle And Overheating100% Duty Cycle At 400 Amperes AC Generator Power Curve Optional Three-Phase Generator Curves12 kVA/kW Single-Phase AC Output No Weld Load 20 kVA/kW Three-Phase AC Output No Weld Load− Installation Installing Welding GeneratorLocation/Airflow Clearance Grounding1Using Lifting Eye Mounting Welding Generator Installing Exhaust Pipe Stop engine and let coolActivating The Dry Charge Battery If Applicable Connecting The BatteryCoolant Recovery Tank Engine Prestart ChecksFuel OilConnecting To Weld Output Terminals Stick and TIG WeldingMIG and Fcaw Welding Stop engineConnecting to Weld Selecting Weld Cable Sizes150 ft 200 ft 250 ft 350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 mConnecting To Remote 14 Receptacle RC14 On CC/CV Models SocketOM-4429 − Operating Welding Generator − CC Models Front Panel Controls For CC Models See SectionEngine Starting Controls To StartEngine Gauges And Meters Weld ControlsRemote Amperage Control On CC Models Optional Weld Control/Arc Condition Information LabelExample Combination Remote Amperage Control Stick OM-4429 − Operating Welding Generator − CC/CV Models Front Panel Controls For CC/CV Models See SectionVoltage/Amperage Adjust Switch And Remote 14 Receptacle 14 AC/DC Voltmeter OptionalProcess/Contactor Switch On CC/CV Models Process/Contactor Switch SettingsRemote Voltage/Amperage Control On CC/CV Models Optional Example Combination Remote Amperage Control TIG− Operating Auxiliary Equipment Volt And 240 Volt ReceptaclesAt least once a month, run en If a SupplementaryThree-Phase Power Connection Rear Of PanelClose panel opening if no connections are made to generator Optional Generator Power Receptacles 240 V 15 a AC South African Receptacle RC1Supplementary Protector CB2 Supplementary Protector CB3 − Maintenance & Troubleshooting Maintenance LabelRoutine Maintenance Servicing Air Cleaner To clean air filterInspecting And Cleaning Optional Spark Arrestor Muffler Checking Generator BrushesServicing Fuel And Lubrication Systems To change oil and filterTo replace primary fuel filter Overload Protection Troubleshooting Welding − CC ModelsWelding − CC/CV Models Standard Generator Power Optional Three-Phase Generator Power CC/CV Models OnlyEngine Check engine wiring harness plug connections Gine Control switch S1Factory Authorized Service Agent Engine cranks but does not start Check fuel levelStart Your Professional Welding Career Now − Electrical Diagrams Circuit Diagram For CC Welding Generator223 525-B Circuit Diagram For CC/CV Welding Generator 223 524-B − RUN-IN Procedure WetstackingWelding Generator Run-In Procedure Using Load Bank Keep exhaust and pipe awayFrom flammables Run-In Procedure Using Resistance Grid Specifications section in thisJust generator A/V control so Manual− Generator Power Guidelines Selecting EquipmentGrounding Generator To Truck Or Trailer Frame Electrically Bond GeneratorGrounding When Supplying Building Systems How Much Power Does Equipment Require?Use ground device as stated in electrical codes Amperes x Volts = WattsApproximate Power Requirements For Industrial Motors Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsPower Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 / Volts = Starting AmperageTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible − Parts List 114 −7 115 CV123 116 CV 112 2831 124 88 −6 6059 58 Dia Part Description Quantity Dia Part Description Quantity Mkgs Figures 13-2 111123 212 Control Box Assembly − CC Models Control Box Assembly − CC Models -1Item Engine ControllerControl Box Assembly − CC/CV Models 134 Panel, Front w/Components − CC Models 3634208278 Panel, Front w/Components − CC/CV Models Panel, Front w/Components − CC/CV Models -1ItemCB1 201 Supplementary PROTECTOR, man reset 2P 20 A, 250VAC Hardware is common 32 31 30053 BEARING, Ball Rdl Sgl Row 1.370 X 2.830 X Main Rectifier Assembly Wiring Harnesses 215207 Service Your distributor also givesSupport To locate a Distributor or Service Agency visit Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s
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