Miller Electric Big Blue 600 X, Big Blue 500 PT manual 208278

Page 81

Item

Dia.

Part

Description

Quantity

No.

Mkgs.

No.

Figure 13-4. Panel, Front w/Components − CC Models (Continued)

. . .

3

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

215 014 . .

PANEL, engine/weld control

1

. . .

3

. . . . . . . . . . . . ♦217 883 . .

PANEL, engine/weld control ss

1

. . .

4

. . . . . S3 . . . .

. 208278 . .

SWITCH, range/changeover

1

. . . 5 . . . . . R1 . . . .

188 635 . .

RHEOSTAT, WW 300W 34 ohm

1

. . .

6

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

202 209 . .

SPACER, nylon

3

. . .

7

. . . . . S6 . . . .

. 011 622 . .

SWITCH, tgl DPDT 15A 125VAC

1

. . .

8

. . . . . S5 . . . .

. 011 609 . .

SWITCH, tgl SPDT 15A 125VAC on-none-on spd term chr

1

. . . 9 . . . . RC13 . . .

032 897 . .

RECEPTACLE, twlk grd 2P3W 15A 125V

1

. . . 10

. . . . . S1 . . . .

212 436 . .

SWITCH, ignition 4 position w/handle

1

. . . 11

. . . . . S2 . . . .

021 467 . .

SWITCH, tgl spst 3a 250v off−none−(on) spd term

1

. . . .

. .

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

201 553 . .

CLIP, circuit breaker retaining

1

. . . 12

. . . . CB1 . . .

201 083 . .

SUPPLEMENTARY PROTECTOR, man reset 2P 20 A, 250VAC

1

. . . 13

. . . . CB2 . . .

093 996 . .

SUPPLEMENTARY PROTECTOR, man reset 1P 20A 250VAC frict . . . .

3

. . . 14

. . . GFCI1 . .

151 981 . .

RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI

1

. . . 15

. . . . RC1 . . .

147 632 . .

RECEPTACLE, tw lk grd 2P3W 30A 250V L6-30R

1

. . . 15

. . . . RC1 . . .

176 355 . .

RECEPTACLE, str 2p3w 16a 220v flange mtg (export models only) . .

1

. . . 16

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

190 861 . .

LABEL, warning electric shock and moving parts etc

1

. . . 17

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

+215 347 . .

PANEL, gen pwr

1

. . . 17

. . . . . . . . . . . ♦+215 405 . .

PANEL, gen pwr ss

1

. . . 17

. . . . . . . . . . . ♦+215 403 . .

PANEL, gen pwr (export models only)

1

. . . 18

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

083 030 . .

STUD, brs .250−20 x 1.750 w/hex collar

1

. . . 19

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

601 836 . .

NUT, 250−20 .50hex .19h brs

3

. . . 20

. . . . . . . . . . . . ♦196 073 . .

LABEL, do not switch while welding

1

. . . 21

. . . . . S12 . . ♦195 825 . .

SWITCH, polarity

1

. . . 22

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

201 125 . .

PANEL, mtg terminal pwr output

1

. . . 22

. . . . . . . . . . . . ♦199 303 . .

PANEL, mtg terminal pwr output ss

1

. . . 23

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

039 046 . .

TERMINAL, pwr output black

1

. . . .

. .

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

180 735 . .

WASHER, output stud

2

. . . 24

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

181 169 . .

SPACER, output stud

2

. . . 25

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

186 621 . .

BOOT, generic output stud

2

. . . 26

. . . . . . . . . . . . ♦059 773 . .

HANDLE, switch

1

. . . 27

. . . . . . . . . . . . ♦010 647 . .

PIN, spring cs .156 x 1.250

1

. . . 28

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

039 047 . .

TERMINAL, pwr output red

1

. . . 29

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

209 056 . .

COVER, receptacle w/gasket

2

. . . 30

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

206 795 . .

BOOT, circuit breaker clear hex nut

1

. . . 31

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

021 385 . .

BOOT, toggle switch lever

2

. . . 32

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

201 045 . .

COVER, receptacle twistlock

1

. . . 33

. . . . . . . . . . . . ♦193 228 . .

METER, Volt Dc 8− 18 Scale 2.250 In Black Face

1

. . . 34

. . . . FUEL . . .

192 265 . .

GAUGE, fuel elec switch w/o sensor

1

. . . 35

. . . . . HM . . . .

210 424 . .

METER, hour 12-24VDC 2.25dia

1

. . . 36

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

217 084 . .

GAUGE, Coolant Temp 0− 300 Deg F Electric

1

. . . .

. .

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

197 798 . .

SENDER, Coolant Temp 300 Deg F M16 X 1.5

1

. . . 37

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

217 083 . .

GAUGE, Pressure Oil 0−100 Psi Electric

1

. . . .

. .

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

193 230 . .

SENDER, Pressure Oil 0− 100 Psi

1

. . . 38

. . . . . . . . . . . . ♦164 873 . .

VOLT METER, W/Leads

1

. . . 39

. . . . . . . . . . . . ♦164 874 . .

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

1

♦Optional

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-4429 Page 77

Page 80 Page 82
Image 81
Page 80 Page 82
Contents Description ProcessesFile Engine Drive Visit our website at OM-44292216 138H 2007−05From Miller to You Table of Contents − Maintenance & Troubleshooting Arc Welding Hazards Symbol UsageElectric Shock can kill HOT Parts can cause severe burnsBuildup of GAS can injure or kill Fumes and Gases can be hazardousARC Rays can burn eyes and skin Welding can cause fire or explosionCompressed Air Hazards Engine HazardsHOT Parts can cause burns and injury Welding Wire can cause injuryFire or Explosion hazard Falling Unit can cause injuryCalifornia Proposition 65 Warnings Principal Safety StandardsEMF Information Radiation can cause interference− Consignes DE Sécurité − Lire Avant Utilisation Signification des symbolesUN Choc Électrique peut tuer Indique des instructions spécifiquesLES Fumées ET LES GAZ peuvent être dangereux DES Pièces Chaudes peuvent provoquer des brûlures gravesLE Soudage peut provoquer un in cendie ou une explosion LE Bruit peut affecter l’ouïeDES Organes Mobiles peuvent pro voquer des blessures ’EXPLOSION DE LA Batterie peuLA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessuresRisque D’INCENDIE OU D’EXPLO- Sion DES Organes Mobiles peuvent provoquer des blessures LE Surchauffement peut endom- mager le moteur électriqueLES Fils DE Soudage peuvent provoquer des blessures ’EMPLOI Excessif peutPrincipales normes de sécurité Proposition californienne 65 AvertissementsInformation EMF En ce qui concerne les implants médicaux− Definitions − 50 h StdStd CC Models Manufacturer’s Rating LabelsSome symbols are found only on CE products Symbols And Definitions− Specifications Weld, Power, And Engine SpecificationsDimensions, Weights, And Operating Angles Volts Volt-Ampere Curves For CC ModelsMIG Mode Stick ModeTIG Mode Volt-Ampere Curves For CC/CV ModelsFuel Consumption Duty Cycle And Overheating100% Duty Cycle At 400 Amperes Optional Three-Phase Generator Curves AC Generator Power Curve12 kVA/kW Single-Phase AC Output No Weld Load 20 kVA/kW Three-Phase AC Output No Weld LoadInstalling Welding Generator − InstallationLocation/Airflow Clearance Grounding1Using Lifting Eye Mounting Welding Generator Stop engine and let cool Installing Exhaust PipeConnecting The Battery Activating The Dry Charge Battery If ApplicableEngine Prestart Checks Coolant Recovery TankFuel OilStick and TIG Welding Connecting To Weld Output TerminalsMIG and Fcaw Welding Stop engineSelecting Weld Cable Sizes Connecting to Weld150 ft 200 ft 250 ft 350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 mSocket Connecting To Remote 14 Receptacle RC14 On CC/CV ModelsOM-4429 Front Panel Controls For CC Models See Section − Operating Welding Generator − CC ModelsTo Start Engine Starting ControlsEngine Gauges And Meters Weld ControlsRemote Amperage Control On CC Models Optional Weld Control/Arc Condition Information LabelExample Combination Remote Amperage Control Stick OM-4429 Front Panel Controls For CC/CV Models See Section − Operating Welding Generator − CC/CV Models14 AC/DC Voltmeter Optional Voltage/Amperage Adjust Switch And Remote 14 ReceptacleProcess/Contactor Switch Settings Process/Contactor Switch On CC/CV ModelsExample Combination Remote Amperage Control TIG Remote Voltage/Amperage Control On CC/CV Models OptionalVolt And 240 Volt Receptacles − Operating Auxiliary EquipmentAt 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 Label − Maintenance & TroubleshootingRoutine Maintenance To clean air filter Servicing Air CleanerChecking Generator Brushes Inspecting And Cleaning Optional Spark Arrestor MufflerServicing Fuel And Lubrication Systems To change oil and filterTo replace primary fuel filter Overload Protection Welding − CC Models TroubleshootingWelding − CC/CV Models Standard Generator Power Optional Three-Phase Generator Power CC/CV Models OnlyEngine Gine Control switch S1 Check engine wiring harness plug connectionsFactory Authorized Service Agent Engine cranks but does not start Check fuel levelStart Your Professional Welding Career Now Circuit Diagram For CC Welding Generator − Electrical Diagrams223 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 Specifications section in this Run-In Procedure Using Resistance GridJust generator A/V control so ManualSelecting Equipment − Generator Power GuidelinesGrounding Generator To Truck Or Trailer Frame Electrically Bond GeneratorHow Much Power Does Equipment Require? Grounding When Supplying Building SystemsUse ground device as stated in electrical codes Amperes x Volts = WattsApproximate Power Requirements For Farm/Home Equipment Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentHow Much Power Can Generator Supply? Power Required To Start MotorSingle-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 111 Figures 13-2123 212 Control Box Assembly − CC Models Engine Controller Control Box Assembly − CC Models -1ItemControl Box Assembly − CC/CV Models 134 3634 Panel, Front w/Components − CC Models208278 Panel, Front w/Components − CC/CV Models -1Item Panel, Front w/Components − CC/CV ModelsCB1 201 Supplementary PROTECTOR, man reset 2P 20 A, 250VAC 32 31 30 Hardware is common053 BEARING, Ball Rdl Sgl Row 1.370 X 2.830 X Main Rectifier Assembly Wiring Harnesses 215207 Service Your distributor also givesSupport Miller Electric Mfg. Co To locate a Distributor or Service Agency visitFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s
Top Page Image Contents