Miller Electric Big Blue 600 X, Big Blue 500 PT manual Wiring Harnesses

Page 87

.Some wiring harness components (switches, relays, circuit breakers) are also referenced elsewhere in this parts list. Purchase components sepa- rately or as part of the associated wiring harness.

Item

Dia.

 

Part

Description

Quantity

No.

Mkgs.

 

No.

 

 

 

 

Wiring Harnesses

 

 

 

 

 

 

 

 

 

. . . . . . .

. . . . . . . . .

. . . .

221374 . .

Harness, Engine (Includes)

. . .

1

. . . . . . .

. D10/C10 . .

189701 . .

Diode/Capacitor Board,

1

. . . . . . .

. . . CB10

. . . .

190374 . .

Circuit Breaker, Auto Reset 12vdc 40 Amp

. . .

1

. . . . . . .

. . . . . . . . .

. . . .

156734 . .

Nut, 010−32 .31hex .13h Stl Pld Sem Cone Wshr.38d

. . .

2

. . . . . . .

. . . CR1

. . . . 090104 . .

Relay, Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg

. . .

1

. . . . . . .

. . . . . . . . .

. . . .

219886 . .

Harness, Governor Control 404.22t

. . .

1

. . . . . . .

. . . . . . . . .

. . . .

218798 . . .

. Conn, Deutsch Dtm 12p 2row Plug ’a’

. . .

1

. . . . . . .

. . . . . . . . .

. . . .

218800 . . .

. Conn, Deutsch Dtm Wedge Lock 12 Position

. . .

1

. . . . . . .

. . . . . . . . .

. . . .

212116 . . .

. Conn, Deutsch 2p 1row Female Plug

. . .

1

. . . . . . .

. . . . . . . . .

. . . .

212117 . . .

. Conn, Deutsch Wedge Lock 2 Position

. . .

1

. . . . . . .

. . . . . . . . .

. . . .

204702 . . .

. Core, Toroidal .187 Id X .375 Od X .125 Thk

. . .

2

. . . . . . .

. . . . . . . . .

. . . .

218799 . .

Conn, Deutsch Dtm 12p 2row Plug ’b’

. . .

1

. . . . . . .

. . . . . . . . .

. . . .

218800 . .

Conn, Deutsch Dtm Wedge Lock 12 Position

. . .

1

. . . . . . .

. . . . . . . . .

. . . .

212116 . .

Conn, Deutsch 2p 1row Female Plug

. . .

2

. . . . . . .

. . . . . . . . .

. . . .

212117 . .

Conn, Deutsch Wedge Lock 2 Position

. . .

2

. . . . . . .

. . . CR8

. . . . 197325 . .

Relay, Encl 12vdc Spst 70a 4pin Flange Mtg

. . .

1

. . . . . . .

. . . . . . . . .

. . . .

204702 . .

Core, Toroidal .187 Id X .375 Od X .125 Thk

. . .

2

. . . . . . .

. . . . . . . . .

. . . .

192558 . .

Harness, Range Switch (Includes)

. . .

1

. . . . . . .

. . . RC6

. . . . 148439 . .

Conn, Rect Univ 084 4p/S 1row Rcpt Cable/Panel Lkg (Service Kit) .

. . .

1

. . . . . . .

. . . . . . . . .

. . . .

190259 . .

Harness, Wrg, Brushholder (Includes)

. . .

1

. . . . . . .

. . . PLG1

. . . .

168071 . .

Conn, Rect Univ 084 9p/S 3row Plug Cable Lkg (Service Kit)

. . .

1

. . . . . . .

. . . . . . . . .

. . . .

187651 . .

Seal, Wire Univ 9p/S 3row

. . .

1

. . . . . . .

. . . . . . . . .

. . . .

215013 . .

Harness, Unit Weld Control CC (Includes)

. . .

1

. . . . . . .

. . . PLG3

. . . .

158465 . .

Conn, Rect Univ 084 12p/S 3row Plug Cable Lkg

. . .

1

. . . . . . .

. . . . . . . . .

. . . .

187654 . .

Seal, Wire Univ 12p/S 3row

. . .

1

. . . . . . .

. . . PLG6

. . . .

114063 . .

Conn, Rect Univ 084 4p/S 1row Plug Cable Lkg

. . .

1

. . . . . . .

. . . . . . . . .

. . . .

215054 . .

Harness, Control Box CC (Includes)

. . .

1

. . . . . . .

. SR1, SR2 . .

035704 . .

Rectifier, Integ Bridge 40. Amp 800v

. . .

2

. . . . . . .

. . D1/C1 . . . 189701 . .

Diode/Capacitor Board,

1

. . . . . . .

. . . RC4 . . . . 047483 . .

Conn, Rect Univ 084 15p/S 3row Rcpt Cable/Panel Lkg

. . .

1

. . . . . . .

CB11, 12, 13

139266 . .

Supplementary Protector,Man Reset 1p 15a 250vac

. . .

3

. . . . . . .

. . . CR7

. . . . 188636 . .

Relay, Ocv Control

. . .

1

. . . . . . .

. . . . . . . . .

. . . .

148850 . .

Socket, Relay 5 Pin

. . .

1

. . . . . . .

. . . . S6 .

. . . .

011622 . .

Switch, Tgl 3pdt 15a 125vac On−none−on Spd Term

. . .

1

. . . . . . .

. . . . S5 .

. . . .

011609 . .

Switch, Tgl Spdt 15a 125vac On−none−on Spd Term Chr

. . .

1

. . . . . . .

. . . . . . . . .

. . . .

211292 . .

Conn, Pack 4p 1row Female

. . .

1

. . . . . . .

. . . . . . . . .

. . . .

211293 . .

Conn, Pack Terminal Position Assurance(Lock)

. . .

1

. . . . . . .

. . . . . . . . .

. . . .

021467 . .

Switch, Tgl Spst 3a 250v Off−none−(On) Spd Term

. . .

1

. . . . . . .

. . . . . . . . .

. . . .

150316 . .

Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg

. . .

5

. . . . . . .

. . . . . . . . .

. . . .

092670 . .

Conn, Rect Univ 084 3p/S 1row Plug Cable Lkg

. . .

1

. . . . . . .

. . . RC3 . . . . 158466 . .

Conn, Rect Univ 084 12p/S 3row Rcpt Cable/Panel Lkg

. . .

1

. . . . . . .

. . . RC1

. . . . 135133 . .

Conn, Rect Univ 084 9p/S 3row Rcpt Cable/Panel Lkg

. . .

1

OM-4429 Page 83

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Contents Visit our website at OM-44292216 138H 2007−05 ProcessesDescription File Engine DriveFrom Miller to You Table of Contents − Maintenance & Troubleshooting HOT Parts can cause severe burns Symbol UsageArc Welding Hazards Electric Shock can killWelding can cause fire or explosion Fumes and Gases can be hazardousBuildup of GAS can injure or kill ARC Rays can burn eyes and skinCompressed Air Hazards Engine HazardsFalling Unit can cause injury Welding Wire can cause injuryHOT Parts can cause burns and injury Fire or Explosion hazardRadiation can cause interference Principal Safety StandardsCalifornia Proposition 65 Warnings EMF InformationIndique des instructions spécifiques Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation UN Choc Électrique peut tuerLE Bruit peut affecter l’ouïe DES Pièces Chaudes peuvent provoquer des brûlures gravesLES Fumées ET LES GAZ peuvent être dangereux LE Soudage peut provoquer un in cendie ou une explosionDES 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 ’EMPLOI Excessif peut LE Surchauffement peut endom- mager le moteur électriqueDES Organes Mobiles peuvent provoquer des blessures LES Fils DE Soudage peuvent provoquer des blessuresEn ce qui concerne les implants médicaux Proposition californienne 65 AvertissementsPrincipales normes de sécurité Information EMF− 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 ModelsVolt-Ampere Curves For CC/CV Models Stick ModeMIG Mode TIG ModeFuel Consumption Duty Cycle And Overheating100% Duty Cycle At 400 Amperes 20 kVA/kW Three-Phase AC Output No Weld Load AC Generator Power CurveOptional Three-Phase Generator Curves 12 kVA/kW Single-Phase AC Output No Weld LoadGrounding1 − InstallationInstalling Welding Generator Location/Airflow ClearanceUsing Lifting Eye Mounting Welding Generator Stop engine and let cool Installing Exhaust PipeConnecting The Battery Activating The Dry Charge Battery If ApplicableOil Coolant Recovery TankEngine Prestart Checks FuelStop engine Connecting To Weld Output TerminalsStick and TIG Welding MIG and Fcaw Welding350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Connecting to WeldSelecting Weld Cable Sizes 150 ft 200 ft 250 ftSocket Connecting To Remote 14 Receptacle RC14 On CC/CV ModelsOM-4429 Front Panel Controls For CC Models See Section − Operating Welding Generator − CC ModelsWeld Controls Engine Starting ControlsTo Start Engine Gauges And MetersRemote 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 OptionalIf a Supplementary − Operating Auxiliary EquipmentVolt And 240 Volt Receptacles At least once a month, run enThree-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 Engine cranks but does not start Check fuel level Check engine wiring harness plug connectionsGine Control switch S1 Factory Authorized Service AgentStart 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 Manual Run-In Procedure Using Resistance GridSpecifications section in this Just generator A/V control soElectrically Bond Generator − Generator Power GuidelinesSelecting Equipment Grounding Generator To Truck Or Trailer FrameAmperes x Volts = Watts Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Use ground device as stated in electrical codesFarm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Industrial Motors Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentKVA/HP x HP x 1000 / Volts = Starting Amperage Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsTypical 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 Your distributor and/or equipment manufacturer’s To locate a Distributor or Service Agency visitMiller Electric Mfg. Co For assistance in filing or settling claims, contact
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