123 212 | Miller Electric Big Blue 600 X, Big Blue 500 PT manual

Item	Dia.	Part	Description	Quantity
No.	Mkgs.	No.	Description	Quantity
			Figure 13-1. Main Assembly (Continued)

. . 123 . . .	. . . . . . . . .	212 944 . .	Label, Weld Control/Arc Condition Information Label	. . .	1
. . 124 . . .	. . . . . . . . .	233 088 . .	Label, Danger Using A Generator Indoors Can Kill You In Minutes (Unit)		1
. . . . . . . . . .	. . . . . . . . .	190 058 . .	Nut, .250−20 U−nut Multi−thread	. . .	19
. . . . . . . . . .	. . . . . . . . .	049 525 . .	Nut, 312−18 U−nut Multi−thread	. . .	32
. . . . . . . . . .	. . . . . . . . .	216 136 . .	Kit, Label (Includes Safety & Informational Labels) (CC Models) . . . .	. . .	1
. . . . . . . . . .	. . . . . . . . .	216 135 . .	Kit, Label (Includes Safety & Informational Labels) (CC/CV Models) .	. . .	1
. . . . . . . . . .	. . . . . . . . .	216 993 . .	Kit, Label (Includes Safety & Informational Labels) (CC Export Models) .		1
. . . . . . . . . .	. . . . . . . . .	216 992 . .	Kit, Label (Includes Safety & Informational Labels) (CC/CV Export Models)1

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

CC CV

CCmodels only.

CC/CV models only.

♦Optional

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 71

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Miller Electric Big Blue 600 X, Big Blue 500 PT manual 123 212

Contents

Visit our website at OM-44292216 138H 2007−05 ProcessesDescription File Engine Drive From Miller to You Table of Contents − Maintenance & Troubleshooting HOT Parts can cause severe burns Symbol UsageArc Welding Hazards Electric Shock can kill Welding can cause fire or explosion Fumes and Gases can be hazardousBuildup of GAS can injure or kill ARC Rays can burn eyes and skin Compressed Air Hazards Engine Hazards Falling Unit can cause injury Welding Wire can cause injuryHOT Parts can cause burns and injury Fire or Explosion hazard Radiation can cause interference Principal Safety StandardsCalifornia Proposition 65 Warnings EMF Information Indique des instructions spécifiques Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation UN Choc Électrique peut tuer LE 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 explosion DES Organes Mobiles peuvent pro voquer des blessures ’EXPLOSION DE LA Batterie peu LA 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 blessures En ce qui concerne les implants médicaux Proposition californienne 65 AvertissementsPrincipales normes de sécurité Information EMF − Definitions − 50 h StdStd CC Models Manufacturer’s Rating Labels Some 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 Models Volt-Ampere Curves For CC/CV Models Stick ModeMIG Mode TIG Mode Fuel 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 Load Grounding1 − InstallationInstalling Welding Generator Location/Airflow Clearance Using Lifting Eye Mounting Welding Generator Stop engine and let cool Installing Exhaust Pipe Connecting The Battery Activating The Dry Charge Battery If Applicable Oil Coolant Recovery TankEngine Prestart Checks Fuel Stop engine Connecting To Weld Output TerminalsStick and TIG Welding MIG and Fcaw Welding 350 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 ft Socket Connecting To Remote 14 Receptacle RC14 On CC/CV Models OM-4429 Front Panel Controls For CC Models See Section − Operating Welding Generator − CC Models Weld Controls Engine Starting ControlsTo Start Engine Gauges And Meters Remote 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 Models 14 AC/DC Voltmeter Optional Voltage/Amperage Adjust Switch And Remote 14 Receptacle Process/Contactor Switch Settings Process/Contactor Switch On CC/CV Models Example Combination Remote Amperage Control TIG Remote Voltage/Amperage Control On CC/CV Models Optional If a Supplementary − Operating Auxiliary EquipmentVolt And 240 Volt Receptacles At least once a month, run en Three-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 & Troubleshooting Routine Maintenance To clean air filter Servicing Air Cleaner Checking Generator Brushes Inspecting And Cleaning Optional Spark Arrestor Muffler Servicing Fuel And Lubrication Systems To change oil and filterTo replace primary fuel filter Overload Protection Welding − CC Models Troubleshooting Welding − 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 Agent Start Your Professional Welding Career Now Circuit Diagram For CC Welding Generator − Electrical Diagrams 223 525-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 so Electrically Bond Generator − Generator Power GuidelinesSelecting Equipment Grounding Generator To Truck Or Trailer Frame Amperes x Volts = Watts Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Use ground device as stated in electrical codes Farm/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 Watts Contractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor Equipment KVA/HP x HP x 1000 / Volts = Starting Amperage Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting Requirements Typical 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 13-2 123 212 Control Box Assembly − CC Models Engine Controller Control Box Assembly − CC Models -1Item Control Box Assembly − CC/CV Models 134 3634 Panel, Front w/Components − CC Models 208278 Panel, Front w/Components − CC/CV Models -1Item Panel, Front w/Components − CC/CV Models CB1 201 Supplementary PROTECTOR, man reset 2P 20 A, 250VAC 32 31 30 Hardware is common 053 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