Hardware is common, 32 31 30 | Miller Electric Big Blue 500 PT

. . . 55	097 922 . .	KNOB, pointer .875 dia x .250 ID w/set screws plstc	1
. . . 56	189 161 . .	HANDLE, switch range	1
. . . 57	010 647 . .	PIN, spring CS .156 x 1.250	1
. . . 58	097 924 . .	KNOB, pointer 1.625 dia x .250 ID w/set scrws plstc	1
. . . . . . . . . . . . . . . . . . .	024 103 . .	BLANK, snap-in nyl .750 mtg hole blk	1
♦. .Optional	120 304 . .	BLANK, snap−in nyl .250 mtg hole black	2
♦. .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.

.Hardware is common and

not available unless listed.					20
					17
			11	16	18
			11	15
				15	21
					21
			12		22
					22
9	10	13	14
					19

	3
1 2	4
1 2

37 36

5

35

8		23
	7	24
	7
6

		25
	28	27 26
	28
33	32 31 30 29
33
34

					804 291-A
				Figure 13-6. Generator
Item		Dia.	Part	Description	Quantity
	No.	Mkgs.	No.	Description	Quantity
				Figure 13-6. Generator (Figure 13-1Item 88)

. . .	1 . . .	. . . . . . . .	. . 132 053 . .	SCREW, .375−16x1.50 hex hd−pln gr5 pld	. . . 6
. . .	2 . . .	. . . . . . . .	. . 183 387 . .	WASHER, conical spring .406 ID x .875 OD pltd	. . . 6
. . .	3 . . .	. . . . . . . .	. . . 195 911 . .	ENDBELL, gen (consisting of)	. . . 1
. . .	4 . . .	. . . . . . . .	. . 143 220 . . .	. O-RING, 2.859 ID x .139CS	. . . 1
. . .	5 . . .	. . . . . . . .	. . 201 099 . .	STATOR, exciter/gen pwr	. . . 1
. . .	6 . . .	. . . . . . . .	. +208 287 . .	STATOR, weld assembly complete	. . . 1
. . .	6 . . .	. . . . . . . .	+♦209 220 . .	STATOR, weld assembly complete (full kVA option)	. . . 1
. . .	7 . . .	. . . . . . . .	. . 225 120 . .	LABEL, warning moving parts can cause injury	. . . 2
. . .	8 . . .	. . . . . . . .	. . 190 197 . .	GUARD, generator wire mesh	. . . 1
. . .	9 . . .	. . . . . . . .	. . 172 674 . .	SPRING, ext .240 OD x .041 wire x 3.500pld	. . . 2
. . . 10 . . .		. . . . . . . .	. . 039 207 . .	BAFFLE, air	. . . 1
. . . 11 . . .		ROTOR	. . 212 997 . .	ROTOR, Generator Segmented Assy (Includes)	. . . 1

OM-4429 Page 80

Image 84

Miller Electric Big Blue 500 PT, Big Blue 600 X manual Hardware is common, 32 31 30

Contents

Processes DescriptionFile Engine Drive Visit our website at OM-44292216 138H 2007−05 From Miller to You Table of Contents − Maintenance & Troubleshooting Symbol Usage Arc Welding HazardsElectric Shock can kill HOT Parts can cause severe burns Fumes and Gases can be hazardous Buildup of GAS can injure or killARC Rays can burn eyes and skin Welding can cause fire or explosion Engine Hazards Compressed Air Hazards Welding Wire can cause injury HOT Parts can cause burns and injuryFire or Explosion hazard Falling Unit can cause injury Principal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interference Signification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer Indique des instructions spécifiques DES 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 blessures LA 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 peut Proposition californienne 65 Avertissements Principales normes de sécuritéInformation EMF En ce qui concerne les implants médicaux − Definitions − 50 h StdStd Manufacturer’s Rating Labels CC Models Symbols 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 Volts Stick Mode MIG ModeTIG Mode Volt-Ampere Curves For CC/CV Models Fuel 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 Grounding1 Using Lifting Eye Mounting Welding Generator Installing Exhaust Pipe Stop engine and let cool Activating The Dry Charge Battery If Applicable Connecting The Battery Coolant Recovery Tank Engine Prestart ChecksFuel Oil Connecting To Weld Output Terminals Stick and TIG WeldingMIG and Fcaw Welding Stop engine Connecting 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 m Connecting To Remote 14 Receptacle RC14 On CC/CV Models Socket OM-4429 − Operating Welding Generator − CC Models Front Panel Controls For CC Models See Section Engine Starting Controls To StartEngine Gauges And Meters Weld Controls Remote 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 Section Voltage/Amperage Adjust Switch And Remote 14 Receptacle 14 AC/DC Voltmeter Optional Process/Contactor Switch On CC/CV Models Process/Contactor Switch Settings Remote 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 Supplementary 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 & Troubleshooting Maintenance Label Routine Maintenance Servicing Air Cleaner To clean air filter Inspecting And Cleaning Optional Spark Arrestor Muffler Checking Generator Brushes Servicing Fuel And Lubrication Systems To change oil and filterTo replace primary fuel filter Overload Protection Troubleshooting Welding − CC Models Welding − 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 level Start Your Professional Welding Career Now − Electrical Diagrams Circuit Diagram For CC Welding Generator 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 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 Generator Grounding When Supplying Building Systems How Much Power Does Equipment Require?Use ground device as stated in electrical codes Amperes x Volts = Watts Approximate 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 Watts Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Power Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 / Volts = Starting Amperage 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 Figures 13-2 111 123 212 Control Box Assembly − CC Models Control Box Assembly − CC Models -1Item Engine Controller Control Box Assembly − CC/CV Models 134 Panel, Front w/Components − CC Models 3634 208278 Panel, Front w/Components − CC/CV Models Panel, Front w/Components − CC/CV Models -1Item CB1 201 Supplementary PROTECTOR, man reset 2P 20 A, 250VAC Hardware is common 32 31 30 053 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