OM-129 647W, Processes | Miller Electric 500DX R instruction

Visit our website at

www.MillerWelds.com

OM-129 647W

July 1999

Processes

Stick (SMAW) Welding

Air Carbon Arc (CAC-A) Cutting

and Gouging

With Optional Equipment:

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Description

Engine Driven Welding Generator

Big BlueR 500DX

Image 1

Miller Electric 500DX R manual OM-129 647W, Processes, Description

Contents

Processes OM-129 647WDescription From Miller to You Table of Contents Page Arc Welding Hazards Symbol UsageElectric Shock can kill ARC Rays can burn eyes and skin Engine Hazards Moving Parts can cause injury Battery Explosion can BlindEngine Exhaust Gases can kill Engine Heat can cause fire EMF Information Principal Safety StandardsRadiation can cause interference ARC Welding can cause interference − Consignes DE Sécurité − Lire Avant Utilisation Signification des symbolesUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereux DES Particules Volantes peuvent blesser les yeux LE Soudage peut provoquer un in- cendie ou une explosionDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut affecter l’ouïe ’EXPLOSION DE LA Batterie peut DES Organes Mobiles peuvent provoquer des blessuresLA Chaleur DU Moteur peut pro- voquer un incendie LA Chute DE L’APPAREIL peut blesser Information sur les champs électromagnétiques Principales normes de sécuritéLE Soudage À L’ARC risque de provoquer des interférences Consignes relatives aux stimulateurs cardiaques Symbols And Definitions − SpecificationsWeld, Power, And Engine Specifications − Definitions Curve shows typical fuel use under weld or power loads Dimensions, Weights, And Operating AnglesFuel Consumption 1898 lb 861 kg Engine End Warranty Minutes Welding Minutes Resting AC Auxiliary PowerDuty Cycle And Overheating 60% Duty Cycle At 500 Amperes Duty Cycle is Percentage CC/DC Standard CV/DC Models With CV Option Volt-Ampere Curves Optional AC Power Plant Curves Installing Welding Generator − InstallationDo Not Lift Unit From End Airflow Clearance Location When electrolyte is low, add Activating The Dry Charge BatteryCharger Maintain proper level Engine Prestart Checks Connecting The BatteryConnect Negative − Cable Last Tools Needed 1/2 Selecting Weld Cable Sizes Connecting To Weld Output Terminals After installing cylinder, wait at Installing Ether Cylinder Optional Ether Starting AidRemote A/V Control Receptacle RC3 Terminal Strip 2T Connections Optional Remote 14 Receptacle RC3 Information OptionalSocket Stop engine Standard Controls See Section − Operating the Welding Generator Description Of Standard Controls See Section Do not switch under loadIf light goes off, stop engine and check oil level If light goes on, stop engine and check engine belt Controls For Models With CV Option See Section This unit has a max OCV control circuit − Operating Auxiliary Equipment Auxiliary power is not affected by weld outputVolt And 240 Volt Duplex Receptacles 120 V 15 a AC Receptacle RC2 240 V 15 a AC Receptacle RC1 Gfci Receptacle Option Optional Auxiliary Power ReceptaclesAustralian And South African Receptacle Options British Receptacle Option Set Engine Control switch to Run when using auxiliary power Connecting Optional Auxiliary Power Plant1011 Load Terminals − Maintenance & Troubleshooting Deutz F3L912 Diesel Engine Maintenance Label To clean air filter Servicing Air CleanerHose Servicing Fuel And Lubrication Systems Servicing Optional Ether Starting Aid Adjusting Engine Speed1850 Checking And Replacing Alternator Belt To adjust belt tension13 mm Max Tools Needed 11/16 Stop engine To check belt tension Resetting Fan Belt Safety Shutdown Stop engine and let cool. Reinstall cleanout plug Inspecting And Cleaning Optional Spark Arrestor MufflerOverload Protection For Models With CV Option Stop engine and let cool Welding Troubleshooting Engine Auxiliary Power Trouble Remedy OM-129 647 Circuit Diagram For Welding Generator Standard Models − Electrical Diagrams Circuit Diagram For Welding Generator Models With CV Option 184 954-C Wetstacking − RUN-IN Procedure Load Bank Run-In Procedure Using Load Bank Do not touch hot exhaust Run-In Procedure Using Resistance GridBank/grid From flammables Selecting Equipment − Auxiliary Power GuidelinesGrounding Generator To Truck Or Trailer Frame How Much Power Does Equipment Require? Grounding When Supplying Building SystemsEarth ground if supplying Use ground device as stated in electrical codes Approximate 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 Watts Contractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor Equipment How Much Power Can Generator Supply? Power Required To Start MotorSingle-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 = Starting Amperage Volts Emergencies or power outages Generator is to supply standby power duringWelding Generator Auxiliary Power output circuit Customer-supplied equipment is required if Selecting Extension Cord Use Shortest Cord Possible 101 100 − Parts List 66 65 102 Dia Part Description Quantity Mkgs Optional Panel, Front w/Components CC Model Illustrated Panel, Front w/Components -1 Item 6 5 Generator Generator -1 Item Hardware is common Not available unless listed 171Includes Control Box CC/CV -1 Item 86 Optional Panel, Mtg Components CC/CV Model Panel, Mtg Components CC Model Page Your distributor also gives ServiceSupport To locate distributor nearest you call 1-800-4-A-Miller Miller Electric Mfg. CoFor assistance in filing or settling claims