Miller Electric 500 X Page 92 Owner'S Manual Download

Page: 92 / 96

OM-4421 Page 86

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 harnes

Description

Part

No.

Dia.

Mkgs.

Item

No.

Wiring Harnesses

Quantity

215054

Harness, control box, CC weld control (includes)

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

. .

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

SR1, SR2

035704

Rectifier, Integ Bridge 40. Amp 800v

. . . . . . . .

. .

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

D1/C1

189701

Diode/Capacitor Board,

. . . . . . . . .

. . .

. .

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

RC4

047483

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

. . . . . . . . . .

. . . .

. .

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

CB11, CB12, CB13

139266

Supplementary Protector, Man Reset 1p 15a 250vac

. .

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

CR7

188636

Relay, Ocv Control

. . . . . . . . . .

. . . .

. .

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

148850

Socket, Relay 5 Pin

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

. .

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

011622

Switch, Tgl 3pdt 15a 125vac On

−

none

−

on Spd Term

. . . . . . . . . . .

. . . . .

. .

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

011609

Switch, Tgl Spdt 15a 125vac On

−

none

−

on Spd Term Chr

. . . . . . . . . . .

. . . . .

. .

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

211292

Conn, Pack 4p 1row Female

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

. .

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

211293

Conn, Pack Terminal Position Assurance(Lock)

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

. .

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

164617

Clip, Wiring Straight

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

. .

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

021467

Switch, Tgl Spst 3a 250v Off

−

none

−

(On) Spd Term

. . . . . . . . . . .

. . . . .

. .

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

150316

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

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

. .

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

RC3

158466

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

. . . . . . . . . .

. . . .

. .

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

RC1

135133

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

. . . . . . . . . .

. . . .

. .

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

215377

Harness, control box, CV weld control (includes)

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

. .

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

CB11, CB12, CB13

139266

Supplementary Protector, Man Reset 1p 15a 250vac

. .

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

SR1

035704

Rectifier, Integ Bridge 40. Amp 800v

. . . . . . . . . .

. . . .

. .

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

148850

Socket, Relay 5 Pin

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

. .

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

RC4

047483

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

. . . . . . . . . .

. . . .

. .

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

RC3

158466

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

. . . . . . . . . .

. . . .

. .

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

RC1

135133

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

. . . . . . . . . .

. . . .

. .

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

150316

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

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

. .

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

193234

Switch, Rotary 6 Posn Gold Contacts

. . . . . . . . . . .

. . . . .

. .

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

021467

Switch, Tgl Spst 3a 250v Off

−

none

−

(On) Spd Term

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

. .

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

011609

Switch, Tgl Spdt 15a 125vac On

−

none

−

on Spd Term Chr

. . . . . . . . . . .

. . . . .

. .

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

D1/C1

189701

Diode/Capacitor Board,

. . . . . . . . .

. . .

. .

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

193183

Conn, Rect Cinch 18 Pin

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

. .

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

196602

Plug, Cavity 18,30 Position Cinch Connector

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

. .

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

196603

Seal, Switch 6 Position Rotary .250 Shaft

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

. .

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

141450

Conn, Rect Metrmate 10skt 1row Plug Cable Lkg

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

. .

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

CB5, CB6

093995

Supplementary Pro, Man Reset 1p 15a 250vac Frict

. . . . . . . .

. .

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

211292

Conn, Pack 4p 1row Female

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

. .

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

211293

Conn, Pack Terminal Position Assurance(Lock)

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

. .

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

215013

Harness, weld control CC (includes)

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

. .

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

PLG3

158465

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

. . . . . . . . . .

. . . .

. .

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

187654

Seal, Wire Univ 12p/S 3row

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

. .

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

PLG6

114063

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

. . . . . . . . . .

. . . .

. .

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

215207

Harness, weld control CV (includes)

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

. .

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

PLG6

114063

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

. . . . . . . . . .

. . . .

. .

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

PLG8

193184

Conn, Rect Cinch 30 Pin

. . . . . . . . . .

. . . .

. .

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

PLG13

147992

Conn, Rect Univ 039 10p/S 2row Plug Cable Lkg

. . . . . . . . .

. . .

. .

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

PLG3

158465

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

. . . . . . . . . .

. . . .

. .

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

187654

Seal, Wire Univ 12p/S 3row

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

. .

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

196602

Plug, Cavity 18,30 Position Cinch Connector

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

. .

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

Summary of Contents for 500 X

Page 1: ... Welding MIG GMAW Welding Engine Driven Welding Generator OM 4421 215 075Q 2007 10 Visit our website at www MillerWelds com Flux Cored FCAW Welding Air Carbon Arc CAC A Cutting and Gouging File Engine Drive Big Blue 400P Big Blue 500 X Perkins Powered ...

Page 2: ...ntinue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operatio...

Page 3: ...CTION 4 SPECIFICATIONS 15 4 1 Weld Power And Engine Specifications 15 4 2 Dimensions Weights And Operating Angles 15 4 3 Volt Ampere Curves For CC Models 16 4 4 Volt Ampere Curves For CC CV Models 17 4 5 Fuel Consumption 18 4 6 Duty Cycle And Overheating 18 4 7 AC Generator Power Curve 19 4 8 Optional Three Phase Generator Curves 19 SECTION 5 INSTALLATION 20 5 1 Installing Welding Generator 20 5 2...

Page 4: ...C CV Models Only 39 8 3 Optional Generator Power Receptacles 40 SECTION 9 MAINTENANCE TROUBLESHOOTING 41 9 1 Maintenance Label 41 9 2 Routine Maintenance 42 9 3 Checking Generator Brushes 43 9 4 Servicing Air Cleaner 44 9 5 Inspecting And Cleaning Optional Spark Arrestor Muffler 45 9 6 Adjusting Engine Speed 46 9 7 Servicing Fuel And Lubrication Systems 47 9 8 Overload Protection 48 9 9 Troublesho...

Page 5: ...ve 73 23 EEC 2006 95 EC Electromagnetic compatibility Directives 89 336 EEC 92 31 EEC 2004 108 EC Machinery Directives 98 37 EEC 91 368 EEC 92 31 EEC 133 04 93 68 EEC Noise level of Welding Generators 2000 14 EC CE Marking Directive 93 68 EEC Standards Arc Welding Equipment Part 1 Welding Power Sources IEC 60974 1 Ed 3 2005 07 Rotating Electrical Machines Part 1 Rating and Performance IEC 60034 1 ...

Page 6: ...seo 6 E Cheadle Heath 20098 San Giuliano Stockport Chesire SK30XU Milanese Italy Phone 39 02 98290 1 Fax 39 02 98290203 European Contact Signature The Manufacturer Declares the Big Blue 500 X Conforms to Directive 2000 14 EC Noise Level of Welding Generators Effective Date 7 2004 Sound Level Information Measured Sound Power Level 97 dB Guaranteed Sound Power Level 97 dB Sound power level requireme...

Page 7: ...h risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone Disconnect input power or stop e...

Page 8: ...ding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards Do not weld where the atmosphere may conta...

Page 9: ...ts bare handed Allow cooling period before working on equip ment To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns STEAM AND HOT COOLANT can burn If possible check coolant level when engine is cold to avoid scalding Always check coolant level at overflow tank if present on unit instead of radiator unless told otherwise in maintenance sect...

Page 10: ...age and frequency caused by low engine speed damage electric motors Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable FLYING SPARKS can cause injury Wear a face shield to protect eyes and face Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face hand and body protection Sparks can cause fires keep flammables away MOVING ...

Page 11: ...c tion Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 4221 Walney Road 5th Floor Chantilly VA 20151 phone 703 788 2700 website www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from CanadianStandards Association Standards ...

Page 12: ...est équipé Des précautions de sécurité supplémentaires sont requises dans des environnements à risque comme les endroits humides ou lorsque l on porte des vêtements mouillés sur des structures mé talliques au sol grillages et échafaudages dans des positions assises à genoux et allongées ou quand il y a un risque important de contact accidentel avec la pièce ou le sol Dans ces cas utiliser les appa...

Page 13: ... Porter des lunettes de sécurité avec écrans latéraux même sous votre casque Avoir recours à des écrans protecteurs ou à des rideaux pour protéger les autres contre les rayonnements les éblouissements et les étincelles prévenir toute personne sur les lieux de ne pas regarder l arc Porter des vêtements confectionnés avec des matières résistan tes et ignifuges cuir coton lourd ou laine et des bottes...

Page 14: ... les batteries Débrancher le câble négatif en premier lieu Le rebrancher en dernier lieu LE CARBURANT MOTEUR peut provo quer un incendie ou une explosion Arrêter le moteur avant de vérifier le niveau de carburant ou de faire le plein Ne pas faire le plein en fumant ou proche d une source d étincelles ou d une flamme nue Ne pas faire le plein de carburant à ras bord prévoir de l espace pour son exp...

Page 15: ...t de changer ou de rajouter des éléments ou avant d ouvrir la purge ou le bouchon de remplissage d huile Le METAL CHAUD lors du coupage et gougeage plasma peut provoquer un in cendie ou une explosion Ne pas couper ou gouger à proximité de pro duits inflammables Surveillez et garder un extincteur à proximité DES PIECES CHAUDES peuvent provo quer des brûlures et blessures Ne pas toucher le compresse...

Page 16: ...IONS Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil N utiliser que les pièces de rechange recom mandées par le constructeur Effectuer la maintenance et le service du moteur et du compres seur d air suivant les instructions dans ce manuel ou le manuel du moteur compresseur si applicable LE RAYONNEMENT HAUTE FRÉ QUENCE H F risque de provoquer des interférences Le ...

Page 17: ...tandards Institute 11 West 43rd Street New York NY 10036 8002 téléphone 212 642 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 téléphone 617 770 3000 site Internet www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 2...

Page 18: ... There are possible hazards as shown by the symbols Read Owner s Manual Follow instructions to activate battery 5 Check oil level Add oil if necessary 6 During the first 50 hours of operation keep welding load above 200 amperes Do not weld below 200 amperes of output 7 After the first 50 hours of operation change the oil and oil filter 2 1 4 DIESEL API CD MIL L 2104D CD SE CD SF 3 S 177 571 0 50 h...

Page 19: ...OM 4421 Page 13 3 2 Manufacturer s Rating Labels CC Models CC CV Models CC Export Models CC CV Export Models ...

Page 20: ... Local Remote Engine Air Temperature Or Engine Temperature Output Alternating Current Stick SMAW Welding Constant Current CC MIG GMAW Welding TIG GTAW Time h Hours s Seconds 1 Single Phase 3 Three Phase Read Operator s Manual Circuit Protector Do Not Switch While Welding Electrode Connection Work Connection 3 G Engine Driven Three Phase Alternator With Rectifier Hz Hertz X Duty Cycle U0 Rated No L...

Page 21: ...50 36A 120 240 VAC 60 Hz In Addition To Standard 4 kVA kW Generator Power Perkins 404 22 Water Cooled Four Cylinder 32 6 HP Diesel Engine 25 gal 95 L 4 2 Dimensions Weights And Operating Angles Dimensions Height 60 in 1524 mm to top of muffler Width 28 1 2 in 724 mm mtg brackets turned in 30 3 4 in 781 mm mtg brackets turned out G Depth 65 1 8 in 1654 mm Do not exceed tilt angles or engine could b...

Page 22: ...age output capabilities of the welding generator Curves of all other settings fall between the curves shown DC AMPERES DC VOLTS 100 80 60 40 20 0 0 100 200 300 400 500 600 700 800 900 1000 Ranges 230 Max 170 365 110 225 70 130 55 85 Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual ...

Page 23: ...tor Curves of all other settings fall between the curves shown A Stick Mode B MIG Mode C TIG Mode DC VOLTS DC AMPERES DC VOLTS DC AMPERES DC VOLTS DC AMPERES 100 80 60 40 20 0 0 100 200 300 400 500 600 700 800 900 1000 100 80 60 40 20 0 0 100 200 300 400 500 600 700 800 900 1000 MAX MIN 100 80 60 40 20 0 0 100 200 300 400 500 RANGES MAX 155 450 115 320 75 195 40 90 RANGES 60 365 35 250 25 155 15 7...

Page 24: ...Hr 0 50 100 150 200 250 300 350 400 450 500 0 00 0 25 0 50 0 75 1 00 1 25 1 50 1 75 2 00 2 25 2 50 IDLE Continuous Welding 4 6 Duty Cycle And Overheating Duty Cycle is percentage of 10 min utes that unit can weld at rated load without overheating NOTICE Exceeding duty cycle can damage unit and void warranty 100 Duty Cycle At 400 Amperes 215 084 A ...

Page 25: ... 60 AC AMPERES IN 120V MODE 4 8 Optional Three Phase Generator Curves 215 086 A 215 087 A The ac power curves show the gen erator power available in amperes at the single phase 120 240 volt re ceptacle or three phase 240 volt terminals A 12 kVA kW Single Phase AC Output No Weld Load B 15 kVA kW Three Phase AC Output No Weld Load AC VOLTS AC VOLTS AC AMPERES AC AMPERES 280 260 240 220 200 180 0 10 ...

Page 26: ...Section 5 3 for mounting in formation Grounding 1 Equipment Grounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Electrically bond generator frame to vehicle frame by met al to metalcontact Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insu lated copper wire Bed liners shipping skids and some running gears insu late the w...

Page 27: ...in place Lower lifting eye when not needed To lock the lifting eye in the upright position insert a 3 8 16 x 1 1 2 in carriage bolt through slot in bracket and secure with nut bolt and nut not supplied Tools Needed 2 1 3 Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual ...

Page 28: ... Supports 2 Mounting Brackets Supplied Mount unit on flat surface or use cross supports to support base Secure unit with mounting brack ets 3 1 2 in Bolt And Washer Minimum Not Supplied 4 3 8 16 x 1 in Screws Supplied To Bolt Unit In Place Remove hardware securing the four mounting brackets to the base Reverse brackets and reattach to base with original hardware Mount unit to truck or trailer with...

Page 29: ...s Needed Ref 803 604 Ref 215 158 Stop engine and let cool Point exhaust pipe in desired di rection but always away from front panel and direction of travel Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual ...

Page 30: ... If necessary add electro lyte to raise to proper level Reins tall vent caps 8 Battery Charger Read and follow all instruc tions supplied with battery charger Charge battery for 12 minutes at 30 amperes or 30 minutes at 5 am peres Disconnect charging cables and install battery When electrolyte is low add only distilled water to cells to maintainproper level 1 Tools Needed 2 4 30 A For 12 Minutes 5...

Page 31: ...aintenance label Coolant Check coolant level in radiator before start ing unit the first time If necessary add cool ant to radiator until coolant level is at bottom of filler neck Check coolant level in recovery tank daily If necessary add coolant to recovery tank until coolant level is between Cold Full and Hot Full levels If recovery tank coolant level was low also check coolant level in radiato...

Page 32: ...tive Weld Output Terminal Failure to properly connect weld cables may cause excessive heat and start a fire or damage your machine 3 Weld Output Terminal 4 Supplied Weld Output Terminal Nut 5 Weld Cable Terminal 6 Copper Bar Remove supplied nut from weld output termi nal Slide weld cable terminal onto weld output terminaland secure with nut so that weld cable terminal is tight against copper bar D...

Page 33: ... ea 2 0 2x70 2 ea 3 0 2x95 2 ea 3 0 2x95 350 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 3 0 2x95 2 ea 4 0 2x120 400 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 4 0 2x120 2 ea 4 0 2x120 500 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 4 0 2x120 3 ea 3 0 3x95 3 ea 3 0 3x95 Chart is a general guideline and may not suit all applications If cables overheat...

Page 34: ...cuit common OUTPUT CONTROL E DC input command signal 0 to 10 volts from min to max of remote control with Voltage Amperage Adjust control at max 115 VOLTS AC I 115 volts 10 amperes 60 Hz ac Protected by supplementary protector CB6 OR J Contact closure to I completes 115 volt ac contactor control circuit GND K Chassis common Ref 803 602 NEUTRAL G Circuit common for 24 and 115 volt ac circuit The re...

Page 35: ...OM 4421 Page 29 Notes ...

Page 36: ...OM 4421 Page 30 SECTION 6 OPERATING WELDING GENERATOR CC MODELS 6 1 Front Panel Controls For CC Models See Section 6 2 12 215 070 803 602 11 2 1 8 13 14 9 7 6 4 5 3 10 ...

Page 37: ...erage Adjust control adjusts amperage only when welding and does not adjust open circuit voltage The max OCV circuit is disabled when the Stick TIG Selection switch is in Scratch Start TIG position see item 10 8 Ampere Range Switch NOTICE Do not switch under load Use switch to select weld amperage range For most welding applications use lowest amperagerange possible to help prevent arc outages 9 A...

Page 38: ...rage Control Stick Adjust Optional Remote Control Set Switches Set Range Set Control Ref 154 862 A Ref 181 711 A 803 602 In Example Range 110 to 225 A DC Percentage Of Range 50 Max About 168 A DC 50 of 110 to 225 Max 168 A DC Min 90 A DC 1 6 4 Weld Control Arc Condition Information Label Set weld controls as shown to achieve softer or stiffer arc condi tions for different applications 212 944 B ...

Page 39: ...OM 4421 Page 33 Notes ...

Page 40: ...OM 4421 Page 34 SECTION 7 OPERATING WELDING GENERATOR CC CV MODELS 7 1 Front Panel Controls For CC CV Models See Section 7 2 215 158 803 602 2 1 9 14 15 10 7 6 4 5 11 8 13 OR 12 3 ...

Page 41: ...ck and TIG welding Read the upper set of numbers at each range for Stick welding and the lower set at each range for TIG welding Use the highest range for MIG welding and for cutting and gouging CAC A For most welding applications use lowest amperagerange possible to help prevent arc outages 10 Voltage AmperageAdjust Control With Process Contactor switch in any Stick or TIG setting use control to ...

Page 42: ...rt arc length conditions to prevent stick ing electrodes The arc drive dig circuit is disabled when switch is in MIG or TIG positions Place switch in Weld Terminals Al ways On Stick position when us ing optional three phase generator see Section 8 2 The engine auto idle option does not work in the Remote On Off Switch Required TIG mode 1 Process Contactor Switch Settings Switch Setting Process Out...

Page 43: ...tch Set Range Control Not Used In Remote Stick Mode Set Remote Process Example Combination Remote Amperage Control TIG Adjust Optional Remote Control Set V A Adjust Switch Set Range Set Control Set Remote Process 1 In Example Process Stick Using Remote On Off Range 115 to 320 A DC Min 115 A DC Max 320 A DC Max 320 A DC Min 115 A DC In Example Process TIG Using Remote On Off Range 35 to 250 A DC Pe...

Page 44: ... button to verify GFCI is working properly 3 Supplementary Protector CB1 4 Supplementary Protector CB2 CB1 protects RC1 and the genera tor winding from overload If CB1 opens RC1 and GFCI1 do not work Place switch in On position to reset CB2 protects GFCI1 from overload If CB2 opens GFCI1 does not work Press button to reset If a supplementary protector continues to open contact Factory Authorized S...

Page 45: ...rcuit Grounding Lead 7 Lead 90 Neutral 8 Isolated Neutral Terminal 9 Jumper Lead 42 10 Grounding Terminal Jumper 42 is connected to lead 90 at factory Jumper 42 may be discon nected from neutral to meet applica ble electrical codes Lead 42 connects to front panel Ground stud 11 User Supplied Leads 12 Supplementary Protector CB7 User Terminals Connect user supplied leads to ter minals on CB7 and to...

Page 46: ...est button to verify GFCI is working properly 5 Supplementary Protector CB2 6 Supplementary Protector CB3 CB2 protects GFCI1 from overload If CB2 opens GFCI1 does not work Press button to reset CB3 protects RC1 from overload If CB3 opens RC1 does not work Press button to reset If a supplementary protector continues to open contact Factory Authorized Service Agent Generator power is not af fected b...

Page 47: ...OM 4421 Page 41 SECTION 9 MAINTENANCE TROUBLESHOOTING 9 1 Maintenance Label ...

Page 48: ... Section 5 7 9 7 Fuel Water Separator Fuel Level Oil Level Oil Fuel Spills Coolant Level Every 50 Hours Weld Terminals Every 100 Hours Section 9 4 Battery Terminals Air Cleaner Hoses Air Cleaner Element Every 250 Hours 1 2 in 13 mm Engine Manual Section 9 5 Unreadable Labels Fan Belt Tension Oil Oil Filter Spark Arrestor Every 500 Hours Weld Cables Every 1000 Hours OR SLUDGE FUEL Section 9 7 9 3 a...

Page 49: ... disconnect leads at brush hold er cap Remove brushes Replace brushes if damaged or if brush material is at or near minimum length 1 Damaged Brushes New Length 1 1 4 in 32 mm Minimum Length 5 8 in 16 mm Replace Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual ...

Page 50: ...afety element after servic ing the primary element three times Clean or replace primary element if dirty see note above before cleaning Re place primary element if damaged Re place primary element yearly or after six cleanings 1 Housing 2 Safety Element Optional 3 Primary Element 4 Dust Cap 5 Dust Ejector To clean air filter Wipe off cap and housing Remove cap and dump out dust Remove element s Wi...

Page 51: ...ol 1 Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole Start engine and run at idle speed to blow out cleanout hole If nothing blows out of hole briefly cover end of exhaust pipe with fireproof material Stop engine and let cool Reinstall cleanout plug Tools Needed 3 8 in 1 2 ...

Page 52: ...ver it must be at least 1 8 in 3 mm away from the throttle arm when engine is running at idle rpm Unhook rubber boot from the sole noid housing but leave connected to plunger Loosen lock nut Place Engine Con trol Switch in Auto position Turn throttle rod and plunger until engine runs at idle speed Tighten lock nut Hook rubber boot back onto sole noid housing Be sure solenoid plunger pulls all the ...

Page 53: ...flows To replace primary fuel filter Turn filter counterclockwise Re move filter Fill new filter with fresh fuel Apply thin coat of fuel to gasket on new fil ter Install new filter and turn clock wise Bleed air from fuel system ac cording to engine manual Inspect fuel lines and replace if cracked or worn To replace secondary fuel filter See engine manual To drain sludge from fuel tank Beware of fi...

Page 54: ...olt output to field current regulator board PC1 CC CV models only If CB5 opens weld out put and 24 volt output to RC14 stops On units with optional three phase genera tor generator power output at receptacle RC5 also stops if CB5 opens CB6 protects the 115 volt ac output to re mote receptacle RC14 CC CV models only If CB6 opens 115 volt output to RC14 stops CB10 protects the engine battery circuit...

Page 55: ...orized Service Agent check brushes and slip rings High weld output Check position of Ampere Range switch and Voltage Amperage Adjust control Check engine speed and have engine manufacturer s factory authorized service agent adjust if neces sary See Section 9 6 for idle speed adjustment Have Factory Authorized Service Agent check OCV control circuit Low weld output Check engine speed and have engin...

Page 56: ...e is clean and tight Use dry properly stored electrodes Remove excessive coils from weld cables Have Factory Authorized Service Agent check brushes and slip rings High weld output Check position of Ampere Range switch and Voltage Amperage Adjust control Check engine speed and have engine manufacturer s factory authorized service agent adjust if nec essary See Section 9 6 for idle speed adjustment ...

Page 57: ...r ac re ceptacles Check engine speed and have engine manufacturer s factory authorized service agent adjust if neces sary See Section 9 6 for idle speed adjustment Have Factory Authorized Service Agent adjust generator power field current resistor R3 Low output at generator power ac recep tacles Check engine speed and have engine manufacturer s factory authorized service agent adjust if neces sary...

Page 58: ... off cold surface Use fuel formulated for cold weather diesel fuel can gel in cold weather Contact local fuel supplier for fuel information Use correct grade oil for cold weather see Section 9 1 Engine suddenly stops Check oil and coolant levels Automatic shutdown system stops engine if oil pressure is too low or coolant temperatureis too high see Section 5 7 Automatic shutdown system is inhibited...

Page 59: ...OM 4421 Page 53 Notes Welding Symbols Ref AWS ANSI A2 4 ...

Page 60: ...OM 4421 Page 54 SECTION 10 ELECTRICAL DIAGRAMS Figure 10 1 Circuit Diagram For CC Welding Generator ...

Page 61: ...OM 4421 Page 55 223 522 B ...

Page 62: ...OM 4421 Page 56 Figure 10 2 Circuit Diagram For CC CV Welding Generator ...

Page 63: ...OM 4421 Page 57 223 523 B ...

Page 64: ...ngs seat faster if engine runs at weld power rpm and the welding generator is kept loaded during run in 2 Engine Exhaust Pipe Wetstacking is unburned fuel and oil in the exhaust pipe and occurs during run in if the engine is run too long at light load or idle rpm If exhaust pipe is coated with a wet black tar like substance dry the engine using one of the following run in procedures See the engine...

Page 65: ...nt of generator see name plate rating label or the specifi cations section in this manual Check generator and load bank meters after first five minutes then every fifteen minutes to be sure generator is loaded properly NOTICE Check oil level frequent ly during run in add oil if needed It is recommended to run the weld ing generator for two hours mini mum and up to four hours under load Place A V c...

Page 66: ... voltage and current of the generator see nameplate rating label or the specifications section in this manual Check generator and meters after first five minutes then every fifteen minutes to be sure generator is loaded properly NOTICE Check oil level frequent ly during run in add oil if needed It is recommended to run the weld ing generator for two hours mini mum and up to four hours under load P...

Page 67: ...ectric shock and static electricity hazards Also see AWS Safety Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Generators 1 EquipmentGrounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insulated copper wire Electrically bond generator frame to vehic...

Page 68: ...e load and requires a constant amount of power 2 Non Resistive Load Equipment with a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when running see Section 12 8 3 Rating Data Rating shows volts and amperes or watts required to run equipment Amperes x Volts Watts Example 1 If a drill uses 4 5 am peres at 115 volts calculate its run nin...

Page 69: ... Home Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 Milker Vacuum Pump 2 HP 10500 2800 FARM DUTY MOTORS 1 3 HP 1720 720 Std e g Conveyors 1 2 HP 2575 975 Feed Augers Air 3 4 HP 4500 1400 Compressors 1 HP 6100 1600 1 1 2 HP 8200 2200 2 HP 10550 2850 3 H...

Page 70: ...HP 6000 1500 1 1 2 HP 8200 2200 2 HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1 3 HP 2100 700 Elec Hedge Trimmer 18 in 400 400 Flood Lights HID 125 100 Metal Halide 313 250 Mercury 1000 Sodium 1400 Vapor 1250 1000 Submersible Pump 400 gph 600 200 Centrifugal Pump 900 gph 900 500 F...

Page 71: ... must be at least twice the motor s running amperage kVA HP x HP x 1000 Volts Starting Amperage Example Calculate starting amper age required for a 230 V 1 4 HP mo tor with a motor start code of M Volts 230 HP 1 4 kVA HP 11 2 11 2 x 1 4 x 1000 230 12 2A Starting the motor requires 12 2 amperes VOLTS AMPS HP 230 2 5 1 4 Hz PHASE CODE 60 1 M AC MOTOR 1 2 3 4 12 9 How Much Power Can Generator Supply ...

Page 72: ... to electric utility when service is re stored Install correct switch customer supplied Switch rating must be same as or greater than the branch overcurrent protection 3 Fused Disconnect Switch Install correct switch customer supplied if required by electrical code 4 Welding Generator Output Generator output voltage and wir ing must be consistent with regular utility system voltage and wiring Conn...

Page 73: ...0 15 40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 2 voltage drop Cord Lengths for 240 Volt Loads If unit does not have GFCI receptacles use GFCI protected extension cord Maximum Allowable Cord Length in ft m for Conductor Size AWG Current Amperes Load Watts 4 6 8 10 12 14 5 1200 700 213 450 137 225 84 200 61 7 1680 800 244 500 152 300 91 20...

Page 74: ...0 P Models Only 1 2 3 4 5 6 7 8 9 10 11 13 14 15 12 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 106 107 108 109 110 111 112 113 114 Fig 13 2 OR 13 3 115 116 CC ONLY 117 118 CV 119 CV 120 121 122 123 124 125 Fig 13 4 OR 13 5 126 Fig 13 7 127 Figure 13 1 Main Assembly Export Model Shown ...

Page 75: ... 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 85 84 86 87 88 89 90 91 93 Fig 13 6 95 96 97 98 99 100 101 102 103 104 105 94 128 ...

Page 76: ...52 EXTRUSION rubber clamp bulb order by ft 3ft 19 189 708 FIREWALL top 1 20 191 307 COVER plate 1 21 189 763 BRACKET mtg air cleaner 1 22 189 618 HOSE air cleaner 1 23 198 457 TUBE air intake 1 24 173 036 HOSE elbow air cleaner 1 010 863 CLAMP hose 1 125 3 000 clp dia 4 25 189 764 AIR CLEANER intake 1 192 938 FILTER air element primary 1 192 939 FILTER air element safety 1 26 189 464 SEAL weather ...

Page 77: ... 53 190 207 CABLE bat pos 45 in lg No 1 awg w clamp and 406rng 1 54 203 430 BRACKET battery holddown 1 55 190 897 BATTERY stor 12V 650crk 110rsv gp 24 1 56 168 385 LABEL warning battery explosion can blind 1 57 225 120 LABEL warning moving parts can cause injury 1 58 201 183 COVER battery access 1 58 202 639 COVER battery access ss 1 59 201 006 BOLT j stl 312 18 x 8 500 pld 2 60 215 006 GUARD fan ...

Page 78: ...87 TANK fuel consisting of 1 95 189 909 FITTING stand pipe hose 250 x 9 260 lg 90deg zinc 1 96 095 636 HOSE sae 187 id x 410 od x 30 000 order by ft 1 97 201 025 CAP fuel fitting 1 98 189 913 FITTING stl barbed elbow zinc pld 1 99 190 142 SENDER fuel gauge 9 7500 deep tank 1 100 189 910 FITTING stand pipe hose 3125 x 9 260 lg 90deg zinc 1 101 181 572 BUSHING tank fuel 1 102 189 908 VALVE drain fue...

Page 79: ... 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 32 215 052 KIT label includes safety informational labels CC models 1 215 212 KIT label includes safety informational labels CC CV models 1 216 989 KIT label includes safety informational labels CC export models 1 216 988 KIT label includes s...

Page 80: ... ohm faston te 1 7 201 078 CONTROL BOX rh 1 8 CR3 090 104 RELAY encl 12VDC SPST 30A 15VDC spin flange mtg 1 9 CR8 197 325 RELAY encl 12vdc spst 70a 4pin flange mtg 1 10 CR1 090 104 RELAY Encl 12vdc Spst 30a 15vdc 5pin Flange Mtg 1 11 CR6 090104 RELAY encl 12vdc spst 30a 15vdc 5pin flange mtg 1 12 D10 C10 D11 C11 189 701 DIODE CAPACITOR BOARD 2 13 CB14 230 635 CIRCUIT BREAKER auto reset 12vdc 8 amp...

Page 81: ...0VDC 1 22 177 136 CLAMP capacitor 1 375dia 1 23 D1 C1 189 701 DIODE CAPACITOR BOARD 1 24 CB11 12 13 139 266 SUPPLEMENTARY PROTECTOR man reset 1p 15a 250vac 3 Optional Recommended Spare Parts 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 ...

Page 82: ... 70a 4pin flange mtg 1 7 CR1 090 104 RELAY Encl 12vdc Spst 30a 15vdc 5pin Flange Mtg 1 8 CR6 090 104 RELAY encl 12vdc spst 30a 15vdc 5pin flange mtg 1 9 D10 C10 D11 C11 189 701 DIODE CAPACITOR BOARD 2 10 CB14 230 635 CIRCUIT BREAKER auto reset 12vdc 8 amp 1 11 CB10 190 374 CIRCUIT BREAKER auto reset 12VDC 40A 1 12 CR5 223 710 RELAY encl 12VDC dpst no 25A 6pin flange 1 13 201 079 COVER control box ...

Page 83: ... CAPACITOR BOARD 1 22 TD1 214 928 TIMER delay on make break open 30 sec 12vdc 1 23 CB11 12 13 139 266 SUPPLEMENTARY PROTECTOR man reset 1p 15a 250vac 3 Optional Recommended Spare Parts 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 ...

Page 84: ...rdware is common and not available unless listed 803 649 1 2 3 4 5 6 7 8 9 11 10 12 13 14 15 16 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 34 33 35 36 37 38 39 40 41 42 17 Figure 13 4 Panel Front w Components CC Models ...

Page 85: ...6 30R 1 15 RC1 176 355 RECEPTACLE str 2p3w 16a 220v flange mtg export models only 1 CB3 139 266 SUPPLEMENTARY PROTECTOR man reset 1p 15a 250vac 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 ...

Page 86: ...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 Hardware is common and not available unless liste...

Page 87: ...d 2P3W 30A 250V L6 30R 1 17 RC1 176 355 RECEPTACLE str 2p3w 16a 220v flange mtg export models only 1 CB3 139 266 SUPPLEMENTARY PROTECTOR man reset 1p 15a 250vac export models only 1 18 RC5 182 954 RCPT str 3P4W 50A 125 250V 1 19 025 248 STAND OFF insul 250 20 x 1 2 1 20 604 102 CONNECTOR clamp cable 1 000 1 21 197 527 GUARD circuit breaker 1 22 197 363 TERMINAL ring tng screw clamp 3 23 CB7 214 92...

Page 88: ... Coolant Temp 0 300 Deg F Electric 1 197 798 SENDER Coolant Temp 300 Deg F M16 X 1 5 1 52 217 083 GAUGE Pressure Oil 0 100 Psi Electric 1 193 230 SENDER Pressure Oil 0 100 Psi 1 53 164 873 METER amp ac dc 0 500 0 600 dc scale 2 5 in 1 54 164 874 METER volt ac dc 0 100 scale 2 5 in 1 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...

Page 89: ...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 212 996 ROTOR Generator Segmented Assy Includes 1 12 210 824 ROTOR Generator Includes 1 13 024 617 RING Rtng Ext 1 375 Shaft X 050 Thk 1 14 053 390 BEARING Ball Rdl Sgl Row 1 370 X 2 83...

Page 90: ... SCREW 312 18 x 2 25hexhd pln gr 5pld 4 29 602 211 WASHER lock 318 ID x 0 586 6 30 139 341 WASHER exciter 4 31 190 823 BRUSH contact 3 32 208 469 CLIP spring 3 33 189 142 BRUSHHOLDER ASSEMBLY gen 1 34 602 242 WASHER flat 375IDx0 875odx 083t stl pld 2 35 602 211 WASHER Lock 318idx0 586odx 078t Stl Pld Split 312 2 36 604 534 SCREW 312 18x1 25 hex hd pln gr5 pld 2 When ordering a component originally...

Page 91: ...ectifier AC 1 2 188 517 BUS BAR connection board 3 3 188 135 ENCLOSURE rectifier 2 4 134 201 STAND OFF support 3 5 PC3 215 755 CIRCUIT CARD ASSEMBLY protection 1 6 188 136 INSULATOR heat sink 8 7 188 493 HEAT SINK rectifier al 2 8 D3 D5 D7 208 334 DIODE rect 275A 300V SP 3 9 D2 D4 D6 208 335 DIODE rect 275A 300V RP 3 To maintain the factory original performance of your equipment use only Manufactu...

Page 92: ...0vac 3 SR1 035704 Rectifier Integ Bridge 40 Amp 800v 1 148850 Socket Relay 5 Pin 1 RC4 047483 Conn Rect Univ 084 15p S 3row Rcpt Cable Panel 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 150316 Conn Rect Univ 039 6p S 3row Plug Cable Lkg 6 S6 193234 Switch Rotary 6 Posn Gold Contacts 1 021467 Switch Tgl Spst 3a ...

Page 93: ...ange Mtg 1 192558 Harness range switch includes 1 RC6 148389 Conn Rect Univ 084 4p S 1row Rcpt Cable Panel Lkg 1 201109 Harness receptacle auxiliary power includes 1 RC1 147632 Rcpt Tw Lk Grd 2p3w 30a 250v L6 30r 1 GFCI1 151981 Rcpt Str Dx Grd 2p3w 15 20a 125v 5 20r Gfi 1 CB2 093996 Supplementary Pro Man Reset 1p 20a 250vac Frict 1 201053 Harness receptacle auxiliary power export models includes 1...

Page 94: ......

Page 95: ...Induction Heating Coils and Blankets Cables and Non Electronic Controls APT SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exceptio...

Page 96: ...d retain with your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering...

Search results

Summary of Contents for 500 X

Reviews:

Related manuals for 500 X

Brands by name

Popular brands

Miller Electric 500 X, Owner'S Manual

Search results

Summary of Contents for 500 X

Reviews:

Related manuals for 500 X

Brands by name

Popular brands