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Big Blue 500DX OM-129 647W July 1999 Processes Description Air Carbon Arc (CAC-A) Cutting and Gouging Stick (SMAW ) W elding MIG (GMAW) W elding Flux Cored (FCA W ) W elding Engine Driven Welding Generator With Optional Equipment: Visit our website at www.MillerWelds.com ...
Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets. T o locate your nearest distributor call 1-800-4-A-Miller . Thank you and congratulations on choosing Miller ...
The following terms are used interchangeably throughout this manual: Stick = SMAW MIG = GMAW CALIFORNIA Proposition 65 W arning Diesel e ngine exhaust and some of its constituents are known to the State of California to cause cancer , birth defects, and other reproductive harm. T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ...
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OM-129 647 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING rom _nd_1 1/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Marks a special safety message. Means “Note”; not safety related. This group of symbols means W arning! ...
OM-129 647 Page 2 Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure th e ...
OM-129 647 Page 3 MOVING P ARTS can cause injury . Keep away from fans, belts, and rotors. Keep all doors, panels, covers, and guards closed and securely in place. Stop engine before installing or connecting unit. Have only qualified people remove guards or covers for maint- enance and troubleshooting as necessary . T o prevent ...
OM-129 647 Page 4 H.F . RADIA TION can cause interference. High-frequency (H.F .) can interfere with radio navigation, safety services, computers, and communications equipment. Have only qualified persons familiar with electronic equipment perform this installation. The user is responsible for having a qualified electrician promptly cor ...
OM-129 647 Page 5 SECTION 1 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION rom _nd_fre 5/97 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Identifie un message de sécurité particulier . ? ...
OM-129 647 Page 6 Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact ...
OM-129 647 Page 7 DES ORGANES MOBILES peuvent provoquer des blessures. Ne pas approcher les mains des ventilateurs, cour- roies et autres pièces en mouvement. Mainten ir fermés et fixement en place les portes, panneaux, recouvrements et di spositifs de protection. Arrêter le moteur avant d’installer ou brancher l’appareil. De ...
OM-129 647 Page 8 LE RA YONNEMENT HAUTE FRÉ- QUENCE (H.F .) risque de provoquer des interférences. Le rayonnement haute fréquence (H.F .) peut provoquer des interférences avec les équipements de radio − navigation et de communication, les services de sécurité et les ordinateurs. Demander seulement à des personnes qualifiées famil ...
OM-129 647 Page 9 SECTION 2 − DEFINITIONS 2-1. Symbols And Definitions Stop Engine Start Engine Ether Starting Aid Engine Do Not Switch While Welding Battery (Engine) Circuit Breaker Engine Oil Check Injectors/ Pump Check V alve Clearance Fuel Protective Earth (Ground) Positive Negative Certified/Trained Mechanic Welding Arc A Amperes V V olts Pa ...
OM-129 647 Page 10 3-2. Dimensions, Weights, And Operating Angles Dimensions Height 47-5/8 in (1210 mm) Width 31-1/4 in (794 mm) L Depth 60-1/2 in (1537 mm) Engine End Do not exceed operating angles while runnin g or en g ine dama g e will occur . A 59-1/8 in (1502 mm) running or engine damage will occur . Do not move or operate unit wh ...
OM-129 647 Page 1 1 3-4. Duty Cycle And Overheating rduty1 5/95 − SB-089 697-D Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. Exceeding duty cycle can damage unit and void warranty . 60% Duty Cycle At 500 Amperes 6 Minutes Welding 4 Minutes Resting 3-5. AC Auxiliary Power rsb3.1 2/92 − Ref. SB-0 ...
OM-129 647 Page 12 3-6. V olt-Ampere Curves ST -183 880-A / ST -186 173-A The volt-ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator . Curves of all other settings fall between the curves shown. A. CC/DC (Standard) B. CV/DC (Models With CV Option) ...
OM-129 647 Page 13 3-7. Optional AC Power Plant Curves rsb13.1 12/94 - SB-005 185-B / SB-159 101-A The ac power curves show the auxiliary power in amperes avail- able at the single-phase 120/240 volt or three-phase 240 volt terminals. A. 7.5 KV A/KW Single-Phase Auxiliary Power Plant (No Weld Load) B. 10 KV A/KW Three-Phase Auxiliary Power Plant (N ...
OM-129 647 Page 14 SECTION 4 − INST ALLA TION 4-1. Installing Welding Generator install1 3/96 − Ref. ST -800 652 / Ref. ST -800 477-A / ST -158 936-A / S-0854 1 2 Electrically bond generator frame to vehicle frame by metal-to-metal contact. GND/PE 3 4 1 Generator Base 2 Metal V ehicle Frame 3 Equipment Grounding T erminal 4 Grounding Cable Use ...
OM-129 647 Page 15 4-3. Activating The Dry Charge Battery drybatt1 2/96 − S-0886 Remove battery from unit. 1 Eye Protection − Safety Glasses Or Face Shield 2 Rubber Gloves 3 V ent Caps 4 Sulfuric Acid Electrolyte (1.265 Specific Gravity) 5 Well Fill each cell with electrolyte to bottom of well (maximum). Do not overfill battery cells. Wait ...
OM-129 647 Page 16 4-4. Connecting The Battery 1/2 in − + Connect Negative ( − ) Cable Last. ST -153 654-B / ST -180 933-B / S-0756-C T ools Needed: 4-5. Engine Prestart Checks Full 1/2 in (13 mm) Full Ref. ST -158 633-C V alve Open Diesel Check all fluids daily . Engine must be cold and on a level surface. Follow run-in procedure in engine ...
OM-129 647 Page 17 4-6. Connecting T o Weld Output T erminals ST -158 700 Open left side door . 1 Bracket Route cables through bracket. 2 Positive (+) Weld Output T erminal 3 Negative ( − ) Weld Output T erminal For Stick welding Direct Current Electrode Positive (DCEP), con- nect work cable to − terminal and electrode holder cable to + termina ...
OM-129 647 Page 18 ether1 7/96 − ST -153 382-A / ST -180 933-B Stop engine. Improper handling or expo- sure to ether can harm your health. Follow manufactur- er’s safety instructions on cylinder . Do not use Ether Starting Aid while engine is running. Open side door(s). 1 Ether Cylinder 2 Nozzle Remove cover and clean cylinder nozzl ...
OM-129 647 Page 19 4-10. Remote 14 Receptacle RC3 Information (Optional) Socket* Socket Information AJ B K I A 24 volts ac. Protected by circuit breaker CB4. B I C L NH D M G B Contact closure to A completes 24 volts ac contactor control circuit. D M G E F I 1 15 volts ac. Protected by circuit breaker CB3. J Contact closure to I completes 1 15 volt ...
OM-129 647 Page 20 SECTION 5 − OPERA TING THE WELDING GENERA T OR 5-1. Standard Controls (See Section 5-2) 1 10 2 3 11 9 8 7 6 5 4 12 ST -158 630-B / Ref. ST -158 631 / ST -180 933-B ...
OM-129 647 Page 21 5-2. Description Of Standard Controls (See Section 5-1) This unit has a max OCV control circuit that resets the Amperage/Voltage Con- trol to maximum when the arc breaks. When an arc is struck, weld output con- trol returns to the front panel or remote control setting. The Amperage/voltage Control adjusts amperage only when w ...
OM-129 647 Page 22 5-3. Controls For Models With CV Option (See Section 5-4) 1 9 2 10 8 7 6 5 4 3 11 ST -158 630-B / Ref. ST -158 631 / Ref. ST-185 762-B / S-185 440 12 13 14 ...
OM-129 647 Page 23 5-4. Description Of Controls For Models With CV Option (See Section 5-3) This unit has a max OCV control circuit that resets Amperage/Voltage Control R1 to maximum when the arc breaks. When an arc is struck, weld output con- trol returns to the R1 front panel or com- bination front panel/remote control setting. The Amperage/V ...
OM-129 647 Page 24 SECTION 6 − OPERA TING AUXILIAR Y EQUIPMENT 6-1. 120 V olt And 240 V olt Duplex Receptacles Ref. ST -180 933-B 3 2 If unit does not have GFCI receptacles, use GFCI-pro- tected extension cord. 1 120 V 15 A AC Receptacle RC2 2 240 V 15 A AC Receptacle RC1 Receptacles supply 60 Hz single- phase power at weld/power speed. 3 Cir ...
OM-129 647 Page 25 6-2. Optional Auxiliary Power Receptacles Ref. ST -180 933-B / Ref. ST-182 266 Auxiliary power is not affected by weld output. If a circuit breaker continues to open, contact Factory Autho- rized Service Agent. GFCI Receptacle Option 1 120 V 15 A AC GFCI Receptacle GFCI1 Auxiliary power output and circuit breaker protection i ...
OM-129 647 Page 26 6-3. Connecting Optional Auxiliary Power Plant Ref. S-180 187-A Stop engine. Power and weld outputs are live at the same time. Discon- nect or insulate unused cables. Have qualified person install according to circuit diagram and Auxiliary Power Guidelines Booklet (M176 712). Remove junction box cover . 1 Lead 93 2 Lead 9 ...
OM-129 647 Page 27 SECTION 7 − MAINTENANCE & TROUBLESHOOTING 7-1. Routine Maintenance Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period. NOTE Recycle engine fluids. Stop engine before maintaining. See also Engine Manual and Maintenance Label. Service engine more often if us ...
OM-129 647 Page 28 7-2. Maintenance Label DEUTZ F3L912 DIESEL ENGINE Check Recommended Oil API Service Classification CD/CE (or better) . . . Oil Change & Filter dirty conditions 100 hours or less . . . . . . . . . . . . normal conditions 125-150 hours . . . . . . . Oil Filter MILLER 064 677, Deutz 1 17-4418, Fram PH6923 . . . . . . . . . . . . ...
OM-129 647 Page 29 7-3. Servicing Air Cleaner aircleaner1 4/96 − ST-153 929-B / ST -153 585 / Ref. ST -180 933-B / Ref. S-0698-B Stop engine. Do not run engine without air cleaner or with dirty element. Clean or replace element if dirty or damaged. Replace element yearly or after six cleanings. 1 Dust Cap 2 Baffle 3 Element 4 Plastic Fins ...
OM-129 647 Page 30 7-4. Servicing Fuel And Lubrication Systems Ref. ST -158 633-C / Ref. ST-180 933-B Stop engine and let cool. 1 Oil Filter 2 Oil Drain Plug 3 Oil Drain Hose (Optional) 4 Oil Fill Cap 5 Primary Fuel Filter (Fuel/ Water Separator) 6 Petcock 7 Secondary Fuel Filter 8 Fuel Shutoff V alve 9 Fuel Line 10 Sludge Drain Plug T o change ...
OM-129 647 Page 31 7-5. Adjusting Engine Speed ST -045 768-B Engine speed is factory set and should not require adjustment. Af- ter tuning engine, check engine speed with tachometer . See table for proper no load speed. If neces- sary , adjust speed as follows: 1 Plastic Cap 2 High Speed Stop Screw 3 Lock Nut Remove plastic cap from screw . Loosen ...
OM-129 647 Page 32 7-7. Checking And Replacing Alternator Belt ST -158 632 / Ref. ST -180 933-B Stop engine. T o check belt tension: Remove rear panel. 1 Alternator V -Belt 2 Crank Pulley 3 Alternator Pulley Place straight edge along top of pulleys. Pull down belt as far as it will go, then measure distance from belt to straight edge. If measur ...
OM-129 647 Page 33 7-8. Resetting Fan Belt Safety Shutdown ST -158 715 / Ref. ST -158 632 / Ref. ST-180 933-B Stop engine. 1 Cooling Fan V -Belt See engine manual to replace or tighten belt. If belt breaks or becomes loose, safety shutdown stops engine. Correct problem, then reset safety shutdown as follows: 2 Rod 3 Stop 4 Bracket 5 Handle Pull ...
OM-129 647 Page 34 7-9. Inspecting And Cleaning Optional Spark Arrestor Muffler ST -800 633-B / Ref. ST -180 933-B Stop engine and let cool. 1 Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole. 3 Exhaust Pipe Start engine and run at idle speed to blow out cleanout hole. If nothing blows out of hole, b ...
OM-129 647 Page 35 7-1 1. T roubleshooting A. Welding T rouble Remedy No weld output. Check position of Ampere Range switch. Check position of optional polarity switch. Disconnect equipment from auxiliary power receptacles during start-up. Place A/V Control switch in Panel position, or place switch in Remote position and connect remote con- trol to ...
OM-129 647 Page 36 T rouble Remedy Repair or replace remote control device. Have Factory Authorized Service Agent check optional CV regulator board PC2. B. Auxiliary Power T rouble Remedy No output at auxiliary power receptacles. Reset receptacle circuit breakers. Have Factory Authorized Service Agent check brushes and slip rings, and optional fiel ...
OM-129 647 Page 37 T rouble Remedy Periodically recharge battery (approximately every 3 months). Engine uses oil during run-in period; wetstacking occurs. Dry engine (see Section 9). ...
OM-129 647 Page 38 Notes ...
OM-129 647 Page 39 SECTION 8 − ELECTRICAL DIAGRAMS 180 941-A Figure 8-1. Circuit Diagram For Welding Generator (Standard Models) ...
OM-129 647 Page 40 Figure 8-2. Circuit Diagram For Welding Generator (Models With CV Option) ...
OM-129 647 Page 41 184 954-C ...
OM-129 647 Page 42 SECTION 9 − RUN-IN PROCEDURE run_in1 6/96 9-1. W etstacking 1 Welding Generator Run diesel engines near rated output during run-in period to prop- erly seat piston rings and prevent wetstacking. See nameplate or rating label to find rated output. Do not idle engine longer than necessary . Piston rings seat faster if engine ...
OM-129 647 Page 43 9-2. Run-In Procedure Using Load Bank S-0683 Stop engine. Do not touch hot exhaust pipe, engine parts, or load bank/grid. Keep exhaust and pipe away from flammables. 1 Load Bank Turn all load bank switches Off. If needed, connect load bank to 1 15 volts ac wall receptacle or genera- tor auxiliary power receptacle. 2 W ...
OM-129 647 Page 44 9-3. Run-In Procedure Using Resistance Grid S-0684 Stop engine. Do not touch hot exhaust pipe, engine parts, or load bank/grid. Keep exhaust and pipe away from flammables. 1 Resistance Grid Use grid sized for generator rated output. Turn Of f grid. 2 Welding Generator Place A/V range switch in maxi- mum position, A/V ...
OM-129 647 Page 45 SECTION 10 − AUXILIAR Y POWER GUIDELINES 10-1. Selecting Equipment aux_pwr 2/99 − Ref. ST -159 730 / ST-800 577 1 Auxiliary Power Receptacles − Neutral Bonded T o Frame 2 3-Prong Plug From Case Grounded Equipment 3 2-Prong Plug From Double Insulated Equipment OR 2 Be sure equipment has this symbol and/or wording. 3 1 10-2. ...
OM-129 647 Page 46 10-3. Grounding When Supplying Building Systems ST -800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 AWG or larger insulated copper wire. 3 Ground Device Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. GND/PE 1 2 Us e ground device as stated in elec ...
OM-129 647 Page 47 10-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 2100 700 1/2 HP 3175 875 Capacitor Start-Induction Run 1/3 HP 2020 720 1/2 HP 3075 975 3/4 HP 4500 1400 1 HP 6100 1600 1-1/2 HP 8200 2200 2 HP 10550 285 ...
OM-129 647 Page 48 10-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running W atts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/2 in 500 500 7-1/4 in 900 900 8-1/4 in 1400 1400 T able Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in 2500 1 100 Bench Grinder 6 in 1720 720 8 i ...
OM-129 647 Page 49 10-8. Power Required T o Start Motor S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor V oltage T o find starting amperage: Step 1: Find code and use table to find kV A/HP . If code is not listed, multiply running amperage by six to find starting amperage. Step 2 : Find Motor HP and V olts. Step 3: Determine startin ...
OM-129 647 Page 50 10-10. T ypical Connections T o Supply Standby Power S-0405-A 1 Power Company Service Meter 2 Main and Branch Overcurrent Protection 3 Double-Pole, Double-Throw Transfer Switch Obtain and install correct switch. Switch rating must be same as or greater than the branch overcur- rent protection. 4 Circuit Breakers or Fused Disconne ...
OM-129 647 Page 51 10-1 1. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 V olt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (A WG)* Current (Amperes) Load (Watts) 4 6 8 10 12 14 5 600 350 (106) 225 (68) 137 (42) 100 (30) 7 ...
OM-129 647 Page 52 SECTION 1 1 − P ARTS LIST 1 3 2 4 5 6 7 6 8 9 10 6 7 11 12 13 14 15 16 17 18 19 20 21 22 23 6 7 6 7 10 24 25 26 70 69 66 65 64 74 75 76 77 78 79 80 81 82 83 84 85 86 Fig 1 1-5 87 Fig 1 1 − 6 & Fig 1 1-7 88 89 90 91 92 93 Fig 1 1-2 96 97 98 99 100 101 94 95 Hardware is common and not available unless listed. Figure 1 1 ...
OM-129 647 Page 53 ST -048 455-AA 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 46 47 48 49 50 45 51 52 53 55 54 56 57 59 60 61 62 63 64 65 66 67 68 Fig 1 1-3 69 70 71 72 73 58 102 ...
OM-129 647 Page 54 Figure 1 1-1. Main Assembly Description Quantity Part No. Dia. Mkgs. Item No. 1 134 771 PLUG, protective .640sq 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 184 675 T ANK, fuel 23gal (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
OM-129 647 Page 55 Figure 1 1-1. Main Assembly (Continued) Description Quantity Part No. Dia. Mkgs. Item No. 53 SPRING, (included w/engine − see engine parts list) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 181 634 ENGINE, diesel electric (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . ...
OM-129 647 Page 56 1 3 4 7 9 10 11 9 14 16 17 18 19 20 21 22 ST -048 457-N 2 Fig 1 1-4 5 6 8 12 13 15 Hardware is common and not available unless listed. Figure 1 1-2. Panel, Front w/Components (CC Model Illustrated) ...
OM-129 647 Page 57 Figure 1 1-2. Panel, Front w/Components (Fig 1 1-1 Item 94) Description Quantity Part No. Dia. Mkgs. Item No. 1 154 292 P ANEL, front upper 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 S3 171 878 SWITCH, range (Fig 1 1-4) 1 . . . . . . . . . . ...
OM-129 647 Page 58 Figure 1 1-3. Generator SD-048 456-E Hardware is common and not available unless listed. 1 2 4 5 6 4 3 7 8 9 11 12 13 10 14 16 15 18 19 20 17 14 21 23 22 24 26 27 28 29 25 ...
OM-129 647 Page 59 FIgure 1 1-3. Generator (Fig 1 1-1 Item 68) Description Quantity Part No. Dia. Mkgs. Item No. 1 106 426 INSULA TOR 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 106 440 BUS BAR, rectifier 2 . . . . . . . . . . . . . . . . . . . . . . ...
OM-129 647 Page 60 Figure 1 1-4. Switch, Range (Fig 1 1-2 Item 2) Description Quantity Part No. 171 878 Item No. Dia. Mkgs. 1 1 14 235 BRACKET , mtg switch range (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 010 671 SPRING, ext .312 OD x .042 wire x 1.875 1 . . . . . . . . . . . . . . . . ...
OM-129 647 Page 61 Figure 1 1-5. Control Box CC/CV (Figure 1 1-1 Item 86) (Optional) Description Quantity Part No. Item No. Dia. Mkgs. 1 605 321 NUT , .468-32 brs blk 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 S6 01 1 61 1 SWITCH, tgl DPDT 15A 125V 1 . . . . . . ...
OM-129 647 Page 62 Figure 1 1-6. Panel, Mtg Components (CC/CV Model) (Figure 1 1-1 Item 87) Description Quantity Part No. Item No. Dia. Mkgs. 1 R2 185 748 RESISTOR BOARD 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SR1,4 035 704 RECTIFIER, integ 40A 800V 2 . . . . . . . ...
OM-129 647 Page 63 Figure 1 1-7. Panel, Mtg Components (CC Model) (Figure 1 1-1 Item 87) Description Quantity Part No. Item No. Dia. Mkgs. 1 170 672 P ANEL, mtg components 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 R6 030 844 RESISTOR, WW fxd 25W 250 ohm 1 . . . . . . . ...
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PRINTED IN USA © 1999 Miller Electric Mfg. Co. 7/99 Miller Elect ric Mfg. Co. An Illinois T ool W orks Compan y 1635 West S pencer S treet Applet on, WI 5 4914 US A International He adquarters − USA USA Phone: 920-735-4505 Aut o-At tended USA & Canada F AX : 920-735-4134 Int ernati onal F A X: 920-735-4125 European Headqua rters − United K ...
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