Miller Electric Big Blue 500 PT Owner's Manual

ProcessesDescriptionTIG (GTAW) WeldingStick (SMAW) WeldingMIG (GMAW) WeldingEngine Driven Welding GeneratorOM-4429 216 138N2008−09Visit our website at

OM-4429 Page 6SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANTUTILISATIONrom_2007−04freSe protéger, ainsi que toute autre personne travaillant sur les

OM-4429 Page 7DES PIÈCES CHAUDES peuventprovoquer des brûlures graves. Ne pas toucher à mains nues les parties chau-des. Prévoir une période de refr

OM-4429 Page 8LES CHAMPS MAGNETIQUES peuventaffecter des implants médicaux. Porteur de simulateur cardiaque ou autre im-plants médicaux, rester à dis

OM-4429 Page 9L’utilisation d’un groupe autonomeà l’intérieur PEUT VOUS TUER ENQUELQUES MINUTES. Les fumées d’un groupe autonome contient dumonoxyde

OM-4429 Page 10LE SURCHAUFFEMENT peut endom-mager le moteur électrique. Arrêter ou déconnecter l’équipement avant dedémarrer ou d’arrêter le moteur.

OM-4429 Page 112-6. Proposition californienne 65 AvertissementsLes équipements de soudage et de coupage produisent desfumées et des gaz qui contiennen

OM-4429 Page 12SECTION 3 − DEFINITIONS3-1. Warning Label Definitions (For Wordless Labels)3/961 Remove unit from shippingcrate. Remove Owner’sManual f

OM-4429 Page 133-2. Symbols And Definitions Some symbols are found only on CE products.Stop EngineFast (Run, Weld/Power)Slow (Idle) Start EngineStart

OM-4429 Page 14SECTION 4 − SPECIFICATIONS4-1. Weld, Power, And Engine SpecificationsWeldingModeWeld OutputRangeRated WeldingOutputMaximumOpen-CircuitV

OM-4429 Page 154-3. Volt-Ampere Curves For CC Models203 412The volt-ampere curve shows theminimum and maximum voltageand amperage output capabilities

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

OM-4429 Page 164-4. Volt-Ampere Curves For CC/CV Models217 811 / 203 415 / 217 810The volt-ampere curves show theminimum and maximum voltageand ampera

OM-4429 Page 174-5. Fuel ConsumptionThe curve shows typical fuel useunder weld or power loads.215 082−AIDLEDC WELD AMPERES AT 100% DUTY CYCLEU.S. GAL.

OM-4429 Page 184-7. AC Generator Power Curve193 018The ac power curve shows the gen-erator power in amperes availableat the 120 and 240 volt receptacl

OM-4429 Page 19SECTION 5 − INSTALLATION! Do not move or operate unitwhere it could tip.! Always securely fasten weld-ing generator onto transportvehic

OM-4429 Page 205-2. Mounting Welding GeneratorTools Needed:9/16 in224Welding Unit In PlaceBolting Unit In Place! Do not weld on base. Weld-ing on base

OM-4429 Page 21! Always ground generatorframe to vehicle frame to pre-vent electric shock and staticelectricity hazards.! Also see AWS Safety &Hea

OM-4429 Page 225-5. Using Lifting EyeLift1 2008−01 804 7121 Lifting Eye2 Nut3 Carriage BoltRaise lifting eye until it snaps inplace. Lower lifting eye

OM-4429 Page 235-7. Activating The Dry Charge Battery (If Applicable)! Always wear a face shield,rubber gloves and protectiveclothing when working on

OM-4429 Page 245-9. Engine Prestart Checks Check all engine fluids daily.Engine must be cold and on a level surface.Unit is shipped with 20W break-in

OM-4429 Page 255-10. Connecting To Weld Output Terminals803 602 / 803 778-BTools Needed:23/4 in1MIG and FCAW WeldingFor MIG and FCAW welding Direct Cu

TABLE OF CONTENTSSECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol U

OM-4429 Page 265-11. Selecting Weld Cable Sizes*Weld Cable Size** and Total Cable (Copper) Length in Weld CircuitNot Exceeding***100 ft (30 m) or Less

OM-4429 Page 275-13. Connecting To Remote 14 Receptacle RC14 On CC/CV ModelsRef. 803 602ORNew! LDR-14 longdistance remote(includes 120 Vreceptacle)Soc

OM-4429 Page 28SECTION 6 − OPERATING WELDING GENERATOR − CC MODELS6-1. Front Panel Controls For CC Models (See Section 6-2)11238 627 / 803 60210217121

OM-4429 Page 296-2. Description Of Front Panel Controls For CC Models (See Section 6-1)Engine Starting Controls1 Starting Aid SwitchUse switch to ener

OM-4429 Page 306-3. Remote Amperage Control On CC Models (Optional)1 Remote Amperage AdjustReceptacle RC13Connect optional remote control toRC13 (see

OM-4429 Page 31NotesWork like a Pro!Pros weld and cutsafely. Read thesafety rules atthe beginningof this manual.

OM-4429 Page 32SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS7-1. Front Panel Controls For CC/CV Models (See Section 7-2)2238 623 / 802 60212O

OM-4429 Page 337-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1)Engine Starting Controls1 Starting Aid SwitchUse switch to e

OM-4429 Page 347-3. Process/Contactor Switch On CC/CV Models1 Process/Contactor Switch! Weld output terminals are ener-gized when Process/Contactorswi

OM-4429 Page 357-4. Remote Voltage/Amperage Control On CC/CV Models (Optional)1 Remote 14 Receptacle RC14Connect optional remote control toRC14 (see S

TABLE OF CONTENTS7-4. Remote Voltage/Amperage Control On CC/CV Models (Optional) 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5. Fuel

OM-4429 Page 367-5. Fuel/Hour Gauge Descriptions

OM-4429 Page 37SECTION 8 − OPERATING AUXILIARY EQUIPMENT8-1. Domestic Auxiliary Power Receptacles191 624-A21 120 V 20 A AC GFCI Receptacle GFCI12 240

OM-4429 Page 388-2. Connecting To Optional Three-Phase Generator (CC/CV Models Only)Ref. 197 399 / 802 332-E / 803 655 Place Process/Contactor switch

OM-4429 Page 398-3. Export Auxiliary Power Receptacles1 120V 15/20A AC Receptacle GFCI1Receptacles supply 60 Hz single-phasepower at weld/power speed.

OM-4429 Page 40SECTION 9 − MAINTENANCE & TROUBLESHOOTING9-1. Maintenance Label

OM-4429 Page 419-2. Routine Maintenance! Stop engine before maintaining. See Engine Manual and Maintenance Labelfor important start-up, service, and

OM-4429 Page 429-3. Servicing Air Cleaner! Stop engine.NOTICE − Do not run engine without aircleaner or with dirty element. Enginedamage caused by usi

OM-4429 Page 439-4. Inspecting And Cleaning Optional Spark Arrestor Muffler803 656 / Ref. 215 158! Stop engine and let cool.1 Spark Arrestor Muffler2

OM-4429 Page 449-6. Servicing Fuel And Lubrication Systems802 490 / Ref. 801 434! Stop engine and let cool.! After servicing, start engineand check fo

OM-4429 Page 459-7. Overload Protection803 605219874! Stop engine. When a supplementary protector,circuit breaker or fuse opens, it usu-ally indicate

OM-4429 Page 1SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USINGrom_2007−04Protect yourself and others from injury — read and follow these precautions

OM-4429 Page 469-8. TroubleshootingA. Welding − CC ModelsTrouble RemedyNo weld output; generator power outputokay at ac receptacles.Check position of

OM-4429 Page 47B. Welding − CC/CV ModelsTrouble RemedyNo weld output; generator power outputokay at ac receptacles.Place Process/Contactor switch in a

OM-4429 Page 48Trouble RemedyCheck and secure connections to Remote 14 receptacle RC14 (see Section 5-13).Repair or replace wire feeder.Low CV weld ou

OM-4429 Page 49Trouble RemedyCheck engine wiring harness plug connections.Have Factory Authorized Service Agent check control relay CR1, diode/capacit

OM-4429 Page 50SECTION 10 − ELECTRICAL DIAGRAMSFigure 10-1. Circuit Diagram For CC Welding Generator

OM-4429 Page 51240167-A

OM-4429 Page 52Figure 10-2. Circuit Diagram For CC/CV Welding Generator

OM-4429 Page 53240 168-A

OM-4429 Page 54SECTION 11 − RUN-IN PROCEDURErun_in1 2007−0411-1. Wetstacking1 Welding GeneratorRun diesel engines near rated volt-age and current duri

OM-4429 Page 5511-2. Run-In Procedure Using Load BankS-06831 Load BankTurn all load bank switches Off. Ifneeded, connect load bank to 115volts ac wall

OM-4429 Page 2Welding produces fumes and gases. Breathing thesefumes and gases can be hazardous to your health.FUMES AND GASES can be hazardous. Keep

OM-4429 Page 5611-3. Run-In Procedure Using Resistance GridS-06841 Resistance GridUse grid sized for generator ratedoutput.Turn Off grid.2 Welding Gen

OM-4429 Page 57SECTION 12 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding gener

OM-4429 Page 5812-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse #10 AWG or larger insulate

OM-4429 Page 5912-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running WattsSplit Phase 1/8 HP 800 3

OM-4429 Page 6012-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHand Drill 1/4 in 350 3503/8

OM-4429 Page 6112-8. Power Required To Start MotorSingle-Phase Induction Motor Starting RequirementsMotor StartCodeG H J K L M N PKVA/HP 6.3 7.1 8.0

OM-4429 Page 6212-10. Typical Connections To Supply Standby PowerTransfer SwitchEssentialLoadsFusedDisconnectSwitch(If Required) UtilityElectricalServ

OM-4429 Page 6312-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt LoadsIf unit does not have GFCI receptacles, use

OM-4429 Page 64SECTION 13 − PARTS LIST Hardware is common andnot available unless listed.1234576891013 1415161718192021222324252610110210310410510010

OM-4429 Page 65803 844-E272829303132333435363738394041424344454647484950515253545657585960616263646566676869707172737475767778798081828384858688 (Fig.

OM-4429 Page 31-3. Engine HazardsBATTERY EXPLOSION can BLIND. Always wear a face shield, rubber gloves, andprotective clothing when working on a batt

OM-4429 Page 66DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-1. Main AssemblyQuantity1 189 824 Panel, Gen Lh 1. . . . . . . . . . . . . . . . . . . .

OM-4429 Page 67DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-1. Main Assembly (Continued)Quantity39 237 011 Engine, Perkins Dsl Elec 404D−22T−W ZA005 1

OM-4429 Page 68DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-1. Main Assembly (Continued)Quantity77 190 190 Tank, Coolant Recovery 1. . . . . . . . . .

OM-4429 Page 69DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-1. Main Assembly (Continued)Quantity123 212 944 Label, Weld Control/Arc Condition Informati

OM-4429 Page 70803 845-D12345678910111213141516171819202122Figure 13-2. Control Box Assembly − CC Models

OM-4429 Page 71DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-2. Control Box Assembly − CC Models (Figure 13-1 Item 111)Quantity1 F1, F2 *085 874 FUSE, m

OM-4429 Page 72803 846-D123456789101112131415161718192021Figure 13-3. Control Box Assembly − CC/CV ModelsDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-3

OM-4429 Page 73 Hardware is common andnot available unless listed.803 64912345678911101213141516181920212223242527282930313233343536373839404117Figur

OM-4429 Page 74DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-4. Panel, Front w/Components − CC Models (Continued)Quantity3 238 616 PANEL, engine/weld co

OM-4429 Page 75 Hardware is common andnot available unless listed.803 6501131143027534252515046474948443940413837363543342928332555456571768109354192

OM-4429 Page 4HOT METAL from air arc cutting andgouging can cause fire or explosion. Do not cut or gouge near flammables. Watch for fire; keep extin

OM-4429 Page 76DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-5. Panel, Front w/Components − CC/CV Models (Continued)Quantity12 S2 021 467 SWITCH, tgl sp

OM-4429 Page 77DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-5. Panel, Front w/Components − CC/CV Models (Continued)Quantity55 189 161 HANDLE, switch ra

OM-4429 Page 78804 291-A Hardware is common andnot available unless listed.24231914131216151118172035302228103437362726721343332312925986521Figure 13

OM-4429 Page 79DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-7. Generator (Continued)Quantity18 083 883 WASHER, Lock .402idx0.709odx.087t Stl Split10mm

OM-4429 Page 80 Hardware is common andnot available unless listed.802 279-A123465789Figure 13-8. Main Rectifier AssemblyDescriptionPartNo.Dia.Mkgs.It

OM-4429 Page 81 Some wiring harness components (switches, relays, circuit breakers) are also referenced elsewhere in this parts list. Purchase compon

OM-4429 Page 82215207 Harness, Unit Weld Control CV (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 2008-01Your distributor also givesyou ...ServiceYou always get the

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OM-4429 Page 5H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommuni