Miller Electric 500DX R Owner's Manual

Big Blue 500DXOM-129 647WJuly 1999ProcessesDescriptionAir Carbon Arc (CAC-A) Cuttingand GougingStick (SMAW) WeldingMIG (GMAW) WeldingFlux Cored (FCAW

OM-129 647 Page 6Le soudage effectué sur des conteneurs fermés tels quedes réservoirs, tambours ou des conduites peut provoquerleur éclatement. Des ét

OM-129 647 Page 7DES ORGANES MOBILES peuventprovoquer des blessures. Ne pas approcher les mains des ventilateurs, cour-roies et autres pièces en mouv

OM-129 647 Page 8LE RAYONNEMENT HAUTE FRÉ-QUENCE (H.F.) risque de provoquerdes interférences. Le rayonnement haute fréquence (H.F.) peutprovoquer des

OM-129 647 Page 9SECTION 2 − DEFINITIONS2-1. Symbols And DefinitionsStop Engine Start Engine Ether Starting Aid EngineDo Not SwitchWhile WeldingBatter

OM-129 647 Page 103-2. Dimensions, Weights, And Operating AnglesDimensionsHeight 47-5/8 in (1210 mm)Width 31-1/4 in (794 mm)LDepth 60-1/2 in (1537 mm

OM-129 647 Page 113-4. Duty Cycle And Overheatingrduty1 5/95 − SB-089 697-DDuty Cycle is percentage of 10minutes that unit can weld at ratedload witho

OM-129 647 Page 123-6. Volt-Ampere CurvesST-183 880-A / ST-186 173-AThe volt-ampere curve shows theminimum and maximum voltageand amperage output capa

OM-129 647 Page 133-7. Optional AC Power Plant Curvesrsb13.1 12/94 - SB-005 185-B / SB-159 101-AThe ac power curves show theauxiliary power in amperes

OM-129 647 Page 14SECTION 4 − INSTALLATION4-1. Installing Welding Generatorinstall1 3/96 − Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854

OM-129 647 Page 154-3. Activating The Dry Charge Batterydrybatt1 2/96 − S-0886Remove battery from unit.1 Eye Protection − SafetyGlasses Or Face Shield

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

OM-129 647 Page 164-4. Connecting The Battery1/2 in−+ Connect Negative (−)Cable Last.ST-153 654-B / ST-180 933-B / S-0756-CTools Needed:4-5. Engine P

OM-129 647 Page 174-6. Connecting To Weld Output Terminals ST-158 700Open left side door.1 BracketRoute cables through bracket.2 Positive (+) Weld Out

OM-129 647 Page 18ether1 7/96 − ST-153 382-A / ST-180 933-B Stop engine. Improper handling or expo-sure to ether can harm yourhealth. Follow manufac

OM-129 647 Page 194-10. Remote 14 Receptacle RC3 Information (Optional)Socket* Socket InformationAJBKIA 24 volts ac. Protected by circuitbreaker CB4.B

OM-129 647 Page 20SECTION 5 − OPERATING THE WELDING GENERATOR5-1. Standard Controls (See Section 5-2)1102 311 9 8 7 6 5 412ST-158 630-B / Ref. ST-158

OM-129 647 Page 215-2. Description Of Standard Controls (See Section 5-1) This unit has a max OCV control circuitthat resets the Amperage/Voltage Con

OM-129 647 Page 225-3. Controls For Models With CV Option (See Section 5-4)19210 8 7 6 5 4 311ST-158 630-B / Ref. ST-158 631 / Ref. ST-185 762-B / S-1

OM-129 647 Page 235-4. Description Of Controls For Models With CV Option (See Section 5-3) This unit has a max OCV control circuitthat resets Amperag

OM-129 647 Page 24SECTION 6 − OPERATING AUXILIARY EQUIPMENT6-1. 120 Volt And 240 Volt Duplex ReceptaclesRef. ST-180 933-B32 If unit does not have GFC

OM-129 647 Page 256-2. Optional Auxiliary Power ReceptaclesRef. ST-180 933-B / Ref. ST-182 266 Auxiliary power is not affectedby weld output.If a cir

The following terms areused interchangeablythroughout this manual:Stick = SMAWMIG = GMAWCALIFORNIAProposition 65WarningDiesel engine exhaust andsome o

OM-129 647 Page 266-3. Connecting Optional Auxiliary Power Plant Ref. S-180 187-A Stop engine. Power and weld outputs arelive at the same time. Disc

OM-129 647 Page 27SECTION 7 − MAINTENANCE & TROUBLESHOOTING7-1. Routine MaintenanceFollow the storage procedure in the engine owner’s manual if th

OM-129 647 Page 287-2. Maintenance LabelDEUTZ F3L912 DIESEL ENGINECheckRecommended Oil API Service Classification CD/CE (or better). . . Oil Change &a

OM-129 647 Page 297-3. Servicing Air Cleaneraircleaner1 4/96 − ST-153 929-B / ST-153 585 / Ref. ST-180 933-B / Ref. S-0698-B Stop engine. Do not run

OM-129 647 Page 307-4. Servicing Fuel And Lubrication SystemsRef. ST-158 633-C / Ref. ST-180 933-B Stop engine and let cool.1 Oil Filter2 Oil Drain

OM-129 647 Page 317-5. Adjusting Engine SpeedST-045 768-BEngine speed is factory set andshould not require adjustment. Af-ter tuning engine, check eng

OM-129 647 Page 327-7. Checking And Replacing Alternator BeltST-158 632 / Ref. ST-180 933-B Stop engine.To check belt tension:Remove rear panel.1 Alt

OM-129 647 Page 337-8. Resetting Fan Belt Safety ShutdownST-158 715 / Ref. ST-158 632 / Ref. ST-180 933-B Stop engine.1 Cooling Fan V-BeltSee engine

OM-129 647 Page 347-9. Inspecting And Cleaning Optional Spark Arrestor MufflerST-800 633-B / Ref. ST-180 933-B Stop engine and let cool.1 Spark Arres

OM-129 647 Page 357-11. TroubleshootingA. WeldingTrouble RemedyNo weld output. Check position of Ampere Range switch.Check position of optional polari

OM-129 647 Page 36Trouble RemedyRepair or replace remote control device.Have Factory Authorized Service Agent check optional CV regulator board PC2.B.

OM-129 647 Page 37Trouble RemedyPeriodically recharge battery (approximately every 3 months).Engine uses oil during run-in period;wetstacking occurs.D

OM-129 647 Page 38Notes

OM-129 647 Page 39SECTION 8 − ELECTRICAL DIAGRAMS180 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 41184 954-C

OM-129 647 Page 42SECTION 9 − RUN-IN PROCEDURErun_in1 6/969-1. Wetstacking1 Welding GeneratorRun diesel engines near ratedoutput during run-in period

OM-129 647 Page 439-2. Run-In Procedure Using Load BankS-0683 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep exhau

OM-129 647 Page 449-3. Run-In Procedure Using Resistance GridS-0684 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep

OM-129 647 Page 45SECTION 10 − AUXILIARY POWER GUIDELINES10-1. Selecting Equipmentaux_pwr 2/99 − Ref. ST-159 730 / ST-800 5771 Auxiliary Power Recepta

OM-129 647 Page 1SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USINGrom _nd_11/981-1. Symbol UsageMeans Warning! Watch Out! There are possiblehazards

OM-129 647 Page 4610-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse #10 AWG or larger insul

OM-129 647 Page 4710-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running WattsSplit Phase 1/8 HP 80

OM-129 647 Page 4810-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHand Drill 1/4 in 350 350

OM-129 647 Page 4910-8. Power Required To Start MotorS-06241 Motor Start Code2 Running Amperage3 Motor HP4 Motor VoltageTo find starting amperage:Step

OM-129 647 Page 5010-10. Typical Connections To Supply Standby PowerS-0405-A1 Power Company ServiceMeter2 Main and Branch OvercurrentProtection3 Doubl

OM-129 647 Page 5110-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacle

OM-129 647 Page 52SECTION 11 − PARTS LIST1324567689106711121314151617181920212223676710242526706966656474757677787980818283848586Fig 11-587Fig 11−6&am

OM-129 647 Page 53ST-048 455-AA2728293031323334353637383940414243444647484950455152535554565759606162636465666768Fig 11-3697071727358102

OM-129 647 Page 54Figure 11-1. Main AssemblyDescription QuantityPartNo.Dia.Mkgs.ItemNo.1 134 771 PLUG, protective .640sq 4. . . . . . . . . . . . . .

OM-129 647 Page 55Figure 11-1. Main Assembly (Continued)Description QuantityPartNo.Dia.Mkgs.ItemNo.53 SPRING, (included w/engine − see engine parts li

OM-129 647 Page 2Welding on closed containers, such as tanks,drums, or pipes, can cause them to blow up. Sparkscan fly off from the welding arc. The f

OM-129 647 Page 5613479101191416171819202122ST-048 457-N2 Fig 11-4568121315 Hardware is common andnot available unless listed.Figure 11-2. Panel, Fro

OM-129 647 Page 57Figure 11-2. Panel, Front w/Components (Fig 11-1 Item 94)Description QuantityPartNo.Dia.Mkgs.ItemNo.1 154 292 PANEL, front upper 1.

OM-129 647 Page 58Figure 11-3. GeneratorSD-048 456-E Hardware is common andnot available unless listed.1245643789111213101416151819201714212322242627

OM-129 647 Page 59FIgure 11-3. Generator (Fig 11-1 Item 68)Description QuantityPartNo.Dia.Mkgs.ItemNo.1 106 426 INSULATOR 4. . . . . . . . . . . . .

OM-129 647 Page 60Figure 11-4. Switch, Range (Fig 11-2 Item 2)Description QuantityPartNo.171 878ItemNo.Dia.Mkgs.1 114 235 BRACKET, mtg switch range (c

OM-129 647 Page 61Figure 11-5. Control Box CC/CV (Figure 11-1 Item 86) (Optional)Description QuantityPartNo.ItemNo.Dia.Mkgs.1 605 321 NUT, .468-32 brs

OM-129 647 Page 62Figure 11-6. Panel, Mtg Components (CC/CV Model) (Figure 11-1 Item 87)Description QuantityPartNo.ItemNo.Dia.Mkgs.1 R2 185 748 RESIST

OM-129 647 Page 63Figure 11-7. Panel, Mtg Components (CC Model) (Figure 11-1 Item 87)Description QuantityPartNo.ItemNo.Dia.Mkgs.1 170 672 PANEL, mtg c

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 7/99Your distributor also givesyou ...ServiceYou always get the fa

OM-129 647 Page 3MOVING PARTS can cause injury. Keep away from fans, belts, and rotors. Keep all doors, panels, covers, and guardsclosed and securel

PRINTED IN USA © 1999 Miller Electric Mfg. Co. 7/99Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US

OM-129 647 Page 4H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcomm

OM-129 647 Page 5SECTION 1 − CONSIGNES DE SÉCURITÉ − LIRE AVANTUTILISATIONrom _nd_fre 5/971-1. Signification des symbolesSignifie Mise en garde ! Soy