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Big Blue 500 X
Miller Big Blue 500 X User Manual
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Processes
Description
TIG (GT
A
W) Welding
Stick (SMAW
)
Welding
MIG (GMAW)
Welding
Engine Driven W
elder/Generator
OM-4421
215 075AL
2015
−
04
Visit our website at
www.MillerWelds.com
Flux Cored (FCA
W
) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
File:
Engine Drive
Big
Blue
400P
B
i
g B
l
u
e 5
0
0 X
CE
(Per
kins-Power
ed)
2
Table of Contents
Table of Contents
3
Section 1 − Safety Precautions − Read before Using
7
Symbol Usage
7
Arc Welding Hazards
7
Engine Hazards
9
Compressed Air Hazards
9
Additional Symbols for Installation, Operation, and Maintenance
10
California Proposition 65 Warnings
12
Principal Safety Standards
12
EMF Information
12
Section 2 − Consignes de Sécurité − Lire Avant Utilisation
13
Signification des Symboles
13
Dangers Relatifs au Soudage à L'arc
13
Dangers Existant en Relation Avec le Moteur
15
Dangers Liés à L'air Comprimé
16
Dangers Supplémentaires en Relation Avec L'installation, le Fonctionnement et la Maintenance
17
Proposition Californienne 65 Avertissements
19
Principales Normes de Sécurité
19
Informations Relatives aux CEM
19
Section 3 − Definitions
21
Additional Safety Symbols and Definitions
21
Miscellaneous Symbols and Definitions
23
Section 4 − Specifications
25
Serial Number and Rating Label Location
25
Weld, Power, and Engine Specifications
25
Dimensions, Weights, and Operating Angles
25
Environmental Specifications
26
Duty Cycle and Overheating
26
Volt-Ampere Curves for CC/CV Models
27
Volt-Ampere Curves for CC Models
28
Fuel Consumption
28
AC Generator Power Curve
29
Optional Three-Phase Generator Curves
29
Section 5 − Installation
30
Installing Welder/Generator
30
Grounding Generator to Truck or Trailer Frame
31
Using Lifting Eye
31
Installing Exhaust Pipe
32
Connecting the Battery
32
Engine Prestart Checks
33
Connecting to Weld Output Terminals
34
Selecting Cable Sizes
35
Connecting to Remote Amperage Adjust Receptacle RC13 on CC Models
35
Connecting to Remote 14 Receptacle RC14 on CC/CV Models
36
Section 6 − Operating Welder/Generator − CC Models
37
Front Panel Controls for CC Models (See Section 6-2)
37
Description of Front Panel Controls for CC Models (See Section 6-1)
38
Remote Amperage Control on CC Models (Optional)
39
Weld Control/Arc Condition Information Label
39
Section 7 − Operating Welder/Generator − CC/CV Models
40
Front Panel Controls for CC/CV Models (See Section 7-2)
40
Description of Front Panel Controls for CC/CV Models (See Section 7-1)
41
Process/Contactor Switch on CC/CV Models
42
Remote Voltage/Amperage Control on CC/CV Models (Optional)
43
Fuel/Hour Gauge Descriptions
44
Optional Oil Pan Heater Operation
45
Section 8 − Operating Auxiliary Equipment
46
Domestic Auxiliary Power Receptacles
46
Connecting to Optional Three-Phase Generator (CC/CV Models Only)
47
Export Auxiliary Power Receptacles
48
GFCI Receptacle Information, Resetting and Testing
49
Section 9 − Maintenance & Troubleshooting
50
Maintenance Label
50
Routine Maintenance
51
Checking Generator Brushes
52
Servicing Air Cleaner
53
Inspecting/Cleaning Optional Spark Arrestor
54
Battery Maintenance
54
Adjusting Engine Speed
55
Servicing Fuel and Lubrication Systems
56
Overload Protection
57
Troubleshooting
58
Section 10 − Parts List
62
Recommended Spare Parts
62
Section 11 − Electrical Diagrams
64
Section 12 − Run-In Procedure
68
Wetstacking
68
Run-In Procedure Using Load Bank or Resistance Grid
69
Section 13 − Generator Power Guidelines
70
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Miller Big Blue 500 X Specifications
General
Brand
Miller
Model
Big Blue 500 X
Category
Welding System
Language
English
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