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OM-129 647W
July 1999
Processes
Stick (SMAW) Welding
Air Carbon Arc (CAC-A) Cutting
and Gouging
With Optional Equipment:
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Engine Driven Welding Generator
Big Blue 500DX
Visit our website at
www.MillerWelds.com
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From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. Today, the people that bu
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TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING rom _nd_11/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards. Means “Note”; not safety related. 1-2. Arc Weldi
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WELDING can cause fire or explosion. HOT PARTS can cause severe burns. Allow cooling period before maintaining. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks Wear protective gloves and clothing when can fly off from the welding arc. The flying sparks, working on a hot engine. hot workpiece, and hot equipment can cause fires Do not touch hot engine parts or just-welded and burns. Accidental contact of electrode to metal objects can parts bar
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BATTERY ACID can BURN SKIN and EYES. MOVING PARTS can cause injury. Do not tip battery. Keep away from fans, belts, and rotors. Replace damaged battery. Keep all doors, panels, covers, and guards closed and securely in place. Flush eyes and skin immediately with water. Stop engine before installing or connecting unit. Have only qualified people remove guards or covers for maint- enance and troubleshooting as necessary. To prevent accidental starting during servicing, disconnect E
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H.F. RADIATION can cause interference. ARC WELDING can cause interference. High-frequency (H.F.) can interfere with radio Electromagnetic energy can interfere with navigation, safety services, computers, and sensitive electronic equipment such as communications equipment. computers and computer-driven equipment such as robots. Have only qualified persons familiar with electronic equipment perform this installation. Be sure all equipment in the welding area is electromagnetically compatib
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SECTION 1 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 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. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN Identifie un message de sécurité particulier. MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous a
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LE SOUDAGE peut provoquer un in- DES PIÈCES CHAUDES peuvent cendie ou une explosion. provoquer des brûlures graves. Prévoir une période de refroidissement avant d’effec- Le soudage effectué sur des conteneurs fermés tels que tuer des travaux d’entretien. des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être projetées de Porter des gants et des vêtements de protection pour l’arc de soudure. La projection d’étincelles, des pièces chaudes et des t
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DES ORGANES MOBILES peuvent L’ACIDE DE LA BATTERIE peut pro- provoquer des blessures. voquer des brûlures dans les YEUX et sur la PEAU. Ne pas approcher les mains des ventilateurs, cour- roies et autres pièces en mouvement. Ne pas renverser la batterie. Maintenir fermés et fixement en place les portes, Remplacer une batterie endommagée. panneaux, recouvrements et dispositifs de protection. Rincer immédiatement les yeux et la peau à l’eau. Arrêter le moteur avant d’installer ou branch
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LE RAYONNEMENT HAUTE FRÉ- LE SOUDAGE À L’ARC risque de QUENCE (H.F.) risque de provoquer provoquer des interférences. des interférences. L’énergie électromagnétique risque de provoquer des interférences pour l’équipement électronique Le rayonnement haute fréquence (H.F.) peut sensible tel que les ordinateurs et l’équipement com- provoquer des interférences avec les équipements mandé par ordinateur tel que les robots. de radio −navigation et de communication, les Veiller à ce que tout l’équ
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SECTION 2 − DEFINITIONS 2-1. Symbols And Definitions Stop Engine Start Engine Ether Starting Aid Engine Do Not Switch Battery (Engine) Circuit Breaker Engine Oil While Welding Check Injectors/ Check Valve Protective Earth Fuel Pump Clearance (Ground) Certified/Trained Positive Negative Welding Arc Mechanic Amperes Volts Panel/Local 14 Remote A V Alternating On Temperature Output Current Stick (SMAW) Constant Current MIG (GMAW) Constant Voltage Welding (CC) Welding (CV) Time Hours Seconds Single
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3-2. Dimensions, Weights, And Operating Angles Dimensions Height 47-5/8 in (1210 mm) L Width 31-1/4 in (794 mm) Do not exceed operating angles while Engine End Depth 60-1/2 in (1537 mm) runnin running g or en or engine damage will occur gine damage will occur.. A 59-1/8 in (1502 mm) Do not move or operate unit where it p could ld ti tip. B 47-1/4 in (1200 mm) C 43-1/4 in (1099 mm) D 32-3/4 in (832 mm) E 24-15/16 in (633 mm) A C C F 10-1/2 in (267 mm) B D D G 6-1/2 in (165 mm) E E 17.5 17
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3-4. Duty Cycle And Overheating 60% Duty Cycle At 500 Amperes 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. 6 Minutes Welding 4 Minutes Resting rduty1 5/95 − SB-089 697-D 3-5. AC Auxiliary Power The ac power curve shows the auxiliary power in amperes avail- able at the 120 and 240 volt recep- tacles. rsb3.1 2/92 − Ref. SB-005 192-C OM-129 647 Page 11
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3-6. Volt-Ampere Curves 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 A. CC/DC (Standard) curves shown. B. CV/DC (Models With CV Option) ST-183 880-A / ST-186 173-A OM-129 647 Page 12
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3-7. Optional AC Power Plant Curves The ac power curves show the auxiliary power in amperes avail- able at the single-phase 120/240 A. 7.5 KVA/KW Single-Phase Auxiliary Power Plant (No Weld Load) volt or three-phase 240 volt terminals. B. 10 KVA/KW Three-Phase Auxiliary Power Plant (No Weld Load) rsb13.1 12/94 - SB-005 185-B / SB-159 101-A OM-129 647 Page 13
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SECTION 4 − INSTALLATION 4-1. Installing Welding Generator Movement Airflow Clearance Location 18 in Do Not Lift Unit From End (460 mm) 18 in (460 mm) 18 in (460 mm) OR OR 18 in 18 in (460 mm) (460 mm) Grounding 1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grounding 3 1 4 Terminal GND/PE 4 Grounding Cable Use #10 AWG or larger insulated copper wire. OR If unit does not have GFCI receptacles, use GFCI- protected extension cord. Electrically bond generator frame to vehicle frame by metal
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4-3. Activating The Dry Charge Battery Remove battery from unit. 1 Eye Protection − Safety Glasses Or Face Shield 2 Rubber Gloves 5 3 Vent Caps 4 Sulfuric Acid Electrolyte (1.265 Specific Gravity) 4 5 Well 1 3 Fill each cell with electrolyte to bottom of well (maximum). Do not overfill battery cells. Wait ten minutes and check elec- trolyte level. If necessary, add elec- trolyte to raise to proper level. Reinstall vent caps. 6 Battery Charger 2 Read and follow all instruc- tions supplied wit
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4-4. Connecting The Battery Connect Negative ( −) Cable Last. + − Tools Needed: 1/2 in ST-153 654-B / ST-180 933-B / S-0756-C 4-5. Engine Prestart Checks Check all fluids daily. Engine must be cold and on a level surface. Follow run-in procedure in engine manual. If unburned fuel and oil collect in exhaust pipe during run- in, see Section 9. 1/2 in 1 Fuel (13 mm) Full Do not use gasoline. Gaso- line will damage engine. Add fresh diesel fuel before start- ing engine the first time (see main-
