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TM-4428L 2016−07

Eff. w/Serial No. LC585264


And Following
Processes
Stick (SMAW) Welding

TIG (GTAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Air Carbon Arc (CAC-A) Cutting


and Gouging

Description

Engine Driven Welder/Generator

Big Blue 500D




Big Blue 600 X




(Deutz-Powered)

File: Engine Drive


Visit our website at
www.MillerWelds.com
INFORMATION ON OLDER UNITS

 This manual includes operating information for current units. To obtain specific operating information for older models, download the applicable
Owner’s Manual from www.MillerWelds.com

 Effective w/Serial No. LJ003065, Fuel/Hour gauge FUEL/HM replaced Hourmeter HM.
 Effective w/Serial No. LJ004970, the Deutz F3L2011L04i engine (Tier III) replaced the Deutz F3L2011 engine.
The Deutz F3L912 engine is not Tier III.

 Effective w/Serial No. LJ005955, ELCB1 replaced CB1 on export receptacle panels.
 Effective w/Serial No. MF340120E, all 500D models were discontinued.
Effective w/Serial No. MG060062E, all 600 X CC/CV models were discontinued.

 See the Miller Extranet for service memos that may aid in the repair of this product.
TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SECTION 2 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SECTION 3 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-2. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-3. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-4. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-5. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-6. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-7. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-8. AC Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-1. Installing Welder/Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-2. Grounding Generator To Truck Or Trailer Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-3. Using Lifting Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-4. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-5. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-6. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-7. Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-8. Connecting Weld Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-9. Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-10. Connecting To Remote Amperage Adjust Receptacle RC13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SECTION 5 − OPERATING WELDER/GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-1. Front Panel Controls (See Section 5-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-2. Description Of Front Panel Controls (See Section 5-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-3. Remote Amperage Control (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5-4. Weld Control/Arc Condition Information Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5-5. Fuel/Hour Gauge Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SECTION 6 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6-1. Export Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6-2. GFCI Receptacle Information, Resetting And Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SECTION 7 − DEUTZ D2011L04i MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7-1. Maintenance Label (Deutz D2011L04i-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7-2. Routine Maintenance (Deutz D2011L04i-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7-3. Operating Optional Oil Pan Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7-4. Checking Generator Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7-5. Servicing Air Cleaner (Deutz D2011L04i-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7-6. Inspecting/Cleaning Optional Spark Arrestor (Deutz D2011L04i-Powered Units) . . . . . . . . . . . . . . . . 27
7-7. Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7-8. Adjusting Engine Speed (Deutz D2011L04i-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7-9. Servicing Fuel And Lubrication Systems (Deutz D2011L04i-Powered Units) . . . . . . . . . . . . . . . . . . . . 29
7-10. Overload Protection (Deutz D2011L04i-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SECTION 8 − DEUTZ F3L912 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8-1. Maintenance Label (Deutz F3L912-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8-2. Routine Maintenance (Deutz F3L912-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8-3. Checking Generator Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8-4. Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
TABLE OF CONTENTS

8-5. Servicing Air Cleaner (Deutz F3L912-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34


8-6. Inspecting/Cleaning Optional Spark Arrestor (Deutz F3L912-Powered Units) . . . . . . . . . . . . . . . . . . . 35
8-7. Adjusting Engine Speed (Deutz F3L912-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8-8. Servicing Fuel And Lubrication Systems (Deutz F3L912-Powered Units) . . . . . . . . . . . . . . . . . . . . . . 37
8-9. Overload Protection (Deutz F3L912-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
SECTION 9 − THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
SECTION 10 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
10-1. Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
10-2. Troubleshooting Circuit Diagram For Welding Generator (Deutz D2011L04i-Powered CC Models) . 52
10-3. Troubleshooting Circuit Diagram For Welding Generator
(Deutz D2011L04i-Powered CC/CV Models) (Use With Section 10-4) . . . . . . . . . . . . . . . . . . . . . . . . . 54
10-4. Troubleshooting Values For Circuit Diagram (Deutz D2011L04i-Powered CC/CV Models)
(Use With Section 10-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
10-5. Troubleshooting Circuit Diagram For Welding Generator (Deutz F3L912-Powered CC Models) . . . . 58
10-6. Troubleshooting Circuit Diagram For Welding Generator (Deutz F3L912-Powered CC/CV Models) . 60
10-7. Waveforms For Sections 10-2 Thru 10-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
10-8. Filter Board PC6 Testing Information (CC/CV Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
10-9. Filter Board PC6 Test Point Values (CC/CV Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
10-10. Field Current Regulator Board PC1 Testing Using LED Board PC9 (CC/CV Only) . . . . . . . . . . . . 66
10-11. Using Diagnostic LEDs On LED Board PC9 (CC/CV Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . 67
10-12. LED Board PC9 Testing (CC/CV Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
10-13. LED Board PC9 Test Point Values (CC/CV Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
10-14. Time Delay Relay TD1 Testing Information (Prior To Serial No. LJ003065) . . . . . . . . . . . . . . . . . . . 70
10-15. Fuel/Hourmeter Testing Information (Eff w/Serial No. LJ003065) . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
10-16. Optional Idle Module PC7 Testing Information And Troubleshooting Flow Chart . . . . . . . . . . . . . . 74
10-17. Replacing Brushes And Cleaning Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
10-18. Checking Unit Output After Servicing (CC Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
10-19. Checking Unit Output After Servicing (CC/CV Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
SECTION 11 − DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
11-1. Disassembly Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
11-2. Disassembly Of Generator (Prior To Serial No. MB360026E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
11-3. Disassembly Of Generator (Eff. W/ Serial No. MB360026E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
SECTION 12 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
SECTION 13 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
13-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
13-2. Run-In Procedure Using Load Bank Or Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
SECTION 14 − PARTS LIST EFF W/SERIAL NO. LC585264 THRU LJ003064 . . . . . . . . . . . . . . . . . . . . . . . 130
SECTION 15 − PARTS LIST EFF W/SERIAL NO. LJ003065 THRU MG060062E . . . . . . . . . . . . . . . . . . . . . 150
SECTION 16 − PARTS LIST EFF W/SERIAL NO. MG060063E AND FOLLOWING . . . . . . . . . . . . . . . . . . . 172
SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.

1-1. Symbol Usage


OM-4428AT - 2016-05, safety_rtm 2015-09
DANGER! − Indicates a hazardous situation which, if  Indicates special instructions.
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
This group of symbols means Warning! Watch Out! ELECTRIC
hazards are shown in the adjoining symbols or ex-
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
plained in the text.
bols and related instructions below for necessary actions to avoid the
NOTICE − Indicates statements not related to personal injury. hazards.

1-2. Servicing Hazards

The symbols shown below are used throughout this manual FLYING METAL or DIRT can injure eyes.
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions  Wear safety glasses with side shields or face
to avoid the hazard. shield during servicing.
 Be careful not to short metal tools, parts, or
Only qualified persons should test, maintain, and repair this wires together during testing and servicing.
unit.
During servicing, keep everybody, especially children, away.
STATIC (ESD) can damage PC boards.
ELECTRIC SHOCK can kill.  Put on grounded wrist strap BEFORE handling
boards or parts.
 Do not touch live electrical parts.  Use proper static-proof bags and boxes to
 Stop engine and remove input power plug from store, move, or ship PC boards.
receptacle (if applicable) before testing or re-
pairing unit unless the procedure specifically
requires an energized unit.
Using a generator indoors CAN KILL
 Insulate yourself from ground by standing or working on dry insu-
lating mats big enough to prevent contact with the ground. YOU IN MINUTES.
 Do not leave live unit unattended.
 Generator exhaust contains carbon monoxide.
 If this procedure requires an energized unit, have only personnel This is a poison you cannot see or smell.
familiar with and following standard safety practices do the job.
 NEVER use inside a home or garage, EVEN IF
 When testing live unit, use the one-hand method. Do not put both doors and windows are open.
hands inside unit. Keep one hand free.
 Only use OUTSIDE and far away from windows, doors, and
SIGNIFICANT DC VOLTAGE exists in inverter power vents.
sources AFTER stopping engine.
 Stop engine on inverter and discharge input capacitors according
to instructions in Troubleshooting Section before touching any HIGH PRESSURE FLUIDS can injure or kill.
parts.
 Engine fuel system components can be under
high pressure.
MOVING PARTS can injure.  Before working on fuel system, turn off engine
to release pressure.
 Keep away from moving parts such as fans,  If ANY fluid is injected in the skin seek medical help immediately.
belts, and rotors.
 Keep away from pinch points such as drive
rolls.
 Have only qualified people remove doors,
FUEL can cause fire or explosion.
panels, covers, or guards for maintenance  Stop engine and let it cool off before checking or
and troubleshooting as necessary. adding fuel.
 Keep hands, hair, loose clothing, and tools  Do not add fuel while smoking or if unit is near
away from moving parts. any sparks or open flames.
 Before working on generator, remove spark plugs or injectors  Do not overfill tank; clean up any spilled fuel.
to keep engine from kicking back or starting.
 Block flywheel so that it will not turn while working on genera- FIRE OR EXPLOSION hazard.
tor components.
 Reinstall doors, panels, covers, or guards when servicing is  Do not place unit on, over, or near combustible surfaces.
finished and before starting engine.  Do not service unit near flammables.

Big Blue 500D, 600 X TM-4428 Page 1


BATTERY EXPLOSION can BLIND. EXPLODING PARTS can injure.
 Always wear a face shield, rubber gloves, and  Failed parts can explode or cause other parts to
protective clothing when working on a battery. explode when power is applied to inverters.
 Stop engine before disconnecting or connect-  Always wear a face shield and long sleeves
ing battery cables. when servicing inverters.
 Do not allow tools to cause sparks when working on a battery.
 Do not use welder to charge batteries or jump start vehicles.
 Observe correct polarity (+ and −) on batteries. H.F. RADIATION can cause interference.
 Disconnect negative (−) cable first and connect it last.  High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
BATTERY ACID can BURN SKIN and EYES.  Have only qualified persons familiar with elec-
tronic equipment perform this installation.
 Do not tip battery.
 The user is responsible for having a qualified electrician promptly
 Replace damaged battery. correct any interference problem resulting from the installation.
 Flush eyes and skin immediately with water.  If notified by the FCC about interference, stop using the equipment
at once.
 Have the installation regularly checked and maintained.
STEAM AND HOT COOLANT can burn.  Keep high-frequency source doors and panels tightly shut, keep
 If possible, check coolant level when engine is spark gaps at correct setting, and use grounding and shielding to
cold to avoid scalding. minimize the possibility of interference.
 Always check coolant level at overflow tank, if
present on unit, instead of radiator. OVERUSE can cause OVERHEATING.
 If the engine is warm, checking is needed, and there is no overflow  Allow cooling period; follow rated duty cycle.
tank, follow the next two statements.  Reduce current or reduce duty cycle before
 Wear safety glasses and gloves and put a rag over radiator cap. starting to weld again.
 Turn cap slightly and let pressure escape slowly before completely  Do not block or filter airflow to unit.
removing cap.

SHOCK HAZARD from testing.


ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.  Stop engine or turn Off welding power source (if
applicable) before making or changing meter
 Wearers of Pacemakers and other Implanted lead connections.
Medical Devices should keep away from serv-  Use at least one meter lead that has a self-
icing areas until consulting their doctor and the retaining spring clip such as an alligator clip.
device manufacturer.
 Read instructions for test equipment.

FALLING EQUIPMENT can injure. READ INSTRUCTIONS.


 Use lifting eye to lift unit and properly installed  Use Testing Booklet (Part No. 150 853) when
accessories only, NOT gas cylinders. Do not servicing this unit.
exceed maximum lift eye weight rating (see  Consult the Owner’s Manual for welding safety
Specifications). precautions.
 Use equipment of adequate capacity to lift and support unit.  Use only genuine replacement parts from the manufacturer.
 If using lift forks to move unit, be sure forks are long enough to  Read and follow all labels and the Technical Manual carefully be-
extend beyond opposite side of unit. fore installing, operating, or servicing unit. Read the safety in-
 Follow the guidelines in the Applications Manual for the Revised formation at the beginning of the manual and in each section.
NIOSH Lifting Equation (Publication No. 94−110) when manu-  Perform installation, maintenance, and service according to the
ally lifting heavy parts or equipment. Technical Manual, industry standards, and national, state, and
local codes.
 Reinstall injectors and bleed air from fuel system according to
HOT PARTS can burn. engine manual.
 Do not touch hot engine parts bare-handed.
 Allow cooling period before working on HYDRAULIC EQUIPMENT can injure
equipment. or kill.
 To handle hot parts, use proper tools and/or wear heavy, insu-  Before working on hydraulic system, turn off
lated welding gloves and clothing to prevent burns. and lockout/tagout unit, release pressure, and
be sure hydraulic pressure cannot be accident-
ally applied.
TILTING OR TIPPING can injure.  Do not work on hydraulic system with unit running unless you are a
qualified person and following the manufacturer’s instructions.
 Do not put any body part under unit while lifting.  Do not modify or alter hydraulic pump or manufacturer-supplied
 Always use proper equipment (hoists, slings, equipment. Do not disconnect, disable, or override any safety
chains, blocks, etc.) of adequate capacity to lift equipment in the hydraulic system.
and support components (stator, rotor, engine,  Keep away from potential pinch points or crush points created by
etc.) as needed during job. equipment connected to the hydraulic system.
PINCH POINTS can injure.  Do not work under or around any equipment that is supported only
 Be careful when working on stator and rotor assemblies. by hydraulic pressure. Properly support equipment by mechanical
means.
TM-4428 Page 2 Big Blue 500D, 600 X
HYDRAULIC FLUID can injure or kill. COMPRESSED AIR can injure or kill.
 Before working on hydraulic system, turn off and  Before working on compressed air system,
lockout/tagout unit, release pressure, and be sure turn off and lockout/tagout unit, release pres-
hydraulic pressure cannot be accidentally applied. sure, and be sure air pressure cannot be acci-
 Relieve pressure before disconnecting or con- dentally applied.
necting hydraulic lines.  Relieve pressure before disconnecting or con-
 Check hydraulic system components and all con- necting air lines.
nections and hoses for damage, leaks, and wear  Check compressed air system components
before operating unit. and all connections and hoses for damage,
 Wear protective equipment such as safety leaks, and wear before operating unit.
glasses, leather gloves, heavy shirt and trousers,  Do not direct air stream toward self or others.
high shoes, and a cap when working on hydraulic  Wear protective equipment such as safety glasses, hearing pro-
system. tection, leather gloves, heavy shirt and trousers, high shoes, and a
 Use a piece of paper or cardboard to search for cap when working on compressed air system.
leaks−−never use bare hands. Do not use equip-  Use soapy water or an ultrasonic detector to search for
ment if leaks are found. leaks−−never use bare hands. Do not use equipment if leaks are
 HYDRAULIC FLUID is FLAMMABLE−−do not work on hydraulics found.
near sparks or flames; do not smoke near hydraulic fluid.  Reinstall doors, panels, covers, or guards when servicing is
 Reinstall doors, panels, covers, or guards when servicing is finished and before starting unit.
finished and before starting unit.  If ANY air is injected into the skin or body seek medical help imme-
 If ANY fluid is injected into the skin seek medical help immediately. diately.
COMPRESSED AIR EQUIPMENT can
TRAPPED AIR PRESSURE AND WHIPPING
injure or kill.
HOSES can injure.
 Before working on compressed air system, turn
 Release air pressure from tools and system be-
off and lockout/tagout unit, release pressure,
fore servicing, adding or changing attach-
and be sure air pressure cannot be accidentally
ments, or opening compressor oil drain or oil fill
applied.
cap.
 Do not work on compressed air system with unit running unless
you are a qualified person and following the manufacturer’s in-
structions.
 Do not modify or alter compressor or manufacturer-supplied
equipment. Do not disconnect, disable, or override any safety
equipment in the compressed air system.
 Keep away from potential pinch points or crush points created by
equipment connected to the compressed air system.
 Do not work under or around any equipment that is supported only
by air pressure. Properly support equipment by mechanical
means.
1-3. California Proposition 65 Warnings
For Gasoline Engines:
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of
cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc-
Health & Safety Code Section 25249.5 et seq.) tive harm.
Battery posts, terminals and related accessories contain lead For Diesel Engines:
and lead compounds, chemicals known to the State of Diesel engine exhaust and some of its constituents are
California to cause cancer and birth defects or other known to the State of California to cause cancer, birth
reproductive harm. Wash hands after handling. defects, and other reproductive harm.
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
1-4. EMF Information
Electric current flowing through any conductor causes localized electric 4. Keep head and trunk as far away from the equipment in the
and magnetic fields (EMF). The current from arc welding (and allied pro- welding circuit as possible.
cesses including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding 5. Connect work clamp to workpiece as close to the weld as
circuit. EMF fields can interfere with some medical implants, e.g. pace- possible.
makers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or con- 6. Do not work next to, sit or lean on the welding power source.
duct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from 7. Do not weld whilst carrying the welding power source or wire
the welding circuit: feeder.
1. Keep cables close together by twisting or taping them, or using a
About Implanted Medical Devices:
cable cover.
Implanted Medical Device wearers should consult their doctor and the
2. Do not place your body between welding cables. Arrange cables device manufacturer before performing or going near arc welding, spot
to one side and away from the operator. welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom-
3. Do not coil or drape cables around your body. mended.
Big Blue 500D, 600 X TM-4428 Page 3
SECTION 2 − DEFINITIONS

2-1. Additional Safety Symbols And Definitions

 Some symbols are found only on CE products.

Warning! Watch Out! There are possible hazards as shown by the symbols.

Safe1 2012−05

Do not use ether or other starting fluids. Using starting fluids voids warranty. See engine Owner’s Manual.

Safe89 2015−02

Hot muffler and exhaust pipe can cause severe burns.

Safe90 2012−07

Welding, cutting, drilling, or grinding on base can cause fire or explosion.

Safe91 2012−07

Remove unit from shipping crate. Remove Owner’s Manual from unit.
Follow instructions to install muffler.

Safe46 2012−05

Read Owner’s Manual. Read labels on unit.

Safe47 2012−05

<12.4 V
Read Owner’s Manual for battery maintenance information.

/ + − + −
Safe117 2014−06

0 - 50 h std
During the first 50 hours of operation keep welding load above 200
amperes. Do not weld below 200 amperes of output.

Safe54 2012−05

50 h std
After the first 50 hours of operation, change the engine oil and filter.

Safe55 2012−05

TM-4428 Page 4 Big Blue 500D, 600 X


Never use generator inside a home or garage, even if doors and win-
dows are open.

Safe87 2012−07

Only use generator outside and far away from windows, doors, and
vents.

Safe88 2012−07

Environmental Protection Use Period (China)

Safe123 2016−06

2-2. Miscellaneous Symbols And Definitions


 Some symbols are found only on CE products.

A
Increase or
Alternating
Amperage Decrease of
Current (AC)
Quantity
(Rotating)

V Voltage Single Phase


Panel/Local

Direct Current
(DC) Three Phase Do Not Switch
While Welding

X Duty Cycle Engine−Driven


3−Phase
Alternator with
Remote

I2
Rectifier
Rated Welding
Current Read Operator’s
Manual
Contractor On

U2 Conventional
Load Voltage
Work Connection
Electrode
Connection

U0 Rated No−Load
Voltage (OCV)
Welding (General)
Negative

I Current Shielded Metal


Arc Welding
(SMAW)
Positive

n Rated Load Gas Tungsten Arc


Speed Welding (GTAW) /
Protective Earth Tungsten Inert
Gas (TIG)

n0 Rated No−Load (Ground)


Welding
Speed
Circuit Breaker Starting Aid
(Preheat)
n1
Supplementary
Rated Idle Speed Protector

Engine

Hz Hertz
Output

Engine
Clock, Time Off
Switch

Hour Meter On

Big Blue 500D, 600 X TM-4428 Page 5


Engine Filter Air Flow

Engine
Slow Temperature Air Cleaner

Fast Battery (Engine)


Check Air Cleaner

Engine RPM Engine Belt Check


Injectors/Pump

Engine Stop Manual Cleaning Check Valve


Clearance

Engine Oil Spark Arrestor Certified/Trained


Mechanic

Fuel Air Filter Call for


Maintenance

Notes

TM-4428 Page 6 Big Blue 500D, 600 X


SECTION 3 − SPECIFICATIONS
3-1. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the front. Use rating label to determine input power requirements and/or rated
output. For future reference, write serial number in space provided on back cover of this manual.

3-2. Weld, Power, And Engine Specifications


Weld Maximum
Welding Rated Welding Generator Power Fuel
Output Open-Circuit Engine
Mode Output Rating Capacity
Range Voltage
Deutz D2011L04i
600 A, 30 Volts DC, Air/Oil-Cooled, Four
40% Duty Cycle Cylinder, 46.3 HP
IFC Rating Single-Phase, Diesel Engine
25 gal
CC/DC 65 − 600 A 500 A, 40 Volts DC, 95 4 kVA/kW, 34/17 A, or
(95 L)
100% Duty Cycle 120/240 V AC, 50/60 Hz Deutz F3L912,
550 A, 40 volts DC, Air-Cooled, Three
60% Duty Cycle Cylinder, 41.5 HP
Diesel Engine

3-3. Dimensions, Weights, And Operating Angles

Dimensions
50 in. (1270 mm)
Height
(to top of muffler)

28-1/2 in. (724 mm)


(mtg. brackets turned in) G
Width
30-3/4 in. (781 mm)
(mtg. brackets turned out)
Depth 65-1/8 in. (1654 mm)
A 65-1/8 in. (1654 mm)
! Do not exceed tilt angles or engine could
B* 56 in. (1422 mm) be damaged or unit could tip.
C* 46-1/2 in. (1181) ! Do not move or operate unit where it could
tip.
D* 9-5/8 in. (244 mm) A
E 27-1/2 in. (699 mm) B C
F 1-1/8 in. (29 mm)
G 29-13/16 in. (757 mm)
9/16 in. (14 mm) Dia.
H H
4 Holes

* With mounting brackets in center


D 30°
position. Dimensions vary with Front Panel End
location of mounting brackets.
30°
20°
Weight F
20°
No fuel: 1690 lb (767 kg) E
D2011L04i
w/fuel: 1880 lb (853 kg)

No fuel: 1785 lb (810 kg) 802 161-A 803 602


F3L912
w/fuel: 1975 lb (896 kg)

Lifting Eye Weight Rating:


2500 lb (1134 kg) Maximum

Big Blue 500D, 600 X TM-4428 Page 7


3-4. Environmental Specifications
A. IP Rating
IP Rating Operating Temperature Range
IP23S
−40 to 104°F (−40 to +40°C)
This equipment is designed for outdoor use. It may be stored, but is not intended IP23S 2014−06
to be used for welding outside during precipitation unless sheltered.

B. China EEP Hazardous Substance Information


质 量
China EEP Hazardous Substance Information

部 


Component Name Hazardous Substance
(适) 铅  镉 铬  醚
(if applicable) Pb Hg Cd Cr6 PBB PBDE
黄铜铜部
X O O O O O
Brass and Copper Parts
装
X O O O O O
Coupling Devices
!"装
O O X O O O
Switching Devices
#$#$配
Cable and Cable X O O O O O
Accessories
%
X O O O O O
Batteries
&表'*+SJ/T 11364 规-.0.
This table is prepared in accordance with China SJ/T 11364.
O:
表5该
质7该部8 9质:; 量97GB/T26572规- 限量要?@A.
Indicates that the concentration of the Hazardous Substance in all homogeneous materials of the part is below the relevant threshold of China
GB/T 26572.
X:
表5该
质CD7该部 EF9质:; 量超HGB/T26572规- 限量要?.
Indicates that the concentration of the Hazardous Substance in at least one homogeneous material of the part is above the relevant threshold of
China GB/T 26572.

 IKLM限*+SJ/Z11388 规-O-.


The EFUP value of this EEP is defined in accordance with China SJ/Z 11388. EEP_2016−06

TM-4428 Page 8 Big Blue 500D, 600 X


3-5. Duty Cycle And Overheating
100% Duty Cycle At 500 Amperes Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
without overheating.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.

Continuous Welding

202 356

3-6. Volt-Ampere Curves


The volt-ampere curve shows the
minimum and maximum voltage
and amperage output capabilities of
the welder/generator. Curves of all
100 other settings fall between the
Ranges curves shown.

300−Max
80 185−425
125−320
85−190
60
55−90
DC VOLTS

40

20

0
0 100 200 300 400 500 600 700 800 900
DC AMPERES

203 412

Big Blue 500D, 600 X TM-4428 Page 9


3-7. Fuel Consumption
The curve shows typical fuel use
under weld or power loads.

1800 RPM

IDLE

0
0 50 100 150 200 250 300 350 400 450 500
DC WELD AMPERES AT 100% DUTY CYCLE

193 093

3-8. AC Generator Power Curve


The AC power curve shows the
generator power in amperes avail-
able at the 120 and 240 volt
receptacles.

150 300

125 250

100 200
AC VOLTS

75 150

50 100

25 50

0 0
0 5 10 15 20 25 30
AC AMPERES IN 240V MODE
0 10 20 30 40 50 60
AC AMPERES IN 120V MODE

193 018

TM-4428 Page 10 Big Blue 500D, 600 X


SECTION 4 − INSTALLATION
4-1. Installing Welder/Generator

Airflow Clearance
Movement 18 in.
(460 mm)
18 in.
18 in. (460 mm)
(460 mm)

OR OR
18 in.
18 in. (460 mm)
(460 mm)

Location/Mounting

Welding Bolting
Unit In Unit In
Place 2 Place 3
2

OR

OR

Tools Needed: 1 1

9/16 in. install3 2014−12 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712

 Go to MillerWelds.com for more ! Do not weld on base. Welding on To Bolt Unit In Place:
information on truck installations. base can cause fuel tank fire or ex- Remove hardware securing the four
plosion. Weld only on the four mounting brackets to the base. Reverse
Movement mounting brackets or bolt unit brackets and reattach to base with original
! Do not move or operate unit where down. hardware.
it could tip. NOTICE − Do not mount unit by supporting
Mount unit to truck or trailer with 1/2 in. (12
the base only at the four mounting bracket-
 See Section 4-3 for lifting eye rating. s. Use cross-supports to adequately sup-
mm) or larger hardware (not supplied).

Airflow Clearance port unit and prevent damage to base. To Weld Unit In Place:
1 Cross-Supports Weld unit to truck or trailer only at the four
NOTICE − Do not install unit where air flow
2 Mounting Brackets (Supplied) mounting brackets.
is restricted or engine may overheat.
Mount unit on flat surface or use cross-sup-
Location/Mounting ports to support base. Secure unit with
! Always securely fasten welding mounting brackets.
generator onto transport vehicle or 3 1/2 in Bolt And Washer (Minimum −
trailer and comply with all DOT and Not Supplied)
other applicable codes. 4 3/8-16 x 1 in. Screws (Supplied)

Big Blue 500D, 600 X TM-4428 Page 11


4-2. Grounding Generator To Truck Or Trailer Frame
! Always ground generator
frame to vehicle frame to pre-
vent electric shock and static
electricity hazards.
! Also see AWS Safety &
Health Fact Sheet No. 29,
Grounding of Portable And
Vehicle Mounted Welding
Generators.
! Bed liners, shipping skids,
and some running gear insu-
late the welder/generator
from the vehicle frame. Al-
ways connect a ground wire
from the generator equip-
ment grounding terminal to
bare metal on the vehicle
frame as shown.
1 2
! Use GFCI protection when
GND/PE operating auxiliary equip-
ment. If unit does not have
GFCI receptacles, use GFCI-
protected extension cord.
Do not use GFCI receptacles
to power life support equip-
ment.
3 1 Equipment Grounding
Terminal (On Front Panel)
2 Grounding Cable (Not
Supplied)
3 Metal Vehicle Frame
Connect cable from equipment
ground terminal to metal vehicle
frame. Use #8 AWG or larger insu-
lated copper wire.

 Electrically bond generator


frame to vehicle frame by met-
al-to-metal contact.

rot_grnd1 2012−03 − 800 652-D

4-3. Using Lifting Eye


1 Lifting Eye
2 Nut
3 Carriage Bolt
1
Raise lifting eye until it snaps in
place. Lower lifting eye when not
needed.
To lock the lifting eye in the upright
position, insert a 3/8-16 x 1-1/2 in.
2 carriage bolt through slot in bracket
and secure with nut (bolt and nut not
supplied).

Tools Needed:
3

Lift1 2008−01 804 712

TM-4428 Page 12 Big Blue 500D, 600 X


4-4. Installing Exhaust Pipe
! Stop engine and let cool.
 Point exhaust pipe in desired di-
rection but always away from front
panel and direction of travel.

Tools Needed:
1/2 in. Exhaust1 2008−01 Ref. 803 604 / Ref. 236 972

4-5. Connecting The Battery

Tools Needed:
1/2 in.
Conn_batt1 2014−11 802 168-E / S-0756-C

NOTICE − Lead acid batteries discharge Battery is most easily accessed through  Never start the engine when the
when stored in any temperature. Units that the rear panel. Remove battery access cables are loose or poorly connected
are stored should have the battery panel from rear panel. Connect battery, to the battery terminals.
recharged every three months and before negative cable last. Reinstall battery ac-  Never disconnect the battery while
being put into service. To preserve opti- cess panel. the engine is running.
mum battery performance and life,
 Do not allow the battery cables to  Never use a quick battery charger to
recharge battery in storage when the
touch opposing terminals. When con- start the engine.
open−circuit voltage drops to 12.4 volts
necting the battery cables attach the
DC when measured across the battery  Do not charge battery with Engine
positive (+) cable to the positive (+)
terminals. Control switch On.
battery terminal first, followed by neg-
! Connect negative (−) cable last. ative (−) cable to negative (−) battery  Always disconnect the negative (−)
NOTICE − Wait two minutes after engine terminal. battery cable before charging battery.
shutdown before disconnecting battery or
engine controller may be damaged.

Big Blue 500D, 600 X TM-4428 Page 13


4-6. Engine Prestart Checks
NOTICE − Follow run-in procedure in engine manual. If un-
burned fuel and oil collect in exhaust pipe, see Section 13.

Full

Diesel

Deutz D2011L04i Engine

Full

NOTICE − Follow run-in procedure in engine manual. If un-


burned fuel and oil collect in exhaust pipe, see Section 13.

Full

Diesel

Deutz F3L912 Engine

Full

Ref. 803 657 / 803 658

 Check all engine fluids daily. cause wetstacking or engine damage.


Follow run-in procedure in engine manu-
Oil
After fueling, check oil with unit on level sur-
al. If unburned fuel and oil collect in ex- face. If oil is not up to full mark on dipstick,
Engine must be cold and on a level surface.
haust pipe, see Section 13. add oil (see maintenance label).
The Automatic shutdown system stops en-
gine if oil pressure is too low or coolant tem-
perature is too high. Fuel
 To improve cold weather starting:
Use optional Starting Aid switch (see
Section 5-1).
 This unit has a low oil pressure shut- NOTICE − Do not use gasoline. Gasoline
down switch. However, some condi- will damage engine. Keep battery in good condition. Store
tions may cause engine damage before battery in warm area.
the engine shuts down. Check oil level
Add fresh diesel fuel before starting to pre-
often and do not use the oil pressure Use fuel formulated for cold weather
vent air from entering the fuel system (see
shutdown system to monitor oil level. (diesel fuel can gel in cold weather).
engine maintenance label for fuel specifica-
Contact local fuel supplier for fuel in-
tions). Leave filler neck empty to allow room
NOTICE − Diesel engines in Miller equip- formation.
for expansion.
ment are meant to operate optimally at
moderate to rated load. Using light or no Use correct grade oil for cold weather
load for extended periods of time may Engine stops if fuel level is low. (see Section 7-1 or 8-1).

TM-4428 Page 14 Big Blue 500D, 600 X


4-7. Weld Output Terminals
! Turn off power before connecting to
weld output terminals.
! Do not use worn, damaged, under-
sized, or repaired cables.
1 Positive (+) Weld Output Terminal
2 Negative (−) Weld Output Terminal
Stick and TIG Welding
For Stick and TIG welding Direct Current Elec-
trode Positive (DCEP), connect electrode
holder cable to Positive (+) terminal on left and
work cable to Negative (−) terminal on right.
For Direct Current Electrode Negative
(DCEN), reverse cable connections.
If equipped with optional Polarity switch or op-
tional Polarity/AC switch, connect electrode
holder cable to Electrode (+) terminal on left
and work cable to Work (−) terminal on right.

803 602

4-8. Connecting Weld Output Cables

2
6
3
1

Tools Needed: 5
3/4 in. (19 mm)

803 778-B

! Turn off power before connecting to sure that the surfaces of the weld cable 5 Weld Cable Terminal
weld output terminals. terminal and copper bar are clean.
6 Copper Bar
! Failure to properly connect weld ca- 1 Correct Weld Cable Connection
bles may cause excessive heat and Remove supplied nut from weld output ter-
start a fire, or damage your machine. 2 Incorrect weld Cable Connection minal. Slide weld cable terminal onto weld
3 Weld Output Terminal output terminal and secure with nut so that
 Do not place anything between weld weld cable terminal is tight against copper
cable terminal and copper bar. Make 4 Supplied Weld Output Terminal Nut bar.
connecting weld output cables 3−2010

Big Blue 500D, 600 X TM-4428 Page 15


4-9. Selecting Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source
is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine
cable size.

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
100 ft (30 m) or Less
(45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
10 − 60%
60 − 100%
Welding Duty 10 − 100% Duty Cycle
Duty Cycle
Amperes Cycle AWG (mm2)
AWG (mm2)
AWG (mm2)
100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)
150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)
200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)
250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x2/0 (2x70)
300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95)
350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95) 2x4/0 (2x120)
400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 2x4/0 (2x120)
500 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 3x3/0 (3x95) 3x3/0 (3x95)
600 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 3x3/0 (3x95) 3x4/0 (3x120) 3x4/0 (3x120)
* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).
Ref. S-0007-L 2015−02

4-10. Connecting To Remote Amperage Adjust Receptacle RC13


1 Remote Amperage Adjust
Receptacle RC13
Connect optional remote control to
RC13 (see Section 5-3).

Ref. 154 862-A / 048 720-K / 803 602

TM-4428 Page 16 Big Blue 500D, 600 X


SECTION 5 − OPERATING WELDER/GENERATOR

5-1. Front Panel Controls (See Section 5-2)

7 8 11 12 5 6 3

10 1 2
9

238 627-B / 803 602

Big Blue 500D, 600 X TM-4428 Page 17


5-2. Description Of Front Panel Controls (See Section 5-1)

Engine Starting Controls information.  The numbers around the control are for
1 Starting Aid Switch (Optional) 4 Battery Voltmeter (Optional) reference only and do not represent an
Use switch to energize starting aid for cold Use gauge to check battery voltage and moni- actual percentage value.
weather starting (see starting instructions fol- tor the engine charging system. The meter 9 Stick/TIG Selection Switch
lowing). should read about 14 volts DC when the en- Use switch to disable the max OCV circuit
2 Engine Control Switch gine is running, and about 12 volts DC when and the arc drive (dig) circuit for scratch start
the engine is stopped. TIG welding (see max OCV note under Weld
NOTICE − Diesel engines in MILLER equip-
ment are meant to operate optimally at mod- 5 Engine Temperature Gauge Controls).
erate to rated load. Using light or no load for Normal temperature is 212 − 239°F (100 − When switch is in the Stick position, the max
extended periods of time may cause wet- 115°C). Engine stops if temperature exceeds OCV circuit resets Amperage Adjust Control
stacking or engine damage. 270°F (132°C). R1 to maximum when the arc breaks.
Use switch to start and stop engine. 6 Engine Oil Pressure Gauge Also in the Stick position, the arc drive (dig)
To Start: Normal pressure is 30 − 60 psi (207 − 414 circuit provides additional amperage during
kPa). Engine stops if pressure is below 10 psi low voltage (short arc length conditions) to
NOTICE − For models with D2011L04i en- prevent “sticking” electrodes.
(69 kPa).
gines: Do not use ether or other starting fluids.
Using starting fluids voids warranty. Weld Controls When switch is in Scratch Start TIG position,
the max OCV and arc drive (dig) circuits are
 If engine does not start, let engine come  Max OCV Control Circuit: This unit has disabled and OCV changes when the control
to a complete stop before attempting re- a max OCV control circuit that resets Am- is adjusted.
start. perage Adjust control R1 to maximum 10 Amperage Adjust Switch And Remote
when the arc breaks. When an arc is Amperage Adjust Receptacle
Above 325 F (05 C): turn Engine Control struck, weld output control returns to the
switch to Start. Release Engine Control R1 front panel or combination front panel/ Connect optional remote control to RC13
switch when engine starts. remote control setting. The Amperage (See Section 4-10). Use switch to select front
Below 325 F (05 C): push Starting Aid switch Adjust control adjusts amperage only panel or remote amperage control. For re-
up for 60 seconds. While still holding Starting when welding and does not adjust open- mote control, place switch in Remote position
Aid switch, turn Engine Control switch to circuit voltage. and connect remote control to Remote Am-
Start. Release Engine Control switch and perage Adjust receptacle RC13 (see Sec-
Starting Aid switch when engine starts. The max OCV circuit is disabled when tions 4-10 and 5-3).
To Stop: turn Engine Control switch to Off the Stick/TIG Selection switch is in Weld Meters
position. Scratch Start TIG position (see item 9).
11 AC/DC Voltmeter (Optional)
Engine Gauges And Meters Voltmeter displays voltage at the weld output
7 Ampere Range Switch
3 Engine Fuel/Hour Gauge terminals, but not necessarily the welding arc
NOTICE − Do not switch under load. due to resistance of cable and connections.
Use gauge to monitor engine running time for
Use switch to select weld amperage range. 12 AC/DC Ammeter (Optional)
scheduling maintenance and to determine
For most welding applications, use lowest
cause of engine shutdowns. Ammeter displays amperage output of the
amperage range possible to help prevent arc
Use gauge to check fuel level. Engine stops outages. unit.
if fuel level is low. 8 Amperage Adjust Control 13 Polarity Switch (Optional) (Not Shown)
To check fuel level when engine is not run- Control adjusts amperage within range se- NOTICE − Do not switch under load.
ning, turn Engine Control switch to Run or lected by Ampere Range switch. Weld output Use switch to change weld output. Select ei-
Run/Idle position. would be about 180 A DC with controls set as ther DC Electrode Positive (DCEP) or DC
See Section 5-5 for complete fuel/hour gauge shown (50% of 150 to 330 A). Electrode Negative (DCEN).

TM-4428 Page 18 Big Blue 500D, 600 X


5-3. Remote Amperage Control (Optional)
1 Remote Amperage Adjust
Receptacle RC13
1
Connect optional remote control to
RC13 (see Section 4-10).

Example: Combination Remote Amperage Control (Stick) In Example:


Range = 115 to 330 A DC
Percentage Of Range = 50%
Max = About 240 A DC (50% of 150 to 330)

Max (240 A DC)

Min (84 A DC)

Set Switches Set Range Set Control Adjust Optional Remote Control
Ref. 154 862-A / Ref. 236 973 / 803 602

5-4. Weld Control/Arc Condition Information Label


 Set weld controls as shown to
achieve softer or stiffer arc condi-
tions for different applications.

212 944-A

Big Blue 500D, 600 X TM-4428 Page 19


5-5. Fuel/Hour Gauge Descriptions

TM-4428 Page 20 Big Blue 500D, 600 X


SECTION 6 − OPERATING AUXILIARY EQUIPMENT

6-1. Export Auxiliary Power Receptacles

4
3

2
1

805 259-A

! Use GFCI protection when operat- ! Test GFCI monthly. See Section 6-2  At least once a month, press test but-
ing auxiliary equipment. If unit does for GFCI information and for reset- ton. If ELCB is working properly, power
not have GFCI receptacles, use ting and testing procedures. will be disconnected. Reset breaker.
GFCI-protected extension cord. Do
not use GFCI receptacles to power 2 Circuit Breaker CB2 4 220V 16A AC International
life support equipment. CB2 protects GFCI1 from overload. If a cir- Receptacle RC1
cuit breaker opens, the receptacle does not Maximum output is 4 kVa/kW from RC1.
! Unplug power cord before attempt-
work. Press CB2 to reset breaker.
ing to service accessories or tools. Maximum combined output of all recep-
3 Earth Leakage Circuit Breaker tacles is 4 kVA/kW.
1 120V 15/20A AC Receptacle GFCI1
ELCB1
Receptacles supply 60 Hz single-phase EXAMPLE: If 13 A is drawn from RC1, only
ELCB1 protects RC1 from Earth leakage 7 A is available at GFCI1:
power at weld/power speed.
fault. If circuit breaker opens the receptacle
Maximum output is 2.4 kVA/kW from does not work. Place circuit breaker switch (240 V x 13 A) + (120 V x 7 A) =
GFCI1. in the On position to reset breaker. 4.0 kVA/kW

Big Blue 500D, 600 X TM-4428 Page 21


6-2. GFCI Receptacle Information, Resetting And Testing

2
3
4

! Test and reset GFCI only at Run speed.

RotGFCI1 2014−09

! Use GFCI protection when operating If a ground fault is detected, the GFCI Reset Resetting GFCI Receptacles
auxiliary equipment. If unit does not button pops out, and the circuit opens to dis-
If a GFCI fault occurs, stop engine and dis-
have GFCI receptacles, use GFCI- connect power to the faulty equipment. A
connect equipment from GFCI receptacle.
protected extension cord. Do not GFCI receptacle does not protect against
Check for damaged or wet tools, cords,
use GFCI receptacle to power life circuit overloads, short circuits, or shocks
plugs, etc. connected to the receptacle.
support equipment. not related to ground faults. Reset and test
Start engine and operate at Run (weld/
GFCI receptacle according to the following
power) speed. Press GFCI Reset button.
! Unplug power cord before attempt- procedures.
Reconnect equipment to GFCI receptacle.
ing to service accessories or tools. Resetting/Testing GFCI Receptacle If GFCI Reset button pops out again, check
the equipment and repair or replace if faulty.
1 120 V 20 A AC GFCI Receptacle ! Test GFCI monthly. See Testing
GFCI Receptacle. Testing GFCI Receptacles
2 GFCI Receptacle Test Button
! Do not test or reset GFCI receptacles  GFCI testing must be done with engine
3 GFCI Receptacle Reset Button at idle speed/low voltage or the GFCI running at Run (weld/power) speed.
will be damaged and not provide Start engine and operate at Run (weld/
4 GFCI Indicator Light (LED) protection from electric shock power) speed.
caused by a ground fault.
GFCI Receptacles Press the GFCI Test button. The GFCI Re-
! If LED blinks, stop using GFCI re- set button should pop out.
GFCI receptacles protect the user from ceptacle and have it replaced. Press the GFCI Reset button.
electric shock if a ground fault occurs in
equipment connected to the receptacle. A ! Extension cords with bad insulation Have GFCI replaced if any of the follow-
ground fault occurs when electrical current or of extended length can allow ing occur:
takes the shortest path to ground (which enough leakage current to trip the GFCI does not trip when tested
could be through a person) rather than fol- GFCI circuit. Reset and test as fol- LED blinks
low its intended safe path. lows. GFCI does not reset.

TM-4428 Page 22 Big Blue 500D, 600 X


SECTION 7 − DEUTZ D2011L04i MAINTENANCE
7-1. Maintenance Label (Deutz D2011L04i-Powered Units)

DEUTZ

DEUTZ Service:
http://www.deutzamericas.com
To ensure rapid, efficient service support, you
should initially contact your nearest DEUTZ ser-
vice distributor or dealer: http://www.deutzamer-
icas.com/deutznew/distributors/index.htm.
They are staffed with highly qualified parts, ser-
vice and engine specialists to handle your differ-
ent needs.
The DEUTZ Service Desk enhances this sup-
port and can be contacted by completing and
submitting the Service Support Form. Customer
in the US and CANADA can also contact the ser-
vice desk by calling our toll free number,
1-800-241-9886.
Our normal hours of operation are from 8:00 AM
to 6:00 PM Monday through Friday EST. You
may contact our on call service 24 hours, 7 days
a week. We ask that when you contact us,
please have available or provide specific engine
information (serial number, model number etc.)
as shown on the Service Support Form.

237352-K

Big Blue 500D, 600 X TM-4428 Page 23


7-2. Routine Maintenance (Deutz D2011L04i-Powered Units)

! Stop engine before maintaining.

Recycle engine
 See Engine Manual and Maintenance Label
for important start-up, service, and storage
fluids.
information. Service engine more often if
used in severe conditions.

 = Check  = Change  = Clean = Replace Reference


* To be done by Factory Authorized Service Agent

Every Section 4-6


8 FUEL
WATER
Hours

 Fuel/Water Separator  Fuel Level  Oil Level  Oil, Fuel Spills


Every
50
Hours

 Weld Terminals

Every Section 7-5


100
Hours

 Battery Terminals  Air Cleaner Hoses  Air Cleaner Element


Every Engine
250 1/2 in.
(13 mm) Manual,
Hours Section 7-6

Unreadable Labels  Fan Belt Tension  Cooling System Spark Arrestor

Every
500
Hours

 Weld Cables
Every NOTICE − Change engine Section 4-6,
1000 oil and filter after first 50 to 7-4, 7-9 and
OR
Hours 75 hours of use. Engine
Manual

 Oil  Oil Filter  Fuel Filter  Inside Unit Valve Clearance*

FUEL

SLUDGE
 Slip Rings*  Drain Sludge
 Brushes*

Every
3000
Hours

 Injectors*

Every
6000
Hours
or 5
Years
 Engine Timing Belt
 = Clean unit exterior, including stainless steel, frequently to prevent rust and corrosion.

TM-4428 Page 24 Big Blue 500D, 600 X


7-3. Operating Optional Oil Pan Heater

1 Optional Oil Heater Plug


Use heater to maintain a constant
engine oil temperature.
To turn on heater, connect heater
plug to 120 volts AC receptacle.
Heater is rated at 300 watts
! Do not run engine while oil
pan heater is on.
NOTICE −In extremely cold weath-
er, heater should be connected to
120 volts AC receptacle when en-
gine oil is warm to eliminate possib-
ility of oil coking on heater.
Severe coking on heater element
may cause damage to engine, en-
gine oil, and oil pan heater.
! The area near the the oil pan
heater gets hot.
Disconnect plug to turn off heater.

803 602 / Ref. 803 145

7-4. Checking Generator Brushes

! Stop engine and let cool.


1 Generator Brush
Mark and disconnect leads at brush hold-
er cap. Remove brushes.
Minimum Length:
Replace brushes if damaged or if brush
5/8 in. (16 mm)
material is at or near minimum length.
New Length:
1-1/4 in. (32 mm)

1
Replace
Damaged Brushes
GenBrush1 2014−10 / Ref 190 823

Big Blue 500D, 600 X TM-4428 Page 25


7-5. Servicing Air Cleaner (Deutz D2011L04i-Powered Units)
! Stop engine.
NOTICE − Do not run engine without air
cleaner or with dirty element. Engine
damage caused by using a damaged ele-
ment is not covered by the warranty.

 The air cleaner primary element can


be cleaned but the dirt holding capac-
ity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while clean-
4 ing and the possibility of filter damage
makes cleaning a risk. Consider the
1 risk of unwarrantable equipment
damage when determining whether
2 to clean or replace the primary ele-
ment.
NOTICE − If you decide to clean the pri-
3 mary element, we strongly recommend
installing an optional safety element to
provide additional engine protection.
Never clean a safety element. Replace
Optional the safety element after servicing the pri-
mary element three times.
1 Intake Manifold
2 Service Indicator (Optional,
Customer Supplied)
3 Service Indicator Window
5 6 7 8 4 Service Indicator Reset Button
Service air cleaner element if red band
appears in window. A green band means
air cleaner is okay. Press button to reset
indicator.
Clean or replace primary element if dirty
(see note above before cleaning). Re-
place primary element if damaged. Re-
place primary element yearly or after six
cleanings.
Optional
5 Housing
9
6 Safety Element (Optional)
7 Primary Element
8 Cover
9 Dust Ejector
To clean air filter
Wipe off cover and housing. Remove
cover and dump out dust. Remove ele-
ment(s). Wipe dust from inside cover and
housing with damp cloth. Reinstall safety
Keep nozzle element (if present). Reinstall cover.
2 in (51 mm)
from element.
! Do not clean housing with air
hose.
Clean primary element with compressed
air only.
Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in (3 mm) nozzle and
keep nozzle at least 2 in (51 mm) from
inside of element. Replace primary ele-
ment if it has holes or damaged gaskets.
Reinstall primary element and cover
Blow Inspect (dust ejector down).

aircleaner1 5/16− ST-153 929-B / ST-153 585 / Ref. S-0698-B

TM-4428 Page 26 Big Blue 500D, 600 X


7-6. Inspecting/Cleaning Optional Spark Arrestor (Deutz D2011L04i-Powered Units)
! Stop engine and let cool.
1 Spark Arrestor Muffler
2 Cleanout Plug
Remove plug and remove any dirt
covering cleanout hole.
Start engine and run at idle speed to
blow out cleanout hole. If nothing
2
blows out of hole, briefly cover end
of exhaust pipe with fireproof
material.
! Stop engine and let cool.
Reinstall cleanout plug.

Tools Needed:
3/8 in.

Ref. 803 656-F / Ref. 236 972

7-7. Battery Maintenance


Lead acid batteries discharge when stored in any temperature. Units that are stored should have the battery recharged every three months and before
being put into service. To preserve optimum battery performance and life, recharge battery in storage when the open−circuit voltage drops to 12.4 volts
DC when measured across the battery terminals.

Big Blue 500D, 600 X TM-4428 Page 27


7-8. Adjusting Engine Speed (Deutz D2011L04i-Powered Units)
! Stop engine and let cool.

 For operation at high altitude,


engine may require adjust-
ments. If adjustment is neces-
sary, contact engine manufac-
turer’s Factory Authorized Ser-
vice Agent.
Engine speed is factory set and
should not require adjustment. Af-
ter tuning engine, check engine no
load speed with a tachometer or fre-
quency meter (see table for no load
speeds). If necessary, adjust speed
as follows:
Start engine and run until warm.
Place Stick/TIG switch in Stick
1850 rpm Max. position.
(61.6 Hz)
1250 rpm Standard Models:
(41.5 Hz) 1 Engine Speed Adjustment
Screw
2 Locking Nut
Loosen nut. Turn screw until engine
runs at weld/power speed. Tighten
nut.
 Do not set engine speed higher
than specified.
Models With Automatic Idle
(Optional)
3 Throttle Rod
Standard Models
4 Locknut
Loosen locknuts. Place engine
control switch in Run/Idle position.
Turn throttle rod until engine runs at
idle speed. Tighten locknuts.
2
5 Engine Speed Adjustment
Screw
1
6 Locknut
Place engine control switch in Run
position.
Loosen locknut. Turn screw until
engine runs at weld/power speed.
Tighten locknut.

Models With Automatic Idle (Optional)


 Do not set engine speed higher
than specified.
! Stop engine.
Close door.

4 3

6
Tools Needed:

3/8, 7/16 in.


803 657

TM-4428 Page 28 Big Blue 500D, 600 X


7-9. Servicing Fuel And Lubrication Systems (Deutz D2011L04i-Powered Units)

Tools Needed:

7
1

803 657

! Stop engine and let cool. maintenance label for oil/filter change in- To replace secondary fuel filter:
formation. See engine manual.
! After servicing, start engine and
check for fuel leaks. Stop engine, Close doors.
To drain water from fuel system:
tighten connections as necessary, To drain sludge from fuel tank:
and wipe up spilled fuel. Open primary fuel filter petcock and drain ! Beware of fire. Do not smoke and
1 Oil Filter water into metal container. Close petcock keep sparks and flames away from
when water-free fuel flows. drained fuel. Dispose of drained fuel
2 Oil Drain Valve And Hose
in an environmentally-safe manner.
3 Oil Fill Cap To replace primary fuel filter: Do not leave unit unattended while
4 Primary Fuel Filter (Fuel/Water Sepa- draining fuel tank.
rator) Turn filter counterclockwise. Remove filter.
! Properly lift unit and secure in a level
5 Petcock position. Use adequate blocks or
Apply thin coat of fuel to gasket on new filter.
6 Secondary Fuel Filter Fill filter with fuel. Install filter and turn clock- stands to support unit while drain-
wise. Bleed air from fuel system according ing fuel tank.
7 Fuel Tank Sludge Drain Valve
to engine manual. Attach 1/2 ID hose to drain valve. Put metal
To change oil and filter: container under drain, and use screwdriver
Route oil drain hose and valve through hole Inspect fuel line, and replace if cracked or to open sludge drain valve. Close valve
in base. See engine manual and engine worn. when sludge has drained. Remove hose.

Big Blue 500D, 600 X TM-4428 Page 29


7-10. Overload Protection (Deutz D2011L04i-Powered Units)
! Stop engine.

 When a supplementary protector,


circuit breaker or fuse opens, it usu-
ally indicates a more serious problem
exists.
1 Fuse F1
2 Fuse F2
F1 and F2 protect the stator exciter wind-
ing from overload. If F1 opens, weld and
generator power is low or stops entirely.
If F2 opens, weld output is low or stops
entirely. 4 kVA/kW generator power is still
available.
3 Circuit Breaker CB4 (Not Shown)
2
1 4 Circuit Breaker CB10 (Not Shown)
5 Supplementary Protector CB11
6 Supplementary Protector CB12
7 Supplementary Protector CB13
8 Circuit Breaker CB14 (Not Shown)
CB4 protects the welding arc drive (dig)
7 circuit. If CB4 opens, electrode may stick
6 to the workpiece more frequently during
5 low voltage (short arc length) conditions.
CB4 automatically resets when the fault
is corrected.
CB10 protects the engine battery circuit.
If CB10 opens, the engine will not crank.
CB10 automatically resets when the fault
is corrected.
CB11 protects the weld control circuit. If
CB11 opens the max OCV circuit does
not work and open circuit voltage is vari-
able at all times (see max OCV note un-
der Weld Controls in Section 5-2).
CB12 protects the field flashing circuit. If
CB12 opens, the generator may not ex-
cite at start-up and weld and generator
power output may not be available.
CB13 protects the engine control circuit.
If CB13 opens, the engine does not
crank.
CB14 protects throttle solenoid TS1 on
units with auto idle option. If CB14 opens,
the engine does not run at idle speed.
CB14 automatically resets when the fault
is corrected.
Press button to reset supplementary pro-
tector.

Ref. 803 657

TM-4428 Page 30 Big Blue 500D, 600 X


SECTION 8 − DEUTZ F3L912 MAINTENANCE
8-1. Maintenance Label (Deutz F3L912-Powered Units)

DEUTZ

DEUTZ Service:
http://www.deutzamericas.com
To ensure rapid, efficient service support, you
should initially contact your nearest DEUTZ ser-
vice distributor or dealer: http://www.deutzamer-
icas.com/deutznew/distributors/index.htm.
They are staffed with highly qualified parts, ser-
vice and engine specialists to handle your differ-
ent needs.
The DEUTZ Service Desk enhances this sup-
port and can be contacted by completing and
submitting the Service Support Form. Customer
in the US and CANADA can also contact the ser-
vice desk by calling our toll free number,
1-800-241-9886.
Our normal hours of operation are from 8:00 AM
to 6:00 PM Monday through Friday EST. You
may contact our on call service 24 hours, 7 days
a week. We ask that when you contact us,
please have available or provide specific engine
information (serial number, model number etc.)
as shown on the Service Support Form.

237 352-K

Big Blue 500D, 600 X TM-4428 Page 31


8-2. Routine Maintenance (Deutz F3L912-Powered Units)
! Stop engine before maintaining.

Recycle engine
 See Engine Manual and Maintenance Label
for important start-up, service, and storage
fluids.
information. Service engine more often if
used in severe conditions.

 = Check  = Change  = Clean = Replace Reference


* To be done by Factory Authorized Service Agent
Every Section 4-6,
8 FUEL
WATER
Hours

 Fuel/Water Separator  Fuel Level  Oil Level  Oil, Fuel Spills


Every
50
Hours

 Weld Terminals
Every Section 8-5
100
Hours

 Battery Terminals  Air Cleaner Hoses  Air Cleaner Element


Every Engine
250 1/2 in.
(13 mm) Manual,
Hours Section 8-6

Unreadable Labels  Fan Belt Tension  Cooling System Spark Arrestor


Every NOTICE − Change engine Section 8-8
500 oil and filter after first 50 to
Hours 75 hours of use.

 Weld Cables  Oil  Oil Filter


Every Section 4-6,
FUEL
1000 OR 8-3 and En-
Hours gine Manual

SLUDGE
 Slip Rings*  Inside Unit  Fuel Filter  Drain Sludge
 Brushes*

Valve Clearance*
Every
3000
Hours

 Injectors*
 = Clean unit exterior, including stainless steel, frequently to prevent rust and corrosion.

TM-4428 Page 32 Big Blue 500D, 600 X


8-3. Checking Generator Brushes

! Stop engine and let cool.


1 Generator Brush
Mark and disconnect leads at brush hold-
er cap. Remove brushes.
Minimum Length:
Replace brushes if damaged or if brush
5/8 in. (16 mm)
material is at or near minimum length.
New Length:
1-1/4 in. (32 mm)

1
Replace
Damaged Brushes
GenBrush1 2014−10 / Ref 190 823

8-4. Battery Maintenance


Lead acid batteries discharge when stored in any temperature. Units that are stored should have the battery recharged every three months and before
being put into service. To preserve optimum battery performance and life, recharge battery in storage when the open−circuit voltage drops to 12.4 volts
DC when measured across the battery terminals.

Notes

Big Blue 500D, 600 X TM-4428 Page 33


8-5. Servicing Air Cleaner (Deutz F3L912-Powered Units)
! Stop engine.
NOTICE − Do not run engine without air
cleaner or with dirty element. Engine
damage caused by using a damaged ele-
ment is not covered by the warranty.

 The air cleaner primary element can


be cleaned but the dirt holding capac-
ity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while clean-
4 ing and the possibility of filter damage
makes cleaning a risk. Consider the
1 risk of unwarrantable equipment
damage when determining whether
2 to clean or replace the primary ele-
ment.
NOTICE − If you decide to clean the pri-
3 mary element, we strongly recommend
installing an optional safety element to
provide additional engine protection.
Never clean a safety element. Replace
Optional the safety element after servicing the pri-
mary element three times.
1 Intake Manifold
2 Service Indicator (Optional,
Customer Supplied)
3 Service Indicator Window
5 6 7 8 4 Service Indicator Reset Button
Service air cleaner element if red band
appears in window. A green band means
air cleaner is okay. Press button to reset
indicator.
Clean or replace primary element if dirty
(see note above before cleaning). Re-
place primary element if damaged. Re-
place primary element yearly or after six
cleanings.
Optional
5 Housing
9
6 Safety Element (Optional)
7 Primary Element
8 Cover
9 Dust Ejector
To clean air filter
Wipe off cover and housing. Remove
cover and dump out dust. Remove ele-
ment(s). Wipe dust from inside cover and
housing with damp cloth. Reinstall safety
Keep nozzle element (if present). Reinstall cover.
2 in (51 mm)
from element.
! Do not clean housing with air
hose.
Clean primary element with compressed
air only.
Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in (3 mm) nozzle and
keep nozzle at least 2 in (51 mm) from
inside of element. Replace primary ele-
ment if it has holes or damaged gaskets.
Reinstall primary element and cover
Blow Inspect (dust ejector down).

aircleaner1 5/16− ST-153 929-B / ST-153 585 / Ref. S-0698-B

TM-4428 Page 34 Big Blue 500D, 600 X


8-6. Inspecting/Cleaning Optional Spark Arrestor (Deutz F3L912-Powered Units)
! Stop engine and let cool.
1 Spark Arrestor Muffler
2 Cleanout Plug
Remove plug and remove any dirt
covering cleanout hole.
Start engine and run at idle speed to
blow out cleanout hole. If nothing
blows out of hole, briefly cover end
of exhaust pipe with fireproof
material.
! Stop engine and let cool.
2
Reinstall cleanout plug.

Tools Needed:
3/8 in.

Ref: 803 047-C / Ref: 803 656 / Ref. 236 972

Big Blue 500D, 600 X TM-4428 Page 35


8-7. Adjusting Engine Speed (Deutz F3L912-Powered Units)
! Stop engine.

 For operation at high altitude,


engine may require adjust-
ments. If adjustment is neces-
sary, contact engine manufac-
turer’s Factory Authorized Ser-
vice Agent.
Engine speeds have been factory
set and should not require adjust-
Engine Speed ment. After tuning engine, check
(No Load) RPM (Hz) engine speeds with a tachometer.
See table for proper no load speed.
1850 If necessary, adjust speed as fol-
Weld/Power (61.6 Hz) lows:
1 Speed Adjustment Screw
2 Locknut
Loosen nut. Start engine.
Turn screw until engine runs at
weld/power speed. Tighten locknut.

 Do not set engine speed higher


than specified.
2 ! Stop engine.
1
Close side door.

Tools Needed:
9/16, 7/8 in.

803 658 / 134 730-C

Notes

TM-4428 Page 36 Big Blue 500D, 600 X


8-8. Servicing Fuel And Lubrication Systems (Deutz F3L912-Powered Units)

Tools Needed:

2
1

803 658

! Stop engine and let cool. maintenance label for oil/filter change in- To replace secondary fuel filter:
formation. See engine manual.
! After servicing, start engine and
check for fuel leaks. Stop engine, Close doors.
To drain water from fuel system:
tighten connections as necessary, To drain sludge from fuel tank:
and wipe up spilled fuel. Open primary fuel filter petcock and drain ! Beware of fire. Do not smoke and
1 Oil Filter water into metal container. Close petcock keep sparks and flames away from
when water-free fuel flows. drained fuel. Dispose of drained fuel
2 Oil Drain Valve And Hose
in an environmentally-safe manner.
3 Oil Fill Cap To replace primary fuel filter: Do not leave unit unattended while
4 Primary Fuel Filter (Fuel/Water Sepa- draining fuel tank.
rator) Turn filter counterclockwise. Remove filter.
! Properly lift unit and secure in a level
5 Petcock position. Use adequate blocks or
Apply thin coat of fuel to gasket on new filter.
6 Secondary Fuel Filter Fill filter with fuel. Install filter and turn clock- stands to support unit while drain-
wise. Bleed air from fuel system according ing fuel tank.
7 Fuel Tank Sludge Drain Valve
to engine manual. Attach 1/2 ID hose to drain valve. Put metal
To change oil and filter: container under drain, and use screwdriver
Route oil drain hose and valve through hole Inspect fuel line, and replace if cracked or to open sludge drain valve. Close valve
in base. See engine manual and engine worn. when sludge has drained. Remove hose.

Big Blue 500D, 600 X TM-4428 Page 37


8-9. Overload Protection (Deutz F3L912-Powered Units)
! Stop engine.

 When a supplementary protector, cir-


cuit breaker or fuse opens, it usually in-
dicates a more serious problem exists.
1 Fuse F1
2 Fuse F2
F1 and F2 protect the stator exciter winding
from overload. If F1 opens, weld and gener-
ator power is low or stops entirely. If F2
opens, weld output is low or stops entirely.
4 kVA/kW generator power is still available.
3 Circuit Breaker CB4 (Not Shown)
4 Circuit Breaker CB10 (Not Shown)
2
1 5 Supplementary Protector CB11
6 Supplementary Protector CB12
7 Supplementary Protector CB13
8 Circuit Breaker CB14
(Not Shown)
CB4 protects the welding arc drive (dig) cir-
7 cuit. If CB4 opens, electrode may stick to
6 the workpiece more frequently during low
voltage (short arc length) conditions. CB4
5
automatically resets when the fault is cor-
rected.
CB10 protects the engine battery circuit. If
CB10 opens, the engine will not crank.
CB10 automatically resets when the fault is
corrected.
CB11 protects the weld control circuit. If
CB11 opens the max OCV circuit does not
work and open circuit voltage is variable at
all times (see max OCV note under Weld
Controls in Section 5-2).
CB12 protects the field flashing circuit. If
CB12 opens, the generator may not excite
at start-up and weld and generator power
output may not be available.
CB13 protects the engine control circuit. If
CB13 opens, the engine does not crank.
CB14 protects fuel solenoid FS1. If CB14
opens, the engine does not start. CB14 au-
tomatically resets when the fault is cor-
rected.
Press button to reset supplementary pro-
tector.

Ref. 803 658

TM-4428 Page 38 Big Blue 500D, 600 X


Notes

Big Blue 500D, 600 X TM-4428 Page 39


SECTION 9 − THEORY OF OPERATION
1 Engine
Supplies force to turn revolving
fields.
2 Control Relays CR1, CR5,
CR9
CR1 energizes at start-up to supply 15 ♦ 15 14 13
power to starter solenoid.
CR5 energizes at start-up to supply Remote Remote Amperage Amperage Amperage
power for field flashing and to the Current Adjust Receptacle Adjust Adjust
fuel solenoid. Control RC13 Switch S5 Control R1
CR9 (export models only) ener-
gizes at start-up to bypass resistor 12
R7. Stick/TIG
3 Control Relay TD1 or Engine Selection
Fuel/Hour Gauge FUEL/HM Switch S6
3 11
 Eff w/LJ003065 Fuel/Hour
gauge FUEL/HM replaced con- Control Relay
Integrated
trol relay TD1. TD1 Or Fuel/ Rectifier
Hour Gauge SR2
Energizes at start-up to supply
FUEL/HM
power to CR5 and enable engine
gauges and shutdown circuit. (En-
gine shutdown inhibited for 30 sec- 2 10 9 9
onds after start-up.) FUEL/HM also
monitors fuel level and engine run Control Integrated
Relays CR1, Rectifier Fuse F1 Fuse F2
time. SR1
CR5, CR9
4 Control Relays CR3, CR4,
CR6
CR3 energizes at no load to supply 8
power to throttle solenoid TS1. 1 7
CR4 energizes at no load to bypass Exciter
Revolving
resistor R3 and prevent loss of field Engine Fields

Weld
excitation. (Rotor) Stator Windings
CR6 energizes when engine is run-
ning to supply power to idle module. Generator Power
5 Idle Module PC7
Controls engine speed. Without a 6♦
signal from CT1, it lowers engine Throttle
speed to idle (1250 RPM). Solenoid TS1
6 Throttle Solenoid TS1 (Pull To Idle)
Decreases engine speed to idle 27
RPM (1250 RPM) when energized.
7 Main And Exciter Revolving Transformer
Fields 5♦ 4♦
T1
Turn at 1850 RPM maximum for Control Relays
weld and power. The speed and ex- Idle Module
PC7 CR3, CR4,
citation current of the field coils de- CR6
termine voltages in stator windings.
8 Stator Windings
Supply power to exciter, generator
power, and weld circuits.
9 Fuses F1, F2
Protects aux. stator (exciter) wind-
ings from overload.
10 Integrated Rectifier SR1
Changes AC output of stator wind- 28
ings to DC to supply excitation cur- Integrated
rent to the exciter revolving field. Rectifiers
11 Integrated Rectifier SR2 SR4, SR5
Changes AC output of exciter stator
to DC to control DC amperage in
main revolving field as set by R1.

Figure 10-1. Functional Diagram For CC Models


TM-4428 Page 40 Big Blue 500D, 600 X
12 Stick/TIG Selector Switch S6
Disables max OCV circuit and op-
AC Or DC Control Circuits tional auto idle circuit.
13 Amperage Adjust Control R1
Adjusts amperage within range se-
3φ Power lected by S3.
14 Amperage Adjust Switch S5
Selects Panel or Remote amper-
age control.
Weld Current Circuit
15 Remote Amperage Adjust Re-
Either Mechanical Coupling ceptacle RC13
Or External Circuits Connects remote current control.
Magnetic Coupling 16 Current Transformer CT1
Senses output from either genera-
♦ Optional tor power or weld windings, and sig-
nals idle module to increase to or
maintain weld speed (1850 RPM).
17 Supplementary Protectors
CB1, CB2
Protect AC receptacles RC1 and
GFCI1 from overload.
19
18 AC Receptacles RC1 And
Max OCV GFCI1
Control
Provide connection points and
Relay CR7
power for auxiliary equipment.
19 Max OCV Control Relay CR7
Bypasses R1 to allow maximum
20 21 22 open-circuit voltage when not weld-
ing for easier arc starting.
Reactor Ampere Main 20 Reactor Z1
Z1 Range Rectifier
Switch S3 SR3 Tapped reactor limits weld output
16 ♦ 23 and provides coarse ranges.
Current
21 Ampere Range Switch S3
Transformer HF Filter
CT1 Selects coarse range of weld out-
Board PC3 put from Z1.
24♦
22 Main Rectifier SR3
Polarity Changes AC weld output to DC.
Switch
S12 23 HF Filter Board PC3
25 ♦
Protects main rectifier from high fre-
quency and voltage spikes.
17 Ammeter
A2 24 Polarity Switch S12
Supplementary 25♦
Protectors CB1, Selects polarity of weld output.
CB2 25 Voltmeter V1, Ammeter A1
Voltmeter
V1 Display weld voltage and current.
26 Electrode And Work Weld
Output Terminals
18♦
Provide weld output. Without S12,
AC terminals are labeled negative (−)
Receptacles and positive (+).
RC1, GFCI1 27 Transformer T1
Supplies power to arc drive (dig)
26 26 circuit. Arc drive circuit only active
in Stick mode.
Electrode Work 28 Integrated Rectifiers SR4,
Weld Output Weld Output SR5
Terminal Terminal
Change AC output of stator wind-
ings to DC to supply power to arc
drive (dig) circuit.

Electrode Work

Big Blue 500D, 600 X TM-4428 Page 41


1 Engine
15 14
Supplies force to turn revolving fields.
2 Control Relays CR1, CR5, CR9 Filter Board Supplementary
PC6/Remote Protectors
CR1 energizes at start-up to supply CB5, CB6 13
Receptacle RC14
power to starter solenoid.
CR5 energizes at start-up to supply
power for field flashing and to the fuel LED Board PC9
solenoid.
CR9 (export models only) energizes at
start-up to bypass resistor R7.
16 17 12
3 Control Relay TD1 or Engine Voltage/
Process/
Fuel/Hour Gauge FUEL/HM Amperage
Contactor Switch S6
 Eff w/LJ003065 Fuel/Hour gauge Remote Always
Adjust
Switch S5
FUEL/HM replaced control relay On
TD1. Field
Energizes at start-up to supply power Current
to CR5 and enable engine gauges and 11 Regulator
shutdown circuit. (Engine shutdown 3 Board
Voltage/ PC1
inhibited for 30 seconds after start-up.) Amperage
Control Relay
FUEL/HM also monitors fuel level and Adjust
TD1 Or Fuel/
engine run time. Control R1
Hour Gauge
4 Control Relays CR3, CR4, CR6 FUEL/HM
CR3 energizes at no load to supply
power to throttle solenoid TS1. 2
CR4 energizes at no load to bypass re- 10 9 9
sistor R3 and prevent loss of field ex- Control
citation. Relays CR1, Integrated
CR5, CR9 Rectifier Fuse F1 Fuse F2
CR6 energizes when engine is running
SR1
to supply power to idle module.
5 Idle Module PC7
1 7 8
Controls engine speed. Without a sig-
nal from CT1, it lowers engine speed to Exciter
Revolving
idle (1250 RPM). Engine Fields

Weld
6 Throttle Solenoid TS1 (Rotor) Stator Windings
(Pull To Idle)
Generator Power
Decreases engine speed to idle RPM
(1250 RPM) when energized.
6♦ 19
7 Main And Exciter Revolving
Fields Throttle
Solenoid TS1 HF Filter
Turn at 1850 RPM maximum for weld
(Pull To Idle) Board PC5
and power. The speed and excitation 18 ♦ 31
current of the field coils determine volt-
ages in stator windings.
Three-Phase Transformer
8 Stator Windings Generator T1
Supply power to exciter, generator 5♦ 4♦
power, and weld circuits.
Idle Module Control Relays
9 Fuses F1, F2 CR3, CR4,
PC7
Protect aux. stator (exciter) windings CR6 19 ♦
from overload.
Supplementary
10 Integrated Rectifier SR1 Protector
Changes AC output of stator windings CB7
to DC to supply excitation current to
the exciter revolving field.
11 Voltage/Amperage Adjust Control
R1
Adjusts voltage/amperage within 32
range selected by S3. Integrated
12 Field Current Regulator Board Rectifiers
PC1 SR4, SR5
Adjust weld output by changing revolv-
ing field current after comparing feed-
back to voltage/amperage setting of
R1.

Figure 10-2. Functional Diagram For CC/CV Models


TM-4428 Page 42 Big Blue 500D, 600 X
13 LED Board PC9
AC Or DC Control Circuits Monitors power, remote control, command,
engine RPM, and field excitation inputs to
PC1.
14 Supplementary Protectors CB5, CB6
3φ Power
Protect PC6/RC14 from overload.
15 Filter Board PC6/Remote 14 Recep-
tacle RC14
Weld Current Circuit PC6 protects unit from high frequency, and
RC14 connects remote voltage/amperage
Either Mechanical Coupling and contactor control to unit.
Or External Circuits
16 Process/Contactor Switch S6
Magnetic Coupling Selects weld process and weld output on/off
control (Weld Terminals Always On or Re-
♦ Optional mote On/Off Switch Required).
17 Voltage/Amperage Adjust Switch S5
Selects Panel or Remote voltage/amperage
control.
18 Three-Phase Generator
Provides connection points and power for
OCV three-phase auxiliary equipment.
Feedback
19 Supplementary Protector CB7
Protects three-phase generator windings
from overload.
20 HF Filter Boards PC4, PC5
Protect unit from high frequency.
21 Current Transformer CT1
Senses output from either auxiliary power or
weld windings, and signals idle module to in-
crease to or maintain weld speed (1850
24 25 26 RPM).
22 Supplementary Protectors CB1, CB2
Reactor Ampere Main Protect AC receptacles RC1 and GFCI1
Z1 Range Rectifier from overload.
Switch S3 SR3
21♦ 27 23 AC Receptacles RC1 And GFCI1
Current Provide connection points and power for
Transformer HF Filter auxiliary equipment.
CT1 Board PC3 24 Reactor Z1
28♦
Tapped reactor limits weld output and pro-
Polarity vides coarse ranges.
Switch 25 Ampere Range Switch S3
S12 Selects coarse range of weld output from
29 ♦
Z1.
22 Ammeter 26 Main Rectifier SR3
29♦ A2 Changes AC weld output to DC.
Supplementary
27 HF Filter Board PC3
Protectors CB1, Voltmeter
CB2 20 V1 Protects main rectifier from high frequency
and voltage spikes, and provides OCV feed-
back signal to PC1.
HF Filter 20 20
Board PC4 28 Polarity Switch S12
23♦ Selects polarity of weld output.
HF Filter HF Filter
AC 29 Voltmeter V1, Ammeter A1
Board PC4 Board PC5
Receptacles Display weld voltage and current.
RC1, GFCI1 30 Electrode And Work Weld Output Ter-
30 30 minals
Provide weld output. Without S12, terminals
Electrode Work are labeled negative (−) and positive (+).
Weld Output Weld Output
Terminal Terminal 31 Transformer T1
Supplies power to arc drive (dig) circuit. Arc
drive circuit only active in Stick mode.
32 Integrated Rectifiers SR4, SR5
Change AC output of stator windings to DC
to supply power to arc drive (dig)
Electrode Work circuit.

Big Blue 500D, 600 X TM-4428 Page 43


Notes

TM-4428 Page 44 Big Blue 500D, 600 X


SECTION 10 − TROUBLESHOOTING
10-1. Troubleshooting Tables
 See Section 10-2 thru 10-6 for test points and values and Section 14 and following for
parts location.
 Use Miller Testing Booklet (Part No. 150853) when servicing this unit.
 See the Miller Extranet for service memos that may aid in the repair of this product.
 Equipment serviced may need to meet additional requirements as specified in
IEC60974-4, Arc Welding Equipment − Part 4: Periodic Inspection and Testing.

A. Welding − CC Models
Trouble Remedy
No weld output; generator power output Check position of Ampere Range switch S3.
okay at AC receptacles.

Check position of optional polarity switch S12.

Place Amperage Adjust switch in Panel position, or place switch in Remote position and connect remote
control to Remote Amperage Adjust receptacle RC13 (see Sections 4-10 and 5-3).

Check and secure connections to Remote Amperage Adjust receptacle RC13 (see Section 4-10).

Check fuse F2, and replace if open (see Section 7-10 or 8-9).

Check resistance and connections of Voltage/Amperage Adjust control R1; R1 is 34 ohms ±10%.
Replace R1 if necessary.

Check integrated rectifier SR2, and replace if necessary.

Disconnect leads 105 and 108 from the rotor, and check continuity across slip rings. Replace rotor if
necessary.

Clean slip rings, and install new brushes if necessary (see Section 10-17).

Check resistance and connections of resistor R2; full resistance of R2 (end to end) is 10 ohms ±10%.
Replace R2 if necessary. If R2 is replaced, adjust R2 (see Section 10-18).

Check main rectifier SR3, and replace if necessary.

Check reactor Z1 for signs of winding failure. Check continuity across windings, and check for proper
connections. Replace Z1 if necessary.

No weld output or generator power out- Disconnect equipment from generator power receptacles during start-up.
put at AC receptacles.

Check fuses F1 and F2, and replace if open (see Section 7-10 or 8-9).

Reset supplementary protector CB12 (see Section 7-10 or 8-9).

Check diode/capacitor board D1/C1, and replace if necessary.

Check integrated rectifier SR1, and replace if necessary.

Check integrated rectifier SR2, and replace if necessary.

Check capacitor C9, and replace if necessary.

Clean slip rings, and install new brushes if necessary (see Section 10-17).

Check control relay CR5: Check all connections, check coil continuity, check for proper coil voltage, and
check contact voltage (input to common and output to common) to ensure contacts are operating. Re-
place CR5 if necessary.

Check resistance and connections of resistor R3; full resistance of R3 (end to end) is 10 ohms ±10%.
Replace R3 if necessary. If R3 is replaced, adjust R3 (see Section 10-18).

Disconnect leads 105 and 106 from the rotor, and check continuity across slip rings. Replace rotor if
necessary.

Disconnect stator excitation leads 100 and 101, and check continuity between leads. Replace stator if
necessary.

Big Blue 500D, 600 X TM-4428 Page 45


Trouble Remedy
Erratic weld output. Use dry, properly stored electrodes.

Be sure connection to work piece is clean and tight.

Remove excessive coils from weld cables.

Check and tighten connections inside and outside unit.

Clean slip rings, and install new brushes if necessary (see Section 10-17).

Place Stick/TIG selection switch S6 in the TIG position and perform test weld. If unit welds okay,
check control relay CR7 for proper coil voltage and connections. Check continuity of coil and condi-
tion of contacts. Replace CR7 if necessary.

Check main rectifier SR3, and replace if necessary.

High weld output. Check position of Ampere Range switch S3 and Voltage/Amperage Adjust control R1.

Check engine weld/power speed, and adjust if necessary (see engine manual and Section 7-8 or 8-7).

Reset supplementary protector CB11 (see Section 7-10 or 8-9).

Check control relay CR7: Check all connections, check coil continuity, check for proper coil voltage, and
check contact voltage (input to common and output to common) to ensure contacts are operating. Re-
place CR7 if necessary.

Low weld output. Check engine speed, and adjust if necessary (see engine manual and Section 7-8 or 8-7).

Check fuses F1 and F2, and replace if open (see Section 7-10 or 8-9).

Check integrated rectifier SR1, and replace if necessary.

Check integrated rectifier SR2, and replace if necessary.

Check capacitor C9, and replace if necessary.

Disconnect leads 105 and 108 from the rotor, and check continuity across slip rings. Replace rotor if
necessary.

Maximum weld output only in each Check control relay CR7: Check all connections, check coil continuity, check for proper coil voltage, and
ampere range (with Stick/TIG Selection check contact voltage (input to common and output to common) to ensure contacts are operating. Re-
switch in Stick position). place CR7 if necessary.

No remote fine amperage control. Place Amperage Adjust switch S5 in correct position.

Check and secure connections to Remote Amperage Adjust receptacle RC13 (see Section 4-10).

Reset supplementary protector CB11 (see Section 7-10 or 8-9).

Check control relay CR7: Check all connections, check coil continuity, check for proper coil voltage, and
check contact voltage (input to common and output to common) to ensure contacts are operating. Re-
place CR7 if necessary.

Repair or replace remote control device.

No control of weld output or low weld Place Amperage Adjust switch S5 in Panel position, or place switch in Remote position and connect re-
output. mote current control to Remote Amperage Adjust Receptacle RC13.

Difficulty in striking an arc when Stick Place Stick/TIG Selection switch S6 in Stick position.
(SMAW) welding.

Reset supplementary protector CB11 (see Section 7-10 or 8-9).

Check control relay CR7: Check all connections, check coil continuity, check for proper coil voltage, and
check contact voltage (input to common and output to common) to ensure contacts are operating. Re-
place CR7 if necessary.

Low weld output. See low weld output remedies earlier in this section.

Electrode sticks to the workpiece more Circuit breaker CB4 may be open. CB4 automatically resets when the fault is corrected (see Section 7-10
frequently during low voltage (short arc or 8-9).
length) conditions.

TM-4428 Page 46 Big Blue 500D, 600 X


Trouble Remedy
Electrode sticks to the workpiece more Check transformer T1 for signs of winding failure. Check continuity across windings, and check for
frequently during low voltage (short arc proper connections. Check secondary voltages. Replace T1 if necessary.
length) conditions (Continued).

Check integrated rectifiers SR4 and SR5, and replace if necessary.

B. Welding − CC/CV Models

Trouble Remedy

No weld output; generator power output Place Process/Contactor switch S6 in a Weld Terminals Always On position, or place switch in a Remote
okay at AC receptacles. On/Off Switch Required position and connect remote contactor to optional Remote 14 receptacle RC14.

Check position of Ampere Range switch S3.

Check position of optional polarity switch S12.

Reset supplementary protector CB11 (see Section 7-10 or 8-9).

Reset supplementary protector CB5 or CB6 (see Section 7-10 or 8-9). Check for faulty remote device
connected to RC14.

Check fuse F2, and replace if open (see Section 7-10 or 8-9).

Check and secure connections to Remote 14 receptacle RC14.

Check connector board PC6 and connections, and replace PC6 if necessary (see Section 10-8).

Clean slip rings, and install new brushes if necessary (see Section 10-17).

Check field current regulator board PC1 and connections, and replace PC1 if necessary (Section 10-10).

Disconnect leads 105 and 108 from rotor, and check continuity across slip rings. Replace rotor if
necessary.

No weld output or generator power out- Disconnect equipment from generator power receptacles during start-up.
put at AC receptacles.

Reset supplementary protector CB12 (see Section 7-10 or 8-9).

Check fuses F1 and F2, and replace if open (see Section 7-10 or 8-9).

Check integrated rectifier SR1, and replace if necessary.

Check diode/capacitor board D1/C1, and replace if necessary.

Check capacitor C9, and replace if necessary.

Check control relay CR5: Check all connections, check coil continuity, check for proper coil voltage, and
check contact voltage (input to common and output to common) to ensure contacts are operating. Re-
place CR5 if necessary.

Clean slip rings, and install new brushes if necessary (see Section 10-17).

Disconnect leads 105 and 106 from the rotor, and check continuity across slip rings. Replace rotor if
necessary.

Disconnect stator excitation leads 100 and 101, and check continuity between leads. Replace stator if
necessary.

Check field current regulator board PC1 and connection, and replace PC1 if necessary (Section 10-10).

Erratic weld output. Use dry, properly stored electrodes.

Be sure connection to work piece is clean and tight.

Remove excessive coils from weld cables.

Check and tighten connections inside and outside unit.

Clean slip rings, and install new brushes if necessary (see Section 10-17).

Check main rectifier SR3, and replace if necessary.

Big Blue 500D, 600 X TM-4428 Page 47


Trouble Remedy
High weld output. Check position of Ampere Range switch S3 and Voltage/Amperage Adjust control R1.

Check engine speed, and adjust if necessary (see engine manual and Section 7-8 or 8-7).

Check field current regulator board PC1 and connections, and replace PC1 if necessary (Section 10-10).

Electrode sticks to the workpiece more Circuit breaker CB4 may be open. CB4 automatically resets when the fault is corrected (see Section 7-10
frequently during low voltage (short arc or 8-9).
length) conditions.

Check transformer T1 for signs of winding failure. Check continuity across windings, and check for
proper connections. Check secondary voltages. Replace T1 if necessary.

Check integrated rectifiers SR4 and SR5, and replace if necessary.

Low weld output. Check engine speed, and adjust if necessary (see engine manual and Section 7-8 or 8-7).

Check fuses F1 and F2, and replace if open (see Section 7-10 or 8-9).

Check integrated rectifier SR1, and replace if necessary.

Check capacitor C9, and replace if necessary.

Check field current regulator board PC1 and connection, and replace PC1 if necessary (Section 10-10).

Clean slip rings, and install new brushes if necessary (see Section 10-17).

Disconnect leads 105 and 108 from the rotor, and check continuity across slip rings. Replace rotor if
necessary.

Low open-circuit voltage. Check engine speed, and adjust if necessary (see engine manual and Section 7-8 or 8-7).

No remote fine amperage or voltage Place Voltage/Amperage Adjust switch S5 in Remote position.
control.

Check and secure connections to Remote 14 receptacle RC14.

Repair or replace remote control device.

Constant speed wire feeder does not Reset supplementary protector CB5 or CB6 (see Section 7-10 or 8-9). Check for faulty remote device
work with welding generator. connected to RC14.

Check and secure connections to Remote 14 receptacle RC14.

Repair or replace wire feeder.

Low CV weld output. Set Ampere Range switch S3 to highest range.

Min or max CV weld output only. Check position of Voltage/Amperage Adjust control R1 and Voltage/Amperage Adjust switch S5.

Repair or replace remote control device.

Check field current regulator board PC1 and connection, and replace PC1 if necessary
(see Section 10-10).

Max CV weld output only: disconnect leads 19 and 30 at PC3 and check voltage feedback circuit.
Feedback voltage should be same as weld terminal open circuit voltage (see Section 10-3 or 10-6).

C. Generator Power

Trouble Remedy
No generator power output at AC recept- Reset receptacle supplementary protectors.
acles; weld output okay.

Check resistance of generator power windings between leads 81 and 84. Replace exciter stator (aux.
stator) if necessary.

No generator power output or weld Disconnect equipment from generator power receptacles during start-up.
output.

Check fuses F1 and F2, and replace if open (see Section 7-10 or 8-9).

Reset supplementary protector CB12 (see Section 7-10 or 8-9).

Check diode/capacitor board D1/C1, and replace if necessary.

TM-4428 Page 48 Big Blue 500D, 600 X


Trouble Remedy
No generator power output or weld Check integrated rectifier SR2, and replace if necessary.
output (continued).

Check integrated rectifier SR1, and replace if necessary.

Check capacitor C9, and replace if necessary.

Clean slip rings, and install new brushes if necessary (see Section 10-17).

Check resistance and connections of resistor R3; full resistance of R3 (end to end) is 10 ohms ±10%.
Replace R3 if necessary. If R3 is replaced, adjust R3 (see Section 10-18 or 10-19).

Disconnect leads 105 and 106 from the rotor, and check continuity across slip rings. Replace rotor
if necessary.

High output at generator power AC Check engine speed, and adjust if necessary (see engine manual and Section 7-8 or 8-7).
receptacles.

Check resistance and connections of resistor R3; full resistance of R3 (end to end) is 10 ohms ±10%.
Replace R3 if necessary. If R3 is replaced, adjust R3 (see Section 10-18 or 10-19).

Low output at generator power AC Check engine speed, and adjust if necessary (see engine manual and Section 7-8 or 8-7)
receptacles.

Check fuse F1, and replace if open (see Section 7-10 or 8-9).

Check integrated rectifier SR1, and replace if necessary.

Check capacitor C9, and replace if necessary.

Check resistance and connections of resistor R3; full resistance of R3 (end to end) is 10 ohms ±10%.
Replace R3 if necessary. If R3 is replaced, adjust R3 (see Section 10-18 or 10-19).

D. Optional Three-Phase Generator (CC/CV Models Only)

Trouble Remedy

No or low output at optional three- Place Process/Contactor switch S6 in Weld Terminals Always On - Stick position.
phase generator/receptacle RC5.

Reset supplementary protector CB7.

Reset supplementary protector CB5 (see Section 7-10 or 8-9).

Check engine weld/power speed, and adjust if necessary (see engine manual and Section 7-8 or
8-7).

Check slip rings, and install new brushes if necessary (see Section 10-17).

Check field current regulator board PC1 and connection, and replace PC1 if necessary (see Section
10-10).

High output at optional three-phase Check engine weld/power speed, and adjust if necessary (see engine manual and Section 7-8 or
generator/receptacle RC5. 8-7).

Check field current regulator board PC1 and connection, and replace PC1 if necessary (see Section
10-10).

Erratic output at optional three-phase Clean slip rings, and install new brushes if necessary (see Section 10-17).
generator/receptacle RC5.

Check field current regulator board PC1 and connections, and replace PC1 if necessary (see Section
10-10).

E. Engine
Trouble Remedy
Engine will not crank. Check battery, and replace if necessary.

Check battery connections and tighten if necessary.

Circuit breaker CB10 may be open. CB10 automatically resets when fault is corrected (see Section 7-10
or 8-9). Check engine wiring harness and components.

Big Blue 500D, 600 X TM-4428 Page 49


Trouble Remedy
Engine will not crank (continued). Reset supplementary protector CB13 (see Section 7-10 or 8-9). Check engine wiring harness and
components.

Check engine wiring harness plug connections.

Check continuity of Engine Control switch S1, and replace if necessary.

Check control relay CR1: Check all connections, check coil continuity, check for proper coil voltage, and
check contact voltage (input to common and output to common) to ensure contacts are operating. Re-
place CR1 if necessary.

Prior to LJ003065, check control relay TD1 for proper operation (see Section 10-14).

Eff w/LJ003065, check Fuel/Hour gauge FUEL/HM according to Section 10-15. Replace FUEL/HM if
necessary.

Check control relay CR5: Check all connections, check coil continuity, check for proper coil voltage, and
check contact voltage (input to common and output to common) to ensure contacts are operating. Re-
place CR5 if necessary.

Engine cranks but does not start. Check fuel level.

Check battery and replace if necessary. Check engine charging system according to engine manual.

Prior to LJ003065, check control relay TD1 for proper operation (see Section 10-14)

Eff w/LJ003065, check Fuel/Hour gauge FUEL/HM according to Section 10-15. Replace FUEL/HM if
necessary.

Eff w/LH024758 (export models), check control relay CR9: Check all connections, check coil continuity,
check for proper coil voltage, and check contact voltage (input to common and output to common) to en-
sure contacts are operating. Replace CR9 if necessary.

Eff w/LH024758 (export models), check resistance and connections of R7. R7 is three ohms. Replace
R7 if necessary.

Deutz F3L912-powered models only: allow circuit breaker CB14 time to reset (see Section 8-9). Check
fuel solenoid FS1.

Check fuel solenoid FS1 for proper coil voltage and connections. Check continuity of coil. Replace
FS1 if necessary.

Air in fuel system. See engine manual.

Engine starts, but stops after 30 Check oil level. Automatic shutdown system stops engine if oil pressure is too low or engine temperature
seconds. is too high (see Section 4-6). Automatic shutdown system is inhibited for 30 seconds after start-up.

Prior to LJ003065, check control relay TD1 for proper operation (see Section 10-14).

Eff w/LJ003065, check Fuel/Hour gauge FUEL/HM according to Section 10-15. Replace FUEL/HM if
necessary.

Check control relay CR5: Check all connections, check coil continuity, check for proper coil voltage, and
check contact voltage (input to common and output to common) to ensure contacts are operating. Re-
place CR5 if necessary.

Engine hard to start in cold weather. Use optional starting aid switch S2 (see Section 5-1).

Check optional starting aid control relay CR8 for proper coil voltage and connections. Check continuity
of coil and condition of contacts. Replace CR8 if necessary.

Keep battery in good condition. Store battery in warm area off cold surface.

Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier for
fuel information.

Use correct grade oil for cold weather (see Section 7-1 or 8-1).

Engine suddenly stops. Check oil level. Automatic shutdown system stops engine if oil pressure is too low or engine temperature
is too high (see Section 4-6). Automatic shutdown system is inhibited for 30 seconds after start-up.

See engine manual.

TM-4428 Page 50 Big Blue 500D, 600 X


Trouble Remedy
Engine slowly stopped and cannot be Check fuel level.
restarted.

Check engine air and fuel filters (see Sections 7-1 and 8-1).

See engine manual.

Battery discharges between uses. Turn Engine Control switch S1 off when unit is not running.

Clean top of battery with baking soda and water solution; rinse with clear water.

Recharge or replace battery if necessary.

Periodically recharge battery (approximately every 3 months).

Engine idles, but does not come up to Check continuity of Engine Control switch S1, and replace if necessary.
weld speed (Deutz F4L2011 and
D2011L04i-powered models with idle
option only).

Check idle module PC7 for proper operation (see Section 10-16).

Check current transformer CT1 for continuity and proper connections. Replace CT1 if necessary.

Check for obstructed throttle solenoid TS1.

Engine does not run at idle speed CC models: place Stick/TIG Selection switch S6 in Stick position.
(Deutz F4L2011 and D2011L04i- CC/CV models: place Process/Contactor switch S6 in any position but Remote On/Off Switch Re-
powered models with idle option only). quired-TIG.

Allow circuit breaker CB14 time to reset (see Section 7-10). Check engine throttle solenoid TS1 and wiring
harness and components.

Check for obstructed throttle solenoid TS1.

Check throttle solenoid TS1 for proper coil voltage and connections. Check continuity of coil. Replace
TS1 if necessary.

Check idle module PC7 for proper operation (see Section 10-16).

Check control relay CR3: Check all connections, check coil continuity, check for proper coil voltage, and
check contact voltage (input to common and output to common) to ensure contacts are operating. Re-
place CR3 if necessary.

Check control relay CR6: Check all connections, check coil continuity, check for proper coil voltage, and
check contact voltage (input to common and output to common) to ensure contacts are operating. Re-
place CR6 if necessary.

Engine uses oil during run-in period; Dry engine (see Section 13).
wetstacking occurs.

Big Blue 500D, 600 X TM-4428 Page 51


10-2. Troubleshooting Circuit Diagram For Welding Generator
(Deutz D2011L04i-Powered CC Models)

Test Equipment Needed:

Voltage Readings
a) Tolerance − ±10%
unless specified
b) Condition − 70°F (21°C);
cold machine (no V3, R3
warm-up); no load
c) Reference − single
arrow: reference to
circuit common (lead V2, R2
42); double arrow:
reference to points
indicated V1, R1
d) Stick/TIG switch S6 in
Stick position unless
noted
e) Wiring Connections −
see Section 12
Adjust R3 V7, R6
V1 126 − 130 volts AC according to
V2 126 − 130 volts AC Section 10-18
V6
V3 252 − 260 volts AC
V4, R4 I2
V4 101 volts AC
V8, R7
V5 167 volts AC
Adjust R2
V6 +135 volts DC according to I1
V5, R5 Section 10-18 Max OCV
V7 +89 volts DC control relay CR7
V8 +48.2 volts DC (R1 at min.
and Stick/TIG switch S6
in TIG position)
+99.5 volts DC (R1 at max.
and Stick/TIG Switch S6 in
Stick position)
V9 69 volts AC (R1 at max.)
V10 69 volts AC (R1 at max.)
V11 69 volts AC (R1 at max.)
V12 +65 volts DC (R1 at min.
and Stick/TIG switch S6
in TIG position) Starter
+92 volts DC (R1 at max. relay CR1
and Stick/TIG switch S6 in
Stick position)
V13 +12 volts DC at idle rpm
V14 +12 volts DC 10 − 15
seconds after load is
removed and engine goes
to idle rpm
V15 +12 volts DC at idle rpm
V16 +12 volts DC with Starting
Aid switch S2 closed
V17 +12 volts DC with engine V15,
running R11

V18 258 volts AC with Stick/TIG


switch S6 in Stick position
V19, 18 volts AC with Stick/TIG V17, V16 Throttle solenoid Field flashing/ Starting Aid
V20 switch S6 in Stick position R12
TS1 (pull to idle) engine control relay CR5 relay CR8

TM-4428 Page 52 Big Blue 500D, 600 X


Amperage Readings Resistance Values
a) Tolerance − ±5% unless specified a) Tolerance − ±10% unless
specified
b) Condition − 70°F (21°C); cold
machine (no warm-up); no load b) Condition − 70°F (21°C); cold
I1 6.6 amps DC (R1 at min., Range
machine (no warm-up)
switch S3 in high range, Stick/TIG c) Wiring Connections − see
switch S6 in Stick position) Section 12
4 amps DC (R1 at min., Range
switch S3 in high range, Stick/TIG d) Stop engine before checking
switch S6 in TIG position) resistance
I2 4.3 − 4.6 amps DC
R1 thru R5 Less than 1 ohm
R6 18.5 ohms
R7 14.2 ohms
R8 thru R10 Less than 1 ohm
R11 Pull In: Less than 1 ohm
Hold: 5.3 ohms
R12 3.6 ohms
V18 V19

V20

See Section 9 for


V9, V11, PC3 information
R8 R10
See Section 10-7
for waveforms
A and B

V12,
A, B
V10, R9

Field current
resistor bypass V14
relay CR4 V13

 Auto Idle Option re-


moved from circuit Idle control
eff w/MD120069E. relay CR3

Idle module
relay CR6
238 628-A

Big Blue 500D, 600 X TM-4428 Page 53


10-3. Troubleshooting Circuit Diagram For Welding Generator
(Deutz D2011L04i-Powered CC/CV Models) (Use With Section 10-4)

V3, R3

V1, R1

V2, R2

V4, R4

Adjust R3
according to
V8, R7
Section 10-19
V9, R8
V5, R5

V7

I2
V20 V21
I1

V19
V6,
R6

V22

V23
See Section
10-8 for
PC6 data

V17

V16,
R12

V18,
R13
Throttle solenoid Starter Field flashing/ Starting Aid
TS1 (pull to idle) relay CR1 Idle module
engine control relay CR8
relay CR6
relay CR5

TM-4428 Page 54 Big Blue 500D, 600 X


V24 V25

V26

See Section
9 for PC3
information

V12, R11 See Section 10-7


for waveforms
C and D
V10,
R9
V13,
C, D

V11, R10

See Section 9
for PC4, PC5
information

V14 V15

Field
current
resistor bypass
relay CR4
Idle control
 Auto Idle Option re- relay CR3
moved from circuit
eff w/MD120069E.

238 630-C

Big Blue 500D, 600 X TM-4428 Page 55


10-4. Troubleshooting Values For Circuit Diagram (Deutz D2011L04i-Powered
CC/CV Models) (Use With Section 10-3)

Test Equipment Needed:

Voltage Readings
a) Tolerance − ±10% unless specified
b) Condition − 70°F (21°C); cold
machine (no warm-up); no load
c) Reference − single arrow: reference
to circuit common (lead 42); double
arrow: reference to points indicated
Resistance Values
d) Process/Contactor switch S6 in
Electrode Hot − Stick position unless a) Tolerance − ±10% unless
noted specified
e) Wiring Connections − see Section 12 b) Condition − 70°F (21°C); cold
machine (no warm-up)
V1 126 − 130 volts AC
V2 126 − 130 volts AC c) Wiring Connections − see
Section 12
V3 252 − 260 volts AC
V4 27 volts AC
d) Stop engine before checking
resistance
V5 101 volts AC
V6 175 volts AC R1 thru R6 Less than 1 ohm
R7 18.5 ohms
V7 +135 volts DC
R8 14.2 ohms
V8 + 89 volts DC
R9 thru R11 Less than 1 ohm
V9 +89 volts DC (S6 in Electrode Hot −Stick R12 Pull In: Less than 1 ohm
position) Hold: 5.3 ohms
+33 volts DC (S6 in Electrode Hot−Scratch
R13 3.6 ohms
Start TIG position)
+11.5 to 40.5 volts DC from min to max of
R1 (S6 in Electrode Hot − MIG position)
V10 69 volts AC (R1 at max.)
V11 69 volts AC (R1 at max.)
Amperage Readings
V12 69 volts AC (R1 at max.)
V13 +89 volts DC (S6 in Electrode Hot − Stick a) Tolerance − ±5% unless specified
position) b) Condition − 70°F (21°C); cold
47 volts DC (S6 in Electrode Hot − Scratch
Start Tig position)
machine (no warm-up); no load
+16 to 56 volts DC from min to max of R1 c) Process/Contactor switch S6 in
(S6 in Electrode hot − MIG position) Electrode Hot − Stick position
V14 +12 volts DC at idle rpm unless noted
V15 +12 volts DC 10 − 15 seconds after load is
I1 6.3 amps DC
removed and engine goes to idle rpm
V16 +12 volts DC at idle rpm I2 4.3 − 4.6 amps DC
V17 +12 volts DC with Starting Aid switch S2
closed
V18 +12 volts DC with engine running
V19 0 to +10 volts DC from min to max of R1
V20 +10 volts DC
V21 0 to +10 volts DC from min to max of R1
V22 +12 volts DC
V23 +12 volts DC
V24 258 volts AC with Process/Contactor
switch S6 in Stick position
V25, 18 volts AC with Process/Contactor
V26 switch S6 in Stick position

TM-4428 Page 56 Big Blue 500D, 600 X


Notes

Start Your Professional 400 Trade Square East, Troy, Ohio 45373 Over 80,000 trained
Welding Career Now! 1−800−332−9448 www.welding.org since 1930!
Big Blue 500D, 600 X TM-4428 Page 57
10-5. Troubleshooting Circuit Diagram For Welding Generator
(Deutz F3L912-Powered CC Models)

Voltage Readings
a) Tolerance − ±10%
unless specified
V3, R3
b) Condition − 70°F
(21°C); cold machine
(no warm-up); no load
c) Reference − single
V2, R2
arrow: reference to
circuit common (lead
42); double arrow: V1, R1
reference to points
indicated
d) Stick/TIG switch S6 in
Stick position unless
noted
Adjust R2 and R3
e) Wiring Connections − according to V7, R6
see Section 12 Section 10-18

V1 126 − 130 volts AC


V6
V2 126 − 130 volts AC V4, R4 I2
V3 252 − 260 volts AC V8, R7

V4 101 volts AC Max OCV


I1 control relay
V5 167 volts AC V5, R5 CR7
V6 +135 volts DC
V7 +89 volts DC
V8 +48.2 volts DC (R1 at min.
and Stick/TIG switch S6
in TIG position)
+99.5 volts DC (R1 at
max. and Stick/TIG Switch
S6 in Stick position)
V9 69 volts AC (R1 at max.)
V10 69 volts AC (R1 at max.)
V11 69 volts AC (R1 at max.)
V12 +65 volts DC (R1 at min.
and Stick/TIG switch S6
in TIG position)
+92 volts DC (R1 at max.
and Stick/TIG switch S6 in
Stick position)
V13 +12 volts DC with engine
running
V14 258 volts AC with
Stick/TIG switch S6 in
Stick position
V15, 18 volts AC with Stick/TIG
V16 switch S6 in Stick position

V13,
R11 Starter Field flashing/
relay CR1 engine control
relay CR5

TM-4428 Page 58 Big Blue 500D, 600 X


Amperage Readings Resistance Values
Test Equipment Needed:
a) Tolerance − ±5% unless specified a) Tolerance − ±10% unless
specified
b) Condition − 70°F (21°C); cold
machine (no warm-up); no load b) Condition − 70°F (21°C);
cold machine (no warm-up)
I1 6.6 amps DC (R1 at min., Range
switch S3 in high range, Stick/TIG c) Wiring Connections − see
switch S6 in Stick position) Section 12
4 amps DC (R1 at min., Range
switch S3 in high range, Stick/TIG d) Stop engine before
switch S6 in TIG position) checking resistance
I2 4.3 − 4.6 amps DC R1 thru R5 Less than 1 ohm
R6 18.5 ohms
R7 14.2 ohms
R8 thru R10 Less than 1 ohm
R11 11 ohms
V14 V15

V16

See Section 9 for


V9, V11, PC3 information
R8 R10

See Section 10-7


for waveforms
A and B

V12,
A, B
V10, R9

Starting Aid
relay CR8

238 930-A

Big Blue 500D, 600 X TM-4428 Page 59


10-6. Troubleshooting Circuit Diagram For Welding Generator
(Deutz F3L912-Powered CC/CV Models)
Amperage Readings
Test Equipment Needed:
a) Tolerance − ±5% unless specified
b) Condition − 70°F (21°C); cold
machine (no warm-up); no load
c) Process/Contactor switch S6 in
Electrode Hot − Stick position
unless noted
I1 6.3 amps DC

I2 4.3 − 4.6 amps DC

V3, R3

V1, R1

V2, R2

V4, R4

Adjust R3
according
V8, R7
to Section V9, R8
10-19

V7
I2
V5, V16 V17
See Section R5 I1
10-8 for
V15
PC6 data

V6, R6

V19
V18

Starting Aid
relay CR8

Field flashing/
V14, Starter engine control
R12 relay CR1 relay CR5

TM-4428 Page 60 Big Blue 500D, 600 X


Resistance Values
a) Tolerance − ±10% unless specified
b) Condition − 70°F (21°C); cold machine (no warm-up) Voltage Readings
c) Wiring Connections − see Section 12
a) Tolerance − ±10% unless
d) Stop engine before checking resistance specified
R1 thru R6 Less than 1 ohm b) Condition − 70°F (21°C); cold
R7 18.5 ohms machine (no warm-up); no
R8 14.2 ohms load
R9 thru R11 Less than 1 ohm c) Reference − single arrow:
R12 11 ohms reference to circuit common
(lead 42); double arrow:
reference to points indicated
d) Process/Contactor switch S6
in Electrode Hot − Stick
position unless noted
e) Wiring Connections − see
V20 V21 Section 12
V1 126 − 130 volts AC
V2 126 − 130 volts AC
V3 252 − 260 volts AC
V4 27 volts AC
V5 101 volts AC
V6 175 volts AC
V7 +135 volts DC
V8 + 89 volts DC
V22 V9 +89 volts DC (S6 in Electrode
See Section Hot −Stick position)
9 for PC3 +33 volts DC (S6 in Electrode
information Hot−Scratch Start TIG position)
V10, V12,
R9 +11.5 to 40.5 volts DC from min
R11
to max of R1 (S6 in Electrode
Hot − MIG position)
V10 69 volts AC (R1 at max.)
See Section
9 for PC4, V11 69 volts AC (R1 at max.)
PC5 V13, V12 69 volts AC (R1 at max.)
information C, D
V13 +89 volts DC (S6 in Electrode
V11, R10
Hot − Stick position)
See Section 47 volts DC (S6 in Electrode
10-7 for Hot − Scratch Start Tig position)
waveforms +16 to 56 volts DC from min to
C and D max of R1 (S6 in Electrode hot
− MIG position)
V14 +12 volts DC with engine
running
V15 0 to +10 volts DC from min to
max of R1
V16 +10 volts DC
V17 0 to +10 volts DC from min to
max of R1
V18 +12 volts DC
V19 +12 volts DC
V20 258 volts AC with
Process/Contactor
switch S6 in Stick position
V21, 18 volts AC with
V22 Process/Contactor
switch S6 in Stick position

238 929-B

Big Blue 500D, 600 X TM-4428 Page 61


10-7. Waveforms For Sections 10-2 Thru 10-6

CC Models Only
 The waveforms represent the output
of the welding power source. When
operating properly, the power source
waveforms match those shown here.
1 ms 20 V 1 ms 5 V

gnd gnd

A. CC Models − DC Open-Circuit Voltage, B. CC Models − DC Output, 25 Volts DC, 200


Ampere Range Switch S3 At Maximum, Amperes, Ampere Range Switch S3 At
Amperage Adjust Control R1 At 100 150-330 Position (Resistive Load)

CC/CV Models Only


1 ms 50 V 1 ms 10 V

gnd gnd

C. CC/CV Models − DC/CC Open-Circuit Volt- D. CC/CV Models − DC/CC Output, 28 Volts
age, Amperage Adjust Control R1 At DC, 200 Amperes, Ampere Range Switch
Maximum S3 At 110-390 Position (Resistive Load)

Test Equipment Needed:

TM-4428 Page 62 Big Blue 500D, 600 X


Notes

Start Your Professional 400 Trade Square East, Troy, Ohio 45373
Over 80,000 trained
Welding Career Now! 1−800−332−9448 www.welding.org since 1930!
Big Blue 500D, 600 X TM-4428 Page 63
10-8. Filter Board PC6 Testing Information (CC/CV Models Only)

! Stop engine.
See Section 10-9 for specific val-
ues during testing. Voltage read-
ings tolerance ±10%.

Test Equipment Needed:

Ref. 803 834 / 242943

TM-4428 Page 64 Big Blue 500D, 600 X


10-9. Filter Board PC6 Test Point Values (CC/CV Models Only)

a) Tolerance − ±10% unless specified


b) Reference − to circuit common (lead 42) unless
noted
c) Condition − no load
PC6 Voltage Readings d) Process/Contactor switch S6 in Weld Terminals
Always On − Stick position

Receptacle Pin Value


RC2 1 Not used

2 115 volt AC input with respect to pin RC2-10

3 24 volt AC input with respect to pin RC2-10

4 24 volt AC output with respect to pin RC2-10

5 Contactor control circuit, 24 volt AC input with contact closure to pin RC2-9 and closure on RC14
between pins A and B or pins I and J

6 Command reference, +10 volt DC input

7 Command common

8 Remote command signal output, 0 to +10 volts DC input from min to max of remote voltage/amperage
control

9 Circuit common for 24 and 115 volt AC contactor control circuits

10 Circuit common for 24 and 115 volt AC circuits

Notes

Work like a Pro!


Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

Big Blue 500D, 600 X TM-4428 Page 65


10-10.Field Current Regulator Board PC1 Testing Using LED Board PC9 (CC/CV Only)

Determine the condition of field cur-


rent regulator board PC1 by ob-
serving the LEDs on LED board
PC9 (in control box).

 Do not open the PC1 sealed


case to service PC1. If PC1 is
not working properly, replace
the entire PC1 module.
Be sure plugs are secure. See Sec-
tion 10-11 for diagnostic information
1 and specific values during testing.
1 Field Current Regulator Board
PC1 Module
2 LED Board PC9
3 Diagnostic LEDs (See Section
10-11)

Test Equipment Needed:

Ref. 803 834 / 242939-A

TM-4428 Page 66 Big Blue 500D, 600 X


10-11. Using Diagnostic LEDs On LED Board PC9 (CC/CV Models Only)
 The LEDs on circuit board PC9 monitor all critical input voltages to field current regulator board PC1.

 If PC9 Power LED, Output On/Off LED, and AC Input LED are on with Process/Contactor switch S6 in Weld Terminals Always On - Stick mode
and engine running at weld/power speed, 89 volts DC should be present at brush leads 105 and 108. This indicates field current regulator board
PC1 is functioning normally.

a) Condition − no load; weld/power


rpm unless noted
b) Voltage/Amperage Adjust switch
S5 in Panel position
b) Reference − to circuit common
(lead 42) unless noted

LED Status Self-Test

POWER On Indicates +12 volts DC is present to energize PC1.

Off If LED is off:


Check control relay CR5 for proper coil voltage and connections. Check continuity of coil and condition
of contacts. Replace CR5 if necessary.
Allow circuit breaker CB10 time to reset automatically and/or reset supplementary protector CB11.
Check for loose electrical connections to PC1.
Check for 12 volt DC supply voltage to PC1. If voltage is low, check battery or engine charging system.

OUTPUT On Indicates 24 volts AC input with Process/Contactor switch S6 in Weld Terminals Always On position, or
ON/OFF with S6 in a Remote On/Off Switch Required position with remote contactor closed.

Off If LED is off:


Place Process/Contactor switch S6 in Weld Terminals Always On position, or place S6 in Remote On/Off
Switch Required position and connect remote contactor to remote receptacle RC14.
Reset supplementary protector CB5 or CB6.
Check filter board PC6 and connections, and replace if necessary (see Section 10-8).

COMMAND On Indicates 0 to +10 volts DC input from min. to max. of Voltage/Amperage Adjust control R1 with Voltage/
Amperage Adjust switch S5 in Panel position.

Off If LED is off:


And Power LED is on, check that Voltage/Amperage Adjust control R1 is not at min.
And Power LED is on, check and tighten connections to Voltage/Amperage Adjust control R1.
And Power LED is on, check voltage at Voltage/Amperage Adjust control R1 (see Section 10-3 or 10-6).
If correct voltage is not present, check connections to PC1.
And Power LED is on, check resistance and connections of Voltage/Amperage Adjust control R1; R1 is
0 to 1000 ohms ±10%. Replace R1 if necessary.

RPM On Indicates engine speed is less than 1704 rpm (approximately).


LIMIT
If LED is on:
 LED normally And AC Input LED is on, check engine weld/power speed and adjust if necessary.
off at weld/
And AC Input LED is off, check position of Engine Control switch S1 (not in idle position).
power speed
And AC Input LED is off, check fuse F2, and replace if open.
And AC Input LED is off, reset supplementary protector CB12.

Off Indicates engine speed is above 1704 rpm (normal operation).

AC INPUT On Indicates + 175 volts AC input from field excitation circuit.

Dim or Off If LED is off, power LED is on, and normal AC voltage is present at AC receptacles (see Section 10-3 or
10-6):
Check fuse F2, and replace if open.
Reset supplementary protector CB12.

Big Blue 500D, 600 X TM-4428 Page 67


10-12.LED Board PC9 Testing (CC/CV Models Only)

Be sure plugs are secure. See Sec-


tion 10-13 for specific values during
testing.
1 LED Board PC9

Test Equipment Needed:

Ref. 803 834 / 242939-A

TM-4428 Page 68 Big Blue 500D, 600 X


10-13.LED Board PC9 Test Point Values (CC/CV Models Only)

a) Tolerance − ±10% unless specified


b) Reference − to circuit common (lead 42) unless noted
c) Condition − no load; weld/power rpm unless noted
d) Process/Contactor switch S6 in Weld Terminals Always On
− Stick position
PC9 Voltage Readings
NOTICE − Do not exceed recommended voltage when testing LEDs or circuit
board may be damaged.

Receptacle Pin Value


PLG13 1 Power LED, +2 volts DC input
To test power LED, apply +2 volts DC to PLG13-1 and connect negative (−) side of power supply to
PLG13-8. LED lights if okay.

2 Not used

3 Not used

4 Not used

5 AC input LED, +1.85 volts DC input with respect to pin PLG13-10 when weld exciter voltage is
present.
To test AC input LED, apply +1.85 volts DC to PLG13-10 and connect negative (−) side of power
supply to PLG13-5. LED lights if okay.

6 Output on/off LED, 0.13 volts DC input with contactor off; + 2 volts DC input with contactor on.
To test output on/off LED, apply +2 volts DC to PLG13-6 and connect negative (−) side of power sup-
ply to PLG13-8. LED lights if okay.

7 Command LED, 0 to 2 volts DC input from min to max of Voltage/Amperage Adjust control R1.
To test command LED, apply +2 volts DC to PLG13-7 and connect negative (−) side of power supply
to PLG13-8. LED lights if okay.

8 Circuit common

9 RPM Limit LED, +10.5 volts DC input at 1850 rpm; voltage decreases as engine speed decreases.
LED goes on when engine speed is less than 1704 rpm (approximately).
To test rpm limit LED, apply +2 volts DC to PLG13-8 and connect negative (−) side of power supply to
PLG13-9. LED lights if okay.

10 AC Input LED, +1.85 volts DC input with respect to pin PLG13-5 when weld exciter voltage is present.
To test AC input LED, apply +1.85 volts DC to PLG13-10 and connect negative (−) side of power
supply to PLG13-5. LED lights if okay.

Big Blue 500D, 600 X TM-4428 Page 69


10-14.Time Delay Relay TD1 Testing Information (Prior To Serial No. LJ003065)

Voltage readings tolerance ±10%.


1 Time Delay Relay TD1

Engine does not start.

Connect meter (DC) between


terminal +12V and terminal
GRD.

Place Engine Control switch in


Run position.

Allow circuit break-


er CB10 to reset or
NO
+12 volts DC present? reset supplementa-
ry protector CB13.
Check Engine
YES Control switch S1
and connections.
Connect meter (DC) between
terminal C (CM) and terminal
GRD.

NO
+12 volts DC present? Replace TD1

YES
1
Check control relay CR5
and engine fuel and
starter solenoids.

Reinstall cover.

Test Equipment Needed:

TM-4428 Page 70 Big Blue 500D, 600 X


Engine starts, but stops within 30 seconds. Engine starts, but stops after 30 seconds.

Connect meter (DC) between Connect meter (DC) between


terminal +12V and terminal terminal +12V and terminal
GRD. GRD.

Place Engine Control switch in Place Engine Control switch in


Run position. Run position.

Allow circuit break- Allow circuit break-


er CB10 to reset or er CB10 to reset or
NO NO reset supplementa-
+12 volts DC present? reset supplementa- +12 volts DC present?
ry protector CB13. ry protector CB13.
Check Engine Check Engine
YES Control switch S1 YES Control switch S1
and connections. and connections.
Connect meter (DC) between
Connect meter (DC) between
terminal C (CM) and terminal
terminal NC and terminal GRD.
GRD.

NO Start engine. When engine begins


+12 volts DC present? Replace TD1
to stop, quickly check voltage.

YES
Check for low oil
level or high engine
Check fuel solenoid FS1 NO temp. condition.
+12 volts DC present?
and connections.

YES

Reinstall cover. Replace TD1

Reinstall cover.

803 834 / 214 928

Big Blue 500D, 600 X TM-4428 Page 71


10-15.Fuel/Hourmeter Testing Information (Eff w/Serial No. LJ003065)
Pin Description 1 Rear of Fuel/Hourmeter
1 Open (no output) with S1 in Run FUEL/HM
1
See Section 5-5 for explanation of
2 Input from temperature switch S7
meter functions.
3 Input from oil pressure switch S8
Wiring harness plug PLG1 con-
4 +12 volts DC input nects to receptacle on rear of meter.
(S1 in any position but Off)
Test meter functions by checking
5 Input from fuel level sender pin inputs and outputs as specified
in the table below.
6 +12 volts DC (S1 in Start)
7 Output to Relay CR5 (engine latch) Voltage readings tolerance ±10%.
8 Negative (−) battery voltage (ground)

Test Equipment Needed:

hm2 2010−08 232 112 or 232 113 / Ref. 803 834

Fuel/Hourmeter Input/Output Information


hm2 2010−08

Oil High
Low Oil View Hours
Hourmeter Maintenance Coolant View Engine Low Fuel Shut-
Pressure Until Next Oil Fuel Gauge
Counts Hours Temp Hours down
Pin Shutdown Change
Countdown Shutdown

Engine Running Engine Not Running Any Engine Mode

1 n/a n/a n/a n/a Open +12 volts DC n/a n/a

2 Open Open Open Ground Open Open Open Open

3 Open Open Ground n/a Ground Ground n/a n/a

4 +12 volts DC +12 volts DC +12 volts DC +12 volts DC +12 volts DC +12 volts DC +12 volts DC +12 volts DC

28 to 33 ohms 28 to 33 ohms 28 to 33 ohms 28 to 33 ohms Assume Assume


w/fuel tank w/fuel tank w/fuel tank w/fuel tank enough fuel to enough fuel to
Greater than 215 Less than 215
5 full; 215 ohms full; 215 ohms full; 215 ohms full; 215 ohms not activate not activate
ohms ohms
starts shut- starts shut- starts shut- starts shut- low fuel shut- low fuel shut-
down down down down down down

+12 volts DC +12 volts DC


applied during applied during
engine crank- engine crank-
ing and then ing and then
6 Open Open removed (fault removed (fault Open Open Open Open
shutdown in- shutdown in-
hibited for 30 hibited for 30
sec. after sec. after
startup) startup)

30 second 30 second
delay after delay after Open after 10
start-up start-up sec. delay (shuts
7 Ground Ground Ground Ground Ground
(deenergizes (deenergizes off CR5 which
CR5 which CR5 which stops unit)
stops unit) stops unit)

8 Ground Ground Ground Ground Ground Ground Ground Ground

TM-4428 Page 72 Big Blue 500D, 600 X


Notes

Work like a Pro!


Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

Big Blue 500D, 600 X TM-4428 Page 73


10-16.Optional Idle Module PC7 Testing Information And Troubleshooting Flow Chart

Voltage readings tolerance ±10%.


1 Idle Module
 Verify engine speeds are correct
 Option removed from circuit eff w/MD120069E. before testing idle module.

Engine does not go to idle speed


(1250 RPM) with no load applied.

Connect meter (DC) between


terminal B (+) and terminal E (−).

Start engine, and place Engine


Control switch in Auto position.
CC models: place Stick/TIG switch
S6 in Stick position.
CC/CV models: place Process/
Contactor switch S6 in
Weld Terminals Always On − Stick
position.

Check connections
to Engine Control
NO
+12 volts DC present? switch S1, control
relay CR6, and
ground connection
YES (lead 42).

Connect meter (AC) between


terminal D and terminal G.
1

Check for internal


NO
D C 0 (zero) volts AC present?
load such as
shorted diode in
main rectifier SR3.
YES
G E
Connect meter (DC) between
terminal C (+) and terminal E (−).

B F
A Approximately +10 volts DC
NO
Replace
present after 12 to 18 seconds? idle module.

YES

Check circuit breaker CB14,


control relay CR3, throttle
solenoid TS1, and connections.
Test Equipment Needed:

Reinstall cover.

TM-4428 Page 74 Big Blue 500D, 600 X


Engine does not go to weld/power Control Relay CR4 does not energize
speed (1850 RPM) with load applied. at idle RPM with no load applied (see
Section 9 for CR4 information).

Connect meter (AC) between Connect meter (DC) between


terminal D and terminal G. terminal A (+) and F (−).

Start engine, and place Engine Start engine. Place Engine Control
Control switch in Auto position. switch S1 in Run position.
CC models: place Stick/TIG switch CC models: place Stick/TIG
S6 in Stick position. switch S6 in Stick position.
CC/CV models: place Process/ CC/CV models: place Process/
Contactor switch S6 in Contactor switch S6 in
Weld Terminals Always On − Stick Weld Terminals Always On − Stick
position. position.

NO
Connect a 100 watt light bulb to 0 (zero) volts DC present? Replace idle
120 volts AC duplex receptacle. module PC1.

YES

NO Check connections Place Engine Control switch S1


Minimum of 1 volt AC present? to current in Auto position.
transformer CT2.
YES

NO
Connect meter (DC) between +12 volts DC present? Replace idle
terminal C (+) and terminal E (−). module PC1.

YES

NO
0 (zero) volts DC present? Replace Check control relay CR4.
idle module.

YES

Check control relay CR3. Reinstall cover.

Disconnect 100 watt light bulb


and meter leads.

Reinstall cover.

803 834 / 195 706

Big Blue 500D, 600 X TM-4428 Page 75


10-17.Replacing Brushes And Cleaning Slip Rings

! Stop engine.
1 Generator Power Panel
Remove screws from panel. Tilt
panel forward.
2 Spring Clip
3 Brush
4 Brush Holder Assembly
Squeeze end of spring clip to re-
move clip and brush from brush
holder assembly. Remove and in-
spect all three brushes.
Replace brushes if damaged, or if
brush is at or near minimum length.
5 Slip Rings

1 Visually inspect slip rings. Under


normal use, rings turn dark brown.
If slip rings are corroded or surface
is uneven, insulate brush leads,
start engine, and clean rings with a
commutator stone. Remove as little
material as possible.
Reinstall generator power panel.
! Stop engine.

Minimum Length: 2
5/8 in (16 mm)

New Length: 1-1/4 in (32 mm)


Tools Needed:

Replace
Damaged Brushes

802 380-F

TM-4428 Page 76 Big Blue 500D, 600 X


10-18.Checking Unit Output After Servicing (CC Models)

 Also use output waveforms to check unit


output after servicing (see Section 10-7).
Check engine speeds, and adjust if neces-
sary (see engine manual and Section 7-8 or
8-7).
1 AC Receptacles GFCI1 And RC1
2 Resistor R3
Start engine and run at weld/power speed
(1850 RPM). Turn Amperage Adjust control
R1 to max.
Check voltage at each receptacle. With no
load applied, there should be 126 to 132 volts
AC present at GFCI1 and 252 to 264 volts AC
at RC1.
If correct voltage is not present, stop engine
and reconnect lead 102 and/or lead 106 to dif-
ferent taps on R3.

 Connect R3 leads so at least half of resis-


tor length is in circuit.
1 Start engine and check GFCI1 and RC1 volt-
age. If necessary, change R3 connections
until correct voltage is obtained at recep-
tacles without exceeding 4.6 amperes DC ex-
citer revolving field current (see Section 10-2
or 10-5).
3 Resistor R2
Turn Amperage Adjust control to min. and
Ampere Range switch to 300-Max. position.
Place Stick/TIG switch in Stick position.
Check open-circuit voltage across weld out-
! Stop engine before adjusting resistor R2 and R3. put terminals. There should be 90 − 94 volts
3 DC present. If correct voltage is not present,
stop engine and reconnect lead 125 and/or
lead 118 to different taps on R2.

2  Connect R2 leads so at least half of resis-


tor length is in circuit.
Start engine and and run at weld/power
speed (1850 rpm). Check weld output volt-
age. If necessary, change R2 connections
until correct voltage is obtained.

 Perform a load bank test to ensure weld-


ing generator operates properly after ser-
vicing. Be sure load bank is capable of
handling the rated output of the welding
generator being tested (see load bank
Owner’s Manual).
The load bank will simulate a weld load
and the electrical demand on the unit.
Test Equipment Needed: See Specifications for rated load.
If unit does not perform at rated load, re-
peat troubleshooting procedures.
! Stop engine.
Allow engine to cool, and then complete pre-
operational checks in table.
Pre-Operational Checks

Wipe engine surfaces clean.

Check labels; replace labels that are unreadable or damaged.

Check fuel and oil (see Section 4-6)


Check and correct any fluid leaks. Tools Needed:

Clean weld output and battery terminals. Tighten connections.


Clean outside of entire unit.
803 834 / Ref. 803 659

Big Blue 500D, 600 X TM-4428 Page 77


10-19.Checking Unit Output After Servicing (CC/CV Models)

 Also use output waveforms to


check unit output after servic-
ing (see Section 10-7).
Check engine speeds, and adjust if
necessary (see engine manual and
Section 7-8 or 8-7).
1 AC Receptacles GFCI1 And
RC1
2 Resistor R3
Start engine and run at weld/power
speed (1850 RPM).
Check voltage at each receptacle.
With no load applied, there should
be 126 to 130 volts AC present at
GFCI1 and 252 to 260 volts AC at
RC1.
If correct voltage is not present,
stop engine and reconnect lead 102
and/or lead 106 to different taps on
R3.

 Connect R3 so at least half of


resistor length is in circuit.
Start engine and check GFCI1 and
1 RC1 voltage. If necessary, change
R3 connections until correct volt-
age is obtained at receptacles with-
out exceeding 4.6 amperes DC ex-
citer revolving field current (see
Section 10-3 or 10-6).
Turn Voltage/Amperage Adjust
control R1 to max. Place Process/
Contactor switch S6 in Weld Termi-
nals Always On − Stick position.
! Stop engine before adjusting resistor R3. Check open-circuit voltage across
weld output terminals. There
should be 90 volts DC present. If
correct voltages are not present, re-
2 peat troubleshooting procedures in
Section 10-1.

 Perform a load bank test to en-


sure welding generator oper-
ates properly after servicing.
Be sure load bank is capable of
handling the rated output of the
welding generator being tested
(see load bank Owner’s Manu-
al).
The load bank will simulate a
weld load and the electrical de-
mand on the unit. See Specific-
ations for rated load.
If unit does not perform at rated
load, repeat troubleshooting
procedures.
Test Equipment Needed:
! Stop engine.

Pre-Operational Checks Allow engine to cool, and then com-


plete pre-operational checks in
table.
Wipe engine surfaces clean.

Check labels; replace labels that are unreadable or damaged.

Check fuel and oil (see Section 4-6)


Tools Needed:
Check and correct any fluid leaks.
Clean weld output and battery terminals. Tighten connections.
Clean outside of entire unit.
Ref. 803 833 / Ref. 803 709

TM-4428 Page 78 Big Blue 500D, 600 X


SECTION 11 − DISASSEMBLY AND REASSEMBLY

11-1. Disassembly Of Unit


Use Section 10 to determine if trouble
is in exciter stator, stator, rotor, engine
or combination of these components.
! Stop engine and let cool. Dis-
connect battery negative (−)
cable.
Remove exhaust pipe, fuel cap, and
top cover. Reinstall fuel cap. Remove
side panels and door(s). Retain all
hardware.
1 Control Box
Disconnect plugs from control box.
Remove box.

 To aid in reassembly, mark leads


before disconnecting. See lead
list summary in Section 12 for
connection information.
Disconnect:

stator weld leads from Ampere
Range switch S3

stator exciter leads from termi-
nal strip 1T

1
resistor R2, R3, and R4 leads
(R2 and R4 are on CC models
only)
2 Front And Center Upright
Assembly
2 3 3 Reactor Z1 Lifting Eye
The entire assembly will be removed
together. Remove bolts securing up-
rights to base. While supporting as-
sembly at front panel and reactor lift-
ing eye, evenly lift and remove
assembly.
4 Engine
4 5 Adapter Plate
6 Front Generator Mounts
Support engine under adapter plate
with a 1 x 3 x 30 in (25 x 76 x 762 mm)
metal bar.

 Do not support engine on fuel


tank or under oil pan.
Remove front generator mounts. Go
to Section 11-2.

Remove brushes
before removing
endbell or rotor.

803 898-B

Big Blue 500 D, 600 X TM-4428 Page 79


11-2. Disassembly Of Generator (Prior To Serial No. MB360026E)

E
2
A
4

A
D B

Torques:

A 30 ft lb (41 N.m)
B 100 in lb (11 N.m)
C 25 ft lb (34 N.m)
D 12 ft lb (16 N.m)
E 18 ft lb (24 N.m)

802 404-D

NOTICE − Do not damage stator or rotor win- 3 Endbell Reassembly Instructions:


dings during this procedure.
4 Exciter Stator Reinstall engine and generator parts as
1 Brushes needed using torque values in table.
Exciter stator comes off with endbell.
Remove brushes from brushholder assembly Reinstall upright assembly. Reconnect fuel
5 Rotor
before disassembling generator. line.
If engine must also be removed, remove en-
2 Stator Reconnect all leads. Use cable ties to secure
gine from base mounts.
leads in existing wiring harness and away
With engine properly supported with metal
from moving and hot parts.
bar (see Section 11-1), remove hardware se-
curing stator to engine. Remove the following Reconnect negative (−) battery cable. Rein-
parts as needed: stall panels, doors, and exhaust pipe.

TM-4428 Page 80 Big Blue 500D, 600 X


11-3. Disassembly Of Generator (Eff. W/ Serial No. MB360026E)

3
C

Torques:

A 30 ft lb (41 N.m)
B 18 ft lb (24 N.m)
C 25 ft lb (34 N.m)
D 12 ft lb (16 N.m)

255861

NOTICE − Do not damage stator or rotor win- 3 Endbell With Exciter Stator Reassembly Instructions:
dings during this procedure.
Exciter stator comes off with endbell. Reinstall engine and generator parts as
1 Brushes needed using torque values in table.
4 Rotor
Remove brushes from brushholder assembly Reinstall upright assembly. Reconnect fuel
If engine must also be removed, remove en-
before disassembling generator. line.
gine from base mounts.
2 Stator Reconnect all leads. Use cable ties to secure
leads in existing wiring harness and away
With engine properly supported with metal
from moving and hot parts.
bar (see Section 11-1), remove hardware se-
curing stator to engine. Remove the following Reconnect negative (−) battery cable. Rein-
parts as needed: stall panels, doors, and exhaust pipe.

Big Blue 500 D, 600 X TM-4428 Page 81


Notes

TM-4428 Page 82 Big Blue 500D, 600X


SECTION 12 − ELECTRICAL DIAGRAMS

 The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit inside
machine case or contact distributor for more information.
The following is a list of all diagrams for models covered by this manual.

Model Serial Or Style Number Circuit Diagram Wiring Diagram

Big Blue 500D CC Models LC585264 Thru LJ003064 215221-E Figure 13-1
(Deutz F4L2011 And D2011L04i
Engines) LJ003065 Thru LJ005954 237427-A Figure 13-2

LJ005955 and following 238628-C Figure 13-3 See Table 13-1

Big Blue 600X CC Models LC585264 Thru LH024757 215221-E Figure 13-1
(Deutz F4L2011 And D2011L04i
Engines) LH024758 Thru LJ003064 235275-A Figure 13-4

LJ003065 Thru LJ005954 237428-A Figure 13-5

LJ005955 Thru MD120068E 238928-B Figure 13-6

MD120069E And Following 238628-C Figure 13-3 See Table 13-1

Big Blue 500D CC/CV Models LC585264 Thru LJ003064 215806-E Figure 13-7
(Deutz F4L2011 And D2011L04i
Engines) LJ003065 Thru LJ005954 237430-A Figure 13-8

LJ005955 And Following 238630-D Figure 13-9

Big Blue 600X CC/CV Models LC585264 Thru LH024757 215806-E Figure 13-7
(Deutz F4L2011 And D2011L04i
Engines) LH024758 Thru LJ003064 235276-A Figure 13-10

LJ003065 Thru LJ005954 237431-A Figure 13-11

LJ005955 Thru MD140053E 238944-C Figure 13-12

MD140054E And Following 238630-D Figure 13-9

Big Blue 500D, 600X CC Models LC585264 Thru LJ003064 215807-D Figure 13-13
(Deutz F3L912 Engine)
LJ003065 Thru LJ005954 237433-A Figure 13-14

LJ005955 And Following 238930-A Figure 13-15 See Table 13-2

Big Blue 500D, 600X CC/CV LC585264 Thru LJ003064 215808-D Figure 13-16
Models (Deutz F3L912 Engine)
LJ003065 Thru LJ005954 237432-A Figure 13-17

LJ005955 And Following 238929-B Figure 13-18

Circuit Board PC4, PC5 LC585264 and following 189746-A Figure 13-19
(HF Filter)

Circuit Board PC3 LC585264 and following 188607-B Figure 13-20


(HF Filter)

Circuit Board PC6 LC585264 and following 192997-A Figure 13-21


(HF Filter − CC/CV Only)

Circuit Board PC9 LC585264 and following 192227-A Figure 13-22


(LED − CC/CV Only)

Big Blue 500D, 600X TM-4428 Page 83


Figure 13-1. Circuit Diagram For Big Blue 500D CC Models
(Deutz F4L2011-Powered Units) Eff w/Serial No. LC585264 Thru LJ003064
And Big Blue 600X CC Models (Deutz F4L2011-Powered Units) Eff. w/Serial No. LC585264 Thru LH024757
TM-4428 Page 84 Big Blue 500D, 600X
215 221-E

Big Blue 500D, 600X TM-4428 Page 85


Figure 13-2. Circuit Diagram For Big Blue 500D CC Models
(Deutz F4L2011 And D2011L04i-Powered Units) Eff w/Serial No. LJ003065 Thru LJ005954
TM-4428 Page 86 Big Blue 500D, 600X
237 427-A

Big Blue 500D, 600X TM-4428 Page 87


Figure 13-3. Circuit Diagram For Big Blue 500D CC Models (Deutz D2011L04i-Powered Units)
Eff w/Serial No. LJ005955 And Following, And Big Blue 600X CC Models (Deutz D2011L04i-Powered
Units) Eff w/ Serial No. MD120069E And Following
TM-4428 Page 88 Big Blue 500D, 600X
238 628-C

Big Blue 500D, 600X TM-4428 Page 89


Figure 13-4. Circuit Diagram For Big Blue 600X CC Models
(Deutz F4L2011-Powered Units) Eff w/Serial No. LH024758 Thru LJ003064
TM-4428 Page 90 Big Blue 500D, 600X
235 275-A

Big Blue 500D, 600X TM-4428 Page 91


Figure 13-5. Circuit Diagram For Big Blue 600X CC Models
(Deutz F4L2011 And D2011L04i-Powered Units) Eff w/Serial No. LJ003065 Thru LJ005954
TM-4428 Page 92 Big Blue 500D, 600X
237 428-A

Big Blue 500D, 600X TM-4428 Page 93


Figure 13-6. Circuit Diagram For Big Blue 600X CC Models
(Deutz D2011L04i-Powered Units) Eff w/Serial No. LJ005955 Thru MD120068E
TM-4428 Page 94 Big Blue 500D, 600X
238 928-B

Big Blue 500D, 600X TM-4428 Page 95


Figure 13-7. Circuit Diagram For Big Blue 500D CC/CV Models (Deutz F4L2011-Powered Units)
Eff w/Serial No. LC585264 Thru LJ003064 And Big Blue 600X CC/CV Models (Deutz F4L2011-Powered
Units) Eff w/Serial No. LC585624 Thru LH024757
TM-4428 Page 96 Big Blue 500D, 600X
215 806-E

Big Blue 500D, 600X TM-4428 Page 97


Figure 13-8. Circuit Diagram For Big Blue 500D CC/CV Models
(Deutz F4L2011 And D2011L04i-Powered Units) Eff w/Serial No. LJ003065 Thru LJ005954
TM-4428 Page 98 Big Blue 500D, 600X
237 430-A

Big Blue 500D, 600X TM-4428 Page 99


Figure 13-9. Circuit Diagram For Big Blue 500D CC/CV Models (Deutz D2011L04i-Powered Units)
Eff w/Serial No. LJ005955 And Following And Big Blue 600X CC/CV Models (Deutz D2011L04i-Powered
Units) Eff w/Serial No. MD140054E And Following
TM-4428 Page 100 Big Blue 500D, 600X
238 630-D

Big Blue 500D, 600X TM-4428 Page 101


Figure 13-10. Circuit Diagram For Big Blue 600X CC/CV Models
(Deutz F4L2011-Powered Units) Eff w/Serial No. LH024758 Thru LJ003064
TM-4428 Page 102 Big Blue 500D, 600X
235 276-A

Big Blue 500D, 600X TM-4428 Page 103


Figure 13-11. Circuit Diagram For Big Blue 600X CC/CV Models
(Deutz F4L2011 And D2011L04i-Powered Units) Eff w/Serial No. LJ003065 Thru LJ005954
TM-4428 Page 104 Big Blue 500D, 600X
237 431-A

Big Blue 500D, 600X TM-4428 Page 105


Figure 13-12. Circuit Diagram For Big Blue 600X CC/CV Models
(Deutz D2011L04i-Powered Units) Eff w/Serial No. LJ005955 Thru MD140053E
TM-4428 Page 106 Big Blue 500D, 600X
238 944-C

Big Blue 500D, 600X TM-4428 Page 107


Figure 13-13. Circuit Diagram For Big Blue 500D, 600X CC Models
(Deutz F3L912-Powered Units) Eff w/Serial No. LC585264 Thru LJ003064
TM-4428 Page 108 Big Blue 500D, 600X
215 807-D

Big Blue 500D, 600X TM-4428 Page 109


Figure 13-14. Circuit Diagram For Big Blue 500D, 600X CC Models
(Deutz F3L912-Powered Units) Eff w/Serial No. LJ003065 Thru LJ005954
TM-4428 Page 110 Big Blue 500D, 600X
237 433-A

Big Blue 500D, 600X TM-4428 Page 111


Figure 13-15. Circuit Diagram For Big Blue 500D, 600X CC Models
(Deutz F3L912-Powered Units) Eff w/Serial No. LJ005955 And Following
TM-4428 Page 112 Big Blue 500D, 600X
238 930-A

Big Blue 500D, 600X TM-4428 Page 113


Figure 13-16. Circuit Diagram For Big Blue 500D, 600X CC/CV Models
(Deutz F3L912-Powered Units) Eff w/Serial No. LC585264 Thru LJ003064
TM-4428 Page 114 Big Blue 500D, 600X
215 808-D

Big Blue 500D, 600X TM-4428 Page 115


Figure 13-17. Circuit Diagram For Big Blue 500D, 600X CC/CV Models
(Deutz F3L912-Powered Units) Eff w/Serial No. LJ003065 Thru LJ005954
TM-4428 Page 116 Big Blue 500D, 600X
237 432-A

Big Blue 500D, 600X TM-4428 Page 117


Figure 13-18. Circuit Diagram For Big Blue 500D, 600X CC/CV Models
(Deutz F3L912-Powered Units) Eff w/Serial No. LJ005955 And Following
TM-4428 Page 118 Big Blue 500D, 600X
238 929-B

Big Blue 500D, 600X TM-4428 Page 119


189 746-A

Figure 13-19. Circuit Board PC4, PC5 (HF Filter) Eff w/Serial No. LC585264 And Following

188 607-B

Figure 13-20. Circuit Board PC3 (HF Filter) Eff w/Serial No. LC585264 And Following
TM-4428 Page 120 Big Blue 500D, 600X
192 997

Figure 13-21. Circuit Board PC6 (HF Filter − CC/CV Only)


Eff w/Serial No. LC585264 And Following

192 227-A

Figure 13-22. Circuit Board PC9 (LED − CC/CV Only) Eff w/Serial No. LC585264 And Following
Big Blue 500D, 600X TM-4428 Page 121
Table 13-1. Lead List Summary For Big Blue 600X CC Models
(Deutz D2011L04i Engine) Eff w/Serial No. MG060063E And Following
 Table shows physical lead connections and should be used with circuit diagram (table replaces wiring diagram).
Apply small amount of dielectric grade, nonconductive electric grease (Miller Part No. 146557) to connectors where factory-applied
grease had been present.

Lead Connections Lead Connections


−−−−B RC6 (2) − S3 (2) 37A PC3 TO BUS BAR
−−−−H RC6 (1) − S3 (1) 37B PC3 (2) (INSTALL SEAL) TO LEAD 37 FROM PLG3 (2)
10A T1 SEC TO SR4 (AC) 37B CR7 (8) TO RC3 (2)
11A STATOR TO EXIT 37B PC3 TO LEAD 37 FROM PLG3 (2)
12A #1 COIL TO RANGE SWITCH 37C PC3 (3) (INSTALL SEAL) TO LEAD 37 FROM
13A #1 COIL TO RANGE SWITCH VOLTMETER
14A #1 COIL TO RANGE SWITCH 37C LEAD 37 FROM SR3 − PLG3 (2)
15A #1 COIL TO RANGE SWITCH 38A T1 SEC TO SR5 (AC)
16A #1 COIL TO RANGE SWITCH 39A T1 SEC TO SR5 (AC)
17A PC3 (4) (INSTALL SEAL) TO BUS BAR 40A CB10 (COPPER−BATT) TO STARTER
17A #1 COIL TO RECTIFIER 41A CB14 TO CR3 (87)
17A PC3 TO BUS BAR 42A SPLICE A TO PLG4 (1)
17C PC3 (5) (INSTALL SEAL) TO LEAD 17 FROM 42AA SPLICE N TO BATT GAUGE (5)
VOLTMETER 42B SPLICE A TO CR3 (85)
18A T1 SEC TO SR4 (AC) 42BB SPLICE C TO RC4 (1)
19A PC3 (9) (INSTALL SEAL) TO HEAT SINK (+) 42C BASE GND TO SPLICE D
19A PC3 TO HEAT SINK (+) 42CC SPLICE C TO CR7 (B)
19B PC3 (10) (INSTALL SEAL) TO LEAD 19 FROM PC1 (E2) 42D SPLICE A TO CR8 (85)
19B PC3 TO LEAD 19 FROM PC1 (E2) 42DD SPLICE D TO CR1 (85)
19C PC3 TO LEAD 19 FROM VOLTMETER (+) 42E SPLICE A TO SPLICE B
19D SR3 (+) TO WELD TERMINAL (+) 42EE SPLICE B TO SPLICE M
19E SR4 (+) TO SR3 (+) 42F SPLICE B TO SPLICE D
19F SR5 (+) TO SR3 (+) 42FF FUEL SENDER TO SPLICE D
21A STATOR TO EXIT 42G SPLICE B TO TS1
22A #2 COIL TO RANGE SWITCH 42J SPLICE B TO PLG12 (8)
23A #2 COIL TO RANGE SWITCH 42J SPLICE B TO PC7 (E)
24A #2 COIL TO RANGE SWITCH 42JJ SPLICE B TO CR6 (85)
25A #2 COIL TO RANGE SWITCH 42KK SPLICE C TO 42 SS
26A #2 COIL TO RANGE SWITCH 42L END BELL (BOTTOM−RIGHT) − TO LEAD 42 FROM
27A PC3 (8) (INSTALL SEAL) TO BUS BAR RC13 (CC ONLY)
27A #2 COIL TO RECTIFIER 42LL SPLICE C TO SPLICE B
27A PC3 TO BUS BAR 42M SPLICE O TO TEMP GAUGE (5)
30A PC3 (6) (INSTALL SEAL) TO HEAT SINK (−) 42N GND STUD (BASE) − GND STUD (AUX. PANEL)
30A PC3 TO HEAT SINK (−) 42P 1T (D−LEFT) TO GRD STUD
30B PC3 (7) (INSTALL SEAL) TO LEAD 30 FROM PC1 (E1) 42PP SPLICE M TO SPLICE N
30B PC3 TO LEAD 30 FROM PC1 (E1) 42R GFCI (GND) TO GND STUD
30C PC3 TO LEAD 30 FROM VOLTMETER (−) 42RR SPLICE M TO SPLICE O
30F SR3 (−) TO WELD TERMINAL (−) 42S RC1 (PE) TO GND STUD
30G SR4 (−) TO SR3 (−) 42SS SPLICE TO 42KK
30H SR5 (−) TO SR3 (−) 42T RC13 GRD TO END BELL LEAD 42
31A STATOR TO EXIT 42U SPLICE O TO HM (8)
32A #3 COIL TO RANGE SWITCH 42Z SPLICE N TO OIL GAUGE (5)
33A #3 COIL TO RANGE SWITCH 43A CR1 (30) TO STARTER
34A #3 COIL TO RANGE SWITCH 44A PLG4 (2) TO CB10 (AUX SILVER)
35A #3 COIL TO RANGE SWITCH 44E CB14 (COPPER) TO CB10 (AUX SILVER)
36A #3 COIL TO RANGE SWITCH 44F CR5 (1) TO CB13.
36A PLG6 (3) − PLG3 (1) 44G RC4 (2) TO CR5 (1)
36B CR7 (5) TO RC3 (1) 46A CR3 (30) TO TS1
36C RC6 (3) − S3 (3) 48A SPLICE TO S1 (D)
37A PC3 (1) (INSTALL SEAL) TO BUS BAR 48B S6 TO SPLICE
37A #3 COIL TO RECTIFIER 48C (1) FUEL GAUGE TO SPLICE
TM-4428 Page 122 Big Blue 500D, 600X
Lead Connections Lead Connections
49C S1 (B) TO CR5(6) 88B PIN SPLICE − PC4 (4)
49D HOUR METER (4) TO CR5(6) 98A S6 (LEFT BOTTOM) TO CB4
51A CR5 (5) TO HOUR METER (7) 99A T1 PRI TO CB4
52A CB13 TO S1 (A) 100B F1 (TOP) TO RC1 (1)
52B CB13 TO CR5 (3) 101B RC1 (3) TO SR1 (AC)
52C CR5 (3) TO S2 (BOTTOM) 102A R3 − PLG3 (4)
53A D8 (CATHODE) TO CR1 (86) 102B C9 (−) TO SPLICE
56A PLG4 (3) TO D8 (ANODE) 102C SR1 (−) TO SPLICE
56B SPLICE TO RC4 (3) 102D RC3 (4) TO SPLICE
56C SPLICE (RESET) TO S1 (S) 102E CR4 (3) OPTION TO SPLICE
56D PLG1 (6) (FUEL GAUGE/HM) TO SPLICE 103C R4 − PLG3 (6)
57A PLG4 (12) TO CR8 (86) 103D RC1 (4) TO SPLICE
57C S2 (CENTER) TO RC4 (12) 103E RC3 (6) TO SPLICE
58A PLG4 (4) TO PLG12 (6) (OIL) 103F C12 (+) TO SPLICE
58C RC4 (4) TO HR METER (3) 103G PLG7 (1) TO SPLICE
59A PLG4 (5) TO PLG12 (4) (TEMP) 103H C12 TO CR7 (7)
59B HR METER (2) TO RC4(5) 103J R1 (CW) TO RC7 (1)
60A D12 (CATH) TO PLG12 (2) 104B F2 (TOP) TO RC1 (6)
61A PLG4 (7) TO D12 (ANODE) 105A BRUSH (CENTER) − PLG1 (2)
61B CR1 (87) TO PLG12 (7) 105B C9 (+) TO SR2 (+)
61C D12 (ANODE) TO CR1 (87) 105C SR1 (+) TO SPLICE
61F SPLICE (G) TO SPLICE (L) 105D SR1 (+) TO SR2 (+)
61G SPLICE (L) TO OIL GUAGE (6) 105E D1/C1 (+) TO SPLICE
61H SPLICE (L) TO TEMP GUAGE (6) 105F RC1 (2) TO SPLICE
61J SPLICE (L) TO BATT GUAGE (6) 106A R3 − PLG3 (7)
61N SPLICE (G) TO CR5 (4) 106A BRUSH (FRONT) − PLG1 (5)
61P SPLICE (G) TO RC4 (7) 106B RC1 (5) TO SPLICE
61S SPLICE (G) TO CR6 (86) OPTION 106C RC3 (7) TO SPLICE
63A PC7 (F) OPTION TO CR4 (B) OPTION 106D CR4 (6) OPTION TO SPLICE
64A PLG4 (8) TO CR3 (86) 107A CR4 (4) OPTION TO CR4 (5) OPTION
64B PC7 (C) OPTION TO RC4 (8) 108A BRUSH (REAR) − PLG1 (8)
65A PC7 (A) OPTION TO CR4 (A) 108B RC1 (8) TO SR2 (−)
66A CT1 TO PC7 (D) 110A D1/C1 TO CB12
67A CT1 TO PC7 (G) 111A CB12 TO CB11
68B CR6 (30) OPTION TO S6 (MIDDLE BOTTOM) 111B CB12 TO CR5 (2)
69A PLG4 (9) TO PLG12 (5) 113A CR7 (A) TO CB11
69C RC4 (9) TO OIL GUAGE (3) 114B R6 TO S6 (MIDDLE RIGHT)
69D DEUTZ HARNESS TO OIL PRESSURE SENDER 114C R6 TO CR7 (4)
70A PLG4 (10) TO PLG12 (3) 115A C12 TO R6
70C RC4 (10) TO TEMP GUAGE (3) 116A S5 (BOTTOM) TO PLG7 (3)
71A PLG4 (11) TO FUEL SENDER 116B RC13 (W) TO EXIT
71C RC4 (11) TO FUEL GUAGE (5) 116D R1 (WIPER) TO RC7 (3)
72A PC7 (B) OPTION TO CR6 (87) OPTION 118A R2 − PLG3 (8)
81B ELCB1 (LINE) TO 1T (A−RIGHT) 118B RC3 (8) TO SR2 (AC)
81E T1 PRI TO EXCITER STATOR 125A S5 (CENTER) TO S6 (MIDDLE CENTER)
82B CB2 (TOP) TO 1T (B−RIGHT) 125C RC13 TO EXIT
84B GFCI (N) TO 1T (D−RIGHT) 125D S6 (MIDDLE) TO RC3 (9)
84C ELCB1 (LINE N) TO 1T (D−RIGHT) 125D PLG6 (1) − R2
85A CB2 (BOTTOM) TO GFCI (HOT) 125E R2 − PLG3 (9)
85B CB2 (BOTTOM) TO PC5 (5) 126A PLG6 (2) − R4
86A ELCB1 (LOAD N) TO RC1 (N) 137A F1 TO SR1 (AC)
88A PIN SPLICE − RC1 (L) 138A F2 TO SR2 (AC)

Big Blue 500D, 600X TM-4428 Page 123


Table 13-2. Lead List Summary For Big Blue 600X CC Models
(Deutz F3L912 Engine) Eff w/Serial No. MG060063E And Following
 Table shows physical lead connections and should be used with circuit diagram (table replaces wiring diagram).
Apply small amount of dielectric grade, nonconductive electric grease (Miller Part No. 146557) to connectors where factory-applied
grease had been present.

Lead Connections Lead Connections


−−−−B RC6 (2) − S3 (2) 37B PC3 (2) (INSTALL SEAL) TO LEAD 37 FROM PLG3 (2)
−−−−H RC6 (1) − S3 (1) 37B CR7 (8) TO RC3 (2)
10A T1 SEC TO SR4 (AC) 37B PC3 TO LEAD 37 FROM PLG3 (2)
11A STATOR TO EXIT 37C PC3 (3) (INSTALL SEAL) TO LEAD 37 FROM
12A #1 COIL TO RANGE SWITCH VOLTMETER
13A #1 COIL TO RANGE SWITCH 37C LEAD 37 FROM SR3 − PLG3 (2)
14A #1 COIL TO RANGE SWITCH 38A T1 SEC TO SR5 (AC)
15A #1 COIL TO RANGE SWITCH 39A T1 SEC TO SR5 (AC)
16A #1 COIL TO RANGE SWITCH 40A CB10 (COPPER−BATT) TO STARTER
17A PC3 (4) (INSTALL SEAL) TO BUS BAR 40B STARTER TO ALT (B+)
17A #1 COIL TO RECTIFIER 42A SPLICE A TO PLG4 (1)
17A PC3 TO BUS BAR 42AA SPLICE N TO BATT GAUGE (5)
17C PC3 (5) (INSTALL SEAL) TO LEAD 17 FROM 42BB SPLICE C TO RC4 (1)
VOLTMETER 42C BASE GND TO SPLICE C
18A T1 SEC TO SR4 (AC) 42CC SPLICE C TO CR1 (85)
19A PC3 (9) (INSTALL SEAL) TO HEAT SINK (+) 42CC SPLICE C TO CR7 (B)
19A PC3 TO HEAT SINK (+) 42D SPLICE A TO CR8 (85)
19B PC3 (10) (INSTALL SEAL) TO LEAD 19 FROM PC1 (E2) 42E SPLICE A TO SPLICE B
19B PC3 TO LEAD 19 FROM PC1 (E2) 42EE SPLICE B TO SPLICE C
19C PC3 TO LEAD 19 FROM VOLTMETER (+) 42EE SPLICE B TO SPLICE M
19D SR3 (+) TO WELD TERMINAL (+) 42F SPLICE A TO FUEL SENDER GND
19E SR4 (+) TO SR3 (+) 42J SPLICE B TO FS1
19F SR5 (+) TO SR3 (+) 42J SPLICE B TO PC7 (E)
21A STATOR TO EXIT 42JJ SPLICE B TO CR6 (85)
22A #2 COIL TO RANGE SWITCH 42KK SPLICE C TO 42 SS
23A #2 COIL TO RANGE SWITCH 42L END BELL (BOTTOM−RIGHT) − TO LEAD 42 FROM
24A #2 COIL TO RANGE SWITCH RC13 (CC ONLY)
25A #2 COIL TO RANGE SWITCH 42LL SPLICE C TO SPLICE B
26A #2 COIL TO RANGE SWITCH 42M SPLICE O TO TEMP GAUGE (5)
27A PC3 (8) (INSTALL SEAL) TO BUS BAR 42N GND STUD (BASE) − GND STUD (AUX. PANEL)
27A #2 COIL TO RECTIFIER 42P 1T (D−LEFT) TO GRD STUD
27A PC3 TO BUS BAR 42PP SPLICE M TO SPLICE N
30A PC3 (6) (INSTALL SEAL) TO HEAT SINK (−) 42R GFCI (GND) TO GND STUD
30A PC3 TO HEAT SINK (−) 42RR SPLICE M TO SPLICE O
30B PC3 (7) (INSTALL SEAL) TO LEAD 30 FROM PC1 (E1) 42S RC1 (PE) TO GND STUD
30B PC3 TO LEAD 30 FROM PC1 (E1) 42SS SPLICE TO 42KK
30C PC3 TO LEAD 30 FROM VOLTMETER (−) 42T RC13 GRD TO END BELL LEAD 42
30F SR3 (−) TO WELD TERMINAL (−) 42U SPLICE O TO HM (8)
30G SR4 (−) TO SR3 (−) 42Z SPLICE N TO OIL GAUGE (5)
30H SR5 (−) TO SR3 (−) 43A CR1 (30) TO STARTER
31A STATOR TO EXIT 44A PLG4 (2) TO CB10 (AUX SILVER)
32A #3 COIL TO RANGE SWITCH 44F CR5 (1) TO CB13.
33A #3 COIL TO RANGE SWITCH 44G RC4 (2) TO CR5 (1)
34A #3 COIL TO RANGE SWITCH 48A SPLICE TO S1 (D)
35A #3 COIL TO RANGE SWITCH 48B S6 TO SPLICE
36A #3 COIL TO RANGE SWITCH 48C (1) FUEL GAUGE TO SPLICE
36A PLG6 (3) − PLG3 (1) 49C S1 (B) TO CR5(6)
36B CR7 (5) TO RC3 (1) 49D HOUR METER (4) TO CR5(6)
36C RC6 (3) − S3 (3) 51A CR5 (5) TO HOUR METER (7)
37A PC3 (1) (INSTALL SEAL) TO BUS BAR 52A CB13 TO S1 (A)
37A #3 COIL TO RECTIFIER 52B CB13 TO CR5 (3)
37A PC3 TO BUS BAR 52C CR5 (3) TO S2 (BOTTOM)
TM-4428 Page 124 Big Blue 500D, 600X
Lead Connections Lead Connections
53A D8 (CATHODE) − CR1 (86) 100B F1 (TOP) TO RC1 (1)
56A PLG4 (3) TO D8 (ANODE) 101B RC1 (3) TO SR1 (AC)
56B D8 (ANODE) TO CR8 (87) 102A R3 − PLG3 (4)
56B SPLICE TO RC4 (3) 102B C9 (−) TO SPLICE
56C SPLICE (RESET) TO S1 (S) 102C SR1 (−) TO SPLICE
56D PLG1 (6) (FUEL GAUGE/HM) TO SPLICE 102D RC3 (4) TO SPLICE
57A PLG4 (12) TO CR8 (86) 102E CR4 (3) OPTION TO SPLICE
57C S2 (CENTER) TO RC4 (12) 103C R4 − PLG3 (6)
58A PLG4 (4) TO OIL PRESSURE SWITCH 103D RC1 (4) TO SPLICE
58C RC4 (4) TO HR METER (3) 103E RC3 (6) TO SPLICE
59A PLG4 (5) TO COOLANT TEMP. SWITCH 103F C12 (+) TO SPLICE
59B HR METER (2) TO RC4(5) 103G PLG7 (1) TO SPLICE
60A D12 (CATH) TO ALT (D+) 103H C12 TO CR7 (7)
61A PLG4 (7) TO D12 (ANODE) 103J R1 (CW) TO RC7 (1)
61B CR1 (87) TO FS1 104B F2 (TOP) TO RC1 (6)
61C CR1 (87) TO D12 (ANODE) 105A BRUSH (CENTER) − PLG1 (2)
61F SPLICE (G) TO SPLICE (L) 105B C9 (+) TO SR2 (+)
61G SPLICE (L) TO OIL GUAGE (6) 105C SR1 (+) TO SPLICE
61H SPLICE (L) TO TEMP GUAGE (6)
105D SR1 (+) TO SR2 (+)
61J SPLICE (L) TO BATT GUAGE (6)
105E D1/C1 (+) TO SPLICE
61N SPLICE (G) TO CR5 (4)
105F RC1 (2) TO SPLICE
61P SPLICE (G) TO RC4 (7)
106A R3 − PLG3 (7)
61S SPLICE (G) TO CR6 (86) OPTION
106A BRUSH (FRONT) − PLG1 (5)
63A PC7 (F) OPTION TO CR4 (B) OPTION
106B RC1 (5) TO SPLICE
64A STARTER TO CB14 (COPPER)
106C RC3 (7) TO SPLICE
64B PC7 (C) OPTION TO RC4 (8)
106D CR4 (6) OPTION TO SPLICE
65A PC7 (A) OPTION TO CR4 (A)
107A CR4 (4) OPTION TO CR4 (5) OPTION
66A CT1 TO PC7 (D)
108A BRUSH (REAR) − PLG1 (8)
67A CT1 TO PC7 (G)
108B RC1 (8) TO SR2 (−)
68B CR6 (30) OPTION TO S6 (MIDDLE BOTTOM)
110A D1/C1 TO CB12
69A PLG4 (9) TO OIL SENDER
111A CB12 TO CB11
69C RC4 (9) TO OIL GUAGE (3)
70A PLG4 (10) TO COOLANT TEMP SENDER (PIN 1) 111B CB12 TO CR5 (2)
70C RC4 (10) TO TEMP GUAGE (3) 113A CR7 (A) TO CB11
71A PLG4 (11) TO FUEL SENDER 114B R6 TO S6 (MIDDLE RIGHT)
71C RC4 (11) TO FUEL GUAGE (5) 114C R6 TO CR7 (4)
72A PC7 (B) OPTION TO CR6 (87) OPTION 115A C12 TO R6
74A CB14 (SILVER) TO FS1 116A S5 (BOTTOM) TO PLG7 (3)
81B ELCB1 (LINE) TO 1T (A−RIGHT) 116B RC13 (W) TO EXIT
81E T1 PRI TO EXCITER STATOR 116D R1 (WIPER) TO RC7 (3)
82B CB2 (TOP) TO 1T (B−RIGHT) 118A R2 − PLG3 (8)
84B GFCI (N) TO 1T (D−RIGHT) 118B RC3 (8) TO SR2 (AC)
84C ELCB1 (LINE N) TO 1T (D−RIGHT) 125A S5 (CENTER) TO S6 (MIDDLE CENTER)
85A CB2 (BOTTOM) TO GFCI (HOT) 125C RC13 TO EXIT
85B CB2 (BOTTOM) TO PC5 (5) 125D S6 (MIDDLE) TO RC3 (9)
86A ELCB1 (LOAD N) TO RC1 (N) 125D PLG6 (1) − R2
88A PIN SPLICE − RC1 (L) 125E R2 − PLG3 (9)
88B PIN SPLICE − PC4 (4) 126A PLG6 (2) − R4
98A S6 (LEFT BOTTOM) TO CB4 137A F1 TO SR1 (AC)
99A T1 PRI TO CB4 138A F2 TO SR2 (AC)

Big Blue 500D, 600X TM-4428 Page 125


SECTION 13 − RUN-IN PROCEDURE
run_in1 2014−09

NOTICE − Diesel engines in MILLER equipment are meant to operate optimally at moderate to rated load. Using light or no load for extended periods
of time may cause wetstacking or other engine damage. Do not idle engine longer than necessary.

13-1. Wetstacking
NOTICE − Do not perform run-in
procedure at less than 20 volts weld
output and do not exceed duty cycle
or equipment damage may occur.
1 Welder/Generator
Run diesel engines near rated volt-
age and current during run-in period
to properly seat piston rings and
prevent wetstacking. See name-
plate, rating label, or specifications
section in this manual to find rated
voltage and current.
2 NOTICE − Do not idle engine longer
than necessary. Piston rings only
seat correctly if engine runs at weld/
power rpm, and the welder/genera-
tor is kept loaded during run-in.
2 Engine Exhaust Pipe
Wetstacking is unburned fuel and oil
in the exhaust pipe and occurs
during run-in if the engine is run too
long at light load or idle rpm.
If exhaust pipe is coated with a wet,
1 black, tar-like substance, dry the
engine using one of the following
run-in procedures.
See the engine manual for additional
engine run-in information.

TM-4428 Page 126 Big Blue 500D, 600 X


13-2. Run-In Procedure Using Load Bank Or Resistance Grid

2
1

4
3

S-0683 / S-0684

! Stop engine. 3 Weld Cables voltage and current of the generator


4 Resistance Grid (see nameplate, rating label, or the
! Do not touch hot exhaust pipe, en-
specifications section in this manual).
gine parts, or load bank/grid. Use grid sized for generator rated output.
! Keep exhaust and pipe away from Turn Off grid. Check generator and meters after first five
flammables. minutes then every fifteen minutes to be
5 Voltmeter sure generator is loaded properly.
NOTICE − Do not perform run-in 6 Clamp-On Ammeter
procedure at less than 20 volts weld output NOTICE − Check oil level frequently during
and do not exceed duty cycle or equipment Connect voltmeter and ammeter as run-in; add oil if needed.
damage may occur. shown, if not provided on generator.
Start engine and run for several minutes. It is recommended to run the welder/gener-
1 Load Bank ator for two hours minimum and up to four
Turn all load bank switches Off. If needed, For Load Bank hours under load. Place A/V control in
connect load bank to 115 volts ac wall Set load bank switches and then adjust minimum position, then shut down load
receptacle or generator auxiliary power generator A/V control so load equals bank or grid to remove load. Run engine
receptacle. rated voltage and current of generator several minutes at no load.
(see nameplate, rating label, or the
2 Welder/Generator ! Stop engine and let cool.
specifications section in this manual).
Place A/V range switch in maximum posi-
For Resistance Grid 7 Engine Exhaust Pipe
tion, A/V control in minimum position, and
Output Selector switch (if present) in either Set grid switches and then adjust gen- Repeat procedure if wetstacking is pres-
DC position. erator A/V control so load equals rated ent.

Big Blue 500D, 600 X TM-4428 Page 127


Notes

TM-4428 Page 128 Big Blue 500D, 600 X


TM-4428L 2016−07

Processes
Stick (SMAW) Welding

TIG (GTAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Air Carbon Arc (CAC-A) Cutting


and Gouging

Description

Engine Driven Welder/Generator

Big Blue 500D




Big Blue 600 X




(Deutz-Powered)

Eff w/Serial No. LC585264 Thru LJ003064

File: Engine Drive

Visit our website at


www.MillerWelds.com
SECTION 14 − PARTS LIST
EFF W/SERIAL NO. LC585264 THRU LJ003064
 Hardware is common and not
available unless listed.

 A Deutz F4L2011 engine-pow-


ered unit is shown below. See
insert for parts specific to a
Deutz F3L912-powered unit.
Parts not related to the engines
are the same in both units. 15

14
3 16
2
17
13
1

12
18

4 11 19
5 6
9
10
8
7

107

106

12 21
100 (Fig. 15-7) 20

101 99 92
22

127 90
105 98 (FIG. 15-2 OR 15-3)
95 (CC ONLY)
91
96
97 (CC ONLY)
93

103 102 94 (CC ONLY)

104 (FIG. 15-4 OR 15-5)

CC CC Models Only
CV CC/CV Models Only

Figure 15-1. Main Assembly


TM-4428 Page 130 Big Blue 500D, 600 X
Eff w/Serial No. LC585264 Thru LJ003064
 A Deutz F4L2011 en- Deutz F3L912 Engine
gine-powered unit is
shown below. See in- 29
sert for parts specific to
a Deutz F3L912-pow- 119 122
2
ered unit. Parts not re-
lated to the engines are 33 124
the same in both units. 118 110
120
117
108

53
114 54

123
121 113 60
115
65

116 61 56
111 62 57
63
109 58
67
112 59
16 68
17
69
29
47
35 (Fig. 15−6) 70
25 44 46
28
31
27
24 26 45

48
23

43 50
33 51
2

126 42
49
30 34
32

41

40 52
39
38
37 67 2
2
36 68
2 53
35 (Fig. 15-6) 54 69
60
61
55 70
74
62 56
65 63 57 72
64 73
58 71
84 59
81 85 75
82 86
83 80
66
76
87

79
88
89
78 77
90 803 659 / 803 665

Big Blue 500D, 600 X TM-4428 Page 131


Eff w/Serial No. LC585264 Thru LJ003064
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 15-1. Main Assembly

. . . 1 . . . . . . . . . . . . . . 189824 .. Panel, Gen Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


. . . 1 . . . . . . . . . . . . ♦199294 .. Panel, Gen Lh Ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . 176106 .. Label, Warning Moving Parts (Prior to LF310974) . . . . . . . . . . . . . . . . . . . . 8
. . . 2 . . . . . . . . . . . . . . 225120 .. Label, Warning Moving Parts Can Cause Injury (Eff w/LF310974) . . . . . . 8
. . . 3 . . . . . . . . . . . . . +189828 .. Panel, Engine Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . ♦+199301 .. Panel, Engine Side Ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦212570 .. Baffle, Engine Side (Export Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . Z1 . . . . . 189395 .. Reactor, Ac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . Z1 . . . ♦201520 .. Reactor, Ac Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . 1T . . . . . 038621 .. Block, Term 30a 4 Pole Frict Term Str . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 038620 .. Link, Jumper Term Blk 30a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . . . . . . . . . . 081499 .. Bracket, Mtg Strip Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . 206352 .. Brace, Front To Center Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 203260 .. Label, Caution Do Not Use Ether . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . SR4, SR5 . . 035704 .. Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . CB4 . . . . 045061 .. Circuit Breaker, Auto Reset 24vdc 7 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . 201697 .. Pan, Reactor And Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . T1 . . . . . 201613 .. Transformer W/Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . T1 . . . ♦205636 .. Transformer W/Bracket (Environmental Coating) . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . 173352 .. Extrusion, Rubber Clamp/Bulb (Order By Ft) . . . . . . . . . . . . . . . . . . . . . . . . 3ft
. . . 13 . . . . . . . . . . . . . . 189708 .. Firewall, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . 191307 .. Cover, Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 191829 .. Hose, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . 189763 .. Bracket, Mtg Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . 189764 .. Air Cleaner, Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *192938 .. Filter, Air Element Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . *♦192939 .. Filter, Air Element Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . 189464 .. Seal, Weather Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 173909 .. Hose, Sae .312 Id X .560 Od X 24.000 (Order By Ft) . . . . . . . . . . . . . . . . . 2
. . . 19 . . . . . . . . . . . . . . 201658 .. Upright, Center Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . +200999 .. Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . ♦+203382 .. Base E-Coat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . 196220 .. Bracket, Hold Down Fuel Tank Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . 192362 .. Bracket, Mtg Nyl 1/2 Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . +201934 .. Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . ♦+202640 .. Cover, Top Ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . 189052 .. Grommet, Plastic Neck Filler Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . 190198 .. Cap, Tank Screw-On 3.500 In W/Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . 176103 .. Label, Use Diesel Fuel Only (Wordless Label) (Prior to LF310974) . . . . . 1
. . . 26 . . . . . . . . . . . . . . 192041 .. Label, Use Diesel Fuel Only (Wordless Label) (Eff w/LF310974) . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . 176104 .. Label, Warning Falling Equipment (Wordless Label) (Prior to LF310974) 1
. . . 27 . . . . . . . . . . . . . . 222513 .. Label, Warning Falling Equipment Can Cause Serious (Eff w/LF310974) 1
. . . 28 . . . . . . . . . . . . . . 176230 .. Label, Warning Hot Exhaust (Prior to LF310974) . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . 224265 .. Label, Warning Hot Exhaust Parts Do Not Touch (Eff w/LF310974) . . . . . 1
. . . 29 . . . . . . . . . . . . . . 105734 .. Pipe, Muffler Extension Elbow 1.875 Od . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . 201592 .. Pipe, Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . 201851 .. Cover, Radiator Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . 191354 .. Support, Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . 202633 .. Support, Cover E-Coat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . . 010875 .. Clamp, Muffler 2.000 Dia U Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . 200730 .. Manifold, Exhaust Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . Figure 15-6 .. Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . . 191577 .. Guard, Starter (Deutz F4L2011 engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . . 191809 .. Bracket, Mtg Engine Lh (Deutz F4L2011 engine) . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . . . 190951 .. Edge Trim, Style Tl750-B2 X 1/16 Black W/Clips 1.625 . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . . 191817 .. Baffle, Air (Deutz F4L2011 engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 15-1. Main Assembly (Continued)

. . . 40 . . . . . . . . . . . . . . 213877 . . Engine, Deutz Dsl Elec F4L2011 (consisting of) . . . . . . . . . . . . . . . . . . . . . 1


. . . . . . . . . . . . . . . . . . . *067265 . . . . Filter, Oil (Engine) (Deutz F4L2011 engine) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *192744 . . . . Filter, Fuel Spin-On (Deutz F4L2011 engine) . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *066217 . . . . Filter, Fuel Secondary (Deutz F4L2011 engine) . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *195745 . . . . Switch, Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *195746 . . . . Sender, Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦174064 . . Idle, Solenoid Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦175937 . . Bracket, Support Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . *067266 . . Belt, Blower (Deutz F4L2011 engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . . . 201714 . . Box, Air Intake (Deutz F4L2011 engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . . . 201748 . . Upright, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . ♦202638 . . Upright, Rear Ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . . 190206 . . Cable, Bat Neg 42 In Lg No. 2 Awg W/Clamp And .375rng . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . . . 108081 . . Terminal Protector, Battery Post Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 46 . . . . . . . . . . . . . . 190207 . . Cable, Bat Pos 45 In Lg No. 1 Awg W/Clamp And .406rng . . . . . . . . . . . . 1
. . . 47 . . . . . . . . . . . . . . 203430 . . Bracket, Battery Holddown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . . . . . . . . . . 190897 . . Battery, Stor 12v 650crk 110rsv Gp 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . . . . . . . . . . . 201006 . . Bolt, J Stl .312−18 X 8.500 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 50 . . . . . . . . . . . . . +201183 . . Cover, Battery Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . . . . . . . . . . 202639 . . Cover, Battery Access Ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . . . . . . . . . . . 176108 . . Label, Warning Battery Explosion Can Blind (Prior to LF310974) . . . . . . . 1
. . . 51 . . . . . . . . . . . . . . 168385 . . Label, Warning Battery Explosion Can Blind (Eff w/LF310974) . . . . . . . . . 1
. . . 52 . . . . . . . . . . . . . +215252 . . Guard, Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 53 . . . . . . . . . . . . . . 199849 . . Screw, 625-11 X 4.00hexhd Pln Gr 5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 54 . . . . . . . . . . . . . . 071731 . . Washer, Flat .656 Id X 2.250 Od X .187t Stl Pld . . . . . . . . . . . . . . . . . . . . . 4
. . . 55 . . . . . . . . . . . . . . 191812 . . Bracket, Mtg Engine Rh (Deutz F4L2011 engine) . . . . . . . . . . . . . . . . . . . . 1
. . . 56 . . . . . . . . . . . . . . 071890 . . Retainer, Mount Eng/Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 57 . . . . . . . . . . . . . . 071730 . . Tubing, Stl .875 Od X 12ga Wall X 2.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 58 . . . . . . . . . . . . . . 083476 . . Mount, Eng/Gen Nprn .875 Id X 2.500 Od X 2.000 . . . . . . . . . . . . . . . . . . . 4
. . . 59 . . . . . . . . . . . . . . 135205 . . Nut, 625-11 .94hex .76h Stl Pld Elastic Stop Nut . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . 199507 . . Hose, Oil Drain Assy 20 In (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 60 . . . . . . . . . . . . . . 165271 . . . . Valve, Oil Drain 3/8-18nptf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 61 . . . . . . . . . . . . . . 176529 . . . . Fitting, Hose Brs Barbed Fem 1/2tbg X 3/8npt . . . . . . . . . . . . . . . . . . . . . 1
. . . 62 . . . . . . . . . . . . . . 113854 . . . . Hose, Sae .500 Id X .780 Od Xc Oil (Order By Ft) . . . . . . . . . . . . . . . . . . 2ft
. . . 63 . . . . . . . . . . . . . . 176528 . . Fitting, Hose Brs Barbed Elbow Fem 1/2 Tbg X 1/2 Npt . . . . . . . . . . . . . . . 1
. . . 64 . . . . . . . . . . . . . . 173336 . . Fitting, Adapter Oil Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 65 . . . . . . . . . . . . . . . . . . . . . . . . Washer, Oil Drain (Available Through Engine Manufacturer) . . . . . . . . . . . 1
. . . 66 . . . . . . . . . . . . . . 219229 . . Bracket, Mtg Solenoid (Deutz F4L2011 engine) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 67 . . . . . . . . . . . . . . 206297 . . Base, Fuel Filter Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 68 . . . . . . . . . . . . . . 145282 . . Fitting, Hose Brs Barbed Elbow M 5/16tbg X 1/4npt . . . . . . . . . . . . . . . . . . 2
. . . 69 . . . . . . . . . . . . . . 196465 . . Hose, Sae .312 Id X .560 Od X 23.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 200032 . . Hose, Sae .312 Id X .560 Od X 38.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 70 . . . . . . . . . . . . . *192744 . . Filter, Fuel Spin-On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 71 . . . . . . . . . . . . . . 190992 . . Keeper, Latch Engine Access Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 72 . . . . . . . . . . . . . . 190076 . . Channel, Stiffener Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 72 . . . . . . . . . . . . ♦202635 . . Channel, Stiffener Engine Access E-Coat . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 73 . . . . . . . . . . . . . . 199592 . . Latch, Paddle Series 20 (Black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 74 . . . . . . . . . . . . . . 215233 . . Label, Diesel Engine Maintenance Deutz (Wordless Label) . . . . . . . . . . . . 1
. . . 75 . . . . . . . . . . . . . +200989 . . Door, Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 75 . . . . . . . . . . . . . +210736 . . Door, Engine Access Ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 76 . . . . . . . . . . . . . . 189975 . . Hinge, Door Access 180deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 77 . . . . . . . . . . . . . . 208141 . . Stop, Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 78 . . . . . . . . . . . . . . 189826 . . Panel, Rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 78 . . . . . . . . . . . . . . 199298 . . Panel, Rocker Ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 79 . . . . . . . . . . . . . . 189827 . . Panel, Gen Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 79 . . . . . . . . . . . . . . 199300 . . Panel, Gen Rh Ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 15-1. Main Assembly (Continued)

. . . 80 . . . . . . . . . . . . . . 191626 . . Bumper, Door Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


. . . 81 . . . . . . . . . . . . . . 218087 . . Tank, Fuel (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 82 . . . . . . . . . . . . . . 124253 . . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . 084173 . . . . Clamp, Hose .460 − .545clp Dia Slfttng . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 83 . . . . . . . . . . . . . . 189912 . . . . Fitting, Stl Barbed Elbow W/.047 In Orf Zinc Pld . . . . . . . . . . . . . . . . . . . 1
. . . 84 . . . . . . . . . . . . . . 189909 . . . . Fitting, Stand Pipe Hose .250 X 9.260 Lg 90deg Zinc . . . . . . . . . . . . . . . 1
. . . 85 . . . . . . . . . . . . . . 189913 . . . . Fitting, Stl Barbed Elbow Zinc Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 86 . . . . . . . . . . . . . . 190142 . . . . Sender, Fuel Gauge 9.7500 Deep Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 87 . . . . . . . . . . . . . . 189910 . . . . Fitting, Stand Pipe Hose .3125 X 9.260 Lg 90deg Zinc . . . . . . . . . . . . . . 1
. . . 88 . . . . . . . . . . . . . . 189908 . . . . Valve, Drain Fuel 180deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 89 . . . . . . . . . . . . . . 181572 . . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 90 . . . . . . . . . . . . . . 191446 . . Extrusion, Rubber W/Adhesive 1.000 X 1.000 D (Order By Ft) . . . . . . . . . 6ft
. . . 91 . . . . . . . . . . . . . . 191897 . . Bracket, Mtg Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 92 . . . . . . . . . . . . . . 218086 . . Bracket, Hold Down Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 93 . . . . . . . . . . . . . . 200864 . . Label, Warning Do Not Weld On Base (Prior to LF310974) . . . . . . . . . . . . 2
. . . 93 . . . . . . . . . . . . . . 224266 . . Label, Warning Do Not Weld On Base (Eff w/LF310974) . . . . . . . . . . . . . . 2
. . . 94 . . . . . . . . . . . . . . 190179 . . Panel, Mtg Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 95 . . . . . R4 . . . CC191292 . . Resistor, Ww Fxd 375w 50 Ohm W/Mtg Bkt . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 96 . . . . . R2 . . . . . 189699 . . Resistor, Ww Tap 375w 10 Ohm W/Mtg Bkt . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 97 . . . . . R3 . . . CC189699 . . Resistor, Ww Tap 375w 10 Ohm W/Mtg Bkt . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 98 . . . . . . Figure 15-2, Figure 15-3 Control Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 99 . . . . . . . . . . . . . . 189731 . . Firewall, Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 100 . . . . . . . . . Figure 15-7 . . Main Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 101 . . . . . . . . . . . . . 191448 . . Top, Cover Front Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 101 . . . . . . . . . . . ♦199305 . . Top, Cover Front Upright Ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 102 . . . . . . . . . . . . +201750 . . Upright, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 102 . . . . . . . . . . ♦+202637 . . Upright, Front Ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 103 . . . . . . . . . . . . . 182761 . . Label, Warning General Precautionary (Prior to LF310974) . . . . . . . . . . . . 1
. . 103 . . . . . . . . . . . . . 223379 . . Label, Warning General Precautionary (Eff w/LF310974 thru LH017115) 1
. . 103 . . . . . . . . . . . . . 233953 . . Label, Warning General Precautionary (Eff w/LH017115) . . . . . . . . . . . . . 1
. . 104 . . . . . Figure 15-4, Figure 15-5 PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 105 . . . . . . . . . . . ♦202130 . . Xfmr, Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 106 . . . . . . . . . . . CV193453 . . Bracket, Mtg Box Fcr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 107 . . . PC1 . . CV207397 . . Module, Field Current Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 190058 . . Nut, .250-20 U-Nut Multi-Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . . 049525 . . Nut, 312-18 U-Nut Multi-Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Prior to LF310974:
. . . . . . . . . . . . . . . . . . . . 202031 . . Kit, Label (Includes Safety And Informational Labels) . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 201062 . . Kit, Label (Includes Safety And Informational Labels) (Wordless Labels) 1
Eff w/LF310974:
. . . . . . . . . . . . . . . . . . . . 215631 . . Kit, Label (Includes Safety & Informational Labels) (CC models) . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 215632 . . Kit, Label (Includes Safety & Informational Labels) (CC/CV models) . . . . 1
. . . . . . . . . . . . . . . . . . . . 216995 . . Kit, Label (Includes Safety & Informational Labels) (CC export models)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Deutz F4L2011 engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 216994 . . Kit, Label (Includes Safety & Informational Labels) (CC/CV export models)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Deutz F4L2011 engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 216991 . . Kit, Label (Includes Safety & Informational Labels) (CC export models)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 216990 . . Kit, Label (Includes Safety & Informational Labels) (CC/CV export models)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 108 . . . . . . . . . . . . . 199063 . . Engine, Deutz Dsl Elec F3l912 D0392−166/00 . . . . . . . . . . . . . . . . . . . . . . 1
. . 109 . . . . . . . . . . . . *064677 . . Filter, Oil (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 110 . . . . . . . . . . . . *066271 . . Belt, Blower (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 111 . . . . . . . . . . . . *195745 . . Switch, Pressure Oil 1.5 Bar Nc Cont . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 112 . . . . . . . . . . . . *195746 . . Sender, Coolant Temp & 130 Degee C Switch . . . . . . . . . . . . . . . . . . . . . . . 1
. . 113 . . . . . . . . . . . . . 194135 . . Backplate, Deutz F3L912 engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 114 . . . . . . . . . . . . . 194572 . . Support, Front Engine (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . . . . . . 1
. . 115 . . . FS1 . . . . 141346 . . Shutdown Kit, Engine (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . . . . . . . 1
TM-4428 Page 134 Big Blue 500D, 600 X
Eff w/Serial No. LC585264 Thru LJ003064
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 15-1. Main Assembly (Continued)

.. 116 . . . . . . . . . . . . . 118452 ..
Ftg, Adapter Oil Drain (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . . . . . . . 1
.. 117 . . . . . . . . . . . . . 193313 ..
Manifold, Exhaust Muffler (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . . . . 1
.. 118 . . . . . . . . . . . . . 194496 ..
Baffle, Lower Air Outlet (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . . . . . 1
.. 119 . . . . . . . . . . . . . 194497 ..
Baffle, Upper Air Outlet (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . . . . . 1
.. 120 . . . . . . . . . . . . . 194500 ..
Baffle, Air Intake (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 121 . . . . . . . . . . . . . 194485 ..
Hose, Air Cleaner (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 122 . . . . . . . . . . . . +201714 ..
Box, Air Intake (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 123 . . . . . . . . . . . . . 195560 ..
Guard, Starter Hole (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 124 . . . . . . . . . . . . . 194467 ..
Washer, Flat 6.25idx11.50odx.062t Buna N . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 125 . . . . . . . . . . . . . 212944 ..
Label, Stick Overlap Weld Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 126 . . . . . . . . . . . . . 233088 ..
Label, Danger Using A Generator Indoors Can Kill You
In Minutes (Unit) (Eff w/LH017115) 1
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
* Recommended Spare Parts. ♦optional
C
C CC models only. C CC/CV models only.
V
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement
Parts. Model and serial number required when ordering parts from your local distributor.
14 4

18

25

23

6
21
3
17

8
7 26

1 22

20
10
15

11 9

19

16

13 24
5
12 803 660-C

Figure 15-2. Control Box Assembly − CC Models

Big Blue 500D, 600 X TM-4428 Page 135


Eff w/Serial No. LC585264 Thru LJ003064
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 15-2. Control Box Assembly − CC Models (Figure 15-1 Item 98)

. . . 1 . . . F1, F2 . . *085874 . . Fuse, Mintr Cer Slo-Blo 10a 250v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


. . . 2 . . . . . . . . . . . . . . 046432 . . Holder, Fuse Mintr .250 X 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . . . . . . . . . . . 201077 . . Control Box, Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . 201078 . . Control Box, Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . 201079 . . Cover, Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . C12 . . . . 191944 . . Capacitor, Polyp Met Film 10. Uf 250 Vac 10% . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 215054 . . Harness, Control Box, Weld Control (Consisting Of) . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . CR7 . . . . 188636 . . . . Relay, Ocv Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . D8/C8 . . . 189701 . . . . Diode/Capacitor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . SR1, SR2 . . 035704 . . . . Rectifier, Integ 40a 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . CR5 . . . . 199999 . . . . Relay, Encl 12vdc Spst 30a/15vdc (Prior to LF310974) . . . . . . . . . . . . . 1
. . . 10 . . . . CR5 . . . . 223710 . . . . Relay, Encl 12vdc Dpst−No 25a 6pin Flange (Eff w/LF310974) . . . . . . . 1
. . . . . . . . . . . S5 . . . . . 011609 . . . . Switch, Tgl Spdt 15a 125vac On−None−On Spd Term Chr
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Located On Front Panel, See Figure 15-4) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . S6 . . . . . 011622 . . . . Switch, Tgl 3pdt 15a 125vac On−None−On Spd Term
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Located On Front Panel, See Figure 15-4) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC4 . . . . 047483 . . . . Connector, Rect Univ 084 15p/S 3 Row Rcpt Cable/Panel Lkg . . . . . . . 1
. . . . . . . . . . RC3 . . . . 158466 . . . . Connector, Rect Univ 084 12p/S 3 Row Rcpt Cable/Panel Lkg . . . . . . . 1
. . . . . . . . . . RC1 . . . . 135133 . . . . Connector, Rect Univ 084 9p/S 3 Row Rcpt Cable/Panel Lkg . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 148850 . . . . Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 177859 . . . . Conn, Body 5 Terminal (To Engine Control Switch S1) . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 150316 . . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . . . . . 092670 . . . . Conn, Rect Univ 084 3p/S 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1
. . . 11 CB11, 12, 13 139266 . . . . Supplementary Protector, Man Reset 1p 15a 250vac . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . 215013 . . Harness, Unit Weld Control (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG3 . . . . 158465 . . . . Conn, Rect Univ 084 12p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 187654 . . . . Seal, Wire Univ 12p/S 3row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG6 . . . . 114063 . . . . Conn, Rect Univ 084 4p/S 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 192309 . . . . Clip, Snap In .630 Bundle .250 Hole .248 Thk . . . . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . . . . . . . . . . . . 177136 . . Clamp, Capacitor 1.375dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . C9 . . . . . 087110 . . Capacitor, Elctlt 240uf 200vdc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . R6 . . . . . 141424 . . Resistor, Ww Fxd 30 W 25 Ohm Faston Te . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . PC7 . . ♦195706 . . Module, Pull To Idle, Two Output, 7 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . CR4 . . . ♦113247 . . Relay, Encl 12vdc Dpdt 20a/120vac 8pin Flange Mtg . . . . . . . . . . . . . . . . 1
. . . 17 . . . . CR6 . . ♦090104 . . Relay, Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . CR3 . . . . 090104 . . Relay, Encl 12vdc Spst 30a/15vdc Spin Flange Mtg . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 215660 . . Harness, Engine Control (Deutz F4L2011 engine) (consisting of) . . . . . . 1
. . . 19 . . . D1/C1 . . . 189701 . . . . Diode/Capacitor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . CB10 . . . . 190374 . . . . Circuit Breaker, Auto Reset 12vdc 40a . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 148850 . . . . Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . PLG4 . . . . 114062 . . . . Connector, Rect Univ 084 15p/S 3 Row Plug Cable Lkg . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 173916 . . . . Housing, Contact 10-Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . CR1 . . . . 214876 . . . . Relay, Encl 6vdc Spst 35a/14vdc 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . CB14 . . ♦205927 . . . . Circuit Breaker, Auto Reset 12vdc 12 Amp . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 205931 . . Harness, Engine Control (Deutz F3L912 engine) (consisting of) . . . . . . . 1
. . . 19 . . . D8/C8 . . . 189701 . . . . Diode/Capacitor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . CB10 . . . . 190374 . . . . Circuit Breaker, Auto Reset 12vdc 40a . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 148850 . . . . Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . PLG4 . . . . 114062 . . . . Connector, Rect Univ 084 15p/S 3 Row Plug Cable Lkg . . . . . . . . . . . . . 1
. . . 21 . . . . CR1 . . . . 214876 . . . . Relay, Encl 6vdc Spst 35a/14vdc 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . CB14 . . . . 205927 . . . . Circuit Breaker, Auto Reset 12vdc 12 Amp . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . CR8 . . ♦197325 . . Relay, Encl 12vdc Spst 70a 4pin Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . TD1 . . . . 214928 . . Timer, Delay On Make/Break Open 30 Sec 12vdc . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . CR9 . . . . 090104 . . Relay, Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg (Eff w/LH024758) . . 1
. . . . . . . . . . . . . . . . . . . . 235251 . . Harness, Fuel Shutdown Solenoid (Consisting Of) (Eff w/LH024758) . . . 1
. . . 26 . . . . . R7 . . . . . 235250 . . . . Resistor, Hsc 30 W 3 Ohm (Eff w/LH024758) . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 148850 . . . . Socket, Relay 5 Pin (Eff w/LH024758) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦Optional *Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
TM-4428 Page 136 Big Blue 500D, 600 X
Eff w/Serial No. LC585264 Thru LJ003064
4

5
24

7
3
8

9
25

2
10
1
11
12
13
23 14

16 15

22
17
18
19

20
21
803 661-C

Figure 15-3. Control Box Assembly − CC/CV Models

Item Dia. Part


No. Mkgs. No. Description Quantity

Figure 15-3. Control Box Assembly − CC/CV Models (Figure 15-1 Item 98)

... 1 . . . F1, F2 . . *085874 .. Fuse, Mintr Cer Slo-Blo 10a 250v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


... 2 . . . . . . . . . . . . . . 046432 .. Holder, Fuse Mintr .250 X 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 3 . . . . . . . . . . . . . . 201077 .. Control Box, Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . . . . . . . . . . . . . . 201078 .. Control Box, Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 . . . . CR3 . . . . 090104 .. Relay, Encl 12vdc Spst 30a/15vdc Spin Flange Mtg . . . . . . . . . . . . . . . . . . 1
... 6 . . . . CR8 . . ♦197325 .. Relay, Encl 12vdc Spst 70a 4pin Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . . CR1 . . . . 214876 .. Relay, Encl 6vdc Spst 35a/14vdc 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . CR6 . . ♦090104 .. Relay, Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg . . . . . . . . . . . . . . . . . . 1
... 9 . . . D8/C8 . . . 189701 .. Diode/Capacitor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 . . . . CB14 . . . . 205927 .. Circuit Breaker, Auto Reset 12vdc 12 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 11 . . . . CB10 . . . . 190374 .. Circuit Breaker, Auto Reset 12vdc 40a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 . . . . CR5 . . . . 199999 .. Relay, Encl 12vdc Spst 30a/15vdc (Prior to LF310974) . . . . . . . . . . . . . . . 1
... 12 . . . . CR5 . . . . 223710 .. Relay, Encl 12vdc Dpst−No 25a 6pin Flange (Eff w/LF310974) . . . . . . . . 1
... 13 . . . . PC7 . . ♦195706 .. Module, Pull To Idle, Two Output, 7 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 14 . . . . SR1 . . . . 035704 .. Rectifier, Integ 40a 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 . . . . . . . . . . . . . . 201079 .. Cover, Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 16 . . . . CR4 . . . ♦113247 .. Relay, Encl 12vdc Dpdt 20a/120vac 8pin Flange Mtg . . . . . . . . . . . . . . . . 1
... 17 . . . . PC9 . . . . 192224 .. Circuit Card Assy, Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 18 . . . . . . . . . . . . . . 134201 .. Stand-Off, Support Pc Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 19 . . . . TD1 . . . . 214928 .. Timer, Delay On Make/Break Open 30 Sec 12vdc . . . . . . . . . . . . . . . . . . . 1
... 20 . . . . . C9 . . . . . 087110 .. Capacitor, Elctlt 240uf 200vdc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 21 . . . . . . . . . . . . . . 177136 .. Clamp, Capacitor 1.375dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 22 . . . D1/C1 . . . 189701 .. Diode Capacitor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Big Blue 500D, 600 X TM-4428 Page 137
Eff w/Serial No. LC585264 Thru LJ003064
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 15-3. Control Box Assembly − CC/CV Models (Continued)

. . . 23 . CB11, 12, 13 139266 . . Supplementary Protector, Man Reset 1p 15a 250vac . . . . . . . . . . . . . . . . 3


. . . 24 . . . . CR9 . . . . 090104 . . Relay, Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg (Eff w/LH024758) . . 1
. . . . . . . . . . . . . . . . . . . . 235251 . . Harness, Fuel Shutdown Solenoid (Consisting Of) (Eff w/LH024758) . . . 1
. . . 25 . . . . . R7 . . . . . 235250 . . . . Resistor, Hsc 30 W 3 Ohm (Eff w/LH024758) . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 148850 . . . . Socket, Relay 5 Pin (Eff w/LH024758) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 215377 . . Harness, Control Box, Cv Weld Control (Consisting Of) . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC4 . . . . 047483 . . . . Connector, Rect Univ 084 15p/S 3 Row Rcpt Cable/Panel Lkg . . . . . . . 1
. . . . . . . . . . RC3 . . . . 158466 . . . . Connector, Rect Univ 084 12p/S 3 Row Rcpt Cable/Panel Lkg . . . . . . . 1
. . . . . . . . . . RC1 . . . . 135133 . . . . Connector, Rect Univ 084 9p/S 3 Row Rcpt Cable/Panel Lkg . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 148850 . . . . Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . S6 . . . . . 193324 . . . . Switch, Rotary 6 Position Gold Contacts
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Located On Front Panel, See Figure 15-5) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . S5 . . . . . 011609 . . . . Switch,Tgl Spdt 15a 125vac On−None−On Spd Term Chr
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Located On Front Panel, See Figure 15-5) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 150316 . . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . . . . . 177859 . . . . Conn, Body 5 Terminal (To Engine Control Switch S1) . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 193183 . . . . Conn, Rect Cinch 18 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 196602 . . . . Plug, Cavity 18,30 Position Cinch Connector . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . 196603 . . . . Seal, Switch 6 Position Rotary .250 Shaft . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 141450 . . . . Conn, Rect Metrmate 10skt 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 206024 . . Harness, Engine Control (Deutz F4l2011 Engine) (Consisting Of) . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 148850 . . . . Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . PLG4 . . . . 114062 . . . . Connector, Rect Univ 084 15p/S 3 Row Plug Cable Lkg . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 173916 . . . . Housing, Contact 10-Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 205931 . . Harness, Engine Control (Deutz F3l912 Engine) (Consisting Of) . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 148850 . . . . Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . PLG4 . . . . 114062 . . . . Connector, Rect Univ 084 15p/S 3 Row Plug Cable Lkg . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 185655 . . . . Seal, Wire Univ 15p/S 3 Row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦Optional
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

TM-4428 Page 138 Big Blue 500D, 600 X


Eff w/Serial No. LC585264 Thru LJ003064
 Hardware is common and 4
not available unless listed.

5
2
1 6
7
8
9
10

42 11

41

40

12
13

14
38 15
39
32 16
37 30
35 17
36 31
34

33

29
28 18
19
21
20

22

27

26

25 24 23 803 662

Figure 15-4. Panel, Front w/Components − CC Models

Item Dia. Part


No. Mkgs. No. Description Quantity

Figure 15-4. Panel, Front w/Components − CC Models (Figure 15-1 Item 104)

. . . 1 . . . . . . . . . . . . . . 215663 . . Plate Screened, Ident Control Rating; When Ordering This Item,
.............................. The Nameplate Should Also Be Ordered) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 2 ........................ Nameplate, Screened (Order By Model And Serial Number) . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . 215014 . . Panel, Engine/Weld Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . ♦220544 . . Panel, Engine/Weld Control Ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . S3 . . . . . 208278 . . Switch, Range/Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Big Blue 500D, 600 X TM-4428 Page 139


Eff w/Serial No. LC585264 Thru LJ003064
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 15-4. Panel, Front w/Components − CC Models (Continued)

. . . . . . . . . . . . . . . . . . . . 192558 . . Harness, Range (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


. . . . . . . . . . RC6 . . . . 148439 . . . . Housing, Rect Univ 084 4p/S 1 Row Rcpt . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . R1 . . . . . 188635 . . Rheostat, Ww 300w 34 Ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . 202209 . . Spacer, Nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 7 . . . . . S6 . . . . . 011622 . . Switch, Tgl Dpdt 15a 125vac (Included In Control Box Harness,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Figure 15-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . S5 . . . . . 011609 . . Switch, Tgl Spdt 15a 125vac On-None-On Spd Term Chr (Included In
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Box Harness, See Figure 15-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . RC13 . . . . 032897 . . Receptacle, Twlk Grd 2p3w 15a 125v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . S2 . . . ♦021467 . . Switch, Tgl Spst 3a 250v Off−None−(On) Spd Term . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . S1 . . . . . 212436 . . Switch, Ignition 4 Position W/Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 201553 . . Clip, Circuit Breaker Retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . CB1 . . . . 201083 . . Supplementary Protector, Man Reset 2p 20a 250vac
(European Receptacle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . CB1 . . ♦202683 . . Supplementary Protector, Man Reset 2p 40a 240vac
(Export Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦197527 . . Guard, Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . CB2, CB3 ♦201083 . . Supplementary Protector, Man Reset 2p 20a 250vac . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 201109 . . Harness, Generator Power (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . CB2 . . . . 093996 . . . . Supplementary Pro, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . 3
. . . 14 . . . GFCI1 . . . 151981 . . . . Receptacle, Str Dx Grd 2p3w 15/20a 125v Gfci . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . RC1 . . . . 147632 . . . . Receptacle, Tw Lk Grd 2p3w 30a 250v L6-30r . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦201053 . . Harness, Generator Power (European Receptacle) (Consisting Of) . . . . . 1
. . . 13 . . . . CB2 . . ♦093996 . . . . Supplementary Pro, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . 1
. . . 13 . . . . CB3 . . ♦139266 . . . . Supplementary Protector, Man Reset 1p 15a 250vac . . . . . . . . . . . . . . 1
. . . 14 . . . GFCI1 . ♦151981 . . . . Receptacle, Str Dx Grd 2p3w 15/20a 125v Gfci . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦213577 . . Harness, Generator Power (Export Models) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦189549 . . Block, Term Assy Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦038620 . . Link, Jumper Term Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . RC1 . . ♦176355 . . Receptacle, Str 2p3w 16a 220v Flange Mtg (European Receptacle) . . . . 1
. . . 15 . . . . RC1 . . ♦173556 . . Receptacle, Str 2p3w 32a 130v Flange Mtg (Export Models) . . . . . . . . . . 1
. . . . . . . . . . RC2 . . ♦176355 . . Receptacle, Str 2p3w 16a 220v Flange Mtg (Export Models) . . . . . . . . . . 1
. . . . . . . . . . RC3 . . ♦173555 . . Receptacle, Str 2p3w 16a 130v Flange Mtg (Export Models) . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . 190861 . . Label, Warning, Electric Shock And Moving Parts Etc . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . +215347 . . Panel, Gen Pwr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . ♦+215045 . . Panel, Gen Pwr Ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . ♦+215403 . . Panel, Gen Pwr (European Receptacle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . ♦+204258 . . Panel, Gen Pwr (110/220 Volt Receptacles) (Export Models) . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . 083030 . . Stud, Brs .250−20 X 1.750 W/Hex Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . 601836 . . Nut, 250−20 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 20 . . . . . . . . . . . . ♦196073 . . Label, Do Not Switch While Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . S12 . . ♦195825 . . Switch, Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . S12 . . ♦220491 . . Switch, Ac/Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . 201125 . . Panel, Mtg Terminal Pwr Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . ♦199303 . . Panel, Mtg Terminal Pwr Output Ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . 039046 . . Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 180735 . . Washer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 24 . . . . . . . . . . . . . . 181169 . . Spacer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 25 . . . . . . . . . . . . . . 186621 . . Boot, Generic Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 26 . . . . . . . . . . . . ♦059773 . . Handle, Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . ♦010647 . . Pin, Spring Cs .156 X 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . 039047 . . Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . 209056 . . Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 30 . . . . . . . . . . . . . . 206795 . . Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . 021385 . . Boot, Toggle Switch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . 201045 . . Cover, Receptacle Twistlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . ♦193228 . . Meter, Volt Dc 8− 18 Scale 2.250 In Black Face . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . FUEL . . . . 192265 . . Gauge, Fuel Elec Switch W/O Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
TM-4428 Page 140 Big Blue 500D, 600 X
Eff w/Serial No. LC585264 Thru LJ003064
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 15-4. Panel, Front w/Components − CC Models (Continued)

. . . 35 . . . . . HM . . . . . 210424 .. Meter, Hour 12-24vdc 2.25dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


. . . 36 . . . . TEMP . . . 217084 .. Gauge, Coolant Temp 0− 300 Deg F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 197798 .. Sender, Coolant Temp 300 Deg F M16 X 1.5 . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . OIL . . . . . 217083 .. Gauge, Pressure Oil 0−100 Psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 193230 .. Sender, Pressure Oil 0− 100 Psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦194403 .. Adapter, Oil Pressure Sender (Deutz F4L2011) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . V1 . . . ♦164874 .. Volt Meter, W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . A1 . . . ♦164873 .. Ammeter, W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . . 189161 .. Handle, Switch Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . . 010647 .. Pin, Spring Cs .156 X 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . . . 019602 .. Knob, Pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 024103 .. Blank, Snap−In Nyl .750 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦Optional

+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Notes

Work like a Pro!


Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

Big Blue 500D, 600 X TM-4428 Page 141


Eff w/Serial No. LC585264 Thru LJ003064
 Hardware is common and
not available unless listed.
4

3
5

6
2
7 8
1 9
10

11
12

58 13
57

56

55 14
15
16
17

54 18
53
52 33 19
48 20
51 21
49 47
46
50
45 22
31
30
23
24
32
43
26
44
29
28 25
34 27

35

42
36

41
40 39 38 37
803 663
Figure 15-5. Panel, Front w/Components − CC/CV Models

Item Dia. Part


No. Mkgs. No. Description Quantity

Figure 15-5. Panel, Front w/Components − CC/CV Models (Figure 15-1 Item 104)

. . . 1 . . . . . . . . . . . . . . 215664 . . Plate Screened, Ident Control; When Ordering This Item,


. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Nameplate Should Also Be Ordered) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . . . . . . . . . . Nameplate, Screened (Order By Model And Serial Number) . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . 215014 . . Panel, Engine/Weld Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . ♦220544 . . Panel, Engine/Weld Control Ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . S3 . . . . . 208278 . . Switch, Range/Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 192558 . . Harness, Range (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC6 . . . . 148439 . . . . Housing, Rect Univ 084 4p/S 1 Row Rcpt . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . R1 . . . . . 193118 . . Pot, Cp Flat 1t 2w 1k Ohm Linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

TM-4428 Page 142 Big Blue 500D, 600 X


Eff w/Serial No. LC585264 Thru LJ003064
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 15-5. Panel, Front w/Components − CC/CV Models (Continued)

. . . 6 . . . . . S6 . . . . . 193234 . . Switch, Rotary 6 Position Gold Contacts (Included In Control Box Harness,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Figure 15-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 197527 . . Guard, Circuit Breaker (For S6 − Not Included W/Harness) . . . . . . . . . . . 1
. . . 7 . . . . . S5 . . . . . 011609 . . Switch, Tgl Spdt 15a 125vac On-None-On Spd Term Chr (Included In
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Box Harness, See Figure 15-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . 202209 . . Spacer, Nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . PC6 . . . . 192995 . . Circuit Card Assy, Connector/Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . CB5 . . . . 139266 . . Supplementary Protector, Man Reset 1p 15a 250vac . . . . . . . . . . . . . . . . 1
. . . 11 . . . . CB6 . . . . 083432 . . Supplementary Pro, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . S2 . . . . . 021467 . . Switch, Tgl Spst 3a 250v Off−None−(On) Spd Term . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . S1 . . . . . 212436 . . Switch, Ignition 4 Position W/Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 201553 . . Clip, Circuit Breaker Retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . CB1 . . . . 201083 . . Supplementary Protector, Man Reset 2p 20a 250vac . . . . . . . . . . . . . . . . 1
. . . 14 . . . . CB1 . . ♦202683 . . Supplementary Protector, Man Reset 2p 40a 240vac . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦197527 . . Guard, Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . CB2, CB3 ♦201083 . . Supplementary Protector, Man Reset 2p 20a 250vac . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 201109 . . Harness, Generator Power (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . CB2 . . . . 093996 . . . . Supplementary Pro, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . 1
. . . 16 . . . GFCI1 . . . 151981 . . . . Receptacle, Str Dx Grd 2p3w 15/20a 125v Gfci . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . RC1 . . . . 147632 . . . . Receptacle, Tw Lk Grd 2p3w 30a 250v L6-30r . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦201053 . . Harness, Generator Power (European Receptacle) (Consisting Of) . . . . . 1
. . . 15 . . . . CB2 . . . . 093996 . . . . Supplementary Pro, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . 1
. . . . . . . . . . CB3 . . . . 139266 . . . . Supplementary Protector, Man Reset 1p 15a 250vac . . . . . . . . . . . . . . 1
. . . 16 . . . GFCI1 . . . 151981 . . . . Receptacle, Str Dx Grd 2p3w 15/20a 125v Gfci . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦213577 . . Harness, Generator Power (Export Models) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦189549 . . Block, Term Assy Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦038620 . . Link, Jumper Term Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . RC1 . . . . 176355 . . Receptacle, Str 2p3w 16a 220v Flange Mtg (European Receptacle) . . . . 1
. . . 17 . . . . RC1 . . ♦173556 . . Receptacle, Str 2p3w 32a 130v Flange Mtg (Export Models) . . . . . . . . . . 1
. . . . . . . . . . RC2 . . ♦176355 . . Receptacle, Str 2p3w 16a 220v Flange Mtg (Export Models) . . . . . . . . . . 1
. . . . . . . . . . RC3 . . ♦173555 . . Receptacle, Str 2p3w 16a 130v Flange Mtg (Export Models) . . . . . . . . . . 1
. . . 18 . . . . RC5 . . ♦182954 . . Rcpt, Str 3p4w 50a 125/250v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . ♦025248 . . Stand-Off, Insul .250-20 X 1.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . ♦604102 . . Connector, Clamp Cable 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . ♦197527 . . Guard, Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . ♦197363 . . Terminal, Ring Tng Screw Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 23 . . . . CB7 . . ♦214926 . . Supplementary Protector, Man Reset 3p 50a 250vac . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . +215347 . . Panel, Generator Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . ♦+215406 . . Panel, Gen Pwr Ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . ♦+215403 . . Panel, Gen Pwr (European Receptacle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . ♦+204258 . . Panel, Gen Pwr (110/220 Volt Receptacles) (Export Models) . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . +♦215363 . . Panel, Generator Power (Full Kva Option) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . ♦214927 . . Boot, Circuit Breaker 3 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . ♦197508 . . Plug, Protective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . ♦077440 . . Bushing, Conduit 1 In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . 601836 . . Nut, 250−20 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 29 . . . . . . . . . . . . . . 209056 . . Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . 083030 . . Stud, Brs .250−20 X 1.750 W/Hex Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CT2 . . ♦197433 . . Transformer, Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . 190861 . . Label, Warning, Electric Shock And Moving Parts Etc . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . ♦197399 . . Label, Warning 3 Ph Generator Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . 209056 . . Cover, Receptacle 2.250 Dia Lexan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 33 . . . . . . . . . . . . . . 206795 . . Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . S12 . . ♦195825 . . Switch, Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . S12 . . ♦220491 . . Switch, Ac/Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . 201125 . . Panel, Mtg Terminal Pwr Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Big Blue 500D, 600 X TM-4428 Page 143


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Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 15-5. Panel, Front w/Components − CC/CV Models (Continued)

. . . 36 . . PC4, PC5 . . 189744 . . Circuit Card Assembly, Filter Hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


. . . 37 . . . . . . . . . . . . . . 039046 . . Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 180735 . . Washer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 38 . . . . . . . . . . . . . . 134201 . . Stand-Off, Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
. . . 39 . . . . . . . . . . . . . . 181169 . . Spacer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 40 . . . . . . . . . . . . . . 186621 . . Boot, Generic Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 41 . . . . . . . . . . . . ♦059773 . . Handle, Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . ♦010647 . . Pin, Spring Cs .156 X 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . . . 039047 . . Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . ♦196073 . . Label, Do Not Switch While Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . . . 021385 . . Boot, Toggle Switch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . . . . . . . . . . 190323 . . Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 47 . . . . . . . . . . . . . . 170391 . . Conn, Circ Ms Protective Cap Size 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . HM . . . . . 210424 . . Meter, Hour 12-24vdc 2.25dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . FUEL . . . . 192265 . . Gauge, Fuel Elec Switch W/O Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . . . . . . . . ♦193228 . . Meter, Volt Dc 8− 18 Scale 2.250 In Black Face . . . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . TEMP . . . 217084 . . Gauge, Coolant Temp 0− 300 Deg F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 197798 . . Sender, Coolant Temp 300 Deg F M16 X 1.5 . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 52 . . . . . OIL . . . . . 217083 . . Gauge, Pressure Oil 0−100 Psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 193230 . . Sender, Pressure Oil 0− 100 Psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 194403 . . Adapter, Oil Pressure Sender (Deutz F4L2011) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 53 . . . . . A1 . . . ♦164873 . . Ammeter, W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 54 . . . . . V1 . . . ♦164874 . . Volt Meter, W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 55 . . . . . . . . . . . . . . 097922 . . Knob, Pointer .875 Dia X .250 Id W/Set Screws Plstc . . . . . . . . . . . . . . . . 1
. . . 56 . . . . . . . . . . . . . . 189161 . . Handle, Switch Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 57 . . . . . . . . . . . . . . 010647 . . Pin, Spring Cs .156 X 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 58 . . . . . . . . . . . . . . 097926 . . Knob, Pointer 2.375 Dia X .250 Id . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 215207 . . Harness, Unit Weld Control − Cv (Consisting Of) . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG6 . . . . 114063 . . . . Connector, Rect Univ 084 4p/S 1 Row Plug Cable Lkg . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG8 . . . . 193184 . . . . Connector, Rect Cinch 30 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG13 . . . 147992 . . . . Connector, Rect Univ 039 10p/S 2 Row Plug Cable . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG3 . . . . 158465 . . . . Connector, Rect Univ 084 12p/S 3 Row Plug Cable . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 088731 . . . . Bushing, Snap-In Nyl .375 Id X .500 Mtg Hole . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 135873 . . . . Clip, Conduit Convoluted 1/2 In Mtg Hole . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 187654 . . . . Seal, Wire Univ 12p/S 3 Row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 024103 . . Blank, Snap-In Nyl .750 Mtg Hole Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 120304 . . Blank, Snap−In Nyl .250 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
♦Optional

+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

TM-4428 Page 144 Big Blue 500D, 600 X


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12

10
14
9
13

19
8 20
21
7
6

5
3 22
4 23
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28
29
30
31

32
33
34 802 404-C

Figure 15-6. Generator


Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 15-6. Generator (Figure 15-1 Item 35)

. . . 1 . . . . . . . . . . . . . . 132053 . . Screw, 375-16 X 1.50hexhd Pln Gr 5pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6


. . . 2 . . . . . . . . . . . . . . 183387 . . Washer, Conical Spring .406 Id X .875 Od Pltd . . . . . . . . . . . . . . . . . . . . . . 6
. . . 3 . . . . . . . . . . . . . . 195911 . . Endbell, Gen (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . 143220 . . . . O-Ring, 2.859 Id X .139cs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . 201099 . . Stator, Exciter/Gen Pwr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . ♦213448 . . Stator, Exciter/Gen Pwr (Export Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . +208287 . . Stator, Weld Assembly Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . +♦209220 . . Stator, Weld Assembly Complete (Full Kva Option) . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . 225120 . . Label, Warning Moving Parts Can Cause Injury . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . . . . . . . . . . . . . . 190197 . . Guard, Generator Wire Mesh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . 172674 . . Spring, Ext .240 Od X .041 Wire X 3.500pld . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . . . . . . . . . . . 039207 . . Baffle, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . ROTOR . . . 212997 . . Rotor, Generator Segmented Assy (Includes) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . 210446 . . . . Rotor, Generator (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . . . . 024617 . . . . . . Ring, Rtng Ext 1.375 Shaft X .050 Thk . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . 053390 . . . . . . Bearing, Ball Rdl Sgl Row 1.370 X 2.830 X .6 . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hub, Drive (Not Sold Separately) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 210447 . . . . Fan, Rotor Assy Generator (Segmented) (Includes) . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 210332 . . . . . . Plate, Flex Hubmount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . 206242 . . . . . . Fan, Rotor Segmented Assy Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 17 . . . . . . . . . . . . . . 049026 . . . . . . Screw, M10−1.5x 25 Hex Hd−Pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . 10
. . . 18 . . . . . . . . . . . . . . 083883 . . . . . . Washer, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . 10
. . . 19 . . . . . . . . . . . . . . 080389 . . . . . . Screw, 312−18x1.00 Hexwhd.66d Stl Pld Slffmg Tap−Rw . . . . . . . . . 8
. . . 20 . . . . . . . . . . . . . . 083883 . . Washer, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . . . . 4

Big Blue 500D, 600 X TM-4428 Page 145


Eff w/Serial No. LC585264 Thru LJ003064
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 15-6. Generator (Continued)

. . . 21 . . . . . . . . . . . . . . 049026 . . Screw, M10−1.5x 25 Hex Hd−Pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . . . 4


. . . 22 . . . . . . . . . . . . . . 191579 . . Cover, Starter Hole Perkins/Continental . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . 083883 . . Washer, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . . . . 6
. . . 24 . . . . . . . . . . . . . . 172555 . . Screw, M10-1.5 X 50hexhd Pln 8.8pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 25 . . . . . . . . . . . . . . 602159 . . Screw, .312−18x .75 Hexwhd.66d Stl Pld Slffmg Tap−Rw . . . . . . . . . . . . . 6
. . . 26 . . . . . . . . . . . . . . 601961 . . Screw, .312-18 X 2.25hexhd Pln Gr 5pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 27 . . . . . . . . . . . . . . 602211 . . Washer, Lock .318 Id X 0.586 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 28 . . . . . . . . . . . . . . 139341 . . Washer, Exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 29 . . . . . . . . . . . . . *190823 . . Brush, Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 30 . . . . . . . . . . . . . . 208469 . . Clip, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 31 . . . . . . . . . . . . . . 189142 . . Brushholder Assembly, Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . 602242 . . Washer, Flat .375idx0.875odx.083t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 33 . . . . . . . . . . . . . . 602211 . . Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . . . 2
. . . 34 . . . . . . . . . . . . . . 604534 . . Screw, .312−18x1.25 Hex Hd−Pln Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 190259 . . Harness, Brush (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG1 . . . . 168071 . . . . Connector, (Kit) Rect Univ 084 9p/S 3 Row Plug Cable Lkg . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 187651 . . . . Seal, Wire Univ 9p/S 3 Row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Notes

TM-4428 Page 146 Big Blue 500D, 600 X


Eff w/Serial No. LC585264 Thru LJ003064
4
 Hardware is common and
not available unless listed. 3

1
5

802 279-A

Figure 15-7. Main Rectifier Assembly

Item Dia. Part


No. Mkgs. No. Description Quantity

Figure 15-7. Main Rectifier Assembly (Figure 15-1 Item 100)

. . . . . . . . . . SR3 . . . . 215909 . . Rectifier (Consisting Of) (Prior to LH002538) . . . . . . . . . . . . . . . . . . . . . . . . 1


. . . . . . . . . . SR3 . . . . 215910 . . Rectifier, Environmental (Consisting Of) (Eff w/LH002538) . . . . . . . . . . . . 1
... 1 .............. 188137 . . . . Connection Board, Rectifier Ac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 2 .............. 188517 . . . . Bus Bar, Connection Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 3 .............. 188135 . . . . Enclosure, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 4 .............. 134201 . . . . Stand-Off, Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 5 . . . . PC3 . . . . 215755 . . . . Circuit Card Assembly, Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 .............. 188136 . . . . Insulator, Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
... 7 .............. 188493 . . . . Heat Sink, Rectifier Al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . D3, D5, D7 . 037956 . . . . Diode, Rect 275a 300v Sp (Prior to LH002538) . . . . . . . . . . . . . . . . . . . . 3
. . . 8 . D3, D5, D7 . 208334 . . . . Diode, Rect 275a 300v Sp (Eff w/LH002538) . . . . . . . . . . . . . . . . . . . . . . 3
. . . 9 . D2, D4, D6 . 037957 . . . . Diode, Rect 275a 300v Rp (Prior to LH002538) . . . . . . . . . . . . . . . . . . . . 3
. . . 9 . D2, D4, D6 . 208335 . . . . Diode, Rect 275a 300v Rp (Eff w/LH002538) . . . . . . . . . . . . . . . . . . . . . . 3
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Big Blue 500D, 600 X TM-4428 Page 147


Eff w/Serial No. LC585264 Thru LJ003064

Notes

Work like a Pro!


Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

TM-4428 Page 148 Big Blue 500D, 600 X


TM-4428L 2016−07

Processes
Stick (SMAW) Welding

TIG (GTAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Air Carbon Arc (CAC-A) Cutting


and Gouging

Description

Engine Driven Welder/Generator

Big Blue 500D




Big Blue 600 X




(Deutz-Powered)

Eff w/Serial No. LJ003065 Thru MG060062E

File: Engine Drive

Visit our website at


www.MillerWelds.com
SECTION 15 − PARTS LIST
EFF W/SERIAL NO. LJ003065 THRU MG060062E
 Hardware is common and not
available unless listed.

 A Deutz 2011 engine-powered


unit is shown below. See insert
for parts specific to a Deutz
912-powered unit. Parts not re-
lated to the engines are the
same in both units.

15

14
3 16
2
17
13
1

12
18

4
5 6 11 19
9

10
8
7
99 (CV Only)

98 (CV Only)

12 21
91 (Figure 15-11) 20

92 83
90 22

117 81
97
89 (Figure 15-2 or 15-3)
86 (CC Only)
82
87
88 (CC Only)
84

93 85 (CC Only)
94

96 (Figure 15-6, 15-7, 15-8, or 15-9)

95 (Figure 15-4 or 15-5)


CC CC Models Only
CV CC/CV Models Only

Figure 15-1. Main Assembly

TM-4428 Page 150 Big Blue 500D, 600 X


Eff w/Serial No. LJ003065 Thru MG060062E
 A Deutz 2011 engine- Deutz 912 Engine
powered unit is shown
below. See insert for 29
parts specific to a
Deutz 912-powered 111 114
2
unit. Parts not related to
the engines are the 33 116
same in both units. 110 102
112
109
100

52
106 53

115
113 105 59
107
64

108 60 55
103 61 56
62
101 57
66
104 58
16 67
17
68
29
46
35 (Fig. 15-10) 69
25 44 45
28
31
27
24 26

47
23

43 49
33 50
2

42
118 48
30 34
32

41

40 51
39
38
37 66 2
2
36 67
2 52
35 (Fig. 15-10) 68
59 53
60
54 69
73
61 55
56 71
64 62 72
63 70
57
58
80 74
65 79
75

78

77 76
81 803 659 / 803 665

Big Blue 500D, 600 X TM-4428 Page 151


Eff w/Serial No. LJ003065 Thru MG060062E
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 15-1. Main Assembly

. . . 1 . . . . . . . . . . . . . . 189824 .. Panel, Gen Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


. . . 1 . . . . . . . . . . . . ♦199294 .. Panel, Gen Lh Ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . 225120 .. Label, Warning Moving Parts Can Cause Injury (Prior to MF510042E) . . 8
. . . 2 . . . . . . . . . . . . . . 272334 .. Label, Warning Moving Parts (En/Fr−Sym) (Eff w/MF510042E) . . . . . . . . 8
. . . 3 . . . . . . . . . . . . . +189828 .. Panel, Engine Side (Prior to ME510133E) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . +252811 .. Panel, Engine Side (Eff w/ME510133E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . ♦+199301 .. Panel, Engine Side Ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦212570 .. Baffle, Engine Side (Export Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . Z1 . . . . . 189395 .. Reactor, AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . Z1 . . . ♦201520 .. Reactor, AC Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . 1T . . . . . 038621 .. Block, Term 30A 4 Pole Frict Term Str . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 038620 .. Link, Jumper Term Blk 30A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . . . . . . . . . . 081499 .. Bracket, Mtg Strip Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . 206352 .. Brace, Front To Center Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 203260 .. Label, Caution Do Not Use Ether (Prior to MF510042E) . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 272332 .. Label, Notice Do Not Use Ether (En/Fr−Sym) (Eff w/MF510042E) . . . . . . 1
. . . 8 . . SR4, SR5 . . 035704 .. Rectifier, Integ Bridge 40. Amp 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . CB4 . . . . 045061 .. Circuit Breaker, Auto Reset 24VDC 7 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . 201697 .. Pan, Reactor And Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . T1 . . . . . 201613 .. Transformer W/Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . T1 . . . ♦205636 .. Transformer W/Bracket (Environmental Coating) . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . 173352 .. Extrusion, Rubber Clamp/Bulb (Order By Ft) . . . . . . . . . . . . . . . . . . . . . . . . 3ft
. . . 13 . . . . . . . . . . . . . . 189708 .. Firewall, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . 191307 .. Cover, Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 191829 .. Hose, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . 189763 .. Bracket, Mtg Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . 189764 .. Air Cleaner, Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *192938 .. Filter, Air Element Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . *♦192939 .. Filter, Air Element Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . 189464 .. Seal, Weather Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 173909 .. Hose, Sae .312 Id X .560 Od X 24.000 (Order By Ft) . . . . . . . . . . . . . . . . . 2
. . . 19 . . . . . . . . . . . . . . 201658 .. Upright, Center Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . 262408 .. Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . ♦+203382 .. Base E-Coat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . 196220 .. Bracket, Hold Down Fuel Tank Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . 192362 .. Bracket, Mtg Nyl 1/2 Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . +201934 .. Cover, Top (Prior to MD440024E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . +263316 .. Cover, Top (Eff w/MD440024E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . ♦+202640 .. Cover, Top Ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . 189052 .. Grommet, Plastic Neck Filler Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . 254678 .. Cap, Tank Screw-On 3.500 In W/Vent W/Lanyard 8in . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . 192041 .. Label, Use Diesel Fuel Only (Wordless Label) (Prior to MF510042E) . . . 1
. . . 26 . . . . . . . . . . . . . . 272338 .. Label, Use Diesel Fuel Only (En/Fr−Sym) (Eff w/MF510042E) . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . 222513 .. Label, Warning Falling Equipment Can Cause Serious
(Prior to MF510042E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 27 . . . . . . . . . . . . . . 272339 .. Label, Warning Falling Equipment (En/Fr−Sym) (Eff w/MF510042E) . . . . 1
... 28 . . . . . . . . . . . . . . 224265 .. Label, Warning Hot Exhaust Parts Do Not Touch (Prior to ME520019E) . 1
... 28 . . . . . . . . . . . . . . 269515 .. Label, Warning Hot Parts (Eff w/ME520019E Thru MF510041E) . . . . . . . 1
... 28 . . . . . . . . . . . . . . 272333 .. Label, Warning Hot Parts (En/Fr−Sym) (Eff w/MF510042E) . . . . . . . . . . . 1
... 29 . . . . . . . . . . . . . . 105734 .. Pipe, Muffler Extension Elbow 1.875 Od . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 30 . . . . . . . . . . . . . . 201592 .. Pipe, Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 31 . . . . . . . . . . . . . . 201851 .. Cover, Radiator Access (Prior to MD440024E) . . . . . . . . . . . . . . . . . . . . . . 1
... 31 . . . . . . . . . . . . . . 234509 .. Cover, Radiator Access (Eff w/MD440024E) . . . . . . . . . . . . . . . . . . . . . . . . 1
... 32 . . . . . . . . . . . . . . 191354 .. Support, Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 32 . . . . . . . . . . . . ♦202633 .. Support, Cover E-Coat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 33 . . . . . . . . . . . . . . 010875 .. Clamp, Muffler 2.000 Dia U Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 34 . . . . . . . . . . . . . . 200730 .. Manifold, Exhaust Muffler (Part of engine eff w/LJ004970) . . . . . . . . . . . . 1
... 35 . . . . . . . . . Figure 15-10 .. Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
TM-4428 Page 152 Big Blue 500D, 600 X
Eff w/Serial No. LJ003065 Thru MG060062E
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 15-1. Main Assembly (Continued)

. . . 36 . . . . . . . . . . . . . . 191577 . . Guard, Starter (Deutz 2011 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


. . . 37 . . . . . . . . . . . . . . 191809 . . Bracket, Mtg Engine Lh (Deutz 2011 Engines) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . . . 190951 . . Edge Trim, Style Tl750-B2 X 1/16 Black W/Clips 1.625
(Prior to LJ004970) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . . 191817 . . Baffle, Air (Deutz 2011 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . . 213877 . . Engine, Deutz Dsl Elec F4L2011 (Prior to LJ004970) (consisting of) . . . . 1
. . . 40 . . . . . . . . . . . . . . 237003 . . Engine, Deutz Dsl Elec D2011L04i
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Eff w/LJ004970 thru MB110095E) (consisting of) . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . . 261638 . . Engine, Deutz Dsl Elec D2011L04i (Eff w/MB110096E) (consisting of) . . 1
. . . . . . . . . . . . . . . . . . . *067265 . . . . Filter, Oil (Engine) (Deutz 2011 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *192744 . . . . Filter, Fuel Spin-On (Deutz 2011 Engines) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *066217 . . . . Filter, Fuel Secondary (Deutz 2011 Engines) . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *195745 . . . . Switch, Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *195746 . . . . Sender, Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 246988 . . . . Filter Kit, Deutz (2011) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
. . . . . . . . . . . . . . . . . . ♦174064 . . Idle, Solenoid Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . *067266 . . Belt, Blower (Deutz 2011 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . . . 201714 . . Box, Air Intake (Deutz 2011 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . . . 201748 . . Upright, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . ♦202638 . . Upright, Rear Ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . . 190206 . . Cable, Bat Neg 42 In Lg No. 2 Awg W/Clamp And .375rng . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . . . 190207 . . Cable, Bat Pos 45 In Lg No. 1 Awg W/Clamp And .406rng . . . . . . . . . . . . 1
. . . 46 . . . . . . . . . . . . . . 261852 . . Bracket, Battery Holddown (Prior to ME020269E) . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . . . . . . . . . . 266385 . . Bracket, Battery Holddown (Eff w/ME020269E) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 47 . . . . . . . . . . . . . . . . . . . . . . . . Battery, Stor 12v 650crk 110rsv Gp 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 264924 . . Bracket, Battery Locator Adj (Eff w/ME020269E) . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . . . . . . . . . . 201006 . . Bolt, J Stl .312−18 X 8.500 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 208041 . . Spacer, Stl .323 Id X .625 Od X .141 Thk (Eff w/ME020269E) . . . . . . . . . 2
. . . 49 . . . . . . . . . . . . . +201183 . . Cover, Battery Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . . . . . . . . . ♦202639 . . Cover, Battery Access Ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . . . . . . . . . . 168385 . . Label, Warning Battery Explosion Can Blind (Prior to MF510042E) . . . . . 1
. . . 50 . . . . . . . . . . . . . . 272341 . . Label, Warning Battery Explosion (En/Fr−Sym) (Eff w/MF510042E) . . . . 1
. . . 51 . . . . . . . . . . . . . +215252 . . Guard, Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 52 . . . . . . . . . . . . . . 199849 . . Screw, 625-11 X 4.00hexhd Pln Gr 5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 53 . . . . . . . . . . . . . . 071731 . . Washer, Flat .656 Id X 2.250 Od X .187t Stl Pld . . . . . . . . . . . . . . . . . . . . . 4
. . . 54 . . . . . . . . . . . . . . 191812 . . Bracket, Mtg Engine Rh (Deutz 2011 Engines) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 55 . . . . . . . . . . . . . . 071890 . . Retainer, Mount Eng/Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 56 . . . . . . . . . . . . . . 071730 . . Tubing, Stl .875 Od X 12ga Wall X 2.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 57 . . . . . . . . . . . . . . 083476 . . Mount, Eng/Gen Nprn .875 Id X 2.500 Od X 2.000 . . . . . . . . . . . . . . . . . . . 4
. . . 58 . . . . . . . . . . . . . . 135205 . . Nut, 625-11 .94hex .76h Stl Pld Elastic Stop Nut . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . 199505 . . Hose Assy, Oil Drain 32.000 Lg (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 59 . . . . . . . . . . . . . . 165271 . . . . Valve, Oil Drain 3/8-18nptf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 60 . . . . . . . . . . . . . . 176529 . . . . Fitting, Hose Brs Barbed Fem 1/2tbg X 3/8npt . . . . . . . . . . . . . . . . . . . . . 1
. . . 61 . . . . . . . . . . . . . . 269052 . . . . Hose, Nitrile .500 Id X .765 Od X Roll Blk Brd . . . . . . . . . . . . . . . . . . . 2.666ft
. . . 62 . . . . . . . . . . . . . . 176528 . . Fitting, Hose Brs Barbed Elbow Fem 1/2 Tbg X 1/2 Npt . . . . . . . . . . . . . . . 1
. . . 63 . . . . . . . . . . . . . . 173336 . . Fitting, Adapter Oil Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 64 . . . . . . . . . . . . . . . . . . . . . . . . Washer, Oil Drain (Available Through Engine Manufacturer) . . . . . . . . . . . 1
. . . 65 . . . . . . . . . . . . . . 219229 . . Bracket, Mtg Solenoid (Deutz 2011 Engines) (Prior to MF040091E) . . . . 1
. . . 65 . . . . . . . . . . . . . . 269216 . . Bracket, Mtg Solenoid (Eff w/MF040091E) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 66 . . . . . . . . . . . . . . 206297 . . Base, Fuel Filter Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 67 . . . . . . . . . . . . . . 145282 . . Fitting, Hose Brs Barbed Elbow M 5/16tbg X 1/4npt . . . . . . . . . . . . . . . . . . 2
. . . 68 . . . . . . . . . . . . . . 196465 . . Hose, Sae .312 Id X .560 Od X 23.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 200032 . . Hose, Sae .312 Id X .560 Od X 38.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 69 . . . . . . . . . . . . . *192744 . . Filter, Fuel Spin-On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 70 . . . . . . . . . . . . . . 190992 . . Keeper, Latch Engine Access Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 71 . . . . . . . . . . . . . . 190076 . . Channel, Stiffener Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 71 . . . . . . . . . . . . ♦202635 . . Channel, Stiffener Engine Access E-Coat . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Big Blue 500D, 600 X TM-4428 Page 153


Eff w/Serial No. LJ003065 Thru MG060062E
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 15-1. Main Assembly (Continued)

. . . 72 . . . . . . . . . . . . . . 245362 . . Latch, Paddle Series 20 (Black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


. . . 73 . . . . . . . . . . . . . . 215233 . . Label, Maintenance Big Blue Deutz Series Ce (Prior to LJ004970) . . . . . 1
. . . 73 . . . . . . . . . . . . . . 237352 . . Label, Maintenance Big Blue Deutz Series (Eff w/LJ004970) . . . . . . . . . . 1
. . . 74 . . . . . . . . . . . . . +200989 . . Door, Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 74 . . . . . . . . . . . ♦+210736 . . Door, Engine Access Ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 75 . . . . . . . . . . . . . . 189975 . . Hinge, Door Access 180deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 76 . . . . . . . . . . . . . . 208141 . . Stop, Door (Prior to MC250042E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 76 . . . . . . . . . . . . . . 254634 . . Bumper, Door 1.000 Od X .750 High Nprn 50 Duro (Eff w/MC250042E) . 2
. . . 77 . . . . . . . . . . . . . . 269531 . . Panel, Rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 77 . . . . . . . . . . . . ♦199298 . . Panel, Rocker Ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 78 . . . . . . . . . . . . . . 189827 . . Panel, Gen Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 78 . . . . . . . . . . . . ♦199300 . . Panel, Gen Rh Ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 79 . . . . . . . . . . . . . . 191626 . . Bumper, Door Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 80 . . . . . . . . . . . . . . 259019 . . Kit, Field Fuel Tank (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 257007 . . . . Tank, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 258232 . . . . Fuel Line Assy, W/Clamps 42.000 In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 218086 . . . . Bracket, Holddown Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 81 . . . . . . . . . . . . . . 191446 . . Extrusion, Rubber W/Adhesive 1.000 X 1.000 D (Order By Ft) . . . . . . . . . 6ft
. . . 82 . . . . . . . . . . . . . . 191897 . . Bracket, Mtg Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 83 . . . . . . . . . . . . . . 218086 . . Bracket, Hold Down Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 84 . . . . . . . . . . . . . . 224266 . . Label, Warning Do Not Weld On Base (Prior to MF510042E) . . . . . . . . . . 2
. . . 84 . . . . . . . . . . . . . . 272342 . . Label, Warning Do Not Weld On Base (En/Fr−Sym) (Eff w/MF510042E) 2
. . . 85 . . . . . . . . . . . . CC190179 . . Panel, Mtg Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 86 . . . . . R4 . . . CC191292 . . Resistor, Ww Fxd 375w 50 Ohm W/Mtg Bkt . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 87 . . . . . R2 . . . . . 189699 . . Resistor, Ww Tap 375w 10 Ohm W/Mtg Bkt . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 88 . . . . . R3 . . . CC189699 . . Resistor, Ww Tap 375w 10 Ohm W/Mtg Bkt . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 89 . . . . . . Figure 15-2, Figure 15-3 Control Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 90 . . . . . . . . . . . . . . 189731 . . Firewall, Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 91 . . . . . . . . . Figure 15-11 . . Main Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 92 . . . . . . . . . . . . . . 191448 . . Top, Cover Front Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 92 . . . . . . . . . . . . ♦199305 . . Top, Cover Front Upright Ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 93 . . . . . . . . . . . . . +201750 . . Upright, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 93 . . . . . . . . . . . ♦+202637 . . Upright, Front Ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 94 . . . . . . . . . . . . . . 233953 . . Label, Warning General Precautionary Csa (Prior to MF510042E) . . . . . . 1
. . . 94 . . . . . . . . . . . . . . 272343 . . Label, Warning General Precautionary (En/Fr−Sym) (Eff w/MF510042E) 2
. . . 95 . . . . . . Figure 15-4, Figure 15-5 Panel, Front W/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 96 . . . . . . Figure 15-6−Figure 15-9 Auxiliary Power Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 97 . . . . . . . . . . . . ♦202130 . . Xfmr, Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 98 . . . . . . . . . . . . CV193453 . . Bracket, Mtg Box Fcr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 99 . . . . PC1 . . CV207397 . . Module, Field Current Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 190058 . . Nut, .250-20 U-Nut Multi-Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . . 049525 . . Nut, 312-18 U-Nut Multi-Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
. . . . . . . . . . . . . . . . . . . . 215631 . . Kit, Label (Includes Safety & Informational Labels) (Cc Models) . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 215632 . . Kit, Label (Includes Safety & Informational Labels) (Cc/Cv Models) . . . . . 1
. . . . . . . . . . . . . . . . . . . . 216995 . . Kit, Label (Includes Safety & Informational Labels) (Cc Export Models)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Deutz 2011 Engines) (Prior to MF510042E) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 216994 . . Kit, Label (Includes Safety & Informational Labels) (Cc/Cv Export Models)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Deutz 2011 Engines) (Prior to MF510042E) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 216991 . . Kit, Label (Includes Safety & Informational Labels) (Cc Export Models)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Deutz 912 Engines) (Prior to MF510042E) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 216990 . . Kit, Label (Includes Safety & Informational Labels) (Cc/Cv Export Models)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Deutz 912 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 100 . . . . . . . . . . . . . 237002 . . Engine, Deutz Dsl Elec F3L912 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 249606 . . . . Filter, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 246989 . . . . Filter Kit, Deutz (912/914) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
. . 101 . . . . . . . . . . . . *249605 . . Filter, Oil (Deutz 912 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 102 . . . . . . . . . . . . *066271 . . Belt, Blower (Deutz 912 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 103 . . . . . . . . . . . . *195745 . . Switch, Pressure Oil 1.5 Bar Nc Cont . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
TM-4428 Page 154 Big Blue 500D, 600 X
Eff w/Serial No. LJ003065 Thru MG060062E
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 15-1. Main Assembly (Continued)

.. 104 . . . . . . . . . . . . *195746 ..
Sender, Coolant Temp & 130 Degee C Switch . . . . . . . . . . . . . . . . . . . . . . . 1
.. 105 . . . . . . . . . . . . . 194135 ..
Backplate, Deutz 912 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 106 . . . . . . . . . . . . . 194572 ..
Support, Front Engine (Deutz 912 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 107 . . . FS1 . . . . 141346 ..
Shutdown Kit, Engine (Deutz 912 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 108 . . . . . . . . . . . . . 118452 ..
Ftg, Adapter Oil Drain (Deutz 912 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 109 . . . . . . . . . . . . . 193313 ..
Manifold, Exhaust Muffler (Deutz 912 Engines) . . . . . . . . . . . . . . . . . . . . . . 1
.. 110 . . . . . . . . . . . . . 194496 ..
Baffle, Lower Air Outlet (Deutz 912 Engines) . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 111 . . . . . . . . . . . . . 194497 ..
Baffle, Upper Air Outlet (Deutz 912 Engines) . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 112 . . . . . . . . . . . . . 194500 ..
Baffle, Air Intake (Deutz 912 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 113 . . . . . . . . . . . . . 194485 ..
Hose, Air Cleaner (Deutz 912 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 114 . . . . . . . . . . . . +201714 ..
Box, Air Intake (Deutz 912 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 115 . . . . . . . . . . . . . 195560 ..
Guard, Starter Hole (Deutz 912 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 116 . . . . . . . . . . . . . 194467 ..
Washer, Flat 6.25idx11.50odx.062t Buna N (Deutz 912 Engines) . . . . . . . 1
.. 117 . . . . . . . . . . . . . 212944 ..
Label, Stick Overlap Weld Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 118 . . . . . . . . . . . . . 233088 ..
Label, Danger Using A Generator Indoors Can Kill You In Minutes (Unit)
(Prior to MF510042E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 118 . . . . . . . . . . . . . 272340 . . Label, Danger Using Generator Indoor (En/Fr/Sp−Sym)
(Eff w/MF510042E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦237013 . . Label, Hour/Fuel Meter Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
* Recommended Spare Parts. ♦ Optional C CC models only.
C
C
V CC/CV models only.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement
Parts. Model and serial number required when ordering parts from your local distributor.

Big Blue 500D, 600 X TM-4428 Page 155


Eff w/Serial No. LJ003065 Thru MG060062E
14 4

18
24

23
6
21
3
17

8
7 25

2
1 22

10 20
15
11 9

16
19 13
12

803 660-D

Figure 15-2. Control Box Assembly − CC Models


Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 15-2. Control Box Assembly − CC Models (Figure 15-1 Item 89)

... 1 . . . F1, F2 . . *085874 ..


Fuse, Mintr Cer Slo-Blo 10A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 2 . . . . . . . . . . . . . . 046432 ..
Holder, Fuse Mintr .250 X 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 3 . . . . . . . . . . . . . . 201077 ..
Control Box, Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . . . . . . . . . . . . . . 201078 ..
Control Box, Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 . . . . . . . . . . . . . . 201079 ..
Cover, Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 . . . . C12 . . . . 191944 ..
Capacitor, Polyp Met Film 10. uF 250 VAC 10% . . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . . CR7 . . . . 188636 ..
Relay, Ocv Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . D8/C8, D12 . 189701 ..
Diode/Capacitor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 9 . . SR1, SR2 . . 035704 ..
Rectifier, Integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 10 . . . . CR5 . . . . 223710 ..
Relay, Encl 12VDC Dpst−No 25A 6pin Flange . . . . . . . . . . . . . . . . . . . . . . . 1
... 11 CB11, 12, 13 139266 ..
Supplementary Protector, Man Reset 1p 15A 250VAC . . . . . . . . . . . . . . . . 3
... 12 . . . . . . . . . . . . . . 177136 ..
Clamp, Capacitor 1.375dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 . . . . . C9 . . . . . 087110 ..
Capacitor, Elctlt 240uF 200VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 14 . . . . . R6 . . . . . 141424 ..
Resistor, Ww Fxd 30 W 25 Ohm Faston Te . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 . . . . PC7 . . ♦195706 ..
Module, Pull To Idle, Two Output, 7 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 16 . . . . CR4 . . . ♦113247 ..
Relay, Encl 12VDC Dpdt 20A/120VAC 8pin Flange Mtg . . . . . . . . . . . . . . . 1
... 17 . . . . CR6 . . ♦090104 ..
Relay, Encl 12VDC Spst 30A/15VDC 5pin Flange Mtg . . . . . . . . . . . . . . . . 1
... 18 . . . . CR3 . . . . 090104 ..
Relay, Encl 12VDC Spst 30A/15VDC Spin Flange Mtg . . . . . . . . . . . . . . . 1
... 19 D1/C1,D8/C8 189701 ..
Diode/Capacitor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 20 . . . . CB10 . . . . 190374 ..
Circuit Breaker, Auto Reset 12VDC 40A . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 21 . . . . CR1 . . . . 214876 ..
Relay, Encl 6VDC Spst 35A/14VDC 5 Pin (Prior to MC030001E) . . . . . . . 1
... 21 . . . . CR1 . . . . 252053 ..
Relay, Encl 12VDC Spst 35A/14VDC 5 Pin (Eff w/MC030001E) . . . . . . . . 1
... 22 . . . . CB14 . . ♦205927 ..
Circuit Breaker, Auto Reset 12VDC 12 Amp . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 23 . . . . CR8 . . ♦197325 ..
Relay, Encl 12VDC Spst 70A 4pin Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . 1
... 24 . . . . CR9 . . . . 090104 ..
Relay, Encl 12VDC Spst 30A/15VDC 5pin Flange Mtg
(Prior to LJ005955) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . R7 . . . . . 235250 . . Resistor, Hsc 30 W 3 Ohm (Prior to MA340014E) . . . . . . . . . . . . . . . . . . . . 1
♦Optional *Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
TM-4428 Page 156 Big Blue 500D, 600 X
Eff w/Serial No. LJ003065 Thru MG060062E
 Hardware is common and 4
not available unless listed.

5
23

7
3

9
24

2
10
1
11
12
13
22 14

15
16
17
21
19 18
20

803 661-D

Figure 15-3. Control Box Assembly − CC/CV Models


Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 15-3. Control Box Assembly − CC/CV Models (Figure 15-1 Item 89)

. . . 1 . . . F1, F2 . . *085874 . . Fuse, Mintr Cer Slo-Blo 10A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


. . . 2 . . . . . . . . . . . . . . 046432 . . Holder, Fuse Mintr .250 X 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . . . . . . . . . . . 201077 . . Control Box, Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . 201078 . . Control Box, Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . CR3 . . . . 090104 . . Relay, Encl 12VDC Spst 30A/15VDC Spin Flange Mtg . . . . . . . . . . . . . . . 1
. . . 6 . . . . CR8 . . ♦197325 . . Relay, Encl 12VDC Spst 70A 4pin Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . CR1 . . . . 214876 . . Relay, Encl 6VDC Spst 35A/14VDC 5 Pin (Prior to MC030001E) . . . . . . . 1
. . . 7 . . . . CR1 . . . . 252053 . . Relay, Encl 12VDC Spst 35A/14VDC 5 Pin (Eff w/MC030001E) . . . . . . . . 1
. . . 8 . . . . CR6 . . . . ♦09104 . . Relay, Encl 12VDC Spst 30A/15VDC 5pin Flange Mtg . . . . . . . . . . . . . . . . 1
. . . 9 . D8/C8, D12 . 189701 . . Diode/Capacitor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . CB14 . . . . 205927 . . Circuit Breaker, Auto Reset 12VDC 12 Amp . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . CB10 . . . . 190374 . . Circuit Breaker, Auto Reset 12VDC 40A . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . CR5 . . . . 223710 . . Relay, Encl 12VDC Dpst−No 25A 6pin Flange . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . PC7 . . ♦195706 . . Module, Pull To Idle, Two Output, 7 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . SR1 . . . . 035704 . . Rectifier, Integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 201079 . . Cover, Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . CR4 . . . ♦113247 . . Relay, Encl 12VDC Dpdt 20A/120VAC 8pin Flange Mtg . . . . . . . . . . . . . . . 1
. . . 17 . . . . PC9 . . . . 192224 . . Circuit Card Assy, Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . 134201 . . Stand-Off, Support Pc Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 19 . . . . . C9 . . . . . 087110 . . Capacitor, Elctlt 240uF 200VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . 177136 . . Clamp, Capacitor 1.375dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . D1/C1 . . . 189701 . . Diode Capacitor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . CB11, 12, 13 139266 . . Supplementary Protector, Man Reset 1p 15A 250VAC . . . . . . . . . . . . . . . . 3
. . . 23 . . . . CR9 . . . . 090104 . . Relay, Encl 12VDC Spst 30A/15VDC 5pin Flange Mtg . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . R7 . . . . . 235250 . . Resistor, Hsc 30 W 3 Ohm (Prior to MA340014E) . . . . . . . . . . . . . . . . . . . . 1
♦Optional *Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Big Blue 500D, 600 X TM-4428 Page 157
Eff w/Serial No. LJ003065 Thru MG060062E
 Hardware is common and 4
not available unless listed.

5
2
1 6
7
8
9
10

27 11

26

25

23
24
22 17
20
21 18
19 16

12

15 14 13

803 662-C

Figure 15-4. Panel, Front w/Components − CC Models

Item Dia. Part


No. Mkgs. No. Description Quantity

Figure 15-4. Panel, Front w/Components − CC Models (Figure 15-1 Item 95)

. . . 1 . . . . . . . . . . . . . . . . . . . . . . . . Plate Screened, Ident Control Rating (Order By Model And Serial Number)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . When Ordering This Item,The Nameplate Should Also Be Ordered) . . . . 1
. . . 2 . . . . . . . . . . . . . . . . . . . . . . . . Nameplate, Screened (Order By Model And Serial Number) . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . 236608 . . Panel, Engine/Weld Control (Prior to LJ005955) . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . 238616 . . Panel, Engine/Weld Control (Eff w/LJ005955) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . S3 . . . . . 208278 . . Switch, Range/Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 192558 . . Harness, Range (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC6 . . . . 148389 . . . . Conn, Rect Univ 084 4p/S 1Row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . 1

TM-4428 Page 158 Big Blue 500D, 600 X


Eff w/Serial No. LJ003065 Thru MG060062E
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 15-4. Panel, Front w/Components − CC Models (Continued)

. . . 5 . . . . . R1 . . . . . 188635 . . Rheostat, Ww 300w 34 Ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


. . . 6 . . . . . . . . . . . . . . 202209 . . Spacer, Nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 7 . . . . . S6 . . . . . 011622 . . Switch, Tgl Dpdt 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . S5 . . . . . 011609 . . Switch, Tgl Spdt 15A 125VAC On-None-On Spd Term Chr . . . . . . . . . . . 1
. . . 9 . . . . RC13 . . . . 032897 . . Receptacle, Twlk Grd 2p3w 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . S2 . . . ♦021467 . . Switch, Tgl Spst 3a 250V Off−None−(On) Spd Term . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . S1 . . . . . 212436 . . Switch, Ignition 4 Position W/Handle (Prior to LJ005955) . . . . . . . . . . . . . 1
. . . 11 . . . . . S1 . . . . . 217680 . . Switch, Ignition 4 Position W/Out Handle (Eff w/LJ005955) . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 207073 . . Lever, Ignition Switch (Eff w/LJ005955) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . 201125 . . Panel, Mtg Terminal Pwr Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . 241433 . . Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 180735 . . Washer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 14 . . . . . . . . . . . . . . 181169 . . Spacer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 15 . . . . . . . . . . . . . . 186621 . . Boot, Generic Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 16 . . . . . . . . . . . . . . 241432 . . Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . 021385 . . Boot, Toggle Switch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . 201045 . . Cover, Receptacle Twistlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . ♦193228 . . Meter, Volt Dc 8− 18 Scale 2.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . FUEL/HM . . 232113 . . Gauge, Fuel Elec/Hour Meter (D2011l04i Engine) . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . FUEL/HM . . 232112 . . Gauge, Fuel Elec/Hour Meter (D912l03 Engine) . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . TEMP . . . 217084 . . Gauge, Coolant Temp 0− 300 Deg F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 197798 . . Sender, Coolant Temp 300 Deg F M16 X 1.5 . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . OIL . . . . . 217083 . . Gauge, Pressure Oil 0−100 Psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 193230 . . Sender, Pressure Oil 0− 100 Psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦194403 . . Adapter, Oil Pressure Sender (Deutz 2011) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . V1 . . . ♦164874 . . Volt Meter, W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . A1 . . . ♦164873 . . Ammeter, W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . 189161 . . Handle, Switch Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . 010647 . . Pin, Spring Cs .156 X 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . 019602 . . Knob, Pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 024103 . . Blank, Snap−In Nyl .750 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦Optional
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Big Blue 500D, 600 X TM-4428 Page 159


Eff w/Serial No. LJ003065 Thru MG060062E
 Hardware is common and
not available unless listed.

4
3
5

6
2 7
8
1 9 10

11
12
37
13
36

35

34

33
32
31 28 23
24
30
29 27
26

25 14

15

22
16

21 20 19 18 17

803 663-D
Figure 15-5. Panel, Front w/Components − CC/CV Models

Item Dia. Part


No. Mkgs. No. Description Quantity

Figure 15-5. Panel, Front w/Components − CC/CV Models (Figure 15-1 Item 95)

. . . 1 . . . . . . . . . . . . . . . . . . . . . . . . Plate Screened, Ident Control (Order By Model And Serial Number)


. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . When Ordering This Item, The Nameplate Should Also Be Ordered) . . . 1
. . . 2 . . . . . . . . . . . . . . . . . . . . . . . . Nameplate, Screened (Order By Model And Serial Number) . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . 236608 . . Panel, Engine/Weld Control (Prior to LJ005955) . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . 238616 . . Panel, Engine/Weld Control (Eff w/LJ005955) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . S3 . . . . . 208278 . . Switch, Range/Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 192558 . . Harness, Range (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC6 . . . . 148389 . . . . Housing, Rect Univ 084 4p/S 1 Row Rcpt . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . R1 . . . . . 193118 . . Pot, Cp Flat 1t 2w 1k Ohm Linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . S6 . . . . . 193234 . . Switch, Rotary 6 Position Gold Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 197527 . . Guard, Circuit Breaker (For S6 − Not Included W/Harness) . . . . . . . . . . . 1
. . . 7 . . . . . S5 . . . . . 011609 . . Switch, Tgl Spdt 15A 125VAC On-None-On Spd Term Chr . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . 202209 . . Spacer, Nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . PC6 . . . . 242944 . . Circuit Card Assy, Connector/Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . CB5 . . . . 139266 . . Supplementary Protector, Man Reset 1p 15A 250VAC . . . . . . . . . . . . . . . . 1
. . . 11 . . . . CB6 . . . . 083432 . . Supplementary Pro, Man Reset 1p 10A 250VAC Frict . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . S2 . . . . . 021467 . . Switch, Tgl Spst 3a 250V Off−None−(On) Spd Term . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . S1 . . . . . 212436 . . Switch, Ignition 4 Position W/ Handle (Prior to LJ005955) . . . . . . . . . . . . . 1
TM-4428 Page 160 Big Blue 500D, 600 X
Eff w/Serial No. LJ003065 Thru MG060062E
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 15-5. Panel, Front w/Components − CC/CV Models (Continued)

. . . 13 . . . . . S1 . . . . . 217680 .. Switch, Ignition 4 Position W/Out Handle (Eff w/LJ005955) . . . . . . . . . . . . 1


. . . . . . . . . . . . . . . . . . . . 207073 .. Lever, Ignition Switch (Eff w/LJ005955) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . S12 . . ♦195825 .. Switch, Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 201125 .. Panel, Mtg Terminal Pwr Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . PC4, PC5 . . 242935 .. Circuit Card Assembly, Filter Hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 17 . . . . . . . . . . . . . . 241433 .. Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 180735 .. Washer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 18 . . . . . . . . . . . . . . 134201 .. Stand-Off, Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
. . . 19 . . . . . . . . . . . . . . 181169 .. Spacer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 20 . . . . . . . . . . . . . . 186621 .. Boot, Generic Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 21 . . . . . . . . . . . . ♦059773 .. Handle, Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . ♦010647 .. Pin, Spring Cs .156 X 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . 241432 .. Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . ♦196073 .. Label, Do Not Switch While Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . 021385 .. Boot, Toggle Switch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . 190323 .. Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 27 . . . . . . . . . . . . . . 170391 .. Conn, Circ Ms Protective Cap Size 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . FUEL/HM . . 232113 .. Gauge, Fuel Elec/Hour Meter (D2011l04i Engine) . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . FUEL/HM . . 232112 .. Gauge, Fuel Elec/Hour Meter (D912l03 Engine) . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . ♦193228 .. Meter, Volt Dc 8− 18 Scale 2.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . TEMP . . . 217084 .. Gauge, Coolant Temp 0− 300 Deg F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 197798 .. Sender, Coolant Temp 300 Deg F M16 X 1.5 . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . OIL . . . . . 217083 .. Gauge, Pressure Oil 0−100 Psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 193230 .. Sender, Pressure Oil 0− 100 Psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 194403 .. Adapter, Oil Pressure Sender (Deutz 2011) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . A1 . . . ♦164873 .. Ammeter, W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . V1 . . . ♦164874 .. Volt Meter, W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . 207080 .. Knob, Pointer 1.125 Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . 189161 .. Handle, Switch Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . . 010647 .. Pin, Spring Cs .156 X 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . . 097924 .. Knob, Pointer 1.625 Dia X .250 Id W/Set Scrws Plstc . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 024103 .. Blank, Snap-In Nyl .750 Mtg Hole Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 143397 .. Blank, Snap−In Nyl .312 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
♦Optional

+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Big Blue 500D, 600 X TM-4428 Page 161


Eff w/Serial No. LJ003065 Thru MG060062E
 Hardware is common and 1
not available unless listed.

10 5

9
7

8
803 662-C
Figure 15-6. Auxiliary Power Group, Domestic CC Models

Item Dia. Part


No. Mkgs. No. Description Quantity
Figure 15-6. Auxiliary Power Group, Domestic CC Models

. . . 1 . . . . CB1 . . . . 201083 . . Supplementary Protector, Man Reset 2p 20A 250VAC . . . . . . . . . . . . . . . . 1


. . . . . . . . CB2, CB3 ♦201083 . . Supplementary Protector, Man Reset 2p 20A 250VAC
(Prior to LJ005955) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 201553 . . Clip, Circuit Breaker Retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 201109 . . Harness, Generator Power (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . CB2 . . . . 093996 . . Supplementary Pro, Man Reset 1p 20A 250VAC Frict . . . . . . . . . . . . . . 3
. . . 3 . . . GFCI1 . . . 246614 . . . . Receptacle, GFCI 15/20A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . RC1 . . . . 147632 . . . . Receptacle, Tw Lk Grd 2p3w 30A 250V L6-30r . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 189549 . . Block, Term Assy Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 038620 . . Link, Jumper Term Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . 190861 . . Label, Warning, Electric Shock And Moving Parts Etc
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Prior to MF510042E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . 272330 . . Label, Warning Electric Shock/Moving Parts (Sym) (Eff w/MF510042E) . 1
. . . 6 . . . . . . . . . . . . . +215347 . . Panel, Gen Pwr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . 083030 . . Stud, Brs .250−20 X 1.750 W/Hex Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . 601836 . . Nut, 250−20 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 9 . . . . . . . . . . . . . . 209056 . . Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . . . . . . . . . . . 190323 . . Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

TM-4428 Page 162 Big Blue 500D, 600 X


Eff w/Serial No. LJ003065 Thru MG060062E
 Hardware is common and 1
not available unless listed. 2
3
4

20
6
7
8

9
18

17 10
11

13
19

12

16
15
803 663-D
14
Figure 15-7. Auxiliary Power Group, Domestic CC/CV Models

Item Dia. Part


No. Mkgs. No. Description Quantity
Figure 15-7. Auxiliary Power Group, Domestic CC/CV Models

. . . 1 . . . . CB1 . . . . 201083 . . Supplementary Protector, Man Reset 2p 20A 250VAC . . . . . . . . . . . . . . . . 1


. . . . . . . . . . . . . . . . . . . . 201553 . . Clip, Circuit Breaker Retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . CB2, CB3 ♦201083 . . Supplementary Protector, Man Reset 2p 20A 250VAC
(Prior to LJ005955) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 201109 . . Harness, Generator Power (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . CB2 . . . . 093996 . . Supplementary Pro, Man Reset 1p 20A 250VAC Frict . . . . . . . . . . . . . . 1
. . . 3 . . . GFCI1 . . . 246614 . . . . Receptacle, GFCI 15/20A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . RC1 . . . . 147632 . . . . Receptacle, Tw Lk Grd 2p3w 30A 250V L6-30r . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 189549 . . Block, Term Assy Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 038620 . . Link, Jumper Term Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . RC5 . . . . 182954 . . Rcpt, Str 3p4w 50A 125/250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . 025248 . . Stand-Off, Insul .250-20 X 1.2 (Prior to ME400131E) . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . 207560 . . Insulator, Stand-off With Stud (Eff w/ME400131E) . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . 604102 . . Connector, Clamp Cable 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . 197527 . . Guard, Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . 197363 . . Terminal, Ring Tng Screw Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 10 . . . . CB7 . . . . 214926 . . Supplementary Protector, Man Reset 3p 50A 250VAC . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . +215363 . . Panel, Generator Power (Full Kva Option) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . +♦215406 . . Panel, Gen Pwr Ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . 214927 . . Boot, Circuit Breaker 3 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . 197508 . . Plug, Protective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . 077440 . . Bushing, Conduit 1 In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 601836 . . Nut, 250−20 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 16 . . . . . . . . . . . . . . 209056 . . Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . 197203 . . Grounding Stud Assy, Brass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CT2 . . . . 197433 . . Transformer, Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . 197399 . . Label, Warning 3 Ph Generator Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . 209056 . . Cover, Receptacle 2.250 Dia Lexan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 20 . . . . . . . . . . . . . . 190323 . . Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Big Blue 500D, 600 X TM-4428 Page 163


Eff w/Serial No. LJ003065 Thru MG060062E
3
1
2

10

9 8

7
805 259-A

Figure 15-8. Auxiliary Power Group, Export (Eff w/LJ005955)

Item Dia. Part


No. Mkgs. No. Description Quantity
Figure 15-8. Auxiliary Power Group, Export (Eff w/LJ005955)

. . . 1 . . . . . . . . . . . . . +223121 . . Panel, Aux Power (Export) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


. . . 2 . . . . . . . . . . . . . . 144844 . . Stand−off, No 6−32 X .875 Lg .250 Hex Al Fem . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . ELCB1 . . . 222991 . . Circuit Breaker, Elcb 20A 220V 0.030A Trip . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . 272330 . . Label, Warning Electric Shock/Moving Parts (Sym) (Eff w/MF510042E) . 1
. . . 5 . . . GFCI1 . . . 246614 . . Receptacle, GFCI 15/20A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . CB2 . . . . 093996 . . Circuit Breaker, Man Reset 1p 20A 250VAC Frict . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . 083030 . . Stud, Brs .250−20 X 1.750 W/Hex Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 601836 . . Nut, 250−20 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 8 . . . . . . . . . . . . . . 190323 . . Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . 209056 . . Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . RC1 . . . . 176355 . . Rcpt, Str 2p3w 16a 220V Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

TM-4428 Page 164 Big Blue 500D, 600 X


Eff w/Serial No. LJ003065 Thru MG060062E
3
1
2

4 5

6
7

13
14
15

11

12 10

250 694-A

Figure 15-9. Auxiliary Power Group, Export Deluxe

Item Dia. Part


No. Mkgs. No. Description Quantity
Figure 15-9. Auxiliary Power Group, Export Deluxe

. . . 1 . . . . . . . . . . . . . +250534 . . Panel, Aux Power (Export) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


. . . 24 . . . . . . . . . . . ♦+204258 . . Panel, Gen Pwr (110/220 Volt Receptacles) (Export Models) . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . 144844 . . Stand−off, No 6−32 X .875 Lg .250 Hex Al Fem . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . ELCB1 . . . 222991 . . Circuit Breaker, Elcb 20A 220V 0.030A Trip . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . 197399 . . Label, Warning 3ph Generator Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . 025248 . . Stand−off, Insul .250−20 X 1.250 Lg X .437 Thd . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . 604102 . . Conn, Clamp Cable 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . 197527 . . Guard, Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . 197363 . . Terminal, Ring Tng Screw Clamp 14ga−6ga . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 9 . . . . CB7 . . . . 214926 . . Supplementary Protector, Man Reset 3p 50A 250VAC . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . 214927 . . Boot, Circuit Breaker 1 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . 197508 . . Plug, Protective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . 077440 . . Bushing, Conduit 1 In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . 197203 . . Grounding Stud Assy, Brass (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 083030 . . . . Stud, Brs .250−20 X 1.750 W/Hex Collar . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 601836 . . . . Nut, 250−20 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . 010915 . . . . Washer, Flat .257idx0.640odx.031t Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . 163167 . . . . Washer, Lock .254idx0.489odx.062t Sst Split.250 . . . . . . . . . . . . . . . . . . 2
. . . 14 . . . . RC1 . . . . 176355 . . Rcpt, Str 2p3w 16a 220V Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 209056 . . Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Big Blue 500D, 600 X TM-4428 Page 165


Eff w/Serial No. LJ003065 Thru MG060062E
 Hardware is common and
not available unless listed. 16
17
18
11 15

12

10
14
9
13

19
8 20
21
7
6

5
3 22
4 23
24
2 26 25
1 27
28
29
30
31

32
33
34 802 404-C

Figure 15-10. Generator


Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 15-10. Generator (Figure 15-1 Item 35)

. . . 1 . . . . . . . . . . . . . . 132053 . . Screw, 375-16 X 1.50hexhd Pln Gr 5pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6


. . . 2 . . . . . . . . . . . . . . 183387 . . Washer, Conical Spring .406 Id X .875 Od Pltd . . . . . . . . . . . . . . . . . . . . . . 6
. . . 3 . . . . . . . . . . . . . . 264056 . . Endbell W/Exciter Stator (Includes)
. . . . . . . . . . . . . . . . . . . . 264058 . . . . Stator, Exciter/Gen Pwr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 257974 . . . . Kit, Endbell, Gen (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . 143220 . . . . . . O-Ring, 2.859 Id X .139cs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . ♦213448 . . Stator, Exciter/Gen Pwr (Export Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . +208287 . . Stator, Weld Assembly Complete (Prior to MB360026E) . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . +254088 . . Stator, Weld Assembly Complete (Eff w/MB360026E) . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . +♦209220 . . Stator, Weld Assembly Complete (Full Kva Option) . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . ♦216320 . . Stator, Weld/Power Assy Complete
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Export Models) (Prior to MB360026E) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . ♦254093 . . Stator, Weld/Power Assy Complete (Export Models) (Eff w/MB360026E) 1
. . . 7 . . . . . . . . . . . . . . 225120 . . Label, Warning Moving Parts Can Cause Injury . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . . . . . . . . . . . . . . 190197 . . Guard, Generator Wire Mesh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . 172674 . . Spring, Ext .240 Od X .041 Wire X 3.500pld . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . . . . . . . . . . . 039207 . . Baffle, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . ROTOR . . . 212997 . . Rotor, Generator Segmented Assy (Includes) (Prior to MB360026E) . . . 1
. . . 12 . . . . . . . . . . . . . . 210446 . . . . Rotor, Generator (Includes) (Prior to MB360026E) . . . . . . . . . . . . . . . . . .
. . . 11 . . . ROTOR . . . 251855 . . Rotor, Generator Segmented Assy (Includes) (Eff w/MB360026E) . . . . . 1
. . . 12 . . . . . . . . . . . . . . 251856 . . . . Rotor, Generator (Includes) (Eff w/MB360026E) . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . . . . 024617 . . . . . . Ring, Rtng Ext 1.375 Shaft X .050 Thk . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . 053390 . . . . . . Bearing, Ball Rdl Sgl Row 1.370 X 2.830 X .6 . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hub, Drive (Not Sold Separately) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 210447 . . . . Fan, Rotor Assy Generator (Segmented) (Includes) . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 210332 . . . . . . Plate, Flex Hubmount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
TM-4428 Page 166 Big Blue 500D, 600 X
Eff w/Serial No. LJ003065 Thru MG060062E
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 15-10. Generator (Continued)

. . . 16 . . . . . . . . . . . . . . 206242 . . . . . . Fan, Rotor Segmented Assy Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4


. . . 17 . . . . . . . . . . . . . . 049026 . . . . . . Screw, M10−1.5x 25 Hex Hd−Pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . 10
. . . 18 . . . . . . . . . . . . . . 083883 . . . . . . Washer, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . 10
. . . 19 . . . . . . . . . . . . . . 080389 . . . . . . Screw, 312−18x1.00 Hexwhd.66d Stl Pld Slffmg Tap−Rw . . . . . . . . . . 8
. . . 20 . . . . . . . . . . . . . . 083883 . . Washer, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . . . . . 4
. . . 21 . . . . . . . . . . . . . . 049026 . . Screw, M10−1.5x 25 Hex Hd−Pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 22 . . . . . . . . . . . . . . 191579 . . Cover, Starter Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . ♦248454 . . Cover, Starter Hole (Zinc Primer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . 191580 . . Cover, Starter Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . 083883 . . Washer, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . . . . . 6
. . . 24 . . . . . . . . . . . . . . 172555 . . Screw, M10-1.5 X 50hexhd Pln 8.8pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 25 . . . . . . . . . . . . . . 602159 . . Screw, .312−18x .75 Hexwhd.66d Stl Pld Slffmg Tap−Rw . . . . . . . . . . . . . 6
. . . 26 . . . . . . . . . . . . . . 601961 . . Screw, .312-18 X 2.25hexhd Pln Gr 5pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 27 . . . . . . . . . . . . . . 602211 . . Washer, Lock .318 Id X 0.586 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 28 . . . . . . . . . . . . . . 139341 . . Washer, Exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 29 . . . . . . . . . . . . . *190823 . . Brush, Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 30 . . . . . . . . . . . . . . 208469 . . Clip, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 31 . . . . . . . . . . . . . . 189142 . . Brushholder Assembly, Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . 602242 . . Washer, Flat .375idx0.875odx.083t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 33 . . . . . . . . . . . . . . 602211 . . Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . . . 2
. . . 34 . . . . . . . . . . . . . . 604534 . . Screw, .312−18x1.25 Hex Hd−Pln Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 190259 . . Harness, Brush (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG1 . . . . 168071 . . . . Connector, (Kit) Rect Univ 084 9p/S 3 Row Plug Cable Lkg . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 187651 . . . . Seal, Wire Univ 9p/S 3 Row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦OPTIONAL

+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Big Blue 500D, 600 X TM-4428 Page 167


Eff w/Serial No. LJ003065 Thru MG060062E
4
 Hardware is common and
not available unless listed. 3

1
5

802 279-A

Figure 15-11. Main Rectifier Assembly

Item Dia. Part


No. Mkgs. No. Description Quantity

Figure 15-11. Main Rectifier Assembly (Figure 15-1 Item 91)

. . . . . . . . . . SR3 . . . . 215910 . . Rectifier, Environmental (Consisting Of) (Prior to MA080188E) . . . . . . . . 1


. . . . . . . . . . SR3 . . . . 239784 . . Rectifier, Environmental High Output (Consisting Of) (Eff w/MA080188E) 1
... 1 .............. 188137 . . . . Connection Board, Rectifier AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 2 .............. 188517 . . . . Bus Bar, Connection Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 3 .............. 188135 . . . . Enclosure, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 4 .............. 134201 . . . . Stand-Off, Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 5 . . . . PC3 . . . . 269140 . . . . Circuit Card Assembly, Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 .............. 188136 . . . . Insulator, Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
... 7 .............. 188493 . . . . Heat Sink, Rectifier Al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . D3, D5, D7 . 208334 . . . . Diode, Rect 275A 300V Sp (Prior to MA080188E) . . . . . . . . . . . . . . . . . . 3
. . . 8 . D3, D5, D7 . 245097 . . . . Diode, Rect 300 A 500V Do−9 (Straight) Modified (Eff w/MA080188E) 3
. . . 9 . D2, D4, D6 . 208335 . . . . Diode, Rect 275A 300V Rp (Prior to MA080188E) . . . . . . . . . . . . . . . . . . 3
. . . 9 . D2, D4, D6 . 245096 . . . . Diode, Rect 300 A 500V Do−9 (Reversed) Modified (Eff w/MA080188E) 3
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

TM-4428 Page 168 Big Blue 500D, 600 X


Eff w/Serial No. LJ003065 Thru MG060062E
 Some wiring harness components (switches, relays, supplementary protectors) are also referenced elsewhere in this parts list. Purchase compo-
nents separately or as part of the associated wiring harness.

Item Dia. Part


No. Mkgs. No. Description Quantity

Wiring Harnesses

. . . . . . . . . . . . . . . . . . . . 236606 . . Harness, Control Box, Weld Control CC


(Prior to LJ005955) (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 238763 . . Harness, Control Box, Weld Control CC
(Eff w/LJ005955) (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CR7 . . . . 188636 . . Relay, Ocv Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . D8/C8, D12 . 189701 . . Diode/Capacitor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . SR1, SR2 . . 035704 . . Rectifier, Integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . CR5 . . . . 223710 . . Relay, Encl 12VDC Dpst−No 25A 6pin Flange . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . S5 . . . . . 011609 . . Switch, Tgl Spdt 15A 125VAC On−None−On Spd Term Chr . . . . . . . . . . . 1
. . . . . . . . . . . S6 . . . . . 011622 . . Switch, Tgl 3pdt 15A 125VAC On−None−On Spd Term . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC4 . . . . 047483 . . Connector, Rect Univ 084 15p/S 3 Row Rcpt Cable/Panel Lkg . . . . . . . . . 1
. . . . . . . . . . RC3 . . . . 158466 . . Connector, Rect Univ 084 12p/S 3 Row Rcpt Cable/Panel Lkg . . . . . . . . . 1
. . . . . . . . . . RC1 . . . . 135133 . . Connector, Rect Univ 084 9p/S 3 Row Rcpt Cable/Panel Lkg . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 148850 . . Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 177859 . . Conn, Body 5 Terminal (To Engine Control Switch S1) . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 150316 . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . . . . . . 092670 . . Conn, Rect Univ 084 3p/S 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . CB11, 12, 13 139266 . . Supplementary Protector, Man Reset 1p 15A 250VAC . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . 214932 . . Conn, Rect Univ 039 8p/S 2row Plug Cable . . . . . . . . . . . . . . . . . . . . . . . . . 1

.................... 215013 .. Harness, Unit Weld Control CC (Consisting Of) . . . . . . . . . . . . . . . . . . . . 1


. . . . . . . . . . PLG3 . . . . 158465 .. Conn, Rect Univ 084 12p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . 1
.................... 187654 .. Seal, Wire Univ 12p/S 3row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG6 . . . . 114063 .. Conn, Rect Univ 084 4p/S 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . 1
.................... 192309 .. Clip, Snap In .630 Bundle .250 Hole .248 Thk . . . . . . . . . . . . . . . . . . . . . . . 2

. . . . . . . . . . . . . . . . . . . . 215660 .. Harness, Engine Control CC (Deutz 2011 Engines) (Consisting Of) . . 1


. . . . . . . . . . . . . . . . . . . . 205931 .. Harness, Engine Control CC (Deutz 912 Engines) (Consisting Of) . . . 1
. . . . . . D1/C1,D8/C8 189701 .. Diode/Capacitor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CB10 . . . . 190374 .. Circuit Breaker, Auto Reset 12VDC 40A . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 148850 .. Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . PLG4 . . . . 114062 .. Connector, Rect Univ 084 15p/S 3 Row Plug Cable Lkg . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 173916 .. Housing, Contact 10-Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CR1 . . . . 214876 .. Relay, Encl 6VDC Spst 35A/14VDC 5 Pin (Prior to MC030001E) . . . . . . . 1
. . . . . . . . . . CR1 . . . . 252053 .. Relay, Encl 12VDC Spst 35A/14VDC 5 Pin (Eff w/MC030001E) . . . . . . . . 1
. . . . . . . . . . CB14 . . ♦205927 .. Circuit Breaker, Auto Reset 12VDC 12 Amp . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 236603 . . Harness, Control Box, CV Weld Control


(Prior to LJ005955) (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 238683 . . Harness, Control Box, CV Weld Control
(Eff w/LJ005955) (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC4 . . . . 047483 . . Connector, Rect Univ 084 15p/S 3 Row Rcpt Cable/Panel Lkg . . . . . . . . . 1
. . . . . . . . . . RC3 . . . . 158466 . . Connector, Rect Univ 084 12p/S 3 Row Rcpt Cable/Panel Lkg . . . . . . . . . 1
. . . . . . . . . . RC1 . . . . 135133 . . Connector, Rect Univ 084 9p/S 3 Row Rcpt Cable/Panel Lkg . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 148850 . . Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . S6 . . . . . 193234 . . Switch, Rotary 6 Position Gold Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . S5 . . . . . 011609 . . Switch,Tgl Spdt 15A 125VAC On−None−On Spd Term Chr . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 214932 . . Conn, Rect Univ 039 8p/S 2row Plug Cable . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 150316 . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . . . . . . 177859 . . Conn, Body 5 Terminal (To Engine Control Switch S1) . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 193183 . . Conn, Rect Cinch 18 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 196602 . . Plug, Cavity 18,30 Position Cinch Connector . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . 196603 . . Seal, Switch 6 Position Rotary .250 Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 141450 . . Conn, Rect Metrmate 10skt 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . 1

Big Blue 500D, 600 X TM-4428 Page 169


Eff w/Serial No. LJ003065 Thru MG060062E
Item Dia. Part
No. Mkgs. No. Description Quantity

Wiring Harnesses

.................... 215207 . . Harness, Unit Weld Control − CV (Consisting Of) . . . . . . . . . . . . . . . . . 1


. . . . . . . . . . PLG6 . . . . 114063 . . . . Connector, Rect Univ 084 4p/S 1 Row Plug Cable Lkg . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG8 . . . . 193184 . . . . Connector, Rect Cinch 30 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG13 . . . 147992 . . . . Connector, Rect Univ 039 10p/S 2 Row Plug Cable . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG3 . . . . 158465 . . . . Connector, Rect Univ 084 12p/S 3 Row Plug Cable . . . . . . . . . . . . . . . . 1
.................... 088731 . . . . Bushing, Snap-In Nyl .375 Id X .500 Mtg Hole . . . . . . . . . . . . . . . . . . . . . 1
.................... 135873 . . . . Clip, Conduit Convoluted 1/2 In Mtg Hole . . . . . . . . . . . . . . . . . . . . . . . . . 2
.................... 187654 . . . . Seal, Wire Univ 12p/S 3 Row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

.................... 206024 . . Harness, Engine Control (Deutz 2011 Engines) (Consisting Of) . . . . . 1
.................... 205931 . . Harness, Engine Control (Deutz 912 Engines) (Consisting Of) . . . . . . 1
. . . . . . D1/C1,D8/C8 189701 . . . . Diode/Capacitor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 148850 . . . . Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . PLG4 . . . . 114062 . . . . Connector, Rect Univ 084 15p/S 3 Row Plug Cable Lkg . . . . . . . . . . . . . 1
.................... 173916 . . . . Housing, Contact 10-Pole (Deutz 2011 Engines) . . . . . . . . . . . . . . . . . . . 1
.................... 185655 . . . . Seal, Wire Univ 15p/S 3 Row (Deutz 912 Engines) . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 235251 . . Harness, Fuel Shutdown Solenoid


(Prior to MA340014E) (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . R7 . . . . . 235250 . . Resistor, Hsc 30 W 3 Ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 148850 . . Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

TM-4428 Page 170 Big Blue 500D, 600 X


TM-4428L 2016−07

Processes
Stick (SMAW) Welding

TIG (GTAW) Welding

Air Carbon Arc (CAC-A) Cutting


and Gouging

Description

Engine Driven Welder/Generator

Big Blue 600 X


Deutz

Eff w/Serial No. MG060063E And Following

File: Engine Drive

Visit our website at


www.MillerWelds.com
SECTION 16 − PARTS LIST
EFF W/SERIAL NO. MG060063E AND FOLLOWING
 Hardware is common and not available unless listed.
 A Deutz 2011 engine-powered unit is shown below. See
inset for parts specific to a Deutz 912-powered unit. Parts
not related to the engines are the same in both units.

14

3 13 15
2
16

1 12

17

4 11
5 6 18
9

10
8
7

20
19
85 − Figure 16-6
77
86
84 21

109
91
83 − Figure 16-2
80
81 76

82

78

90 − 88 87
79
Figure 16-4

89 − Figure 16-3

Figure 16-1. Main Assembly

TM-4428 Page 172 Big Blue 600 X


Eff w/Serial No. MG060063E And Following
 A Deutz 2011 engine- Deutz 912 Engine
powered unit is shown
below. See inset for 28
parts specific to a 103 106
Deutz 912-powered 2
unit. Parts not related to
32 108
the engines are the
same in both units. 102 94
104
101
92

49
98 50

107
105 97 56
99
61

100 57 52
58 53
95 59
93 54
96 63
15 55
16

28
43
33 − Figure 16-5 64
24 41 42
27
30
25 26
23

22 44

40 46
32 47
2
39
110
29 45
31

38

37
36 48
35 63
34 2 2
2
49
33 − Figure 16-5
56 50
57
51 64 68
52
58 66
61 53 67
60 59 65
54
55
75
69
74
62
70

73

72 71
Ref. 803 659 / 803 665

Big Blue 600 X TM-4428 Page 173


Eff w/Serial No. MG060063E And Following
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 16-1. Main Assembly

. . . 1 . . . . . . . . . . . . . . 189824 . . Panel, Gen Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


. . . 2 . . . . . . . . . . . . . . 272334 . . Label, Warning Moving Parts (En/Fr−Sym) . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . 3 . . . . . . . . . . . . . +252811 . . Panel, Engine Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . Z1 . . . . . 189395 . . Reactor, AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . 1T . . . . . 038621 . . Block, Term 30A 4 Pole Frict Term Str . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 038620 . . Link, Jumper Term Blk 30A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . . . . . . . . . . 081499 . . Bracket, Mtg Strip Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . 206352 . . Brace, Front To Center Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 272332 . . Label, Notice Do Not Use Ether (En/Fr−Sym) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . SR4, SR5 . . 035704 . . Rectifier, Integ Bridge 40. Amp 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . CB4 . . . . 045061 . . Circuit Breaker, Auto Reset 24VDC 7 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . 201697 . . Pan, Reactor And Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . T1 . . . . . 201613 . . Transformer W/Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . 189708 . . Firewall, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . 191307 . . Cover, Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . 191829 . . Hose, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 189763 . . Bracket, Mtg Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . 189764 . . Air Cleaner, Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *192938 . . Filter, Air Element Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . *♦192939 . . Filter, Air Element Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . 189464 . . Seal, Weather Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . 201658 . . Upright, Center Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . 262408 . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . 196220 . . Bracket, Hold Down Fuel Tank Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . 192362 . . Bracket, Mtg Nyl 1/2 Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . +263316 . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . 189052 . . Grommet, Plastic Neck Filler Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . 254678 . . Cap, Tank Screw-On 3.500 In W/Vent W/Lanyard 8in . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . 272338 . . Label, Use Diesel Fuel Only (En/Fr−Sym) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . 272339 . . Label, Warning Falling Equipment (En/Fr−Sym) . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . 272333 . . Label, Warning Hot Parts (En/Fr−Sym) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 28 . . . . . . . . . . . . . . 105734 . . Pipe, Muffler Extension Elbow 1.875 Od . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . 201592 . . Pipe, Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . 234509 . . Cover, Radiator Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . 191354 . . Support, Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . 010875 . . Clamp, Muffler 2.000 Dia U Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . Figure 16-5 . . Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . 191577 . . Guard, Starter (Deutz 2011 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . 191809 . . Bracket, Mtg Engine Lh (Deutz 2011 Engines) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . . 191817 . . Baffle, Air (Deutz 2011 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . . 261638 . . Engine, Deutz Dsl Elec D2011l04i (consisting of) . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *067265 . . . . Filter, Oil (Engine) (Deutz 2011 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *192744 . . . . Filter, Fuel Spin-On (Deutz 2011 Engines) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *066217 . . . . Filter, Fuel Secondary (Deutz 2011 Engines) . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *195745 . . . . Switch, Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *195746 . . . . Sender, Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 246988 . . . . Filter Kit, Deutz (2011) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
. . . . . . . . . . . . . . . . . . ♦174064 . . Idle, Solenoid Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . . *067266 . . Belt, Blower (Deutz 2011 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . . 201714 . . Box, Air Intake (Deutz 2011 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . . 201748 . . Upright, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . . 190206 . . Cable, Bat Neg 42 In Lg No. 2 Awg W/Clamp And .375rng . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . . . 190207 . . Cable, Bat Pos 45 In Lg No. 1 Awg W/Clamp And .406rng . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . . . 266385 . . Bracket, Battery Holddown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . . . . . . . . . . . . Battery, Stor 12v 650crk 110rsv Gp 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 264924 . . Bracket, Battery Locator Adj . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . . . 201006 . . Bolt, J Stl .312−18 X 8.500 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 208041 . . Spacer, Stl .323 Id X .625 Od X .141 Thk . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
TM-4428 Page 174 Big Blue 600 X
Eff w/Serial No. MG060063E And Following
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 16-1. Main Assembly (Continued)


. . . 46 . . . . . . . . . . . . . +201183 . . Cover, Battery Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 47 . . . . . . . . . . . . . . 272341 . . Label, Warning Battery Explosion (En/Fr−Sym) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . . . . . . . . . +215252 . . Guard, Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . . . . . . . . . . . 199849 . . Screw, 625-11 X 4.00hexhd Pln Gr 5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 50 . . . . . . . . . . . . . . 071731 . . Washer, Flat .656 Id X 2.250 Od X .187t Stl Pld . . . . . . . . . . . . . . . . . . . . . 4
. . . 51 . . . . . . . . . . . . . . 191812 . . Bracket, Mtg Engine Rh (Deutz 2011 Engines) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 52 . . . . . . . . . . . . . . 071890 . . Retainer, Mount Eng/Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 53 . . . . . . . . . . . . . . 071730 . . Tubing, Stl .875 Od X 12ga Wall X 2.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 54 . . . . . . . . . . . . . . 083476 . . Mount, Eng/Gen Nprn .875 Id X 2.500 Od X 2.000 . . . . . . . . . . . . . . . . . . . 4
. . . 55 . . . . . . . . . . . . . . 135205 . . Nut, 625-11 .94hex .76h Stl Pld Elastic Stop Nut . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . 199505 . . Hose Assy, Oil Drain 32.000 Lg (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 56 . . . . . . . . . . . . . . 165271 . . . . Valve, Oil Drain 3/8-18nptf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 57 . . . . . . . . . . . . . . 176529 . . . . Fitting, Hose Brs Barbed Fem 1/2tbg X 3/8npt . . . . . . . . . . . . . . . . . . . . . 1
. . . 58 . . . . . . . . . . . . . . 269052 . . . . Hose, Nitrile .500 Id X .765 Od x Roll Blk Brd (Order By Ft) . . . . . . . 2.666ft
. . . 59 . . . . . . . . . . . . . . 176528 . . Fitting, Hose Brs Barbed Elbow Fem 1/2 Tbg X 1/2 Npt . . . . . . . . . . . . . . . 1
. . . 60 . . . . . . . . . . . . . . 173336 . . Fitting, Adapter Oil Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 61 . . . . . . . . . . . . . . . . . . . . . . . . Washer, Oil Drain (Available Through Engine Manufacturer) . . . . . . . . . . . 1
. . . 62 . . . . . . . . . . . . . . 269216 . . Bracket, Mtg Solenoid (Deutz 2011 Engines) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 63 . . . . . . . . . . . . . . 206297 . . Base, Fuel Filter Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 64 . . . . . . . . . . . . . *192744 . . Filter, Fuel Spin-On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 65 . . . . . . . . . . . . . . 190992 . . Keeper, Latch Engine Access Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 66 . . . . . . . . . . . . . . 190076 . . Channel, Stiffener Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 67 . . . . . . . . . . . . . . 199592 . . Latch, Paddle Series 20 (Black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 68 . . . . . . . . . . . . . . 237352 . . Label, Maintenance Big Blue Deutz Series . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 69 . . . . . . . . . . . . . +200989 . . Door, Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 70 . . . . . . . . . . . . . . 189975 . . Hinge, Door Access 180deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 71 . . . . . . . . . . . . . . 254634 . . Bumper, Door 1.000 Od X .7509 High Nprn 50 Duro . . . . . . . . . . . . . . . . . 2
. . . 72 . . . . . . . . . . . . . . 269531 . . Panel, Rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 73 . . . . . . . . . . . . . . 189827 . . Panel, Gen Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 74 . . . . . . . . . . . . . . 191626 . . Bumper, Door Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 75 . . . . . . . . . . . . . . 259019 . . Kit, Field Fuel Tank (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 257007 . . . . Tank, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 258232 . . . . Fuel Line Assy, W/Clamps 42.000 In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 218086 . . . . Bracket, Holddown Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 76 . . . . . . . . . . . . . . 191897 . . Bracket, Mtg Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 77 . . . . . . . . . . . . . . 218086 . . Bracket, Hold Down Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 78 . . . . . . . . . . . . . . 272342 . . Label, Warning Do Not Weld On Base (En/Fr−Sym) . . . . . . . . . . . . . . . . . . 2
. . . 79 . . . . . . . . . . . . . . 190179 . . Panel, Mtg Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 80 . . . . . R4 . . . . . 191292 . . Resistor, Ww Fxd 375w 50 Ohm W/Mtg Bkt . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 81 . . . . . R2 . . . . . 189699 . . Resistor, Ww Tap 375w 10 Ohm W/Mtg Bkt . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 82 . . . . . R3 . . . . . 189699 . . Resistor, Ww Tap 375w 10 Ohm W/Mtg Bkt . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 83 . . . . . . . . . . Figure 16-2 . . Control Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 84 . . . . . . . . . . . . . . 189731 . . Firewall, Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 85 . . . . . . . . . . Figure 16-6 . . Main Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 86 . . . . . . . . . . . . . . 191448 . . Top, Cover Front Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 87 . . . . . . . . . . . . . +201750 . . Upright, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 88 . . . . . . . . . . . . . . 272343 . . Label, Warning General Precautionary (En/Fr−Sym) . . . . . . . . . . . . . . . . . 2
. . . 89 . . . . . . . . . . Figure 16-3 . . Panel, Front W/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 90 . . . . . . . . . . Figure 16-4 . . Auxiliary Power Group, Export . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 91 . . . . . . . . . . . . ♦202130 . . Xfmr, Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 190058 . . Nut, .250-20 U-Nut Multi-Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . . 049525 . . Nut, 312-18 U-Nut Multi-Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
. . . 92 . . . . . . . . . . . . . . 237002 . . Engine, Deutz Dsl Elec F3l912 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 249606 . . . . Filter, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 246989 . . . . Filter Kit, Deutz (912/914) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
. . . 93 . . . . . . . . . . . . . *249605 . . Filter, Oil (Deutz 912 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 94 . . . . . . . . . . . . . *066271 . . Belt, Blower (Deutz 912 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 95 . . . . . . . . . . . . . *195745 . . Switch, Pressure Oil 1.5 Bar Nc Cont . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Big Blue 600 X TM-4428 Page 175


Eff w/Serial No. MG060063E And Following
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 16-1. Main Assembly (Continued)

. . . 96 . . . . . . . . . . . . . *195746 . . Sender, Coolant Temp & 130 Degree C Switch . . . . . . . . . . . . . . . . . . . . . . 1


. . . 97 . . . . . . . . . . . . . . 194135 . . Backplate, Deutz 912 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 98 . . . . . . . . . . . . . . 194572 . . Support, Front Engine (Deutz 912 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 99 . . . . FS1 . . . . 141346 . . Shutdown Kit, Engine (Deutz 912 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 100 . . . . . . . . . . . . . 118452 . . Ftg, Adapter Oil Drain (Deutz 912 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 101 . . . . . . . . . . . . . 193313 . . Manifold, Exhaust Muffler (Deutz 912 Engines) . . . . . . . . . . . . . . . . . . . . . . 1
. . 102 . . . . . . . . . . . . . 194496 . . Baffle, Lower Air Outlet (Deutz 912 Engines) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 103 . . . . . . . . . . . . . 194497 . . Baffle, Upper Air Outlet (Deutz 912 Engines) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 104 . . . . . . . . . . . . . 194500 . . Baffle, Air Intake (Deutz 912 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 105 . . . . . . . . . . . . . 194485 . . Hose, Air Cleaner (Deutz 912 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 106 . . . . . . . . . . . . +201714 . . Box, Air Intake (Deutz 912 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 107 . . . . . . . . . . . . . 195560 . . Guard, Starter Hole (Deutz 912 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 108 . . . . . . . . . . . . . 194467 . . Washer, Flat 6.25idx11.50odx.062t Buna N (Deutz 912 Engines) . . . . . . . 1
. . 109 . . . . . . . . . . . . . 212944 . . Label, Stick Overlap Weld Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 110 . . . . . . . . . . . . . 272340 . . Label, Danger Using Generator Indoor (En/Fr/Sp−Sym) . . . . . . . . . . . . . . 1
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
* Recommended Spare Parts.
♦Optional
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement
Parts. Model and serial number required when ordering parts from your local distributor.

TM-4428 Page 176 Big Blue 600 X


Eff w/Serial No. MG060063E And Following
14 4

18

6
21
3
17

8
7

1 22

20
10
15

11 9

16
19 13

12

5
Ref. 803 660-D

Figure 16-2. Control Box Assembly


Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 16-2. Control Box Assembly (Figure 16-1 Item 83)

... 1 . . . F1, F2 . . *085874 .. Fuse, Mintr Cer Slo-Blo 10A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


... 2 . . . . . . . . . . . . . . 046432 .. Holder, Fuse Mintr .250 X 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 3 . . . . . . . . . . . . . . 201077 .. Control Box, Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . . . . . . . . . . . . . . 201078 .. Control Box, Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 . . . . . . . . . . . . . . 201079 .. Cover, Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 . . . . C12 . . . . 191944 .. Capacitor, Polyp Met Film 10. uF 250 VAC 10% . . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . . CR7 . . . . 188636 .. Relay, Ocv Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . D8/C8, D12 . 189701 .. Diode/Capacitor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 9 . . SR1, SR2 . . 035704 .. Rectifier, Integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 10 . . . . CR5 . . . . 223710 .. Relay, Encl 12VDC Dpst−No 25A 6pin Flange . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 . . . . . . . . . . . . . . 177136 .. Clamp, Capacitor 1.375dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 . . . . . C9 . . . . . 087110 .. Capacitor, Elctlt 240uF 200VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 14 . . . . . R6 . . . . . 141424 .. Resistor, Ww Fxd 30 W 25 Ohm Faston Te . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 . . . . PC7 . . ♦195706 .. Module, Pull To Idle, Two Output, 7 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 16 . . . . CR4 . . . ♦113247 .. Relay, Encl 12VDC Dpdt 20A/120VAC 8pin Flange Mtg . . . . . . . . . . . . . . . 1
... 17 . . . . CR6 . . ♦090104 .. Relay, Encl 12VDC Spst 30A/15VDC 5pin Flange Mtg . . . . . . . . . . . . . . . . 1
... 18 . . . . CR3 . . . . 090104 .. Relay, Encl 12VDC Spst 30A/15VDC Spin Flange Mtg . . . . . . . . . . . . . . . 1
... 19 D1/C1,D8/C8 189701 .. Diode/Capacitor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 20 . . . . CB10 . . . . 190374 .. Circuit Breaker, Auto Reset 12VDC 40 Amp . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 21 . . . . CR1 . . . . 252053 .. Relay, Encl 12VDC Spst 35A/14VDC 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 22 . . . . CB14 . . . . 205927 .. Circuit Breaker, Auto Reset 12VDC 12 Amp . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦Optional
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Big Blue 600 X TM-4428 Page 177
Eff w/Serial No. MG060063E And Following
 Hardware is common and 4
not available unless listed.

5
2
1
6
7
8
9

26 10

25

24

23
22
21 16
19
20 17
18

15

11

14 13 12

Ref. 803 662-C

Figure 16-3. Panel, Front w/Components

Item Dia. Part


No. Mkgs. No. Description Quantity

Figure 16-3. Panel, Front w/Components (Figure 16-1 Item 88)

. . . 1 . . . . . . . . . . . . . . . . . . . . . . . . Plate Screened, Ident Control Rating (Order By Model And Serial Number)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . When Ordering This Item,The Nameplate Should Also Be Ordered) . . . . 1
. . . 2 . . . . . . . . . . . . . . . . . . . . . . . . Nameplate, Screened (Order By Model And Serial Number) . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . 238616 . . Panel, Engine/Weld Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . S3 . . . . . 208278 . . Switch, Range/Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 192558 . . Harness, Range (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC6 . . . . 148389 . . . . Conn, Rect Univ 084 4P/S 1row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . 1
. . . 5 . . . . . R1 . . . . . 188635 . . Rheostat, Ww 300w 34 Ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

TM-4428 Page 178 Big Blue 600 X


Eff w/Serial No. MG060063E And Following
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 16-3. Panel, Front w/Components (Continued)

. . . 6 . . . . . S6 . . . . . 011622 . . Switch, Tgl Dpdt 15A 125VAC (Included In Control Box Harness,
.............................. See Figure 16-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . S5 . . . . . 011609 . . Switch, Tgl Spdt 15A 125VAC On-None-On Spd Term Chr (Included In
.............................. Control Box Harness, See Figure 15-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . RC13 . . . . 032897 . . Receptacle, Twlk Grd 2p3w 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . S2 . . . ♦021467 . . Switch, Tgl Spst 3a 250V Off−None−(On) Spd Term . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . S1 . . . . . 217680 . . Switch, Ignition 4 Position W/Out Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 207073 . . Lever, Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . 201125 . . Panel, Mtg Terminal Pwr Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . 241433 . . Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 180735 . . Washer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 13 . . . . . . . . . . . . . . 181169 . . Spacer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 14 . . . . . . . . . . . . . . 186621 . . Boot, Generic Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 15 . . . . . . . . . . . . . . 241432 . . Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . 021385 . . Boot, Toggle Switch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . 201045 . . Cover, Receptacle Twistlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . ♦193228 . . Meter, Volt Dc 8− 18 Scale 2.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . FUEL/HM . . 232113 . . Gauge, Fuel Elec/Hour Meter (D2011l04i Engine) . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . FUEL/HM . . 232112 . . Gauge, Fuel Elec/Hour Meter (D912l03 Engine) . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . TEMP . . . 217084 . . Gauge, Coolant Temp 0− 300 Deg F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 195746 . . Sender, Coolant Temp & 130C Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . OIL . . . . . 217083 . . Gauge, Pressure Oil 0−100 Psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 193230 . . Sender, Pressure Oil 0− 100 Psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 194403 . . Adapter, Oil Pressure Sender (Deutz 2011) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . V1 . . . ♦164874 . . Volt Meter, W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . A1 . . . ♦164873 . . Ammeter, W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . 189161 . . Handle, Switch Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . 010647 . . Pin, Spring Cs .156 X 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . 019602 . . Knob, Pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 024103 . . Blank, Snap−In Nyl .750 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦Optional

+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Big Blue 600 X TM-4428 Page 179


Eff w/Serial No. MG060063E And Following
3
1
2

10

9 8

7
805 259-A

Figure 16-4. Auxiliary Power Group, Export

Item Dia. Part


No. Mkgs. No. Description Quantity
Figure 16-4. Auxiliary Power Group, Export

. . . 1 . . . . . . . . . . . . . +223121 . . Panel, Aux Power (Export) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


. . . 2 . . . . . . . . . . . . . . 144844 . . Stand−off, No 6−32 X .875 Lg .250 Hex Al Fem . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . ELCB1 . . . 222991 . . Circuit Breaker, Elcb 20A 220V 0.030A Trip . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . 272330 . . Label, Warning Electric Shock/Moving Parts (Sym) . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . GFCI1 . . . 246614 . . Receptacle, GFCI 15/20A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . CB2 . . . . 093996 . . Circuit Breaker, Man Reset 1p 20A 250VAC Frict . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . 083030 . . Stud, Brs .250−20 X 1.750 W/Hex Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 601836 . . Nut, 250−20 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 8 . . . . . . . . . . . . . . 190323 . . Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . 209056 . . Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . RC1 . . . . 176355 . . Rcpt, Str 2p3w 16a 220V Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

TM-4428 Page 180 Big Blue 600 X


Eff w/Serial No. MG060063E And Following
 Hardware is common and 13 14
not available unless listed.
12

7 11
10

9
6
8
5 15

3 16

1
2 17  Cover location and appearance
vary according to engine model.

18
20 19
21 Ref. 255 861

Figure 16-5. Generator


Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 16-5. Generator (Figure 16-1 Item 33)

. . . 1 . . . . . . . . . . . . . . 132053 . . Screw, 375-16 X 1.50hexhd Pln Gr 5pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6


. . . 2 . . . . . . . . . . . . . . 183387 . . Washer, Conical Spring .406 Id X .875 Od Pltd . . . . . . . . . . . . . . . . . . . . . . 6
. . . 3 . . . . . . . . . . . . . . 264056 . . Endbell W/Exciter Stator (Includes)
. . . . . . . . . . . . . . . . . . . . 264058 . . . . Stator, Exciter/Gen Pwr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 257974 . . . . Kit, Endbell, Gen (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 143220 . . . . . . O-Ring, 2.859 Id X .139cs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 4 . . . . . . . . . . . . . +254088 . . Stator, Weld Assembly Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . 190197 . . Guard, Generator Wire Mesh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 172674 . . Spring, Ext .240 Od X .041 Wire X 3.500pld . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . . . . . . . . . . 039207 . . Baffle, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . ROTOR . . . 251855 . . Rotor, Generator Segmented Assy (Includes) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . 024617 . . . . Ring, Rtng Ext 1.375 Shaft X .050 Thk . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . 053390 . . . . Bearing, Ball Rdl Sgl Row 1.370 X 2.830 X .6 . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hub, Drive (Not Sold Separately) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . 080389 . . . . Screw, 312−18x1.00 Hexwhd.66d Stl Pld Slffmg Tap−Rw . . . . . . . . . . . 8
. . . 11 . . . . . . . . . . . . . . 083883 . . . . Washer, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . . . 8
. . . 12 . . . . . . . . . . . . . . 206242 . . . . Fan, Rotor Segmented Assy Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 13 . . . . . . . . . . . . . . 083883 . . . . Washer, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . . . 10
. . . 14 . . . . . . . . . . . . . . 049026 . . . . Screw, M10−1.5x 25 Hex Hd−Pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . . 10
. . . 15 . . . . . . . . . . . . . . 210332 . . . . Plate, Flex Hubmount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . 191579 . . Cover, Starter Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . 191580 . . Cover, Starter Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . 189142 . . Brushholder Assembly, Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *190823 . . . . Brush, Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . 208469 . . . . Clip, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Big Blue 600 X TM-4428 Page 181


Eff w/Serial No. MG060063E And Following
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 16-5. Generator (Continued)

. . . 19 . . . . . . . . . . . . . . 602242 . . Washer, Flat .375idx0.875odx.083t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 2


. . . 20 . . . . . . . . . . . . . . 602211 . . Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . . . 2
. . . 21 . . . . . . . . . . . . . . 604534 . . Screw, .312−18x1.25 Hex Hd−Pln Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 2
.................... 190259 . . Harness, Brush (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG1 . . . . 168071 . . . . Connector, (Kit) Rect Univ 084 9p/S 3 Row Plug Cable Lkg . . . . . . . . . . 1
.................... 187651 . . . . Seal, Wire Univ 9p/S 3 Row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦OPTIONAL

+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

TM-4428 Page 182 Big Blue 600 X


Eff w/Serial No. MG060063E And Following
4
 Hardware is common and
not available unless listed. 3

1
5

802 279-A

Figure 16-6. Main Rectifier Assembly

Item Dia. Part


No. Mkgs. No. Description Quantity

Figure 16-6. Main Rectifier Assembly (Figure 16-1 Item 85)

. . . . . . . . . . SR3 . . . . 239784 . . Rectifier, Environmental High Output (Consisting Of) . . . . . . . . . . . . . . . . . 1


. . . 1 . . . . . . . . . . . . . . 188137 . . . . Connection Board, Rectifier AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . 188517 . . . . Bus Bar, Connection Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 3 . . . . . . . . . . . . . . 188135 . . . . Enclosure, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . . . . . . . . . . . 134201 . . . . Stand-Off, Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 5 . . . . PC3 . . . . 269140 . . . . Circuit Card Assembly, Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . 188136 . . . . Insulator, Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . 7 . . . . . . . . . . . . . . 188493 . . . . Heat Sink, Rectifier Al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . D3, D5, D7 . 245097 . . . . Diode, Rect 300 A 500V Do−9 (Straight) Modified . . . . . . . . . . . . . . . . . . 3
. . . 9 . D2, D4, D6 . 245096 . . . . Diode, Rect 300 A 500V Do−9 (Reversed) Modified . . . . . . . . . . . . . . . . 3
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Big Blue 600 X TM-4428 Page 183


Eff w/Serial No. MG060063E And Following
 Some wiring harness components (switches, relays, supplementary protectors) are also referenced elsewhere in this parts list. Purchase compo-
nents separately or as part of the associated wiring harness.

Item Dia. Part


No. Mkgs. No. Description Quantity

Wiring Harnesses

.................... 238763 .. Harness, Control Box (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


. . . . . . . . . . CR7 . . . . 188636 .. Relay, Ocv Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . D8/C8, D12 . 189701 .. Diode/Capacitor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . SR1, SR2 . . 035704 .. Rectifier, Integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . CR5 . . . . 223710 .. Relay, Encl 12VDC Dpst−No 25A 6pin Flange . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . S5 . . . . . 011609 .. Switch, Tgl Spdt 15A 125VAC On−None−On Spd Term Chr . . . . . . . . . . . 1
. . . . . . . . . . . S6 . . . . . 011622 .. Switch, Tgl 3pdt 15A 125VAC On−None−On Spd Term . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC4 . . . . 047483 .. Connector, Rect Univ 084 15p/S 3 Row Rcpt Cable/Panel Lkg . . . . . . . . . 1
. . . . . . . . . . RC3 . . . . 158466 .. Connector, Rect Univ 084 12p/S 3 Row Rcpt Cable/Panel Lkg . . . . . . . . . 1
. . . . . . . . . . RC1 . . . . 135133 .. Connector, Rect Univ 084 9p/S 3 Row Rcpt Cable/Panel Lkg . . . . . . . . . . 1
.................... 148850 .. Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 177859 .. Conn, Body 5 Terminal (To Engine Control Switch S1) . . . . . . . . . . . . . . . . 1
.................... 150316 .. Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . 5
.................... 092670 .. Conn, Rect Univ 084 3p/S 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . CB11, 12, 13 139266 .. Supplementary Protector, Man Reset 1p 15A 250VAC . . . . . . . . . . . . . . . . 3
.................... 214932 .. Conn, Rect Univ 039 8p/S 2row Plug Cable . . . . . . . . . . . . . . . . . . . . . . . . . 1

.................... 215013 .. Harness, Unit Weld Control (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


. . . . . . . . . . PLG3 . . . . 158465 .. Conn, Rect Univ 084 12p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . 1
.................... 187654 .. Seal, Wire Univ 12p/S 3row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG6 . . . . 114063 .. Conn, Rect Univ 084 4p/S 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . 1
.................... 192309 .. Clip, Snap In .630 Bundle .250 Hole .248 Thk . . . . . . . . . . . . . . . . . . . . . . . 2

.................... 215659 .. Harness, Engine Control (Deutz 2011 Engines) (includes) . . . . . . . . .