Checking Generator Brushes; Battery Replacement; Battery Maintenance - Miller Big Blue 500X Pro Owner's Manual

8-5.

Checking Generator Brushes

8-6.

Battery Replacement

Larger Battery
Smaller Battery
allen_wrench allen_set
pliers needlenose
8-7.

Battery Maintenance

Lead acid batteries discharge when stored in any temperature. Units that are stored should have the battery recharged every three months and
solderiron
stripcrimp
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.
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Complete Parts List is available at www.MillerWelds.com
allen_wrench allen_set
tools/
pliers needlenose
flathead
knife steelbrush
solderiron
stripcrimp
heavy-duty workclamp
torque screwdriver
socket wrench
torque wrench
1 Generator Brush
2 Minimum Length: 5/8 in. (16 mm)
3 New Length: 1–1/4 in. (32 mm)
4 Damaged Brush
Mark and disconnect leads at brushholder
cap. Remove brushes.
Replace brushes if damaged or if brush ma-
terial is at or near minimum length.
allen_wrench allen_set
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pliers needlenose
1 Battery Locator Bracket Mounting Holes
Access battery as shown in Section 5-4. Dis-
tools/
connect battery.
Remove J-bolts securing battery and remove
battery.
flathead
Battery locator brackets can be moved to ac-
solderiron
stripcrimp
commodate batteries of different physical
sizes.
Install and secure replacement battery.
knife steelbrush
philips head
torque screwdriver
socket wrench
torque wrench
nutdriver
heavy-duty workclamp
strapwrench
airgun
light-duty workclamp wirecutter
drill
Stop engine and let cool.
flathead
Stop engine.
knife
Shown from top of unit.
philips head
heavy-duty workclamp
Connect negative (-) battery cable
last.
nutdriver
wrench
crescent wrench
drill
light-duty workclamp
chippinghammer
hammer
frontcutter
OM-285665 Page 49
greasegun
tools/
ph
steelbrush
wrench
cres
light-duty work
chipp
wirecutter f
handream
awl
filter