Miller Electric Big Blue 402P, Big Blue 602P, Big Blue 502P manual Engine Hazards

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WELDING can cause fire or explosion.

Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot

equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding.

DProtect yourself and others from flying sparks and hot metal.

DDo not weld where flying sparks can strike flammable material.

DRemove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers.

DBe alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.

DWatch for fire, and keep a fire extinguisher nearby.

DBe aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.

DDo not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared according to AWS F4.1 (see Safety Standards).

DConnect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock and fire hazards.

DDo not use welder to thaw frozen pipes.

DRemove stick electrode from holder or cut off welding wire at contact tip when not in use.

DWear oil-free protective garments such as leather gloves, heavy shirt, cuf- fless trousers, high shoes, and a cap.

DRemove any combustibles, such as a butane lighter or matches, from your person before doing any welding.

DFollow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot work and have a fire watcher and extinguisher nearby.

FLYING METAL can injure eyes.

DWelding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag.

DWear approved safety glasses with side shields even under your welding helmet.

HOT PARTS can cause severe burns.

DAllow cooling period before maintaining.

D Wear protective gloves and clothing when working on a hot engine.

DDo not touch hot engine parts or just-welded parts bare-handed.

NOISE can damage hearing.

Noise from some processes or equipment can damage hearing.

DWear approved ear protection if noise level is high.

MAGNETIC FIELDS can affect pacemakers.

D Pacemaker wearers keep away.

D Wearers should consult their doctor before going near arc welding, gouging, or spot welding opera- tions.

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully.

DProtect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs.

DInstall cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping.

DKeep cylinders away from any welding or other electrical circuits.

DNever drape a welding torch over a gas cylinder.

DNever allow a welding electrode to touch any cylinder.

DNever weld on a pressurized cylinder — explosion will result.

DUse only correct shielding gas cylinders, regulators, hoses, and fittings de- signed for the specific application; maintain them and associated parts in good condition.

DTurn face away from valve outlet when opening cylinder valve.

DKeep protective cap in place over valve except when cylinder is in use or connected for use.

DRead and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards.

1-3. Engine Hazards

BATTERY EXPLOSION can BLIND.

DAlways wear a face shield, rubber gloves, and protec-

tive clothing when working on a battery.

D Stop engine before disconnecting or connecting bat- tery cables or servicing battery.

DDo not allow tools to cause sparks when working on a battery.

DDo not use welder to charge batteries or jump start vehicles.

DObserve correct polarity (+ and −) on batteries.

DDisconnect negative (−) cable first and connect it last.

FUEL can cause fire or explosion.

D Stop engine and let it cool off before checking or add- ing fuel.

DDo not add fuel while smoking or if unit is near any sparks or open flames.

DDo not overfill tank — allow room for fuel to expand.

DDo not spill fuel. If fuel is spilled, clean up before starting engine.

DDispose of rags in a fireproof container.

DAlways keep nozzle in contact with tank when fueling.

MOVING PARTS can cause injury.

D Keep away from fans, belts, and rotors.

D Keep all doors, panels, covers, and guards closed and securely in place.

DStop engine before installing or connecting unit.

DHave only qualified people remove guards or covers for maintenance and troubleshooting as necessary.

DTo prevent accidental starting during servicing, disconnect negative (−) battery cable from battery.

DKeep hands, hair, loose clothing, and tools away from moving parts.

DReinstall panels or guards and close doors when servicing is finished and before starting engine.

DBefore working on generator, remove spark plugs or injectors to keep engine from kicking back or starting.

DBlock flywheel so that it will not turn while working on generator compo- nents.

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Contents OM-491 ProcessesDescription From Miller to You Table of Contents 11-1 11-211-3 Symbol Usage Arc Welding HazardsEngine Hazards Compressed Air Hazards EMF Information Principal Safety StandardsCalifornia Proposition 65 Warnings Radiation can cause interferenceUN Choc Électrique peut tuer Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation LES Fumées ET LES GAZ peuvent être dangereuxDES Pièces Chaudes peuvent provoquer des brûlures graves LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux LE Bruit peut affecter l’ouïeLA Chaleur DU Moteur peut pro- voquer un incendie ’EXPLOSION DE LA Batterie peutDES Organes Mobiles peuvent provoquer des blessures ’AIR Comprimé peut provoque r des blessuresPrincipales normes de sécurité Information sur les champs électromagnétiques− Specifications Symbols And Definitions− Definitions Weld, Power, And Engine Specifications Dimensions, Weights, And Operating AnglesVolt-Ampere Curves For CC Models 55−90TIG Mode Stick ModeMIG Mode Volt-Ampere Curves For CC/CV ModelsDuty Cycle And Overheating Exceeding duty cycle can damage unit and void warrantyFuel Consumption 100% Duty Cycle At 400 Amperes12 kVA/kW Single-Phase AC Output No Weld Load AC Generator Power CurveOptional Three-Phase Generator Curves 20 kVA/kW Three-Phase AC Output No Weld LoadMovement Location Grounding − InstallationInstalling Welding Generator Airflow ClearanceMounting Surface Mounting Welding GeneratorSupporting The Unit To Bolt Unit In PlaceUsing Lifting Eye Installing Exhaust PipeStop engine and let cool Activating The Dry Charge Battery If Applicable Read and follow all instrucCharger Connecting The Battery Connect Negative − Cable LastFuel Do not use gasoline. Gasoline will damage engine Coolant Recovery TankEngine Prestart Checks OilConnecting To Weld Output Terminals Selecting Weld Cable SizesConnecting To Remote 14 Receptacle RC14 On CC/CV Models Socket− Operating Welding Generator − CC Models Front Panel Controls For CC Models See SectionEngine Starting Controls Engine Indicator LightsDo not switch under load To StartConnect optional remote control to RC13 see Section Example Remote Amperage Control On CC Models OptionalWeld Control/Arc Condition Information Label OM-491 − Operating Welding Generator − CC/CV Models Front Panel Controls For CC/CV Models See SectionVoltage/Amperage Adjust Control Voltage/Amperage Adjust Switch And Remote 14 ReceptacleProcess/Contactor Switch On CC/CV Models Process/Contactor Switch SettingsSet Remote Set Range Remote Voltage/Amperage Control On CC/CV Models OptionalExample Combination Remote Amperage Control Stick Process− Operating Auxiliary Equipment Volt And 240 Volt ReceptaclesSingle-Phase Power Connection Single-Phase Generator Power Three-Phase Power ConnectionRear Of Panel Optional Generator Power Receptacles 240 V 15 a AC South African Receptacle RC1Circuit Breaker CB2 Circuit Breaker CB3 − Maintenance & Troubleshooting Every 800 h Every 400 hEvery 500 h Every 1000 hMaintenance Label To clean air filter Servicing Air CleanerBy the warranty Do not clean housing with air hoseInspecting And Cleaning Optional Spark Arrestor Muffler Reinstall cleanout plug Tools Needed 3/8Weld/Power Speed Adjustment Adjusting Engine SpeedModels With Automatic Idle Optional Idle Speed Adjustment Engine Speed No LoadServicing Fuel And Lubrication Systems Overload Protection Stop engineStart Engine With No Load Applied Diagnosing Causes Of Engine Fault ShutdownsDiagnostic Checks While Running ConditionTroubleshooting Welding − CC ModelsWelding − CC/CV Models Standard Generator Power Optional Three-Phase Generator Power CC/CV Models OnlyEngine Ing harness and components Shutdown switch is released OutTemperature is too high see Sections 5-7and Air in fuel system. See engine manualReturn To Table Of Contents − Electrical Diagrams Circuit Diagram For CC Welding Generator215 304-A Circuit Diagram For CC/CV Welding Generator 215 305-A − RUN-IN Procedure WetstackingWelding Generator Stop engine Do not touch hot exhaust Run-In Procedure Using Load BankProcedure at less than From flammables Do not PerformFrom flammables Run-In Procedure Using Resistance GridBank/grid Do not perform run-in− Generator Power Guidelines Selecting EquipmentGrounding Generator To Truck Or Trailer Frame Earth ground if supplying Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Amperes x Volts = WattsIndustrial Motors Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsSingle-Phase Induction Motor Starting Requirements Power Required To Start MotorHow Much Power Can Generator Supply? KVA/HP x HP xTypical Connections To Supply Standby Power Work like a ProSelecting Extension Cord Use Shortest Cord Possible Current Load Watts Amperes− Parts List 114 113 110 109 116105 CC only 102 106 107 100 Big Blue 502, 602 Only 115 114Dia Part Mkgs Description Quantity Dia Part 124 Control Box Assembly − CC Models Control Box Assembly − CC/CV Models Control Box Assembly − CC/CV Models -1Item Panel, Front w/Components − CC Models MS1 Panel, Front w/Components − CC/CV Models Panel, Front w/Components − CC/CV Models -1ItemPC6 192 Generator Generator -1Item Main Rectifier Assembly Service Your distributor also givesSupport Your distributor and/or equipment manufacturer’s Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Transportation Department

Big Blue 602P, Big Blue 502P, Big Blue 402P specifications

Miller Electric is a well-respected name in the welding industry, known for its high-quality portable welders that cater to a wide range of applications. Among their iconic products are the Big Blue 502P, Big Blue 402P, and Big Blue 602P, each offering unique features and capabilities suited to professional welders.

The Miller Big Blue 502P is recognized for its robust construction and high-performance capabilities. Powered by a reliable diesel engine, it provides 500 amps of welding power at a duty cycle of 100%. This model is particularly favored for its versatility, accommodating both stick and TIG welding processes. One of its key technologies is the Auto-Set feature, which automatically adjusts settings for optimal performance based on the material thickness. This welder also boasts a user-friendly interface, complete with easy-to-read digital displays for monitoring essential parameters.

In contrast, the Big Blue 402P offers a slightly lower welding output while maintaining many of the advanced features seen in its larger counterpart. With a maximum output of 400 amps, it is perfectly suited for light to medium-duty applications. The 402P is particularly lightweight for a diesel welder, making it an ideal choice for contractors who need mobility without sacrificing power. It includes the X-Mode technology, which ensures reliable performance in challenging conditions and offers an intuitive control panel for ease of use.

The Big Blue 602P, on the other hand, stands out for its high output and exceptional reliability. With a maximum capacity of 600 amps, this machine is designed for heavy-duty applications, making it perfect for industrial settings. The welder features advanced cooling systems and robust construction, which enhance durability and longevity. One notable characteristic of the 602P is its ability to handle various welding processes, including Stick, TIG, and MIG, making it a versatile tool for skilled welders. Additionally, the Big Blue 602P incorporates advanced inverter technology, resulting in a lighter and more energy-efficient model without compromising power performance.

All three models benefit from Miller's commitment to innovation and user-centric design features. Built to thrive in tough work environments, the Big Blue series is equipped with protective casings and vibration-resistant components. Safety is also a priority, with several built-in features that help protect users during operation.

In summary, the Miller Electric Big Blue 502P, 402P, and 602P each bring unique strengths to the welding market. Their notable features include advanced technologies, robust construction, and versatile applications, ensuring that professionals have the right tool for any welding job. Whether for light-duty tasks or heavy industrial applications, Miller Electric's Big Blue series remains a cornerstone for welders around the globe.
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