Miller Electric Big Blue 602P, Big Blue 402P, Big Blue 502P manual 124

Page 70

 

Item

Dia.

Part

 

 

 

No.

Mkgs.

No.

Description

Quantity

 

 

 

 

Figure 13-1. Main Assembly (Continued)

 

 

 

 

 

 

. . . 79 . . . .

. . . . . .

. . . 191 610 . .

FITTING, hose stl elbow .500tbg x 3/4-16

. . . 1

. . . 80 . . . .

. . . . . .

. . . 190 180 . .

WASHER, flat .750 ID x 1.250 OD x .125T stl

. . . 1

. . . 81 . . . .

. . . . . .

. . . 191 499 . .

LINE, fuel return

. . . 1

. .

. . . . . . . .

. . . . . .

. . . 191 608 . .

FITTING, cprsn brs nut 1/4tbg

. . . 1

. .

. . . . . . . .

. . . . . .

. . . 191 606 . .

FITTING, cprsn brs sleeve 1/4tbg

. . . 1

. . . 82 . . . .

. . . . . .

. . . 191 500 . .

LINE, fuel supply

. . . 1

. . . 83 . . . .

. . . . . .

. . . 189 245 . .

TANK, fuel 23gal (consisting of)

. . . 1

. . . 84 . . . .

. . . . . .

. . . 124 253 . . .

. BUSHING, tank fuel

. . . 4

. .

. . . . . . . .

. . . . . .

. . . 084 173 . . .

. CLAMP, hose .460 − .545clp dia slfttng

. . . 2

. . . 85 . . . .

. . . . . .

. . . 189 912 . . .

. FITTING, stl barbed elbow w/.047 in orf zinc pld

. . . 1

. . . 86 . . . .

. . . . . .

. . . 189 909 . . .

. FITTING, stand pipe hose .250 x 9.260 lg 90deg zinc

. . . 1

. . . 87 . . . .

. . . . . .

. . . 201 025 . . .

. CAP, fuel fitting

. . . 1

. . . 88 . . . .

. . . . . .

. . . 189 913 . . .

. FITTING, stl barbed elbow zinc pld

. . . 1

. . . 89 . . . .

. . . . . .

. . . 190 142 . . .

. SENDER, fuel gauge 9.7500 deep tank

. . . 1

. . . 90 . . . .

. . . . . .

. . . 189 910 . . .

. FITTING, stand pipe hose .3125 x 9.260 lg 90deg zinc

. . . 1

. . . 91 . . . .

. . . . . .

. . . 189 908 . . .

. VALVE, drain fuel 180deg

. . . 1

. . . 92 . . . .

. . . . . .

. . . 181 572 . . .

. BUSHING, tank fuel

. . . 1

. . . 93 . . . .

. . . . . .

. . . 191 446 . .

EXTRUSION, rubber w/adhesive 1.000 x 1.000 D (order by ft)

. . . 6ft

. . . 94 . . . .

. . . . . .

. . . 190 250 . .

LABEL, warning do not weld on base

. . . 2

. . . 95 . . . .

. . . . . .

. . . 191 897 . .

BRACKET, mtg unit

. . . 4

. . . 96 . . . .

. . . . . .

. . . 192 362 . .

BRACKET, mtg nyl 1/2 conduit

. . . 1

. . . 97 . . . .

. . . . . .

. . . 196 220 . .

BRACKET, hold down fuel tank rear

. . . 1

. . . 98 . . . .

. . . . . .

. . +200 999 . .

BASE

. . . 1

. . . 98 . . . .

. . . . . .

. ♦+203 382 . .

BASE e-coat

. . . 1

. . . 99 . . . .

. . . . . .

. . . 191 512 . .

BRACKET, hold down fuel tank

. . . 1

. . 100 . . .

. . . . . .

. . . 190 179 . .

PANEL, mtg components

. . . 1

. . 101 . . . . R4 .

. . CC191 292 . .

RESISTOR, WW fxd 375W 50 ohm w/mtg bkt

. . . 1

. . 102 . . . . R3 .

. . . 189 699 . .

RESISTOR, WW tap 375W 10 ohm w/mtg bkt

. . . 1

. . 103 . . . . R2 .

. . CC189 699 . .

RESISTOR, WW tap 375W 10 ohm w/mtg bkt

. . . 1

. . 104 . . . . . Figure 13-2, 13-3

CONTROL BOX ASSEMBLY

. . . 1

. . 105 . . .

. . . . . .

. . . 189 731 . .

FIREWALL, lower

. . . 1

. . 106 . . .

. . . . . .

. . +201 750 . .

UPRIGHT, front

. . . 1

. . 106 . . .

. . . . . .

. ♦+202 637 . .

UPRIGHT, front ss

. . . 1

. . 107 . . .

. . . . . .

. . . 182 761 . .

LABEL, warning general precautionary

. . . 1

. . 108 . . .

. . . . . .

. . . . 13-4,13-5 . .

PANEL, front w/components

. . . 1

. .

109 . . .

. . . . . .

. . ♦202 130 . .

XFMR, current sensing (auto idle option)

. . . 1

. .

110 . . .

. . . . . .

. . . 190 010 . .

LABEL, warning do not use ether

. . . 1

. .

111 . . .

. . . . . .

. . . 191 448 . .

TOP, cover front upright

. . . 1

. .

111 . . .

. . . . . .

. . ♦199 305 . .

TOP, cover front upright ss

. . . 1

. . 112 . . .

. . . . . .

Figure 13-7 . .

MAIN RECTIFIER ASSEMBLY

. . . 1

. . 113 . . .

. . . . . .

. . CV193 453 . .

BRACKET, mtg box fcr

. . . 1

. . 114 . . . PC1

. . CV189 143 . .

MODULE, field current regulator

. . . 1

. .

114 . . .

. . . . . .

. . . 189 535 . .

PIPE, exhaust (Big Blue 502 and 602 only)

. . . 1

. .

115 . . .

. . . . . .

. . . 105 740 . .

MUFFLER, exhaust engine 1.925 inlet/outlet (Big Blue 502 & 602 only) . 1

. . 116 . . .

. . . . . .

. . . 212 944 . .

LABEL, CC Stick Overlap Weld Ranges

. . . 1

. .

. . . . . . . .

. . . . . .

. . . 190 058 . .

NUT, .250-20 u-nut multi-thread

. . . 19

. .

. . . . . . . .

. . . . . .

. . . 049 525 . .

NUT, 312-18 u-nut multi-thread

. . . 32

. .

. . . . . . . .

. . . . . .

. . . 202 021 . .

KIT, label (includes safety and informational labels)

. . . 1

+When ordering a component originally displaying a precautionary label, the label should also be ordered. Order label individually or as part of Label Kit 202 021.

*Recommended Spare Parts.

CC

CV

CCmodels only.

CC/CV models only.

♦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.

OM-491 Page 66

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Contents Processes OM-491Description From Miller to You Table of Contents 11-2 11-111-3 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 électromagnétiquesSymbols And Definitions − Specifications− 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 PlaceInstalling Exhaust Pipe Using Lifting EyeStop engine and let cool Read and follow all instruc Activating The Dry Charge Battery If ApplicableCharger 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 StartRemote Amperage Control On CC Models Optional Connect optional remote control to RC13 see Section ExampleWeld 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 ReceptaclesThree-Phase Power Connection Single-Phase Power Connection Single-Phase Generator PowerRear Of Panel 240 V 15 a AC South African Receptacle RC1 Optional Generator Power ReceptaclesCircuit 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 Optional Three-Phase Generator Power CC/CV Models Only Standard Generator PowerEngine 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 Wetstacking − RUN-IN ProcedureWelding 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-inSelecting Equipment − Generator Power GuidelinesGrounding 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 Amperes114 113 110 109 116 − Parts List105 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 Your distributor also gives ServiceSupport 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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