Miller Electric Big Blue 602P, Big Blue 402P, Big Blue 502P manual Generator -1Item

Page 79

Item

Dia.

Part

 

 

 

No.

Mkgs.

No.

Description

Quantity

 

 

 

 

Figure 13-6. Generator (Figure 13-1Item 46)

 

 

 

 

 

 

 

. . .

1 . . .

. . . . . . . .

. . 132 053 . .

SCREW, 375-16 x 1.50hexhd pln gr 5pld

. . . 6

. . .

2 . . .

. . . . . . . .

. . 183 387 . .

WASHER, conical spring .406 ID x .875 OD pltd

. . . 6

. . .

3 . . .

. . . . . . . .

. . . 195 911 . .

ENDBELL, gen (consisting of)

. . . 1

. . .

4 . . .

. . . . . . . .

. . 143 220 . . .

. O-RING, 2.859 ID x .139CS

. . . 1

. . .

5 . . .

. . . . . . . .

. . 201 099 . .

STATOR, exciter/gen pwr

. . . 1

. . .

6 . . .

. . . . . . . .

. +208 287 . .

STATOR, weld assembly complete

. . . 1

. . .

6 . . .

. . . . . . . .

+♦209 220 . .

STATOR, weld assembly complete (full kVA option)

. . . 1

. . .

7 . . .

. . . . . . . .

. . 013 367 . .

LABEL, warning moving parts

. . . 2

. . .

8 . . .

. . . . . . . .

. . 190 197 . .

GUARD, generator wire mesh

. . . 1

. . .

9 . . .

. . . . . . . .

. . 172 674 . .

SPRING, ext .240 OD x .041 wire x 3.500pld

. . . 2

. . . 10 . . .

. . . . . . . .

. . 191 580 . .

COVER, starter hole

. . . 1

. . . 11 . . .

. . . . . . . .

. . 191 576 . .

GUARD, starter Perkins

. . . 1

. . . 12 . . .

. . . . . . . .

. . 039 207 . .

BAFFLE, air

. . . 1

. . . 13 . . .

ROTOR

. . 212 997 . .

ROTOR, Generator Segmented Assy (Includes)

. . . 1

. . . 14 . . .

. . . . . . . .

. . 210 446 . . .

. ROTOR, Generator (Includes)

. . . 1

. . . 15 . . .

. . . . . . . .

. . 024 617 . . .

. . . RING, Rtng Ext 1.375 Shaft X .050 Thk

. . . 1

. . . 16 . . .

. . . . . . . .

. . 053 390 . . .

. . . BEARING, Ball Rdl Sgl Row 1.370 X 2.830 X .6

. . . 1

. . .

. . . . . .

. . . . . . . .

. . . . . . . . . . . . . .

. . . HUB, Drive (Not Sold Separately)

. . . 1

. . .

. . . . . .

. . . . . . . .

. . 210 447 . . .

. FAN, Rotor Assy Generator (Segmented) (includes)

. . . 1

. . . 17 . . .

. . . . . . . .

. . 210 332 . . .

. . . PLATE, Flex Hubmount

. . . 1

. . . 18 . . .

. . . . . . . .

. . 206 242 . . .

. . . FAN, Rotor Segmented Assy Gen

. . . 4

. . . 19 . . .

. . . . . . . .

. . 049 026 . . .

. . . SCREW, M10−1.5x 25 Hex Hd−pln 8.8 Pln

. . .10

. . . 20 . . .

. . . . . . . .

. . 083 883 . . .

. . . WASHER, Lock .402idx0.709odx.087t Stl Split10mm

. . . 10

. . . 21 . . .

. . . . . . . .

. . 080 389 . . .

. . . SCREW, 312−18x1.00 Hexwhd.66d Stl Pld Slffmg Tap−rw

. . . 8

. . . 22 . . .

. . . . . . . .

. . 083 883 . .

WASHER, Lock .402idx0.709odx.087t Stl Split10mm

. . . 4

. . . 23 . . .

. . . . . . . .

. . 049 026 . .

SCREW, M10−1.5x 25 Hex Hd−pln 8.8 Pln

. . .4

. . . 24 . . .

. . . . . . . .

. . 191 579 . .

COVER, starter hole Perkins/Continental

. . . 1

. . . 25 . . .

. . . . . . . .

. . 083 883 . .

WASHER, Lock .402idx0.709odx.087t Stl Split10mm

. . . 6

. . . 26 . . .

. . . . . . . .

. . 172 555 . .

SCREW, M10-1.5 x 50hexhd pln 8.8pld

. . . 6

. . . 27 . . .

. . . . . . . .

. . 602 159 . .

SCREW, .312-18 X .75hexwhd

. . . 6

. . . 28 . . .

. . . . . . . .

. . 601 961 . .

SCREW, .312-18 x 2.25hexhd pln gr 5pld

. . . 4

. . . 29 . . .

. . . . . . . .

. . . 602 211 . .

WASHER, lock .318 ID x 0.586

. . . 2

. . . 30 . . .

. . . . . . . .

. . 139 341 . .

WASHER, exciter

. . . 4

. . . 31 . . .

. . . . . . . .

. . *190 823 . .

BRUSH, contact

. . . 3

. . . 32 . . .

. . . . . . . .

. . 208 469 . .

CLIP, spring

. . . 3

. . . 33 . . .

. . . . . . . .

. . 189 142 . .

BRUSHHOLDER ASSEMBLY, gen

. . . 1

. . . 34 . . .

. . . . . . . .

. . 602 242 . .

WASHER, flat .375idx0.875odx.083t stl pld

. . . 2

. . . 35 . . .

. . . . . . . .

. . . 602 211 . .

WASHER, Lock .318idx0.586odx.078t Stl Pld Split.312

. . . 2

. . . 36 . . .

. . . . . . . .

. . 604 534 . .

SCREW, 312−18X1.25 hex hd−pln gr5 pld

. . .2

. . .

. . . . . .

. . . . . . . .

. . 190 259 . .

HARNESS, brush (consisting of)

. . . 1

. . .

. . . . . .

. PLG1 .

. . 168 071 . . .

. CONNECTOR, (kit) rect univ 084 9P/S 3 row plug cable lkg

. . . 1

. . .

. . . . . .

. . . . . . . .

. . 187 651 . . .

. SEAL, wire univ 9P/S 3 row

. . . 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.

♦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.

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Contents Processes OM-491Description From Miller to You Table of Contents 11-2 11-111-3 Arc Welding Hazards Symbol UsageEngine Hazards Compressed Air Hazards Radiation can cause interference Principal Safety StandardsCalifornia Proposition 65 Warnings EMF InformationLES Fumées ET LES GAZ peuvent être dangereux Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation UN Choc Électrique peut tuerLE Bruit peut affecter l’ouïe LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux DES Pièces Chaudes peuvent provoquer des brûlures graves’AIR Comprimé peut provoque r des blessures ’EXPLOSION DE LA Batterie peutDES Organes Mobiles peuvent provoquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendieInformation sur les champs électromagnétiques Principales normes de sécuritéSymbols And Definitions − Specifications− Definitions Dimensions, Weights, And Operating Angles Weld, Power, And Engine Specifications55−90 Volt-Ampere Curves For CC ModelsVolt-Ampere Curves For CC/CV Models Stick ModeMIG Mode TIG Mode100% Duty Cycle At 400 Amperes Exceeding duty cycle can damage unit and void warrantyFuel Consumption Duty Cycle And Overheating20 kVA/kW Three-Phase AC Output No Weld Load AC Generator Power CurveOptional Three-Phase Generator Curves 12 kVA/kW Single-Phase AC Output No Weld LoadAirflow Clearance − InstallationInstalling Welding Generator Movement Location GroundingTo Bolt Unit In Place Mounting Welding GeneratorSupporting The Unit Mounting SurfaceInstalling Exhaust Pipe Using Lifting EyeStop engine and let cool Read and follow all instruc Activating The Dry Charge Battery If ApplicableCharger Connect Negative − Cable Last Connecting The BatteryOil Coolant Recovery TankEngine Prestart Checks Fuel Do not use gasoline. Gasoline will damage engineSelecting Weld Cable Sizes Connecting To Weld Output TerminalsSocket Connecting To Remote 14 Receptacle RC14 On CC/CV ModelsFront Panel Controls For CC Models See Section − Operating Welding Generator − CC ModelsTo Start Engine Indicator LightsDo not switch under load Engine Starting ControlsRemote Amperage Control On CC Models Optional Connect optional remote control to RC13 see Section ExampleWeld Control/Arc Condition Information Label OM-491 Front Panel Controls For CC/CV Models See Section − Operating Welding Generator − CC/CV ModelsVoltage/Amperage Adjust Switch And Remote 14 Receptacle Voltage/Amperage Adjust ControlProcess/Contactor Switch Settings Process/Contactor Switch On CC/CV ModelsProcess Remote Voltage/Amperage Control On CC/CV Models OptionalExample Combination Remote Amperage Control Stick Set Remote Set RangeVolt And 240 Volt Receptacles − Operating Auxiliary EquipmentThree-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 1000 h Every 400 hEvery 500 h Every 800 hMaintenance Label Do not clean housing with air hose Servicing Air CleanerBy the warranty To clean air filterReinstall cleanout plug Tools Needed 3/8 Inspecting And Cleaning Optional Spark Arrestor MufflerEngine Speed No Load Adjusting Engine SpeedModels With Automatic Idle Optional Idle Speed Adjustment Weld/Power Speed AdjustmentServicing Fuel And Lubrication Systems Stop engine Overload ProtectionCondition Diagnosing Causes Of Engine Fault ShutdownsDiagnostic Checks While Running Start Engine With No Load AppliedWelding − CC Models TroubleshootingWelding − CC/CV Models Optional Three-Phase Generator Power CC/CV Models Only Standard Generator PowerEngine Air in fuel system. See engine manual Shutdown switch is released OutTemperature is too high see Sections 5-7and Ing harness and componentsReturn To Table Of Contents Circuit Diagram For CC Welding Generator − Electrical Diagrams215 304-A Circuit Diagram For CC/CV Welding Generator 215 305-A Wetstacking − RUN-IN ProcedureWelding Generator From flammables Do not Perform Run-In Procedure Using Load BankProcedure at less than Stop engine Do not touch hot exhaustDo not perform run-in Run-In Procedure Using Resistance GridBank/grid From flammablesSelecting Equipment − Generator Power GuidelinesGrounding Generator To Truck Or Trailer Frame Amperes x Volts = Watts Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Earth ground if supplyingFarm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Industrial Motors Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentKVA/HP x HP x Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsWork like a Pro Typical Connections To Supply Standby PowerCurrent Load Watts Amperes Selecting Extension Cord Use Shortest Cord Possible114 113 110 109 116 − Parts List105 CC only 102 106 107 100 115 114 Big Blue 502, 602 OnlyDia 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 -1Item Panel, Front w/Components − CC/CV ModelsPC6 192 Generator Generator -1Item Main Rectifier Assembly Your distributor also gives ServiceSupport Transportation Department Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s

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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