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Miller Electric
Big Blue 402P, Big Blue 502P, Big Blue 602P manual
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Contents
Main
Big Blue 402P, 502P, 602P
From Miller to You
Page
TABLE OF CONTENTS
OM-491 Page 1
Return To Table Of Contents
SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING
Warning: Protect yourself and others from injury read and follow these precautions.
1-1. Symbol Usage
Marks a special safety message.
1-2. Arc Welding Hazards
1-3. Engine Hazards
BATTERY EXPLOSION can BLIND.
FUEL can cause fire or explosion.
MOVING PARTS can cause injury.
OM-491 Page 3
1-4. Compressed Air Hazards
cause serious injury or death.
COMPRESSED AIR can cause injury
HOSES can cause injury.
HOT METAL from air arc cutting and gouging can cause fire or explosion.
1-6. California Proposition 65 Warnings
1-7. Principal Safety Standards
1-8. EMF Information
OM-491 Page 5 Revenez la table des matires
SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION
Avertissement: Protgez vous et les autres des blessures lisez et suivez ces prcautions.
2-1. Signification des symboles
Identifie un message de scurit particulier.
2-2. Dangers relatifs au soudage larc
2-3. Dangers existant en relation avec le moteur
LES ACCUMULATIONS DE GAZ ris- quent de provoquer des blessures ou mme la mort.
LACIDE DE LA BATTERIE peut pro- voquer d e s brlures dans les YEUX et sur la PEAU.
OM-491 Page 7 Revenez la table des matires
LEXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE.
2-4. Dangers lis lair comprim
RESPIRER LAIR COMPRIM peut pro
voquer des blessures graves ou cause
la mort.
LAIR COMPRIM peut provoque
2-6. Principales normes de scurit
2-7. Information sur les champs lectromagntiques
SECTION 3 DEFINITIONS
3-1. Symbols And Definitions
NOTE
A
SECTION 4 SPECIFICATIONS
A CC/DC model is shown in this manual.
4-1. Weld, Power, And Engine Specifications
Welding Mode Weld Output
Output
Range Rated W elding
Maximum Open- Circuit Voltage
4-3. Volt-Ampere Curves For CC Models
4-4. Volt-Ampere Curves For CC/CV Models
4-5. Fuel Consumption
4-6. Duty Cycle And Overheating
4-7. AC Generator Power Curve
4-8. Optional Three-Phase Generator Curves
SECTION 5 INSTALLATION
5-1. Installing Welding Generator
5-2. Mounting W elding Generator
5-3. Using Lifting Eye
5-4. Installing Exhaust Pipe
5-5. Activating The Dry Charge Battery (If Applicable)
+
Notes
5-7. Engine Prestart Checks
5-8. Connecting To Weld Output Terminals
5-9. Selecting Weld Cable Sizes*
5-10. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models
5-11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models
115 VOLTS AC
OUTPUT
24 VOLTS AC
SECTION 6 OPERATING WELDING GENERATOR CC MODELS
6-1. Front Panel Controls For CC Models (See Section 6-2 )
6-2. Description Of Front Panel Controls For CC Models (See Section 6-1)
6-3. Remote Amperage Control On CC Models (Optional)
6-4. Weld Control/Arc Condition Information Label
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SECTION 7 OPERATING WELDING GENERATOR CC/CV MODELS
7-1. Front Panel Controls For CC/CV Models (See Section 7-2 )
7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1)
7-3. Process/Contactor Switch On CC/CV Models
Process/Contactor Switch Settings
7-4. Remote Voltage/Amperage Control On CC/CV Models (Optional)
SECTION 8 OPERATING AUXILIARY EQUIPMENT
8-1. 120 Volt And 240 Volt Receptacles
8-2. Connecting To Optional Three-Phase Generator (CC/CV Models Only)
8-3. Optional Generator Power Receptacles
SECTION 9 MAINTENANCE & TROUBLESHOOTING
9-1. Routine Maintenance
Continued on next page.
Note
Every 8 h
Every 400 h
Every 500 h
Every 800 h
Every 1000 h
Page
9-3. Servicing Air Cleaner
9-4. Inspecting And Cleaning Optional Spark Arrestor Muffler
9-5. Adjusting Engine Speed
9-6. Servicing Fuel And Lubrication Systems
9-7. Overload Protection
9-8. Diagnosing Causes Of Engine Fault Shutdowns
9-9. Troubleshooting
A. Welding CC Models
B. Welding CC/CV Models
C. Standard Generator Power
D. Optional Three-Phase Generator Power (CC/CV Models Only)
E. Engine
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SECTION 11 RUN-IN PROCEDURE
11-1. Wetstacking
11-2. Run-In Procedure Using Load Bank
11-3. Run-In Procedure Using Resistance Grid
+
SECTION 12 GENERATOR POWER GUIDELINES
1
NOTE
12-1. Selecting Equipment
2-2. Grounding Generator To Truck Or Trailer Frame
12-3. Grounding When Supplying Building Systems
12-4. How Much Power Does Equipment Require?
12-5. Approximate Power Requirements For Industrial Motors
12-6. Approximate Power Requirements For Farm/Home Equipment
12-7. Approximate Power Requirements For Contractor Equipment
12-8. Power Required To Start Motor
12-9. How Much Power Can Generator Supply?
12-10.Typical Connections To Supply Standby Power
Notes
Work like a Pro!
Pros weld and cut safely. Read the safety rules at the beginning of this manual.
12-11. Selecting Extension Cord (Use Shortest Cord Possible)
SECTION 13 PARTS LIST
Figure 13-1. Main Assembly
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Warranty Questions?
Call 1-800-4-A-MILLER for your local Miller distributor.
Effective January 1, 2003 (Equipment with a serial number preface of LC or newer)
Please complete and retain with your personal records.
For Service
Always provide Model Name and Serial/Style Number.
Owners Record