Manuals / Miller Electric / Power Tools / Welding System

Miller Electric Big Blue 502P Mounting Welding Generator, Supporting The Unit, Inadequate support

Models: Big Blue 402P

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5-2. Mounting Welding Generator

5-2. Mounting Welding Generator

Supporting The Unit

2

OR

1

Inadequate support.

YDo not use flexible mounts.

1

Using Mounting Brackets

2

Welding Unit In Place

Bolting Unit In Place

3

2

4

Tools Needed:

9/16 in

YDo not weld on base. Weld- ing on base can cause fuel tank fire or explosion. Weld only on the four mounting brackets or bolt unit down.

YDo not mount unit by sup- porting the base only at the four mounting brackets. Use cross-supports to ade- quately support unit and pre- vent damage to base.

Mounting Surface:

1Cross-Supports

2Mounting Brackets (Supplied)

Mount unit on flat surface or use cross-supports to support base. Secure unit with mounting brack- ets.

31/2 in Bolt And Washer (Minimum − Not Supplied)

43/8-16 x 1 in Screws (Supplied)

To Bolt Unit In Place:

Remove hardware securing the four mounting brackets to the base. Reverse brackets and reattach to base with original hardware.

Mount unit to truck or trailer with 1/2 in (12 mm) or larger hardware (not supplied).

To Weld Unit In Place:

Weld unit to truck or trailer only at the four mounting brackets.

install3 6/03 803 274 / 190 250-A / 803 231

OM-491 Page 16

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Miller Electric Big Blue 502P Mounting Welding Generator, Supporting The Unit, Inadequate support, Using Mounting Brackets

Contents

Big BlueR 402P, 502P, 602P OM-491Processes DescriptionFrom Miller to You TABLE OF CONTENTS SECTION 5 − INSTALLATIONTABLE OF CONTENTS OPTIONS AND ACCESSORIESWARRANTY SECTION1-1. Symbol Usage 1-2. Arc Welding HazardsSECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING Means “Note” not safety related1-3. Engine Hazards BATTERY EXPLOSION can BLINDReturn To Table Of Contents WELDING can cause fire or explosion1-5. Additional Symbols For Installation, Operation, And Maintenance 1-4. Compressed Air HazardsSTEAM AND HOT COOLANT can burn ENGINE EXHAUST GASES can kill1-7. Principal Safety Standards 1-6. California Proposition 65 Warnings1-8. EMF Information READ INSTRUCTIONS2-1. Signification des symboles SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION2-2. Dangers relatifs au soudage à l’arc UN CHOC ÉLECTRIQUE peut tuer2-3. Dangers existant en relation avec le moteur LE SOUDAGE peut provoquer un in- cendie ou une explosionDES PARTICULES VOLANTES peuvent blesser les yeux DES PIÈCES CHAUDES peuvent provoquer des brûlures graves2-4. Dangers liés à l’air comprimé L’EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLEDES ORGANES MOBILES peuvent provoquer des blessures LA CHALEUR DU MOTEUR peut pro- voquer un incendie2-6. Principales normes de sécurité 2-7. Information sur les champs électromagnétiquesLE SURCHAUFFEMENT peut endom- mager le moteur électrique LES ÉTINCELLES VOLANTES ris- quent de provoquer des blessuresSECTION 4 − SPECIFICATIONS 3-1. Symbols And DefinitionsSECTION 3 − DEFINITIONS Return To Table Of Contents4-1. Weld, Power, And Engine Specifications 4-2. Dimensions, Weights, And Operating Angles4-3. Volt-Ampere Curves For CC Models 300−Max4-4. Volt-Ampere Curves For CC/CV Models A. Stick ModeB. MIG Mode C. TIG Mode1800 RPM IDLE 4-5. Fuel Consumption4-6. Duty Cycle And Overheating 4-7. AC Generator Power Curve 4-8. Optional Three-Phase Generator CurvesA. 12 kVA/kW Single-Phase AC Output No Weld Load B. 20 kVA/kW Three-Phase AC Output No Weld LoadSECTION 5 − INSTALLATION 5-1. Installing Welding GeneratorReturn To Table Of Contents Movement5-2. Mounting Welding Generator Using Mounting BracketsSupporting The Unit Inadequate support5-3. Using Lifting Eye 5-4. Installing Exhaust PipeReturn To Table Of Contents Y Stop engine and let cool5-5. Activating The Dry Charge Battery If Applicable When electrolyte is low, addReturn To Table Of Contents Y Read and follow all instruc5-6. Connecting The Battery Reinstall cover after connecting batteryReturn To Table Of Contents Y Connect Negative − Cable Last5-7. Engine Prestart Checks Check radiator coolant level when fluid is low in recovery tankCoolant Recovery Tank Return To Table Of Contents5-8. Connecting To Weld Output Terminals 5-9. Selecting Weld Cable Sizes5-11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models 24 VOLTS ACREMOTE OUTPUTSECTION 6 − OPERATING WELDING GENERATOR − CC MODELS 6-1. Front Panel Controls For CC Models See SectionReturn To Table Of Contents 6-2. Description Of Front Panel Controls For CC Models See Section Engine Indicator LightsY Stop engine and fix trouble if Battery Charging light goes on Y Do not switch under load6-3. Remote Amperage Control On CC Models Optional 6-4. Weld Control/Arc Condition Information LabelReturn To Table Of Contents Set weld controls as shown toReturn To Table Of Contents OM-491 PageSECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS 7-1. Front Panel Controls For CC/CV Models See SectionReturn To Table Of Contents 7-2. Description Of Front Panel Controls For CC/CV Models See Section Engine Indicator LightsY Stop engine and fix trouble if Battery Charging light goes on Y Do not switch under load7-3. Process/Contactor Switch On CC/CV Models Process/Contactor Switch SettingsProcess/Contactor Switch switch is in an Electrode HotExample Combination Remote Amperage Control TIG 7-4. Remote Voltage/Amperage Control On CC/CV Models OptionalExample Combination Remote Amperage Control Stick SECTION 8 − OPERATING AUXILIARY EQUIPMENT 8-1. 120 Volt And 240 Volt Receptaclesrized Service Agent power8-2. Connecting To Optional Three-Phase Generator CC/CV Models Only Single-Phase Power ConnectionSingle-Phase Generator Power Three-Phase Power Connection8-3. Optional Generator Power Receptacles Generator power is not af- fected by weld outputReturn To Table Of Contents European ReceptacleSECTION 9 − MAINTENANCE & TROUBLESHOOTING 9-1. Routine MaintenanceEvery 8 h Every 50 hEvery 400 h Every 500 hEvery 800 h Every 1000 hOM-491 Page Maintenance LabelReturn To Table Of Contents 9-3. Servicing Air Cleaner by the warrantyThe air cleaner primary element can To clean air filter9-4. Inspecting And Cleaning Optional Spark Arrestor Muffler Y Stop engine and let coolY Stop engine and let cool 802 160-E / Ref. 2029-5. Adjusting Engine Speed Models With Automatic Idle Optional Idle Speed AdjustmentWeld/Power Speed Adjustment Return To Table Of Contents9-6. Servicing Fuel And Lubrication Systems Y Stop engine and let coolTo change oil and filter To drain water from fuel system9-7. Overload Protection When a circuit breaker or fusemore serious problem exists Service Agent9-8. Diagnosing Causes Of Engine Fault Shutdowns Pre-Start Diagnostic ChecksDiagnostic Checks While Running Battery Charging, Fuel, And Temperature Lights OffA. Welding − CC Models 9-9. TroubleshootingReturn To Table Of Contents Remedy B. Welding − CC/CV ModelsTrouble C. Standard Generator Power D. Optional Three-Phase Generator Power CC/CV Models OnlyReturn To Table Of Contents E. EngineEngine starts, but stops when Magnetic Return To Table Of Contents OM-491 PageReturn To Table Of Contents SECTION 10 − ELECTRICAL DIAGRAMSFigure 10-1. Circuit Diagram For CC Welding Generator 215 304-A Return To Table Of ContentsOM-491 Page OM-491 Page Figure 10-2. Circuit Diagram For CC/CV Welding GeneratorReturn To Table Of Contents 215 305-A Return To Table Of ContentsOM-491 Page SECTION 11 − RUN-IN PROCEDURE 11-1. Wetstacking11-2. Run-In Procedure Using Load Bank procedure at less thanReturn To Table Of Contents Y Stop engine11-3. Run-In Procedure Using Resistance Grid procedure at less thanStop engine Y Do not touch hot exhaustSECTION 12 − GENERATOR POWER GUIDELINES 12-1. Selecting Equipment12-2. Grounding Generator To Truck Or Trailer Frame has this symbol12-3. Grounding When Supplying Building Systems 12-4. How Much Power Does Equipment Require?earth ground if supplying Use ground device as stated in electrical codes12-5. Approximate Power Requirements For Industrial Motors 12-6. Approximate Power Requirements For Farm/Home EquipmentReturn To Table Of Contents Industrial Motors12-7. Approximate Power Requirements For Contractor Equipment ContractorRating Starting Watts12-8. Power Required To Start Motor 12-9. How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements Return To Table Of Contents12-10. Typical Connections To Supply Standby Power Work like a Pro12-11. Selecting Extension Cord Use Shortest Cord Possible Return To Table Of ContentsCord Lengths for 120 Volt Loads CurrentSECTION 13 − PARTS LIST Figure 13-1. Main Assembly46 FIG Return To Table Of ContentsBig Blue 502, 602 Only Figure 13-1. Main Assembly Figure 13-1. Main Assembly Continued Figure 13-1. Main Assembly Continued CC CV802 551-E Figure 13-2. Control Box Assembly − CC ModelsFigure13-2. Control Box Assembly − CC Models Figure 13-1 Item 802 360-D Figure 13-2. Control Box Assembly − CC Models ContinuedFigure 13-3. Control Box Assembly − CC/CV Models Figure 13-3. Control Box Assembly − CC/CV Models Figure 13-1 Item 802 266-D Figure 13-4. Panel, Front w/Components − CC ModelsFigure 13-4. Panel, Front w/Components − CC Models Figure 13-1 Item Figure 13-4. Panel, Front w/Components − CC Models Continued OptionalFigure 13-5. Panel, Front w/Components − CC/CV Models 802 332-FFigure 13-5. Panel, Front w/Components − CC/CV Models Continued 802 267-B Figure 13-5. Panel, Front w/Components − CC/CV Models ContinuedFigure 13-6. Generator Figure 13-6. Generator Figure 13-1 Item Figure 13-7. Main Rectifier Assembly Figure 13-7. Main Rectifier Assembly Figure 13-1 ItemHardware is common and not available unless listedWarranty Questions? ServiceCall 1-800-4-A-MILLER for your local Miller distributor SupportFor Service Owner’s RecordPlease complete and retain with your personal records Always provide Model Name and Serial/Style Number