Manuals / Miller Electric / Power Tools / Welding System

Miller Electric Big Blue 502P Maintenance & Troubleshooting, Routine Maintenance, Every 8 h, Fuel

Models: Big Blue 402P

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SECTION 9 − MAINTENANCE & TROUBLESHOOTING

9-1. Routine Maintenance

Note	Follow the storage procedure in the engine owner’s manual if the unit will not be used for an
	extended period.

Recycle engine

fluids.

YStop engine before maintaining.

.See Engine Manual and Maintenance Label for important start-up, service, and storage information. Service unit more often if used in severe conditions.

*To be done by Factory Authorized Service Agent.

Every 8 h

Wipe

Spills.

Coolant

Full

OIL

Full

Check Fluid	FUEL	Drain Water
	WATER
Levels. See		From Fuel

Section 5-7.		System.

Every 50 h

Clean Air Filter.

See Section 9-3.

Clean And

Tighten

Weld

Terminals.

Every 100 h

Check air cleaner hoses for cracks and loose clamps.

Clean And

Tighten

Battery

Connections.

	Every 200 h
1/2 in.	Check Belt
(13 mm)	Tension.

Every 250 h

Replace

Unreadable

Labels.

Check And

Clean Spark

Arrestor. See

Section 9-4.

Continued on next page.

OM-491 Page 34

Return To Table Of Contents

Page 38

Image 38

Miller Electric Big Blue 502P Maintenance & Troubleshooting, Routine Maintenance, Every 8 h, Every 50 h, Every 100 h, Fuel

Contents

Processes Big BlueR 402P, 502P, 602POM-491 DescriptionFrom Miller to You TABLE OF CONTENTS SECTION 5 − INSTALLATIONWARRANTY TABLE OF CONTENTSOPTIONS AND ACCESSORIES SECTIONSECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1-1. Symbol Usage1-2. Arc Welding Hazards Means “Note” not safety relatedReturn To Table Of Contents 1-3. Engine HazardsBATTERY EXPLOSION can BLIND WELDING can cause fire or explosionSTEAM AND HOT COOLANT can burn 1-5. Additional Symbols For Installation, Operation, And Maintenance1-4. Compressed Air Hazards ENGINE EXHAUST GASES can kill1-8. EMF Information 1-7. Principal Safety Standards1-6. California Proposition 65 Warnings READ INSTRUCTIONS2-2. Dangers relatifs au soudage à l’arc 2-1. Signification des symbolesSECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION UN CHOC ÉLECTRIQUE peut tuerDES PARTICULES VOLANTES peuvent blesser les yeux 2-3. Dangers existant en relation avec le moteurLE SOUDAGE peut provoquer un in- cendie ou une explosion DES PIÈCES CHAUDES peuvent provoquer des brûlures gravesDES ORGANES MOBILES peuvent provoquer des blessures 2-4. Dangers liés à l’air compriméL’EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE LA CHALEUR DU MOTEUR peut pro- voquer un incendieLE SURCHAUFFEMENT peut endom- mager le moteur électrique 2-6. Principales normes de sécurité2-7. Information sur les champs électromagnétiques LES ÉTINCELLES VOLANTES ris- quent de provoquer des blessuresSECTION 3 − DEFINITIONS SECTION 4 − SPECIFICATIONS3-1. Symbols And 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−MaxB. MIG Mode 4-4. Volt-Ampere Curves For CC/CV ModelsA. Stick Mode C. TIG Mode1800 RPM IDLE 4-5. Fuel Consumption4-6. Duty Cycle And Overheating A. 12 kVA/kW Single-Phase AC Output No Weld Load 4-7. AC Generator Power Curve4-8. Optional Three-Phase Generator Curves B. 20 kVA/kW Three-Phase AC Output No Weld LoadReturn To Table Of Contents SECTION 5 − INSTALLATION5-1. Installing Welding Generator MovementSupporting The Unit 5-2. Mounting Welding GeneratorUsing Mounting Brackets Inadequate supportReturn To Table Of Contents 5-3. Using Lifting Eye5-4. Installing Exhaust Pipe Y Stop engine and let coolReturn To Table Of Contents 5-5. Activating The Dry Charge Battery If ApplicableWhen electrolyte is low, add Y Read and follow all instrucReturn To Table Of Contents 5-6. Connecting The BatteryReinstall cover after connecting battery Y Connect Negative − Cable LastCoolant Recovery Tank 5-7. Engine Prestart ChecksCheck radiator coolant level when fluid is low in recovery tank Return To Table Of Contents5-8. Connecting To Weld Output Terminals 5-9. Selecting Weld Cable SizesREMOTE 5-11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models24 VOLTS AC OUTPUTSECTION 6 − OPERATING WELDING GENERATOR − CC MODELS 6-1. Front Panel Controls For CC Models See SectionReturn To Table Of Contents Y Stop engine and fix trouble if Battery Charging light goes on 6-2. Description Of Front Panel Controls For CC Models See SectionEngine Indicator Lights Y Do not switch under loadReturn To Table Of Contents 6-3. Remote Amperage Control On CC Models Optional6-4. Weld Control/Arc Condition Information Label 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 Y Stop engine and fix trouble if Battery Charging light goes on 7-2. Description Of Front Panel Controls For CC/CV Models See SectionEngine Indicator Lights Y Do not switch under loadProcess/Contactor Switch 7-3. Process/Contactor Switch On CC/CV ModelsProcess/Contactor Switch Settings 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 rized Service Agent SECTION 8 − OPERATING AUXILIARY EQUIPMENT8-1. 120 Volt And 240 Volt Receptacles powerSingle-Phase Generator Power 8-2. Connecting To Optional Three-Phase Generator CC/CV Models OnlySingle-Phase Power Connection Three-Phase Power ConnectionReturn To Table Of Contents 8-3. Optional Generator Power ReceptaclesGenerator power is not af- fected by weld output European ReceptacleEvery 8 h SECTION 9 − MAINTENANCE & TROUBLESHOOTING9-1. Routine Maintenance Every 50 hEvery 800 h Every 400 hEvery 500 h Every 1000 hOM-491 Page Maintenance LabelReturn To Table Of Contents The air cleaner primary element can 9-3. Servicing Air Cleanerby the warranty To clean air filterY Stop engine and let cool 9-4. Inspecting And Cleaning Optional Spark Arrestor MufflerY Stop engine and let cool 802 160-E / Ref. 202Weld/Power Speed Adjustment 9-5. Adjusting Engine SpeedModels With Automatic Idle Optional Idle Speed Adjustment Return To Table Of ContentsTo change oil and filter 9-6. Servicing Fuel And Lubrication SystemsY Stop engine and let cool To drain water from fuel systemmore serious problem exists 9-7. Overload ProtectionWhen a circuit breaker or fuse Service AgentDiagnostic Checks While Running 9-8. Diagnosing Causes Of Engine Fault ShutdownsPre-Start Diagnostic Checks Battery Charging, Fuel, And Temperature Lights OffA. Welding − CC Models 9-9. TroubleshootingReturn To Table Of Contents Remedy B. Welding − CC/CV ModelsTrouble Return To Table Of Contents C. Standard Generator PowerD. Optional Three-Phase Generator Power CC/CV Models Only 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. WetstackingReturn To Table Of Contents 11-2. Run-In Procedure Using Load Bankprocedure at less than Y Stop engineStop engine 11-3. Run-In Procedure Using Resistance Gridprocedure at less than Y Do not touch hot exhaust12-2. Grounding Generator To Truck Or Trailer Frame SECTION 12 − GENERATOR POWER GUIDELINES12-1. Selecting Equipment has this symbolearth ground if supplying 12-3. Grounding When Supplying Building Systems12-4. How Much Power Does Equipment Require? Use ground device as stated in electrical codesReturn To Table Of Contents 12-5. Approximate Power Requirements For Industrial Motors12-6. Approximate Power Requirements For Farm/Home Equipment Industrial MotorsRating 12-7. Approximate Power Requirements For Contractor EquipmentContractor Starting WattsSingle-Phase Induction Motor Starting Requirements 12-8. Power Required To Start Motor12-9. How Much Power Can Generator Supply? Return To Table Of Contents12-10. Typical Connections To Supply Standby Power Work like a ProCord Lengths for 120 Volt Loads 12-11. Selecting Extension Cord Use Shortest Cord PossibleReturn To Table Of Contents 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 Hardware is common and Figure 13-7. Main Rectifier AssemblyFigure 13-7. Main Rectifier Assembly Figure 13-1 Item not available unless listedCall 1-800-4-A-MILLER for your local Miller distributor Warranty Questions?Service SupportPlease complete and retain with your personal records For ServiceOwner’s Record Always provide Model Name and Serial/Style Number

SECTION 9 − MAINTENANCE & TROUBLESHOOTING

9-1. Routine Maintenance

extended period.

YStop engine before maintaining.

Every 8 h

FUEL

WATER

Every 50 h

Every 100 h

Every 200 h

Every 250 h

Continued on next page.