Manuals / Miller Electric / Power Tools / Welding System

Miller Electric Big Blue 402P Every 400 h, Every 500 h, Every 800 h, Every 1000 h, Fuel, Sludge

Models: Big Blue 402P

1 82

Page 39

		Every 400 h
Check Radiator		Change Oil. See		Change Oil
Fluid Level. See		Section 9-6.		Filter. See
Section 5-7.				Section 9-6.
	Change Fuel		Check
	Filters. See		Valve
	Section 9-6.		Clearance.*
		Every 500 h
		Repair Or
		Replace
		Damaged
		Cables.
		Every 800 h
		Clean/Set
		Injectors.*
		Every 1000 h
	Blow Out Or		FUEL	Drain Sludge
	Vacuum Inside.		FUEL
OR
				From Fuel
	During Heavy	SLUDGE		From Fuel
	During Heavy			Tank. See
	Service,

				Section 9-6.
	Clean Monthly.			Section 9-6.
	Clean Monthly.
		Service Welding Generator
		Brushes And Slip Rings. Service
		More Often In Dirty Conditions.*

Return To Table Of Contents

OM-491 Page 35

Page 39

Image 39

Miller Electric Big Blue 402P, Big Blue 602P manual Every 400 h, Every 500 h, Every 800 h, Every 1000 h, Fuel, Sludge

Contents

Description Big BlueR 402P, 502P, 602POM-491 ProcessesFrom Miller to You SECTION 5 − INSTALLATION TABLE OF CONTENTSSECTION TABLE OF CONTENTSOPTIONS AND ACCESSORIES WARRANTYMeans “Note” not safety related 1-1. Symbol Usage1-2. Arc Welding Hazards SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USINGWELDING can cause fire or explosion 1-3. Engine HazardsBATTERY EXPLOSION can BLIND Return To Table Of ContentsENGINE EXHAUST GASES can kill 1-5. Additional Symbols For Installation, Operation, And Maintenance1-4. Compressed Air Hazards STEAM AND HOT COOLANT can burnREAD INSTRUCTIONS 1-7. Principal Safety Standards1-6. California Proposition 65 Warnings 1-8. EMF InformationUN CHOC ÉLECTRIQUE peut tuer 2-1. Signification des symbolesSECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 2-2. Dangers relatifs au soudage à l’arcDES PIÈCES CHAUDES peuvent provoquer des brûlures graves 2-3. Dangers existant en relation avec le moteurLE SOUDAGE peut provoquer un in- cendie ou une explosion DES PARTICULES VOLANTES peuvent blesser les yeuxLA CHALEUR DU MOTEUR peut pro- voquer un incendie 2-4. Dangers liés à l’air compriméL’EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE DES ORGANES MOBILES peuvent provoquer des blessuresLES ÉTINCELLES VOLANTES ris- quent de provoquer des blessures 2-6. Principales normes de sécurité2-7. Information sur les champs électromagnétiques LE SURCHAUFFEMENT peut endom- mager le moteur électriqueReturn To Table Of Contents SECTION 4 − SPECIFICATIONS3-1. Symbols And Definitions SECTION 3 − DEFINITIONS4-2. Dimensions, Weights, And Operating Angles 4-1. Weld, Power, And Engine Specifications300−Max 4-3. Volt-Ampere Curves For CC ModelsC. TIG Mode 4-4. Volt-Ampere Curves For CC/CV ModelsA. Stick Mode B. MIG Mode4-5. Fuel Consumption 4-6. Duty Cycle And Overheating1800 RPM IDLE B. 20 kVA/kW Three-Phase AC Output No Weld Load 4-7. AC Generator Power Curve4-8. Optional Three-Phase Generator Curves A. 12 kVA/kW Single-Phase AC Output No Weld LoadMovement SECTION 5 − INSTALLATION5-1. Installing Welding Generator Return To Table Of ContentsInadequate support 5-2. Mounting Welding GeneratorUsing Mounting Brackets Supporting The UnitY Stop engine and let cool 5-3. Using Lifting Eye5-4. Installing Exhaust Pipe Return To Table Of ContentsY Read and follow all instruc 5-5. Activating The Dry Charge Battery If ApplicableWhen electrolyte is low, add Return To Table Of ContentsY Connect Negative − Cable Last 5-6. Connecting The BatteryReinstall cover after connecting battery Return To Table Of ContentsReturn To Table Of Contents 5-7. Engine Prestart ChecksCheck radiator coolant level when fluid is low in recovery tank Coolant Recovery Tank5-9. Selecting Weld Cable Sizes 5-8. Connecting To Weld Output TerminalsOUTPUT 5-11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models24 VOLTS AC REMOTE6-1. Front Panel Controls For CC Models See Section Return To Table Of ContentsSECTION 6 − OPERATING WELDING GENERATOR − CC MODELS Y Do not switch under load 6-2. Description Of Front Panel Controls For CC Models See SectionEngine Indicator Lights Y Stop engine and fix trouble if Battery Charging light goes onSet weld controls as shown to 6-3. Remote Amperage Control On CC Models Optional6-4. Weld Control/Arc Condition Information Label Return To Table Of ContentsOM-491 Page Return To Table Of Contents7-1. Front Panel Controls For CC/CV Models See Section Return To Table Of ContentsSECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS Y Do not switch under load 7-2. Description Of Front Panel Controls For CC/CV Models See SectionEngine Indicator Lights Y Stop engine and fix trouble if Battery Charging light goes onswitch is in an Electrode Hot 7-3. Process/Contactor Switch On CC/CV ModelsProcess/Contactor Switch Settings Process/Contactor Switch7-4. Remote Voltage/Amperage Control On CC/CV Models Optional Example Combination Remote Amperage Control StickExample Combination Remote Amperage Control TIG power SECTION 8 − OPERATING AUXILIARY EQUIPMENT8-1. 120 Volt And 240 Volt Receptacles rized Service AgentThree-Phase Power Connection 8-2. Connecting To Optional Three-Phase Generator CC/CV Models OnlySingle-Phase Power Connection Single-Phase Generator PowerEuropean Receptacle 8-3. Optional Generator Power ReceptaclesGenerator power is not af- fected by weld output Return To Table Of ContentsEvery 50 h SECTION 9 − MAINTENANCE & TROUBLESHOOTING9-1. Routine Maintenance Every 8 hEvery 1000 h Every 400 hEvery 500 h Every 800 hMaintenance Label Return To Table Of ContentsOM-491 Page To clean air filter 9-3. Servicing Air Cleanerby the warranty The air cleaner primary element can802 160-E / Ref. 202 9-4. Inspecting And Cleaning Optional Spark Arrestor MufflerY Stop engine and let cool Y Stop engine and let coolReturn To Table Of Contents 9-5. Adjusting Engine SpeedModels With Automatic Idle Optional Idle Speed Adjustment Weld/Power Speed AdjustmentTo drain water from fuel system 9-6. Servicing Fuel And Lubrication SystemsY Stop engine and let cool To change oil and filterService Agent 9-7. Overload ProtectionWhen a circuit breaker or fuse more serious problem existsBattery Charging, Fuel, And Temperature Lights Off 9-8. Diagnosing Causes Of Engine Fault ShutdownsPre-Start Diagnostic Checks Diagnostic Checks While Running9-9. Troubleshooting Return To Table Of ContentsA. Welding − CC Models B. Welding − CC/CV Models TroubleRemedy E. Engine C. Standard Generator PowerD. Optional Three-Phase Generator Power CC/CV Models Only Return To Table Of ContentsEngine starts, but stops when Magnetic OM-491 Page Return To Table Of ContentsSECTION 10 − ELECTRICAL DIAGRAMS Figure 10-1. Circuit Diagram For CC Welding GeneratorReturn To Table Of Contents Return To Table Of Contents OM-491 Page215 304-A Figure 10-2. Circuit Diagram For CC/CV Welding Generator Return To Table Of ContentsOM-491 Page Return To Table Of Contents OM-491 Page215 305-A 11-1. Wetstacking SECTION 11 − RUN-IN PROCEDUREY Stop engine 11-2. Run-In Procedure Using Load Bankprocedure at less than Return To Table Of ContentsY Do not touch hot exhaust 11-3. Run-In Procedure Using Resistance Gridprocedure at less than Stop enginehas this symbol SECTION 12 − GENERATOR POWER GUIDELINES12-1. Selecting Equipment 12-2. Grounding Generator To Truck Or Trailer FrameUse ground device as stated in electrical codes 12-3. Grounding When Supplying Building Systems12-4. How Much Power Does Equipment Require? earth ground if supplyingIndustrial Motors 12-5. Approximate Power Requirements For Industrial Motors12-6. Approximate Power Requirements For Farm/Home Equipment Return To Table Of ContentsStarting Watts 12-7. Approximate Power Requirements For Contractor EquipmentContractor RatingReturn To Table Of Contents 12-8. Power Required To Start Motor12-9. How Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsWork like a Pro 12-10. Typical Connections To Supply Standby PowerCurrent 12-11. Selecting Extension Cord Use Shortest Cord PossibleReturn To Table Of Contents Cord Lengths for 120 Volt LoadsFigure 13-1. Main Assembly SECTION 13 − PARTS LISTReturn To Table Of Contents Big Blue 502, 602 Only46 FIG Figure 13-1. Main Assembly Figure 13-1. Main Assembly Continued CC CV Figure 13-1. Main Assembly ContinuedFigure 13-2. Control Box Assembly − CC Models Figure13-2. Control Box Assembly − CC Models Figure 13-1 Item802 551-E Figure 13-2. Control Box Assembly − CC Models Continued Figure 13-3. Control Box Assembly − CC/CV Models802 360-D Figure 13-3. Control Box Assembly − CC/CV Models Figure 13-1 Item Figure 13-4. Panel, Front w/Components − CC Models Figure 13-4. Panel, Front w/Components − CC Models Figure 13-1 Item802 266-D Optional Figure 13-4. Panel, Front w/Components − CC Models Continued802 332-F Figure 13-5. Panel, Front w/Components − CC/CV ModelsFigure 13-5. Panel, Front w/Components − CC/CV Models Continued Figure 13-5. Panel, Front w/Components − CC/CV Models Continued Figure 13-6. Generator802 267-B Figure 13-6. Generator Figure 13-1 Item not available unless listed Figure 13-7. Main Rectifier AssemblyFigure 13-7. Main Rectifier Assembly Figure 13-1 Item Hardware is common andSupport Warranty Questions?Service Call 1-800-4-A-MILLER for your local Miller distributorAlways provide Model Name and Serial/Style Number For ServiceOwner’s Record Please complete and retain with your personal records

Every 400 h

Every 500 h

Every 800 h

Every 1000 h

SLUDGE