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Miller Electric Big Blue 602P manual Table Of Contents, Section, 11-1, 11-2, 11-3, Warranty

Models: Big Blue 402P

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TABLE OF CONTENTS


SECTION 8		− OPERATING AUXILIARY EQUIPMENT	31
8-1.	120 Volt And 240 Volt Receptacles		31
8-2.	Connecting To Optional Three-Phase Generator (CC/CV Models Only)		32
8-3.	Optional Generator Power Receptacles		33
SECTION 9		− MAINTENANCE & TROUBLESHOOTING	34

9-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

9-2. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

9-3. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

9-4. Inspecting And Cleaning Optional Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

9-5. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

9-6. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

9-7. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

9-8. Diagnosing Causes Of Engine Fault Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

9-9. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

SECTION 10 − ELECTRICAL DIAGRAMS		48
SECTION 11 − RUN-IN PROCEDURE		52
11-1.	Wetstacking	52
11-2.	Run-In Procedure Using Load Bank	53
11-3.	Run-In Procedure Using Resistance Grid	54
SECTION 12 − GENERATOR POWER GUIDELINES		55
SECTION 13 − PARTS LIST		62
OPTIONS AND ACCESSORIES
WARRANTY

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Miller Electric Big Blue 602P manual Table Of Contents, Section, 11-1, 11-2, 11-3, Options And Accessories, Warranty

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 Mode4-6. Duty Cycle And Overheating 4-5. Fuel Consumption1800 RPM IDLE 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 OUTPUTReturn To Table Of Contents 6-1. Front Panel Controls For CC Models See SectionSECTION 6 − OPERATING WELDING GENERATOR − CC MODELS 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 PageReturn To Table Of Contents 7-1. Front Panel Controls For CC/CV Models See SectionSECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS 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 Stick 7-4. Remote Voltage/Amperage Control On CC/CV Models OptionalExample Combination Remote Amperage Control TIG 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 hReturn To Table Of Contents Maintenance LabelOM-491 Page 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 OffReturn To Table Of Contents 9-9. TroubleshootingA. Welding − CC Models Trouble B. Welding − CC/CV ModelsRemedy 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 PageFigure 10-1. Circuit Diagram For CC Welding Generator SECTION 10 − ELECTRICAL DIAGRAMSReturn To Table Of Contents OM-491 Page Return To Table Of Contents215 304-A Return To Table Of Contents Figure 10-2. Circuit Diagram For CC/CV Welding GeneratorOM-491 Page OM-491 Page Return To Table Of Contents215 305-A 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 AssemblyBig Blue 502, 602 Only Return To Table Of Contents46 FIG Figure 13-1. Main Assembly Figure 13-1. Main Assembly Continued Figure 13-1. Main Assembly Continued CC CVFigure13-2. Control Box Assembly − CC Models Figure 13-1 Item Figure 13-2. Control Box Assembly − CC Models802 551-E Figure 13-3. Control Box Assembly − CC/CV Models Figure 13-2. Control Box Assembly − CC Models Continued802 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 13-1 Item Figure 13-4. Panel, Front w/Components − CC Models802 266-D 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 Figure 13-6. Generator Figure 13-5. Panel, Front w/Components − CC/CV Models Continued802 267-B 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