Trouble

Remedy

 

 

Engine cranks but does not start.

Press Magnetic Shutdown switch MS1 when starting engine.

 

 

 

Check fuel level.

 

 

 

Reset circuit breaker CB13 (see Section 9-7). Have Factory Authorized Service Agent check engine wir-

 

ing harness and components.

 

 

 

Check battery and replace if necessary. Check engine charging system according to engine manual.

 

 

 

Have Factory Authorized Service Agent check control relay CR2, and fuel solenoid FS1.

 

 

 

Air in fuel system. See engine manual.

 

 

Engine starts, but stops when Magnetic

When starting engine, continue holding Magnetic Shutdown switch until after engine indicator lights go

Shutdown switch is released.

out.

 

 

 

Check oil, and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolant

 

temperature is too high (see Sections 5-7and 9-8).

 

 

Engine hard to start in cold weather.

Use starting aid switch (see Section 6-1or 7-1).

 

 

 

Keep battery in good condition. Store battery in warm area off cold surface.

 

 

 

Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier for

 

fuel information.

 

 

 

Use correct grade oil for cold weather (see Section 9-2).

 

 

Engine suddenly stops.

Check fuel, oil, and coolant levels. Automatic shutdown system stops engine if fuel level or oil pressure

 

is too low, or coolant temperature is too high (see Sections 5-7and 9-8).

 

 

 

See engine manual.

 

 

Engine slowly stopped and cannot be

Check fuel level.

restarted.

 

 

 

 

Check engine air and fuel filters (see Sections 9-3and 9-6).

 

 

 

See engine manual.

 

 

Battery discharges between uses.

Turn Engine Control switch off when unit is not running.

 

 

 

Clean top of battery with baking soda and water solution; rinse with clear water.

 

 

 

Recharge or replace battery if necessary.

 

 

 

Periodically recharge battery (approximately every 3 months).

 

 

Engine idles, but does not come up to

Have Factory Authorized Service Agent check idle module PC7 and current transformer CT1.

weld speed (models with idle option

 

only).

 

 

 

 

Check for obstructed throttle solenoid.

 

 

Engine does not run at idle speed

CC models: place Stick/TIG Selection switch in Stick position.

(models with idle option only).

CC/CV models: place Process/Contactor switch in any position but Remote-TIG.

 

 

 

Check for obstructed throttle solenoid.

 

 

 

Have Factory Authorized Service Agent check idle module PC7, and control relays CR3 and CR6.

 

 

Engine uses oil during run-in period;

Dry engine according to run-in procedure (see Section 11).

wetstacking occurs.

 

 

 

OM-491 Page 46

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Miller Electric Big Blue 502P Ing harness and components, Air in fuel system. See engine manual, Fuel information

Big Blue 602P, Big Blue 502P, Big Blue 402P specifications

Miller Electric is a well-respected name in the welding industry, known for its high-quality portable welders that cater to a wide range of applications. Among their iconic products are the Big Blue 502P, Big Blue 402P, and Big Blue 602P, each offering unique features and capabilities suited to professional welders.

The Miller Big Blue 502P is recognized for its robust construction and high-performance capabilities. Powered by a reliable diesel engine, it provides 500 amps of welding power at a duty cycle of 100%. This model is particularly favored for its versatility, accommodating both stick and TIG welding processes. One of its key technologies is the Auto-Set feature, which automatically adjusts settings for optimal performance based on the material thickness. This welder also boasts a user-friendly interface, complete with easy-to-read digital displays for monitoring essential parameters.

In contrast, the Big Blue 402P offers a slightly lower welding output while maintaining many of the advanced features seen in its larger counterpart. With a maximum output of 400 amps, it is perfectly suited for light to medium-duty applications. The 402P is particularly lightweight for a diesel welder, making it an ideal choice for contractors who need mobility without sacrificing power. It includes the X-Mode technology, which ensures reliable performance in challenging conditions and offers an intuitive control panel for ease of use.

The Big Blue 602P, on the other hand, stands out for its high output and exceptional reliability. With a maximum capacity of 600 amps, this machine is designed for heavy-duty applications, making it perfect for industrial settings. The welder features advanced cooling systems and robust construction, which enhance durability and longevity. One notable characteristic of the 602P is its ability to handle various welding processes, including Stick, TIG, and MIG, making it a versatile tool for skilled welders. Additionally, the Big Blue 602P incorporates advanced inverter technology, resulting in a lighter and more energy-efficient model without compromising power performance.

All three models benefit from Miller's commitment to innovation and user-centric design features. Built to thrive in tough work environments, the Big Blue series is equipped with protective casings and vibration-resistant components. Safety is also a priority, with several built-in features that help protect users during operation.

In summary, the Miller Electric Big Blue 502P, 402P, and 602P each bring unique strengths to the welding market. Their notable features include advanced technologies, robust construction, and versatile applications, ensuring that professionals have the right tool for any welding job. Whether for light-duty tasks or heavy industrial applications, Miller Electric's Big Blue series remains a cornerstone for welders around the globe.