OM-491
Big BlueR 402P, 502P, 602P
Processes
Description
From Miller to You
SECTION 5 − INSTALLATION
TABLE OF CONTENTS
OPTIONS AND ACCESSORIES
TABLE OF CONTENTS
WARRANTY
SECTION
1-2. Arc Welding Hazards
1-1. Symbol Usage
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
Means “Note” not safety related
BATTERY EXPLOSION can BLIND
1-3. Engine Hazards
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WELDING can cause fire or explosion
1-4. Compressed Air Hazards
1-5. Additional Symbols For Installation, Operation, And Maintenance
STEAM AND HOT COOLANT can burn
ENGINE EXHAUST GASES can kill
1-6. California Proposition 65 Warnings
1-7. Principal Safety Standards
1-8. EMF Information
READ INSTRUCTIONS
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
2-1. Signification des symboles
2-2. Dangers relatifs au soudage à l’arc
UN CHOC ÉLECTRIQUE peut tuer
LE SOUDAGE peut provoquer un in- cendie ou une explosion
2-3. Dangers existant en relation avec le moteur
DES PARTICULES VOLANTES peuvent blesser les yeux
DES PIÈCES CHAUDES peuvent provoquer des brûlures graves
L’EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE
2-4. Dangers liés à l’air comprimé
DES ORGANES MOBILES peuvent provoquer des blessures
LA CHALEUR DU MOTEUR peut pro- voquer un incendie
2-7. Information sur les champs électromagnétiques
2-6. Principales normes de sécurité
LE SURCHAUFFEMENT peut endom- mager le moteur électrique
LES ÉTINCELLES VOLANTES ris- quent de provoquer des blessures
3-1. Symbols And Definitions
SECTION 4 − SPECIFICATIONS
SECTION 3 − DEFINITIONS
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4-2. Dimensions, Weights, And Operating Angles
4-1. Weld, Power, And Engine Specifications
300−Max
4-3. Volt-Ampere Curves For CC Models
A. Stick Mode
4-4. Volt-Ampere Curves For CC/CV Models
B. MIG Mode
C. TIG Mode
1800 RPM IDLE
4-5. Fuel Consumption
4-6. Duty Cycle And Overheating
4-8. Optional Three-Phase Generator Curves
4-7. AC Generator Power Curve
A. 12 kVA/kW Single-Phase AC Output No Weld Load
B. 20 kVA/kW Three-Phase AC Output No Weld Load
5-1. Installing Welding Generator
SECTION 5 − INSTALLATION
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Movement
Using Mounting Brackets
5-2. Mounting Welding Generator
Supporting The Unit
Inadequate support
5-4. Installing Exhaust Pipe
5-3. Using Lifting Eye
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Y Stop engine and let cool
When electrolyte is low, add
5-5. Activating The Dry Charge Battery If Applicable
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Y Read and follow all instruc
Reinstall cover after connecting battery
5-6. Connecting The Battery
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Y Connect Negative − Cable Last
Check radiator coolant level when fluid is low in recovery tank
5-7. Engine Prestart Checks
Coolant Recovery Tank
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5-9. Selecting Weld Cable Sizes
5-8. Connecting To Weld Output Terminals
24 VOLTS AC
5-11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models
REMOTE
OUTPUT
SECTION 6 − OPERATING WELDING GENERATOR − CC MODELS
6-1. Front Panel Controls For CC Models See Section
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Engine Indicator Lights
6-2. Description Of Front Panel Controls For CC Models See Section
Y Stop engine and fix trouble if Battery Charging light goes on
Y Do not switch under load
6-4. Weld Control/Arc Condition Information Label
6-3. Remote Amperage Control On CC Models Optional
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Set weld controls as shown to
OM-491 Page
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SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS
7-1. Front Panel Controls For CC/CV Models See Section
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Engine Indicator Lights
7-2. Description Of Front Panel Controls For CC/CV Models See Section
Y Stop engine and fix trouble if Battery Charging light goes on
Y Do not switch under load
Process/Contactor Switch Settings
7-3. Process/Contactor Switch On CC/CV Models
Process/Contactor Switch
switch is in an Electrode Hot
Example Combination Remote Amperage Control TIG
7-4. Remote Voltage/Amperage Control On CC/CV Models Optional
Example Combination Remote Amperage Control Stick
8-1. 120 Volt And 240 Volt Receptacles
SECTION 8 − OPERATING AUXILIARY EQUIPMENT
rized Service Agent
power
Single-Phase Power Connection
8-2. Connecting To Optional Three-Phase Generator CC/CV Models Only
Single-Phase Generator Power
Three-Phase Power Connection
Generator power is not af- fected by weld output
8-3. Optional Generator Power Receptacles
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European Receptacle
9-1. Routine Maintenance
SECTION 9 − MAINTENANCE & TROUBLESHOOTING
Every 8 h
Every 50 h
Every 500 h
Every 400 h
Every 800 h
Every 1000 h
OM-491 Page
Maintenance Label
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by the warranty
9-3. Servicing Air Cleaner
The air cleaner primary element can
To clean air filter
Y Stop engine and let cool
9-4. Inspecting And Cleaning Optional Spark Arrestor Muffler
Y Stop engine and let cool
802 160-E / Ref. 202
Models With Automatic Idle Optional Idle Speed Adjustment
9-5. Adjusting Engine Speed
Weld/Power Speed Adjustment
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Y Stop engine and let cool
9-6. Servicing Fuel And Lubrication Systems
To change oil and filter
To drain water from fuel system
When a circuit breaker or fuse
9-7. Overload Protection
more serious problem exists
Service Agent
Pre-Start Diagnostic Checks
9-8. Diagnosing Causes Of Engine Fault Shutdowns
Diagnostic Checks While Running
Battery Charging, Fuel, And Temperature Lights Off
A. Welding − CC Models
9-9. Troubleshooting
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Remedy
B. Welding − CC/CV Models
Trouble
D. Optional Three-Phase Generator Power CC/CV Models Only
C. Standard Generator Power
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E. Engine
Engine starts, but stops when Magnetic
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SECTION 10 − ELECTRICAL DIAGRAMS
Figure 10-1. Circuit Diagram For CC Welding Generator
215 304-A
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Figure 10-2. Circuit Diagram For CC/CV Welding Generator
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215 305-A
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11-1. Wetstacking
SECTION 11 − RUN-IN PROCEDURE
procedure at less than
11-2. Run-In Procedure Using Load Bank
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Y Stop engine
procedure at less than
11-3. Run-In Procedure Using Resistance Grid
Stop engine
Y Do not touch hot exhaust
12-1. Selecting Equipment
SECTION 12 − GENERATOR POWER GUIDELINES
12-2. Grounding Generator To Truck Or Trailer Frame
has this symbol
12-4. How Much Power Does Equipment Require?
12-3. Grounding When Supplying Building Systems
earth ground if supplying
Use ground device as stated in electrical codes
12-6. Approximate Power Requirements For Farm/Home Equipment
12-5. Approximate Power Requirements For Industrial Motors
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Industrial Motors
Contractor
12-7. Approximate Power Requirements For Contractor Equipment
Rating
Starting Watts
12-9. How Much Power Can Generator Supply?
12-8. Power Required To Start Motor
Single-Phase Induction Motor Starting Requirements
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Work like a Pro
12-10. Typical Connections To Supply Standby Power
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12-11. Selecting Extension Cord Use Shortest Cord Possible
Cord Lengths for 120 Volt Loads
Current
Figure 13-1. Main Assembly
SECTION 13 − PARTS LIST
46 FIG
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Big Blue 502, 602 Only
Figure 13-1. Main Assembly
Figure 13-1. Main Assembly Continued
CC CV
Figure 13-1. Main Assembly Continued
802 551-E
Figure 13-2. Control Box Assembly − CC Models
Figure13-2. Control Box Assembly − CC Models Figure 13-1 Item
802 360-D
Figure 13-2. Control Box Assembly − CC Models Continued
Figure 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 Models
Figure 13-4. Panel, Front w/Components − CC Models Figure 13-1 Item
Optional
Figure 13-4. Panel, Front w/Components − CC Models Continued
802 332-F
Figure 13-5. Panel, Front w/Components − CC/CV Models
Figure 13-5. Panel, Front w/Components − CC/CV Models Continued
802 267-B
Figure 13-5. Panel, Front w/Components − CC/CV Models Continued
Figure 13-6. Generator
Figure 13-6. Generator Figure 13-1 Item
Figure 13-7. Main Rectifier Assembly Figure 13-1 Item
Figure 13-7. Main Rectifier Assembly
Hardware is common and
not available unless listed
Service
Warranty Questions?
Call 1-800-4-A-MILLER for your local Miller distributor
Support
Owner’s Record
For Service
Please complete and retain with your personal records
Always provide Model Name and Serial/Style Number