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Miller Electric Big Blue 402D, Big Blue 502D, Big Blue 602DR manual

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Big Blue 402D, 502D, 602D

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OM-495 192 774AR

October 2003

Processes

Description

Air Carbon Arc (CAC-A)

Cutting and Gouging

Stick (SMAW) Welding

Engine Driven Welding Generator

TIG (GTAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Visit our website at

www.MillerWelds.com

And Non-CE Models

Contents

Main Big Blue 402D, 502D, 602D And Non-CE Models From Miller to You Page TABLE OF CONTENTS Declaration of Conformity for European Community (CE) Products Appleton, WI 54914 USA Declaration of Conformity for European Community (CE) Products Appleton, WI 54914 USA OM-495 Page 1 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING Warning: Protect yourself and others from injury read and follow these precautions. 1-1. Symbol Usage Marks a special safety message. 1-2. Arc Welding Hazards 1-3. Engine Hazards BATTERY EXPLOSION can BLIND. FUEL can cause fire or explosion. MOVING PARTS can cause injury. OM-495 Page 3 1-4. Compressed Air Hazards BREATHING COMPRESSED AIR can cause serious injury or death. COMPRESSED AIR can cause injury. TRAPPED AIR PRESSURE AND WHIPPING HOSES can cause injury. HOT METAL from air arc cutting and gouging can cause fire or explosion. 1-6. California Proposition 65 Warnings 1-7. Principal Safety Standards 1-8. EMF Information OM-495 Page 5 SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION Avertissement: Protgez vous et les autres des blessures lisez et suivez ces prcautions. 2-1. Signification des symboles Identifie un message de scurit particulier. 2-2. Dangers relatifs au soudage larc 2-3. Dangers existant en relation avec le moteur LES ACCUMULATIONS DE GAZ ris- quent de provoquer des blessures ou mme la mort. LACIDE DE LA BATTERIE peut pro- voquer des brlures dans les YEUX et sur la PEAU. OM-495 Page 7 LEXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE. 2-4. Dangers lis lair comprim RESPIRER LAIR COMPRIM peut pro- voquer des blessures graves ou causer la mort. LAIR COMPRIM peut provoquer des blessures. LAIR COMPRIME EMMAGASINE ET DES TUYAUX SOUS PRESSION peuvent provo- quer des blessures. Le METAL CHAUD lors du coupage et gougeage plasma peut provoquer un in- cendie ou une explosion. 2-6. Principales normes de scurit 2-7. Information sur les champs lectromagntiques SECTION 3 DEFINITIONS 3-1. Warning Label Definitions (For Wordless Labels) + Page Page + 2 3 4 1+ 3-3. Manufacturers Rating Labels For CE Products 3-4. Symbols And Definitions AAmperes VVolts Panel/Local Remote 3 n X Duty Cycle U0 SECTION 4 SPECIFICATIONS 4-1. Weld, Power, And Engine Specifications Welding Mode Weld Output Range Rated Welding Output 4-3. Volt-Ampere Curves For CC Models 4-4. Volt-Ampere Curves For CC/CV Models 4-5. Fuel Consumption 4-6. Duty Cycle And Overheating A. Deutz F4L-1011-Powered Units B. Deutz F3L912-Powered Units 4-7. AC Generator Power Curve 4-8. Optional Three-Phase Generator Curves Page SECTION 5 INSTALLATION 5-1. Installing Welding Generator (See Sections 5-2 And 5-3) Page 5-3. Mounting Welding Generator 5-4. Installing Exhaust Pipe 5-5. Installing Engine Side Baffle (CE Models Only) 5-6. Activating The Dry Charge Battery (If Applicable) + 5-7. Connecting The Battery + 5-8. Installing Optional Ether Cylinder (Deutz F3L912 Engine Only) 5-9. Engine Prestart Checks 5-10. Connecting To Weld Output Terminals 5-11. Selecting Weld Cable Sizes* 5-12. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models 5-13. Connecting To Remote 14 Receptacle RC14 On CC/CV Models Page SECTION 6 OPERATING WELDING GENERATOR CC MODELS 6-1. Front Panel Controls For CC Models (See Section 6-2) 6-2. Description Of Front Panel Controls For CC Models (See Section 6-1) 6-3. Remote Amperage Control On CC Models (Optional) 6-4. Weld Control/Arc Condition Information Label Page SECTION 7 OPERATING WELDING GENERATOR CC/CV MODELS 7-1. Front Panel Controls For CC/CV Models (See Section 7-2) 7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1) 7-3. Process/Contactor Switch On CC/CV Models Process/Contactor Switch Settings 7-4. Remote Voltage/Amperage Control On CC/CV Models (Optional) SECTION 8 OPERATING AUXILIARY EQUIPMENT 8-1. Generator Power Receptacles (Standard Models) 8-2. Connecting To Optional Three-Phase Generator (CC/CV Standard Models Only) 8-3. Optional Generator Power Receptacles (Standard Models) 8-4. Generator Power Receptacles (CE Models) SECTION 9 MAINTENANCE (DEUTZ F4L2011POWERED UNITS) 9-1. Routine Maintenance (Deutz F4L2011-Powered Units) Every 8 h Every 50 h Every 100 h Every 1000 h Every 3000 h Page 9-3. Servicing Air Cleaner (Deutz F4L2011-Powered Units) 9-4. Inspecting/Cleaning Optional Spark Arrestor (Deutz F4L2011-Powered Units) 9-5. Adjusting Engine Speed (Deutz F4L2011-Powered Units) 9-6. Servicing Fuel And Lubrication Systems (Deutz F4L2011-Powered Units) 9-7. Overload Protection (Deutz F4L2011-Powered Units) SECTION 10 MAINTENANCE (DEUTZ F3L912POWERED UNITS) 10-1. Routine Maintenance (Deutz F3L912-Powered Units) Every 8 h Every 50 h Every 100 h Every 500 h Every 1000 h Every 3000 h Page 10-3. Servicing Air Cleaner (Deutz F3L912-Powered Units) 10-4. Inspecting/Cleaning Optional Spark Arrestor (Deutz F3L912-Powered Units) 10-5. Adjusting Engine Speed (Deutz F3L912-Powered Units) RPM Engine Speed (No Load) 10-6. Servicing Optional Ether Starting Aid (Deutz F3L912-Powered Units) 10-7. Servicing Fuel And Lubrication Systems (Deutz F3L912-Powered Units) 10-8. Overload Protection (Deutz F3L912-Powered Units) SECTION 11 TROUBLESHOOTING 11-1. Diagnosing Causes Of Engine Fault Shutdowns 11-2. Troubleshooting Tables A. Welding CC Models B. Welding CC/CV Models C. Standard Generator Power D. Optional Three-Phase Generator Power (CC/CV Models Only) E. Engine Page Page Page Page Page Page Page Page Page Page Page Page Page Page SECTION 13 RUN-IN PROCEDURE 13-1. Wetstacking 13-2. Run-In Procedure Using Load Bank 13-3. Run-In Procedure Using Resistance Grid + SECTION 14 GENERATOR POWER GUIDELINES 14-1. Selecting Equipment 14-2. Grounding Generator To Truck Or Trailer Frame 14-3. Grounding When Supplying Building Systems 14-4. How Much Power Does Equipment Require? 14-5. Approximate Power Requirements For Industrial Motors 14-6. Approximate Power Requirements For Farm/Home Equipment 14-7. Approximate Power Requirements For Contractor Equipment 14-8. Power Required To Start Motor 14-9. How Much Power Can Generator Supply? 14-10. Typical Connections To Supply Standby Power Pros weld and cut safely. Read the safety rules at the beginning of this manual. 14-11. Selecting Extension Cord (Use Shortest Cord Possible) SECTION 15 PARTS LIST Figure 15-1. Main Assembly Page Page Page Page Page Page Page Page Page Page Pros weld and cut safely. Read the safety rules at the beginning of this manual. Page Page Page Page Page Page Page Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Effective January 1, 2003 (Equipment with a serial number preface of LC or newer) Please complete and retain with your personal records. For Service Always provide Model Name and Serial/Style Number. Owners Record