Miller Big Blue 502P - Manuals

OM-491 Page 2 Return To Table Of Contents Welding on closed containers, such as tanks, drums, orpipes, can cause them to blow up. Sparks can fly off from thewelding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metalobjects can...

OM-491 Page 3 Return To Table Of Contents STEAM AND HOT COOLANT can burn. If possible, check coolant level when engine is cold toavoid scalding. Always check coolant level at overflow tank, if pres-ent on unit, instead of radiator (unless told otherwisein maintenance section or engine manual). If th...

OM-491 Page 4 Return To Table Of Contents READ INSTRUCTIONS. Use only genuine MILLER/Hobart replacementparts. Perform engine and air compressor (if applicable)maintenance and service according to this manualand the engine/air compressor (if applicable) manu-als. H.F. RADIATION can cause interference...

OM-491 Page 5 Revenez à la table des matières SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION rom_fre 8/03 Avertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions. 2-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédurep...

OM-491 Page 6 Revenez à la table des matières LES ACCUMULATIONS DE GAZ ris-quent de provoquer des blessures oumême la mort. Fermer l’alimentation du gaz protecteur en cas denon utilisation. Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi-rateur d’adduction d’air homologué....

OM-491 Page 7 Revenez à la table des matières L’EXPLOSION DE LA BATTERIE peutRENDRE AVEUGLE. Toujours porter une protection faciale, des gants encaoutchouc et vêtements de protection lors d’une in-tervention sur la batterie. Arrêter le moteur avant de débrancher ou de brancher les câbles debatterie....

OM-491 Page 8 Revenez à la table des matières LE SURCHAUFFEMENT peut endom-mager le moteur électrique. Arrêter ou déconnecter l’équipement avant de dé-marrer ou d’arrêter le moteur. Ne pas laisser tourner le moteur trop lentement sousrisque d’endommager le moteur électrique à caused’une tension et d...

OM-491 Page 9 Return To Table Of Contents SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions Stop Engine Fast (Run, Weld/ Power) Slow (Idle) Start Engine Starting Aid Battery (Engine) Engine Oil Pressure Engine Oil Check Injectors/ Pump Check Valve Clearance Fuel Protective Earth (Ground) Positive...

OM-491 Page 10 Return To Table Of Contents 4-1. Weld, Power, And Engine Specifications Welding Mode Weld Output Range Rated Welding Output Maximum Open- Circuit Voltage Generator Power Rating Engine Fuel Capacity CC/DC 55 − 600 A (CC Models) 20 − 600 A (CC/CV Models) 400 A, 40 Volts DC, 100% Duty Cy...

OM-491 Page 11 Return To Table Of Contents 4-3. Volt-Ampere Curves For CC Models 203 412 The volt-ampere curve shows theminimum and maximum voltageand amperage output capabilities ofthe welding generator. Curves of allother settings fall between thecurves shown. 0 20 40 60 80 100 0 100 200 300 400 5...

OM-491 Page 13 Return To Table Of Contents 4-5. Fuel Consumption The curve shows typical fuel useunder weld or power loads. 193 093 0 50 100 150 200 250 300 350 400 450 500 DC WELD AMPERES AT 100% DUTY CYCLE 1800 RPM 0 IDLE Continuous Welding 4-6. Duty Cycle And Overheating Duty Cycle is percentage ...

OM-491 Page 14 Return To Table Of Contents 4-7. AC Generator Power Curve 193 018 The ac power curve shows the gen-erator power in amperes availableat the 120 and 240 volt receptacles. 0 50 100 150 200 250 300 0 5 10 15 20 25 30 AC AMPERES IN 240V MODE AC VOL TS 0 25 50 75 100 150 125 0 10 20 30 40 5...

OM-491 Page 15 Return To Table Of Contents SECTION 5 − INSTALLATION install3 6/03 − Ref. 800 652 / Ref. 800 477-A / 803 274 Always securely fasten weld-ing generator onto transportvehicle or trailer and complywith all DOT and other applica-ble codes. Always ground generatorframe to vehicle frame to ...

OM-491 Page 16 Return To Table Of Contents 5-2. Mounting Welding Generator Tools Needed: 9/16 in 2 2 3 4 Welding Unit In Place Bolting Unit In Place Do not weld on base. Weld-ing on base can cause fueltank fire or explosion. Weldonly on the four mountingbrackets or bolt unit down. Do not mount unit ...

OM-491 Page 17 Return To Table Of Contents 5-3. Using Lifting Eye Ref. 802 169-F 1 Lifting Eye 2 Nut 3 Carriage Bolt Raise lifting eye until it snaps inplace. Lower lifting eye when notneeded. To lock the lifting eye in the uprightposition, insert a 3/8-16 x 1-1/2 incarriage bolt through slot in bra...

OM-491 Page 18 Return To Table Of Contents 5-5. Activating The Dry Charge Battery (If Applicable) Remove battery from unit. 1 Eye Protection − SafetyGlasses Or Face Shield 2 Rubber Gloves 3 Vent Caps 4 Sulfuric Acid Electrolyte(1.265 Specific Gravity) 5 Well Fill each cell with electrolyte tobottom ...

OM-491 Page 19 Return To Table Of Contents 5-6. Connecting The Battery 1/2 in − + Connect Negative (−) Cable Last. Tools Needed: 802 168-E / Ref. 202 705 / 802 313 / S-0756-C Reinstall cover after connecting battery. Notes

OM-491 Page 20 Return To Table Of Contents Ref. 802 168-E 5-7. Engine Prestart Checks Check all engine fluids daily. Engine must be cold and on a level surface.Unit is shipped with 20W break-in oil. The Automatic shutdown system stops en-gine if fuel level or oil pressure is too low, orcoolant tempe...

OM-491 Page 21 Return To Table Of Contents 5-8. Connecting To Weld Output Terminals Ref. 802 169-E Stop engine. 1 Positive (+) Weld Output Terminal 2 Negative (−) Weld Output Terminal For Stick and TIG welding Direct Cur-rent Electrode Positive (DCEP), con-nect electrode holder cable to Positive(+) ...

OM-491 Page 22 Return To Table Of Contents 5-10. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models Ref. 154 862-A / 048 720-K / 802 160-E 1 Remote Amperage AdjustReceptacle RC13 Connect optional remote control toRC13 (see Section 6-3). 1 5-11. Connecting To Remote 14 Receptacle RC14 ...

OM-491 Page 23 Return To Table Of Contents SECTION 6 − OPERATING WELDING GENERATOR − CC MODELS 6-1. Front Panel Controls For CC Models (See Section 6-2) 17 202 705 / 802 169-F 15 16 2 1 3 13 18 19 14 12 10 11 9 8 6 5 4 7

OM-491 Page 24 Return To Table Of Contents 6-2. Description Of Front Panel Controls For CC Models (See Section 6-1) Engine Starting Controls1 Magnetic Shutdown Switch Use switch during start-up to bypass engineshutdown system. System stops engine if oilpressure or fuel level is too low or coolant te...

OM-491 Page 25 Return To Table Of Contents 6-3. Remote Amperage Control On CC Models (Optional) 1 Remote Amperage AdjustReceptacle RC13 Connect optional remote control toRC13 (see Section 5-10). Example: Combination Remote Amperage Control (Stick) In Example: Range = 125 to 320 A DC Percentage Of Ra...

OM-491 Page 27 Return To Table Of Contents SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS 7-1. Front Panel Controls For CC/CV Models (See Section 7-2) 202 706 / 802 311-D 6 5 4 7 13 16 2 1 3 14 18 19 15 12 10 11 9 8 17

OM-491 Page 29 Return To Table Of Contents 7-3. Process/Contactor Switch On CC/CV Models 1 Process/Contactor Switch Weld output terminals are ener-gized when Process/Contactorswitch is in an Electrode Hotposition and the engine is run-ning. DC voltage is still present at theweld terminals when Proce...

OM-491 Page 31 Return To Table Of Contents SECTION 8 − OPERATING AUXILIARY EQUIPMENT 8-1. 120 Volt And 240 Volt Receptacles 191 624-A 2 1 3 4 1 120 V 20 A AC GFCI Receptacle GFCI1 2 240 V 30 A AC TwistlockReceptacle RC1 Receptacles supply 60 Hz single-phase power at weld/power speed. If a ground fau...

OM-491 Page 33 Return To Table Of Contents 8-3. Optional Generator Power Receptacles 2 1 120 V 20 A AC GFCI Receptacle GFCI1 2 240 V 16 A AC EuropeanReceptacle RC1 3 240 V 15 A AC AustralianReceptacle RC1 4 240 V 15 A AC South AfricanReceptacle RC1 Receptacles supply 60 Hz single-phase power at weld...

OM-491 Page 34 Return To Table Of Contents SECTION 9 − MAINTENANCE & TROUBLESHOOTING 9-1. Routine Maintenance Follow the storage procedure in the engine owner’s manual if the unit will not be used for anextended period. Note Recycle engine fluids. Stop engine before maintaining. See Engine Manua...

OM-491 Page 36 Return To Table Of Contents 9-2. Maintenance Label

OM-491 Page 37 Return To Table Of Contents 9-3. Servicing Air Cleaner aircleaner1 9/00 − ST-153 929-B / ST-153 585 / Ref. S-0698-B / Ref. 202 705 Stop engine. Do not run engine without aircleaner or with dirty element. En-gine damage caused by using adamaged element is not coveredby the warranty. Th...

OM-491 Page 38 Return To Table Of Contents 9-4. Inspecting And Cleaning Optional Spark Arrestor Muffler 802 160-E / Ref. 202 705 Stop engine and let cool. 1 Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirtcovering cleanout hole. 3 Exhaust Pipe Start engine and run at idle speed...

OM-491 Page 39 Return To Table Of Contents 9-5. Adjusting Engine Speed 802 168-C / 802 229-A / Ref. 202 705 Stop engine and let cool. Engine speed is factory set andshould not require adjustment. Af-ter tuning engine, check enginespeed with tachometer or frequen-cy meter. See table for proper noload...

OM-491 Page 40 Return To Table Of Contents 9-6. Servicing Fuel And Lubrication Systems 802 170-D / Ref. 802 168-B / Ref. 801 434 Stop engine and let cool. After servicing, start engineand check for fuel leaks.Stop engine, tighten connec-tions as necessary, and wipeup spilled fuel. 1 Oil Filter 2 Oil...

OM-491 Page 41 Return To Table Of Contents 9-7. Overload Protection 802 170-E 2 1 9 8 7 4 Stop engine. When a circuit breaker or fuseopens, it usually indicates amore serious problem exists.Contact Factory AuthorizedService Agent. 1 Fuse F1 2 Fuse F2 F1 and F2 protect the stator exciterwinding from ...

OM-491 Page 42 Return To Table Of Contents 9-8. Diagnosing Causes Of Engine Fault Shutdowns Ref. 202 705 Use the front panel engine lights tohelp determine the cause of an au-tomatic engine shutdown. Correct the cause of the shut-down before operating thewelding generator. This unit does not have a ...

OM-491 Page 43 Return To Table Of Contents 9-9. Troubleshooting A. Welding − CC Models Trouble Remedy No weld output; generator power outputokay at ac receptacles. Check position of Ampere Range switch. Check position of optional polarity switch. Place Amperage Adjust switch in Panel position, or pl...

OM-491 Page 45 Return To Table Of Contents Trouble Remedy Min or max CV weld output only. Check position of Voltage/Amperage Adjust control and Voltage/Amperage Adjust switch. Repair or replace remote control device. Have Factory Authorized Service Agent check field current regulator board PC1. C. S...

OM-491 Page 48 Return To Table Of Contents SECTION 10 − ELECTRICAL DIAGRAMS Figure 10-1. Circuit Diagram For CC Welding Generator

OM-491 Page 52 Return To Table Of Contents SECTION 11 − RUN-IN PROCEDURE run_in1 8/01 11-1. Wetstacking Do not perform run-inprocedure at less than 20volts weld output and do notexceed duty cycle or equip-ment damage may occur. 1 Welding Generator Run diesel engines near rated volt-age and current d...

OM-491 Page 55 Return To Table Of Contents SECTION 12 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-drivenwelding generators. Your unit may differ from those shown. NOTE 12-1. Selecting Equipment gen_pwr 11/02 − Ref. ST-159 730 / ST-800 577 1 ...

OM-491 Page 56 Return To Table Of Contents 12-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment GroundingTerminal 2 Grounding Cable Use #10 AWG or larger insulatedcopper wire. 3 Ground Device Ground generator to systemearth ground if supplyingpower to a premises (home,shop, farm)...

OM-491 Page 57 Return To Table Of Contents 12-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 2100 700 1/2 HP 3175 875 Capacitor Start-Induction Run 1/3 HP 2020 720 1/2 HP ...

OM-491 Page 58 Return To Table Of Contents 12-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/2 in 500 500 7-1/4 in 900 900 8-1/4 in 1400 1400 Table Saw 9 in 4500 1500 1...

OM-491 Page 60 Return To Table Of Contents 12-10. Typical Connections To Supply Standby Power Have only qualified persons performthese connections according to allapplicable codes and safety practic-es. Properly install and ground thisequipment according to its Owner’sManual and national, state, and...

OM-491 Page 62 Return To Table Of Contents SECTION 13 − PARTS LIST Hardware is common andnot available unless listed. 3 2 1 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 30 29 31 32 33 34 93 94 95 96 97 98 99 100 102 101 (CC ONLY) 104 FIG 13-2 OR 13-3) 105 21 106 107 108 (FIG ...

OM-491 Page 67 Return To Table Of Contents 802 551-E 2 1 11 8 6 3 7 14 20 13 16 12 5 22 15 10 9 18 17 4 21 19 Figure 13-2. Control Box Assembly − CC Models Description Part No. Dia. Mkgs. Item No. Figure13-2. Control Box Assembly − CC Models (Figure 13-1 Item 104) Quantity 1 F1, F2 *085 874 FUSE, mi...

OM-491 Page 72 Return To Table Of Contents Hardware is common andnot available unless listed. 802 332-F 1 2 3 4 5 6 7 9 48 50 51 52 53 59 60 61 62 13 18 19 20 21 22 23 24 25 26 27 30 28 29 15 16 34 33 32 17 35 42 43 41 40 39 38 37 36 44 47 14 10 49 11 8 31 45 46 12 54 55 56 57 58 63 Figure 13-5. Pan...

Warranty Questions? Call1-800-4-A-MILLERfor your localMiller distributor. miller_warr 8/03 Your distributor also givesyou ... ServiceYou always get the fast,reliable response youneed. Most replacementparts can be in yourhands in 24 hours. SupportNeed fast answers to thetough welding questions?Contac...

PRINTED IN USA  2003 Miller Electric Mfg. Co. 1/03 Miller Electric Mfg. Co. An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 USA International Headquarters−USAUSA Phone: 920-735-4505 Auto-AttendedUSA & Canada FAX: 920-735-4134International FAX: 920-735-4125 European Head...