Miller Electric Big Blue 502P Owner'S Manual Download Page 61

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OM-491 Page 57

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 11-4. Generator (Figure 11-1 Item 53)

Quantity

127 595

SCREW, 375-16 x 2.50hexhd pln gr 5pld

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

183 387

WASHER, conical spring .406 ID x .875 OD pltd

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . .

191 420

ENDBELL, gen (consisting of)

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

143 220

O-RING, 2.859 ID x .139CS

. . .

. . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

190 464

STATOR, exciter/aux pwr

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+191 478

STATOR, weld assembly complete

. . .

. . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

013 367

LABEL, warning moving parts

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

190 197

GUARD, generator wire mesh

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

172 674

SPRING, ext .240 OD x .041 wire x 3.500pld

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . .

191 580

COVER, starter hole

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

191 576

GUARD, starter Perkins

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

039 207

BAFFLE, air

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

191 441

ROTOR, gen (consisting of)

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

024 617

RING, rtng ext 1.375 shaft x .050thk

. . .

. . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

053 390

BEARING, ball rdl sgl row 1.370 x 2.830 x .6

. . .

. . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . .

192 963

FAN, rotor gen

. . .

. . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

049 026

SCREW, M10-1.5 x 25hexhd pln 8.8pln

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

083 883

WASHER, lock .042 ID x 0.709 OD

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

192 962

ADAPTER, fan/flywheel

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

049 026

SCREW, M10-1.5 x 25hexhd pln 8.8pln

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

183 387

WASHER, conical spring .406 ID x .875 OD pltd

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . .

191 579

COVER, starter hole Perkins/Continental

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

602 211

WASHER, lock .318 ID x 0.586 OD x .07

. . .

. . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

172 555

SCREW, M10-1.5 x 50hexhd pln 8.8pld

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

097 153

SCREW, .312-18 X .5 hexwhd .66d stl pld

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . .

601 961

SCREW, .312-18 x 2.25hexhd pln gr 5pld

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

139 341

WASHER, exciter

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*190 823

BRUSH, contact

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

188 560

CLIP, spring

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

189 142

BRUSHHOLDER ASSEMBLY, gen

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

602 211

WASHER, lock .318 ID x 0.586

. . .

. . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

602 159

SCREW, .312-18 X .75hexwhd

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

190 259

HARNESS, brush (consisting of)

. . . . . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

135 134

CONNECTOR, rect univ 084 9P/S 3 row plug cable lkg

. . . . . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . .

187 651

SEAL, wire univ 9P/S 3 row

. . . . . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

When ordering a component originally displaying a precautionary label, the label should also be ordered. Order

label individually or as part of Label Kit 190 469.

*Recommended Spare Parts.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested

Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Summary of Contents for Big Blue 502P

Page 1: ...02P 602P Processes Description Air Carbon Arc CAC A Cutting and Gouging Stick SMAW Welding Engine Driven Welding Generator OM 491 190 355 January 1999 TIG GTAW Welding Visit our website at www Miller...

Page 2: ...ner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the works...

Page 3: ...Using Lifting Eye 13 4 3 Mounting Welding Generator 14 4 4 Installing Muffler 14 4 5 Activating The Dry Charge Battery If Applicable 15 4 6 Connecting The Battery 16 4 7 Engine Prestart Checks 17 4 8...

Page 4: ......

Page 5: ...n not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable Do...

Page 6: ...ch hot engine parts or just welded parts bare handed NOISE can damage hearing Noise from some processes or equipment can damage hearing Wear approved ear protection if noise level is high MAGNETIC FIE...

Page 7: ...mmables Keep exhaust and exhaust pipes way from flammables EXHAUST SPARKS can cause fire Do not let engine exhaust sparks cause fire Use approved engine exhaust spark arrestor in required areas see ap...

Page 8: ...une Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet...

Page 9: ...rifier fr quemment le cordon d alimentation pour voir s il n est pas en dommag ou d nud remplacer le cordon imm diatement s il est endommag un c ble d nud peut provoquer une lectrocution Mettre l appa...

Page 10: ...lures graves Pr voir une p riode de refroidissement avant d effec tuer des travaux d entretien Porter des gants et des v tements de protection pour travailler sur un moteur chaud Ne pas toucher mains...

Page 11: ...enir distance les produits inflammables de l chappement LES TINCELLES L CHAPPEMENT peuvent provoquer un incendie Emp cher les tincelles d chappement du moteur de provoquer un incendie Utiliser uniquem...

Page 12: ...Lejeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 de la National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pa...

Page 13: ...rent Stick SMAW Welding Constant Current CC Do Not Switch While Welding TIG GTAW Time h Hours s Seconds 1 Single Phase 3 Three Phase Read Operator s Manual Circuit Breaker SECTION 3 SPECIFICATIONS 3 1...

Page 14: ...8 in 1419 mm B C 9 1 2 in 241 mm D 27 1 2 in 699 mm G 30 E 1 in 25 mm G 30 30 F 28 1 2 in 729 mm Front Panel End C 25 30 G 9 16 in 14 mm Dia 4 Holes Front Panel End E 25 Weight E D w Perkins 3 152 No...

Page 15: ...50 200 250 300 350 400 450 500 DC WELD AMPERES AT 100 DUTY CYCLE 1800 RPM 0 Continuous Welding 3 5 Duty Cycle And Overheating Duty Cycle is percentage of 10 min utes that unit can weld at rated load w...

Page 16: ...The ac power curve shows the aux iliary power in amperes available at 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 VOLTS 0 25 50 75 100 150 1...

Page 17: ...AWG or larger insulated copper wire If unit does not have GFCI re ceptacles use GFCI protected extension cord 2 OR 18 in 460 mm 18 in 460 mm 18 in 460 mm 18 in 460 mm 18 in 460 mm OR Movement Airflow...

Page 18: ...Place Remove hardware securing the four mounting brackets to the base Reverse brackets and reattach to base with original hardware Mount unit to truck or trailer with 1 2 in 12 mm hardware not suppli...

Page 19: ...Wait ten minutes and check electro lyte level If necessary add electro lyte to raise to proper level Reins tall vent caps 6 Battery Charger Read and follow all instruc tions supplied with battery cha...

Page 20: ...OM 491 Page 16 4 6 Connecting The Battery 1 2 in Connect Negative Cable Last Tools Needed ST 802 168 A Ref ST 191 631 A S 0756 C...

Page 21: ...first time If necessary add cool ant to radiator until coolant level is at bottom of filler neck Check coolant level in recovery tank daily If necessary add coolant to recovery tank until coolant lev...

Page 22: ...g Weld Cable Sizes Total Cable Copper Length In Weld Circuit Not Exceeding Welding Amperes 100 ft 30 m Or Less 150 ft 45 m 200 ft 60 m 250 ft 70 m 300 ft 90 m 350 ft 105 m 400 ft 120 m Amperes 10 60 D...

Page 23: ...491 Page 19 4 10 Connecting To Remote Amperage Adjust Receptacle RC13 Ref 154 862 A 048 720 K 802 160 A 1 Remote Amperage Adjust Receptacle RC13 Connect optional remote control to RC13 see Section 5 3...

Page 24: ...OM 491 Page 20 SECTION 5 OPERATING THE WELDING GENERATOR 5 1 Front Panel Controls See Section 5 2 17 191 631 A 802 160 A 15 16 2 1 3 13 18 19 14 12 10 11 9 8 6 5 4 7...

Page 25: ...voltage and moni tor the engine charging system The meter should read about 14 volts dc when the en gine is running and about 12 volts dc when the engine is stopped 11 Engine Coolant Temperature Gauge...

Page 26: ...trol to RC13 see Section 4 10 0774 Ref 154 862 A Ref 181 711 A 802 160 A Example Combination Remote Amperage Control Stick In Example Range 125 to 320 A DC Percentage Of Range 50 Max About 223 A DC 50...

Page 27: ...is working properly 3 Circuit Breaker CB1 4 Circuit Breaker CB2 5 Circuit Breaker CB3 CB1 and CB3 protect RC1 from overload If CB1 or CB3 opens RC1 does not work 120 volts may still be present at RC1...

Page 28: ...ce Agent 8 h Check Fluid Levels See Section 4 7 Wipe Up Spills Drain Water From Fuel System OIL Full FUEL WATER Coolant Full 50 h Clean Air Filter See Section 7 3 Clean And Tighten Weld Terminals 100...

Page 29: ...h Repair Or Replace Damaged Cables 800 h Clean Set Injectors 1000 h Blow Out Or Vacuum Inside During Heavy Service Clean Monthly OR Drain Sludge From Fuel Tank See Section 7 6 FUEL SLUDGE Service Wel...

Page 30: ...OM 491 Page 26 7 2 Maintenance Label...

Page 31: ...cap Do not clean housing with air hose Clean element with compressed air Max air pressure 100 psi 690 kPa Replace element if it has holes or damaged gaskets Reinstall element and cap 4 3 Blow Inspect...

Page 32: ...ble for proper no load speed If neces sary adjust speed as follows 1 Adjustment Screw 2 Lock Nut Loosen nuts Turn screws out sev eral turns 3 Speed Lever Start engine and move lever until engine runs...

Page 33: ...ne maintenance label for oil filter change in formation To drain water from fuel system Open primary fuel filter petcock and drain water into metal container Close petcock when water free fuel flows T...

Page 34: ...11 5 Circuit Breaker CB12 6 Circuit Breaker CB13 CB10 protects the engine battery circuit If CB10 opens the engine will not crank CB10 automatically resets when the fault is corrected CB11 protects th...

Page 35: ...g Light Is Off Check Alternator And Belt If Temperature Light Is On Correct Cause Of Overheating See Engine Manual If Engine Is Okay See Factory Authorized Service Agent If Fuel Light Is On Check Fuel...

Page 36: ...c weld output Check and tighten connections inside and outside unit Be sure connection to work piece is clean and tight Use dry properly stored electrodes Remove excessive coils from weld cables Check...

Page 37: ...10 automatical ly resets when fault is corrected see Section 7 7 Check engine wiring harness plug connections Have Factory Authorized Service Agent check Engine Control switch S1 Engine cranks but doe...

Page 38: ...speed models with idle option only Have Factory Authorized Service Agent check Engine Control switch S1 Have Factory Authorized Service Agent check idle module PC7 and current transformer CT1 Check f...

Page 39: ...OM 491 Page 35 Notes...

Page 40: ...OM 491 Page 36 SECTION 8 ELECTRICAL DIAGRAMS Figure 8 1 Circuit Diagram For Welding Generator...

Page 41: ...OM 491 Page 37 191 550 C...

Page 42: ...er than necessary Piston rings seat faster if engine runs at weld power rpm and the welding generatoris kept loaded during run in 2 Engine Exhaust Pipe Wetstacking is unburned fuel and oil in the exha...

Page 43: ...ad bank to generator weld output terminals using proper size weld cables with correct connectors Observe correct polarity Start engine and run for several minutes Set load bank switches and then adjus...

Page 44: ...correct connec tors polarity is not important 4 Voltmeter 5 Clamp On Ammeter Connect voltmeter and ammeter as shown if not provided on generator Start engine and run for several minutes Set grid switc...

Page 45: ...le Insulated Equipment OR 2 Be sure equipment has this symbol and or wording 3 1 10 2 Grounding Generator To Truck Or Trailer Frame S 0854 1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grounding...

Page 46: ...istive Load Equipmentwith a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when run ning see Section 10 8 3 Rating Data Rating shows volt...

Page 47: ...ome Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 Mi...

Page 48: ...P 6000 1500 1 1 2 HP 8200 2200 2 HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1 3...

Page 49: ...Starting Requirements Motor Start Code G H J K L M N P KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0 EXAMPLE Calculate the starting amperage required for a 230 V 1 4 HP motor with a motor start code of...

Page 50: ...Connections Connect terminals or plug of ade quate amperage capacity to cord Follow all applicable codes and safety practices Turn off or unplug all equipment connected to generator before starting o...

Page 51: ...15 40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 2 voltage drop Cord Lengths for 240 Volt Loads If unit does not have GFCI receptacles use GFCI...

Page 52: ...dware is common and not available unless listed 1 2 3 4 5 6 7 8 9 10 13 14 15 16 17 18 19 20 21 22 23 24 25 26 28 29 30 31 32 33 34 97 98 99 100 102 101 103 Fig 11 5 105 106 107 108 109 Fig 11 3 11 12...

Page 53: ...802 265 35 36 37 38 39 40 41 42 43 45 46 47 48 49 50 53 Fig 11 4 54 55 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 89 90 91 92 93 Fig 11 2 94 51 44 52 86 87 88 58 59...

Page 54: ...ME mtg reactor and rectifier 1 18 189 708 FIREWALL top 1 19 190 182 PANEL side air box 1 20 189 763 BRACKET mtg air cleaner 1 21 189 764 AIR CLEANER intake 1 192 938 FILTER air element primary 1 192 9...

Page 55: ...1 awg w clamp and 406rng 1 65 108 081 TERMINAL PROTECTOR battery post mtg 2 66 190 206 CABLE bat neg 42 in lg No 2 awg w clamp and 375rng 1 67 190 896 BATTERY stor 12V 650crk 110rsv gp 24 1 68 168 38...

Page 56: ...do not weld on base 2 98 191 512 BRACKET hold down fuel tank 1 99 191 897 BRACKET mtg unit 4 100 190 179 PANEL mtg components 1 101 R4 191 292 RESISTOR WW fxd 375W 50 ohm w mtg bkt 1 102 R2 R3 189 69...

Page 57: ...A 800V 2 7 CR5 090 104 RELAY encl 12VDC SPST 30A 15VDC 1 8 2T 3T 190 210 BLOCK term 5 3 3 2 RC5 047 483 CONNECTOR rect univ 084 15P S 3 row rcpt cable panel lkg 1 RC3 RC4 158 466 CONNECTOR rect univ 0...

Page 58: ...age 54 Hardware is common and not available unless listed 802 266 1 2 3 4 5 6 7 8 11 14 12 15 16 17 19 20 21 22 24 25 28 31 30 32 33 34 35 36 37 9 13 10 18 23 11 29 26 27 Figure 11 3 Panel Front w Com...

Page 59: ...v 6P S 3 row 1 190 258 HARNESS auxiliary power consisting of 1 15 CB1 2 3 093 996 CIRCUIT BREAKER man reset 1P 20A 250VAC frict 3 16 GFCI1 151 981 RECEPTACLE str dx grd 2P3W 15 20A 125V GFCI 1 17 RC1...

Page 60: ...OM 491 Page 56 802 267 5 6 8 9 10 11 22 26 27 28 29 30 1 2 7 13 14 15 16 23 24 31 32 4 3 12 17 18 19 20 21 25 Figure 11 4 Generator...

Page 61: ...eel 1 20 049 026 SCREW M10 1 5 x 25hexhd pln 8 8pln 6 21 183 387 WASHER conical spring 406 ID x 875 OD pltd 6 22 191 579 COVER starter hole Perkins Continental 1 23 602 211 WASHER lock 318 ID x 0 586...

Page 62: ...BAR connection board 3 3 188 135 ENCLOSURE rectifier 2 4 134 201 STAND OFF support 3 5 PC3 188 610 CIRCUIT CARD ASSEMBLY protection 1 6 188 136 INSULATOR heat sink 8 7 188 493 HEAT SINK rectifier al 2...

Page 63: ...orches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate 185 Miller s True Blue Limited Warranty shall not apply to 1 Items furnished by Miller but manufactured by others such as eng...

Page 64: ...ss City State Zip Please complete and retain with your personal records Always provide Model Name and Serial Style Number Contact your Distributor for To locate distributor nearest you call 1 800 4 A...

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