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Big Blue 402D
Miller Electric Big Blue 402D User Manual
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Big
Blue
402D,
502D,
602D
OM-495
192 774AR
October 2003
Processes
Description
Air Carbon Arc (CAC-A)
Cutting and Gouging
Stick (SMAW
)
W
elding
Engine Driven Welding Generator
TIG (GT
A
W
) W
elding
MIG (GMAW)
W
elding
Flux Cored (FCA
W
) W
elding
Visit our website at
www.MillerWelds.com
And Non-CE Models
2
Table of Contents
Default Chapter
3
Table of Contents
3
Section 1 − Safety Precautions − Read before Using
7
Symbol Usage
7
Arc Welding Hazards
7
Engine Hazards
8
Compressed Air Hazards
9
Additional Symbols for Installation, Operation, and Maintenance
9
California Proposition 65 Warnings
10
Principal Safety Standards
10
EMF Information
10
Section 2 − Consignes de Sécurité − Lire Avant Utilisation
11
Signification des Symboles
11
Dangers Relatifs Au Soudage À L'arc
11
Dangers Existant en Relation Avec Le Moteur
12
Dangers Liés À L'air Comprimé
13
Dangers Supplémentaires en Relation Avec L'installation, Le Fonctionnement Et la Maintenance
13
Principales Normes de Sécurité
14
Information Sur Les Champs Électromagnétiques
14
Section 3 − Definitions
15
Warning Label Definitions (for Wordless Labels)
15
Manufacturer's Rating Labels for Non-CE Products
19
Manufacturer's Rating Labels for CE Products
20
Symbols and Definitions
21
Section 4 − Specifications
22
Weld, Power, and Engine Specifications
22
Dimensions, Weights, and Operating Angles
22
Volt-Ampere Curves for CC Models
23
Volt-Ampere Curves for CC/CV Models
24
Fuel Consumption
25
Duty Cycle and Overheating
26
AC Generator Power Curve
27
Optional Three-Phase Generator Curves
28
Section 5 − Installation
30
Installing Welding Generator (See Sections 5-2 and 5-3)
30
Using Lifting Eye
31
Mounting Welding Generator
32
Installing Exhaust Pipe
33
Installing Engine Side Baffle (CE Models Only)
33
Activating the Dry Charge Battery (if Applicable)
34
Connecting the Battery
35
Installing Optional Ether Cylinder (Deutz F3L912 Engine Only)
35
Engine Prestart Checks
36
Connecting to Weld Output Terminals
37
Selecting Weld Cable Sizes
37
Connecting to Remote Amperage Adjust Receptacle RC13 on CC Models
38
Connecting to Remote 14 Receptacle RC14 on CC/CV Models
38
Section 6 − Operating Welding Generator − CC Models
40
Front Panel Controls for CC Models (See Section 6-2)
40
Description of Front Panel Controls for CC Models (See Section 6-1)
41
Remote Amperage Control on CC Models (Optional)
42
Weld Control/Arc Condition Information Label
42
Section 7 − Operating Welding Generator − CC/CV Models
44
Front Panel Controls for CC/CV Models (See Section 7-2)
44
Description of Front Panel Controls for CC/CV Models (See Section 7-1)
45
Process/Contactor Switch on CC/CV Models
46
Remote Voltage/Amperage Control on CC/CV Models (Optional)
47
Section 8 − Operating Auxiliary Equipment
48
Generator Power Receptacles (Standard Models)
48
Connecting to Optional Three-Phase Generator (CC/CV Standard Models Only)
49
Optional Generator Power Receptacles (Standard Models)
50
Generator Power Receptacles (CE Models)
51
Section 9 − Maintenance (Deutz F4L2011−Powered Units)
52
Routine Maintenance (Deutz F4L2011-Powered Units)
52
Maintenance Label
54
Servicing Air Cleaner (Deutz F4L2011-Powered Units)
55
Inspecting/Cleaning Optional Spark Arrestor (Deutz F4L2011-Powered Units)
56
Adjusting Engine Speed (Deutz F4L2011-Powered Units)
57
Servicing Fuel and Lubrication Systems (Deutz F4L2011-Powered Units)
58
Overload Protection (Deutz F4L2011-Powered Units)
59
Section 10 − Maintenance (Deutz F3L912−Powered Units)
60
Routine Maintenance (Deutz F3L912-Powered Units)
60
Maintenance Label
62
Servicing Air Cleaner (Deutz F3L912-Powered Units)
63
Inspecting/Cleaning Optional Spark Arrestor (Deutz F3L912-Powered Units)
64
Adjusting Engine Speed (Deutz F3L912-Powered Units)
65
Servicing Optional Ether Starting Aid (Deutz F3L912-Powered Units)
65
Servicing Fuel and Lubrication Systems (Deutz F3L912-Powered Units)
66
Overload Protection (Deutz F3L912-Powered Units)
67
Section 11 − Troubleshooting
68
Diagnosing Causes of Engine Fault Shutdowns
68
Troubleshooting Tables
69
Section 12 − Electrical Diagrams
74
Section 13 − Run-In Procedure
86
Wetstacking
86
Run-In Procedure Using Load Bank
87
Run-In Procedure Using Resistance Grid
88
Section 14 − Generator Power Guidelines
89
Grounding When Supplying Building Systems
90
Section 15 − Parts List
96
Options and Accessories
116
5
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Miller Electric Big Blue 402D Specifications
General
Brand
Miller Electric
Model
Big Blue 402D
Category
Welding System
Language
English
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