Miller Electric Big Blue 452P, Big Blue 302P manual Dia Part Mkgs Description Quantity

Page 78

Item

Dia.

 

Part

 

 

 

 

No.

Mkgs.

 

No.

Description

 

Quantity

 

 

 

 

 

 

Figure 13-1. Main Assembly

 

 

 

 

 

 

 

 

 

 

 

. . .

1

. . . .

. . . . . .

. . .

189 824 . .

PANEL, gen LH

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

. . . 1

. . .

1

. . . .

. . . . . .

. . ♦199 294 . .

PANEL, gen LH ss

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

. . . 1

. . .

2

. . . .

. . . . . .

. . .

191 623 . .

LABEL, warning all panels must be in place while running

. . . 2

. . .

2

. . . .

. . . . . .

. . .

176 106 . .

LABEL, warning moving parts (CE models only)

. . . 2

. . .

3

. . . .

. . . . . .

. .

+189 828 . .

PANEL, engine side

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

. . . 1

. . .

3

. . . .

. . . . . .

♦++199 301 . .

PANEL, engine side ss

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

. . . 1

. . . 4

. . . . . Z1 .

. . CC202 151 . .

REACTOR, ac

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

. . . 1

. . . 4

. . . . . Z1 .

. . CV201 514 . .

REACTOR, ac

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

. . . 1

. . .

5

. . . . . 1T .

. . .

038 621 . .

BLOCK, term 30A 4 pole frict term str

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

. . . 1

. . .

. . .

. . . .

. . . . . .

. . .

038 620 . .

LINK, jumper term blk 30A

. . . 2

. . .

6

. . . .

. . . . . .

. . .

081 499 . .

BRACKET, mtg strip terminal

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

. . . 1

. . .

7

. . . .

. . . . . .

. . .

206 352 . .

BRACE, front to center upright

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

. . . 2

. . .

8

. . SR4, SR5 .

035 704 . .

RECTIFIER, integ bridge 40. amp 800v

. . . 2

. . . 9

. . . . CB4

. . .

045 061 . .

CIRCUIT BREAKER, auto reset 24vdc 7 amp

. . . 1

. . . 10 . . . .

. . . . . .

. . .

201 697 . .

PAN, reactor and rectifier

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

. . . 1

. . . 11

. . . .

. T1 .

. . .

201 613 . .

TRANSFORMER w/bracket

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

. . . 1

. . . 11

. . . .

. T1 .

. . ♦205 636 . .

TRANSFORMER w/bracket (environmental coating)

. . . 1

. . . 12 . . . .

. . . . . .

. . .

173 352 . .

EXTRUSION, rubber clamp/bulb (order by ft)

. . . 3ft

. . . 13 . . . .

. . . . . .

. . .

189 708 . .

FIREWALL, top

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

. . . 1

. . . 14 . . . .

. . . . . .

. . .

191 307 . .

COVER, plate

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

. . . 1

. . . 15 . . . .

. . . . . .

. . .

189 763 . .

BRACKET, mtg air cleaner

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

. . . 1

. . . 16 . . . .

. . . . . .

. . .

189 764 . .

AIR CLEANER, intake

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

. . . 1

. . .

. . .

. . . .

. . . . . .

. . .

*192 938 . .

FILTER, air element primary

. . . 1

. . .

. . .

. . . .

. . . . . .

. *♦192 939 . .

FILTER, air element safety

. . . 1

. . . 17 . . . .

. . . . . .

. . .

189 618 . .

HOSE, air cleaner

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

. . . 1

. . . 18 . . . .

. . . . . .

. . .

198 457 . .

TUBE, air intake perkins 104.22

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

. . . 1

. . . 19 . . . .

. . . . . .

. . .

173 036 . .

HOSE, elbow air cleaner

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

. . . 1

. . .

. . .

. . . .

. . . . . .

. . .

010 863 . .

CLAMP, hose 1.125 − 3.000 clp dia

. . . 4

. . . 20 . . . .

. . . . . .

. . .

189 464 . .

SEAL, weather lift eye

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

. . . 1

. . .

. . .

. . . .

. . . . . .

. . .

173 909 . .

HOSE, sae .312 id x .560 od x 24.000

(order by ft)

. . . 2

. . . 21 . . . .

. . . . . .

. . .

201 658 . .

UPRIGHT, center assembly

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

. . . 1

. . . 22 . . . .

. . . . . .

. . .

191 819 . .

HOSE, sae .312 id x .560 od x 14.000

(order by ft)

. . . 2

. . .

. . .

. . . .

. . . . . .

. . .

198 584 . .

HOSE, sae .312 id x .560 od x 5.000 (order by ft)

. . . 1

. . . 23 . . . .

. . . . . .

. . .

095 636 . .

HOSE, sae .187 id x .41 od x 30.000

(order by ft)

. . . 1

. . . 24 . . . .

. . . . . .

. . .

192 750 . .

BASE, fuel filter w/adapter

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

. . . 1

. . . 25 . . . .

. . . . . .

. . .

*192 744 . .

FILTER, fuel spin-on

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

. . . 1

. . . 26 . . . .

. . . . . .

. . .

192 741 . .

BLOCK, spacer mtg filter base

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

. . . 1

. . . 27 . . . .

. . . . . .

. .

+201 934 . .

COVER, top

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

. . . 1

. . . 27 . . . .

. . . . . .

. ♦+202 640 . .

COVER, top ss

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

. . . 1

. . . 28 . . . .

. . . . . .

. . .

189 052 . .

GROMMET, plastic neck filler fuel . . .

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

. . . 1

. . . 29 . . . .

. . . . . .

. . .

190 198 . . .

. CAP, tank screw-on 3.500 in w/vent

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

. . . 1

. . . 30 . . . .

. . . . . .

. . .

192 041 . .

LABEL, use diesel fuel only

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

. . . 1

. . . 30 . . . .

. . . . . .

. . .

176 103 . .

LABEL, use diesel fuel only (CE models only)

. . . 1

. . . 31 . . . .

. . . . . .

. . .

108 487 . .

LABEL, warning falling equipment . . .

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

. . . 2

. . . 31 . . . .

. . . . . .

. . .

176 104 . .

LABEL, warning falling equipment (CE models only)

. . . 2

. . . 32 . . . .

. . . . . .

. . .

176 230 . .

LABEL, warning hot exhaust

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

. . . 1

. . . 33 . . . .

. . . . . .

. . .

105 734 . .

PIPE, muffler extension elbow 1.750 od

. . . 1

. . . 34 . . . .

. . . . . .

. . .

201 851 . .

COVER, radiator access

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

. . . 1

. . . 34 . . . .

. . . . . .

. . ♦202 629 . .

COVER, radiator access ss

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

. . . 1

. . . 35 . . . .

. . . . . .

. . .

191 354 . .

SUPPORT, cover

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

. . . 1

. . . 35 . . . .

. . . . . .

. . ♦202 633 . .

SUPPORT, cover e-coat

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

. . . 1

. . . 36 . . . .

. . . . . .

. . .

010 875 . .

CLAMP, muffler 2.000 dia

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

. . . 1

. . . 37 . . . .

. . . . . .

. . .

203 180 . .

MANIFOLD, exhaust muffler perkins 104.22

. . . 1

. . .

. . .

. . . .

. . . . . .

. . .

203 179 . .

BRACKET, support muffler

. . . 2

OM-496 Page 72

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Contents OM-496 ProcessesDescription From Miller to You Table of Contents 11-1 11-211-3 Directives StandardsDeccon1 11/02 Sound Level Information Deccon1 5/98Symbol Usage Arc Welding HazardsEngine Hazards Compressed Air Hazards EMF Information Principal Safety StandardsCalifornia Proposition 65 Warnings Radiation can cause interferenceUN Choc Électrique peut tuer Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation LES Fumées ET LES GAZ peuvent être dangereuxDES Pièces Chaudes peuvent provoquer des brûlures graves LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux LE Bruit peut affecter l’ouïeLA Chaleur DU Moteur peut pro- voquer un incendie ’EXPLOSION DE LA Batterie peutDES Organes Mobiles peuvent provoquer des blessures ’AIR Comprimé peut provoque r des blessuresPrincipales normes de sécurité Information sur les champs électromagnétiques− Definitions + − Starting InstructionsCan cause severe burns. Do Are possible hazards asHot muffler and exhaust pipes EngineReturn To Table Of Contents Std Manufacturer’s Rating Labels For CE Products− 50 h Std CC Models CC/CV ModelsSymbols And Definitions − Specifications Weld, Power, And Engine SpecificationsDimensions, Weights, And Operating Angles Volt-Ampere Curves For CC Models TIG Mode Stick ModeMIG Mode Volt-Ampere Curves For CC/CV ModelsFuel Consumption Duty Cycle And Overheating12 kVA/kW Single-Phase AC Output No Weld Load AC Generator Power CurveOptional Three-Phase Generator Curves 15 kVA/kW Three-Phase AC Output No Weld LoadLocation Grounding − InstallationInstalling Welding Generator See Sections 5-2And Airflow ClearanceUsing Lifting Eye Work like a ProMounting Surface Mounting Welding GeneratorSupporting The Unit To Bolt Unit In PlaceInstalling Exhaust Pipe Stop engine and let coolRead and follow all instruc Activating The Dry Charge Battery If ApplicableWhen electrolyte is low, add ChargerConnecting The Battery Reinstall cover after connecting batteryConnect Negative − Cable Last Coolant Recovery Tank Engine Prestart ChecksConnecting To Weld Output Terminals Selecting Weld Cable SizesRef 862-A / 048 720-K / 802 Connecting To Remote 14 Receptacle RC14 On CC/CV Models Socket− Operating Welding Generator − CC Models Front Panel Controls For CC Models See SectionDo not switch under load To Start Do not use ether. Using ether voids warrantyEngine Indicator Lights Engine Starting ControlsExample Combination Remote Amperage Control Stick Remote Amperage Control On CC Models OptionalWeld Control/Arc Condition Information Label Set weld controls as shown toReturn To Table Of Contents − Operating Welding Generator − CC/CV Models Front Panel Controls For CC/CV Models See SectionUse switch to select weld amperage range Voltage/Amperage Adjust Switch And Remote 14 ReceptacleProcess/Contactor Switch On CC/CV Models Process/Contactor Switch SettingsRemote Voltage/Amperage Control On CC/CV Models Optional Example Combination Remote Amperage Control TIGAt least once a month, run en − Operating Auxiliary EquipmentVolt And 240 Volt Receptacles Open, contact Factory AuthoThree-Phase Power Connection Rear Of PanelClose panel opening if no connections are made to generator Optional Generator Power Receptacles 240 V 15 a AC South African Receptacle RC1Circuit Breaker CB2 Circuit Breaker CB3 − Maintenance & Troubleshooting Maintenance LabelsFor Non-CE Products Every 50 h Routine MaintenanceEvery 8 h Every 100 hEvery 2000 h Clean/Set InjectorsEvery 1000 h Change FuelTo clean air filter Servicing Air CleanerBy the warranty Do not clean housing with air hoseInspecting And Cleaning Optional Spark Arrestor Muffler Reinstall cleanout plug Tools NeededDo not set engine speed higher than specified Adjusting Engine Speed On Standard ModelsMaximum Close door Tools Needed 10 mmEngine Speed No Load Idle Speed AdjustmentWeld/Power Speed Adjustment Rpm max 61.6 Hz 1250 rpm 41.6 HzServicing Fuel And Lubrication Systems Overload Protection Correct the cause of the shut Diagnosing Causes Of Engine Fault ShutdownsDiagnostic Checks While Running Down before operatingTroubleshooting Welding − CC ModelsWelding − CC/CV Models Standard Generator Power Optional Three-Phase Generator Power CC/CV Models OnlyEngine Temperature is too high see Sections 5-7and Wiring harness and componentsShutdown switch is released Out Air in fuel system. See engine manualReturn To Table Of Contents − Electrical Diagrams Circuit Diagram For CC Welding Generator215 296-B Circuit Diagram For CC/CV Welding Generator 215 297-B − RUN-IN Procedure WetstackingMent damage may occur Stop engine Do not touch hot exhaust Run-In Procedure Using Load BankProcedure at less than From flammables Do not PerformFrom flammables Run-In Procedure Using Resistance GridBank/grid Do not perform run-inSelecting Equipment − Generator Power GuidelinesHas this symbol Grounding Generator To Truck Or Trailer FrameEarth ground if supplying Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Use ground device as stated in electrical codesIndustrial Motors Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsSingle-Phase Induction Motor Starting Requirements Power Required To Start MotorHow Much Power Can Generator Supply? KVA/HP x HP xTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Current Load Watts Amperes− Parts List 109 111 -4 or118 85 FigDia Part Mkgs Description Quantity 209 Figures 13-2 Control Box Assembly − CC Models PLG3 Control Box Assembly − CC/CV Models PC7 195 Panel, Front w/Components − CC Models RC13 032 Panel, Front w/Components − CC/CV Models 41 40Panel, Front w/Components − CC/CV Models -1Item PC4, PC5 189 Generator Generator -1Item602 SCREW, .312−18x .75 hexwhd.66d stl pld slffmg tap−rw 601 Main Rectifier Assembly Page Page Service Your distributor also givesSupport Your distributor and/or equipment manufacturer’s Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Transportation Department
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