Miller Electric Big Blue 452P, Big Blue 302P manual Figures 13-2

Page 80

 

Item

Dia.

Part

 

 

 

No.

Mkgs.

No.

Description

Quantity

 

 

 

 

Figure 13-1. Main Assembly (Continued)

 

 

 

 

 

 

. . . 76 . . . .

. . . . . .

. . . 071 730 . .

TUBING, stl .875 OD x 12ga wall x 2.500

. . . 4

. . . 77 . . . .

. . . . . .

. . . 083 476 . .

MOUNT, eng/gen nprn .875 ID x 2.500 OD x 2.000

. . . 4

. . . 78 . . . .

. . . . . .

. . . 135 205 . .

NUT, 625-11 .94hex .76H stl pld elastic stop nut

. . . 4

. . . 79 . . . .

. . . . . .

. . . *197 997 . .

FILTER, fuel secondary

. . . 1

. . . 80 . . . .

. . . . . .

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

PUMP, fuel (available through engine manufacturer)

. . . 1

. . . 81 . . . .

. . . . . .

. . . 173 909 . .

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

. . . 1

. . . 82 . . . .

. . . . . .

. . . 198 548 . .

BRACKET, mtg fuel filter/pump

. . . 1

. . . 83 . . . .

. . . . . .

. . ♦198 624 . .

IDLE SOLENOID ASSEMBLY (consisting of)

. . . 1

. .

. . . . . . . .

. . . . . .

. . . 049 839 . . .

. Bracket, Adjustment Solenoid

. . . 1

. .

. . . . . . . .

. . . . . .

. . . 080 517 . . .

. Solenoid, 12vdc Pull Type Tubular

. . . 1

. .

. . . . . . . .

. . . . . .

. . . 203 716 . . .

. Bracket, Mtg Solenoid 104.22

. . . 1

. .

. . . . . . . .

. . . . . .

. . . 605 277 . . .

. Pin, Cotter .093 X .750 Zinc Pld

. . . 1

. .

. . . . . . . .

. . . . . .

. . . 198 370 . . .

. Rod, Throttle

. . . 1

. .

. . . . . . . .

. . . . . .

. . . 206 209 . . .

. Ball Joint, .250−28 Thd

. . . 1

. .

. . . . . . . .

. . . . . .

. . . 198 609 . . .

. Arm, Throttle 104.22

. . . 1

. . . 84 . . . .

. . . . . .

. . . 013 367 . .

LABEL, warning moving parts

. . . 2

. . . 84 . . . .

. . . . . .

. . . 176 106 . .

LABEL, warning moving parts (CE models only)

. . . 2

. . . 85 . . . .

. . . . . .

. Figure13-6 . .

GENERATOR

. . . 1

. . . 86 . . . .

. . . . . .

. . . 095 636 . .

HOSE, sae .312 id x .560 od x 14.000 (order by ft)

. . . 1

. . . 87 . . . .

. . . . . .

. . . 218 087 . .

TANK, fuel 23gal (consisting of)

. . . 1

. . . 88 . . . .

. . . . . .

. . . 124 253 . . .

. BUSHING, tank fuel

. . . 4

. .

. . . . . . . .

. . . . . .

. . . 084 173 . . .

. CLAMP, hose .460 − .545clp dia slfttng

. . . 2

. . . 89 . . . .

. . . . . .

. . . 189 912 . . .

. FITTING, stl barbed elbow w/.047 in orf zinc pld

. . . 1

. . . 90 . . . .

. . . . . .

. . . 189 909 . . .

. FITTING, stand pipe hose .250 x 9.260 lg 90deg zinc

. . . 1

. . . 91 . . . .

. . . . . .

. . . 201 025 . . .

. CAP, fuel fitting

. . . 1

. . . 92 . . . .

. . . . . .

. . . 189 913 . . .

. FITTING, stl barbed elbow zinc pld

. . . 1

. . . 93 . . . .

. . . . . .

. . . 190 142 . . .

. SENDER, fuel gauge 9.7500 deep tank

. . . 1

. . . 94 . . . .

. . . . . .

. . . 189 910 . . .

. FITTING, stand pipe hose .3125 x 9.260 lg 90deg zinc

. . . 1

. . . 95 . . . .

. . . . . .

. . . 189 908 . . .

. VALVE, drain fuel 180deg

. . . 1

. . . 96 . . . .

. . . . . .

. . . 181 572 . . .

. BUSHING, tank fuel

. . . 1

. . . 97 . . . .

. . . . . .

. . . 191 446 . .

EXTRUSION, rubber w/adhesive 1.000 x 1.000 D (order by ft)

. . . 6ft

. . . 98 . . . .

. . . . . .

. . . 190 179 . .

PANEL, mtg components

. . . 1

. . . 99 . . . .

. . . . . .

. . . 190 250 . .

LABEL, warning do not weld on base

. . . 2

. . . 99 . . . .

. . . . . .

. . . 200 864 . .

LABEL, do not weld on base (CE models only)

. . . 2

. . 100 . . .

. . . . . .

. . . 191 897 . .

BRACKET, mtg unit

. . . 4

. . 101 . . .

. . . . . .

. . . 192 362 . .

BRACKET, mtg nyl 1/2 conduit

. . . 1

. . 102 . . .

. . . . . .

. . . 196 220 . .

BRACKET, hold down fuel tank rear

. . . 1

. . 103 . . .

. . . . . .

. . +200 999 . .

BASE

. . . 1

. . 103 . . .

. . . . . .

. ♦+203 382 . .

BASE e-coat

. . . 1

. . 104 . . .

. . . . . .

. . . 218 086 . .

BRACKET, hold down fuel tank

. . . 1

. . 105 . . .

. . . . . .

. . . 189 731 . .

FIREWALL, lower

. . . 1

. . 106 . . . . . Figures 13-2, 13-3

CONTROL BOX ASSEMBLY

. . . 1

. . 107 . . . . R2 .

. . CC189 699 . .

RESISTOR, WW tap 375W 10 ohm w/mtg bkt

. . . 1

. . 108 . . . . R3 .

. . . 189 699 . .

RESISTOR, WW tap 375W 10 ohm w/mtg bkt

. . . 1

. . 109 . . .

. . . . . .

. . +201 750 . .

UPRIGHT, front

. . . 1

. . 109 . . .

. . . . . .

. ♦+202 637 . .

UPRIGHT, front ss

. . . 1

. .

110 . . .

. . . . . .

. . . 182 761 . .

LABEL, warning general precautionary

. . . 1

. .

110 . . .

. . . . . .

. . . 176 105 . .

LABEL, warning general precautionary (CE models only)

. . . 1

. .

111 . . .

. . . . . .

. . . . 13-4,13-5 . .

PANEL, front w/components

. . . 1

. .

112 . . .

. . . . . .

. . . . 202130 . .

XFMR, current sensing

. . . 1

. .

113 . . .

. . . . . .

. . . 190 010 . .

LABEL, caution do not use ether

. . . 1

. .

113 . . .

. . . . . .

. . . 176 109 . .

LABEL, caution using ether to aid engine (CE models only)

. . . 1

. .

114 . . .

. . . . . .

. . . 191 448 . .

TOP, cover front upright

. . . 1

. .

114 . . .

. . . . . .

. . ♦199 305 . .

TOP, cover front upright ss

. . . 1

. . 115 . . .

. . . . . .

Figure 13-7 . .

MAIN RECTIFIER ASSEMBLY

. . . 1

. . 116 . . .

. . . . . .

. . CV193 453 . .

BRACKET, mtg box fcr

. . . 1

. . 117 . . . PC1

. . CV189 143 . .

MODULE, field current regulator

. . . 1

. .

118 . . .

. . . . . .

. . +147 923 . .

LABEL, warning moving parts can cause serious injury

. . . 1

OM-496 Page 74

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Contents Description OM-496Processes From Miller to You Table of Contents 11-3 11-111-2 Deccon1 11/02 DirectivesStandards Sound Level Information Deccon1 5/98Symbol Usage Arc Welding HazardsEngine Hazards Compressed Air Hazards Principal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interferenceSignification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un in- cendie ou une explosion DES Particules Volantes peuvent blesser les yeuxDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peut DES Organes Mobiles peuvent provoquer des blessuresLA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoque r des blessuresPrincipales normes de sécurité Information sur les champs électromagnétiques− Definitions + − Starting InstructionsAre possible hazards as Hot muffler and exhaust pipesCan cause severe burns. Do EngineReturn To Table Of Contents Manufacturer’s Rating Labels For CE Products − 50 h StdStd CC Models CC/CV ModelsSymbols And Definitions Dimensions, Weights, And Operating Angles − SpecificationsWeld, Power, And Engine Specifications Volt-Ampere Curves For CC Models Stick Mode MIG ModeTIG Mode Volt-Ampere Curves For CC/CV ModelsFuel Consumption Duty Cycle And OverheatingAC Generator Power Curve Optional Three-Phase Generator Curves12 kVA/kW Single-Phase AC Output No Weld Load 15 kVA/kW Three-Phase AC Output No Weld Load− Installation Installing Welding Generator See Sections 5-2AndLocation Grounding Airflow ClearanceUsing Lifting Eye Work like a ProMounting Welding Generator Supporting The UnitMounting Surface To Bolt Unit In PlaceInstalling Exhaust Pipe Stop engine and let coolActivating The Dry Charge Battery If Applicable When electrolyte is low, addRead and follow all instruc ChargerConnect Negative − Cable Last Connecting The BatteryReinstall cover after connecting battery 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 SectionTo Start Do not use ether. Using ether voids warranty Engine Indicator LightsDo not switch under load Engine Starting ControlsRemote Amperage Control On CC Models Optional Weld Control/Arc Condition Information LabelExample Combination Remote Amperage Control Stick 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 TIG− Operating Auxiliary Equipment Volt And 240 Volt ReceptaclesAt least once a month, run en Open, contact Factory AuthoClose panel opening if no connections are made to generator Three-Phase Power ConnectionRear Of Panel Circuit Breaker CB2 Circuit Breaker CB3 Optional Generator Power Receptacles240 V 15 a AC South African Receptacle RC1 For Non-CE Products − Maintenance & TroubleshootingMaintenance Labels Routine Maintenance Every 8 hEvery 50 h Every 100 hClean/Set Injectors Every 1000 hEvery 2000 h Change FuelServicing Air Cleaner By the warrantyTo clean air filter Do not clean housing with air hoseInspecting And Cleaning Optional Spark Arrestor Muffler Reinstall cleanout plug Tools NeededAdjusting Engine Speed On Standard Models MaximumDo not set engine speed higher than specified Close door Tools Needed 10 mmIdle Speed Adjustment Weld/Power Speed AdjustmentEngine Speed No Load Rpm max 61.6 Hz 1250 rpm 41.6 HzServicing Fuel And Lubrication Systems Overload Protection Diagnosing Causes Of Engine Fault Shutdowns Diagnostic Checks While RunningCorrect the cause of the shut Down before operatingTroubleshooting Welding − CC ModelsWelding − CC/CV Models Engine Standard Generator PowerOptional Three-Phase Generator Power CC/CV Models Only Wiring harness and components Shutdown switch is released OutTemperature is too high see Sections 5-7and 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 Ment damage may occur − RUN-IN ProcedureWetstacking Run-In Procedure Using Load Bank Procedure at less thanStop engine Do not touch hot exhaust From flammables Do not PerformRun-In Procedure Using Resistance Grid Bank/gridFrom flammables Do not perform run-in− Generator Power Guidelines Has this symbolSelecting Equipment Grounding Generator To Truck Or Trailer FrameGrounding When Supplying Building Systems How Much Power Does Equipment Require?Earth ground if supplying Use ground device as stated in electrical codesApproximate Power Requirements For Industrial Motors Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsPower Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements 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 Support ServiceYour distributor also gives Miller Electric Mfg. Co For assistance in filing or settling claims, contactYour distributor and/or equipment manufacturer’s Transportation Department
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