Miller Electric Big Blue 302P, Big Blue 452P manual PC4, PC5 189

Page 89

Item

Dia.

 

Part

 

 

No.

Mkgs.

 

No.

Description

Quantity

 

 

 

Figure 13-5. Panel, Front w/Components − CC/CV Models (Continued)

 

 

 

 

 

 

 

. . . 36 . .

. . . . . . . .

. . .

199 303

. . PANEL, mtg terminal pwr output ss

. . . 1

. . . 37 . .

PC4, PC5 .

189 744

. . CIRCUIT CARD ASSEMBLY, filter hf

. . . 2

. . . 38 . .

. . . . . . . .

. . .

039 046

. . TERMINAL, pwr output black

. . . 1

. . . . . . . .

. . . . . . . .

. . .

180 735

. . WASHER, output stud

. . . 2

. . . 39 . .

. . . . . . . .

. . .

134 201

. . STAND-OFF, support

. . . 12

. . . 40 . .

. . . . . . . .

. . .

181 169

. . SPACER, output stud

. . . 2

. . . 41 . .

. . . . . . . .

. . .

186 621

. . BOOT, generic output stud

. . . 2

. . . 42 . .

. . . . . . . .

. . ♦059 773

. . HANDLE, switch

. . . 1

. . . 43 . .

. . . . . . . .

. . ♦010 647

. . PIN, spring cs .156 x 1.250

. . . 1

. . . 44 . .

. . . . . . . .

. . .

039 047

. . TERMINAL, pwr output red

. . . 1

. . . 45 . .

. . . . . . . .

. . ♦196 073

. . LABEL, do not switch while welding

. . . 1

. . . 46 . .

. . . . . . . .

. . .

193 143

. . BOOT, magnetic shutdown switch

. . . 1

. . . 47 . .

. . . . . . . .

. . .

021 385

. . BOOT, toggle switch lever

. . . 1

. . . 48 . .

. . . . . . . .

. . .

. 119 014

. . LEVER, switch black

. . . 1

. . . 49 . .

. . . . . . . .

. . .

190 323

. . BOOT, circuit breaker clear hex nut

. . . 2

. . . 50 . .

. . . . . . . .

. . .

170 391

. . CONN, circ ms protective cap size 20

. . . 1

. . . 51 . .

. . . PL1

. . .

191 241

. . LED, red 12V 4 ind lights panel mtg round

. . . 1

. . . 52 . .

. . FUEL

. . .

192 265

. . GAUGE, fuel elec switch w/o sensor

. . . 1

. . . 53 . .

. . . HM .

. . .

. 118 058

. . METER, hour 12-24VDC 2.25dia

. . . 1

. . . 54 . .

. . . . . . . .

. ♦193 228

. . METER, Volt Dc 8− 18 Scale 2.250 In Black Face

. . . 1

. . . 55 . .

. . . . . . . .

. ♦193 229

. . GAUGE, Coolant Temp 0− 300 Deg F Electric Switch

. . . 1

. . . . . . . .

. . . . . . . .

. ♦193 231

. . SENDER, Coolant Temp 300 Deg F 1/2−14 Npt

 

. . . . . . . .

. . . . . . . .

.. . ♦. .197. . . .798. . . .

. . (Perkins 3.152 engine only

. . . 1

. . . . . . . .

. . . . . . . .

. . SENDER, Coolant Temp 300 Deg F M16 X 1.5

 

. . . . . . . .

. . . . . . . .

.. . ♦. .193. . . .227. . . .

. . (Perkins 104.22 engine only)

. . . 1

. . . 56 . .

. . . . . . . .

. . GAUGE, Pressure Oil 0−100 Psi Electric Switch

. . . 1

. . . . . . . .

. . . . . . . .

. ♦193 230

. . SENDER, Pressure Oil 0− 100 Psi

. . . 1

. . . 57 . .

. . . . . . . .

. ♦194 348

. . AMMETER, W/Leads

. . . 1

. . . . . . . .

. . . . . . . .

. ♦030 084

. . SHUNT, Meter 50mv 600 Amp Lt Wt

. . . 1

. . . 58 . .

. . . . . . . .

. ♦194 345

. . VOLT METER, W/Leads

. . . 1

. . . 59 . .

. . . . . . . .

. . .

097 922

. . KNOB, pointer .875 dia x .250 ID w/set screws plstc

. . . 1

. . . 60 . .

. . . . . . . .

. . .

189 161

. . HANDLE, switch range

. . . 1

. . . 61 . .

. . . . . . . .

. . .

010 647

. . PIN, spring CS .156 x 1.250

. . . 1

. . . 62 . .

. . . . . . . .

. . .

097 924

. . KNOB, pointer 1.625 dia x .250 ID w/set scrws plstc

. . . 1

. . . 63 . .

. . CB6

. . .

083 432

. . CIRCUIT BREAKER, Man Reset 1p 10a 250vac Frict

. . . 1

. . . . . . . .

. . . . . . . .

. . .

193 158

. . HARNESS, unit weld control − CV (consisting of)

. . . 1

. . . . . . . .

. . PLG6

. . .

. 114 063

. . . . CONNECTOR, rect univ 084 4p/s 1 row plug cable lkg

. . . 1

. . . . . . . .

. . PLG8

. . .

193 184

. . . . CONNECTOR, rect cinch 30 pin

. . . 1

. . . . . . . .

. PLG13 . .

147 992

. . . . CONNECTOR, rect univ 039 10p/s 2 row plug cable

. . . 1

. . . . . . . .

. . PLG3

. . .

158 465

. . . . CONNECTOR, rect univ 084 12p/s 3 row plug cable

. . . 1

. . . . . . . .

. . . . . . . .

. . .

088 731

. . . . BUSHING, snap-in nyl .375 ID x .500 mtg hole

. . . 1

. . . . . . . .

. . . . . . . .

. . .

135 873

. . . . CLIP, conduit convoluted 1/2 in mtg hole

. . . 2

. . . . . . . .

. . . . . . . .

. . .

187 654

. . . . SEAL, wire univ 12p/s 3 row

. . . 1

. . . . . . . .

. . . . . . . .

. . .

024 103

. . BLANK, snap-in nyl .750 mtg hole blk

. . . 1

♦. .Optional

. . .

120 304

. . BLANK, snap−in nyl .250 mtg hole black

. . . 2

 

 

 

 

+When ordering a component originally displaying a precautionary label, the label should also be ordered. Order label individually or as part of Label Kit 202 021 or Label Kit 201 061 (CE models only).

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.

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OM-496 Page 83

Page 88 Page 90
Image 89
Page 88 Page 90
Contents Description OM-496Processes From Miller to You Table of Contents 11-3 11-111-2 Deccon1 11/02 DirectivesStandards Deccon1 5/98 Sound Level InformationArc Welding Hazards Symbol UsageEngine Hazards Compressed Air Hazards California Proposition 65 Warnings Principal Safety StandardsEMF Information Radiation can cause interference− Consignes DE Sécurité − Lire Avant Utilisation Signification des symbolesUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereuxDES Particules Volantes peuvent blesser les yeux LE Soudage peut provoquer un in- cendie ou une explosionDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut affecter l’ouïeDES Organes Mobiles peuvent provoquer des blessures ’EXPLOSION DE LA Batterie peutLA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoque r des blessuresInformation sur les champs électromagnétiques Principales normes de sécurité− Definitions Starting Instructions + −Hot muffler and exhaust pipes Are possible hazards asCan cause severe burns. Do EngineReturn To Table Of Contents − 50 h Std Manufacturer’s Rating Labels For CE ProductsStd CC Models CC/CV ModelsSymbols And Definitions Dimensions, Weights, And Operating Angles − SpecificationsWeld, Power, And Engine Specifications Volt-Ampere Curves For CC Models MIG Mode Stick ModeTIG Mode Volt-Ampere Curves For CC/CV ModelsDuty Cycle And Overheating Fuel ConsumptionOptional Three-Phase Generator Curves AC Generator Power Curve12 kVA/kW Single-Phase AC Output No Weld Load 15 kVA/kW Three-Phase AC Output No Weld LoadInstalling Welding Generator See Sections 5-2And − InstallationLocation Grounding Airflow ClearanceWork like a Pro Using Lifting EyeSupporting The Unit Mounting Welding GeneratorMounting Surface To Bolt Unit In PlaceStop engine and let cool Installing Exhaust PipeWhen electrolyte is low, add Activating The Dry Charge Battery If ApplicableRead and follow all instruc ChargerConnect Negative − Cable Last Connecting The BatteryReinstall cover after connecting battery Engine Prestart Checks Coolant Recovery TankSelecting Weld Cable Sizes Connecting To Weld Output TerminalsRef 862-A / 048 720-K / 802 Socket Connecting To Remote 14 Receptacle RC14 On CC/CV ModelsFront Panel Controls For CC Models See Section − Operating Welding Generator − CC ModelsEngine Indicator Lights To Start Do not use ether. Using ether voids warrantyDo not switch under load Engine Starting ControlsWeld Control/Arc Condition Information Label Remote Amperage Control On CC Models OptionalExample Combination Remote Amperage Control Stick Set weld controls as shown toReturn To Table Of Contents Front Panel Controls For CC/CV Models See Section − Operating Welding Generator − CC/CV ModelsVoltage/Amperage Adjust Switch And Remote 14 Receptacle Use switch to select weld amperage rangeProcess/Contactor Switch Settings Process/Contactor Switch On CC/CV ModelsExample Combination Remote Amperage Control TIG Remote Voltage/Amperage Control On CC/CV Models OptionalVolt And 240 Volt Receptacles − Operating Auxiliary EquipmentAt 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 Every 8 h Routine MaintenanceEvery 50 h Every 100 hEvery 1000 h Clean/Set InjectorsEvery 2000 h Change FuelBy the warranty Servicing Air CleanerTo clean air filter Do not clean housing with air hoseReinstall cleanout plug Tools Needed Inspecting And Cleaning Optional Spark Arrestor MufflerMaximum Adjusting Engine Speed On Standard ModelsDo not set engine speed higher than specified Close door Tools Needed 10 mmWeld/Power Speed Adjustment Idle Speed AdjustmentEngine Speed No Load Rpm max 61.6 Hz 1250 rpm 41.6 HzServicing Fuel And Lubrication Systems Overload Protection Diagnostic Checks While Running Diagnosing Causes Of Engine Fault ShutdownsCorrect the cause of the shut Down before operatingWelding − CC Models TroubleshootingWelding − CC/CV Models Engine Standard Generator PowerOptional Three-Phase Generator Power CC/CV Models Only Shutdown switch is released Out Wiring harness and componentsTemperature is too high see Sections 5-7and Air in fuel system. See engine manualReturn To Table Of Contents Circuit Diagram For CC Welding Generator − Electrical Diagrams215 296-B Circuit Diagram For CC/CV Welding Generator 215 297-B Ment damage may occur − RUN-IN ProcedureWetstacking Procedure at less than Run-In Procedure Using Load BankStop engine Do not touch hot exhaust From flammables Do not PerformBank/grid Run-In Procedure Using Resistance GridFrom flammables Do not perform run-inHas this symbol − Generator Power GuidelinesSelecting Equipment Grounding Generator To Truck Or Trailer FrameHow Much Power Does Equipment Require? Grounding When Supplying Building SystemsEarth ground if supplying Use ground device as stated in electrical codesApproximate Power Requirements For Farm/Home Equipment Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentHow Much Power Can Generator Supply? Power Required To Start MotorSingle-Phase Induction Motor Starting Requirements KVA/HP x HP xTypical Connections To Supply Standby Power Current Load Watts Amperes Selecting Extension Cord Use Shortest Cord Possible109 111 -4 or − Parts List85 Fig 118Dia 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 41 40 Panel, Front w/Components − CC/CV ModelsPanel, Front w/Components − CC/CV Models -1Item PC4, PC5 189 Generator -1Item Generator602 SCREW, .312−18x .75 hexwhd.66d stl pld slffmg tap−rw 601 Main Rectifier Assembly Page Page Support ServiceYour distributor also gives For assistance in filing or settling claims, contact Miller Electric Mfg. CoYour distributor and/or equipment manufacturer’s Transportation Department
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