Miller Electric Big Blue 302P manual SCREW, .312−18x .75 hexwhd.66d stl pld slffmg tap−rw 601

Page 91

Item	Dia.	Part
No.	Mkgs.	No.	Description	Quantity
			Figure 13-6. Generator (Continued)

. . . 21 . . . .	. . . . . . . . .	197 486 . .	ADAPTER, Engine Perkins 104.22	. . . 1
. . . 22 . . . .	. . . . . . . . .	083 883 . .	WASHER, Lock .402idx0.709odx.087t Stl Split10mm	. . . 4
. . . 23 . . . .	. . . . . . . . .	049 026 . .	SCREW, M10−1.5x 25 Hex Hd−pln 8.8 Pln	. . .4
. . . 24 . . . .	. . . . . . . . .	191 579 . .	COVER, starter hole Perkins/Continental	. . . 1
. . . . . . . . . .	. . . . . . . . .	195 560 . .	GUARD, starter hole deutz 912	. . . 1
. . . 25 . . . .	. . . . . . . . .	083 883 . .	WASHER, Lock .402idx0.709odx.087t Stl Split10mm	. . . 6
. . . 26 . . . .	. . . . . . . . .	172 555 . .	SCREW, M10-1.5 x 50hexhd pln 8.8pld	. . . 6
. . . 27 . . . .	. . . . . . . . .	602 159 . .	SCREW, .312−18x .75 hexwhd.66d stl pld slffmg tap−rw	. . .6
. . . 28 . . . .	. . . . . . . . .	601 961 . .	SCREW, .312-18 x 2.25hexhd pln gr 5pld	. . . 4
. . . 29 . . . .	. . . . . . . . .	. 602 211 . .	WASHER, lock .318 ID x 0.586	. . . 6
. . . 30 . . . .	. . . . . . . . .	139 341 . .	WASHER, exciter	. . . 4
. . . 31 . . . .	. . . . . . . . .	*190 823 . .	BRUSH, contact	. . . 3
. . . 32 . . . .	. . . . . . . . .	208 469 . .	CLIP, spring	. . . 3
. . . 33 . . . .	. . . . . . . . .	189 142 . .	BRUSHHOLDER ASSEMBLY, gen	. . . 1
. . . 34 . . . .	. . . . . . . . .	602 242 . .	WASHER, flat .375IDx0.875odx.083t stl pld	. . . 2
. . . 35 . . . .	. . . . . . . . .	. 602 211 . .	WASHER, Lock .318idx0.586odx.078t Stl Pld Split.312	. . . 2
. . . 36 . . . .	. . . . . . . . .	604 534 . .	SCREW, .312−18x1.25 hex hd−pln gr5 pld	. . .2
. . . . . . . . . .	. . . . . . . . .	190 259 . .	HARNESS, brush (consisting of)	. . . 1
. . . . . . . . . .	PLG1 . . .	168 071 . . .	. CONNECTOR, (kit) rect univ 084 9P/S 3 row plug cable lkg	. . . 1
. . . . . . . . . .	. . . . . . . . .	187 651 . . .	. SEAL, wire univ 9P/S 3 row	. . . 1

+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).

*Recommended Spare Parts.

♦Optional

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 85

Image 91

Contents Processes OM-496Description From Miller to You Table of Contents 11-2 11-111-3 Standards DirectivesDeccon1 11/02 Deccon1 5/98 Sound Level InformationArc Welding Hazards Symbol UsageEngine Hazards Compressed Air Hazards Radiation can cause interference Principal Safety StandardsCalifornia Proposition 65 Warnings EMF InformationLES Fumées ET LES GAZ peuvent être dangereux Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation UN Choc Électrique peut tuerLE Bruit peut affecter l’ouïe LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux DES Pièces Chaudes peuvent provoquer des brûlures graves’AIR Comprimé peut provoque r des blessures ’EXPLOSION DE LA Batterie peutDES Organes Mobiles peuvent provoquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendieInformation sur les champs électromagnétiques Principales normes de sécurité− Definitions Starting Instructions + −Engine Are possible hazards asHot muffler and exhaust pipes Can cause severe burns. DoReturn To Table Of Contents CC Models CC/CV Models Manufacturer’s Rating Labels For CE Products− 50 h Std StdSymbols And Definitions Weld, Power, And Engine Specifications − SpecificationsDimensions, Weights, And Operating Angles Volt-Ampere Curves For CC Models Volt-Ampere Curves For CC/CV Models Stick ModeMIG Mode TIG ModeDuty Cycle And Overheating Fuel Consumption15 kVA/kW Three-Phase AC Output No Weld Load AC Generator Power CurveOptional Three-Phase Generator Curves 12 kVA/kW Single-Phase AC Output No Weld LoadAirflow Clearance − InstallationInstalling Welding Generator See Sections 5-2And Location GroundingWork like a Pro Using Lifting EyeTo Bolt Unit In Place Mounting Welding GeneratorSupporting The Unit Mounting SurfaceStop engine and let cool Installing Exhaust PipeCharger Activating The Dry Charge Battery If ApplicableWhen electrolyte is low, add Read and follow all instrucReinstall cover after connecting battery Connecting The BatteryConnect Negative − Cable Last 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 Starting Controls To Start Do not use ether. Using ether voids warrantyEngine Indicator Lights Do not switch under loadSet weld controls as shown to Remote Amperage Control On CC Models OptionalWeld Control/Arc Condition Information Label Example Combination Remote Amperage Control StickReturn 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 OptionalOpen, contact Factory Autho − Operating Auxiliary EquipmentVolt And 240 Volt Receptacles At least once a month, run enRear Of Panel Three-Phase Power ConnectionClose panel opening if no connections are made to generator 240 V 15 a AC South African Receptacle RC1 Optional Generator Power ReceptaclesCircuit Breaker CB2 Circuit Breaker CB3 Maintenance Labels − Maintenance & TroubleshootingFor Non-CE Products Every 100 h Routine MaintenanceEvery 8 h Every 50 hChange Fuel Clean/Set InjectorsEvery 1000 h Every 2000 hDo not clean housing with air hose Servicing Air CleanerBy the warranty To clean air filterReinstall cleanout plug Tools Needed Inspecting And Cleaning Optional Spark Arrestor MufflerClose door Tools Needed 10 mm Adjusting Engine Speed On Standard ModelsMaximum Do not set engine speed higher than specifiedRpm max 61.6 Hz 1250 rpm 41.6 Hz Idle Speed AdjustmentWeld/Power Speed Adjustment Engine Speed No LoadServicing Fuel And Lubrication Systems Overload Protection Down before operating Diagnosing Causes Of Engine Fault ShutdownsDiagnostic Checks While Running Correct the cause of the shutWelding − CC Models TroubleshootingWelding − CC/CV Models Optional Three-Phase Generator Power CC/CV Models Only Standard Generator PowerEngine Air in fuel system. See engine manual Wiring harness and componentsShutdown switch is released Out Temperature is too high see Sections 5-7andReturn To Table Of Contents Circuit Diagram For CC Welding Generator − Electrical Diagrams215 296-B Circuit Diagram For CC/CV Welding Generator 215 297-B Wetstacking − RUN-IN ProcedureMent damage may occur From flammables Do not Perform Run-In Procedure Using Load BankProcedure at less than Stop engine Do not touch hot exhaustDo not perform run-in Run-In Procedure Using Resistance GridBank/grid From flammablesGrounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesHas this symbol Selecting EquipmentUse ground device as stated in electrical codes Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Earth ground if supplyingFarm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Industrial Motors Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentKVA/HP x HP x Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsTypical 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 Your distributor also gives ServiceSupport Transportation Department Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s