PC7 195 | Miller Electric Big Blue 452P, Big Blue 302P guide

Item	Dia.		Part
No.	Mkgs.		No.	Description	Quantity
			Figure 13-3. Control Box Assembly − CC/CV Models (Continued)

. . . . . . . . . . . . . . . .		. . .	196 602 . . .	. PLUG, cavity 18,30 position cinch connector	. . . 4
. . . . . . . . . . . . . . . .		. . .	196 603 . . .	. SEAL, switch 6 position rotary .250 shaft	. . . 1
. . . . . . . . . . . . . . . .		. . .	141 450 . . .	. CONN, rect metrmate 10skt 1row plug cable lkg	. . . 1
. . . 13 .	. . . PC7	. . ♦195 706 . .		MODULE, pull to idle, two output, 7 pin	. . . 1
. . . 14 .	. . . CR4	. . ♦113 247 . .		RELAY, encl 12vdc dpdt 20a/120vac 8pin flange mtg	. . . 1
. . . 15 .	. . . CR6 . . ♦090104 . .			RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg	. . . 1
. . . 16	CR2, CR3, CR9 090 104 . .			RELAY, encl 12VDC SPST 30A/15VDC spin flange mtg	. . . 3
. . . . . . . . . . . . . . . .		. . .	212 452 . .	HARNESS, engine control (consisting of)	. . . 1
. . . 17 D10/C10, D11/C11 189 701 . . .				. DIODE/CAPACITOR BOARD	. . . 2
. . . 18 .	. . . . R8 .	. . .	217 335 . . .	. RESISTOR BOARD	. . . 1
. . . 19 .	. . . CB10	. . .	190 374 . . .	. CIRCUIT BREAKER, auto reset 12VDC 40A	. . . 1
. . . . . . . . . . . . . . . .		. . .	148 850 . . .	. SOCKET, relay 5 pin	. . . 2
. . . . . . .	. . . PLG4	. . . .	114 062 . . .	. CONNECTOR, rect univ 084 15P/S 3 row plug cable lkg	. . . 1
. . . . . . . . . . . . . . . .		. . .	185 655 . . .	. SEAL, wire univ 15P/S 3 row	. . . 1
. . . 20 .	. . . CR1	. . .	214 876 . . .	. RELAY, Encl 6vdc Spst 35a/14vdc 5 Pin	. . . 1
. . . 21 .	. . . CR8 . . .		155 309 . .	CONTACTOR, Solenoid 12vdc Continuous 400a Inrush	. . . 1
♦Optional

*Recommended Spare Parts.

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.

OM-496 Page 78

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Miller Electric Big Blue 452P, Big Blue 302P manual PC7 195

Contents

OM-496 ProcessesDescription From Miller to You Table of Contents 11-1 11-211-3 Directives StandardsDeccon1 11/02 Sound Level Information Deccon1 5/98 Symbol Usage Arc Welding Hazards Engine Hazards Compressed Air Hazards Principal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interference Signification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereux LE 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 blessures Principales normes de sécurité Information sur les champs électromagnétiques − Definitions + − Starting Instructions Are possible hazards as Hot muffler and exhaust pipesCan cause severe burns. Do Engine Return To Table Of Contents Manufacturer’s Rating Labels For CE Products − 50 h StdStd CC Models CC/CV Models Symbols And Definitions − Specifications Weld, Power, And Engine SpecificationsDimensions, Weights, And Operating Angles Volt-Ampere Curves For CC Models Stick Mode MIG ModeTIG Mode Volt-Ampere Curves For CC/CV Models Fuel Consumption Duty Cycle And Overheating AC 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 Clearance Using Lifting Eye Work like a Pro Mounting Welding Generator Supporting The UnitMounting Surface To Bolt Unit In Place Installing Exhaust Pipe Stop engine and let cool Activating The Dry Charge Battery If Applicable When electrolyte is low, addRead and follow all instruc Charger Connecting The Battery Reinstall cover after connecting batteryConnect Negative − Cable Last Coolant Recovery Tank Engine Prestart Checks Connecting To Weld Output Terminals Selecting Weld Cable Sizes Ref 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 Section To Start Do not use ether. Using ether voids warranty Engine Indicator LightsDo not switch under load Engine Starting Controls Remote Amperage Control On CC Models Optional Weld Control/Arc Condition Information LabelExample Combination Remote Amperage Control Stick Set weld controls as shown to Return To Table Of Contents − Operating Welding Generator − CC/CV Models Front Panel Controls For CC/CV Models See Section Use switch to select weld amperage range Voltage/Amperage Adjust Switch And Remote 14 Receptacle Process/Contactor Switch On CC/CV Models Process/Contactor Switch Settings Remote 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 Autho Three-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 Routine Maintenance Every 8 hEvery 50 h Every 100 h Clean/Set Injectors Every 1000 hEvery 2000 h Change Fuel Servicing Air Cleaner By the warrantyTo clean air filter Do not clean housing with air hose Inspecting And Cleaning Optional Spark Arrestor Muffler Reinstall cleanout plug Tools Needed Adjusting Engine Speed On Standard Models MaximumDo not set engine speed higher than specified Close door Tools Needed 10 mm Idle Speed Adjustment Weld/Power Speed AdjustmentEngine Speed No Load Rpm max 61.6 Hz 1250 rpm 41.6 Hz Servicing Fuel And Lubrication Systems Overload Protection Diagnosing Causes Of Engine Fault Shutdowns Diagnostic Checks While RunningCorrect the cause of the shut Down before operating Troubleshooting Welding − CC Models Welding − CC/CV Models Standard Generator Power Optional Three-Phase Generator Power CC/CV Models OnlyEngine Wiring harness and components Shutdown switch is released OutTemperature is too high see Sections 5-7and Air in fuel system. See engine manual Return To Table Of Contents − Electrical Diagrams Circuit Diagram For CC Welding Generator 215 296-B Circuit Diagram For CC/CV Welding Generator 215 297-B − RUN-IN Procedure WetstackingMent damage may occur Run-In Procedure Using Load Bank Procedure at less thanStop engine Do not touch hot exhaust From flammables Do not Perform Run-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 Frame Grounding When Supplying Building Systems How Much Power Does Equipment Require?Earth ground if supplying Use ground device as stated in electrical codes Approximate 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 Watts Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Power Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements KVA/HP x HP x Typical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Current Load Watts Amperes − Parts List 109 111 -4 or 118 85 Fig Dia 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 40 Panel, Front w/Components − CC/CV Models -1Item PC4, PC5 189 Generator Generator -1Item 602 SCREW, .312−18x .75 hexwhd.66d stl pld slffmg tap−rw 601 Main Rectifier Assembly Page Page Service Your distributor also givesSupport Miller Electric Mfg. Co For assistance in filing or settling claims, contactYour distributor and/or equipment manufacturer’s Transportation Department