Miller Electric Mfg. Co | Miller Electric Big Blue 452P instruction

Owner’s Record

Please complete and retain with your personal records.

Model Name	Serial/Style Number
Purchase Date	(Date which equipment was delivered to original customer.)

Distributor

Address

City

State	Zip

For Service

Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:	Welding Supplies and Consumables
	Options and Accessories
	Personal Safety Equipment
	Service and Repair
	Replacement Parts
	Training (Schools, Videos, Books)
	Technical Manuals (Servicing Information
	and Parts)
	Circuit Diagrams
	Welding Process Handbooks

Contact the Delivering Carrier to:	File a claim for loss or damage during
	shipment.
	For assistance in filing or settling claims, contact
	your distributor and/or equipment manufacturer’s
	Transportation Department.
PRINTED IN USA	 2004 Miller Electric Mfg. Co. 1/04

Miller Electric Mfg. Co.

An Illinois Tool Works Company

1635 West Spencer Street

Appleton, WI 54914 USA

International Headquarters−USA

USA Phone: 920-735-4505 Auto-Attended

USA & Canada FAX: 920-735-4134

International FAX: 920-735-4125

European Headquarters −

United Kingdom

Phone: 44 (0) 1204-593493

FAX: 44 (0) 1204-598066

www.MillerWelds.com

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Miller Electric Big Blue 452P, Big Blue 302P Miller Electric Mfg. Co, For assistance in filing or settling claims, contact

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