Miller Electric Big Blue 452P manual

Big Blue 302P Big Blue 452P (CE Compliant )  OM -496 197 761AT March 2004 Visit our website at www.Miller Welds.c om Pro cesses Descrip ti on Air Carbon Arc (CAC-A) Cutting and Gouging Stick (SMAW ) W elding Engine Driven Welding Generator TIG (GT A W) W elding MIG (GMAW ) W elding Flux Cored (FCA W ) W elding And Non-CE Models [...]

Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .MillerW eld[...]

T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . [...]

T ABLE OF CONTENTS SECTION 8 − OPERA TING AUXILIARY EQUIPMENT 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. 120 V olt And 240 V olt Receptacles 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2. Connecting T o Optional Three-Phas[...]

dec_con1 _1 1/02 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). NOTE Manufacturer ’s Name: Miller Electric Mfg. Co. Manufacturer ’s Address: 1635 W . Spencer Street Appleton, WI 54914 USA Declares that the product: Big Blue  452P conforms[...]

dec_con1 5/98 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). NOTE Manufacturer ’s Name: Miller Electric Mfg. Co. Manufacturer ’s Address: 1635 W . Spencer Street Appleton, WI 54914 USA Declares that the product: Big Blue  452P conforms to[...]

OM-496 Page 1 Return T o T able Of Contents SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom _nd_8/03  W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining sym[...]

OM-496 Page 2 Return T o T able Of Contents W elding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fi[...]

OM-496 Page 3 Return T o T able Of Contents STEAM AN D H O T C OOLANT can burn.  If possible, check coolant level when engine is cold to avoid scalding.  Always check coolant level at overflow tank, if pres- ent on unit, instead of radiator (unless told otherwise in maintenance section or engine manual).  If the engine is warm, checking is[...]

OM-496 Page 4 Return T o T able Of Contents READ INSTRUCTIONS.  Use only genuine MILLER/Hobart replacement parts.  Perform engine and air compressor (if applicable) maintenance and service according to this manual and the engine/air compressor (if applicable) manu- als. H. F . RADIA TION can cause interference.  High-frequency (H.F .) can [...]

OM-496 Page 5 Revenez à la table des matières SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION rom_fre 8/03  A vertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions. 2-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de dang[...]

OM-496 Page 6 Revenez à la table des matières LES ACCUMULA TIONS DE GAZ ris- quent de provoquer des blessures ou même la mort.  Fermer l’alimentation du gaz protecteur en cas de non utilisation.  V eiller toujours à bien aérer les espaces confinés ou se servir d’un respi- rateur d’adduction d’air homologué. Le rayonnement de l?[...]

OM-496 Page 7 Revenez à la table des matières L ’EXPLOSION DE LA BA TTERIE peut RENDRE A VEUGLE.  T oujours porter une protection faciale, des gants en caoutchouc et vêtements de protection lors d’une in- tervention sur la batterie.  Arrêter le moteur avant de débrancher ou de brancher les câbles de batterie.  Eviter de provoquer[...]

OM-496 Page 8 Revenez à la table des matières LE SURCHAUFFEMENT peut endom- mager le moteur électrique.  Arrêter ou déconnecter l’équipement avant de dé- marrer ou d’arrêter le moteur .  Ne pas laisser tourner le moteur trop lentement sous risque d’endommager le moteur électrique à cause d’une tension et d’une fréquence t[...]

OM-496 Page 9 Return T o T able Of Contents SECTION 3 − DEFINITIONS 3-1. W arning Label Definitions (CE Models Only) 3/96 W arning! Watch Out! There are possible hazards as shown by the symbols. Become trained and read the instructions before working on the machine or welding. 1 Electric shock from welding electrode or wiring can kill. 1.1 W ear [...]

OM-496 Page 10 Return T o T able Of Contents 3/96 1 Warning! W atch Out! There are possible hazards as shown by the symbols. 2 Do not smoke and keep matches and flames away from battery . 3 Sparks can cause battery gases to explode. Battery explosion can blind and injure. W ear a face shield. 4 Battery acid can burn skin. Do not spill acid. 5 Read [...]

OM-496 Page 1 1 Return T o T able Of Contents 3/96 1 Warning! W atch Out! There are possible hazards as shown by the symbols. 2 Hot muf fler and exhaust pipes can cause severe burns. Do not touch hot muf fler or pipes. 1 S-176 230 2 3/96 1 2 4 3 5 6 1 Warning! W atch Out! There are possible hazards as shown by the symbols. 2 Engine fuel plus flames[...]

OM-496 Page 12 Return T o T able Of Contents 1 Warning! W atch Out! There are possible hazards as shown by the symbols. 2 Fire hazard from leaking engine fuel. Fire can result from welding on base at non-designated areas causing a possible fuel leak. 3 Fuel tank is located inside base. 4 Do not weld on base of unit. 5 Wel d only on supplied bracket[...]

OM-496 Page 13 Return T o T able Of Contents 3/96 1 Remove unit from shipping crate. Remove Owner’s Manual from unit. Follow instructions to install muf fler . 2 Read Owner ’s Manual. Read labels on unit. 3 Use Diesel Fuel only , and fill fuel tank. Leave room for expansion. 4 Warning! W atch Out! There are possible hazards as shown by the symb[...]

OM-496 Page 14 Return T o T able Of Contents 3-3. Symbols And Definitions Some symbols are found only on CE products. NOTE Stop Engine Fast (Run, W eld/ Power) Slow (Idle) Start Engine Starting Aid Battery (Engine) Engine Oil Pressure Engine Oil Check Injectors/ Pump Check V alve Clearance Fuel Protective Earth (Ground) Positive Negative Certified/[...]

OM-496 Page 15 Return T o T able Of Contents SECTION 4 − SPECIFICA TIONS 4-1. W eld, Power , And Engine Specifications W elding Mode W eld Output Range Rated W elding Output Maximum Open- Circuit V oltage Generator Power Rating Engine Fuel Capacity CC/DC 45 − 500 A (CC Models) 15 − 500 A (CC/CV Models) 300 A, 40 V olts DC , 100% Duty Cycle 40[...]

OM-496 Page 16 Return T o T able Of Contents 0 20 40 60 80 100 0 100 200 300 400 500 600 700 4-3. V olt-Ampere Curves For CC Models 202 666-A The volt-ampere curve shows the minimum and maximum voltage an d amperage output capabilities of th e welding generator . Curves of all other settings fall between the curves shown. DC AMPERES DC VOL TS Range[...]

OM-496 Page 17 Return T o T able Of Contents 4-4. V olt-Ampere Curves For CC/CV Models 202 655 / 202 656 / 202 654 The volt-ampere curves show the minimum and maximum voltage an d amperage output capabilities of th e welding generator . Curves of all other settings fall between the curves shown. A. Stick Mode B. MIG Mode C. TIG Mode 0 20 40 60 80 1[...]

OM-496 Page 18 Return T o T able Of Contents 4-5. Fuel Consumption The curve shows typical fuel use under weld or power loads. 199 032 0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 0 50 100 150 200 250 300 350 400 DC WELD AMPERES A T 100% DUTY CYCLE US GAL/HR. IDLE Continuous W elding 4-6. Duty Cycle And Overheating Duty Cycle is percentage of 10 mi[...]

OM-496 Page 19 Return T o T able Of Contents 4-7. AC Generator Power Curve 193 018 Th e ac power curve shows the gen- erator power in amperes available at the 120 and 240 volt receptacles. 0 50 100 150 200 250 300 0 5 10 15 20 25 30 AC AMPERES IN 240V MODE AC VOL TS 0 25 50 75 100 150 125 0 1 02 03 0 4 0 5 0 6 0 AC AMPERES IN 120V MODE 4-8. Optiona[...]

OM-496 Page 20 Return T o T able Of Contents SECTION 5 − INST ALLA TION install3 6/03 − Ref. 800 652 / Ref. 800 477-A / 803 274  Always securely fasten weld- ing generator onto transport vehicle or trailer and comply with all DOT and other applica- ble codes.  Always ground generator frame to vehicle frame to pre- vent electric shock and [...]

OM-496 Page 21 Return T o T able Of Contents 5-2. Using Lifting Eye Ref. 802 31 1 1 Lifting Eye 2 Nut 3 Carriage Bolt Raise lifting eye until it snaps in place. Lower lifting eye when not needed. T o lock the lifting eye in the upright position, insert a 3/8-16 x 1-1/2 in carriage bolt through slot in bracket a n d secure with nut (bolt and nut not[...]

OM-496 Page 22 Return T o T able Of Contents 5-3. Mounting Welding Generator T ools Nee d e d : 9/16 in 2 2 3 4 W elding Unit In Place Bolting Unit In Place  Do not weld on base. W eld- ing on base can cause fuel tank fire or explosion. Weld only on the four mounting brackets or bolt unit down.  Do not mount unit by sup- porting the base only[...]

OM-496 Page 23 Return T o T able Of Contents 5-4. Installing Exhaust Pipe 1/2 i n T ools Needed: Ref. 802 31 1 / Ref. 201 841  Stop engine and let cool.  Point exhaust pipe in desired di- rection but always away from front panel and direction of travel. Notes W or k l i ke a P r o ! Pros wel d and cut safel y . R ead the safety rules at the b[...]

OM-496 Page 24 Return T o T able Of Contents 5-5. Activating The Dry Charge Battery (If Applicable) Remove b attery from unit. 1 Eye Protection − Safety Glasses Or Face Shield 2 Rubber Gloves 3 V ent Caps 4 Sulfuric Acid Electrolyte (1.265 Specific Gravity) 5 W ell Fill each cell with electrolyte to bottom of well (maximum).  Do not overfill b[...]

OM-496 Page 25 Return T o T able Of Contents 5-6. Connecting The Battery 1/2 i n − +  Connect Negative (−) Cable Last. T ools Needed: 802 168-B / Ref. 201 841 / 802 313 / S-0756-C  Reinstall cover after connecting batter y. Notes[...]

OM-496 Page 26 Return T o T able Of Contents 5-7. Engine Prestart Checks  Check all engine fluids daily . Engine must be cold and on a level surface. Unit is shipped with 20W break-in oil. Automatic shutdown system stops engine if oil pressure is too low or coolant tempera- ture is too high.  This unit has a low oil pressure shut- down switch[...]

OM-496 Page 27 Return T o T able Of Contents 5-8. Connecting T o W eld Output T erminals 802 31 1 T ools N eeded: 2 3/4 in 1  Stop engine. 1 Positive (+) Weld Output T erminal 2 Negative (−) Weld Output T erminal Stick and TIG W elding Fo r Stick and TIG welding Direct Current Elec- trode Positive (DCEP), connect electrode holder cable to Posi[...]

OM-496 Page 28 Return T o T able Of Contents 5-10. Connecting T o Remote Amperage Adjust Receptacle RC13 On CC Models Ref. 154 862-A / 048 720-K / 802 31 1 1 Remote Amperage Adjust Receptacle RC13 Connect optional remote control to RC13 (see Section 6-3). 1 Notes W or k l i ke a P r o ! Pros wel d and cut safel y . R ead the safety rules at the beg[...]

OM-496 Page 29 Return T o T able Of Contents 5-1 1. Connecting T o Remote 14 Receptacle RC14 On CC/CV Models Socket* Socket Information 24 VOL TS AC A 24 volts ac. Protected by circuit breaker CB5. 24 VOL TS AC B Contact closure to A completes 24 volt ac contactor control circuit. C Output to remote control:+10 volts dc in MIG or Stick mode; 0 to +[...]

OM-496 Page 30 Return T o T able Of Contents SECTION 6 − OPERA TING WELDING GENERA T OR − CC MODELS 6-1. Front Panel Controls For CC Models (See Section 6-2 ) 17 201 841 / 802 31 1 6 5 47 15 16 2 1 3 13 18 19 14 12 10 1 1 9 8[...]

OM-496 Page 31 Return T o T able Of Contents 6-2. Description Of Front Panel Controls For CC Models (See Section 6-1 ) Engine Starting Controls 1 Magnetic Shutdown Switch Use switch during start-up to bypass engine shutdown system. System stops engine if oil pressure is too low or coolant temperature is too high. 2 Starting Aid Switch Use switch to[...]

OM-496 Page 32 Return T o T able Of Contents 6-3. Remote Amperage Control On CC Models (Optional) 1 Remote Amperage Adjust Receptacle RC13 Connect optional remote control to RC13 (see Section 5-10 ). Example: Combination Remote Amperage Control (Stick) Adjust Optional Remote Control Set Switches Set Range Set Control Ref. 154 862-A / Ref. 181 71 1-[...]

OM-496 Page 33 Return T o T able Of Contents Notes[...]

OM-496 Page 34 Return T o T able Of Contents SECTION 7 − OPERA TING WELDING GENERA TOR − CC/CV MODELS 7-1. Front Panel Controls For CC/CV Models (See Section 7-2 ) 201 579 / 802 31 1-D 6 5 47 2 1 3 14 19 20 15 12 10 1 1 9 8 16 13 18 OR 17[...]

OM-496 Page 35 Return T o T able Of Contents 7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1 ) Engine Starting Controls 1 Magnetic Shutdown Switch Use switch during start-up to bypass engine shutdown system. System stops engine if oil pressure is too low or engine temperature is too high. 2 Starting Aid Switch Use switch [...]

OM-496 Page 36 Return T o T able Of Contents 7-3. Process/Contactor Switch On CC/CV Models 1 Process/Contactor Switch  W eld output terminals are ener- gized when Process/Contactor switch is in an Electrode Hot position and the engine is run- ning.  DC voltage is still present at the weld terminals when Process/ Contactor switch is in the Rem[...]

OM-496 Page 37 Return T o T able Of Contents 7-4. Remote V oltage/Amperage Control On CC/CV Models (Optional) 1 Remote 14 Receptacle RC14 Connect optional remote control to RC14 (see Section 5-1 1). 0774 / Ref. 201 579 / 802 169-E Example: Combination Remote Amperage Control (Stick) Adjust Optional Remote Control Set V/A Adjust Switch Set Range Con[...]

OM-496 Page 38 Return T o T able Of Contents SECTION 8 − OPERA TING AUXILIAR Y EQUIPMENT 8-1. 120 V olt And 240 V olt Receptacles 191 624-A 2 1 120 V 20 A AC GFCI Receptacle GFCI1 2 240 V 30 A AC T wistlock Receptacle RC1 Receptacles supply 60 Hz single- phase power at weld/power speed. If a ground fault is detected, GFCI Reset button pops out an[...]

OM-496 Page 39 Return T o T able Of Contents 8-2. Connecting T o Optional Three-Phase Generator (CC/CV Models Only) Ref. 197 399 / 802 332-E  Place Process/Contactor switch in Electrode Hot - Stick position when using three-phase genera- tor (see Section 7-3). Single-Phase Generator Power 1 120/240 V 50 A Receptacle RC5 RC5 is connected to the o[...]

OM-496 Page 40 Return T o T able Of Contents 8-3. Optional Generator Power Receptacles 2 1 120 V 20 A AC GFCI Receptacle GFCI1 2 240 V 16 A AC European Receptacle RC1 3 240 V 15 A AC Australian Receptacle RC1 4 240 V 15 A AC South African Receptacle RC1 Receptacles supply 60 Hz single- phase power at weld/power speed. If a ground fault is detected,[...]

OM-496 Page 41 Return T o T able Of Contents SECTION 9 − MAINTENANCE & TROUBLESHOOTING 9-1. Maintenance Labels For Non-CE Products For CE Products Only[...]

OM-496 Page 42 Return T o T able Of Contents 9-2. Routine Maintenance The engine oil/filter and fuel injector maintenance intervals are different for the Perkins 404.22 and 3.152 engines (see maintenance schedule following). Note Follow the storage procedure in the engine owner ’s manual if the unit will not be used for an extended period. Note R[...]

OM-496 Page 43 Return T o T able Of Contents Every 1000 h Blow Out Or V acuum Inside. During Heavy Service, Clean Monthly . OR Drain Sludge From Fuel T ank. See Section 9-7. FUEL SLUDGE Service W elding Generator Brushes And Slip Rings. Service More Often In Dirty Conditions.* Change Fuel Filters. See Section 9-7. Check V alve Clearance.* Check Rad[...]

OM-496 Page 44 Return T o T able Of Contents 9-3. Servicing Air Cleaner  Stop engine.  Do not run engine without air cleaner or with dirty element. En- gine damage caused by using a damaged element is not covered by the warranty .  The air cleaner primary element can be cleaned but the dirt holding capac- ity of the filter is reduced with [...]

OM-496 Page 45 Return T o T able Of Contents 9-4. Inspecting And Cleaning Optional Spark Arrestor Muffler Ref. 802 31 1 / Ref. 802 160 / Ref. 201 841  Stop engine and let cool. 1 Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole. 3 Exhaust Pipe Start engine and run at idle speed to blow out cleanout ho[...]

OM-496 Page 46 Return T o T able Of Contents 9-5. Adjusting Engine Speed On Standard Models 802 490-D / 802 491  Stop engine and let cool. Engine speed is factory set and should not require adjustment. Af- ter tuning engine, check engine speed with tachometer or frequen- cy meter . See table for proper no load speed. If necessary , adjust speed [...]

OM-496 Page 47 Return T o T able Of Contents 9-6. Adjusting Engine Speed On Models With Automatic Idle (Optional) 802 490 / 802 538-A After tuning engine, check engine speed with tachometer or frequency meter . See table for proper no load speed. If necessary , adjust speed as follows: Start engine and run until warm. On CC models, place Stick/TIG [...]

OM-496 Page 48 Return T o T able Of Contents 9-7. Servicing Fuel And Lubrication Systems 802 490 / Ref. 801 434  Stop engine and let cool.  After servicing, start engine and check for fuel leaks. Stop engine, tighten connec- tions as necessary , and wipe up spilled fuel. 1 Oil Filter 2 Oil Drain V alve And Hose 3 Oil Fill Cap 4 Fuel Line 5 Pr[...]

OM-496 Page 49 Return T o T able Of Contents 9-8. Overload Protection 802 170-D / Ref. 802 31 1 21 9 8 7 4  Stop engine.  When a circuit breaker or fuse opens, i t usually indicates a more serious problem exists. Contact Factory Authorized Service Agent. 1 Fuse F 1 2 Fuse F2 F1 and F2 protect the stator exciter winding from overload. If F1 op[...]

OM-496 Page 50 Return T o T able Of Contents 9-9. Diagnosing Causes Of Engine Fault Shutdowns Ref. 201 841 Use the front panel engine lights to help determine the cause of an au- tomatic engine shutdown.  Correct the cause of the shut- down before operating the welding generator .  This unit does not have a bat- tery charging fault shutdown. [...]

OM-496 Page 51 Return T o T able Of Contents 9-10. T roubleshooting A. Welding − CC Models T rouble Remedy No weld output; generator power output okay at ac receptacles. Check position of Ampere Range switch. Check position of optional Polarity switch. Place Amperage Adjust switch in Panel position, or place switch in Remote position and connect [...]

OM-496 Page 52 Return T o T able Of Contents B. Welding − CC/CV Models T rouble Remedy No weld output; generator power output okay at ac receptacles. Place Process/Contactor switch in a Electrode Hot position, or place switch in a Remot e p osition and connect remote contactor to optional Remote 14 receptacle RC14 (see Sections 5-1 1 and 7-1). Ch[...]

OM-496 Page 53 Return T o T able Of Contents T rouble Remedy Min or max CV weld output only . Check position of V oltage/Amperage Adjust control and V oltage/Amperage Adjust switch. Repair or replace remote control device. Have Factory Authorized Service Agent check field current regulator board PC1. C. Standard Generator Power T rouble Remedy No g[...]

OM-496 Page 54 Return T o T able Of Contents T rouble Remedy Engine cranks but does not start. Press Magnetic Shutdown switch MS1 when starting engine. Check fuel level. Reset circuit breaker CB13 (see Section 9-8). Have Factory Authorized Service Agent check engine- wiring harness and components. Check battery and replace if necessary . Check engi[...]

OM-496 Page 55 Return T o T able Of Contents Notes[...]

OM-496 Page 56 Return T o T able Of Contents SECTION 10 − ELECTRICAL DIAGRAMS Figure 10-1. Circuit Diagram For CC Welding Generator[...]

OM-496 Page 57 Return T o T able Of Contents 215 296-B[...]

OM-496 Page 58 Return T o T able Of Contents Figure 10-2. Circuit Diagram For CC/CV Welding Generator[...]

OM-496 Page 59 Return T o T able Of Contents 215 297-B[...]

OM-496 Page 60 Return T o T able Of Contents SECTION 1 1 − RUN-IN PROCEDURE run_in1 8/0 1 1 1-1. Wetstacking  Do not perform run-in procedure at less than 20 volts weld output and do n ot exceed duty cycle or equip- ment damage may occur . 1 Welding Generator Ru n diesel engines near rated volt- ag e and current during run-in period to properl[...]

OM-496 Page 61 Return T o T able Of Contents 1 1-2. Run-In Procedure Using Load Bank S-0683  Stop engine.  Do not touch hot exhaust pipe, engine parts, or load bank/grid.  Keep exhaust and pipe away from flammables.  Do not perform run-in procedure at less than 20 volts weld output and do n ot exceed duty cycle or equip- ment damage may[...]

OM-496 Page 62 Return T o T able Of Contents 1 1-3. Run-In Procedure Using Resistance Grid S-0684  Stop engine.  Do not touch hot exhaust pipe, engine parts, or load bank/grid.  Keep exhaust and pipe away from flammables.  Do not perform run-in procedure at less than 20 volts weld output and do n ot exceed duty cycle or equip- ment dama[...]

OM-496 Page 63 Return T o T able Of Contents SECTION 12 − GENERA TOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding generators. Y our unit may differ from those shown. NOTE 12-1. Selecting Equipment gen_pwr 1 1/02 − Ref. ST -159 730 / ST-800 577 1 Generator Power Receptacle s − Neutra[...]

OM-496 Page 64 Return T o T able Of Contents 12-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 A WG or larger insulated copper wire. 3 Ground Device  Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. GND/PE 1 2 Us e groun[...]

OM-496 Page 65 Return T o T able Of Contents 12-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting W atts Running W atts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 2100 700 1/2 HP 3175 875 Capacitor Start-Induction Run 1/3 HP 2020 720 1/2 HP 3075 975 3/4 HP 4500 1400 1 HP 6100 1600 1-1/2[...]

OM-496 Page 66 Return T o T able Of Contents 12-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting W atts Running W atts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/2 in 500 500 7-1/4 in 900 900 8-1/4 in 1400 1400 T able Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in 2500 1 100 Benc[...]

OM-496 Page 67 Return T o T able Of Contents 12-8. Power Required T o Start Motor S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor V oltage T o find starting amperage: Step 1: Find code and use table to find kVA/HP . If code is not listed, multiply running amperage by six to find starting amperage. Step 2 : Find Motor HP and V olts. [...]

OM-496 Page 68 Return T o T able Of Contents 12-10. T ypical Connections T o Supply Standby Power  Have only qualified persons perform these connections according to all applicable codes and safety practic- es.  Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes.  Customer -sup[...]

OM-496 Page 69 Return T o T able Of Contents 12-1 1. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 V olt Loads  If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (A WG)* Current (Amperes) Load (W atts) 4 6 8 10 12 14 5 600 350 (106) 2[...]

OM-496 Page 70 Return T o T able Of Contents SECTION 13 − P ARTS LIST  Hardware is common and not available unless listed. 17 18 19 15 16 26 25 24 22 23 1 2 3 4 5 6 7 10 11 12 13 14 20 21 103 102 101 100 104 99 98 107 (CC ONL Y) 108 106 (FIG 13-2 OR 13-3) 105 12 109 11 0 1 1 1 (FIG. 13-4 OR 13-5) 11 2 11 4 1 15 (FIG 13-7) 1 16 (CV) 1 17 (CV) 9[...]

OM-496 Page 71 Return T o T able Of Contents 802 550-E 85 (Fig. 13-6) 84 43 56 57 41 55 33 36 37 72 73 76 74 75 77 78 58 59 38 60 40 54 79 80 82 86 32 27 28 29 30 31 34 35 87 88 89 90 91 92 93 94 95 96 97 71 69 68 67 66 65 64 63 62 61 44 53 70 81 83 39 42 47 48 49 50 51 52 11 8 45 46[...]

OM-496 Page 72 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 13-1. Main Assembly Quanti ty 1 189 824 P ANEL, gen LH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦ 199 294 P ANEL, gen LH ss 1 . . . . . . . . . . . . . . . . [...]

OM-496 Page 73 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 13-1. Main Assembly (Continued) Quanti ty 38 209 393 ENGINE, Perkins dsl elec 404.22bw 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . *215 093 SWITCH, coolant temperature 1 . . . . . . . . . . . . . . . .[...]

OM-496 Page 74 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 13-1. Main Assembly (Continued) Quanti ty 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 . . . . . .[...]

OM-496 Page 75 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 13-1. Main Assembly (Continued) Quanti ty 1 19 212 944 LABEL, weld control/arc condition information label 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 058 NUT , .250-20 u-nut multi-thread 19 . . . . . . . . . . . . . . . . . . [...]

OM-496 Page 76 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 13-2. Control Box Assembly − CC Models (Continued) Quanti ty 4 201 078 CONTROL BOX, rh 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 201 079 COVER, control box 1 . . . .[...]

OM-496 Page 77 Return T o T able Of Contents Ref. 802 360 12 1 2 3 14 9 6 8 7 10 13 5 21 16 17 19 11 15 4 20 18 Figure 13-3. Control Box Assembly − CC/CV Models Description Part No. Dia. Mkgs. Item No. Figure 13-3. Control Box Assembly − CC/CV Models (Figure 13-1 Item 106) Quanti ty 1 F1, F2 *085 874 FUSE, mintr cer slo-blo 10A 250V 2 . . . . .[...]

OM-496 Page 78 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 13-3. Control Box Assembly − CC/CV Models (Continued) Quanti ty 196 602 PLUG, cavity 18,30 position cinch connector 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 603 SEAL, switch 6 position rotary .250 sha[...]

OM-496 Page 79 Return T o T able Of Contents  Hardware is common and not available unless listed. 802 266-D 1 3 4 5 12 15 18 23 24 26 29 32 35 36 37 38 44 45 46 17 25 30 31 16 20 2 22 27 28 13 19 14 6 7 8 9 10 21 34 33 11 39 40 41 42 43 Figure 13-4. Panel, Front w/Components − CC Models Description Part No. Dia. Mkgs. Item No. Figure 13-4. Pan[...]

OM-496 Page 80 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 13-4. Panel, Front w/Components − CC Models (Continued) Quanti ty 8 S5 01 1 609 SWITCH, tgl SPDT 15A 125V AC on-none-on spd term chr (included in . . . . . . . . . . . . . . . control box harness, see 13-2) 1 . . . . . . . . . . . . . . . . . . . . . . . [...]

OM-496 Page 81 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 13-4. Panel, Front w/Components − CC Models (Continued) Quanti ty 43 ♦ 194 345 VOL T METER, W/Leads 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 189 161 HANDLE, switch range 1 . .[...]

OM-496 Page 82 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 13-5 . Panel, Front w/Components − CC/CV Models (Figure 13-1 Item 1 1 1) Quanti ty 1 201 579 PLA TE SCREENED, ident control; when ordering this item, . . . . . . . . . . . . . . . . . . the nameplate should also be ordered) 1 . . . . . . . . . . . . . . .[...]

OM-496 Page 83 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 13-5. Panel, Front w/Components − CC/CV Models (Continued) Quanti ty 36 199 303 P ANEL, mtg terminal pwr output ss 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 PC4, PC5 189 744 CIRCUIT CARD ASSEM[...]

OM-496 Page 84 Return T o T able Of Contents 802 552-B  Hardware is common and not available unless listed. 5 6 8 9 24 28 30 31 32 33 1 2 7 25 26 35 36 4 3 10 27 21 29 34 20 17 18 11 15 16 12 13 14 19 22 23 Figure 13-6. Generator Description Part No. Dia. Mkgs. Item No. Figure 13-6. Generator (Figure 13-1 Item 85) Quanti ty 1 132 053 SCREW , .37[...]

OM-496 Page 85 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 13-6. Generator (Continued) Quanti ty 21 197 486 ADAPTER, Engine Perkins 104.22 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 083 883 WASHER, Lock .402idx0.709odx.087t Stl Split10mm 4 . . . . . . . [...]

OM-496 Page 86 Return T o T able Of Contents  Hardware is common and not available unless listed. 802 279-A 1 2 3 4 6 5 7 8 9 Figure 13-7. Main Rectifier Assembly Description Part No. Dia. Mkgs. Item No. Figure 13-7. Main Rectifier Assembly (Figure 13-1 Item 1 15) Quanti ty SR3 201 747 RECTIFIER (consisting of) 1 . . . . . . . . . . . . . . . . [...]

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Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 8/03 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor . The expertise o[...]

PRINTED IN USA  2004 Miller Electric Mfg. Co. 1/04 Miller Elect ric Mfg. Co. An I l li noi s T ool Works Com pany 1635 West Spenc er S t reet Applet on, W I 54914 USA International He adquarters− USA USA P hone: 920-735-4505 Auto-A t t ended USA & C anada F AX : 9 20-735-4134 Int ernat i onal F AX : 920-735-4125 European He adqua rt ers ?[...]