Miller Electric Big Blue 452P Owner's Manual

Big Blue 302PBig Blue 452P (CE Compliant)OM-496 197 761ATMarch 2004Visit our website atwww.MillerWelds.comProcessesDescriptionAir Carbon Arc (CAC-A)C

OM-496 Page 4 Return To Table Of ContentsREAD INSTRUCTIONS. Use only genuine MILLER/Hobart replacementparts. Perform engine and air compressor (if a

OM-496 Page 5Revenez à la table des matièresSECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANTUTILISATIONrom_fre 8/03 Avertissement: Protégez vous et le

OM-496 Page 6Revenez à la table des matièresLES ACCUMULATIONS DE GAZ ris-quent de provoquer des blessures oumême la mort. Fermer l’alimentation du ga

OM-496 Page 7Revenez à la table des matièresL’EXPLOSION DE LA BATTERIE peutRENDRE AVEUGLE. Toujours porter une protection faciale, des gants encaoutc

OM-496 Page 8Revenez à la table des matièresLE SURCHAUFFEMENT peut endom-mager le moteur électrique. Arrêter ou déconnecter l’équipement avant de dé-

OM-496 Page 9Return To Table Of ContentsSECTION 3 − DEFINITIONS3-1. Warning Label Definitions (CE Models Only)3/96Warning! Watch Out! There arepossibl

OM-496 Page 10Return To Table Of Contents3/961 Warning! Watch Out! Thereare possible hazards asshown by the symbols.2 Do not smoke and keepmatches and

OM-496 Page 11Return To Table Of Contents3/961 Warning! Watch Out! Thereare possible hazards asshown by the symbols.2 Hot muffler and exhaust pipescan

OM-496 Page 12Return To Table Of Contents1 Warning! Watch Out! Thereare possible hazards asshown by the symbols.2 Fire hazard from leakingengine fuel.

OM-496 Page 13Return To Table Of Contents3/961 Remove unit from shippingcrate. Remove Owner’sManual from unit. Followinstructions to install muffler.2

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

OM-496 Page 14Return To Table Of Contents3-3. Symbols And DefinitionsSome symbols are found only on CE products.NOTEStop EngineFast (Run, Weld/Power)S

OM-496 Page 15Return To Table Of ContentsSECTION 4 − SPECIFICATIONS4-1. Weld, Power, And Engine SpecificationsWeldingModeWeld OutputRangeRated Welding

OM-496 Page 16Return To Table Of Contents0204060801000 100 200 300 400 500 600 7004-3. Volt-Ampere Curves For CC Models202 666-AThe volt-ampere curve

OM-496 Page 17Return To Table Of Contents4-4. Volt-Ampere Curves For CC/CV Models202 655 / 202 656 / 202 654The volt-ampere curves show theminimum and

OM-496 Page 18Return To Table Of Contents4-5. Fuel ConsumptionThe curve shows typical fuel useunder weld or power loads.199 0320.000.250.500.751.001.2

OM-496 Page 19Return To Table Of Contents4-7. AC Generator Power Curve193 018The ac power curve shows the gen-erator power in amperes availableat the

OM-496 Page 20Return To Table Of ContentsSECTION 5 − INSTALLATIONinstall3 6/03 − Ref. 800 652 / Ref. 800 477-A / 803 274 Always securely fasten weld-

OM-496 Page 21Return To Table Of Contents5-2. Using Lifting EyeRef. 802 3111 Lifting Eye2 Nut3 Carriage BoltRaise lifting eye until it snaps inplace.

OM-496 Page 22Return To Table Of Contents5-3. Mounting Welding GeneratorTools Needed:9/16 in2234Welding Unit In PlaceBolting Unit In Place Do not wel

OM-496 Page 23Return To Table Of Contents5-4. Installing Exhaust Pipe1/2 inTools Needed:Ref. 802 311 / Ref. 201 841 Stop engine and let cool. Point

TABLE OF CONTENTSSECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol

OM-496 Page 24Return To Table Of Contents5-5. Activating The Dry Charge Battery (If Applicable)Remove battery from unit.1 Eye Protection − SafetyGlass

OM-496 Page 25Return To Table Of Contents5-6. Connecting The Battery1/2 in−+ Connect Negative (−) Cable Last.Tools Needed:802 168-B / Ref. 201 841 /

OM-496 Page 26Return To Table Of Contents5-7. Engine Prestart Checks Check all engine fluids daily.Engine must be cold and on a level surface.Unit is

OM-496 Page 27Return To Table Of Contents5-8. Connecting To Weld Output Terminals802 311Tools Needed:23/4 in1 Stop engine.1 Positive (+) Weld Output

OM-496 Page 28Return To Table Of Contents5-10. Connecting To Remote Amperage Adjust Receptacle RC13 On CC ModelsRef. 154 862-A / 048 720-K / 802 3111

OM-496 Page 29Return To Table Of Contents5-11. Connecting To Remote 14 Receptacle RC14 On CC/CV ModelsSocket* Socket Information24 VOLTS ACA 24 volts

OM-496 Page 30Return To Table Of ContentsSECTION 6 − OPERATING WELDING GENERATOR − CC MODELS6-1. Front Panel Controls For CC Models (See Section 6-2)1

OM-496 Page 31Return To Table Of Contents6-2. Description Of Front Panel Controls For CC Models (See Section 6-1)Engine Starting Controls1 Magnetic Sh

OM-496 Page 32Return To Table Of Contents6-3. Remote Amperage Control On CC Models (Optional)1 Remote Amperage AdjustReceptacle RC13Connect optional r

OM-496 Page 33Return To Table Of ContentsNotes

TABLE OF CONTENTSSECTION 8 − OPERATING AUXILIARY EQUIPMENT 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-496 Page 34Return To Table Of ContentsSECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS7-1. Front Panel Controls For CC/CV Models (See Section

OM-496 Page 35Return To Table Of Contents7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1)Engine Starting Controls1 Magnetic

OM-496 Page 36Return To Table Of Contents7-3. Process/Contactor Switch On CC/CV Models1 Process/Contactor Switch Weld output terminals are ener-gized

OM-496 Page 37Return To Table Of Contents7-4. Remote Voltage/Amperage Control On CC/CV Models (Optional)1 Remote 14 Receptacle RC14Connect optional re

OM-496 Page 38Return To Table Of ContentsSECTION 8 − OPERATING AUXILIARY EQUIPMENT8-1. 120 Volt And 240 Volt Receptacles191 624-A21 120 V 20 A AC GFCI

OM-496 Page 39Return To Table Of Contents8-2. Connecting To Optional Three-Phase Generator (CC/CV Models Only)Ref. 197 399 / 802 332-E Place Process/

OM-496 Page 40Return To Table Of Contents8-3. Optional Generator Power Receptacles21 120 V 20 A AC GFCI Receptacle GFCI12 240 V 16 A AC EuropeanRecept

OM-496 Page 41Return To Table Of ContentsSECTION 9 − MAINTENANCE & TROUBLESHOOTING9-1. Maintenance Labels For Non-CE Products For CE Products Only

OM-496 Page 42Return To Table Of Contents9-2. Routine MaintenanceThe engine oil/filter and fuel injector maintenance intervals are different for the P

OM-496 Page 43Return To Table Of ContentsEvery 1000 hBlow Out OrVacuum Inside.During HeavyService,Clean Monthly.ORDrain SludgeFrom FuelTank. SeeSectio

dec_con1 _11/02Declaration of Conformity forEuropean Community (CE) ProductsThis information is provided for units with CE certification (see rating l

OM-496 Page 44Return To Table Of Contents9-3. Servicing Air Cleaner Stop engine. Do not run engine without aircleaner or with dirty element. En-gine

OM-496 Page 45Return To Table Of Contents9-4. Inspecting And Cleaning Optional Spark Arrestor MufflerRef. 802 311 / Ref. 802 160 / Ref. 201 841 Stop

OM-496 Page 46Return To Table Of Contents9-5. Adjusting Engine Speed On Standard Models802 490-D / 802 491 Stop engine and let cool.Engine speed is f

OM-496 Page 47Return To Table Of Contents9-6. Adjusting Engine Speed On Models With Automatic Idle (Optional)802 490 / 802 538-AAfter tuning engine, c

OM-496 Page 48Return To Table Of Contents9-7. Servicing Fuel And Lubrication Systems802 490 / Ref. 801 434 Stop engine and let cool. After servicing

OM-496 Page 49Return To Table Of Contents9-8. Overload Protection802 170-D / Ref. 802 311219874 Stop engine. When a circuit breaker or fuseopens, it

OM-496 Page 50Return To Table Of Contents9-9. Diagnosing Causes Of Engine Fault ShutdownsRef. 201 841Use the front panel engine lights tohelp determin

OM-496 Page 51Return To Table Of Contents9-10. TroubleshootingA. Welding − CC ModelsTrouble RemedyNo weld output; generator power outputokay at ac rec

OM-496 Page 52Return To Table Of ContentsB. Welding − CC/CV ModelsTrouble RemedyNo weld output; generator power outputokay at ac receptacles.Place Pro

OM-496 Page 53Return To Table Of ContentsTrouble RemedyMin or max CV weld output only. Check position of Voltage/Amperage Adjust control and Voltage/A

dec_con1 5/98Declaration of Conformity forEuropean Community (CE) ProductsThis information is provided for units with CE certification (see rating lab

OM-496 Page 54Return To Table Of ContentsTrouble RemedyEngine cranks but does not start. Press Magnetic Shutdown switch MS1 when starting engine.Check

OM-496 Page 55Return To Table Of ContentsNotes

OM-496 Page 56Return To Table Of ContentsSECTION 10 − ELECTRICAL DIAGRAMSFigure 10-1. Circuit Diagram For CC Welding Generator

OM-496 Page 57Return To Table Of Contents215 296-B

OM-496 Page 58Return To Table Of ContentsFigure 10-2. Circuit Diagram For CC/CV Welding Generator

OM-496 Page 59Return To Table Of Contents215 297-B

OM-496 Page 60Return To Table Of ContentsSECTION 11 − RUN-IN PROCEDURErun_in1 8/0111-1. Wetstacking Do not perform run-inprocedure at less than 20vol

OM-496 Page 61Return To Table Of Contents11-2. Run-In Procedure Using Load BankS-0683 Stop engine. Do not touch hot exhaustpipe, engine parts, or lo

OM-496 Page 62Return To Table Of Contents11-3. Run-In Procedure Using Resistance GridS-0684 Stop engine. Do not touch hot exhaustpipe, engine parts,

OM-496 Page 63Return To Table Of ContentsSECTION 12 − GENERATOR POWER GUIDELINESThe views in this section are intended to be representative of all eng

OM-496 Page 1Return To Table Of ContentsSECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USINGrom _nd_8/03 Warning: Protect yourself and others from inju

OM-496 Page 64Return To Table Of Contents12-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse

OM-496 Page 65Return To Table Of Contents12-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running Wat

OM-496 Page 66Return To Table Of Contents12-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHa

OM-496 Page 67Return To Table Of Contents12-8. Power Required To Start MotorS-06241 Motor Start Code2 Running Amperage3 Motor HP4 Motor VoltageTo find

OM-496 Page 68Return To Table Of Contents12-10. Typical Connections To Supply Standby Power Have only qualified persons performthese connections acco

OM-496 Page 69Return To Table Of Contents12-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt Loads If unit does no

OM-496 Page 70Return To Table Of ContentsSECTION 13 − PARTS LIST Hardware is common andnot available unless listed.1718191516262524222312345 67101112

OM-496 Page 71Return To Table Of Contents802 550-E85 (Fig. 13-6)84435657415533363772737674757778585938604054798082863227282930313435878889909192939495

OM-496 Page 72Return To Table Of ContentsDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-1. Main AssemblyQuantity1 189 824 PANEL, gen LH 1. . . . . . . .

OM-496 Page 73Return To Table Of ContentsDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-1. Main Assembly (Continued)Quantity38 209 393 ENGINE, Perkins ds

OM-496 Page 2 Return To Table Of ContentsWelding on closed containers, such as tanks, drums, orpipes, can cause them to blow up. Sparks can fly off fr

OM-496 Page 74Return To Table Of ContentsDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-1. Main Assembly (Continued)Quantity76 071 730 TUBING, stl .875 O

OM-496 Page 75Return To Table Of ContentsDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-1. Main Assembly (Continued)Quantity119 212 944 LABEL, weld contr

OM-496 Page 76Return To Table Of ContentsDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-2. Control Box Assembly − CC Models (Continued)Quantity4 201 078

OM-496 Page 77Return To Table Of ContentsRef. 802 360121231496871013521161719111542018Figure 13-3. Control Box Assembly − CC/CV ModelsDescriptionPartN

OM-496 Page 78Return To Table Of ContentsDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-3. Control Box Assembly − CC/CV Models (Continued)Quantity196 602

OM-496 Page 79Return To Table Of Contents Hardware is common andnot available unless listed.802 266-D134512151823242629323536373844454617253031162022

OM-496 Page 80Return To Table Of ContentsDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-4. Panel, Front w/Components − CC Models (Continued)Quantity8 S5

OM-496 Page 81Return To Table Of ContentsDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-4. Panel, Front w/Components − CC Models (Continued)Quantity43 ♦1

OM-496 Page 82Return To Table Of ContentsDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-5. Panel, Front w/Components − CC/CV Models (Figure 13-1 Item 111

OM-496 Page 83Return To Table Of ContentsDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-5. Panel, Front w/Components − CC/CV Models (Continued)Quantity36

OM-496 Page 3Return To Table Of ContentsSTEAM AND HOT COOLANT can burn. If possible, check coolant level when engine is cold toavoid scalding. Alway

OM-496 Page 84Return To Table Of Contents802 552-B Hardware is common andnot available unless listed.568924283031323312725263536431027212934201718111

OM-496 Page 85Return To Table Of ContentsDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-6. Generator (Continued)Quantity21 197 486 ADAPTER, Engine Perkin

OM-496 Page 86Return To Table Of Contents Hardware is common andnot available unless listed.802 279-A123465789Figure 13-7. Main Rectifier AssemblyDes

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 8/03Your distributor also givesyou ...ServiceYou always get the fa

PRINTED IN USA  2004 Miller Electric Mfg. Co. 1/04Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US