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OM-491 Page 53

Hardware is common and
not available unless listed.

802 278

Figure 11-2. Control Box Assembly

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 11-2. Control Box Assembly (Figure 11-1 Item 93)

Quantity

F1, F2

*085 874

FUSE, mintr cer slo-blo 10A 250V

. . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

046 432

HOLDER, fuse mintr .250 x 1.250

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

189 385

CONTROL BOX

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

190 253

HARNESS, control box, weld control (consisting of)

. . . . . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . .

CR7

188 636

RELAY, OCV control

. . .

. . . .

. . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D1/C1

189 701

DIODE/CAPACITOR BOARD

. . .

. .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SR1, SR2

035 704

RECTIFIER, integ 40A 800V

. . .

. .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CR5

090 104

RELAY, encl 12VDC SPST 30A/15VDC

. . .

. . . .

. . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

2T, 3T

190 210

BLOCK, term 5-3-3

. . .

. . . .

. .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC5

047 483

CONNECTOR, rect univ 084 15P/S 3 row rcpt cable/panel lkg

. . . . . . . . . .

. . .

. . . .

. . . . . . .

RC3, RC4

158 466

CONNECTOR, rect univ 084 12P/S 3 row rcpt cable/panel lkg

. . . . . . . .

. . . .

. . . . . . .

RC1, 2, 7

135 133

CONNECTOR, rect univ 084 9P/S 3 row rcpt cable/panel lkg

. . . .

. . .

. . . .

. . . . . . . .

9 CB11, 12, 13 139 266

CIRCUIT BREAKER, man reset 1P 15A 250VAC frict

. . .

. . . .

. . . . . . . . . . . . . .

189 386

COVER, control box

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

177 136

CLAMP, capacitor 1.375dia

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

087 110

CAPACITOR, elctlt 240uf 200VDC

. . .

. . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*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.

Содержание Big Blue 502P

Страница 1: ...02P 602P Processes Description Air Carbon Arc CAC A Cutting and Gouging Stick SMAW Welding Engine Driven Welding Generator OM 491 190 355 January 1999 TIG GTAW Welding Visit our website at www Miller...

Страница 2: ...ner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the works...

Страница 3: ...Using Lifting Eye 13 4 3 Mounting Welding Generator 14 4 4 Installing Muffler 14 4 5 Activating The Dry Charge Battery If Applicable 15 4 6 Connecting The Battery 16 4 7 Engine Prestart Checks 17 4 8...

Страница 4: ......

Страница 5: ...n not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable Do...

Страница 6: ...ch hot engine parts or just welded parts bare handed NOISE can damage hearing Noise from some processes or equipment can damage hearing Wear approved ear protection if noise level is high MAGNETIC FIE...

Страница 7: ...mmables Keep exhaust and exhaust pipes way from flammables EXHAUST SPARKS can cause fire Do not let engine exhaust sparks cause fire Use approved engine exhaust spark arrestor in required areas see ap...

Страница 8: ...une Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet...

Страница 9: ...rifier fr quemment le cordon d alimentation pour voir s il n est pas en dommag ou d nud remplacer le cordon imm diatement s il est endommag un c ble d nud peut provoquer une lectrocution Mettre l appa...

Страница 10: ...lures graves Pr voir une p riode de refroidissement avant d effec tuer des travaux d entretien Porter des gants et des v tements de protection pour travailler sur un moteur chaud Ne pas toucher mains...

Страница 11: ...enir distance les produits inflammables de l chappement LES TINCELLES L CHAPPEMENT peuvent provoquer un incendie Emp cher les tincelles d chappement du moteur de provoquer un incendie Utiliser uniquem...

Страница 12: ...Lejeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 de la National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pa...

Страница 13: ...rent Stick SMAW Welding Constant Current CC Do Not Switch While Welding TIG GTAW Time h Hours s Seconds 1 Single Phase 3 Three Phase Read Operator s Manual Circuit Breaker SECTION 3 SPECIFICATIONS 3 1...

Страница 14: ...8 in 1419 mm B C 9 1 2 in 241 mm D 27 1 2 in 699 mm G 30 E 1 in 25 mm G 30 30 F 28 1 2 in 729 mm Front Panel End C 25 30 G 9 16 in 14 mm Dia 4 Holes Front Panel End E 25 Weight E D w Perkins 3 152 No...

Страница 15: ...50 200 250 300 350 400 450 500 DC WELD AMPERES AT 100 DUTY CYCLE 1800 RPM 0 Continuous Welding 3 5 Duty Cycle And Overheating Duty Cycle is percentage of 10 min utes that unit can weld at rated load w...

Страница 16: ...The ac power curve shows the aux iliary 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 VOLTS 0 25 50 75 100 150 1...

Страница 17: ...AWG or larger insulated copper wire If unit does not have GFCI re ceptacles use GFCI protected extension cord 2 OR 18 in 460 mm 18 in 460 mm 18 in 460 mm 18 in 460 mm 18 in 460 mm OR Movement Airflow...

Страница 18: ...Place Remove hardware securing the four mounting brackets to the base Reverse brackets and reattach to base with original hardware Mount unit to truck or trailer with 1 2 in 12 mm hardware not suppli...

Страница 19: ...Wait ten minutes and check electro lyte level If necessary add electro lyte to raise to proper level Reins tall vent caps 6 Battery Charger Read and follow all instruc tions supplied with battery cha...

Страница 20: ...OM 491 Page 16 4 6 Connecting The Battery 1 2 in Connect Negative Cable Last Tools Needed ST 802 168 A Ref ST 191 631 A S 0756 C...

Страница 21: ...first time If necessary add cool ant to radiator until coolant level is at bottom of filler neck Check coolant level in recovery tank daily If necessary add coolant to recovery tank until coolant lev...

Страница 22: ...g Weld Cable Sizes Total Cable Copper Length In Weld Circuit Not Exceeding Welding Amperes 100 ft 30 m Or Less 150 ft 45 m 200 ft 60 m 250 ft 70 m 300 ft 90 m 350 ft 105 m 400 ft 120 m Amperes 10 60 D...

Страница 23: ...491 Page 19 4 10 Connecting To Remote Amperage Adjust Receptacle RC13 Ref 154 862 A 048 720 K 802 160 A 1 Remote Amperage Adjust Receptacle RC13 Connect optional remote control to RC13 see Section 5 3...

Страница 24: ...OM 491 Page 20 SECTION 5 OPERATING THE WELDING GENERATOR 5 1 Front Panel Controls See Section 5 2 17 191 631 A 802 160 A 15 16 2 1 3 13 18 19 14 12 10 11 9 8 6 5 4 7...

Страница 25: ...voltage and moni tor the engine charging system The meter should read about 14 volts dc when the en gine is running and about 12 volts dc when the engine is stopped 11 Engine Coolant Temperature Gauge...

Страница 26: ...trol to RC13 see Section 4 10 0774 Ref 154 862 A Ref 181 711 A 802 160 A Example Combination Remote Amperage Control Stick In Example Range 125 to 320 A DC Percentage Of Range 50 Max About 223 A DC 50...

Страница 27: ...is working properly 3 Circuit Breaker CB1 4 Circuit Breaker CB2 5 Circuit Breaker CB3 CB1 and CB3 protect RC1 from overload If CB1 or CB3 opens RC1 does not work 120 volts may still be present at RC1...

Страница 28: ...ce Agent 8 h Check Fluid Levels See Section 4 7 Wipe Up Spills Drain Water From Fuel System OIL Full FUEL WATER Coolant Full 50 h Clean Air Filter See Section 7 3 Clean And Tighten Weld Terminals 100...

Страница 29: ...h Repair Or Replace Damaged Cables 800 h Clean Set Injectors 1000 h Blow Out Or Vacuum Inside During Heavy Service Clean Monthly OR Drain Sludge From Fuel Tank See Section 7 6 FUEL SLUDGE Service Wel...

Страница 30: ...OM 491 Page 26 7 2 Maintenance Label...

Страница 31: ...cap Do not clean housing with air hose Clean element with compressed air Max air pressure 100 psi 690 kPa Replace element if it has holes or damaged gaskets Reinstall element and cap 4 3 Blow Inspect...

Страница 32: ...ble for proper no load speed If neces sary adjust speed as follows 1 Adjustment Screw 2 Lock Nut Loosen nuts Turn screws out sev eral turns 3 Speed Lever Start engine and move lever until engine runs...

Страница 33: ...ne maintenance label for oil filter change in formation To drain water from fuel system Open primary fuel filter petcock and drain water into metal container Close petcock when water free fuel flows T...

Страница 34: ...11 5 Circuit Breaker CB12 6 Circuit Breaker CB13 CB10 protects the engine battery circuit If CB10 opens the engine will not crank CB10 automatically resets when the fault is corrected CB11 protects th...

Страница 35: ...g Light Is Off Check Alternator And Belt If Temperature Light Is On Correct Cause Of Overheating See Engine Manual If Engine Is Okay See Factory Authorized Service Agent If Fuel Light Is On Check Fuel...

Страница 36: ...c weld output Check and tighten connections inside and outside unit Be sure connection to work piece is clean and tight Use dry properly stored electrodes Remove excessive coils from weld cables Check...

Страница 37: ...10 automatical ly resets when fault is corrected see Section 7 7 Check engine wiring harness plug connections Have Factory Authorized Service Agent check Engine Control switch S1 Engine cranks but doe...

Страница 38: ...speed models with idle option only Have Factory Authorized Service Agent check Engine Control switch S1 Have Factory Authorized Service Agent check idle module PC7 and current transformer CT1 Check f...

Страница 39: ...OM 491 Page 35 Notes...

Страница 40: ...OM 491 Page 36 SECTION 8 ELECTRICAL DIAGRAMS Figure 8 1 Circuit Diagram For Welding Generator...

Страница 41: ...OM 491 Page 37 191 550 C...

Страница 42: ...er than necessary Piston rings seat faster if engine runs at weld power rpm and the welding generatoris kept loaded during run in 2 Engine Exhaust Pipe Wetstacking is unburned fuel and oil in the exha...

Страница 43: ...ad bank to generator weld output terminals using proper size weld cables with correct connectors Observe correct polarity Start engine and run for several minutes Set load bank switches and then adjus...

Страница 44: ...correct connec tors polarity is not important 4 Voltmeter 5 Clamp On Ammeter Connect voltmeter and ammeter as shown if not provided on generator Start engine and run for several minutes Set grid switc...

Страница 45: ...le Insulated Equipment OR 2 Be sure equipment has this symbol and or wording 3 1 10 2 Grounding Generator To Truck Or Trailer Frame S 0854 1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grounding...

Страница 46: ...istive Load Equipmentwith a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when run ning see Section 10 8 3 Rating Data Rating shows volt...

Страница 47: ...ome Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 Mi...

Страница 48: ...P 6000 1500 1 1 2 HP 8200 2200 2 HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1 3...

Страница 49: ...Starting Requirements Motor Start Code G H J K L M N P KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0 EXAMPLE Calculate the starting amperage required for a 230 V 1 4 HP motor with a motor start code of...

Страница 50: ...Connections Connect terminals or plug of ade quate amperage capacity to cord Follow all applicable codes and safety practices Turn off or unplug all equipment connected to generator before starting o...

Страница 51: ...15 40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 2 voltage drop Cord Lengths for 240 Volt Loads If unit does not have GFCI receptacles use GFCI...

Страница 52: ...dware is common and not available unless listed 1 2 3 4 5 6 7 8 9 10 13 14 15 16 17 18 19 20 21 22 23 24 25 26 28 29 30 31 32 33 34 97 98 99 100 102 101 103 Fig 11 5 105 106 107 108 109 Fig 11 3 11 12...

Страница 53: ...802 265 35 36 37 38 39 40 41 42 43 45 46 47 48 49 50 53 Fig 11 4 54 55 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 89 90 91 92 93 Fig 11 2 94 51 44 52 86 87 88 58 59...

Страница 54: ...ME mtg reactor and rectifier 1 18 189 708 FIREWALL top 1 19 190 182 PANEL side air box 1 20 189 763 BRACKET mtg air cleaner 1 21 189 764 AIR CLEANER intake 1 192 938 FILTER air element primary 1 192 9...

Страница 55: ...1 awg w clamp and 406rng 1 65 108 081 TERMINAL PROTECTOR battery post mtg 2 66 190 206 CABLE bat neg 42 in lg No 2 awg w clamp and 375rng 1 67 190 896 BATTERY stor 12V 650crk 110rsv gp 24 1 68 168 38...

Страница 56: ...do not weld on base 2 98 191 512 BRACKET hold down fuel tank 1 99 191 897 BRACKET mtg unit 4 100 190 179 PANEL mtg components 1 101 R4 191 292 RESISTOR WW fxd 375W 50 ohm w mtg bkt 1 102 R2 R3 189 69...

Страница 57: ...A 800V 2 7 CR5 090 104 RELAY encl 12VDC SPST 30A 15VDC 1 8 2T 3T 190 210 BLOCK term 5 3 3 2 RC5 047 483 CONNECTOR rect univ 084 15P S 3 row rcpt cable panel lkg 1 RC3 RC4 158 466 CONNECTOR rect univ 0...

Страница 58: ...age 54 Hardware is common and not available unless listed 802 266 1 2 3 4 5 6 7 8 11 14 12 15 16 17 19 20 21 22 24 25 28 31 30 32 33 34 35 36 37 9 13 10 18 23 11 29 26 27 Figure 11 3 Panel Front w Com...

Страница 59: ...v 6P S 3 row 1 190 258 HARNESS auxiliary power consisting of 1 15 CB1 2 3 093 996 CIRCUIT BREAKER man reset 1P 20A 250VAC frict 3 16 GFCI1 151 981 RECEPTACLE str dx grd 2P3W 15 20A 125V GFCI 1 17 RC1...

Страница 60: ...OM 491 Page 56 802 267 5 6 8 9 10 11 22 26 27 28 29 30 1 2 7 13 14 15 16 23 24 31 32 4 3 12 17 18 19 20 21 25 Figure 11 4 Generator...

Страница 61: ...eel 1 20 049 026 SCREW M10 1 5 x 25hexhd pln 8 8pln 6 21 183 387 WASHER conical spring 406 ID x 875 OD pltd 6 22 191 579 COVER starter hole Perkins Continental 1 23 602 211 WASHER lock 318 ID x 0 586...

Страница 62: ...BAR connection board 3 3 188 135 ENCLOSURE rectifier 2 4 134 201 STAND OFF support 3 5 PC3 188 610 CIRCUIT CARD ASSEMBLY protection 1 6 188 136 INSULATOR heat sink 8 7 188 493 HEAT SINK rectifier al 2...

Страница 63: ...orches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate 185 Miller s True Blue Limited Warranty shall not apply to 1 Items furnished by Miller but manufactured by others such as eng...

Страница 64: ...ss City State Zip Please complete and retain with your personal records Always provide Model Name and Serial Style Number Contact your Distributor for To locate distributor nearest you call 1 800 4 A...

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