EasyManua.ls Logo

Miller Electric Big Blue 302P - User Manual

Miller Electric Big Blue 302P
96 pages
Print Icon
To Next Page IconTo Next Page
To Next Page IconTo Next Page
Loading...
Big Blue 302P
Big Blue 452P
(CE Compliant)
OM-496 197 761AT
March 2004
Visit our website at
www.MillerWelds.com
Processes
Description
Air Carbon Arc (CAC-A)
Cutting and Gouging
Stick (SMAW) Welding
Engine Driven Welding Generator
TIG (GTAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
And Non-CE Models

Table of Contents

Question and Answer IconNeed help?

Do you have a question about the Miller Electric Big Blue 302P and is the answer not in the manual?

Summary

OWNERS MANUAL

From Miller to You

SECTION 1 - SAFETY PRECAUTIONS - READ BEFORE USING

1-1. Symbol Usage

Explains safety symbols used in the manual.

1-2. Arc Welding Hazards

Details potential dangers associated with arc welding processes.

1-3. Engine Hazards

Outlines risks related to the generator's engine operation and fuel.

1-4. Compressed Air Hazards

Lists dangers associated with compressed air usage.

1-5. Additional Symbols For Installation, Operation, And Maintenance

Presents symbols for installation, operation, and maintenance tasks.

1-6. California Proposition 65 Warnings

Provides state-specific warnings regarding chemicals in products.

1-7. Principal Safety Standards

Lists relevant safety standards and organizations.

1-8. EMF Information

Discusses electromagnetic fields and their potential effects.

SECTION 3 - DEFINITIONS

3-1. Warning Label Definitions (CE Models Only)

Explains warning labels specific to CE-certified models.

3-3. Symbols And Definitions

Defines various symbols used throughout the manual for clarity.

SECTION 4 - SPECIFICATIONS

4-1. Weld, Power, And Engine Specifications

Details technical specifications for welding, power output, and engine.

4-2. Dimensions, Weights, And Operating Angles

Provides physical dimensions, weight, and safe operating angles.

4-3. Volt-Ampere Curves For CC Models

Shows voltage-amperage output capabilities for CC models.

4-4. Volt-Ampere Curves For CC;CV Models

Displays voltage-amperage output for CC/CV models across different modes.

4-5. Fuel Consumption

Illustrates typical fuel usage under various load conditions.

4-6. Duty Cycle And Overheating

Explains duty cycle percentages and overheating risks.

4-7. AC Generator Power Curve

Shows AC power availability at 120V and 240V receptacles.

4-8. Optional Three-Phase Generator Curves

Details power curves for optional three-phase generator outputs.

SECTION 5 - INSTALLATION

5-1. Installing Welding Generator (See Sections 5-2 And 5-3)

Guides on securely installing the welding generator onto vehicles.

5-2. Using Lifting Eye

Instructions on safely using the lifting eye for moving the unit.

5-3. Mounting Welding Generator

Details methods for securely mounting the generator to surfaces or trailers.

5-4. Installing Exhaust Pipe

Provides instructions for correctly installing the exhaust pipe.

5-5. Activating The Dry Charge Battery (If Applicable)

Steps for preparing and activating a dry charge battery.

5-6. Connecting The Battery

Explains the correct procedure for connecting the unit's battery.

5-7. Engine Prestart Checks

Lists essential checks before starting the engine for the first time.

5-8. Connecting To Weld Output Terminals

Guides on connecting welding cables to the output terminals correctly.

5-9. Selecting Weld Cable Sizes*

Provides a chart for choosing appropriate weld cable sizes based on length and current.

5-10. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models

Details connecting a remote amperage control to the RC13 receptacle.

5-11. Connecting To Remote 14 Receptacle RC14 On CC;CV Models

Explains connections for remote controls using the RC14 receptacle.

SECTION 6 - OPERATING WELDING GENERATOR - CC MODELS

6-1. Front Panel Controls For CC Models (See Section 6-2)

Identifies and locates front panel controls for CC models.

6-2. Description Of Front Panel Controls For CC Models (See Section 6-1)

Explains the function of each front panel control for CC models.

6-3. Remote Amperage Control On CC Models (Optional)

Details how to use optional remote amperage control with CC models.

6-4. Weld Control;Arc Condition Information Label

Guides on setting weld controls for desired arc conditions.

SECTION 7 - OPERATING WELDING GENERATOR - CC;CV MODELS

7-1. Front Panel Controls For CC;CV Models (See Section 7-2)

Identifies and locates front panel controls for CC/CV models.

7-2. Description Of Front Panel Controls For CC;CV Models (See Section 7-1)

Explains the function of each front panel control for CC/CV models.

7-3. Process;Contactor Switch On CC;CV Models

Explains selecting weld processes and output control modes.

7-4. Remote Voltage;Amperage Control On CC;CV Models (Optional)

Details using optional remote voltage/amperage controls with CC/CV models.

SECTION 8 - OPERATING AUXILIARY EQUIPMENT

8-1. 120 Volt And 240 Volt Receptacles

Describes the available 120V and 240V AC power receptacles.

8-2. Connecting To Optional Three-Phase Generator (CC;CV Models Only)

Guides on connecting to an optional three-phase generator.

8-3. Optional Generator Power Receptacles

Details optional generator power receptacle types and their usage.

SECTION 9 - MAINTENANCE & TROUBLESHOOTING

9-1. Maintenance Labels

Identifies key maintenance labels and their locations on the unit.

9-2. Routine Maintenance

Outlines regular maintenance tasks and their intervals.

9-3. Servicing Air Cleaner

Provides instructions for cleaning or replacing the air cleaner element.

9-4. Inspecting And Cleaning Optional Spark Arrestor Muffler

Details inspection and cleaning procedures for the spark arrestor muffler.

9-5. Adjusting Engine Speed On Standard Models

Guides on adjusting engine speed for standard models.

9-6. Adjusting Engine Speed On Models With Automatic Idle (Optional)

Explains how to adjust engine speed on models with automatic idle.

9-7. Servicing Fuel And Lubrication Systems

Covers maintenance of fuel and lubrication systems, including oil and filters.

9-8. Overload Protection

Explains the function of circuit breakers and fuses for overload protection.

9-9. Diagnosing Causes Of Engine Fault Shutdowns

Helps identify reasons for automatic engine shutdowns using indicator lights.

9-10. Troubleshooting

Lists common problems and their remedies for welding and generator functions.

SECTION 10 - ELECTRICAL DIAGRAMS

Figure 10-1. Circuit Diagram For CC Welding Generator

Presents the electrical circuit diagram for CC welding generators.

Figure 10-2. Circuit Diagram For CC;CV Welding Generator

Provides the electrical circuit diagram for CC/CV welding generators.

SECTION 11 - RUN-IN PROCEDURE

11-1. Wetstacking

Explains wetstacking and its prevention during engine break-in.

11-2. Run-In Procedure Using Load Bank

Details the process for running in the generator using a load bank.

11-3. Run-In Procedure Using Resistance Grid

Outlines the procedure for running in the generator using a resistance grid.

SECTION 12 - GENERATOR POWER GUIDELINES

12-1. Selecting Equipment

Advises on selecting appropriate electrical equipment for generator use.

12-2. Grounding Generator To Truck Or Trailer Frame

Explains the importance and method of grounding the generator frame to vehicles.

12-3. Grounding When Supplying Building Systems

Guides on proper grounding when supplying power to building systems.

12-4. How Much Power Does Equipment Require?

Helps calculate power requirements for various electrical equipment.

12-5. Approximate Power Requirements For Industrial Motors

Lists power requirements for different types of industrial motors.

12-6. Approximate Power Requirements For Farm;Home Equipment

Details power needs for common farm and home appliances.

12-7. Approximate Power Requirements For Contractor Equipment

Shows power requirements for various contractor tools and equipment.

12-8. Power Required To Start Motor

Explains how to determine starting amperage for motors.

12-9. How Much Power Can Generator Supply?

Advises on generator output limits and load management.

12-10. Typical Connections To Supply Standby Power

Illustrates typical setups for supplying standby power.

12-11. Selecting Extension Cord (Use Shortest Cord Possible)

Provides guidelines for selecting appropriate extension cords based on load and length.

SECTION 13 - PARTS LIST

Figure 13-1. Main Assembly

Illustrates and lists parts for the main assembly of the unit.

Figure 13-2. Control Box Assembly - CC Models

Shows and lists components of the control box for CC models.

Figure 13-3. Control Box Assembly - CC;CV Models

Illustrates and lists parts for the CC/CV models' control box assembly.

Figure 13-4. Panel, Front w;Components - CC Models

Details components on the front panel for CC models.

Figure 13-5. Panel, Front w;Components - CC;CV Models

Lists and illustrates components on the front panel for CC/CV models.

Figure 13-6. Generator

Exploded view and parts list for the generator assembly.

Figure 13-7. Main Rectifier Assembly

Shows and lists parts for the main rectifier assembly.

WARRANTY

LIMITED WARRANTY

Outlines the terms and conditions of Miller's limited warranty.

Miller Electric Big Blue 302P Specifications

General IconGeneral
TypeEngine-Driven Welding Generator
Welding Amperage Range30 - 300 A
Fuel Tank Capacity12 Gallons
Frequency60 Hz
Power Factor1.0
Max Output300 A
Horsepower24.8 HP
DimensionsWidth: 25 in (635 mm)
Input PowerN/A (Engine-driven)
Generator Output10, 000 Watts Peak, 9, 000 Watts Continuous
EngineKubota D722, 3-cylinder diesel
Weight690 lb (313 kg)

Related product manuals