Miller-electric Big Blue 251D User Manual

Visit our website atwww.MillerWelds.comProcessesOM-480 128 576ACJanuary 2005Big Blue 251DStick (SMAW) WeldingFlux Cored (FCAW) WithVoltage-Sensing Wi

OM-480 Page 6LES ACCUMULATIONS DE GAZ ris-quent de provoquer des blessures oumême la mort. Fermer l’alimentation du gaz protecteur en cas denon utili

OM-480 Page 7L’EXPLOSION DE LA BATTERIE peutRENDRE AVEUGLE. Toujours porter une protection faciale, des gants encaoutchouc et vêtements de protection

OM-480 Page 8LE SURCHAUFFEMENT peut endom-mager le moteur électrique. Arrêter ou déconnecter l’équipement avant de dé-marrer ou d’arrêter le moteur.

OM-480 Page 9SECTION 3 − DEFINITIONS3-1. Symbols And DefinitionsStop EngineFast (Run, Weld/Power)Slow (Idle) Start EngineFast/Slow(Run/Idle)Battery (E

OM-480 Page 10SECTION 4 − SPECIFICATIONS4-1. Weld, Power, And Engine SpecificationsRated WeldingOutputAmperageRangeMaximumOpen-CircuitVoltage DC(Nomin

OM-480 Page 114-3. Fuel ConsumptionSB-137 487-AThe curve shows typical fuel useunder weld or power loads.4-4. Duty Cycle And Overheatingrduty1 5/95 −

OM-480 Page 124-5. AC Generator PowerThe ac power curve shows the gen-erator power in amperes availableat the 120 and 240 volt receptacles.rsb3.1 2/92

OM-480 Page 134-7. Optional AC Power Plant Curvesrsb13.1 12/94 - 134 636-A / 206 032The ac power curves show the gen-erator power in amperes available

OM-480 Page 14SECTION 5 − INSTALLATION5-1. Installing Welding Generatorinstall1 11/02 − Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854Ele

OM-480 Page 155-3. Installing Muffler Pipeexh_pipe2 12/96 − 154 089-A / 154 611 / Ref. 206 029 Stop engine and let cool. Do not blow exhaust towarda

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

OM-480 Page 16ether1 12/96 − 153 382-A / Ref. 206 029 Stop engine. Improper handling or expo-sure to ether can harm yourhealth. Follow manufactur-er

OM-480 Page 175-7. Selecting Weld Cable Sizes*Weld Cable Size** and Total Cable (Copper) Length in Weld CircuitNot Exceeding***100 ft (30 m) or Less15

OM-480 Page 18SECTION 6 − OPERATING THE WELDING GENERATOR6-1. Controls (See Section 6-2)Ref. 206 029 / 800 162-A / 800 159-D121213534671011891415

OM-480 Page 196-2. Description Of Front Panel Controls (See Section 6-1)This unit has a max OCV control circuitthat resets the Amperage/Voltage Con-t

OM-480 Page 20SECTION 7 − OPERATING AUXILIARY EQUIPMENT127-1. 120 Volt Duplex And Optional GFCI ReceptaclesRef. 206 02943 If unit does not have GFCI

OM-480 Page 217-2. 240 Volt Duplex Receptacle (Optional)Ref. 206 029 / 174 408 If unit does not have GFCI re-ceptacles, use GFCI-pro-tected extension

OM-480 Page 227-3. Connecting Optional AC Power Plant Ref. S-179 637-B Stop engine. Power and weld outputs arelive at the same time.Disconnect or in

OM-480 Page 237-4. 120/240 Volt Twistlock Receptacle (Optional)801 057-A1 120/240 V 50 A Twistlock Re-ceptacle RC9RC9 is connected to the optional acp

OM-480 Page 24SECTION 8 − MAINTENANCE AND TROUBLESHOOTING8-1. Routine MaintenanceRecycle enginefluids. Stop engine before maintaining. See Engine M

OM-480 Page 25Follow the storage procedure in the engine owner’s manual if the unit will not beused for an extended period.NOTE8-2. Maintenance Label

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

OM-480 Page 268-3. Servicing Air Cleaneraircleaner4 9/02− 802 495 / Ref. S-0698-B Stop engine. Do not run engine without aircleaner or with dirty el

OM-480 Page 278-4. Servicing Fuel And Lubrication Systems Ref. 800 159-E / Ref. 206 029 Stop engine and let cool.1 Oil Filter2 Oil Drain Plug3 Oil F

OM-480 Page 288-5. Adjusting Engine SpeedRef. 801 179 / Ref. 800 159-D / Ref. 800 161After tuning engine, check engineno load speed with a tachometer(

OM-480 Page 298-6. Overload ProtectionRef. 156 199-B / 801 320-B Stop engine. When a fuse opens, it usuallyindicates a more serious prob-lem exists.

OM-480 Page 308-8. Inspecting And Cleaning Optional Spark Arrestor800 523 / Ref. 206 029 Stop engine and let cool.1 Spark Arrestor2 Cleanout PlugRemo

OM-480 Page 31B. Generator PowerTrouble RemedyNo output at generator powerreceptacles.Reset circuit breaker CB1 and/or CB2 (see Section 7-1 or 7-2).Di

OM-480 Page 32SECTION 9 − ELECTRICAL DIAGRAMSC-190 650-BFigure 9-1. Circuit Diagram For Welding Generator

OM-480 Page 33SECTION 10 − RUN-IN PROCEDURErun_in1 8/0110-1. Wetstacking Do not perform run-inprocedure at less than 20volts weld output and do notex

OM-480 Page 3410-2. Run-In Procedure Using Load BankS-0683 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep exhaust

OM-480 Page 3510-3. Run-In Procedure Using Resistance GridS-0684 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep ex

TABLE OF CONTENTSSECTION 8 − MAINTENANCE AND TROUBLESHOOTING 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. R

OM-480 Page 36SECTION 11 − GENERATOR POWER GUIDELINESThe views in this section are intended to be representative of all engine-drivenwelding generator

OM-480 Page 3711-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse #10 AWG or larger insulated

OM-480 Page 3811-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running WattsSplit Phase 1/8 HP 800 30

OM-480 Page 3911-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHand Drill 1/4 in 350 3503/8

OM-480 Page 4011-8. Power Required To Start MotorS-06241 Motor Start Code2 Running Amperage3 Motor HP4 Motor VoltageTo find starting amperage:Step 1:

OM-480 Page 4111-10. Typical Connections To Supply Standby Power Have only qualified persons performthese connections according to allapplicable code

OM-480 Page 4211-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, us

OM-480 Page 43Notes

OM-480 Page 44SECTION 12 − PARTS LISTFigure 12-1. Main Assembly Hardware is common andnot available unless listed.13245789101112131415161718737481828

OM-480 Page 45ST-129 956-U1920212223242526272829454647484950515253545556575859606162636465(Fig 12-3)66676869703031333435363738324041424344126

OM-480 Page 1SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USINGrom _nd_8/03 Warning: Protect yourself and others from injury — read and follow these

OM-480 Page 46DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-1. Main AssemblyQuantity1 134 771 PLUG, protective .640sq 2. . . . . . . . . . . . . . . .

OM-480 Page 47DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-1. Main AssemblyQuantity128 287 STUD, adjusting throttle 1. . . . . . . . . . . . . . . . .

OM-480 Page 48DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-1. Main AssemblyQuantity101 173 982 PANEL, mtg components 1. . . . . . . . . . . . . . . .

OM-480 Page 49DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-2. Panel, Front w/Components (Fig 12-1 Item 111) (Cont’d)Quantity13 021 385 BOOT, toggle swi

OM-480 Page 50ST-110 922-F Hardware is common andnot available unless listed.141516171812202319242526272812456431229211371089Figure 12-3. Generator22

OM-480 Page 51DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-3. Generator (Fig 12-1 Item 65)Quantity1 106 426 INSULATOR 4. . . . . . . . . . . . . . .

OM-480 Page 52Description QuantityPartNo.ItemNo.114 193 Figure 12-4. Switch, Range (Fig 12-2 Item 1)1 114 235 BRACKET, mtg switch (consisting of) 1. .

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 1/05Your distributor also givesyou ...ServiceYou always get the fa

OM-480 Page 2Welding on closed containers, such as tanks, drums, orpipes, can cause them to blow up. Sparks can fly off from thewelding arc. The flyin

PRINTED IN USA  2005 Miller Electric Mfg. Co. 1/05Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US

OM-480 Page 3STEAM AND HOT COOLANT can burn. If possible, check coolant level when engine is cold toavoid scalding. Always check coolant level at ov

OM-480 Page 4READ INSTRUCTIONS. Use only genuine MILLER/Hobart replacementparts. Perform engine and air compressor (if applicable)maintenance and se

OM-480 Page 5SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANTUTILISATIONrom_fre 8/03 Avertissement: Protégez vous et les autres des blessures − lisez