Miller Electric Big Blue 300 P User Manual

Big Blue 300 POM-4433 218 314K2006−11ProcessesDescriptionAir Carbon Arc (CAC-A)Cutting and GougingStick (SMAW) WeldingEngine Driven Welding GeneratorT

OM-4433 Page 6Le soudage effectué sur des conteneurs fermés tels que desréservoirs, tambours ou des conduites peut provoquer leuréclatement. Des étinc

OM-4433 Page 7 Si le moteur est chaud et que le liquide doit être vérifié, opérer comme suivant. Mettre des lunettes de sécurité et des gants, place

OM-4433 Page 8LIRE LES INSTRUCTIONS. Utiliser seulement les pièces de rechange d’origine. Effectuer la maintenance du moteur et du compresseur(si ap

OM-4433 Page 9SECTION 3 − DEFINITIONS3-1. Warning Label Definitions3/961 Remove unit from shippingcrate. Remove Owner’sManual from unit. Followinstruc

OM-4433 Page 103-2. Manufacturer’s Rating LabelRef. 218 304-A

OM-4433 Page 113-3. Symbols And DefinitionsSome symbols are found only on CE products.NOTEStop EngineFast (Run, Weld/Power)Slow (Idle) Start EngineSta

OM-4433 Page 12SECTION 4 − SPECIFICATIONS4-1. Weld, Power, And Engine SpecificationsWeldingModeWeld OutputRangeRated WeldingOutputMaximumOpen-CircuitV

OM-4433 Page 134-3. Volt-Ampere Curves217 517 / 217 516 / 217 518The volt-ampere curves show theminimum and maximum voltageand amperage output capabil

OM-4433 Page 144-4. Fuel ConsumptionThe curve shows typical fuel useunder weld or power loads.217 509IDLEDC WELD AMPERES AT 100% DUTY CYCLEU.S. GAL/HR

OM-4433 Page 154-6. AC Generator Power Curve217 519The ac power curve shows the gen-erator power in amperes availableat the 120 and 240 volt receptacl

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

OM-4433 Page 16SECTION 5 − INSTALLATIONinstall3 8/06 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712 Always securely fasten weld-ing generator on

OM-4433 Page 175-2. Mounting Welding GeneratorTools Needed:9/16 in224Welding Unit In PlaceBolting Unit In Place Do not weld on base. Weld-ing on base

OM-4433 Page 185-3. Installing Exhaust Pipe1/2 inTools Needed:803 582 / Ref. 217 357-A Stop engine and let cool. Point exhaust pipe in desired di-re

OM-4433 Page 195-4. Activating The Dry Charge Battery (If Applicable) Always wear a face shield,rubber gloves and protectiveclothing when working on

OM-4433 Page 205-6. Engine Prestart Checks Check all engine fluids daily.Engine must be cold and on a level surface.Unit is shipped with 20W break-in

OM-4433 Page 215-7. Connecting To Weld Output Terminals803 562 / 803 778-ATools Needed:3/4 inMIG and FCAW WeldingFor MIG and FCAW welding Direct Curre

OM-4433 Page 225-8. Selecting Weld Cable Sizes*Weld Cable Size** and Total Cable (Copper) Length in Weld CircuitNot Exceeding***100 ft (30 m) or Less1

OM-4433 Page 235-9. Connecting To Remote 14 Receptacle RC14Socket* Socket Information24 VOLTS ACA 24 volts ac. Protected by sup-plementary protector C

OM-4433 Page 24SECTION 6 − OPERATING WELDING GENERATOR6-1. Front Panel Controls (See Section 6-2)217 357-B / 803 56312546789103

OM-4433 Page 256-2. Description Of Front Panel Controls (See Section 6-1)Engine Starting Controls1 Preheat SwitchUse switch to energize starting aid f

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

OM-4433 Page 266-3. Process/Contactor Switch1 Process/Contactor Switch Weld output terminals are ener-gized when Process/Contactorswitch is in a Weld

OM-4433 Page 276-4. Lift-Arc™ Start ProcedureLift-Arc  TIGWith Lift-Arc TIG selected, startarc as follows:1 TIG Electrode2 WorkpieceTurn gas on. Tou

OM-4433 Page 286-5. Remote Voltage/Amperage Control1 Remote 14 Receptacle RC14Connect optional remote control to RC14 (seeSection 5-9). When a remote

OM-4433 Page 29SECTION 7 − OPERATING AUXILIARY EQUIPMENT7-1. Generator Power Receptacles217 357-A1 120 V 20 A AC (shown) Receptacle RC5 and/or GFCI12

OM-4433 Page 30SECTION 8 − MAINTENANCE & TROUBLESHOOTING8-1. Routine Maintenance Stop engine before maintaining. See Engine Manual and Maintena

OM-4433 Page 318-2. Maintenance Label

OM-4433 Page 328-3. Servicing Air Cleaner Stop engine. Do not run engine without aircleaner or with dirty element. En-gine damage caused by using ad

OM-4433 Page 338-4. Inspecting And Cleaning Optional Spark Arrestor Muffler803 582 / Ref. 217 357-A Stop engine and let cool.1 Spark Arrestor Muffler

OM-4433 Page 348-6. Adjusting Engine Speed On Standard Models803 563-E312RPM (Hz)Engine Speed(No Load)Weld/Power1880 (61.7)Maximum Stop engine and le

OM-4433 Page 358-7. Adjusting Engine Speed On Models With Automatic Idle (Optional)803 563-G1880 rpm max(62.6 Hz)1250 rpm(41.6 Hz)Engine Speed(No Load

TABLE OF CONTENTS8-5. Servicing Engine Cooling System 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-4433 Page 368-8. Servicing Fuel And Lubrication Systems802 490 / Ref. 801 434 Stop engine and let cool. After servicing, start engineand check fo

OM-4433 Page 378-9. Overload Protection803 562 / 803 56615 Stop engine. When a circuit breaker, supple-mentary protector, or fuseopens, it usually i

OM-4433 Page 388-10. Checking Generator BrushesRef 2114 778−D / S−0233−A Stop engine and let cool.1 Generator Brush With SpringMark and disconnect le

OM-4433 Page 398-11. Voltmeter/Ammeter Help DisplaysUse the Voltmeter/Ammeter helpdisplays to diagnose and correctfault conditions. When a help code

OM-4433 Page 408-12. Troubleshooting Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (seeSection 8-11).NoteA. Weld

OM-4433 Page 41B. Generator PowerTrouble RemedyNo generator power output at ac recep-tacles; weld output okay.Reset receptacle supplementary protector

OM-4433 Page 42Trouble RemedyEngine slowly stopped and cannot berestarted.Check fuel level.Check engine air and fuel filters (see Sections 8-3 and 8-8

OM-4433 Page 43Notes16 Gauge (.063 in)22 Gauge (.031 in)24 Gauge (.025 in)20 Gauge (.037 in)18 Gauge (.050 in)14 Gauge (.078 in)1/8 in (.125 in)3/16 i

OM-4433 Page 44SECTION 9 − ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For Welding Generator

OM-4433 Page 45219 228−D

OM-4433 Page 1SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USINGrom _nd_3/05 Warning: Protect yourself and others from injury — read and follow these

OM-4433 Page 46SECTION 10 − RUN-IN PROCEDURErun_in1 8/0110-1. Wetstacking Do not perform run-inprocedure at less than 20volts weld output and do note

OM-4433 Page 4710-2. Run-In Procedure Using Load BankS-0683 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep exhaust

OM-4433 Page 4810-3. Run-In Procedure Using Resistance GridS-0684 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep e

OM-4433 Page 49SECTION 11 − GENERATOR POWER GUIDELINESThe views in this section are intended to be representative of all engine-drivenwelding generato

OM-4433 Page 5011-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse #10 AWG or larger insulate

OM-4433 Page 5111-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running WattsSplit Phase 1/8 HP 800 3

OM-4433 Page 5211-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHand Drill 1/4 in 350 3503/8

OM-4433 Page 5311-8. Power Required To Start MotorS-06241 Motor Start Code2 Running Amperage3 Motor HP4 Motor VoltageTo find starting amperage:Step 1:

OM-4433 Page 5411-10. Typical Connections To Supply Standby Power Have only qualified persons performthese connections according to allapplicable cod

OM-4433 Page 5511-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, u

OM-4433 Page 2Welding on closed containers, such as tanks, drums, orpipes, can cause them to blow up. Sparks can fly off from thewelding arc. The flyi

OM-4433 Page 56SECTION 12 − PARTS LIST Hardware is common and notavailable unless listed.Wirng harnesses are listed atthe end of parts section.1 (Fig

OM-4433 Page 57803 683-B2930313233343536373839404142434445464748495051525354555657585960616263646566676968707174727375767778798081 (Fig. 12-4)82838485

OM-4433 Page 58DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-1. Main AssemblyQuantity1 Figure 12−3 Control Panel 1. . . . . . . . . . . . . . . . . .

OM-4433 Page 59DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-1. Main Assembly (Continued)Quantity46 220295 Bracket, Stiffener 1. . . . . . . . . . . .

OM-4433 Page 60DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-1. Main Assembly (Continued)Quantity83 213266 Mount, Engine/Generator Flange Mtg 1. . .

OM-4433 Page 61 Hardware is common and notavailable unless listed.Wirng harnesses are listed atthe end of parts section.803 684-B12345637367891011121

OM-4433 Page 62DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-2. Panel, Front w/Components (Continued)Quantity10 214543 Enclosure, Circuit Card Assy 1.

OM-4433 Page 63 Hardware is common and notavailable unless listed.Wirng harnesses are listed atthe end of parts section.803 689-D12345678910131211141

OM-4433 Page 64803 686-A Hardware is common and notavailable unless listed.Wirng harnesses are listed atthe end of parts section.23145678910111213141

OM-4433 Page 65803 685-A Hardware is common and notavailable unless listed.Wirng harnesses are listed atthe end of parts section.12364598107Figure 12

OM-4433 Page 3STEAM AND HOT COOLANT can burn. If possible, check coolant level when engine is cold toavoid scalding. Always check coolant level at o

OM-4433 Page 66 Some wiring harness components (switches, relays, supplementary protectors) are alsoreferenced elsewhere in this parts list. Purchase

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 2006−01Your distributor also givesyou ...ServiceYou always get the

PRINTED IN USA © 2006 Miller Electric Mfg. Co.2006−01Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914

OM-4433 Page 4READ INSTRUCTIONS. Use only genuine MILLER/Hobart replacementparts. Perform engine and air compressor (if applicable)maintenance and s

OM-4433 Page 5SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANTUTILISATIONrom_fre 3/05 Avertissement: Protégez vous et les autres des blessures − lisez