Big Blue 300 POM-4433 218 314P2007−11ProcessesDescriptionAir Carbon Arc (CAC-A)Cutting and GougingStick (SMAW) WeldingEngine Driven Welding GeneratorT
OM-4433 Page 6SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANTUTILISATIONrom_2007−04freSe protéger, ainsi que toute autre personne travaillant sur les
OM-4433 Page 7DES PIÈCES CHAUDES peuventprovoquer des brûlures graves. Ne pas toucher à mains nues les parties chau-des. Prévoir une période de refr
OM-4433 Page 8LES CHAMPS MAGNETIQUES peuv-ent affecter des implants médicaux. Porteur de simulateur cardiaque ou autre im-plants médicaux, rester à d
OM-4433 Page 9L’utilisation d’un groupe autonomeà l’intérieur PEUT VOUS TUER ENQUELQUES MINUTES. Les fumées d’un groupe autonome contient dumonoxyde
OM-4433 Page 10LE SURCHAUFFEMENT peut endom-mager le moteur électrique. Arrêter ou déconnecter l’équipement avant dedémarrer ou d’arrêter le moteur.
OM-4433 Page 112-6. Proposition californienne 65 AvertissementsLes équipements de soudage et de coupage produisent desfumées et des gaz qui contiennen
OM-4433 Page 12SECTION 3 − DEFINITIONS3-1. Warning Label Definitions3/961 Remove unit from shippingcrate. Remove Owner’sManual from unit. Followinstru
OM-4433 Page 133-2. Manufacturer’s Rating Label228 417-B / 803 562-F
OM-4433 Page 143-3. Symbols And Definitions Some symbols are found only on CE products.Stop EngineFast (Run, Weld/Power)Slow (Idle) Start EngineStart
OM-4433 Page 15SECTION 4 − SPECIFICATIONS4-1. Weld, Power, And Engine SpecificationsWeldingModeWeld OutputRangeRated WeldingOutputMaximumOpen-CircuitV
Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M
OM-4433 Page 164-3. Volt-Ampere Curves217 517 / 217 516 / 217 518The volt-ampere curves show theminimum and maximum voltageand amperage output capabil
OM-4433 Page 174-4. 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 184-6. AC Generator Power Curve217 519The ac power curve shows the gen-erator power in amperes availableat the 120 and 240 volt receptacl
OM-4433 Page 19SECTION 5 − INSTALLATIONinstall3 2007−04 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712! Always securely fasten weld-ing generator
OM-4433 Page 205-2. 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 215-3. 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 225-4. Activating The Dry Charge Battery (If Applicable)! Always wear a face shield,rubber gloves and protectiveclothing when working on
OM-4433 Page 235-6. 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 245-7. 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 255-8. Selecting Weld Cable Sizes*Weld OutputTerminalsWeld Cable Size** and Total Cable (Copper) Length in Weld CircuitNot Exceeding***Te
TABLE OF CONTENTSSECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol
OM-4433 Page 265-9. Connecting To Remote 14 Receptacle RC14Socket* Socket Information24 VOLTS ACA 24 volts ac. Protected by sup-plementary protector C
OM-4433 Page 27NotesWelding SymbolsRef. AWS/ANSI A2.4
OM-4433 Page 28SECTION 6 − OPERATING WELDING GENERATOR6-1. Front Panel Controls (See Section 6-2)217 357-B / 803 56312546789103
OM-4433 Page 296-2. Description Of Front Panel Controls (See Section 6-1)Engine Starting Controls1 Preheat SwitchUse switch to energize starting aid f
OM-4433 Page 306-3. Process/Contactor Switch1 Process/Contactor Switch! Weld output terminals are ener-gized when Process/Contactorswitch is in a Weld
OM-4433 Page 316-4. Lift-Arc™ Start ProcedureLift-Arc TIGWith Lift-Arc TIG selected, startarc as follows:1 TIG Electrode2 WorkpieceTurn gas on. Tou
OM-4433 Page 326-5. Remote Voltage/Amperage Control1 Remote 14 Receptacle RC14Connect optional remote control to RC14 (seeSection 5-9). When a remote
OM-4433 Page 33SECTION 7 − OPERATING AUXILIARY EQUIPMENT7-1. Generator Power Receptacles217 357-A1 120 V 20 A AC (shown) Receptacle RC5 and/or GFCI12
OM-4433 Page 34SECTION 8 − MAINTENANCE & TROUBLESHOOTING8-1. Routine Maintenance! Stop engine before maintaining. See Engine Manual and Maintena
OM-4433 Page 358-2. Maintenance Label
TABLE OF CONTENTS8-5. Servicing Engine Cooling System 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-4433 Page 368-3. Servicing Air Cleaner! Stop engine.NOTICE − Do not run engine without aircleaner or with dirty element. Enginedamage caused by usi
OM-4433 Page 378-4. Inspecting And Cleaning Optional Spark Arrestor Muffler803 582 / Ref. 214 778-B! Stop engine and let cool.1 Spark Arrestor Muffler
OM-4433 Page 388-6. 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 398-7. Adjusting Engine Speed On Models With Automatic Idle (Optional)803 563-G1880 rpm max(62.6 Hz)1500 rpm(50 Hz)Engine Speed(No Load)1
OM-4433 Page 408-8. Servicing Fuel And Lubrication Systems802 490 / Ref. 801 434! Stop engine and let cool.! After servicing, start engineand check fo
OM-4433 Page 418-9. Overload Protection803 562 / 803 56615! Stop engine. When a circuit breaker, supple-mentary protector, or fuseopens, it usually i
OM-4433 Page 428-10. 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 438-11. Voltmeter/Ammeter Help DisplaysUse the Voltmeter/Ammeter helpdisplays to diagnose and correctfault conditions. When a help code
OM-4433 Page 448-12. Troubleshooting Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 8-11).A. Weldin
OM-4433 Page 45B. Generator PowerTrouble RemedyNo generator power output at ac recep-tacles; weld output okay.Reset receptacle supplementary protector
OM-4433 Page 1SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USINGrom_2007−04Protect yourself and others from injury — read and follow these precautions
OM-4433 Page 46Trouble 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 47Notes16 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 48SECTION 9 − ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For Welding Generator
OM-4433 Page 49219 228−E
OM-4433 Page 50SECTION 10 − RUN-IN PROCEDURErun_in1 2007−0410-1. Wetstacking1 Welding GeneratorRun diesel engines near rated volt-age and current duri
OM-4433 Page 5110-2. Run-In Procedure Using Load BankS-0683! Stop engine.! Do not touch hot exhaustpipe, engine parts, or loadbank/grid.! Keep exhaust
OM-4433 Page 5210-3. Run-In Procedure Using Resistance GridS-0684! Stop engine.! Do not touch hot exhaustpipe, engine parts, or loadbank/grid.! Keep e
OM-4433 Page 53SECTION 11 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding gener
OM-4433 Page 5411-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse #10 AWG or larger insulate
OM-4433 Page 5511-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running WattsSplit Phase 1/8 HP 800 3
OM-4433 Page 2Welding produces fumes and gases. Breathing thesefumes and gases can be hazardous to your health.FUMES AND GASES can be hazardous. Keep
OM-4433 Page 5611-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHand Drill 1/4 in 350 3503/8
OM-4433 Page 5711-8. Power Required To Start MotorSingle-Phase Induction Motor Starting RequirementsMotor StartCodeG H J K L M N PKVA/HP 6.3 7.1 8.0
OM-4433 Page 5811-10. Typical Connections To Supply Standby PowerTransfer SwitchEssentialLoadsFusedDisconnectSwitch(If Required) UtilityElectricalServ
OM-4433 Page 5911-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt LoadsIf unit does not have GFCI receptacles, use
OM-4433 Page 60SECTION 12 − PARTS LIST Hardware is common and notavailable unless listed.Wirng harnesses are listed atthe end of parts section.110 (F
OM-4433 Page 61803 683-F2829303132333435363738394041424647484950515253545556575859606162636465666867697073717274757677787980(Fig.12−4)8182848586878889
OM-4433 Page 62DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-1. Main AssemblyQuantity1 HD1 168829 Transducer, Current 1000a Module Max Open Loop 1. . .
OM-4433 Page 63DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-1. Main Assembly (Continued)Quantity49 199592 Latch, Paddle Series 20 (Black) 1. . . . .
OM-4433 Page 64DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-1. Main Assembly (Continued)Quantity172071 Clamp, Hose .520 − .605 Clp Dia Slfttng Black 8
OM-4433 Page 65 Hardware is common and notavailable unless listed.Wirng harnesses are listed atthe end of parts section.803 684-B12345637367891011121
OM-4433 Page 31-3. Engine HazardsBATTERY EXPLOSION can BLIND. Always wear a face shield, rubber gloves, andprotective clothing when working on a batt
OM-4433 Page 66DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-2. Panel, Front w/Components (Continued)Quantity10 214543 Enclosure, Circuit Card Assy 1.
OM-4433 Page 67 Hardware is common and notavailable unless listed.Wirng harnesses are listed atthe end of parts section.803 689-D12345678910131211141
OM-4433 Page 68803 686-B Hardware is common and notavailable unless listed.Wirng harnesses are listed atthe end of parts section.23145678910111213141
OM-4433 Page 69803 685-A Hardware is common and notavailable unless listed.Wirng harnesses are listed atthe end of parts section.12364598107Figure 12
OM-4433 Page 70 Some wiring harness components (switches, relays, supplementary protectors) are also referenced elsewhere in this parts list. Purchas
Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 2007−01Your distributor also givesyou ...ServiceYou always get the
PRINTED IN USA © 2007 Miller Electric Mfg. Co.2007−01Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914
OM-4433 Page 4HOT METAL from air arc cutting andgouging can cause fire or explosion. Do not cut or gouge near flammables. Watch for fire; keep extin
OM-4433 Page 5H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommuni
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