Miller Big Blue 251D- Manuals

OM-480 Page 2 BUILDUP OF GAS can injure or kill. Shut off shielding gas supply when not in use. Always ventilate confined spaces or useapproved air-supplied respirator. Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. ...

OM-480 Page 3 MOVING PARTS can cause injury. Keep away from fans, belts, and rotors. Keep all doors, panels, covers, and guardsclosed and securely in place. Stop engine before installing or connecting unit. Have only qualified people remove guards or covers for maint-enance and troubleshooting as ne...

OM-480 Page 4 FLYING SPARKS can cause injury. Wear a face shield to protect eyes and face. Shape tungsten electrode only on grinder withproper guards in a safe location wearing properface, hand, and body protection. Sparks can cause fires — keep flammables away. OVERUSE can cause OVERHEATING. Allow ...

OM-480 Page 5 SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION rom _nd_fre 4/02 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédureprésente des risques de danger ! Ceux-ci sont identifiéspar des symboles adjacents aux directives. Identifie un message d...

OM-480 Page 6 Le soudage effectué sur des conteneurs fermés tels quedes réservoirs, tambours ou des conduites peut provoquerleur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et deséquipements chauds peut provoquer des incendies...

OM-480 Page 7 DES ORGANES MOBILES peuventprovoquer des blessures. Ne pas approcher les mains des ventilateurs, cour-roies et autres pièces en mouvement. Maintenir fermés et fixement en place les portes,panneaux, recouvrements et dispositifs deprotection. Arrêter le moteur avant d’installer ou branch...

OM-480 Page 9 SECTION 2 – DEFINITIONS 2-1. Symbols And Definitions Stop Engine Fast (Run, Weld/ Power) Slow (Idle) Start Engine Fast/Slow (Run/Idle) Battery (Engine) Circuit Breaker Engine Oil Check Injectors/ Pump Check Valve Clearance Fuel Protective Earth (Ground) Positive Negative Certified/Trai...

OM-480 Page 10 SECTION 3 – SPECIFICATIONS 3-1. Weld, Power, And Engine Specifications Rated Welding Output Amperage Range Maximum Open-Circuit Voltage DC (Nominal) Generator Power Rating Engine Fuel Capacity 250 A, 40 Volts DC, 100% Duty Cycle 40 – 400 95 (90) Single-Phase, 3 kVA/kW, 26 A,120 V AC, ...

OM-480 Page 12 3-5. AC Generator Power The ac power curve shows the gen-erator power in amperes availableat the 120 and 240 volt receptacles. rsb3.1 2/92 – 206 031 0 50 100 150 200 250 300 0 5 10 15 20 25 30 AC AMPERES IN 240V MODE AC VOL TS 0 25 50 75 100 1 5 0 1 2 5 0 10 20 30 40 50 60 AC AMPERES ...

OM-480 Page 13 3-7. Optional AC Power Plant Curves rsb13.1 12/94 - 134 636-A / 206 032 The ac power curves show the gen-erator power in amperes availableat the single-phase 120/240 volt orthree-phase 240 volt terminals. A. 7.5 KVA/KW Single-Phase AC Power Plant (No Weld Load) B. 10 KVA/KW Three-Phas...

OM-480 Page 14 SECTION 4 – INSTALLATION 4-1. Installing Welding Generator install1 7/02 – Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854 Electrically bond generator frame tovehicle frame by metal-to-metalcontact. GND/PE 1 2 Always securely fasten weldinggenerator onto transport vehicleo...

OM-480 Page 15 4-3. Installing Muffler Pipe exh_pipe2 12/96 – 154 089-A / 154 611 / Ref. 206 029 Stop engine and let cool. Do not blow exhaust towardair cleaner or air intake. Top View 1/2 in Tools Needed: 4-4. Engine Prestart Checks Ref. 800 159-D Full 1/2 in (13 mm) Full Diesel Valve Open Check al...

OM-480 Page 17 4-7. Selecting Weld Cable Sizes* Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding*** 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) Weld Output Terminals Turn off power beforeconnecting to weld...

OM-480 Page 18 SECTION 5 – OPERATING THE WELDING GENERATOR 5-1. Controls (See Section 5-2) Ref. 206 029 / 800 162-A / 800 159-D 1 2 12 13 5 3 4 6 7 10 11 8 9 14 15

OM-480 Page 20 SECTION 6 – OPERATING AUXILIARY EQUIPMENT 1 2 6-1. 120 Volt Duplex And Optional GFCI Receptacles Ref. 206 029 4 3 If unit does not have GFCI re-ceptacles, use GFCI-pro-tected extension cord. 1 120 V 15 A AC ReceptacleRC1 2 120 V 15 A AC ReceptacleRC2 3 120 V 20 A AC GFCIReceptacles GF...

OM-480 Page 22 6-3. Connecting Optional AC Power Plant Ref. S-179 637-B Stop engine. Power and weld outputs arelive at the same time.Disconnect or insulateunused cables. Have qualified person installaccording to circuit diagramand Generator Power Guide-lines (Section 10). Remove junction box cover. ...

OM-480 Page 24 SECTION 7 – MAINTENANCE AND TROUBLESHOOTING 7-1. Routine Maintenance Recycle engine fluids. Stop engine before maintaining. See also Engine Manual and Maintenance Label.Service engine more often if used in severe condi-tions. * To be done by Factory Authorized Service Agent. 8 h Wipe ...

OM-480 Page 25 Follow the storage procedure in the engine owner ’s manual if the unit will not beused for an extended period. NOTE 7-2. Maintenance Label

OM-480 Page 26 7-3. Servicing Air Cleaner aircleaner4 9/02– 802 495 / Ref. S-0698-B Stop engine. Do not run engine without aircleaner or with dirty element. En-gine damage caused by using adamaged element is not coveredby the warranty. The air cleaner primary element canbe cleaned but the dirt holdi...

OM-480 Page 27 7-4. Servicing Fuel And Lubrication Systems Ref. 800 159-E / Ref. 206 029 Stop engine and let cool. 1 Oil Filter 2 Oil Drain Plug 3 Oil Fill Cap 4 Primary Fuel Filter (Fuel/Water Separator) 5 Petcock 6 Secondary Fuel Filter 7 Fuel Shutoff Valve 8 Fuel Line 9 Sludge Drain Plug To chang...

OM-480 Page 28 7-5. Adjusting Engine Speed Ref. 801 179 / Ref. 800 159-D / Ref. 800 161 After tuning engine, check engineno load speed with a tachometer(see table for no load speeds). Ifnecessary, adjust speed as follows: Start engine and run until warm.Turn Amperage/Voltage Control to100. Standard ...

OM-480 Page 30 7-8. Inspecting And Cleaning Optional Spark Arrestor 800 523 / Ref. 206 029 Stop engine and let cool. 1 Spark Arrestor 2 Cleanout Plug Remove plug and remove any dirtcovering cleanout hole. 3 Exhaust Pipe Start engine and run at idle speed toblow out cleanout hole. If nothingblows out...

OM-480 Page 32 SECTION 8 – ELECTRICAL DIAGRAM SC-190 650-B Figure 8-1. Circuit Diagram For Welding Generator

OM-480 Page 33 SECTION 9 – RUN-IN PROCEDURE run_in1 8/01 9-1. Wetstacking Do not perform run-inprocedure at less than 20volts weld output and do notexceed duty cycle or equip-ment damage may occur. 1 Welding Generator Run diesel engines near rated volt-age and current during run-in periodto properly...

OM-480 Page 34 9-2. Run-In Procedure Using Load Bank S-0683 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep exhaust and pipe awayfrom flammables. Do not perform run-inprocedure at less than 20volts weld output and do notexceed duty cycle or equip-ment damage may occur...

OM-480 Page 35 9-3. Run-In Procedure Using Resistance Grid S-0684 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep exhaust and pipe awayfrom flammables. Do not perform run-inprocedure at less than 20volts weld output and do notexceed duty cycle or equip-ment damage may...

OM-480 Page 36 SECTION 10 – GENERATOR POWER GUIDELINES 10-1. Selecting Equipment gen_pwr 6/02 – Ref. ST-159 730 / ST-800 577 1 Generator Power Receptacles– Neutral Bonded To Frame 2 3-Prong Plug From CaseGrounded Equipment 3 2-Prong Plug From DoubleInsulated Equipment Do not use 2-prong plug un-less...

OM-480 Page 37 10-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment GroundingTerminal 2 Grounding Cable Use #10 AWG or larger insulatedcopper wire. 3 Ground Device Ground generator to systemearth ground if supplyingpower to a premises (home,shop, farm) wiring system. GND/PE 1 2 U...

OM-480 Page 38 10-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 2100 700 1/2 HP 3175 875 Capacitor Start-Induction Run 1/3 HP 2020 720 1/2 HP 3075 975 3/4 HP 4500 1400 1 ...

OM-480 Page 39 10-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/2 in 500 500 7-1/4 in 900 900 8-1/4 in 1400 1400 Table Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 i...

OM-480 Page 41 10-10. Typical Connections To Supply Standby Power Have only qualified persons performthese connections according to allapplicable codes and safety practic-es. Properly install and ground thisequipment according to its Owner’sManual and national, state, and localcodes. Customer-suppli...

OM-480 Page 44 SECTION 11 – PARTS LIST Figure 11-1. Main Assembly Hardware is common andnot available unless listed. 1 3 2 4 5 7 8 9 10 11 12 13 14 15 16 17 18 73 74 81 82 83 84 85 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111(Fig 11-2) 112 114 115 116 117 11...

Warranty Questions? Call1-800-4-A-MILLERfor your localMiller distributor. miller_warr 6/02 Your distributor also givesyou ... ServiceYou always get the fast,reliable response youneed. Most replacementparts can be in yourhands in 24 hours. SupportNeed fast answers to thetough welding questions?Contac...

PRINTED IN USA  2002 Miller Electric Mfg. Co. 8/02 Miller Electric Mfg. Co. An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 USA International Headquarters–USAUSA Phone: 920-735-4505 Auto-AttendedUSA & Canada FAX: 920-735-4134International FAX: 920-735-4125 European Head...

OM-480 Page 4 READ INSTRUCTIONS. Use only genuine MILLER/Hobart replacement parts. Perform engine and air compressor (if applicable) maintenance and service according to this manual and the engine/air compressor (if applicable) manu- als. H.F. RADIATION can cause interference. High-frequency (H.F.) ...

OM-480 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION rom_fre 8/03 Avertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions. 2-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger !...

OM-480 Page 6 LES ACCUMULATIONS DE GAZ ris- quent de provoquer des blessures ou même la mort. Fermer l’alimentation du gaz protecteur en cas de non utilisation. Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi- rateur d’adduction d’air homologué. Le rayonnement de l’arc du ...

OM-480 Page 7 L’EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE. Toujours porter une protection faciale, des gants en caoutchouc et vêtements de protection lors d’une in- tervention sur la batterie. Arrêter le moteur avant de débrancher ou de brancher les câbles de batterie. Eviter de provoquer des éti...

OM-480 Page 8 LE SURCHAUFFEMENT peut endom- mager le moteur électrique. Arrêter ou déconnecter l’équipement avant de dé- marrer ou d’arrêter le moteur. Ne pas laisser tourner le moteur trop lentement sous risque d’endommager le moteur électrique à cause d’une tension et d’une fréquence trop faibles....

OM-480 Page 13 4-7. Optional AC Power Plant Curves rsb13.1 12/94 - 134 636-A / 206 032 The ac power curves show the gen- erator power in amperes available at the single-phase 120/240 volt or three-phase 240 volt terminals. A. 7.5 KVA/KW Single-Phase AC Power Plant (No Weld Load) B. 10 KVA/KW Three-P...

OM-480 Page 16 ether1 12/96 − 153 382-A / Ref. 206 029 Stop engine. Improper handling or expo- sure to ether can harm your health. Follow manufactur- er’s safety instructions on cylinder. Do not use Ether Starting Aid while engine is running. Open side door(s).1 Ether Cylinder 2 Nozzle Remove cover ...

OM-480 Page 20 SECTION 7 − OPERATING AUXILIARY EQUIPMENT 1 2 7-1. 120 Volt Duplex And Optional GFCI Receptacles Ref. 206 029 4 3 If unit does not have GFCI re- ceptacles, use GFCI-pro- tected extension cord. 1 120 V 15 A AC Receptacle RC1 2 120 V 15 A AC Receptacle RC2 3 120 V 20 A AC GFCI Receptacl...

OM-480 Page 24 SECTION 8 − MAINTENANCE AND TROUBLESHOOTING 8-1. Routine Maintenance Recycle engine fluids. Stop engine before maintaining. See Engine Manual and Maintenance Label for impor-tant start-up, service, and storage information. Serviceengine more often if used in severe conditions. * To be...

OM-480 Page 25 Follow the storage procedure in the engine owner ’s manual if the unit will not beused for an extended period. NOTE 8-2. Maintenance Label

OM-480 Page 29 8-6. Overload Protection Ref. 156 199-B / 801 320-B Stop engine. When a fuse opens, it usuallyindicates a more serious prob-lem exists. Contact a FactoryAuthorized Service Agent. 1 Magnetic Shutdown Switch MS1 (Optional) 2 Fuse F (See Parts List) Fuse F protects magnetic shut- down sw...

OM-480 Page 30 8-8. Inspecting And Cleaning Optional Spark Arrestor 800 523 / Ref. 206 029 Stop engine and let cool. 1 Spark Arrestor 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole.3 Exhaust Pipe Start engine and run at idle speed to blow out cleanout hole. If nothing blows o...

OM-480 Page 32 SECTION 9 − ELECTRICAL DIAGRAM SC-190 650-B Figure 9-1. Circuit Diagram For Welding Generator

OM-480 Page 36 SECTION 11 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-drivenwelding generators. Your unit may differ from those shown. NOTE 11-1. Selecting Equipment gen_pwr 11/02 − Ref. ST-159 730 / ST-800 577 1 Generator Power Receptacles ...

OM-480 Page 37 11-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding Terminal 2 Grounding Cable Use #10 AWG or larger insulated copper wire.3 Ground Device Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. GND/PE 1...

OM-480 Page 38 11-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 2100 700 1/2 HP 3175 875 Capacitor Start-Induction Run 1/3 HP 2020 720 1/2 HP 3075 975 3/4 HP 4500 1400 1 ...

OM-480 Page 39 11-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/2 in 500 500 7-1/4 in 900 900 8-1/4 in 1400 1400 Table Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 i...

OM-480 Page 41 11-10. Typical Connections To Supply Standby Power Have only qualified persons perform these connections according to all applicable codes and safety practic- es. Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes. Customer-...

OM-480 Page 44 SECTION 12 − PARTS LIST Figure 12-1. Main Assembly Hardware is common andnot available unless listed. 1 3 2 4 5 7 8 9 10 11 12 13 14 15 16 17 18 73 74 81 82 83 84 85 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111(Fig 12-2) 112 114 115 116 117 11...

Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 1/05 Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding quest...

PRINTED IN USA  2005 Miller Electric Mfg. Co. 1/05 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters − USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 Europe...