Miller Big Blue 251D Owner's manual

Brand: Miller

Model: Big Blue 251D

Category: Engine

Type: Owner's manual

This manual is also suitable for

KC288497

cover 8/92 − ST-130 895-C PRINTED IN USA

Read and follow these instructions and all

safety blocks carefully.

Have only trained and qualified persons

install, operate, or service this unit.

Call your distributor if you do not understand

the directions.

Give this manual to the operator.

For help, call your distributor

or: MILLER ELECTRIC Mfg. Co., P.O. Box

1079, Appleton, WI 54912 414-734-9821

OWNER’S

MANUAL

April 1993 Form: OM-480C

Effective With Serial No. KC288497

CC/DC Welding Generator

For SMAW Welding

250 Amperes, 40 Volts DC At 100% Duty Cycle

3 kVA/kW AC Auxiliary Power With Overload Protection

Optional 7.5/10 kVA/kW AC Auxiliary Power Plant

Deutz F3L-1011, Air/Oil-Cooled, Diesel Engine

Optional Low Oil Pressure/High Oil Temperature Shutdown System

Big Blue™ 251D

OM-480C − 4/93

TABLE OF CONTENTS

SECTION 1 − SAFETY INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − SPECIFICATIONS

2-1. Volt-Ampere Curves And Duty Cycle 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Fuel Consumption 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. AC Auxiliary Power Curve 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4. Optional AC Power Plant Curves 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − INSTALLATION

3-1. Selecting A Location And Moving Welding Generator 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Muffler Pipe Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Connecting The Battery 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Engine Prestart Checks 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Grounding The Generator 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Selecting And Preparing Weld Output Cables 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7. Connecting To Weld Output Terminals 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8. Installing Ether Cylinder (Optional Ether Starting Aid) 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-9. Optional Remote A/V Receptacle Information And Connections 9. . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − OPERATING THE WELDING GENERATOR 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − OPERATING AUXILIARY EQUIPMENT

5-1. 120 Volt Duplex Receptacles 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Optional 240 Volt Duplex Receptacle 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Connecting Optional Auxiliary Power Plant 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − MAINTENANCE & TROUBLESHOOTING

6-1. Routine Maintenance 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Maintenance Lights 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Servicing Air Cleaner 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. Oil And Fuel System Components 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-5. Adjusting Engine Speed 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-6. Replacing Battery Or Checking Battery Voltage 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-7. Checking And Replacing Engine Belt 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-8. Optional Ether Starting Aid Maintenance 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-9. Optional Overspeed Shutdown Valve Adjustment 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-10. Optional Low Oil Pressure/High Oil Temperature Shutdown System Fuse F 26. . . . . . . . . . . .

6-11. Troubleshooting 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − ELECTRICAL DIAGRAMS 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − RUN-IN PROCEDURE

8-1. Run-In Procedure Using Load Bank 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2. Run-In Procedure Using Resistance Grid 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − AUXILIARY POWER GUIDELINES

9-1. How Much Power Does Equipment Require? 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-2. How Much Power Can Generator Supply? 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3. Typical Connections To Supply Standby Power 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-4. Selecting Extension Cord 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 − PARTS LIST

Figure 10-1. Main Assembly 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 10-2. Panel, Front w/Components 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 10-3. Switch, Range 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 10-4. Generator 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 10-5. Terminal Assembly, Pwr Output 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Optional Equipment 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-480 Page 1

SECTION 1 − SAFETY INFORMATION

mod1.1 2/93

Read all safety messages throughout this manual.

Obey all safety messages to avoid injury.

Learn the meaning of WARNING and CAUTION.

1 Safety Alert Symbol

2 Signal Word

WARNING means possible death

or serious injury can happen.

CAUTION means possible minor

injury or equipment damage can

happen.

3 Statement Of Hazard And Re-

sult

4 Safety Instructions To Avoid

Hazard

5 Hazard Symbol (If Available)

6 Safety Banner

Read safety blocks for each sym-

bol shown.

7 NOTE

Special instructions for best oper-

ation − not related to safety.

NOTE

ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Disconnect input power before

installing or servicing.

WARNING

READ SAFETY BLOCKS at start of

Section 3-1 before proceeding.

WARNING

1 2

CAUTION

MOVING PARTS can injure.

• Keep away from moving parts.

• Keep all panels and covers closed

when operating.

Turn Off switch when using high frequency.

Figure 1-1. Safety Information

SECTION 2 − SPECIFICATIONS

Table 2-1. Welding Generator

Specification Description

Type Of Output Constant Current/Direct Current (CC/DC)

Rated Weld Output NEMA Class I (100) − 250 Amperes, 40 Volts At 100% Duty Cycle (See Section 2-1)

Amperage Range 40-400 A

Max. Open-Circuit Voltage 95 Volts DC

Welding Process Shielded Metal Arc Welding (SMAW)

Engine Deutz F3L-1011, Air/Oil-Cooled, Three-Cylinder, Diesel Engine

Engine Speed (No Load) Weld/Power Speed: 1850 rpm

Fuel Tank Capacity 11.3 U.S. gal (42.8L)

Optional Auxiliary Power Plant Single-Phase, 7.5 kVA/kW, 120/240 Volts AC, 31 Amperes, 60 Hz

Three-Phase, 10 kVA/kW, 240 Volts AC, 24 Amperes, 60 Hz

Maximum Auxiliary Power From

Receptacles

Single-Phase, 3 kVA/kW, 120 Volts AC, 26 Amperes, 60 Hz

Overall Dimensions See Figure 3-2

Weight Net: 1475 lb (670 kg); Ship: 1510 lb (685 kg)

Options See Rear Cover

OM-480 Page 2

2-1. Volt-Ampere Curves And Duty Cycle

CAUTION

EXCEEDING DUTY CYCLE RATINGS will damage unit.

• Do not exceed indicated duty cycles.

warn7.1 2/92

The volt-ampere curves show the

minimum and maximum voltage

and amperage output capabilities of

the welding generator. Curves of

other settings fall between the

curves shown.

Duty cycle is how long the unit can

operate within a ten minute period

without causing overheating or

damage.

This unit is rated at 100% duty cycle

allowing continuous operation at

rated load.

rsb1.1 10/91 − SB-070 042-B / sb1.1 2/92 − SB-070 999-A

A. Volt-Ampere Curves

B. Duty Cycle

Figure 2-1. Volt-Ampere Curves And Duty Cycle Chart

2-2. Fuel Consumption

The fuel consumption curve shows

typical fuel use under weld or power

loads.

rsb2.1 10/91 − SB-137 487

Figure 2-2. Fuel Consumption Curve

OM-480 Page 3

2-3. AC Auxiliary Power Curve

The ac power curve shows the auxil-

iary power in amperes available at

the 120 and 240 volt receptacles.

rsb3.1 10/91 − SB-109 365-B

Figure 2-3. AC Power Curve For 120 And 240 Volt Receptacles

2-4. Optional AC Power Plant Curves

rsb13.1 3/92 − SB-134 636 / SB-134 637

The ac power curves show the aux-

iliary power in amperes available at

the single-phase 120/240 volt or

three-phase 240 volt terminals.

A. 7.5 KVA/KW Single-Phase Auxiliary Power

Plant (No Weld Load)

B. 10 KVA/KW Three-Phase Auxiliary Power

Plant (No Weld Load)

Figure 2-4. AC Power Plant Curves

OM-480 Page 4

SECTION 3 − INSTALLATION

3-1. Selecting A Location And Moving Welding Generator

WARNING

ENGINE EXHAUST GASES can kill.

• Do not breathe exhaust fumes.

• Use in open, well-ventilated areas, or vent exhaust

outside and away from building air intakes.

ENGINE EXHAUST SPARKS can cause

fire.

• Use only U.S. Forestry Department approved spark

arrestor and comply with all local, state, and federal

laws.

• A spark arrestor is mandatory in all National Forests

and in grass, brush, or forest covered lands in

California, Oregon, and Washington. Check with

state and local authorities in other areas.

• Properly maintain the spark arrestor.

• Stop engine and allow exhaust system to cool down

before servicing spark arrestor.

• Service spark arrestor away from flammables.

HOT ENGINE EXHAUST AND EXHAUST

PIPE can cause fires.

• Keep exhaust and pipe away from flammables.

FALLING EQUIPMENT can cause

serious personal injury and equipment

damage.

• Use lifting eye to lift unit only, NOT running gear, gas

cylinders, trailer, or any other heavy options,

accessories, or devices.

• Use equipment of adequate capacity to lift the unit.

TILTING OF TRAILER can result in

personal injury or equipment damage.

• Install unit properly on trailer (if applicable)

according to trailer manual.

rwarn1.1 12/91

ST-155 965

1 18 in (457 mm) Open Space

On All Sides For Good Airflow

2 Lifting Eye

Use lifting eye to move unit.

3 Muffler Pipe

Install according to Section 3-2.

4 Lifting Forks

If using lifting forks, extend forks out

opposite side of base.

Front

Left

To p

Right

Rear

Figure 3-1. Location And Movement Of Welding Generator

Ref. ST-110 850-D

Inches Millimeters

A 36-1/2 927

B 24-5/8 625

C 55-1/2 1410

D 23-1/4 591

E 24-5/8 625

F 11/16 17

G 2-7/8 73

H 4-1/2 114

J 27 686

K 41-1/4 1048

L 51-1/8 1299

M 54 1372

N 21/32 Dia 16.7 Dia

4 Holes 4 Holes

P 1/2 Dia 12.7 Dia

6 Holes 6 Holes

Figure 3-2. Overall Dimensions And Base Mounting Hole Layout

OM-480 Page 5

1 Trailer Hitch

Install unit onto trailer according to

trailer manual.

S-0024-B

30°

Engine

End

Figure 3-3. Maximum Welding Generator Tilt Angles

3-2. Muffler Pipe Installation

rsb19.5 5/92 − ST-154 089-A / ST-154 611

Stop engine and allow to cool.

Open and secure left side door.

1 Muffler Pipe

2 Exhaust Manifold

Install pipe over manifold so pipe

faces exactly as shown.

3 Clamp

Secure pipe with clamp.

Close door.

1/2 in

Tools Needed:

Top View

Do not blow exhaust toward

air cleaner or air intake.

Figure 3-4. Installing Muffler Pipe

3-3. Connecting The Battery

WARNING

SPARKS can cause BATTERY GASES TO EXPLODE; BATTERY ACID can burn eyes and skin.

• Stop engine before disconnecting or connecting battery cables.

• Always wear a face shield and proper protective clothing when working on a battery.

• Do not allow tools to cause sparks when working on a battery.

rwarn2.1 9/91

ST-156 011-A / Ref. ST-142 560 / S-0756

1 Engine Control Switch

Place switch in the Off position.

Open left side door.

2 Positive (+) Battery Terminal

3 Positive (+) Battery Cable

Connect positive cable first.

4 Negative (−) Battery Terminal

5 Negative (−) Battery Cable

Connect negative cable last.

Close side door.

If engine does not crank, check bat-

tery voltage according to Section

6-6.

Tools Needed:

1/2 in

−

Figure 3-5. Connecting The Battery

OM-480 Page 6

3-4. Engine Prestart Checks

ENGINE FUEL can cause fire or

explosion.

• Stop engine before fueling.

• Do not fuel while smoking or near sparks or flames.

• Do not overfill tank; clean up any spilled fuel.

USE OF GASOLINE will damage engine.

• Do not use gasoline.

Lack of lubrication in gasoline damages injector pump

and injectors.

REMOVE FUEL CAP SLOWLY; FUEL

SPRAY may cause injury; FUEL may be

under pressure.

• Turn fuel cap slowly and wait until hissing stops

before removing cap.

WARNING

rwarn3.1* 9/91

rsb4.2* 11/92 − ST-130 894 / Ref. ST-155 966

FUEL

OIL

Full

1/2 in

(13 mm)

Check all fluids daily. Engine must

be cold and on a level surface.

Add fresh fuel before starting

engine the first time (see Figure

6-2).

1 Fuel Cap

Do not run out of fuel or air enters

fuel system and causes starting

problems.

2 Fuel Valve

Open valve.

3 Oil Dipstick

4 Oil Fill Tube

If oil is not up to full mark, add oil

(see Figure 6-2).

5 Muffler Pipe

Follow break-in procedure in

engine manual.

If unburned fuel and oil collect in

muffler pipe during break-in, see

Section 8.

Full

Valve Open

Figure 3-6. Checking Fluid Levels

OM-480 Page 7

3-5. Grounding The Generator

rsb5.1 1/93 − Ref. ST-156 024-A / Ref. ST142 560

1 Equipment Grounding

Terminal

Tools Needed:

1/2 in

Connect To Earth Ground

According To Codes

The generator auxiliary power neutral

is connected to the machine frame.

Figure 3-7. Equipment Grounding Connection

3-6. Selecting And Preparing Weld Output Cables

sb6.1 11/92 − S-0653

1 Weld Output Cable

Determine total cable length in weld

circuit and maximum welding am-

peres. Use Table 3-1 to select prop-

er cable size.

Use shortest cables possible.

Do not use damaged cables.

2 Terminal Lug

Use lugs of proper amperage

capacity and hole size for connect-

ing to work clamp, electrode holder,

and weld output terminals.

3 Insulated Electrode Holder

Install according to manufacturer’s

instructions.

4 Work Clamp

Install onto work cable.

Tools Needed:

10 ft (3 m)

Total Cable

Length In Weld

Circuit = 20 ft (6 m)

10 ft (3 m)

For Example,

Figure 3-8. Selecting And Preparing Weld Output Cables

OM-480 Page 8

Table 3-1. Weld Cable Size*

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)

Welding

Amperes

10 To 60%

Duty Cycle

60 Thru 100%

Duty Cycle

10 Thru 100% Duty Cycle

100 4 4 4 3 2 1 1/0 1/0

150 3 3 2 1 1/0 2/0 3/0 3/0

200 3 2 1 1/0 2/0 3/0 4/0 4/0

250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0

300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0

350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0

400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0

500 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-3/0

*Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of not more than 300 circular mils per ampere. S-0007-C

3-7. Connecting To Weld Output Terminals

WARNING

ELECTRIC SHOCK can kill.

• Always wear dry insulating gloves.

• Do not touch live electrical parts.

• Stop engine before making any weld output connections.

• Read Safety Precautions at beginning of this manual.

rwarn13.1 2/92

ST-133 520

Open left side door.

1 Bracket

Route weld cables through bracket.

2 Positive (+) Weld Output

Terminal

3 Negative (−) Weld Output Ter-

minal

For Direct Current Electrode Posi-

tive (DCEP), connect work cable to

− terminal and electrode holder

cable to + terminal.

For Direct Current Electrode Nega-

tive (DCEN), reverse cable

connections.

If equipped with optional Polarity

switch, connect electrode holder

cable to Electrode (−) terminal and

work cable to Work (+) terminal.

Close door.

Tools Needed:

3/4 in

Figure 3-9. Weld Output Connections

OM-480 Page 9

3-8. Installing Ether Cylinder (Optional Ether Starting Aid)

WARNING

IMPROPER HANDLING OR EXPOSURE TO ETHER

can seriously harm your health.

• Follow manufacturer’s safety instructions on cylinder.

INJECTING ETHER WHILE ENGINE IS RUNNING

can damage engine.

• Do not use Ether Starting Aid while engine is running.

After installing cylinder, wait at least 10 minutes before use to let ether

particles settle to prevent atomizer plugging.

rsb15.1 6/92A − ST-153 382

Stop engine. Open side door(s) to

locate ether starting aid.

1 Ether Cylinder

Obtain cylinder.

2 Nozzle

Remove protective cover, and

clean nozzle and fitting area on

cylinder.

3 Clamp

4 Fitting

5 Cap

6 Valve

Remove valve cap, and clean fitting

area.

Insert cylinder through clamp and

onto fitting.

Tighten clamp when cylinder is tight

in fitting.

Put cap on fitting when cylinder is

removed.

Figure 3-10. Installing Ether Cylinder

3-9. Optional Remote A/V Receptacle Information And Connections

Ref. ST-142 560

1 Remote A/V Receptacle RC3

2 Keyway

To connect to this receptacle, align

keyway, insert plug, and turn plug

clockwise.

Figure 3-11. Remote A/V Receptacle Connections

OM-480 Page 10

SECTION 4 − OPERATING THE WELDING GENERATOR

ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Always wear dry insulating gloves.

• Insulate yourself from work and ground.

• Stop engine before installing or servicing.

• Keep all panels and covers securely in place.

WELDING can cause fire or explosion.

• Do not weld near flammable material.

• Watch for fire; keep extinguisher nearby.

• Do not locate unit over combustible surfaces.

• Do not weld on closed containers.

• Allow work and equipment to cool before handling.

ARC RAYS can burn eyes and skin;

NOISE can damage hearing.

• Wear welding helmet with correct shade of filter.

• Wear correct eye, ear, and body protection.

FUMES AND GASES can be hazardous.

• Keep your head out of the fumes.

• Ventilate area, or use breathing device.

• Read Material Safety Data Sheets (MSDSs) and

manufacturer’s instructions for material used.

ENGINE EXHAUST GASES can kill.

• Do not breathe exhaust fumes.

• Use in open, well-ventilated areas, or vent exhaust

outside and away from any building air intakes.

ENGINE FUEL can cause fire or explo-

sion.

• Stop engine before fueling.

• Do not fuel while smoking or near sparks or flames.

• Do not overfill tank; clean up any spilled fuel.

MOVING PARTS can cause injury.

• Keep away from moving parts such as fans, belts,

and rotors.

• Keep all doors, panels, covers, and guards closed

and securely in place.

MAGNETIC FIELDS FROM HIGH CUR-

RENTS can affect pacemaker operation.

• Pacemaker wearers keep away.

• Wearers should consult their doctor before going

near any welding operations.

See Safety Precautions at beginning of manual for ba-

sic welding safety information.

WARNING

rwarn5.1 10/91

ST-156 024-A

1 Ampere Ranges Switch

2 Oil Temperature Gauge

(Optional)

3 Oil Pressure Gauge

(Optional)

4 Remote A/V Control Switch

(Optional)

5 Voltmeter (Optional)

6 Amperage/Voltage Adjustment

Control

7 Ammeter (Optional)

8 Polarity Switch (Optional)

9 Low Oil Pressure/High Oil

Temperature Shutdown Sys-

tem Switch (Optional)

10 Engine Control Switch

11 Ether Starting Aid Switch (Op-

tional)

12 Engine Hour Meter

13 Low Oil Pressure Light

(Section 6-2)

14 Engine Battery Light

(Section 6-2)

12345

Figure 4-1. Controls

1 Insulating Gloves

2 Safety Glasses With Side

Shields

3 Welding Helmet

Wear dry insulating gloves, safety

glasses with side shields, and a

welding helmet with a correct shade

of filter (see ANSI Z49.1).

sb3.1 10/91

123

Figure 4-2. Safety Equipment

OM-480 Page 11

1 Work Clamp

Use wire brush or sandpaper to

clean metal at weld joint area. Use

chipping hammer to remove slag

after welding.

Connect work clamp to a clean,

paint-free location on workpiece, as

close to weld area as possible.

sb4.1 5/92

Tools Needed:

Figure 4-3. Work Clamp

CAUTION

ARCING can damage switch.

• Do not change Ampere Ranges switch position while welding.

Arcing inside switch can damage contacts, causing switch to fail.

rwarn6.1 9/91

Ref. ST-142 560

1 Ampere Ranges Switch

Use switch to select weld amper-

age range.

Figure 4-4. Ampere Ranges Switch

1 Amperage/Voltage Adjustment

Control

Use control to adjust amperage

within range selected by Ampere

Ranges switch. Numbers around

control are for reference only.

Figure 4-5. Amperage/Voltage Adjustment Control

OM-480 Page 12

WARNING

ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Do not touch weld output terminals when engine is running.

• Do not touch electrode and work clamp at the same time.

rwarn7.1 9/91

S-0774

1 Amperage/Voltage Control

Switch

Use switch to select way of control-

ling amperage and voltage adjust-

ment.

For front panel control, place switch

in Panel position.

For remote control, place switch in

Remote position (see Section 3-9).

2 Remote Amperage Control

Min (90 A DC)

Max (158 A DC)

Set Switch Adjust Remote ControlSet Range Set Percentage

EXAMPLE Of Combination Remote Amperage Control

Min = 90 A DC

Percentage Of Range = 50%

Max = 158 A DC (50% of 90 to 225)

In Example:

Figure 4-6. Remote A/V Control (Optional)

OM-480 Page 13

WARNING

INJECTING ETHER WHILE ENGINE IS RUNNING can damage engine.

• Do not use Ether Starting Aid while engine is running.

After installing cylinder, wait at least 10 minutes before use to let ether particles settle to prevent atomizer plugging.

rsb16.1 4/92 − Ref. SD-118 111-B

1 Ether Starting Aid Switch

Push switch up and release while

cranking engine. Ether is sprayed

into engine manifold when switch is

released.

Figure 4-7. Ether Starting Aid Switch (Optional)

1 Engine Control Switch

Use switch to start engine, select

engine speed, and stop engine.

To start, turn switch to Start position

and release as soon as engine

starts. Do not engage starter while

flywheel is rotating.

In Run position, engine runs at

weld/power speed all the time.

To stop engine, turn switch to Off

position.

2 Low Oil Pressure/High Oil

Temperature Shutdown Sys-

tem Switch (Optional)

Use switch during start-up to by-

pass engine shutdown system.

Shutdown system stops engine if

oil pressure drops between 15 and

20 psi (103 to 138 kPa) or oil tem-

perature rises to 250°F (121°C).

To start, turn engine control switch

to Start position while pressing

shutdown switch. Release both

switches when engine starts and

Oil Pressure light goes off.

Figure 4-8. Engine Controls

1 Engine Hour Meter

Use meter to check total operating

hours (see Section 6-1). This meter

operates only when engine is run-

ning.

rsb6.1 2/92

Figure 4-9. Engine Hour Meter

OM-480 Page 14

CAUTION

ARCING can damage switch.

• Do not change Polarity switch position while welding.

Arcing inside switch can damage contacts, causing switch to fail.

rwarn6.1* 9/91

1 Polarity Switch

Use switch to select polarity of weld

output (see Section 3-7).

+()

ELECTRODE

POSITIVE

()

ELECTRODE

NEGATIVE

110 501

110 500

Figure 4-10. Polarity Switch (Optional)

1 Oil Temperature Gauge/Shut-

down Switch

Use gauge/switch to check oil tem-

perature. If oil temperature rises to

250°F (121°C), the engine stops

(see Section 6-10).

2 Oil Pressure Gauge

Use gauge to check oil pressure. If

oil pressure drops between 15 and

20 psi (103 to 138 kPa) the engine

stops (see Section 6-10).

3 Voltmeter

Voltmeter displays voltage at the

weld output terminals, but not nec-

essarily the welding arc due to

cable resistance, poor connec-

tions, etc.

4 Ammeter

Ammeter displays dc amperage

output of the unit.

1 2

3 4

Figure 4-11. Gauges And Meters (Optional)

Insert

Electrode

Into Holder

rsb8.1 9/92

Install &

Connect

Equipment

Select

Electrode

Put On

Personal Safety

Equipment

Set Controls Start Engine

Turn On Auxiliary

Equipment

Begin Welding

Figure 4-12. Sequence Of Shielded Metal Arc Welding (SMAW)

OM-480 Page 15

SECTION 5 − OPERATING AUXILIARY EQUIPMENT

WARNING

ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Stop engine before making internal inspection or

reconnection.

• Ground generator according to all applicable

national, state, and local codes.

• Connect equipment grounding terminal to a proper

earth ground.

• Do not connect to any electrical distribution system

normally supplied by utility power unless a proper

transfer switch and grounding procedure are

employed (see Section 9).

MOVING PARTS can cause serious

injury.

• Keep away from moving parts such as fans, belts,

and rotors.

• Keep all doors, panels, covers, and guards closed

and securely in place.

ELECTRIC SPARKS can cause fire.

• If using auxiliary power only and not welding,

disconnect both welding cables to prevent live

electrode from causing electric shock and fire

hazards.

• Watch for fire.

• Keep a fire extinguisher nearby, and know how to

use it.

The weld output terminals are electrically energized

when the engine is running and the contactor, if

applicable, is energized.

LOW VOLTAGE AND FREQUENCY can

damage electrical equipment.

• Turn off or unplug all electrical equipment connected

to auxiliary power receptacles before starting or

stopping the engine.

When starting or stopping, the engine has low speed

which causes low voltage and frequency.

rwarn8.1 10/92

5-1. 120 Volt Duplex Receptacles

Ref. ST-142 560

1 120 V 15 A AC Duplex Re-

ceptacle RC1

2 120 V 15 A AC Duplex Re-

ceptacle RC2

These receptacles supply 60 Hz

single-phase power at weld/power

speed. Maximum output from each

receptacle is 3 kVA/kW.

3 Circuit Breaker CB1

4 Circuit Breaker CB2

CB1 protects RC1 and CB2 pro-

tects RC2 from overload. If CB1 or

CB2 opens, the receptacle does

not work. Press button to reset

breaker.

5 Total Auxiliary Power Output

Combined output of all receptacles

limited to 3 kVA/kW output of the

generator.

EXAMPLE: If 15 A is drawn from a

120 V receptacle, only 10 A is avail-

able at the other receptacle:

(120 V x 15 A) + (120 V x 10 A) = 3.0

kVA/kW

Auxiliary power is not affected by

weld output.

Figure 5-1. Auxiliary Power Receptacles And Circuit Breakers

OM-480 Page 16

5-2. Optional 240 Volt Duplex Receptacle

Ref. ST-142 560 / ST-140 864

1 240 V 13 A AC Duplex Re-

ceptacle RC1

This receptacle supplies 60 Hz

single-phase power at weld/power

speed. Maximum output is 3 kVA/

kW.

2 120 V 15 A AC Duplex Re-

ceptacle RC2

See Figure 5-1 for description.

3 Circuit Breaker CB1

4 Circuit Breaker CB2

CB1 and CB2 protect the 120 V and

240 V receptacles from overload. If

CB1 or CB2 opens, the 240 V re-

ceptacle and half of the 120 V re-

ceptacle will not work. Press button

to reset breaker.

5 Total Auxiliary Power Output

Combined output of all receptacles

limited to 3 kVA/kW output of the

generator.

EXAMPLE: If 10 A is drawn from a

240 V receptacle, only 5 A is avail-

able at the 120 V receptacle:

(240 V x 10 A) + (120 V x 5 A) = 3.0

kVA/kW

Auxiliary power is not affected by

weld output.

Figure 5-2. Optional 240 Volt Duplex Receptacle And Circuit Breakers

Place Engine

Control Switch In

Run Position

See Section 9

Auxiliary Power

Guidelines

Install &

Connect

Equipment

Start Engine

Turn On

Auxiliary

Equipment

Begin Operation

rsb11.1 4/92

Figure 5-3. Sequence Of Auxiliary Equipment Operation

5-3. Connecting Optional Auxiliary Power Plant

WARNING

ELECTRIC SHOCK can kill.

• Stop engine before making or changing connections

or changing fuses.

• Keep junction box cover in place while engine is

running.

• Do no connect to any electrical distribution system

normally supplied by utility power unless a proper

transfer switch and grounding procedure are

employed.

• Ground in accordance with NEC, state, and local

codes; be sure that a proper ground is connected to

the Equipment Grounding Terminal provided on the

equipment frame.

INCORRECT CONNECTIONS or

IMPROPER VOLTAGE OR FREQUENCY

can damage equipment and cause fire.

• Read all equipment instruction manuals before

making connections.

• Use only equipment suitable for operation on 60 or

50/60 Hz power.

• Switch off electrical equipment before starting or

stopping engine.

• Have only a qualified electrician make or change

connections.

ELECTRIC SPARKS can cause fire.

• If using auxiliary power only and not welding,

disconnect both welding cables to prevent live

electrode from causing electric shock and fire

hazards.

• Watch for fire.

• Keep a fire extinguisher nearby, and know how to

use it.

The weld output terminals are electrically energized

when using auxiliary power.

MOVING PARTS can cause serious

injury.

• Keep away from moving parts such as fans, belts,

and rotors.

• Keep all doors, panels, covers, and guards closed

and securely in place.

INCORRECT FUSES can cause

equipment damage.

• Use only fuses of correct size, type, and rating (see

Parts List).

• Set Engine Control switch to Run position.

• Rotate Amperage & Voltage Adjustment control to

100 for power.

OM-480 Page 17

240V

120V120V

240V

1 3

rsb14.1 2/93A − S-160 622-A

Have only qualified persons make

this installation.

Stop engine. Open right side door.

1 Lead 42 (Circuit Grounding

Lead)

2 Lead 90 (Neutral)

3 Isolated Neutral Terminal

4 Jumper Lead 42

5 Grounding Terminal

Jumper lead 42 may be discon-

nected from neutral to meet appli-

cable codes, such as National

Electrical Code.

6 Strain Relief

7 User-Supplied Conductors

Strip back cord jacket approximate-

ly 12 in (305 mm). Strip 3/4 in (19

mm) insulation from ends of leads.

Route cord through strain relief.

8 Load Terminals

Connect leads to proper load termi-

nals as shown in connection dia-

gram. Tighten connections and

strain relief.

9 Fuses F1, F2, And F3 (see

Parts List for rating)

F1, F2, and F3 protect each load

line from overload. If output from the

power plant stops, a fuse may be

open.

Reinstall cover, and close side

door.

Tools Needed:

Generator Windings

(See Section 7 For Complete Circuit)

Volts

Amps

KVA/KW

Single

120/240

7.5

Three

240

60 HzFrequency

Engine Speed

Max. Fuse Size 35 Amperes

1850 RPM

Phase

Output

1. Set Engine Control switch to RUN.

2. Set AMPERAGE & VOLTAGE ADJUST-

MENT control to 100.

Lead 42 connects to GROUND stud on front of unit.

Jumper 42 is connected to 90 at factory.

Power and weld outputs

are live at the same time.

Disconnect or insulate

unused cables.

Front

Unit

3451

Figure 5-4. Auxiliary Power Plant Connections And Overload Protection

See Section 9

Auxiliary Power

Guidelines

Install & Connect

Welding

Generator

Connect Auxiliary

Equipment To

Power Plant

Place Engine

Control Switch In

Run Position

Start Engine

Turn On

Auxiliary

Equipment

Turn Amperage &

Voltage Control

To 100

Begin Operation

Figure 5-5. Sequence Of Operating Auxiliary Equipment From Power Plant

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Miller Big Blue 251D Owner's manual

Brand: Miller

Model: Big Blue 251D

Category: Engine

Type: Owner's manual

This manual is also suitable for

KC288497

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Miller Big Blue 251D Owner's manual

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Miller Big Blue 251D Owner's manual

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