Instruction/ maintenance manual of the product Big Blue 300 Miller Electric
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B i g B l u e 3 0 0 P OM -4433 218 314P 2007 − 11 Pro cesses Descrip tio n Air Carbon Arc (CAC-A) Cutting and Gouging Stick (SMAW ) W elding Engine Driven Welding Generator TIG (GT A W ) W elding MIG (GMAW) W elding Flux Cored (FCA W ) W elding ® Visit our website at www.
Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .
T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T ABLE OF CONTENTS 8-5. Servicing Engine Cooling System 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6. Adjusting Engine Speed On Standard Models 38 . . . . . . . . . . . . . . . .
OM-4433 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2007 − 04 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury .
OM-4433 Page 2 W elding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous. Keep your head out of the fumes. Do not breathe the fumes. If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases.
OM-4433 Page 3 1-3. Engine Hazards BA TTER Y EXPLOSION can BLIND. Always wear a face shield, rubber gloves, and protective clothing when working on a battery . Stop engine before disconnecting or connect- ing battery cables or servicing battery .
OM-4433 Page 4 HOT MET AL from air arc cutting and gouging can cause fire or explosion. Do not cut or gouge near flammables. W atch for fire; keep extinguisher nearby . HOT P ARTS can cause burns and injury . Do not touch hot compressor or air system parts.
OM-4433 Page 5 H. F . RADIA TION can cause interference. High-frequency (H.F .) can interfere with radio navigation, safety services, computers, and communications equipment. Have only qualified persons familiar with electronic equipment perform this installation.
OM-4433 Page 6 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION rom_2007 − 04fre Se protéger , ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud.
OM-4433 Page 7 DES PIÈCES CHAUDES peuvent provoquer des brûlures graves. Ne pas toucher à mains nues les parties chau - des. Prévoir une période de refroidissement avant d e travailler à l’équipement.
OM-4433 Page 8 LES CHAMPS MAGNETIQUES peuv- ent affecter des implants médicaux. Porteur de simulateur cardiaque ou autre im- plants médicaux, rester à distance.
OM-4433 Page 9 L ’utilisation d’un groupe autonome à l’intérieur PEUT VOUS TUER EN QUELQUES MINUTES. Le s fumées d’un groupe autonome contient du monoxyde de carbone. C’est un poison invisi- ble et inodore. JAMAIS utiliser dans une maison ou garage, même avec les portes et fenêtres ouvertes.
OM-4433 Page 10 LE SURCHAUFFEMENT peut endom- mager le moteur électrique. Arrêter ou déconnecter l’équipement avant d e démarrer ou d ’a rrêter le moteur . Ne pas laisser tourner le moteur trop lentement sous risque d’en - dommager le moteur électrique à cause d’une tension et d’une fré - quence trop faibles.
OM-4433 Page 1 1 2-6. P r oposition californienne 65 A vertissements Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des mal- formations congénitales et, dans certains cas, des cancers.
OM-4433 Page 12 SECTION 3 − DEFINITIONS 3-1. W arning Label Definitions 3/96 1 Remove unit from shipping crate. Remove Owner’s Manual from unit. Follow instructions to install muf fler . 2 Read Owner ’s Manual. Read labels on unit. 3 Use Diesel Fuel only , and fill fuel tank.
OM-4433 Page 13 3-2. Manufacturer ’s Rating Label 228 417-B / 803 562-F.
OM-4433 Page 14 3-3. Symbols And Definitions Some symbols are found only on CE products. Stop Engine Fast (Run, W eld/ Power) Slow (Idle) Start Engine Starting Aid (Preheat) Battery (Engine) Engin.
OM-4433 Page 15 SECTION 4 − SPECIFICA TIONS 4-1. W eld, Power , And Engine Specifications W elding Mode W eld Output Range Rated W elding Output Maximum Open- Circuit V oltage Generator Power Rating.
OM-4433 Page 16 4-3. V olt-Ampere Curves 217 517 / 217 516 / 217 518 The volt-ampere curves show the minimum and maximum voltage an d amperage output capabilities of th e welding generator . Curves of al l other settings fall between the curves shown.
OM-4433 Page 17 4-4. Fuel Consumption The curve shows typical fuel use under weld or power loads. 217 509 ID LE DC WELD AMPERES A T 100% DUTY CYCLE U.S.
OM-4433 Page 18 4-6. AC Generator Power Curve 217 519 Th e ac power curve shows the gen- erator power in amperes available at the 120 and 240 volt receptacles. 0 40 80 120 160 0 2 04 0 6 08 0 AC AMPERES IN 120 V MODE AC AMPERES IN 240 V MODE 300 250 200 150 100 50 0 150 125 100 75 50 25 0 AC VOL TS Notes 16 Gauge (.
OM-4433 Page 19 SECTION 5 − INST ALLA TION install3 2007 − 04 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712 ! Always securely fasten weld- ing generator onto transport vehicle or trailer and comply with all DOT and other applica- ble codes.
OM-4433 Page 20 5-2. Mounting W elding Generator T ools Needed: 9/16 in 2 2 4 W elding Unit In Place Bolting Unit In Place ! Do not weld on base. W eld- ing on base can cause fuel tank fire or explosion. Weld only on the four mounting brackets or bolt unit down.
OM-4433 Page 21 5-3. Installing Exhaust Pipe 1/2 in T ools Needed: 803 582 / Ref. 217 357-A ! Stop engine and let cool. Point exhaust pipe in desired di- rection but always away from front panel and direction of travel. Notes W or k l i k e a Pr o! Pros wel d and cut safel y .
OM-4433 Page 22 5-4. Activating The Dry Charge Battery (If Applicable) ! Always wear a face shield, rubber gloves and protective clothing when working on a battery . Remove battery from unit. 5 V ent Caps 6 Sulfuric Acid Electrolyte (1.265 Specific Gravity) 7 W ell Fill each cell with electrolyte to bottom of well (maximum).
OM-4433 Page 23 5-6. Engine Prestart Checks Check all engine fluids daily . Engine must be cold and on a level surface. Unit is shipped with 20W break-in oil. Automatic shutdown system stops engine if oil pressure is too low or coolant tempera- ture is too high.
OM-4433 Page 24 5-7. Connecting T o Weld Output T erminals 803 562 / 803 778-A T ools Needed: 3/4 in MIG and FC A W Welding For MIG and FCA W welding Direct Current Electrode Positive (DCEP) connect wire feed- er cable to CV (Wire) terminal on right and work cable to W ork/Negative ( − ) terminal on left.
OM-4433 Page 25 5-8. Selecting W eld Cable Sizes* W eld Output T erminals W eld Cable Size** and T otal Cable (Copper) Length in Weld Circuit Not Exceeding*** T erminals ! Stop engine before connecting to weld output terminals. ! Do not use worn, dam- aged, undersized, or poorly spliced cables.
OM-4433 Page 26 5-9. Connecting T o Remote 14 Receptacle RC14 Socket* Socket Information 24 VOL TS AC A 24 volts ac. Protected by sup- plementary protector CB8. 24 VOL TS AC B Contact closure to A completes 24 volt ac contactor control circuit. C Output to remote control:+10 volts dc in MIG mode; 0 to +10 volts dc in Stick or TIG mode.
OM-4433 Page 27 Notes Welding Symbols Ref. AWS/ANSI A2.4.
OM-4433 Page 28 SECTION 6 − OPERA TING WELDING GENERA TOR 6-1. Front Panel Controls (See Section 6-2) 217 357-B / 803 563 1 2 5 4 6 78 91 0 3.
OM-4433 Page 29 6-2. Description Of Front Panel Controls (See Section 6-1 ) Engine Starting Controls 1 Preheat Switch Use switch to energize starting aid for cold weather starting (see starting instructions fol- lowing). 2 Engine Control Switch Use switch to start engine, select engine speed (if unit has auto idle option), and stop engine.
OM-4433 Page 30 6-3. Process/Contactor Switch 1 Process/Contactor Switch ! W eld output terminals are ener- gized when Process/Contactor switch is in a Weld T erminals Al- ways On position and the engine is running. Use switch to select weld process and weld output on/off control (see table be- low).
OM-4433 Page 31 6-4. Lift-Arc ™ Start Procedure Lift-Arc TIG With Lift-Arc TIG selected, start arc as follows: 1 TIG Electrode 2 W orkpiece T urn gas on. T ouch tungsten electrode to workpiece at weld start point. Hold electrode to workpiece for 1-2 seconds , and slowly lift electrode.
OM-4433 Page 32 6-5. Remote V oltage/Amperage Control 1 Remote 14 Receptacle RC14 Connect optional remote control to RC14 (see Section 5-9). When a remote control is connected to the Remote receptacle, the Auto Sense Re- mote feature automatically switches volt- age/amperage control to the remote con- trol.
OM-4433 Page 33 SECTION 7 − OPERA TING AUXILIAR Y EQUIPMENT 7-1. Generator Power Receptacles 217 357-A 1 120 V 20 A AC (shown) Receptacle RC5 and/or GFCI1 2 120 V 20 A AC GFCI (shown) Receptacle RC6 and/or GFCI2 3 240 V 50 A AC Receptacle RC1 1 RC 5 / 6 and GFCI1 / 2 supply 60 Hz single- phase power at weld/power speed.
OM-4433 Page 34 SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Routine Maintenance ! Stop engine before maintaining. S ee Engine Manual and Maintenance Label for important start-up, service, and storage information. Service engine more often if used in severe conditions.
OM-4433 Page 35 8-2. Maintenance Label.
OM-4433 Page 36 8-3. Servicing Air Cleaner ! Stop engine. NOTICE − Do not run engine without air cleaner or with dirty element. Engine damage caused by using a damaged ele- ment is not covered by the warranty . The air cleaner primary element can be cleaned but the dirt holding capac- ity of the filter is reduced with each cleaning.
OM-4433 Page 37 8-4. Inspecting And Cleaning Optional Spark Arrestor Muffler 803 582 / Ref. 214 778-B ! Stop engine and let cool. 1 Spark Arrestor Muffler 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.
OM-4433 Page 38 8-6. Adjusting Engine Speed On Standard Models 803 563-E 3 1 2 RPM (Hz) Engine Speed (No Load) W eld/Power 1880 (61.7) Maximum ! Stop engine and let cool. Engine speed is factory set and should not require adjustment. Af- ter tuning engine, check engine speed with tachometer or frequen- cy meter .
OM-4433 Page 39 8-7. Adjusting Engine Speed On Models With Automatic Idle (Optional) 803 563-G 1880 rpm max (62.6 Hz) 1500 rpm (50 Hz) Engine Speed (No Load) 1 2 3 4 T o prevent solenoid damage, be sure a 1/8 in (3 mm) gap exists be- tween the engine low speed screw and throttle lever when the solenoid is held in the energized position.
OM-4433 Page 40 8-8. Servicing Fuel And Lubrication Systems 802 490 / Ref. 801 434 ! Stop engine and let cool. ! After servicing, start engine and check for fuel leaks.
OM-4433 Page 41 8-9. Overload Protection 803 562 / 803 566 1 5 ! Stop engine. When a circuit breaker , supple- mentary protector , or fuse opens, it usually indicates a more serious problem exists. Contact Factory Authorized Service Agent. 1 Fuse F1 F1 protects the stator exciter wind- ing from overload.
OM-4433 Page 42 8-10. Checking Generator Brushes Ref 21 14 778 − D / S − 0233 − A ! Stop engine and let cool. 1 Generator Brush With Spring Mark and disconnect leads at brush hold- er cap. Remove brushes. Replace brushes if damaged or if brush material is at o r near minimum length.
OM-4433 Page 43 8-1 1. V oltmeter/Ammeter Help Displays Use the V oltmeter/Ammeter help displays to diagnose and correct fault conditions. When a help code is displayed normally weld output has stopped but generator power output may be okay . T o reset help displays, stop unit and then restart.
OM-4433 Page 44 8-12. T roubleshooting Also see V oltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 8-1 1). A.
OM-4433 Page 45 B. Generator Power T rouble Remedy No generator power output at ac recep- tacles; weld output okay . Reset receptacle supplementary protector(s) (see Section 7-1). No generator power or weld output. Disconnect equipment from generator power receptacles during start-up.
OM-4433 Page 46 T rouble Remedy Engine slowly stopped and cannot be restarted. Check fuel level. Check engine air and fuel filters (see Sections 8-3 and 8-8). See engine manual. Battery discharges between uses. Turn Engine Control switch of f when unit is not running.
OM-4433 Page 47 Notes 16 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 in (.
OM-4433 Page 48 SECTION 9 − ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For Welding Generator.
OM-4433 Page 49 219 228 − E.
OM-4433 Page 50 SECTION 10 − RUN-IN PROCEDURE run_in1 2007 − 04 10-1. W etstacking 1 W elding Generator Ru n diesel engines near rated volt- ag e and current during run-in period to properly seat piston rings and prevent wetstacking. See name- plate, rating label, or specifications section in this manual to find rated voltage and current.
OM-4433 Page 51 10-2. Run-In Procedure Using Load Bank S-0683 ! Stop engine. ! Do not touch hot exhaust pipe, engine parts, or load bank/grid. ! Keep exhaust and pipe away from flammables. NOTICE − Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur .
OM-4433 Page 52 10-3. Run-In Procedure Using Resistance Grid S-0684 ! Stop engine. ! Do not touch hot exhaust pipe, engine parts, or load bank/grid. ! Keep exhaust and pipe away from flammables. NOTICE − Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur .
OM-4433 Page 53 SECTION 1 1 − GENERA TOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding generators. Y our unit may differ from those shown. 1 1-1. Selecting Equipment gen_pwr 2007 − 04 − Ref.
OM-4433 Page 54 1 1-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 AWG or larger insulated copper wire.
OM-4433 Page 55 1 1-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Star ting W atts Running W atts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 2.
OM-4433 Page 56 1 1-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running W atts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/.
OM-4433 Page 57 1 1-8. Power Required T o Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code G H J K L M N P KV A/HP 6.3 7.1 8.0 9.0 10.0 1 1.2 12.5 14.0 S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor V oltage T o find starting amperage: Step 1: Find code and use table to find kV A/HP .
OM-4433 Page 58 1 1-10. T ypical Connections T o Supply Standby Power T ransfer Switch Essential Loads Fused Disconnect Switch (If Required) Utility Electrical Service 12 3 4 5 W elding Generator Output ! Have only qualified persons perform these connections according to all applicable codes and safety practices.
OM-4433 Page 59 1 1-1 1. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 V olt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord.
OM-4433 Page 60 SECTION 12 − P ARTS LIST Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. 1 10 (Fig.12 − 3) 1 2 3 4 (Fig.12 − 5) 5 6 7 8 9 10 11 12 14 15 16 17 18 19 20 21 13 22 23 24 25 26 90 91 92 93 94 95 96 98 97 99 100 101 102 103 104 105 106 107 108 (Fig.
OM-4433 Page 61 803 683-F 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 68 67 69 70 73 71 72 74 75 76 77 78 79 80(Fig.
OM-4433 Page 62 Description Part No. Dia. Mkgs. Item No. Figure 12-1. Main Assembly Quantity 1 HD1 168829 T ransducer , Current 1000a Module Max Open Loop 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 R3 213027 Resistor , WW T ap 300 W 40 Ohm 1 .
OM-4433 Page 63 Description Part No. Dia. Mkgs. Item No. Figure 12-1. Main Assembly (Continued) Quantity 49 199592 Latch, Paddle Series 20 (Black) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-4433 Page 64 Description Part No. Dia. Mkgs. Item No. Figure 12-1. Main Assembly (Continued) Quantity 172071 Clamp, Hose .520 − .605 Clp Dia Slfttng Black 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 1961 Hose, Sae .
OM-4433 Page 65 Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. 803 684-B 1 2 3 4 5 6 37 36 7 8 9 10 11 12 13 14 15 16 17 18 19 31 32 33 34 35 20 21 22 23 24 25 26 27 28 29 30 24 Figure 12-2.
OM-4433 Page 66 Description Part No. Dia. Mkgs. Item No. Figure 12-2. Panel, Front w/Components (Continued) Quantity 10 214543 Enclosure, Circuit Card Assy 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-4433 Page 67 Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. 803 689-D 1 2 3 4 5 6 7 8 9 10 13 12 11 14 15 Figure 12-3. Control Panel Description Part No. Dia. Mkgs. Item No. Figure 12-3.
OM-4433 Page 68 803 686-B Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. 2 3 1 4 5 6 7 8 9 10 11 12 13 14 19 20 18 15 17 16 Figure 12-4. Generator Description Part No. Dia. Mkgs. Item No.
OM-4433 Page 69 803 685-A Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. 1 2 3 6 4 5 9 8 10 7 Figure 12-5. Rectifier Assembly Description Part No. Dia. Mkgs. Item No. Figure 12-5. Rectifier Assembly (Figure 12-1 Item 4) Quantity 217081 Rectifier , Assembly (Includes) 1 .
OM-4433 Page 70 Some wiring harness components (switches, relays, supplementary protectors) are also referenced elsewhere in this parts list. Purchase compo- nents separately or as part of the associated wiring harness. Description Part No. Dia. Mkgs.
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007 − 01 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.
PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007 − 01 Miller Elect ric Mfg. Co. An Illinois T ool W orks Compan y 1635 West S pencer Street Applet on, WI 54914 USA International He adquarters .
An important point after buying a device Miller Electric Big Blue 300 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Miller Electric Big Blue 300 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Miller Electric Big Blue 300 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Miller Electric Big Blue 300 you will learn all the available features of the product, as well as information on its operation. The information that you get Miller Electric Big Blue 300 will certainly help you make a decision on the purchase.
If you already are a holder of Miller Electric Big Blue 300, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Miller Electric Big Blue 300.
However, one of the most important roles played by the user manual is to help in solving problems with Miller Electric Big Blue 300. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Miller Electric Big Blue 300 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
