Miller Big Blue 300 D Owner's Manual
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Miller Big Blue 300 D Owner's Manual

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Big Blue 300 D
PRO 300 D
OM-236 949B
2013-09
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
Description
Engine Driven Welding Generator
®
File: Engine Drive

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Summary of Contents for Miller Big Blue 300 D

  • Page 1 Stick (SMAW) Welding TIG (GTAW) Welding MIG (GMAW) Welding Flux Cored (FCAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging Description Engine Driven Welding Generator Big Blue 300 D ® PRO 300 D File: Engine Drive Visit our website at www.MillerWelds.com...
  • Page 2 We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING ........1-1.
  • Page 4 TABLE OF CONTENTS 8-4. Inspecting And Cleaning Optional Spark Arrestor Muffler ........8-5.

  • Page 5: Section 1 − Safety Precautions − Read Before Using

    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 Indicates special instructions. not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
  • Page 6 D Do not weld on closed containers such as tanks, drums, or pipes, FUMES AND GASES can be hazardous. unless they are properly prepared according to AWS F4.1 (see Safety Standards). Welding produces fumes and gases. Breathing these D Do not weld where the atmosphere may contain flammable dust, fumes and gases can be hazardous to your health.

  • Page 7: Engine Hazards

    1-3. Engine Hazards STEAM AND HOT COOLANT can burn. BATTERY EXPLOSION can BLIND. D If possible, check coolant level when engine is D Always wear a face shield, rubber gloves, and cold to avoid scalding. protective clothing when working on a battery. D Always check coolant level at overflow tank, if D Stop engine before disconnecting or connect- present on unit, instead of radiator (unless told...

  • Page 8: Additional Symbols For Installation, Operation, And Maintenance

    HOT METAL from air arc cutting and READ INSTRUCTIONS. gouging can cause fire or explosion. D Read Owner’s Manual before using or servic- D Do not cut or gouge near flammables. ing unit. D Watch for fire; keep extinguisher nearby. D Stop engine and release air pressure before servicing.

  • Page 9: California Proposition 65 Warnings

    H.F. RADIATION can cause interference. ARC WELDING can cause interference. D High-frequency (H.F.) can interfere with radio D Electromagnetic energy can interfere with navigation, safety services, computers, and sensitive electronic equipment such as micro- communications equipment. processors, computers, and computer-driven equipment such as robots.

  • Page 10: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 CONSIGNES DE SÉCURITÉ − LIRE AVANT − UTILISATION rom_2007−04fre Se protéger, ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud. 2-1. Signification des symboles DANGER! − Indique une situation dangereuse qui si on Indique des instructions spécifiques.
  • Page 11 D Porter un casque de soudage approuvé muni de verres filtrants DES PIÈCES CHAUDES peuvent approprié pour protéger visage et yeux pendant le soudage provoquer des brûlures graves. (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité). D Porter des lunettes de sécurité avec écrans latéraux même sous D Ne pas toucher à...

  • Page 12: Dangers Existant En Relation Avec Le Moteur

    D Placer les bouteilles debout en les fixant dans un support station- LES CHAMPS MAGNETIQUES peuvent naire ou dans un porte-bouteilles pour les empêcher de tomber ou affecter des implants médicaux. de se renverser. D Tenir les bouteilles éloignées des circuits de soudage ou autres D Porteur de simulateur cardiaque ou autre im- circuits électriques.

  • Page 13: Dangers Liés À L'air Comprimé

    L’utilisation d’un groupe autonome LA CHALEUR DU MOTEUR peut pro- à l’intérieur PEUT VOUS TUER EN voquer un incendie. QUELQUES MINUTES. D Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces inflammables. D Les fumées d’un groupe autonome contient du D Tenir à...
  • Page 14 UNE REMORQUE QUI BASCULE peut LE SURCHAUFFEMENT peut endom- entraîner des blessures. mager le moteur électrique. D Utiliser les supports de la remorque ou des D Arrêter ou déconnecter l’équipement avant de blocs pour soutenir le poids. démarrer ou d’arrêter le moteur. D Installer convenablement le poste sur la remor- D Ne pas laisser tourner le moteur trop lentement sous risque d’en- que comme indiqué...

  • Page 15: Proposition Californienne 65 Avertissements

    2-6. Proposition californienne 65 Avertissements Pour les moteurs à essence : Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques Les gaz d’échappement des moteurs contiennent des pro- dont l’État de Californie reconnaît qu’ils provoquent des mal- duits chimiques dont l’État de Californie reconnaît qu’ils formations congénitales et, dans certains cas, des cancers.

  • Page 16: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Warning Label Definitions Remove unit from shipping S-177 571 crate. Remove Owner’s Manual from unit. Follow instructions to install muffler. Read Owner’s Manual. Read labels on unit. Use Diesel Fuel only, and fill fuel tank. Leave room for expansion.

  • Page 17: Symbols And Definitions

    3-2. Symbols And Definitions Some symbols are found only on CE products. Fast (Run, Weld/ Stop Engine Slow (Idle) Start Engine Power) Starting Aid Engine Oil Battery (Engine) Engine Oil (Preheat) Pressure Check Injectors/ Check Valve Protective Earth Fuel Pump Clearance (Ground) Certified/Trained...

  • Page 18: Section 4 − Specifications

    SECTION 4 − SPECIFICATIONS 4-1. Weld, Power, And Engine Specifications Maximum Welding Weld Output Rated Welding Open- Generator Power Fuel Engine Mode Range Output Circuit Rating Capacity Voltage 400 A, 23 Volts DC, 30% Duty Cycle Stick: 40 − 410 A Stick: 40 410 A 300 A, 32 Volts DC...

  • Page 19: Volt-Ampere Curves

    4-3. Volt-Ampere Curves A. Stick Mode The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the curves shown. DC Amperes B. MIG Mode DC Amperes C.

  • Page 20: Fuel Consumption

    4-4. Fuel Consumption The curve shows typical fuel use under weld or power loads. 2.00 1.75 1.50 1.25 1.00 0.75 0.50 Idle 0.25 0.00 DC WELD AMPERES AT 100% DUTY CYCLE 237 299 4-5. Duty Cycle And Overheating 100% Duty Cycle Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating.

  • Page 21: Ac Generator Power Curve

    4-6. AC Generator Power Curve The ac power curve shows the gen- erator power in amperes available at the 120 and 240 volt receptacles. AC AMPERES IN 240 V MODE AC AMPERES IN 120 V MODE 237 303 Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge (.025 in) 22 Gauge (.031 in) 20 Gauge (.037 in)

  • Page 22: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Installing Welding Generator Do not move or operate unit where it could tip. Always securely fasten weld- Movement ing generator onto transport vehicle or trailer and comply with all DOT and other applica- ble codes. NOTICE −...

  • Page 23: Mounting Welding Generator

    5-2. Mounting Welding Generator Do not weld on base. Weld- ing on base can cause fuel tank fire or explosion. Weld only on the four mounting brackets or bolt unit down. Supporting The Unit NOTICE − Do not mount unit by supporting the base only at the four mounting brackets.

  • Page 24: Rating Label Location

    5-3. Grounding Generator To Truck Or Trailer Frame Always ground generator frame to vehicle frame to pre- vent electric shock and static electricity hazards. Also see AWS Safety & Health Fact Sheet No. 29, Grounding of Portable And Vehicle Mounted Welding Generators.

  • Page 25: Installing Exhaust Pipe

    5-5. Installing Exhaust Pipe Stop engine and let cool. Point exhaust pipe in desired di- rection but always away from front panel and direction of travel. Tools Needed: 1/2 in 803 582 / Ref. 217 357-A Notes Work like a Pro! Pros weld and cut safely.

  • Page 26: Activating The Dry Charge Battery (If Applicable)

    5-6. 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. Vent Caps Sulfuric Acid Electrolyte (1.265 Specific Gravity) Well Fill each cell with electrolyte to bottom of well (maximum).

  • Page 27: Engine Prestart Checks

    5-8. Engine Prestart Checks Check radiator coolant level when fluid is low in recovery tank. Full Full Diesel Capacity: 6 qt (5.7 L) Coolant Recovery Tank Hot Full Cold Full Full 805 177-A Engine stops if fuel level is low. freeze to mixture if using the unit in tempera- Check all engine fluids daily.

  • Page 28: Connecting To Weld Output Terminals

    5-9. Connecting To Weld Output Terminals Stick and TIG Welding MIG and FCAW Welding For Stick and TIG welding Direct Current Elec- For MIG and FCAW welding Direct Current trode Positive (DCEP), connect electrode Electrode Positive (DCEP) connect wire feed- holder cable to CC (Stick/TIG) terminal on er cable to CV (Wire) terminal on right and right and work cable to Work/Negative (−) ter-...

  • Page 29: Selecting Weld Cable Sizes

    5-10. Selecting Weld Cable Sizes* Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding*** Weld Output Terminals Terminals Stop engine before connecting to weld output terminals. 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 100 ft (30 m) or Less (45 m)

  • Page 30: Connecting To Remote 14 Receptacle Rc14

    5-11. Connecting To Remote 14 Receptacle RC14 Socket* Socket Information 24 volts ac. Protected by sup- plementary protector CB8. 24 VOLTS AC 24 VOLTS AC Contact closure to A completes 24 volt ac contactor control circuit. Output to remote control:+10 volts dc in MIG mode;...
  • Page 31 Notes Welding Symbols Ref. AWS/ANSI A2.4 OM-236 949 Page 27...

  • Page 32: Section 6 − Operating Welding Generator

    SECTION 6 − OPERATING WELDING GENERATOR 6-1. Front Panel Controls (See Section 6-2) 217 357-D / 803 563 OM-236 949 Page 28...

  • Page 33: Description Of Front Panel Controls (See Section 6-1)

    6-2. Description Of Front Panel Controls (See Section 6-1) Engine Starting Controls To check fuel level or engine hours when en- Process/Contactor Switch gine is not running, turn Engine Control switch Preheat Switch See Section 6-3 for Process/Contactor to Run position. switch information.

  • Page 34: Process/Contactor Switch

    6-3. Process/Contactor Switch Process/Contactor Switch Weld output terminals are ener- gized when Process/Contactor switch is in a Weld Terminals 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).

  • Page 35: Lift-Arct Tig With Crater-Out And Auto-Stopt

    6-4. Lift-Arct TIG With Crater-Out And Auto-Stopt Arc Start With Lift-Arc TIG Lift-Arc is used for the DCEN GTAW process when HF Start method is not permitted. Select Lift-Arc at Process/Contac- tor switch. Arc Start With Lift-Arc Turn gas on. Touch or scratch.

  • Page 36: Remote Voltage/Amperage Control

    6-5. Remote Voltage/Amperage Control Remote 14 Receptacle RC14 Connect optional remote control to RC14 (see Section 5-11). 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.

  • Page 37: Fuel/Hour Gauge Descriptions

    6-6. Fuel/Hour Gauge Descriptions OM-236 949 Page 33...

  • Page 38: Section 7 − Operating Auxiliary Equipment

    SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. Generator Power Receptacles 217 357-A 120 V 20 A AC (shown) overload. If CB5 opens, the receptacles do At least once a month, run engine at Receptacle RC5 and/or GFCI1 not work. Place CB5 switch in On position weld/power speed and press test but- to reset circuit breaker.

  • Page 39: Section 8 − Maintenance & Troubleshooting

    SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Routine Maintenance Stop engine before maintaining. See Engine Manual and Maintenance Label Recycle engine for important start-up, service, and storage fluids. information. Service engine more often if used in severe conditions. n = Check Z = Change ~ = Clean l = Replace...

  • Page 40: Maintenance Label

    8-2. Maintenance Label OM-236 949 Page 36...

  • Page 41: Servicing Air Cleaner

    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.

  • Page 42: Inspecting And Cleaning Optional Spark Arrestor Muffler

    8-4. Inspecting And Cleaning Optional Spark Arrestor Muffler Stop engine and let cool. Tools Needed: Spark Arrestor Muffler 3/8 in Cleanout Plug Remove plug and remove any dirt covering cleanout hole. Exhaust Pipe Start engine and run at idle speed to blow out cleanout hole.

  • Page 43: Servicing Fuel And Lubrication Systems

    8-6. Servicing Fuel And Lubrication Systems Stop engine and let cool. After servicing, start engine and check for fuel leaks. Stop engine, tighten connec- tions as necessary, and wipe up spilled fuel. Oil Filter Oil Drain Valve And Hose Oil Fill Cap Primary (Canister) Fuel Filter Secondary (In-Line) Fuel Filter...

  • Page 44: Overload Protection

    8-7. Overload Protection 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. Fuse F1 F1 protects the stator exciter wind- ing from overload. If F1 opens, weld and generator power is low or stops entirely.

  • Page 45: Checking Generator Brushes

    8-8. Checking Generator Brushes Stop engine and let cool. 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 or near minimum length. 5/16 in. (8 mm) Minimum Length 9/16 in.

  • Page 46: Voltmeter/Ammeter Help Displays

    8-10. Voltmeter/Ammeter Help Displays Use the Voltmeter/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. To reset help displays, stop unit and then restart. See item 6 below to reset Help 25 dis- play.

  • Page 47: Troubleshooting

    8-11. Troubleshooting Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 8-10). A. Welding Trouble Remedy No weld output; generator power output Place Process/Contactor switch in a Weld Terminals Always On position, or place switch in a Remote okay at ac receptacles.
  • Page 48 B. Generator Power Trouble Remedy No generator power output at ac recep- Reset receptacle supplementary protector(s) (see Section 7-1). tacles; weld output okay. No generator power or weld output. Disconnect equipment from generator power receptacles during start-up. Check fuse F1, and replace if open (see Section 8-7). Have Factory Authorized Service Agent check field excitation circuit.
  • Page 49 Trouble Remedy Engine slowly stopped and cannot be Check fuel level. restarted. Check engine air and fuel filters (see Sections 8-3 and 8-6). See engine manual. Battery discharges between uses. Turn Engine Control switch off when unit is not running. Clean top of battery with baking soda and water solution;...

  • Page 50: Section 9 − Electrical Diagrams

    SECTION 9 − ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For Welding Generator OM-236 949 Page 46...
  • Page 51 236 892-A OM-236 949 Page 47...

  • Page 52: Section 10 − Run-In Procedure

    SECTION 10 − RUN-IN PROCEDURE run_in1 2007−04 10-1. Wetstacking 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. Welding Generator Run diesel engines near rated volt- age and current during run-in period to properly seat piston rings and prevent wetstacking.

  • Page 53: Run-In Procedure Using Load Bank

    10-2. Run-In Procedure Using Load Bank 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.

  • Page 54: Run-In Procedure Using Resistance Grid

    10-3. Run-In Procedure Using Resistance Grid 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.

  • Page 55: Section 11 − Generator Power Guidelines

    SECTION 11 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown. 11-1. Selecting Equipment Generator Power Receptacles − Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment...
  • Page 56 11-3. Grounding When Supplying Building Systems Equipment Grounding Terminal Grounding Cable GND/PE Use #10 AWG or larger insulated copper wire. Ground Device Use ground device as stated in electrical codes. Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system.
  • Page 57 11-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1/8 HP 1/6 HP 1225 1/4 HP 1600 1/3 HP 2100 1/2 HP 3175 Capacitor Start-Induction Run 1/3 HP 2020 1/2 HP 3075 3/4 HP 4500 1400 1 HP...
  • Page 58 11-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1/4 in 3/8 in 1/2 in Circular Saw 6-1/2 in 7-1/4 in 8-1/4 in 1400 1400 Table Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in...
  • Page 59 11-8. Power Required To Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code KVA/HP 10.0 11.2 12.5 14.0 Motor Start Code Running Amperage Motor HP Motor Voltage AC MOTOR To find starting amperage: VOLTS AMPS Step 1: Find code and use table to CODE find kVA/HP.
  • Page 60 11-10. Typical Connections To Supply Standby Power Have only qualified persons perform these connections according to all applicable codes and safety practices. Fused Properly install and ground Welding Utility Disconnect this equipment according to Electrical Generator Transfer Switch Switch its Owner’s Manual and na- Output Service (If Required)
  • Page 61 11-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current Load (Watts) (Amperes) 350 (106) 225 (68) 137 (42)

  • Page 62: Section 12 − Parts List

    SECTION 12 − PARTS LIST Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. 4 (Fig.15−5) 109 (Fig.15−2) 107 (Fig.15−2) Figure 12-1. Main Assembly OM-236 949 Page 58...
  • Page 63 79 (Fig 12−4) 805 178-A OM-236 949 Page 59...
  • Page 64 Item Dia. Part Mkgs. Description Quantity Figure 12-1. Main Assembly ... 168829 Transducer, Current 1000a Module Max Open Loop ....
  • Page 65 Item Dia. Part Mkgs. Description Quantity Figure 12-1. Main Assembly (Continued) ....190190 Tank, Coolant Recovery ......... .
  • Page 66 Item Dia. Part Mkgs. Description Quantity Figure 12-1. Main Assembly (Continued) ....213465 Bolt, J Stl .312−18 X 7.250 Pld ........
  • Page 67 Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. 803 684-C Figure 12-2. Panel, Front w/Components Item Dia. Part Mkgs. Description Quantity Figure 12-2. Panel, Front w/Components (Figure 12-1 Item 108) .
  • Page 68 Item Dia. Part Mkgs. Description Quantity Figure 12-2. Panel, Front w/Components (Continued) ....214543 Enclosure, Circuit Card Assy ........
  • Page 69 Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. 805 180-A Figure 12-3. Control Panel Item Dia. Part Mkgs. Description Quantity Figure 12-3. Control Panel (Figure 12-1 Item 109) ..
  • Page 70 Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. 805 179-A Figure 12-4. Generator Item Dia. Part Mkgs. Description Quantity Figure 12-4. Generator (Figure 12-1 Item 79) ..ROTOR .
  • Page 71 Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. 803 685-A Figure 12-5. Rectifier Assembly Item Dia. Part Mkgs. Description Quantity Figure 12-5. Rectifier Assembly (Figure 12-1 Item 4) ....217081 Rectifier, Assembly (Includes) .
  • Page 72 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. Item Dia. Part Mkgs. Description Quantity Wiring Harnesses ....231122 Harness, Engine (Includes) .
  • Page 73 Notes Start Your Professional Over 80,000 400 Trade Square East, Troy, Ohio 45373 Welding Career Now! trained since 1930! 1-800-332-9448 www.welding.org OM-236 949 Page 69...
  • Page 74 Notes SOCKET/WRENCH SELECTION TABLE SOCKET/WRENCH SELECTION TABLE (U.S. STANDARD) (METRIC) Specifications Socket or Wrench Size Specifications Socket or Wrench Size U.S. Bolt Decimal Bolt Bolt Decimal Bolt Diameter Equivalent Diameter Equivalent 1/4 in .250 in 3/8 in 7/16 in 6 mm .2362 in 10 mm 10 mm...
  • Page 75 Effective January 1, 2008 (Equipment with a serial number preface of LJ or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions...

  • Page 76: Options And Accessories

    Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. © PRINTED IN USA 2008 Miller Electric Mfg. Co. 2008−01...

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