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OM-229 979L 2009−01 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 Big Blue 400 PX File: Engine Drive Visit our website at www.MillerWelds.com...
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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.
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DECLARATION OF CONFORMITY for European Community (CE marked) products. MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(s) and Standard(s).
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2008−08 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.
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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.
1-3. Engine Hazards HOT PARTS can cause severe burns. BATTERY EXPLOSION can BLIND. D Do not touch hot parts bare handed. D Always wear a face shield, rubber gloves, and protective clothing when working on a battery. D Allow cooling period before working on equip- ment.
D Keep hands, hair, loose clothing, and tools away from moving HYDRAULIC FLUID can injure or kill. parts. D Before working on hydraulic system, turn off and lockout/tagout D Before working on hydraulic system, turn off and unit, release pressure, and be sure hydraulic pressure cannot be lockout/tagout unit, release pressure, and be sure accidentally applied.
MOVING PARTS can injure. HOT PARTS can cause severe burns. D Do not touch hot compressor or air system D Keep away from fans, belts and rotors. parts. D Keep all doors, panels, covers, and guards D Let system cool down before touching or ser- closed and securely in place.
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.
SECTION 2 CONSIGNES DE SÉCURITÉ − LIRE AVANT − UTILISATION rom_2008−08fre 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.
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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...
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.
L’utilisation d’un groupe autonome L’ACIDE DE LA BATTERIE peut pro- à l’intérieur PEUT VOUS TUER EN voquer des brûlures dans les YEUX et QUELQUES MINUTES. sur la PEAU. D Ne pas renverser la batterie. D Les fumées d’un groupe autonome contient du D Remplacer une batterie endommagée.
LIRE LES INSTRUCTIONS. D Lire le manuel d’utilisation avant d’installer, d’utiliser ou d’intervenir sur l’appareil. D N’utiliser que les pièces de rechange recommandées par le constructeur. D Effectuer l’entretien en respectant les manuels d’utilisation, les normes industrielles et les codes nationaux, d’état et locaux. 2-5.
MÉTAL CHAUD provenant LIRE LES INSTRUCTIONS. découpage ou du gougeage à l’arc risque de provoquer un incendie ou une explosion. D Lire le manuel d’utilisation avant d’installer, d’utiliser ou d’intervenir sur l’appareil. D Ne pas découper ou gouger à proximité D N’utiliser que les pièces de rechange de produits inflammables.
LE RAYONNEMENT HAUTE FRÉ- LE SOUDAGE À L’ARC risque de QUENCE (H.F.) risque de provoquer provoquer des interférences. des interférences. D L’énergie électromagnétique risque de provo- quer des interférences pour l’équipement élec- D Le rayonnement haute fréquence (H.F.) peut tronique sensible tel que les ordinateurs et provoquer des interférences avec les équipe- l’équipement commandé...
2-9. Information EMF Considérations sur le soudage et les effets de basse fréquence et des 1. Garder les câbles ensemble, les torsader, les scotcher, ou les champs magnétiques et électriques. recouvrir d’une housse. Le courant de soudage, pendant son passage dans les câbles de sou- 2.
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.
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...
SECTION 4 − SPECIFICATIONS 4-1. Weld, Power, And Engine Specifications Maximum Welding Weld Output Rated Welding Open- Fuel Auxiliary Power Rating Engine Mode Range Output Circuit Capacity Voltage Generator 300 A, 32 Volts DC Single-Phase, 20 − 365 A 60% Duty Cycle 10 kVA/kW, 91/46 A, CC/DC 110/220 V AC,...
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.
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 0.25 IDLE 0.00 DC WELD AMPERES AT 100% DUTY CYCLE 237 471 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.
4-6. AC Generator Power Curve The ac power curve shows the gen- erator power in amperes. AC AMPERES IN 110V MODE AC AMPERES IN 220V MODE 220 346−B Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge (.025 in) 22 Gauge (.031 in) 20 Gauge (.037 in) 18 Gauge (.050 in) 16 Gauge (.063 in)
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 −...
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.
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.
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−F / Ref. 287 126-A Notes Work like a Pro! Pros weld and cut safely.
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).
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 Ref. 804 009−C Engine stops if fuel level is low. freeze to mixture if using the unit in tempera- Check all engine fluids daily.
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 holder cable to Positive (+) terminal and work feeder cable to Positive (+) terminal and work cable to Negative (−) terminal on left.
5-10. Selecting Weld Cable Sizes* Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding*** 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 100 ft (30 m) or Less (45 m) (60 m) (70 m) (90 m) (105 m)
5-11. Connecting To Remote 14 Receptacle RC14 Socket* Socket Information 24 volts ac. Protected by sup- plementary protector CB8. 24 VOLTS AC Contact closure to A completes 24 volt ac contactor control circuit. Output to remote control:+10 volts dc in MIG mode; 0 to +10 volts dc in Stick or TIG mode.
6-2. Description Of Front Panel Controls (See Section 6-1) Engine Starting Controls Engine Gauges, Meters, And Lights Process/Contactor Switch See Section 6-5 for complete fuel/hour See Section 6-3 for Process/Contactor Preheat Switch switch information. gauge information. Use switch to energize starting aid for cold Fuel Gauge/Hourmeter weather starting (see starting instructions fol- Voltage/Amperage Control...
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).
6-4. 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.
SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. 110 Volt Receptacles Ref. 229 747-A 110 V 32 A AC Receptacle RC11 ceptacle RC12 from overload. CB6 pro- ing receptacle does not work. Place circuit tects RC13 from overload. If a supplemen- breaker switch in the On position to reset 110 V 16A AC Receptacle RC12 tary protector opens, the receptacle does...
8-2. 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 Reference * To be done by Factory Authorized Service Agent...
8-3. Perkins Customer Assistance Service a problem that has not been handled to your Please follow the above steps in sequence complete satisfaction, follow these steps: if a problem arises. When a problem arises concerning the op- Discuss your problem with a local eration or service of the engine, the prob- dealer or distributor.
8-5. 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.
8-6. Inspecting And Cleaning Spark Arrestor Muffler Stop engine and let cool. Spark Arrestor Muffler 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. If nothing blows out of hole, briefly cover end of exhaust pipe with fireproof material.
8-8. Adjusting Engine Speed On Standard Models Stop engine and let cool. Engine speed is factory set and should not require adjustment. Af- ter tuning engine, check engine Engine Speed speed with tachometer or frequen- RPM (Hz) (No Load) cy meter. See table for proper no load speed.
8-9. Adjusting Engine Speed On Models With Automatic Idle (Optional) Engine Speed Adjustment Engine Speed After tuning engine, check en- (No Load) gine speed with tachometer or frequency meter. See table for 1880 rpm max proper no load speed. If neces- (62.6 Hz) sary, adjust speed as follows: 1500 rpm...
8-10. 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...
8-11. 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.
8-12. Optional 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- HL.P play.
8-13. Troubleshooting Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 8-12). 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.
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Trouble Remedy Check Voltmeter/Ammeter help displays (see Section 8-12). Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit. High output at generator power ac re- Have Factory Authorized Service Agent check voltage regulator module PC3. ceptacles.
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Trouble Remedy Battery discharges between uses. Turn Engine Control switch off when unit is not running. Clean top of battery with baking soda and water solution; rinse with clear water. Recharge or replace battery if necessary. Periodically recharge battery (approximately every 3 months). Engine idles, but does not come up to Have Factory Authorized Service Agent check fuel/hour gauge FUEL/HM and current transformer weld speed (units with idle option only).
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.
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.
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.
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...
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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.
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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...
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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...
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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.
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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)
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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)
SECTION 12 − PARTS LIST Hardware is common and not available unless listed. Wiring harnesses are listed at the end of parts section. 4−Fig.12−5 2−Fig.12−3 97−Fig.12−2 Figure 12-1. Main Assembly OM-229 979 Page 62...
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Hardware is common and not available unless listed. Wiring harnesses are listed at the end of parts section. 804 633-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 97 ) .
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Item Dia. Part Mkgs. Description Quantity Figure 12-2. Panel, Front w/Components (Continued) ... . . 217680 Switch, Ignition 4 Position W/Out Handle ......
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Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. 803 689-E Figure 12-3. Control Panel Item Dia. Part Mkgs. Description Quantity Figure 12-3. Control Panel (Figure 12-1 Item 2) ..
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Hardware is common and not available unless listed. Wiring harnesses are listed at the end of parts section. 803 686-A Figure 12-4. Generator Item Dia. Part Mkgs. Description Quantity Figure 12-4. Generator (Figure 12-1 Item 72) ..ROTOR .
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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) .
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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 ....235012 Harness, Engine (Includes) .
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Effective January 1, 2009 (Equipment with a serial number preface of LK 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...