Miller Electric Big Blue 251D Owner's Manual
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Miller Electric Big Blue 251D Owner's Manual

Miller Electric Big Blue 251D Owner's Manual

Engine driven welding generator
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Big Blue 251D
OM-480
128 576AC
January 2005
Processes
Stick (SMAW) Welding
Air Carbon Arc (CAC-A)
Cutting And Gouging
With Optional Equipment:
Flux Cored (FCAW) With
Voltage-Sensing Wire Feeder
Description
Engine Driven Welding Generator

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  • Page 1 Big Blue 251D Visit our website at www.MillerWelds.com OM-480 128 576AC January 2005 Processes Stick (SMAW) Welding Air Carbon Arc (CAC-A) Cutting And Gouging With Optional Equipment: Flux Cored (FCAW) With Voltage-Sensing Wire Feeder Description Engine Driven Welding Generator...
  • Page 2 ISO 9001:2000 Quality System Standard. particular model are also provided. 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 catalog sheets.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1-1. Symbol Usage ............... . 1-2.
  • Page 4 TABLE OF CONTENTS SECTION 8 − MAINTENANCE AND TROUBLESHOOTING 8-1. Routine Maintenance ..............8-2.

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

    SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING Y Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.

  • Page 6: Engine Hazards

    WELDING can cause fire or explosion. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire.

  • Page 7: Compressed Air Hazards

    STEAM AND HOT COOLANT can burn. D If possible, check coolant level when engine is cold to avoid scalding. D Always check coolant level at overflow tank, if pres- ent on unit, instead of radiator (unless told otherwise in maintenance section or engine manual). D If the engine is warm, checking is needed, and there is no overflow tank, follow the next two statements.

  • Page 8: California Proposition 65 Warnings

    READ INSTRUCTIONS. D Use only genuine MILLER/Hobart replacement parts. D Perform engine and air compressor (if applicable) maintenance and service according to this manual and the engine/air compressor (if applicable) manu- als. H.F. RADIATION can cause interference. D High-frequency (H.F.) can interfere with radio naviga- tion, safety services, computers, and communica- tions equipment.

  • Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT Y Avertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions. 2-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives.

  • Page 10: Dangers Existant En Relation Avec Le Moteur

    LES ACCUMULATIONS DE GAZ ris- quent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz protecteur en cas de non utilisation. D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi- rateur d’adduction d’air homologué. LES RAYONS DE L’ARC peuvent pro- voquer des brûlures dans les yeux et sur la peau.

  • Page 11: Dangers Liés À L'air Comprimé

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

  • Page 12: Principales Normes De Sécurité

    LE SURCHAUFFEMENT peut endom- mager le moteur électrique. D Arrêter ou déconnecter l’équipement avant de dé- marrer ou d’arrêter le moteur. D Ne pas laisser tourner le moteur trop lentement sous risque d’endommager le moteur électrique à cause d’une tension et d’une fréquence trop faibles. D Ne pas brancher de moteur de 50 ou de 60 Hz à...

  • Page 13: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions Stop Engine Fast/Slow (Run/Idle) Check Injectors/ Pump Positive Amperes Read Operator’s Manual Alternating Current Do Not Switch While Welding Engine Coolant Temperature Fast (Run, Weld/ Slow (Idle) Power) Battery (Engine) Circuit Breaker Check Valve Fuel Clearance...

  • Page 14: Section 4 − Specifications

    SECTION 4 − SPECIFICATIONS 4-1. Weld, Power, And Engine Specifications Maximum Open-Circuit Rated Welding Amperage Voltage DC Output Range (Nominal) 250 A, 40 Volts DC, 40 − 400 95 (90) 100% Duty Cycle 4-2. Dimensions, Weights, And Operating Angles Dimensions Height 40-1/2 in (1029 mm) Width...

  • Page 15: Fuel Consumption

    4-3. Fuel Consumption 4-4. Duty Cycle And Overheating 100% Duty Cycle At 250 Amperes Continuous Welding The curve shows typical fuel use under weld or power loads. SB-137 487-A Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating.

  • Page 16: Ac Generator Power

    4-5. AC Generator Power 4-6. Volt-Ampere Curves OM-480 Page 12 AC AMPERES IN 240V MODE AC AMPERES IN 120V MODE RANGES: AMPERES The ac power curve shows the gen- erator power in amperes available at the 120 and 240 volt receptacles. rsb3.1 2/92 −...

  • Page 17: Optional Ac Power Plant Curves

    4-7. Optional AC Power Plant Curves A. 7.5 KVA/KW Single-Phase AC Power Plant (No Weld Load) B. 10 KVA/KW Three-Phase AC Power Plant (No Weld Load) AC AMPERES The ac power curves show the gen- erator power in amperes available at the single-phase 120/240 volt or three-phase 240 volt terminals.

  • Page 18: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Installing Welding Generator Movement Y Do Not Lift Unit From End Grounding Electrically bond generator frame to vehicle frame by metal-to-metal contact. Y Bed liners, shipping skids, and some running gears insulate the welding generator from the vehicle frame.

  • Page 19: Installing Muffler Pipe

    5-3. Installing Muffler Pipe Tools Needed: 1/2 in 5-4. Engine Prestart Checks 1/2 in (13 mm) Full Diesel Valve Open Y Stop engine and let cool. Y Do not blow exhaust toward air cleaner or air intake. Top View exh_pipe2 12/96 − 154 089-A / 154 611 / Ref. 206 029 Check all fluids daily.

  • Page 20: Installing Ether Cylinder (Optional Ether Starting Aid)

    5-5. Installing Ether Cylinder (Optional Ether Starting Aid) 5-6. Connecting To Weld Output Terminals Tools Needed: 3/4 in OM-480 Page 16 Y Stop engine. Y Improper handling or expo- sure to ether can harm your health. Follow manufactur- er’s safety instructions on cylinder.

  • Page 21: Selecting Weld Cable Sizes

    5-7. Selecting Weld Cable Sizes* Weld Output Terminals Y Turn off power before Welding connecting to weld out- Amperes put terminals. Y Do not use worn, dam- aged, undersized, or poorly spliced cables. This chart is a general guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), use next size larger cable.

  • Page 22: Section 6 − Operating The Welding Generator

    SECTION 6 − OPERATING THE WELDING GENERATOR 6-1. Controls (See Section 6-2) OM-480 Page 18 Ref. 206 029 / 800 162-A / 800 159-D...

  • Page 23: Description Of Front Panel Controls (See Section 6-1)

    6-2. Description Of Front Panel Controls (See Section 6-1) This unit has a max OCV control circuit that resets the Amperage/Voltage Con- trol to maximum when the arc breaks. When an arc is struck, weld output control returns to the front panel or remote con- trol setting.

  • Page 24: Section 7 − Operating Auxiliary Equipment

    SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. 120 Volt Duplex And Optional GFCI Receptacles OM-480 Page 20 Y If unit does not have GFCI re- ceptacles, use GFCI-pro- tected extension cord. 120 V 15 A AC Receptacle 120 V 15 A AC Receptacle 120 V 20 A AC GFCI Receptacles GFCI1 And GFCI2 (Optional)

  • Page 25: 240 Volt Duplex Receptacle (Optional)

    7-2. 240 Volt Duplex Receptacle (Optional) Y If unit does not have GFCI re- ceptacles, use GFCI-pro- tected extension cord. 240 V 15 A AC Receptacle Receptacle supplies 60 Hz single- phase power at weld/power speed. Maximum output is 3 kVA/kW. Circuit Breakers CB1 And protect receptacles from overload.

  • Page 26: Connecting Optional Ac Power Plant

    7-3. Connecting Optional AC Power Plant OM-480 Page 22 Single Three Phase Phase Output Volts 120/240 Amps KVA/KW Frequency 60 Hz Engine Speed 1850 RPM Max. Fuse Size 35 Amperes Lead 42 connects to GROUND stud on front of unit. Jumper 42 is connected to 90 at factory.

  • Page 27: 120/240 Volt Twistlock Receptacle (Optional)

    7-4. 120/240 Volt Twistlock Receptacle (Optional) RC9 is connected to the optional ac power plant and supplies 60 Hz single-phase power at weld/power speed. Maximum output from re- ceptacle is 7.5 kVA/kW. Power available at RC9 is reduced when welding. Fuses F1 and F2 protect RC9 from overload (see Section 7-3).

  • Page 28: Section 8 − Maintenance And Troubleshooting

    SECTION 8 − MAINTENANCE AND TROUBLESHOOTING 8-1. Routine Maintenance Wipe Up Spills. See Section 8-3. Check cleaner hoses for cracks and loose clamps. Every 200 h Change Oil. See Section 8-4. Blow Out Or Vacuum Inside. During Heavy Service, Clean Monthly. Check 1/2 in.

  • Page 29: Maintenance Label

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

  • Page 30: Servicing Air Cleaner

    8-3. Servicing Air Cleaner Keep nozzle 2 in (51 mm) from element. Blow OM-480 Page 26 Inspect Y Stop engine. Y Do not run engine without air cleaner or with dirty element. En- gine damage caused by using a damaged element is not covered by the warranty.

  • Page 31: Servicing Fuel And Lubrication Systems

    8-4. Servicing Fuel And Lubrication Systems Valve Open Tools Needed: 7/16, 11/16 in Y Stop engine and let cool. Oil Filter Oil Drain Plug Oil Fill Cap Primary Fuel Filter (Fuel/ Water Separator) Petcock Secondary Fuel Filter Fuel Shutoff Valve Fuel Line Sludge Drain Plug To change oil and filter:...

  • Page 32: Adjusting Engine Speed

    8-5. Adjusting Engine Speed Models With Automatic Idle (Optional) Tools Needed: 3/8, 7/16 in OM-480 Page 28 1850 rpm (61.6 Hz) 1250 rpm (41.5 Hz) Standard Models After tuning engine, check engine no load speed with a tachometer (see table for no load speeds). If necessary, adjust speed as follows: Start engine and run until warm.

  • Page 33: Overload Protection

    8-6. Overload Protection 8-7. Servicing Optional Ether Starting Aid 33 oz (935 g) Full 15 oz (425 g) Empty Y Stop engine. When a fuse opens, it usually indicates a more serious prob- lem exists. Contact a Factory Authorized Service Agent. Magnetic Shutdown Switch MS1 (Optional) Fuse F (See Parts List)

  • Page 34: Inspecting And Cleaning Optional Spark Arrestor

    8-8. Inspecting And Cleaning Optional Spark Arrestor Tools Needed: 3/8 in 8-9. Troubleshooting A. Welding Trouble No weld output. Check position of Ampere Range switch. Check position of optional Polarity switch. Place A/V control switch in Panel position, or place switch in Remote position and connect Remote Am- perage control to Remote A/V receptacle RC3 (see Section 6-3).
  • Page 35 B. Generator Power Trouble output generator power Reset circuit breaker CB1 and/or CB2 (see Section 7-1 or 7-2). receptacles. Disconnect equipment from generator power receptacles during start-up. Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit. Low or high output at generator power Check engine speed, and adjust if necessary (see Section 8-5).

  • Page 36: Section 9 − Electrical Diagram

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

  • Page 37: Section 10 − Run-In Procedure

    SECTION 10 − RUN-IN PROCEDURE 10-1. Wetstacking run_in1 8/01 Y Do perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment 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 38: Run-In Procedure Using Load Bank

    10-2. Run-In Procedure Using Load Bank OM-480 Page 34 Y Stop engine. Y Do not touch hot exhaust pipe, engine parts, or load bank/grid. Y Keep exhaust and pipe away from flammables. Y Do perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur.

  • Page 39: Run-In Procedure Using Resistance Grid

    10-3. Run-In Procedure Using Resistance Grid Y Stop engine. Y Do not touch hot exhaust pipe, engine parts, or load bank/grid. Y Keep exhaust and pipe away from flammables. Y Do perform procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur.

  • Page 40: Section 11 − Generator Power Guidelines

    SECTION 11 − GENERATOR POWER GUIDELINES NOTE 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 11-2. Grounding Generator To Truck Or Trailer Frame Electrically bond generator frame to vehicle frame by metal-to-metal contact.

  • Page 41: Grounding When Supplying Building Systems

    11-3. Grounding When Supplying Building Systems 11-4. How Much Power Does Equipment Require? AMPERES x VOLTS = WATTS EXAMPLE 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power requirement in watts. The load applied by the drill is 520 watts. EXAMPLE 2: If three 200 watt flood lamps are used with the drill from Example 1, add the individual loads to calculate total load.
  • Page 42 11-5. Approximate Power Requirements For Industrial Motors Industrial Motors Split Phase Capacitor Start-Induction Run Capacitor Start-Capacitor Run Fan Duty 11-6. Approximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Stock Tank De-Icer Grain Cleaner Portable Conveyor Grain Elevator Milk Cooler Milker (Vacuum Pump) FARM DUTY MOTORS Std.
  • Page 43 11-7. Approximate Power Requirements For Contractor Equipment Contractor Hand Drill Circular Saw Table Saw Band Saw Bench Grinder Air Compressor Electric Chain Saw Electric Trimmer Electric Cultivator Elec. Hedge Trimmer Flood Lights Submersible Pump Centrifugal Pump Floor Polisher High Pressure Washer 55 gal Drum Mixer Wet &...
  • Page 44 11-8. Power Required To Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code KVA/HP kVA/HP x HP x 1000 VOLTS EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4 HP motor with a motor start code of M. Volts = 230 HP = 1/4 11.2 x 1/4 x 1000...
  • Page 45 11-10. Typical Connections To Supply Standby Power Y Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes. Utility Electrical Service Y Have only qualified persons perform these connections according to all applicable codes and safety practic- Y Properly install and ground this equipment according to its Owner’s Manual and national, state, and local...
  • Page 46 11-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord. Current Load (Watts) (Amperes) 1200 1800 2400 3000 3600 4200 4800 5400 6000 *Conductor size is based on maximum 2% voltage drop Cord Lengths for 240 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord.
  • Page 47 Notes OM-480 Page 43...

  • Page 48: Section 12 − Parts List

    SECTION 12 − PARTS LIST Hardware is common and not available unless listed. 111(Fig 12-2) OM-480 Page 44 Figure 12-1. Main Assembly 71(Includes 72−77)
  • Page 49 65(Fig 12-3) ST-129 956-U OM-480 Page 45...
  • Page 50 Item Dia. Part Mkgs....134 771 ....184 676 .
  • Page 51 Item Dia. Part Mkgs..... . 128 287 ....127 648 .
  • Page 52 Item Dia. Part Mkgs....173 982 ..168 071 ... . 173 423 .
  • Page 53 Item Dia. Part Mkgs....021 385 ....129 860 .
  • Page 54 Hardware is common and not available unless listed. Figure 12-3. Generator ST-110 922-F OM-480 Page 50...
  • Page 55 Item Dia. Part Mkgs....106 426 INSULATOR ....106 440 BUS BAR, rectifier .
  • Page 56 Item Part 114 193 Figure 12-4. Switch, Range (Fig 12-2 Item 1) ....114 235 BRACKET, mtg switch (consisting of) ....010 671 .
  • Page 59 Warranty Questions? Call LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to 1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after for your local the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.

  • Page 60: Options And Accessories

    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. 2005 Miller Electric Mfg. Co. 1/05 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA...

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