Summary of Contents for Miller Big Blue 300 PRO Series
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OM-259 355A 2012−12 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 300 PRO ® Series CAT, Kubota, Mitsubishi Engines 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.
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2011−10 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury.
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D Do not weld on containers that have held combustibles, or on FUMES AND GASES can be hazardous. closed containers such as tanks, drums, or pipes unless they are properly prepared according to AWS F4.1 and AWS A6.0 (see Welding produces fumes and gases. Breathing these Safety Standards).
1-3. Engine Hazards EXHAUST SPARKS can cause fire. BATTERY EXPLOSION can injure. D Do not let engine exhaust sparks cause fire. D Always wear a face shield, rubber gloves, and protective clothing when working on a battery. D Use approved engine exhaust spark arrestor in required areas —...
HOT METAL from air arc cutting and MOVING PARTS can injure. gouging can cause fire or explosion. D Keep away from moving parts such as fans, D Do not cut or gouge near flammables. belts and rotors. D Watch for fire; keep extinguisher nearby. D Keep all doors, panels, covers, and guards closed and securely in place.
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BATTERY CHARGING OUTPUT and BATTERY STATIC (ESD) can damage PC boards. EXPLOSION can injure. D Put on grounded wrist strap BEFORE handling Battery charging not present on all models. boards or parts. D Use proper static-proof bags and boxes to D Always wear a face shield, rubber gloves, and protective store, move, or ship PC boards.
1-6. California Proposition 65 Warnings For Gasoline Engines: Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc- Health &...
SECTION 2 CONSIGNES DE SÉCURITÉ − LIRE AVANT − UTILISATION fre_rom_2011−10 Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
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Il reste une TENSION DC NON NÉGLIGEABLE dans les LES RAYONS DE L’ARC peuvent sources de soudage onduleur UNE FOIS le moteur coupé. provoquer des brûlures dans les yeux et sur la peau. D Couper l’alimentation du poste et décharger les condensateurs d’entrée comme indiqué...
D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, LE BRUIT peut affecter l’ouïe. des chocs mécaniques, des dommages physiques, du laitier, des flammes ouvertes, des étincelles et des arcs. Le bruit des processus et des équipements peut D Placer les bouteilles debout en les fixant dans un support station- affecter l’ouïe.
LA VAPEUR ET LE LIQUIDE DE L’ACIDE DE LA BATTERIE peut pro- REFROIDISSEMENT CHAUD peuvent voquer des brûlures dans les YEUX et provoquer des brûlures. sur la PEAU. D Il est préférable de vérifier le liquide de refroi- D Ne pas renverser la batterie. dissement une fois le moteur refroidi pour éviter D Remplacer une batterie endommagée.
détendre la pression et s’assurer que le circuit d’air ne peut être L’INHALATION D’AIR COMPRIMÉ risque mis sous pression par inadvertance. de provoquer des blessures ou même D Demander seulement à un personnel qualifié d’enlever la mort. les dispositifs de sécurité ou les recouvrements pour effectuer, s’il y a lieu, des travaux d’entretien et de dépannage.
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LA SORTIE DE RECHARGE et L’EXPLO- LES CHARGES ÉLECTROSTATI- SION BATTERIE peuvent QUES peuvent endommager les provoquer des blessures. circuits imprimés. D Établir la connexion avec la barrette de terre La recharge de batterie n’existe pas sur tous les avant de manipuler des cartes ou des pièces. modèles.
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.
Complete Parts List is available at www.MillerWelds.com SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbols And Definitions Some symbols are found only on CE products. Remove unit from shipping crate. Remove Owner’s Manual from unit. Follow instructions to install muffler. Safe46 2012−05 Read Owner’s Manual.
Complete Parts List is available at www.MillerWelds.com 3-2. Miscellaneous Symbols And Definitions Some symbols are found only on CE products. Fast (Run, Weld/ Stop Engine Slow (Idle) Start Engine Power) Starting Aid Battery (Engine) Engine Coolant Engine Oil (Preheat) Check Injectors/ Check Valve Protective Earth Fuel...
Complete Parts List is available at www.MillerWelds.com SECTION 4 − SPECIFICATIONS 4-1. Weld, Power, And Engine Specifications Maximum Generator Power Weld Output Rated Welding Fuel Engine Welding Mode Open-Circuit Rating Range Output Capacity Voltage Catepillar C1.5 Single-Phase, Water−Cooled 10 kVA/kW, Stick: 40 −...
Complete Parts List is available at www.MillerWelds.com 4-4. Volt-Ampere Curves For Models With CAT Or Kubota Engine 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.
Complete Parts List is available at www.MillerWelds.com 4-5. Volt-Ampere Curves For Models With Mitsubishi Engine 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.
Complete Parts List is available at www.MillerWelds.com 4-6. CAT Or Kubota Engine 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 4-7.
Complete Parts List is available at www.MillerWelds.com 4-8. Duty Cycle And Overheating 100% Duty Cycle Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. This unit is rated for welding at 250 amperes continuously. NOTICE −...
Complete Parts List is available at www.MillerWelds.com SECTION 5 − INSTALLATION 5-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the front. Use rating label to determine input power requirements and/or rated output.
Complete Parts List is available at www.MillerWelds.com 5-3. 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. NOTICE − Do not mount unit by supporting the base only at the four mounting brackets.
Complete Parts List is available at www.MillerWelds.com 5-4. Grounding Generator To Truck Or Trailer Frame GND/PE rot_grnd2 2012−03− 800 652-D frame. Always connect a ground Equipment Grounding Terminal (On Always ground generator frame to wire from the generator equipment Front Panel) vehicle frame to prevent electric grounding terminal to bare metal on shock and static electricity hazards.
Complete Parts List is available at www.MillerWelds.com 5-6. Connecting The Battery Connect negative (−) battery cable last. Close door after connecting battery. − Shown with rocker panel removed. Tools Needed: 1/2 in. Conn_Batt2 2010−04 / S-0756-C / 161-002 Notes OM-259 355 Page 24...
Complete Parts List is available at www.MillerWelds.com 5-7. Engine General Information level often and do not use the oil pres- Check all engine fluids daily. sure shutdown system to monitor oil Keep battery in good condition. Store Engine must be cold and on a level sur- level.
Complete Parts List is available at www.MillerWelds.com 5-9. CAT Engine Oil Prestart Information Check oil with unit on level surface. If oil is not up to full mark on dipstick, add oil (see maintenance label). Full 907 427-6 5-10. Kubota Engine Oil Prestart Information Check oil with unit on level surface.
Complete Parts List is available at www.MillerWelds.com 5-12. Weld Output Terminals Work/Negative (−) Weld Output Terminal CV (wire) Weld Output Terminal CC (Stick/TIG) Weld Output Terminal Stick and TIG Welding For Stick and TIG welding Direct Current Elec- trode Positive (DCEP), connect electrode holder cable to CC (Stick/TIG) terminal on right and work cable to Work/Negative (−) ter- minal on left.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. ( ) = mm for metric use ***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart). Ref. S-0007-J 2011−07 5-15. Connecting To Remote 14 Receptacle RC14...
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Complete Parts List is available at www.MillerWelds.com Notes OM-259 355 Page 29...
Complete Parts List is available at www.MillerWelds.com 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/Idle position.
Complete Parts List is available at www.MillerWelds.com 6-3. Process/Contactor Switch Process/Contactor Switch Weld output terminals are en- ergized when Process/Con- tactor switch is in a Weld Ter- minals Always On position and the engine is running. Use switch to select weld process and weld output on/off control (see table below).
Complete Parts List is available at www.MillerWelds.com 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.
Complete Parts List is available at www.MillerWelds.com 6-5. Remote Voltage/Amperage Control Remote 14 Receptacle RC14 Connect optional remote control to RC14 (see Section 5-15). When a remote control is con- nected to the Remote recep- tacle, the Auto Sense Remote feature automatically switches voltage/amperage control to the remote control.
Complete Parts List is available at www.MillerWelds.com 6-6. Operating Engine Block Heater Engine Block Heater Plug Use heater to maintain a constant engine coolant temperature. To turn on heater, connect heater CAT And Mitsubishi Engine plug to 120 volts AC receptacle. Coolant Heater Specifications Do not run engine while en-...
Complete Parts List is available at www.MillerWelds.com SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. Generator Power Receptacles 245 609 overload. If CB5 opens, the receptacles do Use GFCI protection when operat- Test GFCI monthly. See Section 7-2 not work. Place CB5 switch in On position ing auxiliary equipment.
Complete Parts List is available at www.MillerWelds.com 7-2. GFCI Receptacle Information, Resetting And Testing Test and reset GFCI only at Run speed. RotGFCI1 2012−05 If a ground fault is detected, the GFCI Reset Check for damaged or wet tools, cords, Use GFCI protection when operat- button pops out, and the circuit opens to plugs, etc.
Complete Parts List is available at www.MillerWelds.com 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.
Complete Parts List is available at www.MillerWelds.com 8-2. Maintenance Label Caterpillar Corporate Headquarters 100 North East Adams Street Peoria, Illinois USA 61629 (309) 675−1000 http://www.cat.com/engines Cat Dealer Locator: Use website to find local engine service facility. Service If your problem cannot be resolved at Please follow the above steps in sequence the dealer level without additional if a problem arises.
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Complete Parts List is available at www.MillerWelds.com 8-2. Maintenance Label (Continued) KUBOTA Service: Kubota Engine America 505 Schelter Road Lincolnshire, IL 60069 Phone: 847-955-2500 Fax: 847-955-2699 To find a service facility near you, contact the KEA distributor in your area: http://www.kubotaengine.com Mitsubishi Engine North America 1250 Greenbriar Dr., Suite E...
Complete Parts List is available at www.MillerWelds.com 8-3. Checking Generator Brushes Stop engine and let cool. Generator Brush Assembly Mark and disconnect leads at brush hold- er assembly. Remove assembly. Press on brush to be sure springs compress. Replace assembly if brushes are dam- aged or if brush material is at or near mini- mum length.
Complete Parts List is available at www.MillerWelds.com 8-5. 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.
Complete Parts List is available at www.MillerWelds.com 8-7. CAT Engine Speed Adjustment Stop engine and let cool. Engine Speed Engine Speed Adjustment (No Load) After tuning engine, check en- 1880 rpm max gine speed with tachometer or (62.6 Hz) frequency meter. See table for 1500 rpm proper no load speed.
Complete Parts List is available at www.MillerWelds.com 8-8. Kubota Engine Speed Adjustment Engine Speed RPM (Hz) (No Load) 1850 (61.6) Weld/Power Maximum Stop Tools Needed: Turn Process/Contactor switch to Stick − Stop engine and let cool. Do not set engine speed higher than Weld Terminals Always On position.
Complete Parts List is available at www.MillerWelds.com 8-10. 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.
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Complete Parts List is available at www.MillerWelds.com Notes OM-259 355 Page 47...
Complete Parts List is available at www.MillerWelds.com 8-11. Servicing Fuel And Lubrication Systems Stop engine and let cool. After servicing, start engine and check for fuel leaks. Stop en- gine, tighten connections as necessary, and wipe up spilled fuel. Oil Filter Oil Drain Valve And Hose Oil Fill Cap Primary Fuel Filter...
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Complete Parts List is available at www.MillerWelds.com To replace primary fuel filter: For CAT and Kubota Engines: Turn filter counterclockwise. Remove fil- ter. Kubota Engine For Mitsubishi Engines: Turn filter retaining ring counterclockwise to remove. Pull filter straight down to remove.
Complete Parts List is available at www.MillerWelds.com 8-12. Voltmeter/Ammeter Help Displays HL.P HL.P HL.P HL.P HL.P 245 609 Use the Voltmeter/Ammeter help displays izer Z1 has opened (Z1 overheated) or Help 23 Display to diagnose and correct fault conditions. thermistor TH1 on the main rectifier heat Can indicate a complete loss of generator sink has failed.
Complete Parts List is available at www.MillerWelds.com 8-14. 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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Complete Parts List is available at www.MillerWelds.com C. Engine Trouble Remedy Engine will not crank. Check battery, and replace if necessary. Check battery connections and tighten if necessary. Circuit breaker CB1 may be open. CB1 automatically resets when fault is corrected (see Section 8-10). Have Factory Authorized Service Agent check engine wiring harness and components.
Complete Parts List is available at www.MillerWelds.com SECTION 9 − PARTS LIST 9-1. Recommended Spare Parts Dia. Part Mkgs. Description Quantity ....085874 Fuse, Mintr Cer Slo−blo 10. Amp 250 Volt .
SECTION 11 − RUN-IN PROCEDURE run_in1 2007−04 11-1. 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.
11-2. 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.
11-3. 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 12 − 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. 12-1. 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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12-3. Grounding When Supplying Building Systems Equipment Grounding Terminal Grounding Cable Use #8 AWG or larger insulated copper wire. GND/PE 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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12-5. 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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12-7. 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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12-8. 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 To find starting amperage: Step 1: Find code and use table to find kVA/HP.
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12-10. Typical Connections To Supply Standby Power Have only qualified persons perform these connections according to all applicable codes and safety practices. Properly install, ground, and operate this equipment ac- cording to its Owner’s Manu- Fused Welding Utility al and national, state, and lo- Disconnect Electrical Generator...
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12-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected exten- sion cord. Do not use GFCI receptacles to power life support equipment. Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current Load (Watts)
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Effective January 1, 2012 (Equipment with a serial number preface of MC 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 90 Days —...
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