Miller Big Blue 300 PRO Kubota Owner's Manual
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Miller Big Blue 300 PRO Kubota Owner's Manual

Engine driven welding generator
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Big Blue 300
PRO Kubota
OM-253 847C
2011−11
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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  • Page 1 OM-253 847C 2011−11 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 Kubota 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 SECTION 8 − MAINTENANCE & TROUBLESHOOTING ......... 8-1.

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

    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.
  • Page 6 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).

  • Page 7: Engine Hazards

    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 —...

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

    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.
  • Page 9 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.

  • Page 10: California Proposition 65 Warnings

    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 &...

  • Page 11: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    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.
  • Page 12 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...

  • Page 13: Dangers Existant En Relation Avec Le Moteur

    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.

  • Page 14: Dangers Liés À L'air Comprimé

    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.

  • Page 15: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    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.
  • Page 16 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.

  • Page 17: 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 18: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Warning Label Definitions Remove unit from shipping 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 19: 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 20: Section 4 − Specifications

    SECTION 4 − SPECIFICATIONS 4-1. Weld, Power, And Engine Specifications Maximum Weld Welding Rated Welding Open- Generator Fuel Output Engine Mode Output Circuit Power Rating Capacity Rating Range Voltage 400 A, 20 Volts DC, 40% Duty Cycle 20 − 410 A 300 A, 32 Volts DC CC/DC 60% Duty Cycle...

  • Page 21: 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 22: 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 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.

  • Page 23: Ac Generator Power Curve

    4-6. AC Generator Power Curve The AC power curve shows the generator power in amperes avail- able at the 120 and 240 volt receptacles. AC AMPERES IN 240 V MODE AC AMPERES IN 120 V MODE 237 494 Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge (.025 in) 22 Gauge (.031 in) 20 Gauge (.037 in)

  • Page 24: Section 5 − Installation

    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. For future reference, write serial number in space provided on back cover of this manual. 5-2.

  • Page 25: Mounting Welding Generator

    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. Supporting The Unit NOTICE − Do not mount unit by supporting the base only at the four mounting brackets.

  • Page 26: Grounding Generator To Truck Or Trailer Frame

    5-4. Grounding Generator To Truck Or Trailer Frame GND/PE rot_grnd2 2011−04 − 800 652-D welding generator from the vehicle Equipment Grounding Terminal (On Always ground generator frame to frame. Always connect a ground Front Panel) vehicle frame to prevent electric wire from the generator equipment shock and static electricity hazards.

  • Page 27: 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 28: Engine Prestart Checks

    5-8. Engine Prestart Checks NOTICE − Follow run-in procedure in engine manual. If unburned fuel and oil collect in exhaust pipe, see Section 10. Check radiator coolant level when fluid is low in recovery tank. Full Full Diesel Engine stops if Capacity: fuel level is low.

  • Page 29: Weld Output Terminals

    5-9. 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.

  • Page 30: Selecting Weld Cable Sizes

    **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 Notes...

  • Page 31: Connecting To Remote 14 Receptacle Rc14

    5-12. Connecting To Remote 14 Receptacle RC14 Socket* Socket Information Not all models have contactor control. See description of front panel controls and circuit diagram. 24 volts AC. Protected by supplementary protector. 24 VOLTS AC Contact closure to A completes 24 volt AC contactor control circuit.

  • Page 32: Section 6 − Operating Welding Generator

    SECTION 6 − OPERATING WELDING GENERATOR 6-1. Front Panel Controls (See Section 6-2) 250 225-A / 803 563 OM-253 847 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- by turning Process/Contactor switch to gine is not running, turn Engine Control switch another position. Preheat Switch to Run/Idle position. Process/Contactor Switch Use switch to energize starting aid for cold To check oil change interval when engine is...

  • Page 34: Process/Contactor Switch

    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).

  • 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 5-12). 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.

  • Page 37: Fuel/Hour Gauge Descriptions

    6-6. Fuel/Hour Gauge Descriptions OM-253 847 Page 33...

  • Page 38: Section 7 − Operating Auxiliary Equipment

    SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. Generator Power Receptacles 245 609 120 V 20 A AC Receptacle RC5 weld/power speed and press test but- not work. Place CB5 switch in On position ton to verify GFCI is working properly. 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 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/distributor/ engine_usa.html OM-253 847 Page 36...

  • Page 41: Servicing Air Cleaner

    8-3. Servicing Air Cleaner Blow Keep nozzle 2 in. (51 mm) from element. Inspect Optional aircleaner1 2/01− ST-153 929-B / ST-153 585 / Ref. S-0698-B / Ref. 226 386-B ment, we strongly recommend instal- To clean air filter: Stop engine. ling an optional safety element to pro- Wipe off cap and housing.

  • Page 42: Inspecting And Cleaning Optional Spark Arrestor Muffler

    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.

  • Page 43: Engine Speed Adjustment

    8-7. Engine Speed Adjustment 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.

  • Page 44: Servicing Fuel And Lubrication Systems

    8-8. 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 Fuel Filter Secondary Fuel Filter Fuel Tank Sludge Drain Valve...

  • Page 45: Operating Optional Engine Block Heater

    8-9. Operating Optional Engine Block Heater Coolant Heater Cord Use heater to maintain a constant engine oil temperature. See table for heater specifications To turn heater on, connect heater cord plug to 120 volt AC grounded Coolant Heater Specifications and protected receptacle. Do not run engine while oil ±...

  • Page 46: Overload Protection

    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. If F1 opens, weld and generator power is low or stops entirely.

  • Page 47: Voltmeter/Ammeter Help Displays

    8-11. 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.

  • Page 48: Troubleshooting

    8-13. Troubleshooting Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 8-11). 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 49 B. Generator Power Trouble Remedy No generator power output at AC recept- Reset receptacle supplementary protector(s) (see Section 7-1). Check and reset GFCI receptacle if ne- acles; weld output okay. cessary (see Section 7-1). No generator power or weld output. Disconnect equipment from generator power receptacles during start-up.
  • Page 50 Trouble Remedy Engine slowly stopped and cannot be Check fuel level. restarted. Check fuel/hour gauge for indication of shutdown. Check engine air and fuel filters (see Sections 8-3 and 8-8). 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 51 Notes OM-253 847 Page 47...

  • Page 52: Section 9 − Electrical Diagrams

    SECTION 9 − ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For Welding Generator OM-253 847 Page 48...
  • Page 53 253 845-A OM-253 847 Page 49...

  • Page 54: 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 55: 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 56: 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 57: 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 58 11-3. 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.
  • Page 59 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 60 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 61 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 To find starting amperage: Step 1: Find code and use table to find kVA/HP.
  • Page 62 11-10. 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...
  • Page 63 11-11. 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. Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current (Amperes) Load (Watts)

  • Page 64: 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. Figure 12-1. Main Assembly OM-253 847 Page 60...
  • Page 65 803 748-L1 / 803 748-J2 OM-253 847 Page 61...
  • Page 66 Item Dia. Part Mkgs. Description Quantity Figure 12-1. Main Assembly ... 168829 Transducer, Current 1000a Module Max Open Loop ....
  • Page 67 Item Dia. Part Mkgs. Description Quantity Figure 12-1. Main Assembly (Continued) ....190190 Tank, Coolant Recovery ......... .
  • Page 68 Item Dia. Part Mkgs. Description Quantity Figure 12-1. Main Assembly (Continued) ....172071 Clamp, Hose .520 − .605 Clp Dia Slfttng Black .
  • Page 69 Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. 803 684-D 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 70 Item Dia. Part Mkgs. Description Quantity Figure 12-2. Panel, Front w/Components (Continued) ....214543 Enclosure, Circuit Card Assy ........
  • Page 71 Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. Ref: 803 689-E Figure 12-3. Control Panel Item Dia. Part Mkgs. Description Quantity Figure 12-3. Control Panel (Figure 12-1 Item 106) ..
  • Page 72 Hardware is common and not available unless listed. Wiring harnesses are listed at the end of parts section. 803 686-C Figure 12-4. Generator Item Dia. Part Mkgs. Description Quantity Figure 12-4. Generator (Figure 12-1 Item 77) ..ROTOR .
  • Page 73 Hardware is common and not available unless listed. Wiring 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 74 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 ....253864 Harness, Engine Kubota (Includes) .
  • Page 75 Effective January 1, 2011 (Equipment with a serial number preface of MB 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 —...

  • 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. © ORIGINAL INSTRUCTIONS − PRINTED IN USA 2011 Miller Electric Mfg. Co. 2011−01...

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