Miller Big Blue 251D Bedienungshandbuch

Visit our website atwww.MillerWelds.comProcessesOM-480 128 576AAOctober 2002Big Blue 251DStick (SMAW) WeldingFlux Cored (FCAW) WithVoltage-Sensing Wi

OM-480 Page 6Le soudage effectué sur des conteneurs fermés tels quedes réservoirs, tambours ou des conduites peut provoquerleur éclatement. Des étince

OM-480 Page 7DES ORGANES MOBILES peuventprovoquer des blessures. Ne pas approcher les mains des ventilateurs, cour-roies et autres pièces en mouvemen

OM-480 Page 8LE RAYONNEMENT HAUTE FRÉ-QUENCE (H.F.) risque de provoquerdes interférences. Le rayonnement haute fréquence (H.F.) peutprovoquer des int

OM-480 Page 9SECTION 2 – DEFINITIONS2-1. Symbols And DefinitionsStop EngineFast (Run, Weld/Power)Slow (Idle) Start EngineFast/Slow(Run/Idle)Battery (E

OM-480 Page 10SECTION 3 – SPECIFICATIONS3-1. Weld, Power, And Engine SpecificationsRated WeldingOutputAmperageRangeMaximumOpen-CircuitVoltage DC(Nomin

OM-480 Page 113-3. Fuel ConsumptionSB-137 487-AThe curve shows typical fuel useunder weld or power loads.3-4. Duty Cycle And Overheatingrduty1 5/95 –

OM-480 Page 123-5. AC Generator PowerThe ac power curve shows the gen-erator power in amperes availableat the 120 and 240 volt receptacles.rsb3.1 2/92

OM-480 Page 133-7. Optional AC Power Plant Curvesrsb13.1 12/94 - 134 636-A / 206 032The ac power curves show the gen-erator power in amperes available

OM-480 Page 14SECTION 4 – INSTALLATION4-1. Installing Welding Generatorinstall1 7/02 – Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854Elec

OM-480 Page 154-3. Installing Muffler Pipeexh_pipe2 12/96 – 154 089-A / 154 611 / Ref. 206 029 Stop engine and let cool. Do not blow exhaust towarda

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

OM-480 Page 16ether1 12/96 – 153 382-A / Ref. 206 029 Stop engine. Improper handling or expo-sure to ether can harm yourhealth. Follow manufactur-er

OM-480 Page 174-7. Selecting Weld Cable Sizes*Weld Cable Size** and Total Cable (Copper) Length in Weld CircuitNot Exceeding***100 ft (30 m) or Less15

OM-480 Page 18SECTION 5 – OPERATING THE WELDING GENERATOR5-1. Controls (See Section 5-2)Ref. 206 029 / 800 162-A / 800 159-D121213534671011891415

OM-480 Page 195-2. Description Of Front Panel Controls (See Section 5-1)This unit has a max OCV control circuitthat resets the Amperage/Voltage Con-t

OM-480 Page 20SECTION 6 – OPERATING AUXILIARY EQUIPMENT126-1. 120 Volt Duplex And Optional GFCI ReceptaclesRef. 206 02943 If unit does not have GFCI

OM-480 Page 216-2. 240 Volt Duplex Receptacle (Optional)Ref. 206 029 / 174 408 If unit does not have GFCI re-ceptacles, use GFCI-pro-tected extension

OM-480 Page 226-3. Connecting Optional AC Power Plant Ref. S-179 637-B Stop engine. Power and weld outputs arelive at the same time.Disconnect or in

OM-480 Page 236-4. 120/240 Volt Twistlock Receptacle (Optional)801 057-A1 120/240 V 50 A Twistlock Re-ceptacle RC9RC9 is connected to the optional acp

OM-480 Page 24SECTION 7 – MAINTENANCE AND TROUBLESHOOTING7-1. Routine MaintenanceRecycleenginefluids. Stop engine before maintaining. See also Engin

OM-480 Page 25Follow the storage procedure in the engine owner’s manual if the unit will not beused for an extended period.NOTE7-2. Maintenance Label

The following terms areused interchangeablythroughout this manual:Stick = SMAWCALIFORNIAProposition 65WarningDiesel engine exhaust andsome of its cons

OM-480 Page 267-3. Servicing Air Cleaneraircleaner4 9/02– 802 495 / Ref. S-0698-B Stop engine. Do not run engine without aircleaner or with dirty el

OM-480 Page 277-4. Servicing Fuel And Lubrication Systems Ref. 800 159-E / Ref. 206 029 Stop engine and let cool.1 Oil Filter2 Oil Drain Plug3 Oil F

OM-480 Page 287-5. Adjusting Engine SpeedRef. 801 179 / Ref. 800 159-D / Ref. 800 161After tuning engine, check engineno load speed with a tachometer(

OM-480 Page 297-6. Overload ProtectionRef. 156 199-B / 801 320-B Stop engine. When a fuse opens, it usuallyindicates a more serious prob-lem exists.

OM-480 Page 307-8. Inspecting And Cleaning Optional Spark Arrestor800 523 / Ref. 206 029 Stop engine and let cool.1 Spark Arrestor2 Cleanout PlugRemo

OM-480 Page 31B. Generator PowerTrouble RemedyNo output at generator powerreceptacles.Reset circuit breaker CB1 and/or CB2 (see Section 6-1 or 6-2).Di

OM-480 Page 32SECTION 8 – ELECTRICAL DIAGRAMSC-190 650-BFigure 8-1. Circuit Diagram For Welding Generator

OM-480 Page 33SECTION 9 – RUN-IN PROCEDURErun_in1 8/019-1. Wetstacking Do not perform run-inprocedure at less than 20volts weld output and do notexce

OM-480 Page 349-2. Run-In Procedure Using Load BankS-0683 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep exhaust a

OM-480 Page 359-3. Run-In Procedure Using Resistance GridS-0684 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep exh

OM-480 Page 36SECTION 10 – GENERATOR POWER GUIDELINES10-1. Selecting Equipmentgen_pwr 6/02 – Ref. ST-159 730 / ST-800 5771 Generator Power Receptacles

OM-480 Page 3710-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse #10 AWG or larger insulated

OM-480 Page 3810-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running WattsSplit Phase 1/8 HP 800 30

OM-480 Page 3910-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHand Drill 1/4 in 350 3503/8

OM-480 Page 4010-8. Power Required To Start MotorS-06241 Motor Start Code2 Running Amperage3 Motor HP4 Motor VoltageTo find starting amperage:Step 1:

OM-480 Page 4110-10. Typical Connections To Supply Standby Power Have only qualified persons performthese connections according to allapplicable code

OM-480 Page 4210-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, us

OM-480 Page 43Notes

OM-480 Page 44SECTION 11 – PARTS LISTFigure 11-1. Main Assembly Hardware is common andnot available unless listed.13245789101112131415161718737481828

OM-480 Page 45ST-129 956-T1920212223242526272829454647484950515253545556575859606162636465(Fig 11–3)66676869703031333435363738324041424344126

OM-480 Page 1SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USINGrom _nd_10/02 Warning: Protect yourself and others from injury — read and follow these

OM-480 Page 46DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-1. Main AssemblyQuantity1 134 771 PLUG, protective .640sq 2. . . . . . . . . . . . . . . .

OM-480 Page 47DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-1. Main AssemblyQuantity128 287 STUD, adjusting throttle 1. . . . . . . . . . . . . . . . .

OM-480 Page 48DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-1. Main AssemblyQuantity101 173 982 PANEL, mtg components 1. . . . . . . . . . . . . . . .

OM-480 Page 49DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-2. Panel, Front w/Components (Fig 11-1 Item 111) (Cont’d)Quantity13 021 385 BOOT, toggle swi

OM-480 Page 50ST-110 922-F Hardware is common andnot available unless listed.141516171812202319242526272812456431229211371089Figure 11-3. Generator22

OM-480 Page 51DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-3. Generator (Fig 11-1 Item 65)Quantity1 106 426 INSULATOR 4. . . . . . . . . . . . . . .

OM-480 Page 52Description QuantityPartNo.ItemNo.114 193 Figure 11-4. Switch, Range (Fig 11-2 Item 1)1 114 235 BRACKET, mtg switch (consisting of) 1. .

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 6/02Your distributor also givesyou ...ServiceYou always get the fa

OM-480 Page 2BUILDUP OF GAS can injure or kill. Shut off shielding gas supply when not in use. Always ventilate confined spaces or useapproved air-s

PRINTED IN USA  2002 Miller Electric Mfg. Co. 8/02Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US

OM-480 Page 3MOVING PARTS can cause injury. Keep away from fans, belts, and rotors. Keep all doors, panels, covers, and guardsclosed and securely in

OM-480 Page 4FLYING SPARKS can cause injury. Wear a face shield to protect eyes and face. Shape tungsten electrode only on grinder withproper guards

OM-480 Page 5SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANTUTILISATIONrom _nd_fre 4/021-1. Signification des symbolesSignifie Mise en garde ! Soyez v