Miller PRO 300 CAT Bedienungshandbuch

Big Blue 300 PRO CATBig Blue 300 PRO PerkinsOM-246 697A2009−12ProcessesDescriptionAir Carbon Arc (CAC-A)Cutting and GougingStick (SMAW) WeldingEngine

OM-246 697 Page 6WELDING WIRE can injure. Do not press gun trigger until instructed to doso. Do not point gun toward any part of the body,other peop

OM-246 697 Page 71-8. Principal Safety StandardsSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,from Global Engineering Document

OM-246 697 Page 8SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANTUTILISATIONfre_rom_2009−10Pour écarter les risques de blessure pour vous−même et pour

OM-246 697 Page 9LES PIÈCES CHAUDES peuventprovoquer des brûlures. Ne pas toucher à mains nues les parties chau-des. Prévoir une période de refroidi

OM-246 697 Page 10Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)peuvent affecter les implants médicaux. Les porteurs de stimulateurs cardiaques etautres implant

OM-246 697 Page 11LES ÉTINCELLES À L’ÉCHAPPEMENTpeuvent provoquer un incendie. Empêcher les étincelles d’échappement dumoteur de provoquer un incendi

OM-246 697 Page 12un médecin familiarisé avec ce type de blessure, faute de quoila gangrène pourrait apparaître.Les PIÈCES MOBILES peuvent causerdes b

OM-246 697 Page 13Une PRESSION D’AIR RÉSIDUELLEET DES FLEXIBLES QUI FOUETTENTrisquent de provoquer des blessures. Détendre la pression pneumatique de

OM-246 697 Page 14LES CHARGES ÉLECTROSTATI-QUES peuvent endommager lescircuits imprimés. Établir la connexion avec la barrette de terreavant de manip

OM-246 697 Page 15intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—phone

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

OM-246 697 Page 16SECTION 3 − DEFINITIONS3-1. Warning Label Definitions3/961 Remove unit from shippingcrate. Remove Owner’sManual from unit. Followins

OM-246 697 Page 173-2. Symbols And Definitions Some symbols are found only on CE products.Stop EngineFast (Run, Weld/Power)Slow (Idle) Start EngineSt

OM-246 697 Page 18SECTION 4 − SPECIFICATIONS4-1. Weld, Power, And Engine SpecificationsWeldingModeWeld OutputRangeRated WeldingOutputMaximumOpen-Circu

OM-246 697 Page 194-3. Volt-Ampere Curves237 466 / 237 468 / 237 470The volt-ampere curves show theminimum and maximum voltageand amperage output capa

OM-246 697 Page 204-4. Fuel ConsumptionThe curve shows typical fuel useunder weld or power loads.237 471DC WELD AMPERES AT 100% DUTY CYCLEU.S. GAL/HR.

OM-246 697 Page 214-6. AC Generator Power Curve237 4940 40 80 120 1600 20406080AC AMPERES IN 120 V MODEAC AMPERES IN 240 V MODE30025020015010050015012

OM-246 697 Page 22SECTION 5 − INSTALLATION5-1. Serial Number And Rating Label LocationThe serial number and rating information for this product is loc

OM-246 697 Page 235-3. Mounting Welding GeneratorTools Needed:9/16 in.224Welding Unit In PlaceBolting Unit In Place! Do not weld on base. Weld-ing on

OM-246 697 Page 24! Always ground generator frame tovehicle frame to prevent electricshock and static electricity hazards.! Also see AWS Safety &

OM-246 697 Page 255-6. Activating The Dry Charge Battery (If Applicable)! Always wear a face shield,rubber gloves and protectiveclothing when working

TABLE OF CONTENTSSECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol U

OM-246 697 Page 265-8. Engine Prestart Checks Check all engine fluids daily.Engine must be cold and on a level surface.Unit is shipped with 20W break

OM-246 697 Page 275-9. Weld Output Terminals245 6091 Work/Negative (−) Weld Output Terminal2 CV (wire) Weld Output Terminal3 CC (Stick/TIG) Weld Outpu

OM-246 697 Page 285-11. Selecting Weld Cable Sizes*NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both we

OM-246 697 Page 295-12. Connecting To Remote 14 Receptacle RC14Rmt14_BF 2009−07OR Accessories dependon unit capabilities.*The remaining socketsare no

OM-246 697 Page 30SECTION 6 − OPERATING WELDING GENERATOR6-1. Front Panel Controls (See Section 6-2)245 609 / 803 563125467893

OM-246 697 Page 316-2. Description Of Front Panel Controls (See Section 6-1)Engine Starting Controls1 Preheat SwitchUse switch to energize starting ai

OM-246 697 Page 326-3. Process/Contactor Switch1 Process/Contactor Switch! Weld output terminals are ener-gized when Process/Contactorswitch is in a W

OM-246 697 Page 336-4. Lift-Arct TIG With Crater-Out And Auto-StoptWM MarketingArc Start With Lift-ArcArc End With Crater-OutArc End With Auto-Stop121

OM-246 697 Page 346-5. Remote Voltage/Amperage Control1 Remote 14 Receptacle RC14Connect optional remote control to RC14 (seeSection 5-12). When a re

OM-246 697 Page 356-6. Fuel/Hour Gauge Descriptions

TABLE OF CONTENTSSECTION 7 − OPERATING AUXILIARY EQUIPMENT 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-246 697 Page 36SECTION 7 − OPERATING AUXILIARY EQUIPMENT7-1. Generator Power Receptacles245 6091 120 V 20 A AC Receptacle RC52 120 V 20 A AC GFCI R

OM-246 697 Page 37SECTION 8 − MAINTENANCE & TROUBLESHOOTING8-1. Routine Maintenance! Stop engine before maintaining. See Engine Manual and Maint

OM-246 697 Page 388-2. Maintenance Label

OM-246 697 Page 398-3. Servicing Air Cleaner! Stop engine.NOTICE − Do not run engine without aircleaner or with dirty element. Engine dam-age caused b

OM-246 697 Page 408-5. Inspecting And Cleaning Optional Spark Arrestor Muffler803 582 / Ref. 245 609! Stop engine and let cool.1 Spark Arrestor Muffle

OM-246 697 Page 418-7. Adjusting Engine Speed On Models With Automatic Idle803 5631880 rpm max(62.6 Hz)1500 rpm(50 Hz)Engine Speed(No Load)Engine Spee

OM-246 697 Page 428-8. Servicing Fuel And Lubrication Systems803 563 / 802 490 / Ref. 801 434! Stop engine and let cool.! After servicing, start engin

OM-246 697 Page 438-9. Overload Protection803 562 / 803 56615! Stop engine. When a circuit breaker, supple-mentary protector, or fuseopens, it usuall

OM-246 697 Page 448-10. Voltmeter/Ammeter Help DisplaysUse the Voltmeter/Ammeter help displaysto diagnose and correct fault conditions. When a help

OM-246 697 Page 458-11. Troubleshooting Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 8-10).A. Wel

OM-246 697 Page 1SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USINGrom_2009−10Protect yourself and others from injury — read, follow, and save these i

OM-246 697 Page 46B. Generator PowerTrouble RemedyNo generator power output at ac recep-tacles; weld output okay.Reset receptacle supplementary protec

OM-246 697 Page 47Trouble RemedyEngine slowly stopped and cannot berestarted.Check fuel level.Check fuel/hour gauge for indication of shutdown.Check e

OM-246 697 Page 48SECTION 9 − ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For Welding Generator

OM-246 697 Page 49240 670-A

OM-246 697 Page 50SECTION 10 − RUN-IN PROCEDURErun_in1 2007−0410-1. Wetstacking1 Welding GeneratorRun diesel engines near rated volt-age and current d

OM-246 697 Page 5110-2. Run-In Procedure Using Load BankS-0683! Stop engine.! Do not touch hot exhaustpipe, engine parts, or loadbank/grid.! Keep exha

OM-246 697 Page 5210-3. Run-In Procedure Using Resistance GridS-0684! Stop engine.! Do not touch hot exhaustpipe, engine parts, or loadbank/grid.! Kee

OM-246 697 Page 53SECTION 11 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding ge

OM-246 697 Page 5411-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse #10 AWG or larger insul

OM-246 697 Page 5511-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running WattsSplit Phase 1/8 HP 80

OM-246 697 Page 2Welding produces fumes and gases. Breathing thesefumes and gases can be hazardous to your health.FUMES AND GASES can be hazardous. K

OM-246 697 Page 5611-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHand Drill 1/4 in 350 350

OM-246 697 Page 5711-8. Power Required To Start MotorSingle-Phase Induction Motor Starting RequirementsMotor StartCodeG H J K L M N PKVA/HP 6.3 7.1 8

OM-246 697 Page 5811-10. Typical Connections To Supply Standby PowerTransfer SwitchEssentialLoadsFusedDisconnectSwitch(If Required) UtilityElectricalS

OM-246 697 Page 5911-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt LoadsIf unit does not have GFCI receptacles, u

OM-246 697 Page 60SECTION 12 − PARTS LIST Hardware is common and notavailable unless listed.Wirng harnesses are listed atthe end of parts section.110

OM-246 697 Page 61803 683-J1 / 803 683-H22829303132333435363738394041424647484950515253545556575859606162636465666867697073717274757677787980(Fig.12−4

OM-246 697 Page 62DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-1. Main AssemblyQuantity1 HD1 168829 Transducer, Current 1000a Module Max Open Loop 1.

OM-246 697 Page 63DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-1. Main Assembly (Continued)Quantity46 190190 Tank, Coolant Recovery 1. . . . . . . .

OM-246 697 Page 64DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-1. Main Assembly (Continued)Quantity83 212623 Tank, Fuel (Includes Fuel Cap And Items Be

OM-246 697 Page 65 Hardware is common and notavailable unless listed.Wirng harnesses are listed atthe end of parts section.803 684-D12345637367891011

OM-246 697 Page 31-3. Engine HazardsBATTERY EXPLOSION can injure. Always wear a face shield, rubber gloves, andprotective clothing when working on a

OM-246 697 Page 66DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-2. Panel, Front w/Components (Continued)Quantity10 214543 Enclosure, Circuit Card Assy

OM-246 697 Page 67 Hardware is common and notavailable unless listed.Wirng harnesses are listed atthe end of parts section.803 689-E12345678910121113

OM-246 697 Page 68803 686-B Hardware is common and notavailable unless listed.Wirng harnesses are listed atthe end of parts section.23145678910111213

OM-246 697 Page 69803 685-A Hardware is common and notavailable unless listed.Wirng harnesses are listed atthe end of parts section.12364598107Figure

OM-246 697 Page 70 Some wiring harness components (switches, relays, supplementary protectors) are also referenced elsewhere in this parts list. Purc

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 2009−10Your distributor also givesyou ...ServiceYou always get the

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2009 Miller Electric Mfg. Co. 2009−01Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer

OM-246 697 Page 41-4. Hydraulic HazardsHYDRAULIC EQUIPMENT can injureor kill. Incorrect installation or operation of this unitcould result in equipm

OM-246 697 Page 5HOT METAL from air arc cutting andgouging can cause fire or explosion. Do not cut or gouge near flammables. Watch for fire; keep ex