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OM-4433 218 314K
2006 −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 P
File: Engine Drive
Visit our website at
www.MillerWelds.com
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From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. 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. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. Today, the people that bu
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TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3. Engine Hazards . . . . . . . .
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TABLE OF CONTENTS 8-5. Servicing Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 8-6. Adjusting Engine Speed On Standard Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 8-7. Adjusting Engine Speed On Models With Automatic Idle (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 8-8. Servicing Fuel And Lubrication Systems . . . . . . .
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SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom _nd_3/05 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. This group of symbols means Warning! Watch Out! possible Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for nece
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WELDING can cause fire or explosion. HOT PARTS can cause severe burns. Do not touch hot parts bare handed. Welding on closed containers, such as tanks, drums, or Allow cooling period before working on equipment. pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot To handle hot parts, use proper tools and/or wear equipment can cause fires and burns. Accidental contact of electrode to metal heavy, insulated welding gloves and c
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BATTERY ACID can BURN SKIN and EYES. STEAM AND HOT COOLANT can burn. Do not tip battery. If possible, check coolant level when engine is cold to avoid scalding. Replace damaged battery. Always check coolant level at overflow tank, if pres- Flush eyes and skin immediately with water. ent on unit, instead of radiator (unless told otherwise in maintenance section or engine manual). If the engine is warm, checking is needed, and there is no overflow tank, ENGINE HEAT can cause fire. foll
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READ INSTRUCTIONS. ARC WELDING can cause interference. Use only genuine MILLER/Hobart replacement Electromagnetic energy can interfere with sensitive parts. electronic equipment such as microprocessors, computers, and computer-driven equipment such as Perform engine and air compressor (if applicable) robots. maintenance and service according to this manual and the engine/air compressor (if applicable) manu- Be sure all equipment in the welding area is electro- als. magnetically compatibl
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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION rom_fre 3/05 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 Ce groupe de symboles signi- présente des risques de danger ! Ceux-ci sont identifiés fie Mise en garde ! Soyez vigi- par des symboles adjacents aux directives. lant ! Il y a des risques de dan- ger reliés aux CHOCS ÉLEC- Identifie un messag
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LE SOUDAGE peut provoquer un in- DES PIÈCES CHAUDES peuvent cendie ou une explosion. provoquer des brûlures graves. Ne pas toucher à mains nues les parties chaudes. Le soudage effectué sur des conteneurs fermés tels que des Prévoir une période de refroidissement avant de travailler à réservoirs, tambours ou des conduites peut provoquer leur l’équipement. éclatement. Des étincelles peuvent être projetées de l’arc de Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et por-
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Si le moteur est chaud et que le liquide doit être vérifié, opérer comme suivant. LA CHALEUR DU MOTEUR peut pro- Mettre des lunettes de sécurité et des gants, placer un torchon sur le bouchon du radiateur. voquer un incendie. Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant d’enle- Ne pas placer l’appareil sur, au-dessus ou à proximité de ver le bouchon. surfaces inflammables. LES ACCUMULATIONS DE GAZ ris- Tenir à distance les produits inflammables de l’échappement.
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LIRE LES INSTRUCTIONS. LE SOUDAGE À L’ARC risque de Utiliser seulement les pièces de rechange d’origine. provoquer des interférences. Effectuer la maintenance du moteur et du compresseur L’énergie électromagnétique risque de provoquer des in- (si applicable) suivant ce manuel et le manuel du moteur/ terférences pour l’équipement électronique sensible tel compresseur (si applicable). que les ordinateurs et l’équipement commandé par ordi- nateur tel que les robots. Veiller à ce que tout l’
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SECTION 3 − DEFINITIONS 3-1. Warning Label Definitions 1 Remove unit from shipping S-177 571 crate. Remove Owner’s Manual from unit. Follow 1 instructions to install muffler. + 2 Read Owner’s Manual. Read labels on unit. 2 3 Use Diesel Fuel only, and fill fuel tank. Leave room for expansion. + 4 Warning! Watch Out! There are possible hazards as shown by the symbols. Read 3 Owner’s Manual. Follow DIESEL instructions to activate battery. 5 Check oil level. Add oil if 4 necessary. 6 During the firs
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3-2. Manufacturer’s Rating Label Ref. 218 304-A OM-4433 Page 10
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3-3. Symbols And Definitions Some symbols are found only on CE products. NOTE 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 Positive Negative Welding Arc Mechanic Amperes Volts Panel/Local Remote A V Air Temperature Or Alternating Engine Engine Output Current Temperature Stick (SMAW) Constant Current MIG (GMAW) TIG (GTA
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SECTION 4 − SPECIFICATIONS 4-1. Weld, Power, And Engine Specifications Maximum Welding Weld Output Rated Welding Open- Generator Power Fuel Engine Mode Range Output Circuit Rating Capacity Voltage 400 A, 23 Volts DC, 40% Duty Cycle 20 20 − 410 A 410 A 300 A, 32 V 300 A, 32 Volts olts DC DC CC/DC CC/DC (CC Models) 60% Duty Cycle Perkins 250 A, 30 Volts DC Single-Phase, 100% Duty cycle Perkins 403C-15 1 10 0 k kV VA/kW A/kW, , 84/42 A 84/42 A,, 1 11.5 gal 1.5 gal 6 65 5 W Wa ater-Cooled, t C l d 1
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4-3. Volt-Ampere Curves The volt-ampere curves show the A. Stick Mode minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all 100 other settings fall between the curves shown. 90 80 70 60 50 40 30 MIN 300 20 MAX 10 0 0 100 200 300 400 500 DC AMPERES B. MIG Mode 100 80 60 40 20 0 0 100 200 300 400 500 DC AMPERES C. TIG Mode 100 80 60 40 20 MIN 300 MAX 0 300 0 100 200 400 500 DC AMPERES 217 517 / 217 516 / 217 518 OM-4433 Page 13 DC VOLTS DC VOLTS DC VO
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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 ID LE 0.25 0.00 0 50 100 150 200 250 300 350 400 DC WELD AMPERES AT 100% DUTY CYCLE 217 509 4-5. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- 100% Duty Cycle At 250 Amperes utes that unit can weld at rated load without overheating. Exceeding duty cycle can damage unit and void warranty. Continuous Welding 1000 800 600 500 400 CC CV 300 250 200 150 100 10 15 20
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4-6. AC Generator Power Curve The ac power curve shows the gen- erator power in amperes available at the 120 and 240 volt receptacles. 150 300 125 250 100 200 75 150 50 100 25 50 0 0 0 2040 6080 AC AMPERES IN 240 V MODE 0 40 80 120 160 AC AMPERES IN 120 V MODE 217 519 Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge (.025 in) 22 Gauge (.031 in) 20 Gauge (.037 in) 18 Gauge (.050 in) 16 Gauge (.063 in) 14 Gauge (.078 in) 1/8 in (.125 in) 3/16 in (.188 in) 1/4 in (.25 in) 5/16 in (.313 in) 3/8 in
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SECTION 5 − INSTALLATION 5-1. Installing Welding Generator Always securely fasten weld- ing generator onto transport vehicle or trailer and comply with all DOT and other applica- Movement ble codes. Always ground generator frame to vehicle frame to pre- vent electric shock and static electricity hazards. If unit does not have GFCI re- ceptacles, use GFCI-protected OR extension cord. Do not install unit where air flow is restricted or engine may overheat. See Section 4-2 for lifting eye
