Miller Electric Big Blue 251D manual

Visit our website at www.Miller Welds .com Pro cesses OM -480 128 576AC January 2005 Big Blue 251D  Stick (SMAW) W elding Flux Cored (FCAW) With V oltage-Sensing Wire Feeder With Optional Equipment: Air Carbon Arc (CAC-A) Cutting And Gouging Engine Driven Welding Generator Descrip ti on[...]

Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .MillerW eld[...]

T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . [...]

T ABLE OF CONTENTS SECTION 8 − MAINTENANCE AND TROUBLESHOOTING 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. Routine Maintenance 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2. Maintenance Label 25 . . . . . . . . [...]

OM-480 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom _nd_8/03  W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.  Marks a special safe[...]

OM-480 Page 2 W elding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area[...]

OM-480 Page 3 STEAM AND HOT COOLANT can burn.  If possible, check coolant level when engine is cold to avoid scalding.  Always check coolant level at overflow tank, if pres- 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 [...]

OM-480 Page 4 READ INSTRUCTIONS.  Use only genuine MILLER/Hobart replacement parts.  Perform engine and air compressor (if applicable) maintenance and service according to this manual and the engine/air compressor (if applicable) manu- als. H. F . RADIA TION can cause interference.  High-frequency (H.F .) can interfere with radio naviga- t[...]

OM-480 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION rom_fre 8/03  A vertissement: 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 présente des risques de danger ! Ceux-ci sont identifiés par [...]

OM-480 Page 6 LES ACCUMULA TIONS DE GAZ ris- quent de provoquer des blessures ou même la mort.  Fermer l’alimentation du gaz protecteur en cas de non utilisation.  V eiller toujours à bien aérer les espaces confinés ou se servir d’un respi- rateur d’adduction d’air homologué. Le rayonnement de l’arc du procédé de soudage gén[...]

OM-480 Page 7 L ’EXPLOSION D E LA B A TTERIE peut RENDRE A VEUGLE.  T oujours porter une protection faciale, des gants en caoutchouc et vêtements de protection lors d’une in- tervention sur la batterie.  Arrêter le moteur avant de débrancher ou de brancher les câbles de batterie.  Eviter de provoquer des étincelles avec les outils[...]

OM-480 Page 8 LE SURCHAUFFEMENT peut endom- mager le moteur électrique.  Arrêter ou déconnecter l’équipement avant de dé- marrer ou d’arrêter le moteur .  Ne pas laisser tourner le moteur trop lentement sous risque d’endommager le moteur électrique à cause d’une tension et d’une fréquence trop faibles.  Ne pas brancher d[...]

OM-480 Page 9 SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions Stop Engine Fast (Run, W eld/ Power) Slow (Idle) Start Engine Fast/Slow (Run/Idle) Battery (Engine) Circuit Breaker Engine Oil Check Injectors/ Pump Check V alve Clearance Fuel Protective Earth (Ground) Positive Negative Certified/T rained Mechanic W elding Arc A Amperes V V olts [...]

OM-480 Page 10 SECTION 4 − SPECIFICA TIONS 4-1. W eld, Power , And Engine Specifications Rated W elding Output Amperage Range Maximum Open-Circuit V oltage DC (Nominal) Generator Power Rating Engine Fuel Capacity 250 A, 40 V olts DC, 100% Duty Cycle 40 − 400 95 (90) Single-Phase, 3 kV A/kW , 26 A, 120 V AC, 60 Hz Deutz F3L-101 1 Air/Oil-Cooled,[...]

OM-480 Page 1 1 4-3. Fuel Consumption SB-137 487-A The curve shows typical fuel use under weld or power loads. 4-4. Duty Cycle And Overheating rduty1 5/95 − SB-070 999-B Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating.  Exceeding duty cycle can damage unit and void warranty . Continuous W elding 10[...]

OM-480 Page 12 4-5. AC Generator Power Th e ac power curve shows the gen- erator power in amperes available at the 120 and 240 volt receptacles. rsb3.1 2/92 − 206 031 0 50 100 150 200 250 300 0 5 10 15 20 25 30 AC AMPERES IN 240V MODE AC VOL TS 0 25 50 75 100 150 125 0 10 20 30 40 50 60 AC AMPERES IN 120V MODE 4-6. V olt-Ampere Curves 206 033 The[...]

OM-480 Page 13 4-7. Optional AC Power Plant Curves rsb13.1 12/94 - 134 636-A / 206 032 Th e ac power curves show the gen- erator power in amperes available at the single-phase 120/240 volt or three-phase 240 volt terminals. A. 7.5 KV A/KW Single-Phase AC Power Plant (No Weld Load) B. 10 KV A/KW Three-Phase AC Power Plant (No Weld Load) 180 200 220 [...]

OM-480 Page 14 SECTION 5 − INST ALLA TION 5-1. Installing Welding Generator install1 1 1/02 − Ref. ST -800 652 / Ref. ST -800 477-A / ST-158 936-A / S-0854 Electrically bond generator frame to vehicle frame by metal-to-metal contact. GND/PE 1 2  Always securely fasten welding generator onto transport vehicle or trailer and comply with all DO[...]

OM-480 Page 15 5-3. Installing Muffler Pipe exh_pipe2 12/96 − 154 089-A / 154 61 1 / Ref. 206 029  Stop engine and let cool.  Do not blow exhaust toward air cleaner or air intake. T op V iew 1/2 in T ools Needed: 5-4. Engine Prestart Checks Ref. 800 159-D Full 1/2 in (13 mm) Full Diesel V alve Open Check all fluids daily . Engine must be co[...]

OM-480 Page 16 ether1 12/96 − 153 382-A / Ref. 206 029  Stop engine.  Improper handling or expo- sure to ether can harm your health. Follow manufactur- er’s safety instructions on cylinder .  Do not use Ether Starting Aid while engine is running. Open side door(s). 1 Ether Cylinder 2 Nozzle Remove cover and clean cylinder nozzle. 3 Cla[...]

OM-480 Page 17 5-7. Selecting W eld Cable Sizes* W eld Cable Size** and T otal Cable (Copper) Length in Weld Circuit Not Exceeding*** 100 ft (30 m) or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft (105 m) 400 ft (120 m) W eld Output T erminals  T urn off power before connecting t o weld out- put terminals.  Do not use wo[...]

OM-480 Page 18 SECTION 6 − OPERA TING THE WELDING GENERA TOR 6-1. Controls (See Section 6-2 ) Ref. 206 029 / 800 162-A / 800 159-D 1 2 12 13 5 3 4 6 7 10 11 8 9 14 15[...]

OM-480 Page 19 6-2. Description Of Front Panel Controls (See Section 6-1 )  This unit has a max OCV control circuit that resets the Amperage/Voltage Con- trol to maximum when the arc breaks. When a n arc is struck, weld output control returns to the front panel or remote con- trol setting. The Amperage/voltage Con- trol adjusts amperage only whe[...]

OM-480 Page 20 SECTION 7 − OPERA TING AUXILIAR Y EQUIPMENT 12 7-1. 120 V olt Duplex And Optional GFCI Receptacles Ref. 206 029 4 3  If unit does not have GFCI re- ceptacles, use GFCI-pro- tected extension cord. 1 120 V 15 A AC Receptacle RC1 2 120 V 15 A AC Receptacle RC2 3 120 V 20 A AC GFCI Receptacles GFCI1 And GFCI2 (Optional) Receptacles [...]

OM-480 Page 21 7-2. 240 V olt Duplex Receptacle (Optional) Ref. 206 029 / 174 408  If unit does not have GFCI re- ceptacles, use GFCI-pro- tected extension cord. 1 240 V 15 A AC Receptacle RC1 Receptacle supplies 60 Hz single- phase power at weld/power speed. Maximum output is 3 kV A/kW . 2 Circuit Breakers CB1 And CB2 CB1 and CB2 protect the re[...]

OM-480 Page 22 7-3. Connecting Optional AC Power Plant Ref. S-179 637-B  Stop engine.  Power and weld outputs are live at the same time. Disconnect or insulate unused cables.  Have qualified person install according to circuit diagram and Generator Power Guide- lines (Section 1 1). Remove junction box cover . 1 Lead 93 2 Lead 92 3 Lead 91 [...]

OM-480 Page 23 7-4. 120/240 V olt T wistlock Receptacle (Optional) 801 057-A 1 120/240 V 50 A T wistlock Re- ceptacle RC9 RC 9 is connected to the optional ac power plant and supplies 60 Hz single-phase power at weld/power speed. Maximum output from re- ceptacle is 7.5 kV A/kW . Power available at RC9 is reduced when welding. Fuses F1 and F2 protec[...]

OM-480 Page 24 SECTION 8 − MAINTENANCE AND TROUBLESHOOTING 8-1. Routine Maintenance Recycle engine fluids.  Stop engine before maintaining.  Se e Engine Manual and Maintenance Label for impor- tant start-up, service, and storage information. Service engine more often if used in severe conditions. * T o be done by Factory Authorized Service [...]

OM-480 Page 25 Follow the storage procedure in the engine owner ’s manual if the unit will not be used for an extended period. NOTE 8-2. Maintenance Label[...]

OM-480 Page 26 8-3. Servicing Air Cleaner aircleaner4 9/02 − 802 495 / Ref. S-0698-B  Stop engine.  Do not run engine without air cleaner or with dirty element. En- gine damage caused by using a damaged element is not covered by the warranty .  Th e air cleaner primary element can be cleaned but the dirt holding ca- pacity of the filter [...]

OM-480 Page 27 8-4. Servicing Fuel And Lubrication Systems Ref. 800 159-E / Ref. 206 029  Stop engine and let cool. 1 Oil Filter 2 Oil Drain Plug 3 Oil Fill Cap 4 Primary Fuel Filter (Fuel/ W ater Separator) 5 Petcock 6 Secondary Fuel Filter 7 Fuel Shutof f V alve 8 Fuel Line 9 Sludge Drain Plug T o change oil and filter: See engine manual. T o [...]

OM-480 Page 28 8-5. Adjusting Engine Speed Ref. 801 179 / Ref. 800 159-D / Ref. 800 161 After tuning engine, check engine no load speed with a tachometer (see table for no load speeds). If necessary , adjust speed as follows: Start engine and run until warm. T urn Amperage/V oltage Control to 100. Standard Models: 1 Engine Speed Adjustment Screw 2 [...]

OM-480 Page 29 8-6. Overload Protection Ref. 156 199-B / 801 320-B  Stop engine.  When a fuse opens, it usually indicates a more serious prob- lem exists. Contact a Factory Authorized Service Agent. 1 Magnetic Shutdown Switch MS1 (Optional) 2 Fuse F (See Parts List) Fuse F protects magnetic shut- down switch MS1. If fuse F opens, the engine s[...]

OM-480 Page 30 8-8. Inspecting And Cleaning Optional Spark Arrestor 800 523 / Ref. 206 029  Stop engine and let cool. 1 Spark Arrestor 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole. 3 Exhaust Pipe Start engine and run at idle speed to blow out cleanout hole. If nothing blows out of hole, briefly cover end of exhaust pipe[...]

OM-480 Page 31 B. Generator Power T rouble Remedy No output at generator power receptacles. Reset circuit breaker CB1 and/or CB2 (see Section 7-1 or 7-2 ). Disconnect equipment from generator power receptacles during start-up. Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit. Low or high output at gen[...]

OM-480 Page 32 SECTION 9 − ELECTRICAL DIAGRAM SC-190 650-B Figure 9-1. Circuit Diagram For Welding Generator[...]

OM-480 Page 33 SECTION 10 − RUN-IN PROCEDURE run_in1 8/01 10-1. W etstacking  Do not perform run-in procedure at less than 20 volts weld output and do n ot exceed duty cycle or equip- ment damage may occur . 1 W elding Generator Ru n diesel engines near rated volt- ag e and current during run-in period to properly seat piston rings and prevent[...]

OM-480 Page 34 10-2. Run-In Procedure Using Load Bank S-0683  Stop engine.  Do not touch hot exhaust pipe, engine parts, or load bank/grid.  Keep exhaust and pipe away from flammables.  Do not perform run-in procedure at less than 20 volts weld output and do n ot exceed duty cycle or equip- ment damage may occur . 1 Load Bank T urn all [...]

OM-480 Page 35 10-3. Run-In Procedure Using Resistance Grid S-0684  Stop engine.  Do not touch hot exhaust pipe, engine parts, or load bank/grid.  Keep exhaust and pipe away from flammables.  Do not perform run-in procedure at less than 20 volts weld output and do n ot exceed duty cycle or equip- ment damage may occur . 1 Resistance Gri[...]

OM-480 Page 36 SECTION 1 1 − GENERA TOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding generators. Y our unit may differ from those shown. NOTE 1 1-1. Selecting Equipment gen_pwr 1 1/02 − Ref. ST -159 730 / ST -800 577 1 Generator Power Receptacles − Neutral Bonded T o Frame 2 3-Prong[...]

OM-480 Page 37 1 1-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 AWG or larger insulated copper wire. 3 Ground Device  Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. GND/PE 1 2 Us e ground device as stated in electric[...]

OM-480 Page 38 1 1-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Star ting W atts Running W atts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 2100 700 1/2 HP 3175 875 Capacitor Start-Induction Run 1/3 HP 2020 720 1/2 HP 3075 975 3/4 HP 4500 1400 1 HP 6100 1600 1-1/2 HP 8200 2200 2 HP 10550 285[...]

OM-480 Page 39 1 1-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting W atts Running W atts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/2 in 500 500 7-1/4 in 900 900 8-1/4 in 1400 1400 T able Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in 2500 1 100 Bench Grinder 6 in 1720 720 8 in [...]

OM-480 Page 40 1 1-8. Power Required T o Start Motor S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor V oltage T o find starting amperage: Step 1: Find code and use table to find kV A/HP . If code is not listed, multiply running amperage by six to find starting amperage. Step 2 : Find Motor HP and V olts. Step 3: Determine starting a[...]

OM-480 Page 41 1 1-10. T ypical Connections T o Supply Standby Power  Have only qualified persons perform these connections according to all applicable codes and safety practic- es.  Properly install and ground this equipment according to its Owner ’s Manual and national, state, and local codes.  Customer -supplied equipment is re- quire[...]

OM-480 Page 42 1 1-1 1. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 V olt Loads  If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (A WG)* Current (Amperes) Load (W atts) 4 6 8 10 12 14 5 600 350 (106) 225 (68) 137 (42) 100 (30) 7 8[...]

OM-480 Page 43 Notes[...]

OM-480 Page 44 SECTION 12 − P ARTS LIST Figure 12-1. Main Assembly  Hardware is common and not available unless listed. 1 3 2 4 5 7 8 9 10 11 12 13 14 15 16 17 18 73 74 81 82 83 84 85 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 11 0 1 1 1(Fig 12-2) 11 2 11 4 11 5 11 6 11 7 11 8 11 9 120 121 122 123 124 125 86[...]

OM-480 Page 45 ST-129 956-U 19 20 21 22 23 24 25 26 27 28 29 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65(Fig 12-3) 66 67 68 69 70 30 31 33 34 35 36 37 38 32 40 41 42 43 44 126[...]

OM-480 Page 46 Description Part No. Dia. Mkgs. Item No. Figure 12-1. Main Assembly Quantity 1 134 771 PLUG, protective .640sq 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 184 676 T ANK, fuel (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

OM-480 Page 47 Description Part No. Dia. Mkgs. Item No. Figure 12-1. Main Assembly Quantity 128 287 STUD, adjusting throttle 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 ♦ 127 648 CLEVIS, throttle 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

OM-480 Page 48 Description Part No. Dia. Mkgs. Item No. Figure 12-1. Main Assembly Quantity 101 173 982 P ANEL, mtg components 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 RC9 168 071 CONNECTOR & SOCKETS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

OM-480 Page 49 Description Part No. Dia. Mkgs. Item No. Figure 12-2 . Panel, Front w/Components (Fig 12-1 Item 1 1 1) (Cont’d) Quantity 13 021 385 BOOT , toggle switch lever 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 ♦ 129 860 GAUGE, oil pressure 1 . . . . . . . . .[...]

OM-480 Page 50 ST-1 10 922-F  Hardware is common and not available unless listed. 14 15 16 17 18 12 20 23 19 24 25 26 27 28 1 2 4 5 6 4 3 12 29 21 13 7 10 8 9 Figure 12-3. Generator 22[...]

OM-480 Page 51 Description Part No. Dia. Mkgs. Item No. Figure 12-3. Generator (Fig 12-1 Item 65) Quantity 1 106 426 INSULA TOR 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 106 440 BUS BAR, rectifier 2 . . . . . . . . . . . . . . . . . . . . . . . . .[...]

OM-480 Page 52 Description Quantity Part No. Item No. 1 14 193 Figure 12-4. Switch, Range (Fig 12-2 Item 1) 1 1 14 235 BRACKET , mtg switch (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 010 671 SPRING, ext x .312 OD x .042 wire x 1.875pld 1 . . . . . . . . . . . . . . . . . . .[...]

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Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 1/05 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor . The expertise o[...]

PRINTED IN USA  2005 Miller Electric Mfg. Co. 1/05 Miller Elect ric Mfg. Co. An Illinois T ool W or ks Compan y 1635 West Spenc er S treet Applet on, W I 54914 USA International He adquarters − USA USA P hone: 920-735-4505 Aut o-At tended USA & C anada F AX : 920-735-4134 Int ernat ional FAX: 920-735-4125 European Headqua rters − United [...]