Miller Big Blue 251D Owner'S Manual Download Page 1

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Processes

OM-480

128 576AA

October 2002

Big Blue 251D



Stick (SMAW) Welding

Flux Cored (FCAW) With
Voltage-Sensing Wire Feeder

With Optional Equipment:

Air Carbon Arc (CAC-A)
Cutting And Gouging

Engine Driven Welding Generator

Description

Summary of Contents for Big Blue 251D

Page 1: ...s com Processes OM 480 128 576AA October 2002 Big Blue 251D Stick SMAW Welding Flux Cored FCAW With Voltage Sensing Wire Feeder With Optional Equipment Air Carbon Arc CAC A Cutting And Gouging Engine Driven Welding Generator Description ...

Page 2: ...lue established in 1929 This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operation quick and easy With Miller you can count on years of reliable service with proper maintenance And if for some reason the unit n...

Page 3: ...nder Optional Ether Starting Aid 16 4 6 Connecting To Weld Output Terminals 16 4 7 Selecting Weld Cable Sizes 17 SECTION 5 Operating the Welding Generator 18 5 1 Controls See Section 5 2 18 5 2 Description Of Front Panel Controls See Section 5 1 19 5 3 Remote A V Control 19 SECTION 6 OPERATING AUXILIARY EQUIPMENT 20 6 1 120 Volt Duplex And Optional GFCI Receptacles 20 6 2 240 Volt Duplex Receptacl...

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Page 5: ...stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards Properly install and ground this equipment according to its Owner s Manual and national state and local codes Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that...

Page 6: ...52 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby FLYING METAL can injure eyes Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag Wear approved safety glasses with side shields even under your welding helmet HOT PARTS can cause severe burns Allow cooling period before maintaining Wear protective gloves a...

Page 7: ...ocate unit on over or near combustible surfaces or flammables Keep exhaust and exhaust pipes way from flammables EXHAUST SPARKS can cause fire Do not let engine exhaust sparks cause fire Use approved engine exhaust spark arrestor in required areas see applicable codes 1 4 Compressed Air Hazards BREATHING COMPRESSED AIR can cause serious injury or death Do not use compressed air for breathing Use o...

Page 8: ...ciety Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Mi ami FL 33126 phone 305 443 9353 website www aws org National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Comp...

Page 9: ...voquer une électrocution Mettre l appareil hors tension quand on ne l utilise pas Ne pas utiliser des câbles usés endommagés de grosseur insuffisante ou mal épissés Ne pas enrouler les câbles autour du corps Si la pièce soudée doit être mise à la terre le faire directement avec un câble distinct ne pas utiliser le connecteur de pièce ou le câble de retour Ne pas toucher l électrode quand on est en...

Page 10: ...tection pour travailler sur un moteur chaud Ne pas toucher à mains nues les parties chaudes du moteur ni les pièces récemment soudées LE BRUIT peut affecter l ouïe Le bruit des processus et des équipements peut affecter l ouïe Porter des protections approuvés pour les oreilles si le niveau sondre est trop élevé LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques Porteurs de stimula...

Page 11: ...istance les produits inflammables de l échappement LES ÉTINCELLES À L ÉCHAPPEMENT peuvent provoquer un incendie Empêcher les étincelles d échappement du moteur de provoquer un incendie Utiliser uniquement un pare étincelles approuvé voir codes en vigueur 1 4 Dangers supplémentaires en relation avec l installation le fonctionnement et la maintenance LA CHUTE DE L APPAREIL peut blesser Utiliser l an...

Page 12: ...550 N W Lejeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 de la National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de la Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Règles de sécurité en soudage coupage et procédés connexes norme CSA W117 2 de l Associatio...

Page 13: ...gine Oil Check Injectors Pump Check Valve Clearance Fuel Protective Earth Ground Positive Negative Certified Trained Mechanic Welding Arc A Amperes V Volts Panel Local Remote Read Operator s Manual 1 G Engine Temperature Output Alternating Current Time h Hours s Seconds Do Not Switch While Welding 1 Single Phase 3 Three Phase Ether Starting Aid Engine Coolant Temperature ...

Page 14: ...ting Angles Dimensions Height 40 1 2 in 1029 mm Width 24 5 8 in 625 mm Depth 56 in 1422 mm N A 23 1 4 in 591 mm Do not exceed tilt angles or engine B 24 5 8 in 625 mm M Do not exceed tilt angles or engine could be damaged or unit could tip C 11 16 in 17 mm L Do not move or operate unit where it could tip D 2 7 8 in 73 mm K E 4 1 2 in 114 mm J F 22 9 16 in 573 mm H G G 27 in 686 mm D F G M 30 H 30 ...

Page 15: ...se under weld or power loads 3 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 Welding 100 Duty Cycle At 250 Amperes ...

Page 16: ...AMPERES IN 240V MODE AC VOLTS 0 25 50 75 100 150 125 0 10 20 30 40 50 60 AC AMPERES IN 120V MODE 3 6 Volt Ampere Curves 206 033 The volt ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator Curves of all other settings fall between the curves shown 0 20 40 60 80 100 0 100 200 300 400 500 600 700 AMPERES VOLTS RANGES MIN 80 65 120 95 200 160 3...

Page 17: ...r 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 KVA KW Single Phase AC Power Plant No Weld Load B 10 KVA KW Three Phase AC Power Plant No Weld Load 180 200 220 240 260 280 0 10 20 30 40 50 60 70 AC AMPERES AC VOLTS ...

Page 18: ...ame to prevent electric shock and static electricity haz ards If unit does not have GFCI recep tacles use GFCI protected exten sion cord 1 Equipment Grounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insulated copper wire 3 18 in 460 mm 18 in 460 mm 18 in 460 mm 18 in 460 mm...

Page 19: ...o 1 2 in 13 mm from top to allow room for expansion Open fuel shut off valve Do not run out of fuel or air enters fuel system and causes starting prob lems See engine manual to bleed air from fuel system Oil After fueling check oil with unit on lev el surface If oil is not up to full mark on dipstick add oil see maintenance la bel Your unit may have the optional low oil pressure shutdown switch Ho...

Page 20: ...ing Put cap on fitting when cylinder is removed 1 2 3 4 6 5 4 5 Installing Ether Cylinder Optional Ether Starting Aid Ref 800 162 A Open left side door 1 Bracket Route cables through bracket 2 Positive Weld Output Terminal 3 Negative Weld Output Ter minal For Stick welding Direct Current Electrode Positive DCEP con nect work cable to terminal and electrode holder cable to terminal For Direct Curre...

Page 21: ...3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 2 0 2x70 300 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 3 0 2x95 350 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 3 0 2x95 2 ea 4 0 2x120 400 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 4 0 2x120 2 ea 4 0 2x120 500 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 4 0 2x120 3 ea 3 0 3x95 3 ea 3 0 3x95...

Page 22: ...OM 480 Page 18 SECTION 5 OPERATING THE WELDING GENERATOR 5 1 Controls See Section 5 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 ...

Page 23: ...me to a complete stop before attempt ing restart In Run position engine runs at weld power speed In Run Idle position optional engine runs at idle speed at no load and weld power speed with load applied To Stop turn switch to Off position 8 Battery Charging Warning Light Light goes on when battery is not charging 9 Oil Pressure Warning Light Light goes on if oil pressure is too low If unit has aut...

Page 24: ...C2 GFCI2 from over load If CB1 or CB2 opens the receptacle does not work If a circuit breaker continues to open contact Factory Autho rized Service Agent If a ground fault is detected GFCI Reset button pops out and receptacle does not work Check for faulty tools plugged in receptacle Press button to reset At least once a month run en gine at weld power speed and press test button to verify GFCI is...

Page 25: ...B1 and CB2 protect the receptacles from overload If CB1 or CB2 opens the 240 V receptacle and half of the 120 V receptacle does not work 120 volts may still be present at the 240 V receptacle If a circuit breaker continues to open contact Factory Autho rized Service Agent Combined output of all receptacles is 3 kVA kW Generator power is not affected by weld output EXAMPLE If 10 A is drawn from the...

Page 26: ...Terminal Jumper 42 is connected to lead 90 at factory Jumper 42 may be dis connected from neutral to meet applicableelectrical codes 9 Lead 80 10 Receptacle RC9 leads 11 Lead 42 12 Lead 81 13 Lead 82 14 Load Terminals Connect leads to terminals 15 Fuses F1 F2 And F3 F1 F2 and F3 protect each load line from overload Set Engine Control switch to Run when using generator power 92 90 91 93 Tools Neede...

Page 27: ...cted 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 kVA kW Power available at RC9 is reduced when welding Fuses F1 and F2 protect RC9 from overload see Section 6 3 If a fuse opens the receptacle does not work 120 volts may still be present at RC9 1 ...

Page 28: ... Weld Terminals 100 h Clean Cooling System Clean And Tighten Battery Connections Check air cleaner hoses for cracks and loose clamps 200 h 250 h Replace Unreadable Labels Check And Clean Spark Arrestor See Section 7 8 500 h Change Oil See Section 7 4 Change Oil Filter See Section 7 4 Repair Or Replace Cracked Cables 1000 h Blow Out Or Vacuum Inside During Heavy Service Clean Monthly OR Change Fuel...

Page 29: ...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 7 2 Maintenance Label ...

Page 30: ...ree times 1 Air Cleaner 2 Service Indicator Optional 3 Window 4 Reset Button Service air cleaner element if red band appears in window A green band means air cleaner is okay Press button to reset indicator Clean or replace primary element if dirty see note above before cleaning Re place primary element if damaged Re place primary element yearly or after six cleanings 5 Housing 6 Safety Element Opt...

Page 31: ...s To replace primary fuel filter Close shutoff valve and turn filter counterclockwise Remove filter Apply thin coat of fuel to gasket on new filter Install new filter and turn clockwise Open shutoff valve Bleed air from fuel system accord ing to engine manual Inspect fuel line and replace if cracked or worn To replace secondary fuel filter See engine manual To drain sludge from fuel tank Put metal...

Page 32: ...ut Turn screw until engine runs at 1850 rpm Tighten nut Models With Automatic Idle Optional 3 Throttle Rod 4 Locknut Loosen locknuts Place engine control switch in Run Idle position Turn throttle rod until engine runs at idle speed Tighten locknuts 5 Engine Speed Adjustment Screw 6 Locknut Place engine control switch in Run position Loosen locknut Turn screw until engine runs at weld power speed T...

Page 33: ...automatic idle option If fuse F4 opens the engine does not run at idle speed Check fuses and replace if open 1 2 3 Tools Needed 7 7 Servicing Optional Ether Starting Aid ether2 7 96 153 382 A S 0692 Stop engine Improper handling or expo sure to ether can harm your health Follow manufactur er s safety instructions on cylinder If engine does not start in cold weather check ether cylinder as follows ...

Page 34: ...e A V receptacle RC3 Disconnect equipment from generator power receptacles during start up Have Factory Authorized Service Agent check brushes and slip rings and field excitation circuit Erratic weld output Use dry properly stored electrode Be sure connection to work piece is clean and tight Remove excessive coils from weld cables Check and tighten connections both inside and outside unit Have Fac...

Page 35: ...k oil level Optional automatic shutdown system stops engine if oil pressure gets too low or oil temperaturegets too high See engine manual Have Factory Authorized Service Agent check engine charging system Engine suddenly stops Check oil level Optional automatic shutdown system stops engine if oil pressure gets too low or oil temperaturegets too high Check optional Magnetic Shutdown switch fuse F ...

Page 36: ...OM 480 Page 32 SECTION 8 ELECTRICAL DIAGRAM SC 190 650 B Figure 8 1 Circuit Diagram For Welding Generator ...

Page 37: ... specifications section in this manual to find rated voltage and current Do not idle engine longer than necessary Piston rings seat faster if engine runs at weld power rpm and the welding generatoris kept loaded during run in 2 Engine Exhaust Pipe Wetstacking is unburned fuel and oil in the exhaust pipe and occurs during run in if the engine is run too long at light load or idle rpm If exhaust pip...

Page 38: ...on 3 Weld Cables Connect load bank to generator weld output terminals using proper size weld cables with correct connectors Observe correct polarity Start engine and run for several minutes Set load bank switches and then adjust generator A V control so load equals rated voltage and current of generator see nameplate rating label or the specifications section in this manual Check generator and loa...

Page 39: ...r size weld cables with correct connec tors polarity is not important 4 Voltmeter 5 Clamp On Ammeter Connect voltmeter and ammeter as shown if not provided on generator Start engine and run for several minutes Set grid switches and then adjust generator A V control so load equals rated voltage and current of the generator see nameplate rat ing label or the specifications sec tion in this manual Ch...

Page 40: ...ymbol and or wording 3 1 0 2 Grounding Generator To Truck Or Trailer Frame S 0854 Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards 1 Equipment Grounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insulated copper wire If ...

Page 41: ...sistive Load Equipment with a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when running see Section 10 8 3 Rating Data Rating shows volts and amperes or watts required to run equipment VOLTS 115 4 5 60 AMPS Hz 1 2 3 3 EXAMPLE 1 If a drill uses 4 5 amperes at 115 volts calculate its running power requirementin watts 4 5 A x 115 V 520 ...

Page 42: ...Home Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 Milker Vacuum Pump 2 HP 10500 2800 FARM DUTY MOTORS 1 3 HP 1720 720 Std e g Conveyors 1 2 HP 2575 975 Feed Augers Air 3 4 HP 4500 1400 Compressors 1 HP 6100 1600 1 1 2 HP 8200 2200 2 HP 10550 2850 3 HP...

Page 43: ...HP 6000 1500 1 1 2 HP 8200 2200 2 HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1 3 HP 2100 700 Elec Hedge Trimmer 18 in 400 400 Flood Lights HID 125 100 Metal Halide 313 250 Mercury 1000 Sodium 1400 Vapor 1250 1000 Submersible Pump 400 gph 600 200 Centrifugal Pump 900 gph 900 500 F...

Page 44: ...r Starting Requirements Motor Start Code G H J K L M N P KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0 EXAMPLE Calculate the starting amperage required for a 230 V 1 4 HP motor with a motor start code of M Starting the motor requires 12 2 amperes 11 2 x 1 4 x 1000 230 12 2 A kVA HP x HP x 1000 VOLTS STARTING AMPERAGE Volts 230 HP 1 4 Using Table Code M results in kVA HP 11 2 10 9 How Much Power Can G...

Page 45: ...if required by electrical code 4 Welding Generator Output Generator output voltage and wiring must be consistent with regular utility system volt age and wiring Connect generator with temporary or perma nent wiring suitable for the installation Turn off or unplug all equipment connected to generator before starting or stopping engine When starting or stopping the engine has low speed which causes ...

Page 46: ... 15 40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 2 voltage drop Cord Lengths for 240 Volt Loads If unit does not have GFCI receptacles use GFCI protected extension cord Maximum Allowable Cord Length in ft m for Conductor Size AWG Current Amperes Load Watts 4 6 8 10 12 14 5 1200 700 213 450 137 225 84 200 61 7 1680 800 244 500 152 300 91 200...

Page 47: ...OM 480 Page 43 Notes ...

Page 48: ...ot 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 99 100 101 102 103 104 105 106 107 108 109 110 111 Fig 11 2 112 114 115 116 117 118 119 120 121 122 123 124 125 86 71 Includes 72 77 72 75 76 77 78 79 80 113 106 ...

Page 49: ...OM 480 Page 45 ST 129 956 T 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 11 3 66 67 68 69 70 30 31 33 34 35 36 37 38 32 40 41 42 43 44 126 ...

Page 50: ... 1 195 869 CABLE TIE 0 17 500 weather resistant 1 23 108 487 LABEL warning falling equipment can cause serious injury 2 24 004 130 BRACKET support door 2 25 173 847 LABEL diesel engine maintenance 1 26 124 687 DOOR side RH 1 124 685 DOOR side LH 1 168 385 LABEL warning battery explosion can blind 1 089 343 RIVET nyl 250dia x 1 000 lg 6 27 178 763 PANEL rear 1 28 162 741 GUARD belt 1 29 146 994 LAB...

Page 51: ...0 KVA opt incl items 72 thru 77 1 72 110 069 FITTING flrd brs elbow M 1 4 1 106 394 FITTING flrd brs conn M HD 1 4 tbg x 1 4 NPT 7 5 10 KVA option 1 73 080 389 SCREW 312 18 x 1 000 cap hexhd 2 74 124 607 STRIP mtg separator fuel 1 75 172 684 NUT 312 18 x 50 hex 2 76 200 787 BASE filter w adapter and vent 1 77 145 282 FITTING hose brs barbed elb M 5 16tbg x 1 4NPT 1 78 134 835 HOSE SAE 312 ID x 560...

Page 52: ...10 BOLT J stl 250 20 x 2 750 4 125 089 517 STRAP fuel tank 2 126 175 465 FITTING pipe brs adapter extender 1 8 x 1 8 120 1 173 919 KIT label 1 168 071 CONNECTOR SOCKETS 2 165 669 CONNECTOR SOCKETS 1 116 045 CONNECTOR SOCKETS 1 OPTIONAL When ordering a component originally displaying a precautionary label the label should also be ordered Recommended Spare Parts To maintain the factory original perf...

Page 53: ...ight ind 2 20 HM 145 247 METER hour 4 40VDC 1 21 019 602 KNOB pointer 1 22 019 754 HANDLE switch range 1 23 NAMEPLATE order by model and serial number 1 24 S1 176 606 SWITCH ignition 4posn 1 25 127 618 PANEL front upper 1 26 189 404 SPACER nylon 1 1 Fig 11 4 2 6 7 8 9 10 17 20 21 23 24 ST 130 264 G 12 4 5 11 13 14 15 16 18 19 22 25 3 Hardware is common and not available unless listed 26 Figure 11 ...

Page 54: ...OM 480 Page 50 ST 110 922 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 11 3 Generator 22 ...

Page 55: ...AFFLE air gen 1 16 204 682 ROTOR gen consisting of 1 17 024 617 RING retaining external 1 18 053 390 BEARING ball 1 19 089 737 FAN rotor 1 035 776 KEY 375 x 375 x 2 000 1 20 204 695 STATOR exciter endbell consisting of 1 21 204 714 STATOR exciter aux power 1 22 173 068 ENDBELL gen consisting of 1 23 143 220 O RING 2 859 ID x 139CS 1 24 173 323 BARREL rectifier 1 25 SR3 106 430 DIODE ASSEMBLY consi...

Page 56: ...ting of 3 7 011 076 SPRING pressure 1 8 011 953 CONTACT 2 9 011 074 SPRING pressure 1 10 011 644 CONTACT stationary 15 11 004 999 CONTACT BOARD stationary 2 12 011 012 SHIM guide contact board 3 13 100 623 GUIDE contact board movable 3 SB 011 273 SB 011 100 1 2 3 4 6 7 8 9 10 Includes Item 7 5 11 12 13 Hardware is common and not available unless listed Figure 11 4 Switch Range To maintain the fact...

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Page 59: ...rols Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Bobcat Trailblazer and Legend models 2 Items furnished by Miller but manu...

Page 60: ... complete and retain with your personal records Always provide Model Name and Serial Style Number Call 1 800 4 A Miller or see our website at www MillerWelds com to locate a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Informati...

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