Miller Big Blue 300 PRO Series Owner'S Manual Download

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TABLE OF CONTENTS

SECTION 6

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OPERATING WELDING GENERATOR

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6-1. Front Panel Controls (See Section 6-2)

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6-2. Description Of Front Panel Controls (See Section 6-1)

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6-3. Process/Contactor Switch

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6-4. Lift-Arc

TIG With Crater-Out And Auto-Stop

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6-5. Remote Voltage/Amperage Control

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6-6. Operating Engine Block Heater

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6-7. Fuel/Hour Gauge Descriptions

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SECTION 7

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OPERATING AUXILIARY EQUIPMENT

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7-1. Generator Power Receptacles

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7-2. GFCI Receptacle Information, Resetting And Testing

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SECTION 8

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MAINTENANCE & TROUBLESHOOTING

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8-1. Routine Maintenance

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8-2. Maintenance Label

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8-3. Checking Generator Brushes

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8-4. Servicing Air Cleaner

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8-5. Inspecting And Cleaning Optional Spark Arrestor Muffler

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8-6. Servicing Engine Cooling System

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8-7. CAT Engine Speed Adjustment

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8-8. Kubota Engine Speed Adjustment

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8-9. Mitsubishi Engine Speed Adjustment

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8-10. Overload Protection

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8-11. Servicing Fuel And Lubrication Systems

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8-12. Voltmeter/Ammeter Help Displays

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8-13. Maintaining Stainless Steel (Models With Optional Package)

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8-14. Troubleshooting

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SECTION 9

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PARTS LIST

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9-1. Recommended Spare Parts

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SECTION 10

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ELECTRICAL DIAGRAMS

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SECTION 11

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RUN-IN PROCEDURE

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11-1. Wetstacking

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11-2. Run-In Procedure Using Load Bank

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11-3. Run-In Procedure Using Resistance Grid

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SECTION 12

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GENERATOR POWER GUIDELINES

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COMPLETE PARTS LIST

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www.MillerWelds.com

WARRANTY

Summary of Contents for Big Blue 300 PRO Series

Page 1: ...es OM 259 355A 2012 12 Processes Description Air Carbon Arc CAC A Cutting and Gouging Stick SMAW Welding Engine Driven Welding Generator TIG GTAW Welding MIG GMAW Welding Flux Cored FCAW Welding Visit our website at www MillerWelds com File Engine Drive ...

Page 2: ...tinue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value 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...

Page 3: ...itions 15 SECTION 4 SPECIFICATIONS 16 4 1 Weld Power And Engine Specifications 16 4 2 Environmental Specifications 16 4 3 Dimensions Weights And Operating Angles 16 4 4 Volt Ampere Curves For Models With CAT Or Kubota Engine 17 4 5 Volt Ampere Curves For Models With Mitsubishi Engine 18 4 6 CAT Or Kubota Engine Fuel Consumption 19 4 7 Mitsubishi Engine Fuel Consumption 19 4 8 Duty Cycle And Overhe...

Page 4: ...king Generator Brushes 42 8 4 Servicing Air Cleaner 42 8 5 Inspecting And Cleaning Optional Spark Arrestor Muffler 43 8 6 Servicing Engine Cooling System 43 8 7 CAT Engine Speed Adjustment 44 8 8 Kubota Engine Speed Adjustment 45 8 9 Mitsubishi Engine Speed Adjustment 45 8 10 Overload Protection 46 8 11 Servicing Fuel And Lubrication Systems 48 8 12 Voltmeter Ammeter Help Displays 50 8 13 Maintain...

Page 5: ...igh risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone Disconnect input power or stop...

Page 6: ...cks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on containers that have held combustibles or on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 and AWS A6 0 see Safety Standards Do not weld where th...

Page 7: ...le hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns 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 present on unit instead of radiator unless told otherwise in maintenance section or engine manual If the engine is warm checking is needed and there ...

Page 8: ... PARTS can burn Do not touch hot compressor or air system parts Allow cooling period before working on equip ment To handle hot parts use proper tools and or wear heavy insu lated welding gloves and clothing to prevent burns READ INSTRUCTIONS Read and follow all labels and the Owner s Manual carefully before installing operating or servicing unit Read the safety information at the beginning of the...

Page 9: ... Reduce current or reduce duty cycle before starting to weld again Do not block or filter airflow to unit STATIC ESD can damage PC boards Put on grounded wrist strap BEFORE handling boards or parts Use proper static proof bags and boxes to store move or ship PC boards TILTING OF TRAILER can injure Use tongue jack or blocks to support weight Properly install welding generator onto trailer according...

Page 10: ...website www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 25 West 43rd Street New York NY 10036 phone 212 642 4900 web site www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone...

Page 11: ...équipé Des précautions de sécurité supplémentaires sont requises dans des environnements à risque comme les endroits humides ou lorsque l on porte des vêtements mouillés sur des structures mé talliques au sol grillages et échafaudages dans des positions assises à genoux et allongées ou quand il y a un risque important de contact accidentel avec la pièce ou le sol Dans ces cas utiliser les appareil...

Page 12: ...n casque de soudage approuvé muni de verres filtrants appropriépour protéger visage et yeux pour protéger votre visage et vos yeux pendant le soudage ou pour regarder voir ANSI Z49 1 et Z87 1 énuméré dans les normes de sécurité Porter des lunettes de sécurité avec écrans latéraux même sous votre casque Avoir recours à des écrans protecteurs ou à des rideaux pour protéger les autres contre les rayo...

Page 13: ...s étincelles avec les outils en travaillant sur la batterie Ne pas utiliser l appareil de soudage pour charger des batteries ou faire démarrer des véhicules à l aide de câbles de démarrage sauf si l appareil dispose d une fonctionnalité de charge de batterie destinée à cet usage Observer la polarité correcte et sur les batteries Débrancher le câble négatif en premier lieu Le rebrancher en dernier ...

Page 14: ...entation électrique verrouiller et étiqueter l appareil détendre la pression et s assurer que le circuit d air ne peut être mis sous pression par inadvertance Ne pas intervenir sur le circuit d air comprimé lorsque l appareil fonctionne Seul un personnel qualifié est autorisé et appliquant les consignes du fabricant Ne pas modifier ou altérer le compresseur ou les équipements fournis par le fabric...

Page 15: ...etien en respectant les manuels d utilisation les normes industrielles et les codes nationaux d état et locaux 2 5 Dangers supplémentaires en relation avec l installation le fonctionnement et la maintenance Risque D INCENDIE OU D EXPLOSION Ne pas placer l appareil sur au dessus ou à proximité de surfaces inflammables Ne pas installer l appareil à proximité de pro duits inflammables Ne pas surcharg...

Page 16: ...e le courant ou le facteur de marche avant de poursuivre le soudage Ne pas obstruer les passages d air du poste LES CHARGES ÉLECTROSTATI QUES peuvent endommager les circuits imprimés Établir la connexion avec la barrette de terre avant de manipuler des cartes ou des pièces Utiliser des pochettes et des boîtes antistatiques pour stocker déplacer ou expédier des cartes de circuits imprimes UNE REMOR...

Page 17: ...dian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Ontario Canada L4W 5NS phone 800 463 6727 website www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 25 West 43rd Street New York NY 10036 phone 212 642 4900 web site www ansi org Standard for Fire Prevention During Wel...

Page 18: ...d Safe54 2012 05 During the first 50 hours of operation keep welding load above 200 amperes Do not weld below 200 amperes of output 50 h std Safe55 2012 05 After the first 50 hours of operation change the engine oil and filter Never use generator inside a home or garage even if doors and win dows are open Safe87 2012 07 Only use generator outside and far away from windows doors and vents Safe88 20...

Page 19: ...ne Temperature Direct Current DC Alternating Current Stick SMAW Welding Lift Arc TIG MIG GMAW Welding TIG GTAW Time h Hours s Seconds 1 Single Phase 3 Three Phase Read Operator s Manual Circuit Protector Contactor On Arc Force Dig Work Connection 3 G Engine Driven Three Phase Alternator With Rectifier Hz Hertz X Duty Cycle U0 Rated No Load Voltage Average U2 Conventional Load Voltage n Rated Load ...

Page 20: ...30 Duty Cycle 300 A 29 Volts DC 60 Duty Cycle 250 A 26 5 Volts DC 100 Duty cycle 4 2 Environmental Specifications IP Rating Operating Temperature Range IP23S This equipment is designed for outdoor use It may be stored but is not intended to be used outside during precipitation unless sheltered 40 to 104 F 40 to 40 C 4 3 Dimensions Weights And Operating Angles Dimensions Front Panel End B A F E H G...

Page 21: ...um voltage and amperage output capabilities of the welding generator Curves of all other settings fall between the curves shown A Stick Mode B MIG Mode C TIG Mode 0 100 200 300 400 500 600 0 10 20 30 40 50 60 70 80 90 100 DC Volts DC Amperes Min Max 0 100 200 300 400 500 600 DC Amperes 0 10 20 30 40 50 60 70 80 90 100 DC Volts 0 100 200 300 400 500 DC Amperes 0 10 20 30 40 50 60 70 80 90 100 DC Vo...

Page 22: ...ximum voltage and amperage output capabilities of the welding generator Curves of all other settings fall between the curves shown A Stick Mode B MIG Mode C TIG Mode 0 100 200 300 400 500 0 10 20 30 40 50 60 70 80 90 100 DC Volts DC Amperes Min Max 0 100 200 300 400 0 10 20 30 40 50 60 70 80 90 100 DC Volts DC Amperes Min Max 0 100 200 300 400 500 0 10 20 30 40 50 60 70 80 90 100 DC Volts DC Amper...

Page 23: ...ads 237 471 DC WELD AMPERES AT 100 DUTY CYCLE U S GAL HR 0 00 0 25 0 50 0 75 1 00 1 25 1 50 1 75 2 00 0 50 100 150 200 250 300 350 400 IDLE 4 7 Mitsubishi Engine Fuel Consumption The curve shows typical fuel use under weld or power loads 250 370 A DC WELD AMPERES AT 100 DUTY CYCLE U S GAL HR 0 00 0 25 0 50 0 75 1 00 1 25 1 50 1 75 2 00 0 50 100 150 200 250 300 350 400 IDLE ...

Page 24: ... continuously NOTICE Exceeding duty cycle can damage unit and void warranty 217 515 10 15 20 25 30 40 50 60 80 100 CC CV 1000 800 600 500 400 300 250 200 150 100 WELD AMPERES DUTY CYCLE 1 4 9 AC Generator Power Curve 237 494 0 40 80 120 160 0 20 40 60 80 AC AMPERES IN 120 V MODE AC AMPERES IN 240 V MODE 300 250 200 150 100 50 0 150 125 100 75 50 25 0 AC VOLTS The AC power curve shows the generator...

Page 25: ...back cover of this manual Do not move or operate unit where it could tip Always securely fasten weld ing generator onto transport vehicle or trailer and comply with all DOT and other applica ble codes NOTICE Do not install unit where air flow is restricted or engine may overheat See Section 4 3 for lifting eye rat ing See Section 5 3 for mounting information install3 2008 01 Ref 800 652 Ref 800 47...

Page 26: ...o base Mounting Surface 1 Cross Supports 2 Mounting Brackets Supplied Mount unit on flat surface or use cross supports to support base Secure unit with mounting brack ets 3 1 2 in Bolt And Washer Minimum Not Supplied 4 3 8 16 x 1 in Screws Supplied To Bolt Unit In Place Remove hardware securing the four mounting brackets to the base Reverse brackets and reattach to base with original hardware Moun...

Page 27: ...t ing auxiliary equipment If unit does not have GFCI receptacles use GFCI protected extension cord Do not use GFCI receptacles to power life support equipment 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 8 AWG or larger insulated copper wire Electrically bond generator fram...

Page 28: ... at www MillerWelds com OM 259 355 Page 24 5 6 Connecting The Battery 1 2 in Tools Needed Conn_Batt2 2010 04 S 0756 C 161 002 Connect negative battery cable last Close door after connecting battery Shown with rocker panel removed Notes ...

Page 29: ...lant Prestart Information Fuel Coolant_engine1 2012 04 Ref 907 427 6 2 Fuel NOTICE Do not use gasoline Gasoline will damage engine Add fresh diesel fuel before starting see engine maintenance label for fuel specifica tions Leave filler neck empty to allow room for expansion Coolant Check coolant level in radiator before start ing unit the first time If necessary add cool ant to radiator until cool...

Page 30: ...stick add oil see maintenance label Full 907 427 6 5 10 Kubota Engine Oil Prestart Information Check oil with unit on level surface If oil is not up to full mark on dipstick add oil see maintenance label Full 803 581 D 5 11 Mitsubishi Engine Oil Prestart Information Check oil with unit on level surface If oil is not up to full mark on dipstick add oil see maintenance label Full 907 427 6 ...

Page 31: ... on right and work cable to Work Negative terminal on left Use Process Contactor switch to select type of weld output see Section 6 3 For Direct Current Electrode Negative DCEN reverse cable connections 1 2 3 3 1 2 5 13 Connecting To Weld Output Terminals Tools Needed 3 4 in 803 778 B 6 4 5 3 Stop engine Failure to properly connect weld cables may cause excessive heat and start a fire or damage yo...

Page 32: ...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 This chart is a general guideline and may not suit all applications If cable overheats use next size larger cable Weld cable size AWG is based on either a 4 volts or less drop or a current density of at least 300 circular mils per amp...

Page 33: ... Complete Parts List is available at www MillerWelds com OM 259 355 Page 29 Notes ...

Page 34: ... Complete Parts List is available at www MillerWelds com OM 259 355 Page 30 SECTION 6 OPERATING WELDING GENERATOR 250 225 A 803 563 1 2 5 4 6 7 8 9 3 ...

Page 35: ... When a remote control is connected to the Remote receptacle the Auto Sense Remote feature automatically switches voltage am perage control to the remote control see Sec tion 5 15 With remote control connected weld output is determined by a combination of front panel and remote control voltage amperage set tings If no remote control is connected to the Re mote receptacle the front panel Voltage Am...

Page 36: ...ort arc length condi tions and prevent sticking elec trodes Turn control from A to D to in crease arc drive dig from min to max Use the Lift Arc TIG mode for TIG GTAW welding using the Lift Arc TIG starting procedure see Section 6 4 1 803 562 250 225 A Process Contactor Switch Settings Switch Setting Process Output On Off Control Engine Auto Idle Optional Remote On Off Switch Re quired TIG HF Requ...

Page 37: ...ngle Touch tungsten electrode to workpiece at weld start point Slowly lift electrode Arc is started when electrode is lifted Maintain shielding gas coverage and eliminate tungsten and work piece contamination by using Auto Crater or Auto Stop to end the arc Arc End With Crater Out Momentary contact switch re quired to start crater out 1 While welding 2 Close momentary contact switch to start Crate...

Page 38: ...ntrol To Desired Maximum Weld Output Using Weld Meters Set TIG or STICK Process In Example Min 20 A DC Max 205 A DC Max 205 A DC Min 20 A DC Connect Remote Control To Remote Receptacle RC14 1 Adjust Optional Remote Control to desired weld output Weld meters show preset output when not welding Set WIRE Process Connect Remote Control To Remote Receptacle RC14 Turn Remote Control On Adjust Optional R...

Page 39: ... volts AC receptacle Do not run engine while en gine block heater is on NOTICE In extremely cold weath er heater should be connected to power source when engine is warm The area near the engine block heater gets hot Disconnect plug to turn off heater 1 Watts Volts 10 1000 120 CAT And Mitsubishi Engine Coolant Heater Specifications Coolant Heater1 2012 05 803 562 Ref 803 145 Watts Volts 10 400 120 ...

Page 40: ... Complete Parts List is available at www MillerWelds com OM 259 355 Page 36 6 7 Fuel Hour Gauge Descriptions ...

Page 41: ...sting procedures 2 240 V 50 A AC Receptacle RC11 RC11 supplies 60 Hz single phase power at weld power speed Maximum output from RC11 is 10 kVA kW 3 Supplementary Protector CB4 4 Supplementary Protector CB6 5 Supplementary Protector CB5 CB4 protects GFCI2 and CB6 protects GFCI1 from overload If a supplementary protector opens the receptacle does not work Press button to reset Supplementary protecto...

Page 42: ...t and test GFCI receptacle according to the following procedures Resetting Testing GFCI Receptacle Test GFCI monthly See Testing GFCI Receptacle Do not test or reset GFCI recept acles at idle speed low voltage or the GFCI will be damaged and not provide protection from electric shock caused by a ground fault If LED blinks stop using GFCI re ceptacle and have it replaced by a Factory Authorized Ser...

Page 43: ...als Every 100 Hours Section 8 4 Battery Terminals Air Cleaner Hoses Air Cleaner Element Unreadable Labels Every 250 Hours CAT And Kubota Engine Every 500 Hours Mitsubishi Engine NOTICE Change engine oil and filter after initial 50 to 75 hours of use 1 2 in 13 mm Engine Manual Section 8 5 8 11 Oil Oil Filter Fan Belt Tension Spark Arrestor Every 500 Hours All Models SLUDGE FUEL Section 8 11 Weld Ca...

Page 44: ...olved at the dealer level without additional assistance call a Field Service Coordinator at 1 800 447 4986 3 If your needs still have not been met submit the matter in writing to Caterpillar Inc Manager Customer Service Engine Division Mossville Bldg A P O Box 600 Peoria IL 61552 0600 Please follow the above steps in sequence if a problem arises Website Address www caterpillar com Altitude Contact...

Page 45: ...e IL 60069 Phone 847 955 2500 Fax 847 955 2699 To find a service facility near you contact the KEA distributor in your area http www kubotaengine com Mitsubishi Engine North America 1250 Greenbriar Dr Suite E Addison IL 60101 630 268 0750 Http www mitsubishi engine com Use web site to locate closest dealer For international information use Http www mhi co jp global network ...

Page 46: ...when determining whether to clean or replace the primary element If you decide to clean the primary ele ment we strongly recommend instal ling an optional safety element to pro vide additional engine protection Nev er clean a safety element Replace the safety element after servicing the primary element three times Clean or replace primary element if dirty see note above before cleaning Replace pri...

Page 47: ...roof material Stop engine and let cool Reinstall cleanout plug Tools Needed 3 8 in 1 2 3 8 6 Servicing Engine Cooling System Coolant1 2010 04 Ref 907 427 6 Stop engine and let cool 4 Radiator Cap Cover 5 Radiator Draincock 6 Coolant Recovery Tank Change coolant according to engine manual Add coolant according to engine maintenancelabel Check coolant level in recovery tank daily If necessary add co...

Page 48: ...t engine speed when auto matic idle option is installed To prevent solenoid dam age be sure a 1 8 in 3 mm gap exists between the en gine low speed screw and throttle lever when the sole noid is held in the energized position Unhook rubber boot from the so lenoid housing but leave con nected to plunger Loosen lock nut Place Engine Control Switch in Auto position Turn throttle rod and plunger un til...

Page 49: ...tart engine and run until warm Turn Process Contactor switch to Stick Weld Terminals Always On position 1 Lock Nut 2 Adjustment Screw Loosen nut Turn screw until engine runs at weld power speed Tighten nut Do not set engine speed higher than specified 3 Engine Stop Lever Use lever to stop engine if Start Preheat switch does not work Stop engine Close door Stop Tools Needed RPM Hz Engine Speed No L...

Page 50: ...ctor CB3 5 Supplementary Protector CB8 6 Circuit Breaker CB9 CB1 protects the engine battery cir cuit If CB1 opens the engine will not crank CB1 automatically resets when the fault is corrected CB2 protects the engine wiring har ness If CB2 opens the engine will not crank CB3 protects part of the weld control wiring harness If CB3 opens weld and generator power output stops CB8 protects the 24 vol...

Page 51: ... Complete Parts List is available at www MillerWelds com OM 259 355 Page 47 Notes ...

Page 52: ...ine tighten connections as necessary and wipe up spilled fuel 1 Oil Filter 2 Oil Drain Valve And Hose 3 Oil Fill Cap 4 Primary Fuel Filter 5 Secondary Fuel Filter 6 Fuel Tank Sludge Drain Valve 7 Fuel Filter Retaining Ring To change oil and filter Route oil drain hose and valve through hole in base See engine manual and engine maintenance label for oil filter change information 8 11 Servicing Fuel...

Page 53: ...in water from fuel system See engine manual To replace secondary fuel filter Note direction of fuel flow as indi cated by arrow on side of filter Re move fuel line clamps and discon nect fuel lines from fuel filter Re place filter reconnect fuel lines and reinstall clamps To drain sludge from fuel tank Beware of fire Do not smoke and keep sparks and flames away from drained fuel Dis pose of draine...

Page 54: ...llow unit to cool be fore restarting If problem continues have Factory Authorized Service Agent check unit 4 Help 23 Display Can indicate a complete loss of generator excitation auxiliary power output and weld output or a failure of one of the rectifier output SCRs If generator output is lost see trouble No generator power or weld output in section 8 14B If generator out put is okay have Factory A...

Page 55: ...orized Service Agent check main control module PC1 and hall device HD1 Low weld output Check engine speed and adjust if necessary Check fuse F1 and replace if open see Section 8 10 If F1 is open have Factory Authorized Service Agent check the rotor Low open circuit voltage Check engine speed and adjust if necessary Have Factory Authorized Service Agent check main control module PC1 field excitatio...

Page 56: ...R3 and the glow plug Engine suddenly stops Check oil and coolant levels Automatic shutdown system stops engine if oil pressure is too low or coolant temperatureis too high see Section 5 7 Check fuel hour gauge for indication of shutdown Circuit breaker CB1 may be open CB1 automatically resets when fault is corrected see Section 8 10 Reset supplementary protector CB2 see Section 8 10 Have Factory A...

Page 57: ...3 Belt Alternator Mitsubishi 1 252782 Filter Kit Mitsubishi S4l2 Includes 1 252781 Filter Fuel Spin on 1 213858 Filter Fuel In line 5 16x5 16 Mic 125 175 1 242882 Filter Lube Oil 1 197676 Element Air Cleaner 1 217686 Belt Alternator CAT 1 202166 Filter Oil CAT 1 213858 Filter Fuel In line 5 16x5 16 Mic 125 175 CAT 1 217687 Filter Fuel Spin on CAT 1 197679 Element Air Cleaner Safety 1 111352 Batter...

Page 58: ...OM 259 355 Page 54 SECTION 10 ELECTRICAL DIAGRAMS Figure 10 1 Circuit Diagram For Welding Generator With CAT Engine ...

Page 59: ...OM 259 355 Page 55 240 670 C ...

Page 60: ...OM 259 355 Page 56 Figure 10 2 Circuit Diagram For Welding Generator With Kubota Engine ...

Page 61: ...OM 259 355 Page 57 253 845 B ...

Page 62: ...OM 259 355 Page 58 Figure 10 3 Circuit Diagram For Welding Generator With Mitsubishi Engine ...

Page 63: ...OM 259 355 Page 59 250 149 B ...

Page 64: ...ings seat faster if engine runs at weld power rpm and the welding generator is 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 pipe is coated with a wet black tar like substance dry the engine using one of the following run in procedures See the engin...

Page 65: ...enerator 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 name plate rating label or the specifi cations section in this manual Check generator and load bank meters after first five minute...

Page 66: ...c 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 ad just generator A V control so load equals rated voltage and current of the generator see nameplate rating label or the specifications section in this manual Check generator and meters after first f...

Page 67: ...Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Gen erators 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 8 AWG or larger insulated copper wire Electrically bond generator frame to ve hicle frame by metal to metal contact Bed liners shipping skids a...

Page 68: ...ve load and requires a constant amount of power 2 Non Resistive 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 12 8 3 Rating Data Rating shows volts and amperes or watts required to run equipment Amperes x Volts Watts Example 1 If a drill uses 4 5 am peres at 115 volts calculate its run ni...

Page 69: ...m 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 ...

Page 70: ...1 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...

Page 71: ...t must be at least twice the motor s running amperage kVA HP x HP x 1000 Volts Starting Amperage Example Calculate starting amper age required for a 230 V 1 4 HP mo tor with a motor start code of M Volts 230 HP 1 4 kVA HP 11 2 11 2 x 1 4 x 1000 230 12 2A Starting the motor requires 12 2 amperes VOLTS AMPS HP 230 2 5 1 4 Hz PHASE CODE 60 1 M AC MOTOR 1 2 3 4 12 9 How Much Power Can Generator Supply...

Page 72: ...ad back to electric utility when service is re stored Install correct switch customer supplied Switch rating must be same as or greater than the branch overcurrent protection 3 Fused Disconnect Switch Install correct switch customer supplied if required by electrical code 4 Welding Generator Output Generator output voltage and wir ing must be consistent with regular utility system voltage and wiri...

Page 73: ...50 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 Use GFCI protection when operating auxiliary equipment If unit does not have GFCI receptacles use GFCI protected exten sion cord Do not use GFCI receptacles to power life support equipment Maximum Allowable Cord Length in ft m for Conductor Siz...

Page 74: ...OM 259 355 Page 70 Notes ...

Page 75: ...Controls and Receivers Work Stations Weld Tables No Labor 5 6 Months Parts Batteries Bernard Guns No Labor Tregaskiss Guns No Labor 6 90 Days Parts Accessory Kits Canvas Covers Induction Heating Coils and Blankets Cables and Non Electronic Controls M Guns MIG Guns and Subarc SAW Guns Remote Controls and RFCS RJ45 Replacement Parts No labor Roughneck Guns Spoolmate Spoolguns Miller s True Blue Limi...

Page 76: ...h your personal records Always provide Model Name and Serial Style Number Contact 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 Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering Carrier to ...

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