Beruflich Dokumente
Kultur Dokumente
200907
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A) Cutting
and Gouging
Description
www.MillerWelds.com
the applicable
Eff w/LG440030E, engine speed adjustment procedures changed. For older models, download applicable Owners Manual from www.MillerWelds.com.
TM-4433
TABLE OF CONTENTS
SECTION 1 SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Manufacturers Rating Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. AC Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Mounting Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Activating The Dry Charge Battery (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Connecting To Remote 14 Receptacle RC14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 OPERATING WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Front Panel Controls (See Section 5-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Description Of Front Panel Controls (See Section 5-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Process/Contactor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Lift-ArcE Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Remote Voltage/Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Generator Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Inspecting And Cleaning Optional Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5. Servicing Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-6. Adjusting Engine Speed On Standard Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-7. Adjusting Engine Speed On Models With Automatic Idle (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-8. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-9. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-10. Checking Generator Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-11. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Troubleshooting Circuit Diagram For Welding Generator (Use With Section 9-3) . . . . . . . . . . . . . . . .
9-3. Troubleshooting Values For Circuit Diagram (Use With Section 9-2) . . . . . . . . . . . . . . . . . . . . . . . . . .
9-4. Waveforms For Sections 9-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
3
4
4
5
6
7
7
7
8
9
9
10
11
11
12
13
14
14
15
16
17
18
20
20
21
22
23
24
25
25
26
26
27
28
29
29
30
31
32
33
34
35
36
40
40
44
46
48
TABLE OF CONTENTS
9-5. Filter Board PC6 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-6. Filter Board PC6 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-7. Module Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-8. Main Control Board PC1 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-9. Main Control Board PC1 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-10. Voltage Regulator Board PC3 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-11. Voltage Regulator Board PC3 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-12. Meter Display Board PC2 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-13. Meter Display Board PC2 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-14. Idle Module PC5 Testing Information And Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . . .
9-15. Replacing Brushes And Cleaning Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-16. Checking Unit Output After Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1. Disassembly Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2. Disassembly Of Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-3. Replacing Rectifier SCR Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 13 PARTS EFF W/LE099775 THRU LJ120250E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50
50
51
52
53
55
56
57
57
58
60
61
62
62
63
64
65
72
72
73
74
76
READ INSTRUCTIONS.
Use Testing Booklet (Part No. 150 853) when
servicing this unit.
Consult the Owners Manual for welding safety
precautions.
Use only genuine replacement parts from the manufacturer.
Read and follow all labels and the Technical Manual carefully before installing, operating, or servicing unit. Read the safety information at the beginning of the manual and in each section.
Reinstall injectors and bleed air from fuel system according to
engine manual.
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: The body of evidence, in the
committees judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
TM-4433 Page 3
SECTION 2 DEFINITIONS
2-1. Warning Label Definitions
S-177 571
2
3
DIESEL
5
0 50 h Std.
200A
0 200A
50 h Std.
3/96
Notes
TM-4433 Page 4
TM-4433 Page 5
Stop Engine
Slow (Idle)
Start Engine
Starting Aid
(Preheat)
Battery (Engine)
Engine Oil
Pressure
Engine Oil
Check Injectors/
Pump
Check Valve
Clearance
Fuel
Protective Earth
(Ground)
Positive
Negative
Certified/Trained
Mechanic
Welding Arc
Volts
Panel/Local
Remote
Engine
Air Temperature Or
Engine
Temperature
Output
Alternating
Current
Stick (SMAW)
Welding
Constant Current
(CC)
MIG (GMAW)
Welding
TIG (GTAW)
Amperes
Time
Hours
Three Phase
Read Operators
Manual
Electrode
Connection
Work Connection
Seconds
Engine-Driven,
Three-Phase
Alternator With
Rectifier
Duty Cycle
U0
Rated No Load
Voltage (Average)
U2
Conventional
Load Voltage
n1
Rated Idle
Speed
n0
Rated No Load
Speed
Current
TM-4433 Page 6
Single Phase
Do Not Switch
While Welding
Circuit Protector
Contactor On
Hz
n
I2
Hertz
Rated Load
Speed
Rated Welding
Current
Lift-Arc TIG
SECTION 3 SPECIFICATIONS
3-1. Weld, Power, And Engine Specifications
Welding
Mode
Weld Output
Range
Rated Welding
Output
Maximum
OpenCircuit
Voltage
Generator Power
Rating
65
Single-Phase,
10 kVA/kW, 84/42 A,
120/240 V AC,
60 Hz
Fuel
Capacity
Engine
20 410 A
(CC Models)
CC/DC
Perkins
250 A, 30 Volts DC
100% Duty cycle
400 A, 23 Volts DC,
30% Duty Cycle
CV/DC
(CC/CV
Models
Only)
300 A, 29 Volts DC
60% Duty Cycle
14 40 V
Perkins 403C-15
Water-Cooled,
Three-Cylinder,
21.7 HP Diesel Engine
11.5 gal
(43.5 L)
Width
32 in (813 mm)
35-3/4 in (908 mm)
(to top of lift eye)
Depth
56 in (1422 mm)
56 in (1422 mm)
54 in (1372 mm)
52 in in (1321 mm)
2 in (51 mm)
26 in (660 mm)
30
Weight
No fuel: 1100 lb (499 kg)
20
H
Front Panel End
D
30
20
F
TM-4433 Page 7
DC VOLTS
100
90
80
70
60
50
40
30
20
10
0
MIN
300
100
200
300
MAX
400
500
400
500
DC AMPERES
B. MIG Mode
100
DC VOLTS
80
60
40
20
0
100
200
300
DC AMPERES
C. TIG Mode
100
DC VOLTS
80
60
40
20
0
MIN
0
300
100
200
300
MAX
400
500
DC AMPERES
217 517 / 217 516 / 217 518
TM-4433 Page 8
2.00
1.75
U.S. GAL/HR.
1.50
1.25
1.00
0.75
0.50
0.25
0.00
IDLE
50
100
150
200
250
300
350
400
217 509
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
1000
WELD AMPERES
800
600
500
400
CC
CV
300
250
200
150
100
10
15
20
25
30
40
50 60
80
100
% DUTY CYCLE
217 515
TM-4433 Page 9
150 300
AC VOLTS
125 250
100 200
75 150
50 100
25
50
20
40
60
80
40
80
120
160
Notes
TM-4433 Page 10
SECTION 4 INSTALLATION
4-1. Installing Welding Generator
!
Movement
OR
Location/Airflow Clearance
rating.
Grounding:
OR
OR
1
2
3
Electrically
bond generator
frame to vehicle frame by metal-to-metal contact.
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
Grounding
1
GND/PE
install3 200704 Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712
TM-4433 Page 11
Mounting Surface:
1
2
OR
Cross-Supports
Mounting Brackets (Supplied)
Inadequate support.
4
Tools Needed:
9/16 in
install3 200704 803 274 / 200 864-A / 803 562
TM-4433 Page 12
Tools Needed:
1/2 in
Notes
TM-4433 Page 13
2
1
Vent Caps
Sulfuric Acid Electrolyte
(1.265 Specific Gravity)
Well
Wait ten minutes and check electrolyte level. If necessary, add electrolyte to raise to proper level. Reinstall vent caps.
8
Battery Charger
When electrolyte
is low, add
only distilled water to cells to
maintain proper level.
5 A For 30 Minutes
OR
Tools Needed:
30 A For 12 Minutes
drybatt1 6/05 S-0886
Tools Needed:
1/2 in
TM-4433 Page 14
Hot Full
Cold Full
Full
803 563
down switch. However, some conditions may cause engine damage before
the engine shuts down. Check oil level
often and do not use the oil pressure
shutdown system to monitor oil level.
Follow run-in procedure in engine manual.
If unburned fuel and oil collect in exhaust
pipe during run-in, see Section 12.
Fuel
NOTICE Do not use gasoline. Gasoline
will damage engine.
The unit is shipped with enough fuel to prevent air from entering fuel system. Add fresh
diesel fuel before starting (see engine maintenance label for fuel specifications). Leave
filler neck empty to allow room for
expansion.
Big Blue 300 P
Do not run out of fuel or air will enter fuel system and cause starting problems. See engine manual to bleed air from fuel system.
Oil
After fueling, check oil with unit on level surface. If oil is not up to full mark on dipstick,
add oil (see maintenance label).
Coolant
Check coolant level in radiator before starting unit the first time. If necessary, add coolant to radiator until coolant level is at bottom
of filler neck.
Check coolant level in recovery tank daily.
If necessary, add coolant to recovery tank
until coolant level is between Cold Full and
Hot Full levels. If recovery tank coolant level
was low, also check coolant level in radiator.
Add coolant if level is below bottom of radiator filler neck.
Unit is shipped with an engine coolant mixture of water and ethylene glycol base antifreeze rated to 34 F (37 C). Add anti-
Stop engine.
4
5
6
7
Remove supplied nut from weld output terminal. Slide weld cable terminal onto weld output
terminal and secure with nut so that weld cable
terminal is tight against copper bar. Do not
place anything between weld cable terminal and copper bar. Make sure that the surfaces of the weld cable terminal and copper bar are clean.
2
3
1
Tools Needed:
3/4 in
1
Do not place
anything between
weld cable terminal
and copper bar.
5
6
Correct Installation
Incorrect Installation
803 562 / 803 778-A
TM-4433 Page 16
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
Weld Output
Terminals
* This
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
400 ft
(105 m) (120 m)
Welding
Amperes
10 60%
Duty
Cycle
60 100%
Duty
Cycle
100
4 (20)
4 (20)
4 (20)
3 (30)
2 (35)
1 (50)
1/0 (60)
1/0 (60)
150
3 (30)
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
200
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
4/0 (120)
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
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)
chart is a general guideline and may not suit all applications. If cables overheat, 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 ampere.
( ) = mm2 for metric use
S-0007-F
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.
Notes
TM-4433 Page 17
Socket Information
24 VOLTS AC
REMOTE
OUTPUT
CONTROL
LDR-14 long
distance remote
(includes 120 V
receptacle)
115 VOLTS AC
OR
803 562
GND
Chassis common.
NEUTRAL
Notes
TM-4433 Page 18
Notes
Welding Symbols
Ref. AWS/ANSI A2.4
TM-4433 Page 19
9
7
10
1
TM-4433 Page 20
Preheat Switch
To Start:
NOTICE Do not use ether.
Fuel Gauge/Hourmeter
Light goes on and engine stops if engine temperature exceeds 230 F (110 C) or engine
oil pressure is below 10 psi (69 kPa).
Process/Contactor Switch
Voltage/Amperage Control
Weld Controls
Voltmeter displays preset voltage (MIG welding) with contactor off, and actual output voltage with the contactor on. Voltmeter displays
voltage at the weld output terminals, but not
necessarily the welding arc due to resistance
of cable and connections.
DC Voltmeter
To set voltage, turn contactor off and turn Process/Contactor switch to Wire position. Turn
V/A control until desired voltage is displayed
on Voltmeter. When welding is finished, voltmeter displays weld voltage and then defaults
to preset voltage.
10 DC Ammeter
Ammeter displays preset amperage (Stick
and TIG only) when not welding, and actual
output amperage when welding.
To set amperage, turn Process/Contactor
switch to Stick or TIG position. Turn V/A control until desired amperage is displayed on
Ammeter. When welding is finished, ammeter
displays weld amperage and then defaults to
preset amperage.
TM-4433 Page 21
Process/Contactor Switch
Process
At Remote 14 Receptacle
Active
At Remote 14 Receptacle
Active
MIG (GMAW)
w/Constant Speed Feeder
At Remote 14 Receptacle
Active
MIG (GMAW)
w/Voltage Sensing Feeder
Electrode Hot
Active
Stick (SMAW),
Air Carbon Arc (CAC-A) Cutting
And Gouging
Electrode Hot
Active
Electrode Hot
Active
TM-4433 Page 22
Touch
12
Seconds
TIG Electrode
Workpiece
Notes
TM-4433 Page 23
In Example:
Min = 20 A DC
Max = 205 A DC
Connect Remote
Control To Remote
Receptacle RC14
Connect Remote
Control To Remote
Receptacle RC14
Set WIRE Process
TM-4433 Page 24
217 357-A
120 V 20 A AC (shown)
Receptacle RC5 and/or GFCI1
240 V 50 A AC
Receptacle RC11
RC5 / 6 and GFCI1 / 2 supply 60 Hz singlephase power at weld/power speed. Receptacle configuration varies depending on
machine model and serial number.
Maximum output from these receptacles is
2.4 kVA/kW.
If a ground fault is detected, GFCI Reset
button pops out and receptacle does not
work. Check for faulty equipment plugged
Big Blue 300 P
weld/power speed and press test button to verify GFCI is working properly.
CB4 protects RC6 / GFCI2 and CB6 protects RC5 / GFCI1 from overload. If a supplementary protector opens, the receptacle
does not work. Press button to reset.
Supplementary protector CB5 protects receptacles and the generator winding from
overload. If CB5 opens, the receptacles do
not work. Place CB5 switch in On position
to reset circuit breaker.
Combined output of all receptacles is limited to the 10 kVA/kw rating of the generator.
EXAMPLE: If 15 A is drawn from each 120
V receptacle , only 26 A is available at the
240 V receptacle:
2 x (120 V x 15 A) + (240 V x 26 A) =
10.0 kVA/kW
TM-4433 Page 25
SECTION 7 MAINTENANCE
7-1. Routine Maintenance
!
Recycle engine
fluids.
= Check
= Change
= Clean
* To be done by Factory Authorized Service Agent
See
= Replace
Reference
Every
8
Hours
Section 4-6,
7-8
Coolant Level
Fuel Level
Oil Level
Every
50
Hours
Weld Terminals
Every
100
Hours
Section 7-3
Battery Terminals
Every
250
Hours
1/2 in.
(13 mm)
Unreadable Labels
Spark Arrestor
Weld Cables
Fuel Filter
Radiator Thermostat
Every
500
Hours
Every
1000
Hours
FUEL
OR
SLUDGE
Radiator Fluid Level
Inside Unit
Valve Clearance*
Section 4-6,
7-10, 7-8
and Engine
Manual
Drain Sludge
Slip Rings*
Brushes*
Every
2000
Hours
Injectors*
TM-4433 Page 26
TM-4433 Page 27
Stop engine.
be cleaned but the dirt holding capacity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while cleaning and the possibility of filter damage
makes cleaning a risk. Consider the
risk of unwarrantable equipment
damage when determining whether
to clean or replace the primary element.
Optional
5
If you decide to clean the primary element, we strongly recommend installing an optional safety element to provide additional engine protection.
Never 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 primary element if damaged. Replace primary element yearly or after six
cleanings.
1
Keep nozzle
2 in (51 mm)
from element.
Housing
Primary Element
Dust Cap
Dust Ejector
Blow
Inspect
aircleaner1 2/01 ST-153 929-B / ST-153 585 / Ref. S-0698-B / Ref. 217 357-A
TM-4433 Page 28
Cleanout Plug
Exhaust Pipe
!
3
Radiator Draincock
803 563
TM-4433 Page 29
Engine Speed
(No Load)
RPM (Hz)
Weld/Power
1880 (61.7)
Maximum
Stop engine.
Close door.
2
1
Tools Needed:
803 563-E
TM-4433 Page 30
Lock Nut
Rubber Boot
Adjustment Screw
Be
Weld/Power Speed
Adjustment
Weld/power speed
Stop engine.
To
prevent solenoid
damage, be sure a 1/8
in (3 mm) gap exists between the engine low
speed
screw
and
throttle lever when the
solenoid is held in the
energized position.
803 563-G
TM-4433 Page 31
1
2
3
Oil Filter
Oil Drain Valve And Hose
Oil Fill Cap
Tools Needed:
1
802 490 / Ref. 801 434
TM-4433 Page 32
Stop engine.
Fuse F1
CB1 protects the engine battery circuit. If CB1 opens, the engine will not
crank. CB1 automatically resets
when the fault is corrected. If CB1
continues to open, check fuel solenoid FS1, the fuel pump, throttle solenoid TS1, integrated rectifier SR1,
engine alternator, glow plug, and circuit boards PC2 and PC3.
CB2 protects the engine wiring harness. If CB2 opens, the engine will
not crank. Press button to reset
breaker. If CB2 continues to open,
check fuel solenoid FS1, the fuel
pump, throttle solenoid TS1, integrated rectifier SR1, and circuit
boards PC2 and PC3.
CB3 protects part of the weld control
wiring harness. If CB3 opens, weld
and generator power output stops. If
CB3 continues to open, check circuit
boards PC1, PC2, and PC3.
TM-4433 Page 33
Replace
Damaged Brushes
1
Ref 2114 778D / S0233A
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)
TM-4433 Page 34
HL.P
20
HL.P
21
HL.P
22
HL.P
23
HL.P
24
HL.P
25
To
Help 20 Display
Help 21 Display
Help 22 Display
Help 23 Display
Help 24 Display
Help 25 Display
TM-4433 Page 35
1 Engine
Supplies force to turn revolving fields.
Voltage
Regulator
Board PC3
4
Fuse F1
3 Stator Windings
Supply power to exciter, generator power, and weld circuits.
Current
Feedback
4 Fuse F1
Protects exciter windings from overload.
1
2
Engine
Stator Windings
Exciter
Revolving
Fields
(Rotor)
Weld
Generator Power
6
Supplementary
Protectors
CB4, CB5, CB6
7
AC
Receptacles
GFCI1, GFCI2,
RC11
9
115 VAC
Supplementary
Protector
CB7
TM-4433 Page 36
24 VAC
Filter Board
PC6/Remote
Receptacle
RC14
8
Supplementary
Protector
CB8
12
Control
Board
PC1
AC Or DC Control Circuits
Weld Current Circuit
External Circuits
3 Power
13 Thermostat TH1
Thermostat opens and stops all
weld output if unit overheats.
14 Meter Board PC2
Displays preset and actual (rectified
and filtered) values of the weld voltage and amperage.
15 Main Rectifier
Changes AC weld current to DC.
18
CC
20
Stabilizer
Z1
CV
Works with PC1 (item 12) to controls weld output by changing rectifier SCR gate pulses (conduction
times) after comparing voltage (CV)
or amperage (CC) feedback to selected voltage or amperage signal.
16
CC Weld
Output
Terminal
16 Burden Resistor R3
Provides a path for a minimum SCR
holding current to flow.
Electrode
Burden
Resistor R3
15
20
19
CV Weld
Output
Terminal
Capacitor
Bank C10
Main
Rectifier
18 Stabilizer Z1
Smooths (filters)
current.
weld
output
20
17
Hall Device
HD1
SCR
Gating
Signals
10
CC or CV
Voltage
Feedback
11
Voltage/
Amperage
Control R2
Work
14
13
Process/
Contactor
Switch R1
Current
Feedback
Work () Weld
Output
Terminal
Thermostat
TH1
Meter
Board PC2
TM-4433 Page 37
TM-4433 Page 38
Reference:
DC common - lead 42
Unless otherwise noted
TM-4433 Page 39
SECTION 9 TROUBLESHOOTING
9-1.
Troubleshooting Tables
See Section 9-2 for test points and
Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 7-11).
A. Welding
Trouble
Remedy
No weld output; generator power output Place Process/Contactor switch in a Weld Terminals Always On position, or place switch in a Remote
okay at AC receptacles.
On/Off Switch Required position and turn remote contactor on (see Section 4-9).
Reset supplementary protector CB7 or CB8 (see Section 7-9). Check for faulty remote device connected
to RC14.
Check and secure connections to Remote Control receptacle RC14 (see Section 4-9).
Check resistance and connections of Voltage/Amperage Adjust control R2; R2 is 1000 ohms 10%.
Replace R2 if necessary.
Check reactor Z1 for signs of winding failure. Check continuity across windings, and check for proper
connections. Replace Z1 if necessary.
Check Voltmeter/Ammeter help displays (see Section 7-11).
No weld output, or generator power out- Disconnect equipment from generator power receptacles during start-up.
put at AC receptacles.
Reset supplementary protector CB3 (see Section 7-9).
Check fuse F1, and replace if open (see Section 7-9). If F1 is open, check the voltage regulator board
PC3. (If PC3 senses an overload condition (shorted rotor), it protects itself by stopping weld output.
Check rotor and brushes before replacing PC3.)
Check Voltmeter/Ammeter help displays (see Section 7-11).
Check control relay CR1 for proper coil voltage and connections. Check continuity of coil. Replace CR1
if necessary.
Clean slip rings, and install new brushes if necessary (see Section 9-15).
Disconnect leads 105 and 108 from the rotor, and check continuity across slip rings. Replace rotor if necessary.
Disconnect stator excitation leads 100 and 101, and check continuity between leads. Replace stator if
necessary.
Check voltage regulator board PC3 and connections, and replace PC3 if necessary (see Section 9-10).
(If PC3 senses an overload condition (shorted rotor), it protects itself by stopping weld output. Check rotor
and brushes before replacing PC3.)
Erratic weld output.
Check hall device HD1, and replace if necessary (see Section 9-2).
TM-4433 Page 40
Trouble
Remedy
Check main control board PC1 and connections, and replace PC1 if necessary.
No 24 volt or 115 volt AC output at Re- Reset supplementary protector CB7 (24 volt) or CB8 (115 volt) (see Section 7-9).
mote receptacle RC14.
Check filter board PC6, and replace if necessary.
B. Generator Power
Trouble
Remedy
No generator power output at AC recep- Reset receptacle supplementary protectors (see Section 6-1).
tacles; weld output okay.
Check resistance of generator power windings between leads 91 and 92. Replace stator if
necessary.
No generator power or weld output.
Check voltage regulator board PC3 and connections, and replace PC3 if necessary (see Section 9-10).
(If PC3 senses an overload condition (shorted rotor), it protects itself by stopping weld output. Check rotor
and brushes before replacing PC3.)
TM-4433 Page 41
Trouble
Low output at generator power AC
receptacles.
Remedy
Check engine speed, and adjust if necessary.
Check fuse F1, and replace if open (see Section 7-9). If F1 is open, check the voltage regulator board
PC3 (see Section 9-10). (If PC3 senses an overload condition (shorted rotor), it protects itself by stopping
weld output. Check rotor and brushes before replacing PC3.)
C. Engine
Trouble
Engine will not crank.
Remedy
Check battery, and replace if necessary.
Check battery connections and tighten if necessary.
Circuit breaker CB1 may be open. CB1 automatically resets when fault is corrected (see Section 7-9).
Check engine wiring harness and components.
Reset supplementary protector CB2 (see Section 7-9).
Check engine wiring harness plug connections.
Check continuity of Engine Control switch S1, and replace if necessary.
Check Fuel Gauge/Hourmeter FUEL HM and connections, and replace FUEL/HM if necessary.
Check control relay CR1 for proper coil voltage and connections. Check continuity of coil and condition
of contacts. Replace CR1 if necessary.
Check control relay CR2 for proper coil voltage and connections. Check continuity of coil and condition
of contacts. Replace CR2 if necessary.
Check oil and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolant
temperature is too high (see Section 4-6 ).
Reset circuit breaker CB1 and/or CB2 (see Section 7-9). Check engine alternator, engine harness,
throttle solenoid TS1, fuel solenoid FS1, and the fuel pump.
Check continuity of Engine Control switch S1, and replace if necessary.
Check control relay CR1 for proper coil voltage and connections. Check continuity of coil and condition
of contacts. Replace CR1 if necessary.
Check integrated rectifier SR2, and replace if necessary.
Check fuel solenoid FS1 for proper coil voltage and connections. Check continuity of coil. Replace
FS1 if necessary.
Check Fuel Gauge/Hourmeter FUEL HM and connections, and replace FUEL/HM if necessary.
TM-4433 Page 42
Trouble
Remedy
Check fuel pump according to engine manual.
Check engine wiring harness and plug connections.
See engine manual.
Engine uses oil during run-in period; Dry engine according to run-in procedure (see Section 12).
wetstacking occurs.
Notes
TM-4433 Page 43
9-2.
Troubleshooting Circuit Diagram For Welding Generator (Use With Section 9-3)
V7,R7
V6,
R6
R13
V8,R8
V1,R1
E
E
V9,R9
V2,R2
I1
V3,R3
V4,R4
See Section 9-10 for
PC3 data
V5,R5
See Section
9-12 for PC2
data
Starter control
relay CR2
V23
Engine
control
relay CR1
V25
V24
V26
R12
V12
V10,
R10
Glow plug
relay CR3
TM-4433 Page 44
Throttle Solenoid
TS1 (Pull To Idle)
V11,
R11
Idle control
relay CR4
V17,
A,C
V18,
B,D
E
E
E
E
E
V21
V22
V19
V20
V13, R14
V14
V15 V16
See Section
9-5 for
PC6 data
See Section
4-9 for RC14
information
219 228-E
TM-4433 Page 45
9-3.
Voltage Readings
a)
b)
c)
d)
e)
Resistance Values
Tolerance
specified
b)
c)
Wiring Connections
Section 11
d)
V1
V2
V3
V4
158 volts ac
V5
24 volts ac
V6
46 volts ac
V7
46 volts ac
V8
46 volts ac
V9
+ 61 volts DC
V10
+12 volts DC
R12
V11
+12 volts DC
V12
+12 volts DC
R13
V13
V14
+5 volts DC
V15
R1 thru R8
R9
R10
R11
R14
10%
a)
unless
see
Amperage Readings
Tolerance 5% unless specified
V16
+5 volts DC
a)
V17
b)
c)
V18
Process/Contactor switch R1 in
Weld Terminals Always On Stick
(Dig-B) position unless noted
I1
V19
Circuit common
3.1 amps DC
4.6 amps at 20 volt, 200 amp load
V20
V21
15 volts DC
V22
+15 volts DC
V23
+12 volts DC
V24
V25
V26
TM-4433 Page 46
Notes
HORIZONTAL
BUTT
1G
VERTICAL
BUTT
2G
FILLET
Ref. AWS/ANSI D1.1
TJOINT
1F
BUTT
4G
BUTT
3G
TJOINT
2F
GROOVE
OVERHEAD
TJOINT
4F
TJOINT
3F
TM-4433 Page 47
9-4.
The waveforms represent the output of the welding power source. When operating properly, the power source waveforms match those shown.
2 ms 50 V
gnd
2 ms 50 V
gnd
2 ms 20 V
gnd
TM-4433 Page 48
2 ms 50 V
gnd
2 ms 20 V
gnd
C. CC/DC Output, 30 Volts DC, 250 Amperes, Process/Contactor Switch R1 In Weld Terminals
Always On Stick (Dig B) Position, (Resistive
Load)
D. CV/DC Output, 30 Volts DC, 250 Amperes, Process/Contactor Switch R1 In Weld Terminals
Always On Wire Position, (Resistive Load)
5 ms 2 V
gnd
TM-4433 Page 49
9-5.
Stop engine.
Prior to LH030117E
1
2
Eff w/LH030117E
9-6.
Receptacle
Pin
RC2
Circuit common for 24 and 115 volt AC contactor control circuits (Lead No. 80)
Contactor control circuit: 24 volt AC input with respect to pin RC2-5 and closure on RC14 between
pins A and B
Command common
Remote command signal input: 0 to +10 volts DC input from min to max of remote voltage/amperage
control
10
TM-4433 Page 50
Value
9-7.
Locate 30pin plug PLG6 and disconnect from PC1 module RC6.
Install jumper wires at the following
pins on PLG6:
G3 (Lead No. 117) to H3 (Lead No.
113)
1
Receptacle RC7
803 702
TM-4433 Page 51
9-8.
Stop engine.
2
3
803 702
TM-4433 Page 52
9-9.
10% unless
Pin
PLG6
A1
A2
+5 volts DC output
A3
CV weld feedback with respect to pin PLG6-B3: same as OCV or load voltage
B2
Command signal input: 0 to +5 volts DC input from min to max of Voltage/Amperage control R2
B3
C1
C2
C3
CC weld feedback with respect to pin PLG6-B3; same as OCV or load voltage
D2
D3
E2
Synchronization signal
E3
F1
F2
F3
G1
G2
G3
Shutoff command output (field current); normal condition: 0 volts DC, fault condition: 0.7 volts DC
H1
H2
Remote command signal input: 0 to +10 volts DC input from min to max of remote voltage/amperage
control
H3
Circuit common
J1
J3
K1
+5 volts DC output
K3
24 volts AC input
A1
0 to +5 volts DC from Weld Terminals Always OnWire position to RemoteWire position of Process
Contactor switch R1 (in 0.45 volt increments)
A2
1 volt DC input per 100 amperes of weld output with respect to pin PLG7-C2
B1
B2
B3
Contactor control circuit: 24 volt AC input with respect to circuit common and closure on RC14 between pins A and B
C1
+5 volts DC output
C2
Circuit common
C3
PLG7
Value
TM-4433 Page 53
Receptacle
PLG11
TM-4433 Page 54
Pin
Value
D1
+2 volts DC input at 77 F
D2
E1
F1
Command common
F2
Weld idle control signal: 0 volts DC output when welding; 3.5 volts DC input when not welding
F3
A1
A2
A3
B1
B2
B3
C1
C2
C3
D1
D2
D3
E1
E2
E3
F1
F2
F3
Stop engine.
2
3
803 702
TM-4433 Page 55
10% unless
Pin
RC1
Circuit common
Circuit common
Shutoff command input (field current): normal condition: 0 volts DC, fault condition: 0.7 volts DC
10
11
Synchronization signal
12
Not used
Not used
Not used
Not used
10
Not used
11
Not used
12
Not used
RC2
TM-4433 Page 56
Value
Stop engine.
See Section 9-13 for specific values during testing. Voltage readings tolerance 10%.
1
10% unless
Pin
RC1
Circuit common
Value
TM-4433 Page 57
9-14. Idle Module PC5 Testing Information And Troubleshooting Flow Chart
Verify engine
H
A
803 566
TM-4433 Page 58
NO
Check Engine
Control switch S1,
and ground connection (lead 42).
YES
NO
Check Engine
Control switch S1,
and ground connection (lead 42).
YES
NO
YES
Check Engine
Control switch S1,
control relay CR1,
and ground connection (lead 42).
NO
Check connections
to current
transformer.
NO
Check main
control board
PC1.
YES
0 (zero) volts ac present?
NO
Disconnect load
from generator
power receptacles.
Check current
transformer.
0 Volts dc present?
YES
NO
Check main
control board
PC1.
YES
Connect meter between
terminal C (+) and terminal E ().
NO
Replace
idle module.
YES
NO
Replace
idle module.
YES
Check control relay CR4,
throttle solenoid TS1,
and connections.
Reinstall cover.
Reinstall cover.
TM-4433 Page 59
Brush Holder
Slip Rings
Stop engine.
6
1
5/16 in (8 mm)
Minimum Length
9/16 in (14.3 mm)
New Length
Tools Needed:
Replace
Damaged Brushes
TM-4433 Page 60
AC Receptacles GFCI1,
GFCI2, RC1
Stop engine.
Pre-Operational Checks
Wipe engine surfaces clean.
Check labels; replace labels that are unreadable or damaged.
Check fuel and oil (see Section 4-7).
Tools Needed:
TM-4433 Page 61
Disconnect:
Go to Section 10-2.
Remove brushes
before removing
endbell or rotor.
803 704
TM-4433 Page 62
A
5
2
3
B
14
Torques:
A
20 ft lb (27 N.m)
10 ft lb (14 N.m)
60 in lb (7 N.m)
30 ft lb ( 41N.m)
803 686
Brushes
Stator
Endbell
Rotor
Stud
Reassembly Instructions:
TM-4433 Page 63
Rectifier Assembly
SCR Module
Remove left side panel. Remove rectifier assembly screws and slowly tilt assembly out.
Remove defective SCR module.
Clean mounting surface where module
will be installed
Apply a thin layer of supplied heat sink
compound to mounting surface of
module.
Install new SCR module. Follow torque
specifications in table when installing
part. Remember to re-torque hardware as specified.
Remove protective foam from SCR terminals (if applicable) before connecting
leads.
803 703
TM-4433 Page 64
The following is a list of all diagrams for models covered by this manual.
Model
Circuit
Diagram
219 228-E
217 005-A
229 948-A
214 535-B
Wiring
Diagram
See Table 11-1
Notes
Figure 11-1. Circuit Diagram For Big Blue 300 P Eff w/LE099775 And Following
TM-4433 Page 66
219 228-E
TM-4433 Page 67
217 005-A
Figure 11-2. Circuit Board PC6 (HF Filter) Effective w/LE099775 Thru LH030117E
TM-4433 Page 68
214 535-B
Figure 11-3. Circuit Board PC2 (Meter Display) Effective w/LE099775 And Following
Big Blue 300 P
TM-4433 Page 69
Table 11-1. Lead List Summary For Big Blue 300 P Models Eff w/LF310974 And Following
Table shows physical lead connections and should be used with circuit diagram (table replaces wiring diagram).
Apply small amount of dielectric grade, nonconductive electric grease (Miller Part No. 146 557) to connectors where factory-applied
grease had been present.
Lead
Connections
Lead
Connections
. .
. .
. .
. .
11A . . .
16A . . .
16A . . .
16B . . .
17A . . .
18A . . .
19A . . .
19A . . .
19B . . .
21A . . .
30A . . .
30A . . .
30B . . .
30B . . .
31A . . .
40A . . .
40B . . .
41A . . .
42A . . .
42A . . .
42A . . .
42AA . .
42AB . .
42B . . .
42B . . .
42B . . .
42C . . .
42C . . .
42D . . .
42E . . .
42F . . .
42G . . .
42H . . .
42J . . .
42K . . .
42L . . .
42M . . .
42N . . .
42P . . .
42Q . . .
42R . . .
42TG . .
42X . . .
42Y . . .
43A . . .
43B . . .
43C . . .
43D . . .
43E . . .
44A . . .
45A . . .
47A . . .
48A . . .
49A . . .
50A . . .
51A . . .
51B . . .
52B . . .
52C . . .
52D . . .
52E . . .
53A . . .
53B . . .
54A . . .
PLG1 TO G2
PLG1 TO K1
PLG1 TO K2
PLG1 TO G1
STATOR TO RECT.
PLG6 (A3) TO R3 RIGHT
SCRS CV (+) TO C10 (+)
SCR CV (+) TO R3 (RIGHT)
Z1 TO SCRS CC (+)
Z1 (CV) TO CV OUTPUT STUD
PLG6 (C3) TO R3 LEFT
Z1 (CC) TO CC OUTPUT STUD
Z1 TO R3 (LEFT)
STATOR TO RECT.
PLG6 (B3) TO R3 CENTER
SCRS () TO C10 ()
C10 () TO NEG OUTPUT STUD
HEAT SINK () TO R3 (CENTER)
STATOR TO RECT.
CR1 (8) TO PLG5 (1)
CR1 (8) TO PLG9 (1)
CB1 (BAT) TO STARTER
GROUND STUD TO TE1
GROUND TERMINAL TO PLG9 (3)
S2 (1) TO GROUND TERMINAL
GFCI1 (GRND) TO GRND STUD ON POWER PANEL
GFCI2 (GRND) TO GRND STUD ON POWER PANEL
GROUND TERMINAL TO PLG5 (2)
S3 (1) TO GROUND TERMINAL
TE1 TO BASE GROUND
GR STUD POWER PANEL TO RC11 (GR)
PLG6 (J1) TO EXIT
FS1 (2) TO GROUND TERMINAL
FUEL PUMP TO GROUND TERMINAL
SR2 TO GROUND TERMINAL
SR3 TO GROUND TERMINAL
PC5 (E) TO GROUND TERMINAL
CR4 (85) TO GROUND TERMINAL
CR3 (85) TO GROUND TERMINAL
PC5 (E) TO CT
GROUND TERMINAL TO GROUND TERMINAL
FUEL LEVEL SENDER TO GROUND TERMINAL
FUEL SENDER GROUND TO PLG1 (8)
ENGINE BLOCK GROUND TO GROUND TERMINAL
GROUND TERMINAL TO CR2
T15 TO TE1
ENGINE BLOCK GROUND TO TS1
FRONT PANEL GROUND STUD TO TE1
ALT (B) TO CB1 (AUX)
CB1 (AUX) TO CB2
CB2 TO CB3
CR3 (87) TO CB1 (AUX)
CB1 (AUX) TO CB9
CR3 (30) TO GLOW PLUG
CB3 TO CR1 (6)
CR2 TO STARTER
CB2 TO S1 (A)
SR1 TO R4
ALT (D+) TO SR1 (+)
CR2 TO S1 (C)
CR2 TO PLG1 (6)
R4 TO CR1 (4)
CR1 (4) TO SR2
SR2 TO CR2
CR2 TO PC5 (B)
FS1 (1) TO SR2
SR2 TO FUEL PUMP
CR1 (1) TO PLG1 (7)
55A . . .
55B . . .
55C . . .
55D . . .
56A . . .
57A . . .
58A . . .
60A . . .
60B . . .
61A . . .
61B . . .
62A . . .
65A . . .
67A . . .
70A . . .
71A . . .
80 . . . .
80A . . .
81A . . .
81A . . .
84A . . .
84C . . .
85A . . .
87 . . . .
90A . . .
90A . . .
90C . . .
90D . . .
91A . . .
91A . . .
91B . . .
91B . . .
91C . . .
92A . . .
92A . . .
92B . . .
92B . . .
94A . . .
94B . . .
95A . . .
95B . . .
99C . . .
100A . .
100B . .
101A . .
105A . .
106A . .
107A . .
108A . .
109A . .
112A . .
113A . .
114A . .
117A . .
120A . .
121A . .
130A . .
132 . . .
135A . .
136A . .
137A . .
140A . .
141A . .
148A . .
150A . .
160A . .
161A . .
162A . .
TM-4433 Page 70
Table 11-1. Lead List Summary For Big Blue 300 P Models Eff w/LF310974 And Following
(Continued)
Lead
165A
166A
167A
180A
181A
..
..
..
..
..
Connections
PLG6 (C2) TO PLG2 (1)
PLG6 (B2) TO PLG2 (2)
PLG6 (A2) TO PLG2 (3)
PLG6 (F1) TO EXIT
PLG6 (G1) TO EXIT
Lead
182A
188A
189A
190A
191A
..
..
..
..
..
Connections
PLG6 (H1) TO EXIT
PLG7 (C1) TO PLG4 (1)
PLG7 (D1) TO PLG4 (2)
PLG6 (A1) TO PLG5 (3)
PLG6 (C1) TO PLG5 (4)
TM-4433 Page 71
12-1. Wetstacking
NOTICE Do not perform run-in
procedure at less than 20 volts
weld output and do not exceed duty
cycle or equipment damage may
occur.
1
2
Welding Generator
Run diesel engines near rated voltage and current during run-in period
to properly seat piston rings and
prevent wetstacking. See nameplate, rating label, or specifications
section in this manual to find rated
voltage and current.
NOTICE Do not idle engine longer
than necessary. Piston rings seat
faster if engine runs at weld/power
rpm, and the welding generator is
kept loaded during run-in.
2
TM-4433 Page 72
4
2
1
S-0683
TM-4433 Page 73
1 Resistance Grid
Use grid sized for generator rated
output.
Turn Off grid.
2 Welding Generator
Place A/V range switch in maximum position, A/V control in minimum position, and Output Selector
switch (if present) in either DC
position.
3 Weld Cables
Connect grid to generator weld
output terminals using proper size
weld cables with correct connectors (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, rating label, or the
specifications section in this
manual).
S-0684
TM-4433 Page 74
TM-4433D
200907
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A) Cutting
and Gouging
Description
www.MillerWelds.com
9
10
17
18
19
20
11
12
21
13
14
23
16
24
15
6 (Fig.13-5)
28
22
27
25 26
2
101
102
103
1 (Fig.13-3)
109
97
98
96
95
94
93
92
100
99
108 (Fig.13-2)
91
90
104
106
105
107
34
33
31
30
35
32
43
110
36
29
38
111
44
42
37
41
45
40
79
39
78
46
77
76 75
80
73
88
81 (Fig. 13-4)
89
74
87
82
86
83
85
84
72
71
48
49
70
59
69
68
67
66
65
64
63
62
61
60
47
50
51
52
58
53
57
56
54
55
TM-4433 Page 77
Dia.
Mkgs.
Part
No.
Description
Quantity
TM-4433 Page 78
1
1
1
1
1
1
1
1
1
1
6
2
1
1
1
1
1
1
1
1
2
1
3
1
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
1
15
1
1
1
1
1
1
1
1
1
1
1
2
1
Dia.
Mkgs.
Part
No.
Description
Quantity
TM-4433 Page 79
Dia.
Mkgs.
Part
No.
Description
Quantity
TM-4433 Page 80
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
8
2
1
1
1
2
1
1
1
4
1
1
1
2
2
1
2
2
1
1
2
1
1
1
1
1
1
Dia.
Mkgs.
Part
No.
Description
Quantity
105
105
106
107
108
109
110
. . . . . . . . . . . . . 200795
. . . . . . . . . . . . . 233953
. . . . . . . . . . . . . 216347
. . . . . . . . . . . . . 220955
. . . . . . . . . Figure 132
. . . . . . . . . . . 105370
. . . . . . . . . . . . 233 088
..
..
..
..
..
..
..
TM-4433 Page 81
11
10
12
8
9
13
14
15
6
16
5
25
4
2
23
17
24
22
18
19
37
36
24
26
27
20
21
35
28
30
29
31
34
32
33
803 684-B
Dia.
Mkgs.
Part
No.
Description
Quantity
1
2
3
4
5
6
7
7
8
. . . . . . . . . . . . . . 097926 . .
. . . . . . . . . . . . . . 072590 . .
. . . . . . . . . . . . . . 170391 . .
. . . . . . . . . . . . . . 190323 . .
. . . . . . . . . . . . . . 097922 . .
........................
. . . . PC6 . . . . 217008 . .
. . . . PC6 . . . . 229949 . .
. . CB7, CB8 . . 083432 . .
TM-4433 Page 82
1
1
1
2
1
1
1
1
2
Dia.
Mkgs.
Part
No.
Description
Quantity
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
24
25
26
27
28
29
30
31
32
33
34
35
36
37
. . . . . . . . . . . . . . 213655 . .
. . . . . . . . . . . . . . 214543 . .
. . . . . . . . . . . . . . 134201 . .
. . . . PC2 . . . . 214660 . .
. . . . . R1 . . . . . 214760 . .
. . . . . R2 . . . . . 193118 . .
. . . . . S4 . . . . . 021467 . .
. . . . . S1 . . . . . 212436 . .
. . . . . . . . . . . . . . 039047 . .
. . . . . . . . . . . . . . 010381 . .
. C13, 14, 15 . 128750 . .
. . . . . . . . . . . . . . 209056 . .
. . . . RC11 . . . . 182954 . .
........................
. . . . . . . . . . . . . . 213509 . .
. . . RC5,6 . . . 214918 . .
. . GFCI1, 2 . . 151981 . .
. . C11, C12 . . 217054 . .
. . CB4, CB6 . . 093996 . .
. . . . CB5 . . . . 203026 . .
. . . . GRD . . . . 083030 . .
. . . . . . . . . . . . . . 010915 . .
. . . . . . . . . . . . . . 601836 . .
........................
. . . . . . . . . . . . . . 181169 . .
. . . . . . . . . . . . . . 186621 . .
. . . . . . . . . . . . . . 180735 . .
. . . . . . . . . . . . . . 039046 . .
. . FUEL/HM . . 214768 . .
. . . . . . . . . . . . . . 021385 . .
Optional
+
When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
TM-4433 Page 83
6
7
9
10
11
12
13
14
803 689-D
15
Dia.
Mkgs.
Part
No.
Description
Quantity
1
2
3
4
5
5
5
6
7
8
9
10
11
12
13
14
15
. . . . . . . . . . . . . . 220981
. . . . . . . . . . . . . . 129524
. . . . CR2 . . . . 214876
. . . . CB1 . . . . 190374
. . . . CR1 . . . . 199999
. . . . CR1 . . . . 223669
. . . . CR1 . . . . 223710
. . . . . . . . . . . . . . 046432
. . . . . F1 . . . . . 085874
. . . . . R4 . . . . . 217335
. . . . CR4 . . 090104
. . . . CR3 . . . . 197325
. . . . SR3 . . 035704
. . SR1, SR2 . . 035704
. . . . PC5 . . 214761
. . CB2, CB3 . . 083432
. . . . CB9 . . 230635
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
1
2
1
1
1
1
1
1
1
1
1
1
1
2
1
2
1
Optional
+
When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
TM-4433 Page 84
6
7
2
8
9
10
11
12
13
14
20
19 18
17 16
803 686-A
15
Dia.
Mkgs.
Part
No.
Description
Quantity
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
. . . ROTOR . . .
..............
..............
..............
..............
..............
..............
..............
..............
..............
. . STATOR . .
..............
..............
..............
..............
..............
..............
..............
..............
..............
212474
053390
192600
159918
212126
602211
192686
602211
192686
212641
212470
160943
167788
218552
047879
161306
126984
005614
125548
158832
1
1
1
1
1
6
6
6
6
4
1
1
4
1
1
2
2
2
1
2
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
Optional
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Big Blue 300 P
TM-4433 Page 85
7
10
8
4
9
803 685-A
Dia.
Mkgs.
Part
No.
Description
Quantity
217081
211984
218296
218292
212602
212639
212601
213930
215611
048420
217085
181853
1
1
3
3
1
3
1
1
3
3
1
4
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
TM-4433 Page 86
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Wiring Harnesses
....................
....................
. . . . . . . . . . . S4 . . . . .
. . . . . . . . SR1, SR2 . .
. . . . . . . . . . CB1 . . . .
. . . . . . . . CB2, CB3 . .
. . . . . . . . . . CR3 . . . .
. . . . . . . . . . CR2 . . . .
. . . . . . . . . . . R4 . . . . .
....................
....................
....................
. . . . . . . . . . PLG1 . . . .
....................
....................
. . . . . . . . . For S1 . . .
. . . . . . . . . For S1 . . .
....................
. . . . . . . . . . CB9 . . . .
219231
231122
021467
035704
190374
083432
197325
214876
217335
148850
212116
212117
214932
214933
214934
211292
211293
129524
230635
1
1
1
2
1
2
1
1
1
1
3
3
1
7
1
1
1
2
1
....................
. . . . . . . . . . PLG2 . . . .
. . . . . . . . . . PLG9 . . . .
....................
....................
. . . . . . . . . . PLG8 . . . .
. . . . . . . . . . PLG6 . . . .
. . . . . . . . . . PLG7 . . . .
. . . . . . . . . . PLG9 . . . .
. . . . . . . . . PLG10 . . .
....................
....................
. . . . . . . . . . PLG5 . . . .
....................
....................
....................
217002
150316
214951
214933
214934
147992
193184
193183
215261
215262
215265
215343
113750
217000
215340
214933
1
1
1
3
3
1
1
1
1
1
2
7
1
1
1
2
....................
. . . . . . . . . PLG11 . . .
....................
....................
214984
193183
207716
207718
1
1
6
3
TM-4433 Page 87
International HeadquartersUSA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
For International Locations Visit
www.MillerWelds.com