Miller Electric Big Blue 251D manual From Miller to You

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Miller is the first welding equipment manufacturer in the U.S.A. to be registered to the ISO 9001:2000 Quality System Standard.

From Miller to You

Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way.

That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy.

Today, the people that build and sell Miller products continue 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 quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there’s a Troubleshooting section that will help you figure out what the problem is. The parts list will then help you to decide the exact part you may need to fix the problem. Warranty and service information for your particular model are also provided.

Miller Electric manufactures a full line

of welders and welding related equipment. For information on other quality Miller

products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets. To locate your nearest distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web.

Mil_Thank 7/03

Working as hard as you do

−every power source from Miller is backed by the most hassle-free warranty in the business.

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Contents Visit our website at OM-480128 576AC January ProcessesDescription Engine Driven Welding GeneratorFrom Miller to You Table of Contents Options and Accessories Warranty Symbol Usage Arc Welding HazardsEngine Hazards Compressed Air Hazards EMF Information Principal Safety StandardsCalifornia Proposition 65 Warnings Radiation can cause interferenceUN Choc Électrique peut tuer Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation LES Fumées ET LES GAZ peuvent être dangereuxDES Pièces Chaudes peuvent provoquer des brûlures graves LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux LE Bruit peut affecter l’ouïeLA Chaleur DU Moteur peut pro- voquer un incendie ’EXPLOSION DE LA Batterie peutDES Organes Mobiles peuvent provoquer des blessures ’AIR Comprimé peut provoquer des blessuresPrincipales normes de sécurité Information sur les champs électromagnétiquesSymbols And Definitions − DefinitionsDimensions, Weights, And Operating Angles − SpecificationsWeld, Power, And Engine Specifications Fuel Consumption Curve shows typical fuel use under weld or power loadsExceeding duty cycle can damage unit and void warranty Duty Cycle And OverheatingAC Generator Power Volt-Ampere CurvesOptional AC Power Plant Curves Connecting The Battery − InstallationInstalling Welding Generator Stop engine and let cool Installing Muffler PipeEngine Prestart Checks Fuel Do not use gasoline. GasolineInstalling Ether Cylinder Optional Ether Starting Aid Connecting To Weld Output Terminals350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Selecting Weld Cable Sizes150 ft 200 ft 250 ft Put terminals− Operating the Welding Generator Controls See SectionStop engine and fix trouble if either light goes on Description Of Front Panel Controls See SectionRemote A/V Control Do not use Ether if engine is runningX 15 a + 120 V x 10 a = 3.0 kVA/kW OM-480 − Operating Auxiliary EquipmentVolt Duplex And Optional Gfci Receptacles Circuit Breakers CB1 And CB2 Volt Duplex Receptacle Optional240 V 15 a AC Receptacle RC1 X 10 a + 120 V x 5 a = 3.0 kVA/kWConnecting Optional AC Power Plant 240 Volt Twistlock Receptacle Optional − Maintenance and Troubleshooting Maintenance Label Servicing Air Cleaner To replace primary fuel filter Servicing Fuel And Lubrication SystemsTo change oil and filter To replace secondary fuel filterModels With Automatic Idle Optional Adjusting Engine SpeedStandard Models Overload Protection Servicing Optional Ether Starting Aid Full EmptyStop engine and let cool. Reinstall cleanout plug Inspecting And Cleaning Optional Spark ArrestorTroubleshooting WeldingEngine Generator PowerCheck connections to ac power plant see Section Maximum see Section− Electrical Diagram Circuit Diagram For Welding GeneratorWelding Generator − RUN-IN ProcedureWetstacking Stop engine Do not touch hot exhaust Run-In Procedure Using Load BankProcedure at less than From flammables Do not PerformFrom flammables Run-In Procedure Using Resistance GridBank/grid Do not perform run-inGrounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesSelecting Equipment Earth ground if supplying Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Amperes x Volts = WattsIndustrial Motors Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsSingle-Phase Induction Motor Starting Requirements Power Required To Start MotorHow Much Power Can Generator Supply? KVA/HP x HP x 1000 = Starting AmperageTypical Connections To Supply Standby Power Work like a ProSelecting Extension Cord Use Shortest Cord Possible Current Load Watts AmperesOM-480 120 121 117 − Parts List125 124 123 122 1162526 126 Dia Part Description Quantity Mkgs 128 Panel, Front w/Components -1Item 111Panel, Front w/Components -1Item 111 Cont’d Generator Generator -1Item 114 IncludesPage Page Support ServiceYour distributor also gives For assistance in filing or settling claims, contact To locate a Distributor or Service Agency visitMiller Electric Mfg. Co Your distributor and/or equipment manufacturer’s