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TM-4433D

200907

Eff. w/LE099775 Thru LJ120230E

Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A) Cutting
and Gouging

Description

Engine Driven Welding Generator

Big Blue 300 P

File: Engine Drive


Visit our website at

www.MillerWelds.com

INFORMATION ON OLDER UNITS


 This manual includes operating information for current units. To obtain specific operating information for older models, download
Owners Manual from www.MillerWelds.com.

the applicable

 Eff w/LG440030E, engine speed adjustment procedures changed. For older models, download applicable Owners Manual from www.MillerWelds.com.

Big Blue 300 P

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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SECTION 1 SAFETY PRECAUTIONS FOR SERVICING


Protect yourself and others from injury read and follow these precautions.

1-1. Symbol Usage


OM-4433P - 200711, safety_rtm 200907

DANGER! Indicates a hazardous situation which, if


not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE Indicates statements not related to personal injury.

 Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC


SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.

1-2. Servicing Hazards


The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard.

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.

Only qualified persons should test, maintain, and repair this


unit.
During servicing, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.






 Do not touch live electrical parts.


 Stop engine and remove input power plug from
receptacle (if applicable) before testing or repairing unit unless the procedure specifically
requires an energized unit.
Insulate yourself from ground by standing or working on dry insulating mats big enough to prevent contact with the ground.
Do not leave live unit unattended.
If this procedure requires an energized unit, have only personnel
familiar with and following standard safety practices do the job.
When testing live unit, use the one-hand method. Do not put both
hands inside unit. Keep one hand free.

SIGNIFICANT DC VOLTAGE exists in inverter power


sources AFTER stopping engine.
 Stop engine on inverter and discharge input capacitors according
to instructions in Troubleshooting Section before touching any
parts.

MOVING PARTS can injure.


 Keep away from moving parts such as fans,
belts, and rotors.
 Keep away from pinch points such as drive
rolls.
 Have only qualified people remove doors,
panels, covers, or guards for maintenance
and troubleshooting as necessary.
 Keep hands, hair, loose clothing, and tools
away from moving parts.
 Before working on generator, remove spark plugs or injectors
to keep engine from kicking back or starting.
 Block flywheel so that it will not turn while working on generator components.
 Reinstall doors, panels, covers, or guards when servicing is
finished and before starting engine.

FLYING METAL or DIRT can injure eyes.


 Wear safety glasses with side shields or face
shield during servicing.
 Be careful not to short metal tools, parts, or
wires together during testing and servicing.
Big Blue 300 P

Using a generator indoors CAN KILL


YOU IN MINUTES.
 Generator exhaust contains carbon monoxide.
This is a poison you cannot see or smell.
 NEVER use inside a home or garage, EVEN IF
doors and windows are open.
 Only use OUTSIDE and far away from windows, doors, and
vents.

FUEL can cause fire or explosion.


 Stop engine and let it cool off before checking or
adding fuel.
 Do not add fuel while smoking or if unit is near
any sparks or open flames.
 Do not overfill tank; clean up any spilled fuel.

FIRE OR EXPLOSION hazard.


 Do not place unit on, over, or near combustible surfaces.
 Do not service unit near flammables.

BATTERY EXPLOSION can BLIND.






 Always wear a face shield, rubber gloves, and


protective clothing when working on a battery.
 Stop engine before disconnecting or connecting battery cables.
Do not allow tools to cause sparks when working on a battery.
Do not use welder to charge batteries or jump start vehicles.
Observe correct polarity (+ and ) on batteries.
Disconnect negative () cable first and connect it last.

BATTERY ACID can BURN SKIN and EYES.


 Do not tip battery.
 Replace damaged battery.
 Flush eyes and skin immediately with water.
TM-4433 Page 1

STEAM AND HOT COOLANT can burn.

H.F. RADIATION can cause interference.

 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.
 If the engine is warm, checking is needed, and there is no overflow tank, follow the next two statements.
 Wear safety glasses and gloves and put a rag over radiator cap.
 Turn cap slightly and let pressure escape slowly before
completely removing cap.






MAGNETIC FIELDS can affect Implanted


Medical Devices.
 Wearers of Pacemakers and other Implanted
Medical Devices should keep away from servicing areas until consulting their doctor and the
device manufacturer.

FALLING EQUIPMENT can injure.


 Use lifting eye to lift unit and properly installed
accessories only, NOT gas cylinders. Do not
exceed maximum lift eye weight rating (see
Specifications).
 Use equipment of adequate capacity to lift and
support unit.
 If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
 Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94110) when manually lifting heavy parts or equipment.

HOT PARTS can burn.


 Do not touch hot engine parts bare-handed.
 Allow cooling period before working on
equipment.
 To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.

TILTING OR TIPPING can injure.


 Do not put any body part under unit while lifting.
 Always use proper equipment (hoists, slings,
chains, blocks, etc.) of adequate capacity to lift
and support components (stator, rotor, engine,
etc.) as needed during job.

PINCH POINTS can injure.


 Be careful when working on stator and rotor assemblies.

EXPLODING PARTS can injure.


 Failed parts can explode or cause other parts to
explode when power is applied to inverters.
 Always wear a face shield and long sleeves
when servicing inverters.
TM-4433 Page 2

 High-frequency (H.F.) can interfere with radio


navigation, safety services, computers, and
communications equipment.
 Have only qualified persons familiar with electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.

OVERUSE can cause OVERHEATING.


 Allow cooling period; follow rated duty cycle.
 Reduce current or reduce duty cycle before
starting to weld again.
 Do not block or filter airflow to unit.

SHOCK HAZARD from testing.


 Stop engine or turn Off welding power source (if
applicable) before making or changing meter
lead connections.
 Use at least one meter lead that has a selfretaining spring clip such as an alligator clip.
 Read instructions for test equipment.

MAGNETIC FIELDS can affect Implanted


Medical Devices.
 Wearers of Pacemakers and other Implanted
Medical Devices should keep away from servicing areas until consulting their doctor and the
device manufacturer.

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.

HYDRAULIC EQUIPMENT can injure


or kill.
 Before working on hydraulic system, turn off
and lockout/tagout unit, release pressure, and
be sure hydraulic pressure cannot be accidentally applied.
 Do not work on hydraulic system with unit running unless you are a
qualified person and following the manufacturers instructions.
 Do not modify or alter hydraulic pump or manufacturer-supplied
equipment. Do not disconnect, disable, or override any safety
equipment in the hydraulic system.
 Keep away from potential pinch points or crush points created by
equipment connected to the hydraulic system.
 Do not work under or around any equipment that is supported only
by hydraulic pressure. Properly support equipment by mechanical
means.
Big Blue 300 P

HYDRAULIC FLUID can injure or kill.


 Before working on hydraulic system, turn off and
lockout/tagout unit, release pressure, and be sure
hydraulic pressure cannot be accidentally applied.
 Relieve pressure before disconnecting or connecting hydraulic lines.
 Check hydraulic system components and all connections and hoses for damage, leaks, and wear
before operating unit.
 Wear protective equipment such as safety
glasses, leather gloves, heavy shirt and trousers,
high shoes, and a cap when working on hydraulic
system.
 Use a piece of paper or cardboard to search for leaksnever use
bare hands. Do not use equipment if leaks are found.
 HYDRAULIC FLUID is FLAMMABLEdo not work on hydraulics
near sparks or flames; do not smoke near hydraulic fluid.
 Reinstall doors, panels, covers, or guards when servicing is
finished and before starting unit.
 If ANY fluid is injected into the skin, it must be surgically removed
within a few hours by a doctor familiar with this type of injury or gangrene may result.

 Do not work on compressed air system with unit running unless


you are a qualified person and following the manufacturers instructions.
 Do not modify or alter compressor or manufacturer-supplied
equipment. Do not disconnect, disable, or override any safety
equipment in the compressed air system.
 Keep away from potential pinch points or crush points created by
equipment connected to the compressed air system.
 Do not work under or around any equipment that is supported only
by air pressure. Properly support equipment by mechanical
means.

COMPRESSED AIR can injure or kill.


 Before working on compressed air system,
turn off and lockout/tagout unit, release pressure, and be sure air pressure cannot be accidentally applied.
 Relieve pressure before disconnecting or connecting air lines.




COMPRESSED AIR EQUIPMENT can


injure or kill.

 Before working on compressed air system, turn


off and lockout/tagout unit, release pressure,
and be sure air pressure cannot be accidentally
applied.




 Check compressed air system components


and all connections and hoses for damage,
leaks, and wear before operating unit.
Do not direct air stream toward self or others.
Wear protective equipment such as safety glasses, hearing protection, leather gloves, heavy shirt and trousers, high shoes, and
a cap when working on compressed air system.
Use soapy water or an ultrasonic detector to search for
leaksnever use bare hands. Do not use equipment if leaks are
found.
Reinstall doors, panels, covers, or guards when servicing is
finished and before starting unit.
If ANY air is injected into the skin or body seek medical help immediately.

1-3. California Proposition 65 Warnings


Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.

For Gasoline Engines:


Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive harm.
For Diesel Engines:
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.

1-4. EMF Information


Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields

1. Keep cables close together by twisting or taping them, or using a


cable cover.

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.

2. Arrange cables to one side and away from the operator.

To reduce magnetic fields in the workplace, use the following


procedures:

Big Blue 300 P

3. Do not coil or drape cables around your body.


4. Keep welding power source and cables as far away from
operator as practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.

TM-4433 Page 3

SECTION 2 DEFINITIONS
2-1. Warning Label Definitions
S-177 571

2
3

DIESEL
5

0 50 h Std.

200A

Remove unit from shipping


crate. Remove Owners
Manual from unit. Follow
instructions to install muffler.
Read Owners Manual. Read
labels on unit.
Use Diesel Fuel only, and fill
fuel tank. Leave room for
expansion.
Warning! Watch Out! There
are possible hazards as
shown by the symbols. Read
Owners Manual. Follow
instructions to activate
battery.
Check oil level. Add oil if
necessary.
During the first 50 hours of
operation, keep welding load
above 200 amperes. Do not
weld below 200 amperes of
output.
After the first 50 hours of
operation, change the oil and
oil filter.

0 200A

50 h Std.

API CD-MIL L 2104D,


CD/SE, CD/SF

3/96

Notes

Work like a Pro!


Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

TM-4433 Page 4

Big Blue 300 P

2-2. Manufacturers Rating Label

228 417-B / 803 562-F

Big Blue 300 P

TM-4433 Page 5

2-3. Symbols And Definitions


 Some symbols are found only on CE products.

Stop Engine

Fast (Run, Weld/


Power)

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

Arc Force (Dig)

Single Phase

Do Not Switch
While Welding

Circuit Protector

Contactor On

Hz

n
I2

Hertz

Rated Load
Speed

Rated Welding
Current

Lift-Arc TIG

Big Blue 300 P

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

400 A, 23 Volts DC,


40% Duty Cycle
300 A, 32 Volts DC
60% Duty Cycle

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)

250 A, 26.5 Volts DC


100% Duty cycle

3-2. Dimensions, Weights, And Operating Angles


Dimensions
Height

Width

32 in (813 mm)
35-3/4 in (908 mm)
(to top of lift eye)

26-1/4 in (667 mm)


(mtg. brackets turned in)

28-3/4 in (730 mm)


(mtg. brackets turned out)

Do not exceed tilt angles or engine could


be damaged or unit could tip.

Do not move or operate unit where it


could tip.

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)

7/8 in (22 mm)

27-3/4 in (705 mm)

30

9/16 in (14 mm) Dia.


4 Holes

Weight
No fuel: 1100 lb (499 kg)

20

H
Front Panel End
D

30

20
F

w/ fuel: 1199 lb (544 kg)


Lifting Eye Weight Rating:
1500 lb (680 Kg) Maximum

Big Blue 300 P

TM-4433 Page 7

3-3. Volt-Ampere Curves


A. Stick Mode

DC VOLTS

100
90
80
70
60
50
40
30
20
10
0

The volt-ampere curves show the


minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
other settings fall between the
curves shown.

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

Big Blue 300 P

3-4. Fuel Consumption


The curve shows typical fuel use
under weld or power loads.

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

DC WELD AMPERES AT 100% DUTY CYCLE

217 509

3-5. Duty Cycle And Overheating


1
1

100% Duty Cycle

Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.

 This unit is rated for welding at


250 amperes continuously.

NOTICE Exceeding duty cycle


can damage unit and void warranty.

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

Big Blue 300 P

TM-4433 Page 9

3-6. AC Generator Power Curve


The ac power curve shows the generator power in amperes available
at the 120 and 240 volt receptacles.

150 300

AC VOLTS

125 250
100 200
75 150
50 100
25

50

20

40

60

80

AC AMPERES IN 240 V MODE

40

80

120

160

AC AMPERES IN 120 V MODE


217 519

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)

3/8 in (.375 in)

1/2 in (.5 in)

TM-4433 Page 10

Big Blue 300 P

SECTION 4 INSTALLATION
4-1. Installing Welding Generator
!

Always securely fasten welding generator onto transport


vehicle or trailer and comply
with all DOT and other applicable codes.

Always ground generator


frame to vehicle frame to prevent electric shock and static
electricity hazards.

If unit does not have GFCI receptacles, use GFCI-protected


extension cord.

Movement

OR

NOTICE Do not install unit where


air flow is restricted or engine may
overheat.

 See Section 3-2 for lifting eye

Location/Airflow Clearance

rating.

 See Section 4-2 for mounting


information.

Grounding:
OR

OR

1
2
3

Equipment Grounding Terminal


(On Front Panel)
Grounding Cable (Not Supplied)
Metal Vehicle Frame

 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

Connect cable from equipment


ground terminal to metal vehicle
frame. Use #10 AWG or larger insulated copper wire.

Bed liners, shipping skids,


and some running gears insulate the welding generator
from the vehicle frame. Always connect a ground wire
from the generator equipment
grounding terminal to bare
metal on the vehicle frame as
shown.

1
GND/PE

install3 200704 Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712

Big Blue 300 P

TM-4433 Page 11

4-2. Mounting Welding Generator


!

Do not weld on base. Welding on base can cause fuel


tank fire or explosion. Weld
only on the four mounting
brackets or bolt unit down.

Supporting The Unit

NOTICE Do not mount unit by


supporting the base only at the four
mounting brackets. Use crosssupports to adequately support unit
and prevent damage to base.

Mounting Surface:
1
2

OR

Cross-Supports
Mounting Brackets (Supplied)

Mount unit on flat surface or use


cross-supports to support base.
Secure unit with mounting brackets.
1

Inadequate support.

1/2 in Bolt And Washer


(Minimum Not Supplied)
3/8-16 x 1 in Screws
(Supplied)

To Bolt Unit In Place:

Do not use flexible mounts.

Remove hardware securing the


four mounting brackets to the base.
Reverse brackets and reattach to
base with original hardware.

Mount unit to truck or trailer with 1/2


in (12 mm) or larger hardware (not
supplied).

Using Mounting Brackets

To Weld Unit In Place:


Weld unit to truck or trailer only at
the four mounting brackets.

Welding Unit In Place


Bolting Unit In Place
3

4
Tools Needed:
9/16 in
install3 200704 803 274 / 200 864-A / 803 562

TM-4433 Page 12

Big Blue 300 P

4-3. Installing Exhaust Pipe


!

Stop engine and let cool.

 Point exhaust pipe in desired di-

rection but always away from front


panel and direction of travel.

Tools Needed:
1/2 in

803 582 / Ref. 217 357-A

Notes

Work like a Pro!


Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

Big Blue 300 P

TM-4433 Page 13

4-4. Activating The Dry Charge Battery (If Applicable)


!
3

Always wear a face shield,


rubber gloves and protective
clothing when working on a
battery.

Remove battery from unit.


5
6

2
1

Vent Caps
Sulfuric Acid Electrolyte
(1.265 Specific Gravity)
Well

Fill each cell with electrolyte to


bottom of well (maximum).

Do not overfill battery cells.

Wait ten minutes and check electrolyte level. If necessary, add electrolyte to raise to proper level. Reinstall vent caps.
8

Battery Charger

Read and follow all instructions supplied with battery


charger.

Charge battery for 12 minutes at 30


amperes or 30 minutes at 5 amperes. Disconnect charging cables
and install battery.

 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

4-5. Connecting The Battery


 Close door after connecting battery.

Connect Negative () Cable Last.

Tools Needed:
1/2 in

803 563 / Ref. 217 357-A / S-0756-C

TM-4433 Page 14

Big Blue 300 P

4-6. Engine Prestart Checks

Check radiator coolant


level when fluid is low in
recovery tank.
Full
Full
Diesel
Capacity:
6 qt (5.7 L)

Coolant Recovery Tank

Hot Full
Cold Full

Full
803 563

 Check all engine fluids daily.


Engine must be cold and on a level surface.
Unit is shipped with 20W break-in oil.
Automatic shutdown system stops engine if
oil pressure is too low or coolant temperature is too high.

 This unit has a low oil pressure shut-

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.

freeze to mixture if using the unit in temperatures below 34 F (37 C).

Oil

Keep radiator and air intake clean and free


of dirt.

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-

NOTICE Incorrect engine temperature


can damage engine. Do not run engine without a properly working thermostat and radiator cap.

 To improve cold weather starting:


Use Preheat switch (see Section 5-1).
Keep battery in good condition. Store
battery in warm area.
Use fuel formulated for cold weather
(diesel fuel can gel in cold weather).
Contact local fuel supplier for fuel information.
Use correct grade oil for cold weather
(see Section 7-2).
TM-4433 Page 15

4-7. Connecting To Weld Output Terminals


Stick and TIG Welding
For Stick and TIG welding Direct Current Electrode Positive (DCEP), connect electrode
holder cable to CC (Stick/TIG) terminal on
right and work cable to Work/Negative () terminal on left.
For Direct Current Electrode Negative
(DCEN), reverse cable connections.
Use Process/Contactor switch to select type
of weld output (see Section 5-3).

Stop engine.

Work/Negative () Weld Output Terminal

CV (wire) Weld Output Terminal

CC (Stick/TIG) Weld Output Terminal

Failure to properly connect weld


cables may cause excessive heat and
start a fire, or damage your machine.

4
5
6
7

Weld Output Terminal


Supplied Weld Output Terminal Nut
Weld Cable Terminal
Copper Bar

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.

MIG and FCAW Welding


For MIG and FCAW welding Direct Current
Electrode Positive (DCEP) connect wire feeder cable to CV (Wire) terminal on right and
work cable to Work/Negative () terminal on
left. Use Process/Contactor switch to select
type of weld output (see Section 5-3).
For Direct Current Electrode Negative
(DCEN), reverse cable connections.

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

Big Blue 300 P

4-8. Selecting Weld Cable Sizes*

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
Weld Output
Terminals

Stop engine before


connecting to weld
output terminals.

Do not use worn, damaged, undersized, or


poorly spliced cables.

* This

100 ft (30 m) or Less

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)

10 100% Duty Cycle

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

Big Blue 300 P

TM-4433 Page 17

4-9. Connecting To Remote 14 Receptacle RC14


Socket*

Socket Information

24 volts AC. Protected by supplementary protector CB8.

Contact closure to A completes


24 volt AC contactor control
circuit.

Output to remote control:+10


volts DC in MIG mode; 0 to +10
volts DC in Stick or TIG mode.

Remote control circuit common.

DC input command signal: 0 to


+10 volts from min. to max. of
remote control with Voltage/
Amperage Adjust control at
max.

24 VOLTS AC

REMOTE
OUTPUT
CONTROL
LDR-14 long
distance remote
(includes 120 V
receptacle)

115 VOLTS AC

115 volts, 10 amperes, 60 Hz


AC. Protected by supplementary protector CB7.

Contact closure to I completes


115 volt AC contactor control
circuit.

Current feedback: 1 volt per


100 amperes.

OR

803 562

Voltage feedback: 1 volt per 10


arc volts.

GND

Chassis common.

NEUTRAL

Circuit common for 24 and 115


volt AC circuit.

*The remaining sockets are not used.

Notes

Work like a Pro!


Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

TM-4433 Page 18

Big Blue 300 P

Notes

Welding Symbols
Ref. AWS/ANSI A2.4

Big Blue 300 P

TM-4433 Page 19

SECTION 5 OPERATING WELDING GENERATOR


5-1. Front Panel Controls (See Section 5-2)

9
7

10
1

217 357-B / 803 563

TM-4433 Page 20

Big Blue 300 P

5-2. Description Of Front Panel Controls (See Section 5-1)

Engine Starting Controls

Engine Gauges, Meters, And Lights

See Section 5-3 for Process/Contactor


switch information.

Preheat Switch

Use switch to energize starting aid for cold


weather starting (see starting instructions following).
2

Engine Control Switch

Use switch to start engine, select engine


speed (if unit has auto idle option), and stop
engine.
In Run position, engine runs at weld/power
speed. In Auto position (optional), engine
runs at idle speed at no load and weld speed
with load applied.
3

Engine Stop Lever

Use lever to stop engine if Engine Control


switch does not work.

 The Engine Stop lever shuts off the fuel

supply. However, the Engine Stop lever


will not stop the engine if the engine can
draw fuel-rich air from the surrounding
atmosphere (oil refineries).

To Start:
NOTICE Do not use ether.

 If engine does not start, let engine come


to a complete stop before attempting restart.

Above 325 F (05 C): turn Engine Control


switch to Start. Release Engine Control
switch when engine starts.
Below 325 F (05 C): turn engine control switch
to Auto position. Push Preheat switch up for
60 seconds. Turn Engine Control switch to
Start. Release Engine Control switch and
Preheat switch when engine starts.
To Stop: turn Engine Control switch to Off
position.

Big Blue 300 P

Fuel Gauge/Hourmeter

Use gauge to check fuel level or total engine


operating hours.
To check fuel level or engine hours when engine is not running, turn Engine Control switch
to Run or Auto (optional) position.
5

Engine Indicator Light

Light goes on and engine stops if engine temperature exceeds 230 F (110 C) or engine
oil pressure is below 10 psi (69 kPa).

 Normal engine temperature is 180 - 203

F (82 - 95 C). Normal oil pressure is 30


- 60 psi (207 - 414 kPa).

NOTICE Do not run engine until trouble is


fixed.

Process/Contactor Switch

Voltage/Amperage Control

With Process/Contactor switch in any Stick or


TIG setting, use control to adjust amperage.
With Process/Contactor switch in any Wire
(MIG) position, use control to adjust voltage.
With Voltage/Amperage Adjust Switch in Remote position, control limits the remote amperage in Stick or TIG mode, but has no effect
in Wire (MIG) modes.
Weld Meters

 Weld meters also work in combination to


display troubleshooting help codes (see
Section 7-11).

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.

Remote Control Receptacle

Use receptacle to connect remote controls,


wire feeders, and tools.
When a remote control is connected to the
Remote receptacle, the Auto Sense Remote
feature automatically switches voltage/amperage control to the remote control (see Section 4-9).
With remote control connected, weld output is
determined by a combination of front panel
and remote control voltage/amperage settings.
If no remote control is connected to the Remote receptacle, the front panel Voltage/Amperage control adjusts voltage and amperage.

 If a remote device connected to Remote

Receptacle RC14 is faulty or is disconnected, the meters display Help 25 (see


Section 7-11). Clear fault by stopping and
restarting the unit or by turning Process/
Contactor switch to another position.

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

5-3. Process/Contactor Switch


1

Process/Contactor Switch

Weld output terminals are energized when Process/Contactor


switch is in a Weld Terminals Always On position and the engine
is running.

Use switch to select weld process and


weld output on/off control (see table below).
Place switch in Remote On/Off Switch
Required positions to turn weld output on
and off with a device connected to the
Remote 14 receptacle.
Place switch in Weld Terminals Always
On positions for weld output to be on
whenever the engine is running.
Use Stick mode for air carbon arc
(CAC-A) cutting and gouging.
When switch is in Stick mode, select one
of four arc drive (dig) settings to provide
additional amperage during low voltage
(short arc length) conditions and prevent
sticking electrodes. Turn control from A
to D to increase 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 5-4).

803 562 / 217 357

Process/Contactor Switch Settings


Switch Setting

Process

Output On/Off Control

Engine Auto Idle (Optional)

Remote On/Off Switch Required TIG HF Required Or


Scratch Start

GTAW With HF Unit, Pulsing


Device, Or Remote Control

At Remote 14 Receptacle

Active

Remote On/Off Switch


Required Stick

Stick (SMAW) With Remote On/Off

At Remote 14 Receptacle

Active

Remote On/Off Switch


Required CV Feeder
Using Remote

MIG (GMAW)
w/Constant Speed Feeder

At Remote 14 Receptacle

Active

Weld Terminals Always On


Wire

MIG (GMAW)
w/Voltage Sensing Feeder

Electrode Hot

Active

Weld Terminals Always On


Stick

Stick (SMAW),
Air Carbon Arc (CAC-A) Cutting
And Gouging

Electrode Hot

Active

Weld Terminals Always On


TIG Lift-Arc

TIG Lift-Arc (GTAW)

Electrode Hot

Active

TM-4433 Page 22

Big Blue 300 P

5-4. Lift-Arc Start Procedure


Lift-Arc  TIG
With Lift-Arc TIG selected, start
arc as follows:
Lift-Arc Start Method
1

Touch

12
Seconds

TIG Electrode

Workpiece

Turn gas on. Touch tungsten


electrode to workpiece at weld start
point.
Hold
electrode
to
workpiece for 1-2 seconds, and
slowly lift electrode. Arc is formed
when electrode is lifted.
Normal open-circuit voltage is not
present before tungsten electrode
touches workpiece; only a low
sensing voltage is present between
electrode and workpiece. The
solid-state output contactor does
not energize until after electrode is
touching workpiece. This allows
electrode to touch workpiece
without overheating, sticking, or being contaminated.
Application:

Do NOT Strike Like A Match!

Lift-Arc is used for the DCEN


GTAW process when HF Start
method is not permitted, or to
replace the scratch method.

Notes

Work like a Pro!


Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

Big Blue 300 P

TM-4433 Page 23

5-5. Remote Voltage/Amperage Control


1

Remote 14 Receptacle RC14

Connect optional remote control to RC14 (see


Section 4-9).

 When a remote control is connected to the


Remote receptacle, the Auto Sense Remote feature automatically switches voltage/amperage control to the remote control. When a device is connected to the Remote receptacle, remote voltage/amperage control is always available regardless
of the position of the Process/Contactor
switch.

In Example:
Min = 20 A DC
Max = 205 A DC

Connect Remote
Control To Remote
Receptacle RC14

Adjust Optional Remote


Control to 100%
Set TIG or STICK Process

Set V/A Control


To Desired Maximum
Weld Output Using Weld
Meters

Max (205 A DC)


Min (20 A DC)
Adjust Optional Remote
Control to desired
weld output

Adjust Optional Remote


Control to desired
weld output

Connect Remote
Control To Remote
Receptacle RC14
Set WIRE Process

Weld meters will always


show the combined main
and remote control
setting; machine welds at
nominal output setting of
the meter.
Weld meters show preset
output when not welding.

0774 / Ref.217 357B / 803 562

TM-4433 Page 24

Big Blue 300 P

SECTION 6 OPERATING AUXILIARY EQUIPMENT


6-1. Generator Power Receptacles

217 357-A

120 V 20 A AC (shown)
Receptacle RC5 and/or GFCI1

in receptacle. Press button to reset GFCI


receptacle.

120 V 20 A AC GFCI (shown)


Receptacle RC6 and/or GFCI2

 At least once a month, run engine at

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.

RC11 supplies 60 Hz single-phase power


at weld/power speed. Maximum output
from RC11 is 10 kVA/kW.
4

Supplementary Protector CB4

Supplementary Protector CB6

Supplementary Protector CB5

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.

 Generator power decreases as weld


output increases.

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

Stop engine before maintaining.

 See

Engine Manual and Maintenance Label


for important start-up, service, and storage
information. Service engine more often if
used in severe conditions.

 = Replace

Reference

Every
8
Hours

Section 4-6,
7-8

 Coolant Level

 Fuel Level

 Oil Level

 Oil, Fuel Spills

Every
50
Hours
 Weld Terminals
Every
100
Hours

Section 7-3

 Battery Terminals
Every
250
Hours

 Air Cleaner Hoses

 Air Cleaner Element


Engine
Manual,
Section 7-4

1/2 in.
(13 mm)

 Unreadable Labels

 Fan Belt Tension

 Oil  Oil Filter

 Spark Arrestor

 Weld Cables

 Fuel Filter

 Inline 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

Big Blue 300 P

7-2. Maintenance Label

Big Blue 300 P

TM-4433 Page 27

7-3. Servicing Air Cleaner


!
1

Stop engine.

NOTICE Do not run engine without air


cleaner or with dirty element. Engine
damage caused by using a damaged element is not covered by the warranty.

 The air cleaner primary element can

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

Safety Element (Optional)

Primary Element

Dust Cap

Dust Ejector

To clean air filter:

Blow

Inspect

Wipe off cap and housing. Remove cap


and dump out dust. Remove element(s).
Wipe dust from inside cap and housing
with damp cloth. Reinstall safety element
(if present). Reinstall cap.
NOTICE Do not clean housing with air
hose.
Clean primary element with compressed
air only.
Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in (3 mm) nozzle and
keep nozzle at least 2 in (51 mm) from
inside of element. Replace primary element if it has holes or damaged gaskets.
Reinstall primary element and cap (dust
ejector down).

aircleaner1 2/01 ST-153 929-B / ST-153 585 / Ref. S-0698-B / Ref. 217 357-A

TM-4433 Page 28

Big Blue 300 P

7-4. Inspecting And Cleaning Optional Spark Arrestor Muffler


Tools Needed:
3/8 in

Stop engine and let cool.

Spark Arrestor Muffler

Cleanout Plug

Remove plug and remove any dirt


covering cleanout hole.
3

Exhaust Pipe

Start engine and run at idle speed to


blow out cleanout hole. If nothing
blows out of hole, briefly cover end
of exhaust pipe with fireproof
material.

!
3

Stop engine and let cool.

Reinstall cleanout plug.

803 582 / Ref. 214 778-B

7-5. Servicing Engine Cooling System


!

Stop engine and let cool.

Radiator Draincock

Radiator Cap Cover

Change coolant according to engine


manual. Add coolant according to Section 4-6).

Run engine until engine reaches normal


operating temperature. Check coolant
level in recovery tank. Add coolant if necessary.
After engine cools, check coolant level
again and add coolant if necessary.

803 563

Big Blue 300 P

TM-4433 Page 29

7-6. Adjusting Engine Speed On Standard Models


!

Engine Speed
(No Load)

RPM (Hz)

Weld/Power

1880 (61.7)
Maximum

Stop engine and let cool.

Engine speed is factory set and


should not require adjustment. After tuning engine, check engine
speed with tachometer or frequency meter. See table for proper no
load speed. If necessary, adjust
speed as follows:
Start engine and run until warm.
Turn Process/Contactor switch to
Weld Terminals Always On Stick
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. Tampering with
adjustments other than shown
may affect engine warranty

Engine Stop Lever

Stop engine.

Close door.

2
1

Tools Needed:

803 563-E

TM-4433 Page 30

Big Blue 300 P

7-7. Adjusting Engine Speed On Models With Automatic Idle (Optional)


Engine Speed
(No Load)
1880 rpm max
(62.6 Hz)
1500 rpm
(50 Hz)

Engine Speed Adjustment


After tuning engine, check engine speed with tachometer or
frequency meter. See table for
proper no load speed. If necessary, adjust speed as follows:
Start engine and run until warm.
Turn Process/Contactor switch
to Stick Weld Terminals Always On position.
1

Throttle Rod / Plunger

Lock Nut

Rubber Boot

Adjustment Screw

Adjustment screw is not used to


adjust engine speed when automatic idle option is installed.
However, it must be at least 1/8
in (3 mm) away from the throttle
arm when engine is running at
idle rpm.
Unhook rubber boot from the solenoid housing but leave connected to plunger.
Loosen lock nut. Place Engine
Control Switch in Auto position.
Turn throttle rod and plunger until engine runs at idle speed.
Tighten lock nut.
Hook rubber boot back onto solenoid housing.

 Be

sure solenoid plunger


pulls all the way in (bottoms) when energized.

Weld/Power Speed
Adjustment

 Weld/power speed

adjustment must be done by the


engine manufacturers factory authorized service
agent.
Tampering with adjustments
other than shown may affect
engine warranty.

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

Big Blue 300 P

TM-4433 Page 31

7-8. Servicing Fuel And Lubrication Systems


!

Stop engine and let cool.

After servicing, start engine


and check for fuel leaks.
Stop engine, tighten connections as necessary, and wipe
up spilled fuel.

1
2
3

Oil Filter
Oil Drain Valve And Hose
Oil Fill Cap

Primary (Canister) Fuel Filter

Secondary (In-Line) Fuel


Filter

Fuel Tank Sludge Drain Valve

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.
To replace primary (canister) fuel
filter:
Turn filter counterclockwise. Remove filter.
Fill new filter with fresh fuel. Apply
thin coat of fuel to gasket on new filter. Install new filter and turn clockwise.
Inspect fuel lines, and replace if
cracked or worn.
To drain water from fuel system:
See engine manual.
6

To replace secondary (in-line)


fuel filter:
Note direction of fuel flow as indicated by arrow on side of filter. Remove fuel line clamps and disconnect fuel lines from fuel filter. Replace 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. Dispose of drained fuel in an environmentally-safe manner.
Do not leave unit unattended
while draining fuel tank.

Properly lift unit and secure


in a level position. Use adequate blocks or stands to
support unit while draining
fuel tank.

Attach 1/2 ID hose to drain valve.


Put metal container under drain,
and use screwdriver to open
sludge drain valve. Close valve
when sludge has drained. Remove
hose.
Close door.

Tools Needed:

1
802 490 / Ref. 801 434

TM-4433 Page 32

Big Blue 300 P

7-9. Overload Protection


!

Stop engine.

Fuse F1

F1 protects the stator exciter winding from overload. If F1 opens, weld


and generator power is low or stops
entirely.
If F1 continues to open, check voltage regulator board PC3.

 If PC3 senses an overload con-

dition (shorted rotor), it protects


itself by stopping weld output.
Check rotor and brushes before
replacing PC3.

Circuit Breaker CB1 (Not


Shown)
Supplementary Protector CB2

Supplementary Protector CB3

Supplementary Protector CB7

Supplementary Protector CB8

Circuit Breaker CB9

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.

CB7 protects the 115 volt AC output


to remote receptacle RC14. If CB7
opens, 115 volt output to RC14
stops. If CB7 continues to open,
check remote controls connected to
Remote receptacle RC14, and circuit board PC6.
CB8 protects the 24 volt AC output to
remote receptacle RC14. If CB8
opens, 24 volt output to RC14 stops.
If CB8 continues to open, check remote controls connected to Remote
receptacle RC14, and circuit board
PC6.
CB9 protects the throttle solenoid
against overload. If CB9 opens, the
engine does not automatically idle
down. Check the linkage and solenoid. CB9 automatically resets.

803 562 / 803 566

Big Blue 300 P

TM-4433 Page 33

7-10. Checking Generator Brushes

Stop engine and let cool.

Generator Brush With Spring

Mark and disconnect leads at brush holder cap. Remove brushes.


Replace brushes if damaged or if brush
material is at or near minimum length.

5/16 in. (8 mm)


Minimum Length
9/16 in. (14.3 mm)
New Length

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)

3/8 in (.375 in)

1/2 in (.5 in)

TM-4433 Page 34

Big Blue 300 P

7-11. Voltmeter/Ammeter Help Displays

 When a help code is displayed,

HL.P

20

HL.P

21

HL.P

22

HL.P

23

HL.P

24

HL.P

25

normally weld output has


stopped but generator power output may be okay. Auxiliary power
must be available and correct before continuing. If auxiliary output
is not correct, disregard help
codes until auxiliary power problem is corrected. If both weld output and auxiliary power are not
available, see Section 9-7 for
module testing information.

Use the Voltmeter/Ammeter help


displays to diagnose and correct
fault conditions.

 To

reset help displays, stop


unit and then restart. See item
6 below to reset Help 25 display.

Help 20 Display

Indicates a failure of meter display


module PC2, or the wiring between
PC2 and main control module PC1.
If this display is shown, check PC1,
PC2, and the wiring between PC1
and PC2.
2

Help 21 Display

Indicates thermistor TH1 on the


main rectifier heat sink has failed.
If this display is shown, check TH1,
and the wiring between TH1 and
PC1.
3

Help 22 Display

Indicates the rectifier heat sink has


overheated. If this display is shown,
check generator cooling system
and/or reduce duty cycle. Keep engine access door closed when running to maintain proper cooling air
flow past rectifier. Allow unit to cool
before restarting.
4

Help 23 Display

Indicates one of the rectifier output


SCRs has failed. If this display is
shown, check the rectifier SCRs.
5

Help 24 Display

Verify engine speed is correct by


checking frequency at 115 volt AC
duplex receptacle (should be
approximately 62 Hertz with Engine
Control switch in the Run position).
If engine speed is correct and weld
open circuit voltage (OCV) is too
high (above 41 volts DC), check
main control module PC1.
6

Help 25 Display

Indicates a remote device connected to Remote Receptacle


RC14 may be faulty. Help 25 is also
displayed whenever a remote device has been connected to RC14
and then disconnected. Clear fault
by stopping and restarting the unit
or by turning Process/Contactor
switch to another position. If problem continues, check the remote
device, filter board PC6, and main
control module PC1.
If no remote control device is
plugged in to Remote receptacle
RC14 and the corrective action
above has been followed, disconnect filter board PC6. If the help
code is still displayed, main control
module PC1 may be at fault. If the
help code clears, replace PC6.

803 562 / 217 357-A

Big Blue 300 P

TM-4433 Page 35

SECTION 8 THEORY OF OPERATION


A. Block Diagram

1 Engine
Supplies force to turn revolving fields.

Voltage
Regulator
Board PC3

2 Revolving Fields (Rotor)


Turn at 1885 rpm maximum for weld and
power. The speed and excitation current
of the field coils determine voltages in
stator windings.

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

Controls field current in response to


changes in output load.
If PC3 senses an overload condition
(shorted rotor), it protects itself by stopping excitation current (weld and generator power output stops).
6

Supplementary Protectors CB4,


CB5, and CB6
Protect AC receptacles from overload.
7

AC Receptacles GFCI1, GFCI2


and RC11
Provide connection points and power for
auxiliary equipment.
Supplementary Protectors CB7
and CB8
Provide overload protection for 24 and
115 volts AC portion of Remote 14 receptacle RC14.

Exciter

Revolving
Fields
(Rotor)

Weld

5 Voltage Regulator Board PC3


Changes AC output of stator windings to
DC to supply excitation current to the exciter revolving field.

Generator Power

6
Supplementary
Protectors
CB4, CB5, CB6
7

AC
Receptacles
GFCI1, GFCI2,
RC11

9
115 VAC

Supplementary
Protector
CB7

Filter Board PC6/Remote Receptacle RC14


PC6 protects unit from high frequency,
and RC14 connects remote amperage/
voltage and contactor controls to unit.
When a remote control is connected to
the Remote receptacle, the Auto Sense
Remote feature automatically switches
voltage/amperage control to the remote
control.
10 Voltage/Amperage Control R2
Adjusts weld output amperage or voltage level.
11 Process/Contactor Switch R1
Selects weld process and weld output
on/off control.

TM-4433 Page 36

24 VAC
Filter Board
PC6/Remote
Receptacle
RC14

8
Supplementary
Protector
CB8
12

+10 VDC Output


Command Voltage

Control
Board
PC1

Big Blue 300 P

12 Control Board PC1


Controls weld output by changing
main rectifier SCR gate pulses
(conduction times) after comparing
amperage (CC) or voltage (CV)
feedback to selected voltage/amperage signal.

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

17 Hall Device HD1


Provides current feedback signal to
PC1.

Burden
Resistor R3

15

20

19

CV Weld
Output
Terminal

Capacitor
Bank C10

Main
Rectifier

18 Stabilizer Z1
Smooths (filters)
current.

weld

output

19 Capacitor Bank C10


Filters the DC output voltage of
main rectifier.
20 Work (), CC, And CV Weld
Output Terminals
Provide weld output and allow
changing of output polarity.

20

17
Hall Device
HD1
SCR
Gating
Signals

10

CC or CV
Voltage
Feedback

11
Voltage/
Amperage
Control R2

Big Blue 300 P

Work

14

13
Process/
Contactor
Switch R1

Current
Feedback

Work () Weld
Output
Terminal

Thermostat
TH1

Meter
Board PC2

TM-4433 Page 37

B. Engine/Generator Training Circuit




This circuit is for training purposes


only. It has been modified for that use
and may not reflect the actual circuit
for your unit.

TM-4433 Page 38

Reference:
DC common - lead 42
Unless otherwise noted

Big Blue 300 P

Training 219 228

Big Blue 300 P

TM-4433 Page 39

SECTION 9 TROUBLESHOOTING
9-1.

Troubleshooting Tables
 See Section 9-2 for test points and

values and Section 13 and following


for parts location.

 Use MILLER Testing Booklet (Part


No. 150 853) when servicing this
unit.

 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 and tighten connections inside and outside unit.


Be sure connection to work piece is clean and tight.
Use dry, properly stored electrodes.
Remove excessive coils from weld cables.
Disconnect leads 105 and 108 from the rotor, and check continuity across slip rings. Replace rotor if
necessary.

High weld output.

Repair or replace remote control device.

High weld output (Continued).

Check hall device HD1, and replace if necessary (see Section 9-2).

TM-4433 Page 40

Big Blue 300 P

Trouble

Remedy
Check main control board PC1 and connections, and replace PC1 if necessary.

Low weld output.

Check engine speed, and adjust if necessary.


Increase Voltage/Amperage Adjust control R2 setting.
Check fuse F1, and replace if open (see Section 7-9).
Repair or replace remote control device.
Disconnect leads 105 and 108 from the rotor, and check continuity across slip rings. Replace rotor if necessary.

Low open-circuit voltage.

Check engine speed, and adjust if necessary.


Check main control board PC1 and connections, and replace PC1 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.)
Check SCRs in main rectifier, and replace if necessary. If any SCRs are replaced, check capacitors
C1 through C9 for a short or open, and check for proper connections. Replace C1 through C9 if
necessary.

No remote fine amperage control.

Repair or replace remote control device.


Check and secure connections to Remote Amperage Adjust receptacle RC14 (see Section 4-9).

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.

Disconnect equipment from generator power receptacles during start-up.


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.)
Reset supplementary protector CB3 (see Section 7-9).
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.)

High output at generator power ac


receptacles.
Big Blue 300 P

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.

Engine cranks but does not start.

Check fuel level.


Check battery and replace if necessary. Check engine charging system according to engine manual.
Check control relay CR1 for proper coil voltage and connections. Check continuity of coil and condition
of contacts. Replace CR1 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.
Check fuel pump according to engine manual.
Air in fuel system. See engine manual.

Engine hard to start in cold weather.

Use Preheat switch (see Section 5-1).


Keep battery in good condition. Store battery in warm area off cold surface.
Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier for
fuel information.
Use correct grade oil for cold weather (see Section 7-2).
Check continuity of Preheat switch S4, and replace if necessary.
Check control relay CR3 for proper coil voltage and connections. Check continuity of coil and condition
of contacts. Replace CR3 if necessary.
Check glow plug for proper operation, and replace if necessary.

Engine suddenly stops.

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

Big Blue 300 P

Trouble

Remedy
Check fuel pump according to engine manual.
Check engine wiring harness and plug connections.
See engine manual.

Engine slowly stopped and cannot be


restarted.

Check fuel level.


Check engine air and fuel filters (see Sections 7-3 and 7-8).
See engine manual.

Battery discharges between uses.

Turn Engine Control switch S1 off when unit is not running.


Clean top of battery with baking soda and water solution; rinse with clear water.
Recharge or replace battery if necessary.
Periodically recharge battery (approximately every 3 months).

Engine idles, but does not come up to


weld speed (units with idle option only).

Check for obstructed throttle solenoid TS1


Eff w/ LG440030E: Circuit breaker CB9 may be open. CB9 automatically resets when the fault is
corrected. Check for obstructed throttle solenoid TS1 and check TS1 voltage.
Check idle module PC5, and replace if necessary.
Check current transformer CT1 for continuity and proper connections. Replace CT1 if necessary.

Engine does not run at idle speed


(units with idle option only).

Check for obstructed throttle solenoid TS1.


Check idle module PC5, and replace if necessary.
Check control relay CR4 for proper coil voltage and connections. Check continuity of coil and condition
of contacts. Replace CR4 if necessary.

Engine uses oil during run-in period; Dry engine according to run-in procedure (see Section 12).
wetstacking occurs.

Notes

Big Blue 300 P

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

See Section 9-14


for PC5 data

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

Big Blue 300 P

See Section 9-4


for waveforms
A,B,C,D,E

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

Big Blue 300 P

TM-4433 Page 45

9-3.

Troubleshooting Values For Circuit Diagram (Use With Section 9-2)


Test Equipment Needed:

Voltage Readings
a)

Tolerance 10% unless specified

b)

Condition 70F (21C); cold machine


(no warm-up); no load; weld/power rpm
unless noted
Reference single arrow: reference to
circuit common (lead 42); double
arrow: reference to points indicated
Process/Contactor switch R1 in Weld
Terminals Always On Stick (Dig-B)
position unless noted
Wiring Connections see Section 11

c)
d)
e)

Resistance Values
Tolerance
specified

b)

Condition 70F (21C); cold


machine (no warm-up)

c)

Wiring Connections
Section 11

d)

Stop engine before checking


resistance

V1

120 124 volts ac

V2

120 124 volts ac

V3

240 248 volts ac

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

0 to +5 volts DC from Weld Terminals


Always OnWire position to RemoteWire
position of Process Contactor switch R1 (in
0.45 volt increments)

V14

+5 volts DC

V15

0 to +5 volts DC from min to max of


Voltage/Amperage control R2

R1 thru R8
R9
R10
R11

R14

10%

a)

unless

see

Less than 1 ohm


22 ohms
14.2 ohms
Throttle plunger pulled in
0.6 ohms
Throttle plunger extended
17 ohms
Empty fuel tank: 250 ohms
Full tank: 0 ohms
30 Kohms cold, drops as
unit heats up
Increases in 1 Kohm
incriments up to 11 Kohms,
then resets to zero.

Amperage Readings
Tolerance 5% unless specified

V16

+5 volts DC

a)

V17

With Process/Contactor switch R1 in Weld


Terminals Always On TIG position +20
volts DC; with R1 in Stick position:
Prior to LH030117E: +41 volts DC
Eff w/LH030117E: +57 volts DC

b)

Condition 70F (21C); cold


machine (no warm-up); no load;
weld/power rpm unless noted

c)

V18

14 to +40 volts DC with Process/Contactor


switch R1 in Weld Terminals Always
OnWire position

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

1 volt DC per 100 amperes of weld output

V21

15 volts DC

V22

+15 volts DC

V23

+12 volts DC

V24

+12 volts DC input with Engine Control


switch S1 in Start position

V25

+12 volts DC input with Engine Control


switch S1 in Start or Run position

V26

Ground path for CR1:


Normal operation: 0 volts DC
Fault shutdown: +12 volts DC

TM-4433 Page 46

Big Blue 300 P

Notes

WELD POSITION: FLAT


WELD JOINT
TYPES

HORIZONTAL

BUTT
1G

VERTICAL

BUTT
2G

FILLET
Ref. AWS/ANSI D1.1

Big Blue 300 P

TJOINT
1F

BUTT
4G

BUTT
3G
TJOINT
2F

GROOVE

OVERHEAD

TJOINT
4F
TJOINT
3F

Ref. 804 248-A

TM-4433 Page 47

9-4.

Waveforms For Sections 9-2

 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

A. Prior to LH030117E: CC/DC Open-Circuit Voltage, Process/Contactor Switch R1 In Weld


Terminals Always On Stick (Dig B) Position,
Voltage/Amperage Control R2 At Max

A. Eff w/LH030117E: CC/DC Open-Circuit Voltage, Process/Contactor Switch R1 In Weld


Terminals Always On Stick (Dig B) Position,
Voltage/Amperage Control R2 At Max

2 ms 20 V

gnd

B. CV/DC Open-Circuit Voltage, Process/Contactor Switch R1 In Weld Terminals Always


On Wire Position, Voltage/Amperage Control R2 At Max

TM-4433 Page 48

Big Blue 300 P

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

Test Equipment Needed:

E. SCR Gate Pulses w/Respect To Cathode At No


Load, Process/Contactor Switch R1 In Weld
Terminals Always On Stick (Dig B) Position,
Voltage/Amperage Control R2 At Max

Big Blue 300 P

TM-4433 Page 49

9-5.

Filter Board PC6 Testing Information


!

Stop engine.

See Section 9-6 for specific values


during testing. Voltage readings tolerance 10%.

Test Equipment Needed:

Prior to LH030117E

1
2

Filter Board PC6


Receptacle RC2

Eff w/LH030117E

803 702 / 217 008 / 805 517A

9-6.

Filter Board PC6 Test Point Values


a) Tolerance 10% unless specified
b) Reference to circuit common (lead 42) unless noted
c) Condition no load; weld/power rpm unless noted
d) Process/Contactor switch S6 in Weld Terminals Always On Stick position
PC6 Voltage Readings

Receptacle

Pin

RC2

Not used on this model

Not used on this model

Not used on this model

Voltage feedback: 1 volt DC per 10 arc volts

Circuit common for 24 and 115 volt AC contactor control circuits (Lead No. 80)

Command reference: +10 volt DC input

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

Current feedback: 1 volt DC per 100 arc amperes

TM-4433 Page 50

Value

Big Blue 300 P

9-7.

Module Testing Information


If there is no weld output and no
auxiliary power output, use this
testing information to determine
which circuit board module may be
at fault.
1
2
3

Main Control Board PC1


Receptacle RC6
Jumper Wires

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

D2 (Lead No. 107) to J3 (Lead No.


130)
Start engine with these jumpers
installed and check for auxiliary
power.

If auxiliary power is present, PC1


could be at fault. Use Sections 9-8
and 9-9 to troubleshoot PC1.
If auxiliary power is not present,
Voltage Regulator board PC3 could
be at fault. Be sure PC3 is supplying the following voltages at PC1
module:
4

Receptacle RC7

Check for +14 volts DC at PLG7 pin


E1 (lead no. 120)
Check for +15 volts DC at PLG6 pin
E3 (lead no. 109)
Check for 15 volts DC at PLG6 pin
F3 (lead no. 106).
Use Sections 9-10 and 9-11 to troubleshoot PC3.
Remove jumper wires before continuing troubleshooting.

803 702

Big Blue 300 P

TM-4433 Page 51

9-8.

Main Control Board PC1 Testing Information


!

Stop engine.

See Section 9-9 for specific values


during testing. Voltage readings tolerance 10%.
1
2
3
4

Main Control Board PC1


Plug PLG6
Plug PLG7
Plug PLG11

2
3

Test Equipment Needed:

803 702

TM-4433 Page 52

Big Blue 300 P

9-9.

Main Control Board PC1 Test Point Values


a) Tolerance
specified

10% unless

b) Reference to circuit common


(lead 42) unless noted

PC1 Voltage Readings

c) Condition no load; weld/power rpm unless noted


d) Process/Contactor switch R1
in Weld Terminals Always On
Stick position
Receptacle

Pin

PLG6

A1

Serial data line

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

Voltage feedback reference

C1

Serial data line

C2

Circuit common for Voltage/Amperage control R2

C3

CC weld feedback with respect to pin PLG6-B3; same as OCV or load voltage

D2

Frequency to voltage signal: +10 volts DC input at 1860 rpm

D3

Not used on this model

E2

Synchronization signal

E3

Power supply input: +15 volts DC

F1

Not used on this model

F2

Voltage feedback: 1 volt DC per 10 arc volts

F3

Power supply input: 15 volts DC

G1

Not used on this model

G2

Command reference: +10 volt DC input

G3

Shutoff command output (field current); normal condition: 0 volts DC, fault condition: 0.7 volts DC

H1

Not used on this model

H2

Remote command signal input: 0 to +10 volts DC input from min to max of remote voltage/amperage
control

H3

Circuit common

J1

Not used on this model

J3

+10 volts DC output

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

Circuit common for Process/Contactor switch R1

B2

+15 volts DC output with respect to pin PLG7-C2

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

SCR fault signal; +5 volts DC output if any SCR fails

PLG7

Big Blue 300 P

Value

TM-4433 Page 53

Receptacle

PLG11

TM-4433 Page 54

Pin

Value

D1

+2 volts DC input at 77 F

D2

15 volts DC with respect to pin PLG7-C2

E1

+13 volts DC input

F1

Command common

F2

Weld idle control signal: 0 volts DC output when welding; 3.5 volts DC input when not welding

F3

Current feedback: 0 volts DC input per 100 arc amperes

A1

Gate Pulse to SCR1 with respect to pin PLG11-A2

A2

Reference for gate pulse to SCR1

A3

Gate Pulse to SCR2 with respect to pin PLG11-B3

B1

Reference for gate pulse to SCR3

B2

Gate Pulse to SCR3 with respect to pin PLG11-B1

B3

Gate Pulse to SCR2 with respect to pin PLG11-A3

C1

Gate Pulse to SCR4 with respect to pin PLG11-C2

C2

Reference for gate pulse to SCR4

C3

Reference for gate pulse to SCR5

D1

Reference for gate pulse to SCR6

D2

Gate Pulse to SCR6 with respect to pin PLG11-D1

D3

Gate Pulse to SCR5 with respect to pin PLG11-C3

E1

Gate Pulse to SCR7 with respect to pin PLG11-E2

E2

Reference for gate pulse to SCR7

E3

Gate Pulse to SCR8 with respect to pin PLG11-F3

F1

Reference for gate pulse to SCR9

F2

Gate Pulse to SCR9 with respect to pin PLG11-F1

F3

Reference for gate pulse to SCR8

Big Blue 300 P

9-10. Voltage Regulator Board PC3 Testing Information


!

Stop engine.

See Section 9-11 for specific values


during testing. Voltage readings tolerance 10%.
1
2
3

Voltage Regulator Board PC3


Receptacle RC1
Receptacle RC2

2
3

Test Equipment Needed:

803 702

Big Blue 300 P

TM-4433 Page 55

9-11. Voltage Regulator Board PC3 Test Point Values


a) Tolerance
specified

10% unless

b) Reference to circuit common


(lead 42) unless noted

PC3 Voltage Readings

c) Condition no load; weld/power rpm unless noted


d) Process/Contactor switch R1
in Weld Terminals Always On
Stick position
Receptacle

Pin

RC1

14 volts DC input with respect to pin RC1-3

+13 volts DC output

Circuit common

Circuit common

Power supply output: +15 volts DC

Power supply output: 15 volts DC

+10 volts DC input

Shutoff command input (field current): normal condition: 0 volts DC, fault condition: 0.7 volts DC

Frequency to voltage signal: +10 volts DC output at 1860 rpm

10

SCR fault signal; +5 volts DC input if SCR fails

11

Synchronization signal

12

Not used

120 volts AC input with respect to pin RC1-3

120 volts AC input with respect to pin RC1-3

Not used

Not used

158 volts AC input with respect to pin RC2-8

+61 volts DC with respect to pin RC2-7

+61 volts DC with respect to pin RC2-6

158 volts AC with respect to pin RC2-5

Not used

10

Not used

11

Not used

12

Not used

RC2

TM-4433 Page 56

Value

Big Blue 300 P

9-12. Meter Display Board PC2 Testing Information

Test Equipment Needed:

Stop engine.

See Section 9-13 for specific values during testing. Voltage readings tolerance 10%.
1

Meter Display Board PC2

803 702 / 214 536

9-13. Meter Display Board PC2 Test Point Values


a) Tolerance
specified

10% unless

b) Reference to circuit common


(lead 42) unless noted

PC2 Voltage Readings

c) Condition no load; weld/power rpm unless noted


d) Process/Contactor switch R1
in Weld Terminals Always On
Stick position
Receptacle

Pin

RC1

+12 volts DC input with respect to pin RC1-2

Circuit common

Serial data line

Serial data line

Big Blue 300 P

Value

TM-4433 Page 57

9-14. Idle Module PC5 Testing Information And Troubleshooting Flow Chart

Voltage readings tolerance 10%.


1

Idle Module PC5

 Engine starts and remains at idle

speed until a power or weld load is


applied.

 Verify engine

speeds are correct


before testing idle module.

H
A

Test Equipment Needed:

803 566

TM-4433 Page 58

Big Blue 300 P

Engine does not go to weld/power speed


(1880 rpm) under power or weld load .

Engine does not go to idle speed (1250 rpm)


with no weld or power load applied.
Connect meter (DC) between
terminal H and terminal E.

Connect meter between


terminal H and terminal E.

Start engine, and place Engine


Control switch S1 in Auto position.
Place Process/Contactor switch
R1 in Weld Terminals
Always On Stick position.

Start engine, and place Engine


Control switch S1 in Auto position.
Place Process/Contactor switch
R1 in Weld Terminals
Always On Stick position.

+12 volts dc present?

NO

Check Engine
Control switch S1,
and ground connection (lead 42).

YES

NO

Check Engine
Control switch S1,
and ground connection (lead 42).

YES

Connect meter DC between


terminal B (+) and terminal E ().

+12 volts dc present?

+12 volts dc present?

Connect meter between


terminal G and terminal E.

NO

YES

Check Engine
Control switch S1,
control relay CR1,
and ground connection (lead 42).

Connect meter between


terminal G and terminal E.

Connect a 100 watt light bulb to


120 volts ac duplex receptacle.

Minimum of 0.75 volt AC present?

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.

Connect meter between


terminal J and terminal E.

Connect meter between


terminal J and terminal E.

0 Volts dc present?
YES

3.5 volts dc present?

NO

Check main
control board
PC1.

Connect meter between


terminal C (+) and terminal E ().

YES
Connect meter between
terminal C (+) and terminal E ().

0 (zero) volts dc present?

NO

Replace
idle module.

YES

About 10 volts DC present?

NO

Replace
idle module.

Check control relay CR4


and throttle solenoid
TS1.

YES
Check control relay CR4,
throttle solenoid TS1,
and connections.

Disconnect 100 watt light bulb


and meter leads.

Reinstall cover.

Reinstall cover.

Big Blue 300 P

TM-4433 Page 59

9-15. Replacing Brushes And Cleaning Slip Rings


!

Stop engine and let cool.

Brush Holder Bracket

Remove brush holder bracket.


Keep hardware for reinstallation.
2

Brush Holder

Brush With Spring

Brush Holder Cap

Brush Holder Retaining Bar

Mark and disconnect leads at caps


and remove retaining bar. Unscrew
caps and remove brushes from
bracket.
Replace brushes if damaged, or if
brush is at or near minimum length.
6

Slip Rings

Inspect slip rings. Under normal


use, rings turn dark brown.
If slip rings are corroded or surface
is uneven, insulate brush leads,
start engine, and clean rings with a
commutator stone. Remove as little
material as possible.

Stop engine.

Install brushes, caps, bar, bracket,


and brush leads. Tighten bracket
hardware.

6
1

5/16 in (8 mm)
Minimum Length
9/16 in (14.3 mm)
New Length
Tools Needed:

Replace
Damaged Brushes

Ref. 803 683 / Ref. 803 686

TM-4433 Page 60

Big Blue 300 P

9-16. Checking Unit Output After Servicing


 Also use output waveforms to

check unit output after servicing (see Section 9-4).

Check engine speeds, and adjust if


necessary (see Section 7-6).
Place Process/Contactor switch
R1 in Weld Terminals Always Hot
Stick position.
1

AC Receptacles GFCI1,
GFCI2, RC1

CC (Stick) And CV (Wire)


Weld Output Terminals

Work Weld Output Terminal

Start engine and run at weld/power


speed (1880 rpm).
Check voltage at each receptacle.
With no load applied, there should
be 126 to 130 volts AC present at
GFCI1 and GFCI2, and 252 to 260
volts AC at RC1.
If correct voltage is not present, repeat troubleshooting procedures in
Section 9-1.

Check open-circuit voltage across


weld output terminals according to
Section 9-2. If correct voltages are
not present, repeat troubleshooting
procedures in Section 9-1.

Stop engine.

Allow engine to cool, and then complete pre-operational checks in


table.

Pre-Operational Checks
Wipe engine surfaces clean.
Check labels; replace labels that are unreadable or damaged.
Check fuel and oil (see Section 4-7).

Test Equipment Needed:

Tools Needed:

Check and correct any fluid leaks.


Clean weld output and battery terminals. Tighten connections.
Clean outside of entire unit.

Big Blue 300 P

TM-4433 Page 61

SECTION 10 DISASSEMBLY AND REASSEMBLY


10-1. Disassembly Of Unit
!

Stop engine and let cool. Disconnect battery negative ()


cable.

Use Section 9-1 to determine if trouble


is in stator, rotor, engine or combination
of these components.
1

Engine Manifold Screw

Generator Mounting Screws

Engine Mounting Screw

Engine Lifting Eyes

Remove side panels, covers, and


doors. Retain all hardware.
Drain radiator according to Section 7-5
and engine manual. Disconnect hoses
at radiator.
Remove rear upright, right fan guard,
and radiator assembly.
Disconnect flexible exhaust pipe at engine manifold.
Disconnect fuel line at engine.

 To aid in reassembly, mark leads

before disconnecting. See lead list


summary in Section 11 for connection information.

Disconnect:

generator cables from rectifier


assembly

generator power leads from terminal strip TE1

engine wiring harness at in-line


connector

engine ground strap from base.

Use a hoist to evenly lift and remove


engine/generator assembly.
3

Go to Section 10-2.

Remove brushes
before removing
endbell or rotor.
803 704

TM-4433 Page 62

Big Blue 300 P

10-2. Disassembly Of Generator

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

NOTICE Do not damage stator or rotor windings during this procedure.

Remove engine and rotor by removing nuts


from studs and separating stator from engine
adapter. With engine properly supported, remove hardware securing endbell to stator.

Use hoist and lifting strap to carefully


remove generator components.

Brushes

Stator

Reinstall engine and generator parts as


needed using torque values in table.

Endbell

Reinstall brushes in brushholder assembly.

Rotor

Stud

Reinstall engine/generator assembly in unit.


Reinstall mounting hardware and torque to 50
ft lb (68 N.m).

Remove brushes from brushholder assembly


before disassembling generator.

Big Blue 300 P

Reassembly Instructions:

Reconnect fuel line and exhaust pipe. Torque


engine manifold screws to 30 ft lb (41 N.m).
Reinstall radiator and rear upright. Refill radiator with coolant (see Section 7-5 and engine manual).
Reconnect all leads. Use cable ties to secure
leads in existing wiring harness and away
from moving and hot parts.
Reconnect negative () battery cable. Reinstall cover, panels, and doors.

TM-4433 Page 63

10-3. Replacing Rectifier SCR Modules


!

Stop engine and let cool. Disconnect battery negative ()


cable.

 Be sure to follow torque specifica-

tions in table when installing and


connecting SCR module. Retorque
mounting hardware after four
hours.

SCR Module Torques:


SCR Mounting Screw
45 in lb, 5 in lb
(5 Nm, 0.5 Nm)
After four hours re-torque to
45 in lb, 5 in lb
(5 Nm, 0.5 Nm)

SCR Connection Screw Terminal


45 in lb, 5 in lb
(5 Nm, 0.5 Nm)

Rectifier Assembly

SCR Module

SCR Connection Screw

SCR Mounting Screw

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

Big Blue 300 P

SECTION 11 ELECTRICAL DIAGRAMS


 The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit inside
machine case or contact distributor for more information.

The following is a list of all diagrams for models covered by this manual.

Model

Circuit
Diagram

Serial Or Style Number

Big Blue 300 P CC/CV Models

LE099775 And Following

219 228-E

Circuit Board PC6


(HF Filter Board)

LE099775 Thru LH030117E

217 005-A

LH030117E And Following

229 948-A

LE099775 and following

214 535-B

Circuit Board PC2


(Meter Display)

Wiring
Diagram
See Table 11-1

Not included in this manual

Notes

Start Your Professional


Welding Career Now!
Big Blue 300 P

400 Trade Square East, Troy, Ohio 45373


1-800-332-9448 www.welding.org

Over 80,000 trained


since 1930!
TM-4433 Page 65

Figure 11-1. Circuit Diagram For Big Blue 300 P Eff w/LE099775 And Following
TM-4433 Page 66

Big Blue 300 P

219 228-E

Big Blue 300 P

TM-4433 Page 67

217 005-A

Figure 11-2. Circuit Board PC6 (HF Filter) Effective w/LE099775 Thru LH030117E
TM-4433 Page 68

Big Blue 300 P

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 . .

CR1 (0) TO CR1 (2)


CR1 (0) TO S4 (NO)
CR1 (2) TO S1 (B)
S4 (NO) TO PLG1 (4)
S2 (2) TO PLG1 (2)
S3 (2) TO PLG1 (3)
CR3 (86) TO S4 (WIPER)
CR4 (30) TO SR3
SR3 TO TS1
PC5 (C) TO SR3
SR3 TO CR4 (86)
PC5 (H) TO S1 (D)
CB9 TO CR4 (87)
PC5 (G) TO CT
PLG7 (F2) TO PC5 (J)
FUEL SENDER TO PLG1 (5)
PC680 TO TE180
STATOR TO TE1
PLG6 (K3) TO CB8
STATOR TO CB8
GFCI1 (H) TO CB6
PLG10 (3) TO #84 STATOR LEAD
GFCI2 (H) TO CB4
PC687 TO CB7
STATOR TO TE1 (C)
TE1 (C) TO RC11 (WB)
GFCI1 (N) TO TE1 (C)
GFCI1 (N) TO GFCI2 (N)
STATOR TO TE1 (B)
TE1 (B) TO CB5
PLG10 (1) TO #91 STATOR LEAD
STATOR TO VR
STATOR TO CB7
STATOR TO TE1 (A)
TE1 (A) TO CB5
PLG10 (2) TO #92 STATOR LEAD
STATOR TO VR
CB5 TO RC11 (X)
CB5 TO CB6
CB5 TO RC11 (Y)
CB5 TO CB4
PLG10 (4) TO #99 STATOR LEAD
STATOR TO SPLICE (PC3)
PLG10 (5) TO STATOR 100A
STATOR TO FUSE 1
PLG10 (6) TO BRUSH
PLG6 (F3) TO PLG9 (6)
PLG6 (D2) TO PLG9 (9)
PLG10 (7) TO BRUSH
PLG6 (E3) TO PLG9 (5)
PLG6 (E2) TO PLG9 (11)
PLG6 (H3) TO PLG9 (4)
PLG10 (8) TO F1
PLG6 (G3) TO PLG9 (8)
PLG7 (E1) TO PLG9 (2)
PLG7 (C3) TO PLG9 (10)
PLG6 (J3) TO PLG9 (7)
PC6132 CB8
PLG6 (G2) TO PLG8 (6)
PLG7 (F1) TO PLG8 (8)
PLG6 (H2) TO PLG8 (9)
PLG7 (F3) TO PLG8 (10)
PLG6 (F2) TO PLG8 (4)
PLG6 (D3) TO PLG8 (2)
PLG7 (B3) TO PLG8 (7)
PLG7 (B1) TO PLG3 (4)
PLG7 (A1) TO PLG3 (5)
PLG6 (K1) TO PLG3 (6)

TM-4433 Page 70

Big Blue 300 P

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

Big Blue 300 P

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

SECTION 12 RUN-IN PROCEDURE


run_in1 200704

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

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 engine manual for additional engine run-in information.

TM-4433 Page 72

Big Blue 300 P

12-2. Run-In Procedure Using Load Bank


Stop engine.
Do not touch hot exhaust pipe,
engine parts, or load bank/grid.
Keep exhaust and pipe away
from flammables.

4
2
1

NOTICE Do not perform runin procedure at less than 20


volts weld output and do not
exceed duty cycle or equipment damage may occur.
1 Load Bank
Turn all load bank switches Off. If
needed, connect load bank to 115
volts ac wall receptacle or generator auxiliary power receptacle.
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 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 load bank
meters after first five minutes then
every fifteen minutes to be sure
generator is loaded properly.
NOTICE Check oil level frequently during run-in; add oil if needed.
It is recommended to run the welding generator for two hours minimum and up to four hours under
load. Place A/V control in minimum
position, then turn off load bank to
remove load. Run engine several
minutes at no load.
Stop engine and let cool.
4 Engine Exhaust Pipe
Repeat procedure if wetstacking
is present.

S-0683

Big Blue 300 P

TM-4433 Page 73

12-3. Run-In Procedure Using Resistance Grid


Stop engine.
Do not touch hot exhaust pipe,
engine parts, or load bank/grid.
Keep exhaust and pipe away
from flammables.

NOTICE Do not perform runin procedure at less than 20


volts weld output and do not
exceed duty cycle or equipment damage may occur.

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).

Check generator and meters after


first five minutes then every fifteen
minutes to be sure generator is
loaded properly.
NOTICE Check oil level frequently during run-in; add oil if needed.
It is recommended to run the welding generator for two hours minimum and up to four hours under
load. Place A/V control in minimum
position, then shut down grid to
remove load. Run engine several
minutes at no load.
Stop engine and let cool.
6 Engine Exhaust Pipe
Repeat procedure if wetstacking is
present.

S-0684

TM-4433 Page 74

Big Blue 300 P

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

Engine Driven Welding Generator

Big Blue 300 P

Eff w/LE099775 Thru LJ120250E


For OM-4433 (218 314) Revisions A Thru P

File: Engine Drive


Visit our website at

www.MillerWelds.com

SECTION 13 PARTS EFF W/LE099775 THRU LJ120250E


 Hardware is common and not
available unless listed.

Wirng harnesses are listed at


the end of parts section.

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

Figure 13-1. Main Assembly


TM-4433 Page 76

Big Blue 300 P

Eff w/LE099775 Thru LJ120250E

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

803 683 Ref. 803 683

Big Blue 300 P

TM-4433 Page 77

Eff w/LE099775 Thru LJ120250E


Item
No.

Dia.
Mkgs.

Part
No.

Description

Quantity

Figure 13-1. Main Assembly


. . . 1 . . . . . . . . . . Figure 133 . . Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . . . 213504 . . Tray, Reactor & Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 213491 . . Insulator, Capacitor Bank (Applies To Reactor/Rectifier Tray) . . . . . . . . . .
. . . 3 . . . . HD1 . . . . 168829 . . Transducer, Current 1000a Module Max Open Loop . . . . . . . . . . . . . . . . .
. . . 4 . . . . . R3 . . . . . 213027 . . Resistor, WW Tap 300 W 40 Ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . . . . . . . . . . 217070 . . Bracket, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . . . . . . Figure 135 . . Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . . . . . . . . . . . 214742 . . Capacitor Assy (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 213489 . . . . Bus Bar, Capacitor Bank Negative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 213490 . . . . Bus Bar, Capacitor Bank Positive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . C10 . . . . 163535 . . . . Capacitor, Elctlt 16000 Uf 60 Vdc Can 1.75 Dia . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 181853 . . Insulator, Screw (For Rectifier Mtg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . . . . . . . . . . . +213488 . . Panel, Engine Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . PC1 . . . . 214769 . . Module, Main Control/Scr Gating (Prior to LF315956) . . . . . . . . . . . . . . . .
. . . 9 . . . . PC1 . . . . 220739 . . Module, Main Control/Scr Gating (Eff w/LF315956 thru LG300055E) . . .
. . . 9 . . . . PC1 . . . . 228727 . . Module, Main Control/Scr Gating (Eff w/LG300055E thru LH030117E) . .
. . . 9 . . . . PC1 . . . . 231705 . . Module, Main Control/Scr Gating (Eff w/LH030117E) . . . . . . . . . . . . . . . . .
. . . 10 . . . . PC3 . . . . 214770 . . Module, Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . . . . . . . . . . . 215522 . . Bracket, Vault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . . . Z1 . . . . . 213929 . . Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 192303 . . Angle, Mtg Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . TE1 . . . . 172661 . . Block, Stud Connection 6 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 173734 . . Link, Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 14 . . . . . . . . . . . . . . 213500 . . Brkt, Beam Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 15 . . . . . . . . . . . . . . 213602 . . Gasket, Exhaust Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . . . . . 214753 . . Bracket, Holddown Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 213506 . . Bracket, HoldDown Fuel Tank (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . . . . . . . . . . . . 213493 . . Upright, Center Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 18 . . . . . . . . . . . . . . 189464 . . Seal, Weather Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . . . 213501 . . Bracket, Fuel Pump/Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . . . . . . . . . . . . . Bracket, Fuel Filter Mtg. (Order Thru Engine Manufacturer) . . . . . . . . . . .
. . . 21 . . . . . . . . . . . . . . 217687 . . Filter, Fuel Spinon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 22 . . . . . . . . . . . . . . 207721 . . Pump, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 23 . . . . . . . . . . . . . *213858 . . Filter, Fuel Inline 5/16x5/16 Mic 125 175 . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 24 . . . . . . . . . . . . . . 212621 . . Pipe, Exhaust Flexible Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 25 . . . . . . . . . . . . . . 183314 . . Clamp, Muffler 1.625 Dia U Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 26 . . . . . . . . . . . . . . 212604 . . Baffle, Air Lower Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 27 . . . . . . . . . . . . . . 201528 . . Muffler, Exhaust Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 28 . . . . . . . . . . . . . . 212605 . . Pipe, Exhaust Blue Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 29 . . . . . . . . . . . . . +213470 . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 049525 . . Nut, 31218 Unut Multithread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 30 . . . . . . . . . . . . . . 189052 . . Grommet, Plastic Neck Filler Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 31 . . . . . . . . . . . . . . 190198 . . Cap, Tank Screwon 3.500 In W/Vent W/Lanyard 8 . . . . . . . . . . . . . . . . .
. . . 32 . . . . . . . . . . . . . . 176104 . . Label, Warning Falling Equip Can Cause Serious (Prior to LF310974) . .
. . . 32 . . . . . . . . . . . . . . 222513 . . Label, Warning Falling Equip Can Cause Serious (Eff w/LF310974) . . . .
. . . 33 . . . . . . . . . . . . . . 201851 . . Cover, Radiator Access (Top) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 34 . . . . . . . . . . . . . . 214604 . . Pipe, Exhaust Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 35 . . . . . . . . . . . . . . 176230 . . Label, Warning Hot Exhaust Parts Do Not Touch (Prior to LF310974) . . .
. . . 35 . . . . . . . . . . . . . . 224265 . . Label, Warning Hot Exhaust Parts Do Not Touch (Eff w/LF310974) . . . . .
. . . 36 . . . . . . . . . . . . . . 176103 . . Label, Use Diesel Fuel Only (Prior to LF310974) . . . . . . . . . . . . . . . . . . . . .
. . . 36 . . . . . . . . . . . . . . 192041 . . Label, Use Diesel Fuel Only (Eff w/LF310974) . . . . . . . . . . . . . . . . . . . . . . .
. . . 37 . . . . . . . . . . . . . . 213472 . . Keeper, Latch Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 38 . . . . . . . . . . . . . . 213471 . . Bracket, Cover Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 39 . . . . . . . . . . . . . . 217387 . . Baffle, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TM-4433 Page 78

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Item
No.

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Mkgs.

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Quantity

Figure 13-1. Main Assembly (Continued)


. . . 40 . . . . . . . . . . . . . . 213503 . . Guard, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . +212607 . . Shroud, Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . . . 212606 . . Radiator, W/14# Cap 3 Row Core 1.25 In
Inlet/Outlet (Includes) (Prior to LH190116E) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . . . 233256 . . Radiator, W/14# Cap 3 Row Core 1.25 In
Inlet/Outlet (Includes) (Eff w/LH190116E) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 187120 . . . . Cap, Radiator Pressure 14lb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . . . 212603 . . Baffle, Air Upper Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . +213469 . . Upright, Rear (Prior to LE302529) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . +220954 . . Upright, Rear (Eff w/LE302529 Thru LJ010064E) . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . +225400 . . Upright, Rear (Eff w/LJ010065E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . . . 176230 . . Label, Warning Hot Exhaust Parts Do Not Touch (Prior to LF310974) . . . 1
. . . 45 . . . . . . . . . . . . . . 224265 . . Label, Warning Hot Exhaust Parts Do Not Touch (Eff w/LF310974) . . . . . 1
. . . 46 . . . . . . . . . . . . . . 220295 . . Bracket, Stiffener (Eff w/LE302529) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 47 . . . . . . . . . . . . . . 190190 . . Tank, Coolant Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . . . . . . . . . . 213502 . . Guard, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . . . . . . . . . . . 218303 . . Label, Diesel Engine Maintenance Perkins 403C15 . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . . . . . . . . . . 199592 . . Latch, Paddle Series 20 (Black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . . . . . . . . . . +213487 . . Door, Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 191626 . . Bumper, Door Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 52 . . . . . . . . . . . . . . 176106 . . Label, Warning Moving Parts Can Cause Injury (Prior to LF310974) . . . . 1
. . . 52 . . . . . . . . . . . . . . 225120 . . Label, Warning Moving Parts Can Cause Injury (Eff w/LF310974) . . . . . . 1
. . . 53 . . . . . . . . . . . . . . 189975 . . Hinge, Door Access 180 Deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 54 . . . . . . . . . . . . . . 087341 . . Bumper, Door 1.000 Od X .750 High Rbr 50 Duro W/O . . . . . . . . . . . . . . 2
. . . 55 . . . . . . . . . . . . . . 213486 . . Panel, Rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 56 . . . . . . . . . . . . . . 217698 . . Label, Help Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 57 . . . . . . . . . . . . . . 176108 . . Label, Warning Battery Explosion Can Blind (Prior to LF310974) . . . . . . . 1
. . . 57 . . . . . . . . . . . . . . 168385 . . Label, Warning Battery Explosion Can Blind (Eff w/LF310974) . . . . . . . . . 1
. . . 58 . . . . . . . . . . . . . . 176109 . . Label, Caution Do Not Use Ether (Prior to LF310974) . . . . . . . . . . . . . . . . 1
. . . 58 . . . . . . . . . . . . . . 203260 . . Label, Caution Do Not Use Ether (Eff w/LF310974) . . . . . . . . . . . . . . . . . . 1
. . . 59 . . . . . . . . . . . . . . 225120 . . Label, Warning Moving Parts Can Cause Injury . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . 214887 . . Idle, Solenoid Assy (Includes) (Prior to LG440030E) . . . . . . . . . . . . . . . . . 1
. . . 60 . . . . . . . . . . . . 213505 . . . . Bracket, Mtg Solenoid Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 61 . . . . TS1 . . 080517 . . . . Solenoid,12vdc Pull Type Tubular . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 62 . . . . . . . . . . . . 049839 . . . . Bracket, Adjustment Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 605277 . . . . Pin,Cotter .093 X .750 Zinc Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 198370 . . . . Rod,Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 206209 . . . . Ball Joint,.25028 Thd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 198609 . . . . Arm,Throttle 104.22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 230637 . . Idle, Solenoid Assy (consisting of) (Eff w/LG440030E) . . . . . . . . . . . . . . . . 1
. . . 60 . . . . . . . . . . . . 230828 . . . . Bracket, Mtg Solenoid Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 61 . . . . TS1 . . 230634 . . . . Solenoid, Throttle W/48.4 Lb Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 198109 . . . . Screw, Shld Stl Sch .25020 X .437 X .500 Shld . . . . . . . . . . . . . . . . . . . 1
. . . 62 . . . . . . . . . . . . 198018 . . . . Linkage, Throttle Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 230830 . . . . Arm, Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 63 . . . . . . . . . . . . . . 213266 . . Mount, Engine/Generator Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 64 . . . . . . . . . . . . . . 197506 . . Screw, M141.5x 30 Hex Hdpln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 65 . . . . . . . . . . . . . . 213480 . . Bracket, Mtg Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 66 . . . . . . . . . . . . . . 083883 . . Washer, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . . . . 2
. . . 67 . . . . . . . . . . . . . . 049026 . . Screw, M101.5x 25 Hex Hdpln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 68 . . . . . . . . . . . . . . . . . . . . . . . . Washer, Oil Drain (Order Thru Engine Manufacturer) . . . . . . . . . . . . . . . . . 1
. . . 69 . . . . . . . . . . . . . . 212612 . . Ftg, Adapter Oil Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 199505 . . Hose Assy, Oil Drain 32.000 Lg (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 70 . . . . . . . . . . . . . . 165271 . . . . Valve, Oil Drain 3/818 Nptf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 71 . . . . . . . . . . . . . . 176529 . . . . Ftg, Hose Brs Barbed Fem 1/2 Tbg X 3/8 Npt . . . . . . . . . . . . . . . . . . . . . 1
. . . 72 . . . . . . . . . . . . . . 113854 . . . . Hose, Sae .500 Id X .780 Od Xcoil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 Ft.
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Mkgs.

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Quantity

Figure 13-1. Main Assembly (Continued)


. . . 73 . . . . . . . . . . . . . . 197448
. . . 74 . . . . . . . . . . . . . . 212614
. . . 75 . . . . . . . . . . . . . . 217686
. . . 76 . . . . . . . . . . . . . . 217651
. . . . . . . . . . . . . . . . . . . . 212600
. . . . . . . . . . . . . . . . . . . *202166
. . . . . . . . . . . . . . . . . . . . 217695
. . . . . . . . . . . . . . . . . . . . 217696
. . . 77 . . . . . . . . . . . . . . 212613
. . . 78 . . . . . . . . . . . . . . 216811
. . . 79 . . . . . . . . . . . . . . 197613
. . . . . . . . . . . . . . . . . . . . 197675
. . . . . . . . . . . . . . . . . . . *197676
. . . . . . . . . . . . . . . . . . . . 197677
. . . . . . . . . . . . . . . . . . . . 197678
. . . . . . . . . . . . . . . . . . *197679
. . . . . . . . . . . . . . . . . . . . 197829
. . . 80 . . . . . . . . . . . . . . 212617
. . . 81 . . . . . . . . . . Figure 134
. . . 82 . . . . . . . . . . . . . . 213461
. . . 83 . . . . . . . . . . . . . . 213266
. . . . . . . . . . . . . . . . . . . . 212623
. . . 84 . . . . . . . . . . . . . . 189908
. . . 85 . . . . . . . . . . . . . . 181572
. . . 86 . . . . . . . . . . . . . . 124253
. . . 87 . . . . . . . . . . . . . . 212611
. . . 88 . . . . . . . . . . . . . . 212610
. . . 89 . . SENDER . . 213265
. . . . . . . . . . . . . . . . . . . . 172071
. . . . . . . . . . . . . . . . . . . . 211961
. . . . . . . . . . . . . . . . . . . . 213804
. . . . . . . . . . . . . . . . . . . . 191819
. . . . . . . . . . . . . . . . . . . . 145054
. . . 90 . . . . . . . . . . . . . . 213465
. . . 91 . . . . . . . . . . . . . . 213466
. . . 92 . . . . BATT . . . . 146237
. . . 93 . . . . . . . . . . . . . . 190207
. . . 94 . . . . . . . . . . . . . . 213668
. . . 95 . . . . . . . . . . . . . . 213458
. . . 96 . . . . . . . . . . . . . . 213483
. . . 97 . . . . . . . . . . . . . . 190206
. . . 98 . . . . . . . . . . . . . . 200864
. . . 98 . . . . . . . . . . . . . . 224266
. . . 99 . . . . . . . . . . . . . . 213462
. . . . . . . . . . . . . . . . . . . . 213670
. . . . . . . . . . . . . . . . . . . . 071731
. . 100 . . . . . . . . . . . . . 213463
. . . . . . . . . . . . . . . . . . . . 213600
. . . . . . . . . . . . . . . . . . . . 071731
. . . . . . . . . . . . . . . . . . . . 213464
. . 101 . . . . . . . . . . . . . 213485
. . 102 . . . . . . . . . . . . . 213459
. . 103 . . . . . . . . . . . . . 213460
. . 104 . . . . . . . . . . . . +220953
. . 104 . . . . . . . . . . . . . 226104

TM-4433 Page 80

. . Ftg, Hose Brs Barbed Elbow M 1/2 Tbg X 3/8 Npt . . . . . . . . . . . . . . . . . . .


. . Hose, Radiator Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Belt, Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Engine, Perkins (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Filter, Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Switch, Coolant Temp N.c. 110c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Switch, Lubricating Oil Pressure N.O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Hose, Radiator Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Clip, Nut Retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Air Cleaner, Intake 5.250 In (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Dust Ejector, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Element, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Cover Assy, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Body, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Element, Air Cleaner Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bracket, Mtg Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Hose, Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Generator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bracket, Mtg Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Mount, Engine/Generator Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Tank, Fuel (Includes Fuel Cap And Items Below) . . . . . . . . . . . . . . . . . . . .
. . . . Valve, Drain Fuel 180 Deg Zinc Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Hose, Fuel Stand Pipe W/3/16 In Ftg (Return) . . . . . . . . . . . . . . . . . . . . .
. . . . Hose, Fuel Stand Pipe W/5/16 In Ftg (Supply) . . . . . . . . . . . . . . . . . . . . .
. . . . Sender, Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Clamp, Hose .520 .605 Clp Dia Slfttng Black . . . . . . . . . . . . . . . . . . . . . .
. . Hose, Sae .312 Id X .560 Od X 16.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Hose, Sae .312 Id X .560 Od X 2.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Hose, Sae .312 Id X .560 Od X 15.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Hose, Sae .187 Id X .410 Od X 26.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bolt, J Stl .31218 X 7.250 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bracket, Battery Holddown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Battery, Stor 12v 585 Crk 95 Rsv Gp 55 Maint Free . . . . . . . . . . . . . . . . .
. . Cable, Bat Pos 45 In Lg No 1 Awg W/Clamp & .406 Rng . . . . . . . . . . . . .
. . Bracket, Mtg Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Support, Engine Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Cable, Bat Neg 42 In Lg 2 Awg W/Clamp & .375 Rng . . . . . . . . . . . . . . . .
. . Label, Warning Do Not Weld On Base (Prior to LF310974) . . . . . . . . . . . .
. . Label, Warning Do Not Weld On Base (Eff w/LF310974) . . . . . . . . . . . . . .
. . Pad, Mtg Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Screw, 50013x2.25 Hex Flangehd Gr8 Pln Chem/Phys . . . . . . . . . . . .
. . Washer, Flat .656idx2.250odx.187t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . .
. . Spacer/Snubber, Generator Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Screw, 50013x3.00 Hex Flangehd Gr8 Pln . . . . . . . . . . . . . . . . . . . . . . .
. . Washer, Flat .656idx2.250odx.187t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bracket, Battery Locator (In Base Not Shown) . . . . . . . . . . . . . . . . . . . .
. . Support, Engine Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Crossmember, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Crossmember, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Upright, Front (Prior to LJ010065E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Upright, Front (Eff w/LJ010065E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Big Blue 300 P

Eff w/LE099775 Thru LJ120250E


Item
No.

Dia.
Mkgs.

Part
No.

Description

Quantity

Figure 13-1. Main Assembly (Continued)


..
..
..
..
..
..
..

105
105
106
107
108
109
110

. . . . . . . . . . . . . 200795
. . . . . . . . . . . . . 233953
. . . . . . . . . . . . . 216347
. . . . . . . . . . . . . 220955
. . . . . . . . . Figure 132
. . . . . . . . . . . 105370
. . . . . . . . . . . . 233 088

..
..
..
..
..
..
..

Label, Warning General Precautionary CSA (Prior to LH190090E) . . . . . 1


Label, Warning General Precautionary CSA (Eff w/LH190090E) . . . . . . . 1
Label, Rating Card Code 151 (Provide Serial No. When Ordering) . . . . . 1
Panel, Front Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Xfmr, Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Label, Danger Using A Generator Indoors Can Kill You
In Minutes (Eff w/LH190090E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 111 . . . . . . . . . . . . . 225412 . . Cover, Radiator Access (Eff w/LJ010065E) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 218306 . . Kit, Label (Includes Safety & Informational Labels) . . . . . . . . . . . . . . . . . . . 1
+ 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 81

Eff w/LE099775 Thru LJ120250E


 Hardware is common and not
available unless listed.

Wirng harnesses are listed at


the end of parts section.

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

Figure 13-2. Panel, Front w/Components


Item
No.

Dia.
Mkgs.

Part
No.

Description

Quantity

Figure 13-2. Panel, Front w/Components (Figure 13-1 Item 108)


...
...
...
...
...
...
...
...
...

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

Knob, Pointer 2.375 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . .


Lock, Shaft Pot .37532 X .250 Dia Shaft Tall . . . . . . . . . . . . . . . . . . . . . . .
Conn, Circ Ms Protective Cap Size 20 Nylon . . . . . . . . . . . . . . . . . . . . . . .
Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knob, Pointer .875 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . . .
Nameplate, Control (Order By Model & Serial No.) . . . . . . . . . . . . . . . . . . .
Circuit Card Assy, Connector/Receptacle (Prior to LH030117E) . . . . . . . .
Circuit Card Assy, Connector/Receptacle (Eff w/LH030117E) . . . . . . . . . .
Supplementary Pro, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . .

1
1
1
2
1
1
1
1
2

Big Blue 300 P

Eff w/LE099775 Thru LJ120250E


Item
No.

Dia.
Mkgs.

Part
No.

Description

Quantity

Figure 13-2. Panel, Front w/Components (Continued)


...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

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 . .

Panel, Front Engine/Weld Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


Enclosure, Circuit Card Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Standoff Support, Pc Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . . . 4
Circuit Card Assy, Display W/Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Switch, Rotary 12 Posn 1p 200ma 28vdc W/Resistors . . . . . . . . . . . . . . . 1
Pot, Cp Flat 1t 2. W 1k Ohm Linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Switch, Tgl Spst 3a 250v Offnone(On) Spd Term . . . . . . . . . . . . . . . . . . 1
Switch, Ignition 4 Position (Includes Knob) . . . . . . . . . . . . . . . . . . . . . . . . 1
Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Connector, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Capacitor, Cer Disc .1 Uf 500 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . . . . . 3
Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Rcpt, Str 3p4w 50a 125/250v Flush Mtg *1450 . . . . . . . . . . . . . . . . . . . . . 1
Nameplate, Generator Power (Order By Model & Serial No.) . . . . . . . . . . 1
Panel, Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Rcpt,Str Dx Grd 2p3w 20a 125v *520r (Order By Model & Serial No.)
Rcpt, Str Dx Grd 2p3w 15/20a 125v *520r Gfi (Order By Model & Serial No.)
Capacitor, Cer Disc .0047 Uf 3000 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . 2
Supplementary Pro, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . 2
Supplementary Protector, Man Reset 2p 50a 240vac . . . . . . . . . . . . . . . . 1
Stud, Brs .25020 X 1.750 W/Hex Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Washer, Flat .257idx0.640odx.031t Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Nut, 25020 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Nameplate, Weld Terminal (Order By Model & Serial No.) . . . . . . . . . . . . . 1
Spacer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Boot, Generic Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Washer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Gauge, Fuel Elec/Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Boot, Toggle Switch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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.

Big Blue 300 P

TM-4433 Page 83

Eff w/LE099775 Thru LJ120250E


 Hardware is common and not

available unless listed.

Wirng harnesses are listed at


the end of parts section.

6
7

9
10

11
12
13
14
803 689-D

15

Figure 13-3. Control Panel


Item
No.

Dia.
Mkgs.

Part
No.

Description

Quantity

Figure 13-3. Control Panel (Figure 13-1 Item 1)


...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

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

..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..

Bracket, Mtg Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Term, Frict 250x032 Uninsul Male .130 Stud Mtg 3pr . . . . . . . . . . . . . . . .
Relay, Encl 6vdc Spst 35a/14vdc 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Breaker, Auto Reset 12vdc 40 Amp . . . . . . . . . . . . . . . . . . . . . . . . .
Relay, Encl 12vdc Dpstno 30a 6pin Flange (Prior to LF065150) . . . . . .
Relay, Assy (Eff w/LF065150 thru LF310974) . . . . . . . . . . . . . . . . . . . . . . .
Relay, Encl 12vdc Dpstno 25a 6pin Flange (Eff w/LF310974) . . . . . . . .
Holder, Fuse Mintr .250 X 1.250 Panel Mtg . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse, Mintr Cer Sloblo 10. Amp 250 Volt . . . . . . . . . . . . . . . . . . . . . . . . . .
Resistor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relay, Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg . . . . . . . . . . . . . . . . . .
Relay, Encl 12vdc Spst 70a 4pin Flange Mtg . . . . . . . . . . . . . . . . . . . . . . .
Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Module, Pull To Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Supplementary Pro, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . .
Circuit Breaker, Auto Reset 12vdc 8 Amp (Eff w/LH440030E) . . . . . . . . .

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

Big Blue 300 P

Eff w/LE099775 Thru LJ120250E


 Hardware is common and not

available unless listed.

Wirng harnesses are listed at


the end of parts section.
1

6
7

2
8
9
10

11
12
13
14

20

19 18
17 16

803 686-A

15

Figure 13-4. Generator


Item
No.

Dia.
Mkgs.

Part
No.

Description

Quantity

Figure 13-4. Generator (Figure 13-1 Item 81)


...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

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

. . Rotor, Generator 4 Pole (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


. . . . Bearing, Ball Rdl Sgl Row 1.370 X 2.830 X .6 . . . . . . . . . . . . . . . . . . . . .
. . . . Fan, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Baffle, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Adapter, Engine Machined . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . .
. . Screw, M 81.25x 25 Hex Hdpln 8.8 Pld Din933 . . . . . . . . . . . . . . . . . . .
. . Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . .
. . Screw, M 81.25x 25 Hex Hdpln 8.8 Pld Din933 . . . . . . . . . . . . . . . . . . .
. . Stud, Stl .37516 1.625x 19.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Stator, Generator 4 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Endbell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Nut, 37516 .56hex .34h Stl Pld Sem Cone Wshr.88d . . . . . . . . . . . . . . .
. . Brush, Assembly 2 Pole (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bar, Retaining Brushholder 2 Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Cap, Brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Brush w/Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Holder, Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Holder, Brush Elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Screw, 01032x .50 Hex Hdslt Stl Pld Sq Cone Sems . . . . . . . . . . . . . .

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

Eff w/LE099775 Thru LJ120250E


 Hardware is common and not

available unless listed.

Wirng harnesses are listed at


the end of parts section.
3
2

7
10
8

4
9
803 685-A

Figure 13-5. Rectifier Assembly


Item
No.

Dia.
Mkgs.

Part
No.

Description

Quantity

Figure 13-5. Rectifier Assembly (Figure 13-1 Item 6)


....................
... 1 ..............
. . . 2 . . MOD1,2,3 . .
. . . 3 . . MOD4,5,6 . .
... 4 ..............
... 5 ..............
... 6 ..............
. . . 7 . . . . TH1 . . . .
. . . 8 . . . . C16 . . . .
. . . 9 . . . C7,8,9 . . .
. . . 10 . . . . . . . . . . . . . .
....................

217081
211984
218296
218292
212602
212639
212601
213930
215611
048420
217085
181853

. . Rectifier, Assembly (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


. . . . Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Kit, Module SCR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Kit, Module SCR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bus Bar, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bus Bar, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Insulator, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Thermistor, Ntc 30k Ohm @ 25 Deg C 8.5in Lead . . . . . . . . . . . . . . . . .
. . . . Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Capacitor, Cer Disc .01 Uf 1000 Vdc W/Terms . . . . . . . . . . . . . . . . . . . .
. . . . Bus Bar, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Insulator, Screw (For Mounting Rectifier) . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Big Blue 300 P

Eff w/LE099775 Thru LJ120250E


 Some wiring harness components (switches, relays, supplementary protectors) are also referenced elsewhere in this parts list. Purchase components separately or as part of the associated wiring harness.

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

. . Harness, Engine (Includes) (Prior to LG440030E) . . . . . . . . . . . . . . . . .


. . Harness, Engine (Includes) (Eff w/LG440030E) . . . . . . . . . . . . . . . . . . .
. . . . Switch, Tgl Spst 3a 250v Offnone(On) Spd Term . . . . . . . . . . . . . . . .
. . . . Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Circuit Breaker, Auto Reset 12vdc 40 Amp . . . . . . . . . . . . . . . . . . . . . . .
. . . . Supplementary Pro, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . .
. . . . Relay, Encl 12vdc Spst 70a 4pin Flange Mtg . . . . . . . . . . . . . . . . . . . . . .
..
Relay, Encl 6vdc Spst 35a/14vdc 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Resistor Board, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Deutsch 2p 1row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Deutsch Wedge Lock 2 Position . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Univ 039 8p/S 2row Plug Cable Lkg Seal . . . . . . . . . . . . . .
. . . . Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Seal, Plug Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Pack 4p 1row Female . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Pack Terminal Position Assurance(Lock) . . . . . . . . . . . . . . . . . . .
. . . . Term, Frict 250x032 Uninsul Male .130 Stud Mtg 3pr . . . . . . . . . . . . . . .
. . . . Circuit Breaker, Auto Reset 12vdc 8 Amp (Eff w/LH440030E) . . . . . . . .

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

. . Harness, Weld Control (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


. . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg Seal . . . . . . . . . . . . . .
. . . . Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Seal, Plug Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Univ 039 10p/S 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Cinch 30 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Cinch 18 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Deutsch 12p 2row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Deutsch 12p 2row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Deutsch Wedge Lock 12 Position . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Seal, Plug Deutsch 1216 Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Mini 045 4skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . .
. . . . Cable, Lem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Univ 039 2p/S 1row Rcpt Cable/Pnl Lkg S . . . . . . . . . . . . .
. . . . Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1
1
1
3
3
1
1
1
1
1
2
7
1
1
1
2

....................
. . . . . . . . . PLG11 . . .
....................
....................

214984
193183
207716
207718

. . Harness, Rectifier Cc/Cv (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


. . . . Conn, Rect Cinch 18 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Faston Mini Polarized 2 Skt G1k1 . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Faston Mini Polarized 2 Skt G2k2 . . . . . . . . . . . . . . . . . . . . . . . . .

1
1
6
3

. . . . . . . . . . . . . . . . . . . . 217010 . . Harness, Receptacle Auxiliary Power (Includes) . . . . . . . . . . . . . . . . . . 1


. . . . . . . . CB4, CB6 . . 093996 . . . . Supplementary Pro, Man Reset 1p 20a 250vac Fric . . . . . . . . . . . . . . . . 2

Big Blue 300 P

TM-4433 Page 87

Miller Electric Mfg. Co.


An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA

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

ORIGINAL INSTRUCTIONS PRINTED IN USA

2009 Miller Electric Mfg. Co.