Miller Big Blue 400 KX - Manuals

dec_rotsound_1/05 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). NOTE Manufacturer : European Contact: Notified Body: Miller Electric Mg. Co. Mr. Danilo Fedolfi, AV Technology Limited 1635 W. Spe...

OM-4423 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom _nd_3/05 Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoi...

OM-4423 Page 4 READ INSTRUCTIONS. Use only genuine MILLER/Hobart replacement parts. Perform engine and air compressor (if applicable) maintenance and service according to this manual and the engine/air compressor (if applicable) manu- als. H.F. RADIATION can cause interference. High-frequency (H.F.)...

OM-4423 Page 7 Si le moteur est chaud et que le liquide doit être vérifié, opérer comme suivant. Mettre des lunettes de sécurité et des gants, placer un torchon sur le bouchon du radiateur. Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant d’enle- ver le bouchon. LES ACCUMULATIONS...

OM-4423 Page 8 LIRE LES INSTRUCTIONS. Utiliser seulement les pièces de rechange d’origine. Effectuer la maintenance du moteur et du compresseur (si applicable) suivant ce manuel et le manuel du moteur/ compresseur (si applicable). LE RAYONNEMENT HAUTE FRÉ- QUENCE (H.F.) risque de provoquer des inter...

OM-4423 Page 9 SECTION 3 − DEFINITIONS 3-1. Warning Label Definitions 3/96 1 Remove unit from shipping crate. Remove Owner’s Manual from unit. Follow instructions to install muffler. 2 Read Owner’s Manual. Read labels on unit. 3 Use Diesel Fuel only, and fill fuel tank. Leave room for expansion. 4 W...

OM-4423 Page 11 3-3. Symbols And Definitions Some symbols are found only on CE products. NOTE 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)...

OM-4423 Page 14 4-4. Fuel Consumption The curve shows typical fuel use under weld or power loads. 217 509 IDLE DC WELD AMPERES AT 100% DUTY CYCLE U.S. GAL/HR. 0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 0 50 100 150 200 250 300 350 400 Continuous Welding 4-5. Duty Cycle And Overheating Duty Cycle i...

OM-4423 Page 15 4-6. AC Generator Power Curve 220 346 − B The ac power curve shows the gen- erator power in amperes. AC AMPERES IN 110V MODE AC AMPERES IN 220V MODE AC VOL TS 0 20 40 60 80 100 120 140 0 10 20 30 40 50 60 70 0 20 40 60 80 100 120 0 40 80 120 160 200 240 Notes 16 Gauge (.063 in) 22 Ga...

OM-4423 Page 21 5-7. Connecting To Weld Output Terminals MIG and FCAW Welding For MIG and FCAW welding Direct Current Electrode Positive (DCEP, connect wire feed- er cable to CV (Wire) terminal on right and work cable to Work/Negative ( − ) terminal on left. Use Process/Contactor switch to select ty...

OM-4423 Page 23 5-9. Connecting To Remote 14 Receptacle RC14 Socket* Socket Information 24 VOLTS AC A 24 volts ac. Protected by circuit breaker CB8. 24 VOLTS AC B Contact closure to A completes 24 volt ac contactor control circuit. C Output to remote control:+10 volts dc in MIG mode; 0 to +10 volts ...

OM-4423 Page 26 6-3. Process/Contactor Switch On CC/CV Models 1 Process/Contactor Switch Weld output terminals are ener- gized when Process/Contactor switch is in a Weld Terminals Al- ways On position and the engine is running. Use switch to select weld process and weld output on/off control (see ta...

OM-4423 Page 27 6-4. Lift-Arc ™ Start Procedure Lift-Arc TIG With Lift-Arc TIG selected, start arc as follows:1 TIG Electrode 2 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 whe...

OM-4423 Page 34 8-6. Adjusting Engine Speed On Standard Models Ref. 803 576 − C 3 2 1 RPM (Hz) Engine Speed (No Load) Weld/Power 1880 (61.7) Maximum Stop engine and let cool. Engine speed is factory set and should not require adjustment. Af- ter tuning engine, check engine speed with tachometer or f...

OM-4423 Page 35 8-7. Servicing Fuel And Lubrication Systems Ref. 217 − 358 − B / 802 490 / 803 576 − C Stop engine and let cool. After servicing, start engine and check for fuel leaks. Stop engine, tighten connec- tions as necessary, and wipe up spilled fuel. 1 Oil Filter 2 Oil Drain Valve And Hose ...

OM-4423 Page 39 8-11. Troubleshooting Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 8-10). Note A. Welding Trouble Remedy No weld output; generator power output okay at ac receptacles. Place Process/Contactor switch in a Weld Terminals Always On pos...

OM-4423 Page 42 SECTION 9 − ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For Welding Generator

OM-4423 Page 47 SECTION 11 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown. NOTE 11-1. Selecting Equipment gen_pwr 11/02 − Ref. ST-159 730 / ST-800 577 1 Generator Power Receptacle...

OM-4423 Page 48 11-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding Terminal 2 Grounding Cable Use #10 AWG or larger insulated copper wire.3 Ground Device Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. GND/PE ...

OM-4423 Page 49 11-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 2100 700 1/2 HP 3175 875 Capacitor Start-Induction Run 1/3 HP 2020 720 1/2 HP 3075 975 3/4 HP 4500 1400 1...

OM-4423 Page 50 11-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/2 in 500 500 7-1/4 in 900 900 8-1/4 in 1400 1400 Table Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 ...

OM-4423 Page 52 11-10. Typical Connections To Supply Standby Power Have only qualified persons perform these connections according to all applicable codes and safety practic- es. Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes. Customer...

OM-4423 Page 54 SECTION 12 − PARTS LIST Hardware is common and notavailable unless listed. Wirng harnesses are listed at the end of parts section. 1 − Fig.12 − 3 2 7 3 − Fig.12 − 5 4 6 8 9 5 10 11 12 14 15 13 16 17 102 100 99 18 19 20 21 22 23 90 91 83 82 81 80 79 84 85 89 88 87 86 93 94 95 98 96 − ...

OM-4423 Page 64 Some wiring harness components (switches, relays, circuit breakers) are also referenced elsewhere in this parts list. Purchase components separately or as part of the associated wiring harness. Note Description Part No. Dia. Mkgs. Item No. Wiring Harnesses Quantity 217113 Harness, En...

Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 1/05 Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding quest...

PRINTED IN USA © 2005 Miller Electric Mfg. Co. 1/05 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters − USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 Europe...