Miller Big Blue 401DXQ - Manuals

Page 2 - From Miller to You

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local Miller distributorto receive the latest full line catalog orindividual catalog sheets. To locate your nearestdistributor or service agency call 1-800-4...

Page 3 - CALIFORNIA; TABLE OF CONTENTS; WARNING

The following terms areused interchangeablythroughout this manual:Stick = SMAWTIG = GTAW CALIFORNIA Proposition 65Warning Diesel engine exhaust andsome of its constituentsare known to the State ofCalifornia to causecancer, birth defects, andother reproductive harm. TABLE OF CONTENTS SECTION 1 – SAFE...

Page 4 - Declaration of Conformity for; NOTE; Big Blue; Directives

dec_con1 5/98 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). NOTE Manufacturer ’s Name: Miller Electric Mfg. Co. Manufacturer ’s Address: 1635 W. Spencer StreetAppleton, WI 54914 USA Declares tha...

Page 5 - SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING; Symbol Usage; Arc Welding Hazards; ELECTRIC SHOCK can kill.

OM-173 413 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING rom _nd_11/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoining symbols. Marks a special safety message. Means “Note”; not safety related. This...

Page 6 - BUILDUP OF GAS can injure or kill.; Engine Hazards; FUEL can cause fire or explosion.

OM-173 413 Page 2 Welding on closed containers, such as tanks,drums, or pipes, can cause them to blow up. Sparkscan fly off from the welding arc. The flying sparks, hotworkpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can causesparks, explosion,...

Page 7 - Additional Symbols For Installation, Operation, And Maintenance

OM-173 413 Page 3 MOVING PARTS can cause injury. Keep away from fans, belts, and rotors. Keep all doors, panels, covers, and guardsclosed and securely in place. Stop engine before installing or connecting unit. Have only qualified people remove guards or covers for maint-enance and troubleshooting a...

Page 8 - Principal Safety Standards

OM-173 413 Page 4 H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommunications equipment. Have only qualified persons familiar withelectronic equipment perform this installation. The user is responsible for having a qu...

Page 9 - Signification des symboles; Dangers relatifs au soudage à l’arc; UN CHOC ÉLECTRIQUE peut tuer.

OM-173 413 Page 5 SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION rom _nd_fre 11/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédureprésente des risques de danger ! Ceux-ci sont identifiéspar des symboles adjacents aux directives. Identifie un mess...

Page 10 - LE BRUIT peut affecter l’ouïe.; Dangers existant en relation avec le moteur

OM-173 413 Page 6 Le soudage effectué sur des conteneurs fermés tels quedes réservoirs, tambours ou des conduites peut provoquerleur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et deséquipements chauds peut provoquer des incen...

Page 11 - LIRE LES INSTRUCTIONS.

OM-173 413 Page 7 DES ORGANES MOBILES peuventprovoquer des blessures. Ne pas approcher les mains des ventilateurs, cour-roies et autres pièces en mouvement. Maintenir fermés et fixement en place les portes,panneaux, recouvrements et dispositifs deprotection. Arrêter le moteur avant d’installer ou br...

Page 13 - SECTION 2 – DEFINITIONS; Warning Label Definitions

OM-173 413 Page 9 SECTION 2 – DEFINITIONS 2-1. Warning Label Definitions 3/96 1 1.1 1.2 1.3 3 3.1 3.2 3.3 4 4.1 S-176 105-A + 2 2.1 2.2 + 5 + 7 7.1 7.2 2.3 + 6 6.1 6.2 6.3 + = Warning! Watch Out! There arepossible hazards as shown by thesymbols. Become trained and read theinstructions before working...

Page 15 - DIESEL

OM-173 413 Page 11 3/96 1 Warning! Watch Out! Thereare possible hazards asshown by the symbols. 2 Hot muffler and exhaust pipescan cause severe burns. Donot touch hot muffler or pipes. 1 S-176 230 2 3/96 1 Warning! Watch Out! Thereare possible hazards asshown by the symbols. 2 Engine fuel plus flame...

Page 16 - Manufacturer ’s Rating Label For CE Products

OM-173 413 Page 12 3/96 1 Remove unit from shippingcrate. Remove Owner’sManual from unit. Followinstructions to install muffler. 2 Read Owner’s Manual. Readlabels on unit. 3 Use Diesel Fuel only, and fillfuel tank. Leave room forexpansion. 4 Warning! Watch Out! Thereare possible hazards asshown by t...

Page 17 - Symbols And Definitions; Hz

OM-173 413 Page 13 2-3. Symbols And Definitions Stop Engine Fast (Run,Weld/Power) Fast/Slow (Run/Idle) Slow (Idle) Start Engine Time Temperature Fuel Engine Oil Remote Panel/Local Certified/Trained Mechanic Check Injectors/ Pump Check Valve Clearance Battery (Engine) V Volts A Amperes Shielded Metal...

Page 18 - SECTION 3 – SPECIFICATIONS; Dimensions, Weights, And Operating Angles

OM-173 413 Page 14 SECTION 3 – SPECIFICATIONS 3-1. Weld, Power, And Engine Specifications Rated Welding Output Amperage Range Maximum Open- Circuit Voltage DC Auxiliary Power Rating Engine Fuel Capacity Sound Power IP Rating 400 A, 30 V DC, 40% Duty Cycle 40 – 400 96 (Average) Single-Phase, 3 kVA/kW...

Page 19 - Duty Cycle And Overheating

OM-173 413 Page 15 3-3. Duty Cycle And Overheating 6 Minutes Welding 4 Minutes Resting Continuous Welding rduty1 5/95 – SB-070 999-B Duty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithout overheating. Exceeding duty cycle candamage unit and voidwarranty. 60% Duty Cycle At 32...

Page 21 - SECTION 4 – INSTALLATION; Installing Welding Generator

OM-173 413 Page 17 SECTION 4 – INSTALLATION 4-1. Installing Welding Generator install1 3/96 – Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854 1 2 Electrically bond generator frame tovehicle frame by metal-to-metalcontact. GND/PE 3 4 1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grou...

Page 22 - Activating The Dry Charge Battery

OM-173 413 Page 18 4-2. Activating The Dry Charge Battery Remove battery from unit. 1 Eye Protection – SafetyGlasses Or Face Shield 2 Rubber Gloves 3 Vent Caps 4 Sulfuric Acid Electrolyte(1.265 Specific Gravity) 5 Well Fill each cell with electrolyte tobottom of well (maximum). Do not overfill batte...

Page 24 - Installing Muffler Pipe; Connecting To Weld Output Terminals

OM-173 413 Page 20 4-5. Installing Muffler Pipe ST-801 376 Stop engine and let cool. Do not blow exhaust towardair cleaner or air intake. Tools Needed: Top View 1/2 in Ref. ST-801 344 1 Positive (+) Weld OutputTerminal 2 Negative (–) Weld Output Ter-minal For Stick welding Direct CurrentElectrode Po...

Page 25 - Selecting Weld Cable Sizes

OM-173 413 Page 21 4-7. Selecting Weld Cable Sizes Total Cable (Copper) Length In Weld Circuit Not Exceeding Welding Amperes 100 ft (30 m) Or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft (105 m) 400 ft (120 m) Amperes 10 – 60% Duty Cycle 60 – 100% Duty Cycle 10 – 100% Duty Cyc...

Page 26 - SECTION 5 – OPERATING THE WELDING GENERATOR; Front Panel Controls

OM-173 413 Page 22 SECTION 5 – OPERATING THE WELDING GENERATOR 5-1. Front Panel Controls Ref. ST-188 449 This unit has a max OCV control circuitthat resets the Amperage/Voltage Con-trol to maximum when the arc breaks.When an arc is struck, weld output con-trol returns to the front panel or remotecon...

Page 27 - Manual Shutoff Lever

OM-173 413 Page 23 Ref. ST-801 344 1 Manual Shutoff Lever Use lever to stop engine if enginecontrol switch does not work. 1 5-2. Manual Shutoff Lever 5-3. Remote A/V Control 1 A/V Control Switch Use switch to select front panel orremote amperage control. 2 Remote A/V Receptacle RC3 Connect optional ...

Page 28 - SECTION 6 – OPERATING AUXILIARY EQUIPMENT; Optional Auxiliary Power Receptacles

OM-173 413 Page 24 SECTION 6 – OPERATING AUXILIARY EQUIPMENT 6-1. 120 Volt And 240 Volt Duplex Receptacles Ref. ST-188 449 If unit does not have GFCI recep-tacles, use GFCI-protected exten-sion cord. If a circuit breaker continues to open,contact Factory Authorized ServiceAgent. Auxiliary power is n...

Page 29 - Connecting Optional Auxiliary Power Plant

OM-173 413 Page 25 6-3. Connecting Optional Auxiliary Power Plant Ref. S-188 059-A Stop engine. Power and weld outputs arelive at the same time.Disconnect or insulateunused cables. Have qualified person installaccording to circuit diagramand Auxiliary Power Guidelines(Section 10). Remove junction bo...

Page 30 - Routine Maintenance

OM-173 413 Page 26 SECTION 7 – MAINTENANCE & TROUBLESHOOTING Follow the storage procedure in the engine owner ’s manual if the unit will not beused for an extended period. NOTE 7-1. Routine Maintenance Recycle engine fluids. Stop engine before maintaining. See also Engine Manual and Maintenance ...

Page 31 - Notes

OM-173 413 Page 27 1000 h Blow Out Or Vacuum Inside. During Heavy Service, Clean Monthly. OR Change Fuel Filters. See Section 7-4. Service Welding Generator Brushes And Slip Rings. Service More Often In Dirty Conditions.* Drain Sludge From Fuel Tank. See Section 7-4. FUEL SLUDGE Check Valve Clearanc...

Page 33 - Servicing Air Cleaner

OM-173 413 Page 29 7-3. Servicing Air Cleaner aircleaner4 9/99– 802 495 / Ref. S-0698-B Stop engine. 1 Air Cleaner 2 Service Indicator (Optional) 3 Window 4 Reset Button Service air cleaner element if redband appears in window. A greenband means air cleaner is okay.Press button to reset indicator. D...

Page 34 - Oil And Fuel System Components

OM-173 413 Page 30 7-4. Oil And Fuel System Components Ref. ST-188 449 / ST-801 334-A / Ref. S-176 697 / Ref. S-0842 Stop engine and let cool. 1 Oil Filter 2 Oil Drain Valve 3 Oil Fill Cap 4 Primary Fuel Filter (Fuel/Water Separator) 5 Petcock 6 Secondary Fuel Filter 7 Fuel Shutoff Valve 8 Fuel Line...

Page 35 - Adjusting Engine Speed

OM-173 413 Page 31 7-5. Adjusting Engine Speed Ref. ST-801 344-A After tuning engine, check engineno load speed with a tachometer(see table for no load speeds). Ifnecessary, adjust speed as follows: Start engine and run until warm.Turn Amperage/Voltage Control to100. Standard Models: 1 Engine Speed ...

Page 37 - Troubleshooting

OM-173 413 Page 33 7-8. Troubleshooting A. Welding Trouble Remedy No weld output. Check position of Ampere Range switch. Place A/V control switch in Panel position, or place switch in Remote position and connect remote amper-age control to Remote A/V receptacle (see Section 5-3). Check and secure co...

Page 39 - SECTION 8 – ELECTRICAL DIAGRAM; Figure 8-1. Circuit Diagram For Welding Generator

OM-173 413 Page 35 SECTION 8 – ELECTRICAL DIAGRAM SC-190 651-A Figure 8-1. Circuit Diagram For Welding Generator

Page 40 - SECTION 9 – RUN-IN PROCEDURE; Wetstacking

OM-173 413 Page 36 SECTION 9 – RUN-IN PROCEDURE run_in1 6/96 9-1. Wetstacking 1 Welding Generator Run diesel engines near rated out-put during run-in period to properlyseat piston rings and prevent wets-tacking. See nameplate or ratinglabel to find rated output. Do not idle engine longer thannecessa...

Page 41 - Run-In Procedure Using Load Bank

OM-173 413 Page 37 9-2. Run-In Procedure Using Load Bank S-0683 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep exhaust and pipe awayfrom flammables. 1 Load Bank Turn all load bank switches Off. Ifneeded, connect load bank to 115volts ac wall receptacle or genera-tor ...

Page 42 - Run-In Procedure Using Resistance Grid

OM-173 413 Page 38 9-3. Run-In Procedure Using Resistance Grid S-0684 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep exhaust and pipe awayfrom flammables. 1 Resistance Grid Use grid sized for generator ratedoutput. Turn Off grid. 2 Welding Generator Place A/V range s...

Page 43 - SECTION 10 – AUXILIARY POWER GUIDELINES; 0-2. Grounding Generator To Truck Or Trailer Frame

OM-173 413 Page 39 SECTION 10 – AUXILIARY POWER GUIDELINES 10-1. Selecting Equipment aux_pwr 2/99 – Ref. ST-159 730 / ST-800 577 1 Auxiliary Power Receptacles– Neutral Bonded To Frame 2 3-Prong Plug From CaseGrounded Equipment 3 2-Prong Plug From DoubleInsulated Equipment OR 2 Be sure equipmenthas t...

Page 44 - 0-3. Grounding When Supplying Building Systems

OM-173 413 Page 40 10-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment GroundingTerminal 2 Grounding Cable Use #10 AWG or larger insulatedcopper wire. 3 Ground Device Ground generator to systemearth ground if supplyingpower to a premises (home,shop, farm) wiring system. GND/PE 1...

Page 45 - 0-5. Approximate Power Requirements For Industrial Motors

OM-173 413 Page 41 10-5. 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 140...

Page 46 - 0-7. Approximate Power Requirements For Contractor Equipment

OM-173 413 Page 42 10-7. 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 ...

Page 48 - 0-10. Typical Connections To Supply Standby Power

OM-173 413 Page 44 10-10. Typical Connections To Supply Standby Power S-0405-A 1 Power Company ServiceMeter 2 Main and Branch OvercurrentProtection 3 Double-Pole, Double-ThrowTransfer Switch Obtain and install correct switch.Switch rating must be same as orgreater than the branch overcurrentprotecti...

Page 50 - SECTION 11 – PARTS LIST

OM-173 413 Page 46 SECTION 11 – PARTS LIST Hardware is common andnot available unless listed. 88 1 2 3 4 5 6 8 7 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 76 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98(Fig.11–3) 100 102 101 103 104 105 106 107 72(Includes 73–77) 73 74 75 73 77 78 79 80 9...

Page 59 - OPTIONAL EQUIPMENT

OM-173 413 Page 55 Description Quantity OPTIONAL EQUIPMENT Part No. 043 096 RECEPTACLE KIT, 120V GFCI 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE PROTECTION PACKAGE, (consisting of) 1 . . . . . . . . . . . . . . . . . . ....

Page 63 - (Equipment with a serial number preface of “LA” or newer)

Warranty Questions? Call1-800-4-A-MILLERfor your localMiller distributor. miller_warr 7/00 Your distributor also givesyou ... ServiceYou always get the fast,reliable response youneed. Most replacementparts can be in yourhands in 24 hours. SupportNeed fast answers to thetough welding questions?Contac...

Page 64 - Please complete and retain with your personal records.; For Service

PRINTED IN USA  2000 Miller Electric Mfg. Co. 6/00 Miller Electric Mfg. Co. An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 USA International Headquarters–USAUSA Phone: 920-735-4505 Auto-AttendedUSA & Canada FAX: 920-735-4134International FAX: 920-735-4125 European Head...