Miller Electric Big Blue 401DXQ Owner's Manual

Visit our website atwww.MillerWelds.comOM-173 413GMarch 1998Big Blue 401DXQProcessesDescriptionAir Carbon Arc (CAC-A) Cuttingand GougingStick (SMAW)

OM-173 413 Page 6Le soudage effectué sur des conteneurs fermés tels quedes réservoirs, tambours ou des conduites peut provoquerleur éclatement. Des ét

OM-173 413 Page 7DES ORGANES MOBILES peuventprovoquer des blessures. Ne pas approcher les mains des ventilateurs, cour-roies et autres pièces en mouv

OM-173 413 Page 8LE RAYONNEMENT HAUTE FRÉ-QUENCE (H.F.) risque de provoquerdes interférences. Le rayonnement haute fréquence (H.F.) peutprovoquer des

OM-173 413 Page 9SECTION 2 − DEFINITIONS2-1. Warning Label Definitions3/961 1.1 1.2 1.33 3.1 3.2 3.34 4.1S-176 105-A+2 2.1 2.2+5+7 7.1 7.22.3+6 6.16.2

OM-173 413 Page 103/961 Warning! Watch Out! Thereare possible hazards asshown by the symbols.2 Do not smoke and keepmatches and flames away frombatter

OM-173 413 Page 113/961 Warning! Watch Out! Thereare possible hazards asshown by the symbols.2 Hot muffler and exhaust pipescan cause severe burns. Do

OM-173 413 Page 123/961 Remove unit from shippingcrate. Remove Owner’sManual from unit. Followinstructions to install muffler.2 Read Owner’s Manual. R

OM-173 413 Page 132-3. Symbols And DefinitionsStop EngineFast(Run,Weld/Power)Fast/Slow(Run/Idle)Slow(Idle)Start Engine Time Temperature FuelEngine Oil

OM-173 413 Page 14SECTION 3 − SPECIFICATIONS3-1. Weld, Power, And Engine SpecificationsRated WeldingOutputAmperageRangeMaximumOpen-CircuitVoltage DCAu

OM-173 413 Page 153-3. Duty Cycle And Overheating6 Minutes Welding 4 Minutes RestingContinuous Weldingrduty1 5/95 − SB-070 999-BDuty Cycle is percenta

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

OM-173 413 Page 163-5. AC Auxiliary PowerThe ac power curve shows the aux-iliary power in amperes available atthe 120 and 240 volt receptacles.rsb3.1

OM-173 413 Page 17SECTION 4 − INSTALLATION4-1. Installing Welding Generatorinstall1 3/96 − Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854

OM-173 413 Page 184-2. Activating The Dry Charge BatteryRemove battery from unit.1 Eye Protection − SafetyGlasses Or Face Shield2 Rubber Gloves3 Vent

OM-173 413 Page 194-3. Connecting The BatteryST-156 011-A / Ref. ST-188 449 / S-0756Tools Needed:1/2 in+− Connect Negative (−)Cable Last4-4. Engine P

OM-173 413 Page 204-5. Installing Muffler Pipe ST-801 376 Stop engine and let cool. Do not blow exhaust towardair cleaner or air intake.Tools Needed

OM-173 413 Page 214-7. Selecting Weld Cable SizesTotal Cable (Copper) Length In Weld Circuit Not ExceedingWeldingAmperes100 ft (30 m) Or Less150 ft(45

OM-173 413 Page 22SECTION 5 − OPERATING THE WELDING GENERATOR5-1. Front Panel ControlsRef. ST-188 449 This unit has a max OCV control circuitthat res

OM-173 413 Page 23Ref. ST-801 3441 Manual Shutoff LeverUse lever to stop engine if enginecontrol switch does not work.15-2. Manual Shutoff Lever5-3. R

OM-173 413 Page 24SECTION 6 − OPERATING AUXILIARY EQUIPMENT6-1. 120 Volt And 240 Volt Duplex ReceptaclesRef. ST-188 449 If unit does not have GFCI re

OM-173 413 Page 256-2. Optional Auxiliary Power ReceptaclesRef. ST-188 449 / Ref. ST-169 671-A If unit does not have GFCI re-ceptacles, use GFCI-pro-

The following terms areused interchangeablythroughout this manual:Stick = SMAWTIG = GTAWCALIFORNIAProposition 65WarningDiesel engine exhaust andsome o

OM-173 413 Page 26SECTION 7 − MAINTENANCE & TROUBLESHOOTING7-1. Routine MaintenanceRecycle enginefluids. Stop engine before maintaining. See als

OM-173 413 Page 277-2. Maintenance LabelDIN 51 601BS 2869: A1, A2ASTM D 975-81: 1-D, 2-DVV-F 800C: DF-A, DF-1, DF-2S t = .5%DEUTZ F3L1011F DIESEL ENGI

OM-173 413 Page 287-3. Servicing Air Cleaneraircleaner2 6/96 − ST-153 929-B / Ref. ST188 449 / ST-153 585 / Ref. S-0698-B Stop engine.1 Intake Manifo

OM-173 413 Page 297-4. Oil And Fuel System ComponentsRef. ST-188 449 / ST-801 334-A / Ref. S-176 697 / Ref. S-0842 Stop engine and let cool.1 Oil Fil

OM-173 413 Page 307-5. Adjusting Engine SpeedRef. ST-801 344-AAfter tuning engine, check engineno load speed with a tachometer(see table for no load s

OM-173 413 Page 317-6. Overload ProtectionRef. ST-801 344 / Ref. ST-156 199-B / ST-801 320-A Stop engine. If any fuse continues to open,contact Fact

OM-173 413 Page 327-8. TroubleshootingA. WeldingTrouble RemedyNo weld output. Check position of Ampere Range switch.Place A/V control switch in Panel

OM-173 413 Page 33C. EngineTrouble RemedyEngine does not start. Check fuel level. Open fuel valve (see Section 4-4).Check optional shutdown switch fus

OM-173 413 Page 34SECTION 8 − ELECTRICAL DIAGRAMSC-188 496-BFigure 8-1. Circuit Diagram For Welding Generator

OM-173 413 Page 35SECTION 9 − RUN-IN PROCEDURErun_in1 6/969-1. Wetstacking1 Welding GeneratorRun diesel engines near rated out-put during run-in perio

dec_con1 1/96Declaration of Conformity forEuropean Community (CE) ProductsThis information is provided for units with CE certification (see rating lab

OM-173 413 Page 369-2. Run-In Procedure Using Load BankS-0683 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep exhau

OM-173 413 Page 379-3. Run-In Procedure Using Resistance GridS-0684 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep

OM-173 413 Page 38SECTION 10 − AUXILIARY POWER GUIDELINES10-1. Selecting Equipmentaux_pwr 12/96 − Ref. ST-159 730 / ST-800 5771 Auxiliary Power Recept

OM-173 413 Page 3910-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse #10 AWG or larger insul

OM-173 413 Page 4010-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running WattsSplit Phase 1/8 HP 80

OM-173 413 Page 4110-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHand Drill 1/4 in 350 350

OM-173 413 Page 4210-8. Power Required To Start MotorS-06241 Motor Start Code2 Running Amperage3 Motor HP4 Motor VoltageTo find starting amperage:Step

OM-173 413 Page 4310-10. Typical Connections To Supply Standby PowerS-0405-A1 Power Company ServiceMeter2 Main and Branch OvercurrentProtection3 Doubl

OM-173 413 Page 4410-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles

OM-173 413 Page 45Notes

OM-173 413 Page 1SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USINGrom _nd_5/971-1. Symbol UsageMeans Warning! Watch Out! There are possible hazardsw

OM-173 413 Page 46SECTION 11 − PARTS LIST12345687910111213141516 17181920212223676869707172737475767778798081838284858687888990919293949596979899Figur

OM-173 413 Page 4724ST-801 345-D2526272838 393134353637404143444647484950 515556575859Figure 11-2333229304245545360616263646566

OM-173 413 Page 48DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-1. Main AssemblyQuantity1 175 657 TERMINAL, output bracket 1. . . . . . . . . . . . . .

OM-173 413 Page 49DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-1. Main Assembly (Continued)Quantity42 173 319 BOX, air intake engine 1. . . . . . . .

OM-173 413 Page 50DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-1. Main Assembly (Continued)Quantity89 173 317 PANEL, front lower 1. . . . . . . . . .

OM-173 413 Page 51Description QuantityPartNo.Dia.Mkgs.ItemNo.Figure 11-2. Generator (Figure 11-1 Item 24)1 106 426 INSULATOR 4. . . . . . . . . . . .

OM-173 413 Page 52123712ST-801 358-BFigure 11-445116891013141516171819202122 Hardware is common andnot available unless listed.Figure 11-3. Panel, Fr

OM-173 413 Page 53DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-3. Panel, Front w/Components (Figure 11-1 Item 90)Quantity1 S3 114 193 SWITCH, range (Fi

OM-173 413 Page 54Description QuantityPartNo.ItemNo.114 193 Figure 11-4. Switch, Range (Figure 11-3 Item 1)1 114 235 BRACKET, mtg switch (consisting o

OM-173 413 Page 55Description QuantityOPTIONAL EQUIPMENTPartNo.043 096 RECEPTACLE KIT, 120V GFCI 1. . . . . . . . . . . . . . . . . . . . . . . . .

OM-173 413 Page 2Welding on closed containers, such as tanks,drums, or pipes, can cause them to blow up. Sparkscan fly off from the welding arc. The f

Notes

Effective January 1, 1998(Equipment with a serial number preface of “KJ” or newer)This limited warranty supersedes all previous Miller warranties and

PRINTED IN USA © 1998 Miller Electric Mfg. Co. 9/98Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US

OM-173 413 Page 3MOVING PARTS can cause injury. Keep away from fans, belts, and rotors. Keep all doors, panels, covers, and guardsclosed and securel

OM-173 413 Page 4H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcomm

OM-173 413 Page 5SECTION 1 − CONSIGNES DE SÉCURITÉ − LIRE AVANTUTILISATIONrom _nd_fre 5/971-1. Signification des symbolesSignifie Mise en garde ! Soy