Miller Electric Big Blue 401DXQ Specifications Page 1

ct0IlVisitourwebsiteatw.MU1erWe~$S~Crn1~Miller.ThePowerofBlue.DM173413CJanuary1997Eff.w/SerialNumberKG214633ProcessesStick(SMAW)WeldingTIG(GTAW)Weldin

PartNo.DescriptionQuantityOPTIONALEQUIPMENT043096..RECEPTACLEKIT,120VGFCI1ENGINEPROTECTIONPACKAGE,(consistingof)1042318...AUTOMATICSHUTDOWN,lowoilpre

Notes________

MOVINGPARTScartcauseInjuryKeepawayfromfans,belts,androtors.Keepalldoors,panels,covers,andguardsclosedandsecurelyinplace.Stopenginebeforeinstallingo

HFRADIATIONcancauseInterferenceHigh-frequency(HF.)caninterferewithradionavigation,safetyservices,computers,andcommunicationsequipment.Haveonlyqualif

rom_nd_fre5/97SECTION1-CONSIGNESDESECURITE-LIREAVANTUTILISATION~1-1Significationdessymboles4ASignifieMiseengarde!Soyezvigilant!CetteprocedureprØsented

LE.SOUDAGEpØtprovoqiiæ.Incendieouune.epiiion.LesoudageeffectuesurdesconteneursfermOstelsquedesreservoirs,tamboursoudesconduitespeutprovoquerleura

Nopasapprocheresmainsdesventilateurs,courrolesetautrospiŁcesenmouvomont.MaintenirfermØsetfixementenplacelosportes,panneaux,recouvrementsetdispositif

ILERAYONNEMENTHAUTEFRE~QUENCE(HF)risquedeprovoquerdesh~iterf6rencŁi.;~Lerayonnementhautefrequence(HF.)peutprovoquerdesinterferencesaveclesequipements

SECTION2-DEFINITIONSBecometrainedandreadtheinstructionsbeforeworkingonthemachineorwelding.1Electricshockfromweldingelectrodeorwiringcankill.1.1Weardry

1Warning!WatchOut!Therearepossiblehazardsasshownbythesymbols.2Donotsmokeandkeepmatchesandflamesawayfrombattery.3Sparkscancausebatterygasestoexplode.Ba

2~1Warning!WatchOutTherearepossiblehazardsasshownbythesymbols.2Hotmufflerandexhaustpipescancausesevereburns.Donottouchhotmufflerorpipes.3196S-1762301

S-176255-ARemoveunitfromshippingS-177571crate.RemoveOwnersManualfromunit.Followinstructionstoinstallmuffler.ReadOwnersManual.Readlabelsonunit.UseDie

Call1-800-4-A-MILLERforyourlocalMillerdistrihutor.YourdistributorgivesyouServiceYoualwaysgetthefast,reliableresponseyouneed.Mostreplacementpartscanbei

2-3.SymbolsAndDefinitionsOM-173413Page13

,ADonotexceedoperatingangleswhilerunningorenginedamagewilloccur.ADonotmoveoroperateunitwhereItcouldtip.SECTION3-SPECIFICATIONS3-1.Weld,Power,AndEngine

3-3.DutyCycleAndOverheating600500400300250200150100100%DutyCycleAt250AmperesContinuousWeldingDutyCycleispercentageof10minutesthatunitcanweldatratedloa

3-5.ACAuxiliaryPowerTheacpowercurveshowstheauxiliarypowerinamperesavailableatthe120and240voltreceptacles.150300:::::~75150C)<5010025500 00510152025

SECTION4-INSTALLATION4-1.InstallingWeldingGenerator18inLocation15in(460mm)MovementAirflowClearanceADoNotLiftUnitFromEndOR(4~m)GroundingORElectricallyb

4-2.ActivatingTheDryChargeBattery05AFor30Minutes30AFor12MinutesRemovebatteryfromunit.1EyeProtectionSafetyGlassesOrFaceShieldRubberGlovesVentCapsSulfu

4-3.ConnectingTheBattery4-4.EnginePrestartChecksOM-173413Page19

4-5.InstallingMufflerPipe1Positive(+)WeldOutputTerminal2Negative()WeldOutputTerminalForStickweldingDirectCurrentElectrodePositive(DCEP),connectworkca

4-7.SelectingWeldCableSizesWeldingAmperesTotalCable(Copper)LengthInWeldCircuitNotExceeding100ft(30m)OrLess150ftI200ftI250ftI300ftI350ftI400ft(45m)I(60

SECTION5-OPERATINGTHEWELDINGGENERATOR5-1.FrontPanelControlsThisunithasamaxOCVcontrolcircuitthatresetsTheAmperageNoltageControltomaximumwhenthearcbreak

DeclarationofConformityforEuropeanCommunity(CE)ProductsNOTE~ThisinformationisprovidedforunitswithCEcertification(seeratinglabelonunit).Manufacturers

5-2.ManualShutoffLever1ManualShutoffLeverUselevertostopengineifenginecontrolswitchdoesnotwork.Ref.ST-8013445-3.RemoteNVControlr1~A/V1~Q~21A/VControlSw

SECTION6-OPERATINGAUXILIARYEQUIPMENT6-1.120VoltAnd240VoltDuplexReceptacles2AIfunitdoesnothaveGFCIreceptacles,useGFCI-protectedextensioncord.~Ifacircui

6-2.OptionalAuxiliaryPowerReceptacles4~17*KDAIfunitdoesnothaveGFCIreceptacles,useGFCI-protectedextensioncord.~Ifcircuitbreakercontinuestoopen,contactF

SECTION7-MAINTENANCE&TROUBLESHOOTING7-1.RoutineMaintenanceAStop enginebeforemaintaining.Recycleenginefluids.SeealsoEngineManualandMaintenanceLabel

12VBCI45520A'-18C(0F)itDIESEL42.8L(11.3gal)~DIN51601ffBS2869:A1,A2IIASTMD975-81:1-D,2-D~..VV-F800C:DF-A,DF-1,DF-2S<=.5%MILLER126880ACA297CDo

7-3.ServicingAirCleanerAStopengine.1IntakeManifold2ServiceIndicator(Optional)3Window4ResetButtonServiceaircleanerelementifredbandappearsinwindow.Agree

7-4.OilAndFuelSystemComponentsAStopengineandletcool.1OilFilter2OilDrainValve3OilFillCap4PrimaryFuelFilter(Fuel/WaterSeparator)5Petcock6SecondaryFuelFi

7-5.AdjustingEngineSpeedStandardModels:1EngineSpeedAdjustmentScrew2LockingNutLoosennut.Turnscrewuntilenginerunsat1850rpm.Tightennut.ModelsWithAutomati

7-6.OverloadProtection7-7.OptionalSparkArrestorInspectionAndCleaningAStopengine.~Ifanyfusecontinuestoopen,contactFacto,yAuthorizedSe,viceAgent.1Magnet

7-8.Troubleshooting~tid~a~i~A.WeldingTroubleRemedyNoweldoutput.CheckpositionofAmpereRangeswitch.PlaceANcontrolswitchinPanelposition,orplaceswitchinRem

SECTION1-SAFETYPRECAUTIONS-READBEFOREUSINGrorn_nd_5/97MeansWarning!WatchOut!Therearepossiblehazardswiththisprocedure!Thepossiblehazardsareshowninthead

7-8.Troubleshooting~I~d~$$~A.WeldingTroubleRemedyNoweldoutput.CheckpositionofAmpereRangeswitch.PlaceNVcontrolswitchinPanelposition,orplaceswitchinRemo

C.EngineTroubleRemedyEnginedoesnotstart.Checkfuellevel.Openfuelvalve(seeSection4-4).CheckoptionalshutdownswitchfuseFandreplaceifopen(seeSection7-6).Ch

SECTION8-ELECTRICALDIAGRAMSC-182851-A~dol:::AW.-~pRrL~II~JFigure8-1.CircuitDiagramForWeldingGeneratorOM-173413Page34

SECTION9-RUN-INPROCEDURErun_in16/969-1.Wetstacking____________________________1WeldingGeneratorRundieselenginesnearratedoutputduringrun-inperiodtoprop

9-2.Run-InProcedureUsingLoadBankAStopengine.ADonottouchhotexhaustpipe,engineparts,orloadbank/grid.AKeepexhaustandpipeawayfromflammables.1LoadBankTurna

9-3.Run-InProcedureUsingResistanceGridADonottouchhotexhaustpipe,engineparts,orloadbank/grid.AKeepexhaustandpipeawayfromflammables.1ResistanceGridUsegr

SECTION10PARTSLIST2267/6869727071Hardwareiscommonandnotavailableunlesslisted.791011129695237576Figure10-1.MainAssemblyOM-173413Page38

11Figure10-244ST-801345-DOM-173413Page393429-27.26436159625357

ItemDia.No.Mkgs.PartNo.1.175657175724Neg039046Pos039 04760187960188021750131750123+1733221733210041301733461767511761084+17331317610517610450359686173

Figure10-1.MainAssembly(Continued)BOX,airintakeengine1DIFFUSORASSEMBLY1HOSE,CWCflexaust2.500IDx6.000Ig1CLAMP,hose1.875-3.75Oclpdia1PANEL,rear1GUARD,be

WELDINGcancausefireorexplosionWeldingonclosedcontainers,suchastanks,drums,orpipes,cancausethemtoblowup.Sparkscanflyofffromtheweldingarc.Theflyingspark

DescriptionQuantityFigure10-1.MainAssembly(Continued)8917331790Figure10-312907492CT1...,105370111310108163...95...R2,3128862960856569711006998175432

ItemDia.PartNo.Mkgs.No.DescriptionQuantityFigure10-2.Generator(Figure10-1Item24)1106426...INSULATOR42106440...BUSBAR,rectifier23SR3106427...DIODEASSEM

Figure10-3.Panel,Frontw/ComponentsST.801358-Bfl~Hardwareiscommonandnotavailableunlesslisted.1Figure10-421~$45186781514131291011OM-173413Page44

ItemDia.PartNo.Mkgs.No.DescriptionQuantityFigure10-3.Panel,Frontw/Components(Figure10-1Item90)1S3114193..SWITCH,range(Figure10-4)12Ri605960..RHEOSTAT,

ItemPartDescriptionQuantity . .1112.114193Figure10-4.Switch,Range(Figure10-3Item1)114235010671017 428004998011980011645011075011953011074011644004999