Miller BIG BLUE 401DX Owner's manual

Miller
Brand
Miller
Model
BIG BLUE 401DX
Category
Welding System
Type
Owner's manual

This manual is also suitable for

Miller
August1996
Effective
With
Form:
Serial
No.
OM-130098M
KG191
348
OWNERS
MANUAL
Big
BIueTM
401
DX
CC/DC
Welding
Generator
For
SMAW
Welding
Rated
Welding
Output
Amperage
Range
Maximum
Open-
Circuit
Voltage
DC
Auxiliary
Power
Rating
Engine
Fuel
Capacity
400
A,
40
Volts
DC,
100%
Duty
Cycle
40
400
95
Single-Phase,
3
kVA/kW,
26
A,
120
V
AC,
60
Hz
Deutz
F3L-1
011
Air/Oil-Cooled,
Three-Cylinder,
29
HP
Diesel
Engine
11.3
gal
(42.8
L)
cover_om
4/95
-
ST-130
895-E
'
1996
MILLER
Eleclnc
Mfg.
Co.
PRINTED
IN
liSA
LIMITED
WARRANTY
Sub(ecttothe
terms
and
conditions
below,
MILLER
Electric
Mfg.
Co.,
Appleton,
Wisconsin,
warrants
to
its
original
retail
purchaser
that
new
MILLER
equipment
sold
after
the
effective
date
of this
limited
warranty
is
free
of
de
fects
in
mateflal
and
woflimanship
at
the
time
it
ia
shipped
by
MILLER.
This
WAR
RANTY
IS
EXPRESSLY
IN
UEU
OF
ALL
OTHER
WARRANTIES,
EXPRESS
OR
IMPLiED,
INCLUDING
THE
WARRANTIES
OF
MERCHANTABILITY
AND
FIT
NESS.
Within
the
warranty
periods
listed
below,
MILLER
will
repair
or
replace
any
war
ranted
parts
orcomponents
that
fail
due
to
such
defects
in
materiel
orworkmsnship.
MILLER
must
be
notified
in
writing
within
thirty
(30)
days
of
such
defect
orfsilure,
st
which
time
MILLER
will
provide
instructions
on
the
warranty
claim
procedures
to
be
followed.
MILLER
shell
honor
warranty
claims
on
wsrrsnted
equipment
listed
below
in
the
event
of
such
s
failure
within
the
warranty
lime
periods.
All
warranty
time
periods
stsrt
on
the
dste
thet
the
equipment
was
delivered
to
the
originsi
retsil
purchaser,
or
one
year
sfter
the
equipment
is
sent
to
a
North
American
distributor
or
eighteen
months
after
the
equipment
is
sent
to
sn
lntemstionsl
distributor.
1.
5YesreParts3YesrsLsbor
*
Originsl
msin
power
rectifiers
Inverters
(input
end
output
rectifiers
only)
2.
3
Yesm
Parts
and
Labor
-
Trsnsfomier/Rectifier
Power
Sources
Plasms
Arc
Cutting
Power
Sources
Semi-Automatic
end
Automatic
Wire
Feeders
Inverter
Power
Supplies
Intellitig
*
Robots
(1
yesr
labor)
5.
6
Months
Batteries
6.
90
Days
Parts
and
Labor
MIG
Guns/TIG
Torches
APT,
ZIPCUT
&
PLAZCIJT
Model
Plasma
Cutting
Torches
Remote
Controls
Accessory
Kits
Replacement
Parts
MILLERS
True
Bluefi
Limited
Werranty
shall
not
apply
to:
1.
Items
furnished
by
MILLER,
but
menufsctured
by
others,
such
as
engines
or
trade
accessories.
These
items
are
covered
by
the
msnufacturere
warranty,
if
any.
2.
Consumable
components;
such
as
contect
tips,
cutting
nozzles,
contactois
and
relays
or
parts
that
fail
due
to
normal
wear.
3.
Equipment
that
has
been
modified
by
any
party
other
than
MILLER,
or
equip
ment
that
has
been
improperly
installed,
improperly
operated
or
misused
based
upon
industry
standards,
or
equipment
which
has
not
had
reasonable
and
necessary
maintenance,
or
equipment
which
has
been
used
for
operation
outside
of
the
specifications
for
the
equipment.
MILLER
PRODUCTS
ARE
INTENDED
FOR
PURCHASE
AND
USE
BYCOMMER
CIAL/INDUSTRIAL
USERS
AND
PERSONS
TRAINED
AND
EXPERIENCED
IN
ThE
USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT.
In
the
event
of
e
warranty
claim
covered
by
this
warranty,
the
exclusive
remedies
shalt
be,
at
MILLERS
option:
(1)
repeic
or
(2)
replacement;
or,
where
authorized
in
writing
by
MILLER
in
appmpriate
cases,
(3)
the
reasonable
cost
of
repeiror
replace-
mental
en
authorized
MILLER
service
station;
or
(4)
peyment
of
orcredit
forthe
pur
chase
price (lees
reasonable
depreciation
based
upon
actual
use)
upon
retum
of
the
goods
at
customers
risk
end
espense.
MILLERS
option
of
repair
or
replacement
will
be
FOB.,
Fectoryet
Appleton,
Wisconsin,
or
FOB.
ate
MILLER
authorized
ser
vice
facility
as
determined
by
MILLER.
Therefore
no
compensation
or
reimburse
ment
for
transportation
costs
of
eny
kind
will
be
ellowed.
TO
ThE
EXTENT
PERMITrED
BY
LAW,
ThE
REMEDIES
PROVIDED
HEREIN
ARE
ThE
SOLE
AND
EXCLUSIVE
REMEDIES.
IN
NO
EVENTSHALL
MILLER
BE
UABLE
FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTALOR
CONSEQUENTIAL
DAMAGES
(INCLUDING
LOSS
OF
PROFIT),
WHETHER
BASED
ON
CON
TRACT,
TORT
OR
ANY
OTHER
LEGAL
ThEORY.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPLIED
WAR
RANTY,
GUARANTY
OR
REPRESENTAtiON
ASTO
PERFORMANCE,
AND
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
TORT
OR
ANY
OThER
LEGAL
ThEORY
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
IN
CLUDING
ANY
IMPUED
WARRANTY
OF
MERCHANTABILITY
OR
FITNESS
FOR
PARTICULAR
PURPOSE,
WITh
RESPECT
TO
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
Some
etstes
in
the
U.S.A.
do
not
allow
limitetions
of
how
long
en
implied
warranty
eats,
or
the
exclusion
of
incidentel,
indirect,
special
or
consequential
demegee,
so
the
above
limitation
or
exclusion
mey
not
apply
to
you.
This
warranty
provides
spe
cific
legel
rights,
end
other
rights
mey
be
aveileble,
but
may
very
from
state
to
state.
In
Canede,
legislation
in
some
provinces
provides
for
cenein
sdditionel
warranties
or
remediea
other
then
ee
stated
herein,
end
to
the
extent
thet
they
may
not
be
waived,
the
limitetione
and
exclusions
eat
out
above
may
not
epply.
This
Umited
Warranty
provides
specific
legal
rights,
end
other
rights
may
be
aveilsble,
but
may
very
from
province
to
province.
WHO
DO
I
CONTACT?
For
help,
contact
your
distributor
For
additional
information,
such
as
Technical
Manuals
(ServiCe
And
Parts)
Engine
Manuals
Circuit
And
Wiring
Diagrams
Process
Handbooks
To
file
a
claim
for
loss
or
damage
during
shipment,
Contact
thB
delivering
carrier
For
assistance
in
filing
or
settling
claims,
U
contact
your
distributor
and/or
equipment
manufacturers
Transportation
Department
~i~j5~
L~T1
Miller
Electric
Mfg.
Co.
CALL;
414-735-4505
FAX;
800-637-2348
(in
USA),
or
414-735-4136
(outside
USA)
Users
Guides
Distributor
Directories
contact
your
distributor
1e
o~
=
WRITE;
Miller
Electric
Mfg.
Co.
P.O.
Box
1079
Appleton,
WI
54912
USA
Always
provide
Model
Name
and
Serial
or
Style
Number
MILLERS
TRUE
BLUEfi
LIMITED
WARRANTY
Effective
February
7,
1996
(Equipment
with
a
serial
number
preface
of
KD
or
newer)
This
limited
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LU
~~1
3.
2
Yeare
Parts
and
Labor
Engine
Driven
Welding
Generators
(NOTE:
Engines
are
warranted
esparetely
by
the
engine
manufactursr.)
-
Air
Compressors
4.
1
Year
Parts
and
Labor
-
Motor
Driven
Guns
-
Proceaa
Controllers
IHPS
Power
Sources
-
Water
Coolant
Systems
-
HFUnits
-
Grids
-
Spot
Welders
-
Load
Banks
-
SDX
Transformers
-
Miller
Cyclomatic
Equipment
-
Running
Gear/Trailers
-
Plasma
Cutting
Torches
(except
APT,
ZIPCUT
&
PLAZCUT
Models)
-
Tecumseh
Engines
Deutz
Engines
(outside
North
America)
-
Field
Options
(NOTE:
Field
options
are
covered
under
True
Bluefi
for
the
remaining
warranty
period
of
the
product
they
are
installed
in,
or
fore
minimum
of
one
year
whichever
is
greater.(
I
miller_wan
3/96
TABLE
OF
CONTENTS
SECTION
1
-
SAFETY
PRECAUTIONS
FOR
ARC
WELDING
1
1-1.
Symbol
Usage
1
1-2.
Arc
Welding
Hazards
1
1-3.
Engine
Hazards
2
1-4.
Additional
Installation,
Operation,
And
Maintenance
Hazards
3
1-5.
Principal
Safety
Standards
3
1-6.
EMF
Information
3
SECTION
2-DEFINITIONS
4
2-1.
Symbols
And
Definitions
4
SECTION
3
INSTALLATION
-
5
3-1.
Installing
Welding
Generator
5
3-2.
Dimensions,
Weights,
And
Operating
Angles
5
3-3.
Activating
The
Dry
Charge
Battery
6
3-4.
Connecting
The
Battery
7
3-5.
Installing
Muffler
Pipe
7
3-6.
Fuel
Consumption
7
3-7.
Engine
Prestart
Checks
8
3-8.
Installing
Ether
Cylinder
(Optional
Ether
Starting
Aid)
8
3-9.
Weld
Output
Terminals
And
Selecting
Cable
Sizes
9
SECTION
4OPERATING
THE
WELDING
GENERATOR
9
4-1.
Duty
Cycle
And
Overheating
9
4-2.
Front
Panel
Controls
10
4-3.
Manual
Shutoff
Lever
And
Optional
Polarity
Switch
11
4-4.
Remote
A/V
Control
11
SECTION
5
OPERATING
AUXILIARY
EQUIPMENT
12
5-1.
120
Volt
And
240
Volt
Duplex
Receptacles
12
5-2.
Optional
Auxiliary
Power
Receptacles
13
5-3.
Connecting
Optional
Auxiliary
Power
Plant
14
SECTION
6
MAINTENANCE
&
TROUBLESHOOTING
15
6-1.
Routine
Maintenance
15
6-2.
Maintenance
Label
16
6-3.
Servicing
Air
Cleaner
17
6-4.
Servicing
Fuel
And
Lubrication
Systems
18
6-5.
Adjusting
Engine
Speed
19
6-6.
Overload
Protection
20
6-7.
Servicing
Optional
Ether
Starting
Aid
20
6-8.
Inspecting
And
Cleaning
Optional
Spark
Arrestor
21
6-9.
Troubleshooting
21
SECTION
7-
ELECTRICAL
DIAGRAM
24
SECTION
8
RUN-IN
PROCEDURE
25
8-1.
Wetstacking
25
8-2.
Run-In
Procedure
Using
Load
Bank
26
8-3.
Run-In
Procedure
Using
Resistance
Grid
27
SECTION
9
PARTS
LIST
28
OM-130
098M
8/96
SECTION
1
-
SAFETY
PRECAUTIONS
FOR
ARC
WELDING
1-1.
Symbol
Usage
1-2.
Arc
Welding
Hazards
WARNING
satoty_romi
4195
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.
The
safety
information
given
below
is
only
a
summary
of
the
more
complete
safety
information
found
In
the
Safety
Standards
listed
in
Section
1-5.
Read
and
follow
all
Safety
Standards.
Only
qualified
persons
should
install,
operate,
maintain,
and
repair
this
unit.
During
operation,
keep
everybody,
especially
children,
away.
ELECTRIC
SHOCK
can
kill.
Touching
live
electrical
parts
can
cause
fatal
shocks
or
severe
bums.
The
electrode
and
work
circuit
is
electrically
live
whenever
the
output
is
on.
The
input
power
circuit
and
machine
internal
circuits
are
also
live
when
power
is
on.
In
semiautomatic
or
automatic
wire
welding,
the
wire,
wire
reel,
drive
roll
housing,
and
all
metal
parts
touching
the
welding
wire
are
electrically
live.
Incorrectly
installed
or
improperly
grounded
equipment
is
a
hazard.
1.
Do
not
touch
live
electrical
parts.
2.
Wear
dry,
hole-free
insulating
gloves
and
body
protection.
3.
Insulate
yourself
from
work
and
ground
using
dry
insulating
mats
or
covers
big
enough
to
prevent
any
physical
contact
with
the
work
or
ground.
4.
Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment.
Lockout/tagout
input
power
according
to
OSHA
29
CFR
191
0.147
(see
Safety
Standards).
5.
Properly
install
and
ground
this
equipment
according
to
its
Owners
Manual
and
national,
state,
and
local
codes.
6.
Always
verify
the
supply
ground
check
and
be
sure
that
input
nower
t~nrd
nrnund
wire
is
nrnnerlv
r.nnner~te1
tn
nrr~tini1
NOISE
ARC
RAYS
can
burn
eyes
and
skin;
NOISE
can
damage
hearing;
FLYING
SLAG
OR
SPARKS
can
injure
eyes.
Arc
rays
from
the
welding
process
produce
intense
visible
and
invisible
(ultraviolet
and
infrared)
rays
that
can
bum
eyes
and
skin.
Noise
from
some
processes
can
damage
hearing.
Chipping,
grinding,
and
welds
cooling
throw
off
pieces
of
metal
or
slag.
1.
Use
approved
ear
plugs
or
ear
muffs
if
noise
level
is
high.
FUMES
AND
GASES
can
be
hazardous
to
your
health.
Welding
produces
fumes
and
gases.
Breathing
these
fumes
and
gases
can
be
hazardous
to
your
health.
1.
Keep
your
head
out
of
the
fumes.
Do
not
breathe
the
fumes.
2.
If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
remove
welding
fumes
and
gases.
3.
If
ventilation
is
poor,
use
an
approved
air-supplied
respirator.
4.
Read
the
Material
Safety
Data
Sheets
(MSDSs)
and
the
manufacturers
instruction
for
metals,
consumables,
coatings,
cleaners,
and
degreasers.
terminal
in
disconnect
box
or
that
cord
plug
is
connected
to
a
properly
grounded
receptacle
outlet.
7.
When
making
input
connections,
attach
proper
grounding
conductor
first
double-check
connections.
8.
Frequently
inspect
input
powercord
for
damage
or
bare
wiring
replace
cord
immediately
if
damaged
bare
wiring
can
kill.
9.
Turn
off
all
equipment
when
not
in
use.
10.
Do
not
use
worn,
damaged,
undersized,
or
pooriy
spliced
cables.
11.
Do
not
drape
cables
over
your
body.
12.
If
earth
grounding
of
the
workpiece
is
required,
ground
It
directly
with
a
separate
cable
do
not
use
work
clamp
or
work
cable.
13.
Do
not
touch
electrode
if
you
are
in
contact
with
the
work,
ground,
or
another
electrode
from
a
different
machine.
14.
Use
only
well-maintained
equipment.
Repair
or
replace
damaged
parts
at
once.
Maintain
unit
according
to
manual.
15.
Wear
a
safety
harness
if
working
above
floor
level.
16.
Keep
all
panels
and
covers
securely
in
place.
17.
Clamp
work
cable
with
good
metal-to-metal
contact
to
workpiece
or
worktable
as near
the
weld
as
practical.
ARC
RAYS
2.
Wear
a
welding
helmet
fitted
with
a
proper
shade
of
filter
to
protect
your
face
and
eyes
when
welding
or
watching
(see
ANSI
Z49.1
and
Z87.1
listed
in
Safety
Standards).
3.
Wear
approved
safety
glasses
with
side
shields.
4.
Use
protective
screens
or
barriers
to
protect
others
from
flash
and
glare;
warn
others
not
to
watch
the
arc.
5.
Wear
protective
clothing
made
from
durable,
flame-resistant
material
(wool
and
leather)
and
foot
protection.
5.
Work
in
a
confined
space
only
if
it
is
well
ventilated,
or
while
wearing
an
air-supplied
respirator.
Always
have
a
trained
watchperson
nearby.
Welding
fumes
and
gases
can
displace
air
and
lower
the
oxygen
level
causing
injury
or
death.
Be
sure
the
breathing
air
is
safe.
6.
Do
not
weld
in
locations
near
degreasing,
cleaning,
or
spraying
operations.
The
heat
and
rays
of
the
arc
can
react
with
vapors
to
form
highly
toxic
and
irritating
gases.
7.
Do
not
weld
on
coated
metals,
such
as
galvanized,
lead,
or
cadmium
plated
steel,
unless
the
coating
is
removed
from
the
weld
area,
the
area
is
well
ventilated,
and
if
necessary,
while
wearing
an
air-supplied
respirator.
The
coatings
and
any
metals
containing
these
elements
can
give
off
toxic
fumes
if
welded.
4A
Means
Warning?
Watch
Out?
There
are
possible
hazards
with
this
procedure?
The
possible
hazards
are
shown
in
the
adjoining
symbols.
This
group
of
symbols
means
Warning?
Watch
Out?
possible
ELECTRIC
SHOCK,
MOVING
PARTS,
and
HOT
PARTS
hazards.
Consult
symbols
and
related
instructions
below
for
necessary
________________________________
actions
to
avoid
the
hazards.
A
Marks
a
specIal
safety
message.
~
Means
NOTE;
not
safety
related.
OM-130
098
Page
1
1-4.
Additional
Installation,
Operation,
And
Maintenance
Hazards
AA
WARNING
MOVING
PARTS
can
cause
injury.
1.
Before
working
of
generator,
remove
spark
plugs
or
injectors
to
keep
engine
from
kicking
back
or
starting.
2.
Block
flywheel
so
that
it
will
not
turn
while
working
on
generator
components.
FLYING
PIECES
OF
METAL
or
DIRT
can
injure
eyes.
1.
Wear
safety
glasses
with
side
shields
or
face
shield.
STATIC
ELECTRICITY
can
damage
parts
on
circuit
boards.
1.
Put
on
grounded
wnst
strap
BEFORE
handling
boards
or
parts.
2.
Use
proper
static-proof
bags
and
boxes
to
store,
move,
or
ship
PC
boards.
MAGNETIC
FIELDS
FROM
HIGH
CURRENTS
can
affect
pacemaker
operation.
1.
Pacemaker
wearers
keep
away.
2.
Wearers
should
consult
their
doctor
before
going
near
arc
welding,
gouging,
or
spot
welding
operations.
HOT
PARTS
can
cause
severe
burns.
1.
Allow
cooling
penod
before
maintaining.
2.
Wear
protective
gloves
and
clothing
when
working
on
a
hot
engine.
FALLING
EQUIPMENT
can
cause
serious
personal
injury
and
equipment
damage.
1.
Use
lifting
eye
to
lift
unit
only,
NOT
running
gear,
gas
cylinders,
or
any
other
accessories.
2.
Use
equipment
of
adequate
capacity
to
lift
unit.
READ
INSTRUCTIONS.
1.
Use
only
genuine
MILLER
replacement
parts.
2.
Reinstall
injectors
and
bleed
air
from
fuel
system
according
to
engine
manual.
6
DO
NOT
LET
ENGINE
EXHAUST
SPARKS
CAUSE
FIRE.
1.
Use
approved
engine
exhaust
spark
arrestor
in
required
areas
see
applicable
codes.
,
~
jJ
U
LOW
VOLTAGE
AND
FREQUENCY
CAN
DAMAGE
electrical
equipment
such
as
MOTORS.
1.
Turn
off
or
unplug
equipment
before
startIng
or
stopping
engine.
..~
III,
~
OVERUSE
can
cause
OVERHEATED
EQUIPMENT.
1.
Allow
cooling
period.
2.
Reduce
current
or
reduce
duty
cycle
before
starting
to
weld
again.
3.
Follow
rated
duty
cycle.
TILTING
OF
TRAILER
can
cause
injury.
1.
Use
tongue
jack
or
blocks
to
support
weight.
2.
Properly
install
welding
generator
onto
trailer
according
to
instructions
supplied
with
trailer.
1-5.
Principal
Safety
Standards
BATTERY
ACID
can
BURN
SKIN
AND
EYES.
1.
Donottip.
2.
Replace
damaged
battery.
3.
Flush
eyes
and
skin
immediately
with
water.
Safety
in
Welding
and
Cutting,
ANSI
Standard
Z49.i,from
American
Safe
Handling
of
Compressed
Gases
in
Cylinders,
CGA
Pamphlet
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami
FL
33126
P-i,
from
Compressed
Gas
Association,
1235
Jefferson
Davis
Safety
and
Health
Standards,
OSHA
29
CFR
1910,
from
Highway,
Suite
501,
Arlington,
VA
22202.
Superintendent
of
Documents,
U.S.
Government
Printing
Office,
Code
for
Safety
in
Welding
and
Cutting,
CSA
Standard
Wi
17.2,
from
Washington,
D.C.
20402.
Canadian
Standards
Association,
Standards
Sales,
178
Rexdale
Recommended
Safe
Practices
for
the
Preparation
for
Welding
and
Boulevard,
Rexdale,
Ontario,
Canada
M9W
1
R3.
Cutting
of
Containers
That
Have
Held
Hazardous
Substances,
Safe
Practices
For
Occupation
And
Educational
Eye
And
Face
American
Welding
Society
Standard
AWS
F4.1,
from
American
Protection,
ANSI
Standard
Z87.1
,from
American
National
Standards
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami,
FL
33126
Institute,
1430
Broadway,
New
York,
NY
10018.
National
Electrical
Code,
NFPA
Standard
70,
from
National
Fire
Cutting
And
Welding
Processes,
NFPA
Standard
51
B,
from
National
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
1-6.
EMF
Information
Considerations
About
Welding
And
The
Effects
Of
Low
Frequency
To reduce
magnetic
fields
in
the
workplace,
use
the
following
Electric
And
Magnetic
Fields
procedures:
The
following
is
a
quotation
from
the
General
Conclusions
Section
of
1.
Keep
cables
close
together
by
twisting
or
taping
them.
the
U.S.
Congress,
Office
of
Technology
Assessment,
Biological
Effects of
Power
Frequency
Electric
&
Magnetic
Fields
Background
2.
Arrange
cables
to
one
side
and
away
from
the
operator.
Paper,
OTA-BP-E-53
(Washington,
DC:
U.S.
Government
Printing
Office,
May
1989):
...
there
is
now
a
very
large
volume
of
scientific
3.
Do
not
coil
or
drape
cables
around
the
body.
findings
based
on
experiments
at
the
cellular
level
and
from
studies
4.
Keep
welding
power
source
and
cables
as
far
away
as
with
animals
and
people
which
clearly
establish
that
low
frequency
practical.
magnetic
fields
can
interact
with,
and
produce
changes
in,
biological
systems.
Whilemostofthisworkisofveryhighquality,theresultsare
5.
Connect
work
clamp
to
workpiece
as
close
to
the
weld
as
complex.
Current
scientific
understanding
does
not
yet
allow
us
to
possible.
interpret
the
evidence
in
a
single
coherent
framework.
Even
more
frustrating,
it
does
not
yet
allow
us
to
draw
definite
conclusions
about
About
Pacemakers.
questions
of
possible
risk
or
to
offer
clear
science-based
advice
on
The
above
procedures
are
also
recommended
for
pacemaker
strategies
to
minimize
or
avoid
potential
risks.~
wearers.
Consult
your
doctor
for
complete
information.
OM-130
098
Page
3
SECTION
2-
DEFINITIONS
2-1.
Symbols
And
Definitions
Stop
Engine
4~9
Fast
(Run,
Weld/
Power)
.-~
Slow
(Idle)
Start
Engine
/
~
Fast/Slow
(Run/Idle)
I
+
I
Battery
(Engine)
Circuit
Breaker
~:?~7~
Engine
Oil
4~
Check
Injectors!
Pump
Check
Valve
Clearance
Fuel
(~)
Protective
Earth
(Ground)
._~_
Positive
Negative
Certified/Trained
Mechanic
/
Welding
Arc
A
Amperes
~J
Volts
Panel/Local
Remote
Read
Operators
Manual
4j~J~
Engine
Temperature
(3~-~.
Output
ft~,
Current
Alternating
PJ
Time
Hours
Seconds
fi
,
Do
Not
Switch
While
Welding
1
\~,#
Single
Phase
3
/~\,
Three
Phase
Ether
Starting
Aid
I
~
~w
Engine
Coolant
Temperature
OM-130
098
Page
4
SECTION
3-
INSTALLATION
3-1.
Installing
Welding
Generator
Height
Width
Depth
A
B
C
D
E
F
G
H
J
K
L
M
N
Dimensions
40-1/2
in
(1029
mm
24-5/8
in
(625
mm)
56
in
(1422
mm)
23-1/4
in
(591
mm)
24-5/8
in
(625
mm)
11/16
in
(17
mm)
2-7/8
in
(73
mm)
4-1/2
in
(114)
mm)
22-9/16
in
(573
mm
27
in
(686
mm)
30-3/8
in
(772
mm)
41-1/4
in
(
mm)
51-1/8
in
(1299
mm)
54
ih
(1372
mm
21/32
in
(16.7
mm)
Dia.
4
Holes
1/2
in
(12.7
mm)
Dia.
10
Holes
3-2.
Dimensions,
Weights,
And
Operating
Angles
A
Do
not
exceed
operating
angles
while
running
or
engine
damage
will
occur.
A
Do
not
move
or
operate
unit
where
It
could
tip.
Pot.
ST-lb
850-F
–
Weight
Net:
1475
lb
(670
kg)
I
I
Ship:
1510
lb
(685
kg)
OM-130
098
Page
5
Remove
battery
from
unit.
Eye
Protection
Safety
Glasses
Or
Face
Shield
Rubber
Gloves
Vent
Caps
Sulfuric
Acid
Electrolyte
(1.265
Specific
Gravity)
Fill
each
cell
with
electrolyte
to
bottom
of
well
(maximum).
A
Do
not
overfill
battery
cells.
Wait
ten
minutes
and
check
elec
trolyte
level,
If
necessary,
add
elec
trolyte
to
raise
to
proper
level.
Reinstall
vent
caps.
6
Battery
Charger
A
Read
and
follow
all
instruc
tions
supplied
with
battery
charger.
Charge
battery
for
12
minutes
at
30
amperes
or
30
minutes
at
5
am
peres.
Disconnect
charging
cables
and
install
battery.
When
electrolyte
is
low,
add
only
distilled
water
to
cells
to
maintain
proper
level.
3-3.
Activating
The
Dry
Charge
Battery
0
For
30
Minutes
30
A
For
12
Minutes
Tools
Needed:
drybatti
2/96
S-0886
OM-130
098
Page
6
3-4.
Connecting
The
Battery
3-5.
Installing
Muffler
Pipe
3-6.
Fuel
Consumption
iLl]
Tools
Needed:
~
1/2in
A
Stop
engine
and
let
cool.
A
Do
not
blow
exhaust
toward
air
cleaner
or
air
Intake.
exh_pipe2
10/95
ST-154
089-A
/
ST-154
611
/
Ret.
ST-181
865
The
curve
shows
typical
fuel
use
under
weld
or
power
loads.
l~!
o
7.57
1.10
2.00
6.82
1.48
1.76
5.67
1.26
1.60
4.13
1.04
1.26
1850
R.P.M.
3.78
0.83
1.00
2.84
0.82
0.76
1.98
0.40 0.60
0.86
0.21
0.26
o
60~0~020250300
DC
WELD
AI~ERE8
AT
100X
DUTY
CYCLE
SB-137
487
OM-130
098
Page
7
3-8.
Installing
Ether
Cylinder
(Optional
Ether
Starling
Aid)
3-7.
Engine
Prestart
Checks
A
Stop
engine.
A
Improper
handling
or
expo
sure
to
ether
can
harm
your
health.
Follow
manufactur
ers
safety
instructions
on
Q
cylinder.
A
Do
not
use
Ether
Starting
Aid
while
engine
is
running.
~
Open
side
door(s).
1
Ether
Cylinder
2
Nozzle
Remove
cover
and
clean
cylinder
nozzle.
3
Clamp
4
Fitting
5
Cap
6
Valve
Remove
cap
and
clean
fitting.
Install
cylinder
on
fitting.
Tighten
3
clamp.
~
Afterinstalling
cylinder,
wait
at
least
10
minutes
before
using
to
let
ether
parti
c/es
settle
and
prevent
atomizer
plugging.
Put
cap
on
fitting
when
cylinder
is
6
removed.
ethert
7/96
ST-i
53
382-A
/
Ref.
ST-i
Si
865
5.
OM-130
098
Page
8
3-9.
Weld
Output
Terminals
And
Selecting
Cable
Sizes
A
ARC
WELDING
can
cause
Electromagnetic
Interference.
To
reduce
possible
interference,
keep
weld
cables
as
short
as
possible,
close
together,
and
down
low,
such
as
on
the
floor.
Locate
welding
operation
100
meters
from
any
sensitive
electronic
equipment.
Be
sure
this
welding
machine
Is
installed
and
grounded
according
to
this
manual.
If
interference
still
occurs,
the
user
must
take
extra
measures
such
as
moving
the
welding
machine,
using
shielded
cables,
using
line
filters,
or
shielding
the
work
area.
Weld
Output
Terminals
Welding
Amperes
Total
Cable
(Copper)
Length
In
Weld
Circuit
Not
ExceedIng
100
(30
m)
Or
Less
150ft
(45
m)
200ft
(60
m)
250ft
(70
m)
300
ft
(90
)_
350ft
(105
m)
400ft
(120
m)
1060%
Duty
cycle
60100%
Duty
Cycle
10100%
Duty
Cycle
Ref.
ST-800
1
62-A
100
4
4
4
3
2
1
1/0
~1/0
150
3
3
2
1
1/0
2/0
3/0
3/0
200
3
2
1
1/0
2/0
3/0
4/0
4/0
250
2
1
1/0
2/0
3/0
4/0
2-2/0
2-2/0
300
1
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
350
1/0
2/0
3/0
4/0
2-2/0
2-3/0 2-3/0
2-4/0
400
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
2-4/0
500
2/0
3/0
4/0 2-2/0
2-3/0
2-4/0
3-3/0
3-3/0
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.
S-0007-D
SECTION
4-
OPERATING
THE
WELDING
GENERATOR
~.
~I
~%
~-
4-1.
Duty
Cycle
And
Overheating
40%
Duty
Cycle
At
400
Amperes
4
Minutes
Welding
Duty
Cycle
is
percentage
of
10
minutes
that
unit
can
weld
at
rated
load
without
overheating.
A
Exceeding
duty
cycle
can
damage
unit
and
void
warranty.
6
Minutes
Resting
RATED
a)
w
w
a
-j
w
a)
40
a)
a)
70
a)
Z
DUTY
CYCLE
5/95
SB-070
999-A
OM-130
098
Page
9
4-2.
Front
Panel
Controls
1
Ampere
Range
Switch
A
Do
not
switch
under
load.
2
AmperageNoltage
Control
Control
adjusts
amperage
within
range
selected
by
Ampere
Range
switch.
Control
adjusts
amperage
only
when
welding,
and
does
not
adjust
open-circuit
voltage.
Weld
output
would
be
158
A
DC
with
controls
set
as
shown
(50%
of
90
to
225
A).
3
DC
Voltmeter
(Optional)
4
DC
Ammeter
(Optional)
5
Remote
A/V
Switch
And
Receptacle
(See
Section
4-4)
6
Magnetic
Shutdown
Switch
(Optional)
Use
switch
during
start-up
to
bypass
optional
engine
shutdown
system.
System
stops
engine
if
oil
pressure
is
too
low
or
oil
temperature
is
too
high.
7
Engine
Control
Switch
To
Start:
turn
switch
to
Start
while
pressing
Shutdown
switch.
Release
switches
when
engine
starts.
Do
not
crank
engine
if
engine
is
still
turning.
In
Run
position,
engine
runs
at
weld/power
speed.
In
Run/Idle
position
(optional),
engine
runs
at
idle
speed
at
no
load
and
weld/power
speed
with
load
applied.
To
Stop:
turn
switch
to
Off
position.
8
Battery
Charging
Warning
Light
Light
goes
on
when
battery
is
not
charging.
9
Oil
Pressure
Warning
Light
Light
goes
on
if
oil
pressure
is
too
low.
If
unit
has
automatic
shutdown
option,
light
also
goes
on
if
oil
temperature
is
too
high.
A
Stop
engine
and
fix
trouble
if
either
light
goes
on.
10
Ether
Starting
Aid
Switch
(Optional)
Push
switch
up
and
release
while
cranking
engine
to
release
ether.
A
Do
not
use
Ether
if
engine
is
running.
11
Engine
Hour
Meter
12
Oil
Temperature
Gauge/Switch
(Optional)
13
Oil
Pressure
Gauge/Switch
(Optional)
I
MIN-70
1
13
~/
90
J
11
120V
15A1
240V
3A
~
nOD
~
nOD
1\,.OOHz
9
8
7
6
5
Ref.
ST.181
865
OM-130
098
Page
10
4-3.
Manual
Shutoff
Lever
And
Optional
Polarity
Switch
C
Mm
(63
A
DC)
1
Manual
Shutoff
Lever
Use
lever
to
stop
engine
if
engine
control
switch
does
not
work.
2
Polarity
Switch
(Optional)
Place
switch
in
Straight
position
for
electrode
negative,
or
Reverse
position
for
electrode
positive.
ST-800
162-A
/
ST-800
159-C
4-4.
Remote
A/V
Control
ZA/V
1~
Example:
Combination
Remote
Amperage
Control
0
Set
Switch
1
NV
Control
Switch
Use
switch
to
select
front
panel
or
remote
amperage
control.
2
Remote
A/V
Receptacle
RC3
2
Connect
optional
remote
control
to
RC3.
In
Example:
Range
=
90
to
225
A
Percentage
Of
Range
=
50%
Max
=
158
A
DC
(50%
of
90
to
225)
50
BO.O~.20
Max(158A
A/V
Set
Range
Set
Percentage
Adjust
Optional
Remote
Control
S-0774
OM-130
098
Page
11
SECTION
5-
OPERATING
AUXILIARY
EQUIPMENT
5-1.
120
Volt
And
240
Volt
Duplex
Receptacles
A
If
unit
does
not
have
GFCI
receptacles,
use
GFCI-pro
________________________________
tected
extension
cord.
~
Auxiliary
power
is
not
affected
by
weld
output.
If
a
circuit
breakercontinues
to
open,
contact
Factory
Autho
nzed
Service
Agent.
1
240
V
15
A
AC
Receptacle
RC1
2
120
V
15
A
AC
Receptacle
RC2
Receptacles
supply
60
Hz
single-
phase
power
at
weld/power
speed.
3
Circuit
Breakers
CB1
And
CB2
CB1
and
CB2
protect
the
receptacles
from
overload.
If
CB1
or
CB2
opens,
RC1
and
half
of
RC2
does
not
work.
120
volts
may
still
be
present
at
RC1.
Maximum
output
from
each
duplex
receptacle
is
1.8
kVA/kW,
and
3
kVAIkW
from
all
receptacles.
Auxiliary
power
is
not
affected
by
weld
output.
EXAMPLE:
If
10
A
is
drawn
from
RC1
only
10
A
is
available
at
RC2:
(240
Vx
10
A)
+
(1
20
V x5
A)
=
3.0
kVNkW
2
1
OM-130
098
Page
12
Ret.
5T-181
865
5-2.
Optional
Auxiliary
Power
Receptacles
5~-.~-c
5~~,O
2
A
If
unit
does
not
have
GFCI
receptacles,
use
GFCI-pro
tected
extension
cord.
~
Auxiliary
power
Is
not
affected
by
weld
output.
If
a
circuitbreakercontinues
to
open,
contact
Factoiy
Autho
rized
Service
Agent.
GFCI
Receptacle
Option
1
12OV15AACGFCI
Receptacle
GFCI1
Auxiliary
power
output
and
circuit
breaker
protection
is
the
same
as
standard
receptacles
(see
Section
5-1).
If
a
ground
fault
Is
detected,
GFCI
Reset
button
pops
out
and
receptacle
does
not
work.
Check
for
faulty
tools
plugged
in
receptacle.
Press
button
to
reset.
~
At
least
once
a
month,
run
en
gine
at
weld/power
speed
and
press
test
button
to
verify
GFCI
is
working
properly.
3
Australian,
BrItIsh,
And
South
African
Receptacle
Options
4
2
240
V
10
A
AC
Australian
Receptacle
RC1
3
240Voltl3AACSouth
African
Receptacle
RC1
4
24OVoltl3AACBritlsh
Receptacle
RC1
RC1
supplies
60
Hz
single-phase
power
at
weld/power
speed.
Maxi
mum
output
from
receptacle
is
3
kVAIkW.
5
Circuit
Breaker
CB1
CB1
protects
RC1
from
overload.
If
CB1
opens,
Rd
does
not
work.
Press
button
to
reset
breaker.
Ret.
ST-181
865/
Ret.
ST-182
096
OM-130
098
Page
13
SECTION
6-
MAINTENANCE
&
TROUBLESHOOTING
6-1.
Routine
Maintenance
fi8h
fi
50h
Recycle
engine
fluids.
Stop
engine
before
maintaining.
See
also
Engine
Manual
and
Mainte
nance
LabeL
Service
engine
more
often
during
severe
conditions.
/
lOOh
I,
Change
Oil.
See
Section
6-4.
500h
1000
h
Change
Oil
Filter.
See
Section
6-4.
4
Blow
Out
Or
Vacuum
Inside.
Dunng
Heavy
Service,
Clean
Monthly.
3000
h
OM-130
098
Page
15
6-2.
Maintenance
Label
DEUTZ
F3LIO11F
DIESEL
ENGINE
Check
daily.
Recommended
Oil
...
API
Service
Classification
CC/SE,
CC/SF
CD/SE,
CD/SF
Oil
Change
&
Filter
dirty
conditions
250
hours
375
hours
normal
conditions
500
hours
750
hours
Oil
Filter
MILLER
067
265,
Deutz
116-4626
Oil
Capacity
5.8
qt
(5.5
L)
or
6.2
qt
(5.9
L)
with
filter
change
Fuel
Capacity
11.3
gal
(42.8
L)
j
Diesel
Fuel
Grade
1
-D
or
2-D
Cetane
No.
45
mm.
Primary
Fuel
Filter/
Water
Separator
MILLER
106467,
Nelson
85254A,
Fram
P3522
Secondary
Fuel
Filter
MILLER
066
217,
Deutz
117-4696
Fill
filter
with
clean
fuel
before
installing
read
instructions
on
filter.
fi
.
~
Air
Filter
Service
....
50
hours
or
less
see
Owners
Manual
Air
Filter
Element
....
AC
A297C,
Donaldson
P1
0-1
275,
Fram
CAK
256,
Nelson
70206,
MILLER
126
880
L)
Blower
Belt
MILLER
067
266,
Deutz
117-9565
o
Avoid
recirculation
of
air
from
hot
air exit
to
blower
intake.
Battery
BClGroup55
Cranking
Performance
at
0F
(-18C)
500
Amps
a
~
~
Valve
Clearance
Cold
Engine
RPM
No
Load
~
Intake...
0.012
in
(0.3
mm)
Weld
1850
Exhaust.
0.020
in
(0.5
mm)
Tq~r~~
~
~
It
Injectors
MILLER
067
267,
Deutz
417-8015
Nozzle
MILLER
067
268,
Deutz
417-8021
Have
only
trained
technician
maintain
injection
pump
and
injectors.
AIR,
WATER,
or
GASOLINE
will
harm
the
injection
system.
If
tank
is
run
out
of
fuel
or
fuel
filter
is
changed,
bleeding
of
air
is
required.
@
Spark
Arrestor
Inspection
And
Service
250
operating
hours
see
Owners
Manual
s-i
73
847-A
See
Engine
Manual
for
complete
engine
care.
Give
Engine
Specification
and
Serial
Number
when
ordering
parts.
OM-130
098
Page
16
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Miller BIG BLUE 401DX Owner's manual

Miller
Brand
Miller
Model
BIG BLUE 401DX
Category
Welding System
Type
Owner's manual
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