Miller BIG BLUE 401DXQ CE Owner's manual

Category
Welding System
Type
Owner's manual

This manual is also suitable for

Miller
August1996
Effective
With
Form:
Serial
No.
OM-173413B
KG191
348
OWNERS
MANUAL
~'
~
CE
Big
Bluefi
401
DXQ
CC/DC
Welding
Generator
For
SMAW
And
GTAW
Welding
Rated
Welding
Output
Amperage
Range
Maximum
Open-
Circuit
Voltage
DC
Auxiliary
Power
Rating
~
Engine
Fuel
Capacity
Sound
Power
IP
Rating
250
A,
30
V
DC,
100%
Duty
cycle
325
A,
33
V
DC,
60%
Duty
Cycle
40400
95
Single-Phase,
3
kVA/kW,
13/13
A,
120/240
V
AC,
60
Hz
Deutz
F3L-1011
Air/Oil-Cooled,
Three-Cylinder,
29
HP
Diesel
Engine
11.3
US
gal
(42.8
L)
100
Lwa
23
coveLom
4/95
-
ST-801
133-A
'
1996
MILLER
Electric
1Mg.
Co.
PRINTED
IN
USA
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.
LIMITED
WARRANTY
Subject
tothe
terms
and
conditions
below,
MILLER
Electric
Mtg.
Co.,
Appleton,
Wisconsin,
warrants
to
its
original
retail
purchaser
thaI
new
MILLER
equipment
sold
after
the
effective
date
of
this
limited
warranty
is
free
of
de
fects
in
material
and
workmanship
at
the
time
it
is
shipped
by
MILLER.
THIS
WAR
RANTY
IS
EXPRESSLY
IN
LIEU
OF
ALL
OTHER
WARRANTIES,
EXPRESS
OR
IMPLIED,
INCLUDING
THE
WARRAN11ES OF
MERCHANTABILITY
AND
FIT
NESS.
Within the
warranty
perioda
listed
below,
MILLER
will
repair
or
replace
any
war-
rented
parts
orcomponents
thatfail
due
to
such
defects
in
material
orwortrmanahip.
MILLER
must
be
notified
in
renting
within
thirty
(30)
days
of
such
defect
orfailure,
at
which
time
MILLER
will
provide
instructions
on
the
warranty
claim
procedures
to
be
followed.
MILLER
ahell
honor
warranty
claims
on
warranted
equipment
listed
below
in
the
event
of
such
a
failure
within
the
warranty
lime
periods.
All
warranty
time
periods
start
on
the
date
that
the
equipment
was
delivered
to
the
original
retail
purchaser,
or
one
year
after
the
equipment
is
sent
to
a
North
American
distributor
or
eighteen
months
after
the
equipment
is
sent
to
an
Intemational
distributor.
2.
Conaumable
components;
such
as
contact
tips,
cutting
nozzles,
contactors
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
a
warranty
claim
covered
by
this
warranty,
the
exclusive
remedies
shall
be,
at
MILLERS
option:
(1)
repair,
or
(2)
replacement;
or,
where
authorized
in
writing
by
MILLER
inappropriate
cases,
(3)
the
reasonable
coat
of
repairor
replace
ment
at
an
authorized
MILLER
service
station;
or
(4)
payment
of
orcredit
forthe
pur
chase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
retum
of
the
goods
at
customers
risk
and
expense.
MILLERS
option
of
repair
or
replacement
will
be
FOB.,
Factory
at
Appleton,
Wisconsin,
or
FOB.
at
a
MILLER
authorized
ser
vice
facility
as
determined
by
MILLER.
Therefore
no
compensation
or
reimburse
ment
for
transportation
coats
of
any
kind
will
be
allowed.
TO
THE
EXTENT
PERMITTED
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
IMPLIED
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
states
in
the
U.S.A.
do
not
allow
limitations
of
how
long
an
implied
warranty
lasts,
or
the
exclusion
of
incidental,
indirect,
special
or
consequential
damages,
so
the
above
limitation
or
exclusion
may
net
apply
to
you.
This
warranty
provides
ape
cthc
legal
rights,
and
other
rights
may
be
available,
but
may
vary
from
state
to
state.
In
Canada,
legislation
in
some
provinces
provides
for
certain
additional
warranties
or
remedies
ether
than
as
stated
herein,
and
to
the
extent
that
they
may
net
be
waived,
the
limitations
and
exclusions
set
out
above
may
not
apply.
This
Limited
Warranty
provides
specific
legal
rights,
and
other
rights
may
be
available,
but
may
vary
from
province
to
province.
5.
6
Months
Batteries
6.
go
Days
Parts
and
Labor
*
MIG
GunslflG
Torches
APT,
ZIPCUT
&
PLAZCUT
Model
Plasma
Cutting
Torches
Remote
Controls
Accessory
IOta
Replacement
Parts
MILLERS
True
Bluefi
Limited
Warranty
shall
not
apply
to:
1.
Items
tumiahed
by
MILLER,
but
manufactured
by
ethers,
such
as
engines
or
trade
accessories.
These
items
are
covered
by
the
manufacturers
warranty,
if
any.
I
IS
5
Years
Parts
-3
Yeara
Labor
Original
main
power
rectifiers
*
Inverters
(input
and
output
rectifiers
only)
2.
3
Years
Parta
and
Labor
*
Transformer/Rectifier
Power
Sources
Plasma
Arc
Cutting
Power
Sources
*
Semi-Automatic
and
Automatic
Wire
Feeders
Inverler
Power
Supplies
Intellitig
*
Robots
(1
year
labor)
3.
2
Years
Parts
and
Labor
Engine
Driven
Welding
Generators
(NOTE:
Engines
are
warranted
separately
by
the
engine
manufacturer.)
*
Air
Compressors
4.
1
Year
Parts
and
Labor
Motor
Driven
Guns
Process
Controllers
IHPSPowerSources
Water
Coolant
Systems
*
HF
Units
Grids
*
Spot
Welders
Load
Banks
SDXTranaformers
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
for
a
minimum
of
one
year
whichever
is
greater.)
.
~~1
I
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
Users
Guides
Distributor
Directories
contact
your
distributor
To
file
a
claim
for
loss
or
damage
during
shipment,
contact
the
delivering
carrier
For
assistance
in
filing
or
settling
claims,
contact
your
distributor
and/or
equipment
manufacturers
Transportation
Department
Miller
Electric
Mfg.
Co.
CALL:
414-735-4505
FAX:
800-637-2348
(in
USA),
or
414-735-4136
(outside
USA)
0
WRITE:
=
Miller
Electric
Mfg.
Co.
EQ.
BOX
1079
Appleton,
WI
54912
USA
Always
provide
Model
Name
and
Serial
or
Style
Number
miller..wal
31%
Declaration
of
Conformity
for
European
Community
(CE)
Products
NOTE
~
This
in
formation
is
provided
for
units
with
CE
certification
(see
rating
label
on
unit).
Manufacturers
Name:
Manufacturers
Address:
Declares
that
the
product
Miller
Electric
Mfg.
Co.
1635
W.
Spencer
Street
Appleton,
WI
54914
USA
Big
Bluefi
401
DXQ
conforms
to
the
following
Directives
and
Standards:
Directives
Low
Voltage
Directive:
73/23/EEC
Machinery
Directives:
89/392/EEC,91
/368/EEC,
93/C
133/04,
93/68/EEC
Noise
Emission
Directive:
79/113/EEC
Noise
level
of
Welding
Generators:
84/535/EEC
Standards
Safety
Requirements
for
Arc
Welding
Equipment
Part
1:
EN
60974-1:
1990
Rotating
Electrical
Machines
Part
1:
Rating
and
Performance:
IEC
34-1:
1994
Rotating
Electrical
Machines
Part
5:
Classification
of
degrees
of
protection
provided
by
enclosure
of
rotating
electrical
machines
(IP
code):
IEC
34-5:1991
Insulation
coordination
for
equipment
within
low-voltage
systems:
Part
1:
Principles,
requirements
and
test:
IEC
664-1:1992
European
Contact:
Telephone:
Fax:
Mr.
Luigi
Vacchini,
Managing
Director
MILLER
Europe
S.P.A.
Via
Privata
lseo
20098
San
Giuliano
Milanese,
Italy
39(02)98290-1
39(02)98281-552
dec_coni
1/96
.
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.
Warning
Label
Definitions
4
2-2.
Manufacturers
Rating
Label
For
CE
Products
7
2-3.
Symbols
And
Definitions
8
SECTION
3
INSTALLATION
9
3-1.
Installing
Welding
Generator
9
3-2.
Dimensions,
Weights,
And
Operating
Angles
9
3-3.
Fuel
Consumption
10
3-4.
Activating
The
Dry
Charge
Battery
11
3-5.
Connecting
The
Battery
12
3-6.
Engine
Prestart
Checks
12
3-7.
Installing
Muffler
Pipe
13
3-8.
Weld
Output
Terminals
And
Selecting
Cable
Sizes
13
SECTION
4OPERATING
THE
WELDING
GENERATOR
14
4-1.
Duty
Cycle
And
Overheating
14
4-2.
Front
Panel
Controls
15
4-3.
Manual
Shutoff
Lever
16
4-4.
Remote
A/V
Control
16
SECTION
5
OPERATING
AUXILIARY
EQUIPMENT
17
5-1.
120
Volt
And
240
Volt
Duplex
Receptacles
17
5-2.
Optional
Auxiliary
Power
Receptacles
18
SECTION
6
MAINTENANCE
&
TROUBLESHOOTING
19
6-1.
Routine
Maintenance
19
6-2.
Maintenance
Label
20
6-3.
Servicing
Air
Cleaner
21
6-4.
Oil
And
Fuel
System
Components
22
6-5.
Adjusting
Engine
Speed
23
6-6.
Overload
Protection
24
6-7.
Optional
Spark
Arrestor
Inspection
And
Cleaning
24
6-8.
Troubleshooting
25
SECTION
7
ELECTRICAL
DIAGRAM
27
SECTION
8
RUN-IN
PROCEDURE
28
8-1.
Wetstacking
28
8-2.
Run-In
Procedure
Using
Load
Bank
29
8-3.
Run-In
Procedure
Using
Resistance
Grid
30
SECTION
9
PARTS
LIST
32
OM-173
413B
8/96
.
SECTION
1
-
SAFETY
PRECAUTIONS
FOR
ARC
WELDING
safety_romi
4/95
.
1-1.
Symbol
Usage
4A
Means
Warning!
Watch
Out!
There
are
possible
hazards
with
this
A
Marks
a
special
safety
message.
I
procedure!
The
possible
hazards
are
shown
in
the
adjoining
symbols.
~
Means
NOTE;
not
safety
related.
I
~
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
I
actions
to
avoid
the
hazards.
1-2.
Arc
Welding
Hazards
4~
WARNING
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
1910.147
(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
nowar
oonl
nrot~ncI
wira
iq~~~
eonnet~t~d
to
rirotinrf
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
power
cord
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
poorly
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
as
naar
th~
weld
I
-
-
-
.
I.~I
JW~I
IV
 
-
--
-
.
YVUI
fljJIC%..O
~I
VV~I
flL~IJIC
- -
-
~O
I.#I
a~.waI.
ARC
RAYS
can
burn
eyes
and
skin;
ARC
RAYS
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
burn
eyes
and
skin.
Noise
from
some
processes
can
damage
hearing.
Chipping,
grinding,
and
welds
cooling
throw
off
pieces
of
metal
or
slag.
NOISE
1.
Use
approved
ear
plugs
or
ear
muffs
if
noise
level
is
high.
2.
3.
4.
5.
Wear
a
welding
helmet
fitted
with
a
proper
shade
of
filter
to
protect
your
face
and
eyes
when
welding
orwatching
(see
ANSI
Z49.1
and
Z87.1
listed
in
Safety
Standards).
Wear
approved
safety
glasses
with
side
shields.
Use
protective
screens
or
barriers
to
protect
others
from
flash
and
glare;
warn
others
not
to
watch
the
arc.
Wear
protective
clothing
made
from
durable,
flame-resistant
material
(wool
and
leather)
and
foot
protection.
FUMES
AND
GASES
can
be
hazardous
5.
Work
in
a
confined
space
only
if
it
is
well
ventilated,
or
while
to
your
health.
~
Welding
produces
fumes
and
gases.
Breathing
these
fumes
and
gases
can
be hazardous
to
your
health,
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.
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
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.
remove
welding
fumes
and
gases.
7.
Do
not
weld
on
coated
metals,
such
as
galvanized,
lead,
or
3.
If
ventilation
is
poor,
use
an
approved
air-supplied
respirator.
cadmium
plated
steel,
unless
the
coating
is
removed
from
the
4.
Read
the
Material
Safety
Data
Sheets
(MSDS5)
and
the
weld
area,
the
area
is
well
ventilated,
and
if
necessary,
while
manufacturers
instruction
for
metals,
consumables,
coatings,
wearing
an
air-supplied
respirator.
The
coatings
and
any
metals
cleaners,
and
degreasers.
containing
these
elements
can
give
off
toxic
fumes
if
welded.
OM-173
413
Page
1
CYLINDERS
can
explode
if
damaged.
Shielding
gas
cylinders
contain
gas
under
high
pressure.
If
damaged,
a
cylinder
can
explode.
Since
gas
cylinders
are
normally
part
of
the
welding
process,
be
sure
to
treat
them
carefully.
1.
Protect
compressed
gas
cylinders
from
excessive
heat,
mechanical
shocks,
slag,
open
flames,
sparks,
and
arcs.
2.
Install
cylinders
in
an
upright
position
by
securing
to
a
stationary
support
or
cylinder
rack
to
prevent
falling
or
tipping.
3.
Keep
cylinders
away
from
any
welding
or
other
electrical
circuits.
4.
Never
drape
a
welding
torch
over
a
gas
cylinder.
5.
Never
allow
a
welding
electrode
to
touch
any
cylinder.
6.
Never
weld
on a
pressurized
cylinder
explosion
will
result.
7.
Use
only
correct
shielding
gas
cylinders,
regulators,
hoses,
and
fittings
designed
for
the
specific application;
maintain
them
and
associated
parts
in
good
condition.
8.
Turn
face
away
from
valve
outlet
when
opening
cylinder
valve.
9.
Keep
protective
cap
in
place
over
valve
except
when
cylinder
is
in
use
or
connected
for
use.
10.
Read
and
follow
instructions
on
compressed
gas
cylinders,
associated
equipment,
and
CGA
publication
P-i
listed
in
Safety
Standards.
WELDING
can
cause
fire
or
explosion.
Welding
on
closed
containers,
such
as
tanks,
drums,
or
pipes,
can
cause
them
to
blow
up.
Sparks
can
fly
off
from
the
welding
arc.
The
flying
sparks,
hot
workpiece,
and
hot
equipment
can
cause
fires
and
burns.
Accidental
contact
of
electrode
to
metal
objects
can
cause
sparks,
explosion,
overheating,
or
fire.
Check
and
be
sure
the
area
is
safe
before
doing
any
welding.
1.
Protect
yourself
and
others
from
flying
sparks
and
hot
metal.
2.
Do
not
weld
where
flying
sparks
can
strike
flammable
material.
3.
Remove
all
flammables
within
35
ft
(10.7
m)
of
the
welding
arc.
If
this
is
not
possible,
tightly
cover
them
with
approved
covers.
4.
Be
alert
that
welding
sparks
and
hot
materials
from
welding
can
easily
go
through
small
cracks
and
openings
to
adjacent
areas.
5.
Watch
for
fire,
and
keep
a
fire
extinguisher
nearby.
6.
Be
aware
that
welding
on
a
ceiling,
floor,
bulkhead,
or
partition
can
cause
fire
on
the
hidden
side.
7.
Do
not
weld
on
closed
containers
such
as
tanks,
drums,
or
pipes,
unless
they
are
properly
prepared
according
to
AWS
F4.1
(see Safety
Standards).
8.
Connect
work
cable
to
the
work
as
close
to
the
welding
area
as
practical
to
prevent
welding
current
from
traveling
long,
possibly
unknown
paths
and
causing
electric
shock
and
fire
hazards.
9.
Do
not
use
welder
to
thaw
frozen
pipes.
10.
Remove
stick
electrode
from
holder
or
cut
oft
welding
wire
at
contact
tip
when
not
in
use.
11.
Wear
oil-free
protective
garments
such
as
leather
gloves,
heavy
shirt,
cuffless
trousers,
high
shoes,
and
a
cap.
12.
Remove
any
combustibles,
such
as
a
butane
lighter
or
matches,
from
your
person
before
doing
any
welding.
1-3.
Engine
Hazards
a
WARNING
-4
~-
I
ENGINE
EXHAUST GASES
can
kill.
I
1.
Use
equipment
outside
in
open,
well-yen
tilated
areas.
Engines
produce
harmful
exhaust
gases.
2.
If
used
in
a
closed
area,
vent
engine
ex
away
from
any
building
air
intakes.
haust
outside
and
.
~
-~,
I
II
i
ENGINE
FUEL
explosion,
Engine
fuel
is
highly
can
cause
fire
or
2.
flammable.
3.
Donotaddfuelwhilesmokingorifunitisnearanysparksor
open
flames.
Do
not
overfill
tank
allow
room
for
fuel
to
expand.
4.
Do
not
spill
fuel.
If
fuel
is
spilled,
clean
up
before
starting
1.
Stop
engine
and
let
it
cool
off
before
checking
or
adding
fuel.
engine.
F
MOVING
PARTS
can
cause
injury.
3.
Have
only
qualified
people
remove
guards
or
covers
for
Moving
parts,
such
as
fans,
rotors,
and
belts
can
cut
fingers
and
hands
and
catch
loose
clothing.
4.
maintenance
and
troubleshooting
as
necessary.
To
prevent
accidental
starting
during
servicing,
disconnect
negative
()
battery
cable
from
battery.
1.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.
5.
6.
Keep
hands,
hair,
loose
clothing,
and
tools
away
from
moving
parts.
Reinstall
panels
or
guards
and
close
doors
when
servicing
is
2.
Stop
engine
before
installing
or
connecting
unit.
finished
and
before
starting
engine.
SPARKS
can
cause
BATTERY
GASES
1.
Always
wear
a
face
shield
when
working
on a
battery.
TO
EXPLODE;
BATTERY
ACID
can
2.
Stop
engine
before
disconnecting
or
connecting
battery
burn
eyes
and
skin,
cables.
Batteries
contain
acid
and
generate
explosive
3.
4.
Do
not
allow
tools
to
cause
sparks
when
working
on
a
battery.
Do
not
use
welder
to
charge
batteries
or
jump
start
vehicles.
gases.
5.
Observe
correct
polarity
(+
and
)
on
batteries.
~
(?~~?
~
~:
STEAM
AND
PRESSURIZED
COOLANT
can
burn
face,
eyes,
skin.
It
is
best
to
check
coolant
level
when
eng
cold
to
avoid
scalding.
HOT
and
me
is
1.
2.
3.
If
the
engine
is
warm
and
checking
is
needed,
follow
steps
2
and
3.
Wear
safety
glasses
and
gloves
and
put
a
rag
over
cap.
Turn
cap
slightly
and
let
pressure
escape
slowly
before
completely
removing
cap.
I
OM-173
413
Page
2
1-4.
Additional
Installation,
Operation,
And
Maintenance
Hazards
a
WARNING
MOVING
PARTS
can
cause
injury.
Before
working
of
generator,
remove
spark
plugs
or
injectors
to
keep
engine
from
kicking
back
or
starting.
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
wrist
strap
BEFORE
handling
boards
or
parts.
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
period
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.
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.
DO
NOT
LET
ENGINE
EXHAUST
SPARKS
CAUSE
FIRE.
1.
Use
approved
engine
exhaust
spark
arrestor
in
required
areas
see
applicable
codes.
,
~
cli
U
LOW
VOLTAGE
AND
FREQUENCY
CAN
DAMAGE
electrical
equipment
such
as
MOTORS.
1.
Turn
off
or
unplug
equipment
before
starting
or
stopping
engine.
.~
t~
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.
I
~
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.l,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.
Govemment
Printing
Office,
Code
forSafetyin
Welding
and
Cutting,
CSA
Standard
Wi17.2,
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,
Batteryrnarch
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
cleariy
establish
that
low
frequency
practical.
magnetic
fields
can
interact
with,
and
produce
changes
in,
biological
systems.
While
most
of
this
work
is
of
very
high
quality,
the
results
are
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-i73
413
Page
3
1
Warning!
Watch
Out!
There
are
possible
hazards
as
shown
by
the
symbols.
2
Do
not
smoke
and
keep
matches
and
flames
away
from
battery.
3
Sparks
can
cause
battery
gases
to
explode.
Battery
explosion
can
blind
and
injure.
Wear
a
face
shield.
4
Battery
acid
can
bum
skin.
Do
not
spi!!
acid.
5
Read
Owners
Manual.
6
Wear
rubber
gloves.
7
Dead
battery
8
Engine
block
9
Fully
charged
battery
10
Do
not
connect
last
negative
cable
to
dead
battery
connect
instead
to
engine
block.
11
Jumper
cables
observe
polarity
and
make
connections
in
numbered
sequence
shown.
12
Once
dead
battery
is
charged,
disconnect
cables
in
sequence
shown.
3/96
Warning!
Watch
Out!
There
are
possible
hazards
as
shown
by
the
symbols.
2
Moving
parts,
such
as
fans,
rotors,
and
belts,
can
cut
fingers
and
hands
and
cause
injury.
Keep
away
from
moving
parts.
3/96
OM-173
413
Page
5
.
2~
1
Warning!
Watch
Out!
There
are
possible
hazards
as
shown
by
the
symbols.
2
Hot
muffler
and
exhaust
pipes
can
cause
severe
bums.
Do
not
touch
hot
muffler
or
pipes.
3/96
S-176
230
1
2
3
4
1
Warning!
Watch
Out!
There
are
possible
hazards
as
shown
by
the
symbols.
2
Engine
fuel
plus
flames
or
sparks
can
cause
fire.
3
Do
not
smoke
while
fueling
or
if
near
fuel.
4
Stop
engine
before
fueling.
5
Do
not
fuel
a
hot
engine.
6
Use
Diesel
Fuel
only.
5
6
3/96
1
Warning!
Watch
Out!
There
are
possible
hazards
as
shown
by
the
symbols.
2
Falling
equipment
can cause
serious
injury
and
damage.
3
Use
lifting
eye
to
lift
or
move
unit
only.
Use
proper
equipment
when
lifting.
4
Do
not
use
lifting
eye
to
lift
and
support
unit
and
trailer
or
other
heavy
devices
or
accessories.
3/96
OM-173
413
Page
6
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
Wamingl
Watch
Out!
There
are
possible
hazards
as
shown
by
the
symbols.
Read
Owners
Manual.
Follow
instructions
to
activate
battery.
5
Check
oil
level.
Add
oil
if
necessary.
Dunng
the
first
50
hours
of
operation,
keep
welding
load
above
200
amperes.
Do
not
weld
below
200
amperes
of
output.
After
the
first
50
hours
of
operation,
change
the
oil
and
oil
filter.
3/96
S-176
255-A
2-2.
Manufacturers
Rating
Label
For
CE
Products
EN
60974-1
40A/21
V
325A/33V
50A/1
2V
400A/26V
n
=
1800
RPM
1
60
Hz
120/240V
OM-173
413
Page
7
2-3.
Symbols
And
Definitions
.
OM-173
413
Page
8
SECTION
3-
INSTALLATION
3-1.
Installing
Welding
Generator
3-2.
Dimensions,
Weights,
And
Operating
Angles
Dimensions
Height
40-1/2
in
(1029
mm)
N~
M~
M
N
A
Do
not
exceed
operating
angles
while
running
or
engine
damage
will
occur.
A
Do
not
move
or
operate
unit
where
it
could
tip.
ii
I
Width
24-5/8
in
(625
mm)
Depth
56
in
(1422
mm)
A
.23-1/4
in
(591
mm)
B
24-5/8
in
(625
mm)
C
11/l6in(l7mm)
D
2-7/8
in
(73
mm)
E
4-1/2in(114)mm)
F
22-9/16
in
(573
mm)
G
27
in
(686
mm)
H
30-3/8
in
(772
mm)
J
41-1/4
in
(1048
mm)
C
Ref.
ST-lb
850-F
I
K
51-1/8
in
(1299
mm)
L
54
in
(1372
mm)
Weight
I
M
21/32
in
(16.7
mm)
Dia.
4Holes
Net:
1500
lb
(680
kg)
N
1/2in(12.7mm)Dia.
10
Holes
Ship:
1587
lb
(720
kg)
OM-173
413
Page
9
3-3.
Fuel
Consumption
I
.
The
curve
shows
typical
fuel
use
under
weld
or
power
loads.
a!
a!
0)
I~
o
~
7.57
1.70
2.00
6.62
1.46
1.75
5.67
1.25
1.50
4.73
1.04
1.25
1850
R.P.M.
3.78
0.83
1.00
2.84
0.62
0.75
1.98
0.40
0.50
0.95
0.21
0.25
0
50
100
150
200
250
300
DC
WELD
AMPERES
AT
bOX
DUTY
CYCLE
SB-137
487
OM-173
413
Page
10
3-4.
Activating
The
Dry
Charge
Battery
Remove
battery
from
unit.
Eye
Protection
Safety
Glasses
Or
Face
Shield
Rubber
Gloves
Vent
Caps
Sutfuric
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.
5
A
For
30
Minutes
30
A
For
12
Minutes
Tools
Needed:
OM-173
413
Page
11
3-5.
Connecting
The
Battery
3-6.
Engine
Prestart
Checks
OM-173
413
Page
12
3-7.
Installing
Muffler
Pipe
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
ft
(30
m)
Or
Less
150ft
(45
m)
200ft
(60
m)
250ft
(70
m)
300ft
(90
m)
350ft
(105
m)
400ft
(120
m)
1060%
Duty
Cycle
60100%
Duty
Cycle
10
100%
Duty
Cycle
Ref.
ST-801
344
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-C)
+
3-8.
Weld
Output
Terminals
And
Selecting
Cable
Sizes
A
ARC
WELDING
can
cause
Electromagnetic
Interference.
OM-173
413
Page
13
4~.
~
s~
s~
c;;
60
60
70
6010W
%
DUTY
CYCLE
100%
Duty
Cycle
At
250
Amperes
Continuous
Welding
60%
Duty
Cycle
At
325
Amperes
6
Minutes
Welding
4
Minutes
Resting
SECTION
4-
OPERATING
THE
WELDING
GENERATOR
4-1.
Duty
Cycle
And
Overheating
RATED
OtflRF~-1
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.
0)
w
0
-I
Ui
$0
40
rdu1y~
5/95
SB-070
999-A
OM-173
413
Page
14
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Miller BIG BLUE 401DXQ CE Owner's manual

Category
Welding System
Type
Owner's manual
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