Miller BIG BLUE 401DXQ CE Owner's manual

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

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

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

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

SECTION

2-

DEFINITIONS

2-1.

Warning

Label

Definitions

Become

trained

and

read

the

instructions

before

working

on

the

machine

or

welding.

1

Electric

shock

from

welding

electrode

or

wiring

can

kill.

1.1

Weardryinsulatinggloves.

Do

not

touch

electrode

with

bare

hand.

Do

not

wear

wet

or

damaged

gloves.

1.2

Protect

yourself

from

electric

shock

by

insulating

yourself

from

work

and

ground.

1.3

Do

not

work

on

unit

if

engine

is

running.

Stop

engine

first.

2

Breathing

welding

fumes

can

be hazardous

to

your

health.

2.1

Keep

your

head

out

of

the

fumes.

2.2

Use

forced

ventilation

or

local

exhaust

to

remove

the

fumes.

2.3

Use

ventilating

fan

to

remove

fumes.

3

Welding

sparks

can

cause

explosion

or

fire.

3.1

Keep

flammables

away

from

welding.

Do

not

weld

near

flammables.

3.2

Welding

sparks

can

cause

fires.

Have

a

fire

exlinguisher

nearby,

and

have

a

watchperson

ready

to

use

it.

3.3

Do

not

weld

on

drums

or

any

closed

containers.

4

Arc

rays

can

bum

eyes

and

injure

skin.

4.1

Wear

hat

and

safety

glasses.

Use

ear

protection

and

button

shirt

collar.

Use

welding

helmet

with

correct

shade

of

filter.

Wear

complete

body

protection.

5

Do

not

remove

or

paint

over

(cover)

the

label.

6

Engine

fuel

plus

flames

or

sparks

can

cause

fire.

6.1

Do

not

smoke

while

fueling

or

if

near

fuel.

6.2

Stop

engine

before

fueling.

6.3

Do

not

fuel

a

hot

engine.

7

Engine

exhaust

gases

can

kill.

7.1

Vent

exhaust

outside.

7.2

Use

unit

outside.

Warning!

Watch

Out!

There

are

possible

hazards

as

shown

by

the

symbols.

.

3/96

OM-173413Page4

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!

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

150

3

2

1

1/0

2/0

3/0

200

3 2

1

1/0

2/0

3/0

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

2-4/0

400

1/0

2/0

3/0

4/0

2-2/0

2-3/0

2-4/0

500

2/0

3/0

4/0

2-2/0 2-3/0

2-4/0

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~

c;;

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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