Miller Electric Big Blue 401DXQ manual

Visit our website at www.Miller Welds .com OM - 173 413M August 2000 Big Blue 401DXQ  Processes Descrip tio n Air Carbon Arc (CAC-A) Cutting and Gouging Stick (SMA W) W elding Engine Driven Welding Generator With Optional Equipment: Flux Cored (FCAW) With V oltage-Sensing Wire Feeder[...]

Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .MillerW eld[...]

The following terms are used interchangeably throughout this manual: Stick = SMAW TIG = GT AW CALIFORNIA Proposition 65 W arning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer , birth defects, and other reproductive harm. T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING[...]

dec_con1 5/98 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). NOTE Manufacturer ’ s Name: Miller Electric Mfg. Co. Manufacturer ’ s Address: 1635 W . Spencer Street Appleton, WI 54914 USA Declares that the product: Big Blue  401DXQ conform[...]

OM-173 413 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING rom _nd_1 1/98 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.  Marks a special safety message.  Means “ Note ” ; not safety related. This group of symbols means W ar[...]

OM-173 413 Page 2 W elding on closed containers, such as tanks, drums, o r pipes, can cause them to blow up. Sparks c a n 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 b e sure [...]

OM-173 413 Page 3 MOVING P ARTS can cause injury .  Keep away from fans, belts, and rotors.  Keep all doors, panels, covers, and guards closed and securely in place.  Stop engine before installing or connecting unit.  Have only qualified people remove guards or covers for maint- enance and troubleshooting as necessary .  T o prevent [...]

OM-173 413 Page 4 H. F . RADIA TION can cause interference.  High-frequency (H.F .) can interfere with radio navigation, safety services, computers, and communications equipment.  Have only qualified persons familiar with electronic equipment perform this installation.  Th e user is responsible for having a qualified electrician prompt- ly[...]

OM-173 413 Page 5 SECTION 1 – CONSIGNES DE S É CURIT É – LIRE A V ANT UTILISA TION rom _nd_fre 1 1/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette proc é dure pr é sente des risques de danger ! Ceux-ci sont identifi é s par des symboles adjacents aux directives.  Identifie un message de s é curit é p[...]

OM-173 413 Page 6 Le soudage ef fectu é sur des conteneurs ferm é s tels que des r é servoirs, tambours ou des conduites peut provoquer leur é clatement. Des é tincelles peuvent ê tre projet é es de l ’ arc de soudure. La projection d ’é tincelles, des pi è ces chaudes et des é quipements chauds peut provoquer des incendies et des br [...]

OM-173 413 Page 7 DES ORGANES MOBILES peuvent provoquer des blessures.  Ne pas approcher les mains des ventilateurs, cour- roies et autres pi è ces en mouvement.  Maintenir ferm é s et fixement en place les portes, panneaux, recouvrements et dispositifs de protection.  Arr ê ter le moteur avant d ’ installer ou brancher l ’ appareil[...]

OM-173 413 Page 8 LE RA YONNEMENT HAUTE FR É - QUENCE (H.F .) risque de provoquer des interf é rences.  Le rayonnement haute fr é quence (H.F .) peut provoquer des interf é rences avec les é quipements de radio – navigation et de communication, les services de s é curit é et les ordinateurs.  Demander seulement à des personnes quali[...]

OM-173 413 Page 9 SECTION 2 – DEFINITIONS 2-1. W arning Label Definitions 3/96 1 1.1 1.2 1.3 3 3.1 3.2 3.3 4 4.1 S-176 105-A + 2 2.1 2.2 + 5 + 7 7.1 7.2 2.3 + 6 6.1 6.2 6.3 + = W arning! Watch Out! There are possible hazards as shown by the symbols. Become trained and read the instructions before working on the machine or welding. 1 Electric shoc[...]

OM-173 413 Page 10 3/96 1 W arning! 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. W ear a face shield. 4 Battery acid can burn skin. Do not spill acid. 5 Read Owner ’ s Manual. 6 W ea[...]

OM-173 413 Page 1 1 3/96 1 W arning! Watch Out! There are possible hazards as shown by the symbols. 2 Hot muf fler and exhaust pipes can cause severe burns. Do not touch hot muf fler or pipes. 1 S-176 230 2 3/96 1 W arning! W atch Out! There are possible hazards as shown by the symbols. 2 Engine fuel plus flames or sparks can cause fire. 3 D o not [...]

OM-173 413 Page 12 3/96 1 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 W arning! W atch Out! There are possible hazards as shown by the symbols. Read Owner ’ s M[...]

OM-173 413 Page 13 2-3. Symbols And Definitions Stop Engine Fast (Run,W eld/Power) Fast/Slow (Run/Idle) Slow (Idle) Start Engine T ime T emperature Fuel Engine Oil Remote Panel/Local Certified/T rained Mechanic Check Injectors/ Pump Check V alve Clearance Battery (Engine) V V olts A Amperes Shielded Metal Arc W elding (SMA W) Arc Force (DIG) Gas Tu[...]

OM-173 413 Page 14 SECTION 3 – SPECIFICA TIONS 3-1. W eld, Power , And Engine Specifications Rated W elding Output Amperage Range Maximum Open- Circuit V oltage DC Auxiliary Power Rating Engine Fuel Capacity Sound Power IP Rating 400 A, 30 V DC, 40% Duty Cycle 40 – 400 96 (A verage) Single-Phase, 3 kV A/kW , 26/13 A, 120/240 V AC, 60 Hz Deutz F[...]

OM-173 413 Page 15 3-3. Duty Cycle And Overheating 6 Minutes W elding 4 Minutes Resting Continuous W elding rduty1 5/95 – SB-070 999-B Duty Cycle is percentage of 10 m i n- utes that unit can weld at rated load without overheating.  Exceeding duty cycle can damage unit and void warranty . 60% Duty Cycle At 325 Amperes 100% Duty Cycle At 250 Am[...]

OM-173 413 Page 16 3-5. AC Auxiliary Power Th e ac power curve shows the aux- iliary power in amperes available at the 120 and 240 volt receptacles. rsb3.1 2/92 – ST-109 365-C 3-6. Fuel Consumption SB-137 487-A The curve shows typical fuel use under weld or power loads.[...]

OM-173 413 Page 17 SECTION 4 – INST ALLA TION 4-1. Installing Welding Generator install1 3/96 – Ref. ST-800 652 / Ref. ST -800 477-A / ST-158 936-A / S-0854 1 2 Electrically bond generator frame to vehicle frame by metal-to-metal contact. GND/PE 3 4 1 Generator Base 2 Metal V ehicle Frame 3 Equipment Grounding T erminal 4 Grounding Cable Use #1[...]

OM-173 413 Page 18 4-2. Activating The Dry Charge Battery Remove b attery from unit. 1 Eye Protection – Safety Glasses Or Face Shield 2 Rubber Gloves 3 V ent Caps 4 Sulfuric Acid Electrolyte (1.265 Specific Gravity) 5 W ell Fill each cell with electrolyte to bottom of well (maximum).  Do not overfill battery cells. Wai t ten minutes and check [...]

OM-173 413 Page 19 4-3. Connecting The Battery ST-156 01 1-A / Ref. ST-188 449 / S-0756 T ools Needed: 1/2 in + –  Connect Negative ( – ) Cable Last 4-4. Engine Prestart Checks Ref. ST-801 344 / Ref. S-176 697 Full 1/2 i n (13 mm) Full V alve Open I O 1 Diesel Check all fluids daily . Engine must be cold and on a level surface. 1 Exhaust Pip[...]

OM-173 413 Page 20 4-5. Installing Muffler Pipe ST-801 376  Stop engine and let cool.  Do not blow exhaust toward air cleaner or air intake. T ools Needed: T op View 1/2 in Ref. ST-801 344 1 Positive (+) W eld Output T erminal 2 Negative ( – ) W eld Output T er- minal For Stick welding Direct Current Electrode Positive (DCEP), con- nect wor[...]

OM-173 413 Page 21 4-7. Selecting W eld Cable Sizes T otal Cable (Copper) Length In W eld Circuit Not Exceeding W elding Amperes 100 ft (30 m) Or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft (105 m) 400 ft (120 m) Amperes 10 – 60% Duty Cycle 60 – 100% Duty Cycle 10 – 100% Duty Cycle 100 4 4 4 3 2 1 1/0 1/0 150 3 3 2 1 1[...]

OM-173 413 Page 22 SECTION 5 – OPERA TING THE WELDING GENERA TOR 5-1. Front Panel Controls Ref. ST-188 449  This unit has a max OCV control circuit that resets the Amperage/V oltage Con- trol to maximum when the arc breaks. When an arc is struck, weld output con- trol returns to the front panel or remote control setting. The Amperage/V oltage [...]

OM-173 413 Page 23 Ref. ST-801 344 1 Manual Shutoff Lever Use lever to stop engine if engine control switch does not work. 1 5-2. Manual Shutoff Lever 5-3. Remote A/V Control 1 A/V Control Switch Use switch to select front panel or remote amperage control. 2 Remote A/V Receptacle RC3 Connect optional remote control to RC3. S-0774 2 Min (66 A DC) Ma[...]

OM-173 413 Page 24 SECTION 6 – OPERA TING AUXILIAR Y EQUIPMENT 6-1. 120 V olt And 240 V olt Duplex Receptacles Ref. ST-188 449  If unit does not have GFCI recep- tacles, use GFCI-protected exten- sion cord.  If a circuit breaker continues to open, contact Factory Authorized Service Agent.  Auxiliary power is not affected by weld output. [...]

OM-173 413 Page 25 6-3. Connecting Optional Auxiliary Power Plant Ref. S-188 059-A  Stop engine.  Power and weld outputs are live at the same time. Disconnect or insulate unused cables.  Have qualified person install according to circuit diagram and Auxiliary Power Guidelines (Section 10). Remove junction box cover . 1 Lead 93 2 Lead 92 3 [...]

OM-173 413 Page 26 SECTION 7 – MAINTENANCE & TROUBLESHOOTING Follow the storage procedure in the engine owner ’ s manual if the unit will not be used for an extended period. NOTE 7-1. Routine Maintenance Recycle engine fluids.  Stop engine before maintaining.  See also Engine Manual and Maintenance Label. Ser- vice engine more often i[...]

OM-173 413 Page 27 1000 h Blow Out Or V acuum Inside. During Heavy Service, Clean Monthly . OR Change Fuel Filters. See Section 7-4. Service W elding Generator Brushes And Slip Rings. Service More Often In Dirty Conditions.* Drain Sludge From Fuel T ank. See Section 7-4. FUEL SLUDGE Check V alve Clearance.* 3000 h Clean/Set Injectors.* Notes[...]

OM-173 413 Page 28 6-2. Maintenance Label[...]

OM-173 413 Page 29 7-3. Servicing Air Cleaner aircleaner4 9/99 – 802 495 / Ref. S-0698-B  Stop engine. 1 Air Cleaner 2 Service Indicator (Optional) 3 Window 4 Reset Button Service air cleaner element if red band appears in window . A green band means air cleaner is okay . Press button to reset indicator .  Do not run engine without ai r cle[...]

OM-173 413 Page 30 7-4. Oil And Fuel System Components Ref. ST-188 449 / ST -801 334-A / Ref. S-176 697 / Ref. S-0842  Stop engine and let cool. 1 Oil Filter 2 Oil Drain V alve 3 Oil Fill Cap 4 Primary Fuel Filter (Fuel/ W ater Separator) 5 Petcock 6 Secondary Fuel Filter 7 Fuel Shutoff V alve 8 Fuel Line 9 Sludge Drain Plug T o change oil and f[...]

OM-173 413 Page 31 7-5. Adjusting Engine Speed Ref. ST-801 344-A After tuning engine, check engine no load speed with a tachometer (see table for no load speeds). If necessary , adjust speed as follows: Start engine and run until warm. T urn Amperage/V oltage Control to 100. Standard Models: 1 Engine Speed Adjustment Screw 2 Locking Nut Loosen nut.[...]

OM-173 413 Page 32 7-6. Overload Protection Ref. ST-801 344 / Ref. ST -156 199-B / ST -801 320-A  Stop engine.  When a fuse opens it usually in- dicates a more serious prob- lem exists. Contact a Factory Authorized Service Agent. 1 Magnetic Shutdown Switch MS1 2 Fuse F (See Parts List For Rating) Fuse F protects magnetic shut- down switch MS1[...]

OM-173 413 Page 33 7-8. T roubleshooting A. Welding T rouble Remedy No weld output. Check position of Ampere Range switch. Place A/V control switch in Panel position, or place switch in Remote position and connect remote amper- age control to Remote A/V receptacle (see Section 5-3). Check and secure connections to Remote A/V receptacle. Have Factor[...]

OM-173 413 Page 34 C. Engine T rouble Remedy Engine does not start. Check fuel level. Open fuel valve (see Section 4-4). Check optional shutdown switch fuse F and replace if open (see Section 7-6). Check battery and replace if necessary . Check connections to Engine Control switch. Check oil level. Optional automatic shutdown system stops engine if[...]

OM-173 413 Page 35 SECTION 8 – ELECTRICAL DIAGRAM SC-190 651-A Figure 8-1. Circuit Diagram For Welding Generator[...]

OM-173 413 Page 36 SECTION 9 – RUN-IN PROCEDURE run_in1 6/96 9-1. W etstacking 1 W elding Generator Run diesel engines near rated out- put during run-in period to properly seat piston rings and prevent wets- tacking. See nameplate or rating label to find rated output.  Do not idle engine longer than necessary . Piston rings seat faster if engi[...]

OM-173 413 Page 37 9-2. Run-In Procedure Using Load Bank S-0683  Stop engine.  Do not touch hot exhaust pipe, engine parts, or load bank/grid.  Keep exhaust and pipe away from flammables. 1 Load Bank T urn all load bank switches Off. If needed, connect load bank to 1 15 volts ac wall receptacle or genera- tor auxiliary power receptacle. 2 [...]

OM-173 413 Page 38 9-3. Run-In Procedure Using Resistance Grid S-0684  Stop engine.  Do not touch hot exhaust pipe, engine parts, or load bank/grid.  Keep exhaust and pipe away from flammables. 1 Resistance Grid Use grid sized for generator rated output. Turn Of f grid. 2 Welding Generator Place A/V range switch in maxi- mum position, A/V [...]

OM-173 413 Page 39 SECTION 10 – AUXILIAR Y POWER GUIDELINES 10-1. Selecting Equipment aux_pwr 2/99 – Ref. ST-159 730 / ST -800 577 1 Auxiliary Power Receptacles – Neutral Bonded T o Frame 2 3-Prong Plug From Case Grounded Equipment 3 2-Prong Plug From Double Insulated Equipment OR 2 Be sure equipment has this symbol and/or wording. 3 1 10-2. [...]

OM-173 413 Page 40 10-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 A WG or larger insulated copper wire. 3 Ground Device  Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. GND/PE 1 2 Us e ground device as stated in elec[...]

OM-173 413 Page 41 10-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting W atts Running W atts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 2100 700 1/2 HP 3175 875 Capacitor Start-Induction Run 1/3 HP 2020 720 1/2 HP 3075 975 3/4 HP 4500 1400 1 HP 6100 1600 1-1/2 HP 8200 2200 2 HP 10550 2[...]

OM-173 413 Page 42 10-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting W atts Running W atts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/2 in 500 500 7-1/4 in 900 900 8-1/4 in 1400 1400 T able Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in 2500 1 100 Bench Grinder 6 in 1720 720 8 [...]

OM-173 413 Page 43 10-8. Power Required T o Start Motor S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor V oltage T o find starting amperage: Step 1: Find code and use table to find kV A/HP . If code is not listed, multiply running amperage by six to find starting amperage. Step 2 : Find Motor HP and V olts. Step 3: Determine startin[...]

OM-173 413 Page 44 10-10. T ypical Connections T o Supply Standby Power S-0405-A 1 Power Company Service Meter 2 Main and Branch Overcurrent Protection 3 Double-Pole, Double-Throw T ransfer Switch Obtain and install correct switch. Switch rating must be same as or greater than the branch overcurrent protection. 4 Circuit Breakers or Fused Disconnec[...]

OM-173 413 Page 45 10-1 1. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 V olt Loads  If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (A WG)* Current (Amperes) Load (W atts) 4 6 8 10 12 14 5 600 350 (106) 225 (68) 137 (42) 100 (30) [...]

OM-173 413 Page 46 SECTION 1 1 – P ARTS LIST  Hardware is common and not available unless listed. 88 1 2 3 4 5 6 8 7 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 76 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98(Fig.1 1 – 3) 100 102 101 103 104 105 106 107 72(Includes 73 – 77) 73 74 75 73 77 78 79 80 99 93 Figure 1 1-1. Main Assembly[...]

OM-173 413 Page 47 ST-801 345-J 24(FIG 1 1 – 2) 25 26 27 28 29 30 39 38 37 36 35 34 33 42 41 40 32 31 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 108[...]

OM-173 413 Page 48 Description Part No. Dia. Mkgs. Item No. Figure 1 1-1. Main Assembly Quantity 1 175 657 TERMINAL, output bracket 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 724 BRACKET , brace terminal weld output 1 . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

OM-173 413 Page 49 Description Part No. Dia. Mkgs. Item No. Figure 1 1-1. Main Assembly (Continued) Quantity 41 124 985 HOSE, air cleaner 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 023 313 CLAMP , hose 1.312-3.250clp dia 2 . . . . . . . . . . . . . . . . .[...]

OM-173 413 Page 50 Description Part No. Dia. Mkgs. Item No. Figure 1 1-1. Main Assembly (Continued) Quantity 88 081 499 BRACKET , mtg strip terminal 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 010 146 CLAMP , nyl .625clp dia 1 . . . . . . . . . . . . . . . . . . . . . . . . . [...]

OM-173 413 Page 51 Description Quantity Part No. Dia. Mkgs. Item No. Figure 1 1-2. Generator (Figure 1 1-1 Item 24) 1 106 426 INSULA TOR 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 106 440 BUS BAR, rectifier 2 . . . . . . . . . . . . . . . . . . . . [...]

OM-173 413 Page 52 1 2 3 7 12 ST-801 358-C Figure 1 1 -4 4 5 11 6 8 9 10 13 14 15 16 17 18 19 20 21 22  Hardware is common and not available unless listed. 23 Figure 1 1-3. Panel, Front w/Components[...]

OM-173 413 Page 53 Description Part No. Dia. Mkgs. Item No. Figure 1 1-3. Panel, Front w/Components (Figure 11-1 Item 98) Quantity 1 S3 1 14 193 SWITCH, range (Figure 1 1-4) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 R1 605 960 RHEOSTA T , WW 300W 34 ohm 1 . . . . . . . . . . . . . . [...]

OM-173 413 Page 54 Description Quantity Part No. Item No. 1 14 193 Figure 1 1-4. Switch, Range (Figure 1 1-3 Item 1) 1 1 14 235 BRACKET , mtg switch (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 010 671 SPRING, ext x .312 OD x .042 wire x 1.875pld 1 . . . . . . . . . . . . . . [...]

OM-173 413 Page 55 Description Quantity OPTIONAL EQUIPMENT Part No. 043 096 RECEPT ACLE KIT , 120V GFCI 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE PROTECTION P ACKAGE, (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

[...]

[...]

[...]

Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 7/00 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor . The expertise o[...]

PRINTED IN USA  2000 Miller Electric Mfg. Co. 6/00 Miller Elect ric Mfg. Co. An I l li noi s T ool Works Com pany 1635 West S pencer Street Applet on, WI 5 4914 US A International He adquarter s – USA USA Phone: 920-735-4505 Auto-A t t ended USA & Canada FAX: 920-735-4134 Int ernati onal F AX: 9 20-735-4125 European Headqua rters – Unite[...]