Miller Electric Big Blue 401DXQ Owner's Manual
  1. Manuals
  2. Brands
  3. Miller Electric Manuals
  4. Welding System
  5. Big Blue 401DXQ
  6. Owner's manual
Miller Electric Big Blue 401DXQ Owner's Manual

Miller Electric Big Blue 401DXQ Owner's Manual

Engine driven welding generator
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Visit our website at
www.MillerWelds.com
Big Blue 401DXQ
OM-173 413M
August 2000
Processes
Stick (SMAW) Welding
Air Carbon Arc (CAC-A) Cutting
and Gouging
With Optional Equipment:
Flux Cored (FCAW) With
Voltage-Sensing Wire Feeder
Description
Engine Driven Welding Generator
R

Advertisement

Table of Contents
loading

Related Manuals for Miller Electric Big Blue 401DXQ

Summary of Contents for Miller Electric Big Blue 401DXQ

  • Page 1 Big Blue 401DXQ Visit our website at www.MillerWelds.com OM-173 413M August 2000 Processes Stick (SMAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging With Optional Equipment: Flux Cored (FCAW) With Voltage-Sensing Wire Feeder Description Engine Driven Welding Generator...
  • Page 2 ISO 9001 Quality System Standard. service information for your particular model are also provided. 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.

  • Page 3: Table Of Contents

    SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING WARNING This product, when used for welding or cutting, SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer.
  • Page 4 Declaration of Conformity for European Community (CE) Products NOTE This information is provided for units with CE certification (see rating label on unit). Miller Electric Mfg. Co. Manufacturer’s Name: 1635 W. Spencer Street Manufacturer’s Address: Appleton, WI 54914 USA Big Blue 401DXQ...

  • Page 5: Section 1 - Safety Precautions - Read Before Using

    SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. Means “Note”; not safety related. 1-2.

  • Page 6: Engine Hazards

    WELDING can cause fire or explo- sion. 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.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    MOVING PARTS can cause injury. D Keep away from fans, belts, and rotors. D Keep all doors, panels, covers, and guards closed and securely in place. D Stop engine before installing or connecting unit. D Have only qualified people remove guards or covers for maint- enance and troubleshooting as necessary.

  • Page 8: Principal Safety Standards

    H.F. RADIATION can cause interference. D High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. D Have only qualified persons familiar with electronic equipment perform this installation. D The user is responsible for having a qualified electrician prompt- ly correct any interference problem resulting from the installa- tion.

  • Page 9: Section 1 - Consignes De Sécurité - Lire Avant Utilisation

    SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Y Identifie un message de sécurité particulier. Signifie NOTA ;...

  • Page 10: Dangers Existant En Relation Avec Le Moteur

    LE SOUDAGE peut provoquer un in- cendie ou une explosion. Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    DES ORGANES MOBILES peuvent provoquer des blessures. D Ne pas approcher les mains des ventilateurs, cour- roies et autres pièces en mouvement. D Maintenir fermés et fixement en place les portes, panneaux, recouvrements protection. D Arrêter le moteur avant d’installer ou brancher l’appareil. D Demander seulement à...

  • Page 12: Principales Normes De Sécurité

    LE RAYONNEMENT HAUTE FRÉ- QUENCE (H.F.) risque de provoquer des interférences. D Le rayonnement haute fréquence (H.F.) peut provoquer des interférences avec les équipements de radio–navigation et de communication, les services de sécurité et les ordinateurs. D Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l’installation.

  • Page 13: Section 2 - Definitions

    SECTION 2 – DEFINITIONS 2-1. Warning Label Definitions Warning! Watch Out! There are possible hazards as shown by the symbols. Become trained and read the instructions before working on the machine or welding. Electric shock from welding electrode or wiring can kill. 1.1 Wear dry insulating gloves.
  • Page 14 – – OM-173 413 Page 10 – – S-176 106 Warning! Watch Out! There are possible hazards as shown by the symbols. Do not smoke and keep matches and flames away from battery. Sparks can cause battery gases to explode. Battery explosion can blind and injure.
  • Page 15 S-176 230 DIESEL S-176 103 Warning! Watch Out! There are possible hazards as shown by the symbols. Hot muffler and exhaust pipes can cause severe burns. Do not touch hot muffler or pipes. Warning! Watch Out! There are possible hazards as shown by the symbols.

  • Page 16: Manufacturer's Rating Label For Ce Products

    0 – 50 h Std. 50 h Std. 2-2. Manufacturer’s Rating Label For CE Products OM-173 413 Page 12 S-177 571 DIESEL 200A 0 – 200A API CD-MIL L 2104D, CD/SE, CD/SF Remove unit from shipping crate. Remove Owner’s Manual from unit. Follow instructions to install muffler.

  • Page 17: Symbols And Definitions

    2-3. Symbols And Definitions Stop Engine Start Engine Engine Oil Check Injectors/ Pump Amperes Engine-Driven, Three-Phase Alternator With Rectifier Positive Protective Earth (Ground) Duty Cycle Rated Idle Speed Single Phase Fast (Run,Weld/Power) Time Remote Check Valve Clearance Shielded Metal Arc Welding (SMAW) Engine Negative...

  • Page 18: Section 3 - Specifications

    SECTION 3 – SPECIFICATIONS 3-1. Weld, Power, And Engine Specifications Maximum Rated Welding Amperage Open- Output Range Circuit Voltage DC 400 A, 30 V DC, 40 – 400 40% Duty Cycle (Average) 3-2. Dimensions, Weights, And Operating Angles Dimensions Height 40-1/2 in (1029 mm) Width 24-5/8 in (625 mm)

  • Page 19: Duty Cycle And Overheating

    3-3. Duty Cycle And Overheating 6 Minutes Welding 3-4. Volt-Ampere Curves 100% Duty Cycle At 250 Amperes Continuous Welding 60% Duty Cycle At 325 Amperes 4 Minutes Resting Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating.

  • Page 20: Ac Auxiliary Power

    3-5. AC Auxiliary Power 3-6. Fuel Consumption OM-173 413 Page 16 The 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 The curve shows typical fuel use under weld or power loads.

  • Page 21: Section 4 - Installation

    SECTION 4 – INSTALLATION 4-1. Installing Welding Generator Movement Y Do Not Lift Unit From End Grounding Electrically bond generator frame to vehicle frame by metal-to-metal contact. Airflow Clearance 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) 18 in 18 in (460 mm)

  • Page 22: Activating The Dry Charge Battery

    4-2. Activating The Dry Charge Battery 5 A For 30 Minutes 30 A For 12 Minutes OM-173 413 Page 18 – Remove battery from unit. Eye Protection – Safety Glasses Or Face Shield Rubber Gloves Vent Caps Sulfuric Acid Electrolyte (1.265 Specific Gravity) Well Fill each cell with electrolyte to...

  • Page 23: Connecting The Battery

    4-3. Connecting The Battery Y Connect Negative (–) Cable Last – 4-4. Engine Prestart Checks 1/2 in (13 mm) Full Diesel Valve Open Full Tools Needed: 1/2 in ST-156 011-A / Ref. ST-188 449 / S-0756 Check all fluids daily. Engine must be cold and on a level surface.

  • Page 24: Installing Muffler Pipe

    4-5. Installing Muffler Pipe Tools Needed: 1/2 in 4-6. Connecting To Weld Output Terminals Tools Needed: 3/4 in OM-173 413 Page 20 Top View Y Stop engine and let cool. Y Do not blow exhaust toward air cleaner or air intake. ST-801 376 Positive (+) Weld Output Terminal...

  • Page 25: Selecting Weld Cable Sizes

    4-7. Selecting Weld Cable Sizes Welding 100 ft (30 m) Or Less Amperes Amperes 10 – 60% 60 – 100% Duty Duty Cycle Cycle 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. Contact your dis- tributor for the mm equivalent weld cable sizes.

  • Page 26: Section 5 - Operating The Welding Generator

    SECTION 5 – OPERATING THE WELDING GENERATOR 5-1. Front Panel Controls This unit has a max OCV control circuit that resets the Amperage/Voltage 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.

  • Page 27: Manual Shutoff Lever

    5-2. Manual Shutoff Lever 5-3. Remote A/V Control Example: Combination Remote Amperage Control Set Switch Set Range Set Percentage Manual Shutoff Lever Use lever to stop engine if engine control switch does not work. Ref. ST-801 344 A/V Control Switch Use switch to select front panel or remote amperage control.

  • Page 28: Section 6 - Operating Auxiliary Equipment

    SECTION 6 – OPERATING AUXILIARY EQUIPMENT 6-1. 120 Volt And 240 Volt Duplex Receptacles Y 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.

  • Page 29: Connecting Optional Auxiliary Power Plant

    6-3. Connecting Optional Auxiliary Power Plant Single Three Phase Phase Output Volts 120/240 Amps KVA/KW Frequency 60 Hz Engine Speed 1850 RPM Max. Fuse Size 35 Amperes Lead 42 connects to GROUND stud on front of unit. Jumper 42 is connected to 90 at factory. Y Stop engine.

  • Page 30: Section 7 - Maintenance & Troubleshooting

    SECTION 7 – MAINTENANCE & TROUBLESHOOTING Follow the storage procedure in the engine owner’s manual if the unit will not be NOTE used for an extended period. 7-1. Routine Maintenance Wipe Up Spills. Service Air Filter. See Section 7-3. Check cleaner hoses for cracks and loose clamps.
  • Page 31 Blow Out Or Vacuum Inside. During Heavy Service, Clean Monthly. Drain Sludge FUEL SLUDGE Notes 1000 h Change Fuel Filters. See Section 7-4. From Fuel Tank. See Section 7-4. 3000 h Clean/Set Injectors.* Service Welding Generator Brushes And Slip Rings. Service More Often In Dirty Conditions.* Check Valve...

  • Page 32: Maintenance Label

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

  • Page 33: Servicing Air Cleaner

    7-3. Servicing Air Cleaner Blow Inspect Y Stop engine. Air Cleaner Service Indicator (Optional) Window 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. Y Do not run engine without air cleaner or with dirty element.

  • Page 34: Oil And Fuel System Components

    7-4. Oil And Fuel System Components OM-173 413 Page 30 Ref. ST-188 449 / ST-801 334-A / Ref. S-176 697 / Ref. S-0842 Y Stop engine and let cool. Oil Filter Oil Drain Valve Oil Fill Cap Primary Fuel Filter (Fuel/ Water Separator) Petcock Secondary Fuel Filter...

  • Page 35: Adjusting Engine Speed

    7-5. Adjusting Engine Speed Models With Automatic Idle (Optional) Tools Needed: 3/8, 7/16 in 1850 rpm 1250 rpm Standard Models 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.

  • Page 36: Overload Protection

    7-6. Overload Protection 7-7. Optional Spark Arrestor Inspection And Cleaning Tools Needed: 3/8 in OM-173 413 Page 32 Y Stop engine. When a fuse opens it usually in- dicates a more serious prob- lem exists. Contact a Factory Authorized Service Agent. Magnetic Shutdown Switch MS1 Fuse F (See Parts List For...

  • Page 37: Troubleshooting

    7-8. Troubleshooting A. Welding Trouble 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.
  • Page 38 C. Engine Trouble 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.

  • Page 39: Section 8 - Electrical Diagram

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

  • Page 40: Section 9 - Run-In Procedure

    SECTION 9 – RUN-IN PROCEDURE 9-1. Wetstacking OM-173 413 Page 36 run_in1 6/96 Welding 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.

  • Page 41: Run-In Procedure Using Load Bank

    9-2. Run-In Procedure Using Load Bank Y Stop engine. Y Do not touch hot exhaust pipe, engine parts, or load bank/grid. Y Keep exhaust and pipe away from flammables. Load Bank Turn all load bank switches Off. If needed, connect load bank to 115 volts ac wall receptacle or genera- tor auxiliary power receptacle.

  • Page 42: Run-In Procedure Using Resistance Grid

    9-3. Run-In Procedure Using Resistance Grid OM-173 413 Page 38 Y Stop engine. Y Do not touch hot exhaust pipe, engine parts, or load bank/grid. Y Keep exhaust and pipe away from flammables. Resistance Grid Use grid sized for generator rated output.

  • Page 43: Section 10 - Auxiliary Power Guidelines

    SECTION 10 – AUXILIARY POWER GUIDELINES 10-1. Selecting Equipment 10-2. Grounding Generator To Truck Or Trailer Frame Be sure equipment has this symbol and/or wording. GND/PE Electrically bond generator frame to vehicle frame by metal-to-metal contact. Auxiliary Power Receptacles – Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double...

  • Page 44: Grounding When Supplying Building Systems

    10-3. Grounding When Supplying Building Systems 10-4. How Much Power Does Equipment Require? AMPERES x VOLTS = WATTS EXAMPLE 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power requirement in watts. The load applied by the drill is 520 watts. EXAMPLE 2: If three 200 watt flood lamps are used with the drill from Example 1, add the individual loads to calculate total load.
  • Page 45 10-5. Approximate Power Requirements For Industrial Motors Industrial Motors Split Phase Capacitor Start-Induction Run Capacitor Start-Capacitor Run Fan Duty 10-6. Approximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Stock Tank De-Icer Grain Cleaner Portable Conveyor Grain Elevator Milk Cooler Milker (Vacuum Pump) FARM DUTY MOTORS Std.
  • Page 46 10-7. Approximate Power Requirements For Contractor Equipment Contractor Hand Drill Circular Saw Table Saw Band Saw Bench Grinder Air Compressor Electric Chain Saw Electric Trimmer Electric Cultivator Elec. Hedge Trimmer Flood Lights Submersible Pump Centrifugal Pump Floor Polisher High Pressure Washer 55 gal Drum Mixer Wet &...
  • Page 47 10-8. Power Required To Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code KVA/HP kVA/HP x HP x 1000 VOLTS EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4 HP motor with a motor start code of M. Volts = 230 HP = 1/4 11.2 x 1/4 x 1000...
  • Page 48 10-10. Typical Connections To Supply Standby Power Customer-supplied equipment is required if generator is to supply standby power during emergencies or power outages. 120/240 Volt 60 Hz Three-Wire Service Load 120/240 Volt Single-Phase Three-Wire Generator Output Connection OM-173 413 Page 44 240 V 120 V 120 V...
  • Page 49 10-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord. Current Load (Watts) (Amperes) 1200 1800 2400 3000 3600 4200 4800 5400 6000 *Conductor size is based on maximum 2% voltage drop Cord Lengths for 240 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord.

  • Page 50: Section 11 - Parts List

    SECTION 11 – PARTS LIST Hardware is common and not available unless listed. 98(Fig.11–3) OM-173 413 Page 46 Figure 11-1. Main Assembly 72(Includes 73–77)
  • Page 51 24(FIG 11–2) ST-801 345-J OM-173 413 Page 47...
  • Page 52 Item Dia. Part Mkgs....175 657 ..... 175 724 .
  • Page 53 Item Dia. Part Mkgs....124 985 ....023 313 .
  • Page 54 Item Dia. Part Mkgs....081 499 ....010 146 .
  • Page 55 Item Dia. Part Mkgs....106 426 ....106 440 ..
  • Page 56 Hardware is common and not available unless listed. OM-173 413 Page 52 Figure 11-3. Panel, Front w/Components Figure 11-4 ST-801 358-C...
  • Page 57 Item Dia. Part Mkgs....114 193 ....605 960 ..
  • Page 58 Item Part 114 193 ....114 235 ....010 671 .
  • Page 59 Part Description OPTIONAL EQUIPMENT . . . 043 096 RECEPTACLE KIT, 120V GFCI ....ENGINE PROTECTION PACKAGE, (consisting of) . . . 042 318 ..AUTOMATIC SHUTDOWN, low oil pres &...
  • Page 63 Warranty Questions? Call LIMITED WARRANTY – Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants 1-800-4-A-MILLER to its original retail purchaser that new Miller equipment sold for your local after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.
  • Page 64 Parts) Circuit Diagrams Welding Process Handbooks File a claim for loss or damage during shipment. 2000 Miller Electric Mfg. Co. 6/00 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters–USA USA Phone: 920-735-4505 Auto-Attended USA &...

Table of Contents