Miller Big Blue 401DX Owner's Manual
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Miller Big Blue 401DX Owner's Manual

Miller Big Blue 401DX Owner's Manual

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Big Blue 401DX
OM-130 098AG
2008−08
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
Air Carbon Arc (CAC-A) Cut-
ting And Gouging
With Optional Equipment:
Flux Cored (FCAW) With Volt-
age-Sensing Wire Feeder
Description
™
File: Engine Drive

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  • Page 1 2008−08 Processes Stick (SMAW) Welding TIG (GTAW) Welding Air Carbon Arc (CAC-A) Cut- ting And Gouging With Optional Equipment: Flux Cored (FCAW) With Volt- age-Sensing Wire Feeder Description Big Blue 401DX ™ File: Engine Drive Visit our website at www.MillerWelds.com...
  • Page 2 We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING ........1-1.
  • Page 4 TABLE OF CONTENTS 8-7. Servicing Optional Ether Starting Aid ........... . . 8-8.

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

    SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2007−04 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
  • Page 6 D Do not weld on closed containers such as tanks, drums, or pipes, FUMES AND GASES can be hazardous. unless they are properly prepared according to AWS F4.1 (see Safety Standards). Welding produces fumes and gases. Breathing these D Do not weld where the atmosphere may contain flammable dust, fumes and gases can be hazardous to your health.

  • Page 7: Engine Hazards

    1-3. Engine Hazards STEAM AND HOT COOLANT can burn. BATTERY EXPLOSION can BLIND. D If possible, check coolant level when engine is D Always wear a face shield, rubber gloves, and cold to avoid scalding. protective clothing when working on a battery. D Always check coolant level at overflow tank, if D Stop engine before disconnecting or connect- present on unit, instead of radiator (unless told...

  • Page 8: Additional Symbols For Installation, Operation, And Maintenance

    HOT METAL from air arc cutting and READ INSTRUCTIONS. gouging can cause fire or explosion. D Read Owner’s Manual before using or servic- D Do not cut or gouge near flammables. ing unit. D Watch for fire; keep extinguisher nearby. D Stop engine and release air pressure before servicing.

  • Page 9: California Proposition 65 Warnings

    H.F. RADIATION can cause interference. ARC WELDING can cause interference. D High-frequency (H.F.) can interfere with radio D Electromagnetic energy can interfere with navigation, safety services, computers, and sensitive electronic equipment such as micro- communications equipment. processors, computers, and computer-driven equipment such as robots.

  • Page 10: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 CONSIGNES DE SÉCURITÉ − LIRE AVANT − UTILISATION rom_2007−04fre Se protéger, ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud. 2-1. Signification des symboles DANGER! − Indique une situation dangereuse qui si on Indique des instructions spécifiques.
  • Page 11 D Porter un casque de soudage approuvé muni de verres filtrants DES PIÈCES CHAUDES peuvent approprié pour protéger visage et yeux pendant le soudage provoquer des brûlures graves. (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité). D Porter des lunettes de sécurité avec écrans latéraux même sous D Ne pas toucher à...

  • Page 12: Dangers Existant En Relation Avec Le Moteur

    D Placer les bouteilles debout en les fixant dans un support station- LES CHAMPS MAGNETIQUES peuvent naire ou dans un porte-bouteilles pour les empêcher de tomber ou affecter des implants médicaux. de se renverser. D Tenir les bouteilles éloignées des circuits de soudage ou autres D Porteur de simulateur cardiaque ou autre im- circuits électriques.

  • Page 13: Dangers Liés À L'air Comprimé

    L’utilisation d’un groupe autonome LA CHALEUR DU MOTEUR peut pro- à l’intérieur PEUT VOUS TUER EN voquer un incendie. QUELQUES MINUTES. D Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces inflammables. D Les fumées d’un groupe autonome contient du D Tenir à...
  • Page 14 UNE REMORQUE QUI BASCULE peut LE SURCHAUFFEMENT peut endom- entraîner des blessures. mager le moteur électrique. D Utiliser les supports de la remorque ou des D Arrêter ou déconnecter l’équipement avant de blocs pour soutenir le poids. démarrer ou d’arrêter le moteur. D Installer convenablement le poste sur la remor- D Ne pas laisser tourner le moteur trop lentement sous risque d’en- que comme indiqué...

  • Page 15: Proposition Californienne 65 Avertissements

    2-6. Proposition californienne 65 Avertissements Pour les moteurs à essence : Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques Les gaz d’échappement des moteurs contiennent des pro- dont l’État de Californie reconnaît qu’ils provoquent des mal- duits chimiques dont l’État de Californie reconnaît qu’ils formations congénitales et, dans certains cas, des cancers.

  • Page 16: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions Fast (Run, Weld/ Stop Engine Slow (Idle) Start Engine Power) Fast/Slow Battery (Engine) Circuit Protector Engine Oil (Run/Idle) Check Injectors/ Check Valve Protective Earth Fuel Pump Clearance (Ground) Certified/Trained Positive Negative Welding Arc Mechanic Amperes Volts...

  • Page 17: Section 4 − Specifications

    SECTION 4 − SPECIFICATIONS 4-1. Weld, Power, And Engine Specifications Maximum Open-Circuit Rated Welding Amperage Generator Power Engine Fuel Capacity Voltage DC Output Range Rating (Nominal) Deutz F3L-2011 400 A, Single-Phase, Air/Oil-Cooled, 40 Volts DC, 40 − 400 95 (90) 3 kVA/kW, 26 A, 11.3 gal (42.8 L) Three-Cylinder,...

  • Page 18: Fuel Consumption

    4-3. Fuel Consumption The curve shows typical fuel use under weld or power loads. SB-137 487-A 4-4. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- 40% Duty Cycle At 400 Amperes utes that unit can weld at rated load without overheating.

  • Page 19: Ac Generator Power

    4-5. AC Generator Power The ac power curve shows the gen- erator power in amperes available at the 120 and 240 volt receptacles. AC AMPERES IN 240V MODE AC AMPERES IN 120V MODE rsb3.1 2/92 − 206 031 4-6. Volt-Ampere Curves The volt-ampere curve shows the minimum and maximum voltage and amperage output capabilities of...

  • Page 20: Optional Three-Phase Generator Curves

    4-7. Optional Three-Phase Generator Curves The ac power curves show the gen- erator power in amperes available at the single-phase 120/240 volt or three-phase 240 volt terminals. A. 7.5 KVA/KW Single-Phase Generator (No Weld Load) B. 10 KVA/KW Three-Phase Generator (No Weld Load) AC AMPERES rsb13.1 12/94 - 134 636-A / 206 032 OM-130 098 Page 16...

  • Page 21: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Installing Welding Generator Always securely fasten welding generator onto transport vehicle or trailer and comply with all DOT and other applicable codes. Movement Always ground generator frame Do not lift unit from end. to vehicle frame to prevent elec- tric shock and static electricity hazards.

  • Page 22: Installing Muffler Pipe

    5-2. Installing Muffler Pipe Stop engine and let cool. Do not blow exhaust toward air cleaner or air intake. Top View Tools Needed: 1/2 in exh_pipe2 12/96 − 154 089-A / 154 611 / Ref. 206 030 5-3. Activating The Dry Charge Battery (If Applicable) Always wear a face shield, rubber gloves and protective clothing when working on a...

  • Page 23: Connecting The Battery

    5-4. Connecting The Battery Connect Negative (−) Cable Last. − Tools Needed: 1/2 in 156 011-A / Ref. 206 030 / S-0756 5-5. Engine Prestart Checks Check all fluids daily. Engine must be cold and on a level surface. Follow run-in procedure in engine manual.

  • Page 24: Installing Ether Cylinder (Optional Ether Starting Aid)

    5-6. Installing Ether Cylinder (Optional Ether Starting Aid) Stop engine. Improper handling or expo- sure to ether can harm your health. Follow manufactur- er’s safety instructions on cylinder. Do not use Ether Starting Aid while engine is running. Open side door(s). Ether Cylinder Nozzle Remove cover and clean cylinder...

  • Page 25: Connecting To Weld Output Terminals

    5-7. Connecting To Weld Output Terminals Stick And TIG Welding FCAW Welding For Stick welding Direct Current Electrode For FCAW welding Direct Current Elec- Positive (DCEP), connect electrode hold- trode Positive (DCEP), connect wire feed- er cable to Positive (+) terminal and work er cable to Positive (+) terminal and work cable to Negative (−) terminal.

  • Page 26: Selecting Weld Cable Sizes

    5-8. Selecting Weld Cable Sizes* Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding*** 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 100 ft (30 m) or Less (45 m) (60 m) (70 m) (90 m) (105 m)
  • Page 27 Notes MATERIAL THICKNESS GAUGE OM-130 098 Page 23...

  • Page 28: Section 6 − Operating The Welding Generator

    SECTION 6 − OPERATING THE WELDING GENERATOR 6-1. Controls (See Section 6-2) Ref. 206 030 / 800 162-A / 800 159-D OM-130 098 Page 24...

  • Page 29: Description Of Front Panel Controls (See Section 6-1)

    6-2. Description Of Front Panel Controls (See Section 6-1) (See Section 6-3) Light goes on if oil pressure is too low. If unit This unit has a max OCV control circuit has automatic shutdown option, light also Magnetic Shutdown Switch (Optional) that resets the Amperage/Voltage Con- goes on if oil temperature is too high.

  • Page 30: Section 7 − Operating Auxiliary Equipment

    SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. 120 Volt And 240 Volt Duplex Receptacles If unit does not have GFCI re- ceptacles, use GFCI-pro- tected extension cord. Generator power is not af- fected by weld output. If a supplementary protector continues to open, contact Factory Authorized Service Agent.

  • Page 31: Optional Generator Power Receptacles

    7-2. Optional Generator Power Receptacles If unit does not have GFCI re- ceptacles, use GFCI-pro- tected extension cord. Generator power is not af- fected by weld output. If a supplementary protector continues to open, contact Factory Authorized Service Agent. GFCI Receptacle Option 120 V 15 A AC GFCI Receptacle GFCI1 Generator power output and circuit...

  • Page 32: Connecting Optional Three-Phase Generator

    7-3. Connecting Optional Three-Phase Generator Stop engine. Power and weld outputs are live same time. Disconnect insulate unused cables. Have qualified person install according to circuit diagram and Generator Power Guide- lines (Section 11). Remove junction box cover. Lead 93 Lead 92 Lead 91 Lead 90 (Neutral)

  • Page 33: Section 8 − Maintenance And Troubleshooting

    SECTION 8 − MAINTENANCE AND TROUBLESHOOTING 8-1. Routine Maintenance Stop engine before maintaining. See Engine Manual and Maintenance Label Recycle engine for important start-up, service, and storage fluids. information. Service engine more often if used in severe conditions. n = Check Z = Change ~ = Clean l = Replace...

  • Page 34: Maintenance Label

    8-2. Maintenance Label OM-130 098 Page 30...

  • Page 35: Servicing Air Cleaner

    8-3. Servicing Air Cleaner Stop engine. NOTICE − Do not run engine without air cleaner or with dirty element. Engine damage caused by using a damaged element is not covered by the warranty. The air cleaner primary element can be cleaned but the dirt holding ca- pacity of the filter is reduced with each cleaning.

  • Page 36: Servicing Fuel And Lubrication Systems

    8-4. Servicing Fuel And Lubrication Systems Stop engine and let cool. Oil Filter Oil Drain Plug Oil Fill Cap Primary Fuel Filter (Fuel/ Water Separator) Petcock Secondary Fuel Filter Fuel Shutoff Valve Fuel Line Sludge Drain Plug To change oil and filter: See engine manual.

  • Page 37: Adjusting Engine Speed

    8-5. Adjusting Engine Speed 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. Turn Amperage/Voltage Control to 100. Standard Models: 1850 rpm 61.6 Hz Engine Speed Adjustment...

  • Page 38: Overload Protection

    8-6. Overload Protection Stop engine. When a fuse opens, it usually indicates a more serious prob- lem exists. Contact a Factory Authorized Service Agent. Magnetic Shutdown Switch MS1 (Optional) Fuse F (See Parts List) Fuse F protects magnetic shut- down switch MS1. If fuse F opens, the engine stops.

  • Page 39: Inspecting And Cleaning Optional Spark Arrestor

    8-8. Inspecting And Cleaning Optional Spark Arrestor Stop engine and let cool. Spark Arrestor Cleanout Plug Remove plug and remove any dirt covering cleanout hole. Exhaust Pipe Start engine and run at idle speed to blow out cleanout hole. If nothing blows out of hole, briefly cover end of exhaust pipe with fireproof material.

  • Page 40: Troubleshooting

    8-10. Troubleshooting A. Welding Trouble Remedy No weld output. Check position of Ampere Range switch. Check position of optional Polarity switch. Place A/V control switch in Panel position, or place switch in Remote position and connect Remote Am- perage control to Remote A/V receptacle RC3 (see Section 6-3). Check and secure connections to Remote A/V receptacle RC3.
  • Page 41 C. Engine Trouble Remedy Engine does not start. Check fuel level. Open fuel valve (see Section 5-5). Check optional Magnetic Shutdown switch fuse F and replace if open (see Section 8-6). Check battery and replace if necessary. Check connections to Engine Control switch. Check oil level.

  • Page 42: Section 9 − Electrical Diagram

    SECTION 9 − ELECTRICAL DIAGRAM SC-190 649-B Figure 9-1. Circuit Diagram For Welding Generator OM-130 098 Page 38...

  • Page 43: Section 10 − Run-In Procedure

    SECTION 10 − RUN-IN PROCEDURE run_in1 2007−04 10-1. Wetstacking NOTICE − Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur. Welding Generator Run diesel engines near rated volt- age and current during run-in period to properly seat piston rings and prevent wetstacking.

  • Page 44: Run-In Procedure Using Load Bank

    10-2. Run-In Procedure Using Load Bank Stop engine. Do not touch hot exhaust pipe, engine parts, or load bank/grid. Keep exhaust and pipe away from flammables. NOTICE − Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur.

  • Page 45: Run-In Procedure Using Resistance Grid

    10-3. Run-In Procedure Using Resistance Grid Stop engine. Do not touch hot exhaust pipe, engine parts, or load bank/grid. Keep exhaust and pipe away from flammables. NOTICE − Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur.

  • Page 46: Section 11 − Generator Power Guidelines

    SECTION 11 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown. 11-1. Selecting Equipment Generator Power Receptacles − Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment...
  • Page 47 11-3. Grounding When Supplying Building Systems Equipment Grounding Terminal Grounding Cable GND/PE Use #10 AWG or larger insulated copper wire. Ground Device Use ground device as stated in electrical codes. Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system.
  • Page 48 11-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1/8 HP 1/6 HP 1225 1/4 HP 1600 1/3 HP 2100 1/2 HP 3175 Capacitor Start-Induction Run 1/3 HP 2020 1/2 HP 3075 3/4 HP 4500 1400 1 HP...
  • Page 49 11-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1/4 in 3/8 in 1/2 in Circular Saw 6-1/2 in 7-1/4 in 8-1/4 in 1400 1400 Table Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in...
  • Page 50 11-8. Power Required To Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code KVA/HP 10.0 11.2 12.5 14.0 Motor Start Code Running Amperage Motor HP Motor Voltage AC MOTOR To find starting amperage: VOLTS AMPS Step 1: Find code and use table to CODE find kVA/HP.
  • Page 51 11-10. Typical Connections To Supply Standby Power Have only qualified persons perform these connections according to all applicable codes and safety practices. Fused Properly install and ground Welding Utility Disconnect this equipment according to Electrical Generator Transfer Switch Switch its Owner’s Manual and na- Output Service (If Required)
  • Page 52 11-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current Load (Watts) (Amperes) 350 (106) 225 (68) 137 (42)
  • Page 53 Notes OM-130 098 Page 49...

  • Page 54: Section 12 − Parts List

    SECTION 12 − PARTS LIST 71(Includes 72−77) 104(Fig.11−2) Figure 12-1. Main Assembly OM-130 098 Page 50...
  • Page 55 65 FIG 12-4 ST-801 653-H OM-130 098 Page 51...
  • Page 56 Item Dia. Part Description Quantity Mkgs. Figure 12-1. Main Assembly ....070 010 BOLT, J stl .250-20 x 2.750 ........
  • Page 57 Item Dia. Part Description Quantity Mkgs. Figure 12-1. Main Assembly (Continued) ....127 994 BALL JOINT, .250-28 ..........
  • Page 58 Item Dia. Part Description Quantity Mkgs. Figure 12-1. Main Assembly (Continued) ..044 588 RELAY, encl 12VDC 3PDT ........
  • Page 59 Part Description Quantity Optional Equipment ....043 096 RECEPTACLE KIT, 120V GFCI ........
  • Page 60 Fig 12-3 ST-801 652-B Figure 12-2. Panel, Front w/Components OM-130 098 Page 56...
  • Page 61 Item Dia. Part Description Quantity Mkgs. Figure 12-2. Panel, Front w/Components (Figure 12-1 Item 104) ....114 193 SWITCH, range (Fig 11-3) ........
  • Page 62 ST-110 922-D Figure 12-3. Generator OM-130 098 Page 58...
  • Page 63 Item Dia. Part Description Quantity Mkgs. Figure 12-3. Generator (Figure 12-1 Item 65) ....106 426 INSULATOR ............
  • Page 64 Item Part Description Quantity 114 193 Figure 12-4. Switch, Range (Figure 12-2 Item 1) ....114 235 BRACKET, mtg switch (consisting of) ........
  • Page 65 Notes Welding Symbols Ref. AWS/ANSI A2.4 OM-130 098 Page 61...
  • Page 66 Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge (.025 in) 22 Gauge (.031 in) 20 Gauge (.037 in) 18 Gauge (.050 in) 16 Gauge (.063 in) 14 Gauge (.078 in) 1/8 in (.125 in) 3/16 in (.188 in) 1/4 in (.25 in) 5/16 in (.313 in) 3/8 in (.375 in) 1/2 in (.5 in)
  • Page 67 Effective January 1, 2008 (Equipment with a serial number preface of LJ or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions...
  • Page 68 Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. © PRINTED IN USA 2008 Miller Electric Mfg. Co. 2008−01...

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