Miller Electric Big Blue 400 KX manual OM-4423 215 178N, Processes, Description

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OM-4423 215 178N

September 2005

Processes

Stick (SMAW) Welding

TIG (GTAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Air Carbon Arc (CAC-A)

Cutting and Gouging

Description

Engine Driven Welding Generator

Big Blue) 400 KX

File: Engine Drive

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Contents Processes OM-4423 215 178NDescription File Engine DriveFrom Miller to You Table of Contents − Maintenance & Troubleshooting 8-1. Routine Maintenance Standards DirectivesDecrot6/05 Decrotsound1/05 Sound Level InformationArc Welding Hazards Symbol UsageEngine Hazards Compressed Air Hazards California Proposition 65 Warnings Principal Safety StandardsEMF Information Radiation can cause interference− Consignes DE Sécurité − Lire Avant Utilisation Signification des symbolesUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereuxDES Particules Volantes peuvent blesser les yeux LE Soudage peut provoquer un in- cendie ou une explosionDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut affecter l’ouïe’EMPLOI Excessif peut ’AIR Comprimé peut provoquer des blessuresLE Surchauffement peut endom- mager le moteur électrique LES Étincelles Volantes risquent de provoquer des blessuresPour les moteurs à essence LE Soudage À L’ARC risque de provoquer des interférencesPour les moteurs diesel Boulevard, Rexdale, Ontario, Canada M9W 1R3 téléphone− 50 h Std − DefinitionsStd Manufacturer’s Rating Label Symbols And Definitions Weld, Power, And Engine Specifications − SpecificationsDimensions, Weights, And Operating Angles MIG Mode Stick ModeTIG Mode Volt-Ampere CurvesExceeding duty cycle can damage unit and void warranty Curve shows typical fuel use under weld or power loadsFuel Consumption Duty Cycle And OverheatingAc power curve shows the gen- erator power in amperes AC Generator Power CurveInstalling Welding Generator − InstallationMounting Welding Generator Tools Needed 1/2 Installing Exhaust PipeStop engine and let cool Connecting The Battery Activating The Dry Charge Battery If ApplicableDo not overfill battery cells Connect Negative − Cable LastEngine Prestart Checks Coolant Recovery TankFuel Do not use gasoline. Gasoline will damage engine OilStick and TIG Welding Connecting To Weld Output TerminalsMIG and Fcaw Welding Stop engine150 ft 200 ft 250 ft Selecting Weld Cable Sizes350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Stop engine beforeSocket Connecting To Remote 14 Receptacle RC14Stop Front Panel Controls See SectionDescription Of Front Panel Controls See Section Process/Contactor Switch Settings Process/Contactor Switch On CC/CV ModelsLift-Arc Start Method Touch Lift-ArcStart ProcedureDo not Strike Like a Match Lift-Arc t TIGRemote Voltage/Amperage Control Volt Receptacles − Operating Auxiliary EquipmentRoutine Maintenance − Maintenance & TroubleshootingMaintenance Label By the warranty Servicing Air CleanerTo clean air filter Do not clean housing with air hoseStop engine and let cool. Reinstall cleanout plug Inspecting And Cleaning Spark Arrestor MufflerServicing Engine Cooling System Maximum Adjusting Engine Speed On Standard ModelsStop engine and let cool After servicing, start engine Servicing Fuel And Lubrication SystemsTo change oil and filter To replace primary canister fuel filterOverload Protection Press button to reset breakerReplace Damaged Brushes Checking Generator BrushesHelp 20 Display Voltmeter/Ammeter Help DisplaysHelp 25 Display Standard Generator Power TroubleshootingWelding Engine Check for obstructed throttle solenoid Circuit Diagram For Welding Generator − Electrical Diagrams221 499-B Wetstacking − RUN-IN ProcedureWelding Generator Procedure at less than Run-In Procedure Using Load BankStop engine Do not touch hot exhaust From flammables Do not PerformBank/grid Run-In Procedure Using Resistance GridFrom flammables Do not perform run-inSelecting Equipment − Generator Power GuidelinesGrounding Generator To Truck Or Trailer Frame How Much Power Does Equipment Require? Grounding When Supplying Building SystemsEarth ground if supplying Amperes x Volts = WattsApproximate Power Requirements For Farm/Home Equipment Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentHow Much Power Can Generator Supply? Power Required To Start MotorSingle-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 = Starting AmperageTypical Connections To Supply Standby Power Current Load Watts Amperes Selecting Extension Cord Use Shortest Cord Possible103 − −5 104 − −3 96− −2 102 101 100 − Parts List3031 5756 71− −4Dia Part Description Quantity Mkgs Dia Part Description Quantity 213600 Panel, Front w/Components -1Item Panel, Front w/ComponentsFUEL/HM Control Panel Generator -1Item GeneratorRectifier Assembly Wiring Harnesses Your distributor also gives ServiceSupport Miller Electric Mfg. Co To locate a Distributor or Service Agency visitFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s