Miller Electric Big Blue 400 KX manual From Miller to You

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Miller is the first welding equipment manufacturer in the U.S.A. to be registered to the ISO 9001:2000 Quality System Standard.

From Miller to You

Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. 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. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy.

Today, the people that build and sell Miller products continue the tradition. They’re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929.

This Owner’s Manual is designed to help you get the most out of your Miller products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite.

We’ve made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there’s a Troubleshooting section that will help you figure out what the problem is. The parts list will then help you to decide the exact part you may need to fix the problem. Warranty and 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 specification sheets. To locate your nearest distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web.

Mil_Thank 4/05

Working as hard as you do

−every power source from Miller is backed by the most hassle-free warranty in the business.

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Contents Description OM-4423 215 178NProcesses File Engine DriveFrom Miller to You Table of Contents − Maintenance & Troubleshooting 8-1. Routine Maintenance Decrot6/05 DirectivesStandards Sound Level Information Decrotsound1/05Symbol Usage Arc Welding HazardsEngine Hazards Compressed Air Hazards EMF Information Principal Safety StandardsCalifornia Proposition 65 Warnings Radiation can cause interferenceUN Choc Électrique peut tuer Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation LES Fumées ET LES GAZ peuvent être dangereuxDES Pièces Chaudes peuvent provoquer des brûlures graves LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux LE Bruit peut affecter l’ouïeLE Surchauffement peut endom- mager le moteur électrique ’AIR Comprimé peut provoquer des blessures’EMPLOI Excessif peut LES Étincelles Volantes risquent de provoquer des blessuresPour les moteurs diesel LE Soudage À L’ARC risque de provoquer des interférencesPour les moteurs à essence Boulevard, Rexdale, Ontario, Canada M9W 1R3 téléphoneStd − Definitions− 50 h Std Manufacturer’s Rating Label Symbols And Definitions Dimensions, Weights, And Operating Angles − SpecificationsWeld, Power, And Engine Specifications TIG Mode Stick ModeMIG Mode Volt-Ampere CurvesFuel Consumption Curve shows typical fuel use under weld or power loadsExceeding duty cycle can damage unit and void warranty Duty Cycle And OverheatingAC Generator Power Curve Ac power curve shows the gen- erator power in amperes− Installation Installing Welding GeneratorMounting Welding Generator Stop engine and let cool Installing Exhaust PipeTools Needed 1/2 Do not overfill battery cells Activating The Dry Charge Battery If ApplicableConnecting The Battery Connect Negative − Cable LastFuel Do not use gasoline. Gasoline will damage engine Coolant Recovery TankEngine Prestart Checks OilMIG and Fcaw Welding Connecting To Weld Output TerminalsStick and TIG Welding Stop engine350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Selecting Weld Cable Sizes150 ft 200 ft 250 ft Stop engine beforeConnecting To Remote 14 Receptacle RC14 SocketFront Panel Controls See Section StopDescription Of Front Panel Controls See Section Process/Contactor Switch On CC/CV Models Process/Contactor Switch SettingsDo not Strike Like a Match Lift-ArcStart ProcedureLift-Arc Start Method Touch Lift-Arc t TIGRemote Voltage/Amperage Control − Operating Auxiliary Equipment Volt Receptacles− Maintenance & Troubleshooting Routine MaintenanceMaintenance Label To clean air filter Servicing Air CleanerBy the warranty Do not clean housing with air hoseServicing Engine Cooling System Inspecting And Cleaning Spark Arrestor MufflerStop engine and let cool. Reinstall cleanout plug Adjusting Engine Speed On Standard Models MaximumTo change oil and filter Servicing Fuel And Lubrication SystemsStop engine and let cool After servicing, start engine To replace primary canister fuel filterPress button to reset breaker Overload ProtectionChecking Generator Brushes Replace Damaged BrushesHelp 25 Display Voltmeter/Ammeter Help DisplaysHelp 20 Display Welding TroubleshootingStandard Generator Power Engine Check for obstructed throttle solenoid − Electrical Diagrams Circuit Diagram For Welding Generator221 499-B Welding Generator − RUN-IN ProcedureWetstacking Stop engine Do not touch hot exhaust Run-In Procedure Using Load BankProcedure at less than From flammables Do not PerformFrom flammables Run-In Procedure Using Resistance GridBank/grid Do not perform run-inGrounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesSelecting Equipment Earth ground if supplying Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Amperes x Volts = WattsIndustrial Motors Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsSingle-Phase Induction Motor Starting Requirements Power Required To Start MotorHow Much Power Can Generator Supply? KVA/HP x HP x 1000 = Starting AmperageTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Current Load Watts Amperes− Parts List 103 − −5 104 − −3 96− −2 102 101 10071− −4 3031 5756Dia Part Description Quantity Mkgs Dia Part Description Quantity 213600 Panel, Front w/Components Panel, Front w/Components -1ItemFUEL/HM Control Panel Generator Generator -1ItemRectifier Assembly Wiring Harnesses Support ServiceYour distributor also gives For assistance in filing or settling claims, contact To locate a Distributor or Service Agency visitMiller Electric Mfg. Co Your distributor and/or equipment manufacturer’s