Miller Electric Big Blue 400 KX manual Compressed Air Hazards

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STEAM AND HOT COOLANT can burn.

DIf possible, check coolant level when engine is cold to avoid scalding.

D Always check coolant level at overflow tank, if pres- ent on unit, instead of radiator (unless told otherwise in maintenance section or engine manual).

DIf the engine is warm, checking is needed, and there is no overflow tank, follow the next two statements.

DWear safety glasses and gloves and put a rag over radiator cap.

DTurn cap slightly and let pressure escape slowly before completely re- moving cap.

ENGINE EXHAUST GASES can kill.

D Use equipment outside in open, well-ventilated ar- eas.

DIf used in a closed area, vent engine exhaust outside and away from any building air intakes.

BATTERY ACID can BURN SKIN and EYES.

DDo not tip battery.

DReplace damaged battery.

DFlush eyes and skin immediately with water.

ENGINE HEAT can cause fire.

DDo not locate unit on, over, or near combustible surfaces or flammables.

DKeep exhaust and exhaust pipes way from flam- mables.

EXHAUST SPARKS can cause fire.

DDo not let engine exhaust sparks cause fire.

DUse approved engine exhaust spark arrestor in re- quired areas — see applicable codes.

1-4. Compressed Air Hazards

BREATHING COMPRESSED AIR can cause serious injury or death.

DDo not use compressed air for breathing.

DUse only for cutting, gouging, and tools.

HOT METAL from air arc cutting and gouging can cause fire or explosion.

DDo not cut or gouge near flammables.

DWatch for fire; keep extinguisher nearby.

COMPRESSED AIR can cause injury.

DWear approved safety goggles.

DDo not direct air stream toward self or others.

HOT PARTS can cause burns and injury.

DDo not touch hot compressor or air system parts.

DLet system cool down before touching or servicing.

TRAPPED AIR PRESSURE AND WHIPPING HOSES can cause injury.

DRelease air pressure from tools and system before servicing, adding or changing attachments, or open- ing compressor oil drain or oil fill cap.

READ INSTRUCTIONS.

DRead Owner’s Manual before using or servicing unit.

DStop engine and release air pressure before servicing.

DUse only genuine Miller/Hobart replacement parts.

1-5. Additional Symbols For Installation, Operation, And Maintenance

FALLING UNIT can cause injury.

DUse lifting eye to lift unit and properly installed acces- sories only. Do not exceed maximum lift eye weight rating (see Specifications).

DLift and support unit only with proper equipment and correct procedures.

DIf using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.

OVERUSE can cause OVERHEATING.

DAllow cooling period; follow rated duty cycle.

DReduce current or reduce duty cycle before starting to weld again.

DDo not block or filter airflow to unit.

OVERHEATING can damage motors.

DTurn off or unplug equipment before starting or stop- ping engine.

DDo not let low voltage and frequency caused by low engine speed damage electric motors.

DDo not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable.

FLYING SPARKS can cause injury.

DWear a face shield to protect eyes and face.

D Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection.

DSparks can cause fires — keep flammables away.

STATIC (ESD) can damage PC boards.

DPut on grounded wrist strap BEFORE handling boards or parts.

DUse proper static-proof bags and boxes to store, move, or ship PC boards.

TILTING OF TRAILER can cause injury.

DUse tongue jack or blocks to support weight.

DProperly install welding generator onto trailer accord- ing to instructions supplied with trailer.

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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 Directives StandardsDecrot6/05 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− Definitions − 50 h StdStd Manufacturer’s Rating Label Symbols And Definitions − Specifications Weld, Power, And Engine 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 Installing Exhaust Pipe Tools Needed 1/2Stop 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 hoseInspecting And Cleaning Spark Arrestor Muffler Stop engine and let cool. Reinstall cleanout plugServicing 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 BrushesVoltmeter/Ammeter Help Displays Help 20 DisplayHelp 25 Display Troubleshooting Standard Generator PowerWelding Engine Check for obstructed throttle solenoid Circuit Diagram For Welding Generator − Electrical Diagrams221 499-B − RUN-IN Procedure WetstackingWelding 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-in− Generator Power Guidelines Selecting EquipmentGrounding 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 Service Your distributor also givesSupport 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