Instruction/ maintenance manual of the product Big Blue 400 KX Miller Electric
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Big Blue 400 KX OM -4423 215 178N September 2005 Pro cesses Descrip tio n Air Carbon Arc (CAC-A) Cutting and Gouging Stick (SMAW ) W elding Engine Driven Welding Generator TIG (GT A W ) W elding MIG (GMAW) W elding Flux Cored (FCA W ) W elding ) Visit our website at www.
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. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .
T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T ABLE OF CONTENTS SECTION 8 − MAINTENANCE & TROUBLESHOOTING 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. Routine Maintenance 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
dec_rot_6/05 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). NOTE Manufacturer : European Contact: Miller Electric Mg. Co. Mr . Danilo Fedolfi, 1635 W .
dec_rotsound_1/05 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). NOTE Manufacturer : European Contact: Notified Body: Miller Electric Mg. Co. Mr .
OM-4423 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom _nd_3/05 W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.
OM-4423 Page 2 W elding 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. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire.
OM-4423 Page 3 STEAM AND HOT COOLANT can burn. If possible, check coolant level when engine is cold to avoid scalding. Always check coolant level at overflow tank, if pres- ent on unit, instead of radiator (unless told otherwise in maintenance section or engine manual).
OM-4423 Page 4 READ INSTRUCTIONS. Use only genuine MILLER/Hobart replacement parts. Perform engine and air compressor (if applicable) maintenance and service according to this manual and the engine/air compressor (if applicable) manu- als. H. F .
OM-4423 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION rom_fre 3/05 Avertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions.
OM-4423 Page 6 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.
OM-4423 Page 7 Si le moteur est chaud et que le liquide doit être vérifié, opérer comme suivant. Mettre des lunettes de sécurité et des gants, placer un torchon sur le bouchon du radiateur . Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant d’enle- ver le bouchon.
OM-4423 Page 8 LIRE LES INSTRUCTIONS. Utiliser seulement les pièces de rechange d’origine. Ef fectuer la maintenance du moteur et du compresseur (s i applicable) suivant ce manuel et le manuel du moteur/ compresseur (si applicable). LE RA YONNEMENT HAUTE FRÉ- QUENCE (H.
OM-4423 Page 9 SECTION 3 − DEFINITIONS 3-1. W arning Label Definitions 3/96 1 Remove unit from shipping crate. Remove Owner’s Manual from unit. Follow instructions to install muf fler . 2 Read Owner ’s Manual. Read labels on unit. 3 Use Diesel Fuel only , and fill fuel tank.
OM-4423 Page 10 3-2. Manufacturer ’ s Rating Label 218 449 − C.
OM-4423 Page 1 1 3-3. Symbols And Definitions Some symbols are found only on CE products. NOTE Stop Engine Fast (Run, Weld/ Power) Slow (Idle) Start Engine Starting Aid (Preheat) Battery (Engine) Engi.
OM-4423 Page 12 SECTION 4 − SPECIFICA TIONS 4-1. W eld, Power , And Engine Specifications W elding Mode W eld Output Range Rated W elding Output Maximum Open- Circuit V oltage Generator Power Rating.
OM-4423 Page 13 4-3. V olt-Ampere Curves 217 517 / 217 516 / 217 518 The volt-ampere curves show the minimum and maximum voltage an d amperage output capabilities of th e welding generator . Curves of al l other settings fall between the curves shown.
OM-4423 Page 14 4-4. Fuel Consumption The curve shows typical fuel use under weld or power loads. 217 509 ID L E DC WELD AMPERES A T 100% DUTY CYCLE U.S. GAL/HR. 0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 0 50 100 150 200 250 300 350 400 Continuous W elding 4-5.
OM-4423 Page 15 4-6. AC Generator Power Curve 220 346 − B Th e ac power curve shows the gen- erator power in amperes. AC AMPERES IN 1 10V MODE AC AMPERES IN 220V MODE AC VOL TS 0 20 40 60 80 100 120 140 0 1 0 2 03 04 0 5 0 6 0 7 0 0 20 40 60 80 100 120 0 40 80 120 160 200 240 Notes 16 Gauge (.
OM-4423 Page 16 SECTION 5 − INST ALLA TION install3 6/05 − Ref. 800 652 / Ref. 800 477-A / 803 274 Always securely fasten weld- ing generator onto transport vehicle or trailer and comply with all DOT and other applica- ble codes. Always ground generator frame to vehicle frame to pre- vent electric shock and static electricity hazards.
OM-4423 Page 17 5-2. Mounting Welding Generator T ools Needed: 9/16 in 2 2 3 4 W elding Unit In Place Bolting Unit In Place Do not weld on base. W eld- ing on base can cause fuel tank fire or explosion. Weld only on the four mounting brackets or bolt unit down.
OM-4423 Page 18 5-3. Installing Exhaust Pipe 1/2 in T ools Needed: 803 582 − B / Ref. 217 358-B Stop engine and let cool. Point exhaust pipe in desired di- rection but always away from front panel and direction of travel. Notes W or k l i k e a Pr o ! Pros wel d and cut safel y .
OM-4423 Page 19 5-4. Activating The Dry Charge Battery (If Applicable) Always wear a face shield, rubber gloves and protective clothing when working on a battery . Remove battery from unit. 5 V ent Caps 6 Sulfuric Acid Electrolyte (1.265 Specific Gravity) 7 W ell Fill each cell with electrolyte to bottom of well (maximum).
OM-4423 Page 20 5-6. Engine Prestart Checks Check all engine fluids daily . Engine must be cold and on a level surface. Unit is shipped with 20W break-in oil. Automatic shutdown system stops engine if oil pressure is too low or coolant tempera- ture is too high.
OM-4423 Page 21 5-7. Connecting T o W eld Output T erminals MIG and FCA W W elding For MIG and FCAW welding Direct Current Electrode Positive (DCEP , connect wire feed- er cable to CV (Wire) terminal on right and work cable to W ork/Negative ( − ) terminal on left.
OM-4423 Page 22 5-8. Selecting W eld Cable Sizes* W eld Cable Size** and T otal Cable (Copper) Length in Weld Circuit Not Exceeding*** 100 ft (30 m) or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft (105 m) 400 ft (120 m) W eld Output T erminals Stop engine before connecting t o weld out- put terminals.
OM-4423 Page 23 5-9. Connecting T o Remote 14 Receptacle RC14 Socket* Socket Information 24 VOL TS AC A 24 volts ac. Protected by circuit breaker CB8. 24 VOL TS AC B Contact closure to A completes 24 volt ac contactor control circuit. C Output to remote control:+10 volts dc in MIG mode; 0 to +10 volts dc in Stick or TIG mode.
OM-4423 Page 24 SECTION 6 − OPERA TING WELDING GENERA TOR 6-1. Front Panel Controls (See Section 6-2) 217 358-B / 803 576 − C 1 25 4 67 8 9 1 0 3 Stop.
OM-4423 Page 25 6-2. Description Of Front Panel Controls (See Section 6-1 ) Engine Starting Controls 1 Preheat Switch Use switch to energize starting aid for cold weather starting (see starting instructions fol- lowing). 2 Engine Control Switch Use switch to start engine, select engine speed (if unit has auto idle option), and stop engine.
OM-4423 Page 26 6-3. Process/Contactor Switch On CC/CV Models 1 Process/Contactor Switch W eld output terminals are ener- gized when Process/Contactor switch is in a Weld T erminals Al- ways On position and the engine is running. Use switch to select weld process and weld output on/off control (see table be- low).
OM-4423 Page 27 6-4. Lift-Arc ™ Start Procedure Lift-Arc TIG With Lift-Arc TIG selected, start arc as follows: 1 TIG Electrode 2 W orkpiece T urn gas on. T ouch tungsten electrode to workpiece at weld start point. Hold electrode to workpiece for 1-2 seconds , and slowly lift electrode.
OM-4423 Page 28 6-5. Remote V oltage/Amperage Control 1 Remote 14 Receptacle RC14 Connect optional remote control to RC14 (see Section 5-9). When a remote control is connected to the Remote receptacle, the Auto Sense Re- mote feature automatically switches volt- age/amperage control to the remote con- trol.
OM-4423 Page 29 SECTION 7 − OPERA TING AUXILIAR Y EQUIPMENT 7-1. 1 10 V olt Receptacles Ref. 217 358-B 1 1 10/55V 32 A AC Receptalce RC1 1 2 1 10/55V 16A AC Receptacle RC12 Receptacles RC 1 1 and RC12 supply 60 Hz single-phase power at weld/power speed.
OM-4423 Page 30 SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Routine Maintenance Stop engine before maintaining. S ee Engine Manual and Maintenance Label for important start-up, service, and storage information. Service engine more often if used in severe conditions.
OM-4423 Page 31 8-2. Maintenance Label 5 5 5 5 5 5.
OM-4423 Page 32 8-3. Servicing Air Cleaner Stop engine. Do not run engine without air cleaner or with dirty element. En- gine 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 capac- ity of the filter is reduced with each cleaning.
OM-4423 Page 33 8-4. Inspecting And Cleaning Spark Arrestor Muffler 803 582 / Ref. 217 358-B Stop engine and let cool. 1 Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole. 3 Exhaust Pipe Start engine and run at idle speed to blow out cleanout hole.
OM-4423 Page 34 8-6. Adjusting Engine Speed On Standard Models Ref. 803 576 − C 3 2 1 RPM (Hz) Engine Speed (No Load) W eld/Power 1880 (61.7) Maximum Stop engine and let cool. Engine speed is factory set and should not require adjustment. Af- ter tuning engine, check engine speed with tachometer or frequen- cy meter .
OM-4423 Page 35 8-7. Servicing Fuel And Lubrication Systems Ref. 217 − 358 − B / 802 490 / 803 576 − C Stop engine and let cool. After servicing, start engine and check for fuel leaks. Stop engine, tighten connec- tions as necessary , and wipe up spilled fuel.
OM-4423 Page 36 8-8. Overload Protection Ref. 217 358 − B / 803 580 / 803 576 − C Stop engine. When a circuit breaker or fuse opens, it usually indicates a more serious problem exists. Contact Factory Authorized Service Agent. 1 Fuse F1 F1 protects the stator exciter wind- ing from overload.
OM-4423 Page 37 8-9. Checking Generator Brushes Ref 21 14 778 − D / S − 0233 − A Stop engine and let cool. 1 Generator Brush With Spring Mark and disconnect leads at brush hold- er cap. Remove brushes. Replace brushes if damaged or if brush material is at o r near minimum length.
OM-4423 Page 38 8-10. V oltmeter/Ammeter Help Displays Use the V oltmeter/Ammeter help displays to diagnose and correct fault conditions. When a help code is displayed normally weld output has stopped but generator power output may be okay . T o reset help displays, stop unit and then restart.
OM-4423 Page 39 8-1 1. T roubleshooting Also see V oltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 8-10). Note A.
OM-4423 Page 40 T rouble Remedy Check fuse F1, and replace if open (see Section 8 - 8). Have Factory Authorized Service Agent check vol- tage regulator module PC3. Reset circuit breaker CB3 (see Section 8-8). Check V oltmeter/Ammeter help displays (see Section 8-10 ).
OM-4423 Page 41 T rouble Remedy Battery discharges between uses. Turn Engine Control switch of f when unit is not running. Clean top of battery with baking soda and water solution; rinse with clear water . Recharge or replace battery if necessary . Periodically recharge battery (approximately every 3 months).
OM-4423 Page 42 SECTION 9 − ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For Welding Generator.
OM-4423 Page 43 221 499-B.
OM-4423 Page 44 SECTION 10 − RUN-IN PROCEDURE run_in1 8/01 10-1. W etstacking Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur .
OM-4423 Page 45 10-2. Run-In Procedure Using Load Bank S-0683 Stop engine. Do not touch hot exhaust pipe, engine parts, or load bank/grid. Keep exhaust and pipe away from flammables. Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur .
OM-4423 Page 46 10-3. Run-In Procedure Using Resistance Grid S-0684 Stop engine. Do not touch hot exhaust pipe, engine parts, or load bank/grid. Keep exhaust and pipe away from flammables. Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur .
OM-4423 Page 47 SECTION 1 1 − GENERA TOR 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. NOTE 1 1-1. Selecting Equipment gen_pwr 1 1/02 − Ref.
OM-4423 Page 48 1 1-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 AWG or larger insulated copper wire. 3 Ground Device Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system.
OM-4423 Page 49 1 1-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Star ting W atts Running W atts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 2.
OM-4423 Page 50 1 1-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running W atts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/.
OM-4423 Page 51 1 1-8. Power Required T o Start Motor S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor V oltage T o find starting amperage: Step 1: Find code and use table to find kV A/HP . If code is not listed, multiply running amperage by six to find starting amperage.
OM-4423 Page 52 1 1-10. T ypical Connections T o Supply Standby Power Have only qualified persons perform these connections according to all applicable codes and safety practic- es. Properly install and ground this equipment according to its Owner’ s Manual and national, state, and local codes.
OM-4423 Page 53 1 1-1 1. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 V olt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord.
OM-4423 Page 54 SECTION 12 − P ARTS LIST Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. 1 − Fig.12 − 3 2 7 3 − Fig.12 − 5 4 6 8 9 5 10 11 12 14 15 13 16 17 102 100 99 18 19 20 21 22 23 90 91 83 82 81 80 79 84 85 89 88 87 86 93 94 95 98 96 − Fig.
OM-4423 Page 55 803 830 − D 55 72 74 73 75 76 77 78 71 − Fig.12 − 4 69 68 67 66 65 63 55 57 56 59 58 62 61 60 36 37 38 39 40 41 32 43 44 48 49 50 51 45 52 53 54 47 46 45 33 34 35 32 31 30 29 28 .
OM-4423 Page 56 Description Part No. Dia. Mkgs. Item No. Figure 12-1. Main Assembly Quantity 1 Figure 12-3 Control Panel 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-4423 Page 57 Description Part No. Dia. Mkgs. Item No. Figure 12-1. Main Assembly (Continued) Quantity 191626 Bumper , Door Engine Access 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-4423 Page 58 Description Part No. Dia. Mkgs. Item No. Figure 12-1. Main Assembly (Continued) Quantity 213600 Screw , 500 − 13x3.00 Hex Flange − hd Gr8 Pln 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-4423 Page 59 Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. 803 831 − A 1 2 3 4 5 6 37 36 7 8 9 10 11 12 13 14 15 16 17 18 19 31 32 33 34 35 29 30 25 20 21 22 24 26 27 28 23 Figure 12-2.
OM-4423 Page 60 Description Part No. Dia. Mkgs. Item No. Figure 12-2. Panel, Front w/Components (Continued) Quantity 10 214543 Enclosure, Circuit Card Assy 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-4423 Page 61 Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. 803 798 − D 1 2 3 5 6 8 9 10 7 4 Figure 12-3. Control Panel Description Part No. Dia. Mkgs. Item No. Figure 12-3. Control Panel (Figure 12-1 Item 1) Quantity 1 220981 Bracket, Mtg Components 1 .
OM-4423 Page 62 803 857 − A Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. 2 3 1 4 5 6 7 8 9 10 11 12 13 14 19 20 18 15 17 16 Figure 12-4. Generator Description Part No. Dia. Mkgs. Item No.
OM-4423 Page 63 803 685-A Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. 1 2 3 6 4 5 9 8 10 7 Figure 12-5. Rectifier Assembly Description Part No. Dia. Mkgs. Item No. Figure 12-5. Rectifier Assembly (Figure 12-1 Item 3) Quantity 217081 Rectifier , Assembly (Includes) 1 .
OM-4423 Page 64 Some wiring harness components (switches, relays, circuit breakers) are also referenced elsewhere in this parts list. Purchase components separately or as part of the associated wiring harness. Note Description Part No. Dia. Mkgs. Item No.
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 1/05 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor .
PRINTED IN USA © 2005 Miller Electric Mfg. Co. 1/05 Miller Elect ric Mfg. Co. An Illinois T ool W orks Compan y 1635 West S pencer St reet Applet on, WI 54914 USA International He adquarters − US A.
An important point after buying a device Miller Electric Big Blue 400 KX (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Miller Electric Big Blue 400 KX yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Miller Electric Big Blue 400 KX - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Miller Electric Big Blue 400 KX you will learn all the available features of the product, as well as information on its operation. The information that you get Miller Electric Big Blue 400 KX will certainly help you make a decision on the purchase.
If you already are a holder of Miller Electric Big Blue 400 KX, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Miller Electric Big Blue 400 KX.
However, one of the most important roles played by the user manual is to help in solving problems with Miller Electric Big Blue 400 KX. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Miller Electric Big Blue 400 KX along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
