Miller Big Blue 400D Owner's Manual
  1. Manuals
  2. Brands
  3. Miller Manuals
  4. Welding System
  5. Big Blue 400D
  6. Owner's manual

Miller Big Blue 400D Owner's Manual

Hide thumbs Also See for Big Blue 400D:
Table of Contents

Advertisement

Quick Links

See also: Owner's Manual
Visit our website at
www.MillerWelds.com
Big Blue 400D
OM-463
December 1998
Processes
Stick (SMAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
With Optional Equipment:
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Engine Driven Welding Generator
R
081 902AD

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Big Blue 400D and is the answer not in the manual?

Questions and answers

Related Manuals for Miller Big Blue 400D

Summary of Contents for Miller Big Blue 400D

  • Page 1 OM-463 081 902AD December 1998 Processes Stick (SMAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging With Optional Equipment: MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Engine Driven Welding Generator Big Blue 400D Visit our website at www.MillerWelds.com...
  • Page 2 This Owner’s Manual is designed to help you get the most out of your do − every power source from Miller is backed by Miller products. Please take time to read the Safety precautions. They will the most hassle-free war- help you protect yourself against potential hazards on the worksite. We’ve ranty in the business.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ......1-1. Symbol Usage .

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

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING rom _nd_5/97 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Y Marks a special safety message.

  • Page 6: Engine Hazards

    WELDING can cause fire or explo- HOT PARTS can cause severe burns. sion. D Allow cooling period before maintaining. Welding on closed containers, such as tanks, D Wear protective gloves and clothing when drums, or pipes, can cause them to blow up. Sparks working on a hot engine.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    READ INSTRUCTIONS. stopping engine. D Do not let low voltage and frequency caused by D Use only genuine MILLER replacement parts. low engine speed damage electric motors. D Perform engine maintenance and service D Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle according to this manual and the engine where applicable.

  • Page 8: Principal Safety Standards

    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 communications equipment. computers and computer-driven equipment D Have only qualified persons familiar with such as robots.

  • Page 9: Section 1 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 1 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION rom _nd_fre 5/97 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Y Identifie un message de sécurité...

  • Page 10: Dangers Existant En Relation Avec Le Moteur

    LE SOUDAGE peut provoquer un in- DES PIÈCES CHAUDES peuvent cendie ou une explosion. provoquer des brûlures graves. D Prévoir une période de refroidissement avant d’effec- Le soudage effectué sur des conteneurs fermés tels que tuer des travaux d’entretien. des réservoirs, tambours ou des conduites peut provoquer D Porter des gants et des vêtements de protection pour leur éclatement.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    électrique à cause d’une tension et d’une fréquence trop faibles. MILLER. D Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz, s’il y a D Effecteur la maintenance et la mise en service lieu.

  • Page 12: Principales Normes De Sécurité

    LE RAYONNEMENT HAUTE FRÉ- LE SOUDAGE À L’ARC risque de QUENCE (H.F.) risque de provoquer provoquer des interférences. des interférences. D L’énergie électromagnétique risque de provoquer des interférences pour l’équipement électronique D Le rayonnement haute fréquence (H.F.) peut sensible tel que les ordinateurs et l’équipement com- provoquer des interférences avec les équipements mandé...

  • Page 13: Section 2 − Definitions

    SECTION 2 − DEFINITIONS 2-1. Symbols And Definitions Stop Engine Start Engine Ether Starting Aid Engine Do Not Switch Battery (Engine) Circuit Breaker Engine Oil While Welding Check Injectors/ Check Valve Protective Earth Fuel Pump Clearance (Ground) Certified/Trained Positive Negative Welding Arc Mechanic Amperes...

  • Page 14: Dimensions, Weights, And Operating Angles

    3-2. Dimensions, Weights, And Operating Angles Dimensions Height 47-5/8 in (1210 mm) Width 31-1/4 in (794 mm) Y Do not exceed operating angles while run- Y Do not exceed operating angles while run- Engine End Depth 60-1/2 in (1537 mm) ning or engine damage will occur.

  • Page 15: Duty Cycle And Overheating

    3-4. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- 100% Duty Cycle At 400 Amperes utes that unit can weld at rated load without overheating. Y Exceeding duty cycle can damage unit void warranty. Continuous Welding rduty1 5/95 − SB-053 147-C 3-5.

  • Page 16: Volt-Ampere Curves

    3-6. Volt-Ampere Curves The volt-ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the A. CC/DC (Standard) curves shown. B. CV/DC (Models With CV Option) ST-183 880-A / ST-186 173-A OM-463 Page 12...

  • Page 17: Optional Ac Power Plant Curves For Standard (Cc) Models

    3-7. Optional AC Power Plant Curves For Standard (CC) Models The ac power curves show the aux- iliary power in amperes available at the single-phase 120/240 volt or A. 7.5 KVA/KW Single-Phase Auxiliary Power Plant (No Weld Load) three-phase 240 volt terminals. B.

  • Page 18: Optional Ac Power Plant Curves For Cv Models

    3-8. Optional AC Power Plant Curves For CV Models The ac power curves show the aux- iliary power in amperes available at the single-phase 120/240 volt or A. 10 KVA/KW Single-Phase Auxiliary Power Plant (No Weld Load) three-phase 240 volt terminals. B.

  • Page 19: Section 4 − Installation

    SECTION 4 − INSTALLATION 4-1. Installing Welding Generator Movement Airflow Clearance Location Y Do Not Lift Unit From End 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) 18 in 18 in (460 mm) (460 mm) Grounding Generator Base Metal Vehicle Frame Equipment Grounding...

  • Page 20: Installing Exhaust Pipe

    4-3. Installing Exhaust Pipe Y Stop engine and let cool. Y Do not blow exhaust toward air cleaner or air intake. Top View Tools Needed: 1/2 in exh_pipe2 4/96 − ST-154 089-A / ST-154 611 / ST-180 933-B 4-4. Engine Prestart Checks Check all fluids daily.

  • Page 21: Connecting To Weld Output Terminals

    4-5. Connecting To Weld Output Terminals Open left side door. Bracket Route cables through bracket. Positive (+) Weld Output Terminal Negative (−) Weld Output Ter- minal For Stick welding Direct Current Electrode Positive (DCEP), con- nect work cable to − terminal and electrode holder cable to + terminal.

  • Page 22: Installing Ether Cylinder (Optional Ether Starting Aid)

    4-7. Installing Ether Cylinder (Optional Ether Starting Aid) Y Stop engine. Y Improper handling or expo- sure to ether can harm your health. Follow manufactur- er’s safety instructions on cylinder. Y Do not use Ether Starting Aid while engine is running. Open side door(s).

  • Page 23: Remote 14 Receptacle Rc3 Information (Models With Cv Option)

    4-9. Remote 14 Receptacle RC3 Information (Models With CV Option) Socket* Socket Information 24 volts ac. Protected by circuit breaker CB4. Contact closure to A completes 24 C L N volts ac contactor control circuit. 115 volts ac. Protected by circuit breaker CB3.

  • Page 24: Section 5 − Operating The Welding Generator

    SECTION 5 − OPERATING THE WELDING GENERATOR 5-1. Standard Controls (See Section 5-2) ST-158 630-B / Ref. ST-158 631 / ST-180 933-B OM-463 Page 20...

  • Page 25: Description Of Standard Controls (See Section 5-1)

    5-2. Description Of Standard Controls (See Section 5-1) would be 223 A DC with controls set as shown Do not crank engine while engine is turning. This unit has a max OCV control circuit (50% of 125 to 320 A). that resets the Amperage/Voltage Con- To Stop: Pull control out and hold.

  • Page 26: Controls For Models With Cv Option (See Section 5-4)

    5-3. Controls For Models With CV Option (See Section 5-4) ST-158 630-B / Ref. ST-158 631 / Ref. ST-185 762-B / S-185 440 OM-463 Page 22...

  • Page 27: Description Of Controls For Models With Cv Option (See Section 5-3)

    5-4. Description Of Controls For Models With CV Option (See Section 5-3) Push switch up and release while cranking Use switch to select type of weld output. Use This unit has a max OCV control circuit engine to release ether. CC for Stick (SMAW) welding.

  • Page 28: Section 6 − Operating Auxiliary Equipment

    SECTION 6 − OPERATING AUXILIARY EQUIPMENT 6-1. 120 Volt And 240 Volt Duplex Receptacles Y If unit does not have GFCI re- ceptacles, use GFCI-pro- tected extension cord. 120 V 15 A AC Receptacle 240 V 15 A AC Receptacle Receptacles supply 60 Hz single- phase power at weld/power speed.

  • Page 29: Optional Auxiliary Power Receptacles

    6-2. Optional Auxiliary Power Receptacles Auxiliary power is not affected by weld output. If a circuit breaker continues to open, contact Factory Autho- rized Service Agent. GFCI Receptacle Option 120 V 15 A AC GFCI Receptacle GFCI1 Auxiliary power output and circuit breaker protection is the same as standard receptacles (see Section 6-1).

  • Page 30: Connecting Optional Auxiliary Power Plant

    6-3. Connecting Optional Auxiliary Power Plant Y Stop engine. Y Power and weld outputs are live at the same time. Discon- nect or insulate unused cables. Have qualified person install according to circuit diagram and Auxiliary Power Guidelines Booklet (M176 712). Auxiliary power plant output on units with CV option is 10/15 kVA/kw (see table below).

  • Page 31: Section 7 − Maintenance & Troubleshooting

    SECTION 7 − MAINTENANCE & TROUBLESHOOTING 7-1. Routine Maintenance Y Stop engine before maintaining. See also Engine Manual and Maintenance Label. Recycle engine Service engine more often if used in severe condi- fluids. tions. To be done by Factory Authorized Service Agent. FUEL Wipe Check Fluid...

  • Page 32: Maintenance Label

    125-150 hours Oil Filter ... . MILLER 064 677, Deutz 117-4418, Fram PH6923 Oil Capacity ..8.5 qt (8 L) or 9 qt (8.5 L) with filter change Fuel Capacity .

  • Page 33: Servicing Air Cleaner

    7-3. Servicing Air Cleaner Y Stop engine. Y Do not run engine without air cleaner or with dirty element. Clean or replace element if dirty or damaged. Replace element yearly or after six cleanings. Dust Cap Baffle Element Plastic Fins Housing To clean air filter: Wipe off cap and housing.

  • Page 34: Servicing Fuel And Lubrication Systems

    7-4. Servicing Fuel And Lubrication Systems Y Stop engine and let cool. Oil Filter Oil Drain Plug Oil Drain Hose (Optional) Oil Fill Cap Primary Fuel Filter (Fuel/ Water Separator) Petcock Secondary Fuel Filter Fuel Shutoff Valve Fuel Line 10 Sludge Drain Plug To change oil and filter: Under Left Side Of Fuel Tank...

  • Page 35: Adjusting Engine Speed

    7-5. Adjusting Engine Speed Engine speed is factory set and should not require adjustment. Af- ter tuning engine, check engine Engine speed with tachometer. See table Speed for proper no load speed. If neces- (No Load) sary, adjust speed as follows: 1850 Weld/Power Plastic Cap...

  • Page 36: Checking And Replacing Alternator Belt

    7-7. Checking And Replacing Alternator Belt Y Stop engine. To check belt tension: Remove rear panel. Alternator V-Belt Crank Pulley Alternator Pulley Place straight edge along top of pul- leys. Pull down belt as far as it will go, then measure distance from belt to straight edge.

  • Page 37: Resetting Fan Belt Safety Shutdown

    7-8. Resetting Fan Belt Safety Shutdown Y Stop engine. Cooling Fan V-Belt See engine manual to replace or tighten belt. If belt breaks or becomes loose, safety shutdown stops engine. Correct problem, then reset safety shutdown as follows: Stop Bracket Handle Pull handle towards front of unit un- til stop snaps in position behind...

  • Page 38: Inspecting And Cleaning Optional Spark Arrestor Muffler

    7-9. Inspecting And Cleaning Optional Spark Arrestor Muffler Y Stop engine and let cool. Spark Arrestor Muffler 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 39: Troubleshooting

    7-11. Troubleshooting A. Welding Trouble Remedy No weld output. Check position of Ampere Range switch. Check position of optional polarity switch. Disconnect equipment from auxiliary power receptacles during start-up. Place A/V Control switch in Panel position, or place switch in Remote position and connect remote control to Remote A/V Control receptacle RC3 (see Sections 4-8 and 5-1).
  • Page 40 Trouble Remedy Min or max CV weld output only (models Check position of Amperage/voltage control and Amperage/Voltage Control switch. with CV option only). Repair or replace remote control device. Have Factory Authorized Service Agent check optional CV regulator board PC2. B.

  • Page 41: Section 8 − Electrical Diagrams

    SECTION 8 − ELECTRICAL DIAGRAMS SC-180 941 Figure 8-1. Circuit Diagram For Welding Generator (Standard Models) OM-463 Page 37...
  • Page 42 Figure 8-2. Circuit Diagram For Welding Generator (Models With CV Option) OM-463 Page 38...
  • Page 43 ST-184 954-B OM-463 Page 39...

  • Page 44: Section 9 − Run-In Procedure

    SECTION 9 − RUN-IN PROCEDURE run_in1 6/96 9-1. Wetstacking Welding Generator Run diesel engines near rated out- put during run-in period to properly seat piston rings and prevent wets- tacking. See nameplate or rating label to find rated output. Do not idle engine longer than necessary.

  • Page 45: Run-In Procedure Using Load Bank

    9-2. Run-In Procedure Using Load Bank Y Stop engine. Y Do not touch hot exhaust pipe, engine parts, or load bank/grid. Y Keep exhaust and pipe away from flammables. Load Bank Turn all load bank switches Off. If needed, connect load bank to 115 volts ac wall receptacle or genera- tor auxiliary power receptacle.

  • Page 46: Run-In Procedure Using Resistance Grid

    9-3. Run-In Procedure Using Resistance Grid Y Stop engine. Y Do not touch hot exhaust pipe, engine parts, or load bank/grid. Y Keep exhaust and pipe away from flammables. Resistance Grid Use grid sized for generator rated output. Turn Off grid. Welding Generator Place A/V range switch in maxi- mum position, A/V control in mini-...

  • Page 47: Section 10 − Auxiliary Power Guidelines

    SECTION 10 − AUXILIARY POWER GUIDELINES 10-1. Selecting Equipment Auxiliary Power Receptacles − Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment Be sure equipment has this symbol and/or wording. aux_pwr 12/96 − Ref. ST-159 730 / ST-800 577 10-2.
  • Page 48 10-3. Grounding When Supplying Building Systems Equipment Grounding Terminal Grounding Cable GND/PE Use #10 AWG or larger insulated copper wire. Ground Device Y Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. Use ground device as stated in electrical codes.
  • Page 49 10-5. 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 50 10-7. 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 51 10-8. Power Required To Start Motor Motor Start Code AC MOTOR Running Amperage VOLTS AMPS Motor HP CODE Motor Voltage PHASE To find starting amperage: Step 1: Find code and use table to find kVA/HP. If code is not listed, multiply running amperage by six to find starting amperage.
  • Page 52 10-10. Typical Connections To Supply Standby Power Power Company Service Meter Main and Branch Overcurrent Protection Double-Pole, Double-Throw Transfer Switch Obtain and install correct switch. Switch rating must be same as or Customer-supplied equipment is required if greater than the branch overcurrent generator is to supply standby power during protection.
  • Page 53 10-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads Y 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)

  • Page 54: Section 11 − Parts List

    SECTION 11 − PARTS LIST Hardware is common and not available unless listed. Fig 11-2 Fig 11−6 & Fig 11-7 Fig 11-5 Figure 11-1. Main Assembly OM-463 Page 50...
  • Page 55 Fig 11-3 ST-048 455-AA OM-463 Page 51...
  • Page 56 Item Dia. Part Description Quantity Mkgs. Figure 11-1. Main Assembly ....134 771 PLUG, protective .640sq ......... . .
  • Page 57 Item Dia. Part Description Quantity Mkgs. Figure 11-1. Main Assembly (Continued) ..... . . SPRING, (included w/engine − see engine parts list) .
  • Page 58 Hardware is common and Fig 11-4 not available unless listed. ST-048 457-N Figure 11-2. Panel, Front w/Components (CC Model Illustrated) OM-463 Page 54...
  • Page 59 Item Dia. Part Description Quantity Mkgs. Figure 11-2. Panel, Front w/Components (Fig 11-1 Item 94) ....154 292 PANEL, front upper ..........
  • Page 60 Hardware is common and not available unless listed. SD-048 456-E Figure 11-3. Generator OM-463 Page 56...
  • Page 61 Item Dia. Part Description Quantity Mkgs. Figure 11-3. Generator (Fig 11-1 Item 68) ....106 426 INSULATOR ............
  • Page 62 Item Dia. Part Description Quantity Mkgs. 171 878 Figure 11-4. Switch, Range (Fig 11-2 Item 2) ..114 235 BRACKET, mtg switch range (consisting of) ......
  • Page 63 Item Dia. Part Description Quantity Mkgs. Figure 11-5. Control Box CC/CV (Figure 11-1 Item 86) (Optional) ..605 321 NUT, .468-32 brs blk ..........
  • Page 64 Item Dia. Part Description Quantity Mkgs. Figure 11-6. Panel, Mtg Components (CC/CV Model) (Figure 11-1 Item 87) ..185 748 RESISTOR BOARD ..........SR1,4 035 704 RECTIFIER, integ 40A 800V...
  • Page 65 Item Dia. Part Description Quantity Mkgs. Figure 11-7. Panel, Mtg Components (CC Model) (Figure 11-1 Item 87) ..170 672 PANEL, mtg components ..........
  • Page 66 Notes...
  • Page 67 Effective January 1, 1998 (Equipment with a serial number preface of “KJ” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions APT, ZIPCUT &...

  • Page 68: Options And Accessories

    Contact the Delivering Carrier for: 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 1998 Miller Electric Mfg. Co. 9/98...

Table of Contents

Save PDF