Miller Big Blue 400 CX CE User manual

Big Blue 400 CX CE
OM-4435 218 759AD
2011−05
Processes
Description
Air Carbon Arc (CAC-A)
Cutting and Gouging
Stick (SMAW) Welding
Engine Driven Welding Generator
TIG (GTAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
)
File: Engine Drive
Visit our website at
www.MillerWelds.com

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.
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 is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.
Working as hard as you do
−every power source from
Miller is backed by the most
hassle-free warranty in the
business.
From Miller to You
Mil_Thank 2009−09

TABLE OF CONTENTS
SECTION 1 −SAFETY PRECAUTIONS −READ BEFORE USING 1................................
1-1. Symbol Usage 1.......................................................................
1-2. Arc Welding Hazards 1.................................................................
1-3. Engine Hazards 3.....................................................................
1-4. Hydraulic Hazards 4...................................................................
1-5. Compressed Air Hazards 4..............................................................
1-6. Additional Symbols For Installation, Operation, And Maintenance 5............................
1-7. California Proposition 65 Warnings 6......................................................
1-8. Principal Safety Standards 7............................................................
1-9. EMF Information 7.....................................................................
SECTION 2 −CONSIGNES DE SÉCURITÉ −LIRE AVANT UTILISATION 8..........................
2-1. Signification des symboles 8............................................................
2-2. Dangers relatifs au soudage à l’arc 8.....................................................
2-3. Dangers existant en relation avec le moteur 10..............................................
2-4. Dangers liés à l’hydraulique 11............................................................
2-5. Dangers liés à l’air comprimé 12..........................................................
2-6. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance 13.....
2-7. Proposition californienne 65 Avertissements 14..............................................
2-8. Principales normes de sécurité 15.........................................................
2-9. Informations relatives aux CEM 15........................................................
SECTION 3 −DEFINITIONS 16.................................................................
3-1. Warning Label Definitions 16.............................................................
3-2. Symbols And Definitions 17..............................................................
SECTION 4 −SPECIFICATIONS 18..............................................................
4-1. Important Information Regarding CE Products (Sold Within The EU) 18..........................
4-2. Weld, Power, And Engine Specifications 18.................................................
4-3. Dimensions, Weights, And Operating Angles 18.............................................
4-4. Volt-Ampere Curves 19..................................................................
4-5. Fuel Consumption 20....................................................................
4-6. Duty Cycle And Overheating 20...........................................................
4-7. AC Generator Power Curve 21............................................................
SECTION 5 −INSTALLATION 22................................................................
5-1. Serial Number And Rating Label Location 22................................................
5-2. Installing Welding Generator 22...........................................................
5-3. Mounting Welding Generator 23...........................................................
5-4. Grounding Generator To Truck Or Trailer Frame 24..........................................
5-5. Installing Exhaust Pipe 25................................................................
5-6. Activating The Dry Charge Battery (If Applicable) 26..........................................
5-7. Connecting The Battery 26...............................................................
5-8. Engine Prestart Checks 27...............................................................
5-9. Connecting To Weld Output Terminals 28...................................................
5-10. Selecting Weld Cable Sizes* 29...........................................................
5-11. Connecting To Remote 14 Receptacle RC14 30.............................................
SECTION 6 −OPERATING WELDING GENERATOR 32............................................
6-1. Front Panel Controls (See Section 6-2) 32..................................................
6-2. Description Of Front Panel Controls (See Section 6-1) 33.....................................
6-3. Process/Contactor Switch 34.............................................................
6-4. Lift-ArctTIG With Crater-Out And Auto-Stopt35..........................................
6-5. Remote Voltage/Amperage Control 36.....................................................
6-6. Fuel/Hour Gauge Descriptions 37.........................................................
SECTION 7 −OPERATING AUXILIARY EQUIPMENT 38...........................................
7-1. Auxiliary Power Receptacles 38...........................................................

TABLE OF CONTENTS
SECTION 8 −MAINTENANCE & TROUBLESHOOTING 39.........................................
8-1. Maintenance Label 39...................................................................
8-2. Routine Maintenance 40.................................................................
8-3. Caterpillar Customer Assistance 41........................................................
8-4. Checking Generator Brushes 41..........................................................
8-5. Servicing Air Cleaner 42.................................................................
8-6. Inspecting And Cleaning Spark Arrestor Muffler 43...........................................
8-7. Servicing Engine Cooling System 43.......................................................
8-8. Adjusting Engine Speed On Standard Models 44.............................................
8-9. Servicing Fuel And Lubrication Systems 45.................................................
8-10. Overload Protection 46..................................................................
8-11. Optional Voltmeter/Ammeter Help Displays 47...............................................
8-12. Troubleshooting 48.....................................................................
SECTION 9 −ELECTRICAL DIAGRAMS 52......................................................
SECTION 10 −RUN-IN PROCEDURE 54.........................................................
10-1. Wetstacking 54.........................................................................
10-2. Run-In Procedure Using Load Bank 55.....................................................
10-3. Run-In Procedure Using Resistance Grid 56................................................
SECTION 11 −GENERATOR POWER GUIDELINES 57............................................
SECTION 12 −PARTS LIST 64.................................................................
OPTIONS AND ACCESSORIES
WARRANTY

DECLARATION OF CONFORMITY
for European Community (CE marked) products.
MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the
product(s) identified in this declaration conform to the essential requirements and provisions of
the stated Council Directive(s) and Standard(s).
Product/Apparatus Identification:
Product Stock Number
Big Blue 400CX CC 907143
Council Directives:
•2006/95/EC Low Voltage
•2004/108/EC Electromagnetic Compatibility
•2000/14/EC Noise Level of Welding Generators
Standards:
•IEC 609741:2005 Arc welding equipment – Part 1: Welding power sources
•IEC 6097410:2007 Arc Welding Equipment – Part 10: Electromagnetic compatibility (EMC) requirements
•EN 50445:2008 Product family standard to demonstrate compliance of equipment for resistance welding,
arc welding and allied processes with the basic restrictions related to human exposure to electromagnetic
fields (0 Hz – 300Hz)
Signatory:
_____________________________________ ___________________________________________
David A. Werba Date of Declaration
MANAGER,PRODUCT DESIGN COMPLIANCE
November 29, 2010
245808B