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Miller Big Blue 400 CX CE User Manual

Miller Big Blue 400 CX CE
82 pages
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Big Blue 400 CX CE
OM-4435 218 759AD
201105
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

Table of Contents

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Miller Big Blue 400 CX CE Specifications

General IconGeneral
BrandMiller
ModelBig Blue 400 CX CE
CategoryWelding System
LanguageEnglish

Summary

From Miller to You

SECTION 1 - SAFETY PRECAUTIONS - READ BEFORE USING

1-1. Symbol Usage

Explains symbols used in the manual for safety warnings.

1-2. Arc Welding Hazards

Details hazards associated with arc welding processes.

1-3. Engine Hazards

Outlines potential dangers related to the engine.

1-4. Hydraulic Hazards

Describes hazards associated with hydraulic systems.

1-5. Compressed Air Hazards

Details risks related to compressed air equipment.

1-6. Additional Symbols For Installation, Operation, And Maintenance

Covers symbols for installation, operation, and maintenance safety.

1-7. California Proposition 65 Warnings

Lists chemical warnings required by California law.

1-8. Principal Safety Standards

References key safety standards applicable to welding equipment.

1-9. EMF Information

Discusses electromagnetic field information and precautions.

SECTION 2 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION

2-1. Signification des symboles

Explains symbols used in the manual for safety warnings.

2-2. Dangers relatifs au soudage à l'arc

Details hazards associated with arc welding processes.

2-3. Dangers existant en relation avec le moteur

Outlines potential dangers related to the engine.

2-4. Dangers liés à l'hydraulique

Describes hazards associated with hydraulic systems.

2-5. Dangers liés à l'air comprimé

Details risks related to compressed air equipment.

2-6. Dangers supplémentaires en relation avec l'installation, le fonctionnement et la maintenance

Covers additional dangers for installation, operation, and maintenance.

2-7. Proposition californienne 65 Avertissements

Lists chemical warnings required by California law.

2-8. Principales normes de sécurité

References key safety standards applicable to welding equipment.

2-9. Informations relatives aux CEM

Discusses electromagnetic field information and precautions.

SECTION 4 – SPECIFICATIONS

4-1. Important Information Regarding CE Products (Sold Within The EU)

Provides information on CE marked products for the EU market.

4-2. Weld, Power, And Engine Specifications

Details welding, power, and engine specifications of the unit.

4-3. Dimensions, Weights, And Operating Angles

Lists the physical dimensions and weight of the generator.

4-4. Volt-Ampere Curves

Shows voltage and amperage output capabilities for different welding modes.

4-5. Fuel Consumption

Illustrates typical fuel usage based on weld output.

4-6. Duty Cycle And Overheating

Explains duty cycle and potential overheating issues.

4-7. AC Generator Power Curve

Shows the generator's AC power output curve in amperes.

SECTION 5 – INSTALLATION

5-1. Serial Number And Rating Label Location

Identifies the location of the serial and rating labels on the unit.

5-2. Installing Welding Generator

Provides guidance on moving and securing the welding generator.

5-3. Mounting Welding Generator

Details methods for mounting the welding generator to a surface or trailer.

5-4. Grounding Generator To Truck Or Trailer Frame

Explains how to properly ground the generator to a vehicle frame.

5-5. Installing Exhaust Pipe

Instructions for installing the exhaust pipe.

5-6. Activating The Dry Charge Battery (If Applicable)

Steps for activating a dry charge battery.

5-7. Connecting The Battery

Procedure for connecting the unit's battery.

5-8. Engine Prestart Checks

Lists essential checks before starting the engine.

5-9. Connecting To Weld Output Terminals

How to connect weld cables to output terminals for various processes.

5-10. Selecting Weld Cable Sizes*

Guide for choosing appropriate weld cable sizes based on length and amperage.

5-11. Connecting To Remote 14 Receptacle RC14

Details connections for remote controls via the RC14 receptacle.

SECTION 6 – OPERATING WELDING GENERATOR

6-1. Front Panel Controls (See Section 6-2)

Overview of the generator's front panel controls.

6-2. Description Of Front Panel Controls (See Section 6-1)

Detailed explanation of each front panel control's function.

6-3. Process/Contactor Switch

Explains the function and settings of the process/contactor switch.

6-4. Lift-Arc™ TIG With Crater-Out And Auto-Stop ™

Describes the Lift-Arc TIG starting and stopping procedures.

6-5. Remote Voltage/Amperage Control

How to use remote controls for voltage and amperage adjustment.

6-6. Fuel/Hour Gauge Descriptions

Explains the fuel/hour gauge and its display indicators.

SECTION 7 – OPERATING AUXILIARY EQUIPMENT

7-1. Auxiliary Power Receptacles

Details the types and functions of auxiliary power receptacles.

SECTION 8 – MAINTENANCE & TROUBLESHOOTING

8-1. Maintenance Label

Explains the maintenance schedule and information found on the unit's label.

8-2. Routine Maintenance

Outlines the regular maintenance schedule based on operating hours.

8-3. Caterpillar Customer Assistance

Provides contact information and steps for engine-related service issues.

8-4. Checking Generator Brushes

Instructions for inspecting and checking generator brushes.

8-5. Servicing Air Cleaner

Steps for cleaning or replacing the air cleaner element.

8-6. Inspecting And Cleaning Spark Arrestor Muffler

Procedure for inspecting and cleaning the spark arrestor muffler.

8-7. Servicing Engine Cooling System

Guidance on checking and servicing the engine's cooling system.

8-8. Adjusting Engine Speed On Standard Models

How to adjust engine speed for optimal performance.

8-9. Servicing Fuel And Lubrication Systems

Maintenance procedures for fuel and lubrication systems.

8-10. Overload Protection

Explains the overload protection devices and their functions.

8-11. Optional Voltmeter/Ammeter Help Displays

Interprets help codes displayed on optional meters for diagnostics.

8-12. Troubleshooting

Provides solutions for common welding and generator operational problems.

SECTION 9 – ELECTRICAL DIAGRAMS

SECTION 10 – RUN-IN PROCEDURE

10-1. Wetstacking

Explains wetstacking and its causes during engine run-in.

10-2. Run-In Procedure Using Load Bank

Step-by-step guide for run-in using a load bank.

10-3. Run-In Procedure Using Resistance Grid

Procedure for engine run-in using a resistance grid.

SECTION 11 – GENERATOR POWER GUIDELINES

11-1. Selecting Equipment

Guidance on selecting appropriate equipment for generator connection.

11-2. Grounding Generator To Truck Or Trailer Frame

How to properly ground the generator when mounted on a vehicle.

11-3. Grounding When Supplying Building Systems

Procedures for grounding the generator when supplying power to building systems.

11-4. How Much Power Does Equipment Require?

Explains how to calculate power requirements for various equipment.

11-5. Approximate Power Requirements For Industrial Motors

Power requirements for different types of industrial motors.

11-6. Approximate Power Requirements For Farm/Home Equipment

Power needs for common farm and home equipment.

11-7. Approximate Power Requirements For Contractor Equipment

Power requirements for various contractor tools and equipment.

11-8. Power Required To Start Motor

Details starting power requirements for single-phase induction motors.

11-9. How Much Power Can Generator Supply?

Guidelines on managing generator load and power supply.

11-10. Typical Connections To Supply Standby Power

Illustrates typical wiring for standby power applications.

11-11. Selecting Extension Cord (Use Shortest Cord Possible)

Charts for selecting appropriate extension cords based on load and length.

SECTION 12 – PARTS LIST

Figure 12-1. Main Assembly

Diagram and list of major components in the main assembly.

Figure 12-2. Panel, Front w/Components

Diagram and list of front panel components.

Figure 12-3. Control Panel

Diagram and list of components on the control panel.

Figure 12-4. Generator

Diagram and list of generator assembly parts.

Figure 12-5. Rectifier Assembly

Diagram and list of rectifier assembly components.

Wiring Harnesses

Lists components related to various wiring harnesses.

WARRANTY

Owner's Record

For Service

Contact information and guidance for obtaining service and support.

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