Miller Electric Big Blue 500 X, Big Blue 400P manual Engine

Page 54

E. Engine

Trouble

Remedy

 

 

Engine will not crank.

Check battery, and replace if necessary.

 

 

 

Check battery connections and tighten if necessary.

 

 

 

Circuit breaker CB10 may be open. CB10 automatically resets when fault is corrected (see Section 9-8).

 

Have Factory Authorized Service Agent check engine wiring harness and components.

 

 

 

Check engine wiring harness plug connections.

 

 

 

Have Factory Authorized Service Agent check control relay CR1 and Engine Control switch S1.

 

 

Engine cranks but does not start.

Check fuel level.

 

 

 

Check battery and replace if necessary. Check engine charging system according to engine manual.

 

 

 

Have Factory Authorized Service Agent check engine wiring harness, time delay relay TD1, control

 

relay CR5, fuel pump, fuel solenoid FS1, and diode/capacitor board D10/C10.

 

 

 

Air in fuel system. See engine manual.

 

 

Engine starts, but stops when Engine

Check oil, and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolant

Control switch is released.

temperature is too high (see Section 5-7). Automatic shutdown system is inhibited for 30 seconds after

 

start-up.

 

 

 

Have Factory Authorized Service Agent check time delay relay TD1, and control relay CR5.

 

 

Engine hard to start in cold weather.

Use starting aid switch (see Section 6-1or 7-1).

 

 

 

Keep battery in good condition. Store battery in warm area off cold surface.

 

 

 

Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier for

 

fuel information.

 

 

 

Use correct grade oil for cold weather (see Section 9-1).

 

 

Engine suddenly stops.

Check oil and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolant

 

temperature is too high (see Section 5-7). Automatic shutdown system is inhibited for 30 seconds after

 

start-up.

 

 

 

See engine manual.

 

 

Engine slowly stopped and cannot be

Check fuel level.

restarted.

 

 

 

 

Check engine air and fuel filters (see Sections 9-4and 9-7).

 

 

 

See engine manual.

 

 

Battery discharges between uses.

Turn Engine Control switch off 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).

 

 

Engine idles, but does not come up to

Have Factory Authorized Service Agent check idle module PC7 and current transformer CT1.

weld speed (models with idle option

 

only).

 

 

 

 

Check for obstructed throttle solenoid.

 

 

Engine does not run at idle speed

CC models: place Stick/TIG Selection switch in Stick position.

(models with idle option only).

CC/CV models: place Process/Contactor switch in any position but Remote On/Off Switch Required-

 

TIG.

 

 

 

Check for obstructed throttle solenoid.

 

 

 

Have Factory Authorized Service Agent check idle module PC7, and control relays CR3 and CR6.

 

 

Engine uses oil during run-in period;

Dry engine according to run-in procedure (see Section 11).

wetstacking occurs.

 

 

 

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Contents Description OM-4421215 075NProcesses File Engine DriveFrom Miller to You Table of Contents − Maintenance & Troubleshooting Directives StandardsDecrot9/06 Manufacturer European Contact Notified Body Decrotsound6/05Symbol Usage Arc Welding HazardsEngine Hazards Compressed Air Hazards EMF Information Principal Safety StandardsCalifornia Proposition 65 Warnings Radiation can cause interferenceUN Choc Électrique peut tuer Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation LES Fumées ET LES GAZ peuvent être dangereuxDES Pièces Chaudes peuvent provoquer des brûlures graves LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux LE Bruit peut affecter l’ouïeLE Surchauffement peut endom- mager le moteur électrique ’AIR Comprimé peut provoquer des blessures’EMPLOI Excessif peut LES Étincelles Volantes risquent de provoquer des blessuresPour les moteurs diesel LE Soudage À L’ARC risque de provoquer des interférencesPour les moteurs à essence Boulevard, Rexdale, Ontario, Canada M9W 1R3 téléphone− Definitions − 50 h StdStd Manufacturer’s Rating Labels CC Models CC/CV Models CC Export ModelsOM-4421 Symbols And Definitions − Specifications Weld, Power, And Engine SpecificationsDimensions, Weights, And Operating Angles Volt-Ampere Curves For CC Models TIG Mode Stick ModeMIG Mode Volt-Ampere Curves For CC/CV ModelsFuel Consumption Curve shows typical fuel use under weld or power loadsExceeding duty cycle can damage unit and void warranty Duty Cycle And Overheating12 kVA/kW Single-Phase AC Output No Weld Load AC Generator Power CurveOptional Three-Phase Generator Curves 15 kVA/kW Three-Phase AC Output No Weld LoadLocation/Airflow Clearance − InstallationInstalling Welding Generator Grounding1Using Lifting Eye Mounting Surface Mounting Welding GeneratorSupporting The Unit To Bolt Unit In PlaceInstalling Exhaust Pipe Tools Needed 1/2Stop engine and let cool Do not overfill battery cells Activating The Dry Charge Battery If ApplicableConnecting The Battery For 30 MinutesFull Capacity Engine 9.5 qt 9.01L Diesel Coolant Recovery TankEngine Prestart Checks Hot Full Cold FullMIG and Fcaw Welding Connecting To Weld Output TerminalsStick and TIG Welding Stop engine350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Selecting Weld Cable Sizes150 ft 200 ft 250 ft Stop engine beforeConnecting To Remote 14 Receptacle RC14 On CC/CV Models Socket− Operating Welding Generator − CC Models Front Panel Controls For CC Models See SectionEngine Starting Controls To Start Do not use ether. Using ether voids warrantyDo not switch under load Engine Gauges And MetersRemote Amperage Control On CC Models Optional Weld Control/Arc Condition Information LabelExample Combination Remote Amperage Control Stick OM-4421 − Operating Welding Generator − CC/CV Models Front Panel Controls For CC/CV Models See SectionUse switch to select weld amperage range Voltage/Amperage Adjust Switch And Remote 14 Receptacle14 AC/DC Voltmeter Optional Process/Contactor Switch On CC/CV Models Process/Contactor Switch SettingsRemote Voltage/Amperage Control On CC/CV Models Optional Example Combination Remote Amperage Control TIG− Operating Auxiliary Equipment Volt And 240 Volt ReceptaclesSingle-Phase Generator Power Three-Phase Power Connection Rear Of PanelClose panel opening if no connections are made to generator Optional Generator Power Receptacles 240 V 15 a AC South African Receptacle RC1Supplementary Protector CB2 Supplementary Protector CB3 − Maintenance & Troubleshooting Maintenance LabelRoutine Maintenance Checking Generator Brushes To clean air filter Servicing Air CleanerBy the warranty Do not clean housing with air hoseInspecting And Cleaning Optional Spark Arrestor Muffler Stop engine and let cool. Reinstall cleanout plugTools Needed 3/8 Engine Speed No Load Adjusting Engine SpeedWeld/Power Speed Adjustment Standard Model Idle Speed Ad- justmentServicing Fuel And Lubrication Systems Overload Protection Troubleshooting Welding − CC ModelsWelding − CC/CV Models Standard Generator Power Optional Three-Phase Generator Power CC/CV Models OnlyEngine OM-4421 − Electrical Diagrams Circuit Diagram For CC Welding Generator223 522-B Circuit Diagram For CC/CV Welding Generator 223 523-B − RUN-IN Procedure WetstackingWelding Generator Stop engine Do not touch hot exhaust Run-In Procedure Using Load BankProcedure at less than From flammables Do not PerformFrom flammables Run-In Procedure Using Resistance GridBank/grid Do not perform run-in− Generator Power Guidelines Selecting EquipmentGrounding Generator To Truck Or Trailer Frame Earth ground if supplying Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Amperes x Volts = WattsIndustrial Motors Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsSingle-Phase Induction Motor Starting Requirements Power Required To Start MotorHow Much Power Can Generator Supply? KVA/HP x HP x 1000 = Starting AmperageTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Current Load Watts Amperes− Parts List 93 −6 105 104 100 101 102 103 Main Assembly 010 Figures 13-2 Figures 13-4 Control Box Assembly − CC Models 087 Control Box Assembly − CC/CV Models Control Box Assembly − CC/CV Models -1ItemTD1 214 Panel, Front w/Components − CC Models 3634Panel, Front w/Components − CC Models -1Item Panel, Front w/Components − CC/CV Models 40 39Panel, Front w/Components − CC/CV Models -1Item 170 Generator Generator -1Item602 SCREW, .312−18x .75 hexwhd.66d stl pld slffmg tap−rw 601 Main Rectifier Assembly Wiring Harnesses Harness, receptacle auxiliary power export models includes PLG4Page Service Your distributor also givesSupport For assistance in filing or settling claims, contact To locate a Distributor or Service Agency visitMiller Electric Mfg. Co Your distributor and/or equipment manufacturer’s

Big Blue 500 X, Big Blue 400P specifications

Miller Electric has long been a trusted name in the welding industry, and their generators, particularly the Big Blue 400P and Big Blue 500 X, stand out for their performance, reliability, and innovative technologies. These portable diesel welding generators cater to a wide range of applications, from construction sites to industrial fabrication.

The Big Blue 400P is designed for heavy-duty utilization, offering a powerful output of 400 amps at a duty cycle of 60%. It features a dependable Kohler engine that not only provides ample power but also contributes to its efficient fuel consumption, making it an economical choice for extended work sessions. The Big Blue 400P comes equipped with Auto-Stop technology, which automatically turns off the machine when not in use, conserving fuel and extending engine life. This feature showcases Miller's commitment to user-friendly designs that enhance both efficiency and sustainability.

On the other hand, the Big Blue 500 X takes performance up a notch with an impressive 500 amps output and a 60% duty cycle. It is powered by a high-efficiency Yanmar engine that ensures top-notch performance even in the most demanding conditions. This generator is equipped with Miller's X-CASE design, which features a rugged weather-resistant enclosure that protects internal components from harsh environmental conditions, ensuring durability and extended lifespan.

Both machines integrate advanced technologies such as Smart Tech, which optimizes the generator's output based on the specific demands of the welding process. This technology helps maintain a stable arc, enhancing welding quality and consistency. Additionally, both models feature the Auto Remote Start, allowing for quick operations without manual intervention, further advancing ease of use.

The versatility of the Big Blue 400P and 500 X is evident in their ability to perform a variety of welding processes, including Stick, MIG, and TIG. They are equipped with multiple outputs, allowing simultaneous powering of tools and auxiliary equipment, making them indispensable for professionals who need adaptability on the job.

Overall, the Miller Electric Big Blue 400P and 500 X embody the quality, performance, and innovative technologies that Miller Electric is known for. Their robust capabilities, coupled with user-friendly features, make these generators ideal for demanding applications in various industries, ensuring that welders can achieve excellent results, no matter the challenges faced on site.
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