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Big Blue 400 KX

OM-4423

215 178N

September 2005

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

)

Visit our website at

www.MillerWelds.com

File: Engine Drive

Содержание Big Blue 400 KX

Страница 1: ...ber 2005 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 Visit our website a...

Страница 2: ...tinue 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...

Страница 3: ...2 Manufacturer s Rating Label 10 3 3 Symbols And Definitions 11 SECTION 4 SPECIFICATIONS 12 4 1 Weld Power And Engine Specifications 12 4 2 Dimensions Weights And Operating Angles 12 4 3 Volt Ampere...

Страница 4: ...g Engine Speed On Standard Models 34 8 7 Servicing Fuel And Lubrication Systems 35 8 8 Overload Protection 36 8 9 Checking Generator Brushes 37 8 10 Voltmeter Ammeter Help Displays 38 8 11 Troubleshoo...

Страница 5: ...ility Directives 89 336 EEC 92 31 EEC Machinery Directives 98 37 EEC 91 368 EEC 92 31 EEC 133 04 93 68 EEC Noise level of Welding Generators 2000 14 EC Standards Arc Welding Equipment Part 1 Welding P...

Страница 6: ...Cheadle Heath 20098 San Giuliano Stockport Chesire SK30XU Milanese Italy Phone 39 02 98290 1 Fax 39 02 98290203 European Contact Signature The Manufacturer Declares the Big Blue 400 KX Conforms to Di...

Страница 7: ...ch proper grounding conductor first double check connections Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipme...

Страница 8: ...o treat them carefully CYLINDERS can explode if damaged Protect compressed gas cylinders from excessive heat mechanical shocks physical damage slag open flames sparks and arcs Install cylinders in an...

Страница 9: ...fire or explosion Do not cut or gouge near flammables Watch for fire keep extinguisher nearby HOT PARTS can cause burns and injury Do not touch hot compressor or air system parts Let system cool down...

Страница 10: ...Standard AWS F4 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 1...

Страница 11: ...rifier les connexions V rifier fr quemment le cordon d alimentation pour voir s il n est pas endom mag ou d nud remplacer le cordon imm diatement s il est endommag un c ble d nud peut provoquer une le...

Страница 12: ...ement partie du proc d de soudage les manipuler avec pr caution Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques des dommages physiques du laitier des flammes ouvert...

Страница 13: ...de toucher ou d effectuer la mainte nance LIRE LES INSTRUCTIONS Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil Arr ter le moteur et rel cher la pression avant d ef...

Страница 14: ...rd Z49 1 de Global Engineering Documents t l phone 1 877 413 5184 site In ternet www global ihs com RecommendedSafe Practices for the Preparation for Welding and Cutting of Containers and Piping Ameri...

Страница 15: ...ossible hazards as shown by the symbols Read Owner s Manual Follow instructions to activate battery 5 Check oil level Add oil if necessary 6 During the first 50 hours of operation keep welding load ab...

Страница 16: ...OM 4423 Page 10 3 2 Manufacturer s Rating Label 218 449 C...

Страница 17: ...mote Engine Air Temperature Or Engine Temperature Output Alternating Current Stick SMAW Welding Constant Current CC MIG GMAW Welding TIG GTAW Time h Hours s Seconds 1 Single Phase 3 Three Phase Read O...

Страница 18: ...5 3 kVA kW 48 96 A 220 V AC Receptacles 10 5 kVA kW 48 A Four Cylinder 20 2 HP Diesel Engine 11 5 gal 43 5 L 4 2 Dimensions Weights And Operating Angles Dimensions Height 32 in 813 mm 35 3 4 in 908 mm...

Страница 19: ...bilities of the welding generator Curves of all other settings fall between the curves shown A Stick Mode B MIG Mode C TIG Mode DC VOLTS DC AMPERES 0 100 200 300 400 500 100 90 80 70 60 50 40 30 20 10...

Страница 20: ...50 1 75 2 00 0 50 100 150 200 250 300 350 400 Continuous Welding 4 5 Duty Cycle And Overheating Duty Cycle is percentage of 10 min utes that unit can weld at rated load without overheating Exceeding...

Страница 21: ...ERES IN 220V MODE AC VOLTS 0 20 40 60 80 100 120 140 0 10 20 30 40 50 60 70 0 20 40 60 80 100 120 0 40 80 120 160 200 240 Notes 16 Gauge 063 in 22 Gauge 031 in 24 Gauge 025 in 20 Gauge 037 in 18 Gauge...

Страница 22: ...ng 1 Equipment Grounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insu late...

Страница 23: ...Brackets Supplied Mount unit on flat surface or use cross supports to support base Secure unit with mounting brack ets 3 1 2 in Bolt And Washer Minimum Not Supplied 4 3 8 16 x 1 in Screws Supplied To...

Страница 24: ...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 Work like a Pro Pros weld and cut safel...

Страница 25: ...necessary add electro lyte to raise to proper level Reins tall vent caps 8 Battery Charger Read and follow all instruc tions supplied with battery charger Charge battery for 12 minutes at 30 amperes...

Страница 26: ...oil see maintenance label Coolant Check coolant level in radiator before start ing unit the first time If necessary add cool ant to radiator until coolant level is at bottom of filler neck Check cool...

Страница 27: ...minal Failure to properly connect weld cables may cause excessive heat and start a fire or damage your machine 4 Weld Output Terminal 5 Supplied Weld Output Terminal Nut 6 Weld Cable Terminal 7 Copper...

Страница 28: ...0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 2 0 2x70 300 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 3 0 2x95 350 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea...

Страница 29: ...r TIG mode REMOTE OUTPUT D Remote control circuit common OUTPUT CONTROL E DC input command signal 0 to 10 volts from min to max of remote control with Voltage Amperage Adjust control at max F Current...

Страница 30: ...OM 4423 Page 24 SECTION 6 OPERATING WELDING GENERATOR 6 1 Front Panel Controls See Section 6 2 217 358 B 803 576 C 1 2 5 4 6 7 8 9 10 3 Stop...

Страница 31: ...is connected to the Remote receptacle the Auto Sense Remote feature automatically switches voltage am perage control to the remote control see Sec tion 5 9 With remote control connected weld output i...

Страница 32: ...trol from A to D to increase arc drive dig from min to max Use the Lift Arc TIG mode for TIG GTAW welding using the Lift Arc TIG starting procedure see Section 6 4 1 Ref 803 576 C 217 358 B Process Co...

Страница 33: ...ode touches workpiece only a low sensing voltage is present between electrode and workpiece The solid state output contactor does not energize until after electrode is touching workpiece This allows e...

Страница 34: ...ss Contactor switch 0774 Ref 217 358 B Ref 803 576 C Adjust Optional Remote Control Set V A Control To Desired Maximum Weld Output Using Weld Meters Set TIG or STICK Process Adjust Optional Remote Con...

Страница 35: ...ined output of RC11 and RC 12 is 4 4 kVa kW 3 Circuit Breaker CB6 4 Circuit Breaker CB5 CB6 protects RC12 from overload If a cir cuit breaker opens the receptacle does not work Press button to reset b...

Страница 36: ...8 Hours FUEL WATER Section 5 6 8 7 Fuel Water Separator Fuel Level Oil Level Oil Fuel Spills Coolant Level Every 50 Hours Section 8 3 Air Cleaner Element Weld Terminals Every 100 Hours Battery Termin...

Страница 37: ...OM 4423 Page 31 8 2 Maintenance Label 5 5 5 5 5 5...

Страница 38: ...ety element after servic ing the primary element three times Clean or replace primary element if dirty see note above before cleaning Re place primary element if damaged Re place primary element yearl...

Страница 39: ...end of exhaust pipe with fireproof material Stop engine and let cool Reinstall cleanout plug Tools Needed 3 8 in 1 2 3 8 5 Servicing Engine Cooling System 803 576 B Ref 217 358 C Stop engine and let...

Страница 40: ...with tachometer or frequen cy meter See table for proper no load speed If necessary adjust speed as follows Start engine and run until warm Place Process Arc Drive Dig Control in Stick position 1 Lock...

Страница 41: ...stall new filter and turn clock wise Inspect fuel lines and replace if cracked or worn To drain water from fuel system See engine manual To replace secondary in line fuel filter Note direction of fuel...

Страница 42: ...t Breaker CB1 Not Shown 3 Circuit Breaker CB2 4 Circuit Breaker CB3 5 Circuit Breaker CB8 CB1 protects the engine battery cir cuit If CB1 opens the engine will not crank CB1 automatically resets when...

Страница 43: ...shes Replace brushes if damaged or if brush material is at or near minimum length 1 5 16 in 8 mm Minimum Length 9 16 in 14 3 mm New Length Replace Damaged Brushes Notes 16 Gauge 063 in 22 Gauge 031 in...

Страница 44: ...reduce duty cycle Keep en gine access door closed when run ning to maintain proper cooling air flow past rectifier Allow unit to cool before restarting If problem contin ues have Factory Authorized S...

Страница 45: ...ule PC3 and field excitation circuit Erratic weld output Check and tighten connections inside and outside unit Be sure connection to work piece is clean and tight Use dry properly stored electrodes Re...

Страница 46: ...relay CR2 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...

Страница 47: ...Engine idles but does not come up to weld speed units with idle option only Have Factory Authorized Service Agent check idle module PC5 and current transformer CT1 Check for obstructed throttle solen...

Страница 48: ...OM 4423 Page 42 SECTION 9 ELECTRICAL DIAGRAMS Figure 9 1 Circuit Diagram For Welding Generator...

Страница 49: ...OM 4423 Page 43 221 499 B...

Страница 50: ...specifications section in this manual to find rated voltage and current Do not idle engine longer than necessary Piston rings seat faster if engine runs at weld power rpm and the welding generatoris...

Страница 51: ...nnect load bank to generator weld output terminals using proper size weld cables with correct connectors Observe correct polarity Start engine and run for several minutes Set load bank switches and th...

Страница 52: ...with correct connec tors polarity is not important 4 Voltmeter 5 Clamp On Ammeter Connect voltmeter and ammeter as shown if not provided on generator Start engine and run for several minutes Set grid...

Страница 53: ...enerator To Truck Or Trailer Frame S 0854 Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards 1 Equipment Grounding Terminal On Front Panel 2 Groun...

Страница 54: ...istive Load Equipment with a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when running see Section 11 8 3 Rating Data Rating shows volt...

Страница 55: ...Home Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 M...

Страница 56: ...P 6000 1500 1 1 2 HP 8200 2200 2 HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1 3...

Страница 57: ...r Starting Requirements Motor Start Code G H J K L M N P KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0 EXAMPLE Calculate the starting amperage required for a 230 V 1 4 HP motor with a motor start code of...

Страница 58: ...f required by electrical code 4 Welding Generator Output Generator output voltage and wiring must be consistent with regular utility system volt age and wiring Connect generator with temporary or perm...

Страница 59: ...15 40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 2 voltage drop Cord Lengths for 240 Volt Loads If unit does not have GFCI receptacles use GFC...

Страница 60: ...e 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 9...

Страница 61: ...M 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 27 26 64 42 7...

Страница 62: ...e Air Lower Radiator 1 22 201528 Muffler Exhaust Engine 1 23 213580 Pipe Exhaust Spark Arrestor 1 24 088528 Spark Arretsor Exhaust 1 25 201399 Pipe Exhaust Extension 5 0 Long 1 26 213470 Cover Top 1 0...

Страница 63: ...leaner Safety 1 197829 Bracket Mtg Air Cleaner 1 69 212618 Hose Air Intake 1 70 221485 Switch Pressure Oil 4psi No 1 8 28 Bspt 1 71 Figure 12 4 Generator Assembly 1 72 213461 Bracket Mtg Generator 1 2...

Страница 64: ...y Reactor Rectifier 1 213491 Insulator Capacitor Bank Applies To Reactor Rectifier Tray 1 100 213500 Brkt Beam Support 1 101 T1 220887 Xfmr Isolation 1 102 TE1 172661 Block Stud Connection 6 Position...

Страница 65: ...Front w Components Figure 12 1 Item 96 Quantity 1 097926 Knob Pointer 2 375 Dia X 250 Id W Set Screwsplstc 1 2 072590 Lock Shaft Pot 375 32 X 250 Dia Shaft Tall 1 3 170391 Conn Circ Ms Protective Cap...

Страница 66: ...er 1 24 C11 C12 217054 Capacitor Cer Disc 0047 Uf 3000 Vdc W Terms 2 25 CB5 222187 Circuit Breaker Man Reset 2p 35a 240vac Screw 90 1 26 GRD 083030 Stud Brs 250 20 X 1 750 W Hex Collar 1 27 010915 Was...

Страница 67: ...der Fuse Mintr 250 X 1 250 Panel Mtg 1 6 F1 085874 Fuse Mintr Cer Slo blo 10 Amp 250 Volt 1 7 CR2 090104 Relay Encl 12vdc Spst 30a 15vdc 5pin Flange Mtg 1 8 CR3 197325 Relay Encl 12vdc Spst 70a 4pin F...

Страница 68: ...92686 Screw M 8 1 25x 25 Hex Hd pln 8 8 Pld Din933 6 10 212641 Stud Stl 375 16 1 625x 19 000 4 11 STATOR 219920 Stator Generator 4 Pole 1 12 160943 Endbell 1 13 167788 Nut 375 16 56hex 34h Stl Pld Sem...

Страница 69: ...Module SCR 3 3 MOD4 5 6 218292 Kit Module SCR 3 4 212602 Bus Bar Rectifier 1 5 212639 Bus Bar Rectifier 3 6 212601 Insulator Rectifier 1 7 TH1 213930 Thermistor Ntc 30k Ohm 25 Deg C 8 5in Lead 1 8 C1...

Страница 70: ...4p 1row Female 1 For S1 211293 Conn Pack Terminal Position Assurance Lock 1 129524 Term Frict 250x032 Uninsul Male 130 Stud Mtg 3pr 1 221864 Harness Weld Control CE Includes 1 PLG2 150316 Conn Rect U...

Страница 71: ...nd Blankets APT SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Co...

Страница 72: ...retain with your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal S...

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