TM-4425Q 2020−01

Eff. w/Serial No. LE028711

And Following
Processes
Stick (SMAW) Welding

TIG (GTAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Air Carbon Arc (CAC-A) Cutting

and Gouging

Description

Engine Driven Welder/Generator

Big Blue 400D



Big Blue 500 X



Deutz

For product information, File: Engine Drive

Owner’s Manual translations,
and more, visit
www.MillerWelds.com Proprietary Information - Do not distribute or allow to be used by unqualified persons.
 INFORMATION ON OLDER UNITS

 This manual includes operating information for current units. To obtain specific operating information for older models, download the applicable
Owner’s Manual from www.MillerWelds.com

 Effective w/Serial No. LJ110096E, Fuel/Hour gauge FUEL/HM replaced Hourmeter HM.
 Effective w/Serial No. LJ150081E, the Deutz F3L2011L03i engine (Tier III) replaced the Deutz F3L2011 engine.
 Effective w/Serial No. LJ005955, ELCB1 replaced CB1 on export receptacle panels.
 Effective w/Serial No. LJ350167E, the Engine Control switch and associated wiring harness were changed.
 Effective w/Serial No. MD230076E, exciter stator 201099 was discontinued. To replace the exciter stator in models prior to MD230076E, the
endbell w/ exciter stator kit 264056 must be ordered. The new exciter stator will not fit in older models without the other items in the kit.

 Effective w/Serial No. MF300014E, all 400D models were discontinued.

Effective w/Serial No. MG060004E, all 500 X CC/CV models were discontinued.

 See the Miller Extranet for service memos that may aid in the repair of this product.
 TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SECTION 2 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SECTION 3 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-2. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-3. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-4. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-5. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-6. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-7. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-8. AC Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4-1. Installing Welder/Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4-2. Grounding Generator To Truck Or Trailer Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-3. Using Lifting Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-4. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-5. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-6. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-7. Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-8. Connecting Weld Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-9. Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-10. Connecting To Remote Amperage Adjust Receptacle RC13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SECTION 5 − OPERATING WELDER/GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-1. Front Panel Controls (See Section 5-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-2. Description Of Front Panel Controls (See Section 5-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-3. Remote Amperage Control (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-4. Weld Control/Arc Condition Information Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-5. Fuel/Hour Gauge Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SECTION 6 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6-1. Export Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6-2. GFCI Receptacle Information, Resetting, And Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SECTION 7 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7-1. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7-2. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7-3. Operating Optional Oil Pan Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7-4. Checking Generator Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7-5. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7-6. Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7-7. Inspecting And Cleaning Optional Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7-8. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7-9. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7-10. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
 TABLE OF CONTENTS

SECTION 8 − THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

SECTION 9 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
9-1. Troubleshooting Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
9-2. Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9-3. Troubleshooting Circuit Diagram (CC Models) (Use With Section 9-4) . . . . . . . . . . . . . . . . . . . . . . . . . 42
9-4. Troubleshooting Values For Circuit Diagram (CC Models) (Use With Section 9-3) . . . . . . . . . . . . . . . 44
9-5. Troubleshooting Values For Circuit Diagram (CC/CV Models)(Use With Section 9-6) . . . . . . . . . . . . 45
9-6. Troubleshooting Circuit Diagram (CC/CV Models) (Use With Section 9-5) . . . . . . . . . . . . . . . . . . . . . . 46
9-7. Waveforms For Sections 9-3 And 9-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
9-8. Volt-Ampere Curves For CC/CV Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
9-9. Optional Three-Phase Generator Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
9-10. Connecting To Remote 14 Receptacle RC14 On CC/CV Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9-11. Filter Board PC6 Testing Information (CC/CV Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
9-12. Filter Board PC6 Test Point Values (CC/CV Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
9-13. Field Current Regulator Board PC1 Testing Using LED Board PC9 (CC/CV Only) . . . . . . . . . . . . . . . 54
9-14. Using Diagnostic LEDs On LED Board PC9 (CC/CV Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
9-15. LED Board PC9 Testing (CC/CV Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
9-16. LED Board PC9 Test Point Values (CC/CV Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
9-17. Optional Idle Module PC7 Testing Information And Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . 58
9-18. Time Delay Relay TD1 Testing Information (Prior To Serial No. LJ110096E) . . . . . . . . . . . . . . . . . . . . 60
9-19. Fuel/Hourmeter Testing Information (Effective w/Serial No. LJ110096E) . . . . . . . . . . . . . . . . . . . . . . . 62
9-20. Replacing Brushes And Cleaning Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
9-21. Checking Unit Output After Servicing (CC Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
9-22. Checking Unit Output After Servicing (CC/CV Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
SECTION 10 − DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
10-1. Disassembly Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
10-2. Disassembly Of Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
SECTION 11 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
SECTION 12 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
12-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
12-2. Run-In Procedure Using Load Bank Or Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
 SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING
7

Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.

1-1. Symbol Usage OM-4425AU 2017-10, safety_rtm 2020-02

DANGER! − Indicates a hazardous situation which, if  Indicates special instructions.

not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible This group of symbols means Warning! Watch Out! ELECTRIC
hazards are shown in the adjoining symbols or ex- SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
plained in the text. bols and related instructions below for necessary actions to avoid
NOTICE − Indicates statements not related to personal injury. these hazards.

1-2. Servicing Hazards

The symbols shown below are used throughout this manual FLYING METAL or DIRT can injure eyes.
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions  Wear safety glasses with side shields or face
to avoid the hazard. shield during servicing.
 Be careful not to short metal tools, parts, or
Only qualified persons should install, operate, maintain, and wires together during testing and servicing.
repair this equipment. A qualified person is defined as one
who, by possession of a recognized degree, certificate, or
professional standing, or who by extensive knowledge, train-
ing and experience, has successfully demonstrated the
ability to solve or resolve problems relating to the subject
matter, the work, or the project and has received safety train-
STATIC (ESD) can damage PC boards.
ing to recognize and avoid the hazards involved.  Put on grounded wrist strap BEFORE handling
boards or parts.
During servicing, keep everybody, especially children, away.
 Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ELECTRIC SHOCK can kill.
 Do not touch live electrical parts.
 Stop engine and remove input power plug from
receptacle (if applicable) before testing or re-
Using a generator indoors CAN KILL
pairing unit unless the procedure specifically YOU IN MINUTES.
requires an energized unit.
 Do not work on equipment unless it has been verified that the  Generator exhaust contains carbon monoxide.
machine case is not energized. This is a poison you cannot see or smell.
 Insulate yourself from ground by standing or working on dry insu-  NEVER use inside a home or garage, EVEN IF
lating mats big enough to prevent contact with the ground. doors and windows are open.
 Do not leave live unit unattended.  Only use OUTSIDE and far away from windows, doors, and
vents.
 If this procedure requires an energized unit, have only personnel
familiar with and following standard safety practices do the job.
 When testing live unit, use the one-hand method. Do not put both
hands inside unit. Keep one hand free.
HIGH PRESSURE FLUIDS can injure or kill.
SIGNIFICANT DC VOLTAGE exists in inverter power
sources AFTER stopping engine.  Engine fuel system components can be under
 Stop engine on inverter and discharge input capacitors according high pressure.
to instructions in Manual before touching any parts.  Before working on fuel system, turn off engine
to release pressure.
 If ANY fluid is injected in the skin seek medical help immediately.
MOVING PARTS can injure.
 Keep away from moving parts such as fans,
belts, and rotors.
 Keep away from pinch points such as drive
FUEL can cause fire or explosion.
rolls.
 Have only qualified people remove doors,  Stop engine and let it cool off before checking or
panels, covers, or guards for maintenance adding fuel.
and troubleshooting as necessary.  Do not add fuel while smoking or if unit is near
 Keep hands, hair, loose clothing, and tools any sparks or open flames.
away from moving parts.  Do not overfill tank; clean up any spilled fuel.
 Before working on generator, remove spark plugs or injectors
to keep engine from kicking back or starting.
 Block flywheel so that it will not turn while working on genera- FIRE OR EXPLOSION hazard.
tor components.
 Reinstall doors, panels, covers, or guards when servicing is  Do not place unit on, over, or near combustible surfaces.
finished and before starting engine.  Do not service unit near flammables.
Big Blue 400D, 500 X TM-4425 Page 1
 BATTERY EXPLOSION can BLIND.
 Always wear a face shield, rubber gloves, and
protective clothing when working on a battery.
 Stop engine before disconnecting or connect-
ing battery cables.
 Do not allow tools to cause sparks when working on a battery.
 Do not use welder to charge batteries or jump start vehicles.
 Observe correct polarity (+ and −) on batteries.
 Disconnect negative (−) cable first and connect it last.
BATTERY ACID can BURN SKIN and EYES.
 Do not tip battery.
 Replace damaged battery.
 Flush eyes and skin immediately with water.
STEAM AND HOT COOLANT can burn.
 If possible, check coolant level when engine is
cold to avoid scalding.
 Always check coolant level at overflow tank, if
present on unit, instead of radiator.
 If the engine is warm, checking is needed, and there is no overflow
tank, follow the next two statements.
 Wear safety glasses and gloves and put a rag over radiator cap.
 Turn cap slightly and let pressure escape slowly before completely
removing cap.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
 Wearers of Pacemakers and other Implanted
Medical Devices should keep away from serv-
icing areas until consulting their doctor and the
device manufacturer.
FALLING EQUIPMENT can injure.
 Use lifting eye to lift unit and properly installed
accessories only, NOT gas cylinders. Do not
exceed maximum lift eye weight rating (see
Specifications).
 Use correct procedures and equipment of adequate capacity to
lift and support unit.
 If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
 Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manu-
ally lifting heavy parts or equipment.
HOT PARTS can burn.
 Do not touch hot engine parts bare-handed.
 Allow cooling period before working on
equipment.
 To handle hot parts, use proper tools and/or wear heavy, insu-
lated welding gloves and clothing to prevent burns.
TILTING OR TIPPING can injure.
 Do not put any body part under unit while lifting.
 Always use proper equipment (hoists, slings,
chains, blocks, etc.) of adequate capacity to lift
and support components (stator, rotor, engine,
etc.) as needed during job.
PINCH POINTS can injure.
 Be careful when working on stator and rotor assemblies.
TM-4425 Page 2
EXPLODING PARTS can injure.
 Failed parts can explode or cause other parts to
explode when power is applied to inverters.
 Always wear a face shield and long sleeves
when servicing inverters.
H.F. RADIATION can cause interference.
 High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
 Have only qualified persons familiar with elec-
tronic equipment perform this installation.
 The user is responsible for having a qualified electrician promptly
correct any interference problem resulting from the installation.
 If notified by the FCC about interference, stop using the equipment
at once.
 Have the installation regularly checked and maintained.
 Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
OVERUSE can cause OVERHEATING.
 Allow cooling period; follow rated duty cycle.
 Reduce current or reduce duty cycle before
starting to weld again.
 Do not block or filter airflow to unit.
SHOCK HAZARD from testing.
 Stop engine or turn Off welding power source (if
applicable) before making or changing meter
lead connections.
 Use at least one meter lead that has a self-
retaining spring clip such as an alligator clip.
 Read instructions for test equipment.
READ INSTRUCTIONS.
 Use Testing Booklet (Part No. 150 853) when
servicing this unit.
 Consult the Owner’s Manual for welding safety
precautions.
 Use only genuine replacement parts from the manufacturer.
 Read and follow all labels and the Technical Manual carefully be-
fore installing, operating, or servicing unit. Read the safety in-
formation at the beginning of the manual and in each section.
 Perform installation, maintenance, and service according to the
Technical Manual, industry standards, and national, state, and
local codes.
 Reinstall injectors and bleed air from fuel system according to
engine manual.
HYDRAULIC EQUIPMENT can injure
or kill.
 Before working on hydraulic system, turn off
and lockout/tagout unit, release pressure, and
be sure hydraulic pressure cannot be accident-
ally applied.
 Do not work on hydraulic system with unit running unless you are a
qualified person and following the manufacturer’s instructions.
 Do not modify or alter hydraulic pump or manufacturer-supplied
equipment. Do not disconnect, disable, or override any safety
equipment in the hydraulic system.
 Keep away from potential pinch points or crush points created by
equipment connected to the hydraulic system.
 Do not work under or around any equipment that is supported only
by hydraulic pressure. Properly support equipment by mechanical
means.
Big Blue 400D, 500 X
 HYDRAULIC FLUID can injure or kill.
 Before working on hydraulic system, turn off and
lockout/tagout unit, release pressure, and be sure
hydraulic pressure cannot be accidentally applied.
 Relieve pressure before disconnecting or con-
necting hydraulic lines.
 Check hydraulic system components and all con-
nections and hoses for damage, leaks, and wear
before operating unit.
 Wear protective equipment such as safety
glasses, leather gloves, heavy shirt and trousers,
high shoes, and a cap when working on hydraulic
system.
 Use a piece of paper or cardboard to search for
leaks−−never use bare hands. Do not use equip-
ment if leaks are found.
 HYDRAULIC FLUID is FLAMMABLE−−do not work on hydraulics
near sparks or flames; do not smoke near hydraulic fluid.
 Reinstall doors, panels, covers, or guards when servicing is
finished and before starting unit.
 If ANY fluid is injected into the skin seek medical help immediately.
COMPRESSED AIR EQUIPMENT can
injure or kill.
 Before working on compressed air system, turn
off and lockout/tagout unit, release pressure,
and be sure air pressure cannot be accidentally
applied.
 Do not work on compressed air system with unit running unless
you are a qualified person and following the manufacturer’s in-
structions.
 Do not modify or alter compressor or manufacturer-supplied
equipment. Do not disconnect, disable, or override any safety
equipment in the compressed air system.
 Keep away from potential pinch points or crush points created by
equipment connected to the compressed air system.
 Do not work under or around any equipment that is supported only
by air pressure. Properly support equipment by mechanical
means.
1-3. California Proposition 65 Warnings
WARNING: This product can expose you to chemicals in-
cluding lead, which are known to the state of California to
cause cancer and birth defects or other reproductive
harm.
For more information, go to www.P65Warnings.ca.gov.
1-4. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied pro-
cesses including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. EMF fields can interfere with some medical implants, e.g. pace-
makers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or con-
duct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
Big Blue 400D, 500 X
COMPRESSED AIR can injure or kill.
 Before working on compressed air system,
turn off and lockout/tagout unit, release pres-
sure, and be sure air pressure cannot be acci-
dentally applied.
 Relieve pressure before disconnecting or con-
necting air lines.
 Check compressed air system components
and all connections and hoses for damage,
leaks, and wear before operating unit.
 Do not direct air stream toward self or others.
 Wear protective equipment such as safety glasses, hearing pro-
tection, leather gloves, heavy shirt and trousers, high shoes, and a
cap when working on compressed air system.
 Use soapy water or an ultrasonic detector to search for
leaks−−never use bare hands. Do not use equipment if leaks are
found.
 Reinstall doors, panels, covers, or guards when servicing is
finished and before starting unit.
 If ANY air is injected into the skin or body seek medical help imme-
diately.
TRAPPED AIR PRESSURE AND WHIPPING
HOSES can injure.
 Release air pressure from tools and system be-
fore servicing, adding or changing attach-
ments, or opening compressor oil drain or oil fill
cap.
For Diesel Engines:
WARNING: Breathing diesel engine exhaust exposes you to
chemicals known to the state of California to cause cancer
and birth defects or other reproductive harm.
 Always start and operate the engine in a well−ventilated
area.
 If in an enclosed area, vent the exhaust to the outside.
 Do not modify or tamper with the exhaust system.
 Do not idle the engine except as necessary.
For more information, go to www.P65Warnings.ca.gov/diesel.
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom-
mended.
TM-4425 Page 3
 SECTION 2 − DEFINITIONS
2-1. Additional Safety Symbols And Definitions
 Some symbols are found only on CE products.

Do not use ether or other starting fluids. Using starting fluids voids warranty. See engine Owner’s Manual.

Safe89 2017−04

Hot muffler and exhaust pipe can cause severe burns.

Safe90 2017−04

Welding, cutting, drilling, or grinding on base can cause fire or explosion.

Safe91 2017−04

Remove unit from shipping crate. Remove Owner’s Manual from unit.
Follow instructions to install muffler.

Safe46 2012−05

Read Owner’s Manual. Read labels on unit.

Safe47 2012−05

<12.4 V
Read Owner’s Manual for battery maintenance information.

/ + − + −
Safe117 2014−06

0 - 50 h std
During the first 50 hours of operation keep welding load above 200
amperes. Do not weld below 200 amperes of output.

Safe54 2017−04

50 h std
After the first 50 hours of operation, change the engine oil and filter.

Safe55 2012−05

Never use generator inside a home or garage, even if doors and win-
dows are open.

Safe87 2012−07

Only use generator outside and far away from windows, doors, and
vents.

Safe88 2012−07

TM-4425 Page 4 Big Blue 400D, 500 X

2-2. Miscellaneous Symbols And Definitions

 Some symbols are found only on CE products.

A Amperage Contactor On Engine

V Voltage
Work Connection
Idle (Slow)

Direct Current Negative

Run (Fast)
(DC)

X
Positive Engine Start
Duty Cycle (Engine RPM)

Protective Earth

I2 Rated Welding
Current
(Ground) Engine Stop

Circuit Breaker

U2 Conventional
Load Voltage
Supplementary
Protector
Engine Oil

U0 Rated No−Load
Voltage (OCV)
Output Fuel

I Current
Off Filter

Engine
On
n Rated Load Temperature
Speed
Increase or Battery (Engine)
Decrease of

n0 Rated No−Load Quantity

Speed (Rotating)
Engine Belt

n1 Rated Idle Speed

Panel/Local

Manual Cleaning

Hz
Do Not Switch
Hertz While Welding
Spark Arrestor
Remote
Hours
Air Filter
Read Operator’s
Clock, Time Manual
Switch
Air Flow
Electrode
Hour Meter Connection
Check Air Cleaner

Alternating Welding (General)

Current (AC) Check
Shielded Metal Injectors/Pump
Arc Welding
Single Phase (SMAW)
Check Valve
Gas Tungsten Arc Clearance
Welding (GTAW) /
Three Phase Tungsten Inert
Gas (TIG) Certified/Trained
Welding Mechanic
Engine−Driven
3−Phase Starting Aid
Alternator with Call for
(Preheat) Maintenance
Rectifier

Big Blue 400D, 500 X TM-4425 Page 5

 SECTION 3 − SPECIFICATIONS
3-1. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the front. Use rating label to determine input power requirements and/or rated
output. For future reference, write serial number in space provided on back cover of this manual.

3-2. Weld, Power, And Engine Specifications

 This equipment will deliver rated output at an ambient air temperature up to 1045F (405C).
Maximum
Welding Weld Output Rated Welding Open- Generator Power Fuel
Engine
Mode Range Output Circuit Rating Capacity
Voltage
500 A, 30 Volts DC
40% Duty Cycle
Single-Phase, Deutz D2011L03i
IEC Rating Air/Oil-Cooled, Three
95 4 kVA/kW, 34/17 A, 25 gal
CC/DC 55 − 500 A 400 A, 36 Volts DC, Cylinder, 31.9 HP
120/240 V AC, (95 L)
100% Duty Cycle 50/60 Hz Diesel Engine
450 A, 38 Volts DC,
60% Duty Cycle

3-3. Dimensions, Weights, And Operating Angles

Dimensions
60 in. (1524 mm)
Height
(to top of muffler)

28.5 in. (724 mm) G

(mtg. brackets turned in)
Width
30.75 in. (781 mm)
(mtg. brackets turned out)
Depth 65.125 in. (1654 mm)
A 65.125 in. (1654 mm) ! Do not exceed tilt angles or engine could
be damaged or unit could tip.
B* 56 in. (1422 mm) ! Do not move or operate unit where it could
C* 46.5 in. (1181) tip.
A
D* 9.625 in. (244 mm) B C
E 27.5 in. (699 mm)
F 1 in. (25 mm)
G 29.8125 in. (757 mm)
H
9/16 in. (14 mm) Dia. 30°
H
4 Holes
D 30°
* With mounting brackets in center 20°
position. Dimensions vary with
location of mounting brackets. 20°
F
Weight E
w/ Deutz No fuel: 1600 lb (726 kg) 802 161-A
F3L2011 W/fuel: 1775 lb (805 kg)

Lifting Eye Weight Rating:

2500 lb (1134 kg) Maximum

3-4. Environmental Specifications

A. IP Rating
IP Rating
IP23S
This equipment is designed for outdoor use. It may be stored, but is not intended to be used for welding outside during precipitation unless
sheltered.
IP23S 2014−06

TM-4425 Page 6 Big Blue 400D, 500 X

B. Temperature Specifications

Operating Temperature Range* Storage/Transportation Temperature Range

−40 to 104°F (−40 to 40°C) −4 to 131°F (−20 to 55°C)

*Output is derated at temperatures above 104°F (40°C). Temp_2016- 07

3-5. Duty Cycle And Overheating

100% Duty Cycle At 400 Amperes
Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
without overheating.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.

Continuous Welding

215 084-A

3-6. Volt-Ampere Curves

The volt-ampere curve shows the
minimum and maximum voltage
and amperage output capabilities of
the welder/generator. Curves of all
100 other settings fall between the
Ranges: curves shown.
230 − Max
170 − 365
80
110 − 225
70 − 130
DC VOLTS

55 − 85
60

40

20

0
0 100 200 300 400 500 600 700 800 900 1000
DC AMPERES
215 081-A

Big Blue 400D, 500 X TM-4425 Page 7

3-7. Fuel Consumption
The curve shows typical fuel use
under weld or power loads.

2.50
2.25
2.00
1.75
US Gal./Hr.

1.50
1.25
1.00
0.75
0.50
0.25 IDLE

0.00
0 50 100 150 200 250 300 350 400 450 500
DC WELD AMPERES AT 100% DUTY CYCLE

199 032-A

3-8. AC Generator Power Curve

The AC power curve shows the
generator power in amperes avail-
able at the 120 and 240 volt
receptacles.

150 300

125 250
AC VOLTS

100 200

75 150

50 100

25 50

0 0
0 5 10 15 20 25 30
AC AMPERES IN 240V MODE
0 10 20 30 40 50 60
AC AMPERES IN 120V MODE

193 018

TM-4425 Page 8 Big Blue 400D, 500 X

 SECTION 4 − INSTALLATION
4-1. Installing Welder/Generator

Airflow Clearance
Movement 18 in.
(460 mm)
18 in.
18 in. (460 mm)
(460 mm)

OR OR
18 in.
18 in. (460 mm)
(460 mm)

Location/Mounting

Welding Bolting
Unit In Unit In
Place 2 Place 3
2

OR

OR

Tools Needed: 1 1

9/16 in. install3 2014−12 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712

 Go to MillerWelds.com for more
information on truck installations.
Movement
! Do not move or operate unit where
it could tip.
 See Section 4-3 for lifting eye rating.
Airflow Clearance
NOTICE − Do not install unit where air flow
is restricted or engine may overheat.
Location/Mounting
! Always securely fasten welding
generator onto transport vehicle or
trailer and comply with all DOT and
other applicable codes.
! Do not weld on base. Welding on To Bolt Unit In Place:
base can cause fuel tank fire or ex- Remove hardware securing the four
plosion. Weld only on the four mounting brackets to the base. Reverse
mounting brackets or bolt unit brackets and reattach to base with original
down. hardware.
NOTICE − Do not mount unit by supporting Mount unit to truck or trailer with 1/2 in. (12
the base only at the four mounting bracket- mm) or larger hardware (not supplied).
s. Use cross-supports to adequately sup-
port unit and prevent damage to base. To Weld Unit In Place:
1 Cross-Supports Weld unit to truck or trailer only at the four
2 Mounting Brackets (Supplied) mounting brackets.
Mount unit on flat surface or use cross-sup-
ports to support base. Secure unit with
mounting brackets.
3 1/2 in Bolt And Washer (Minimum −
Not Supplied)
4 3/8-16 x 1 in. Screws (Supplied)

Big Blue 400D, 500 X TM-4425 Page 9

4-2. Grounding Generator To Truck Or Trailer Frame
! Always ground generator
frame to vehicle frame to pre-
vent electric shock and static
electricity hazards.

! Also see AWS Safety &

Health Fact Sheet No. 29,
Grounding of Portable And
Vehicle Mounted Welding
Generators.

! Bed liners, shipping skids,

and some running gear insu-
late the welder/generator
from the vehicle frame. Al-
ways connect a ground wire
from the generator equip-
ment grounding terminal to
bare metal on the vehicle
1 2 frame as shown.

GND/PE
! Use GFCI protection when
operating auxiliary equip-
ment. If unit does not have
GFCI receptacles, use GFCI-
protected extension cord.
Do not use GFCI receptacles
to power life support equip-
ment.
3
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 #8 AWG or larger insu-
lated copper wire.

 Electrically bond generator

frame to vehicle frame by met-
al-to-metal contact.
rot_grnd1 2012−03 − 800 652-D

4-3. Using Lifting Eye

1 Lifting Eye
2 Nut
3 Carriage Bolt
1
Raise lifting eye until it snaps in
place. Lower lifting eye when not
needed.
To lock the lifting eye in the upright
position, insert a 3/8-16 x 1-1/2 in.
2 carriage bolt through slot in bracket
and secure with nut (bolt and nut not
supplied).

Tools Needed:
3

907185-TP1

TM-4425 Page 10 Big Blue 400D, 500 X

4-4. Installing Exhaust Pipe
Tools Needed:
1/2 in.
4-5. Connecting The Battery
Tools Needed:
1/2 in.
NOTICE − Lead acid batteries discharge
when stored in any temperature. Units that
are stored should have the battery
recharged every three months and before
being put into service. To preserve opti-
mum battery performance and life,
recharge battery in storage when the
open−circuit voltage drops to 12.4 volts
DC when measured across the battery
terminals.
! Connect negative (−) cable last.
NOTICE − Wait two minutes after engine
shutdown before disconnecting battery or
engine controller may be damaged.
Big Blue 400D, 500 X
Battery is most easily accessed through
the rear panel. Remove battery access
panel from rear panel. Connect battery,
negative cable last. Reinstall battery ac-
cess panel.
 Do not allow the battery cables to
touch opposing terminals. When con-
necting the battery cables attach the
positive (+) cable to the positive (+)
battery terminal first, followed by neg-
ative (−) cable to negative (−) battery
terminal.
! Stop engine and let cool.
 Point exhaust pipe in desired di-
rection but always away from front
panel and direction of travel.
Exhaust1 2008−01 Ref. 803 604 / Ref. 215 664
Conn_batt1 2014−11 802 168-E / S-0756-C
 Never start the engine when the
cables are loose or poorly connected
to the battery terminals.
 Never disconnect the battery while
the engine is running.
 Never use a quick battery charger to
start the engine.
 Do not charge battery with Engine
Control switch On.
 Always disconnect the negative (−)
battery cable before charging battery.
TM-4425 Page 11
4-6. Engine Prestart Checks

Full
 Follow run-in procedure
in engine manual. If un-
burned fuel and oil collect
Diesel in exhaust pipe during
run-in, see Section 12.

Full

907185-TP2

 Check all engine fluids daily.
Engine must be cold and on a level surface.
Automatic shutdown system stops engine if
oil pressure is too low or engine tempera-
ture is too high.
 This unit has a low oil pressure shut-
down switch. However, some condi-
tions may cause engine damage before
the engine shuts down. Check oil level
often and do not use the oil pressure
shutdown system to monitor oil level.
NOTICE − Diesel engines in Miller equip-
ment are meant to operate optimally at mod-
erate to rated load. Using light or no load for
extended periods of time may cause wet-
stacking or engine damage.
Follow run-in procedure in engine manual.
If unburned fuel and oil collect in exhaust
 To improve cold weather starting:
pipe during run-in, see Section 12.
Use Starting Aid switch (see Section
Fuel 5-1).
NOTICE − Do not use gasoline. Gasoline
Keep battery in good condition. Store
will damage engine.
battery in warm area.
Add fresh diesel fuel before starting (see
engine maintenance label for fuel specifica- Use fuel formulated for cold weather
tions). Leave filler neck empty to allow room (diesel fuel can gel in cold weather).
for expansion. Contact local fuel supplier for fuel in-
formation.
Engine stops if fuel level is low.
Oil Use correct grade oil for cold weather
After fueling, check oil with unit on level sur- (see Section 7-1).
face. If oil is not up to full mark on dipstick,
add oil (see maintenance label).

TM-4425 Page 12 Big Blue 400D, 500 X

4-7. Weld Output Terminals

! Turn off power before connecting to

weld output terminals.

! Do not use worn, damaged, under-

sized, or repaired cables.
1 Positive (+) Weld Output Terminal
2 Negative (−) Weld Output Terminal
Stick and TIG Welding
For Stick and TIG welding Direct Current Elec-
trode Positive (DCEP), connect electrode
holder cable to Positive (+) terminal on left and
work cable to Negative (−) terminal on right.
For Direct Current Electrode Negative
(DCEN), reverse cable connections.
If equipped with optional Polarity switch or op-
tional Polarity/AC switch, connect electrode
holder cable to Electrode (+) terminal on left
and work cable to Work (−) terminal on right.

Ref. 907185 TP1

4-8. Connecting Weld Output Cables

2
6
3
1

Tools Needed: 5
3/4 in. (19 mm)

803 778-B

! Turn off power before connecting to
weld output terminals.
! Failure to properly connect weld ca-
bles may cause excessive heat and
start a fire, or damage your machine.
 Do not place anything between weld
cable terminal and copper bar. Make
sure that the surfaces of the weld cable
terminal and copper bar are clean.
1 Correct Weld Cable Connection
2 Incorrect weld Cable Connection
3 Weld Output Terminal
4 Supplied Weld Output Terminal Nut
5 Weld Cable Terminal
6 Copper Bar
Remove supplied nut from weld output ter-
minal. Slide weld cable terminal onto weld
output terminal and secure with nut so that
weld cable terminal is tight against copper
bar.
connecting weld output cables 3−2010

Big Blue 400D, 500 X TM-4425 Page 13

4-9. Selecting Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source
is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine
cable size.

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
100 ft (30 m) or Less
(45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
10 − 60%
60 − 100%
Welding Duty 10 − 100% Duty Cycle
Duty Cycle
Amperes Cycle AWG (mm2)
AWG (mm2)
AWG (mm2)
100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)
150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)
200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)
250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x2/0 (2x70)
300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95)
350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95) 2x4/0 (2x120)
400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 2x4/0 (2x120)
500 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 3x3/0 (3x95) 3x3/0 (3x95)
* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***For distances longer than those shown in this guide, see AWS Fact Sheet No. 39, Welding Cables, available from the American Welding
Society at http://www.aws.org.
Ref. S-0007-M 2017−08

4-10. Connecting To Remote Amperage Adjust Receptacle RC13

1 Remote Amperage Adjust
Receptacle RC13
Connect optional remote control to
1 RC13 (see Section 5-3).

Ref. 154 862-A / 048 720-K / 907185 TP1

TM-4425 Page 14 Big Blue 400D, 500 X

 SECTION 5 − OPERATING WELDER/GENERATOR

5-1. Front Panel Controls (See Section 5-2)

11 12 5 4 3
6 7

13

8 1 2
9

10

240 162-D / Ref. 907185 TP1

Big Blue 400D, 500 X TM-4425 Page 15

5-2. Description Of Front Panel Controls (See Section 5-1)
Engine Starting Controls
1 Starting Aid Switch
Use switch to energize starting aid for cold
weather starting (see starting instructions fol-
lowing).
2 Engine Control Switch
Use switch to start and stop engine.
NOTICE − Diesel engines in MILLER equip-
ment are meant to operate optimally at moder-
ate to rated load. Using light or no load for ex-
tended periods of time may cause wetstack-
ing or engine damage.
To Start:
NOTICE − Do not use ether or other starting
fluids. Using starting fluids voids warranty.
 If engine does not start, let engine come
to a complete stop before attempting re-
start.
Above 325 F (05 C): turn Engine Control
switch to Start. Release Engine Control
switch when engine starts.
Below 325 F (05 C): push Starting Aid switch
up for 60 seconds. While still holding Starting
Aid switch, turn Engine Control switch to
Start. Release Engine Control switch and
Starting Aid switch when engine starts.
To Stop: turn Engine Control switch to Off
position.
Engine Gauges And Meters
3 Engine Fuel/Hour Gauge
Use gauge to monitor engine running time for
scheduling maintenance and to determine
cause of engine shutdowns.
Use gauge to check fuel level. Engine stops
if fuel level is low.
To check fuel level when engine is not run-
ning, turn Engine Control switch to Run or
Run/Idle position.
See Section 5-5 for complete fuel/hour gauge
information.
TM-4425 Page 16
4 Engine Temperature Gauge
Normal temperature is 212 − 239°F (100 −
115°C). Engine stops if temperature exceeds
270°F (132°C).
5 Engine Oil Pressure Gauge
Normal pressure is 30 − 60 psi (207 − 414
kPa). Engine stops if pressure is below 10 psi
(69 kPa).
Weld Controls
 Max OCV Control Circuit: This unit has
a max OCV control circuit that resets Am-
perage Adjust control R1 to maximum
when the arc breaks. When an arc is
struck, weld output control returns to the
R1 front panel or combination front panel/
remote control setting. The Amperage
Adjust control adjusts amperage only
when welding and does not adjust open-
circuit voltage.
The max OCV circuit is disabled when the
Stick/TIG Selection switch is in Scratch
Start TIG position (see item 8).
6 Ampere Range Switch
NOTICE − Do not switch under load.
Use switch to select weld amperage range.
For most welding applications, use lowest
amperage range possible to help prevent arc
outages.
7 Amperage Adjust Control
Control adjusts amperage within range se-
lected by Ampere Range switch. Weld output
would be about 168 A DC with controls set as
shown (50% of 110 to 225 A).
 The numbers around the control are for
reference only and do not represent an
actual percentage value.
8 Stick/TIG Selection Switch
Use switch to disable the max OCV circuit
and the arc drive (dig) circuit for scratch start
TIG welding (see max OCV note under Weld
Controls).
When switch is in the Stick position, the max
OCV circuit resets Amperage Adjust Control
R1 to maximum when the arc breaks.
Also in the Stick position, the arc drive (dig)
circuit provides additional amperage during
low voltage (short arc length conditions) to
prevent “sticking” electrodes.
When switch is in Scratch Start TIG position,
the max OCV and arc drive (dig) circuits are
disabled and OCV changes when the control
is adjusted.
9 Amperage Adjust Switch And Remote
Amperage Adjust Receptacle
Connect optional remote control to RC13
(See Section 4-10). Use switch to select front
panel or remote amperage control. For re-
mote control, place switch in Remote position
and connect remote control to Remote Am-
perage Adjust receptacle RC13 (see Sec-
tions 4-10 and 5-3).
10 Polarity Switch (Optional)
NOTICE − Do not switch under load.
Use switch to change weld output. Select ei-
ther DC Electrode Positive (DCEP) or DC
Electrode Negative (DCEN).
Weld Meters
11 AC/DC Voltmeter (Optional)
Voltmeter displays voltage at the weld output
terminals, but not necessarily the welding arc
due to resistance of cable and connections.
12 AC/DC Ammeter (Optional)
Ammeter displays amperage output of the
unit.
13 Battery Voltmeter (Optional)
Use gauge to check battery voltage and moni-
tor the engine charging system. The meter
should read about 14 volts dc when the en-
gine is running, and about 12 volts dc when
the engine is stopped.
Big Blue 400D, 500 X
5-3. Remote Amperage Control (Optional)
1 Remote Amperage Adjust
Receptacle RC13
1 Connect optional remote control to
RC13 (see Section 4-10).

Example: Combination Remote Amperage Control (Stick) In Example:

Range = 110 to 225 A DC
Percentage Of Range = 50%
Max = About 168 A DC (50% of 110 to 225)

Max (168 A DC)

Min (90 A DC)

Set Switches Set Range Set Control Adjust Optional Remote Control
Ref. 154 862-A / Ref. 181 711-A / 803 602

5-4. Weld Control/Arc Condition Information Label

 Set weld controls as shown to
achieve softer or stiffer arc condi-
tions for different applications.

212 944-B

Big Blue 400D, 500 X TM-4425 Page 17

5-5. Fuel/Hour Gauge Descriptions

TM-4425 Page 18 Big Blue 400D, 500 X

 SECTION 6 − OPERATING AUXILIARY EQUIPMENT
6-1. Export Auxiliary Power Receptacles
4
3
Australian Receptacle
South African Receptacle
! Use GFCI protection when operat-
ing auxiliary equipment. If unit does
not have GFCI receptacles, use
GFCI-protected extension cord. Do
not use GFCI receptacles to power
life support equipment.
! Unplug power cord before attempt-
ing to service accessories or tools.
1 120V 15/20A AC Receptacle GFCI1
Receptacles supply 60 Hz single-phase
power at weld/power speed.
! Test GFCI monthly. See Section 6-2
for GFCI information and for reset-
ting and testing procedures.
Big Blue 400D, 500 X
European Receptacle
5
Maximum output is 2.4 kVA/kW from GFCI1
and 4 kVa/kW from RC1.
Maximum combined output of all recep-
tacles is 4 kVA/kW.
EXAMPLE: If 13 A is drawn from RC1, only
7 A is available at GFCI1:
(240 V x 13 A) + (120 V x 7 A) =
4.0 kVA/kW
2 Circuit Breaker CB2
CB2 protects GFCI1 from overload. If a cir-
cuit breaker opens, the receptacle does not
work. Press CB2 to reset breaker.
3 Earth Leakage Circuit Breaker
ELCB1
2
1
238 127-A / 805 259-A
ELCB1 protects RC1 from Earth leakage
fault. If circuit breaker opens the receptacle
does not work. Place circuit breaker switch
in the On position to reset breaker.
 At least once a month, press test but-
ton. If ELCB is working properly, power
will be disconnected. Reset breaker.
4 220V 16A AC European
Receptacle RC1
5 240 V 15 A AC Australian
Receptacle RC1
6 240 V 15 A AC South African
Receptacle RC1
TM-4425 Page 19
6-2. GFCI Receptacle Information, Resetting, And Testing
 Alternate location for red
and green indicator LEDs.
5
 Orientation of receptacle may be different in other applications.
! Use GFCI protection when operat-
ing auxiliary equipment. If unit does
not have GFCI receptacles, use
GFCI-protected extension cord. Do
not use GFCI receptacle to power
life support equipment.
! Unplug power cord before attempt-
ing to service accessories or tools.
1 120 V 20 A AC GFCI Receptacle
2 GFCI Receptacle Test Button
3 GFCI Receptacle Reset Button
4 Red GFCI Indicator Light (LED)
5 Green GFCI Indicator Light (LED)
 Red and Green indicator lights may be
combined in a single LED.
GFCI Receptacles
GFCI receptacles protect the user from
electric shock if a ground fault occurs in
equipment connected to the receptacle. A
ground fault occurs when electrical current
takes the shortest path to ground (which
could be through a person) rather than fol-
low its intended safe path.
TM-4425 Page 20
If a ground fault is detected, the GFCI Reset
button pops out, and the circuit opens to
disconnect power to the faulty equipment.
A GFCI receptacle does not protect against
circuit overloads, short circuits, or shocks
not related to ground faults. Reset and test
GFCI receptacle according to the following
procedures.
A solid green LED indicates power to the
GFCI. A solid red LED indicates that the
GFCI has been tripped.
Resetting/Testing GFCI Receptacle
! Test GFCI monthly.
! If Red LED blinks, stop using GFCI
receptacle and have it replaced.
! Extension cords with bad insulation
or of extended length can allow
enough leakage current to trip the
GFCI circuit. Reset and test as
follows.
2
RotGFCI1 2017-10
Resetting GFCI Receptacles
If a GFCI fault occurs, stop engine and dis-
connect equipment from GFCI receptacle.
Check for damaged or wet tools, cords,
plugs, etc. connected to the receptacle.
Start engine, place ignition switch in RUN
position, and press GFCI Reset button. Re-
connect equipment to GFCI receptacle. If
GFCI Reset button pops out again, check
the equipment and repair or replace if faulty.
Testing GFCI Receptacles
Start engine and press the GFCI Test but-
ton. The GFCI Reset button should pop out.
Press the GFCI Reset button.
Have GFCI replaced if any of the follow-
ing occur:
GFCI does not trip when tested
Red LED blinks
GFCI does not reset.
Big Blue 400D, 500 X
 SECTION 7 − MAINTENANCE
7-1. Maintenance Label

DEUTZ

DEUTZ Service:
http://www.deutzamericas.com
To ensure rapid, efficient service support, you
should initially contact your nearest DEUTZ ser-
vice distributor or dealer.
They are staffed with highly qualified parts, ser-
vice and engine specialists to handle your differ-
ent needs.
The DEUTZ Service Desk enhances this sup-
port and can be contacted by completing and
submitting the Service Support Form. Customer
in the US and CANADA can also contact the ser-
vice desk by calling our toll free number,
1-800-241-9886.
Our normal hours of operation are from 8:00 AM
to 6:00 PM Monday through Friday EST. You
may contact our on call service 24 hours, 7 days
a week. We ask that when you contact us,
please have available or provide specific engine
information (serial number, model number etc.)
as shown on the Service Support Form.

237 352-K

Big Blue 400D, 500 X TM-4425 Page 21

7-2. Routine Maintenance

! Stop engine before maintaining.

Recycle engine  See Engine Manual and Maintenance Label
fluids. for important start-up, service, and storage
information. Service engine more often if
used in severe conditions.

 = Check  = Change  = Clean = Replace Reference

* To be done by Factory Authorized Service Agent

Every Section 4-6,

8 FUEL 7-8
WATER
Hours

 Fuel/Water Separator  Fuel Level  Oil Level  Oil, Fuel Spills

Every
50
Hours

 Weld Terminals

Every Section 7-5

100
Hours

 Battery Terminals  Air Cleaner Hoses  Air Cleaner Element

Every Engine
250 1/2 in.
(13 mm) Manual,
Hours Section 7-7

Unreadable Labels  Fan Belt Tension  Cooling System Spark Arrestor

Every
500
Hours

 Weld Cables
Every NOTICE − Change engine Section 7-8,
1000 oil and filter after initial 50 7-4 and En-
Hours to 75 hours of use. gine Manual

 Oil  Oil Filter  Fuel Filter

FUEL
OR

SLUDGE
 Slip Rings*  Inside Unit Valve Clearance*  Drain Sludge
 Brushes*

Every
3000
Hours

 Injectors*

Every
6000
Hours
or 5
Years
 Engine Timing Belt
 = Clean unit exterior, including stainless steel, frequently to prevent rust and corrosion.

TM-4425 Page 22 Big Blue 400D, 500 X

7-3. Operating Optional Oil Pan Heater

1 Optional Oil Heater Plug

Use heater to maintain a constant
engine oil temperature.
To turn on heater, connect heater
plug to 120 volts AC receptacle.
Heater rated at 300 watts.

! Do not run engine while oil

pan heater is on.
NOTICE −In extremely cold weath-
er, heater should be connected to
120 volts AC receptacle when en-
gine oil is warm to eliminate possib-
ility of oil coking on heater.
Severe coking on heater element
may cause damage to engine, en-
gine oil, and oil pan heater.

! The area near the oil pan

heater gets hot.
Disconnect plug to turn off heater.

803 602 / 907185 TP1

7-4. Checking Generator Brushes

! Stop engine and let cool.

1 Generator Brush
Mark and disconnect leads at brush hold-
er cap. Remove brushes.
Minimum Length:
5/8 in. (16 mm) Replace brushes if damaged or if brush
New Length: material is at or near minimum length.
1-1/4 in. (32 mm)

1
Replace
Damaged Brushes
GenBrush1 2012−05 / Ref 190 823

Big Blue 400D, 500 X TM-4425 Page 23

7-5. Servicing Air Cleaner
! Stop engine.
NOTICE − Do not run engine without air
cleaner or with dirty element. Engine
damage caused by using a damaged ele-
ment is not covered by the warranty.

 The air cleaner primary element can

be cleaned but the dirt holding capac-
ity of the filter is reduced with each
cleaning. The chance of dirt reaching
4 the clean side of the filter while clean-
ing and the possibility of filter damage
1 makes cleaning a risk. Consider the
risk of unwarrantable equipment
damage when determining whether
2 to clean or replace the primary ele-
ment.
NOTICE − If you decide to clean the pri-
3 mary element, we strongly recommend
installing an optional safety element to
provide additional engine protection.
Never clean a safety element. Replace
Optional the safety element after servicing the pri-
mary element three times.
1 Intake Manifold
2 Service Indicator (Optional,
Customer Supplied)
3 Service Indicator Window
5 6 7 8 4 Service Indicator Reset Button
Service air cleaner element if red band
appears in window. A green band means
air cleaner is okay. Press button to reset
indicator.
Clean or replace primary element if dirty
(see note above before cleaning). Re-
place primary element if damaged. Re-
place primary element yearly or after six
Optional cleanings.
5 Housing
9
6 Safety Element (Optional)
7 Primary Element
8 Cover
9 Dust Ejector
To clean air filter
Wipe off cover and housing. Remove
cover and dump out dust. Remove ele-
ment(s). Wipe dust from inside cover and
housing with damp cloth. Reinstall safety
Keep nozzle element (if present). Reinstall cover.
2 in (51 mm)
from element. ! Do not clean housing with air
hose.
Clean primary element with compressed
air only.
Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in (3 mm) nozzle and
keep nozzle at least 2 in (51 mm) from
inside of element. Replace primary ele-
ment if it has holes or damaged gaskets.
Blow Inspect Reinstall primary element and cover
(dust ejector down).

aircleaner1 5/16− ST-153 929-B / ST-153 585 / Ref. S-0698-B

TM-4425 Page 24 Big Blue 400D, 500 X

7-6. Battery Maintenance

Lead acid batteries discharge when stored in any temperature. Units that are stored should have the battery recharged every three months and before
being put into service. To preserve optimum battery performance and life, recharge battery in storage when the open−circuit voltage drops to 12.4 volts
DC when measured across the battery terminals.

7-7. Inspecting And Cleaning Optional Spark Arrestor Muffler

! Stop engine and let cool.
1 Spark Arrestor Muffler
2 Cleanout Plug
Remove plug and remove any dirt
covering cleanout hole.
Start engine and run at idle speed to
2 blow out cleanout hole. If nothing
blows out of hole, briefly cover end
of exhaust pipe with fireproof
material.

! Stop engine and let cool.

Reinstall cleanout plug.
1

Tools Needed:
3/8 in.

907185 TP1 / Ref. 236 970

Big Blue 400D, 500 X TM-4425 Page 25

7-8. Adjusting Engine Speed
! Stop engine and let cool.
 For operation at high altitude,
engine may require adjust-
ments. If adjustment is neces-
sary, contact engine manufac-
turer’s Factory Authorized Ser-
vice Agent.
Engine speed is factory set and
should not require adjustment. Af-
ter tuning engine, check engine no
load speed with a tachometer or fre-
quency meter (see table for no load
speeds). If necessary, adjust speed
as follows:
Start engine and run until warm.
1850 rpm Max. Place Stick/TIG switch in Stick
(61.6 Hz) position.
1250 rpm Standard Models:
(41.6 Hz) 1 Engine Speed Adjustment
Screw
2 Locking Nut
Loosen nut. Turn screw until engine
runs at weld/power speed. Tighten
nut.
 Do not set engine speed higher
than specified.
Models With Automatic Idle
(Optional)
Standard Models 3 Throttle Rod
4 Locknut
5 Throttle Stop Screw
6 Throttle Lever
Loosen locknuts. Place engine
2 control switch in Run/Idle position.
Turn throttle rod until engine runs at
1 idle speed. Tighten locknuts.
NOTICE − To prevent solenoid
damage, be sure a 1/8 in. (3 mm)
gap exists between the throttle stop
screw and throttle lever when the
solenoid is held in the energized
position.
7 Engine Speed Adjustment
Models With Automatic Idle (Optional) Screw
8 Locknut
Place engine control switch in Run
position.
Loosen locknut. Turn screw until
4 3 engine runs at weld/power speed.
Tighten locknut.

 Do not set engine speed higher

than specified.

! Stop engine.
Close door.
5
6
7

8
Tools Needed:

3/8, 7/16 in.

803 644 / Ref. 800 159

TM-4425 Page 26 Big Blue 400D, 500 X

7-9. Servicing Fuel And Lubrication Systems
! Stop engine and let cool.
! After servicing, start engine and
check for fuel leaks. Stop engine,
tighten connections as necessary,
and wipe up spilled fuel.
1 Oil Filter
2 Oil Drain Valve And Hose
3 Oil Fill Cap
4 Primary Fuel Filter (Fuel/Water Sepa-
rator)
5 Petcock
6 Secondary Fuel Filter
7 Fuel Tank Sludge Drain Valve
To change oil and filter:
Route oil drain hose and valve through hole
Big Blue 400D, 500 X
in base. See engine manual and engine
maintenance label for oil/filter change in-
formation.
To drain water from fuel system:
Open primary fuel filter petcock and drain
water into metal container. Close petcock
when water-free fuel flows.
To replace primary fuel filter:
Turn filter counterclockwise. Remove filter.
Apply thin coat of fuel to gasket on new filter.
Fill filter with fuel. Install filter and turn clock-
wise. Bleed air from fuel system according
to engine manual.
Inspect fuel line, and replace if cracked or
worn.
Tools Needed:
907185 TP2
To replace secondary fuel filter:
See engine manual.
Close doors.
To drain sludge from fuel tank:
! Beware of fire. Do not smoke and
keep sparks and flames away from
drained fuel. Dispose of drained fuel
in an environmentally-safe manner.
Do not leave unit unattended while
draining fuel tank.
! Properly lift unit and secure in a level
position. Use adequate blocks or
stands to support unit while drain-
ing fuel tank.
Attach 1/2 ID hose to drain valve. Put metal
container under drain, and use screwdriver
to open sludge drain valve. Close valve
when sludge has drained. Remove hose.
TM-4425 Page 27
7-10. Overload Protection
! Stop engine.
 When a supplementary protector, cir-
cuit breaker or fuse opens, it usually
indicates a more serious problem ex-
ists.
1 Fuse F1
2 Fuse F2
F1 and F2 protect the stator exciter wind-
ing from overload. If F1 opens, weld and
generator power is low or stops entirely. If
F2 opens, weld output is low or stops en-
tirely. 4 kVA/kW generator power is still
available.
3 Circuit Breaker CB4 (Not Shown)
2 1
4 Circuit Breaker CB10 (Not Shown)
5 Supplementary Protector CB11
6 Supplementary Protector CB12
7 Supplementary Protector CB13
8 Circuit Breaker CB14 (Not Shown)
7 CB4 protects the welding arc drive (dig)
6 circuit. If CB4 opens, electrode may stick
5 to the workpiece more frequently during
low voltage (short arc length) conditions.
CB4 automatically resets when the fault is
corrected.
CB10 protects the engine battery circuit. If
CB10 opens, the engine will not crank.
CB10 automatically resets when the fault
is corrected.
CB11 protects the engine weld control cir-
cuit. On CC models, if CB11 opens the
max OCV circuit does not work and open
circuit voltage is variable at all times (see
max OCV note under Weld Controls in
Section 5-2).
CB12 protects the field flashing circuit. If
CB12 opens, the generator may not excite
at start-up and weld and generator power
output may not be available.
CB13 protects the engine control circuit. If
CB13 opens, the engine does not crank.
CB14 protects throttle solenoid TS1 on
units with auto idle option. If CB14 opens,
the engine does not run at idle speed.
CB14 automatically resets when the fault
is corrected.
Press button to reset.

Ref. 907185 TP1

TM-4425 Page 28 Big Blue 400D, 500 X

Notes

Big Blue 400D, 500 X TM-4425 Page 29

 SECTION 8 − THEORY OF OPERATION
1 Engine
Supplies force to turn revolving
fields.
2 Control Relays CR1, CR5,
CR9
CR1 energizes at start-up to supply 15 ♦ 15 14 13
power to starter solenoid.
CR5 energizes at start-up to supply Remote Remote Amperage Amperage Amperage
power for field flashing and to the Current Adjust Receptacle Adjust Adjust
Control RC13 Switch S5 Control R1
fuel solenoid.
CR9 (export models only) ener- 12
gizes at start-up to bypass resistor
R7. Stick/TIG
3 Control Relay TD1 or Engine Selection
Fuel/Hour Gauge FUEL/HM Switch S6
3 11
 Eff w/Serial No. LJ110096E
Control Relay
Fuel/Hour gauge FUEL/HM Integrated
TD1 Or
replaced control relay TD1. Rectifier
Fuel/Hour Gauge SR2
Energizes at start-up to supply FUEL/HM
power to CR5 and enable engine
gauges and shutdown circuit. (En-
2 10 9 9
gine shutdown inhibited for 30 sec-
onds after start-up.) FUEL/HM also
Control Integrated
monitors fuel level and engine run Rectifier Fuse F1 Fuse F2
Relays CR1,
time. SR1
CR5, CR9
4 Control Relays CR3, CR4,
CR6
CR3 energizes at no load to supply 1 7 8
power to throttle solenoid TS1.
Exciter
CR4 energizes at no load to bypass Revolving
Engine Fields

Weld
resistor R3 and prevent loss of field Stator Windings
excitation. (Rotor)
CR6 energizes when engine is run- Generator Power
ning to supply power to idle module.
5 Idle Module PC7 6♦
Controls engine speed. Without a
Throttle
signal from CT1, it lowers engine
Solenoid TS1
speed to idle (1250 RPM).
(Pull To Idle)
6 Throttle Solenoid TS1
27
Decreases engine speed to idle
rpm (1250 RPM) when energized.
5♦ Transformer
7 Main And Exciter Revolving 4♦
T1
Fields
Idle Module Control Relays
Turn at 1850 RPM maximum for CR3, CR4, CR6
PC7
weld and power. The speed and ex-
citation current of the field coils de-
termine voltages in stator windings.
8 Stator Windings
Supply power to exciter, generator
power, and weld circuits.
9 Fuses F1, F2
Protects aux. stator (exciter) wind-
ings from overload.
10 Integrated Rectifier SR1 28

Changes AC output of stator wind- Integrated

ings to DC to supply excitation cur- Rectifiers
rent to the exciter revolving field. SR4, SR5
11 Integrated Rectifier SR2
Changes AC output of exciter stator
to DC to control DC amperage in
main revolving field as set by R1.

Figure 8-1. Functional Diagram For CC Models

TM-4425 Page 30 Big Blue 400D, 500 X
 12 Stick/TIG Selection Switch S6
Disables max OCV circuit and op-
AC Or DC Control Circuits tional auto idle circuit.
13 Amperage Adjust Control R1
Adjusts amperage within range se-
3φ Power lected by S3.
14 Amperage Adjust Switch S5
Selects Panel or Remote amper-
Weld Current Circuit age control.
15 Remote Amperage Adjust Re-
Either Mechanical Coupling ceptacle RC13
Or External Circuits
Connects remote current control.
Magnetic Coupling 16 Current Transformer CT1
♦ Optional Senses output from either genera-
tor power or weld windings, and sig-
nals idle module to increase to or
maintain weld speed (1850 RPM).
17 Supplementary Protectors
CB1, CB2
Protect AC receptacles RC1 and
19 GFCI1 from overload.
Max OCV 18 AC Receptacles RC1 And
Control GFCI1
Relay CR7
Provide connection points and
power for auxiliary equipment.
19 Max OCV Control Relay CR7
20 21 22 Bypasses R1 to allow maximum
open-circuit voltage when not weld-
Reactor Ampere Main ing for easier arc starting.
Z1 Range Rectifier
Switch S3 SR3 20 Reactor Z1
16 ♦ 23
Tapped reactor limits weld output
Current
and provides coarse ranges.
Transformer HF Filter
CT1 21 Ampere Range Switch S3
Board PC3
24♦ Selects coarse range of weld out-
put from Z1.
Polarity
Switch 22 Main Rectifier SR3
S12 Changes AC weld output to DC.
25 ♦
23 HF Filter Board PC3
17 Ammeter Protects main rectifier from high fre-
A1 quency and voltage spikes.
Supplementary 25♦
Protectors 24 Polarity Switch S12
CB1, CB2 Voltmeter Selects polarity of weld output.
V1
25 Voltmeter V1, Ammeter A1
Display weld voltage and current.
18♦
26 Electrode And Work Weld
AC Output Terminals
Receptacles Provide weld output. Without S12,
RC1, GFCI1 terminals are labeled negative (−)
and positive (+).
26 26 27 Transformer T1
Supplies power to arc drive (dig)
Electrode Work circuit. Arc drive circuit only active
Weld Output Weld Output in Stick mode.
Terminal Terminal
28 Integrated Rectifiers SR4,
SR5
Change AC output of stator wind-
ings to DC to supply power to arc
drive (dig) circuit.
Electrode Work

Big Blue 400D, 500 X TM-4425 Page 31

1 Engine
15 14
Supplies force to turn revolving fields.
2 Control Relays CR1, CR5, CR9 Filter Board Supplementary
CR1 energizes at start-up to supply PC6/Remote Protectors
Receptacle RC14 CB5, CB6 13
power to starter solenoid.
CR5 energizes at start-up to supply
power for field flashing and to the fuel LED Board PC9
solenoid.
CR9 (export models only) energizes at
start-up to bypass resistor R7.
16 17 12
3 Control Relay TD1 or Engine Fuel/
Hour Gauge FUEL/HM Process/ Voltage/
Contactor Switch S6 Amperage
 Eff w/Serial No. LJ110096E Adjust
Fuel/Hour gauge FUEL/HM Remote Always Switch S5
On
replaced control relay TD1.
Field
Energizes at start-up to supply power to Current
CR5 and enable engine gauges and Regulator
shutdown circuit. (Engine shutdown in- 11
3 Board
hibited for 30 seconds after start-up.) Voltage/ PC1
FUEL/HM also monitors fuel level and Control Relay Amperage
engine run time. TD1 Or Adjust
Fuel/Hour Gauge Control R1
4 Control Relays CR3, CR4, CR6
FUEL/HM
CR3 energizes at no load to supply
power to throttle solenoid TS1.
2
CR4 energizes at no load to bypass re- 10 9 9
sistor R3 and prevent loss of field ex- Control
citation. Relays CR1, Integrated
CR6 energizes when engine is running CR5, CR9 Rectifier Fuse F1 Fuse F2
to supply power to idle module. SR1
5 Idle Module PC7
Controls engine speed. Without a signal 1 7 8
from CT1, it lowers engine speed to idle Exciter
(1250 RPM). Revolving
Engine Fields

Weld
6 Throttle Solenoid TS1 (Rotor) Stator Windings
(Pull To Idle)
Decreases engine speed to idle rpm Generator Power
(1250 RPM) when energized.
7 Main And Exciter Revolving Fields 6♦ 20
Turn at 1850 RPM maximum for weld
Throttle
and power. The speed and excitation HF Filter
Solenoid TS1
current of the field coils determine volt- Board PC5
(Pull To Idle)
ages in stator windings. 18 ♦ 31
8 Stator Windings
Supply power to exciter, generator pow- Three-Phase Transformer
er, and weld circuits. Generator T1
5♦ 4♦
9 Fuses F1, F2
Protect aux. stator (exciter) windings Idle Module Control Relays
from overload. PC7 CR3, CR4,
CR6 19 ♦
10 Integrated Rectifier SR1
Changes AC output of stator windings
to DC to supply excitation current to the Supplementary
exciter revolving field. Protector CB7
11 Voltage/Amperage Adjust Control
R1
Adjusts voltage/amperage within range
selected by S3.
32
12 Field Current Regulator Board
PC1 Integrated
Adjust weld output by changing revolv- Rectifiers
ing field current after comparing feed- SR4, SR5
back to voltage/amperage setting of R1.
13 LED Board PC9
Monitors power, remote control, com-
mand, engine RPM, and field excitation
inputs to PC1.

Figure 8-2. Functional Diagram For CC/CV Models

TM-4425 Page 32 Big Blue 400D, 500 X
 14 Supplementary Protectors CB5,
CB6
AC Or DC Control Circuits Protect PC6/RC14 from overload.
15 Filter Board PC6/Remote 14 Recep-
tacle RC14
3φ Power PC6 protects unit from high frequency,
and RC14 connects remote voltage/am-
perage and contactor control to unit.
Weld Current Circuit 16 Process/Contactor Switch S6
Selects weld process and weld output on/
Either Mechanical Coupling off control (Weld Terminals Always On or
Or External Circuits Remote On/Off Switch Required).
17 Voltage/Amperage Adjust Switch S5
Magnetic Coupling
Selects Panel or Remote voltage/amper-
♦ Optional age control.
18 Three-Phase Generator
Provides connection points and power for
three-phase auxiliary equipment.
19 Supplementary Protector CB7
Protects three-phase generator windings
OCV
from overload.
Feedback
20 HF Filter Boards PC4, PC5
Protect unit from high frequency.
21 Current Transformer CT1
Senses output from either auxiliary power
or weld windings, and signals idle module
to increase to or maintain weld speed
(1850 RPM).
22 Supplementary Protectors CB1,
CB2
24 25 26 Protect AC receptacles RC1 and GFCI1
from overload.
Reactor Ampere Main
Range Rectifier 23 AC Receptacles RC1 And GFCI1
Z1 Switch S3 SR3 Provide connection points and power for
21♦ 27 auxiliary equipment.
Current
Transformer 24 Reactor Z1
HF Filter Tapped reactor limits weld output and pro-
CT1 Board PC3
28♦ vides coarse ranges.
25 Ampere Range Switch S3
Polarity Selects coarse range of weld output from
Switch Z1.
S12
29 ♦ 26 Main Rectifier SR3
Changes AC weld output to DC.
22 Ammeter
29♦ A1 27 HF Filter Board PC3
Supplementary Protects main rectifier from high frequen-
Protectors CB1, Voltmeter cy and voltage spikes, and provides OCV
CB2 20 V1 feedback signal to PC1.
28 Polarity Switch S12
HF Filter 20 20 Selects polarity of weld output.
Board PC4
23♦ 29 Voltmeter V1, Ammeter A1
HF Filter HF Filter Display weld voltage and current.
AC Board PC4 Board PC5
Receptacles 30 Electrode And Work Weld Output
RC1, GFCI1 Terminals
Provide weld output. Without S12, termi-
30 30
nals are labeled negative (−) and positive
(+).
Electrode Work
Weld Output Weld Output 31 Transformer T1
Terminal Terminal Supplies power to arc drive (dig) circuit.
Arc drive circuit only active in Stick mode.
32 Integrated Rectifiers SR4, SR5
Change AC output of stator windings to
DC to supply power to arc drive (dig) cir-
Electrode Work cuit.

Big Blue 400D, 500 X TM-4425 Page 33

 SECTION 9 − TROUBLESHOOTING

9-1. Troubleshooting Flowchart

This flowchart is intended as a general guide only. Always read and follow the safety
information and specific instructions given elsewhere in this Technical Manual.

Note stock number and serial number of machine.

What does the operator say is wrong?
Gather Information What was the operator doing?
When and where does the problem occur?
Has any part of the system recently changed?

Check for signs of damage and for proper connections, gas

Visual Inspection supply, cable routing, consumables, and wire feed system.

For inverter power sources that have unknown problems or

Pre-Power Checks are not powering up.

Check for required input voltage, phases, and frequency.

Check Input Power Make sure power source and plugs are wired correctly. VAC
Make sure engine speed is set to correct RPM.

For important service memos and software updates.

Check Extranet It is possible the issue has already been identified and
addressed by Miller.

Check open-circuit voltage for each process and polarity.

Check OCV Check auxiliary power output if available.

Test machine under load with a load bank.

Load/Function Test Test all system functions.
Perform a weld test when possible.

Trouble1_2018-05

TM-4425 Page 34 Big Blue 400D, 500 X

9-2. Troubleshooting Tables

 See Section 9-3 or 9-6 for test points and values and Section 13 and following for parts location.
 Use Testing Booklet (Miller Part No. 150853) when servicing this unit.
 See the Miller Extranet for service memos that may aid in the repair of this product.

A. Welding − CC Models

Trouble Remedy
No weld output; generator power output Check position of Ampere Range switch S3.
okay at AC receptacles.
Check position of optional polarity switch S12.

Place Amperage Adjust switch in Panel position, or place switch in Remote position and connect remote
control to Remote Amperage Adjust receptacle RC13 (see Sections 4-10 and 5-3).

Check and secure connections to Remote Amperage Adjust receptacle RC13 (see Section 4-10).

Check fuse F2, and replace if open (see Section 7-10).

If fuse continues to open, check SR2, R1, and R2. For CC/CV machines, check PC1 field current regula-
tor board brushes and brush holder; remove wires 105 and 108 from the brushes and check the rotor
winding for correct resistance and that it is not shorted to the machine chassis.

Check resistance and connections of Voltage/Amperage Adjust control R1; R1 is 34 ohms ±10%.
Replace R1 if necessary.

Check integrated rectifier SR2, and replace if necessary.

Disconnect leads 105 and 108 from the rotor, and check continuity across slip rings. Replace rotor if
necessary.

Clean slip rings, and install new brushes if necessary (see Section 9-20).

Check resistance and connections of resistor R2; full resistance of R2 (end to end) is 10 ohms ±10%.
Replace R2 if necessary. If R2 is replaced, adjust R2 (see Section 9-21).

Check main rectifier SR3, and replace if necessary.

Check reactor Z1 for signs of winding failure. Check continuity across windings, and check for proper
connections. Replace Z1 if necessary.

No weld output or generator power out- Disconnect equipment from generator power receptacles during start-up.
put at AC receptacles.
Check fuses F1 and F2, and replace if open (see Section 7-10).
If fuse F1 continues to open, check SR1, C9, R3, brushes, and brush holder. Remove wires 105 and 106
from the brushes and check the rotor winding for correct resistance and that it is not shorted to the ma-
chine chassis. If fuse F2 continues to open, check SR2, R1, and R2. For CC/CV machines, check PC1
field current regulator board brushes and brush holder; remove wires 105 and 108 from the brushes and
check the rotor winding for correct resistance and that it is not shorted to the machine chassis.

Reset supplementary protector CB12 (see Section 7-10).

If CB12 continues to open, check D1, SR1, C9, R3, brushes, and brush holder. Remove wires 105 and
106 from the brushes and check the rotor for correct resistance and that it is not shorted to the machine
chassis.

Check diode/capacitor board D1/C1, and replace if necessary.

Check integrated rectifier SR1, and replace if necessary.

Check integrated rectifier SR2, and replace if necessary.

Check capacitor C9, and replace if necessary.

Clean slip rings, and install new brushes if necessary (see Section 9-20).

Check control relay CR5: Check all connections, check coil continuity, check for proper coil voltage, and
check contact voltage (input to common and output to common) to ensure contacts are operating. Re-
place CR5 if necessary.

Big Blue 400D, 500 X TM-4425 Page 35

 Trouble Remedy
No weld output or generator power out- Check resistance and connections of resistor R3; full resistance of R3 (end to end) is 10 ohms ±10%.
put at AC receptacles (Continued). Replace R3 if necessary. If R3 is replaced, adjust R3 (see Section 9-21).

Disconnect leads 105 and 106 from the rotor, and check continuity across slip rings. Replace rotor if
necessary.

Disconnect stator excitation leads 100 and 101, and check continuity between leads. Replace stator if
necessary.

Erratic weld output. Use dry, properly stored electrodes.

Be sure connection to work piece is clean and tight.

Remove excessive coils from weld cables.

Check and tighten connections inside and outside unit.

Clean slip rings, and install new brushes if necessary (see Section 9-20).

Place Stick/TIG selection switch S6 in the TIG position and perform test weld. If unit welds okay,
check control relay CR7: Check all connections, check coil continuity, check for proper coil voltage,
and check contact voltage (input to common and output to common) to ensure contacts are operating.
Replace CR7 if necessary.

Check main rectifier SR3, and replace if necessary.

High weld output. Check position of Ampere Range switch S3 and Voltage/Amperage Adjust control R1.

Check engine weld/power speed, and adjust if necessary (see engine manual and Section 7-8).

Reset supplementary protector CB11 (see Section 7-10).

If CB11 continues to open, on CC-only machines, check control relay CR7. On CC/CV machines, check
field current regulator board PC1.

Check control relay CR7: Check all connections, check coil continuity, check for proper coil voltage, and
check contact voltage (input to common and output to common) to ensure contacts are operating. Re-
place CR7 if necessary.

Low weld output. Check engine speed, and adjust if necessary (see engine manual and Section 7-8).

Check fuses F1 and F2, and replace if open (see Section 7-10).
If fuse F1 continues to open, check SR1, C9, R3, brushes, and brush holder. Remove wires 105 and 106
from the brushes and check the rotor winding for correct resistance and that it is not shorted to the ma-
chine chassis. If fuse F2 continues to open, check SR2, R1, and R2. For CC/CV machines, check PC1
field current regulator board brushes and brush holder; remove wires 105 and 108 from the brushes and
check the rotor winding for correct resistance and that it is not shorted to the machine chassis.

Check integrated rectifier SR1, and replace if necessary.

Check integrated rectifier SR2, and replace if necessary.

Check capacitor C9, and replace if necessary.

Disconnect leads 105 and 108 from the rotor, and check continuity across slip rings. Replace rotor if
necessary.

Maximum weld output only in each Check control relay CR7: Check all connections, check coil continuity, check for proper coil voltage, and
ampere range (with Stick/TIG Selection check contact voltage (input to common and output to common) to ensure contacts are operating. Re-
switch in Stick position). place CR7 if necessary.

No remote fine amperage control. Place Amperage Adjust switch S5 in correct position.

Check and secure connections to Remote Amperage Adjust receptacle RC13 (see Section 4-10).

Reset supplementary protector CB11 (see Section 7-10).

If CB11 continues to open, on CC-only machines, check control relay CR7. On CC/CV machines, check
field current regulator board PC1.

Check control relay CR7: Check all connections, check coil continuity, check for proper coil voltage, and
check contact voltage (input to common and output to common) to ensure contacts are operating. Re-
place CR7 if necessary.

Repair or replace remote control device.

No control of weld output or low weld Place Amperage Adjust switch S5 in Panel position, or place switch in Remote position and connect re-
output. mote current control to Remote Amperage Adjust Receptacle RC13.

TM-4425 Page 36 Big Blue 400D, 500 X

 Trouble Remedy
Difficulty in striking an arc when Stick Place Stick/TIG Selection switch S6 in Stick position.
(SMAW) welding.
Reset supplementary protector CB11 (see Section 7-10).
If CB11 continues to open, on CC-only machines, check control relay CR7. On CC/CV machines, check
field current regulator board PC1.

Check control relay CR7: Check all connections, check coil continuity, check for proper coil voltage, and
check contact voltage (input to common and output to common) to ensure contacts are operating. Re-
place CR7 if necessary.

Low weld output. See low weld output remedies earlier in this section.

Electrode sticks to the workpiece more Circuit breaker CB4 may be open. CB4 automatically resets when the fault is corrected (see Section
frequently during low voltage (short arc 7-10).
length) conditions.
Check transformer T1 for signs of winding failure. Check continuity across windings, and check for
proper connections. Check secondary voltages. Replace T1 if necessary.

Check integrated rectifiers SR4 and SR5, and replace if necessary.

B. Welding − CC/CV Models

Trouble Remedy
No weld output; generator power output Place Process/Contactor switch S6 in a Weld Terminals Always On position, or place switch in a Remote
okay at AC receptacles. On/Off Switch Required position and connect remote contactor to optional Remote 14 receptacle RC14
(see Section 9-10).

Check position of Ampere Range switch S3.

Check position of optional polarity switch S12.

Reset supplementary protector CB11 (see Section 7-10).

If CB11 continues to open, on CC-only machines, check control relay CR7. On CC/CV machines, check
field current regulator board PC1.

Reset supplementary protector CB5 or CB6 (see Section 7-10). Check for faulty remote device con-
nected to RC14.

Check fuse F2, and replace if open (see Section 7-10).

If fuse continues to open, check SR2, R1, and R2. For CC/CV machines, check PC1 field current regula-
tor board brushes and brush holder; remove wires 105 and 108 from the brushes and check the rotor
winding for correct resistance and that it is not shorted to the machine chassis.

Check and secure connections to Remote 14 receptacle RC14 (see Section 9-10).

Check connector board PC6 and connections, and replace PC6 if necessary (see Section 9-11).

Clean slip rings, and install new brushes if necessary (see Section 9-20).

Check field current regulator board PC1 and connections, and replace PC1 if necessary (Section 9-13).

Disconnect leads 105 and 108 from rotor, and check continuity across slip rings. Replace rotor if
necessary.

No weld output or generator power out- Disconnect equipment from generator power receptacles during start-up.
put at AC receptacles.
Reset supplementary protector CB12 (see Section 7-10).
If CB12 continues to open, check D1, SR1, C9, R3, brushes, and brush holder. Remove wires 105 and
106 from the brushes and check the rotor for correct resistance and that it is not shorted to the machine
chassis.

Check fuses F1 and F2, and replace if open (see Section 7-10).
If fuse F1 continues to open, check SR1, C9, R3, brushes, and brush holder. Remove wires 105 and 106
from the brushes and check the rotor winding for correct resistance and that it is not shorted to the ma-
chine chassis. If fuse F2 continues to open, check SR2, R1, and R2. For CC/CV machines, check PC1
field current regulator board brushes and brush holder; remove wires 105 and 108 from the brushes and
check the rotor winding for correct resistance and that it is not shorted to the machine chassis.

Check control relay CR5: Check all connections, check coil continuity, check for proper coil voltage,
and check contact voltage (input to common and output to common) to ensure contacts are operating.
Replace CR5 if necessary.

Check integrated rectifier SR1, and replace if necessary.

Big Blue 400D, 500 X TM-4425 Page 37

 Trouble Remedy
No weld output or generator power out- Check capacitor C9, and replace if necessary.
put at AC receptacles (Continued).
Clean slip rings, and install new brushes if necessary (see Section 9-20).

Disconnect leads 105 and 106 from the rotor, and check continuity across slip rings. Replace rotor if
necessary.

Disconnect stator excitation leads 100 and 101, and check continuity between leads. Replace stator if
necessary.

Check field current regulator board PC1 and connection, and replace PC1 if necessary (see Section
9-13).

Erratic weld output. Use dry, properly stored electrodes.

Be sure connection to work piece is clean and tight.

Remove excessive coils from weld cables.

Check and tighten connections inside and outside unit.

Clean slip rings, and install new brushes if necessary (see Section 9-20).

Check main rectifier SR3, and replace if necessary.

High weld output. Check position of Ampere Range switch S3 and Voltage/Amperage Adjust control R1.

Check engine speed, and adjust if necessary (see engine manual and Section 7-8).

Check field current regulator board PC1 and connection, and replace PC1 if necessary
(see Section 9-13).

Electrode sticks to the workpiece more Circuit breaker CB4 may be open. CB4 automatically resets when the fault is corrected (see Section
frequently during low voltage (short arc 7-10).
length) conditions.
Check transformer T1 for signs of winding failure. Check continuity across windings, and check for
proper connections. Check secondary voltages. Replace T1 if necessary.

Check integrated rectifiers SR4 and SR5, and replace if necessary.

Low weld output. Check engine speed, and adjust if necessary (see engine manual and Section 7-8).

Check fuses F1 and F2, and replace if open (see Section 7-10).
If fuse F1 continues to open, check SR1, C9, R3, brushes, and brush holder. Remove wires 105 and 106
from the brushes and check the rotor winding for correct resistance and that it is not shorted to the ma-
chine chassis. If fuse F2 continues to open, check SR2, R1, and R2. For CC/CV machines, check PC1
field current regulator board brushes and brush holder; remove wires 105 and 108 from the brushes and
check the rotor winding for correct resistance and that it is not shorted to the machine chassis.

Check integrated rectifier SR1, and replace if necessary.

Check capacitor C9, and replace if necessary.

Check field current regulator board PC1 and connection, and replace PC1 if necessary (see Section
9-13).

Clean slip rings, and install new brushes if necessary (see Section 9-20).

Disconnect leads 105 and 108 from the rotor, and check continuity across slip rings. Replace rotor if
necessary.

Low open-circuit voltage. Check engine speed, and adjust if necessary (see engine manual and Section 7-8).

No remote fine amperage or voltage Place Voltage/Amperage Adjust switch S5 in Remote position.
control.
Check and secure connections to Remote 14 receptacle RC14 (see Section 9-10).

Repair or replace remote control device.

Constant speed wire feeder does not Reset supplementary protector CB5 or CB6 (see Section 7-10). Check for faulty remote device con-
work with welder/generator. nected to RC14.

Check and secure connections to Remote 14 receptacle RC14 (see Section 9-10).

Repair or replace wire feeder.

TM-4425 Page 38 Big Blue 400D, 500 X

 Trouble Remedy
Low CV weld output. Set Ampere Range switch S3 to highest range.

Min or max CV weld output only. Check position of Voltage/Amperage Adjust control R1 and Voltage/Amperage Adjust switch S5.

Repair or replace remote control device.

Check field current regulator board PC1 and connection, and replace PC1 if necessary
(see Section 9-13).

Max CV weld output only: disconnect leads 19 and 30 at PC3 and check voltage feedback circuit.
Feedback voltage should be the same as weld terminal open circuit voltage (see Section 9-6).

C. Generator Power

Trouble Remedy

No generator power output at AC recep- Reset receptacle supplementary protectors.

tacles; weld output okay.
Check resistance of generator power windings between leads 81 and 84. Replace exciter stator (aux.
stator) if necessary.

No generator power output or weld Disconnect equipment from generator power receptacles during start-up.
output.
Check fuses F1 and F2, and replace if open (see Section 7-10).
If fuse F1 continues to open, check SR1, C9, R3, brushes, and brush holder. Remove wires 105 and 106
from the brushes and check the rotor winding for correct resistance and that it is not shorted to the ma-
chine chassis. If fuse F2 continues to open, check SR2, R1, and R2. For CC/CV machines, check PC1
field current regulator board brushes and brush holder; remove wires 105 and 108 from the brushes and
check the rotor winding for correct resistance and that it is not shorted to the machine chassis.

Reset supplementary protector CB12 (see Section 7-10).

If CB12 continues to open, check D1, SR1, C9, R3, brushes, and brush holder. Remove wires 105 and
106 from the brushes and check the rotor for correct resistance and that it is not shorted to the machine
chassis.

Check diode/capacitor board D1/C1, and replace if necessary.

Check integrated rectifier SR1, and replace if necessary.

On CC models only, check integrated rectifier SR2, and replace if necessary.

Check capacitor C9, and replace if necessary.

Clean slip rings, and install new brushes if necessary (see Section 9-20).

Check resistance and connections of resistor R3; full resistance of R3 (end to end) is 10 ohms ±10%.
Replace R3 if necessary. If R3 is replaced, adjust R3 (see Section 9-21 or 9-22).

Disconnect leads 105 and 106 from the rotor, and check continuity across slip rings. Replace rotor
if necessary.

High output at generator power AC Check engine speed, and adjust if necessary (see engine manual and Section 7-8).
receptacles.
Check resistance and connections of resistor R3; full resistance of R3 (end to end) is 10 ohms ±10%.
Replace R3 if necessary. If R3 is replaced, adjust R3 (see Section 9-21 or 9-22).

Low output at generator power AC
receptacles.
Check engine speed, and adjust if necessary (see engine manual and Section 7-8)
Check fuse F1, and replace if open (see Section 7-10).
If fuse continues to open, check SR1, C9, R3, brushes, and brush holder. Remove wires 105 and 106
from the brushes and check the rotor winding for correct resistance and that it is not shorted to the ma-
chine chassis.

Check integrated rectifier SR1, and replace if necessary.

Check capacitor C9, and replace if necessary.

Check resistance and connections of resistor R3; full resistance of R3 (end to end) is 10 ohms ±10%.
Replace R3 if necessary. If R3 is replaced, adjust R3 (see Section 9-21 or 9-22).

Big Blue 400D, 500 X TM-4425 Page 39

D. Optional Three-Phase Generator (CC/CV Models Only)

Trouble Remedy

No or low output at optional three- Place Process/Contactor switch S6 in Weld Terminals Always On - Stick position.
phase generator/receptacle RC5.
Reset supplementary protector CB7.
If CB7 continues to open, check external wiring and the load connected to CB7.

Reset supplementary protector CB5 (see Section 7-10).

If CB5 continues to open, check filter board PC6 and field current regulator board PC1.

Check engine weld/power speed, and adjust if necessary (see engine manual and Section 7-8).

Check slip rings, and install new brushes if necessary (see Section 9-20).

Check field current regulator board PC1 and connection, and replace PC1 if necessary (see Section 9-13).

High output at optional three-phase Check engine weld/power speed, and adjust if necessary (see engine manual and Section 7-8).
generator/receptacle RC5.
Check field current regulator board PC1 and connection, and replace PC1 if necessary (see Section 9-13).

Erratic output at optional three-phase Clean slip rings, and install new brushes if necessary (see Section 9-20).
generator/receptacle RC5.
Check field current regulator board PC1 and connections, and replace PC1 if necessary (see Section
9-13).

E. Engine

Trouble Remedy
Engine will not crank. Check battery, and replace if necessary.

Check battery connections and tighten if necessary.

Reset supplementary protector CB13 (see Section 7-10). Check engine wiring harness and components.

Check control relay CR5: Check all connections, check coil continuity, check for proper coil voltage, and
check contact voltage (input to common and output to common) to ensure contacts are operating. Re-
place CR5 if necessary.

Circuit breaker CB10 may be open. CB10 automatically resets when fault is corrected (see Section 7-10).
Check engine wiring harness and components.

Check engine wiring harness plug connections.

Check continuity of Engine Control switch S1, and replace if necessary.

Check control relay CR1: Check all connections, check coil continuity, check for proper coil voltage, and
check contact voltage (input to common and output to common) to ensure contacts are operating. Re-
place CR1 if necessary.

Prior to Serial No. LJ110096E, check control relay TD1 for proper operation according to Section 9-18.
Replace TD1 if necessary.

Eff w/Serial No. LJ110096E, check Fuel/Hour gauge FUEL/HM for proper operation according to Section
9-19. Replace FUEL/HM if necessary.

Engine cranks but does not start. Check fuel level.

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

Prior to Serial No. LJ110096E, check control relay TD1 for proper operation according to Section 9-18.
Replace TD1 if necessary.

Eff w/Serial No. LJ110096E, check Fuel/Hour gauge FUEL/HM for proper operation according to Section
9-19. Replace FUEL/HM if necessary.

Eff w/Serial No. LH023056 thru MA340014E, check control relay CR9: Check all connections, check coil
continuity, check for proper coil voltage, and check contact voltage (input to common and output to
common) to ensure contacts are operating. Replace CR9 if necessary.

Eff w/Serial No. LH023056 thru MA340014E, check resistance and connections of R7. R7 is three ohms.
Replace R7 if necessary.

Check fuel solenoid FS1 for proper coil voltage and connections. Check continuity of coil. Replace
FS1 if necessary.

Air in fuel system. See engine manual.

TM-4425 Page 40 Big Blue 400D, 500 X

 Trouble Remedy
Engine starts, but stops when Engine Check oil level. Automatic shutdown system stops engine if oil pressure is too low or engine temperature
Control switch S1 is released. is too high (see Section 4-6). Automatic shutdown system is inhibited for 30 seconds after start-up.

Prior to Serial No. LJ110096E, check control relay TD1 for proper operation according to Section 9-18.
Replace TD1 if necessary.

Eff w/Serial No. LJ110096E, check Fuel/Hour gauge FUEL/HM for proper operation according to Section
9-19. Replace FUEL/HM if necessary.

Check control relay CR5: Check all connections, check coil continuity, check for proper coil voltage, and
check contact voltage (input to common and output to common) to ensure contacts are operating. Re-
place CR5 if necessary.

Engine hard to start in cold weather. Use optional starting aid switch S2 (see Section 5-2).

Check optional starting aid control relay CR8 for proper coil voltage and connections. Check continuity
of coil and condition of contacts. Replace CR8 if necessary.

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 7-1).

Engine suddenly stops. Check oil level. Automatic shutdown system stops engine if oil pressure is too low or engine temperature
is too high (see Section 4-6). Automatic shutdown system is inhibited for 30 seconds after start-up.

Eff w/Serial No. LJ110096E, check Fuel/Hour gauge FUEL/HM for proper operation according to Section
9-19. Replace FUEL/HM if necessary.

See engine manual.

Engine slowly stopped and cannot be Check fuel level.

restarted.
Check engine air and fuel filters (see Sections 7-5 and 7-9).

See engine manual.

Battery discharges between uses. Turn Engine Control switch S1 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 Check continuity of Engine Control switch S1, and replace if necessary.
weld speed (models with idle option
only). Check idle module PC7 and connections, and replace if necessary.

Check current transformer CT1 for continuity and proper connections. Replace CT1 if necessary.

Check for obstructed throttle solenoid TS1.

Engine does not run at idle speed CC models: place Stick/TIG Selection switch S6 in Stick position.
(models with idle option only). CC/CV models: place Process/Contactor switch S6 in any position but Remote On/Off Switch Re-
quired-TIG.

Allow circuit breaker CB14 time to reset (see Section 7-10). Check engine throttle solenoid TS1 and wiring
harness and components.

Check for obstructed throttle solenoid TS1.

Check throttle solenoid TS1 for proper coil voltage and connections. Check continuity of coil. Replace
TS1 if necessary.

Check idle module PC7, and replace if necessary.

Check control relay CR3: Check all connections, check coil continuity, check for proper coil voltage, and
check contact voltage (input to common and output to common) to ensure contacts are operating. Re-
place CR3 if necessary.

Check control relay CR6: Check all connections, check coil continuity, check for proper coil voltage, and
check contact voltage (input to common and output to common) to ensure contacts are operating. Re-
place CR6 if necessary.

Engine uses oil during run-in period; Dry engine (see Section 12).
wetstacking occurs.

Big Blue 400D, 500 X TM-4425 Page 41

9-3. Troubleshooting Circuit Diagram (CC Models) (Use With Section 9-4)

V3, R3

V2, R2

V1, R1

V7, R6
Adjust R3
according to
Section 9-21

V6
I2

V8, R7
V4, R4
Adjust R2 I1
according to
Section 9-21 Max OCV
control relay
CR7
V5, R5

Field flashing/
engine enable
relay CR5

Starting Aid
V15, relay CR8
R11

V16, Throttle Solenoid Starter

R12 TS1 (Pull To Idle) relay CR1

TM-4425 Page 42 Big Blue 400D, 500 X

 V18
V17

V19

See Section 8 for

PC3 information
V9, V11,
R8 R10 See Section
9-7 for wave-
forms A and
B

V12,
A, B

V10, R9

Idle control
relay CR3
V14
V13

Field current
resistor bypass relay CR4

R13

Idle module
relay CR6
238 628-C

Big Blue 400D, 500 X TM-4425 Page 43

9-4. Troubleshooting Values For Circuit Diagram (CC Models) (Use With Section 9-3)

Test Equipment Needed:

Voltage Readings
a) Tolerance − ±10% unless specified
b) Condition − 70°F (21°C); cold machine (no
warm-up); no load
c) Reference − single arrow: reference to
circuit common (lead 42); double arrow:
reference to points indicated
d) Stick/TIG switch S6 in Stick position Amperage Readings
unless noted
a) Tolerance − ±5% unless specified
e) Wiring Connections − see Section 11
b) Condition − 70°F (21°C); cold
V1 126 to 130 volts AC machine (no warm-up); no load
V2 126 to 130 volts AC I1 6.6 amps DC (R1 at min., Range switch
S3 in high range, Stick/TIG switch S6 in
V3 252 to 260 volts AC Stick position)
V4 101 volts AC 4 amps DC (R1 at min., Range switch S3
in high range, Stick/TIG switch S6 in TIG
V5 167 volts AC position)
V6 +135 volts DC I2 4.3 to 4.6 amps DC
V7 +89 volts DC
V8 +48.2 volts DC (R1 at min. and Stick/TIG switch
S6 in TIG position)
+99.5 volts DC (R1 at max. and Stick/TIG Switch
S6 in Stick position) Resistance Values
V9 69 volts AC (R1 at max.) a) Tolerance − ±10% unless specified
V10 69 volts AC (R1 at max.)
b) Condition − 70°F (21°C); cold
V11 69 volts AC (R1 at max.) machine (no warm-up)
V12 +65 volts DC (R1 at min. and Stick/TIG switch S6 c) Wiring Connections − see Section 11
in TIG position)
+92 volts DC (R1 at max. and Stick/TIG switch d) Stop engine before checking
S6 in Stick position) resistance
V13 +12 volts DC at idle RPM R1 thru R5 Less than 1 ohm
V14 +12 volts DC 10 − 15 seconds after load is R6 18.5 ohms
removed and engine goes to idle RPM R7 14.2 ohms
V15 +12 volts DC at idle RPM R8 thru R10 Less than 1 ohm
V16 +12 volts DC with engine running R11 Pull-in: Less than 1 ohm
Hold: 5.3 ohms
V17 258 volts AC
R12 3.6 ohms
V18, 18 volts AC R13 28 to 33 ohms Full Tank
V19 182 to 215 ohms LCD and
fuel tank icon blink
216 ohms Fuel icon blinks and
shutdown initiates after 10
second delay
240 to 245 ohms Empty Tank

TM-4425 Page 44 Big Blue 400D, 500 X

9-5. Troubleshooting Values For Circuit Diagram (CC/CV Models)(Use With Section 9-6)

Test Equipment Needed:

Voltage Readings
a) Tolerance − ±10% unless specified
b) Condition − 70°F (21°C); cold machine
(no warm-up); no load
c) Reference − single arrow: reference to
circuit common (lead 42); double
Resistance Values
arrow: reference to points indicated
d) Process/Contactor switch S6 in Weld a) Tolerance − ±10% unless
Terminals Always On − Stick position specified
unless noted b) Condition − 70°F (21°C); cold
e) Wiring Connections − see Section 11 machine (no warm-up)
V1 126 to 130 volts AC c) Wiring Connections − see
V2 126 to 130 volts AC Section 11
V3 252 to 260 volts AC d) Stop engine before checking
resistance
V4 27 volts AC
V5 101 volts AC R1 thru R6 Less than 1 ohm
R7 18.5 ohms
V6 175 volts AC
R8 14.2 ohms
V7 +135 volts DC R9 thru R11 Less than 1 ohm
V8 + 89 volts DC R12 Pull-in: Less than 1 ohm
V9 +89 volts DC (S6 in Weld Terminals Always Hold: 5.3 ohms
On −Stick position) R13 3.6 ohms
+33 volts DC (S6 in Weld Terminals Always R14 28−33 ohms Full Tank
On−Scratch Start TIG position) 182−215 ohms LCD and
+11.5 to 40.5 volts DC from min to max of fuel tank icon blink
R1 (S6 in Weld Terminals Always On − 216 ohms Fuel icon
Wire position) blinks and shutdown
V10 69 volts AC (R1 at max.) initiates after 10 second
delay
V11 69 volts AC (R1 at max.) 240−245 ohms Empty
V12 69 volts AC (R1 at max.) Tank
V13 +89 volts DC (S6 in Weld Terminals Always
On − Stick position)
47 volts DC (S6 in Weld Terminals Always
On − Scratch Start Tig position)
+16 to 56 volts DC from min to max of R1
(S6 in Weld Terminals Always On − Wire
position) Amperage Readings
V14 +12 volts DC at idle RPM a) Tolerance − ±5% unless specified
V15 +12 volts DC 10 − 15 seconds after load is b) Condition − 70°F (21°C); cold
removed and engine goes to idle RPM
machine (no warm-up); no load
V16 +12 volts DC at idle RPM
c) Process/Contactor switch S6 in
V17 +12 volts DC with engine running Weld Terminals Always On − Stick
V18 0 to +10 volts DC from min to max of R1 position unless noted
V19 +10 volts DC I1 6.3 amps DC
V20 0 to +10 volts DC from min to max of R1
I2 4.3 − 4.6 amps DC
V21 +12 volts DC
V22 +12 volts DC
V23 258 volts AC
V24, 18 volts AC
V25

Big Blue 400D, 500 X TM-4425 Page 45

9-6. Troubleshooting Circuit Diagram (CC/CV Models) (Use With Section 9-5)

V3, R3

V1, R1

V2, R2

V4, R4

Adjust R3
according to
Section 9-22 V8, R7
V9, R8
See Section
9-11 for
PC6 data V7
I2

V5, V19 V20

R5 I1

V6, V18
R6

See Section V22

V21
9-10 for RC14
information

V16, R14
R12

V17, Field flashing/

R13 engine enable Starting Aid
Throttle Solenoid Starter relay CR5 relay CR8
TS1 (Pull To Idle) relay CR1

TM-4425 Page 46 Big Blue 400D, 500 X

 V23 V24

V25

V12, R11 See Section 9-7

for waveforms
V10, C and D
R9
See Section
8 for PC3
V13,
information C, D

V11, R10

See Section 8
for PC4, PC5
information

Idle control
relay CR3
V14 V15

Field
current
resistor bypass
relay CR4

Idle module
relay CR6

240 205-D

Big Blue 400D, 500 X TM-4425 Page 47

9-7. Waveforms For Sections 9-3 And 9-6

CC Models Only
 The waveforms represent the output
of the welding power source. When
operating properly, the power source
waveforms match those shown here.
1 ms 20 V 1 ms 5 V

gnd gnd

A. CC Models − DC Open-Circuit Voltage, B. CC Models − DC Output, 25 Volts DC, 200

Ampere Range Switch S3 At Maximum, Amperes, Ampere Range Switch S3 At
Amperage Adjust Control R1 At 100 110-225 Position (Resistive Load)

CC/CV Models Only

1 ms 50 V 1 ms 10 V

gnd gnd

C. CC/CV Models − DC/CC Open-Circuit Volt- D. CC/CV Models − DC/CC Output, 28 Volts
age, Amperage Adjust Control R1 At DC, 200 Amperes, Ampere Range Switch
Maximum S3 At 115-320 Position (Resistive Load)

Test Equipment Needed:

TM-4425 Page 48 Big Blue 400D, 500 X

9-8. Volt-Ampere Curves For CC/CV Models
A. Stick Mode The volt-ampere curves show the
minimum and maximum voltage
100 and amperage output capabilities of
the welder/generator. Curves of all
RANGES:
other settings fall between the
MAX curves shown.
80 155 − 450
115 − 320  See Section 3-6 for curves for
75 − 195 CC models.
60 40 − 90
DC VOLTS

40

20

0
0 100 200 300 400 500 600 700 800 900 1000
DC AMPERES
B. MIG Mode

100

80

60
MAX
DC VOLTS

40

20
MIN

0
0 100 200 300 400 500 600 700 800 900 1000
DC AMPERES
C. TIG Mode

100
RANGES:
60 − 365
80 35 − 250
25 − 155
15 − 75
DC VOLTS

60

40

20

0
0 100 200 300 400 500
DC AMPERES
215 080-A / 215 083-A / 215 079-A

Big Blue 400D, 500 X TM-4425 Page 49

9-9. Optional Three-Phase Generator Curves
The AC power curves show the
generator power available in am-
peres at the single-phase 120/240
volt receptacle or three-phase 240
volt terminals.

 See Section 3-8 for standard

generator power curve.

A. 12 kVA/kW Single-Phase AC Output (No Weld Load)

280

260

240
AC VOLTS

220

200

180
0 10 20 30 40 50 60 70 80 90 100
AC AMPERES

B. 15 kVA/kW Three-Phase AC Output (No Weld Load)

280

260
AC VOLTS

240

220

200

180
0 10 20 30 40 50 60 70
AC AMPERES

215 086-A / 215 087-A

TM-4425 Page 50 Big Blue 400D, 500 X

9-10. Connecting To Remote 14 Receptacle RC14 On CC/CV Models

Socket* Socket Information

A 24 volts AC. Protected by sup-

plementary protector CB5.
24 VOLTS AC
B Contact closure to A completes
24 volt AC contactor control
circuit.

C Output to remote control:+10

volts DC in MIG or Stick mode;
0 to +10 volts DC in TIG mode.

REMOTE D Remote control circuit common.

OUTPUT
LDR-14 long CONTROL E DC input command signal: 0 to
distance remote +10 volts from min. to max. of
(includes 120 V remote control with Voltage/
receptacle) Amperage Adjust control at
max.

115 volts, 10 amperes, 60 Hz

I AC. Protected by supplementa-
115 VOLTS AC ry protector CB6.

Contact closure to I completes

J 115 volt AC contactor control
OR circuit.

GND K Chassis common.

NEUTRAL G Circuit common for 24 and 115

Ref. 803 602 volt AC circuit.

*The remaining sockets are not used.

Big Blue 400D, 500 X TM-4425 Page 51

Notes

TM-4425 Page 52 Big Blue 400D, 500 X

9-11. Filter Board PC6 Testing Information (CC/CV Models Only)
! Stop engine.
See Section 9-12 for specific val-
ues during testing. Voltage read-
ings tolerance ±10%.

Test Equipment Needed:

Ref. 803 834 / 192 998

9-12. Filter Board PC6 Test Point Values (CC/CV Models Only)

a) Tolerance − ±10% unless specified

b) Reference − to circuit common (lead 42) unless noted
c) Condition − no load
PC6 Voltage Readings d) Process/Contactor switch S6 in Weld Terminals Always
On − Stick position

Receptacle Pin Value

RC2 1 Not used

2 115 volt AC input with respect to pin RC2-10

3 24 volt AC input with respect to pin RC2-10

4 24 volt AC output with respect to pin RC2-10

5 Contactor control circuit, 24 volt AC input with contact closure to pin RC2-9 and closure on RC14
between pins A and B or pins I and J

6 Command reference, +10 volt DC input

7 Command common

8 Remote command signal output, 0 to +10 volts DC input from min to max of remote voltage/amperage
control

9 Circuit common for 24 and 115 volt AC contactor control circuits

10 Circuit common for 24 and 115 volt AC circuits

Big Blue 400D, 500 X TM-4425 Page 53

9-13. Field Current Regulator Board PC1 Testing Using LED Board PC9 (CC/CV Only)
Determine the condition of field cur-
rent regulator board PC1 by ob-
serving the LEDs on LED board
PC9 (in control box).

 Do not open the PC1 sealed

case to service PC1. If PC1 is
not working properly, replace
the entire PC1 module.
Be sure plugs are secure. See Sec-
tion 9-14 for diagnostic information
1 and specific values during testing.
1 Field Current Regulator Board
PC1 Module
2 LED Board PC9
3 Diagnostic LEDs (See Section
9-14)

Test Equipment Needed:

Ref. 803 834 / 192 226-A

TM-4425 Page 54 Big Blue 400D, 500 X

9-14. Using Diagnostic LEDs On LED Board PC9 (CC/CV Models Only)
 The LEDs on circuit board PC9 monitor all critical input voltages to field current regulator board PC1.
 If PC9 Power LED, Output On/Off LED, and AC Input LED are on with Process/Contactor switch S6 in Weld Terminals Always On - Stick mode
and engine running at weld/power speed, 89 volts DC should be present at brush leads 105 and 108. This indicates field current regulator board
PC1 is functioning normally.

a) Condition − no load; weld/power RPM unless noted

b) Voltage/Amperage Adjust switch S5 in Panel position
c) Reference − to circuit common (lead 42) unless noted

LED Status Self-Test

POWER On Indicates +12 volts DC is present to energize PC1.

Off If LED is off:

Check control relay CR5 for proper coil voltage and connections. Check continuity of coil and condition
of contacts. Replace CR5 if necessary.
Reset supplementary protector CB10 and/or CB11.
Check for loose electrical connections to PC1.
Check for 12 volt DC supply voltage to PC1. If voltage is low, check battery or engine charging system.

OUTPUT On Indicates 24 volts AC input with Process/Contactor switch S6 in Weld Terminals Always On position, or
ON/OFF with S6 in a Remote On/Off Switch Required position with remote contactor closed.

Off If LED is off:

Place Process/Contactor switch S6 in Weld Terminals Always On position, or place S6 in Remote On/Off
Switch Required position and connect remote contactor to remote receptacle RC14.
Reset supplementary protector CB5 or CB6.
Check filter board PC6 and connections, and replace if necessary (see Section 9-11).

COMMAND On Indicates 0 to +10 volts DC input from min. to max. of Voltage/Amperage Adjust control R1 with Voltage/
Amperage Adjust switch S5 in Panel position.

Off If LED is off:

And Power LED is on, check that Voltage/Amperage Adjust control R1 is not at min.
And Power LED is on, check and tighten connections to Voltage/Amperage Adjust control R1.
And Power LED is on, check voltage at Voltage/Amperage Adjust control R1 (see Section 9-6). If correct
voltage is not present, check connections to PC1.
And Power LED is on, check resistance and connections of Voltage/Amperage Adjust control R1; R1 is
0 to 1000 ohms ±10%. Replace R1 if necessary.

RPM On Indicates engine speed is less than 1704 RPM (approximately).

LIMIT
If LED is on:
 LED normally And AC Input LED is on, check engine weld/power speed and adjust if necessary.
off at weld/
And AC Input LED is off, check position of Engine Control switch S1 (not in idle position).
power speed
And AC Input LED is off, check fuse F2, and replace if open.
And AC Input LED is off, reset supplementary protector CB12.

Off Indicates engine speed is above 1704 RPM (normal operation).

AC INPUT On Indicates + 175 volts AC input from field excitation circuit.

Dim or Off If LED is off, power LED is on, and normal AC voltage is present at AC receptacles (see Section 9-3 or
9-6):
Check fuse F2, and replace if open.
Reset supplementary protector CB12.

Big Blue 400D, 500 X TM-4425 Page 55

9-15. LED Board PC9 Testing (CC/CV Models Only)
Be sure plugs are secure. See Sec-
tion 9-16 for specific values during
testing.
1 LED Board PC9

Test Equipment Needed:

Ref. 803 834 / 192 226-A

TM-4425 Page 56 Big Blue 400D, 500 X

9-16. LED Board PC9 Test Point Values (CC/CV Models Only)

PC9 Voltage Readings

a) Tolerance − ±10% unless specified

b) Reference − to circuit common (lead 42) unless noted
c) Condition − no load; weld/power RPM unless noted
d) Process/Contactor switch S6 in Weld Terminals Always On − Stick position
 Do not exceed recommended voltage when testing LEDs or circuit board may be damaged.
Receptacle Pin Value
PLG13 1 Power LED, +2 volts DC input
To test power LED, apply +2 volts DC to PLG13-1 and connect negative (−) side of power supply to
PLG13-8. LED lights if okay.

2 Not used

3 Not used

4 Not used

5 AC input LED, +1.85 volts DC input with respect to pin PLG13-10 when weld exciter voltage is
present.
To test AC input LED, apply +1.85 volts DC to PLG13-10 and connect negative (−) side of power
supply to PLG13-5. LED lights if okay.

6 Output on/off LED, 0.13 volts DC input with contactor off; + 2 volts DC input with contactor on.
To test output on/off LED, apply +2 volts DC to PLG13-6 and connect negative (−) side of power sup-
ply to PLG13-8. LED lights if okay.

7 Command LED, 0 to 2 volts DC input from min to max of Voltage/Amperage Adjust control R1.
To test command LED, apply +2 volts DC to PLG13-7 and connect negative (−) side of power supply
to PLG13-8. LED lights if okay.

8 Circuit common

9 RPM Limit LED, +10.5 volts DC input at 1850 RPM; voltage decreases as engine speed decreases.
LED goes on when engine speed is less than 1704 RPM (approximately).
To test RPM limit LED, apply +2 volts DC to PLG13-8 and connect negative (−) side of power supply
to PLG13-9. LED lights if okay.

10 AC Input LED, +1.85 volts DC input with respect to pin PLG13-5 when weld exciter voltage is present.
To test AC input LED, apply +1.85 volts DC to PLG13-10 and connect negative (−) side of power
supply to PLG13-5. LED lights if okay.

Big Blue 400D, 500 X TM-4425 Page 57

9-17. Optional Idle Module PC7 Testing Information And Troubleshooting Flow Chart

Voltage readings tolerance ±10%.

1 Idle Module Verify engine speeds are correct
before testing idle module.

Engine does not go to idle speed

(1250 RPM) with no load applied.

Connect meter (DC) between

terminal B (+) and terminal E (−).

Start engine, and place Engine

Control switch in Auto position.
CC models: place Stick/TIG switch
S6 in Stick position.
CC/CV models: place Process/
Contactor switch S6 in
Weld Terminals Always On − Stick
position.

Check connections
to Engine Control
NO
+12 volts DC present? switch S1, control
relay CR6, and
ground connection
YES (lead 42).

Connect meter (AC) between

1 terminal D and terminal G.

Check for internal

NO
D C 0 (zero) volts AC present?
load such as
shorted diode in
main rectifier SR3.
YES
G E
Connect meter (DC) between
terminal C (+) and terminal E (−).

B F
A NO
Approximately +10 volts DC Replace
present after 12 to 18 seconds? idle module.

YES

Check circuit breaker

CB14, control relay CR3,
throttle solenoid TS1, and
Test Equipment Needed: connections.

Reinstall cover.

Ref. 803 834

TM-4425 Page 58 Big Blue 400D, 500 X

 Engine does not go to weld/power Control Relay CR4 does not energize
speed (1850 RPM) with load applied. at idle RPM with no load applied (see
Section 8 for CR4 information).

Connect meter (AC) between Connect meter (DC) between

terminal D and terminal G. terminal A (+) and F (−).

Start engine, and place Engine Start engine. Place Engine Control
Control switch in Auto position. switch S1 in Run position.
CC models: place Stick/TIG switch CC models: place Stick/TIG
S6 in Stick position. switch S6 in Stick position.
CC/CV models: place Process/ CC/CV models: place Process/
Contactor switch S6 in Contactor switch S6 in
Weld Terminals Always On − Stick Weld Terminals Always On − Stick
position. position.

NO
Connect a 100 watt light bulb to 0 (zero) volts DC present? Replace idle
120 volts AC duplex receptacle. module PC1.

YES

NO Check connections Place Engine Control switch S1

Minimum of 1 volt AC present? to current in Auto position.
transformer CT2.
YES

NO
Connect meter (DC) between +12 volts DC present? Replace idle
terminal C (+) and terminal E (−). module PC1.

YES

NO
0 (zero) volts DC present? Replace Check control relay CR4.
idle module.

YES

Check control relay CR3. Reinstall cover.

Disconnect 100 watt light bulb

and meter leads.

Reinstall cover.

Big Blue 400D, 500 X TM-4425 Page 59

9-18. Time Delay Relay TD1 Testing Information (Prior To Serial No. LJ110096E)

Voltage readings tolerance ±10%.

1 Time Delay Relay TD1

Engine does not start.

Connect meter (DC) between

terminal +12V and terminal
GRD.

Place Engine Control switch in

Run position.

Reset supplemen-
tary protector(s)
NO
+12 volts DC present? CB10 and CB13.
Check Engine
Control switch S1
YES and connections.

Connect meter (DC) between

terminal C (CM) and terminal
GRD.

NO
+12 volts DC present? Replace TD1

YES
1
Check control relay CR5
and engine fuel and
starter solenoids.

Reinstall cover.

Test Equipment Needed:

Ref. 803 834

TM-4425 Page 60 Big Blue 400D, 500 X

Engine starts, but stops within 30 seconds. Engine starts, but stops after 30 seconds.

Connect meter (DC) between Connect meter (DC) between

terminal +12V and terminal terminal +12V and terminal
GRD. GRD.

Place Engine Control switch in Place Engine Control switch in

Run position. Run position.

Reset supplemen- Reset supplemen-

tary protector(s) tary protector(s)
NO NO
+12 volts DC present? CB10 and CB13. CB10 and CB13.
Check Engine +12 volts DC present? Check Engine
Control switch S1 Control switch S1
YES and connections. YES and connections.

Connect meter (DC) between

Connect meter (DC) between
terminal C (CM) and terminal
terminal NC and terminal GRD.
GRD.

NO Start engine. When engine begins

+12 volts DC present? Replace TD1
to stop, quickly check voltage.

YES
Check for low oil
level or high engine
Check fuel solenoid FS1 NO temp. condition.
+12 volts DC present?
and connections.

YES

Reinstall cover. Replace TD1

Reinstall cover.

803 834 / 214 928

Big Blue 400D, 500 X TM-4425 Page 61

9-19. Fuel/Hourmeter Testing Information (Effective w/Serial No. LJ110096E)
Pin Description 1 Rear of Fuel/Hourmeter
1 +12 Volts DC Input S1 In Run/Idle; FUEL/HM
Open (No Output) With S1 in Run 1 See Section 5-5 for explanation of
meter functions.
2 Input From Temperature Switch S7
Wiring harness plug PLG1 con-
3 Input From Oil Pressure Switch S8
nects to receptacle on rear of meter.
4 +12 Volts DC Input (S1 In Any Position
Test meter functions by checking
But Off)
pin inputs and outputs as specified
5 Input From Fuel Level Sender in the table below.
6 +12 volts DC (S1 In Start) Voltage readings tolerance ±10%.
7 Output To Relay CR1 (Engine Latch)
8 Negative (−) Battery Voltage (Ground)

Test Equipment Needed:

hm2 2010−08 232 112 or 232 113 / Ref. 803 834

Fuel/Hourmeter Input/Output Information

hm2 2010−08

Oil High
Low Oil View Hours
Hourmeter Maintenance Coolant View Engine Low Fuel Shut-
Pressure Until Next Oil Fuel Gauge
Counts Hours Temp Hours down
Pin Shutdown Change
Countdown Shutdown

Engine Running Engine Not Running Any Engine Mode

1 n/a n/a n/a n/a Open +12 volts DC n/a n/a

2 Open Open Open Ground Open Open Open Open

3 Open Open Ground n/a Ground Ground n/a n/a

4 +12 volts DC +12 volts DC +12 volts DC +12 volts DC +12 volts DC +12 volts DC +12 volts DC +12 volts DC

28 to 33 ohms 28 to 33 ohms 28 to 33 ohms 28 to 33 ohms Assume Assume

w/fuel tank w/fuel tank w/fuel tank w/fuel tank enough fuel to enough fuel to
Greater than 215 Less than 215
5 full; 215 ohms full; 215 ohms full; 215 ohms full; 215 ohms not activate not activate
ohms ohms
starts shut- starts shut- starts shut- starts shut- low fuel shut- low fuel shut-
down down down down down down

+12 volts DC +12 volts DC

applied during applied during
engine crank- engine crank-
ing and then ing and then
6 Open Open removed (fault removed (fault Open Open Open Open
shutdown in- shutdown in-
hibited for 30 hibited for 30
sec. after sec. after
startup) startup)

30 second 30 second
delay after delay after Open after 10
start-up start-up sec. delay (shuts
7 Ground Ground Ground Ground Ground
(deenergizes (deenergizes off CR5 which
CR5 which CR5 which stops unit)
stops unit) stops unit)

8 Ground Ground Ground Ground Ground Ground Ground Ground

TM-4425 Page 62 Big Blue 400D, 500 X

9-20. Replacing Brushes And Cleaning Slip Rings
! Stop engine.
1 Generator Power Panel
Remove screws from panel. Tilt
panel forward.
2 Spring Clip
3 Brush
4 Brush Holder Assembly
Squeeze end of spring clip to re-
move clip and brush from brush
holder assembly. Remove and in-
spect all three brushes.
Replace brushes if damaged, or if
brush is at or near minimum length.
5 Slip Rings
1 Visually inspect slip rings. Under
normal use, rings turn dark brown.
If slip rings are corroded or surface
is uneven, insulate brush leads,
start engine, and clean rings with a
commutator stone. Remove as little
material as possible.
Reinstall generator power panel.

! Stop engine.

Minimum Length: 2
5/8 in (16 mm)

New Length: 1-1/4 in (32 mm)

Tools Needed:

Replace
Damaged Brushes

802 380-F

Big Blue 400D, 500 X TM-4425 Page 63

9-21. Checking Unit Output After Servicing (CC Models)
 Also use output waveforms to check
unit output after servicing (see Sec-
tion 9-7).
Check engine speeds, and adjust if nec-
essary (see engine manual and Section
7-8).
1 AC Receptacles GFCI1 And RC1
2 Resistor R3
Start engine and run at weld/power speed
(1850 RPM). Turn Amperage Adjust con-
trol R1 to max.
Check voltage at each receptacle. With
no load applied, there should be 126 to
132 volts AC present at GFCI1 and 252 to
264 volts AC at RC1.
If correct voltage is not present, stop en-
gine and reconnect lead 102 and/or lead
106 to different taps on R3.

 Connect R3 leads so at least half of

1 receptacles without exceeding 4.6 am-
! Stop engine before adjusting resistors R2 and R3.
resistor length is in circuit.
Start engine and check GFCI1 and RC1
voltage. If necessary, change R3 connec-
tions until correct voltage is obtained at
peres DC exciter revolving field current
(see Section 9-3).
3 Resistor R2
Turn Amperage Adjust control to min. and
Ampere Range switch to 230-Max. posi-
tion. Place Stick/TIG switch in Stick posi-
tion.
Check open-circuit voltage across weld
output terminals. There should be 90 − 94
volts DC present. If correct voltage is not
present, stop engine and reconnect lead
125 and/or lead 118 to different taps on
R2.

 Connect R2 leads so at least half of

2 resistor length is in circuit.
Start engine and and run at weld/power
speed (1850 RPM). Check weld output
voltage. If necessary, change R2 connec-
3 tions until correct voltage is obtained.

 Perform a load bank test to ensure

welder/generator operates properly
after servicing. Be sure load bank is
capable of handling the rated output
of the welder/generator being tested
(see load bank Owner’s manual).
The load bank will simulate a weld
load and the electrical demand on the
unit. See Specifications for rated
load.
Test Equipment Needed: If unit does not perform at rated load,
repeat troubleshooting procedures.
Pre-Operational Checks
! Stop engine.
Wipe engine surfaces clean.
Allow engine to cool, and then complete
Check labels; replace labels that are unreadable or damaged. pre-operational checks in table.
Check fuel and oil (see Section 4-9).
Check and correct any fluid leaks.
Tools Needed:
Clean weld output and battery terminals. Tighten connections.
Clean outside of entire unit.

Ref. 803 832-C

TM-4425 Page 64 Big Blue 400D, 500 X

9-22. Checking Unit Output After Servicing (CC/CV Models)
 Also use output waveforms to
check unit output after servic-
ing (see Section 9-7).
Check engine speeds, and adjust if
necessary (see engine manual and
Section 7-8).
1 AC Receptacles GFCI1 And
RC1
2 Resistor R3
Start engine and run at weld/power
speed (1850 RPM).
Check voltage at each receptacle.
With no load applied, there should
be 126 to 130 volts AC present at
GFCI1 and 252 to 260 volts AC at
RC1.
If correct voltage is not present,
stop engine and reconnect lead 102
and/or lead 106 to different taps on
R3.

 Connect R3 so at least half of

resistor length is in circuit.
Start engine and check GFCI1 and
1 RC1 voltage. If necessary, change
R3 connections until correct volt-
age is obtained at receptacles with-
out exceeding 4.6 amperes DC ex-
citer revolving field current (see
Section 9-6).
Turn Voltage/Amperage Adjust
control R1 to max. Place Process/
Contactor switch S6 in Weld Termi-
nals Always On − Stick position.
! Stop engine before adjusting resistor R3. Check open-circuit voltage across
weld output terminals. There
should be 90 volts DC present. If
correct voltages are not present, re-
2 peat troubleshooting procedures in
Section 9-2.

 Perform a load bank test to en-

sure welder/generator oper-
ates properly after servicing.
Be sure load bank is capable of
handling the rated output of the
welder/generator being tested
(see load bank Owner’s manu-
al).
The load bank will simulate a
weld load and the electrical de-
mand on the unit. See Specific-
ations for rated load.
If unit does not perform at rated
load, repeat troubleshooting
procedures.
Test Equipment Needed:
! Stop engine.
Pre-Operational Checks Allow engine to cool, and then com-
plete pre-operational checks in
Wipe engine surfaces clean. table.

Check labels; replace labels that are unreadable or damaged.

Check fuel and oil (see Section 4-9).
Tools Needed:
Check and correct any fluid leaks.
Clean weld output and battery terminals. Tighten connections.
Clean outside of entire unit.

Ref. 803 833-A

Big Blue 400D, 500 X TM-4425 Page 65

 SECTION 10 − DISASSEMBLY AND REASSEMBLY
10-1. Disassembly Of Unit
Use Section 9 to determine if trouble
is in exciter stator, stator, rotor, engine
or combination of these components.

 As an alternative to the complete dis-
assembly procedure shown, the en-
gine and rotor can be removed as one
assembly from the engine end. Re-
move brush block from endbell, sup-
port stator with blocks, and remove
hardware holding stator to engine. Use
a hoist to carefully lift the engine/rotor
assembly away from unit.
! Stop engine and let cool. Dis-
connect battery negative (−)
cable.
Remove exhaust pipe, fuel cap, and
top cover. Reinstall fuel cap. Remove
side panels and door(s). Retain all
hardware.
1 Control Box
Disconnect plugs from control box.
Remove box.

 To aid in reassembly, mark leads

before disconnecting. See lead
list summary in Section 11 for
connection information.
Disconnect:

stator weld leads from Ampere
Range switch S3

stator exciter leads from termi-
nal strip 1T

resistor R2 and R3 leads (R2 is
on CC models only)

1
and optional polarity switch
leads.
2 Front And Center Upright As-
sembly
3
3 Reactor Z1 Lifting Eye
The entire assembly will be removed
2 together. Remove bolts securing up-
rights to base. While supporting as-
sembly at front panel and reactor lift-
ing eye, evenly lift and remove
assembly.
4 Engine
4 5 Adapter Plate
6 Front Generator Mounts
Support engine under adapter plate
with a 1 x 3 x 30 in (25 x 76 x 762 mm)
metal bar.

 Do not support engine on fuel

tank or under oil pan.
Remove front generator mounts. Go
to Section 10-2.

Remove brushes
before removing
endbell or rotor.

6
803 835-C

TM-4425 Page 66 Big Blue 400D, 500 X

10-2. Disassembly Of Generator
Prior to Serial No. MD230076E
2 E
4
D
1
D C
Eff w/Serial No. MD230076E
NOTICE − Do not damage stator or rotor win-
dings during this procedure.
1 Brushes
Remove brushes from brushholder assembly
before disassembling generator.
2 Stator
With engine properly supported with metal
bar (see Section 10-1), remove hardware se-
curing stator to engine. Remove the following
parts as needed:
3 Endbell
Big Blue 400D, 500 X
A
A
B
2
3
4
Torques: 255 861 802 552-B
A 30 ft lb (41 N.m)
B 100 in lb (11 N.m)
C 25 ft lb (34 N.m)
D 12 ft lb (16 N.m)
E 18 ft lb (24 N.m)
4 Exciter Stator Reassembly Instructions:
Exciter stator comes off with endbell. Reinstall engine and generator parts as need-
ed using torque values in table. Reinstall en-
5 Rotor
gine/generator onto base. Torque hardware
If engine must also be removed, remove en- to 100 ft lb (135 N.m).
gine from base mounts.
Reinstall upright assembly. Torque hardware
to 140 ft lb (190 N.m). Reconnect fuel line.
Reconnect all leads. Use cable ties to secure
leads in existing wiring harness and away
from moving and hot parts.
Reconnect negative (−) battery cable. Rein-
stall panels, doors, and exhaust pipe.
TM-4425 Page 67
Notes

TM-4425 Page 68 Big Blue 400D, 500 X

 SECTION 11 − ELECTRICAL DIAGRAMS

 The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit inside
machine case or contact distributor for more information.
The following is a list of all diagrams for models covered by this manual.

Model Serial Or Style Number Circuit Diagram Wiring Diagram

Big Blue Domestic CC Models LE028711 thru LJ110095E 215221-E

LJ110096E thru LJ350166E 237427-A

LJ350167E and following 238628-C Table 11-1

Big Blue Domestic CC/CV Models LE028711 thru LJ110095E 215243-F

LJ110096E thru LJ350166E 237426-A

LJ350167E and following 240205-D Table 11-2

Big Blue Export CC Models LH023056 thru LJ003099 235275-A

LJ003100 thru LJ005954 237428-A

LJ005955 thru LJ350166E 238971-A

LJ350167E thru MD120068E 240583-E

MD120069E and following 238628-C Table 11-3

Big Blue Export CC/CV Models LH023056 thru LJ005049 235277-A

LJ005050 thru LJ005954 237429-A

LJ005955 thru LJ350166E 238924-A

LJ350167E thru MD120068E 240206-D

MD120069E and following 240205-D Table 11-4

Circuit Board PC4, PC5 LE028711 and following 189746-A

(HF Filter)

Circuit Board PC3 LE028711 and following 188607-B

(HF Filter)

Circuit Board PC6 LE028711 and following 192997

(HF Filter − CC/CV Only)

Circuit Board PC9 LE028711 and following 192227-A

(LED − CC/CV Only)

Big Blue 400D, 500 X TM-4425 Page 69

 Figure 11-1. Circuit Diagram For Big Blue Domestic CC Models
Effective w/Serial No. LE028711 Thru LJ110095E
TM-4425 Page 70 Big Blue 400D, 500 X
 215 221-E

Big Blue 400D, 500 X TM-4425 Page 71

 Figure 11-2. Circuit Diagram For Big Blue Domestic CC Models
Effective w/Serial No. LJ110096E Thru LJ350166E
TM-4425 Page 72 Big Blue 400D, 500 X
 237 427-A

Big Blue 400D, 500 X TM-4425 Page 73

 Figure 11-3. Circuit Diagram For Big Blue Domestic CC Models
Effective w/Serial No. LJ350167E And Following
Circuit Diagram for Domestic And Export CC Models Eff w/Serial No. MD120069E And Following
TM-4425 Page 74 Big Blue 400D, 500 X
 238 628-C

Big Blue 400D, 500 X TM-4425 Page 75

 Figure 11-4. Circuit Diagram For Big Blue Domestic CC/CV Models
Effective w/Serial No. LE028711 Thru LJ110095E
TM-4425 Page 76 Big Blue 400D, 500 X
 215 243-F

Big Blue 400D, 500 X TM-4425 Page 77

 Figure 11-5. Circuit Diagram For Big Blue Domestic CC/CV Models
Effective w/Serial No. LJ110096E Thru LJ350166E
TM-4425 Page 78 Big Blue 400D, 500 X
 237 426-A

Big Blue 400D, 500 X TM-4425 Page 79

 Figure 11-6. Circuit Diagram For Big Blue Domestic CC/CV Models
Effective w/Serial No. LJ350167E And Following
Circuit Diagram for Big Blue Domestic And Export CC/CV Models
Eff w/Serial No. MD120069E And Following
TM-4425 Page 80 Big Blue 400D, 500 X
 240 205-D

Big Blue 400D, 500 X TM-4425 Page 81

 Figure 11-7. Circuit Diagram For Big Blue Export CC Models
Effective w/Serial No. LH023056 Thru LJ003099
TM-4425 Page 82 Big Blue 400D, 500 X
 235 275-A

Big Blue 400D, 500 X TM-4425 Page 83

 Figure 11-8. Circuit Diagram For Big Blue Export CC Models
Effective w/Serial No. LJ003100 Thru LJ005954
TM-4425 Page 84 Big Blue 400D, 500 X
 237 428-A

Big Blue 400D, 500 X TM-4425 Page 85

 Figure 11-9. Circuit Diagram For Big Blue Export CC Models
Effective w/Serial No. LJ005955 Thru LJ350166E
TM-4425 Page 86 Big Blue 400D, 500 X
 238 971-A

Big Blue 400D, 500 X TM-4425 Page 87

 Figure 11-10. Circuit Diagram For Big Blue Export CC Models
Effective w/Serial No. LJ350167E Thru MD120068E
TM-4425 Page 88 Big Blue 400D, 500 X
 240 583-E

Big Blue 400D, 500 X TM-4425 Page 89

 Figure 11-11. Circuit Diagram For Big Blue Export CC/CV Models
Effective w/Serial No. LH023056 Thru LJ005049
TM-4425 Page 90 Big Blue 400D, 500 X
 235 277-A

Big Blue 400D, 500 X TM-4425 Page 91

 Figure 11-12. Circuit Diagram For Big Blue Export CC/CV Models
Effective w/Serial No. LJ005050 Thru LJ005954
TM-4425 Page 92 Big Blue 400D, 500 X
 237 429-A

Big Blue 400D, 500 X TM-4425 Page 93

 Figure 11-13. Circuit Diagram For Big Blue Export CC/CV Models
Effective w/Serial No. LJ005955 Thru LJ350166E
TM-4425 Page 94 Big Blue 400D, 500 X
 238 924-A

Big Blue 400D, 500 X TM-4425 Page 95

 Figure 11-14. Circuit Diagram For Big Blue Export CC/CV Models
Effective w/Serial No. LJ350167E Thru MD120068E
TM-4425 Page 96 Big Blue 400D, 500 X
 240 206-D

Big Blue 400D, 500 X TM-4425 Page 97

 189 746-A

Figure 11-15. Circuit Board PC4, PC5 (HF Filter) Effective w/Serial No. LE028711 And Following

188 607-B

Figure 11-16. Circuit Board PC3 (HF Filter) Effective w/Serial No. LE028711 And Following
TM-4425 Page 98 Big Blue 400D, 500 X
 192 997

Figure 11-17. Circuit Board PC6 (HF Filter − CC/CV Only) Effective w/Serial No. LE028711 And Following

192 227-A

Figure 11-18. Circuit Board PC9 (LED − CC/CV Only) Effective w/Serial No. LE028711 And Following
Big Blue 400D, 500 X TM-4425 Page 99
 Table 11-1. Lead List Summary For Big Blue 400D CC Models Eff w/Serial No. MD120069E And Following
 Table shows physical lead connections and should be used with circuit diagram (table replaces wiring diagram).
Apply small amount of dielectric grade, nonconductive electric grease (Miller Part No. 146557) to connectors where factory-applied
grease had been present.

Lead Connections Lead Connections

−−−−B RC6 (2) − S3 (2) 42PP SPLICE M TO SPLICE N
−−−−H RC6 (1) − S3 (1) 42R GFCI (GND) − GND STUD
10A T1 SEC TO SR4 (AC) 42RR SPLICE M TO SPLICE O
11A STATOR TO EXIT 42S RC1 (GND) − GND STUD
17A PC3 (4) (INSTALL SEAL) TO BUS BAR 42SS SPLICE TO 42KK
17A Z1 (17) TO SR3 (BOTTOM) 42T RC13 GRD TO END BELL LEAD 42
17A PC3 TO BUS BAR 42U SPLICE O TO HM (8)
17C PC3 (5) (INSTALL SEAL) TO LEAD 17 FROM VOLTMETER 42Z SPLICE N TO OIL GAUGE (5)
18A T1 SEC TO SR4 (AC) 43A CR1 (30) TO STARTER
19A PC3 (9) (INSTALL SEAL) TO HEAT SINK (+) 44A PLG4 (2) TO CB10 (AUX SILVER)
19A PC3 TO HEAT SINK (+) 44E CB14 (COPPER) TO CB10 (AUX SILVER)
19B PC3 (10) (INSTALL SEAL) TO LEAD 19 FROM PC1 (E2) 44F CR5 (1) TO CB13.
19B PC3 TO LEAD 19 FROM PC1 (E2) 44G RC4 (2) TO CR5 (1)
19C PC3 TO LEAD 19 FROM VOLTMETER (+) 46A CR3 (30) TO TS1
19D SR3 (+) TO WELD TERMINAL (+) 48A SPLICE TO S1 (D)
19E SR4 (+) TO SR3 (+) 48B S6 TO SPLICE
19F SR5 (+) TO SR3 (+) 48C (1) FUEL GAUGE TO SPLICE
21A STATOR TO EXIT 49C S1 (B) TO CR5(6)
27A PC3 (8) (INSTALL SEAL) TO BUS BAR 49D HOUR METER (4) TO CR5(6)
27A Z1 (27) TO SR3 (MIDDLE) 51A CR5 (5) TO HOUR METER (7)
27A PC3 TO BUS BAR 52A CB13 TO S1 (A)
30A PC3 (6) (INSTALL SEAL) TO HEAT SINK (−) 52B CB13 TO CR5 (3)
30A PC3 TO HEAT SINK (−) 52C CR5 (3) TO S2 (BOTTOM)
30B PC3 (7) (INSTALL SEAL) TO LEAD 30 FROM PC1 (E1) 53A D8 (CATHODE) TO CR1 (86)
30B PC3 TO LEAD 30 FROM PC1 (E1) 56A PLG4 (3) TO D8 (ANODE)
30C PC3 TO LEAD 30 FROM VOLTMETER (−) 56B SPLICE TO RC4 (3)
30F SR3 (−) TO WELD TERMINAL (−) 56C SPLICE (RESET) TO S1 (S)
30G SR4 (−) TO SR3 (−) 56D PLG1 (6) (FUEL GAUGE/HM) TO SPLICE
30H SR5 (−) TO SR3 (−) 57A PLG4 (12) TO CR8 (86)
31A STATOR TO EXIT 57C S2 (CENTER) TO RC4 (12)
36A PLG6 (3) − PLG3 (1) 58A PLG4 (4) TO PLG12 (6) (OIL)
36B CR7 (5) TO RC3 (1) 58C RC4 (4) TO HR METER (3)
36C RC6 (3) − S3 (3) 59A PLG4 (5) TO PLG12 (4) (TEMP)
37A PC3 (1) (INSTALL SEAL) TO BUS BAR 59B HR METER (2) TO RC4(5)
37A Z1 (37) TO SR3 (TOP) 60A D12 (CATH) TO PLG12 (2)
37A PC3 TO BUS BAR 61A PLG4 (7) TO D12 (ANODE)
37B PC3 (2) (INSTALL SEAL) TO LEAD 37 FROM PLG3 (2) 61B CR1 (87) TO PLG12 (7)
37B CR7 (8) TO RC3 (2) 61C D12 (ANODE) TO CR1 (87)
37B PC3 TO LEAD 37 FROM PLG3 (2) 61F SPLICE (G) TO SPLICE (L)
37C PC3 (3) (INSTALL SEAL) TO LEAD 37 FROM VOLTMETER 61G SPLICE (L) TO OIL GUAGE (6)
37C LEAD 37 FROM SR3 − PLG3 (2) 61H SPLICE (L) TO TEMP GUAGE (6)
38A T1 SEC TO SR5 (AC) 61J SPLICE (L) TO BATT GUAGE (6)
39A T1 SEC TO SR5 (AC) 61N SPLICE (G) TO CR5 (4)
40A CB10 (COPPER−BATT) TO STARTER 61P SPLICE (G) TO RC4 (7)
41A CB14 TO CR3 (87) 61S SPLICE (G) TO CR6 (86) OPTION
42A SPLICE A TO PLG4 (1) 63A PC7 (F) OPTION TO CR4 (B) OPTION
42AA SPLICE N TO BATT GAUGE (5) 64A PLG4 (8) TO CR3 (86)
42B SPLICE A TO CR3 (85) 64B PC7 (C) OPTION TO RC4 (8)
42BB SPLICE C TO RC4 (1) 65A PC7 (A) OPTION TO CR4 (A)
42C BASE GND TO SPLICE D 66A CT1 TO PC7 (D)
42CC SPLICE C TO CR7 (B) 67A CT1 TO PC7 (G)
42D SPLICE A TO CR8 (85) 68B CR6 (30) OPTION TO S6 (MIDDLE BOTTOM)
42DD SPLICE D TO CR1 (85) 69A PLG4 (9) TO PLG12 (5)
42E SPLICE A TO SPLICE B 69C RC4 (9) TO OIL GUAGE (3)
42EE SPLICE B TO SPLICE M 69D DEUTZ HARNESS TO OIL PRESSURE SENDER
42F SPLICE B TO SPLICE D 70A PLG4 (10) TO PLG12 (3)
42FF FUEL SENDER TO SPLICE D 70C RC4 (10) TO TEMP GUAGE (3)
42G SPLICE B TO TS1 71A PLG4 (11) TO FUEL SENDER
42J SPLICE B TO PLG12 (8) 71C RC4 (11) TO FUEL GUAGE (5)
42J SPLICE B TO PC7 (E) 72A PC7 (B) OPTION TO CR6 (87) OPTION
42JJ SPLICE B TO CR6 (85) 81A EXCITER STATOR − 1T (A−LEFT)
42KK SPLICE C TO 42 SS 81B CB1 (BOTTOM) − 1T (A−RIGHT)
42L END BELL (BOTTOM−RIGHT) − TO LEAD 42 FROM RC13 81D EXCITER TO T1
(CC ONLY) 81E T1 PRI TO EXCITER STATOR
42LL SPLICE C TO SPLICE B 82A EXCITER STATOR − 1T (B−LEFT)
42M SPLICE O TO TEMP GAUGE (5) 82B GFCI (N) − 1T (B−RIGHT)
42N GND STUD (BASE) − GND STUD (AUX. PANEL) 83A EXCITER STATOR − 1T (C−LEFT)
42P 1T (C−RIGHT) − GND STUD 84A EXCITER STATOR − 1T (D−LEFT)
TM-4425 Page 100 Big Blue 400D, 500 X
 Table 11-1. Lead List Summary For Big Blue 400D CC Models Eff w/Serial No. MD120069E And Following
(Continued)
Lead Connections Lead Connections
84B CB1 (BOTTOM) − 1T (D−RIGHT) 105C SR1 (+) TO SPLICE
84D EXCITER TO S6 105D SR1 (+) TO SR2 (+)
85A CB2 (BOTTOM) − GFCI (HOT) 105E D1/C1 (+) TO SPLICE
85B CB2 (BOTTOM) − PC4 (5) 105F RC1 (2) TO SPLICE
86A CB1 (TOP) − RC1 (BOTTOM−RIGHT) 106A R3 − PLG3 (7)
86D CB1 (TOP) − CB2 (TOP) 106A BRUSH (FRONT) − PLG1 (5)
88A CB1 (TOP) − RC1 (BOTTOM−LEFT) 106B RC1 (5) TO SPLICE
88B CB1 (TOP) − PC4 (4) 106C RC3 (7) TO SPLICE
89A EXCITER TO CB5 (TOP) 106D CR4 (6) OPTION TO SPLICE
98A S6 (LEFT BOTTOM) TO CB4 107A CR4 (4) OPTION TO CR4 (5) OPTION
99A T1 PRI TO CB4 108A BRUSH (REAR) − PLG1 (8)
100A EXCITER STATOR − PLG1 (1) 108B RC1 (8) TO SR2 (−)
100B F1 (TOP) TO RC1 (1) 110A D1/C1 TO CB12
101A EXCITER STATOR − PLG1 (3) 111A CB12 TO CB11
101B RC1 (3) TO SR1 (AC) 111B CB12 TO CR5 (2)
102A R3 − PLG3 (4) 113A CR7 (A) TO CB11
102B C9 (−) TO SPLICE 114B R6 TO S6 (MIDDLE RIGHT)
102C SR1 (−) TO SPLICE 114C R6 TO CR7 (4)
102D RC3 (4) TO SPLICE 115A C12 TO R6
102E CR4 (3) OPTION TO SPLICE 116A S5 (BOTTOM) TO PLG7 (3)
103A EXCITER STATOR − PLG1 (4) 116B RC13 (W) TO EXIT
103C R4 − PLG3 (6) 116D R1 (WIPER) TO RC7 (3)
103D RC1 (4) TO SPLICE 118A R2 − PLG3 (8)
103E RC3 (6) TO SPLICE 118B RC3 (8) TO SR2 (AC)
103F C12 (+) TO SPLICE 125A S5 (CENTER) TO S6 (MIDDLE CENTER)
103G PLG7 (1) TO SPLICE 125C RC13 TO EXIT
103H C12 TO CR7 (7) 125D S6 (MIDDLE) TO RC3 (9)
103J R1 (CW) TO RC7 (1) 125D PLG6 (1) − R2
104A EXCITER STATOR − PLG1 (6) 125E R2 − PLG3 (9)
104B F2 (TOP) TO RC1 (6) 126A PLG6 (2) − R4
105A BRUSH (CENTER) − PLG1 (2) 137A F1 TO SR1 (AC)
105B C9 (+) TO SR2 (+) 138A F2 TO SR2 (AC)

Big Blue 400D, 500 X TM-4425 Page 101

Table 11-2. Lead List Summary For Big Blue 400D CC/CV Models Eff w/Serial No. MD120069E And Following
 Table shows physical lead connections and should be used with circuit diagram (table replaces wiring diagram).
Apply small amount of dielectric grade, nonconductive electric grease (Miller Part No. 146557) to connectors where factory-applied
grease had been present.

Lead Connections Lead Connections

−−−−A OUTPUT STUD TO PC4 (1), PC5 (1) 42K PC1 (PLG8−C1) TO PLG3 (2)
−−−−B RC6 (2) − S3 (2) 42KK SPLICE C TO 42 SS
−−−−H RC6 (1) − S3 (1) 42L END BELL (BOTTOM−RIGHT) − PC5 (GND) (CV ONLY)
10A T1 SEC TO SR4 (AC) 42L END BELL (BOTTON−LEFT) − PC4 (GND) (CV ONLY)
11A STATOR TO EXIT 42L END BELL (TOP−LEFT) − PC6 (GND) (CV ONLY)
17A PC3 (4) (INSTALL SEAL) TO BUS BAR 42LL SPLICE C TO SPLICE B
17A Z1 (17) TO SR3 (BOTTOM) 42M SPLICE O TO TEMP GAUGE (5)
17A PC3 TO BUS BAR 42N GND STD (BASE) TO GND STUD (AUX PANEL)
17B SR3 (BOTTOM) TO S3 (25) 42P 1T (C−RIGHT) − GND STUD
17C PC3 (5) (INSTALL SEAL) TO LEAD 17 FROM VOLTMETER 42PP SPLICE M TO SPLICE N
17D 17C TO VOLTMETER 42R GFCI (GND) − GND STUD
18A T1 SEC TO SR4 (AC) 42RR SPLICE M TO SPLICE O
19A PC3 (9) (INSTALL SEAL) TO HEAT SINK (+) 42S RC1 (GND) − GND STUD
19A PC3 TO HEAT SINK (+) 42SS SPLICE TO 42KK
19B PC3 (10) (INSTALL SEAL) TO LEAD 19 FROM PC1 (E2) 42T 076 (K) TO LEAD 42 FROM END BELL
19B PC3 TO LEAD 19 FROM PC1 (E2) 42U SPLICE O TO PLG1 (8) (FUEL GAUGE/HM)
19C PC3 TO LEAD 19 FROM VOLTMETER (+) 42Z SPLICE N TO OIL PRESSURE GAUGE (5)
19D SR3 (+) TO WELD TERMINAL (+) 42ZY GRND STUD TO RC5 (GNO)
19E SR4 (+) TO SR3 (+) 42ZZ GRND STUD TO NEUTRAL STUD
19F SR5 (+) TO SR3 (+) 43A CR1 (30) TO STARTER
19J PC1 (PLG8−E2) TO LEAD 19 FROM PC3 44A PLG4 (2) TO CB10 (AUX SILVER)
21A STATOR TO EXIT 44E CB14 (COPPER) TO CB10 (AUX SILVER)
27A PC3 (8) (INSTALL SEAL) TO BUS BAR 44F CR5 (1) TO CB13
27A Z1 (27) TO SR3 (MIDDLE) 44G RC4 (2) TO CR5 (1)
27A PC3 TO BUS BAR 46A CR3 (30) TO TS1
27B SR3 (MIDDLE) TO S3 (17) 48A SPLICE TO S1 (L)
30A PC3 (6) (INSTALL SEAL) TO HEAT SINK (−) 48B SPLICE TO S6
30A PC3 TO HEAT SINK (−) 48C SPLICE TO PLG1 (1) (FUEL GAUGE/HM)
30B PC3 (7) (INSTALL SEAL) TO LEAD 30 FROM PC1 (E1) 49C SPLICE TO S1 (B)
30B PC3 TO LEAD 30 FROM PC1 (E1) 49D (4) FUEL GAUGE TO SPLICE
30C PC3 TO LEAD 30 FROM VOLTMETER (−) 49E SPLICE (COMMON) TO CR5 (6)
30F SR3 (−) TO WELD TERMINAL (−) 51A FUEL GAUGE TO CR5 (5)
30G SR4 (−) TO SR3 (−) 52A CB13 TO S1 (A)
30H SR5 (−) TO SR3 (−) 52B CB13 TO CR5 (3)
30J PC1 (PLG8−E1) TO LEAD 30 FROM PC3 52C CR5 (3) TO S2 BOTTOM
31A STATOR TO EXIT 53A D8 (CATHODE) TO CR1 (86)
36A PC8 (PLG1−G1) TO PLG6 (3) 56A PLG4 (3) TO D8 (ANODE)
36C RC6 (3) − S3 (3) 56B SPLICE TO RC4 (3)
37A PC3 (1) (INSTALL SEAL) TO BUS BAR 56C SPLICE (RESET) TO S1 (S)
37A Z1 (37) TO SR3 (TOP) 56D PLG1 (6) (FUEL GAUGE/HM) TO SPLICE
37A PC1 (PLG8−G2) TO LEAD 37 FROM SR3 57A PLG4 (12) TO CR8 (86)
37A PC3 TO BUS BAR 57C RC4 (12) TO S2 CENTER
37B PC3 (2) (INSTALL SEAL) TO LEAD 37 FROM PLG3 (2) 58A PLG4 (4) TO PLG12 (6) (OIL)
37B SR3 (TOP) TO S3 (9) 58C FUEL/HM TO RC4 (4)
37B PC3 TO LEAD 37 FROM PLG3 (2) 59A PLG4 (5) TO PLG12 (4) (TEMP)
37C PC3 (3) (INSTALL SEAL) TO LEAD 37 FROM VOLTMETER 59B FUEL/HM TO RC4 (5)
37E 37D TO VOLTMETER 60A D12 (CATH) TO PLG12 (2)
38A T1 SEC TO SR5 (AC) 61A PLG4 (7) TO D12 (ANODE)
39A T1 SEC TO SR5 (AC) 61B CR1 (87) TO PLG12 (7)
40A CB10 (COPPER−BATT) TO STARTER 61C D12 (ANODE) TO CR1 (87)
41A CB14 TO CR3 (87) 61F SPLICE (G) TO SPLICE (L)
42A SPLICE A TO PLG4 (1) 61G SPLICE (L) TO OIL GUAGE (6)
42AA SPLICE N TO BATT GAUGE (5) 61H SPLICE (L) TO TEMP GUAGE (6)
42B SPLICE A TO CR3 (85) 61J SPLICE (L) TO BATT GUAGE (6)
42BB SPLICE C TO RC4 (1) 61N SPLICE (G) TO CR5 (4)
42C BASE GND TO SPLICE D 61P SPLICE (G) TO RC4 (7)
42CC SPLICE C TO RC3 (2) 61S SPLICE (G) TO CR6 (86) OPTION
42D SPLICE A TO CR8 (85) 63A CR4 (B) TO PC7 (F)
42DD SPLICE D TO CR1 (85) 64A PLG4 (8) TO CR3 (86)
42E SPLICE A TO SPLICE B 64B RC4 (8) TO PC7 (C)
42EE SPLICE B TO SPLICE M 65A CR4 (A) TO PC7 (A)
42F SPLICE B TO SPLICE D 66A CT1 TO PC7 (D)
42FF FUEL SENDER TO SPLICE D 67A CT1 TO PC7 (G)
42G SPLICE B TO TS1 68B S6 (10) TO CR6 (30)
42H PC1 (PLG8−F3) TO PC8 (PLG13−8) 69A PLG4 (9) TO PLG12 (5)
42J SPLICE B TO PLG12 (8) 69C RC4 (4) TO OIL PRESSURE GAUGE (3)
42J SPLICE B TO PC7 (E) 69D DEUTZ HARNESS TO OIL PRESSURE SENDER
42JJ SPLICE B TO CR6 (85) 70A PLG4 (10) TO PLG12 (3)
TM-4425 Page 102 Big Blue 400D, 500 X
Table 11-2. Lead List Summary For Big Blue 400D CC/CV Models Eff w/Serial No. MD120069E And Following
(Continued)
Lead Connections Lead Connections
70C RC4 (10) TO TEMP GAUGE (3) 105G D1 (CATHODE) TO SPLICE
71A PLG4 (11) TO FUEL SENDER 106A BRUSH (FRONT) − PLG1 (5)
71C RC4 (11) TO FUEL GAUGE/HM (5) 106B RC1 (5) TO SPLICE
72A CR6 (87) TO PC7 (B) 106C RC3 (7) TO SPLICE
81B CB1 (BOTTOM) − 1T (A−RIGHT) 106D CR4 (6) OPTION TO SPLICE
81E T1 PRI TO EXCITER STATOR 106D R3 TO PLG3 (7)
82B GFCI (N) − 1T (B−RIGHT) 107A CR4 (4) TO CR4 (5)
83B PC6 (PLG14−10) TO (1T−C) 108A BRUSH (REAR) − PLG1 (8)
83D PC6 (PLG14−9) TO PC1 (PLG9−F2) 108B RC1 (8) TO RC3 (9)
84B CB1 (BOTTOM) − 1T (D−RIGHT) 108C PC1 (PLG8−A2) TO PLG3 (9)
84E AUX STATOR TO S6 (11) 110A CB12 TO D1 (ANODE)
84F 1T−D TO CB6 111A CB12 TO CB11
85A CB2 (BOTTOM) − GFCI (HOT) 111B CB12 TO CR5 (2)
85B CB2 (BOTTOM) − PC4 (5) 113A CB11 TO RC3 (12)
86A CB1 (TOP) − RC1 (BOTTOM−RIGHT) 113B PC1 (PLG8−B1) TO PLG3 (12)
86D CB1 (TOP) − CB2 (TOP) 116A PC6 (PLG14−8) TO PC1 (PLG9−B1)
87A CB6 TO PLG14 #2 117A PC6 (PLG14−7) TO PC1 (PLG9−C3)
88A CB1 (TOP) − RC1 (BOTTOM−LEFT) 118A PC6 (PLG14−6) TO PC1 (PLG9−B2)
88B CB1 (TOP) − PC4 (4) 119A S6 (1) TO PC6 (PLG14−5)
90A STATOR TO EXIT 120A S6 (2) TO PC1 (PLG9−F1)
90B NEUTRAL STUD TO RC5 (WHT) 121A S6 (3) TO PC6 (PLG14−4)
91A STATOR TO EXIT 121B PC6 (PLG14−3) TO CB5
91B CB7 BOTTOM TO PC5 (3)
122A PC1 (PLG9−A1) TO S6 (5)
92A STATOR TO EXIT
123A PC1 (PLG9−A2) TO S6 (6)
92B CB7 BOTTOM TO PC5 (4)
93A STATOR TO EXIT 124A S6 (7) TO PC1 (PLG9−D3)
93B CB7 BOTTOM TO PC5 (5) 125A PC1 (PLG8−F1) TO PLG6 (1)
94A CB TO RC5 (X) 126A PC1 (PLG8−F2) TO PLG6 (2)
95A CB TO RC5 (Y) 127A S5 (TOP) TO PC1 (PLG9−B3)
98A S6 (12) TO CB4 128A S5 (CENTER) TO PC1 (PLG9−D2)
99A T1 PRI TO CB4 129A S5 (BOTTOM) TO PC1 (PLG9−C2)
100B RC1 (1) TO F1 130A LEAD 130B TO PC1 (PLG8−K1)
101B RC1 (3) TO SR1 (AC) 131A LEAD 131B TO PC1 (PLG8−H2)
102B C9 (−) TO SPLICE 132A LEAD 132B TO PC1 (PLG8−J1)
102C SR1 (−) TO SPLICE 133A LEAD 133B TO PC1 (PLG8−H1)
102D RC3 (4) TO SPLICE 134A R1 (PLG10−1) TO PC1 (PLG9−D1)
102E CR4 (3) OPTION TO SPLICE 135A R1 (PLG10−2) TO PC1 (PLG9−C1)
102E R3 TO PLG3 (4) 136A R1 (PLG10−3) TO PC1 (PLG9−A3)
103B PC1 (PLG8−A1) TO PLG3 (6) 137A SR1 (AC) TO F1
103D RC3 (6) TO RC1 (4) 138A RC3 (1) TO F2
104B RC1 (6) TO F2 138B PC1 (PLG8−A3) TO PLG3 (1)
105A BRUSH (CENTER) − PLG1 (2) 139A PC1 (PLG8−C3) TO PC9 (PLG13−1)
105B SR1 (+) TO C9 140A PC1 (PLG8−D2) TO PC9 (PLG13−5)
105C SR1 (+) TO SPLICE 141A PC1 (PLG8−D3) TO PC9 (PLG13−6)
105D RC3 (8) TO SPLICE 142A PC1 (PLG8−K2) TO PC9 (PLG13−7)
105E PC1 (PLG8−D1) TO PLG3 (8) 143A PC1 (PLG8−J2) TO PC9 (PLG13−9)
105F RC1 (2) TO SPLICE 144A PC1 (PLG8−B3) TO PC9 (PLG13−10)

Big Blue 400D, 500 X TM-4425 Page 103

 Table 11-3. Lead List Summary For Big Blue 500 X CC Models Eff w/Serial No. MD120069E And Following
 Table shows physical lead connections and should be used with circuit diagram (table replaces wiring diagram).
Apply small amount of dielectric grade, nonconductive electric grease (Miller Part No. 146557) to connectors where factory-applied
grease had been present.

Lead Connections Lead Connections

−−−−B RC6 (2) − S3 (2) 42PP SPLICE M TO SPLICE N
−−−−H RC6 (1) − S3 (1) 42R GFCI (GND) TO GND STUD
10A T1 SEC TO SR4 (AC) 42RR SPLICE M TO SPLICE O
11A STATOR TO EXIT 42S RC1 (PE) TO GND STUD
17A PC3 (4) (INSTALL SEAL) TO BUS BAR 42SS SPLICE TO 42KK
17A Z1 (17) TO SR3 (BOTTOM) 42T RC13 GRD TO END BELL LEAD 42
17A PC3 TO BUS BAR 42U SPLICE O TO HM (8)
17C PC3 (5) (INSTALL SEAL) TO LEAD 17 FROM VOLTMETER 42Z SPLICE N TO OIL GAUGE (5)
18A T1 SEC TO SR4 (AC) 43A CR1 (30) TO STARTER
19A PC3 (9) (INSTALL SEAL) TO HEAT SINK (+) 44A PLG4 (2) TO CB10 (AUX SILVER)
19A PC3 TO HEAT SINK (+) 44E CB14 (COPPER) TO CB10 (AUX SILVER)
19B PC3 (10) (INSTALL SEAL) TO LEAD 19 FROM PC1 (E2) 44F CR5 (1) TO CB13.
19B PC3 TO LEAD 19 FROM PC1 (E2) 44G RC4 (2) TO CR5 (1)
19C PC3 TO LEAD 19 FROM VOLTMETER (+) 46A CR3 (30) TO TS1
19D SR3 (+) TO WELD TERMINAL (+) 48A SPLICE TO S1 (D)
19E SR4 (+) TO SR3 (+) 48B S6 TO SPLICE
19F SR5 (+) TO SR3 (+) 48C (1) FUEL GAUGE TO SPLICE
21A STATOR TO EXIT 49C S1 (B) TO CR5(6)
27A PC3 (8) (INSTALL SEAL) TO BUS BAR 49D HOUR METER (4) TO CR5(6)
27A Z1 (27) TO SR3 (MIDDLE) 51A CR5 (5) TO HOUR METER (7)
27A PC3 TO BUS BAR 52A CB13 TO S1 (A)
30A PC3 (6) (INSTALL SEAL) TO HEAT SINK (−) 52B CB13 TO CR5 (3)
30A PC3 TO HEAT SINK (−) 52C CR5 (3) TO S2 (BOTTOM)
30B PC3 (7) (INSTALL SEAL) TO LEAD 30 FROM PC1 (E1) 53A D8 (CATHODE) TO CR1 (86)
30B PC3 TO LEAD 30 FROM PC1 (E1) 56A PLG4 (3) TO D8 (ANODE)
30C PC3 TO LEAD 30 FROM VOLTMETER (−) 56B SPLICE TO RC4 (3)
30F SR3 (−) TO WELD TERMINAL (−) 56C SPLICE (RESET) TO S1 (S)
30G SR4 (−) TO SR3 (−) 56D PLG1 (6) (FUEL GAUGE/HM) TO SPLICE
30H SR5 (−) TO SR3 (−) 57A PLG4 (12) TO CR8 (86)
31A STATOR TO EXIT 57C S2 (CENTER) TO RC4 (12)
36A PLG6 (3) − PLG3 (1) 58A PLG4 (4) TO PLG12 (6) (OIL)
36B CR7 (5) TO RC3 (1) 58C RC4 (4) TO HR METER (3)
36C RC6 (3) − S3 (3) 59A PLG4 (5) TO PLG12 (4) (TEMP)
37A PC3 (1) (INSTALL SEAL) TO BUS BAR 59B HR METER (2) TO RC4(5)
37A Z1 (37) TO SR3 (TOP) 60A D12 (CATH) TO PLG12 (2)
37A PC3 TO BUS BAR 61A PLG4 (7) TO D12 (ANODE)
37B PC3 (2) (INSTALL SEAL) TO LEAD 37 FROM PLG3 (2) 61B CR1 (87) TO PLG12 (7)
37B CR7 (8) TO RC3 (2) 61C D12 (ANODE) TO CR1 (87)
37B PC3 TO LEAD 37 FROM PLG3 (2) 61F SPLICE (G) TO SPLICE (L)
37C PC3 (3) (INSTALL SEAL) TO LEAD 37 FROM VOLTMETER 61G SPLICE (L) TO OIL GUAGE (6)
37C LEAD 37 FROM SR3 − PLG3 (2) 61H SPLICE (L) TO TEMP GUAGE (6)
38A T1 SEC TO SR5 (AC) 61J SPLICE (L) TO BATT GUAGE (6)
39A T1 SEC TO SR5 (AC) 61N SPLICE (G) TO CR5 (4)
40A CB10 (COPPER−BATT) TO STARTER 61P SPLICE (G) TO RC4 (7)
41A CB14 TO CR3 (87) 61S SPLICE (G) TO CR6 (86) OPTION
42A SPLICE A TO PLG4 (1) 63A PC7 (F) OPTION TO CR4 (B) OPTION
42AA SPLICE N TO BATT GAUGE (5) 64A PLG4 (8) TO CR3 (86)
42B SPLICE A TO CR3 (85) 64B PC7 (C) OPTION TO RC4 (8)
42BB SPLICE C TO RC4 (1) 65A PC7 (A) OPTION TO CR4 (A)
42C BASE GND TO SPLICE D 66A CT1 TO PC7 (D)
42CC SPLICE C TO CR7 (B) 67A CT1 TO PC7 (G)
42D SPLICE A TO CR8 (85) 68B CR6 (30) OPTION TO S6 (MIDDLE BOTTOM)
42DD SPLICE D TO CR1 (85) 69A PLG4 (9) TO PLG12 (5)
42E SPLICE A TO SPLICE B 69C RC4 (9) TO OIL GUAGE (3)
42EE SPLICE B TO SPLICE M 69D DEUTZ HARNESS TO OIL PRESSURE SENDER
42F SPLICE B TO SPLICE D 70A PLG4 (10) TO PLG12 (3)
42FF FUEL SENDER TO SPLICE D 70C RC4 (10) TO TEMP GUAGE (3)
42G SPLICE B TO TS1 71A PLG4 (11) TO FUEL SENDER
42J SPLICE B TO PLG12 (8) 71C RC4 (11) TO FUEL GUAGE (5)
42J SPLICE B TO PC7 (E) 72A PC7 (B) OPTION TO CR6 (87) OPTION
42JJ SPLICE B TO CR6 (85) 81A EXCITER STATOR − 1T (A−LEFT)
42KK SPLICE C TO 42 SS 81B ELCB1 (LINE) TO 1T (A−RIGHT)
42L END BELL (BOTTOM−RIGHT) − TO LEAD 42 FROM RC13 81D EXCITER TO T1
(CC ONLY) 81E T1 PRI TO EXCITER STATOR
42LL SPLICE C TO SPLICE B 82A EXCITER STATOR − 1T (B−LEFT)
42M SPLICE O TO TEMP GAUGE (5) 82B CB2 (TOP) TO 1T (B−RIGHT)
42N GND STUD (BASE) − GND STUD (AUX. PANEL) 83A EXCITER STATOR − 1T (C−LEFT)
42P 1T (D−LEFT) TO GRD STUD 84A EXCITER STATOR − 1T (D−LEFT)
TM-4425 Page 104 Big Blue 400D, 500 X
 Table 11-3. Lead List Summary For Big Blue 500 X CC Models Eff w/Serial No. MD120069E And Following
(Continued)
Lead Connections Lead Connections
84B GFCI (N) TO 1T (D−RIGHT) 105C SR1 (+) TO SPLICE
84C ELCB1 (LINE N) TO 1T (D−RIGHT) 105D SR1 (+) TO SR2 (+)
84D EXCITER TO S6 105E D1/C1 (+) TO SPLICE
85A CB2 (BOTTOM) TO GFCI (HOT) 105F RC1 (2) TO SPLICE
85B CB2 (BOTTOM) TO PC5 (5) 106A R3 − PLG3 (7)
86A ELCB1 (LOAD N) TO RC1 (N) 106A BRUSH (FRONT) − PLG1 (5)
88A PIN SPLICE − RC1 (L) 106B RC1 (5) TO SPLICE
88B PIN SPLICE − PC4 (4) 106C RC3 (7) TO SPLICE
89A EXCITER TO CB5 (TOP) 106D CR4 (6) OPTION TO SPLICE
98A S6 (LEFT BOTTOM) TO CB4 107A CR4 (4) OPTION TO CR4 (5) OPTION
99A T1 PRI TO CB4 108A BRUSH (REAR) − PLG1 (8)
100A EXCITER STATOR − PLG1 (1) 108B RC1 (8) TO SR2 (−)
100B F1 (TOP) TO RC1 (1) 110A D1/C1 TO CB12
101A EXCITER STATOR − PLG1 (3) 111A CB12 TO CB11
101B RC1 (3) TO SR1 (AC) 111B CB12 TO CR5 (2)
102A R3 − PLG3 (4) 113A CR7 (A) TO CB11
102B C9 (−) TO SPLICE 114B R6 TO S6 (MIDDLE RIGHT)
102C SR1 (−) TO SPLICE 114C R6 TO CR7 (4)
102D RC3 (4) TO SPLICE 115A C12 TO R6
102E CR4 (3) OPTION TO SPLICE 116A S5 (BOTTOM) TO PLG7 (3)
103A EXCITER STATOR − PLG1 (4) 116B RC13 (W) TO EXIT
103C R4 − PLG3 (6) 116D R1 (WIPER) TO RC7 (3)
103D RC1 (4) TO SPLICE 118A R2 − PLG3 (8)
103E RC3 (6) TO SPLICE 118B RC3 (8) TO SR2 (AC)
103F C12 (+) TO SPLICE 125A S5 (CENTER) TO S6 (MIDDLE CENTER)
103G PLG7 (1) TO SPLICE 125C RC13 TO EXIT
103H C12 TO CR7 (7) 125D S6 (MIDDLE) TO RC3 (9)
103J R1 (CW) TO RC7 (1) 125D PLG6 (1) − R2
104A EXCITER STATOR − PLG1 (6) 125E R2 − PLG3 (9)
104B F2 (TOP) TO RC1 (6) 126A PLG6 (2) − R4
105A BRUSH (CENTER) − PLG1 (2) 137A F1 TO SR1 (AC)
105B C9 (+) TO SR2 (+) 138A F2 TO SR2 (AC)

Big Blue 400D, 500 X TM-4425 Page 105

Table 11-4. Lead List Summary For Big Blue 500 X CC/CV Models Eff w/Serial No. MD120069E And Following
 Table shows physical lead connections and should be used with circuit diagram (table replaces wiring diagram).
Apply small amount of dielectric grade, nonconductive electric grease (Miller Part No. 146557) to connectors where factory-applied
grease had been present.

Lead Connections Lead Connections

−−−−A OUTPUT STUD TO PC4 (1), PC5 (1) 42L END BELL (BOTTOM−RIGHT) − PC5 (GND) (CV ONLY)
−−−−B RC6 (2) − S3 (2) 42L END BELL (BOTTON−LEFT) − PC4 (GND) (CV ONLY)
−−−−H RC6 (1) − S3 (1) 42L END BELL (TOP−LEFT) − PC6 (GND) (CV ONLY)
10A T1 SEC TO SR4 (AC) 42LL SPLICE C TO SPLICE B
11A STATOR TO EXIT 42M SPLICE O TO TEMP GAUGE (5)
17A PC3 (4) (INSTALL SEAL) TO BUS BAR 42N GND STD (BASE) TO GND STUD (AUX PANEL)
17A Z1 (17) TO SR3 (BOTTOM) 42P 1T (D−LEFT) TO GRD STUD
17A PC3 TO BUS BAR 42PP SPLICE M TO SPLICE N
17B SR3 (BOTTOM) TO S3 (25) 42R GFCI (GND) TO GND STUD
17C PC3 (5) (INSTALL SEAL) TO LEAD 17 FROM VOLTMETER 42RR SPLICE M TO SPLICE O
18A T1 SEC TO SR4 (AC) 42S RC1 (PE) TO GND STUD
19A PC3 (9) (INSTALL SEAL) TO HEAT SINK (+) 42SS SPLICE TO 42KK
19A PC3 TO HEAT SINK (+) 42T 076 (K) TO LEAD 42 FROM END BELL
19B PC3 (10) (INSTALL SEAL) TO LEAD 19 FROM PC1 (E2) 42U SPLICE O TO PLG1 (8) (FUEL GAUGE/HM)
19B PC3 TO LEAD 19 FROM PC1 (E2) 42Z SPLICE N TO OIL PRESSURE GAUGE (5)
19C PC3 TO LEAD 19 FROM VOLTMETER (+) 43A CR1 (30) TO STARTER
19D SR3 (+) TO WELD TERMINAL (+) 44A PLG4 (2) TO CB10 (AUX SILVER)
19E SR4 (+) TO SR3 (+) 44E CB14 (COPPER) TO CB10 (AUX SILVER)
19F SR5 (+) TO SR3 (+) 44F CR5 (1) TO CB13
19J PC1 (PLG8−E2) TO LEAD 19 FROM PC3 44G RC4 (2) TO CR5 (1)
21A STATOR TO EXIT 46A CR3 (30) TO TS1
27A PC3 (8) (INSTALL SEAL) TO BUS BAR 48A SPLICE TO S1 (L)
27A Z1 (27) TO SR3 (MIDDLE) 48B SPLICE TO S6
27A PC3 TO BUS BAR 48C SPLICE TO PLG1 (1) (FUEL GAUGE/HM)
27B SR3 (MIDDLE) TO S3 (17) 49C SPLICE TO S1 (B)
30A PC3 (6) (INSTALL SEAL) TO HEAT SINK (−) 49D (4) FUEL GAUGE TO SPLICE
30A PC3 TO HEAT SINK (−) 49E SPLICE (COMMON) TO CR5 (6)
30B PC3 (7) (INSTALL SEAL) TO LEAD 30 FROM PC1 (E1) 51A FUEL GAUGE TO CR5 (5)
30B PC3 TO LEAD 30 FROM PC1 (E1) 52A CB13 TO S1 (A)
30C PC3 TO LEAD 30 FROM VOLTMETER (−) 52B CB13 TO CR5 (3)
30F SR3 (−) TO WELD TERMINAL (−) 52C CR5 (3) TO S2 BOTTOM
30G SR4 (−) TO SR3 (−) 53A D8 (CATHODE) TO CR1 (86)
30H SR5 (−) TO SR3 (−) 56A PLG4 (3) TO D8 (ANODE)
30J PC1 (PLG8−E1) TO LEAD 30 FROM PC3 56B SPLICE TO RC4 (3)
31A STATOR TO EXIT 56C SPLICE (RESET) TO S1 (S)
36A PC8 (PLG1−G1) TO PLG6 (3) 56D PLG1 (6) (FUEL GAUGE/HM) TO SPLICE
36C RC6 (3) − S3 (3) 57A PLG4 (12) TO CR8 (86)
37A PC3 (1) (INSTALL SEAL) TO BUS BAR 57C RC4 (12) TO S2 CENTER
37A Z1 (37) TO SR3 (TOP) 58A PLG4 (4) TO PLG12 (6) (OIL)
37A PC1 (PLG8−G2) TO LEAD 37 FROM SR3 58C FUEL/HM TO RC4 (4)
37A PC3 TO BUS BAR 59A PLG4 (5) TO PLG12 (4) (TEMP)
37B PC3 (2) (INSTALL SEAL) TO LEAD 37 FROM PLG3 (2) 59B FUEL/HM TO RC4 (5)
37B SR3 (TOP) TO S3 (9) 60A D12 (CATH) TO PLG12 (2)
37B PC3 TO LEAD 37 FROM PLG3 (2) 61A PLG4 (7) TO D12 (ANODE)
37C PC3 (3) (INSTALL SEAL) TO LEAD 37 FROM VOLTMETER 61B CR1 (87) TO PLG12 (7)
38A T1 SEC TO SR5 (AC) 61C D12 (ANODE) TO CR1 (87)
39A T1 SEC TO SR5 (AC) 61F SPLICE (G) TO SPLICE (L)
40A CB10 (COPPER−BATT) TO STARTER 61G SPLICE (L) TO OIL GUAGE (6)
41A CB14 TO CR3 (87) 61H SPLICE (L) TO TEMP GUAGE (6)
42A SPLICE A TO PLG4 (1) 61J SPLICE (L) TO BATT GUAGE (6)
42AA SPLICE N TO BATT GAUGE (5) 61N SPLICE (G) TO CR5 (4)
42B SPLICE A TO CR3 (85) 61P SPLICE (G) TO RC4 (7)
42BB SPLICE C TO RC4 (1) 61S SPLICE (G) TO CR6 (86) OPTION
42C BASE GND TO SPLICE D 63A CR4 (B) TO PC7 (F)
42CC SPLICE C TO RC3 (2) 64A PLG4 (8) TO CR3 (86)
42D SPLICE A TO CR8 (85) 64B RC4 (8) TO PC7 (C)
42DD SPLICE D TO CR1 (85) 65A CR4 (A) TO PC7 (A)
42E SPLICE A TO SPLICE B 66A CT1 TO PC7 (D)
42EE SPLICE B TO SPLICE M 67A CT1 TO PC7 (G)
42F SPLICE B TO SPLICE D 68B S6 (10) TO CR6 (30)
42FF FUEL SENDER TO SPLICE D 69A PLG4 (9) TO PLG12 (5)
42G SPLICE B TO TS1 69C RC4 (4) TO OIL PRESSURE GAUGE (3)
42H PC1 (PLG8−F3) TO PC8 (PLG13−8) 69D DEUTZ HARNESS TO OIL PRESSURE SENDER
42J SPLICE B TO PLG12 (8) 70A PLG4 (10) TO PLG12 (3)
42J SPLICE B TO PC7 (E) 70C RC4 (10) TO TEMP GAUGE (3)
42JJ SPLICE B TO CR6 (85) 71A PLG4 (11) TO FUEL SENDER
42K PC1 (PLG8−C1) TO PLG3 (2) 71C RC4 (11) TO FUEL GAUGE/HM (5)
42KK SPLICE C TO 42 SS 72A CR6 (87) TO PC7 (B)
TM-4425 Page 106 Big Blue 400D, 500 X
Table 11-4. Lead List Summary For Big Blue 500 X CC/CV Models Eff w/Serial No. MD120069E And Following
(Continued)
Lead Connections Lead Connections
81A EXCITER STATOR − 1T (A−LEFT) 106A BRUSH (FRONT) − PLG1 (5)
81B ELCB1 (LINE) TO 1T (A−RIGHT) 106B RC1 (5) TO SPLICE
81D EXCITER TO T1 106C RC3 (7) TO SPLICE
81E T1 PRI TO EXCITER STATOR 106D CR4 (6) OPTION TO SPLICE
82A EXCITER STATOR − 1T (B−LEFT) 106D R3 TO PLG3 (7)
82B CB2 (TOP) TO 1T (B−RIGHT) 107A CR4 (4) TO CR4 (5)
83A EXCITER STATOR − 1T (C−LEFT) 108A BRUSH (REAR) − PLG1 (8)
83B PC6 (PLG14−10) TO (1T−C) 108B RC1 (8) TO RC3 (9)
83D PC6 (PLG14−9) TO PC1 (PLG9−F2) 108C PC1 (PLG8−A2) TO PLG3 (9)
84A EXCITER STATOR − 1T (D−LEFT) 110A CB12 TO D1 (ANODE)
84B GFCI (N) TO 1T (D−RIGHT) 111A CB12 TO CB11
84C ELCB1 (LINE N) TO 1T (D−RIGHT) 111B CB12 TO CR5 (2)
84D EXCITER TO S6 113A CB11 TO RC3 (12)
84E AUX STATOR TO S6 (11) 113B PC1 (PLG8−B1) TO PLG3 (12)
84F 1T−D TO CB6 116A PC6 (PLG14−8) TO PC1 (PLG9−B1)
85A CB2 (BOTTOM) TO GFCI (HOT) 117A PC6 (PLG14−7) TO PC1 (PLG9−C3)
85B CB2 (BOTTOM) TO PC5 (5) 118A PC6 (PLG14−6) TO PC1 (PLG9−B2)
86A ELCB1 (LOAD N) TO RC1 (N) 119A S6 (1) TO PC6 (PLG14−5)
87A CB6 TO PLG14 #2 120A S6 (2) TO PC1 (PLG9−F1)
88A PIN SPLICE − RC1 (L) 121A S6 (3) TO PC6 (PLG14−4)
88B PIN SPLICE − PC4 (4) 121B PC6 (PLG14−3) TO CB5
89A EXCITER TO CB5 (TOP) 122A PC1 (PLG9−A1) TO S6 (5)
98A S6 (12) TO CB4 123A PC1 (PLG9−A2) TO S6 (6)
99A T1 PRI TO CB4 124A S6 (7) TO PC1 (PLG9−D3)
100A EXCITER STATOR − PLG1 (1) 125A PC1 (PLG8−F1) TO PLG6 (1)
100B RC1 (1) TO F1 126A PC1 (PLG8−F2) TO PLG6 (2)
101A EXCITER STATOR − PLG1 (3) 127A S5 (TOP) TO PC1 (PLG9−B3)
101B RC1 (3) TO SR1 (AC) 128A S5 (CENTER) TO PC1 (PLG9−D2)
102B C9 (−) TO SPLICE 129A S5 (BOTTOM) TO PC1 (PLG9−C2)
102C SR1 (−) TO SPLICE 130A LEAD 130B TO PC1 (PLG8−K1)
102D RC3 (4) TO SPLICE 131A LEAD 131B TO PC1 (PLG8−H2)
102E CR4 (3) OPTION TO SPLICE 132A LEAD 132B TO PC1 (PLG8−J1)
102E R3 TO PLG3 (4) 133A LEAD 133B TO PC1 (PLG8−H1)
103A EXCITER STATOR − PLG1 (4) 134A R1 (PLG10−1) TO PC1 (PLG9−D1)
103B PC1 (PLG8−A1) TO PLG3 (6) 135A R1 (PLG10−2) TO PC1 (PLG9−C1)
103D RC3 (6) TO RC1 (4) 136A R1 (PLG10−3) TO PC1 (PLG9−A3)
104A EXCITER STATOR − PLG1 (6) 137A SR1 (AC) TO F1
104B RC1 (6) TO F2 138A RC3 (1) TO F2
105A BRUSH (CENTER) − PLG1 (2) 138B PC1 (PLG8−A3) TO PLG3 (1)
105B SR1 (+) TO C9 139A PC1 (PLG8−C3) TO PC9 (PLG13−1)
105C SR1 (+) TO SPLICE 140A PC1 (PLG8−D2) TO PC9 (PLG13−5)
105D RC3 (8) TO SPLICE 141A PC1 (PLG8−D3) TO PC9 (PLG13−6)
105E PC1 (PLG8−D1) TO PLG3 (8) 142A PC1 (PLG8−K2) TO PC9 (PLG13−7)
105F RC1 (2) TO SPLICE 143A PC1 (PLG8−J2) TO PC9 (PLG13−9)
105G D1 (CATHODE) TO SPLICE 144A PC1 (PLG8−B3) TO PC9 (PLG13−10)

Big Blue 400D, 500 X TM-4425 Page 107

 SECTION 12 − RUN-IN PROCEDURE
run_in1 2014−09

NOTICE − Diesel engines in MILLER equipment are meant to operate optimally at moderate to rated load. Using light or no load for extended periods
of time may cause wetstacking or other engine damage. Do not idle engine longer than necessary.

12-1. Wetstacking
NOTICE − Do not perform run-in
procedure at less than 20 volts weld
output and do not exceed duty cycle
or equipment damage may occur.
1 Welder/Generator
Run diesel engines near rated volt-
age and current during run-in period
to properly seat piston rings and
prevent wetstacking. See name-
plate, rating label, or specifications
section in this manual to find rated
voltage and current.
2 NOTICE − Do not idle engine longer
than necessary. Piston rings only
seat correctly if engine runs at weld/
power rpm, and the welder/genera-
tor is kept loaded during run-in.
2 Engine Exhaust Pipe
Wetstacking is unburned fuel and oil
in the exhaust pipe and occurs
during run-in if the engine is run too
long at light load or idle rpm.
If exhaust pipe is coated with a wet,
1 black, tar-like substance, dry the
engine using one of the following
run-in procedures.
See the engine manual for additional
engine run-in information.

TM-4425 Page 108 Big Blue 400D, 500 X

12-2. Run-In Procedure Using Load Bank Or Resistance Grid
2
3
! Stop engine.
! Do not touch hot exhaust pipe, en-
gine parts, or load bank/grid.
! Keep exhaust and pipe away from
flammables.
NOTICE − Do not perform run-in
procedure at less than 20 volts weld output
and do not exceed duty cycle or equipment
damage may occur.
1 Load Bank
Turn all load bank switches Off. If needed,
connect load bank to 115 volts ac wall
receptacle or generator auxiliary power
receptacle.
2 Welder/Generator
Place A/V range switch in maximum posi-
tion, A/V control in minimum position, and
Output Selector switch (if present) in either
DC position.
Big Blue 400D, 500 X
1
3 Weld Cables
4 Resistance Grid
Use grid sized for generator rated output.
Turn Off grid.
5 Voltmeter
6 Clamp-On Ammeter
Connect voltmeter and ammeter as
shown, if not provided on generator.
Start engine and run for several minutes.
For Load Bank
Set load bank switches and then adjust
generator A/V control so load equals
rated voltage and current of generator
(see nameplate, rating label, or the
specifications section in this manual).
For Resistance Grid
Set grid switches and then adjust gen-
erator A/V control so load equals rated
4
S-0683 / S-0684
voltage and current of the generator
(see nameplate, rating label, or the
specifications section in this manual).
Check generator and meters after first five
minutes then every fifteen minutes to be
sure generator is loaded properly.
NOTICE − Check oil level frequently during
run-in; add oil if needed.
It is recommended to run the welder/gener-
ator for two hours minimum and up to four
hours under load. Place A/V control in
minimum position, then shut down load
bank or grid to remove load. Run engine
several minutes at no load.
! Stop engine and let cool.
7 Engine Exhaust Pipe
Repeat procedure if wetstacking is pres-
ent.
TM-4425 Page 109
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An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
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