Big Blue 400 D CC/CV Wont Strike an Arc
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  1. #1

    Big Blue 400 D CC/CV Wont Strike an Arc

    Can anyone point me in the right direction regarding the reason my 400 D will not weld, I do have 120 and 240 volts at the receptacles, the serial number of the machine is ME060257E

    Ive also checked the fuses F1 & F2 both are fine

  2. #2
    Join Date
    Jul 2012
    Posts
    709

    Re: Big Blue 400 D CC/CV Wont Strike an Arc

    https://www.millerwelds.com/support/manuals-and-parts

    Print a copy of owners manual which has a trouble shooting section.

    You will need to test CR2

    Search for BCGT generators AC electrical testing and troubleshooting manual. It has pictures on how to test components or look up on Utube for videos.
    Last edited by guajilloweld03; 07-20-2019 at 04:30 PM.

  3. #3

    Re: Big Blue 400 D CC/CV Wont Strike an Arc

    Quote Originally Posted by guajilloweld03 View Post
    https://www.millerwelds.com/support/manuals-and-parts

    Print a copy of owners manual which has a trouble shooting section.

    You will need to test CR2

    Search for BCGT generators AC electrical testing and troubleshooting manual. It has pictures on how to test components or look up on Utube for videos.
    Ive downloaded the owner's manual and have found the wiring diagram but so far CR2 is not shown ???, also the fuel gauge has an orange light showing and no fuel level is shown.

  4. #4
    Join Date
    Jul 2012
    Posts
    709

    Re: Big Blue 400 D CC/CV Wont Strike an Arc

    Well my bad, it's SR2 and C9. Does your machine have CC/CV.

  5. #5

    Re: Big Blue 400 D CC/CV Wont Strike an Arc

    Quote Originally Posted by guajilloweld03 View Post
    Well my bad, it's SR2 and C9. Does your machine have CC/CV.
    Yes it's a CC/CV machine, I will check SR2 , also today i have power at the 120 volt and 240 Volt Single phase but nothing at the 240 Volt 3 Phase ??

  6. #6
    Join Date
    Jul 2012
    Posts
    709

    Re: Big Blue 400 D CC/CV Wont Strike an Arc

    Being CC/CV your machine will not have SR2.
    Follow trouble shooting guide in owners manual.
    Check CB7 & CB5 and check brushes & slip rings and field current regulator board PC1. Also check for broken wires, corroded or loose connections.



    Did you have a dead battery and use jumper cable to jump start your welder. On the trailblazer 302 jump starting because of a dead battery will mess up your computer board.

    If PC1 is bad you can have it repaired at
    https://www.innovatcorp.com/

    Or get a new one
    https://www.miller4less.com/
    Last edited by guajilloweld03; 07-21-2019 at 11:32 AM.

  7. #7

    Re: Big Blue 400 D CC/CV Wont Strike an Arc

    Quote Originally Posted by guajilloweld03 View Post
    Being CC/CV your machine will not have SR2.
    Follow trouble shooting guide in owners manual.
    Check CB7 & CB5 and check brushes & slip rings and field current regulator board PC1. Also check for broken wires, corroded or loose connections.



    Did you have a dead battery and use jumper cable to jump start your welder. On the trailblazer 302 jump starting because of a dead battery will mess up your computer board.

    If PC1 is bad you can have it repaired at
    https://www.innovatcorp.com/

    Or get a new one
    https://www.miller4less.com/
    Thanks for all your help, ive sent the machine to the Miller Dealer, and should get the problem sorted out in the next few days.

  8. #8
    Join Date
    Dec 2014
    Posts
    30

    Re: Big Blue 400 D CC/CV Wont Strike an Arc

    Quote Originally Posted by Alan J View Post
    Thanks for all your help, ive sent the machine to the Miller Dealer, and should get the problem sorted out in the next few days.
    Depending on the age and prior use of the machine, but...

    I had a similar issue with a nearly new, but several years idle Miller Diesel unit, that was, in the end, snot-balled up dried factory grease on the main switch gear (Current range/ polarity switches) under the front panel. Had power right up to the switches, and at the receptacles on the front panel.

    Had I seen this earlier, it may have done you some good. But I'll throw this out for the next guy, anyways.

    Wasn't too hard to drive out the cross pin, and clean the contacts with some solvent. Replaced the dried grease with a dielectric grease and all is working really well.

  9. #9

    Re: Big Blue 400 D CC/CV Wont Strike an Arc

    Thanks to all who have had provided a probable diagnosis, well Miller just came back and confirmed its the PC 1 Field Current Regulator.

  10. #10
    Join Date
    Jul 2012
    Posts
    709

    Re: Big Blue 400 D CC/CV Wont Strike an Arc

    Thank you for posting outcome, did repair tech give a reason for failure.

  11. #11

    Re: Big Blue 400 D CC/CV Wont Strike an Arc

    No, but I will ask I have 3 weeks for the delivery of the part, once I get the old PC1 back I will send it to Innovate Corp to see if they can do a repair.

  12. #12
    Join Date
    Nov 2012
    Location
    North Port Florida
    Posts
    11

    Re: Big Blue 400 D CC/CV Wont Strike an Arc

    I have the same machine, and a Miller tech on the phone helped traced it down to a slow blow 10 fuse which was hard to find local.
    It seemed like a good idea at the time!

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