Miller Electric Big Blue 500 X, Big Blue 400P manual Main Assembly

Page 72

Item

Dia.

 

Part

Description

 

Quantity

 

No.

Mkgs.

 

No.

 

 

 

 

 

 

Figure 13-1. Main Assembly

 

 

 

 

 

 

 

 

 

 

. . .

1 . .

. . . . . . . .

. . .

189 824

. . PANEL, gen LH

. . . 1

. . .

1 . .

. . . . . . . .

. . ♦199 294

. . PANEL, gen LH ss

. . . 1

. . .

2 . .

. . . . . . . .

. . .

191 626

. . BUMPER, door engine access

. . . 2

. . .

3 . .

. . . . . . . .

. . .

189 975

. . HINGE, door access 180deg

. . . 2

. . .

4 . .

. . . . . . . .

. .

+200 989

. . DOOR, engine access

. . . 1

. . .

4 . .

. . . . . . . .

. ♦+210 736

. . DOOR, engine access ss

. . . 1

. . .

5 . .

. . . . . . . .

. . .

199 592

. . LATCH, paddle series 20 (black)

. . . 1

. . .

6 . .

. . . . . . . .

. . .

190 076

. . CHANNEL, stiffener engine access

. . . 1

. . .

6 . .

. . . . . . . .

. . ♦202 635

. . CHANNEL, stiffener engine access e−coat

. . . 1

. . .

7 . .

. . . . . . . .

. . .

190 992

. . KEEPER, latch engine access door

. . . 1

. . .

8 . .

. . . . . . . .

. . .

. 220539

. . LABEL, diesel engine maintenance (required on rh door only)

. . . 1

. . .

9 . .

. . . . . . . .

. . .

208 141

. . STOP, door

. . . 1

. . . 10 . .

. . . . . . . .

. . .

189 826

. . PANEL, rocker

. . . 1

. . . 10 . .

. . . . . . . .

. . ♦199 298

. . PANEL, rocker ss

. . . 1

. . . 11 . .

. . . Z1 .

. . CC214 972

. . REACTOR, ac

. . . 1

. . . 11 . .

. . . Z1 .

. . CV214 964

. . REACTOR, ac

. . . 1

. . . 12 . .

. . . . . . . .

. . .

206 352

. . BRACE, front to center upright

. . . 2

. . . 13 . .

. . . 1T .

. . .

038 621

. . BLOCK, term 30A 4 pole frict term str

. . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . .

. . . . .

. . . . . . . .

. . .

038 620

. . . . LINK, jumper term blk 30A

. . . 2

. . . 14 . .

. . . . . . . .

. . .

081 499

. . BRACKET, mtg strip terminal

. . . 1

. . . 15 . .

SR4, SR5 .

035 704

. . RECTIFIER, integ bridge 40. amp 800v

. . . 2

. . . 16 . .

. . CB4

. . .

045 061

. . CIRCUIT BREAKER, auto reset 24vdc 7 amp

. . . 1

. . . 17 . .

. . . T1 .

. . .

201 613

. . TRANSFORMER w/bracket

. . . 1

. . . 17 . .

. . . T1 .

. . ♦205 636

. . TRANSFORMER w/bracket (environmental coating)

. . . 1

. . . 18 . .

. . . . . . . .

. . .

173 352

. . EXTRUSION, rubber clamp/bulb (order by ft)

. . . 3ft

. . . 19 . .

. . . . . . . .

. . .

189 708

. . FIREWALL, top

. . . 1

. . . 20 . .

. . . . . . . .

. . .

191 307

. . COVER, plate

. . . 1

. . . 21 . .

. . . . . . . .

. . .

189 763

. . BRACKET, mtg air cleaner

. . . 1

. . . 22 . .

. . . . . . . .

. . .

189 618

. . HOSE, air cleaner

. . . 1

. . . 23 . .

. . . . . . . .

. . .

198 457

. . TUBE, air intake

. . . 1

. . . 24 . .

. . . . . . . .

. . .

173 036

. . HOSE, elbow air cleaner

. . . 1

. . .

. . . . .

. . . . . . . .

. . .

010 863

. . . . CLAMP, hose 1.125 − 3.000 clp dia

. . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 4

. . . 25 . .

. . . . . . . .

. . .

189 764

. . AIR CLEANER, intake

. . . 1

. . .

. . . . .

. . . . . . . .

. . .

*192 938

. . . . FILTER, air element primary

. . . 1

. . .

. . . . .

. . . . . . . .

. *♦192 939

. . . . FILTER, air element safety

. . . 1

. . . 26 . .

. . . . . . . .

. . .

189 464

. . SEAL, weather lift eye

. . . 1

. . .

. . . . .

. . . . . . . .

. . .

173 909

. . HOSE, sae .312 id x .560 od x 24.000

(order by ft)

. . . 2

. . . 27 . .

. . . . . . . .

. . .

191 819

. . HOSE, sae .312 id x .560 od x 14.000

(order by ft)

. . . 2

. . .

. . . . .

. . . . . . . .

. . .

198 584

. . HOSE, sae .312 id x .560 od x 5.000 (order by ft)

. . . 1

. . . 28 . .

. . . . . . . .

. . .

095 636

. . HOSE, sae .187 id x .41 od x 30.000

(order by ft)

. . . 1

. . . 29 . .

. . . . . . . .

. . .

206 297

. . BASE, fuel filter w/fittings

. . . 1

. . .

. . . . .

. . . . . . . .

. . .

192 741

. . . . BLOCK, spacer mtg filter base

. . . 1

. . . 30 . .

. . . . . . . .

. . .

*192 744

. . FILTER, fuel spin−on

. . . 1

. . . 31 . .

. . . . . . . .

. . .

201 658

. . UPRIGHT, center assembly

. . . 1

. . . 32 . .

. . . . . . . .

. . .

201 697

. . PAN, reactor and rectifier

. . . 1

. . .

. . . . .

. . . . . . . .

. . .

203 260

. . . . LABEL, caution do not use ether

. . . 1

. . . 33 . .

. . . . . . . .

. .

+201 934

. . COVER, top

. . . 1

. . . 33 . .

. . . . . . . .

. ♦+202 640

. . COVER, top ss

. . . 1

. . . 34 . .

. . . . . . . .

. . .

189 052

. . GROMMET, plastic neck filler fuel

. . . 1

. . . 35 . .

. . . . . . . .

. . .

190 198

. . CAP, tank screw−on 3.500 in w/vent

. . . 1

. . . 36 . .

. . . . . . . .

. . .

192 041

. . LABEL, use diesel fuel only

. . . 1

. . . 37 . .

. . . . . . . .

. . .

222 513

. . LABEL, warning falling equipment can cause serious

. . . 1

. . . 38 . .

. . . . . . . .

. . .

224 265

. . LABEL, warning hot exhaust parts do not touch

. . . 1

. . . 39 . .

. . . . . . . .

. . .

105 734

. . PIPE, muffler extension elbow 1.750 od

. . . 1

. . . 40 . .

. . . . . . . .

. . .

201 851

. . COVER, radiator access

. . . 1

OM-4421 Page 66

Page 71 Page 73
Image 72
Page 71 Page 73
Contents OM-4421215 075N ProcessesDescription File Engine DriveFrom Miller to You Table of Contents − Maintenance & Troubleshooting Directives StandardsDecrot9/06 Manufacturer European Contact Notified Body Decrotsound6/05Symbol Usage Arc Welding HazardsEngine Hazards Compressed Air Hazards Principal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interferenceSignification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un in- cendie ou une explosion DES Particules Volantes peuvent blesser les yeuxDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut affecter l’ouïe’AIR Comprimé peut provoquer des blessures ’EMPLOI Excessif peutLE Surchauffement peut endom- mager le moteur électrique LES Étincelles Volantes risquent de provoquer des blessuresLE Soudage À L’ARC risque de provoquer des interférences Pour les moteurs à essencePour les moteurs diesel Boulevard, Rexdale, Ontario, Canada M9W 1R3 téléphone− Definitions − 50 h StdStd Manufacturer’s Rating Labels CC Models CC/CV Models CC Export ModelsOM-4421 Symbols And Definitions − Specifications Weld, Power, And Engine SpecificationsDimensions, Weights, And Operating Angles Volt-Ampere Curves For CC Models Stick Mode MIG ModeTIG Mode Volt-Ampere Curves For CC/CV ModelsCurve shows typical fuel use under weld or power loads Exceeding duty cycle can damage unit and void warrantyFuel Consumption Duty Cycle And OverheatingAC Generator Power Curve Optional Three-Phase Generator Curves12 kVA/kW Single-Phase AC Output No Weld Load 15 kVA/kW Three-Phase AC Output No Weld Load− Installation Installing Welding GeneratorLocation/Airflow Clearance Grounding1Using Lifting Eye Mounting Welding Generator Supporting The UnitMounting Surface To Bolt Unit In PlaceInstalling Exhaust Pipe Tools Needed 1/2Stop engine and let cool Activating The Dry Charge Battery If Applicable Connecting The BatteryDo not overfill battery cells For 30 MinutesCoolant Recovery Tank Engine Prestart ChecksFull Capacity Engine 9.5 qt 9.01L Diesel Hot Full Cold FullConnecting To Weld Output Terminals Stick and TIG WeldingMIG and Fcaw Welding Stop engineSelecting Weld Cable Sizes 150 ft 200 ft 250 ft350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Stop engine beforeConnecting To Remote 14 Receptacle RC14 On CC/CV Models Socket− Operating Welding Generator − CC Models Front Panel Controls For CC Models See SectionTo Start Do not use ether. Using ether voids warranty Do not switch under loadEngine Starting Controls Engine Gauges And MetersRemote Amperage Control On CC Models Optional Weld Control/Arc Condition Information LabelExample Combination Remote Amperage Control Stick OM-4421 − Operating Welding Generator − CC/CV Models Front Panel Controls For CC/CV Models See SectionUse switch to select weld amperage range Voltage/Amperage Adjust Switch And Remote 14 Receptacle14 AC/DC Voltmeter Optional Process/Contactor Switch On CC/CV Models Process/Contactor Switch SettingsRemote Voltage/Amperage Control On CC/CV Models Optional Example Combination Remote Amperage Control TIG− Operating Auxiliary Equipment Volt And 240 Volt ReceptaclesSingle-Phase Generator Power Three-Phase Power Connection Rear Of PanelClose panel opening if no connections are made to generator Optional Generator Power Receptacles 240 V 15 a AC South African Receptacle RC1Supplementary Protector CB2 Supplementary Protector CB3 − Maintenance & Troubleshooting Maintenance LabelRoutine Maintenance Checking Generator Brushes Servicing Air Cleaner By the warrantyTo clean air filter Do not clean housing with air hoseInspecting And Cleaning Optional Spark Arrestor Muffler Stop engine and let cool. Reinstall cleanout plugTools Needed 3/8 Adjusting Engine Speed Weld/Power Speed AdjustmentEngine Speed No Load Standard Model Idle Speed Ad- justmentServicing Fuel And Lubrication Systems Overload Protection Troubleshooting Welding − CC ModelsWelding − CC/CV Models Standard Generator Power Optional Three-Phase Generator Power CC/CV Models OnlyEngine OM-4421 − Electrical Diagrams Circuit Diagram For CC Welding Generator223 522-B Circuit Diagram For CC/CV Welding Generator 223 523-B − RUN-IN Procedure WetstackingWelding Generator Run-In Procedure Using Load Bank Procedure at less thanStop engine Do not touch hot exhaust From flammables Do not PerformRun-In Procedure Using Resistance Grid Bank/gridFrom flammables Do not perform run-in− Generator Power Guidelines Selecting EquipmentGrounding Generator To Truck Or Trailer Frame Grounding When Supplying Building Systems How Much Power Does Equipment Require?Earth ground if supplying Amperes x Volts = WattsApproximate Power Requirements For Industrial Motors Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsPower Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 = Starting AmperageTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Current Load Watts Amperes− Parts List 93 −6 105 104 100 101 102 103 Main Assembly 010 Figures 13-2 Figures 13-4 Control Box Assembly − CC Models 087 Control Box Assembly − CC/CV Models Control Box Assembly − CC/CV Models -1ItemTD1 214 Panel, Front w/Components − CC Models 3634Panel, Front w/Components − CC Models -1Item Panel, Front w/Components − CC/CV Models 40 39Panel, Front w/Components − CC/CV Models -1Item 170 Generator Generator -1Item602 SCREW, .312−18x .75 hexwhd.66d stl pld slffmg tap−rw 601 Main Rectifier Assembly Wiring Harnesses Harness, receptacle auxiliary power export models includes PLG4Page Service Your distributor also givesSupport To locate a Distributor or Service Agency visit Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s

Big Blue 500 X, Big Blue 400P specifications

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

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

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

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

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

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