Miller Electric Big Blue 400P, Big Blue 500 X manual 010

Page 73

Item

Dia.

Part

Description

Quantity

No.

Mkgs.

No.

 

 

 

Figure 13-1. Main Assembly (Continued)

 

 

 

 

 

 

. . . 40 . . .

. . . . . . . .

. ♦202 629

. . COVER, radiator access ss

. . . 1

. . . 41 . . .

. . . . . . . .

. . 191 354

. . SUPPORT, cover

. . . 1

. . . 41 . . .

. . . . . . . .

. ♦202 633

. . SUPPORT, cover e−coat

. . . 1

. . . 42 . . .

. . . . . . . .

. . 010 875

. . CLAMP, muffler 2.000 dia

. . . 1

. . . 43 . . .

. . . . . . . .

. . 203 180

. . MANIFOLD, exhaust muffler

. . . 1

. . . . . . . . .

. . . . . . . .

. . 203 179

. . . . BRACKET, support muffler

. . . 2

. . . 43 . . .

. . . . . . . .

. . 195 012

. . SPARK ARRESTOR KIT (Horizontal) (export models only)

. . . 1

. . . 44 . . .

. . . . . . . .

. . 209 393

. . ENGINE, Perkins dsl elec 404.22bw

. . . 1

. . . . . . . . .

. . . . . . . .

. . *214 931

. . . . SENDER, Coolant Temp & 110c N.o. Switch

. . . 1

. . . . . . . . .

. . . . . . . .

. . *215 094

. . . . SWITCH, oil pressure

. . . 1

. . . . . . . . .

. . . . . . . .

. . 023 562

. . . . CLAMP, hose .312 − .875 clp dia

. . . 1

. . . . . . . . .

. . . . . . . .

. . *197 899

. . . . FILTER, oil

. . . 1

. . . . . . . . .

. . . . . . . .

. . *192 744

. . . . FILTER, fuel spin−on

. . . 1

. . . . . . . . .

. . . . . . . .

. . *197 997

. . . . FILTER, fuel secondary

. . . 1

. . . 45 . . .

. . . . . . . .

. . 214 658

. . HOSE, radiator upper

. . . 1

. . . 46 . . .

. . . . . . . .

. . *197 944

. . BELT, fan

. . . 1

. . . 47 . . .

. . . . . . . .

. . 217 775

. . GUARD, belt (export models only)

. . . 1

. . . 47 . . .

. . . . . . . .

. . 202 017

. . GUARD, belt

. . . 1

. . . 48 . . .

. . . . . . . .

. . 220 280

. . RADIATOR, w/shroud (includes)

. . . 1

. . . . . . . . .

. . . . . . . .

. . 220 281

. . . . SHROUD, radiator

. . . 1

. . . . . . . . .

. . . . . . . .

. . 214 884

. . . . RADIATOR, w/14# cap 4 row core 3 pass

. . . 1

. . . . . . . . .

. . . . . . . .

. . 187 120

. . . . CAP, radiator pressure 14 lb

. . . 1

. . . 49 . . .

. . . . . . . .

. . 225 120

. . LABEL, warning moving parts can cause injury

. . . 1

. . . 50 . . .

. . . . . . . .

. . 201 749

. . UPRIGHT, rear

. . . 1

. . . 50 . . .

. . . . . . . .

. ♦207 188

. . UPRIGHT, rear ss

. . . 1

. . . 50 . . .

. . . . . . . .

. ♦207 005

. . GRILL, rear panel ss

. . . 1

. . . 51 . . .

. . . . . . . .

. . 108 081

. . TERMINAL PROTECTOR, battery post mtg

. . . 2

. . . 52 . . .

. . . . . . . .

. . 190 206

. . CABLE, bat neg 42 in lg No. 2 awg w/clamp and .375rng

. . . 1

. . . 53 . . .

. . . . . . . .

. . 190 207

. . CABLE, bat pos 45 in lg No. 1 awg w/clamp and .406rng

. . . 1

. . . 54 . . .

. . . . . . . .

. . 203 430

. . BRACKET, battery holddown

. . . 1

. . . 55 . . .

. . . . . . . .

. . 190 897

. . BATTERY, stor 12V 650crk 110rsv gp 24

. . . 1

. . . 56 . . .

. . . . . . . .

. . 168 385

. . LABEL, warning battery explosion can blind

. . . 1

. . . 57 . . .

. . . . . . . .

. +225 120

. . LABEL, warning moving parts can cause injury

. . . 1

. . . 58 . . .

. . . . . . . .

. +201 183

. . COVER, battery access

. . . 1

. . . 58 . . .

. . . . . . . .

♦+202 639

. . COVER, battery access ss

. . . 1

. . . 59 . . .

. . . . . . . .

. . 201 006

. . BOLT, j stl .312−18 x 8.500 pld

. . . 2

. . . 60 . . .

. . . . . . . .

. +215 006

. . GUARD, fan

. . . 1

. . . 61 . . .

. . . . . . . .

. . 197 496

. . HOSE, radiator lower

. . . 1

. . . . . . . . .

. . . . . . . .

. . 199 505

. . HOSE, oil drain assy 32 in (consisting of)

. . . 1

. . . 62 . . .

. . . . . . . .

. . 165 271

. . . . VALVE, oil drain 3/8−18NPTF

. . . 1

. . . 63 . . .

. . . . . . . .

. . 176 529

. . . . FITTING, hose brs barbed fem 1/2tbg x 3/8NPT

. . . 1

. . . 64 . . .

. . . . . . . .

. . . 113 854

. . . . HOSE, SAE .500 ID x .780 OD xc oil (order by ft)

. . . 3ft

. . . 65 . . .

. . . . . . . .

. . 197 448

. . FITTING, hose brs barbed elbow m 1/2 tbg x 3/8 npt

. . . 1

. . . 66 . . .

. . . . . . . .

. . . . . . . . . . .

. . WASHER, oil drain (available through engine manufacturer)

. . . 1

. . . 67 . . .

. . . . . . . .

. . 197 196

. . FITTING, adapter oil drain 12mm male x 3/8 npt female

. . . 1

. . . 68 . . .

. . . . . . . .

. . 199 849

. . SCREW, 625−11 x 4.00hexhd pln gr 5 pld

. . . 4

. . . 69 . . .

. . . . . . . .

. . 071 731

. . WASHER, flat .656 ID x 2.250 OD x .187T stl pld

. . . 4

. . . 70 . . .

. . . . . . . .

. . 197 489

. . BRACKET, mtg RH

. . . 1

. . . 70 . . .

. . . . . . . .

. . 197 488

. . BRACKET, mtg LH

. . . 1

. . . 71 . . .

. . . . . . . .

. . 071 890

. . RETAINER, mount eng/gen

. . . 4

. . . 72 . . .

. . . . . . . .

. . 071 730

. . TUBING, stl .875 OD x 12ga wall x 2.500

. . . 4

. . . 73 . . .

. . . . . . . .

. . 083 476

. . MOUNT, eng/gen nprn .875 ID x 2.500 OD x 2.000

. . . 4

. . . 74 . . .

. . . . . . . .

. . 135 205

. . NUT, 625−11 .94hex .76H stl pld elastic stop nut

. . . 4

. . . 75 . . .

. . . . . . . .

. . 190 992

. . KEEPER, latch engine access door

. . . 2

. . . 76 . . .

. . . . . . . .

. . 190 076

. . CHANNEL, stiffener engine access

. . . 2

. . . 76 . . .

. . . . . . . .

. ♦202 635

. . CHANNEL, stiffener engine access e−coat

. . . 1

OM-4421 Page 67

Page 72 Page 74
Image 73
Page 72 Page 74
Contents Processes OM-4421215 075NDescription File Engine DriveFrom Miller to You Table of Contents − Maintenance & Troubleshooting Standards DirectivesDecrot9/06 Decrotsound6/05 Manufacturer European Contact Notified BodyArc Welding Hazards Symbol UsageEngine Hazards Compressed Air Hazards California Proposition 65 Warnings Principal Safety StandardsEMF Information Radiation can cause interference− Consignes DE Sécurité − Lire Avant Utilisation Signification des symbolesUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereuxDES Particules Volantes peuvent blesser les yeux LE Soudage peut provoquer un in- cendie ou une explosionDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut affecter l’ouïe’EMPLOI Excessif peut ’AIR Comprimé peut provoquer des blessuresLE Surchauffement peut endom- mager le moteur électrique LES Étincelles Volantes risquent de provoquer des blessuresPour les moteurs à essence LE Soudage À L’ARC risque de provoquer des interférencesPour les moteurs diesel Boulevard, Rexdale, Ontario, Canada M9W 1R3 téléphone− 50 h Std − DefinitionsStd CC Models CC/CV Models CC Export Models Manufacturer’s Rating LabelsOM-4421 Symbols And Definitions Weld, Power, And Engine Specifications − SpecificationsDimensions, Weights, And Operating Angles Volt-Ampere Curves For CC Models MIG Mode Stick ModeTIG Mode Volt-Ampere Curves For CC/CV ModelsExceeding duty cycle can damage unit and void warranty Curve shows typical fuel use under weld or power loadsFuel Consumption Duty Cycle And OverheatingOptional Three-Phase Generator Curves AC Generator Power Curve12 kVA/kW Single-Phase AC Output No Weld Load 15 kVA/kW Three-Phase AC Output No Weld LoadInstalling Welding Generator − InstallationLocation/Airflow Clearance Grounding1Using Lifting Eye Supporting The Unit Mounting Welding GeneratorMounting Surface To Bolt Unit In PlaceTools Needed 1/2 Installing Exhaust PipeStop engine and let cool Connecting The Battery Activating The Dry Charge Battery If ApplicableDo not overfill battery cells For 30 MinutesEngine Prestart Checks Coolant Recovery TankFull Capacity Engine 9.5 qt 9.01L Diesel Hot Full Cold FullStick and TIG Welding Connecting To Weld Output TerminalsMIG and Fcaw Welding Stop engine150 ft 200 ft 250 ft Selecting Weld Cable Sizes350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Stop engine beforeSocket Connecting To Remote 14 Receptacle RC14 On CC/CV ModelsFront Panel Controls For CC Models See Section − Operating Welding Generator − CC ModelsDo not switch under load To Start Do not use ether. Using ether voids warrantyEngine Starting Controls Engine Gauges And MetersWeld Control/Arc Condition Information Label Remote Amperage Control On CC Models OptionalExample Combination Remote Amperage Control Stick OM-4421 Front Panel Controls For CC/CV Models See Section − Operating Welding Generator − CC/CV ModelsVoltage/Amperage Adjust Switch And Remote 14 Receptacle Use switch to select weld amperage range14 AC/DC Voltmeter Optional Process/Contactor Switch Settings Process/Contactor Switch On CC/CV ModelsExample Combination Remote Amperage Control TIG Remote Voltage/Amperage Control On CC/CV Models OptionalVolt And 240 Volt Receptacles − Operating Auxiliary EquipmentRear Of Panel Single-Phase Generator Power Three-Phase Power ConnectionClose panel opening if no connections are made to generator 240 V 15 a AC South African Receptacle RC1 Optional Generator Power ReceptaclesSupplementary Protector CB2 Supplementary Protector CB3 Maintenance Label − Maintenance & TroubleshootingRoutine Maintenance Checking Generator Brushes By the warranty Servicing Air CleanerTo clean air filter Do not clean housing with air hoseStop engine and let cool. Reinstall cleanout plug Inspecting And Cleaning Optional Spark Arrestor MufflerTools Needed 3/8 Weld/Power Speed Adjustment Adjusting Engine SpeedEngine Speed No Load Standard Model Idle Speed Ad- justmentServicing Fuel And Lubrication Systems Overload Protection Welding − CC Models TroubleshootingWelding − CC/CV Models Optional Three-Phase Generator Power CC/CV Models Only Standard Generator PowerEngine OM-4421 Circuit Diagram For CC Welding Generator − Electrical Diagrams223 522-B Circuit Diagram For CC/CV Welding Generator 223 523-B Wetstacking − RUN-IN ProcedureWelding Generator Procedure at less than Run-In Procedure Using Load BankStop engine Do not touch hot exhaust From flammables Do not PerformBank/grid Run-In Procedure Using Resistance GridFrom flammables Do not perform run-inSelecting Equipment − Generator Power GuidelinesGrounding Generator To Truck Or Trailer Frame How Much Power Does Equipment Require? Grounding When Supplying Building SystemsEarth ground if supplying Amperes x Volts = WattsApproximate Power Requirements For Farm/Home Equipment Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentHow Much Power Can Generator Supply? Power Required To Start MotorSingle-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 = Starting AmperageTypical Connections To Supply Standby Power Current Load Watts Amperes Selecting Extension Cord Use Shortest Cord Possible− 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 -1Item Control Box Assembly − CC/CV ModelsTD1 214 3634 Panel, Front w/Components − CC ModelsPanel, Front w/Components − CC Models -1Item 40 39 Panel, Front w/Components − CC/CV ModelsPanel, Front w/Components − CC/CV Models -1Item 170 Generator -1Item Generator602 SCREW, .312−18x .75 hexwhd.66d stl pld slffmg tap−rw 601 Main Rectifier Assembly Wiring Harnesses PLG4 Harness, receptacle auxiliary power export models includesPage Your distributor also gives ServiceSupport Miller Electric Mfg. Co To locate a Distributor or Service Agency visitFor 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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