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Manual Miller Electric Big Blue 400 PX

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  • Miller Electric Big Blue 400 PX - page 1

    Big Blue 400 PX OM -223 037M 2007 − 11 Pro cesses Descrip tio n Air Carbon Arc (CAC-A) Cutting and Gouging Stick (SMAW ) Welding Engine Driven Welding Generator TIG (GT A W) W elding MIG (GMAW) Welding Flux Cored (FCA W ) W elding ) (50/60 Hz) V isit our website at www.MillerWelds.com File: Engine Drive ...

  • Miller Electric Big Blue 400 PX - page 2

    Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .Mille ...

  • Miller Electric Big Blue 400 PX - page 3

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . ...

  • Miller Electric Big Blue 400 PX - page 4

    T ABLE OF CONTENTS SECTION 8 − MAINTENANCE & TROUBLESHOOTING 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. Routine Maintenance 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2. Maintenance Label 34 . . ...

  • Miller Electric Big Blue 400 PX - page 5

    dec_rot_1/07 Declaration of Conformity for European Community (CE) Products  This information is provided for units with CE certification (see rating label on unit). Manufacturer : European Contact: Miller Electric Mg. Co. Mr . Danilo Fedolfi, 1635 W . Spencer St. Managing Director Appleton, WI 54914 USA ITW Welding Products Italy S.r .l. Phone: ...

  • Miller Electric Big Blue 400 PX - page 6

    dec_rotsound2007_10 Declaration of Conformity for European Community (CE) Products  This information is provided for units with CE certification (see rating label on unit). Manufacturer : European Contact: Notified Body: Miller Electric Mg. Co. Mr . Danilo Fedolfi, A V T echnology Limited 1635 W . Spencer St. Managing Director A VTECH House Appl ...

  • Miller Electric Big Blue 400 PX - page 7

    OM-223 037 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2007 − 04 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury . The possible hazards are shown in the adjoining symbols ...

  • Miller Electric Big Blue 400 PX - page 8

    OM-223 037 Page 2 W elding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous.  Keep your head out of the fumes. Do not breathe the fumes.  If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases.  If ventilation ...

  • Miller Electric Big Blue 400 PX - page 9

    OM-223 037 Page 3 1-3. Engine Hazards BA TTER Y 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 or servicing battery .  Do not allow tools to cause sparks when working on a battery .  Do not use welder to ...

  • Miller Electric Big Blue 400 PX - page 10

    OM-223 037 Page 4 HOT MET AL from air arc cutting and gouging can cause fire or explosion.  Do not cut or gouge near flammables.  W atch for fire; keep extinguisher nearby . HOT P ARTS can cause burns and injury .  Do not touch hot compressor or air system parts.  Let system cool down before touching or ser- vicing. READ INSTRUCTIONS. ? ...

  • Miller Electric Big Blue 400 PX - page 11

    OM-223 037 Page 5 H. F . RADIA TION can cause interference.  High-frequency (H.F .) can interfere with radio navigation, safety services, computers, and communications equipment.  Have only qualified persons familiar with electronic equipment perform this installation.  The user is responsible for having a qualified electrician promptly co ...

  • Miller Electric Big Blue 400 PX - page 12

    OM-223 037 Page 6 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION rom_2007 − 04fre Se protéger , ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud. 2-1. Signification des symboles DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des ...

  • Miller Electric Big Blue 400 PX - page 13

    OM-223 037 Page 7 DES PIÈCES CHAUDES peuvent provoquer des brûlures graves.  Ne pas toucher à mains nues les parties chau - des.  Prévoir une période de refroidissement avant d e travailler à l’équipement.  Ne pas toucher aux pièces chaudes, utiliser les outils recomman - dés et porter des gants de soudage et des vêtements épa ...

  • Miller Electric Big Blue 400 PX - page 14

    OM-223 037 Page 8 LES CHAMPS MAGNETIQUES peuv- ent affecter des implants médicaux.  Porteur de simulateur cardiaque ou autre im- plants médicaux, rester à distance.  Les porteurs d’implants doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de sou- dage par points, de gougeage, du coup ...

  • Miller Electric Big Blue 400 PX - page 15

    OM-223 037 Page 9 L ’utilisation d’un groupe autonome à l’intérieur PEUT VOUS TUER EN QUELQUES MINUTES.  Le s fumées d’un groupe autonome contient du monoxyde de carbone. C’est un poison invisi- ble et inodore.  JAMAIS utiliser dans une maison ou garage, même avec les portes et fenêtres ouvertes.  Uniquement utiliser à l’ ...

  • Miller Electric Big Blue 400 PX - page 16

    OM-223 037 Page 10 LE SURCHAUFFEMENT peut endom- mager le moteur électrique.  Arrêter ou déconnecter l’équipement avant d e démarrer ou d ’a rrêter le moteur .  Ne pas laisser tourner le moteur trop lentement sous risque d’en - dommager le moteur électrique à cause d’une tension et d’une fré - quence trop faibles.  N e p ...

  • Miller Electric Big Blue 400 PX - page 17

    OM-223 037 Page 1 1 2-6. P r oposition californienne 65 A vertissem ents Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des mal- formations congénitales et, dans certains cas, des cancers. (Code de santé et de sécurité ...

  • Miller Electric Big Blue 400 PX - page 18

    OM-223 037 Page 12 SECTION 3 − DEFINITIONS 3-1. W arning Label Definitions 3/96 1 Remove unit from shipping crate. Remove Owner’s Manual from unit. Follow instructions to install muf fler . 2 Read Owner ’s Manual. Read labels on unit. 3 Use Diesel Fuel only , and fill fuel tank. Leave room for expansion. 4 Warning! W atch Out! There are possi ...

  • Miller Electric Big Blue 400 PX - page 19

    OM-223 037 Page 13 3-2. Manufacturer ’ s Rating Label 223 081-A / Ref 804 068-E ...

  • Miller Electric Big Blue 400 PX - page 20

    OM-223 037 Page 14 3-3. Symbols And Definitions  Some symbols are found only on CE products. Stop Engine Fast (Run, W eld/ Power) Slow (Idle) Start Engine Starting Aid (Preheat) Battery (Engine) Engine Oil Pressure Engine Oil Check Injectors/ Pump Check V alve Clearance Fuel Protective Earth (Ground) Positive Negative Certified/T rained Mechanic ...

  • Miller Electric Big Blue 400 PX - page 21

    OM-223 037 Page 15 SECTION 4 − SPECIFICA TIONS 4-1. W eld And Power Specifications W elding Mode W eld Output Range At 60 Hz (1800 rpm) W eld Output Range At 50 Hz (1500 rpm) Rated W elding Output At 60 Hz (1800 rpm) Rated W elding Output At 50 Hz (1500 rpm) Maximum Open- Circuit V oltage Generator Power Rating CC/DC 20 − 410 A 20 − 300 A 300 ...

  • Miller Electric Big Blue 400 PX - page 22

    OM-223 037 Page 16 4-4. V olt-Ampere Curves − 50 Hz Operation 223 186-A / 223 187-A / 223 188-A The volt-ampere curves show the minimum and maximum voltage an d amperage output capabilities of th e welding generator . Curves of al l other settings fall between the curves shown. A. Stick Mode B. MIG Mode C. TIG Mode 0 10 20 30 40 50 60 70 80 90 10 ...

  • Miller Electric Big Blue 400 PX - page 23

    OM-223 037 Page 17 4-5. V olt-Ampere Curves − 60 Hz Operation 217 517 / 217 516 / 217 518 The volt-ampere curves show the minimum and maximum voltage an d amperage output capabilities of th e welding generator . Curves of al l other settings fall between the curves shown. A. Stick Mode B. MIG Mode C. TIG Mode DC VOL TS DC AMPERES 0 100 200 300 40 ...

  • Miller Electric Big Blue 400 PX - page 24

    OM-223 037 Page 18 4-6. Fuel Consumption The curve shows typical fuel use under weld or power loads. 217 509 ID L E DC WELD AMPERES A T 100% DUTY CYCLE − 60 HZ U.S. GAL/HR. 0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 0 50 100 150 200 250 300 350 400 4-7. Duty Cycle And Overheating − 50 Hz Operation 100% Duty Cycle At 250 Amperes Continuous Wel ...

  • Miller Electric Big Blue 400 PX - page 25

    OM-223 037 Page 19 4-8. Duty Cycle And Overheating − 60 Hz Operation 217 515 10 15 20 25 30 40 50 60 80 100 CC CV 1000 800 600 500 400 300 250 200 150 100 WELD AMPERES % DUTY CYCLE 100% Duty Cycle At 250 Amperes Continuous Welding Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. NOTICE − Exceeding d ...

  • Miller Electric Big Blue 400 PX - page 26

    OM-223 037 Page 20 SECTION 5 − INST ALLA TION install3 2007 − 04 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712 ! Always securely fasten weld- ing generator onto transport vehicle or trailer and comply with all DOT and other applica- ble codes. ! Always ground generator frame to vehicle frame to pre- vent electric shock and static electr ...

  • Miller Electric Big Blue 400 PX - page 27

    OM-223 037 Page 21 5-2. Mounting Welding Generator T ools Needed: 9/16 in 2 2 4 W elding Unit In Place Bolting Unit In Place ! Do not weld on base. W eld- ing on base can cause fuel tank fire or explosion. Weld only on the four mounting brackets or bolt unit down. NOTICE − Do not mount unit by supporting the base only at the four mounting bracket ...

  • Miller Electric Big Blue 400 PX - page 28

    OM-223 037 Page 22 5-3. Installing Exhaust Pipe 1/2 in T ools Needed: 803 582 − G / Ref. 222 875-A ! Stop engine and let cool.  Point exhaust pipe in desired di- rection but always away from front panel and direction of travel. Notes W or k l i ke a P r o ! Pros wel d and cut safel y . R ead the safety rules at the beginni ng of this manual . ...

  • Miller Electric Big Blue 400 PX - page 29

    OM-223 037 Page 23 5-4. Activating The Dry Charge Battery (If Applicable) ! Always wear a face shield, rubber gloves and protective clothing when working on a battery . Remove battery from unit. 5 V ent Caps 6 Sulfuric Acid Electrolyte (1.265 Specific Gravity) 7 W ell Fill each cell with electrolyte to bottom of well (maximum). ! Do not overfill ba ...

  • Miller Electric Big Blue 400 PX - page 30

    OM-223 037 Page 24 5-6. Engine Prestart Checks  Check all engine fluids daily .  Th e engine will not run if engine access door is open or Emergency Stop switch has been pressed (see Section 6-1). Engine must be cold and on a level surface. Unit is shipped with 20W break-in oil. Automatic shutdown system stops engine if oil pressure is too lo ...

  • Miller Electric Big Blue 400 PX - page 31

    OM-223 037 Page 25 5-7. Connecting T o Weld Output T erminals T ools Needed: 3/4 in Ref. 804 068 / 803 778 / 222 875-A 13 2 ! Stop engine. 1 Work ( − ) Weld Output T erminal 2 CV (Wire) Weld Output T erminal 3 CC (Stick/TI G) Weld Output T erminal Making Connections 4 Weld Output T erminal 5 Supplied Weld Output T erminal Nut 6 Weld Cable T ermin ...

  • Miller Electric Big Blue 400 PX - page 32

    OM-223 037 Page 26 5-8. Selecting Weld Cable Sizes* W eld Cable Size** and T otal Cable (Copper) Length in Weld Circuit Not Exceeding*** 100 ft (30 m) or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft (105 m) 400 ft (120 m) W eld Output T erminals ! Stop engine before connecting to weld output terminals. ! Do not use worn, dam- ...

  • Miller Electric Big Blue 400 PX - page 33

    OM-223 037 Page 27 5-9. Connecting T o Remote 14 Receptacle RC14 Socket* Socket Information 24 VOL TS AC A 24 volts ac. Protected by sup- plementary protector CB8. 24 VOL TS AC B Contact closure to A completes 24 volt ac contactor control circuit. C Output to remote control:+10 volts dc in MIG mode; 0 to +10 volts dc in Stick or TIG mode. REMOTE OU ...

  • Miller Electric Big Blue 400 PX - page 34

    OM-223 037 Page 28 SECTION 6 − OPERA TING WELDING GENERA TOR 6-1. Front Panel Controls (See Section 6-2 ) 218 379 − A / Ref 804 068 / 804 009 − A 1 27 6 8 9 10 1 1 12 4 Stop 3 5 ...

  • Miller Electric Big Blue 400 PX - page 35

    OM-223 037 Page 29 6-2. Description Of Front Panel Controls (See Section 6-1 ) Engine Controls  The engine will not run if engine access door is open or Emergency Stop switch has been pressed. 1 Preheat Switch Use switch to energize starting aid for cold weather starting (see starting instructions fol- lowing). 2 Engine Control Switch Use switch ...

  • Miller Electric Big Blue 400 PX - page 36

    OM-223 037 Page 30 6-3. Process/Contactor Switch 1 Process/Contactor Switch ! W eld output terminals are ener- gized when Process/Contactor switch is in a Weld T erminals Al- ways On position and the engine is running. Use switch to select weld process and weld output on/of f control (see table be- low). Place switch in Remote On/Off Switch Require ...

  • Miller Electric Big Blue 400 PX - page 37

    OM-223 037 Page 31 6-4. Remote V oltage/Amperage Control 1 Remote 14 Receptacle RC14 Connect optional remote control to RC14 (see Section 5-9).  When a remote control is connected to the Remote receptacle, the Auto Sense Re- mote feature automatically switches volt- age/amperage control to the remote con- trol. When a device is connected to the ...

  • Miller Electric Big Blue 400 PX - page 38

    OM-223 037 Page 32 SECTION 7 − OPERA TING AUXILIAR Y EQUIPMENT 7-1. 1 10 V olt Receptacles 222 975 1 1 10 V 32 A AC Receptacle RC1 1 2 1 10 V 16A AC Receptacle RC12 3 1 10 V 16 A AC Receptacle RC13 Receptacles supply 50 Hz single-phase power with Engine Speed switch in 50 Hz/20-300A (1500 rpm) position (see Sec- tion 6-1). Maximum output from RC1 ...

  • Miller Electric Big Blue 400 PX - page 39

    OM-223 037 Page 33 SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Routine Maintenance  The engine will not run if engine access door is open or Emergency Stop switch has been pressed (see Section 6-1). ! Stop engine before maintaining.  S ee Engine Manual and Maintenance Label for important start-up, service, and storage information. Se ...

  • Miller Electric Big Blue 400 PX - page 40

    OM-223 037 Page 34 8-2. Maintenance Label ...

  • Miller Electric Big Blue 400 PX - page 41

    OM-223 037 Page 35 8-3. Perkins Customer Assistance Service When a problem arises concerning the op- eration or service of the engine, the prob- le m will normally be managed by the dealer in your area. Y our satisfaction is a primary concern to Perkins and to Perkins dealers. If you have a problem that has not been handled to your complete satisfa ...

  • Miller Electric Big Blue 400 PX - page 42

    OM-223 037 Page 36 8-5. 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 ch ...

  • Miller Electric Big Blue 400 PX - page 43

    OM-223 037 Page 37 8-6. Inspecting And Cleaning Spark Arrestor Muffler 803 582 / Ref. 222 875 ! Stop engine and let cool. 1 Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole. 3 Exhaust Pipe Start engine and run at idle speed to blow out cleanout hole. If nothing blows out of hole, briefly cover end of exh ...

  • Miller Electric Big Blue 400 PX - page 44

    OM-223 037 Page 38 8-8. Servicing Fuel And Lubrication Systems Ref 222 875 / 804 009 − A ! Stop engine and let cool. ! After servicing, start engine and check for fuel leaks. Stop engine, tighten connec- tions as necessary , and wipe up spilled fuel. 1 Oil Filter 2 Oil Drain V alve And Hose 3 Oil Fill Cap 4 Primary (Canister) Fuel Filter 5 Second ...

  • Miller Electric Big Blue 400 PX - page 45

    OM-223 037 Page 39 8-9. Overload Protection Ref. 222 875-A / 803 566 / 804 068 ! Stop engine.  When a supplementary protec- tor , circuit breaker or fuse opens, it usually indicates a more serious problem exists. Contact Factory Authorized Service Agent. 1 Fuse F1 F1 protects the stator exciter wind- ing from overload. If F1 opens, weld and gene ...

  • Miller Electric Big Blue 400 PX - page 46

    OM-223 037 Page 40 8-10. Optional V oltmeter/Ammeter Help Displays Use the V oltmeter/Ammeter help displays to diagnose and correct fault conditions.  When a help code is displayed normally weld output has stopped but generator power output may be okay .  T o reset help displays, stop unit and then restart. See item 6 below to reset Help 25 d ...

  • Miller Electric Big Blue 400 PX - page 47

    OM-223 037 Page 41 8-1 1. T roubleshooting  Also see V oltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 8-10 ). Engine speed is controlled by an electronic governor and throttle actuator. Governor adjustment should only be done by a Factor y Authorized Service Agent. A. Welding T rouble Remedy No weld output ...

  • Miller Electric Big Blue 400 PX - page 48

    OM-223 037 Page 42 T rouble Remedy Check fuse F1, and replace if open (see Section 8 - 9). Have Factory Authorized Service Agent check vol- tage regulator module PC3. Reset supplementary protector CB3 (see Section 8-9). Check V oltmeter/Ammeter help displays (see Section 8-10 ). Have Factory Authorized Service Agent check brushes and slip rings, an ...

  • Miller Electric Big Blue 400 PX - page 49

    OM-223 037 Page 43 T rouble Remedy Engine suddenly stops. Close engine access door . Engine access door switch LS1 prevents engine from starting or running if door is open Check oil and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolant temperature is too high (see Section 5-6). Circuit breaker CB1 may be o ...

  • Miller Electric Big Blue 400 PX - page 50

    OM-223 037 Page 44 SECTION 9 − ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For Welding Generator ...

  • Miller Electric Big Blue 400 PX - page 51

    OM-223 037 Page 45 222 966--C ...

  • Miller Electric Big Blue 400 PX - page 52

    OM-223 037 Page 46 SECTION 10 − RUN-IN PROCEDURE run_in1 2007 − 04 10-1. W etstacking 1 W elding Generator Ru n diesel engines near rated volt- ag e 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. NO ...

  • Miller Electric Big Blue 400 PX - page 53

    OM-223 037 Page 47 10-2. Run-In Procedure Using Load Bank S-0683 ! Stop engine. ! Do not touch hot exhaust pipe, engine 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 T urn al ...

  • Miller Electric Big Blue 400 PX - page 54

    OM-223 037 Page 48 10-3. Run-In Procedure Using Resistance Grid S-0684 ! Stop engine. ! Do not touch hot exhaust pipe, engine 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 Resistance G ...

  • Miller Electric Big Blue 400 PX - page 55

    OM-223 037 Page 49 SECTION 1 1 − GENERA TOR POWER GUIDELINES  The views in this section are intended to be representative of all engine-driven welding generators. Y our unit may differ from those shown. 1 1-1. Selecting Equipment gen_pwr 2007 − 04 − Ref. ST -159 730 / ST-800 577 1 Generator Power Receptacles − Neutral Bonded T o Frame 2 ...

  • Miller Electric Big Blue 400 PX - page 56

    OM-223 037 Page 50 1 1-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 AWG or larger insulated copper wire. 3 Ground Device  Us e ground device as stated in electrical codes. ! Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring sys ...

  • Miller Electric Big Blue 400 PX - page 57

    OM-223 037 Page 51 1 1-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Star ting W atts Running W atts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 2100 700 1/2 HP 3175 875 Capacitor Start-Induction Run 1/3 HP 2020 720 1/2 HP 3075 975 3/4 HP 4500 1400 1 HP 6100 1600 1-1/2 HP 8200 2200 2 HP 10550 ...

  • Miller Electric Big Blue 400 PX - page 58

    OM-223 037 Page 52 1 1-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting W atts Running W atts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/2 in 500 500 7-1/4 in 900 900 8-1/4 in 1400 1400 T able Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in 2500 1 100 Bench Grinder 6 in 1720 720 8 ...

  • Miller Electric Big Blue 400 PX - page 59

    OM-223 037 Page 53 1 1-8. Power Required T o Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code G H J K L M N P KV A/HP 6.3 7.1 8.0 9.0 10.0 1 1.2 12.5 14.0 S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor V oltage T o find starting amperage: Step 1: Find code and use table to find kVA/HP . If code is not ...

  • Miller Electric Big Blue 400 PX - page 60

    OM-223 037 Page 54 1 1-10. T ypical Connections T o Supply Standby Power T ransfer Switch Essential Loads Fused Disconnect Switch (If Required) Utility Electrical Service 12 3 4 5 W elding Generator Output ! Have only qualified persons perform these connections according to all applicable codes and safety practices. ! Properly install and ground th ...

  • Miller Electric Big Blue 400 PX - page 61

    OM-223 037 Page 55 1 1-1 1. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 V olt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (A WG)* Current (Amperes) Load (W atts) 4 6 8 10 12 14 5 600 350 (106) 225 (68) 137 (42) 100 (30) 7 8 ...

  • Miller Electric Big Blue 400 PX - page 62

    OM-223 037 Page 56 SECTION 12 − P ARTS LIST  Hardware is common and not available unless listed. Wiring harnesses are listed at the end of parts section. 109 − Fig.12 − 3 1 11 0 − Fig.12 − 5 106 6 7 4 8 9 10 12 13 11 14 15 105 103 102 17 18 19 20 21 92 93 85 84 83 82 81 86 87 91 90 89 88 96 97 99 100 − Fig.12 − 2 107 108 22 23 95 1 ...

  • Miller Electric Big Blue 400 PX - page 63

    OM-223 037 Page 57 804 069-F 55 74 76 75 77 78 79 80 73 71 68 67 66 65 63 55 57 56 59 58 62 61 60 36 37 38 39 40 43 44 49 50 51 45 52 53 54 47 46 45 32 33 34 31 30 29 28 27 26 24 64 72 70 35 111 69 11 2 48 41 25 42 Fig. 12 − 4 ...

  • Miller Electric Big Blue 400 PX - page 64

    OM-223 037 Page 58 Description Part No. Dia. Mkgs. Item No. Figure 12-1. Main Assembly Quantity 1 +213488 Panel, Engine Side 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223005 Foam, Acoustical Side Panel 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Miller Electric Big Blue 400 PX - page 65

    OM-223 037 Page 59 Description Part No. Dia. Mkgs. Item No. Figure 12-1. Main Assembly (Continued) Quantity 48 217387 Baffle, Fan 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 218303 Label, Diesel Engine Maintenance Perkins 403c–15 1 . . . . . . ...

  • Miller Electric Big Blue 400 PX - page 66

    OM-223 037 Page 60 Description Part No. Dia. Mkgs. Item No. Figure 12-1. Main Assembly (Continued) Quantity 85 213668 Bracket, Mtg Unit 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 224266 Label, W arning Do Not W eld On Base 2 . . . . . . . . . . . . . . . . ...

  • Miller Electric Big Blue 400 PX - page 67

    OM-223 037 Page 61  Hardware is common and not available unless listed. Wiring harnesses are listed at the end of parts section. 804 070-B 1 2 3 4 5 6 41 40 7 8 9 10 11 12 13 14 15 16 17 18 19 35 36 37 38 39 33 34 28 20 21 22 29 30 31 23 42 43 24 25 26 27 32 Figure 12-2. Panel, Front w/Components Description Part No. Dia. Mkgs. Item No. Figure 1 ...

  • Miller Electric Big Blue 400 PX - page 68

    OM-223 037 Page 62 Description Part No. Dia. Mkgs. Item No. Figure 12-2. Panel, Front w/Components (Continued) Quantity 16 S1 212436 Switch, Ignition 4 Position (Includes Knob) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 039047 T erminal, Pwr Output Red 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Miller Electric Big Blue 400 PX - page 69

    OM-223 037 Page 63  Hardware is common and not available unless listed. Wiring harnesses are listed at the end of parts section. 804 071-B 1 2 4 6 7 9 10 11 8 3 12 13 5 Figure 12-3. Control Panel Description Part No. Dia. Mkgs. Item No. Figure 12-3. Control Panel (Figure 12-1 Item 109) Quantity 1 220981 Bracket, Mtg Components 1 . . . . . . . . ...

  • Miller Electric Big Blue 400 PX - page 70

    OM-223 037 Page 64 803 686-B  Hardware is common and not available unless listed. Wiring harnesses are listed at the end of parts section. Figure 12-4. Generator Description Part No. Dia. Mkgs. Item No. Figure 12-4. Generator (Figure 12-1 Item 73) Quantity 1 ROTOR 212474 Rotor , Generator 4 Pole (Includes) 1 . . . . . . . . . . . . . . . . . . . ...

  • Miller Electric Big Blue 400 PX - page 71

    OM-223 037 Page 65 803 685-A  Hardware is common and not available unless listed. Wirng harnesses are listed at the end of parts section. 1 2 3 6 4 5 9 8 10 7 Figure 12-5. Rectifier Assembly Description Part No. Dia. Mkgs. Item No. Figure 12-5. Rectifier Assembly (Figure 12-1 Item 1 10) Quantity 217081 Rectifier , Assembly (Includes) 1 . . . . . ...

  • Miller Electric Big Blue 400 PX - page 72

    OM-223 037 Page 66  Some wiring harness components (switches, relays, circuit breakers) are also referenced elsewhere in this parts list. Purchase components sepa- rately or as part of the associated wiring harness. Description Part No. Dia. Mkgs. Item No. Wiring Harnesses Quantity 223030 Harness, Engine Perkins (Includes )1 . . . . . . . . . . ...

  • Miller Electric Big Blue 400 PX - page 73

    OM-223 037 Page 67 Notes 229895 MA TERIAL THICKNESS GAUGE ...

  • Miller Electric Big Blue 400 PX - page 74

    OM-223 037 Page 68 Notes 400 T rade Square East, T roy , Ohio 45373 1-800-332-9448 www.welding.org Over 80,000 trained since 1930! Start Y our Professional W elding Career Now! ...

  • Miller Electric Big Blue 400 PX - page 75

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007 − 01 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor . The expe ...

  • Miller Electric Big Blue 400 PX - page 76

    PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007 − 01 Miller Elect ric Mfg. Co. An Illinois T ool W orks Comp any 1635 West Spenc er St reet Applet on, W I 54914 USA International He adquarters − USA USA Phone: 920-735-4505 Auto-A tt ended USA & C anada F AX: 920-735-4134 Int ernati onal F A X: 920-735-4125 European Headqua rters − Un ...

Manufacturer Miller Electric Category Welding System

Documents that we receive from a manufacturer of a Miller Electric Big Blue 400 PX can be divided into several groups. They are, among others:
- Miller Electric technical drawings
- Big Blue 400 PX manuals
- Miller Electric product data sheets
- information booklets
- or energy labels Miller Electric Big Blue 400 PX
All of them are important, but the most important information from the point of view of use of the device are in the user manual Miller Electric Big Blue 400 PX.

A group of documents referred to as user manuals is also divided into more specific types, such as: Installation manuals Miller Electric Big Blue 400 PX, service manual, brief instructions and user manuals Miller Electric Big Blue 400 PX. Depending on your needs, you should look for the document you need. In our website you can view the most popular manual of the product Miller Electric Big Blue 400 PX.

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A complete manual for the device Miller Electric Big Blue 400 PX, how should it look like?
A manual, also referred to as a user manual, or simply "instructions" is a technical document designed to assist in the use Miller Electric Big Blue 400 PX by users. Manuals are usually written by a technical writer, but in a language understandable to all users of Miller Electric Big Blue 400 PX.

A complete Miller Electric manual, should contain several basic components. Some of them are less important, such as: cover / title page or copyright page. However, the remaining part should provide us with information that is important from the point of view of the user.

1. Preface and tips on how to use the manual Miller Electric Big Blue 400 PX - At the beginning of each manual we should find clues about how to use the guidelines. It should include information about the location of the Contents of the Miller Electric Big Blue 400 PX, FAQ or common problems, i.e. places that are most often searched by users in each manual
2. Contents - index of all tips concerning the Miller Electric Big Blue 400 PX, that we can find in the current document
3. Tips how to use the basic functions of the device Miller Electric Big Blue 400 PX - which should help us in our first steps of using Miller Electric Big Blue 400 PX
4. Troubleshooting - systematic sequence of activities that will help us diagnose and subsequently solve the most important problems with Miller Electric Big Blue 400 PX
5. FAQ - Frequently Asked Questions
6. Contact detailsInformation about where to look for contact to the manufacturer/service of Miller Electric Big Blue 400 PX in a specific country, if it was not possible to solve the problem on our own.

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