Miller Electric Big Blue 400 PX Owner's Manual

Big Blue 400 PXOM-229 979B2006−08ProcessesDescriptionAir Carbon Arc (CAC-A)Cutting and GougingStick (SMAW) WeldingEngine Driven Welding GeneratorTIG (

OM-229 979 Page 4READ INSTRUCTIONS. Use only genuine MILLER/Hobart replacementparts. Perform engine and air compressor (if applicable)maintenance an

OM-229 979 Page 5SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANTUTILISATIONrom_fre 3/05 Avertissement: Protégez vous et les autres des blessures − li

OM-229 979 Page 6Le soudage effectué sur des conteneurs fermés tels que desréservoirs, tambours ou des conduites peut provoquer leuréclatement. Des ét

OM-229 979 Page 7 Si le moteur est chaud et que le liquide doit être vérifié, opérer comme suivant. Mettre des lunettes de sécurité et des gants, pl

OM-229 979 Page 8LIRE LES INSTRUCTIONS. Utiliser seulement les pièces de rechange d’origine. Effectuer la maintenance du moteur et du compresseur(si

OM-229 979 Page 9SECTION 3 − DEFINITIONS3-1. Warning Label Definitions3/961 Remove unit from shippingcrate. Remove Owner’sManual from unit. Followinst

OM-229 979 Page 103-2. Manufacturer’s Rating Label

OM-229 979 Page 113-3. Symbols And DefinitionsSome symbols are found only on CE products.NOTEStop EngineFast (Run, Weld/Power)Slow (Idle) Start Engine

OM-229 979 Page 12SECTION 4 − SPECIFICATIONS4-1. Weld, Power, And Engine SpecificationsWeldingModeWeld OutputRangeRated WeldingOutputMaximumOpen-Circu

OM-229 979 Page 13DC AMPERES0 100 200 300 400 500020406080100DC VOLTS4-3. Volt-Ampere Curves222 108 / 221 800 / 217 518The volt-ampere curves show the

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

OM-229 979 Page 144-4. Fuel ConsumptionThe curve shows typical fuel useunder weld or power loads.217 509IDLEDC WELD AMPERES AT 100% DUTY CYCLEU.S. GAL

OM-229 979 Page 154-6. AC Generator Power Curve220 346−BThe ac power curve shows the gen-erator power in amperes.AC AMPERES IN 110V MODEAC AMPERES IN

OM-229 979 Page 16SECTION 5 − INSTALLATIONinstall3 8/06 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712 Always securely fasten weld-ing generator

OM-229 979 Page 175-2. Mounting Welding GeneratorTools Needed:9/16 in224Welding Unit In PlaceBolting Unit In Place Do not weld on base. Weld-ing on b

OM-229 979 Page 185-3. Installing Exhaust Pipe1/2 inTools Needed:803 582−F / Ref. 229 747-A Stop engine and let cool. Point exhaust pipe in desired

OM-229 979 Page 195-4. Activating The Dry Charge Battery (If Applicable) Always wear a face shield,rubber gloves and protectiveclothing when working

OM-229 979 Page 205-6. Engine Prestart Checks Check all engine fluids daily.Engine must be cold and on a level surface.Unit is shipped with 20W break

OM-229 979 Page 215-7. Connecting To Weld Output TerminalsTools Needed:3/4 inRef.804 630-A / Ref. 229 747-A / 803 778-A645Do not placeanything between

OM-229 979 Page 225-8. Selecting Weld Cable Sizes*Weld Cable Size** and Total Cable (Copper) Length in Weld CircuitNot Exceeding***100 ft (30 m) or Le

OM-229 979 Page 235-9. Connecting To Remote 14 Receptacle RC14Socket* Socket Information24 VOLTS ACA 24 volts ac. Protected by sup-plementary protecto

TABLE OF CONTENTSSECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol

OM-229 979 Page 24SECTION 6 − OPERATING THE WELDING GENERATOR6-1. Front Panel Controls (See Section 6-2)229 747-A / 804 009-C1 2546789103Stop

OM-229 979 Page 256-2. Description Of Front Panel Controls (See Section 6-1)Engine Starting Controls1 Preheat SwitchUse switch to energize starting ai

OM-229 979 Page 266-3. Process/Contactor Switch1 Process/Contactor Switch Weld output terminals are ener-gized when Process/Contactorswitch is in a W

OM-229 979 Page 276-4. Lift-Arc™ Start ProcedureLift-Arc  TIGWith Lift-Arc TIG selected, startarc as follows:1 TIG Electrode2 WorkpieceTurn gas on.

OM-229 979 Page 286-5. Remote Voltage/Amperage Control1 Remote 14 Receptacle RC14Connect optional remote control to RC14 (seeSection 5-9). When a rem

OM-229 979 Page 29SECTION 7 − OPERATING AUXILIARY EQUIPMENT7-1. 110 Volt ReceptaclesRef. 229 747-A1 110 V 32 A AC Receptacle RC112 110 V 16A AC Recept

OM-229 979 Page 30SECTION 8 − MAINTENANCE & TROUBLESHOOTING8-1. Maintenance Label

OM-229 979 Page 318-2. Routine Maintenance Stop engine before maintaining. See Engine Manual and Maintenance Labelfor important start-up, service,

OM-229 979 Page 328-3. Perkins Customer AssistanceServiceWhen a problem arises concerning the op-eration or service of the engine, the prob-lem will n

OM-229 979 Page 338-5. Servicing Air Cleaner Stop engine. Do not run engine without aircleaner or with dirty element. En-gine damage caused by using

TABLE OF CONTENTS8-5. Servicing Air Cleaner 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-229 979 Page 348-6. Inspecting And Cleaning Spark Arrestor Muffler803 582-F / Ref. 229 747-A Stop engine and let cool.1 Spark Arrestor Muffler2 Cl

OM-229 979 Page 358-8. Adjusting Engine Speed On Standard Models804 009−C312RPM (Hz)Engine Speed(No Load)Weld/Power1850 (61.7)Maximum Stop engine and

OM-229 979 Page 368-9. Servicing Fuel And Lubrication SystemsRef 229 747-A / 804 009−C Stop engine and let cool. After servicing, start engineand ch

OM-229 979 Page 378-10. Overload ProtectionRef. 229 747-A / 803 566-E / 804 630-A Stop engine. When a circuit breaker, supple-mentary protector, or

OM-229 979 Page 388-11. Optional Voltmeter/Ammeter Help DisplaysUse the Voltmeter/Ammeter helpdisplays to diagnose and correctfault conditions. When

OM-229 979 Page 39Notes16 Gauge (.063 in)22 Gauge (.031 in)24 Gauge (.025 in)20 Gauge (.037 in)18 Gauge (.050 in)14 Gauge (.078 in)1/8 in (.125 in)3/1

OM-229 979 Page 408-12. Troubleshooting Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (seeSection 8-11).NoteA. W

OM-229 979 Page 41Trouble RemedyCheck fuse F1, and replace if open (see Section 8-10). Have Factory Authorized Service Agent checkvoltage regulator mo

OM-229 979 Page 42Trouble RemedyBattery discharges between uses. Turn Engine Control switch off when unit is not running.Clean top of battery with bak

OM-229 979 Page 43Notes

dec_rot_6/05Declaration of Conformity forEuropean Community (CE) ProductsThis information is provided for units with CE certification (see rating labe

OM-229 979 Page 44SECTION 9 − ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For Welding Generator

OM-229 979 Page 45229 746-A

OM-229 979 Page 46SECTION 10 − RUN-IN PROCEDURErun_in1 11/0510-1. Wetstacking Do not perform run-inprocedure at less than 20volts weld output and do

OM-229 979 Page 4710-2. Run-In Procedure Using Load BankS-0683 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Keep exha

OM-229 979 Page 4810-3. Run-In Procedure Using Resistance GridS-0684 Stop engine. Do not touch hot exhaustpipe, engine parts, or loadbank/grid. Kee

OM-229 979 Page 49SECTION 11 − GENERATOR POWER GUIDELINESThe views in this section are intended to be representative of all engine-drivenwelding gener

OM-229 979 Page 5011-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse #10 AWG or larger insul

OM-229 979 Page 5111-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running WattsSplit Phase 1/8 HP 80

OM-229 979 Page 5211-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHand Drill 1/4 in 350 350

OM-229 979 Page 5311-8. Power Required To Start MotorS-06241 Motor Start Code2 Running Amperage3 Motor HP4 Motor VoltageTo find starting amperage:Step

dec_rotsound_6/05Declaration of Conformity forEuropean Community (CE) ProductsThis information is provided for units with CE certification (see rating

OM-229 979 Page 5411-10. Typical Connections To Supply Standby Power Have only qualified persons performthese connections according to allapplicable

OM-229 979 Page 5511-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles

OM-229 979 Page 56SECTION 12 − PARTS LIST Hardware is common and notavailable unless listed.Wiring harnesses are listed atthe end of parts section.2−

OM-229 979 Page 57804 632-A557375747677787972−Fig.12−47069686766645658575960636261363738394041444549505152465354554847463334353231302928272665714243

OM-229 979 Page 58DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-1. Main AssemblyQuantity1 HD1 168829 Transducer, Current 1000a Module Max Open Loop 1.

OM-229 979 Page 59DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-1. Main Assembly (Continued)Quantity54 087341 Bumper, Door 1.000 Od X .750 High Rbr 50 D

OM-229 979 Page 60DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-1. Main Assembly (Continued)Quantity213600 Screw, 500−13x3.00 Hex Flange−hd Gr8 Pln 1.

OM-229 979 Page 61 Hardware is common and notavailable unless listed.Wiring harnesses are listed atthe end of parts section.804 633-A1234563635789101

OM-229 979 Page 62DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-2. Panel, Front w/Components (Continued)Quantity16 S1 212436 Switch, Ignition 4 Position

OM-229 979 Page 63 Hardware is common and notavailable unless listed.Wirng harnesses are listed atthe end of parts section.803 689-C12345678910131211

OM-229 979 Page 1SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USINGrom _nd_3/05 Warning: Protect yourself and others from injury — read and follow th

OM-229 979 Page 64803 686-A Hardware is common and notavailable unless listed.Wiring harnesses are listed atthe end of parts section.2314567891011121

OM-229 979 Page 65803 685-A Hardware is common and notavailable unless listed.Wirng harnesses are listed atthe end of parts section.12364598107Figure

OM-229 979 Page 66Some wiring harness components (switches, relays, circuit breakers) are also referencedelsewhere in this parts list. Purchase compon

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 2006−01Your distributor also givesyou ...ServiceYou always get the

PRINTED IN USA © 2006 Miller Electric Mfg. Co.2006−01Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914

OM-229 979 Page 2Welding on closed containers, such as tanks, drums, orpipes, can cause them to blow up. Sparks can fly off from thewelding arc. The f

OM-229 979 Page 3STEAM AND HOT COOLANT can burn. If possible, check coolant level when engine is cold toavoid scalding. Always check coolant level a