Miller Big Blue 400D Owner'S Manual Download Page 3

Page: 3 / 68

The following terms are
used interchangeably
throughout this manual:

Stick = SMAW
MIG = GMAW

CALIFORNIA

Proposition 65
Warning

Diesel engine exhaust and
some of its constituents
are known to the State of
California to cause
cancer, birth defects, and
other reproductive harm.

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

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1-1.

Symbol Usage

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1-2.

Arc Welding Hazards

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1-3.

Engine Hazards

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1-4.

Additional Symbols For Installation, Operation, And Maintenance

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1-5.

Principal Safety Standards

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1-6.

EMF Information

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SECTION 1 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION

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1-1.

Signification des symboles

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1-2.

Dangers relatifs au soudage à l’arc

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1-3.

Dangers existant en relation avec le moteur

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1-4.

Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance

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1-5.

Principales normes de sécurité

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1-6.

Information sur les champs électromagnétiques

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SECTION 2 − DEFINITIONS

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SECTION 3 − SPECIFICATIONS

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3-1.

Weld, Power, And Engine Specifications

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3-2.

Dimensions, Weights, And Operating Angles

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3-3.

Fuel Consumption

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3-4.

Duty Cycle And Overheating

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3-5.

AC Auxiliary Power

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3-6.

Volt-Ampere Curves

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3-7.

Optional AC Power Plant Curves For Standard (CC) Models

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3-8.

Optional AC Power Plant Curves For CV Models

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SECTION 4 − INSTALLATION

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4-1.

Installing Welding Generator

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4-2.

Connecting The Battery

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4-3.

Installing Exhaust Pipe

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4-4.

Engine Prestart Checks

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4-5.

Connecting To Weld Output Terminals

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4-6.

Selecting Weld Cable Sizes

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4-7.

Installing Ether Cylinder (Optional Ether Starting Aid)

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4-8.

Remote A/V Control Receptacle RC3

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4-9.

Remote 14 Receptacle RC3 Information (Models With CV Option)

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4-10. Terminal Strip 2T Connections (Models With CV Option)

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SECTION 5 − OPERATING THE WELDING GENERATOR

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5-1.

Standard Controls (See Section 5-2)

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5-2.

Description Of Standard Controls (See Section 5-1)

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5-3.

Controls For Models With CV Option (See Section 5-4)

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5-4.

Description Of Controls For Models With CV Option (See Section 5-3)

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SECTION 6 − OPERATING AUXILIARY EQUIPMENT

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6-1.

120 Volt And 240 Volt Duplex Receptacles

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6-2.

Optional Auxiliary Power Receptacles

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6-3.

Connecting Optional Auxiliary Power Plant

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SECTION 7 − MAINTENANCE & TROUBLESHOOTING

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7-1.

Routine Maintenance

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7-2.

Maintenance Label

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7-3.

Servicing Air Cleaner

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7-4.

Servicing Fuel And Lubrication Systems

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7-5.

Adjusting Engine Speed

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7-6.

Servicing Optional Ether Starting Aid

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7-7.

Checking And Replacing Alternator Belt

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7-8.

Resetting Fan Belt Safety Shutdown

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7-9.

Inspecting And Cleaning Optional Spark Arrestor Muffler

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7-10. Overload Protection For Models With CV Option

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7-11. Troubleshooting

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SECTION 8 − ELECTRICAL DIAGRAMS

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SECTION 9 − RUN-IN PROCEDURE

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9-1.

Wetstacking

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9-2.

Run-In Procedure Using Load Bank

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9-3.

Run-In Procedure Using Resistance Grid

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SECTION 10 − AUXILIARY POWER GUIDELINES

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SECTION 11 − PARTS LIST

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OPTIONS AND ACCESSORIES
WARRANTY

WARNING

This product, when used
for welding or cutting,
produces fumes or
gases which contain
chemicals known to the
State of California to
cause birth defects and,
in some cases, cancer.
(California Health &
Safety Code Section
25249.5 et seq.)

Summary of Contents for Big Blue 400D

Page 1: ...Welds com Big Blue 400D Processes Description Air Carbon Arc CAC A Cutting and Gouging Stick SMAW Welding MIG GMAW Welding Flux Cored FCAW Welding Engine Driven Welding Generator OM 463 081 902AD December 1998 With Optional Equipment ...

Page 2: ...wner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operation quick and easy With Miller you can count on years of reliable service with proper maintenance And if for some reason the unit needs repair there s a Troubles...

Page 3: ...Cable Sizes 17 4 7 Installing Ether Cylinder Optional Ether Starting Aid 18 4 8 Remote A V Control Receptacle RC3 18 4 9 Remote 14 Receptacle RC3 Information Models With CV Option 19 4 10 Terminal Strip 2T Connections Models With CV Option 19 SECTION 5 OPERATING THE WELDING GENERATOR 20 5 1 Standard Controls See Section 5 2 20 5 2 Description Of Standard Controls See Section 5 1 21 5 3 Controls Fo...

Page 4: ......

Page 5: ...lace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable do not use work clamp or work cable Do not touch electrode if you are in contact with the work ground or another electrode ...

Page 6: ...maintaining Wear protective gloves and clothing when working on a hot engine Do not touch hot engine parts or just welded parts bare handed NOISE can damage hearing Noise from some processes or equipment can damage hearing Wear approved ear protection if noise level is high MAGNETIC FIELDS can affect pacemak ers Pacemaker wearers keep away Wearers should consult their doctor before going near arc ...

Page 7: ...ammables Keep exhaust and exhaust pipes way from flammables EXHAUST SPARKS can cause fire Do not let engine exhaust sparks cause fire Use approved engine exhaust spark arrestor in required areas see applicable codes 1 4 Additional Symbols For Installation Operation And Maintenance FALLING UNIT can cause injury Use lifting eye to lift unit only NOT running gear gas cylinders trailer or any other ac...

Page 8: ...eune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards...

Page 9: ...ur voir s il n est pas en dommagé ou dénudé remplacer le cordon immédiatement s il est endommagé un câble dénudé peut provoquer une électrocution Mettre l appareil hors tension quand on ne l utilise pas Ne pas utiliser des câbles usés endommagés de grosseur insuffisante ou mal épissés Ne pas enrouler les câbles autour du corps Si la pièce soudée doit être mise à la terre le faire directement avec ...

Page 10: ...froidissement avant d effec tuer des travaux d entretien Porter des gants et des vêtements de protection pour travailler sur un moteur chaud Ne pas toucher à mains nues les parties chaudes du moteur ni les pièces récemment soudées LE BRUIT peut affecter l ouïe Le bruit des processus et des équipements peut affecter l ouïe Porter des protections approuvés pour les oreilles si le niveau sondre est t...

Page 11: ...distance les produits inflammables de l échappement LES ÉTINCELLES À L ÉCHAPPEMENT peuvent provoquer un incendie Empêcher les étincelles d échappement du moteur de provoquer un incendie Utiliser uniquement un pare étincelles approuvé voir codes en vigueur 1 4 Dangers supplémentaires en relation avec l installation le fonctionnement et la maintenance LA CHUTE DE L APPAREIL peut blesser Utiliser l a...

Page 12: ...550 N W Lejeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 de la National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de la Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Règles de sécurité en soudage coupage et procédés connexes norme CSA W117 2 de l Associatio...

Page 13: ...Current CC MIG GMAW Welding Constant Voltage CV Time h Hours s Seconds 1 Single Phase 3 Three Phase Read Operator s Manual SECTION 3 SPECIFICATIONS 3 1 Weld Power And Engine Specifications Welding Mode Weld Output Range Rated Welding Output Maximum Open Circuit Voltage Auxiliary Power Rating Engine Fuel Capacity CC DC 45 500 A 400 A 40 Volts DC 100 Duty Cycle 95 88 in CC mode on units with CV Sing...

Page 14: ...ccur Do not move or operate unit where it could tip B 47 1 4 in 1200 mm Do not move or operate unit where it could tip C 43 1 4 in 1099 mm D 32 3 4 in 832 mm E 24 15 16 in 633 mm A C F 10 1 2 in 267 mm A B C D G 6 1 2 in 165 mm B D E 17 5 H 2 7 8 in 73 mm E F 17 5 J 29 7 8 in 759 mm F G 20 17 5 K 11 16 in 24 mm G H J K 20 20 L 21 32 in 17 mm Dia 16 Holes H J K angles_1 3 96 Weight ST 158 699 angle...

Page 15: ...tage of 10 min utes that unit can weld at rated load without overheating Exceeding duty cycle can damage unit and void warranty 100 Duty Cycle At 400 Amperes 3 5 AC Auxiliary Power rsb3 1 2 92 Ref SB 005 192 C The ac power curve shows the aux iliary power in amperes available at the 120 and 240 volt receptacles ...

Page 16: ...3 880 A ST 186 173 A The volt ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator Curves of all other settings fall between the curves shown A CC DC Standard B CV DC Models With CV Option ...

Page 17: ...2 94 SB 005 185 B SB 159 101 A The ac power curves show the aux iliary power in amperes available at the single phase 120 240 volt or three phase 240 volt terminals A 7 5 KVA KW Single Phase Auxiliary Power Plant No Weld Load B 10 KVA KW Three Phase Auxiliary Power Plant No Weld Load ...

Page 18: ...94 ST 187 726 ST 187 727 The ac power curves show the aux iliary power in amperes available at the single phase 120 240 volt or three phase 240 volt terminals A 10 KVA KW Single Phase Auxiliary Power Plant No Weld Load B 15 KVA KW Three Phase Auxiliary Power Plant No Weld Load ...

Page 19: ...tact GND PE 3 4 1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grounding Terminal 4 Grounding Cable Use 10 AWG or larger insulated copper wire If unit does not have GFCI re ceptacles use GFCI protected extension cord 2 OR 18 in 460 mm 18 in 460 mm 18 in 460 mm 18 in 460 mm 18 in 460 mm OR Movement Airflow Clearance Location Grounding OR Do Not Lift Unit From End 4 2 Connecting The Battery Conn...

Page 20: ... Add fresh diesel fuel before starting engine the first time see mainte nance label for specifications Fill fuel tank up to 1 2 in 13 mm from top to allow room for expansion Open fuel shut off valve Do not run out of fuel or air enters fuel system and causes starting problems See engine manual to bleed air from fuel system 2 Oil After fueling check oil with unit on level surface If oil is not up t...

Page 21: ...e to terminal Close door Tools Needed 3 Left Side 2 1 3 4 in 4 6 Selecting Weld Cable Sizes Total Cable Copper Length In Weld Circuit Not Exceeding Welding Amperes 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 Amperes 10 60 Duty Cycle 60 100 Duty Cycle 10 100 Duty Cycle 100 4 4 4 3 2 1 1 0 1 0 150 3 3 2 1 1 0 2 0 3 0 3 0 200 3 2 1 1 0 2 0 3 0 4 0 4 0...

Page 22: ...der nozzle 3 Clamp 4 Fitting 5 Cap 6 Valve Remove cap and clean fitting Install cylinder on fitting Tighten clamp After installing cylinder wait at least 10 minutes before using to let ether particles settle and prevent atomizer plugging Put cap on fitting when cylinder is removed 1 2 3 4 6 5 4 7 Installing Ether Cylinder Optional Ether Starting Aid 4 8 Remote A V Control Receptacle RC3 Ref ST 154...

Page 23: ...to max of Amper age Voltage control R1 A V D Remote control circuit common Ref ST 800 862 B A V E 0 to 10 volts dc input command signal from remote control Ref ST 800 862 B K Chassis common The remaining sockets are not used 4 10 Terminal Strip 2T Connections Models With CV Option Ref ST 800 862 B Ref ST 185 316 Stop engine If remote control plug does not fit in receptacle RC3 wire cord directly t...

Page 24: ...OM 463 Page 20 SECTION 5 OPERATING THE WELDING GENERATOR 5 1 Standard Controls See Section 5 2 1 10 2 3 11 9 8 7 6 5 4 12 ST 158 630 B Ref ST 158 631 ST 180 933 B ...

Page 25: ...tch to select front panel or remote amperage control see example be low 4 Manual Stop Control 5 Engine Start Button 6 Ether Starting Aid Switch Optional Push switch up and release while cranking engine to release ether Do not use Ether if engine is running To Start Press button and use Ether switch if necessary Release button when engine starts Do not crank engine while engine is turning To Stop P...

Page 26: ...OM 463 Page 22 5 3 Controls For Models With CV Option See Section 5 4 1 9 2 10 8 7 6 5 4 3 11 ST 158 630 B Ref ST 158 631 Ref ST 185 762 B S 185 440 12 13 14 ...

Page 27: ...oltmeter Optional 8 Oil Pressure Warning Light Light goes off if oil pressure is too low If light goes off stop engine and check oil level 9 Battery Charging Warning Light Light goes on when battery is not charging If light goes on stop engine and check engine belt 10 Engine Hour Meter 11 Polarity Switch Optional 12 Constant Current Constant Voltage CC CV Switch Use switch to select type of weld o...

Page 28: ...3 Circuit Breakers CB1 And CB2 CB1 and CB2 protect RC1 and RC2 from overload If CB1 or CB2 opens RC1 and one half of RC2 does not work 120 volts may still be present at RC1 Press button to re set breaker If a circuit breaker continues to open contact Factory Autho rized Service Agent Maximum output from each duplex receptacle is 1 8 kVA kW and 3 kVA kW from all receptacles Auxiliary power is not a...

Page 29: ...weld power speed and press test button to verify GFCI is working properly Australian And South African Receptacle Options 2 240 V 10 A AC Australian Re ceptacle RC1 3 240 Volt 13 A AC South African Receptacle RC1 RC1 supplies 60 Hz single phase power at weld power speed Maxi mum output from receptacle is 3 kVA kW 4 Circuit Breaker CB1 CB1 protects RC1 from overload If CB1 opens RC1 does not work P...

Page 30: ...rom overload Set Engine Control switch to Run when using auxiliary power 4 5 7 8 9 6 10 11 Tools Needed 93 91 90 92 240V 120V 120V 240V 240V 240V 1 3 Volts Amps KVA KW Single 120 240 31 7 5 Three 240 24 10 60 Hz Frequency Engine Speed Max Fuse Size 35 Amperes 1850 RPM AC Phase 1 Phase 3 Output Lead 42 connects to GROUND stud on front of unit Jumper 42 is connected to 90 at factory F3 F2 F1 1 2 3 7...

Page 31: ...er See Section 7 3 Clean And Tighten Weld Terminals 100 h Clean And Tighten Battery Connections Change Oil See Section 7 4 Change Oil Filter See Section 7 4 250 h 200 h Check And Clean Spark Arrestor See Section 7 9 Replace Unreadable Labels 500 h Repair Or Replace Cracked Cables 1000 h Blow Out Or Vacuum Inside During Heavy Service Clean Monthly OR Drain Sludge From Fuel Tank See Section 7 4 FUEL...

Page 32: ...ee Owner s Manual Air Filter Element MILLER 020 319 Donaldson P181052 Fram CAK 253 Alternator Belt Gates 7425 Deutz 0223 5179 Blower Belt MILLER 064 690 Deutz 223 5531 Gates N7500 Avoid recirculation of air from hot air exit to blower intake Have only trained technician maintain injection pump and injectors AIR WATER or GASOLINE will harm the injection system If engine has run out of fuel or fuel ...

Page 33: ...ent 4 Plastic Fins 5 Housing To clean air filter Wipe off cap and housing Remove cap and dump out dust Wipe dust from inside cap and housing with damp cloth Remove element and reinstall cap Do not clean housing with air hose Clean element with compressed air only Keep nozzle at least 1 in 25 mm from inside of element Max air pressure 100 psi 690 kPa Do not remove plastic fins Replace ele ment if i...

Page 34: ... To replace primary fuel filter Close shutoff valve and turn filter counterclockwise Remove filter Apply thin coat of fuel to gasket on new filter Install new filter and turn clockwise Open shutoff valve Bleed air from fuel system accord ing to engine manual Inspect fuel line and replace if cracked or worn To replace secondary fuel filter See engine manual To drain sludge from fuel tank Put metal ...

Page 35: ...l Lever Turn screw in until screw touches lever Tighten lock nut on screw and reinstall plastic cap Close side door 1 3 8 in 2 4 3 5 Right Side 6 RPM 1850 Tools Needed Engine Speed No Load Weld Power 7 6 Servicing Optional Ether Starting Aid ether2 7 96 ST 153 382 A Ref ST 180 933 B S 0692 Stop engine Improper handling or expo sure to ether can harm your health Follow manufactur er s safety instru...

Page 36: ...than 1 2 in 13 mm belt is okay If not okay adjust belt tension To adjust belt tension 4 Hex Nuts 2 5 Alternator Bracket Loosen nuts Pivot alternator until belt is tight Tighten nuts Recheck tightness of belt Readjust if necessary Replace belt if damaged or cracked To replace belt Loosen hex nuts and pivot alterna tor clockwise Remove belt Install new belt pivot alternator until belt is tight and t...

Page 37: ... manual to replace or tighten belt If belt breaks or becomes loose safety shutdown stops engine Correct problem then reset safety shutdown as follows 2 Rod 3 Stop 4 Bracket 5 Handle Pull handle towards front of unit un til stop snaps in position behind bracket Close door 1 3 8 in Right Side 5 2 3 4 Tools Needed Pull Handle To Reset Shutdown ...

Page 38: ...eproof material Stop engine and let cool Reinstall cleanout plug Tools Needed 3 2 1 3 8 in 7 10 Overload Protection For Models With CV Option 1 Circuit Breaker CB3 CB3 protects the 115 volt ac output to Remote receptacle RC3 and ter minal strip 2T If CB3 opens the 115 volt ac output stops 2 Circuit Breaker CB4 CB4 protects the 24 volts ac output to Remote receptacle RC3 and ter minal strip 2T If C...

Page 39: ...ltage Check engine speed and adjust if necessary see Section 7 5 Check optional CC CV switch position Have Factory Authorized Service Agent check optional field current regulator board PC1 and CV regula tor board PC2 Maximum weld output only in each ampere range Have Factory Authorized Service Agent check Amperage Voltage control R1 capacitor C8 diode D8 integrated rectifier SR4 control relay CR2 ...

Page 40: ...ect remote contactor to optional Remote 14 receptacle RC3 or terminal strip 2T see Sections 4 9 and 4 10 Place optional CC CV switch in CC position see Section 5 4 Have Factory Authorized Service Agent check brushes and slip rings and optional field current regulator board PC1 High output at optional auxiliary power plant Check engine speed and adjust if necessary see Section 7 5 Have Factory Auth...

Page 41: ...OM 463 Page 37 SECTION 8 ELECTRICAL DIAGRAMS SC 180 941 Figure 8 1 Circuit Diagram For Welding Generator Standard Models ...

Page 42: ...OM 463 Page 38 Figure 8 2 Circuit Diagram For Welding Generator Models With CV Option ...

Page 43: ...OM 463 Page 39 ST 184 954 B ...

Page 44: ...ger than necessary Piston rings seat faster if engine runs at weld power rpm and the welding generatoris kept loaded during run in 2 Engine Exhaust Pipe Wetstacking is unburned fuel and oil in the exhaust pipe and occurs during run in if the engine is run too long at light load or idle rpm If exhaust pipe is coated with a wet black tar like substance dry the engine using one of the following run i...

Page 45: ...oad bank to generator weld output terminals using proper size weld cables with correct connectors Observe correct polarity Start engine and run for several minutes Set load bank switches and then adjust generator A V control so load equals rated generator output see nameplate Check generator and load bank meters after first five minutes then every fifteen minutes to be sure generator is loaded pro...

Page 46: ... correct connec tors polarity is not important 4 Voltmeter 5 Clamp On Ammeter Connect voltmeter and ammeter as shown if not provided on generator Start engine and run for several minutes Set grid switches and then adjust generator A V control so load equals rated generator output see nameplate Check generator and meters after first five minutes then every fifteen minutes to be sure generator is lo...

Page 47: ...ble Insulated Equipment OR 2 Be sure equipment has this symbol and or wording 3 1 10 2 Grounding Generator To Truck Or Trailer Frame S 0854 1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grounding Terminal 4 Grounding Cable Use 10 AWG or larger insulated copper wire If unit does not have GFCI re ceptacles use GFCI pro tected extension cord OR 1 2 Electrically bond generator frame to vehicle fr...

Page 48: ...sistive Load Equipmentwith a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when run ning see Section 10 8 3 Rating Data Rating shows volts and amperes or watts required to run equipment VOLTS 115 4 5 60 AMPS Hz 1 2 3 3 EXAMPLE 1 If a drill uses 4 5 amperes at 115 volts calculate its running power requirementin watts 4 5 A x 115 V 520 ...

Page 49: ...Home Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 Milker Vacuum Pump 2 HP 10500 2800 FARM DUTY MOTORS 1 3 HP 1720 720 Std e g Conveyors 1 2 HP 2575 975 Feed Augers Air 3 4 HP 4500 1400 Compressors 1 HP 6100 1600 1 1 2 HP 8200 2200 2 HP 10550 2850 3 HP...

Page 50: ...HP 6000 1500 1 1 2 HP 8200 2200 2 HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1 3 HP 2100 700 Elec Hedge Trimmer 18 in 400 400 Flood Lights HID 125 100 Metal Halide 313 250 Mercury 1000 Sodium 1400 Vapor 1250 1000 Submersible Pump 400 gph 600 200 Centrifugal Pump 900 gph 900 500 F...

Page 51: ...r Starting Requirements Motor Start Code G H J K L M N P KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0 EXAMPLE Calculate the starting amperage required for a 230 V 1 4 HP motor with a motor start code of M Starting the motor requires 12 2 amperes 11 2 x 1 4 x 1000 230 12 2 A kVA HP x HP x 1000 VOLTS STARTING AMPERAGE Volts 230 HP 1 4 Using Table Code M results in kVA HP 11 2 10 9 How Much Power Can G...

Page 52: ...r Connections Connect terminals or plug of ade quate amperage capacity to cord Follow all applicable codes and safety practices Turn off or unplug all equipment connected to generator before starting or stopping engine When starting or stopping the engine has low speed which causes low volt age and frequency 7 Load Connections Customer supplied equipment is required if generator is to supply stand...

Page 53: ... 15 40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 2 voltage drop Cord Lengths for 240 Volt Loads If unit does not have GFCI receptacles use GFCI protected extension cord Maximum Allowable Cord Length in ft m for Conductor Size AWG Current Amperes Load Watts 4 6 8 10 12 14 5 1200 700 213 450 137 225 84 200 61 7 1680 800 244 500 152 300 91 200...

Page 54: ...12 13 14 15 16 17 18 19 20 21 22 23 6 7 6 7 10 24 25 26 70 69 66 65 64 74 75 76 77 78 79 80 81 82 83 84 85 86 Fig 11 5 87 Fig 11 6 Fig 11 7 88 89 90 91 92 93 Fig 11 2 96 97 98 99 100 101 94 95 Hardware is common and not available unless listed Figure 11 1 Main Assembly ...

Page 55: ...OM 463 Page 51 ST 048 455 AA 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 46 47 48 49 50 45 51 52 53 55 54 56 57 59 60 61 62 63 64 65 66 67 68 Fig 11 3 69 70 71 72 73 58 102 ...

Page 56: ... 553 BASE filter fuel w adapter 1 24 145 282 FITTING hose brs barbed elb M 5 16tbg x 1 4NPT 1 25 062 342 SEPARATOR fuel filter water 1 26 116 707 SUPPORT front engine 1 27 010 875 CLAMP muffler 2 000dia U 1 28 105 734 PIPE muffler ext elb 1 29 176 232 BAFFLE air muffler exhaust 1 30 048 216 BRACKET mtg breather 1 31 087 341 BUMPER door 1 000 OD x 750 high 4 32 004 130 BRACKET support door 2 33 091...

Page 57: ...0 184 499 BRACKET mtg terminal strip 1 PLG21 168 071 CONNECTOR SOCKETS 1 81 603 107 HOSE nprn slit bk 156 ID x 343 OD order by ft 1ft 82 053 967 INSULATION rectifier 1 83 TE1 TE4 038 621 BLOCK term 30A 4P 1 038 620 LINK jumper 2 84 081 499 BRACKET mtg 1 85 010 146 CLAMP nyl 625clp dia 1 86 Fig 11 5 CV 3 CONTROL BOX 1 87 Fig 11 6 PANEL mtg components CC CV model 1 87 Fig 11 7 PANEL mtg components C...

Page 58: ...M 463 Page 54 1 3 4 7 9 10 11 9 14 16 17 18 19 20 21 22 ST 048 457 N 2 Fig 11 4 5 6 8 12 13 15 Hardware is common and not available unless listed Figure 11 2 Panel Front w Components CC Model Illustrated ...

Page 59: ...5 234 PLUG str grd 2P3W 15A 250V Arrow Hart 5666V 9 PB1 046 433 SWITCH PB MC NO w black cap 1 10 180 904 PLATE ident control rating CC model 1 10 185 763 PLATE ident control rating CC CV model 1 11 088 731 BUSHING snap in nyl 375 ID x 500mtg hole 1 12 021 385 BOOT toggle switch lever 1 13 148 723 KNOB pointer 1 14 046 652 METER amp DC 50MV 0 600 1 15 046 654 METER volt DC 0 100 1 003 645 BUS BAR s...

Page 60: ...OM 463 Page 56 Figure 11 3 Generator SD 048 456 E Hardware is common and not available unless listed 1 2 4 5 6 4 3 7 8 9 11 12 13 10 14 16 15 18 19 20 17 14 21 23 22 24 26 27 28 29 25 ...

Page 61: ...BAFFLE air gen 1 17 083 751 ROTOR gen consisting of 1 18 024 617 RING retaining external 1 19 053 390 BEARING ball 1 20 083 748 FAN rotor 1 21 044 374 STATOR excitor CC model 1 21 180 684 STATOR excitor CC CV model 1 22 173 068 ENDBELL gen consisting of 1 23 143 220 O RING 2 859 ID x 139CS 1 24 106 424 BARREL rectifier 1 25 SR3 106 430 DIODE ASSEMBLY consisting of 1 26 C5 7 048 420 CAPACITOR recti...

Page 62: ...thk 1 12 011 007 SPRING pressure 1 13 011 018 CONTACT stationary 9 14 172 702 CONTACT stationary switch consisting of 6 15 011 018 CONTACT stationary 2 16 171 856 SPACER contact 250thk 1 17 011 095 CONTACT BOARD stationary switch 2 18 011 019 CONTACT BOARD movable switch 2 19 011 012 SHIM guide contact board 6 20 011 013 GUIDE contact board movable switch 3 9 10 11 12 13 14 15 16 17 18 19 20 8 15 ...

Page 63: ... 1 15 134 201 STAND OFF support PC card 11 16 PC2 185 747 CIRCUIT CARD ASSEMBLY voltage 1 17 RC1 115 092 CONNECTOR SOCKETS 1 18 PC3 150 415 CIRCUIT CARD ASSEMBLY CONNECTOR 1 19 185 761 COVER CV control box 1 20 PLG3 5 165 668 CONNECTOR PINS 3 21 CB3 4 083 432 CIRCUIT BREAKER man reset 1P 10A 250VAC 2 22 RC3 143 976 CONNECTOR SOCKETS 1 23 039 885 CONNECTOR circ MS protective 1 24 147 195 NUT 375 27...

Page 64: ...0 20 x 1 750 hex collar 1 10 010 913 WASHER flat brs 1 11 1T 038 639 BLOCK terminal 30A 6P 1 12 164 617 CLIP wiring 2 13 D1 128 299 DIODE BOARD 1 14 C8 170 674 CAPACITOR BOARD 1 15 R6 030 844 RESISTOR WW fxd 25W 25 ohm 1 16 605 741 CLIP mtg resistor 2 17 CR1 2 044 588 RELAY encl 12VDC 3PDT 2 1 ST 801 851 2 3 4 2 5 6 7 8 9 10 5 11 14 13 12 12 15 16 17 Hardware is common and not available unless lis...

Page 65: ... 2T 038 621 TERMINAL BLOCK 30A 4P 1 7 CR2 044 588 RELAY encl 12VDC 3PDT 1 8 D1 128 299 DIODE BOARD 1 9 D8 034 502 DIODE zener 12V 50W 1 170 673 KIT diode mtg 1 10 C8 170 674 CAPACITOR BOARD 1 ST 801 852 1 2 3 4 5 6 7 8 9 10 Hardware is common and not available unless listed Figure 11 7 Panel Mtg Components CC Model To maintain the factory original performance of your equipment use only Manufacture...

Page 66: ...Notes ...

Page 67: ...vered by the manufacturer s warranty if any 2 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear 3 Equipment that has been modified by any party other than Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and...

Page 68: ...ess City State Zip Please complete and retain with your personal records Always provide Model Name and Serial Style Number Contact your Distributor for To locate distributor nearest you call 1 800 4 A Miller Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information an...

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Miller Big Blue 400D, Owner'S Manual

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