Miller Electric Big Blue 400 PX manual From Miller to You

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Miller is the first welding equipment manufacturer in the U.S.A. to be registered to the ISO 9001:2000 Quality System Standard.

From Miller to You

Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way.

That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy.

Today, the people that build and sell Miller products continue the tradition. They’re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929.

This Owner’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 Troubleshooting section that will help you figure out what the problem is. The parts list will then help you to decide the exact part you may need to fix the problem. Warranty and service information for your particular model are also provided.

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. To locate your nearest distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web.

Mil_Thank 4/05

Working as hard as you do

−every power source from Miller is backed by the most hassle-free warranty in the business.

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Contents Description OM-223 037MProcesses File Engine DriveFrom Miller to You Table of Contents Warranty Decrot1/07 DirectivesStandards Sound Level Information Decrotsound200710Electric Shock can kill Symbol UsageArc Welding Hazards HOT Parts can cause severe burnsARC Rays can burn eyes and skin Fumes and Gases can be hazardousBuildup of GAS can injure or kill Welding can cause fire or explosionEngine Hazards Compressed Air HazardsFire or Explosion hazard Welding Wire can cause injuryHOT Parts can cause burns and injury Falling Unit can cause injuryEMF Information Principal Safety StandardsCalifornia Proposition 65 Warnings Radiation can cause interferenceUN Choc Électrique peut tuer Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation LE Soudage peut provoquer un in cendie ou une explosion DES Pièces Chaudes peuvent provoquer des brûlures gravesLES Fumées ET LES GAZ peuvent être dangereux LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peu DES Organes Mobiles peuvent pro voquer des blessuresRisque D’INCENDIE OU D’EXPLO- Sion LA Chaleur DU Moteur peut pro- voquer un incendie’AIR Comprimé peut provoquer des blessures LES Fils DE Soudage peuvent provoquer des blessures LE Surchauffement peut endom- mager le moteur électriqueDES Organes Mobiles peuvent provoquer des blessures ’EMPLOI Excessif peutInformation EMF Proposition californienne 65 AvertissementsPrincipales normes de sécurité En ce qui concerne les implants médicauxStd − Definitions− 50 h Std Manufacturer’s Rating Label Symbols And Definitions Engine Specifications − SpecificationsWeld And Power Specifications Dimensions, Weights, And Operating AnglesTIG Mode Stick ModeMIG Mode Volt-Ampere Curves − 50 Hz OperationVolt-Ampere Curves − 60 Hz Operation DC AmperesDuty Cycle And Overheating − 50 Hz Operation Curve shows typical fuel use under weld or power loadsFuel Consumption 100% Duty Cycle At 250 AmperesDuty Cycle And Overheating − 60 Hz Operation AC Generator Power CurveAc power curve shows the gen- erator power in amperes Location/Airflow Clearance − InstallationInstalling Welding Generator Grounding1Mounting Welding Generator Tools Needed Installing Exhaust PipeStop engine and let cool Activating The Dry Charge Battery If Applicable Connecting The BatteryFuel Coolant Recovery TankEngine Prestart Checks OilConnecting To Weld Output Terminals Selecting Weld Cable Sizes Socket Information Connecting To Remote 14 Receptacle RC14Gas Connections OM-223 Front Panel Controls See SectionStop Description Of Front Panel Controls See Section Process/Contactor Switch Process/Contactor Switch SettingsConnect Remote Set Wire ProcessRemote Voltage/Amperage Control Receptacle RC14− Operating Auxiliary Equipment Volt Receptacles− Maintenance & Troubleshooting Routine MaintenanceMaintenance Label Checking Generator Brushes ServicePerkins Customer Assistance Website AddressReinstall primary element and cap dust ejector down Servicing Air CleanerTo clean air filter Tools Needed 3/8 Inspecting And Cleaning Spark Arrestor MufflerServicing Engine Cooling System Stop engine and let cool Radiator DraincockTo replace primary canister fuel filter Servicing Fuel And Lubrication SystemsTo change oil and filter To drain water from fuel systemOverload Protection Help 25 Display Optional Voltmeter/Ammeter Help DisplaysHelp 20 Display Welding TroubleshootingStandard Generator Power Engine Engine suddenly stops Coolant temperature is too high see SectionWhen the engine is restarted Sphere oil refineries− Electrical Diagrams Circuit Diagram For Welding Generator222 966--C Welding Generator − RUN-IN ProcedureWetstacking Run-In Procedure Using Load Bank From flammablesRun-In Procedure Using Resistance Grid Grounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesSelecting Equipment Amperes x Volts = Watts Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Industrial Motors Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsSingle-Phase Induction Motor Starting Requirements Power Required To Start MotorHow Much Power Can Generator Supply? KVA/HP x HP x 1000 / Volts = Starting AmperageTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible − Parts List 110− −5 108 109− −3 101 105 104 107 106 102 103 100− −212−4 5756 112 Dia Part Description Quantity Mkgs Dia Part Description Quantity 213668 Panel Front w/ComponentsPanel Front w/Components Control Panel Generator Rectifier Assembly Wiring Harnesses Material Thickness Gauge Start Your Professional Welding Career Now Your distributor also gives SupportFor assistance in filing or settling claims, contact To locate a Distributor or Service Agency visitMiller Electric Mfg. Co Your distributor and/or equipment manufacturer’s