To Next PageTo Next PageWhy doesn't my Miller Welding System engine run at idle speed?
For CC models of your Miller Welding System, place the Stick/TIG Selection switch in the Stick position. For CC/CV models, place the Process/Contactor switch in any position but Remote On/Off Switch Required- TIG. Check for an obstructed throttle solenoid.
Why does the engine on my Miller Big Blue 400D Welding System suddenly stop?
If the engine of your Miller Welding System suddenly stops, first check the oil level. The automatic shutdown system may stop the engine if the oil pressure is too low or the engine temperature is too high.
How to troubleshoot low weld output on a Miller Welding System?
If your Miller Welding System has low weld output, first check the engine speed and adjust it if necessary. Also, check fuses F1 and F2, and replace them if they are open.
What to do if there is no weld output or generator power output on my Miller Big Blue 400D?
If your Miller Welding System has no weld output or generator power output at AC receptacles, disconnect equipment from generator power receptacles during start-up. Check fuses F1 and F2, and replace them if open. Reset supplementary protector CB12.
Why won't the engine crank on my Miller Big Blue 400D?
If the engine of your Miller Welding System will not crank, check the battery and replace it if necessary. Ensure that the battery connections are secure and tight. Also, check if circuit breaker CB10 is open.
How to troubleshoot low open-circuit voltage on a Miller Big Blue 400D?
If your Miller Welding System has low open-circuit voltage, check the engine speed and adjust if necessary.
What to do if my Miller Welding System engine slowly stopped and won't restart?
If the engine of your Miller Welding System slowly stopped and cannot be restarted, check the fuel level and the engine air and fuel filters.
Why is the output high at the three-phase generator on my Miller Big Blue 400D Welding System?
If your Miller Welding System has high output at the optional three-phase generator/receptacle RC5, check the engine weld/power speed, and adjust if necessary.
Why does my Miller Big Blue 400D engine start but stop when the switch is released?
If the engine of your Miller Welding System starts but stops when the Engine Control switch is released, check the oil level. The automatic shutdown system stops the engine if oil pressure is too low or engine temperature is too high.
Why is the weld output too high on my Miller Welding System?
If your Miller Welding System has high weld output, check the engine speed and adjust if necessary.
Explains hazard symbols (Danger, Warning, Notice) used throughout the manual.
Details electric shock, moving parts, hot parts, and EMF hazards during arc welding.
Risks from inhaling welding fumes and gases, ventilation requirements.
Protection against intense visible and invisible welding arc rays and sparks.
Precautions against fire and explosion from welding operations and sparks.
Safety warnings related to batteries, fuel, exhaust, hot parts, and engine moving parts.
Risks and safety measures for compressed air equipment and systems.
Symbols for fire/explosion, falling equipment, overheating, sparks, and moving parts hazards.
Safety precautions and hazards associated with battery charging.
Potential interference issues caused by high-frequency radiation.
Potential electromagnetic interference from arc welding processes.
Warnings about chemicals in fumes, gases, and batteries per California law.
Information on electromagnetic fields and precautions for medical implants.
Explanation of various safety symbols found on CE products.
Definitions of various operational and technical symbols used in the manual.
Technical data for welding output, generator power, and engine.
Explanation of duty cycle and how to prevent overheating.
Graphical output curves showing voltage and amperage for CC models.
Graphical output curves for CC/CV models in various welding modes.
Graph illustrating typical fuel usage under different load conditions.
Graph showing AC power availability from generator receptacles.
Instructions for unit placement, mounting, airflow clearance, and securing.
Procedures for safely grounding the generator frame to a vehicle.
Step-by-step instructions for correctly connecting the unit's battery.
Essential checks for fluids, battery, and fuel before starting the engine.
Identification and connection of weld output terminals for various processes.
Proper procedure for connecting weld cables to the output terminals.
Guidelines for choosing appropriate weld cable sizes based on amperage and length.
Identification of all controls and indicators on the CC model front panel.
Detailed explanations of the function of each front panel control.
Identification of all controls and indicators on the CC/CV model front panel.
Detailed explanations of the function of each front panel control.
How to select welding processes using the Process/Contactor switch.
Explains the indicators and warnings on the fuel/hour gauge.
Information on 120V and 240V receptacles, GFCI, and protectors.
How to use, test, and reset Ground Fault Circuit Interrupter (GFCI) receptacles.
Schedule and tasks for routine maintenance based on operating hours.
Procedures for cleaning or replacing the air cleaner element.
How to adjust engine speed for optimal operation and performance.
Procedures for servicing fuel filters, oil, and the fuel tank.
Troubleshooting common welding issues and remedies for CC models.
Troubleshooting common welding issues and remedies for CC/CV models.
Troubleshooting common generator power output issues and remedies.
Troubleshooting common engine starting, running, and idling issues.
List of recommended spare parts including part numbers.
Detailed electrical schematic for the CC welding generator.
Detailed electrical schematic for the CC/CV welding generator.
Explanation of wetstacking, its causes and prevention.
Step-by-step guide for performing engine run-in using load banks.
Procedures for safely grounding the generator to vehicle frames.
Grounding procedures for connecting to building electrical systems.
Calculating power requirements for various connected equipment.
Charts for selecting extension cord lengths based on current, voltage, and conductor size.
Explains hazard symbols (Danger, Warning, Notice) used throughout the manual.
Details electric shock, moving parts, hot parts, and EMF hazards during arc welding.
Risks from inhaling welding fumes and gases, ventilation requirements.
Protection against intense visible and invisible welding arc rays and sparks.
Precautions against fire and explosion from welding operations and sparks.
Safety warnings related to batteries, fuel, exhaust, hot parts, and engine moving parts.
Risks and safety measures for compressed air equipment and systems.
Symbols for fire/explosion, falling equipment, overheating, sparks, and moving parts hazards.
Safety precautions and hazards associated with battery charging.
Potential interference issues caused by high-frequency radiation.
Potential electromagnetic interference from arc welding processes.
Warnings about chemicals in fumes, gases, and batteries per California law.
Information on electromagnetic fields and precautions for medical implants.
Explanation of various safety symbols found on CE products.
Definitions of various operational and technical symbols used in the manual.
Technical data for welding output, generator power, and engine.
Explanation of duty cycle and how to prevent overheating.
Graphical output curves showing voltage and amperage for CC models.
Graphical output curves for CC/CV models in various welding modes.
Graph illustrating typical fuel usage under different load conditions.
Graph showing AC power availability from generator receptacles.
Instructions for unit placement, mounting, airflow clearance, and securing.
Procedures for safely grounding the generator frame to a vehicle.
Step-by-step instructions for correctly connecting the unit's battery.
Essential checks for fluids, battery, and fuel before starting the engine.
Identification and connection of weld output terminals for various processes.
Proper procedure for connecting weld cables to the output terminals.
Guidelines for choosing appropriate weld cable sizes based on amperage and length.
Identification of all controls and indicators on the CC model front panel.
Detailed explanations of the function of each front panel control.
Identification of all controls and indicators on the CC/CV model front panel.
Detailed explanations of the function of each front panel control.
How to select welding processes using the Process/Contactor switch.
Explains the indicators and warnings on the fuel/hour gauge.
Information on 120V and 240V receptacles, GFCI, and protectors.
How to use, test, and reset Ground Fault Circuit Interrupter (GFCI) receptacles.
Schedule and tasks for routine maintenance based on operating hours.
Procedures for cleaning or replacing the air cleaner element.
How to adjust engine speed for optimal operation and performance.
Procedures for servicing fuel filters, oil, and the fuel tank.
Troubleshooting common welding issues and remedies for CC models.
Troubleshooting common welding issues and remedies for CC/CV models.
Troubleshooting common generator power output issues and remedies.
Troubleshooting common engine starting, running, and idling issues.
List of recommended spare parts including part numbers.
Detailed electrical schematic for the CC welding generator.
Detailed electrical schematic for the CC/CV welding generator.
Explanation of wetstacking, its causes and prevention.
Step-by-step guide for performing engine run-in using load banks.
Procedures for safely grounding the generator to vehicle frames.
Grounding procedures for connecting to building electrical systems.
Calculating power requirements for various connected equipment.
Charts for selecting extension cord lengths based on current, voltage, and conductor size.
General| Welding Output | 400A at 36V, 100% duty cycle |
|---|---|
| Generator Output | 10, 000W (Peak), 8, 000W (Continuous) |
| Rated Output | 400A at 36V, 100% duty cycle |
| Welding Amperage Range | 20 - 400 A |
| Net Weight | 690 lbs (313 kg) |
| Output Current Range | 30-400A |
| Fuel Tank Capacity | 12.5 gallons (47.3 liters) |
| Welding Processes | Stick, TIG, MIG, Flux-Cored |
| Auxiliary Power | 10, 000 Watts continuous, 12, 000 Watts peak |
