Miller Electric 400P User Manual

ProcessesDescriptionTIG (GTAW) WeldingStick (SMAW) WeldingMIG (GMAW) WeldingEngine Driven Welding GeneratorOM-4421 215 075Q2007−10Visit our website at

OM-4421 Page 4HOT METAL from air arc cutting andgouging can cause fire or explosion. Do not cut or gouge near flammables. Watch for fire; keep extin

OM-4421 Page 5H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommuni

OM-4421 Page 6SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANTUTILISATIONrom_2007−04freSe protéger, ainsi que toute autre personne travaillant sur les

OM-4421 Page 7DES PIÈCES CHAUDES peuventprovoquer des brûlures graves. Ne pas toucher à mains nues les parties chau-des. Prévoir une période de refr

OM-4421 Page 8LES CHAMPS MAGNETIQUES peuv-ent affecter des implants médicaux. Porteur de simulateur cardiaque ou autre im-plants médicaux, rester à d

OM-4421 Page 9L’utilisation d’un groupe autonomeà l’intérieur PEUT VOUS TUER ENQUELQUES MINUTES. Les fumées d’un groupe autonome contient dumonoxyde

OM-4421 Page 10LE SURCHAUFFEMENT peut endom-mager le moteur électrique. Arrêter ou déconnecter l’équipement avant dedémarrer ou d’arrêter le moteur.

OM-4421 Page 112-6. Proposition californienne 65 AvertissementsLes équipements de soudage et de coupage produisent desfumées et des gaz qui contiennen

OM-4421 Page 12SECTION 3 − DEFINITIONS3-1. Warning Label Definitions (For Wordless Labels)3/961 Remove unit from shippingcrate. Remove Owner’sManual f

OM-4421 Page 133-2. Manufacturer’s Rating LabelsCC Models CC/CV ModelsCC Export Models CC/CV Export Models

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

OM-4421 Page 143-3. Symbols And Definitions Some symbols are found only on export products.Stop EngineFast (Run, Weld/Power)Slow (Idle) Start EngineS

OM-4421 Page 15SECTION 4 − SPECIFICATIONS4-1. Weld, Power, And Engine SpecificationsWeldingModeWeld OutputRangeRated WeldingOutputMaximumOpen-CircuitV

OM-4421 Page 164-3. Volt-Ampere Curves For CC Models215 081-AThe volt-ampere curve shows theminimum and maximum voltageand amperage output capabilitie

OM-4421 Page 174-4. Volt-Ampere Curves For CC/CV Models215 080-A / 215 083-A / 215 079-AThe volt-ampere curves show theminimum and maximum voltageand

OM-4421 Page 184-5. Fuel ConsumptionThe curve shows typical fuel useunder weld or power loads.199 032−ADC WELD AMPERES AT 100% DUTY CYCLEUS Gal./Hr.0

OM-4421 Page 194-7. AC Generator Power Curve193 018The ac power curve shows the gen-erator power in amperes availableat the 120 and 240 volt receptacl

OM-4421 Page 20SECTION 5 − INSTALLATIONinstall3 2007−04 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712! Always securely fasten weld-ing generator

OM-4421 Page 215-2. Using Lifting EyeRef. 802 3111 Lifting Eye2 Nut3 Carriage BoltRaise lifting eye until it snaps inplace. Lower lifting eye when not

OM-4421 Page 225-3. Mounting Welding GeneratorTools Needed:9/16 in224Welding Unit In PlaceBolting Unit In Place! Do not weld on base. Weld-ing on base

OM-4421 Page 235-4. Installing Exhaust Pipe1/2 inTools Needed:Ref. 803 604 / Ref. 215 158! Stop engine and let cool. Point exhaust pipe in desired di

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

OM-4421 Page 245-5. Activating The Dry Charge Battery (If Applicable)! Always wear a face shield,rubber gloves and protectiveclothing when working on

OM-4421 Page 255-7. Engine Prestart Checks Check all engine fluids daily.Engine must be cold and on a level surface.Unit is shipped with 20W break-in

OM-4421 Page 265-8. Connecting To Weld Output Terminals803 602 / 803 778-ATools Needed:23/4 in1MIG and FCAW WeldingFor MIG and FCAW welding Direct Cur

OM-4421 Page 275-9. Selecting Weld Cable Sizes*Weld Cable Size** and Total Cable (Copper) Length in Weld CircuitNot Exceeding***100 ft (30 m) or Less1

OM-4421 Page 285-11. Connecting To Remote 14 Receptacle RC14 On CC/CV ModelsSocket* Socket Information24 VOLTS ACA 24 volts ac. Protected by sup-pleme

OM-4421 Page 29Notes

OM-4421 Page 30SECTION 6 − OPERATING WELDING GENERATOR − CC MODELS6-1. Front Panel Controls For CC Models (See Section 6-2)12215 070 / 803 60211218131

OM-4421 Page 316-2. Description Of Front Panel Controls For CC Models (See Section 6-1)Engine Starting Controls1 Starting Aid SwitchUse switch to ener

OM-4421 Page 326-3. Remote Amperage Control On CC Models (Optional)1 Remote Amperage AdjustReceptacle RC13Connect optional remote control toRC13 (see

OM-4421 Page 33Notes

TABLE OF CONTENTSSECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Front Panel

OM-4421 Page 34SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS7-1. Front Panel Controls For CC/CV Models (See Section 7-2)215 158 / 803 6022191

OM-4421 Page 357-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1)Engine Starting Controls1 Starting Aid SwitchUse switch to e

OM-4421 Page 367-3. Process/Contactor Switch On CC/CV Models1 Process/Contactor Switch! Weld output terminals are ener-gized when Process/Contactorswi

OM-4421 Page 377-4. Remote Voltage/Amperage Control On CC/CV Models (Optional)1 Remote 14 Receptacle RC14Connect optional remote control toRC14 (see S

OM-4421 Page 38SECTION 8 − OPERATING AUXILIARY EQUIPMENT8-1. 120 Volt And 240 Volt Receptacles191 624-A21 120 V 20 A AC GFCI Receptacle GFCI12 240 V 3

OM-4421 Page 398-2. Connecting To Optional Three-Phase Generator (CC/CV Models Only)Ref. 197 399 / 802 332-E / 803 655 Place Process/Contactor switch

OM-4421 Page 408-3. Optional Generator Power Receptacles21 120 V 20 A AC GFCI Receptacle GFCI12 240 V 16 A AC EuropeanReceptacle RC13 240 V 15 A AC Au

OM-4421 Page 41SECTION 9 − MAINTENANCE & TROUBLESHOOTING9-1. Maintenance Label

OM-4421 Page 429-2. Routine Maintenance! Stop engine before maintaining. See Engine Manual and Maintenance Labelfor important start-up, service, and

OM-4421 Page 439-3. Checking Generator BrushesRef 215 158! Stop engine and let cool.1 Generator BrushMark and disconnect leads at brush hold-er cap. R

dec_rot_1/07Declaration of Conformity forEuropean Community (CE) ProductsThis information is provided for units with CE certification (see rating labe

OM-4421 Page 449-4. Servicing Air Cleaner! Stop engine.NOTICE − Do not run engine without aircleaner or with dirty element. Enginedamage caused by usi

OM-4421 Page 459-5. Inspecting And Cleaning Optional Spark Arrestor Muffler803 656 / Ref. 215 158! Stop engine and let cool.1 Spark Arrestor Muffler2

OM-4421 Page 469-6. Adjusting Engine Speed803 606-CAfter tuning engine, check enginespeed with tachometer or frequencymeter. See table for proper no l

OM-4421 Page 479-7. Servicing Fuel And Lubrication Systems802 490 / Ref. 801 434! Stop engine and let cool.! After servicing, start engineand check fo

OM-4421 Page 489-8. Overload Protection803 605219874! Stop engine. When a supplementary protector,circuit breaker or fuse opens, it usu-ally indicate

OM-4421 Page 499-9. TroubleshootingA. Welding − CC ModelsTrouble RemedyNo weld output; generator power outputokay at ac receptacles.Check position of

OM-4421 Page 50Trouble RemedyNo remote fine amperage control. Repair or replace remote control device.Have Factory Authorized Service Agent check OCV

OM-4421 Page 51Trouble RemedyNo remote fine amperage or voltagecontrol.Repair or replace remote control device.Have Factory Authorized Service Agent c

OM-4421 Page 52E. EngineTrouble RemedyEngine will not crank. Check battery, and replace if necessary.Check battery connections and tighten if necessar

OM-4421 Page 53NotesWelding SymbolsRef. AWS/ANSI A2.4

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

OM-4421 Page 54SECTION 10 − ELECTRICAL DIAGRAMSFigure 10-1. Circuit Diagram For CC Welding Generator

OM-4421 Page 55223 522-B

OM-4421 Page 56Figure 10-2. Circuit Diagram For CC/CV Welding Generator

OM-4421 Page 57223 523-B

OM-4421 Page 58SECTION 11 − RUN-IN PROCEDURErun_in1 2007−0411-1. Wetstacking1 Welding GeneratorRun diesel engines near rated volt-age and current duri

OM-4421 Page 5911-2. Run-In Procedure Using Load BankS-06831 Load BankTurn all load bank switches Off. Ifneeded, connect load bank to 115volts ac wall

OM-4421 Page 6011-3. Run-In Procedure Using Resistance GridS-06841 Resistance GridUse grid sized for generator ratedoutput.Turn Off grid.2 Welding Gen

OM-4421 Page 61SECTION 12 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding gener

OM-4421 Page 6212-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse #10 AWG or larger insulate

OM-4421 Page 6312-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running WattsSplit Phase 1/8 HP 800 3

OM-4421 Page 1SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USINGrom_2007−04Protect yourself and others from injury — read and follow these precautions

OM-4421 Page 6412-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHand Drill 1/4 in 350 3503/8

OM-4421 Page 6512-8. Power Required To Start MotorSingle-Phase Induction Motor Starting RequirementsMotor StartCodeG H J K L M N PKVA/HP 6.3 7.1 8.0

OM-4421 Page 6612-10. Typical Connections To Supply Standby PowerTransfer SwitchEssentialLoadsFusedDisconnectSwitch(If Required) UtilityElectricalServ

OM-4421 Page 6712-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt LoadsIf unit does not have GFCI receptacles, use

OM-4421 Page 68SECTION 13 − PARTS LIST Hardware is common andnot available unless listed.400 P ModelsOnly12345678910111314151216171819202122232425262

OM-4421 Page 69803 646-E3334353637383940414243444546474849505152535455565758596162636465666768697071727374757677787980818283858486878889909193 (Fig. 1

OM-4421 Page 70DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-1. Main AssemblyQuantity1 189 824 PANEL, gen LH 1. . . . . . . . . . . . . . . . . . . .

OM-4421 Page 71DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-1. Main Assembly (Continued)Quantity40 ♦202 629 COVER, radiator access ss 1. . . . . . . .

OM-4421 Page 72DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-1. Main Assembly (Continued)Quantity77 191 626 BUMPER, door engine access 4. . . . . . . .

OM-4421 Page 73DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-1. Main Assembly (Continued)Quantity120 ♦199 305 TOP, cover front upright ss 1. . . . . .

OM-4421 Page 2Welding produces fumes and gases. Breathing thesefumes and gases can be hazardous to your health.FUMES AND GASES can be hazardous. Keep

OM-4421 Page 74 Hardware is common andnot available unless listed.803 647-F212423543614211822201615178117101291913Figure 13-2. Control Box Assembly −

OM-4421 Page 75DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-2. Control Box Assembly − CC Models ContinuedQuantity20 201 079 COVER, control box 1. . .

OM-4421 Page 76803 648-F2312316201819171514511847961222211013Figure 13-3. Control Box Assembly − CC/CV ModelsDescriptionPartNo.Dia.Mkgs.ItemNo.Figure

OM-4421 Page 77DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-3. Control Box Assembly − CC/CV Models (Continued)Quantity20 177 136 CLAMP, capacitor 1.375

OM-4421 Page 78 Hardware is common andnot available unless listed.803 649123456789111012131415161819202122232425262728293031323433353637383940414217F

OM-4421 Page 79DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-4. Panel, Front w/Components − CC Models (Figure 13-1 Item 125)Quantity1 215 070 PLATE SCRE

OM-4421 Page 80DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-4. Panel, Front w/Components − CC Models (Continued)Quantity197 798 SENDER, Coolant Temp 30

OM-4421 Page 81DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-5. Panel, Front w/Components − CC/CV Models (Figure 13-1 Item 125)Quantity1 215 158 PLATE

OM-4421 Page 82DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-5. Panel, Front w/Components − CC/CV Models (Continued)Quantity38 134 201 STAND-OFF, suppor

OM-4421 Page 83802 552-B Hardware is common andnot available unless listed.568924283031323312725263536431027212934201718111516121314192223Figure 13-6

OM-4421 Page 31-3. Engine HazardsBATTERY EXPLOSION can BLIND. Always wear a face shield, rubber gloves, andprotective clothing when working on a batt

OM-4421 Page 84DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-6. Generator (Continued)Quantity21 197 486 ADAPTER, Engine 1. . . . . . . . . . . . . . .

OM-4421 Page 85 Hardware is common andnot available unless listed.802 279-A123465789Figure 13-7. Main Rectifier AssemblyDescriptionPartNo.Dia.Mkgs.It

OM-4421 Page 86 Some wiring harness components (switches, relays, circuit breakers) are also referenced elsewhere in this parts list. Purchase compon

OM-4421 Page 87DescriptionPartNo.Dia.Mkgs.ItemNo.Wiring Harnesses (Continued)Quantity221376 Harness, engine control (includes) 1. . . . . . . . . . .

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 2007−01Your distributor also givesyou ...ServiceYou always get the

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