Miller Electric Big Blue 500 PT Check engine wiring harness plug connections, Seconds, Start-up

Page 54

Trouble

Remedy

 

 

 

Check engine wiring harness plug connections.

 

 

 

Have Factory Authorized Service Agent check control relay CR1, diode/capacitor board D8/C8, and En-

 

gine Control switch S1.

 

 

Engine cranks but does not start.

Check fuel level.

 

 

 

Check battery and replace if necessary. Check engine charging system according to engine manual.

 

 

 

Have Factory Authorized Service Agent check engine wiring harness, time delay relay TD1, control

 

relay CR5, fuel pump, fuel solenoid FS1, and diode/capacitor board D10/C10.

 

 

 

Air in fuel system. See engine manual.

 

 

Engine starts, but stops after 30

Check oil, and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolant

seconds.

temperature is too high (see Section 5-7). Automatic shutdown system is inhibited for 30 seconds after

 

start-up.

 

 

 

Check engine speed. Overspeed shutdown automatically stops engine if speed is too high. Turn engine

 

off and restart to resume operation. If unit continues to overspeed and shut down, have unit checked by

 

a Factory Authorized Service Agent.

 

 

 

Have Factory Authorized Service Agent check time delay relay TD1, and control relay CR5.

 

 

Engine hard to start in cold weather.

Use starting aid switch (see Section 6-1or 7-1).

 

 

 

Keep battery in good condition. Store battery in warm area off cold surface.

 

 

 

Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier for

 

fuel information.

 

 

 

Use correct grade oil for cold weather (see Section 9-1).

 

 

 

Have Factory Authorized Service Agent check starting aid switch and glow plugs.

 

 

Engine suddenly stops.

Check oil and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolant

 

temperature is too high (see Section 5-7). Automatic shutdown system is inhibited for 30 seconds after

 

start-up.

 

 

 

See engine manual.

 

 

 

Have Factory Authorized Service Agent check engine speed sensor.

 

 

Engine slowly stopped and cannot be

Check fuel level.

restarted.

 

 

 

 

Check engine air and fuel filters (see Sections 9-3and 9-6).

 

 

 

See engine manual.

 

 

Battery discharges between uses.

Turn Engine Control switch off when unit is not running.

 

 

 

Clean top of battery with baking soda and water solution; rinse with clear water.

 

 

 

Recharge or replace battery if necessary.

 

 

 

Periodically recharge battery (approximately every 3 months).

 

 

Engine does not run at weld/power

Have Factory Authorized Service Agent check engine controller, throttle actuator TS1, and speed sensor.

speed.

 

 

 

Engine idles, but does not come up to

Check for obstructed throttle actuator TS1.

weld speed (models with idle option

 

only).

 

 

 

 

Have Factory Authorized Service Agent check idle module PC7, current transformer CT1, throttle actua-

 

tor TS1, and engine controller.

 

 

Engine does not run at idle speed

CC models: place Stick/TIG Selection switch in Stick position.

(models with idle option only).

CC/CV models: place Process/Contactor switch in any position but Remote On/Off Switch Required-

 

TIG.

 

 

 

Check for obstructed throttle actuator.

 

 

 

Have Factory Authorized Service Agent check idle module PC7, control relay CR6, throttle actuator TS1,

 

speed sensor, and engine controller.

 

 

Engine uses oil during run-in period;

Dry engine according to run-in procedure (see Section 11).

wetstacking occurs.

 

 

 

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Contents File Engine Drive ProcessesDescription Visit our website at OM-44292216 138H 2007−05From Miller to You Table of Contents − Maintenance & Troubleshooting Electric 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 Indique des instructions spécifiquesLE 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 blessuresLA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessuresRisque D’INCENDIE OU D’EXPLO- Sion 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 médicaux− Definitions − 50 h StdStd Manufacturer’s Rating Labels CC ModelsSymbols And Definitions Some symbols are found only on CE products− Specifications Weld, Power, And Engine SpecificationsDimensions, Weights, And Operating Angles Volt-Ampere Curves For CC Models VoltsTIG Mode Stick ModeMIG Mode Volt-Ampere Curves For CC/CV ModelsFuel Consumption Duty Cycle And Overheating100% Duty Cycle At 400 Amperes 12 kVA/kW Single-Phase AC Output No Weld Load AC Generator Power CurveOptional Three-Phase Generator Curves 20 kVA/kW Three-Phase AC Output No Weld LoadLocation/Airflow Clearance − InstallationInstalling Welding Generator Grounding1Using Lifting Eye Mounting Welding Generator Installing Exhaust Pipe Stop engine and let coolActivating The Dry Charge Battery If Applicable Connecting The BatteryFuel Coolant Recovery TankEngine Prestart Checks OilMIG and Fcaw Welding Connecting To Weld Output TerminalsStick and TIG Welding Stop engine150 ft 200 ft 250 ft Connecting to WeldSelecting Weld Cable Sizes 350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 mConnecting To Remote 14 Receptacle RC14 On CC/CV Models SocketOM-4429 − Operating Welding Generator − CC Models Front Panel Controls For CC Models See SectionEngine Gauges And Meters Engine Starting ControlsTo Start Weld ControlsRemote Amperage Control On CC Models Optional Weld Control/Arc Condition Information LabelExample Combination Remote Amperage Control Stick OM-4429 − Operating Welding Generator − CC/CV Models Front Panel Controls For CC/CV Models See SectionVoltage/Amperage Adjust Switch And Remote 14 Receptacle 14 AC/DC Voltmeter OptionalProcess/Contactor Switch On CC/CV Models Process/Contactor Switch SettingsRemote Voltage/Amperage Control On CC/CV Models Optional Example Combination Remote Amperage Control TIGAt least once a month, run en − Operating Auxiliary EquipmentVolt And 240 Volt Receptacles If a SupplementaryThree-Phase Power Connection Rear Of PanelClose panel opening if no connections are made to generator Optional Generator Power Receptacles 240 V 15 a AC South African Receptacle RC1Supplementary Protector CB2 Supplementary Protector CB3 − Maintenance & Troubleshooting Maintenance LabelRoutine Maintenance Servicing Air Cleaner To clean air filterInspecting And Cleaning Optional Spark Arrestor Muffler Checking Generator BrushesServicing Fuel And Lubrication Systems To change oil and filterTo replace primary fuel filter Overload Protection Troubleshooting Welding − CC ModelsWelding − CC/CV Models Standard Generator Power Optional Three-Phase Generator Power CC/CV Models OnlyEngine Factory Authorized Service Agent Check engine wiring harness plug connectionsGine Control switch S1 Engine cranks but does not start Check fuel levelStart Your Professional Welding Career Now − Electrical Diagrams Circuit Diagram For CC Welding Generator223 525-B Circuit Diagram For CC/CV Welding Generator 223 524-B − RUN-IN Procedure WetstackingWelding Generator Run-In Procedure Using Load Bank Keep exhaust and pipe awayFrom flammables Just generator A/V control so Run-In Procedure Using Resistance GridSpecifications section in this ManualGrounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesSelecting Equipment Electrically Bond GeneratorUse ground device as stated in electrical codes Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Amperes x Volts = WattsIndustrial 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 114 −7 115 CV123 116 CV 112 2831 124 88 −6 6059 58 Dia Part Description Quantity Dia Part Description Quantity Mkgs Figures 13-2 111123 212 Control Box Assembly − CC Models Control Box Assembly − CC Models -1Item Engine ControllerControl Box Assembly − CC/CV Models 134 Panel, Front w/Components − CC Models 3634208278 Panel, Front w/Components − CC/CV Models Panel, Front w/Components − CC/CV Models -1ItemCB1 201 Supplementary PROTECTOR, man reset 2P 20 A, 250VAC Hardware is common 32 31 30053 BEARING, Ball Rdl Sgl Row 1.370 X 2.830 X Main Rectifier Assembly Wiring Harnesses 215207 Service Your distributor also givesSupport For 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
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