Miller Electric 500DX R, OM-129 manual Maintenance & Troubleshooting

Page 31

SECTION 7 − MAINTENANCE & TROUBLESHOOTING

7-1. Routine Maintenance

NOTE

Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period.

Y Stop engine before maintaining.

Recycle . See also Engine Manual and Maintenance Label.

engine Service engine more often if used in severe

fluids. conditions.

*To be done by Factory Authorized Service Agent.

8 h

Wipe

Up

Spills.

OIL Full

	Check Fluid	FUEL	Drain Water
		WATER
	Levels. See		From Fuel

	Section 4-5.		System.

50 h

Clean Air Filter. 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.

200 h

250 h

Replace

Unreadable

Labels.

Check And

Clean Spark

Arrestor. See

Section 7-9.

500 h

Repair

Or

Replace

Cracked

Cables.

1000 h

Blow Out Or

ORVacuum Inside.

During Heavy

Service,

Clean Monthly.

Service Welding

Generator Brushes

And Slip Rings.

Service More Often

In Dirty Conditions.*

FUEL	Drain Sludge
SLUDGE	From Fuel
	Tank. See
	Section 7-4.

Change Fuel

Filters. See

Section 7-4.

1/2 in.

(13 mm)

Check Belt

Tension. See

Section 7-7.

Check

Valve

Clearance.*

OM-129 647 Page 27

Image 31

Contents Processes OM-129 647WDescription From Miller to You Table of Contents Page ARC Rays can burn eyes and skin Symbol UsageArc Welding Hazards Electric Shock can killEngine Hazards Engine Heat can cause fire Battery Explosion can BlindMoving Parts can cause injury Engine Exhaust Gases can killARC Welding can cause interference Principal Safety StandardsEMF Information Radiation can cause interferenceLES Fumées ET LES GAZ peuvent être dangereux Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation UN Choc Électrique peut tuerLE Bruit peut affecter l’ouïe LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux DES Pièces Chaudes peuvent provoquer des brûlures gravesLA Chute DE L’APPAREIL peut blesser DES Organes Mobiles peuvent provoquer des blessures’EXPLOSION DE LA Batterie peut LA Chaleur DU Moteur peut pro- voquer un incendieConsignes relatives aux stimulateurs cardiaques Principales normes de sécuritéInformation sur les champs électromagnétiques LE Soudage À L’ARC risque de provoquer des interférences− Definitions − SpecificationsSymbols And Definitions Weld, Power, And Engine Specifications1898 lb 861 kg Engine End Dimensions, Weights, And Operating AnglesCurve shows typical fuel use under weld or power loads Fuel Consumption60% Duty Cycle At 500 Amperes Duty Cycle is Percentage AC Auxiliary PowerWarranty Minutes Welding Minutes Resting Duty Cycle And OverheatingCC/DC Standard CV/DC Models With CV Option Volt-Ampere CurvesOptional AC Power Plant Curves Location − InstallationInstalling Welding Generator Do Not Lift Unit From End Airflow ClearanceMaintain proper level Activating The Dry Charge BatteryWhen electrolyte is low, add ChargerTools Needed 1/2 Connecting The BatteryEngine Prestart Checks Connect Negative − Cable LastSelecting Weld Cable Sizes Connecting To Weld Output TerminalsAfter installing cylinder, wait at Installing Ether Cylinder Optional Ether Starting AidRemote A/V Control Receptacle RC3 Stop engine Remote 14 Receptacle RC3 Information OptionalTerminal Strip 2T Connections Optional SocketStandard Controls See Section − Operating the Welding GeneratorIf light goes on, stop engine and check engine belt Do not switch under loadDescription Of Standard Controls See Section If light goes off, stop engine and check oil levelControls For Models With CV Option See Section This unit has a max OCV control circuit 120 V 15 a AC Receptacle RC2 240 V 15 a AC Receptacle RC1 Auxiliary power is not affected by weld output − Operating Auxiliary Equipment Volt And 240 Volt Duplex ReceptaclesBritish Receptacle Option Optional Auxiliary Power ReceptaclesGfci Receptacle Option Australian And South African Receptacle OptionsLoad Terminals Connecting Optional Auxiliary Power PlantSet Engine Control switch to Run when using auxiliary power 1011− Maintenance & Troubleshooting Deutz F3L912 Diesel Engine Maintenance LabelTo clean air filter Servicing Air CleanerHose Servicing Fuel And Lubrication Systems Servicing Optional Ether Starting Aid Adjusting Engine Speed1850 Stop engine To check belt tension To adjust belt tensionChecking And Replacing Alternator Belt 13 mm Max Tools Needed 11/16Resetting Fan Belt Safety Shutdown Stop engine and let cool Inspecting And Cleaning Optional Spark Arrestor MufflerStop engine and let cool. Reinstall cleanout plug Overload Protection For Models With CV OptionWelding TroubleshootingEngine Auxiliary PowerTrouble Remedy OM-129 647 Circuit Diagram For Welding Generator Standard Models − Electrical DiagramsCircuit Diagram For Welding Generator Models With CV Option 184 954-C Wetstacking − RUN-IN ProcedureLoad Bank Run-In Procedure Using Load BankFrom flammables Run-In Procedure Using Resistance GridDo not touch hot exhaust Bank/gridSelecting Equipment − Auxiliary Power GuidelinesGrounding Generator To Truck Or Trailer Frame Use ground device as stated in electrical codes Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Earth ground if supplyingFarm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Industrial Motors Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentKVA/HP x HP x 1000 = Starting Amperage Volts Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsCustomer-supplied equipment is required if Generator is to supply standby power duringEmergencies or power outages Welding Generator Auxiliary Power output circuitSelecting Extension Cord Use Shortest Cord Possible 101 100 − Parts List66 65 102 Dia Part Description Quantity Mkgs Optional Panel, Front w/Components CC Model Illustrated Panel, Front w/Components -1 Item 6 5 GeneratorGenerator -1 Item Hardware is common Not available unless listed 171Includes Control Box CC/CV -1 Item 86 Optional Panel, Mtg Components CC/CV Model Panel, Mtg Components CC Model Page Your distributor also gives ServiceSupport To locate distributor nearest you call 1-800-4-A-Miller Miller Electric Mfg. CoFor assistance in filing or settling claims