Miller Electric Big 40G Engine, Coolant temperature gets too high see Section, See engine manual

Page 37

Trouble	Remedy

	Have Factory Authorized Service Agent check brushes and slip rings, and field current regulator board
	PC1.

High or low voltage at auxiliary power	Check engine weld/power speed, and adjust if necessary (see Section 7-8).
ac receptacles.

	Have Factory Authorized Service Agent check field current resistor R3.

High output at optional auxiliary power	Check engine weld/power speed, and adjust if necessary (see Section 7-8).
plant.

	Have Factory Authorized Service Agent check field current regulator board PC1.

C. Engine

Trouble	Remedy

Engine does not start.	Check fuel level. Open fuel shutoff valve (see Section 4-4).

	Check battery and replace if necessary (see Section 4-2).

	Check oil and water levels. Automatic shutdown system stops engine if oil pressure gets too low or
	coolant temperature gets too high (see Section 4-4).

	Check Engine Control switch, and replace if necessary.

	Check Magnetic Shutdown switch MS1 fuse F and replace if open (see Section 7-4).

	See engine manual.

	Have Factory Authorized Service Agent check engine charging system.

Battery discharges between uses.	Clean battery, terminals, and posts with baking soda and water solution; rinse with clear water.

	Periodically recharge battery (approximately every 3 months).

	Replace battery (see Section 4-2).

	Have Factory Authorized Service Agent check engine charging system.

Engine idles, but does not come up to	Check Engine Control switch, and replace if necessary.
weld speed.

	Have Factory Authorized Service Agent check idle module and current transformer CT1.

Engine does not run at idle speed.	Move Optional Process switch to Stick position (see Section 5-1). Unit does not run at idle speed
	when operated in MIG (CV) mode.

Engine slowly stopped and cannot be	Check fuel level. Open fuel shutoff valve (see Section 4-4).
restarted.

	Check oil and water levels. Automatic shutdown system stops engine if oil pressure gets too low or
	coolant temperature gets too high (see Section 4-4).

	See engine manual.

OM-477 Page 33

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Contents Processes OM-477Description From Miller to You Table of Contents Page Arc Welding Hazards Symbol UsageElectric Shock can kill ARC Rays can burn eyes and skinEngine Hazards Moving Parts can cause injury Battery Explosion can BlindEngine Exhaust Gases can kill Engine Heat can cause fireEMF Information Principal Safety StandardsRadiation can cause interference ARC Welding can cause interferenceConsignes DE SÉ Curité Lire Avant Utilisation Signification des symbolesUN Choc É Lectrique peut tuer LES Fumé ES ET LES GAZ peuvent ê tre dangereuxDES Particules Volantes peuvent blesser les yeux LE Soudage peut provoquer un in- cendie ou une explosionDES PIÈ CES Chaudes peuvent provoquer des brû lures graves LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peut DES Organes Mobiles peuvent provoquer des blessuresLA Chaleur DU Moteur peut pro- voquer un incendie LA Chute DE L’APPAREIL peut blesserInformation sur les champs é lectromagné tiques Principales normes de sé curitéLE Soudage À L’ARC risque de provoquer des interfé rences Consignes relatives aux stimulateurs cardiaquesSymbols And Definitions SpecificationsWeld, Power, And Engine Specifications DefinitionsDimensions Dimensions, Weights, And Operating AnglesWeight Fuel ConsumptionDuty Cycle And Overheating AC Auxiliary PowerMinutes Welding Minutes Resting 5 KVA/KW Single-Phase Auxiliary Power Plant No Weld Load Optional AC Power Plant Curves12.5 KVA/KW Three-Phase Auxiliary Power Plant No Weld Load DC Volts CC/DC Standard Volt-Ampere CurvesAC Amperes CV/DC Models with Optional CV-3 Module 100Installing Welding Generator InstallationConnecting The Battery Installing Muffler13 mm Full Gasoline Capacity 9 qt 8.5 L Engine Prestart ChecksTop View Selecting Weld Cable Sizes Connecting To Weld Output Terminals100 ft 30 m Or Less 10 100% Duty CycleTerminal Strip 3T Connections Optional Remote 14 Receptacle RC3 Information Optional, See SectionSocket Information Stop engineFront Panel Controls See Section Operating Welding GeneratorDo not switch under load Ampere Range SwitchDescription Of Front Panel Controls See Section Stop engine and fix trouble if either warning light goes onExample Combination remote amperage control Remote Control OptionalVolt Duplex And Optional Gfci Receptacles Operating Auxiliary EquipmentX 10 a + 120 V x 5 a = 3.0 kVA/kW Volt Duplex Receptacle OptionalFront Connecting Optional Auxiliary Power PlantMaintenance and Troubleshooting Maintenance Label To Clean air filter Servicing Air CleanerDo not clean housing with air hose Overload ProtectionStop engine and let cool Standard Oil Filter Changing Engine Oil And FilterCation makes it difficult to change Standard filterChanging Fuel Filter Inspecting And Cleaning Optional Spark Arrestor MufflerStop engine and let cool 1850 rpm Max Adjusting Engine Weld/Power SpeedAdjusting Governor Sensitivity Adjusting Engine Idle SpeedTroubleshooting Adjusting Optional High Altitude CarburetorWelding Trouble RemedyAuxiliary Power Check Engine Control switch, and replace if necessary Coolant temperature gets too high see SectionEngine See engine manualOM-477 Circuit Diagram For Welding Generator For Standard Models Electrical DiagramsOM-477 193 967-A Selecting Equipment Auxiliary Power GuidelinesGrounding Generator To Truck Or Trailer Frame How Much Power Does Equipment Require? Grounding When Supplying Building SystemsEarth ground if supplying Amperes x Volts = WattsApproximate Power Requirements For Farm/Home Equipment Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentHow Much Power Can Generator Supply? Power Required To Start MotorSingle-Phase Induction Motor Starting Requirements KVA/HP x HP x240 120 Ground Typical Connections To Supply Standby PowerCurrent Load Watts Amperes Selecting Extension Cord Use Shortest Cord PossibleOM-477 114 113 112 111 110 109 108 107 106 105 104 103 102 101 100 Parts ListIncludes 39 43 Dia Part Description Mkgs Quantity 025 2523 GeneratorGenerator -1 Item Includes 2539CB1,2 139 Control Box w/Components -3 Item Your distributor also gives ServiceSupport Miller Electric Mfg. Co Owner’s Record