Miller Electric Big 40 WG manual Diagnosing Causes Of Engine Fault Shutdowns, Fault Condition

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8-10. Diagnosing Causes Of Engine Fault Shutdowns

Use the front panel engine lights to help determine the cause of an au- tomatic engine shutdown.

Pre-Start Diagnostic Checks	. Correct the cause of the shut-
	down before operating the
	welding generator.

. This unit does not have a bat- tery charging fault shutdown. The engine continues to run if the Battery Charging Light goes on.

Turn Engine Control Switch To Run/Idle	Normal Condition:
Position While Pressing Magnetic Shut-	Oil Pressure Light On;
down Switch.	Battery Charging, Fuel, And Temperature Lights Off.
	If Oil Pressure Light Is Off, See Factory Authorized Service Agent.
	If Battery Charging Light Is On, Have Factory Authorized Service Agent
	Check Alternator.
	If Temperature Light Is On, Correct Cause Of Overheating
	(See Engine Manual).
	If Engine Is Okay, See Factory Authorized Service Agent.
	If Fuel Light Is On, Check Fuel Level.
	If Fault Continues, See Factory Authorized Service Agent.

Diagnostic Checks While Running

20s

Start Engine (With No Load Applied).	Continue Pressing Shutdown Switch	Normal Condition:
	Until Engine Lights Go Off.	Engine Lights Go Off As Engine Reaches
		Normal Operating Condition.
		Lights That Stay On After 20 Sec. Indicate
		Fault Condition.
		Stop Engine And Correct Fault (See Above) If
		Fault Continues, See Factory Authorized Ser-
		vice Agent.

Ref. 201 841

OM-4405 Page 42

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Contents Processes OM-4405Description From Miller to You Table of Contents Options and Accessories Warranty Electric Shock can kill Symbol UsageArc Welding Hazards ARC Rays can burn eyes and skinEngine Hazards Engine Exhaust Gases can kill Battery Explosion can BlindMoving Parts can cause injury Engine Heat can cause fireRadiation can cause interference Principal Safety StandardsEMF Information ARC Welding can cause interferenceUN Choc É Lectrique peut tuer Signification des symbolesConsignes DE SÉ Curité Lire Avant Utilisation LES Fumé ES ET LES GAZ peuvent ê tre dangereuxDES PIÈ CES Chaudes peuvent provoquer des brû lures graves LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux LE Bruit peut affecter l’ouïeLA Chaleur DU Moteur peut pro- voquer un incendie DES Organes Mobiles peuvent provoquer des blessures’EXPLOSION DE LA Batterie peut LA Chute DE L’APPAREIL peut blesserLE Soudage À L’ARC risque de provoquer des interfé rences Principales normes de sé curitéInformation sur les champs é lectromagné tiques Consignes relatives aux stimulateurs cardiaquesWeld, Power, And Engine Specifications SpecificationsSymbols And Definitions DefinitionsDimensions, Weights, And Operating Angles Volt-Ampere Curves For CC ModelsTIG Mode Stick ModeMIG Mode Volt-Ampere Curves for CC/CV ModelsFuel Consumption Duty Cycle And Overheating12 kVA/kW Single-Phase Auxiliary Power Plant No Weld Load AC Auxiliary Power CurveOptional AC Power Plant Curves 15 kVA/kW Three-Phase Auxiliary Power Plant No Weld LoadInstalling Welding Generator See Sections 4-2 InstallationUsing Lifting Eye Welding Unit In Place Bolting Unit In Place Installing Exhaust PipeMounting Welding Generator To Bolt Unit In PlaceRead and follow all instruc Activating The Dry Charge Battery If ApplicableDo not overfill battery cells ChargerConnecting The Battery Connect Negative Cable LastFuel Coolant Recovery TankEngine Prestart Checks OilConnecting To Weld Output Terminals Selecting Weld Cable SizesRef 862-A / 048 720-K / 802 Connecting To Remote 14 Receptacle RC14 On CC/CV Models Socket InformationOperating Welding Generator CC Models Front Panel Controls For CC Models See SectionEngine Starting Controls Engine Indicator LightsDo not switch under load To StartRemote Amperage Control On CC Models Optional OM-4405 Operating Welding Generator CC/CV Models Front Panel Controls For CC/CV Models See SectionUse switch to select weld amperage range Voltage/Amperage Adjust Switch And Remote 14 ReceptacleProcess/Contactor Switch Process/Contactor Switch On CC/CV ModelsProcess/Contactor Switch Settings RunningProcess Remote Voltage/Amperage Control On CC/CV Models OptionalSet Remote Set Range Set RemoteOperating Auxiliary Equipment Volt And 240 Volt ReceptaclesThree-Phase Power Connection Single-Phase Power Connection Single-Phase Auxiliary PowerRear Of Panel 240 V 15 a AC South African Receptacle RC1 Optional Auxiliary Power ReceptaclesCircuit Breaker CB2 Circuit Breaker CB3 Maintenance & Troubleshooting Maintenance Label100 h Routine Maintenance50 h 250 h1000 h Inspecting And Cleaning Optional Spark Arrestor Muffler500 h Stop engine and let coolServicing Air Cleaner Adjusting Engine Weld/Power Speed MaximumEngine Speed Adjusting Engine Idle SpeedNo Load Adjusting Governor Sensitivity Tools Needed 1/2Servicing Fuel And Lubrication Systems Press button to reset breaker Overload ProtectionFault Condition Diagnosing Causes Of Engine Fault ShutdownsDiagnostic Checks While Running 20s Start Engine With No Load AppliedTroubleshooting Welding CC ModelsWelding CC/CV Models Repair or replace wire feederTacle see Section Optional Auxiliary Power Plant Standard Auxiliary PowerEngine Ant temperature is too high see Sections 4-7 Wiring harness and componentsShutdown switch is released Out Or coolant temperature is too high see Sections 4-7OM-4405 Electrical Diagrams Circuit Diagram For CC Welding Generator201 991-A Circuit Diagram For CC/CV Welding Generator 201 992-A Selecting Equipment Auxiliary Power GuidelinesGrounding Generator To Truck Or Trailer Frame Earth ground if supplying 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 xTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Current Load Watts AmperesOM-4405 107 106 101 105 103 Parts ListCC only 104 -4 or 108 See FIGDia Part Description Dia Part Description Mkgs Quantity Control Box Assembly CC Models Control Box Assembly CC Models -1 Item Control Box Assembly CC/CV Models 177 CONN, body 5 terminal to engine control switch S1 193 Panel, Front w/Components CC Models MS1 Panel, Front w/Components CC/CV Models Panel, Front w/Components CC/CV Models -1 ItemPC6 192 Generator Generator -1 Item Main Rectifier Assembly Your distributor also gives ServiceSupport Owner’s Record Miller Electric Mfg. Co