Miller Electric Big Blue 400 KX manual Maintenance & Troubleshooting, Routine Maintenance

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SECTION 8 − MAINTENANCE & TROUBLESHOOTING

8-1. Routine Maintenance

Y Stop engine before maintaining.

. See Engine Manual and Maintenance Label

Recycle engine for important start-up, service, and storage

fluids. information. Service engine more often if

used in severe conditions.

n = Check	Z = Change	~ = Clean	l = Replace	Reference
* To be done by Factory Authorized Service Agent

Every	FUEL				Section 5-6,
8	FUEL				8-7
8	WATER				8-7
Hours	WATER
	n Fuel/Water Separator	n Fuel Level	n Oil Level	~ Oil, Fuel Spills
	n Coolant Level
Every					Section 8-3
50
Hours
	~ Air Cleaner Element	~ Weld Terminals
Every
100
Hours
	~ Battery Terminals	n Air Cleaner Hoses
Every					Engine
250		1/2 in.			Manual,
Hours		(13 mm)			Section 8-4,
Hours					Section 8-4,
					8-7
	l Unreadable Labels	n Fan Belt Tension	Z Oil Z Oil Filter	n~Spark Arrestor
Every				FUEL	Section 5-6,
500				FUEL	8-7
Hours
				SLUDGE
	nl Weld Cables	nRadiator Fluid Level	Z FuelFilter	~ Drain Sludge
Every					Section 8-9
1000			OR		and Engine
Hours			OR		Manual
Hours					Manual
	n~ Slip Rings*	nValve Clearance*	~ Inside Unit
	nl Brushes*
Every
2000
Hours
	~ Injectors*
OM-4423 Page 30

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Contents OM-4423 215 178N ProcessesDescription File Engine DriveFrom Miller to You Table of Contents − Maintenance & Troubleshooting 8-1. Routine Maintenance Directives StandardsDecrot6/05 Sound Level Information Decrotsound1/05Symbol Usage Arc Welding HazardsEngine Hazards Compressed Air Hazards Principal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interferenceSignification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un in- cendie ou une explosion DES Particules Volantes peuvent blesser les yeuxDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut affecter l’ouïe’AIR Comprimé peut provoquer des blessures ’EMPLOI Excessif peutLE Surchauffement peut endom- mager le moteur électrique LES Étincelles Volantes risquent de provoquer des blessuresLE Soudage À L’ARC risque de provoquer des interférences Pour les moteurs à essencePour les moteurs diesel Boulevard, Rexdale, Ontario, Canada M9W 1R3 téléphone− Definitions − 50 h StdStd Manufacturer’s Rating Label Symbols And Definitions − Specifications Weld, Power, And Engine SpecificationsDimensions, Weights, And Operating Angles Stick Mode MIG ModeTIG Mode Volt-Ampere CurvesCurve shows typical fuel use under weld or power loads Exceeding duty cycle can damage unit and void warrantyFuel Consumption Duty Cycle And OverheatingAC Generator Power Curve Ac power curve shows the gen- erator power in amperes− Installation Installing Welding GeneratorMounting Welding Generator Installing Exhaust Pipe Tools Needed 1/2Stop engine and let cool Activating The Dry Charge Battery If Applicable Connecting The BatteryDo not overfill battery cells Connect Negative − Cable LastCoolant Recovery Tank Engine Prestart ChecksFuel Do not use gasoline. Gasoline will damage engine OilConnecting To Weld Output Terminals Stick and TIG WeldingMIG and Fcaw Welding Stop engineSelecting Weld Cable Sizes 150 ft 200 ft 250 ft350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Stop engine beforeConnecting To Remote 14 Receptacle RC14 SocketFront Panel Controls See Section StopDescription Of Front Panel Controls See Section Process/Contactor Switch On CC/CV Models Process/Contactor Switch SettingsLift-ArcStart Procedure Lift-Arc Start Method TouchDo not Strike Like a Match Lift-Arc t TIGRemote Voltage/Amperage Control − Operating Auxiliary Equipment Volt Receptacles− Maintenance & Troubleshooting Routine MaintenanceMaintenance Label Servicing Air Cleaner By the warrantyTo clean air filter Do not clean housing with air hoseInspecting And Cleaning Spark Arrestor Muffler Stop engine and let cool. Reinstall cleanout plugServicing Engine Cooling System Adjusting Engine Speed On Standard Models MaximumServicing Fuel And Lubrication Systems Stop engine and let cool After servicing, start engineTo change oil and filter To replace primary canister fuel filterPress button to reset breaker Overload ProtectionChecking Generator Brushes Replace Damaged BrushesVoltmeter/Ammeter Help Displays Help 20 DisplayHelp 25 Display Troubleshooting Standard Generator PowerWelding Engine Check for obstructed throttle solenoid − Electrical Diagrams Circuit Diagram For Welding Generator221 499-B − RUN-IN Procedure WetstackingWelding Generator Run-In Procedure Using Load Bank Procedure at less thanStop engine Do not touch hot exhaust From flammables Do not PerformRun-In Procedure Using Resistance Grid Bank/gridFrom flammables Do not perform run-in− Generator Power Guidelines Selecting EquipmentGrounding Generator To Truck Or Trailer Frame Grounding When Supplying Building Systems How Much Power Does Equipment Require?Earth ground if supplying Amperes x Volts = WattsApproximate Power Requirements For Industrial Motors Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsPower Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 = Starting AmperageTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Current Load Watts Amperes− Parts List 103 − −5 104 − −3 96− −2 102 101 10071− −4 3031 5756Dia Part Description Quantity Mkgs Dia Part Description Quantity 213600 Panel, Front w/Components Panel, Front w/Components -1ItemFUEL/HM Control Panel Generator Generator -1ItemRectifier Assembly Wiring Harnesses Service Your distributor also givesSupport To locate a Distributor or Service Agency visit Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s