Miller Electric Big Blue 400 KX manual Maintenance & Troubleshooting 8-1. Routine Maintenance

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TABLE OF CONTENTS

SECTION 8 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 8-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

8-2. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

8-3. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

8-4. Inspecting And Cleaning Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

8-5. Servicing Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

8-6. Adjusting Engine Speed On Standard Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

8-7. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

8-8. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

8-9. Checking Generator Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 8-10. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 8-11. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

SECTION 9 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 SECTION 10 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

10-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

10-2.Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

10-3.Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

SECTION 11 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 SECTION 12 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

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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 Standards DirectivesDecrot6/05 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− 50 h Std − DefinitionsStd Manufacturer’s Rating Label Symbols And Definitions Weld, Power, And Engine Specifications − 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 Tools Needed 1/2 Installing Exhaust PipeStop 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 hoseStop engine and let cool. Reinstall cleanout plug Inspecting And Cleaning Spark Arrestor MufflerServicing 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 BrushesHelp 20 Display Voltmeter/Ammeter Help DisplaysHelp 25 Display Standard Generator Power TroubleshootingWelding Engine Check for obstructed throttle solenoid − Electrical Diagrams Circuit Diagram For Welding Generator221 499-B Wetstacking − RUN-IN ProcedureWelding 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-inSelecting Equipment − Generator Power GuidelinesGrounding 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 Your distributor also gives ServiceSupport 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
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