Miller Electric Big Blue 400 KX manual Engine

Page 46

Trouble

 

Remedy

 

 

 

Check fuse F1, and replace if open (see Section 8-8). Have Factory Authorized Service Agent check vol-

 

tage regulator module PC3.

 

 

 

Reset circuit breaker CB3 (see Section 8-8).

 

 

 

Check Voltmeter/Ammeter help displays (see Section 8-10).

 

 

 

Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.

 

 

High output at generator power ac re-

Have Factory Authorized Service Agent check voltage regulator module PC3.

ceptacles.

 

 

 

 

Low output at generator power ac recep-

Check engine speed, and adjust if necessary.

tacles.

 

 

 

 

 

Check fuse F1, and replace if open (see Section 8-8). If F1 is open, have Factory Authorized Service

 

Agent check

the rotor.

 

 

 

C. Engine

 

Trouble

Remedy

 

 

Engine will not crank.

Check battery, and replace if necessary.

 

 

 

Check battery connections and tighten if necessary.

 

 

 

Circuit breaker CB1 may be open. CB1 automatically resets when fault is corrected (see Section 8-8).

 

Have Factory Authorized Service Agent check engine wiring harness and components.

 

 

 

Reset circuit breaker CB2 (see Section 8-8).

 

 

 

Check engine wiring harness plug connections.

 

 

 

Have Factory Authorized Service Agent check Engine Control switch S1, and control relay CR2.

 

 

Engine cranks but does not start.

Check fuel level.

 

 

 

Check battery and replace if necessary. Check engine charging system according to engine manual.

 

 

 

Have Factory Authorized Service Agent check control relay CR1, fuel solenoid FS1, and the fuel

 

pump.

 

 

 

Air in fuel system. See engine manual.

 

 

Engine hard to start in cold weather.

Use Preheat switch S4 (see Section 6-2).

 

 

 

Keep battery in good condition. Store battery in warm area off cold surface.

 

 

 

Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier for

 

fuel information.

 

 

 

Use correct grade oil for cold weather (see Section 8-2).

 

 

 

Have Factory Authorized Service Agent check Preheat switch S4, control relay CR3, and the glow

 

plug.

 

 

Engine suddenly stops.

Check oil and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolant

 

temperature is too high (see Section 5-6).

 

 

 

Reset circuit breaker CB1 and/or CB2 (see Section 8-8). Have Factory Authorized Service Agent

 

check engine alternator, engine harness, fuel solenoid FS1, and the fuel pump.

 

 

 

Have Factory Authorized Service Agent check Engine Control switch S1, control relay CR1, inte-

 

grated rectifier SR2, fuel solenoid FS1, and the fuel pump.

 

 

 

See engine manual.

 

 

Engine slowly stopped and cannot be

Check fuel level.

restarted.

 

 

 

 

Check engine air and fuel filters (see Sections 8-3and 8-7).

 

 

 

See engine manual.

 

 

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Contents Description OM-4423 215 178NProcesses 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 EMF Information Principal Safety StandardsCalifornia Proposition 65 Warnings Radiation can cause interferenceUN Choc Électrique peut tuer Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation LES Fumées ET LES GAZ peuvent être dangereuxDES Pièces Chaudes peuvent provoquer des brûlures graves LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux LE Bruit peut affecter l’ouïeLE Surchauffement peut endom- mager le moteur électrique ’AIR Comprimé peut provoquer des blessures’EMPLOI Excessif peut LES Étincelles Volantes risquent de provoquer des blessuresPour les moteurs diesel LE Soudage À L’ARC risque de provoquer des interférencesPour les moteurs à essence 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 TIG Mode Stick ModeMIG Mode Volt-Ampere CurvesFuel Consumption Curve shows typical fuel use under weld or power loadsExceeding duty cycle can damage unit and void warranty 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 Do not overfill battery cells Activating The Dry Charge Battery If ApplicableConnecting The Battery Connect Negative − Cable LastFuel Do not use gasoline. Gasoline will damage engine Coolant Recovery TankEngine Prestart Checks OilMIG and Fcaw Welding Connecting To Weld Output TerminalsStick and TIG Welding Stop engine350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Selecting Weld Cable Sizes150 ft 200 ft 250 ft 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 SettingsDo not Strike Like a Match Lift-ArcStart ProcedureLift-Arc Start Method Touch Lift-Arc t TIGRemote Voltage/Amperage Control − Operating Auxiliary Equipment Volt Receptacles− Maintenance & Troubleshooting Routine MaintenanceMaintenance Label To clean air filter Servicing Air CleanerBy the warranty 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 MaximumTo change oil and filter Servicing Fuel And Lubrication SystemsStop engine and let cool After servicing, start engine 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 Stop engine Do not touch hot exhaust Run-In Procedure Using Load BankProcedure at less than From flammables Do not PerformFrom flammables Run-In Procedure Using Resistance GridBank/grid Do not perform run-inSelecting Equipment − Generator 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 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 For assistance in filing or settling claims, contact To locate a Distributor or Service Agency visitMiller Electric Mfg. Co Your distributor and/or equipment manufacturer’s