Manuals / Miller Electric / Power Tools / Welding System

Miller Electric Big Blue 602P Diagnosing Causes Of Engine Fault Shutdowns, welding generator

Models: Big Blue 402P

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9-8. Diagnosing Causes Of Engine Fault Shutdowns

9-8. 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

Position While Pressing Magnetic

Shutdown Switch.

Diagnostic Checks While Running

Start Engine (With No Load Applied).

Normal Condition:

Oil Pressure Light On;

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 Fuel Light Is On, Check Fuel Level.

If Engine Is Okay, See Factory Authorized Service Agent.

20s

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 Service Agent.

Ref. 202 705

OM-491 Page 42

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Image 46

Miller Electric Big Blue 602P Diagnosing Causes Of Engine Fault Shutdowns, Pre-Start Diagnostic Checks, welding generator

Contents

Processes Big BlueR 402P, 502P, 602POM-491 DescriptionFrom Miller to You TABLE OF CONTENTS SECTION 5 − INSTALLATIONWARRANTY TABLE OF CONTENTSOPTIONS AND ACCESSORIES SECTIONSECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1-1. Symbol Usage1-2. Arc Welding Hazards Means “Note” not safety relatedReturn To Table Of Contents 1-3. Engine HazardsBATTERY EXPLOSION can BLIND WELDING can cause fire or explosionSTEAM AND HOT COOLANT can burn 1-5. Additional Symbols For Installation, Operation, And Maintenance1-4. Compressed Air Hazards ENGINE EXHAUST GASES can kill1-8. EMF Information 1-7. Principal Safety Standards1-6. California Proposition 65 Warnings READ INSTRUCTIONS2-2. Dangers relatifs au soudage à l’arc 2-1. Signification des symbolesSECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION UN CHOC ÉLECTRIQUE peut tuerDES PARTICULES VOLANTES peuvent blesser les yeux 2-3. Dangers existant en relation avec le moteurLE SOUDAGE peut provoquer un in- cendie ou une explosion DES PIÈCES CHAUDES peuvent provoquer des brûlures gravesDES ORGANES MOBILES peuvent provoquer des blessures 2-4. Dangers liés à l’air compriméL’EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE LA CHALEUR DU MOTEUR peut pro- voquer un incendieLE SURCHAUFFEMENT peut endom- mager le moteur électrique 2-6. Principales normes de sécurité2-7. Information sur les champs électromagnétiques LES ÉTINCELLES VOLANTES ris- quent de provoquer des blessuresSECTION 3 − DEFINITIONS SECTION 4 − SPECIFICATIONS3-1. Symbols And Definitions Return To Table Of Contents4-1. Weld, Power, And Engine Specifications 4-2. Dimensions, Weights, And Operating Angles4-3. Volt-Ampere Curves For CC Models 300−MaxB. MIG Mode 4-4. Volt-Ampere Curves For CC/CV ModelsA. Stick Mode C. TIG Mode4-6. Duty Cycle And Overheating 4-5. Fuel Consumption1800 RPM IDLE A. 12 kVA/kW Single-Phase AC Output No Weld Load 4-7. AC Generator Power Curve4-8. Optional Three-Phase Generator Curves B. 20 kVA/kW Three-Phase AC Output No Weld LoadReturn To Table Of Contents SECTION 5 − INSTALLATION5-1. Installing Welding Generator MovementSupporting The Unit 5-2. Mounting Welding GeneratorUsing Mounting Brackets Inadequate supportReturn To Table Of Contents 5-3. Using Lifting Eye5-4. Installing Exhaust Pipe Y Stop engine and let coolReturn To Table Of Contents 5-5. Activating The Dry Charge Battery If ApplicableWhen electrolyte is low, add Y Read and follow all instrucReturn To Table Of Contents 5-6. Connecting The BatteryReinstall cover after connecting battery Y Connect Negative − Cable LastCoolant Recovery Tank 5-7. Engine Prestart ChecksCheck radiator coolant level when fluid is low in recovery tank Return To Table Of Contents5-8. Connecting To Weld Output Terminals 5-9. Selecting Weld Cable SizesREMOTE 5-11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models24 VOLTS AC OUTPUTReturn To Table Of Contents 6-1. Front Panel Controls For CC Models See SectionSECTION 6 − OPERATING WELDING GENERATOR − CC MODELS Y Stop engine and fix trouble if Battery Charging light goes on 6-2. Description Of Front Panel Controls For CC Models See SectionEngine Indicator Lights Y Do not switch under loadReturn To Table Of Contents 6-3. Remote Amperage Control On CC Models Optional6-4. Weld Control/Arc Condition Information Label Set weld controls as shown toReturn To Table Of Contents OM-491 PageReturn To Table Of Contents 7-1. Front Panel Controls For CC/CV Models See SectionSECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS Y Stop engine and fix trouble if Battery Charging light goes on 7-2. Description Of Front Panel Controls For CC/CV Models See SectionEngine Indicator Lights Y Do not switch under loadProcess/Contactor Switch 7-3. Process/Contactor Switch On CC/CV ModelsProcess/Contactor Switch Settings switch is in an Electrode HotExample Combination Remote Amperage Control Stick 7-4. Remote Voltage/Amperage Control On CC/CV Models OptionalExample Combination Remote Amperage Control TIG rized Service Agent SECTION 8 − OPERATING AUXILIARY EQUIPMENT8-1. 120 Volt And 240 Volt Receptacles powerSingle-Phase Generator Power 8-2. Connecting To Optional Three-Phase Generator CC/CV Models OnlySingle-Phase Power Connection Three-Phase Power ConnectionReturn To Table Of Contents 8-3. Optional Generator Power ReceptaclesGenerator power is not af- fected by weld output European ReceptacleEvery 8 h SECTION 9 − MAINTENANCE & TROUBLESHOOTING9-1. Routine Maintenance Every 50 hEvery 800 h Every 400 hEvery 500 h Every 1000 hReturn To Table Of Contents Maintenance LabelOM-491 Page The air cleaner primary element can 9-3. Servicing Air Cleanerby the warranty To clean air filterY Stop engine and let cool 9-4. Inspecting And Cleaning Optional Spark Arrestor MufflerY Stop engine and let cool 802 160-E / Ref. 202Weld/Power Speed Adjustment 9-5. Adjusting Engine SpeedModels With Automatic Idle Optional Idle Speed Adjustment Return To Table Of ContentsTo change oil and filter 9-6. Servicing Fuel And Lubrication SystemsY Stop engine and let cool To drain water from fuel systemmore serious problem exists 9-7. Overload ProtectionWhen a circuit breaker or fuse Service AgentDiagnostic Checks While Running 9-8. Diagnosing Causes Of Engine Fault ShutdownsPre-Start Diagnostic Checks Battery Charging, Fuel, And Temperature Lights OffReturn To Table Of Contents 9-9. TroubleshootingA. Welding − CC Models Trouble B. Welding − CC/CV ModelsRemedy Return To Table Of Contents C. Standard Generator PowerD. Optional Three-Phase Generator Power CC/CV Models Only E. EngineEngine starts, but stops when Magnetic Return To Table Of Contents OM-491 PageFigure 10-1. Circuit Diagram For CC Welding Generator SECTION 10 − ELECTRICAL DIAGRAMSReturn To Table Of Contents OM-491 Page Return To Table Of Contents215 304-A Return To Table Of Contents Figure 10-2. Circuit Diagram For CC/CV Welding GeneratorOM-491 Page OM-491 Page Return To Table Of Contents215 305-A SECTION 11 − RUN-IN PROCEDURE 11-1. WetstackingReturn To Table Of Contents 11-2. Run-In Procedure Using Load Bankprocedure at less than Y Stop engineStop engine 11-3. Run-In Procedure Using Resistance Gridprocedure at less than Y Do not touch hot exhaust12-2. Grounding Generator To Truck Or Trailer Frame SECTION 12 − GENERATOR POWER GUIDELINES12-1. Selecting Equipment has this symbolearth ground if supplying 12-3. Grounding When Supplying Building Systems12-4. How Much Power Does Equipment Require? Use ground device as stated in electrical codesReturn To Table Of Contents 12-5. Approximate Power Requirements For Industrial Motors12-6. Approximate Power Requirements For Farm/Home Equipment Industrial MotorsRating 12-7. Approximate Power Requirements For Contractor EquipmentContractor Starting WattsSingle-Phase Induction Motor Starting Requirements 12-8. Power Required To Start Motor12-9. How Much Power Can Generator Supply? Return To Table Of Contents12-10. Typical Connections To Supply Standby Power Work like a ProCord Lengths for 120 Volt Loads 12-11. Selecting Extension Cord Use Shortest Cord PossibleReturn To Table Of Contents CurrentSECTION 13 − PARTS LIST Figure 13-1. Main AssemblyBig Blue 502, 602 Only Return To Table Of Contents46 FIG Figure 13-1. Main Assembly Figure 13-1. Main Assembly Continued Figure 13-1. Main Assembly Continued CC CVFigure13-2. Control Box Assembly − CC Models Figure 13-1 Item Figure 13-2. Control Box Assembly − CC Models802 551-E Figure 13-3. Control Box Assembly − CC/CV Models Figure 13-2. Control Box Assembly − CC Models Continued802 360-D Figure 13-3. Control Box Assembly − CC/CV Models Figure 13-1 Item Figure 13-4. Panel, Front w/Components − CC Models Figure 13-1 Item Figure 13-4. Panel, Front w/Components − CC Models802 266-D Figure 13-4. Panel, Front w/Components − CC Models Continued OptionalFigure 13-5. Panel, Front w/Components − CC/CV Models 802 332-FFigure 13-5. Panel, Front w/Components − CC/CV Models Continued Figure 13-6. Generator Figure 13-5. Panel, Front w/Components − CC/CV Models Continued802 267-B Figure 13-6. Generator Figure 13-1 Item Hardware is common and Figure 13-7. Main Rectifier AssemblyFigure 13-7. Main Rectifier Assembly Figure 13-1 Item not available unless listedCall 1-800-4-A-MILLER for your local Miller distributor Warranty Questions?Service SupportPlease complete and retain with your personal records For ServiceOwner’s Record Always provide Model Name and Serial/Style Number