Manuals / Miller Electric / Power Tools / Welding System

Miller Electric Big Blue 500 X Engine Prestart Checks, Full Capacity Engine 9.5 qt 9.01L Diesel

Models: Big Blue 500 X Big Blue 400P

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Page 28

5-7. Engine Prestart Checks

Check radiator coolant level when fluid is low in recovery tank.

Full

Capacity:

404.22 Engine: 9.5 qt (9.01L)

Full

Diesel

Full

Coolant Recovery Tank

Hot Full

Cold Full

				803 603
	. Check all engine fluids daily.	Do not run out of fuel or air will enter fuel sys-	freeze to mixture if using the unit in tempera-
		tem and cause starting problems. See en-	°	°
	Engine must be cold and on a level surface.	gine manual to bleed air from fuel system.	tures below −34	F (−37 C).
	Unit is shipped with 20W break-in oil.	Oil	Keep radiator and air intake clean and free
	Automatic shutdown system stops engine if
			of dirt.
	oil pressure is too low or coolant tempera-	After fueling, check oil with unit on level sur-
	ture is too high.		Y Incorrect engine temperature can
		face. If oil is not up to full mark on dipstick,
	. This unit has a low oil pressure shut-		damage engine. Do not run engine
		add oil (see maintenance label).
	down switch. However, some condi-		without a properly working thermo-
		Coolant	stat and radiator cap.
	tions may cause engine damage before

	the engine shuts down. Check oil level	Check coolant level in radiator before start-	. To improve cold weather starting:
	often and do not use the oil pressure
		ing unit the first time. If necessary, add cool-
	shutdown system to monitor oil level.
		ant to radiator until coolant level is at bottom	Use Starting Aid switch (see Section
	Follow run-in procedure in engine manual.
		of filler neck.
	If unburned fuel and oil collect in exhaust	Check coolant level in recovery tank daily.	6-1or 7-1).
	pipe during run-in, see Section 11.		Keep battery in good condition. Store
	Fuel	If necessary, add coolant to recovery tank
		until coolant level is between Cold Full and	battery in warm area.
	Y Do not use gasoline. Gasoline will
		Hot Full levels. If recovery tank coolant level
	damage engine.		Use fuel formulated for cold weather
		was low, also check coolant level in radiator.
	The unit is shipped with enough fuel to pre-	Add coolant if level is below bottom of radia-	(diesel fuel can gel in cold weather).
	vent air from entering fuel system. Add fresh	tor filler neck.	Contact local fuel supplier for fuel in-
	diesel fuel before starting (see engine main-	Unit is shipped with an engine coolant mix-	formation.
	tenance label for fuel specifications). Leave
	filler neck empty to allow room for ex-	ture of water and ethylene glycol base anti-	Use correct grade oil for cold weather
	pansion.	freeze rated to −34° F (−37° C). Add anti-	(see Section 9-1).

OM-4421 Page 22

Image 28

Miller Electric Big Blue 500 X Engine Prestart Checks, Full Capacity Engine 9.5 qt 9.01L Diesel, Coolant Recovery Tank

Contents

OM-4421215 075N ProcessesDescription File Engine DriveFrom Miller to You Table of Contents − Maintenance & Troubleshooting Standards DirectivesDecrot9/06 Manufacturer European Contact Notified Body Decrotsound6/05Symbol 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 CC Models CC/CV Models CC Export Models Manufacturer’s Rating LabelsOM-4421 Symbols And Definitions Weld, Power, And Engine Specifications − SpecificationsDimensions, Weights, And Operating Angles Volt-Ampere Curves For CC Models Stick Mode MIG ModeTIG Mode Volt-Ampere Curves For CC/CV ModelsCurve 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 Optional Three-Phase Generator Curves12 kVA/kW Single-Phase AC Output No Weld Load 15 kVA/kW Three-Phase AC Output No Weld Load− Installation Installing Welding GeneratorLocation/Airflow Clearance Grounding1Using Lifting Eye Mounting Welding Generator Supporting The UnitMounting Surface To Bolt Unit In PlaceTools Needed 1/2 Installing Exhaust PipeStop engine and let cool Activating The Dry Charge Battery If Applicable Connecting The BatteryDo not overfill battery cells For 30 MinutesCoolant Recovery Tank Engine Prestart ChecksFull Capacity Engine 9.5 qt 9.01L Diesel Hot Full Cold FullConnecting 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 On CC/CV Models Socket− Operating Welding Generator − CC Models Front Panel Controls For CC Models See SectionTo Start Do not use ether. Using ether voids warranty Do not switch under loadEngine Starting Controls Engine Gauges And MetersWeld Control/Arc Condition Information Label Remote Amperage Control On CC Models OptionalExample Combination Remote Amperage Control Stick OM-4421 − Operating Welding Generator − CC/CV Models Front Panel Controls For CC/CV Models See SectionVoltage/Amperage Adjust Switch And Remote 14 Receptacle Use switch to select weld amperage range14 AC/DC Voltmeter Optional Process/Contactor Switch On CC/CV Models Process/Contactor Switch SettingsRemote Voltage/Amperage Control On CC/CV Models Optional Example Combination Remote Amperage Control TIG− Operating Auxiliary Equipment Volt And 240 Volt ReceptaclesRear Of Panel Single-Phase Generator Power Three-Phase Power ConnectionClose panel opening if no connections are made to generator 240 V 15 a AC South African Receptacle RC1 Optional Generator Power ReceptaclesSupplementary Protector CB2 Supplementary Protector CB3 − Maintenance & Troubleshooting Maintenance LabelRoutine Maintenance Checking Generator Brushes Stop engine and let coolServicing 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 Optional Spark Arrestor MufflerTools Needed 3/8 Adjusting Engine Speed Weld/Power Speed AdjustmentEngine Speed No Load Standard Model Idle Speed Ad- justmentServicing Fuel And Lubrication Systems Overload Protection Troubleshooting Welding − CC ModelsWelding − CC/CV Models Standard Generator Power Optional Three-Phase Generator Power CC/CV Models OnlyEngine OM-4421 − Electrical Diagrams Circuit Diagram For CC Welding Generator223 522-B Circuit Diagram For CC/CV Welding Generator 223 523-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 93 −6 105 104 100 101 102 103 Main Assembly 010 Figures 13-2 Figures 13-4 Control Box Assembly − CC Models 087 Control Box Assembly − CC/CV Models Control Box Assembly − CC/CV Models -1ItemTD1 214 Panel, Front w/Components − CC Models 3634Panel, Front w/Components − CC Models -1Item Panel, Front w/Components − CC/CV Models 40 39Panel, Front w/Components − CC/CV Models -1Item 170 Generator Generator -1Item602 SCREW, .312−18x .75 hexwhd.66d stl pld slffmg tap−rw 601 Main Rectifier Assembly Wiring Harnesses Harness, receptacle auxiliary power export models includes PLG4Page 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