Miller Electric OM-4409 manual Battery Charge Cable Connections, Stop engine

Page 44

8-3. Battery Charge Cable Connections

4

1

! Stop engine.

! Do not charge or jump start a battery which has loose terminals or one showing damage such as a cracked case or cover.

! Have only qualified persons do bat- tery charging work.

! Keep cables away from moving parts.

! Do not use damaged cables.

! Be sure charger output voltage matches battery voltage.

+

3

2

−

! Read BCI Battery Service Manual before charging or jump starting.

.Before connecting to battery, place

Output Selector switch in position matching voltage of battery being charged.

1Battery

2Battery Charging Cables

For battery charging, use less than 20 feet (6.1 m) of AWG #1 or larger cable. For jump starting, use less than 20 feet (6.1 m) of AWG 2/0 or larger cable.

3 Terminal Lug

5

803 231-A / 210 156 / Ref. S-0714 / Ref. S-0756

Use lugs of proper amperage capacity and hole size for connecting to charge output terminals.

Install suitable connectors on remaining ends of battery cables.

4Battery Charge Positive (+) Output Terminal

5Battery Charge Negative (−) Output Terminal

.Connect charging cables to battery

charge output terminals before con- necting to battery terminals.

Connect Battery Charge Positive (+) cable to battery positive (+) terminal, and battery Charge Negative (−) cable to battery nega- tive (−) terminal.

OM-4409 Page 40

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Contents OM-4409206 ProcessesDescription File Engine DriveFrom Miller to You Table of Contents − Operating Optional Battery Charger − TroubleshootingTroubleshooting Tables − Parts ListSymbol Usage Arc Welding HazardsElectric Shock can kill HOT Parts can cause severe burnsFumes and Gases can be hazardous Buildup of GAS can injure or killARC Rays can burn eyes and skin Welding can cause fire or explosionEngine Hazards Compressed Air HazardsWelding Wire can cause injury HOT Parts can cause burns and injuryFire or Explosion hazard Falling Unit can cause injuryPrincipal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interferenceSignification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer Indique des instructions spécifiquesDES Pièces Chaudes peuvent provoquer des brûlures graves LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un in cendie ou une explosion LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peu DES Organes Mobiles peuvent pro voquer des blessuresRisque D’INCENDIE OU D’EXPLO- Sion LA Chaleur DU Moteur peut pro- voquer un incendie’AIR Comprimé peut provoquer des blessures LE Surchauffement peut endom- mager le moteur électrique DES Organes Mobiles peuvent provoquer des blessuresLES Fils DE Soudage peuvent provoquer des blessures ’EMPLOI Excessif peutProposition californienne 65 Avertissements Principales normes de sécuritéInformation EMF En ce qui concerne les implants médicauxSymbols And Definitions − Definitions− Specifications Weld, Power, And Engine SpecificationsAir Compressor Specifications Sound Level TableLifting Eye Weight Rating Dimensions, Weights, And Operating AnglesWeight DC Stick Mode AC Stick Mode OptionalMIG Mode Stick And MIG Volt-Ampere CurvesTIG Volt-Ampere Curves DC TIG ModeAC TIG Mode Optional Fuel Consumption Duty Cycle And Overheating100% Duty Cycle At 500 Amperes 40% Duty Cycle At 600 AmperesGenerator AC Power Curve 20 kVA/kW Three-Phase AC Output No Weld Load Optional 3-Phase Generator Power Curves12 kVA/kW Single-Phase AC Output No Weld Load Optional Battery Charging Output Curve Air Compressor Output CurveManufacturing Rating Label − Installation Installing Welding GeneratorLocation/Airflow Clearance Grounding1Mounting Welding Generator Supporting The UnitMounting Surface To Bolt Unit In PlaceInstalling Optional Spark Arrestor Muffler Mount the muffler with the clean- out plug to the outsideStop engine and let cool Be sure to tighten rain cap mounting screwActivating The Dry Charge Battery If Applicable Connecting The BatteryDo not overfill battery cells Reinstall cover after connecting batteryStop engine Using The Optional Battery Disconnect SwitchSwitch may be locked using a customer-supplied padlock Engine/Compressor Prestart Checks MIG And Fcaw Welding Connecting To Weld Output TerminalsStick And TIG Welding 150 ft 200 ft 250 ft Connecting to weld Output terminalsSelecting Weld Cable Sizes Connecting To Remote 14 Receptacle RC14 SocketConnecting To The Air Compressor Open Position Closed Position− Operating the Welding Generator Controls See SectionDescription Of Controls See Section Process/Contactor Switch Process/Contactor Switch SettingsExample Combination Remote Amperage Control TIG Using Remote Voltage/Amperage ControlExample Combination Remote Amperage Control Stick − Operating Auxiliary Equipment Volt And 240 Volt ReceptaclesAt least once a month, run en Is working properly Connecting To Optional AC Power Plant Supplementary Protector CB2 Supplementary Protector CB3 Optional Generator Power Receptacles240 V 15 a AC South African Receptacle RC1 − Operating Optional Battery Charger Battery Charge ControlsDetermining Battery Charging Current Output Selector SwitchBattery Charge Cable Connections Battery Charging Procedure To control battery charging output using aJump Starting Procedure Charge battery for 10 minutes before jump starting batteryConnect Remote Or Control Device Momentary-On Switch Cables− ENGINE/GENERATOR Maintenance Engine Maintenance LabelRoutine Engine/Generator Maintenance Material Thickness Reference Chart Checking Generator BrushesServicing Engine Air Cleaner Air cleaner primary element canTo clean air filter Optional Keep nozzle 2 in 51 mm from elementInspecting/Cleaning Optional Spark Arrestor Muffler Reinstall cleanout plug Tools NeededAdjusting Engine Speed Do not set engine speed higher than specifiedServicing Engine Fuel And Lubrication Systems Wipe up spilled fuelTo change oil and filter To drain water from fuel systemEngine/Generator Overload Protection − AIR Compressor Maintenance Air Compressor Maintenance LabelRoutine Air Compressor Maintenance Servicing Compressor Air Cleaner Compressor Air CleanerRemove engine air cleaner cover Reinstall primary element and cover dust ejector downCompressor Overload Protection See -8for engine/genera- tor overload protectionServicing Air Compressor To change compressor oil and filterEngine oil drain and compressor oil To replace air/oil separatorAdjusting Compressor Air Pressure Welding − TroubleshootingTroubleshooting Tables Standard Generator Power Optional AC Power PlantEngine Optional Battery Charging Air Compressor− AIR Compressor Diagram Circuit Diagram For Air Compressor− Circuit Diagram Circuit Diagram For Welding Generator221 915−C Welding Generator − RUN-IN ProcedureWetstacking Run-In Procedure Using Load Bank From flammablesOutput and do not exceed duty Cycle or equipment damage mayRun-In Procedure Using Resistance Grid − AIR Compressor Tables Flow Of Free Air CFM Through Orifices Of Various DiametersSec 15 sec 21 sec Grounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesSelecting Equipment Grounding When Supplying Building Systems How Much Power Does Equipment Require?Use ground device as stated in electrical codes 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 / Volts = Starting AmperageTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Amperage Range Gas Type Polarity Preparing Tungsten For DC Electrode Negative Dcen WeldingPreparing Tungsten For AC Welding − Guidelines for TIG Welding Gtaw Positioning The TorchTorch Movement During Welding Tungsten Without Filler RodWelding direction Form pool Tilt torch Tungsten With Filler RodPositioning Torch Tungsten For Various Weld Joints Butt Weld And Stringer Bead Joint Lap Joint Corner Joint− Parts List Hardware is common and not available unless listed133 148 147 126121 109 120 122 108 102 103 105 106 107 7273 Dia Part Description Quantity Mkgs 224265 199505 CT1 21 22 C1/D1CB11,CB12,CB13 Hardware is common Not available unless listed 2724 40 39CB2 Fuel Generator Generator -1Item172555 Main Rectifier Assembly Air Compressor Assembly 10 9 1516 8281 7371Air Compressor Assembly -1Item Clutch Support ServiceYour distributor also gives 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