Miller Electric Big 40 CAT Engine Starting Controls, To Start Do not use ether, Engine Gauges

Page 37

6-2. Description Of Front Panel Controls For CC Models (See Section 6-1)

Engine Starting Controls

1 Magnetic Shutdown Switch

Use switch during start-up to bypass engine shutdown system. System stops engine if oil pressure is too low or coolant temperature is too high.

2 Starting Aid Switch

Use switch to energize starting aid for cold weather starting (see starting instructions fol- lowing).

3 Engine Control Switch

Use switch to start engine, select engine speed (if unit has auto idle option), and stop engine.

In Run position, engine runs at weld/power speed. In Run/Idle position (optional), engine runs at idle speed at no load and weld speed with load applied.

To Start:

YDo not use ether.

.If engine does not start, let engine come

to a complete stop before attempting re- start.

Above 325 F (05 C): turn Engine Control switch to Start while pressing Shutdown switch. Release Engine Control switch when engine starts. Continue holding Shutdown switch until engine indicator lights go out.

Below 325 F (05 C): turn engine control switch to Run/Idle position. Push Starting Aid switch up for 60 seconds. While still holding Starting Aid switch, press Magnetic Shutdown switch and turn Engine Control switch to Start. Re- lease Engine Control switch and Starting Aid switch when engine starts. Continue holding Shutdown switch until engine indicator lights go out.

To Stop: turn Engine Control switch to Off position.

Engine Indicator Lights

4 Battery Charging Light

Light goes on if engine alternator is not charg- ing battery. Engine continues to run.

YStop engine and fix trouble if Battery Charging light goes on.

5 Engine Temperature Light

Light goes on and engine stops if engine tem- perature is above 221 ° F (105° C).

YStop engine and fix trouble if Engine Temperature light goes on.

6 Engine Oil Pressure Light

Light goes on and engine stops if oil pressure

is below 5 psi (34 kPa). Light goes on momen- tarily during start-up but goes out when en- gine reaches normal oil pressure.

YStop engine and fix trouble if Engine Oil Pressure light stays on after start- up.

7 Fuel Light

Light is not active on this model.

8Engine Hour Meter

Engine Gauges

.To read gauges and engine indicator

lights with engine off, turn Engine Control switch to Run/Idle and press Magnetic Shutdown switch (see Section 9-9).

9 Fuel Gauge

Use gauge to check fuel level.

To check fuel level when engine is not run- ning, turn Engine Control switch to Run/Idle position and press Magnetic Shutdown switch.

10 Battery Voltmeter (Optional)

Use gauge to check battery voltage and moni- tor the engine charging system. The meter should read about 14 volts dc when the en- gine is running, and about 12 volts dc when the engine is stopped.

11Engine Coolant Temperature Gauge (Optional)

Normal temperature is 180 - 203° F (82 - 95° C). When equipped with gauge option, engine stops if temperature exceeds 220° F (104° C).

12 Engine Oil Pressure Gauge (Optional)

Normal pressure is 30 − 60 psi (207 − 414 kPa). When equipped with gauge option, en- gine stops if pressure is below 10 psi (69 kPa).

Weld Controls

.Max OCV Control Circuit: This unit has

a max OCV control circuit that resets Am- perage Adjust control R1 to maximum when the arc breaks. When an arc is struck, weld output control returns to the R1 front panel or combination front panel/ remote control setting. The Amperage Adjust control adjusts amperage only when welding and does not adjust open- circuit voltage.

The max OCV circuit is disabled when the Stick/TIG Selection switch is in Scratch Start TIG position (see item 15).

13 Ampere Range Switch

YDo not switch under load.

Use switch to select weld amperage range. For most welding applications, use lowest amperage range possible to help prevent arc outages.

14 Amperage Adjust Control

Control adjusts amperage within range se- lected by Ampere Range switch. Weld output would be about 153 A DC with controls set as shown (50% of 100 to 205 A).

.The numbers around the control are for

reference only and do not represent an actual percentage value.

15 Stick/TIG Selection Switch

Use switch to disable the max OCV circuit and the arc drive (dig) circuit for scratch start TIG welding (see max OCV note under Weld Controls).

When switch is in the Stick position, the max OCV circuit resets Amperage Adjust Control R1 to maximum when the arc breaks.

Also in the Stick position, the arc drive (dig) circuit provides additional amperage during low voltage (short arc length conditions) to prevent “sticking” electrodes.

When switch is in Scratch Start TIG position, the max OCV and arc drive (dig) circuits are disabled and OCV changes when the control is adjusted.

16Amperage Adjust Switch And Remote Amperage Adjust Receptacle

Connect optional remote control to RC13 (See Section 5-10). Use switch to select front panel or remote amperage control. For re- mote control, place switch in Remote position and connect remote control to Remote Am- perage Adjust receptacle RC13 (see Sec- tions 5-10and 6-3).

17Polarity Switch (Optional)

Y Do not switch under load.

Use switch to change weld output. Select ei- ther DC Electrode Positive (DCEP) or DC Electrode Negative (DCEN).

Weld Meters

18 DC Voltmeter (Optional)

Voltmeter displays voltage at the weld output terminals, but not necessarily the welding arc due to resistance of cable and connections.

19 DC Ammeter (Optional)

Ammeter displays amperage output of the unit.

Return To Table Of Contents

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Contents Processes OM-4406Description From Miller to You Table of Contents − Maintenance & Troubleshooting Standards DirectivesDeccon111/02 Deccon1sound11/02 Sound Level InformationArc Welding Hazards Symbol UsageEngine Hazards Compressed Air Hazards California Proposition 65 Warnings Principal Safety StandardsEMF Information Radiation can cause interference− Consignes DE Sécurité − Lire Avant Utilisation Signification des symbolesUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereuxDES Particules Volantes peuvent blesser les yeux LE Soudage peut provoquer un in- cendie ou une explosionDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut affecter l’ouïeDES Organes Mobiles peuvent provoquer des blessures ’EXPLOSION DE LA Batterie peutLA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessuresInformation sur les champs électromagnétiques Principales normes de sécurité− Definitions Starting Instructions + −Can cause severe burns. Do Are possible hazards asFalling equipment can cause Serious injury and damageReturn To Table Of Contents − 50 h Std Manufacturer’s Rating Labels For CE ProductsStd CC Models CC/CV ModelsSymbols And Definitions Weld, Power, And Engine Specifications − SpecificationsDimensions, Weights, And Operating Angles Volt-Ampere Curves For CC Models MIG Mode Stick ModeTIG Mode Volt-Ampere Curves For CC/CV ModelsDuty Cycle And Overheating Fuel ConsumptionOptional Three-Phase Generator Curves AC Generator Power Curve12 kVA/kW Single-Phase AC Output No Weld Load 15 kVA/kW Three-Phase AC Output No Weld LoadVolt-Ampere Curve For CC/CV Models In AC TIG Mode Installing Welding Generator See Sections 5-2And − InstallationLocation Grounding Airflow ClearanceUsing Lifting Eye Supporting The Unit Mounting Welding GeneratorMounting Surface To Bolt Unit In PlaceTools Needed 1/2 Installing Exhaust PipeStop engine and let cool Point exhaust pipe in desired diDo not overfill battery cells Activating The Dry Charge Battery If ApplicableRead and follow all instruc ChargerReinstall cover after connecting battery Connecting The BatteryConnect Negative − Cable Last Engine Prestart Checks Coolant Recovery TankSelecting Weld Cable Sizes Connecting To Weld Output TerminalsSocket Connecting To Remote 14 Receptacle RC14 On CC/CV ModelsFront Panel Controls For CC Models See Section − Operating Welding Generator − CC ModelsDo not switch under load Engine Indicator LightsEngine Starting Controls To Start Do not use etherWeld Control/Arc Condition Information Label Remote Amperage Control On CC Models OptionalExample Set weld controls as shown toReturn To Table Of Contents Front Panel Controls For CC/CV Models See Section − Operating Welding Generator − CC/CV ModelsVoltage/Amperage Adjust Switch And Remote 14 Receptacle Use switch to select weld amperage rangeEngine Oil Pressure Light Process/Contactor Switch Settings Process/Contactor Switch On CC/CV ModelsExample Combination Remote Amperage Control Stick Remote Voltage/Amperage Control On CC/CV Models OptionalExample Combination Remote Amperage Control TIG Volt And 240 Volt Receptacles − Operating Auxiliary EquipmentAt least once a month, run en Open, contact Factory AuthoRear Of Panel 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 ReceptaclesCircuit Breaker CB2 Circuit Breaker CB3 Maintenance Label − Maintenance & TroubleshootingEvery 8 h Routine MaintenanceEvery 50 h Every 100 hEvery 1000 h ServiceEvery 2000 h Caterpillar Customer AssistanceBy the warranty Servicing Air CleanerTo 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 Idle Speed Adjustment Adjusting Engine SpeedWeld/Power Speed Adjustment Engine Speed No LoadServicing Fuel And Lubrication Systems Overload Protection Pre-Start Diagnostic Checks Diagnosing Causes Of Engine Fault ShutdownsDiagnostic Checks While Running Start Engine With No Load AppliedWelding − CC Models TroubleshootingWelding − CC/CV Models Optional Three-Phase Generator Power CC/CV Models Standard Generator PowerEngine Shutdown switch is released Out Wiring harness and componentsTemperature is too high see Sections 5-7and Air in fuel system. See engine manualCircuit Diagram For CC Welding Generator − Electrical Diagrams215 296-B Circuit Diagram For CC/CV Welding Generator 215 297-B Wetstacking − RUN-IN ProcedureWelding Generator Procedure at less than Run-In Procedure Using Load BankStop engine Do not touch hot exhaust From flammables Do not PerformBank/grid Run-In Procedure Using Resistance GridFrom flammables Do not perform run-inHas this symbol − Generator Power GuidelinesSelecting Equipment Grounding Generator To Truck Or Trailer FrameHow Much Power Does Equipment Require? Grounding When Supplying Building SystemsEarth ground if supplying Use ground device as stated Electrical codesApproximate Power Requirements For Farm/Home Equipment Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentHow Much Power Can Generator Supply? Power Required To Start MotorSingle-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 = Starting AmperageTypical Connections To Supply Standby Power Current Load Watts Amperes Selecting Extension Cord Use Shortest Cord Possible117 116 103 102 115 FIG 114 105 104 101 120 − Parts List113 108 100 CC only 119 110 109 111 -4 or 85 Fig 51 52Dia Part Description Quantity Dia Part Description Quantity Mkgs 095 Control Box Assembly − CC Models Control Box Assembly − CC/CV Models Control Box Assembly − CC/CV Models -1Item Panel, Front w/Components − CC Models MS1 Panel, Front w/Components − CC/CV Models -1Item Panel, Front w/Components − CC/CV ModelsPC6 192 PLG6 34 36 27 26 Hardware is common Not available unless listedMain Rectifier Assembly -1Item Main Rectifier Assembly Page Support Your distributor also givesFor assistance in filing or settling claims, contact Miller Electric Mfg. CoYour distributor and/or equipment manufacturer’s Transportation Department
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