Miller Electric Big 40 CAT Run-In Procedure Using Load Bank, Stop engine Do not touch hot exhaust

Page 65

11-2. Run-In Procedure Using Load Bank

 

 

 

Y Stop engine.

 

 

 

 

Y Do not touch hot exhaust

 

 

 

 

pipe, engine parts, or load

 

 

 

 

bank/grid.

 

 

4

 

 

Y Keep exhaust and pipe away

 

 

 

from flammables.

 

 

 

 

 

 

 

 

2

Y Do not

perform

run-in

 

 

 

procedure at less than 20

 

 

 

1

volts weld output and do not

 

 

 

exceed duty cycle or equip-

 

 

 

 

ment damage may occur.

 

 

 

1

Load Bank

 

 

 

 

 

Turn all load bank switches Off. If

 

 

 

needed, connect load bank to 115

 

 

 

volts ac wall receptacle or genera-

 

 

 

tor auxiliary power receptacle.

 

 

 

2

Welding Generator

 

 

 

 

Place A/V range switch in maxi-

 

 

 

mum position, A/V control in mini-

 

 

 

mum position, and Output Selector

 

 

 

switch (if present) in either DC

 

 

 

position.

 

 

 

 

 

3

Weld Cables

 

 

 

 

Connect load bank to generator

 

 

 

weld output terminals using proper

 

 

 

size weld cables with correct

 

 

 

connectors.

Observe

correct

 

 

 

polarity.

 

 

 

 

 

Start engine and run for several

 

3

 

minutes.

 

 

 

 

Set load bank switches and then

 

 

 

 

 

 

adjust generator A/V control so load

 

 

 

equals rated voltage and current of

 

 

 

generator (see nameplate, rating

 

 

 

label, or the specifications section

 

 

 

in this manual).

 

 

 

 

 

Check generator and load bank

 

 

 

meters after first five minutes then

 

 

 

every fifteen minutes to be sure

 

 

 

generator is loaded properly.

 

 

 

. Check oil level frequently dur-

 

 

 

 

ing run-in; add oil if needed.

 

 

 

After one hour (minimum) place A/V

 

 

 

control in minimum position, then

 

 

 

turn off load bank to remove load.

 

 

 

Run engine several minutes at no

 

 

 

load.

 

 

 

 

 

Y Stop engine and let cool.

 

 

 

4

Engine Exhaust Pipe

 

 

 

 

Repeat procedure if wetstacking is

 

 

 

present.

 

 

S-0683

Return To Table Of Contents

OM-4406 Page 59

Page 64 Page 66
Image 65
Page 64 Page 66
Contents Description OM-4406Processes From Miller to You Table of Contents − Maintenance & Troubleshooting Deccon111/02 DirectivesStandards 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 Dimensions, Weights, And Operating Angles − SpecificationsWeld, Power, And Engine Specifications 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 ChargerConnect Negative − Cable Last Connecting The BatteryReinstall cover after connecting battery 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 ModelsEngine Oil Pressure Light Use switch to select weld amperage rangeVoltage/Amperage Adjust Switch And Remote 14 Receptacle Process/Contactor Switch Settings Process/Contactor Switch On CC/CV ModelsExample Combination Remote Amperage Control TIG Remote Voltage/Amperage Control On CC/CV Models OptionalExample Combination Remote Amperage Control Stick Volt And 240 Volt Receptacles − Operating Auxiliary EquipmentAt least once a month, run en Open, contact Factory AuthoClose panel opening if no connections are made to generator Three-Phase Power ConnectionRear Of Panel Circuit Breaker CB2 Circuit Breaker CB3 Optional Generator Power Receptacles240 V 15 a AC South African Receptacle RC1 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 hoseTools Needed 3/8 Inspecting And Cleaning Optional Spark Arrestor MufflerStop engine and let cool. Reinstall cleanout plug 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 Engine Standard Generator PowerOptional Three-Phase Generator Power CC/CV Models 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 Welding Generator − RUN-IN ProcedureWetstacking 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 Possible113 108 100 CC only 119 110 109 111 -4 or − Parts List117 116 103 102 115 FIG 114 105 104 101 120 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
Top Page Image Contents