Miller Electric Big 40 CAT manual Dia Part Description Quantity

Page 76

Item

Dia.

 

Part

Description

 

Quantity

 

No.

 

Mkgs.

 

No.

 

 

 

 

 

 

 

Figure 13-1. Main Assembly

 

 

 

 

 

 

 

 

 

 

 

. . .

1

. . . .

. . . . . .

. . .

189 824 . .

PANEL, gen LH

. . . 1

. . .

2

. . . .

. . . . . .

. . .

191 623 . .

LABEL, warning all panels must be in place while running

. . . 2

. . .

2

. . . .

. . . . . .

. . .

176 106 . .

LABEL, warning moving parts (CE models only)

. . . 2

. . .

3

. . . .

. . . . . .

. .

+189 828 . .

PANEL, engine side

. . . 1

. . . 4 . . . . . Z1 .

. . CC202 151 . .

REACTOR, ac

. . . 1

. . . 4 . . . . . Z1 .

. . CV201 514 . .

REACTOR, ac

. . . 1

. . .

5

. . . . . 1T .

. . .

038 621 . .

BLOCK, term 30A 4 pole frict term str

. . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . .

. . .

. . . .

. . . . . .

. . .

038 620 . .

LINK, jumper term blk 30A

. . . 2

. . .

6

. . . .

. . . . . .

. . .

081 499 . .

BRACKET, mtg strip terminal

. . . 1

. . .

7

. . . .

. . . . . .

. . .

206 352 . .

BRACE, front to center upright

. . . 2

. . .

8

. . SR4, SR5 .

035 704 . .

RECTIFIER, integ bridge 40. amp 800v

. . . 2

. . . 9 . . . . CB4

. . .

045 061 . .

CIRCUIT BREAKER, auto reset 24vdc 7 amp

. . . 1

. . . 10

. . . .

. . . . . .

. . .

201 697 . .

PAN, reactor and rectifier

. . . 1

. . . 11

. . . .

. T1 .

. . .

201 613 . .

TRANSFORMER w/bracket

. . . 1

. . . 11

. . . .

. T1 .

. . ♦205 636 . .

TRANSFORMER w/bracket (environmental coating)

. . . 1

. . . 12

. . . .

. . . . . .

. . .

173 352 . .

EXTRUSION, rubber clamp/bulb (order by ft)

. . . 3ft

. . . 13

. . . .

. . . . . .

. . .

189 708 . .

FIREWALL, top

. . . 1

. . . 14

. . . .

. . . . . .

. . .

191 307 . .

COVER, plate

. . . 1

. . . 15

. . . .

. . . . . .

. . .

189 763 . .

BRACKET, mtg air cleaner

. . . 1

. . . 16

. . . .

. . . . . .

. . .

189 764 . .

AIR CLEANER, intake

. . . 1

. . .

. . .

. . . .

. . . . . .

. . .

*192 938 . .

FILTER, air element primary

. . . 1

. . .

. . .

. . . .

. . . . . .

. *♦192 939 . .

FILTER, air element safety

. . . 1

. . . 17

. . . .

. . . . . .

. . .

189 618 . .

HOSE, air cleaner

. . . 1

. . . 18

. . . .

. . . . . .

. . .

198 457 . .

TUBE, air intake

. . . 1

. . . 19

. . . .

. . . . . .

. . .

173 036 . .

HOSE, elbow air cleaner

. . . 1

. . .

. . .

. . . .

. . . . . .

. . .

010 863 . .

CLAMP, hose 1.125 − 3.000 clp dia

. . . 4

. . . 20

. . . .

. . . . . .

. . .

189 464 . .

SEAL, weather lift eye

. . . 1

. . .

. . .

. . . .

. . . . . .

. . .

173 909 . .

HOSE, sae .312 id x .560 od x 24.000

(order by ft)

. . . 2

. . . 21

. . . .

. . . . . .

. . .

201 658 . .

UPRIGHT, center assembly

. . . 1

. . . 22

. . . .

. . . . . .

. . .

191 819 . .

HOSE, sae .312 id x .560 od x 14.000

(order by ft)

. . . 2

. . .

. . .

. . . .

. . . . . .

. . .

198 584 . .

HOSE, sae .312 id x .560 od x 5.000 (order by ft)

. . . 1

. . . 23

. . . .

. . . . . .

. . .

095 636 . .

HOSE, sae .187 id x .41 od x 30.000

(order by ft)

. . . 1

. . . 24

. . . .

. . . . . .

. . .

192 750 . .

BASE, fuel filter w/adapter

. . . 1

. . . 25

. . . .

. . . . . .

. . .

*192 744 . .

FILTER, fuel spin-on

. . . 1

. . . 26

. . . .

. . . . . .

. . .

192 741 . .

BLOCK, spacer mtg filter base

. . . 1

. . . 27

. . . .

. . . . . .

. .

+201 934 . .

COVER, top

. . . 1

. . . 28

. . . .

. . . . . .

. . .

189 052 . .

GROMMET, plastic neck filler fuel

. . . 1

. . . 29

. . . .

. . . . . .

. . .

190 198 . . .

. CAP, tank screw-on 3.500 in w/vent

. . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1

. . . 30

. . . .

. . . . . .

. . .

192 041 . .

LABEL, use diesel fuel only

. . . 1

. . . 30

. . . .

. . . . . .

. . .

176 103 . .

LABEL, use diesel fuel only (CE models only)

. . . 1

. . . 31

. . . .

. . . . . .

. . .

108 487 . .

LABEL, warning falling equipment

. . . 2

. . . 31

. . . .

. . . . . .

. . .

176 104 . .

LABEL, warning falling equipment (CE models only)

. . . 2

. . . 32

. . . .

. . . . . .

. . .

176 230 . .

LABEL, warning hot exhaust

. . . 1

. . . 33

. . . .

. . . . . .

. . .

105 734 . .

PIPE, muffler extension elbow 1.750 od

. . . 1

. . . 34

. . . .

. . . . . .

. . .

201 851 . .

COVER, radiator access

. . . 1

. . . 35

. . . .

. . . . . .

. . .

191 354 . .

SUPPORT, cover

. . . 1

. . . 36

. . . .

. . . . . .

. . .

010 875 . .

CLAMP, muffler 2.000 dia

. . . 1

. . . 37

. . . .

. . . . . .

. . .

203 180 . .

MANIFOLD, exhaust muffler

. . . 1

. . .

. . .

. . . .

. . . . . .

. . .

203 179 . .

BRACKET, support muffler

. . . 2

. . . 38

. . . .

. . . . . .

. . .

213 185 . .

ENGINE, Caterpillar 3024C

. . . 1

. . .

. . .

. . . .

. . . . . .

. . .

*215 093 . . .

. SWITCH, coolant temperature

. . . 1

. . .

. . .

. . . .

. . . . . .

. . .

*215 094 . . .

. SWITCH, oil pressure

. . . 1

. . .

. . .

. . . .

. . . . . .

. . .

192 664 . .

HOSE, pvc .500 id x .750 od x 10.000 (order by ft)

. . . 1

. . .

. . .

. . . .

. . . . . .

. . .

198 694 . .

FTG, hose poly barbed 5/8id x 1/2id

. . . 1

. . .

. . .

. . . .

. . . . . .

. . .

023 562 . .

CLAMP, hose .312 − .875 clp dia

. . . 1

. . .

. . .

. . . .

. . . . . .

. . .

*202 166 . .

FILTER, oil

. . . 1

. . .

. . .

. . . .

. . . . . .

. . .

*192 744 . .

FILTER, fuel spin-on

. . . 1

. . .

. . .

. . . .

. . . . . .

. . .

*202 167 . .

FILTER, fuel secondary

. . . 1

. . . 39

. . . .

. . . . . .

. . .

202 017 . .

GUARD, belt

. . . 1

OM-4406 Page 70

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Contents Processes OM-4406Description From Miller to You Table of Contents − Maintenance & Troubleshooting Standards DirectivesDeccon111/02 Sound Level Information Deccon1sound11/02Symbol 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’EXPLOSION DE LA Batterie peut DES Organes Mobiles peuvent provoquer des blessuresLA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessuresPrincipales normes de sécurité Information sur les champs électromagnétiques− Definitions + − Starting InstructionsAre possible hazards as Can cause severe burns. DoFalling equipment can cause Serious injury and damageReturn To Table Of Contents Manufacturer’s Rating Labels For CE Products − 50 h StdStd CC Models CC/CV ModelsSymbols 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 ModelsFuel 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 LoadVolt-Ampere Curve For CC/CV Models In AC TIG Mode − Installation Installing Welding Generator See Sections 5-2AndLocation Grounding Airflow ClearanceUsing Lifting Eye Mounting Welding Generator Supporting The UnitMounting Surface To Bolt Unit In PlaceInstalling Exhaust Pipe Tools Needed 1/2Stop engine and let cool Point exhaust pipe in desired diActivating The Dry Charge Battery If Applicable Do not overfill battery cellsRead and follow all instruc ChargerReinstall cover after connecting battery Connecting The BatteryConnect Negative − Cable Last Coolant Recovery Tank Engine Prestart ChecksConnecting To Weld Output Terminals Selecting Weld Cable SizesConnecting To Remote 14 Receptacle RC14 On CC/CV Models Socket− Operating Welding Generator − CC Models Front Panel Controls For CC Models See SectionEngine Indicator Lights Do not switch under loadEngine Starting Controls To Start Do not use etherRemote Amperage Control On CC Models Optional Weld Control/Arc Condition Information LabelExample Set weld controls as shown toReturn To Table Of Contents − 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 rangeEngine Oil Pressure Light Process/Contactor Switch On CC/CV Models Process/Contactor Switch SettingsExample Combination Remote Amperage Control Stick Remote Voltage/Amperage Control On CC/CV Models OptionalExample Combination Remote Amperage Control TIG − Operating Auxiliary Equipment Volt And 240 Volt ReceptaclesAt 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 & Troubleshooting Maintenance LabelRoutine Maintenance Every 8 hEvery 50 h Every 100 hService Every 1000 hEvery 2000 h Caterpillar Customer AssistanceServicing 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 Idle Speed AdjustmentWeld/Power Speed Adjustment Engine Speed No LoadServicing Fuel And Lubrication Systems Overload Protection Diagnosing Causes Of Engine Fault Shutdowns Pre-Start Diagnostic ChecksDiagnostic Checks While Running Start Engine With No Load AppliedTroubleshooting Welding − CC ModelsWelding − CC/CV Models Optional Three-Phase Generator Power CC/CV Models Standard Generator PowerEngine Wiring harness and components Shutdown switch is released OutTemperature is too high see Sections 5-7and Air in fuel system. See engine manual− Electrical Diagrams Circuit Diagram For CC Welding Generator215 296-B Circuit Diagram For CC/CV Welding Generator 215 297-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-in− Generator Power Guidelines Has this symbolSelecting Equipment Grounding Generator To Truck Or Trailer FrameGrounding When Supplying Building Systems How Much Power Does Equipment Require?Earth ground if supplying Use ground device as stated Electrical codesApproximate 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 Amperes117 116 103 102 115 FIG 114 105 104 101 120 − Parts List113 108 100 CC only 119 110 109 111 -4 or 51 52 85 FigDia 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 Panel, Front w/Components − CC/CV Models -1ItemPC6 192 PLG6 Hardware is common Not available unless listed 34 36 27 26Main Rectifier Assembly -1Item Main Rectifier Assembly Page Your distributor also gives SupportMiller Electric Mfg. Co For assistance in filing or settling claims, contactYour distributor and/or equipment manufacturer’s Transportation Department
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