Miller Electric Big 40 CAT manual Dia Part Description Quantity Mkgs

Page 77

Item

Dia.

Part

Description

Quantity

No.

Mkgs.

No.

 

 

 

Figure 13-1. Main Assembly (Continued)

 

 

 

 

 

 

. . . 40 . . . .

. . . . . . . .

. 214 658

. . HOSE, radiator upper

. . . 1

. . . 41 . . . .

. . . . . . . .

. *197 944

. . BELT, fan

. . . 1

. . . 42 . . . .

. . . . . . . .

+215 006

. . GUARD, fan

. . . 1

. . . 43 . . . .

. . . . . . . .

. 214 884

. . RADIATOR, w/14# cap 4 row core 3 pass

. . . 1

. . . . . . . . . .

. . . . . . . .

. 187 120

. . . . CAP, radiator pressure 14lb

. . . 1

. . . . . . . . . .

. . . . . . . .

. 214 885

. . SHROUD, radiator

. . . 1

. . . 44 . . . .

. . . . . . . .

. 201 749

. . UPRIGHT, rear

. . . 1

. . . 45 . . . .

. . . . . . . .

. 190 206

. . CABLE, bat neg 42 in lg No. 2 awg w/clamp and .375rng

. . . 1

. . . 46 . . . .

. . . . . . . .

. 108 081

. . TERMINAL PROTECTOR, battery post mtg

. . . 2

. . . 47 . . . .

. . . . . . . .

. 190 207

. . CABLE, bat pos 45 in lg No. 1 awg w/clamp and .406rng

. . . 1

. . . 48 . . . .

. . . . . . . .

. 203 430

. . BRACKET, battery holddown

. . . 1

. . . 49 . . . .

. . . . . . . .

. 190 897

. . BATTERY, stor 12V 650crk 110rsv gp 24

. . . 1

. . . 50 . . . .

. . . . . . . .

. 201 006

. . BOLT, j stl .312−18 x 8.500 pld

. . . 2

. . . 51 . . . .

. . . . . . . .

+201 183

. . COVER, battery access

. . . 1

. . . 52 . . . .

. . . . . . . .

. 168 385

. . LABEL, warning battery explosion can blind

. . . 1

. . . 52 . . . .

. . . . . . . .

. 176 108

. . LABEL, warning battery explosion can blind (CE models only)

. . . 1

. . . 53 . . . .

. . . . . . . .

. 201 996

. . LABEL, warning do not operate with guard missing

. . . 2

. . . 54 . . . .

. . . . . . . .

. 197 496

. . HOSE, radiator lower

. . . 1

. . . . . . . . . .

. . . . . . . .

. 199 505

. . HOSE, oil drain assy 32 in (consisting of)

. . . 1

. . . 55 . . . .

. . . . . . . .

. 165 271

. . . . VALVE, oil drain 3/8-18NPTF

. . . 1

. . . 56 . . . .

. . . . . . . .

. 176 529

. . . . FITTING, hose brs barbed fem 1/2tbg x 3/8NPT

. . . 1

. . . 57 . . . .

. . . . . . . .

. . 113 854

. . . . HOSE, SAE .500 ID x .780 OD xc oil (order by ft)

. . . 3ft

. . . 58 . . . .

. . . . . . . .

. 197 448

. . FITTING, hose brs barbed elbow m 1/2 tbg x 3/8 npt

. . . 1

. . . 59 . . . .

. . . . . . . .

. . . . . . . . . .

. . WASHER, oil drain (available through engine manufacturer)

. . . 1

. . . 60 . . . .

. . . . . . . .

. 197 196

. . FITTING, adapter oil drain 12mm male x 3/8 npt female

. . . 1

. . . 61 . . . .

. . . . . . . .

. 190 992

. . KEEPER, latch engine access door

. . . 1

. . . 62 . . . .

. . . . . . . .

. 190 076

. . CHANNEL, stiffener engine access

. . . 1

. . . 63 . . . .

. . . . . . . .

. 199 592

. . LATCH, paddle series 20 (black)

. . . 1

. . . 64 . . . .

. . . . . . . .

. 202 165

. . LABEL, diesel engine maintenance Caterpillar 3024

. . . 1

. . . 65 . . . .

. . . . . . . .

+200 989

. . DOOR, engine access

. . . 1

. . . 66 . . . .

. . . . . . . .

. 189 975

. . HINGE, door access 180deg

. . . 2

. . . 67 . . . .

. . . . . . . .

. 190 190

. . TANK, coolant recovery

. . . 1

. . . 68 . . . .

. . . . . . . .

. 208 141

. . STOP, door

. . . 2

. . . 69 . . . .

. . . . . . . .

. 189 826

. . PANEL, rocker

. . . 1

. . . 70 . . . .

. . . . . . . .

. 191 626

. . BUMPER, door engine access

. . . 2

. . . 71 . . . .

. . . . . . . .

. 189 827

. . PANEL, gen RH

. . . 1

. . . 72 . . . .

. . . . . . . .

. 199 849

. . SCREW, 625-11 x 4.00hexhd pln gr 5 pld

. . . 4

. . . 73 . . . .

. . . . . . . .

. 071 731

. . WASHER, flat .656 ID x 2.250 OD x .187T stl pld

. . . 4

. . . 74 . . . .

. . . . . . . .

. 197 489

. . BRACKET, mtg RH

. . . 1

. . . . . . . . . .

. . . . . . . .

. 197 488

. . BRACKET, mtg LH

. . . 1

. . . 75 . . . .

. . . . . . . .

. 071 890

. . RETAINER, mount eng/gen

. . . 4

. . . 76 . . . .

. . . . . . . .

. 071 730

. . TUBING, stl .875 OD x 12ga wall x 2.500

. . . 4

. . . 77 . . . .

. . . . . . . .

. 083 476

. . MOUNT, eng/gen nprn .875 ID x 2.500 OD x 2.000

. . . 4

. . . 78 . . . .

. . . . . . . .

. 135 205

. . NUT, 625-11 .94hex .76H stl pld elastic stop nut

. . . 4

. . . 79 . . . .

. . . . . . . .

. *197 997

. . FILTER, fuel secondary

. . . 1

. . . 80 . . . .

. . . . . . . .

. . . . . . . . . .

. . PUMP, fuel

. . . 1

. . . 81 . . . .

. . . . . . . .

. 173 909

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

. . . 1

. . . 82 . . . .

. . . . . . . .

. 198 548

. . BRACKET, mtg fuel filter/pump

. . . 1

. . . 83 . . . .

. . . . . . . .

♦198 624

. . IDLE SOLENOID ASSEMBLY (consisting of)

. . . 1

. . . . . . . . . .

. . . . . . . .

. 049839

. . . . Bracket, Adjustment Solenoid

. . . 1

. . . . . . . . . .

. . . . . . . .

. 080517

. . . . Solenoid, 12vdc Pull Type Tubular

. . . 1

. . . . . . . . . .

. . . . . . . .

. 203716

. . . . Bracket, Mtg Solenoid

. . . 1

. . . . . . . . . .

. . . . . . . .

. 605277

. . . . Pin, Cotter .093 X .750 Zinc Pld

. . . 1

. . . . . . . . . .

. . . . . . . .

. 198370

. . . . Rod, Throttle

. . . 1

. . . . . . . . . .

. . . . . . . .

. 206209

. . . . Ball Joint, .250−28 Thd

. . . 1

. . . . . . . . . .

. . . . . . . .

. 198609

. . . . Arm, Throttle 104.22

. . . 1

. . . 84 . . . .

. . . . . . . .

. 013 367

. . LABEL, warning moving parts

. . . 2

. . . 84 . . . .

. . . . . . . .

. 176 106

. . LABEL, warning moving parts (CE models only)

. . . 2

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OM-4406 Page 71

Page 76 Page 78
Image 77
Page 76 Page 78
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
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