Miller Electric Big 40 CAT manual 095

Page 78

 

Item

Dia.

Part

Description

Quantity

 

No.

Mkgs.

No.

 

 

 

 

Figure 13-1. Main Assembly (Continued)

 

 

 

 

 

 

. . . 85 . . . .

. . . . . .

. Figure13-6 . .

GENERATOR

. . . 1

. . . 86 . . . .

. . . . . .

. . . 095 636 . .

HOSE, sae .312 id x .560 od x 14.000 (order by ft)

. . . 1

. . . 87 . . . .

. . . . . .

. . . 189 245 . .

TANK, fuel 23gal (consisting of)

. . . 1

. . . 88 . . . .

. . . . . .

. . . 124 253 . . .

. BUSHING, tank fuel

. . . 4

. .

. . . . . . . .

. . . . . .

. . . 084 173 . . .

. CLAMP, hose .460 − .545clp dia slfttng

. . . 2

. . . 89 . . . .

. . . . . .

. . . 189 912 . . .

. FITTING, stl barbed elbow w/.047 in orf zinc pld

. . . 1

. . . 90 . . . .

. . . . . .

. . . 189 909 . . .

. FITTING, stand pipe hose .250 x 9.260 lg 90deg zinc

. . . 1

. . . 91 . . . .

. . . . . .

. . . 201 025 . . .

. CAP, fuel fitting

. . . 1

. . . 92 . . . .

. . . . . .

. . . 189 913 . . .

. FITTING, stl barbed elbow zinc pld

. . . 1

. . . 93 . . . .

. . . . . .

. . . 190 142 . . .

. SENDER, fuel gauge 9.7500 deep tank

. . . 1

. . . 94 . . . .

. . . . . .

. . . 189 910 . . .

. FITTING, stand pipe hose .3125 x 9.260 lg 90deg zinc

. . . 1

. . . 95 . . . .

. . . . . .

. . . 189 908 . . .

. VALVE, drain fuel 180deg

. . . 1

. . . 96 . . . .

. . . . . .

. . . 181 572 . . .

. BUSHING, tank fuel

. . . 1

. . . 97 . . . .

. . . . . .

. . . 191 446 . .

EXTRUSION, rubber w/adhesive 1.000 x 1.000 D (order by ft)

. . . 6ft

. . . 98 . . . .

. . . . . .

. . . 190 179 . .

PANEL, mtg components

. . . 1

. . . 99 . . . .

. . . . . .

. . . 190 250 . .

LABEL, warning do not weld on base

. . . 2

. . . 99 . . . .

. . . . . .

. . . 200 864 . .

LABEL, do not weld on base ce

. . . 2

. . 100 . . .

. . . . . .

. . . 191 897 . .

BRACKET, mtg unit

. . . 4

. . 101 . . .

. . . . . .

. . . 192 362 . .

BRACKET, mtg nyl 1/2 conduit

. . . 1

. . 102 . . .

. . . . . .

. . . 196 220 . .

BRACKET, hold down fuel tank rear

. . . 1

. . 103 . . .

. . . . . .

. . +200 999 . .

BASE

. . . 1

. . 104 . . .

. . . . . .

. . . 191 512 . .

BRACKET, hold down fuel tank

. . . 1

. . 105 . . .

. . . . . .

. . . 189 731 . .

FIREWALL, lower

. . . 1

. . 106 . . . . . Figure 13-2, 13-3

CONTROL BOX ASSEMBLY

. . . 1

. . 107 . . . . R2 .

. . CC189 699 . .

RESISTOR, WW tap 375W 10 ohm w/mtg bkt

. . . 1

. . 108 . . . . R3 .

. . . 189 699 . .

RESISTOR, WW tap 375W 10 ohm w/mtg bkt

. . . 1

. . 109 . . .

. . . . . .

. . +201 750 . .

UPRIGHT, front

. . . 1

. .

110 . . .

. . . . . .

. . . 182 761 . .

LABEL, warning general precautionary

. . . 1

. .

110 . . .

. . . . . .

. . . 176 105 . .

LABEL, warning general precautionary (CE models only)

. . . 1

. .

111 . . .

. . . . . .

. . . . 13-4,13-5 . .

PANEL, front w/components

. . . 1

. .

112 . . .

. . . . . .

. . . . 202130 . .

XFMR, current sensing

. . . 1

. .

113 . . .

. . . . . .

. . . 176 109 . .

LABEL, caution using ether to aid engine

. . . 1

. .

114 . . .

. . . . . .

. . . 191 448 . .

TOP, cover front upright

. . . 1

. . 115 . . .

. . . . . .

Figure 13-7 . .

MAIN RECTIFIER ASSEMBLY

. . . 1

. . 116 . . .

. . . . . .

. . CV193 453 . .

BRACKET, mtg box fcr

. . . 1

. . 117 . . . PC1

. . CV189 143 . .

MODULE, field current regulator

. . . 1

. .

118 . . .

. . . . . .

. . +147 923 . .

LABEL, warning moving parts can cause serious injury

. . . 1

. .

119 . . .

. . . . . .

. . ♦138 074 . .

LABEL, warning electric shock do not use AC output

. . . 1

. . 120 . . .

. . . . . .

. . . 212 944 . .

LABEL, cc stick overlap weld ranges

. . . 1

. .

. . . . . . . .

. . . . . .

. . . 190 058 . .

NUT, .250-20 u-nut multi-thread

. . . 19

. .

. . . . . . . .

. . . . . .

. . . 049 525 . .

NUT, 312-18 u-nut multi-thread

. . . 32

. .

. . . . . . . .

. . . . . .

. . . 202 758 . .

KIT, label (includes safety and informational labels)

. . . 1

. .

. . . . . . . .

. . . . . .

. . . 201 061 . .

KIT, label (includes safety and informational labels) (CE models only)

. . 1

+When ordering a component originally displaying a precautionary label, the label should also be ordered. Order label individually or as part of Label Kit 202 758.

*Recommended Spare Parts. CC CC models only.

CV CC/CV models only. ♦Optional

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-4406 Page 72

Return To Table Of Contents

Page 77 Page 79
Image 78
Page 77 Page 79
Contents OM-4406 ProcessesDescription From Miller to You Table of Contents − Maintenance & Troubleshooting Directives StandardsDeccon111/02 Sound Level Information Deccon1sound11/02Symbol Usage Arc Welding HazardsEngine Hazards Compressed Air Hazards EMF Information Principal Safety StandardsCalifornia Proposition 65 Warnings Radiation can cause interferenceUN Choc Électrique peut tuer Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation LES Fumées ET LES GAZ peuvent être dangereuxDES Pièces Chaudes peuvent provoquer des brûlures graves LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux LE Bruit peut affecter l’ouïeLA Chaleur DU Moteur peut pro- voquer un incendie ’EXPLOSION DE LA Batterie peutDES Organes Mobiles peuvent provoquer des blessures ’AIR Comprimé peut provoquer des blessuresPrincipales normes de sécurité Information sur les champs électromagnétiques− Definitions + − Starting InstructionsFalling equipment can cause Are possible hazards asCan cause severe burns. Do Serious injury and damageReturn To Table Of Contents Std Manufacturer’s Rating Labels For CE Products− 50 h Std CC Models CC/CV ModelsSymbols And Definitions − Specifications Weld, Power, And Engine SpecificationsDimensions, Weights, And Operating Angles Volt-Ampere Curves For CC Models TIG Mode Stick ModeMIG Mode Volt-Ampere Curves For CC/CV ModelsFuel Consumption Duty Cycle And Overheating12 kVA/kW Single-Phase AC Output No Weld Load AC Generator Power CurveOptional Three-Phase Generator Curves 15 kVA/kW Three-Phase AC Output No Weld LoadVolt-Ampere Curve For CC/CV Models In AC TIG Mode Location Grounding − InstallationInstalling Welding Generator See Sections 5-2And Airflow ClearanceUsing Lifting Eye Mounting Surface Mounting Welding GeneratorSupporting The Unit To Bolt Unit In PlaceStop engine and let cool Installing Exhaust PipeTools Needed 1/2 Point exhaust pipe in desired diRead and follow all instruc Activating The Dry Charge Battery If ApplicableDo not overfill battery cells ChargerConnecting The Battery Reinstall cover after connecting 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 Starting Controls Engine Indicator LightsDo not switch under load To Start Do not use etherExample Remote Amperage Control On CC Models OptionalWeld Control/Arc Condition Information Label Set weld controls as shown toReturn To Table Of Contents − Operating Welding Generator − CC/CV Models Front Panel Controls For CC/CV Models See SectionUse switch to select weld amperage range Voltage/Amperage Adjust Switch And Remote 14 ReceptacleEngine Oil Pressure Light Process/Contactor Switch On CC/CV Models Process/Contactor Switch SettingsRemote Voltage/Amperage Control On CC/CV Models Optional Example Combination Remote Amperage Control StickExample Combination Remote Amperage Control TIG At least once a month, run en − Operating Auxiliary EquipmentVolt And 240 Volt Receptacles Open, contact Factory AuthoThree-Phase Power Connection Rear Of PanelClose panel opening if no connections are made to generator Optional Generator Power Receptacles 240 V 15 a AC South African Receptacle RC1Circuit Breaker CB2 Circuit Breaker CB3 − Maintenance & Troubleshooting Maintenance LabelEvery 50 h Routine MaintenanceEvery 8 h Every 100 hEvery 2000 h ServiceEvery 1000 h Caterpillar Customer AssistanceTo clean air filter Servicing Air CleanerBy the warranty Do not clean housing with air hoseInspecting And Cleaning Optional Spark Arrestor Muffler Stop engine and let cool. Reinstall cleanout plugTools Needed 3/8 Weld/Power Speed Adjustment Adjusting Engine SpeedIdle Speed Adjustment Engine Speed No LoadServicing Fuel And Lubrication Systems Overload Protection Diagnostic Checks While Running Diagnosing Causes Of Engine Fault ShutdownsPre-Start Diagnostic Checks Start Engine With No Load AppliedTroubleshooting Welding − CC ModelsWelding − CC/CV Models Standard Generator Power Optional Three-Phase Generator Power CC/CV ModelsEngine Temperature is too high see Sections 5-7and Wiring harness and componentsShutdown switch is released Out 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 − RUN-IN Procedure WetstackingWelding Generator Stop engine Do not touch hot exhaust Run-In Procedure Using Load BankProcedure at less than From flammables Do not PerformFrom flammables Run-In Procedure Using Resistance GridBank/grid Do not perform run-inSelecting Equipment − Generator Power GuidelinesHas this symbol Grounding Generator To Truck Or Trailer FrameEarth ground if supplying Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Use ground device as stated Electrical codesIndustrial Motors Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsSingle-Phase Induction Motor Starting Requirements Power Required To Start MotorHow Much Power Can Generator Supply? KVA/HP x HP x 1000 = Starting AmperageTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Current Load Watts Amperes− Parts List 117 116 103 102 115 FIG 114 105 104 101 120113 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 SupportYour distributor and/or equipment manufacturer’s Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Transportation Department
Top Page Image Contents