Miller Electric Big 40 CAT manual Control Box Assembly − CC Models

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12	Ref. 802 551-E

				Figure 13-2. Control Box Assembly − CC Models
Item			Dia.	Part	Description	Quantity
No.			Mkgs.	No.	Description	Quantity
				Figure 13-2. Control Box Assembly − CC Models (Figure 13-1Item 106)

. . .	1	. . . F1, F2 . . *085 874 . .			FUSE, mintr cer slo-blo 10A 250V	. . . 2
. . .	2	. . . .	. . . . . . . . .	046 432 . .	HOLDER, fuse mintr .250 x 1.250	. . . 2
. . . 3		. . . .	. . . . . . . . .	201 077 . .	CONTROL BOX, lh	. . . 1
. . . 4		. . . .	. . . . . . . . .	201 078 . .	CONTROL BOX, rh	. . . 1
. . .	5	. . . .	. . . . . . . . .	201 079 . .	COVER, control box	. . . 1
. . .	6	. . . .	C12 . . .	191 944 . .	CAPACITOR, polyp met film 10. uf 250 vac 10%	. . . 1
. . . .	. .	. . . .	. . . . . . . . .	204 812 . .	HARNESS, control box, weld control (consisting of)	. . . 1
. . .	7	. . . . CR7 . . .		188 636 . . .	. RELAY, OCV control	. . . 1
. . . 8 . . . D1/C1 . .				189 701 . . .	. DIODE/CAPACITOR BOARD	. . . 1
. . .	9	. . SR1, SR2 .		035 704 . . .	. RECTIFIER, integ 40A 800V	. . . 2
. . . 10		. . . .	CR5 . . .	090 104 . . .	. RELAY, encl 12VDC SPST 30A/15VDC	. . . 1
. . . .	. .	. . . .	. S5	011 609 . . .	. SWITCH, tgl spdt 15a 125vac on−none−on spd term chr
. . . .	. .	. . . .	. . . . . . . . . .	. . . . . . . . . . .	. (located on front panel, see 13-4)	. . . 1
. . . .	. .	. . . .	. S6	011 622 . . .	. SWITCH, tgl 3pdt 15a 125vac on−none−on spd term
. . . .	. .	. . . .	. . . . . . . . . .	. . . . . . . . . . .	. (located on front panel, see 13-4	. . . 1
. . . .	. .	. . . .	RC4 . . .	047 483 . . .	. CONNECTOR, rect univ 084 15P/S 3 row rcpt cable/panel lkg . . . .	. . . 1
. . . .	. .	. . . .	RC3 . . .	158 466 . . .	. CONNECTOR, rect univ 084 12P/S 3 row rcpt cable/panel lkg . . . .	. . . 1
. . . .	. . . . . . RC1 . . .			135 133 . . .	. CONNECTOR, rect univ 084 9P/S 3 row rcpt cable/panel lkg	. . . 1
. . . .	. .	. . . .	. . . . . . . . .	148 850 . . .	. SOCKET, relay 5 pin	. . . 1
. . . .	. .	. . . .	. . . . . . . . .	177 859 . . .	. CONN, body 5 terminal (to engine control switch S1)	. . . 1
. . . .	. .	. . . .	. . . . . . . . .	150 316 . . .	. CONN, rect univ 039 6p/s 3row plug cable lkg	. . . 6
. . . .	. .	. . . .	. . . . . . . . .	092 670 . . .	. CONN, rect univ 084 3p/s 1row plug cable lkg	. . . 1
. . . 11		CB11, 12, 13		139 266 . . .	. CIRCUIT BREAKER, man reset 1P 15A 250VAC frict	. . . 3

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OM-4406 Page 73

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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 Radiation can cause interference Principal Safety StandardsCalifornia Proposition 65 Warnings EMF InformationLES Fumées ET LES GAZ peuvent être dangereux Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation UN Choc Électrique peut tuerLE Bruit peut affecter l’ouïe LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux DES Pièces Chaudes peuvent provoquer des brûlures graves’AIR Comprimé peut provoquer des blessures ’EXPLOSION DE LA Batterie peutDES Organes Mobiles peuvent provoquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendieInformation sur les champs électromagnétiques Principales normes de sécurité− Definitions Starting Instructions + −Serious injury and damage Are possible hazards asCan cause severe burns. Do Falling equipment can causeReturn To Table Of Contents CC Models CC/CV Models Manufacturer’s Rating Labels For CE Products− 50 h Std StdSymbols And Definitions Weld, Power, And Engine Specifications − SpecificationsDimensions, Weights, And Operating Angles Volt-Ampere Curves For CC Models Volt-Ampere Curves For CC/CV Models Stick ModeMIG Mode TIG ModeDuty Cycle And Overheating Fuel Consumption15 kVA/kW Three-Phase AC Output No Weld Load AC Generator Power CurveOptional Three-Phase Generator Curves 12 kVA/kW Single-Phase AC Output No Weld LoadVolt-Ampere Curve For CC/CV Models In AC TIG Mode Airflow Clearance − InstallationInstalling Welding Generator See Sections 5-2And Location GroundingUsing Lifting Eye To Bolt Unit In Place Mounting Welding GeneratorSupporting The Unit Mounting SurfacePoint exhaust pipe in desired di Installing Exhaust PipeTools Needed 1/2 Stop engine and let coolCharger Activating The Dry Charge Battery If ApplicableDo not overfill battery cells Read and follow all instrucReinstall 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 ModelsTo Start Do not use ether Engine Indicator LightsDo not switch under load Engine Starting ControlsSet weld controls as shown to Remote Amperage Control On CC Models OptionalWeld Control/Arc Condition Information Label ExampleReturn 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 Open, contact Factory Autho − Operating Auxiliary EquipmentVolt And 240 Volt Receptacles At least once a month, run enRear 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 100 h Routine MaintenanceEvery 8 h Every 50 hCaterpillar Customer Assistance ServiceEvery 1000 h Every 2000 hDo not clean housing with air hose Servicing Air CleanerBy the warranty To clean air filterStop engine and let cool. Reinstall cleanout plug Inspecting And Cleaning Optional Spark Arrestor MufflerTools Needed 3/8 Engine Speed No Load Adjusting Engine SpeedIdle Speed Adjustment Weld/Power Speed AdjustmentServicing Fuel And Lubrication Systems Overload Protection Start Engine With No Load Applied Diagnosing Causes Of Engine Fault ShutdownsPre-Start Diagnostic Checks Diagnostic Checks While RunningWelding − CC Models TroubleshootingWelding − CC/CV Models Optional Three-Phase Generator Power CC/CV Models Standard Generator PowerEngine Air in fuel system. See engine manual Wiring harness and componentsShutdown switch is released Out Temperature is too high see Sections 5-7andCircuit Diagram For CC Welding Generator − Electrical Diagrams215 296-B Circuit Diagram For CC/CV Welding Generator 215 297-B Wetstacking − RUN-IN ProcedureWelding Generator From flammables Do not Perform Run-In Procedure Using Load BankProcedure at less than Stop engine Do not touch hot exhaustDo not perform run-in Run-In Procedure Using Resistance GridBank/grid From flammablesGrounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesHas this symbol Selecting EquipmentUse ground device as stated Electrical codes Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Earth ground if supplyingFarm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Industrial Motors Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentKVA/HP x HP x 1000 = Starting Amperage Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsTypical 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 givesTransportation Department Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s