Miller Electric Big 40 CAT manual MS1

Page 83

Item

Dia.

 

Part

Description

Quantity

 

No.

 

Mkgs.

 

No.

 

 

 

 

 

Figure 13-4. Panel, Front w/Components − CC Models (Continued)

 

 

 

 

 

 

 

 

. . .

7

. . . . . S6 .

. . .

. 011 622 . .

SWITCH, tgl DPDT 15A 125VAC (included in control box harness,

 

. . .

. . .

. . . .

. . . . . .

. . .

. . . . . . . . . . .

see 13-2

. . . 1

. . .

8

. . . . . S5 .

. . .

. 011 609 . .

SWITCH, tgl SPDT 15A 125VAC on-none-on spd term chr (included in

. . .

. . .

. . . .

. . . . . .

. . .

. . . . . . . . . . .

control box harness, see 13-2)

. . . 1

. . . 9 . . . . RC13

. . .

032 897 . .

RECEPTACLE, twlk grd 2P3W 15A 125V

. . . 1

. . . 10

. . . .

. S1 .

. . .

176 606 . .

SWITCH, ignition 4posn w/o handle

. . . 1

. . . 11

. . . .

. S2 .

. . .

021 467 . .

SWITCH, tgl spst 3a 250v off−none−(on) spd term

. . . 1

. . . 12

. . . .

MS1

. . .

189 698 . .

SWITCH, magnetic manual reset low current

. . . 1

. . .

. . .

. . . .

. . . . . .

. . .

201 553 . .

CLIP, circuit breaker retaining

. . . 1

. . . 13

. . . .

CB1

. . .

201 083 . .

CIRCUIT BREAKER, man reset 2P 20 A, 250VAC

. . . 1

. . .

. . .

. . . .

. . . . . .

. . .

201 109 . .

HARNESS, generator power (consisting of)

. . . 1

. . . 14

. . . .

CB2

. . .

093 996 . . .

. CIRCUIT BREAKER, man reset 1P 20A 250VAC frict

. . . 3

. . . 15

. . .

GFCI1

. .

151 981 . . .

. RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI

. . . 1

. . . 16

. . . .

RC1 . . .

147 632 . . .

. RECEPTACLE, tw lk grd 2P3W 30A 250V L6-30R

. . . 1

. . . 17

. . . .

. . . . . .

. . .

190 861 . .

LABEL, warning electric shock and moving parts

. . . 1

. . . 18

. . . .

. . . . . .

. .

+201 106 . .

PANEL, gen pwr

. . . 1

. . . 18

. . . .

. . . . . .

. ♦+210 750 . .

PANEL, gen pwr ss (CE models only)

. . . 1

. . . 19

. . . .

. . . . . .

. . .

083 030 . .

STUD, brs .250−20 x 1.750 w/hex collar

. . . 1

. . . 20

. . . .

. . . . . .

. . .

601 836 . .

NUT, 250−20 .50hex .19h brs

. . . 3

. . . 21

. . . .

. . . . . .

. . ♦196 073 . .

LABEL, do not switch while welding

. . . 1

. . . 22

. . . .

. S12

. . ♦195 825 . .

SWITCH, polarity

. . . 1

. . . 23

. . . .

. . . . . .

. . .

201 125 . .

PANEL, mtg terminal pwr output

. . . 1

. . . 24

. . . .

. . . . . .

. . .

039 046 . .

TERMINAL, pwr output black

. . . 1

. . .

. . .

. . . .

. . . . . .

. . .

180 735 . .

WASHER, output stud

. . . 2

. . . 25

. . . .

. . . . . .

. . .

181 169 . .

SPACER, output stud

. . . 2

. . . 26

. . . .

. . . . . .

. . .

186 621 . .

BOOT, generic output stud

. . . 2

. . . 27

. . . .

. . . . . .

. . ♦059 773 . .

HANDLE, switch

. . . 1

. . . 28

. . . .

. . . . . .

. . ♦010 647 . .

PIN, spring cs .156 x 1.250

. . . 1

. . . 29

. . . .

. . . . . .

. . .

039 047 . .

TERMINAL, pwr output red

. . . 1

. . . 30

. . . .

. . . . . .

. . .

193 260 . .

COVER, receptacle 2.250 dia lexan

. . . 1

. . . 31

. . . .

. . . . . .

. . .

193 258 . .

COVER, receptacle GFCI

. . . 1

. . . 32

. . . .

. . . . . .

. . .

190 323 . .

BOOT, circuit breaker clear hex nut

. . . 1

. . . 33

. . . .

. . . . . .

. . .

193 143 . .

BOOT, magnetic shutdown switch

. . . 1

. . . 34

. . . .

. . . . . .

. . .

021 385 . .

BOOT, toggle switch lever

. . . 1

. . . 35

. . . .

. . . . . .

. . .

. 119 014 . .

LEVER, switch black

. . . 1

. . . 36

. . . .

. . . . . .

. . .

201 045 . .

COVER, receptacle twistlock

. . . 1

. . . 37

. . . .

. PL1

. . .

191 241 . .

LED, red 12V 4 ind lights panel mtg round

. . . 1

. . . 38

. . . .

FUEL

. . .

192 265 . .

GAUGE, fuel elec switch w/o sensor

. . . 1

. . . 39

. . . .

. HM .

. . .

. 118 058 . .

METER, hour 12-24VDC 2.25dia

. . . 1

. . . 40

. . . .

. . . . . .

. ♦193 228 . .

METER, Volt Dc 8− 18 Scale 2.250 In Black Face

. . . 1

. . . 41

. . . .

. . . . . .

. ♦193 229 . .

GAUGE, Coolant Temp 0− 300 Deg F Electric Switch

. . . 1

. . .

. . .

. . . .

. . . . . .

. ♦197 798 . .

SENDER, Coolant Temp 300 Deg F M16 X 1.5 (Caterpillar 3024) . . .

. . . 1

. . . 42

. . . .

. . . . . .

. ♦193 227 . .

GAUGE, Pressure Oil 0−100 Psi Electric Switch

. . . 1

. . .

. . .

. . . .

. . . . . .

. ♦193 230 . .

SENDER, Pressure Oil 0− 100 Psi

. . . 1

. . . 43

. . . .

. . . . . .

. ♦194 348 . .

AMMETER, W/Leads

. . . 1

. . .

. . .

. . . .

. . . . . .

. ♦030 084 . .

SHUNT, Meter 50mv 600 Amp Lt Wt

. . . 1

. . . 44

. . . .

. . . . . .

. ♦194 345 . .

VOLT METER, W/Leads

. . . 1

. . . 45

. . . .

. . . . . .

. . .

189 161 . .

HANDLE, switch range

. . . 1

. . . 46

. . . .

. . . . . .

. . .

010 647 . .

PIN, spring CS .156 x 1.250

. . . 1

. . . 47

. . . .

. . . . . .

. . .

019 602 . .

KNOB, pointer

. . . 1

♦. .Optional

. . . . . .

. . .

024 103 . .

BLANK, snap−in nyl .750 mtg hole black

. . . 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.

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.

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OM-4406 Page 77

Page 82 Page 84
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Page 82 Page 84
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 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 Dimensions, Weights, And Operating Angles − SpecificationsWeld, Power, And Engine Specifications 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 instrucConnect 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 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 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 Open, contact Factory Autho − Operating Auxiliary EquipmentVolt And 240 Volt Receptacles At least once a month, run enClose 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 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 filterTools Needed 3/8 Inspecting And Cleaning Optional Spark Arrestor MufflerStop engine and let cool. Reinstall cleanout plug 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 Engine Standard Generator PowerOptional Three-Phase Generator Power CC/CV Models 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 Welding Generator − RUN-IN ProcedureWetstacking 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 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 givesTransportation Department Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s
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