Miller Electric Big 40 CAT manual PC6 192

Page 85

Item

Dia.

 

Part

Description

Quantity

 

No.

 

Mkgs.

 

No.

 

 

 

 

 

Figure 13-5. Panel, Front w/Components − CC/CV Models (Continued)

 

 

 

 

 

 

 

 

. . .

5

. . . . . R1 .

. . .

. 193 118 . .

POT, cp flat 1t 2w 1k ohm linear

. . . 1

. . .

6

. . . . . S6 .

. . .

193 234 . .

SWITCH, rotary 6 position gold contacts (included in control box harness,

. . .

. . .

. .

. . . . . . . .

. . .

. . . . . . . . . . .

see 13-3)

. . . 1

. . .

7

. . . . . S5 .

. . .

. 011 609 . .

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

. . .

. . .

. .

. . . . . . . .

. . .

. . . . . . . . . . .

control box harness, see 13-3)

. . . 1

. . .

8

. .

. . . . . . . .

. . .

202 209 . .

SPACER, nylon

. . . 2

. . .

9

. . . . PC6

. . .

192 995 . .

CIRCUIT CARD ASSY, connector/receptacle

. . . 1

. . . 10

. .

. . CB5

. . .

139 266 . .

CIRCUIT BREAKER, man reset 1p 15a 250vac frict

. . . 1

. . . 11

. .

. . . S1 .

. . .

176 606 . .

SWITCH, ignition 4posn w/o handle

. . . 1

. . . 12

. .

. . . S2 .

. . .

021 467 . .

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

. . . 1

. . . 13

. .

. . MS1

. . .

189 698 . .

SWITCH, magnetic manual reset low current

. . . 1

. . . 14

. .

. . CB1

. . .

201 083 . .

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

. . . 1

. . .

. . .

. .

. . . . . . . .

. . .

201 553 . .

CLIP, circuit breaker retaining

. . . 1

. . .

. . .

. .

. . . . . . . .

. . .

201 109 . .

HARNESS, generator power (consisting of)

. . . 1

. . . 15

. .

. . CB2

. . .

093 996 . . .

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

. . . 1

. . . 16

. .

. GFCI1

. .

151 981 . . .

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

. . . 1

. . . 17

. .

. . RC1 . . .

147 632 . . .

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

. . . 1

. . . 18

. .

. . RC5 . . ♦182 954 . .

RCPT, str 3P4W 50A 125/250V

. . . 1

. . . 19

. .

. . . . . . . .

. . ♦025 248 . .

STAND-OFF, insul .250-20 x 1.2

. . . 1

. . . 20

. .

. . . . . . . .

. . ♦604 102 . .

CONNECTOR, clamp cable 1.000

. . . 1

. . . 21

. .

. . . . . . . .

. . ♦197 527 . .

GUARD, circuit breaker

. . . 1

. . . 22

. .

. . . . . . . .

. . ♦197 363 . .

TERMINAL, ring tng screw clamp

. . . 3

. . . 23

. .

. . CB7

. . ♦196 780 . .

CIRCUIT BREAKER, man reset 3p

. . . 1

. . . 24

. .

. . . . . . . .

. .

+201 106 . .

PANEL, gen power

. . . 1

. . . 24

. .

. . . . . . . .

. +♦201 107 . .

PANEL, gen power (full kVA option)

. . . 1

. . . 25

. .

. . . . . . . .

. . ♦196 781 . .

BOOT, circuit breaker 3 pole

. . . 1

. . . 26

. .

. . . . . . . .

. . ♦197 508 . .

PLUG, protective

. . . 1

. . . 27

. .

. . . . . . . .

. . ♦077 440 . .

BUSHING, conduit 1 in

. . . 1

. . . 28

. .

. . . . . . . .

. . .

601 836 . .

NUT, 250−20 .50hex .19h brs

. . . 3

. . . 39

. .

. . . . . . . .

. . ♦197 291 . .

COVER, receptacle w/gasket

. . . 1

. . . 30

. .

. . . . . . . .

. . .

083 030 . .

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

. . . 1

. . .

. . .

. .

. . CT2

. . ♦197 433 . .

TRANSFORMER, current sensing

. . . 1

. . . 31

. .

. . . . . . . .

. . .

190 861 . .

LABEL, warning electric shock and moving parts

. . . 1

. . . 31

. .

. . . . . . . .

. . ♦197 399 . .

LABEL, warning 3 ph generator power

. . . 1

. . . 32

. .

. . . . . . . .

. . .

193 260 . .

COVER, receptacle 2.250 dia lexan

. . . 1

. . . 33

. .

. . . . . . . .

. . .

193 258 . .

COVER, receptacle GFCI

. . . 1

. . . 34

. .

. . . . . . . .

. . .

190 323 . .

BOOT, circuit breaker clear hex nut

. . . 1

. . . 35

. .

. . . S12

. . ♦195 825 . .

SWITCH, polarity

. . . 1

. . . 35

. .

. . . S12

. . ♦211 137 . .

SWITCH, polarity/AC

. . . 1

. . .

. . .

. .

. . . . . . . .

. .

♦070572 . .

Label, Electrode

. . . 1

. . .

. . .

. .

. . . . . . . .

. .

♦070571 . .

Label, Work

. . . 1

. . .

. . .

. .

. . . . . . . .

. .

♦203305 . .

Label, AC

. . . 1

. . . 36

. .

. . . . . . . .

. . .

201 125 . .

PANEL, mtg terminal pwr output

. . . 1

. . . 37

. .

PC4, PC5 .

189 744 . .

CIRCUIT CARD ASSEMBLY, filter hf

. . . 2

. . . 38

. .

. . . . . . . .

. . .

039 046 . .

TERMINAL, pwr output black

. . . 1

. . .

. . .

. .

. . . . . . . .

. . .

180 735 . .

WASHER, output stud

. . . 2

. . . 39

. .

. . . . . . . .

. . .

134 201 . .

STAND-OFF, support

. . . 12

. . . 40

. .

. . . . . . . .

. . .

181 169 . .

SPACER, output stud

. . . 2

. . . 41

. .

. . . . . . . .

. . .

186 621 . .

BOOT, generic output stud

. . . 2

. . . 42

. .

. . . . . . . .

. . ♦059 773 . .

HANDLE, switch

. . . 1

. . . 43

. .

. . . . . . . .

. . ♦010 647 . .

PIN, spring cs .156 x 1.250

. . . 1

. . . 44

. .

. . . . . . . .

. . .

039 047 . .

TERMINAL, pwr output red

. . . 1

. . . 45

. .

. . . . . . . .

. . ♦196 073 . .

LABEL, do not switch while welding

. . . 1

. . . 46

. .

. . . . . . . .

. . .

193 143 . .

BOOT, magnetic shutdown switch

. . . 1

. . . 47

. .

. . . . . . . .

. . .

021 385 . .

BOOT, toggle switch lever

. . . 1

. . . 48

. .

. . . . . . . .

. . .

. 119 014 . .

LEVER, switch black

. . . 1

. . . 49

. .

. . . . . . . .

. . .

190 323 . .

BOOT, circuit breaker clear hex nut

. . . 2

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OM-4406 Page 79

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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 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 Weld, Power, And Engine Specifications − SpecificationsDimensions, Weights, And Operating Angles 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 ChargerReinstall 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 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 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 Volt And 240 Volt Receptacles − Operating Auxiliary EquipmentAt 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 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 hoseStop engine and let cool. Reinstall cleanout plug Inspecting And Cleaning Optional Spark Arrestor MufflerTools Needed 3/8 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 Optional Three-Phase Generator Power CC/CV Models Standard Generator PowerEngine 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 Wetstacking − RUN-IN ProcedureWelding Generator 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 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 givesFor assistance in filing or settling claims, contact Miller Electric Mfg. CoYour distributor and/or equipment manufacturer’s Transportation Department
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