Miller Electric Big 40 CAT manual Main Rectifier Assembly -1Item

Page 88

Item

Dia.

Part

Description

Quantity

No.

Mkgs.

No.

 

 

 

Figure 13-6. Generator (Continued)

 

 

 

 

 

 

. . . 21 . . . .

. . . . . . . . .

197 486 . .

ADAPTER, Engine Perkins 104.22

. . . 1

. . . 22 . . . .

. . . . . . . . .

083 883 . .

WASHER, Lock .402idx0.709odx.087t Stl Split10mm

. . . 4

. . . 23 . . . .

. . . . . . . . .

049 026 . .

SCREW, M10−1.5x 25 Hex Hd−pln 8.8 Pln

. . . 4

. . . 24 . . . .

. . . . . . . . .

191 579 . .

COVER, starter hole Perkins/Continental

. . . 1

. . . . . . . . . .

. . . . . . . . .

195 560 . .

GUARD, starter hole deutz 912

. . . 1

. . . 25 . . . .

. . . . . . . . .

083 883 . .

WASHER, Lock .402idx0.709odx.087t Stl Split10mm

. . . 6

. . . 26 . . . .

. . . . . . . . .

172 555 . .

SCREW, M10-1.5 x 50hexhd pln 8.8pld

. . . 6

. . . 27 . . . .

. . . . . . . . .

602 159 . .

SCREW, .312−18x .75 hexwhd.66d stl pld slffmg tap−rw

. . . 6

. . . 28 . . . .

. . . . . . . . .

601 961 . .

SCREW, .312-18 x 2.25hexhd pln gr 5pld

. . . 4

. . . 29 . . . .

. . . . . . . . .

. 602 211 . .

WASHER, lock .318 ID x 0.586

. . . 6

. . . 30 . . . .

. . . . . . . . .

139 341 . .

WASHER, exciter

. . . 4

. . . 31 . . . .

. . . . . . . . .

*190 823 . .

BRUSH, contact

. . . 3

. . . 32 . . . .

. . . . . . . . .

208 469 . .

CLIP, spring

. . . 3

. . . 33 . . . .

. . . . . . . . .

189 142 . .

BRUSHHOLDER ASSEMBLY, gen

. . . 1

. . . 34 . . . .

. . . . . . . . .

602 242 . .

WASHER, flat .375IDx0.875odx.083t stl pld

. . . 2

. . . 35 . . . .

. . . . . . . . .

. 602 211 . .

WASHER, Lock .318idx0.586odx.078t Stl Pld Split.312

. . . 2

. . . 36 . . . .

. . . . . . . . .

604 534 . .

SCREW, .312−18x1.25 hex hd−pln gr5 pld

. . . 2

. . . . . . . . . .

. . . . . . . . .

190 259 . .

HARNESS, brush (consisting of)

. . . 1

. . . . . . . . . .

PLG1 . . .

168 071 . . .

. CONNECTOR, (kit) rect univ 084 9P/S 3 row plug cable lkg

. . . 1

. . . . . . . . . .

. . . . . . . . .

187 651 . . .

. SEAL, wire univ 9P/S 3 row

. . . 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. ♦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.

Item

Dia.

Part

Description

Quantity

 

No.

 

Mkgs.

No.

 

 

 

 

 

Figure 13-7. Main Rectifier Assembly (Figure 13-1Item 115)

 

 

 

 

 

 

 

 

. . .

. . .

. . . .

. . . . . . . . .

201 747 . .

RECTIFIER (consisting of)

. . . 1

. . .

1

. . . .

. . . . . . . . .

188 137 . . .

. CONNECTION BOARD, rectifier AC

. . . 1

. . .

2

. . . .

. . . . . . . . .

188 517 . . .

. BUS BAR, connection board

. . . 3

. . .

3

. . . .

. . . . . . . . .

188 135 . . .

. ENCLOSURE, rectifier

. . . 2

. . .

4

. . . .

. . . . . . . . .

134 201 . . .

. STAND-OFF, support

. . . 3

. . .

5

. . . . PC3 . . .

201 449 . . .

. CIRCUIT CARD ASSEMBLY, protection

. . . 1

. . .

6

. . . .

. . . . . . . . .

188 136 . . .

. INSULATOR, heat sink

. . . 8

. . .

7

. . . .

. . . . . . . . .

188 493 . . .

. HEAT SINK, rectifier al

. . . 2

. . .

8

. D3, D5, D7

037 956 . . .

. DIODE, rect 275A 300V SP

. . . 3

. . .

9

. D2, D4, D6

037 957 . . .

. DIODE, rect 275A 300V RP

. . . 3

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 82

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Contents Processes OM-4406Description From Miller to You Table of Contents − Maintenance & Troubleshooting Standards DirectivesDeccon111/02 Sound Level Information Deccon1sound11/02Symbol Usage Arc Welding HazardsEngine Hazards Compressed Air Hazards Principal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interferenceSignification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un in- cendie ou une explosion DES Particules Volantes peuvent blesser les yeuxDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peut DES Organes Mobiles peuvent provoquer des blessuresLA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessuresPrincipales normes de sécurité Information sur les champs électromagnétiques− Definitions + − Starting InstructionsAre possible hazards as Can cause severe burns. DoFalling equipment can cause Serious injury and damageReturn To Table Of Contents Manufacturer’s Rating Labels For CE Products − 50 h StdStd CC Models CC/CV ModelsSymbols And Definitions Weld, Power, And Engine Specifications − SpecificationsDimensions, Weights, And Operating Angles Volt-Ampere Curves For CC Models Stick Mode MIG ModeTIG Mode Volt-Ampere Curves For CC/CV ModelsFuel Consumption Duty Cycle And OverheatingAC Generator Power Curve Optional Three-Phase Generator Curves12 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 − Installation Installing Welding Generator See Sections 5-2AndLocation Grounding Airflow ClearanceUsing Lifting Eye Mounting Welding Generator Supporting The UnitMounting Surface To Bolt Unit In PlaceInstalling Exhaust Pipe Tools Needed 1/2Stop engine and let cool Point exhaust pipe in desired diActivating The Dry Charge Battery If Applicable Do not overfill battery cellsRead and follow all instruc ChargerReinstall cover after connecting battery Connecting The 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 Indicator Lights Do not switch under loadEngine Starting Controls To Start Do not use etherRemote Amperage Control On CC Models Optional Weld Control/Arc Condition Information LabelExample Set weld controls as shown toReturn To Table Of Contents − Operating Welding Generator − CC/CV Models Front Panel Controls For CC/CV Models See SectionVoltage/Amperage Adjust Switch And Remote 14 Receptacle Use switch to select weld amperage rangeEngine Oil Pressure Light Process/Contactor Switch On CC/CV Models Process/Contactor Switch SettingsExample Combination Remote Amperage Control Stick Remote Voltage/Amperage Control On CC/CV Models OptionalExample Combination Remote Amperage Control TIG − Operating Auxiliary Equipment Volt And 240 Volt ReceptaclesAt 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 & Troubleshooting Maintenance LabelRoutine Maintenance Every 8 hEvery 50 h Every 100 hService Every 1000 hEvery 2000 h Caterpillar Customer AssistanceServicing Air Cleaner By the warrantyTo 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 Adjusting Engine Speed Idle Speed AdjustmentWeld/Power Speed Adjustment Engine Speed No LoadServicing Fuel And Lubrication Systems Overload Protection Diagnosing Causes Of Engine Fault Shutdowns Pre-Start Diagnostic ChecksDiagnostic Checks While Running Start Engine With No Load AppliedTroubleshooting Welding − CC ModelsWelding − CC/CV Models Optional Three-Phase Generator Power CC/CV Models Standard Generator PowerEngine Wiring harness and components Shutdown switch is released OutTemperature is too high see Sections 5-7and 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 Wetstacking − RUN-IN ProcedureWelding Generator Run-In Procedure Using Load Bank Procedure at less thanStop engine Do not touch hot exhaust From flammables Do not PerformRun-In Procedure Using Resistance Grid Bank/gridFrom flammables Do not perform run-in− Generator Power Guidelines Has this symbolSelecting Equipment Grounding Generator To Truck Or Trailer FrameGrounding When Supplying Building Systems How Much Power Does Equipment Require?Earth ground if supplying Use ground device as stated Electrical codesApproximate Power Requirements For Industrial Motors Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsPower Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 = Starting AmperageTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Current Load Watts Amperes117 116 103 102 115 FIG 114 105 104 101 120 − Parts List113 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 SupportMiller Electric Mfg. Co For assistance in filing or settling claims, contactYour distributor and/or equipment manufacturer’s Transportation Department
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