Miller Electric Big 40 CAT manual Compressed Air Hazards

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STEAM AND HOT COOLANT can burn.

DIf possible, check coolant level when engine is cold to avoid scalding.

D Always check coolant level at overflow tank, if pres- ent on unit, instead of radiator (unless told otherwise in maintenance section or engine manual).

DIf the engine is warm, checking is needed, and there is no overflow tank, follow the next two statements.

DWear safety glasses and gloves and put a rag over radiator cap.

DTurn cap slightly and let pressure escape slowly before completely re- moving cap.

ENGINE EXHAUST GASES can kill.

D Use equipment outside in open, well-ventilated ar- eas.

DIf used in a closed area, vent engine exhaust outside and away from any building air intakes.

BATTERY ACID can BURN SKIN and EYES.

DDo not tip battery.

DReplace damaged battery.

DFlush eyes and skin immediately with water.

ENGINE HEAT can cause fire.

DDo not locate unit on, over, or near combustible surfaces or flammables.

DKeep exhaust and exhaust pipes way from flam- mables.

EXHAUST SPARKS can cause fire.

DDo not let engine exhaust sparks cause fire.

DUse approved engine exhaust spark arrestor in re- quired areas — see applicable codes.

1-4. Compressed Air Hazards

BREATHING COMPRESSED AIR can cause serious injury or death.

DDo not use compressed air for breathing.

DUse only for cutting, gouging, and tools.

HOT METAL from air arc cutting and gouging can cause fire or explosion.

DDo not cut or gouge near flammables.

DWatch for fire; keep extinguisher nearby.

COMPRESSED AIR can cause injury.

DWear approved safety goggles.

DDo not direct air stream toward self or others.

HOT PARTS can cause burns and injury.

DDo not touch hot compressor or air system parts.

DLet system cool down before touching or servicing.

TRAPPED AIR PRESSURE AND WHIPPING HOSES can cause injury.

DRelease air pressure from tools and system before servicing, adding or changing attachments, or open- ing compressor oil drain or oil fill cap.

READ INSTRUCTIONS.

DRead Owner’s Manual before using or servicing unit.

DStop engine and release air pressure before servicing.

1-5. Additional Symbols For Installation, Operation, And Maintenance

FALLING UNIT can cause injury.

DUse lifting eye to lift unit only, NOT running gear, gas cylinders, trailer, or any other accessories.

DUse equipment of adequate capacity to lift and support unit.

DIf using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.

OVERUSE can cause OVERHEATING.

DAllow cooling period; follow rated duty cycle.

DReduce current or reduce duty cycle before starting to weld again.

DDo not block or filter airflow to unit.

OVERHEATING can damage motors.

DTurn off or unplug equipment before starting or stop- ping engine.

DDo not let low voltage and frequency caused by low

engine speed damage electric motors.

DDo not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable.

FLYING SPARKS can cause injury.

D Wear a face shield to protect eyes and face.

D Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection.

DSparks can cause fires — keep flammables away.

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STATIC (ESD) can damage PC boards.

DPut on grounded wrist strap BEFORE handling boards or parts.

DUse proper static-proof bags and boxes to store, move, or ship PC boards.

TILTING OF TRAILER can cause injury.

DUse tongue jack or blocks to support weight.

DProperly install welding generator onto trailer accord- ing to instructions supplied with trailer.

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Contents OM-4406 ProcessesDescription From Miller to You Table of Contents − Maintenance & Troubleshooting Directives StandardsDeccon111/02 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 − Specifications Weld, Power, And Engine 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 ChargerConnecting The Battery Reinstall cover after connecting 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 ModelsUse switch to select weld amperage range Voltage/Amperage Adjust Switch And Remote 14 ReceptacleEngine Oil Pressure Light Process/Contactor Switch Settings Process/Contactor Switch On CC/CV ModelsRemote Voltage/Amperage Control On CC/CV Models Optional Example Combination Remote Amperage Control StickExample Combination Remote Amperage Control TIG Volt And 240 Volt Receptacles − Operating Auxiliary EquipmentAt least once a month, run en 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 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 hoseInspecting And Cleaning Optional Spark Arrestor Muffler Stop engine and let cool. Reinstall cleanout plugTools 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 Standard Generator Power Optional Three-Phase Generator Power CC/CV ModelsEngine 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 − RUN-IN Procedure WetstackingWelding 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 Possible− Parts List 117 116 103 102 115 FIG 114 105 104 101 120113 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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