OM-4406, Processes, Description | Miller Electric Big 40 CAT

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OM-4406	202 759T
January 2004
Processes

Stick (SMAW) Welding

TIG (GTAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Air Carbon Arc (CAC-A)

Cutting and Gouging

Description

Engine Driven Welding Generator

Big 40R CAT(CE Compliant)

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Miller Electric Big 40 CAT manual OM-4406, Processes, Description

Contents

Processes OM-4406Description From Miller to You Table of Contents − Maintenance & Troubleshooting Standards DirectivesDeccon111/02 Deccon1sound11/02 Sound Level Information Arc Welding Hazards Symbol Usage Engine 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 dangereux DES 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’ouïe DES Organes Mobiles peuvent provoquer des blessures ’EXPLOSION DE LA Batterie peutLA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessures Information 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 damage Return To Table Of Contents − 50 h Std Manufacturer’s Rating Labels For CE ProductsStd CC Models CC/CV Models Symbols 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 Models Duty Cycle And Overheating Fuel Consumption Optional 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 Load Volt-Ampere Curve For CC/CV Models In AC TIG Mode Installing Welding Generator See Sections 5-2And − InstallationLocation Grounding Airflow Clearance Using Lifting Eye Supporting The Unit Mounting Welding GeneratorMounting Surface To Bolt Unit In Place Tools Needed 1/2 Installing Exhaust PipeStop engine and let cool Point exhaust pipe in desired di Do not overfill battery cells Activating The Dry Charge Battery If ApplicableRead and follow all instruc Charger Reinstall cover after connecting battery Connecting The BatteryConnect Negative − Cable Last Engine Prestart Checks Coolant Recovery Tank Selecting Weld Cable Sizes Connecting To Weld Output Terminals Socket Connecting To Remote 14 Receptacle RC14 On CC/CV Models Front Panel Controls For CC Models See Section − Operating Welding Generator − CC Models Do not switch under load Engine Indicator LightsEngine Starting Controls To Start Do not use ether Weld Control/Arc Condition Information Label Remote Amperage Control On CC Models OptionalExample Set weld controls as shown to Return To Table Of Contents Front Panel Controls For CC/CV Models See Section − Operating Welding Generator − CC/CV Models Voltage/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 Models Example 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 Autho Rear 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 & Troubleshooting Every 8 h Routine MaintenanceEvery 50 h Every 100 h Every 1000 h ServiceEvery 2000 h Caterpillar Customer Assistance By the warranty Servicing Air CleanerTo clean air filter Do not clean housing with air hose Stop 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 Load Servicing Fuel And Lubrication Systems Overload Protection Pre-Start Diagnostic Checks Diagnosing Causes Of Engine Fault ShutdownsDiagnostic Checks While Running Start Engine With No Load Applied Welding − CC Models Troubleshooting Welding − 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 manual Circuit Diagram For CC Welding Generator − Electrical Diagrams 215 296-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 Perform Bank/grid Run-In Procedure Using Resistance GridFrom flammables Do not perform run-in Has this symbol − Generator Power GuidelinesSelecting Equipment Grounding Generator To Truck Or Trailer Frame How Much Power Does Equipment Require? Grounding When Supplying Building SystemsEarth ground if supplying Use ground device as stated Electrical codes Approximate 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 Watts Contractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor Equipment How Much Power Can Generator Supply? Power Required To Start MotorSingle-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 = Starting Amperage Typical Connections To Supply Standby Power Current Load Watts Amperes Selecting Extension Cord Use Shortest Cord Possible 117 116 103 102 115 FIG 114 105 104 101 120 − Parts List113 108 100 CC only 119 110 109 111 -4 or 85 Fig 51 52 Dia 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 Models PC6 192 PLG6 34 36 27 26 Hardware is common Not available unless listed Main Rectifier Assembly -1Item Main Rectifier Assembly Page Support Your distributor also gives For assistance in filing or settling claims, contact Miller Electric Mfg. CoYour distributor and/or equipment manufacturer’s Transportation Department