Mounting Welding Generator | Miller Electric Big 40 CAT guide

5-3. Mounting Welding Generator

Supporting The Unit

2

OR

1

Inadequate support.

YDo not use flexible mounts.

1

Using Mounting Brackets

2

Welding Unit In Place

Bolting Unit In Place

3

2

4

Tools Needed: 9/16 in

YDo not weld on base. Weld- ing on base can cause fuel tank fire or explosion. Weld only on the four mounting brackets or bolt unit down.

YDo not mount unit by sup- porting the base only at the four mounting brackets. Use cross-supports to ade- quately support unit and pre- vent damage to base.

Mounting Surface:

1Cross-Supports

2Mounting Brackets (Supplied)

Mount unit on flat surface or use cross-supports to support base. Secure unit with mounting brack- ets.

31/2 in Bolt And Washer (Minimum − Not Supplied)

43/8-16 x 1 in Screws

(Supplied)

To Bolt Unit In Place:

Remove hardware securing the four mounting brackets to the base. Reverse brackets and reattach to base with original hardware.

Mount unit to truck or trailer with 1/2 in (12 mm) or larger hardware (not supplied).

To Weld Unit In Place:

Weld unit to truck or trailer only at the four mounting brackets.

install3 5/02 803 274 / 190 250-A / 803 231 / 802 311

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OM-4406 Page 23

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Miller Electric Big 40 CAT manual Mounting Welding Generator, Supporting The Unit, Mounting Surface, To Bolt Unit In Place

Contents

Description OM-4406Processes From Miller to You Table of Contents − Maintenance & Troubleshooting Deccon111/02 DirectivesStandards 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 Dimensions, Weights, And Operating Angles − SpecificationsWeld, Power, And Engine Specifications 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 Connect Negative − Cable Last Connecting The BatteryReinstall cover after connecting battery 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 Engine 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 Models Example Combination Remote Amperage Control TIG Remote Voltage/Amperage Control On CC/CV Models OptionalExample Combination Remote Amperage Control Stick Volt And 240 Volt Receptacles − Operating Auxiliary EquipmentAt least once a month, run en Open, contact Factory Autho Close 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 & 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 Tools Needed 3/8 Inspecting And Cleaning Optional Spark Arrestor MufflerStop engine and let cool. Reinstall cleanout plug 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 Engine Standard Generator PowerOptional Three-Phase Generator Power CC/CV Models 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 Welding Generator − RUN-IN ProcedureWetstacking 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 113 108 100 CC only 119 110 109 111 -4 or − Parts List117 116 103 102 115 FIG 114 105 104 101 120 85 Fig 51 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