Routine Maintenance, Every 8 h | Miller Electric Big 40 CAT specs

9-2. Routine Maintenance

Note	Follow the storage procedure in the engine owner’s manual if the unit will not be used for an
	extended period.

Recycle engine

fluids.

YStop engine before maintaining.

.See Engine Manual and Maintenance

Label for important start-up, service, and storage information. Service unit more often if used in severe conditions.

*To be done by Factory Authorized Service Agent.

Every 8 h

Wipe

Up

Spills.

Coolant

Full

OIL

Full

	Check Fluid	FUEL	Drain Water
		WATER
	Levels. See		From Fuel

	Section 5-7.		System.

Every 50 h

Clean Air Filter. See Section 9-4.

Clean And

Tighten

Weld

Terminals.

Every 100 h

Check air cleaner hoses for cracks and loose clamps.

Clean And

Tighten

Battery

Connections.

Every 250 h

Replace

Unreadable

Labels.

1/2 in.	Check Belt
(13 mm)	Tension.

Change Oil. See

Section 9-7.

Change Oil Filter. See Section 9-7.

Check And

Clean Spark

Arrestor. See

Section 9-5.

Every 500 h

Repair Or

Replace

Damaged

Cables.

OM-4406 Page 42

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Image 48

Miller Electric Big 40 CAT manual Routine Maintenance, Every 8 h, Every 50 h, Every 100 h, Every 250 h, Every 500 h

Contents

OM-4406 ProcessesDescription From Miller to You Table of Contents − Maintenance & Troubleshooting Directives StandardsDeccon111/02 Sound Level Information Deccon1sound11/02 Symbol Usage Arc Welding Hazards Engine Hazards Compressed Air Hazards Principal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interference Signification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereux LE 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 blessures Principales normes de sécurité Information sur les champs électromagnétiques − Definitions + − Starting Instructions Are possible hazards as Can cause severe burns. DoFalling equipment can cause Serious injury and damage Return To Table Of Contents Manufacturer’s Rating Labels For CE Products − 50 h StdStd CC Models CC/CV Models Symbols And Definitions − Specifications Weld, Power, And Engine SpecificationsDimensions, Weights, And Operating Angles Volt-Ampere Curves For CC Models Stick Mode MIG ModeTIG Mode Volt-Ampere Curves For CC/CV Models Fuel Consumption Duty Cycle And Overheating AC 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 Load Volt-Ampere Curve For CC/CV Models In AC TIG Mode − Installation Installing Welding Generator See Sections 5-2AndLocation Grounding Airflow Clearance Using Lifting Eye Mounting Welding Generator Supporting The UnitMounting Surface To Bolt Unit In Place Installing Exhaust Pipe Tools Needed 1/2Stop engine and let cool Point exhaust pipe in desired di Activating The Dry Charge Battery If Applicable Do not overfill battery cellsRead and follow all instruc Charger Connecting The Battery Reinstall cover after connecting batteryConnect Negative − Cable Last Coolant Recovery Tank Engine Prestart Checks Connecting To Weld Output Terminals Selecting Weld Cable Sizes Connecting To Remote 14 Receptacle RC14 On CC/CV Models Socket − Operating Welding Generator − CC Models Front Panel Controls For CC Models See Section Engine Indicator Lights Do not switch under loadEngine Starting Controls To Start Do not use ether Remote Amperage Control On CC Models Optional Weld Control/Arc Condition Information LabelExample Set weld controls as shown to Return To Table Of Contents − Operating Welding Generator − CC/CV Models Front Panel Controls For CC/CV Models See Section Use switch to select weld amperage range Voltage/Amperage Adjust Switch And Remote 14 ReceptacleEngine Oil Pressure Light Process/Contactor Switch On CC/CV Models Process/Contactor Switch Settings Remote Voltage/Amperage Control On CC/CV Models Optional Example Combination Remote Amperage Control StickExample Combination Remote Amperage Control TIG − Operating Auxiliary Equipment Volt And 240 Volt ReceptaclesAt least once a month, run en Open, contact Factory Autho Three-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 & Troubleshooting Maintenance Label Routine Maintenance Every 8 hEvery 50 h Every 100 h Service Every 1000 hEvery 2000 h Caterpillar Customer Assistance Servicing Air Cleaner By the warrantyTo clean air filter Do not clean housing with air hose Inspecting And Cleaning Optional Spark Arrestor Muffler Stop engine and let cool. Reinstall cleanout plugTools Needed 3/8 Adjusting Engine Speed Idle Speed AdjustmentWeld/Power Speed Adjustment Engine Speed No Load Servicing Fuel And Lubrication Systems Overload Protection Diagnosing Causes Of Engine Fault Shutdowns Pre-Start Diagnostic ChecksDiagnostic Checks While Running Start Engine With No Load Applied Troubleshooting Welding − CC Models Welding − CC/CV Models Standard Generator Power Optional Three-Phase Generator Power CC/CV ModelsEngine 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 Generator 215 296-B Circuit Diagram For CC/CV Welding Generator 215 297-B − RUN-IN Procedure WetstackingWelding Generator Run-In Procedure Using Load Bank Procedure at less thanStop engine Do not touch hot exhaust From flammables Do not Perform Run-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 Frame Grounding When Supplying Building Systems How Much Power Does Equipment Require?Earth ground if supplying Use ground device as stated Electrical codes Approximate 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 Watts Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Power Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 = Starting Amperage Typical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Current Load Watts Amperes − Parts List 117 116 103 102 115 FIG 114 105 104 101 120113 108 100 CC only 119 110 109 111 -4 or 51 52 85 Fig 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 Panel, Front w/Components − CC/CV Models -1Item PC6 192 PLG6 Hardware is common Not available unless listed 34 36 27 26 Main Rectifier Assembly -1Item Main Rectifier Assembly Page Your distributor also gives Support Miller Electric Mfg. Co For assistance in filing or settling claims, contactYour distributor and/or equipment manufacturer’s Transportation Department