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Miller Electric Big 40 CAT 9-2. Routine Maintenance, , Every 8 h, Every 50 h, Every 100 h, Every 250 h, Every 500 h

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9-2. Routine Maintenance

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

extended period.

Note

Recycle engine

fluids.

Stop 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

Check Fluid

Levels. See

Section 5-7.

Wipe

Spills.

Drain Water

From Fuel

System.

OIL

Full

FUEL

WATER

Coolant

Full

Every 50 h

Clean Air Filter.

See Section 9-4.

Clean And

Tighten

Weld

Terminals.

Every 100 h

Clean And

Tighten

Battery

Connections.

Check air cleaner

hoses for cracks

and loose clamps.

Every 250 h

Replace

Unreadable

Labels.

1/2 in.

(13 mm) Check Belt

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.

Contents

Main Big 40 CA T From Miller to You Page TABLE OF CONTENTS Declaration of Conformity for European Community (CE) Products Appleton, WI 54914 USA Declaration of Conformity for European Community (CE) Products Appleton, WI 54914 USA OM-4406 Page 1 Return To Table Of Contents SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING Warning: Protect yourself and others from injury read and follow these precautions. 1-1. Symbol Usage Marks a special safety message. 1-2. Arc Welding Hazards 1-3. Engine Hazards BATTERY EXPLOSION can BLIND. FUEL can cause fire or explosion. MOVING PARTS can cause injury. OM-4406 Page 3 1-4. Compressed Air Hazards BREATHING COMPRESSED AIR can cause serious injury or death. COMPRESSED AIR can cause injury. TRAPPED AIR PRESSURE AND WHIPPING HOSES can cause injury. HOT METAL from air arc cutting and gouging can cause fire or explosion. 1-6. California Proposition 65 Warnings 1-7. Principal Safety Standards 1-8. EMF Information OM-4406 Page 5 Revenez la table des matires SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION Avertissement: Protgez vous et les autres des blessures lisez et suivez ces prcautions. 2-1. Signification des symboles Identifie un message de scurit particulier. 2-2. Dangers relatifs au soudage larc 2-3. Dangers existant en relation avec le moteur LES ACCUMULATIONS DE GAZ ris- quent de provoquer des blessures ou mme la mort. LACIDE DE LA BATTERIE peut pro- voquer des brlures dans les YEUX et sur la PEAU. OM-4406 Page 7 Revenez la table des matires LEXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE. 2-4. Dangers lis lair comprim RESPIRER LAIR COMPRIM peut pro- voquer des blessures graves ou causer la mort. LAIR COMPRIM peut provoquer des blessures. LAIR COMPRIME EMMAGASINE ET DES TUYAUX SOUS PRESSION peuvent provo- quer des blessures. Le METAL CHAUD lors du coupage et gougeage plasma peut provoquer un in- cendie ou une explosion. 2-6. Principales normes de scurit 2-7. Information sur les champs lectromagntiques SECTION 3 DEFINITIONS 3-1. Warning Label Definitions + Page Page + 2 3 4 1+ AAmperes VVolts Panel/Local Remote 3 n X Duty Cycle U0 SECTION 4 SPECIFICATIONS 4-1. Weld, Power, And Engine Specifications Output Range Rated Welding Welding Mode Weld Output 4-3. Volt-Ampere Curves For CC Models 4-4. Volt-Ampere Curves For CC/CV Models 4-5. Fuel Consumption 4-6. Duty Cycle And Overheating 4-7. AC Generator Power Curve 4-8. Optional Three-Phase Generator Curves 4-9. Volt-Ampere Curve For CC/CV Models In AC TIG Mode SECTION 5 INSTALLATION 5-1. Installing Welding Generator (See Sections 5-2 And 5-3) Page 5-3. Mounting Welding Generator Page 5-5. Activating The Dry Charge Battery (If Applicable) + Page 5-7. Engine Prestart Checks 5-8. Connecting To Weld Output Terminals 5-9. Selecting Weld Cable Sizes* 5-10. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models 5-11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models SECTION 6 OPERATING WELDING GENERATOR CC MODELS 6-1. Front Panel Controls For CC Models (See Section 6-2) 6-2. Description Of Front Panel Controls For CC Models (See Section 6-1) 6-3. Remote Amperage Control On CC Models (Optional) 6-4. Weld Control/Arc Condition Information Label Page SECTION 7 OPERATING WELDING GENERATOR CC/CV MODELS 7-1. Front Panel Controls For CC/CV Models (See Section 7-2) 7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1) 7-3. Process/Contactor Switch On CC/CV Models Process/Contactor Switch Settings 7-4. Remote Voltage/Amperage Control On CC/CV Models (Optional) SECTION 8 OPERATING AUXILIARY EQUIPMENT 8-1. 120 Volt And 240 Volt Receptacles 8-2. Connecting To Optional Three-Phase Generator (CC/CV Models Only) 8-3. Optional Generator Power Receptacles Page 9-2. Routine Maintenance Every 8 h Every 50 h Every 100 h Every 250 h Every 1000 h Every 2000 h 9-3. Caterpillar Customer Assistance 9-4. Servicing Air Cleaner 9-5. Inspecting And Cleaning Optional Spark Arrestor Muffler 9-6. Adjusting Engine Speed 9-7. Servicing Fuel And Lubrication Systems 9-8. Overload Protection 9-9. Diagnosing Causes Of Engine Fault Shutdowns 9-10. Troubleshooting A. Welding CC Models B. Welding CC/CV Models C. Standard Generator Power D. Optional Three-Phase Generator Power (CC/CV Models) E. Engine Page Page Page Page Page SECTION 11 RUN-IN PROCEDURE 11-1. Wetstacking 11-2. Run-In Procedure Using Load Bank 11-3. Run-In Procedure Using Resistance Grid + SECTION 12 GENERATOR POWER GUIDELINES 12-1. Selecting Equipment 12-2. Grounding Generator To Truck Or Trailer Frame 12-3. Grounding When Supplying Building Systems 12-4. How Much Power Does Equipment Require? 12-5. Approximate Power Requirements For Industrial Motors 12-6. Approximate Power Requirements For Farm/Home Equipment 12-7. Approximate Power Requirements For Contractor Equipment 12-8. Power Required To Start Motor 12-9. How Much Power Can Generator Supply? 12-10. Typical Connections To Supply Standby Power Pros weld and cut safely. Read the safety rules at the beginning of this manual. 12-11. Selecting Extension Cord (Use Shortest Cord Possible) SECTION 13 PARTS LIST Figure 13-1. Main Assembly Page Page Page Page Page Page Page Page Page Page Page Page Page Page Figure 13-7. Main Rectifier Assembly Page Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Effective January 1, 2003 (Equipment with a serial number preface of LC or newer) Please complete and retain with your personal records. For Service Always provide Model Name and Serial/Style Number. Owners Record