RUN-IN Procedure, Wetstacking | Miller Electric Big 40 CAT guide

SECTION 11 − RUN-IN PROCEDURE

11-1. Wetstacking

2

1

run_in1 8/01

YDo not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur.

1 Welding Generator

Run diesel engines near rated volt- age and current during run-in period to properly seat piston rings and prevent wetstacking. See name- plate, rating label, or specifications section in this manual to find rated voltage and current.

.Do not idle engine longer than

necessary. Piston rings seat faster if engine runs at weld/ power rpm, and the welding generator is kept loaded during run-in.

2 Engine Exhaust Pipe

Wetstacking is unburned fuel and oil in the exhaust pipe and occurs during run-in if the engine is run too long at light load or idle rpm.

If exhaust pipe is coated with a wet, black, tar-like substance, dry the engine using one of the following run-in procedures.

See the engine manual for addition- al engine run-in information.

OM-4406 Page 58

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Miller Electric Big 40 CAT manual RUN-IN Procedure, Wetstacking, Welding Generator

Contents

Processes OM-4406Description From Miller to You Table of Contents − Maintenance & Troubleshooting Standards DirectivesDeccon111/02 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 Weld, Power, And Engine Specifications − 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 Reinstall cover after connecting battery Connecting The 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 Voltage/Amperage Adjust Switch And Remote 14 Receptacle Use switch to select weld amperage rangeEngine Oil Pressure Light Process/Contactor Switch On CC/CV Models Process/Contactor Switch Settings Example Combination Remote Amperage Control Stick Remote Voltage/Amperage Control On CC/CV Models OptionalExample Combination Remote Amperage Control TIG − Operating Auxiliary Equipment Volt And 240 Volt ReceptaclesAt 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 & 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 Stop engine and let cool. Reinstall cleanout plug Inspecting And Cleaning Optional Spark Arrestor MufflerTools 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 Optional Three-Phase Generator Power CC/CV Models Standard Generator PowerEngine 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 Wetstacking − RUN-IN ProcedureWelding 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 117 116 103 102 115 FIG 114 105 104 101 120 − Parts List113 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