34 36 27 26 | Miller Electric Big 40 CAT specification

. Hardware is common and				20
not available unless listed.
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		11	16	18
		11		18
			15
		12
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9	10	14
9		13
		13
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5

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4

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	30	29	28
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802 552-A

				Figure 13-6. Generator
Item		Dia.	Part	Description	Quantity
	No.	Mkgs.	No.	Description	Quantity
				Figure 13-6. Generator (Figure 13-1Item 85)

. . .	1 . . .	. . . . . . . .	. . 132 053 . .	SCREW, .375−16x1.50 hex hd−pln gr5 pld	. . . 6
. . .	2 . . .	. . . . . . . .	. . 183 387 . .	WASHER, conical spring .406 ID x .875 OD pltd	. . . 6
. . .	3 . . .	. . . . . . . .	. . . 195 911 . .	ENDBELL, gen (consisting of)	. . . 1
. . .	4 . . .	. . . . . . . .	. . 143 220 . . .	. O-RING, 2.859 ID x .139CS	. . . 1
. . .	5 . . .	. . . . . . . .	. . 201 099 . .	STATOR, exciter/gen pwr	. . . 1
. . .	6 . . .	. . . . . . . .	. +201 110 . .	STATOR, weld assembly complete	. . . 1
. . .	6 . . .	. . . . . . . .	+♦201 089 . .	STATOR, weld assembly complete (full kVA option)	. . . 1
. . .	7 . . .	. . . . . . . .	. . 013 367 . .	LABEL, warning moving parts	. . . 2
. . .	7 . . .	. . . . . . . .	. . 176 106 . .	LABEL, warning moving parts (CE models only)	. . . 2
. . .	8 . . .	. . . . . . . .	. . 190 197 . .	GUARD, generator wire mesh	. . . 1
. . .	9 . . .	. . . . . . . .	. . 172 674 . .	SPRING, ext .240 OD x .041 wire x 3.500pld	. . . 2
. . . 10 . . .		. . . . . . . .	. . 039 207 . .	BAFFLE, air	. . . 1
. . . 11 . . .		ROTOR	. . 212 996 . .	ROTOR, Generator Segmented Assy (Includes)	. . . 1
. . . 12 . . .		. . . . . . . .	. . 210 824 . . .	. ROTOR, Generator (Includes)	. . . 1
. . . 13 . . .		. . . . . . . .	. . 024 617 . . .	. . . RING, Rtng Ext 1.375 Shaft X .050 Thk	. . . 1
. . . 14 . . .		. . . . . . . .	. . 053 390 . . .	. . . BEARING, Ball Rdl Sgl Row 1.370 X 2.830 X .6	. . . 1
. . .	. . . . . .	. . . . . . . .	. . . . . . . . . . . . . .	. . . HUB, Drive (Not Sold Separately)	. . . 1
. . .	. . . . . .	. . . . . . . .	. . 210 447 . . .	. FAN, Rotor Assy Generator (Segmented) (includes)	. . . 1
. . . 15 . . .		. . . . . . . .	. . 210 332 . . .	. . . PLATE, Flex Hubmount	. . . 1
. . . 16 . . .		. . . . . . . .	. . 206 242 . . .	. . . FAN, Rotor Segmented Assy Gen	. . . 4
. . . 17 . . .		. . . . . . . .	. . 049 026 . . .	. . . SCREW, M10−1.5x 25 Hex Hd−pln 8.8 Pln	. . . 10
. . . 18 . . .		. . . . . . . .	. . 083 883 . . .	. . . WASHER, Lock .402idx0.709odx.087t Stl Split10mm	. . . 10
. . . 19 . . .		. . . . . . . .	. . 080 389 . . .	. . . SCREW, 312−18x1.00 Hexwhd.66d Stl Pld Slffmg Tap−rw	. . . 8
. . . 20 . . .		. . . . . . . .	. . 197 487 . . .	. FLYWHEEL, Perkins 104.22	. . . 1

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OM-4406 Page 81

Image 87

Miller Electric Big 40 CAT manual Hardware is common Not available unless listed, 34 36 27 26

Contents

OM-4406 ProcessesDescription From Miller to You Table of Contents − Maintenance & Troubleshooting Directives StandardsDeccon111/02 Deccon1sound11/02 Sound Level Information Arc Welding Hazards Symbol Usage Engine Hazards Compressed Air Hazards Radiation can cause interference Principal Safety StandardsCalifornia Proposition 65 Warnings EMF Information LES Fumées ET LES GAZ peuvent être dangereux Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation UN Choc Électrique peut tuer LE Bruit peut affecter l’ouïe LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux DES Pièces Chaudes peuvent provoquer des brûlures graves ’AIR Comprimé peut provoquer des blessures ’EXPLOSION DE LA Batterie peutDES Organes Mobiles peuvent provoquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendie Information sur les champs électromagnétiques Principales normes de sécurité − Definitions Starting Instructions + − Serious injury and damage Are possible hazards asCan cause severe burns. Do Falling equipment can cause Return To Table Of Contents CC Models CC/CV Models Manufacturer’s Rating Labels For CE Products− 50 h Std Std Symbols And Definitions − Specifications Weld, Power, And Engine SpecificationsDimensions, Weights, And Operating Angles Volt-Ampere Curves For CC Models Volt-Ampere Curves For CC/CV Models Stick ModeMIG Mode TIG Mode Duty Cycle And Overheating Fuel Consumption 15 kVA/kW Three-Phase AC Output No Weld Load AC Generator Power CurveOptional Three-Phase Generator Curves 12 kVA/kW Single-Phase AC Output No Weld Load Volt-Ampere Curve For CC/CV Models In AC TIG Mode Airflow Clearance − InstallationInstalling Welding Generator See Sections 5-2And Location Grounding Using Lifting Eye To Bolt Unit In Place Mounting Welding GeneratorSupporting The Unit Mounting Surface Point exhaust pipe in desired di Installing Exhaust PipeTools Needed 1/2 Stop engine and let cool Charger Activating The Dry Charge Battery If ApplicableDo not overfill battery cells Read and follow all instruc Connecting The Battery Reinstall cover after connecting 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 To Start Do not use ether Engine Indicator LightsDo not switch under load Engine Starting Controls Set weld controls as shown to Remote Amperage Control On CC Models OptionalWeld Control/Arc Condition Information Label Example Return To Table Of Contents Front Panel Controls For CC/CV Models See Section − Operating Welding Generator − CC/CV Models Use switch to select weld amperage range Voltage/Amperage Adjust Switch And Remote 14 ReceptacleEngine Oil Pressure Light Process/Contactor Switch Settings Process/Contactor Switch On CC/CV Models Remote Voltage/Amperage Control On CC/CV Models Optional Example Combination Remote Amperage Control StickExample Combination Remote Amperage Control TIG Open, contact Factory Autho − Operating Auxiliary EquipmentVolt And 240 Volt Receptacles At least once a month, run en 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 Label − Maintenance & Troubleshooting Every 100 h Routine MaintenanceEvery 8 h Every 50 h Caterpillar Customer Assistance ServiceEvery 1000 h Every 2000 h Do not clean housing with air hose Servicing Air CleanerBy the warranty To clean air filter Inspecting And Cleaning Optional Spark Arrestor Muffler Stop engine and let cool. Reinstall cleanout plugTools Needed 3/8 Engine Speed No Load Adjusting Engine SpeedIdle Speed Adjustment Weld/Power Speed Adjustment Servicing Fuel And Lubrication Systems Overload Protection Start Engine With No Load Applied Diagnosing Causes Of Engine Fault ShutdownsPre-Start Diagnostic Checks Diagnostic Checks While Running Welding − CC Models Troubleshooting Welding − CC/CV Models Standard Generator Power Optional Three-Phase Generator Power CC/CV ModelsEngine Air in fuel system. See engine manual Wiring harness and componentsShutdown switch is released Out Temperature is too high see Sections 5-7and Circuit Diagram For CC Welding Generator − Electrical Diagrams 215 296-B Circuit Diagram For CC/CV Welding Generator 215 297-B − RUN-IN Procedure WetstackingWelding Generator From flammables Do not Perform Run-In Procedure Using Load BankProcedure at less than Stop engine Do not touch hot exhaust Do not perform run-in Run-In Procedure Using Resistance GridBank/grid From flammables Grounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesHas this symbol Selecting Equipment Use ground device as stated Electrical codes Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Earth ground if supplying Farm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Industrial Motors Rating Starting Watts Running Watts Contractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor Equipment KVA/HP x HP x 1000 = Starting Amperage Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting Requirements Typical Connections To Supply Standby Power Current Load Watts Amperes Selecting Extension Cord Use Shortest Cord Possible − Parts List 117 116 103 102 115 FIG 114 105 104 101 120113 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 Transportation Department Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s