Miller Electric Big 40 CAT Owner'S Manual Download Page 81

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Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 13-3. Control Box Assembly

−

CC/CV Models (Figure 13-1 Item 106)

Quantity

F1, F2

*085 874

FUSE, mintr cer slo-blo 10A 250V

. . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

046 432

HOLDER, fuse mintr .250 x 1.250

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201 077

CONTROL BOX, lh

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201 078

CONTROL BOX, rh

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201 079

COVER, control box

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

134 201

STAND-OFF, support pc card

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PC9

192 224

CIRCUIT CARD ASSY, display

. . .

. . . .

. . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

087 110

CAPACITOR, elctlt 240uf 200VDC

. . .

. . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

177 136

CLAMP, capacitor 1.375dia

. . .

. . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

204 811

HARNESS, control box, cv weld control (consisting of)

. . . . . . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . .

SR1

035 704

RECTIFIER, integ 40A 800V

. . .

. . . .

. . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CR5

090 104

RELAY, encl 12VDC SPST 30A/15VDC

. . .

. . . .

. . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

RC4

047 483

CONNECTOR, rect univ 084 15P/S 3 row rcpt cable/panel lkg

. . . . . . . . . .

. . .

. . . .

. . . . . . .

RC3

158 466

CONNECTOR, rect univ 084 12P/S 3 row rcpt cable/panel lkg

. . . . . . . . . .

. . .

. . . .

. . . . . . .

RC1

135 133

CONNECTOR, rect univ 084 9P/S 3 row rcpt cable/panel lkg

. . . .

. . . . . .

. . .

. . . .

. . . . . . . .

12 CB11, 12, 13 139 266

CIRCUIT BREAKER, man reset 1P 15A 250VAC frict

. . .

. . . .

. . . . . . . . . . . . . .

148 850

SOCKET, relay 5 pin

. . . . . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

193 324

SWITCH, rotary 6 position gold contacts

. . . . . . . . . . .

. . . .

(located on front panel, see 13-5)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

011 609

SWITCH,tgl spdt 15a 125vac on

−

none

−

on spd term chr

. . . . . . . . . . .

. . . . .

. . . .

(located on front panel, see 13-5)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

150 316

CONN, rect univ 039 6p/s 3row plug cable lkg

. . . . . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . .

177 859

CONN, body 5 terminal (to engine control switch S1)

. . . . . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . .

193 183

CONN, rect cinch 18 pin

. . . . . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

196 602

PLUG, cavity 18,30 position cinch connector

. . . . . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . .

196 603

SEAL, switch 6 position rotary .250 shaft

. . . . . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

141 450

CONN, rect metrmate 10skt 1row plug cable lkg

. . . . . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . .

PC7

♦

195 706

MODULE, pull to idle, two output, 7 pin

. . .

. . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

CR4

♦

113 247

RELAY, encl 12vdc dpdt 20a/120vac 8pin flange mtg

. . .

. . . .

. .

. . . . . . . . . . . . . . . .

CR6

♦

090104

RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg

. . .

. . . .

. .

. . . . . . . . . . . . . . . . . .

CR2, CR3

090 104

RELAY, encl 12VDC SPST 30A/15VDC spin flange mtg

. . .

. .

. . . . . . . . . . . . . .

212 452

HARNESS, engine control (consisting of)

. . . . . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . .

D10/C10, D11/C11

189 701

DIODE/CAPACITOR BOARD

. . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

217 335

RESISTOR BOARD

. . .

. . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CB10

190 374

CIRCUIT BREAKER, auto reset 12VDC 40A

. . .

. . . .

. . .

. . . .

. . . . . . . . . . . . . . . . . . . . . .

148 850

SOCKET, relay 5 pin

. . . . . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG4

114 062

CONNECTOR, rect univ 084 15P/S 3 row plug cable lkg

. . . . . . . . . .

. . . .

. . . . . . . . . . . .

185 655

SEAL, wire univ 15P/S 3 row

. . . . . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CR1

214 876

RELAY, Encl 6vdc Spst 35a/14vdc 5 Pin

. . .

. . . .

. . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

CR9

090 104

RELAY, encl 12VDC SPST 30A/15VDC spin flange mtg

. . .

. . . .

. . .

. . . .

. . . . . . . . . . . . .

CR8

155 309

CONTACTOR, Solenoid 12vdc Continuous 400a Inrush

. . .

. . . .

. . .

. .

. . . . . . . . . . . . . .

♦

Optional

*Recommended Spare Parts.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested

Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Summary of Contents for Big 40 CAT

Page 1: ...202 759T January 2004 Visit our website at www MillerWelds com Processes Description Air Carbon Arc CAC A Cutting and Gouging Stick SMAW Welding Engine Driven Welding Generator TIG GTAW Welding MIG GMAW Welding Flux Cored FCAW Welding ...

Page 2: ...nue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operation q...

Page 3: ...ifications 15 4 2 Dimensions Weights And Operating Angles 15 4 3 Volt Ampere Curves For CC Models 16 4 4 Volt Ampere Curves For CC CV Models 17 4 5 Fuel Consumption 18 4 6 Duty Cycle And Overheating 18 4 7 AC Generator Power Curve 19 4 8 Optional Three Phase Generator Curves 19 4 9 Volt Ampere Curve For CC CV Models In AC TIG Mode 20 SECTION 5 INSTALLATION 21 5 1 Installing Welding Generator See S...

Page 4: ...or Power Receptacles 40 SECTION 9 MAINTENANCE TROUBLESHOOTING 41 9 1 Maintenance Label 41 9 2 Routine Maintenance 42 9 3 Caterpillar Customer Assistance 43 9 4 Servicing Air Cleaner 44 9 5 Inspecting And Cleaning Optional Spark Arrestor Muffler 45 9 6 Adjusting Engine Speed 46 9 7 Servicing Fuel And Lubrication Systems 47 9 8 Overload Protection 48 9 9 Diagnosing Causes Of Engine Fault Shutdowns 4...

Page 5: ...lity Directives 89 336 EEC 92 31 EEC Standards Safety Requirements for Arc Welding Equipment IEC 60974 1 1998 09 Rotating Electrical Machines Part 1 Rating and Performance IEC 34 1 1994 Rotating Electrical Machines Part 5 Classification of degrees of protection provided by enclosure of rotating electrical machines IP code IEC 34 5 1991 Insulation coordination for equipment within low voltage syste...

Page 6: ...0 14 EC Sound Level Information Measured Sound Power Level 98 dB Guaranteed Sound Power Level 98 dB This equipment conforms to requirements brought forth by 2000 14 EC Noise conformity assessment procedure followed with notified body AV Technology Limited AVTECH House Birdhall Lane Cheadle Heath Stockport Cheshire SK3OXU Sound power level requirements determined by the 40 duty cycle of 500 A 30 V ...

Page 7: ...ox or that cord plug is connected to a properly grounded receptacle outlet When making input connections attach proper grounding conductor first double check connections Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape...

Page 8: ... Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully CYLINDERS can explode if damaged Protect compressed gas cylinders from excessive heat mechanical shocks slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or...

Page 9: ...il fill cap HOT METAL from air arc cutting and gouging can cause fire or explosion Do not cut or gouge near flammables Watch for fire keep extinguisher nearby HOT PARTS can cause burns and injury Do not touch hot compressor or air system parts Let system cool down before touching or servicing READ INSTRUCTIONS Read Owner s Manual before using or servicing unit Stop engine and release air pressure ...

Page 10: ... American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Mi ami FL 33126 phone 305 443 9353 website www aws org National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pa...

Page 11: ...à l installation à la réparation ou à l entretien de l appareil Déverrouiller l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de sécurité Installer et mettre à la terre correctement cet appareil conformément à son manuel d utilisation et aux codes nationaux provinciaux et municipaux Toujours vérifier la terre du cordon d alimentation Vérifier et s assurer que le fil de terre du cord...

Page 12: ...ourd des pantalons sans revers des chaussures hautes et un couvre chef Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes Suivre les recommandations dans OSHA 1910 252 a 2 iv et NFPA 51B pour les travaux à chaud et avoir de la surveillance et un extincteur à proxi mité DES PARTICULES VOLANTES peuvent blesser les yeux Le soudage l éca...

Page 13: ...ans le vase d ex pansion si présent et non dans le radiateur sauf si précisé autrement dans la section maintenance du manuel du moteur Si le moteur est chaud et que le liquide doit être vérifié opérer comme sui vant Mettre des lunettes de sécurité et des gants placer un torchon sur le bou chon du radiateur Dévisser le bouchon légèrement et laisser la vapeur s échapper avant d enlever le bouchon LA...

Page 14: ...dre des mesures supplémentaires telles que le déplacement du poste l utilisation de câbles blindés l utilisation de fil tres de ligne ou la pose de protecteurs dans la zone de travail 2 6 Principales normes de sécurité Safety in Welding Cutting and Allied Processes norme ANSI Z49 1 de l American Welding Society 550 N W LeJeune Rd Miami FL 33126 télé phone 305 443 9353 site Web www aws org Recommen...

Page 15: ...umes 2 2 Use forced ventilation or local exhaust to remove the fumes 2 3 Use ventilating fan to remove fumes 3 Welding sparks can cause explosion or fire 3 1 Keep flammables away from welding Do not weld near flammables 3 2 Welding sparks can cause fires Have a fire extinguisher nearby and have a watchperson ready to use it 3 3 Do not weld on drums or any closed containers 4 Arc rays can burn eyes...

Page 16: ...larity and make connections in numbered sequence shown 12 Once dead battery is charged disconnect cables in sequence shown 1 S 176 108 1 4 2 3 4 1 3 2 2 3 4 5 6 10 11 7 8 9 12 S 176 106 3 96 1 Warning Watch Out There are possible hazards as shown by the symbols 2 Moving parts such as fans rotors and belts can cut fingers and hands and cause injury Keep away from moving parts 1 2 Starting Aid Switc...

Page 17: ...touch hot muffler or pipes 1 S 176 230 2 3 96 1 2 4 3 5 6 S 176 104 3 96 1 Warning Watch Out There are possible hazards as shown by the symbols 2 Falling equipment can cause serious injury and damage 3 Use lifting eye to lift or move unit only Use proper equipmentwhen lifting 4 Do not use lifting eye to lift and support unit and trailer or other heavy devices or accessories 1 2 3 4 ...

Page 18: ...esignatedareas causing a possible fuel leak 3 Fuel tank is located inside base 4 Do not weld on base of unit 5 Weld only on supplied brackets or bolt unit down 1 5 3 4 2 1 Warning Watch Out There are possible hazards as shown by the symbols 2 Electric shock from wiring can kill 3 Moving parts such as fans rotors and belts can cut fingers and hands and cause injury Keep away from moving parts 1 2 3...

Page 19: ...re possible hazards as shown by the symbols Read Owner s Manual Follow instructions to activate battery 5 Check oil level Add oil if necessary 6 During the first 50 hours of operation keep welding load above 200 amperes Do not weld below 200 amperes of output 7 After the first 50 hours of operation change the oil and oil filter 2 1 4 DIESEL API CD MIL L 2104D CD SE CD SF 3 S 177 571 0 50 h Std 0 2...

Page 20: ...es V Volts Panel Local Remote Engine Air Temperature Or Engine Temperature Output Alternating Current Stick SMAW Welding Constant Current CC MIG GMAW Welding TIG GTAW Time h Hours s Seconds 1 Single Phase 3 Three Phase Read Operator s Manual Circuit Breaker Do Not Switch While Welding Electrode Connection Work Connection 3 G Engine Driven Three Phase Alternator With Rectifier Hz Hertz X Duty Cycle...

Page 21: ...A kW Generator Power Caterpillar 3024C Water Cooled Four Cylinder 32 8 HP Diesel Engine 25 gal 95 L 4 2 Dimensions Weights And Operating Angles Dimensions Height 60 in 1524 mm to top of exhaust G Width 28 1 2 in 724 mm mtg brackets turned in 30 3 4 in 781 mm mtg brackets turned out G Do not exceed tilt angles or engine could be damaged or unit could tip Do not move or operate unit where it could D...

Page 22: ...4 3 Volt Ampere Curves For CC Models 202 666 A The volt ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator Curves of all other settings fall between the curves shown DC AMPERES DC VOLTS Ranges 165 350 210 Max 100 250 45 85 65 120 Notes ...

Page 23: ... Curves of all other settings fall between the curves shown A Stick Mode B MIG Mode C TIG Mode 0 20 40 60 80 100 0 100 200 300 400 500 600 700 800 900 DC AMPERES DC VOLTS Ranges Max 150 420 110 315 75 200 40 90 0 20 40 60 80 100 0 100 200 300 400 500 600 700 800 900 1000 MAX MIN 0 10 20 30 40 50 60 70 80 90 100 0 50 100 150 200 250 300 350 400 450 500 Ranges 50 335 40 240 25 150 15 75 DC AMPERES D...

Page 24: ... 25 1 50 1 75 2 00 0 50 100 150 200 250 300 350 400 DC WELD AMPERES AT 100 DUTY CYCLE US Gal Hr IDLE Continuous Welding 4 6 Duty Cycle And Overheating Duty Cycle is percentage of 10 min utes that unit can weld at rated load without overheating Exceeding duty cycle can damage unit and void warranty 100 Duty Cycle At 300 Amperes 199 140 WELD AMPERES DUTY CYCLE ...

Page 25: ...50 125 0 10 20 30 40 50 60 AC AMPERES IN 120V MODE 4 8 Optional Three Phase Generator Curves 198 868 198 869 The ac power curves show the gen erator power available in amperes at the single phase 120 240 volt re ceptacle or three phase 240 volt terminals A 12 kVA kW Single Phase AC Output No Weld Load B 15 kVA kW Three Phase AC Output No Weld Load 180 200 220 240 260 280 0 10 20 30 40 50 60 70 AC ...

Page 26: ...its equipped with optional Polarity AC switch The volt ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator Curves of all other settings fall between the curves shown 0 20 40 60 80 100 0 50 100 150 200 250 300 350 400 450 500 Ranges 55 350 35 205 25 105 15 45 AC AMPERES AC VOLTS Notes ...

Page 27: ...unding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insu lated copper wire Electrically bond generator frame to vehicle frame by metal to metal contact GND PE 1 2 3 18 in 460 mm 18 in 460 mm 18 in 460 mm 18 in 460 mm 18 in 460 mm Movement Airflow Clearance 5 1 Installing Welding...

Page 28: ...ntil it snaps in place Lower lifting eye when not needed To lock the lifting eye in the upright position insert a 3 8 16 x 1 1 2 in carriage bolt through slot in bracket and secure with nut bolt and nut not supplied Tools Needed 2 1 3 Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual ...

Page 29: ...2 Mounting Brackets Supplied Mount unit on flat surface or use cross supports to support base Secure unit with mounting brack ets 3 1 2 in Bolt And Washer Minimum Not Supplied 4 3 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...

Page 30: ...pe 1 2 in Tools Needed Ref 802 311 Ref 201 841 Stop engine and let cool Point exhaust pipe in desired di rection but always away from front panel and direction of travel Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual ...

Page 31: ...l battery cells Wait ten minutes and check electro lyte level If necessary add electro lyte to raise to proper level Reins tall vent caps 6 Battery Charger Read and follow all instruc tions supplied with battery charger Charge battery for 12 minutes at 30 amperes or 30 minutes at 5 am peres Disconnect charging cables and install battery When electrolyte is low add only distilled water to cells to ...

Page 32: ...M 4406 Page 26 Return To Table Of Contents 5 6 Connecting The Battery 1 2 in Connect Negative Cable Last Tools Needed 802 168 B Ref 201 841 802 313 S 0756 C Reinstall cover after connecting battery Notes ...

Page 33: ... oil see maintenance label Coolant Check coolant level in radiator before start ing unit the first time If necessary add cool ant to radiator until coolant level is at bottom of filler neck Check coolant level in recovery tank daily If necessary add coolant to recovery tank until coolant level is between Cold Full and Hot Full levels If recovery tank coolant level was low also check coolant level ...

Page 34: ...zes Weld Cable Size and Total Cable Copper Length in Weld Circuit Not Exceeding 100 ft 30 m or Less 150 ft 45 m 200 ft 60 m 250 ft 70 m 300 ft 90 m 350 ft 105 m 400 ft 120 m Weld Output Terminals Stop engine before connectingto weld out put terminals Do not use worn dam aged undersized or poorly spliced cables Welding Amperes 10 60 Duty Cycle 60 100 Duty Cycle 10 100 Duty Cycle 100 4 20 4 20 4 20 ...

Page 35: ...t ac contactor control circuit C Output to remote control 10 volts dc in MIG or Stick mode 0 to 10 volts dc in TIG mode New LDR 14 long distance remote REMOTE OUTPUT D Remote control circuit common distance remote includes 120 V receptacle OUTPUT CONTROL E DC input command signal 0 to 10 volts from min to max of remote control with Voltage Amperage Adjust control at max OR 115 VOLTS AC I 115 volts...

Page 36: ...4406 Page 30 Return To Table Of Contents SECTION 6 OPERATING WELDING GENERATOR CC MODELS 6 1 Front Panel Controls For CC Models See Section 6 2 201 841 802 311 6 5 4 7 15 16 2 1 3 13 18 19 14 12 10 11 9 8 ...

Page 37: ... the engine charging system The meter should read about 14 volts dc when the en gine is running and about 12 volts dc when the engine is stopped 11 Engine Coolant Temperature Gauge Optional Normal temperature is 180 203 F 82 95 C When equipped with gauge option engine stops if temperature exceeds 220 F 104 C 12 Engine Oil Pressure Gauge Optional Normal pressure is 30 60 psi 207 414 kPa When equipp...

Page 38: ...on Remote Amperage Control Stick Adjust Optional Remote Control Set Switches Set Range Set Control Ref 154 862 A Ref 181 711 A 802 311 In Example Range 100 to 205 A DC Percentage Of Range 50 Max About 153 A DC 50 of 100 to 205 Max 153 A DC Min 75 A DC 1 6 4 Weld Control Arc Condition Information Label Set weld controls as shown to achieve softer or stiffer arc condi tions for different application...

Page 39: ...OM 4406 Page 33 Return To Table Of Contents Notes ...

Page 40: ...e 34 Return To Table Of Contents SECTION 7 OPERATING WELDING GENERATOR CC CV MODELS 7 1 Front Panel Controls For CC CV Models See Section 7 2 201 579 802 311 D 6 5 4 7 2 1 3 14 19 20 15 12 10 11 9 8 16 13 18 OR 17 ...

Page 41: ...unning and about 12 volts dc when the engine is stopped 11 Engine Coolant Temperature Gauge Optional Normal temperature is 180 203 F 82 95 C When equipped with gauge option engine stops if temperature exceeds 220 F 104 C 12 Engine Oil Pressure Gauge Optional Normal pressure is 30 60 psi 207 414 kPa When equipped with gauge option en gine stops if pressure is below 10 psi 69 kPa Weld Controls 13 Pr...

Page 42: ...he arc drive dig circuit provides additional am perage during low voltage short arc length conditions to prevent sticking electrodes The arc drive dig circuit is disabled when switch is in MIG or TIG positions Place switch in Electrode Hot Stick position when using optional three phase generator see Section 8 2 The engine auto idle option does not work in the Remote TIG mode 1 Process Contactor Sw...

Page 43: ... A Adjust Switch Set Range Control Not Used In Remote Stick Mode Set Remote Process Example Combination Remote Amperage Control TIG Adjust Optional Remote Control Set V A Adjust Switch Set Range Set Control Set Remote Process 1 In Example Process Stick Using Remote On Off Range 110 to 315 A DC Min 110 A DC Max 315 A DC Max 315 A DC Min 110 A DC In Example Process TIG Using Remote On Off Range 40 t...

Page 44: ...ed and press test button to verify GFCI is working properly 3 Circuit Breaker CB1 4 Circuit Breaker CB2 CB1 protects RC1 and the genera tor winding from overload If CB1 opens RC1 and GFCI1 do not work Place switch in On position to reset breaker CB2 protects GFCI1 from overload If CB2 opens GFCI1 does not work Press button to reset breaker If a circuit breaker continues to open contact Factory Aut...

Page 45: ...42 Circuit Grounding Lead 7 Lead 90 Neutral 8 Isolated Neutral Terminal 9 Jumper Lead 42 10 Grounding Terminal Jumper 42 is connected to lead 90 at factory Jumper 42 may be discon nected from neutral to meet applica ble electrical codes Lead 42 connects to front panel Ground stud 11 User Supplied Leads 12 Circuit Breaker CB7 User Terminals Connect user supplied leads to ter minals on CB7 and to th...

Page 46: ...speed and press test button to verify GFCI is working properly 5 Circuit Breaker CB2 6 Circuit Breaker CB3 CB2 protects GFCI1 from overload If CB2 opens GFCI1 does not work Press button to reset breaker CB3 protects RC1 from overload If CB3 opens RC1 does not work Press button to reset breaker If a circuit breaker continues to open contact Factory Autho rized Service Agent Generator power is not a...

Page 47: ...OM 4406 Page 41 Return To Table Of Contents SECTION 9 MAINTENANCE TROUBLESHOOTING 9 1 Maintenance Label ...

Page 48: ...ditions To be done by Factory Authorized Service Agent Every 8 h Check Fluid Levels See Section 5 7 Wipe Up 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...

Page 49: ... satisfaction is a primary concern to Caterpillar and to Caterpillar dealers If you have a problem that has not been handledto your complete satisfaction fol low these steps 1 Discuss your problem with a manager from the dealership 2 If your problem cannot be resolved at the dealer level without additional assistance call a Field Service Coordinator at 1 800 447 4986 3 If your needs still have not...

Page 50: ...Re place the safety element after servic ing the primary element three times Clean or replace primary element if dirty see note above before cleaning Re place primary element if damaged Re place primary element yearly or after six cleanings 1 Housing 2 Safety Element Optional 3 Primary Element 4 Dust Cap 5 Dust Ejector To clean air filter Wipe off cap and housing Remove cap and dump out dust Remov...

Page 51: ...ine and let cool 1 Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole 3 Exhaust Pipe Start engine and run at idle speed to blow out cleanout hole If nothing blows out of hole briefly cover end of exhaust pipe with fireproof material Stop engine and let cool Reinstall cleanout plug Tools Needed 3 2 1 3 8 in ...

Page 52: ...throttle rod and plunger until engine runs at idle speed Tighten locknut Be sure solenoid plunger pulls all the way in bottoms when energized If necessary move linkage to other hole in bracket or move cotter pin to other hole in throttle arm to set idle speed correctly Weld Power Speed Adjustment 3 Engine Weld Power Speed Adjustment Screw 4 Locknut Place Engine Control switch in Run position Loose...

Page 53: ...ter free fuel flows To replace primary fuel filter Turn filter counterclockwise Re move filter Fill new filter with fresh fuel Apply thin coat of fuel to gasket on new fil ter Install new filter and turn clock wise Bleed air from fuel system ac cording to engine manual Inspect fuel lines and replace if cracked or worn To replace secondary fuel filter See engine manual To drain sludge from fuel tan...

Page 54: ...ts the 24 volt ac output to remote receptacle RC14 and 24 volt output to field current regulator board PC1 CC CV models only If CB5 opens weld output and 24 volt out put to RC14 stops On units with op tional three phase generator gener ator power output at receptacle RC5 also stops if CB5 opens CB6 protects the 115 volt ac output to remote receptacle RC14 CC CV models only If CB6 opens 115 volt ou...

Page 55: ...Authorized Service Agent If Battery Charging Light Is On Have Factory Authorized Service Agent Check Alternator If Temperature Light Is On Correct Cause Of Overheating See Engine Manual If Engine Is Okay See Factory Authorized Service Agent Start Engine With No Load Applied Continue Pressing Shutdown Switch Until Engine Lights Go Off Normal Condition Engine Lights Go Off As Engine Reaches Normal O...

Page 56: ...ions inside and outside unit Be sure connection to work piece is clean and tight Use dry properly stored electrodes Remove excessive coils from weld cables Have Factory Authorized Service Agent check brushes and slip rings High weld output Check engine speed and adjust if necessary Have Factory Authorized Service Agent check OCV control circuit Low weld output Check engine speed and adjust if nece...

Page 57: ... clean and tight Use dry properly stored electrodes Remove excessive coils from weld cables Have Factory Authorized Service Agent check brushes and slip rings High weld output Check position of Ampere Range switch and Voltage Amperage Adjust control Check engine speed and adjust if necessary Have Factory Authorized Service Agent check field current regulator board PC1 Voltage Amperage control does...

Page 58: ...e F1 and replace if open see Section 9 8 Have Factory Authorized Service Agent check inte grated rectifier SR1 resistor R3 and capacitor C9 D Optional Three Phase Generator Power CC CV Models Trouble Remedy No or low output at optional three phase generator receptacle RC5 Place Process Contactor switch in Electrode Hot Stick position see Section 7 3 Reset circuit breaker CB7 see Section 8 2 Reset ...

Page 59: ...fuel supplier for fuel information Use correct grade oil for cold weather see Section 9 1 Engine suddenly stops Check oil and coolant levels Automatic shutdown system stops engine if oil pressure is too low or coolant temperatureis too high see Sections 5 7 and 9 9 See engine manual Engine slowly stopped and cannot be restarted Check fuel level Check engine air and fuel filters see Sections 9 4 an...

Page 60: ...OM 4406 Page 54 Return To Table Of Contents SECTION 10 ELECTRICAL DIAGRAMS Figure 10 1 Circuit Diagram For CC Welding Generator ...

Page 61: ...OM 4406 Page 55 Return To Table Of Contents 215 296 B ...

Page 62: ...OM 4406 Page 56 Return To Table Of Contents Figure 10 2 Circuit Diagram For CC CV Welding Generator ...

Page 63: ...OM 4406 Page 57 Return To Table Of Contents 215 297 B ...

Page 64: ...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 generatoris 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...

Page 65: ...ither DC position 3 Weld Cables Connect load bank to generator weld output terminals using proper size weld cables with correct connectors Observe correct polarity Start engine and run for several minutes Set load bank switches and then adjust generator A V control so load equals rated voltage and current of generator see nameplate rating label or the specifications section in this manual Check ge...

Page 66: ...als using proper size weld cables with correct connec tors polarity is not important 4 Voltmeter 5 Clamp On Ammeter Connect voltmeter and ammeter as shown if not provided on generator Start engine and run for several minutes Set grid switches and then adjust generator A V control so load equals rated voltage and current of the generator see nameplate rat ing label or the specifications sec tion in...

Page 67: ...2 2 Grounding Generator To Truck Or Trailer Frame S 0854 Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards 1 Equipment Grounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insulated copper wire If unit does not have GFCI r...

Page 68: ...power 2 Non Resistive Load Equipment with a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when running see Section 12 8 3 Rating Data Rating shows volts and amperes or watts required to run equipment VOLTS 115 4 5 60 AMPS Hz 1 2 3 3 EXAMPLE 1 If a drill uses 4 5 amperes at 115 volts calculate its running power requirementin watts 4 5 ...

Page 69: ...Equipment Farm Home Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 Milker Vacuum Pump 2 HP 10500 2800 FARM DUTY MOTORS 1 3 HP 1720 720 Std e g Conveyors 1 2 HP 2575 975 Feed Augers Air 3 4 HP 4500 1400 Compressors 1 HP 6100 1600 1 1 2 HP 8200 2200 2 HP ...

Page 70: ...P 3000 1000 1 HP 6000 1500 1 1 2 HP 8200 2200 2 HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1 3 HP 2100 700 Elec Hedge Trimmer 18 in 400 400 Flood Lights HID 125 100 Metal Halide 313 250 Mercury 1000 Sodium 1400 Vapor 1250 1000 Submersible Pump 400 gph 600 200 Centrifugal Pump 900...

Page 71: ... Induction Motor Starting Requirements Motor Start Code G H J K L M N P KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0 EXAMPLE Calculate the starting amperage required for a 230 V 1 4 HP motor with a motor start code of M Starting the motor requires 12 2 amperes 11 2 x 1 4 x 1000 230 12 2 A kVA HP x HP x 1000 VOLTS STARTING AMPERAGE Volts 230 HP 1 4 Using Table Code M results in kVA HP 11 2 12 9 How M...

Page 72: ...omer supplied if required by electrical code 4 Welding Generator Output Generator output voltage and wiring must be consistent with regular utility system volt age and wiring Connect generator with temporary or perma nent wiring suitable for the installation Turn off or unplug all equipment connected to generator before starting or stopping engine When starting or stopping the engine has low speed...

Page 73: ...125 38 75 23 50 15 40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 2 voltage drop Cord Lengths for 240 Volt Loads If unit does not have GFCI receptacles use GFCI protected extension cord Maximum Allowable Cord Length in ft m for Conductor Size AWG Current Amperes Load Watts 4 6 8 10 12 14 5 1200 700 213 450 137 225 84 200 61 7 1680 800 244 500...

Page 74: ...s common and not available unless listed 17 18 19 15 16 26 25 24 22 23 1 2 3 4 5 6 7 10 11 12 13 14 20 21 103 102 101 100 104 99 98 107 CC ONLY 108 106 FIG 13 2 OR 13 3 105 12 109 110 111 FIG 13 4 OR 13 5 112 114 115 FIG 13 7 116 117 97 9 8 113 119 120 Figure 13 1 Main Assembly ...

Page 75: ...ents 802 550 E 85 Fig 13 4 84 43 56 57 41 55 33 36 37 72 73 76 74 75 77 78 58 59 38 60 40 54 79 80 82 86 32 27 28 29 30 31 34 35 87 88 89 90 91 92 93 94 95 96 97 71 69 68 67 66 65 64 63 62 61 44 53 70 81 83 39 42 47 48 49 50 51 52 118 45 46 ...

Page 76: ...ia 4 20 189 464 SEAL weather lift eye 1 173 909 HOSE sae 312 id x 560 od x 24 000 order by ft 2 21 201 658 UPRIGHT center assembly 1 22 191 819 HOSE sae 312 id x 560 od x 14 000 order by ft 2 198 584 HOSE sae 312 id x 560 od x 5 000 order by ft 1 23 095 636 HOSE sae 187 id x 41 od x 30 000 order by ft 1 24 192 750 BASE fuel filter w adapter 1 25 192 744 FILTER fuel spin on 1 26 192 741 BLOCK space...

Page 77: ...lable through engine manufacturer 1 60 197 196 FITTING adapter oil drain 12mm male x 3 8 npt female 1 61 190 992 KEEPER latch engine access door 1 62 190 076 CHANNEL stiffener engine access 1 63 199 592 LATCH paddle series 20 black 1 64 202 165 LABEL diesel engine maintenance Caterpillar 3024 1 65 200 989 DOOR engine access 1 66 189 975 HINGE door access 180deg 2 67 190 190 TANK coolant recovery 1...

Page 78: ...89 699 RESISTOR WW tap 375W 10 ohm w mtg bkt 1 108 R3 189 699 RESISTOR WW tap 375W 10 ohm w mtg bkt 1 109 201 750 UPRIGHT front 1 110 182 761 LABEL warning general precautionary 1 110 176 105 LABEL warning general precautionary CE models only 1 111 13 4 13 5 PANEL front w components 1 112 202130 XFMR current sensing 1 113 176 109 LABEL caution using ether to aid engine 1 114 191 448 TOP cover fron...

Page 79: ... 8 D1 C1 189 701 DIODE CAPACITOR BOARD 1 9 SR1 SR2 035 704 RECTIFIER integ 40A 800V 2 10 CR5 090 104 RELAY encl 12VDC SPST 30A 15VDC 1 S5 011 609 SWITCH tgl spdt 15a 125vac on none on spd term chr located on front panel see 13 4 1 S6 011 622 SWITCH tgl 3pdt 15a 125vac on none on spd term located on front panel see 13 4 1 RC4 047 483 CONNECTOR rect univ 084 15P S 3 row rcpt cable panel lkg 1 RC3 15...

Page 80: ...15vdc 5pin flange mtg 1 18 CR2 CR3 090 104 RELAY encl 12VDC SPST 30A 15VDC spin flange mtg 2 212 452 HARNESS engine control consisting of 1 19 D10 C10 D11 C11 189 701 DIODE CAPACITOR BOARD 2 20 R8 217 335 RESISTOR BOARD 1 21 CB10 190 374 CIRCUIT BREAKER auto reset 12VDC 40A 1 148 850 SOCKET relay 5 pin 2 PLG4 114 062 CONNECTOR rect univ 084 15P S 3 row plug cable lkg 1 22 CR1 214 876 RELAY Encl 6v...

Page 81: ... on front panel see 13 5 1 150 316 CONN rect univ 039 6p s 3row plug cable lkg 6 177 859 CONN body 5 terminal to engine control switch S1 1 193 183 CONN rect cinch 18 pin 1 196 602 PLUG cavity 18 30 position cinch connector 4 196 603 SEAL switch 6 position rotary 250 shaft 1 141 450 CONN rect metrmate 10skt 1row plug cable lkg 1 13 PC7 195 706 MODULE pull to idle two output 7 pin 1 14 CR4 113 247 ...

Page 82: ...Part No Dia Mkgs Item No Figure 13 4 Panel Front w Components CC Models Figure 13 1 Item 111 Quantity 1 201 841 PLATE SCREENED ident control rating when ordering this item the nameplate should also be ordered 1 2 NAMEPLATE screened order by model and serial number 1 3 201 580 PANEL engine weld control 1 4 S3 189 382 SWITCH range changeover 1 192 558 HARNESS range consisting of 1 RC6 148 439 HOUSIN...

Page 83: ... 181 169 SPACER output stud 2 26 186 621 BOOT generic output stud 2 27 059 773 HANDLE switch 1 28 010 647 PIN spring cs 156 x 1 250 1 29 039 047 TERMINAL pwr output red 1 30 193 260 COVER receptacle 2 250 dia lexan 1 31 193 258 COVER receptacle GFCI 1 32 190 323 BOOT circuit breaker clear hex nut 1 33 193 143 BOOT magnetic shutdown switch 1 34 021 385 BOOT toggle switch lever 1 35 119 014 LEVER sw...

Page 84: ...gure 13 5 Panel Front w Components CC CV Models Description Part No Dia Mkgs Item No Figure 13 5 Panel Front w Components CC CV Models Figure 13 1 Item 111 Quantity 1 201 579 PLATE SCREENED ident control when ordering this item the nameplate should also be ordered 1 2 NAMEPLATE screened order by model and serial number 1 3 201 580 PANEL engine weld control 1 4 S3 189 382 SWITCH range changeover 1 ...

Page 85: ...it breaker 1 22 197 363 TERMINAL ring tng screw clamp 3 23 CB7 196 780 CIRCUIT BREAKER man reset 3p 1 24 201 106 PANEL gen power 1 24 201 107 PANEL gen power full kVA option 1 25 196 781 BOOT circuit breaker 3 pole 1 26 197 508 PLUG protective 1 27 077 440 BUSHING conduit 1 in 1 28 601 836 NUT 250 20 50hex 19h brs 3 39 197 291 COVER receptacle w gasket 1 30 083 030 STUD brs 250 20 x 1 750 w hex co...

Page 86: ... 647 PIN spring CS 156 x 1 250 1 62 097 924 KNOB pointer 1 625 dia x 250 ID w set scrws plstc 1 63 CB6 083 432 CIRCUIT BREAKER Man Reset 1p 10a 250vac Frict 1 193 158 HARNESS unit weld control CV consisting of 1 PLG6 114 063 CONNECTOR rect univ 084 4p s 1 row plug cable lkg 1 PLG8 193 184 CONNECTOR rect cinch 30 pin 1 PLG13 147 992 CONNECTOR rect univ 039 10p s 2 row plug cable 1 PLG3 158 465 CONN...

Page 87: ...plete 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...

Page 88: ... CONNECTOR kit rect univ 084 9P S 3 row plug cable lkg 1 187 651 SEAL wire univ 9P S 3 row 1 When ordering a component originally displaying a precautionary label the label should also be ordered Order label individually or as part of Label Kit 202 758 Recommended Spare Parts Optional To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts...

Page 89: ...OM 4406 Page 83 Return To Table Of Contents Hardware is common and not available unless listed 802 279 A 1 2 3 4 6 5 7 8 9 Figure 13 7 Main Rectifier Assembly ...

Page 90: ......

Page 91: ...trols Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Bobcat Trailblazer and Legend models 2 Items furnished by Miller but man...

Page 92: ... complete and retain with your personal records Always provide Model Name and Serial Style Number Call 1 800 4 A Miller or see our website at www MillerWelds com to locate a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Informati...

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Miller Electric Big 40 CAT, Owner'S Manual

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