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OM-4427 Page 82

Some wiring harness components (switches, relays, circuit breakers) are also referenced

elsewhere in this parts list. Purchase components separately or as part of the associated

wiring harness.

Note

Description

Part

No.

Dia.

Mkgs.

Item

No.

Wiring Harnesses

Quantity

215054

Harness, control box, CC weld control (includes)

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

. .

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

SR1, SR2

035704

Rectifier, Integ Bridge 40. Amp 800v

. . . . . . . .

. .

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

D1/C1

189701

Diode/Capacitor Board,

. . . . . . . . .

. . .

. .

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

RC4

047483

Conn, Rect Univ 084 15p/S 3row Rcpt Cable/Panel Lkg

. . . . . . . . . .

. . . .

. .

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

CB11, CB12, CB13

139266

Circuit Breaker, Man Reset 1p 15a 250vac Frict

. .

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

CR7

188636

Relay, Ocv Control

. . . . . . . . . .

. . . .

. .

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

148850

Socket, Relay 5 Pin

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

. .

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

011622

Switch, Tgl 3pdt 15a 125vac On

−

none

−

on Spd Term

. . . . . . . . . . .

. . . . .

. .

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

011609

Switch, Tgl Spdt 15a 125vac On

−

none

−

on Spd Term Chr

. . . . . . . . . . .

. . . . .

. .

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

211292

Conn, Pack 4p 1row Female

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

. .

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

211293

Conn, Pack Terminal Position Assurance(Lock)

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

. .

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

164617

Clip, Wiring Straight

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

. .

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

021467

Switch, Tgl Spst 3a 250v Off

−

none

−

(On) Spd Term

. . . . . . . . . . .

. . . . .

. .

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

150316

Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg

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

. .

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

RC3

158466

Conn, Rect Univ 084 12p/S 3row Rcpt Cable/Panel Lkg

. . . . . . . . . .

. . . .

. .

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

RC1

135133

Conn, Rect Univ 084 9p/S 3row Rcpt Cable/Panel Lkg

. . . . . . . . . .

. . . .

. .

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

215377

Harness, control box, CV weld control (includes)

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

. .

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

CB11, CB12, CB13

139266

Circuit Breaker, Man Reset 1p 15a 250vac Frict

. .

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

SR1

035704

Rectifier, Integ Bridge 40. Amp 800v

. . . . . . . . . .

. . . .

. .

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

148850

Socket, Relay 5 Pin

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

. .

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

RC4

047483

Conn, Rect Univ 084 15p/S 3row Rcpt Cable/Panel Lkg

. . . . . . . . . .

. . . .

. .

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

RC3

158466

Conn, Rect Univ 084 12p/S 3row Rcpt Cable/Panel Lkg

. . . . . . . . . .

. . . .

. .

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

RC1

135133

Conn, Rect Univ 084 9p/S 3row Rcpt Cable/Panel Lkg

. . . . . . . . . .

. . . .

. .

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

150316

Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg

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

. .

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

193234

Switch, Rotary 6 Posn Gold Contacts

. . . . . . . . . . .

. . . . .

. .

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

021467

Switch, Tgl Spst 3a 250v Off

−

none

−

(On) Spd Term

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

. .

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

011609

Switch, Tgl Spdt 15a 125vac On

−

none

−

on Spd Term Chr

. . . . . . . . . . .

. . . . .

. .

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

D1/C1

189701

Diode/Capacitor Board,

. . . . . . . . .

. . .

. .

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

193183

Conn, Rect Cinch 18 Pin

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

. .

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

196602

Plug, Cavity 18,30 Position Cinch Connector

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

. .

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

196603

Seal, Switch 6 Position Rotary .250 Shaft

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

. .

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

141450

Conn, Rect Metrmate 10skt 1row Plug Cable Lkg

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

. .

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

093995

Circuit Breaker, Man Reset 1p 15a 250vac Frict

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

. .

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

211292

Conn, Pack 4p 1row Female

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

. .

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

211293

Conn, Pack Terminal Position Assurance(Lock)

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

. .

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

215013

Harness, weld control CC (includes)

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

. .

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

PLG3

158465

Conn, Rect Univ 084 12p/S 3row Plug Cable Lkg

. . . . . . . . . .

. . . .

. .

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

187654

Seal, Wire Univ 12p/S 3row

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

. .

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

PLG6

114063

Conn, Rect Univ 084 4p/S 1row Plug Cable Lkg

. . . . . . . . . .

. . . .

. .

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

215207

Harness, weld control CV (includes)

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

. .

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

PLG6

114063

Conn, Rect Univ 084 4p/S 1row Plug Cable Lkg

. . . . . . . . . .

. . . .

. .

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

PLG8

193184

Conn, Rect Cinch 30 Pin

. . . . . . . . . .

. . . .

. .

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

PLG13

147992

Conn, Rect Univ 039 10p/S 2row Plug Cable Lkg

. . . . . . . . .

. . .

. .

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

PLG3

158465

Conn, Rect Univ 084 12p/S 3row Plug Cable Lkg

. . . . . . . . . .

. . . .

. .

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

187654

Seal, Wire Univ 12p/S 3row

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

. .

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

196602

Plug, Cavity 18,30 Position Cinch Connector

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

. .

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

Содержание Big 40 C

Страница 1: ...ng Stick SMAW Welding MIG GMAW Welding Engine Driven Welding Generator OM 4427 215 622L 2006 01 Visit our website at www MillerWelds com Flux Cored FCAW Welding Air Carbon Arc CAC A Cutting and Gouging File Engine Drive Big 40 C Big 40 CX ...

Страница 2: ...ntinue 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 operatio...

Страница 3: ...ON 4 SPECIFICATIONS 12 4 1 Weld Power And Engine Specifications 12 4 2 Dimensions Weights And Operating Angles 12 4 3 Volt Ampere Curves For CC Models 13 4 4 Volt Ampere Curves For CC CV Models 14 4 5 Fuel Consumption 15 4 6 Duty Cycle And Overheating 15 4 7 AC Generator Power Curve 16 4 8 Optional Three Phase Generator Curves 16 SECTION 5 INSTALLATION 17 5 1 Installing Welding Generator 17 5 2 Us...

Страница 4: ... 8 3 Optional Generator Power Receptacles 36 SECTION 9 MAINTENANCE TROUBLESHOOTING 37 9 1 Maintenance Label 37 9 2 Routine Maintenance 38 9 3 Checking Generator Brushes 39 9 4 Servicing Air Cleaner 40 9 5 Inspecting And Cleaning Optional Spark Arrestor Muffler 41 9 6 Adjusting Engine Speed On Models With Automatic Idle Optional 42 9 7 Servicing Fuel And Lubrication Systems 43 9 8 Overload Protecti...

Страница 5: ...ach 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 cables over your body If earth grounding of the workpiece is required ground it directly with a sep arate c...

Страница 6: ...to treat them carefully CYLINDERS can explode if damaged Protect compressed gas cylinders from excessive heat mechanical shocks physical damage slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over ...

Страница 7: ...e 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 before servicing Use only genuine Miller Hobart replacement par...

Страница 8: ...y Standard AWS F4 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com 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 Pamphlet P 1 from Compressed Gas Association 173...

Страница 9: ... vérifier les connexions Vérifier fréquemment le cordon d alimentation pour voir s il n est pas endom magé ou dénudé remplacer le cordon immédiatement s il est endommagé un câble dénudé peut provoquer une électrocution Mettre l appareil hors tension quand on ne l utilise pas Ne pas utiliser des câbles usés endommagés de grosseur insuffisante ou mal épissés Ne pas enrouler les câbles autour du corp...

Страница 10: ... de gaz font normalement partie du procédé de soudage les manipuler avec précaution Protéger les bouteilles de gaz comprimé d une chaleur excessive des chocs mécaniques des dommages physiques du laitier des flammes ouvertes des étincelles et des arcs Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte bouteilles pour les empêcher de tomber ou de se renverser Te...

Страница 11: ... avant de toucher ou d effectuer la mainte nance LIRE LES INSTRUCTIONS Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil Arrêter le moteur et relâcher la pression avant d ef fectuer la maintenance Utiliser uniquement des pièces de rechange Miller Hobart 2 5 Dangers supplémentaires en relation avec l installation le fonctionnement et la maintenance LA CHUTE DE L APP...

Страница 12: ...es ANSI Standard Z49 1 de Global Engineering Documents téléphone 1 877 413 5184 site In ternet www global ihs com RecommendedSafe Practices for the Preparation for Welding and Cutting of Containers and Piping American Welding Society Standard AWS F4 1 de Global Engineering Documents téléphone 1 877 413 5184 site In ternet www global ihs com National Electrical Code NFPA Standard 70 de National Fir...

Страница 13: ...ds 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 200A 200A 5 50 h S...

Страница 14: ...OM 4427 Page 10 3 2 Manufacturer s Rating Labels CC Export Models CC CV Models CC Models CC CV Export Models ...

Страница 15: ...anel 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 U0 Rated No...

Страница 16: ...240 VAC 60 Hz In Addition To Standard 4 kVA kW Generator Power Caterpillar 3024C Water Cooled Four Cylinder 32 6 HP Diesel Engine 25 gal 95 L 4 2 Dimensions Weights And Operating Angles Dimensions Height 60 in 1524 mm to top of muffler Width 28 1 2 in 724 mm mtg brackets turned in 30 3 4 in 781 mm mtg brackets turned out G Depth 65 1 8 in 1654 mm Do not exceed tilt angles or engine could be damage...

Страница 17: ...age output capabilities of the welding generator Curves of all other settings fall between the curves shown DC AMPERES DC VOLTS 100 80 60 40 20 0 0 100 200 300 400 500 600 700 800 900 1000 Ranges 230 Max 170 365 110 225 70 130 55 85 Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual ...

Страница 18: ...tor Curves of all other settings fall between the curves shown A Stick Mode B MIG Mode C TIG Mode DC VOLTS DC AMPERES DC VOLTS DC AMPERES DC VOLTS DC AMPERES 100 80 60 40 20 0 0 100 200 300 400 500 600 700 800 900 1000 100 80 60 40 20 0 0 100 200 300 400 500 600 700 800 900 1000 MAX MIN 100 80 60 40 20 0 0 100 200 300 400 500 RANGES MAX 155 450 115 320 75 195 40 90 RANGES 60 365 35 250 25 155 15 7...

Страница 19: ...Gal Hr 0 50 100 150 200 250 300 350 400 450 500 0 00 0 25 0 50 0 75 1 00 1 25 1 50 1 75 2 00 2 25 2 50 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 400 Amperes 215 084 A ...

Страница 20: ... 60 AC AMPERES IN 120V MODE 4 8 Optional Three Phase Generator Curves 215 086 A 215 087 A 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 AC VOLTS AC VOLTS AC AMPERES AC AMPERES 280 260 240 220 200 180 0 10 ...

Страница 21: ...g 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 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 I...

Страница 22: ...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 ...

Страница 23: ...rackets 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 mm or large...

Страница 24: ...s Needed Ref 803 604 Ref 215 158 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 ...

Страница 25: ... If necessary add electro lyte to raise to proper level Reins tall vent caps 8 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 maintainproper level 1 Tools Needed 2 4 30 A For 12 Minutes 5...

Страница 26: ...aintenance 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 in radiato...

Страница 27: ...tive Weld Output Terminal Failure to properly connect weld cables may cause excessive heat and start a fire or damage your machine 3 Weld Output Terminal 4 Supplied Weld Output Terminal Nut 5 Weld Cable Terminal 6 Copper Bar Remove supplied nut from weld output termi nal Slide weld cable terminal onto weld output terminaland secure with nut so that weld cable terminal is tight against copper bar D...

Страница 28: ... ea 2 0 2x70 2 ea 3 0 2x95 2 ea 3 0 2x95 350 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 3 0 2x95 2 ea 4 0 2x120 400 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 4 0 2x120 2 ea 4 0 2x120 500 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 4 0 2x120 3 ea 3 0 3x95 3 ea 3 0 3x95 Chart is a general guideline and may not suit all applications If cables overheat...

Страница 29: ...cuit common 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 10 amperes 60 Hz ac Protected by circuit breaker CB6 J Contact closure to I completes 115 volt ac contactor control circuit Ref 803 602 GND K Chassis common NEUTRAL G Circuit common for 24 and 115 volt ac circuit The remaining ...

Страница 30: ...OM 4427 Page 26 SECTION 6 OPERATING WELDING GENERATOR CC MODELS 6 1 Front Panel Controls For CC Models See Section 6 2 12 215 070 803 602 11 2 1 8 13 14 9 7 6 4 5 3 10 ...

Страница 31: ...Amperage Adjust control adjusts amperage only when welding and does not adjust open circuit voltage The max OCV circuit is disabled when the Stick TIG Selection switch is in Scratch Start TIG position see item 10 8 Ampere Range Switch Do not switch under load Use switch to select weld amperage range For most welding applications use lowest amperagerange possible to help prevent arc outages 9 Amper...

Страница 32: ... Amperage Control Stick Adjust Optional Remote Control Set Switches Set Range Set Control Ref 154 862 A Ref 181 711 A 803 602 In Example Range 110 to 225 A DC Percentage Of Range 50 Max About 168 A DC 50 of 110 to 225 Max 168 A DC Min 90 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 applications ...

Страница 33: ...OM 4427 Page 29 Notes ...

Страница 34: ...OM 4427 Page 30 SECTION 7 OPERATING WELDING GENERATOR CC CV MODELS 7 1 Front Panel Controls For CC CV Models See Section 7 2 215 158 802 602 2 1 9 14 15 10 7 6 4 5 11 8 13 OR 12 3 ...

Страница 35: ...ck and TIG welding Read the upper set of numbers at each range for Stick welding and the lower set at each range for TIG welding Use the highest range for MIG welding and for cutting and gouging CAC A For most welding applications use lowest amperagerange possible to help prevent arc outages 10 Voltage AmperageAdjust Control With Process Contactor switch in any Stick or TIG setting use control to ...

Страница 36: ...rt arc length conditions to prevent stick ing electrodes The arc drive dig circuit is disabled when switch is in MIG or TIG positions Place switch in Weld Terminals Al ways On Stick position when us ing optional three phase generator see Section 8 2 The engine auto idle option does not work in the Remote On Off Switch Required TIG mode 1 Process Contactor Switch Settings Switch Setting Process Out...

Страница 37: ...tch 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 115 to 320 A DC Min 115 A DC Max 320 A DC Max 320 A DC Min 115 A DC In Example Process TIG Using Remote On Off Range 35 to 250 A DC Pe...

Страница 38: ...est 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 Autho rized Servi...

Страница 39: ...rcuit 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 the iso...

Страница 40: ...s 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 af fected by we...

Страница 41: ...OM 4427 Page 37 SECTION 9 MAINTENANCE TROUBLESHOOTING 9 1 Maintenance Label ...

Страница 42: ...L WATER Section 5 7 9 7 Fuel Water Separator Fuel Level Oil Level Oil Fuel Spills Coolant Level Every 50 Hours Section 9 4 Air Cleaner Element Weld Terminals Every 100 Hours Battery Terminals Air Cleaner Hoses Every 250 Hours 1 2 in 13 mm Engine Manual Section 9 5 Unreadable Labels Fan Belt Tension Oil Oil Filter Spark Arrestor Every 500 Hours Weld Cables Every 1000 Hours OR SLUDGE FUEL Section 5 ...

Страница 43: ... disconnect leads at brush hold er cap Remove brushes Replace brushes if damaged or if brush material is at or near minimum length 1 Damaged Brushes New Length 1 1 4 in 32 mm Minimum Length 5 8 in 16 mm Replace Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual ...

Страница 44: ...afety 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 Remove element s Wi...

Страница 45: ...ol 1 Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole 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 8 in 1 2 ...

Страница 46: ...itch to Stick Weld Terminals Always On position Idle Speed Adjustment 1 Throttle Rod Plunger 2 Locknut Loosen locknut Place Engine Con trol switch in Auto position Turn 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 th...

Страница 47: ...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 tank Beware of fi...

Страница 48: ...urrent regulator board PC1 CC CV models only If CB5 opens weld out put and 24 volt output to RC14 stops On units with optional three phase genera tor generator power output at receptacle RC5 also stops if CB5 opens CB6 protects the 115 volt ac output to re mote receptacle RC14 CC CV models only If CB6 opens 115 volt output to RC14 stops CB10 protects the engine battery circuit If CB10 opens the en...

Страница 49: ...sive 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 have Factory Authorized Service Agent adjust if necessary Have Factory Authorized Service Agent check OCV control circuit Low weld output Check engine speed and have Factory Authorized Servic...

Страница 50: ...t check brushes and slip rings High weld output Check position of Ampere Range switch and Voltage Amperage Adjust control Check engine speed and have Factory Authorized Service Agent adjust if necessary Have Factory Authorized Service Agent check field current regulator board PC1 and PC1 voltage feed back circuit Voltage Amperage control does not work when welding in Stick mode Place Ampere Range ...

Страница 51: ...vice Agent adjust if necessary Have Factory Authorized Service Agent adjust generator power field current resistor R3 Low output at generator power ac recep tacles Check engine speed and have Factory Authorized Service Agent adjust if necessary Check fuse 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 Opti...

Страница 52: ... off cold surface Use fuel formulated for cold weather diesel fuel can gel in cold weather Contact local 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 Section 5 7 Automatic shutdown system is inhibited...

Страница 53: ...OM 4427 Page 49 Notes ...

Страница 54: ...OM 4427 Page 50 SECTION 10 ELECTRICAL DIAGRAMS Figure 10 1 Circuit Diagram For CC Welding Generator ...

Страница 55: ...OM 4427 Page 51 223 522 B ...

Страница 56: ...OM 4427 Page 52 Figure 10 2 Circuit Diagram For CC CV Welding Generator ...

Страница 57: ...OM 4427 Page 53 223 523 B ...

Страница 58: ...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 If exhaust p...

Страница 59: ...nerator 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 name plate rating label or the specifi cations section in this manual Check generator and load bank meters after first five minutes...

Страница 60: ... 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 ad just generator A V control so load equals rated voltage and current of the generator see nameplate rating label or the specifications section in this manual Check generator and meters after first fi...

Страница 61: ...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 re ceptacles us...

Страница 62: ...sistive 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 A x 115 V 520 ...

Страница 63: ... 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 10550 2850 3 H...

Страница 64: ...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 gph 900 500 F...

Страница 65: ...or 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 Much Power Can ...

Страница 66: ...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 which causes ...

Страница 67: ...0 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 800 244 500 152 300 91 20...

Страница 68: ...0C Models Only 1 2 3 4 5 6 7 8 9 10 11 13 14 15 12 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 106 107 108 109 110 111 112 113 114 Fig 13 2 OR 13 3 115 116 CC ONLY 117 118 CV 119 CV 120 121 122 123 124 125 Fig 13 4 OR 13 5 126 127 Fig 13 7 Figure 13 1 Main Assembly Export Model Shown ...

Страница 69: ...34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 85 84 86 87 88 89 90 91 93 FIG 13 6 95 96 97 98 99 100 101 102 103 104 105 94 92 60 ...

Страница 70: ... bracket environmental coating 1 18 173 352 EXTRUSION rubber clamp bulb order by ft 3ft 19 189 708 FIREWALL top 1 20 191 307 COVER plate 1 21 189 763 BRACKET mtg air cleaner 1 22 189 618 HOSE air cleaner 1 23 198 457 TUBE air intake 1 24 173 036 HOSE elbow air cleaner 1 010 863 CLAMP hose 1 125 3 000 clp dia 4 25 189 764 AIR CLEANER intake 1 192 938 FILTER air element primary 1 192 939 FILTER air ...

Страница 71: ... lg No 1 awg w clamp and 406rng 1 54 203 430 BRACKET battery holddown 1 55 190 897 BATTERY stor 12V 650crk 110rsv gp 24 1 56 168 385 LABEL warning battery explosion can blind 1 57 225 120 LABEL warning moving parts can cause injury 1 58 201 183 COVER battery access 1 58 202 639 COVER battery access ss 1 59 201 006 BOLT j stl 312 18 x 8 500 pld 2 60 215 006 GUARD fan 1 61 197 496 HOSE radiator lowe...

Страница 72: ...gure13 6 GENERATOR 1 94 218 087 TANK fuel consisting of 1 95 189 909 FITTING stand pipe hose 250 x 9 260 lg 90deg zinc 1 96 095 636 HOSE sae 187 id x 410 od x 30 000 order by ft 1 97 201 025 CAP fuel fitting 1 98 189 913 FITTING stl barbed elbow zinc pld 1 99 190 142 SENDER fuel gauge 9 7500 deep tank 1 100 189 910 FITTING stand pipe hose 3125 x 9 260 lg 90deg zinc 1 101 181 572 BUSHING tank fuel ...

Страница 73: ...u nut multi thread 19 049 525 NUT 312 18 u nut multi thread 32 215 627 KIT label includes safety informational labels CC models 1 215 629 KIT label includes safety informational labels CC CV models 1 216 985 KIT label includes safety informational labels CC export models 1 216 984 KIT label includes safety informational labels CC CV export models 1 When ordering a component originally displaying a...

Страница 74: ...ohm faston te 1 7 201 078 CONTROL BOX rh 1 8 CR3 090 104 RELAY encl 12VDC SPST 30A 15VDC spin flange mtg 1 9 CR8 197 325 RELAY encl 12vdc spst 70a 4pin flange mtg 1 10 CR1 090 104 RELAY Encl 12vdc Spst 30a 15vdc 5pin Flange Mtg 1 11 CR6 090104 RELAY encl 12vdc spst 30a 15vdc 5pin flange mtg 1 12 D10 C10 D11 C11 189 701 DIODE CAPACITOR BOARD 2 13 CB10 190 374 CIRCUIT BREAKER auto reset 12VDC 40A 1 ...

Страница 75: ...00VDC 1 22 177 136 CLAMP capacitor 1 375dia 1 23 D1 C1 189 701 DIODE CAPACITOR BOARD 1 24 CB11 12 13 139 266 CIRCUIT BREAKER man reset 1P 15A 250VAC frict 3 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 ...

Страница 76: ... 70a 4pin flange mtg 1 7 CR1 090 104 RELAY Encl 12vdc Spst 30a 15vdc 5pin Flange Mtg 1 8 CR6 090 104 RELAY encl 12vdc spst 30a 15vdc 5pin flange mtg 1 9 D10 C10 D11 C11 189 701 DIODE CAPACITOR BOARD 2 10 CB10 190 374 CIRCUIT BREAKER auto reset 12VDC 40A 1 11 CB14 205 927 CIRCUIT BREAKER auto reset 12vdc 12 amp 1 12 CR5 223 710 RELAY encl 12vdc dpst no 25a 6pin flange 1 13 201 079 COVER control box...

Страница 77: ...E CAPACITOR BOARD 1 22 TD1 214 928 TIMER delay on make break open 30 sec 12vdc 1 23 CB11 12 13 139 266 CIRCUIT BREAKER man reset 1P 15A 250VAC frict 3 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 ...

Страница 78: ...rdware is common and not available unless listed 803 649 1 2 3 4 5 6 7 8 9 11 10 12 13 14 15 16 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 34 33 35 36 37 38 39 40 41 42 17 Figure 13 4 Panel Front w Components CC Models ...

Страница 79: ...1 14 GFCI1 151 981 RECEPTACLE str dx grd 2P3W 15 20A 125V GFCI 1 15 RC1 176 355 RECEPTACLE str 2p3w 16a 220v flange mtg export models only 1 16 190 861 LABEL warning electric shock and moving parts etc 1 17 215 347 PANEL gen pwr 1 17 215 405 PANEL gen pwr ss 1 17 215 403 PANEL gen pwr export models only 1 18 083 030 STUD brs 250 20 x 1 750 w hex collar 1 19 601 836 NUT 250 20 50hex 19h brs 3 20 19...

Страница 80: ...mponent originally displaying a precautionary label the label should also be ordered 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 Hardware is common and not available unless listed 803 650 11 31 14 30 27 54 42 53 52 51 50 46 47 49 48 44 39 40 41 38 ...

Страница 81: ...30R 1 15 CB2 093 996 CIRCUIT BREAKER man reset 1P 20A 250VAC frict 1 15 CB3 139 266 CIRCUIT BREAKER man reset 1P 15A 250VAC 1 16 GFCI1 151 981 RECEPTACLE str dx grd 2P3W 15 20A 125V GFCI 1 17 RC1 176 355 RECEPTACLE str 2p3w 16a 220v flange mtg export models only 1 18 RC5 182 954 RCPT str 3P4W 50A 125 250V 1 19 025 248 STAND OFF insul 250 20 x 1 2 1 20 604 102 CONNECTOR clamp cable 1 000 1 21 197 5...

Страница 82: ...DER Coolant Temp 300 Deg F M16 X 1 5 1 52 217 083 GAUGE Pressure Oil 0 100 Psi Electric 1 193 230 SENDER Pressure Oil 0 100 Psi 1 53 164 873 METER amp ac dc 0 500 0 600 dc scale 2 5 in 1 54 164 874 METER volt ac dc 0 100 scale 2 5 in 1 55 097 922 KNOB pointer 875 dia x 250 ID w set screws plstc 1 56 189 161 HANDLE switch range 1 57 010 647 PIN spring CS 156 x 1 250 1 58 097 924 KNOB pointer 1 625 ...

Страница 83: ...assembly complete full kVA option 1 7 225 120 LABEL warning moving parts can cause injury 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 83...

Страница 84: ...11 WASHER lock 318 ID x 0 586 6 30 139 341 WASHER exciter 4 31 190 823 BRUSH contact 3 32 208 469 CLIP spring 3 33 189 142 BRUSHHOLDER ASSEMBLY gen 1 34 602 242 WASHER flat 375IDx0 875odx 083t stl pld 2 35 602 211 WASHER Lock 318idx0 586odx 078t Stl Pld Split 312 2 36 604 534 SCREW 312 18x1 25 hex hd pln gr5 pld 2 When ordering a component originally displaying a precautionary label the label shou...

Страница 85: ...NNECTION BOARD rectifier AC 1 2 188 517 BUS BAR connection board 3 3 188 135 ENCLOSURE rectifier 2 4 134 201 STAND OFF support 3 5 PC3 215 755 CIRCUIT CARD ASSEMBLY protection 1 6 188 136 INSULATOR heat sink 8 7 188 493 HEAT SINK rectifier al 2 8 D3 D5 D7 037 956 DIODE rect 275A 300V SP 3 9 D2 D4 D6 037 957 DIODE rect 275A 300V RP 3 To maintain the factory original performance of your equipment us...

Страница 86: ...vac Frict 3 SR1 035704 Rectifier Integ Bridge 40 Amp 800v 1 148850 Socket Relay 5 Pin 1 RC4 047483 Conn Rect Univ 084 15p S 3row Rcpt Cable Panel Lkg 1 RC3 158466 Conn Rect Univ 084 12p S 3row Rcpt Cable Panel Lkg 1 RC1 135133 Conn Rect Univ 084 9p S 3row Rcpt Cable Panel Lkg 1 150316 Conn Rect Univ 039 6p S 3row Plug Cable Lkg 6 S6 193234 Switch Rotary 6 Posn Gold Contacts 1 021467 Switch Tgl Sps...

Страница 87: ... Flange Mtg 1 192558 Harness range switch includes 1 RC6 148389 Conn Rect Univ 084 4p S 1row Rcpt Cable Panel Lkg 1 201109 Harness receptacle auxiliary power includes 1 RC1 147632 Rcpt Tw Lk Grd 2p3w 30a 250v L6 30r 1 GFCI1 151981 Rcpt Str Dx Grd 2p3w 15 20a 125v 5 20r Gfi 1 CB2 093996 Circuit Breaker Man Reset 1p 20a 250vac Frict 1 201053 Harness receptacle auxiliary power export models includes ...

Страница 88: ......

Страница 89: ...and Blankets APT SAF Model Plasma Cutting Torches Remote Controls 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 Trail...

Страница 90: ... retain with your personal records Always provide Model Name and Serial Style Number Contact 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 Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering ...

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