Miller Electric Big 40 CAT User Manual

Big 40 CAT (CE Compliant)OM-4406 202 759TJanuary 2004Visit our website atwww.MillerWelds.comProcessesDescriptionAir Carbon Arc (CAC-A)Cutting and Gou

OM-4406 Page 4 Return To Table Of ContentsREAD INSTRUCTIONS. Use only genuine MILLER/Hobart replacementparts. Perform engine and air compressor (if

OM-4406 Page 5Revenez à la table des matièresSECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANTUTILISATIONrom_fre 8/03 Avertissement: Protégez vous et l

OM-4406 Page 6Revenez à la table des matièresLES ACCUMULATIONS DE GAZ ris-quent de provoquer des blessures oumême la mort. Fermer l’alimentation du g

OM-4406 Page 7Revenez à la table des matièresL’EXPLOSION DE LA BATTERIE peutRENDRE AVEUGLE. Toujours porter une protection faciale, des gants encaout

OM-4406 Page 8Revenez à la table des matièresLE SURCHAUFFEMENT peut endom-mager le moteur électrique. Arrêter ou déconnecter l’équipement avant de dé

OM-4406 Page 9Return To Table Of ContentsSECTION 3 − DEFINITIONS3-1. Warning Label Definitions3/96Warning! Watch Out! There arepossible hazards as sho

OM-4406 Page 10Return To Table Of Contents3/961 Warning! Watch Out! Thereare possible hazards asshown by the symbols.2 Do not smoke and keepmatches an

OM-4406 Page 11Return To Table Of Contents3/961 Warning! Watch Out! Thereare possible hazards asshown by the symbols.2 Hot muffler and exhaust pipesca

OM-4406 Page 12Return To Table Of Contents1 Warning! Watch Out! Thereare possible hazards asshown by the symbols.2 Fire hazard from leakingengine fuel

OM-4406 Page 13Return To Table Of Contents3/961 Remove unit from shippingcrate. Remove Owner’sManual from unit. Followinstructions to install muffler.

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

OM-4406 Page 14Return To Table Of Contents3-3. Symbols And DefinitionsSome symbols are found only on CE products.NOTEStop EngineFast (Run, Weld/Power)

OM-4406 Page 15Return To Table Of ContentsSECTION 4 − SPECIFICATIONS4-1. Weld, Power, And Engine SpecificationsWeldingModeWeld OutputRangeRated Weldin

OM-4406 Page 16Return To Table Of Contents0204060801000 100 200 300 400 500 600 7004-3. Volt-Ampere Curves For CC Models202 666-AThe volt-ampere curve

OM-4406 Page 17Return To Table Of Contents4-4. Volt-Ampere Curves For CC/CV Models202 655 / 202 656 / 202 654The volt-ampere curves show theminimum an

OM-4406 Page 18Return To Table Of Contents4-5. Fuel ConsumptionThe curve shows typical fuel useunder weld or power loads.199 0320.000.250.500.751.001.

OM-4406 Page 19Return To Table Of Contents4-7. AC Generator Power Curve193 018The ac power curve shows the gen-erator power in amperes availableat the

OM-4406 Page 20Return To Table Of Contents4-9. Volt-Ampere Curve For CC/CV Models In AC TIG Mode207 045 AC output is only available onunits equipped

OM-4406 Page 21Return To Table Of ContentsSECTION 5 − INSTALLATIONinstall3 6/03 − Ref. 800 652 / Ref. 800 477-A / 803 274 Always securely fasten weld

OM-4406 Page 22Return To Table Of Contents5-2. Using Lifting EyeRef. 802 3111 Lifting Eye2 Nut3 Carriage BoltRaise lifting eye until it snaps inplace.

OM-4406 Page 23Return To Table Of Contents5-3. Mounting Welding GeneratorTools Needed:9/16 in2234Welding Unit In PlaceBolting Unit In Place Do not we

TABLE OF CONTENTSSECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol

OM-4406 Page 24Return To Table Of Contents5-4. Installing Exhaust Pipe1/2 inTools Needed:Ref. 802 311 / Ref. 201 841 Stop engine and let cool. Point

OM-4406 Page 25Return To Table Of Contents5-5. Activating The Dry Charge Battery (If Applicable)Remove battery from unit.1 Eye Protection − SafetyGlas

OM-4406 Page 26Return To Table Of Contents5-6. Connecting The Battery1/2 in−+ Connect Negative (−) Cable Last.Tools Needed:802 168-B / Ref. 201 841 /

OM-4406 Page 27Return To Table Of Contents5-7. Engine Prestart Checks Check all engine fluids daily.Engine must be cold and on a level surface.Unit i

OM-4406 Page 28Return To Table Of Contents5-8. Connecting To Weld Output Terminals802 311Tools Needed:3/4 in12 Stop engine.1 Positive (+) Weld Output

OM-4406 Page 29Return To Table Of Contents5-10. Connecting To Remote Amperage Adjust Receptacle RC13 On CC ModelsRef. 154 862-A / 048 720-K / 802 3111

OM-4406 Page 30Return To Table Of ContentsSECTION 6 − OPERATING WELDING GENERATOR − CC MODELS6-1. Front Panel Controls For CC Models (See Section 6-2)

OM-4406 Page 31Return To Table Of Contents6-2. Description Of Front Panel Controls For CC Models (See Section 6-1)Engine Starting Controls1 Magnetic S

OM-4406 Page 32Return To Table Of Contents6-3. Remote Amperage Control On CC Models (Optional)1 Remote Amperage AdjustReceptacle RC13Connect optional

OM-4406 Page 33Return To Table Of ContentsNotes

TABLE OF CONTENTSSECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Front Panel

OM-4406 Page 34Return To Table Of ContentsSECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS7-1. Front Panel Controls For CC/CV Models (See Sectio

OM-4406 Page 35Return To Table Of Contents7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1)Engine Starting Controls1 Magneti

OM-4406 Page 36Return To Table Of Contents7-3. Process/Contactor Switch On CC/CV Models1 Process/Contactor Switch Weld output terminals are ener-gize

OM-4406 Page 37Return To Table Of Contents7-4. Remote Voltage/Amperage Control On CC/CV Models (Optional)1 Remote 14 Receptacle RC14Connect optional r

OM-4406 Page 38Return To Table Of ContentsSECTION 8 − OPERATING AUXILIARY EQUIPMENT8-1. 120 Volt And 240 Volt Receptacles191 624-A21 120 V 20 A AC GFC

OM-4406 Page 39Return To Table Of Contents8-2. Connecting To Optional Three-Phase Generator (CC/CV Models Only)Ref. 197 399 / 802 332-E Place Process

OM-4406 Page 40Return To Table Of Contents8-3. Optional Generator Power Receptacles21 120 V 20 A AC GFCI Receptacle GFCI12 240 V 16 A AC EuropeanRecep

OM-4406 Page 41Return To Table Of ContentsSECTION 9 − MAINTENANCE & TROUBLESHOOTING9-1. Maintenance Label

OM-4406 Page 42Return To Table Of Contents9-2. Routine Maintenance Follow the storage procedure in the engine owner’s manual if the unit will not be u

OM-4406 Page 43Return To Table Of ContentsEvery 1000 hCheck RadiatorFluid Level. SeeSection 5-7.Change FuelFilters. SeeSection 9-7.Service WeldingGene

dec_con1_11/02Declaration of Conformity forEuropean Community (CE) ProductsThis information is provided for units with CE certification (see rating la

OM-4406 Page 44Return To Table Of Contents9-4. Servicing Air Cleaner Stop engine. Do not run engine without aircleaner or with dirty element. En-gin

OM-4406 Page 45Return To Table Of Contents9-5. Inspecting And Cleaning Optional Spark Arrestor MufflerRef. 802 311 / Ref. 802 160 / Ref. 201 841 Stop

OM-4406 Page 46Return To Table Of Contents9-6. Adjusting Engine Speed802 490 / 802 538-AAfter tuning engine, check enginespeed with tachometer or freq

OM-4406 Page 47Return To Table Of Contents9-7. Servicing Fuel And Lubrication Systems802 490 / Ref. 801 434 Stop engine and let cool. After servicin

OM-4406 Page 48Return To Table Of Contents9-8. Overload Protection802 170-D / Ref. 802 311219874 Stop engine. When a circuit breaker or fuseopens, i

OM-4406 Page 49Return To Table Of Contents9-9. Diagnosing Causes Of Engine Fault ShutdownsRef. 201 841Use the front panel engine lights tohelp determi

OM-4406 Page 50Return To Table Of Contents9-10. TroubleshootingA. Welding − CC ModelsTrouble RemedyNo weld output; generator power outputokay at ac re

OM-4406 Page 51Return To Table Of ContentsB. Welding − CC/CV ModelsTrouble RemedyNo weld output; generator power outputokay at ac receptacles.Place Pr

OM-4406 Page 52Return To Table Of ContentsTrouble RemedyMin or max CV weld output only. Check position of Voltage/Amperage Adjust control and Voltage/

OM-4406 Page 53Return To Table Of ContentsTrouble RemedyEngine cranks but does not start. Press Magnetic Shutdown switch MS1 when starting engine.Chec

dec_con1_sound11/02Declaration of Conformity forEuropean Community (CE) ProductsThis information is provided for units with CE certification (see rati

OM-4406 Page 54Return To Table Of ContentsSECTION 10 − ELECTRICAL DIAGRAMSFigure 10-1. Circuit Diagram For CC Welding Generator

OM-4406 Page 55Return To Table Of Contents215 296-B

OM-4406 Page 56Return To Table Of ContentsFigure 10-2. Circuit Diagram For CC/CV Welding Generator

OM-4406 Page 57Return To Table Of Contents215 297-B

OM-4406 Page 58Return To Table Of ContentsSECTION 11 − RUN-IN PROCEDURErun_in1 8/0111-1. Wetstacking Do not perform run-inprocedure at less than 20vo

OM-4406 Page 59Return To Table Of Contents11-2. Run-In Procedure Using Load BankS-0683 Stop engine. Do not touch hot exhaustpipe, engine parts, or l

OM-4406 Page 60Return To Table Of Contents11-3. Run-In Procedure Using Resistance GridS-0684 Stop engine. Do not touch hot exhaustpipe, engine parts

OM-4406 Page 61Return To Table Of ContentsSECTION 12 − GENERATOR POWER GUIDELINESThe views in this section are intended to be representative of all en

OM-4406 Page 62Return To Table Of Contents12-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse

OM-4406 Page 63Return To Table Of Contents12-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running Wa

OM-4406 Page 1Return To Table Of ContentsSECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USINGrom _nd_8/03 Warning: Protect yourself and others from inj

OM-4406 Page 64Return To Table Of Contents12-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsH

OM-4406 Page 65Return To Table Of Contents12-8. Power Required To Start MotorS-06241 Motor Start Code2 Running Amperage3 Motor HP4 Motor VoltageTo fin

OM-4406 Page 66Return To Table Of Contents12-10. Typical Connections To Supply Standby Power Have only qualified persons performthese connections acc

OM-4406 Page 67Return To Table Of Contents12-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt Loads If unit does n

OM-4406 Page 68Return To Table Of ContentsSECTION 13 − PARTS LIST Hardware is common andnot available unless listed.1718191516262524222312345 6710111

OM-4406 Page 69Return To Table Of Contents802 550-E85 (Fig. 13-4)8443565741553336377273767475777858593860405479808286322728293031343587888990919293949

OM-4406 Page 70Return To Table Of ContentsDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-1. Main AssemblyQuantity1 189 824 PANEL, gen LH 1. . . . . . .

OM-4406 Page 71Return To Table Of ContentsDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-1. Main Assembly (Continued)Quantity40 214 658 HOSE, radiator up

OM-4406 Page 72Return To Table Of ContentsDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-1. Main Assembly (Continued)Quantity85 Figure13-6 GENERATOR 1. .

OM-4406 Page 73Return To Table Of ContentsRef. 802 551-E211163714211316125241510918174221982023Figure 13-2. Control Box Assembly − CC ModelsDescriptio

OM-4406 Page 2 Return To Table Of ContentsWelding on closed containers, such as tanks, drums, orpipes, can cause them to blow up. Sparks can fly off f

OM-4406 Page 74Return To Table Of ContentsDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-2. Control Box Assembly − CC Models (Continued)Quantity190 260 H

OM-4406 Page 75Return To Table Of ContentsDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-3. Control Box Assembly − CC/CV Models (Figure 13-1 Item 106)Qua

OM-4406 Page 76Return To Table Of Contents Hardware is common andnot available unless listed.802 266-E13451215182324262932353738394546471725303116202

OM-4406 Page 77Return To Table Of ContentsDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-4. Panel, Front w/Components − CC Models (Continued)Quantity7 S6

OM-4406 Page 78Return To Table Of Contents Hardware is common andnot available unless listed.802 332-F12345679485051525359606162131819202122232425262

OM-4406 Page 79Return To Table Of ContentsDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-5. Panel, Front w/Components − CC/CV Models (Continued)Quantity5

OM-4406 Page 80Return To Table Of ContentsDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-5. Panel, Front w/Components − CC/CV Models (Continued)Quantity5

OM-4406 Page 81Return To Table Of Contents802 552-A Hardware is common andnot available unless listed.56892428303132331272526353643102721293420171811

OM-4406 Page 82Return To Table Of ContentsDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-6. Generator (Continued)Quantity21 197 486 ADAPTER, Engine Perki

OM-4406 Page 83Return To Table Of Contents Hardware is common andnot available unless listed.802 279-A123465789Figure 13-7. Main Rectifier Assembly

OM-4406 Page 3Return To Table Of ContentsSTEAM AND HOT COOLANT can burn. If possible, check coolant level when engine is cold toavoid scalding. Alwa

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 8/03Your distributor also givesyou ...ServiceYou always get the fa

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