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Big 40 CAT
Miller Electric Big 40 CAT - User Manual
92 pages
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Big
40
CA
T
(CE
Compliant
)
OM
-4406
202 759T
January 2004
Visit our website at
www.Miller
Welds
.c
om
Pro
cesses
Descrip
tio
n
Air Carbon Arc (CAC-A)
Cutting and Gouging
Stick (SMAW
)
W
elding
Engine Driven Welding Generator
TIG (GT
A
W
) W
elding
MIG (GMAW)
W
elding
Flux Cored (FCA
W
) W
elding
2
Table of Contents
Main Page
Default Chapter
3
Table of Contents
3
Section 1 − Safety Precautions − Read before Using
7
Symbol Usage
7
Arc Welding Hazards
7
NOISE Can Damage Hearing
8
CYLINDERS Can Explode if Damaged
8
Engine Hazards
8
Compressed Air Hazards
9
Additional Symbols for Installation, Operation, and Maintenance
9
California Proposition 65 Warnings
10
Principal Safety Standards
10
EMF Information
10
Section 2 − Consignes de Sécurité − Lire Avant Utilisation
11
Signification des Symboles
11
Dangers Relatifs au Soudage à L'arc
11
Dangers Existant en Relation Avec le Moteur
12
Dangers Liés à L'air Comprimé
13
Dangers Supplémentaires en Relation Avec L'installation, le Fonctionnement et la Maintenance
13
Principales Normes de Sécurité
14
Information Sur les Champs Électromagnétiques
14
Section 3 − Definitions
15
Warning Label Definitions
15
Manufacturer's Rating Labels for CE Products
19
Symbols and Definitions
20
Section 4 − Specifications
21
Weld, Power, and Engine Specifications
21
Dimensions, Weights, and Operating Angles
21
Volt-Ampere Curves for CC Models
22
Volt-Ampere Curves for CC/CV Models
23
Fuel Consumption
24
Duty Cycle and Overheating
24
AC Generator Power Curve
25
Optional Three-Phase Generator Curves
25
Volt-Ampere Curve for CC/CV Models in AC TIG Mode
26
Section 5 − Installation
27
Installing Welding Generator (See Sections 5-2 and 5-3)
27
Using Lifting Eye
28
Mounting Welding Generator
29
Installing Exhaust Pipe
30
Activating the Dry Charge Battery (if Applicable)
31
Connecting the Battery
32
Engine Prestart Checks
33
Connecting to Weld Output Terminals
34
Selecting Weld Cable Sizes
34
Connecting to Remote Amperage Adjust Receptacle RC13 on CC Models
35
Connecting to Remote 14 Receptacle RC14 on CC/CV Models
35
Section 6 − Operating Welding Generator − CC Models
36
Front Panel Controls for CC Models (See Section 6-2)
36
Description of Front Panel Controls for CC Models (See Section 6-1)
37
Remote Amperage Control on CC Models (Optional)
38
Weld Control/Arc Condition Information Label
38
Section 7 − Operating Welding Generator − CC/CV Models
40
Front Panel Controls for CC/CV Models (See Section 7-2)
40
Description of Front Panel Controls for CC/CV Models (See Section 7-1)
41
Process/Contactor Switch on CC/CV Models
42
Remote Voltage/Amperage Control on CC/CV Models (Optional)
43
Section 8 − Operating Auxiliary Equipment
44
120 Volt and 240 Volt Receptacles
44
Connecting to Optional Three-Phase Generator (CC/CV Models Only)
45
Optional Generator Power Receptacles
46
Section 9 − Maintenance & Troubleshooting
47
Maintenance Label
47
Routine Maintenance
48
Caterpillar Customer Assistance
49
Servicing Air Cleaner
50
Inspecting and Cleaning Optional Spark Arrestor Muffler
51
Adjusting Engine Speed
52
Servicing Fuel and Lubrication Systems
53
Overload Protection
54
Diagnosing Causes of Engine Fault Shutdowns
55
Troubleshooting
56
Section 10 − Electrical Diagrams
60
Section 11 − Run-In Procedure
64
Wetstacking
64
Run-In Procedure Using Load Bank
65
Run-In Procedure Using Resistance Grid
66
Section 12 − Generator Power Guidelines
67
Selecting Equipment
67
Grounding Generator to Truck or Trailer Frame
67
Grounding When Supplying Building Systems
68
Power Required to Start Motor
71
Selecting Extension Cord (Use Shortest Cord Possible)
73
Section 13 − Parts List
74
Owner's Record
92
For Service
92
Options and Accessories
92
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Miller Electric Big 40 CAT Specifications
General
Brand
Miller Electric
Model
Big 40 CAT
Category
Welding System
Language
English
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