Miller Electric Big 40 CAT Owner's Manual
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Miller Electric Big 40 CAT Owner's Manual

Miller Electric Big 40 CAT Owner's Manual

Engine driven welding generator
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www.MillerWelds.com
Big 40 CAT
OM-4406
January 2004
Processes
Description
Engine Driven Welding Generator
R
202 759T
Stick (SMAW) Welding
TIG (GTAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
(CE Compliant)

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Summary of Contents for Miller Electric Big 40 CAT

  • Page 1 Big 40 CAT Visit our website at www.MillerWelds.com OM-4406 January 2004 Processes Stick (SMAW) Welding TIG (GTAW) Welding MIG (GMAW) Welding Flux Cored (FCAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging Description Engine Driven Welding Generator (CE Compliant) 202 759T...
  • Page 2 ISO 9001:2000 Quality System Standard. particular model are also provided. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1-1. Symbol Usage ............... . 1-2.
  • Page 4 TABLE OF CONTENTS SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS 7-1. Front Panel Controls For CC/CV Models (See Section 7-2) 7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1) 7-3. Process/Contactor Switch On CC/CV Models 7-4.
  • Page 5 Declaration of Conformity for European Community (CE) Products NOTE This information is provided for units with CE certification (see rating label on unit). Miller Electric Mfg. Co. Manufacturer’s Name: 1635 W. Spencer Street Manufacturer’s Address: Appleton, WI 54914 USA Big 40...
  • Page 6 Declaration of Conformity for European Community (CE) Products NOTE This information is provided for units with CE certification (see rating label on unit). Miller Electric Mfg. Co. Manufacturer’s Name: 1635 W. Spencer Street Manufacturer’s Address: Appleton, WI 54914 USA Big 40 CAT...

  • Page 7: Section 1 − Safety Precautions − Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING Y Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.

  • Page 8: Engine Hazards

    WELDING can cause fire or explosion. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire.

  • Page 9: Compressed Air Hazards

    STEAM AND HOT COOLANT can burn. D If possible, check coolant level when engine is cold to avoid scalding. D Always check coolant level at overflow tank, if pres- ent on unit, instead of radiator (unless told otherwise in maintenance section or engine manual). D If the engine is warm, checking is needed, and there is no overflow tank, follow the next two statements.

  • Page 10: California Proposition 65 Warnings

    READ INSTRUCTIONS. D Use only genuine MILLER/Hobart replacement parts. D Perform engine and air compressor (if applicable) maintenance and service according to this manual and the engine/air compressor (if applicable) manu- als. H.F. RADIATION can cause interference. D High-frequency (H.F.) can interfere with radio naviga- tion, safety services, computers, and communica- tions equipment.

  • Page 11: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT Y Avertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions. 2-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives.

  • Page 12: Dangers Existant En Relation Avec Le Moteur

    LES ACCUMULATIONS DE GAZ ris- quent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz protecteur en cas de non utilisation. D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi- rateur d’adduction d’air homologué. LES RAYONS DE L’ARC peuvent pro- voquer des brûlures dans les yeux et sur la peau.

  • Page 13: Dangers Liés À L'air Comprimé

    L’EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE. D Toujours porter une protection faciale, des gants en caoutchouc et vêtements de protection lors d’une in- tervention sur la batterie. D Arrêter le moteur avant de débrancher ou de brancher les câbles de batterie.

  • Page 14: Principales Normes De Sécurité

    LE SURCHAUFFEMENT peut endom- mager le moteur électrique. D Arrêter ou déconnecter l’équipement avant de dé- marrer ou d’arrêter le moteur. D Ne pas laisser tourner le moteur trop lentement sous risque d’endommager le moteur électrique à cause d’une tension et d’une fréquence trop faibles. D Ne pas brancher de moteur de 50 ou de 60 Hz à...

  • Page 15: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Warning Label Definitions Return To Table Of Contents Warning! Watch Out! There are possible hazards as shown by the symbols. Become trained and read the instructions before working on the machine or welding. Electric shock from welding electrode or wiring can kill.
  • Page 16 − − OM-4406 Page 10 − − S-176 106 Return To Table Of Contents Warning! Watch Out! There are possible hazards as shown by the symbols. Do not smoke and keep matches and flames away from battery. Sparks can cause battery gases to explode.
  • Page 17 S-176 230 Return To Table Of Contents Warning! Watch Out! There are possible hazards as shown by the symbols. Hot muffler and exhaust pipes can cause severe burns. Do not touch hot muffler or pipes. Warning! Watch Out! There are possible hazards as shown by the symbols.
  • Page 18 OM-4406 Page 12 Return To Table Of Contents Warning! Watch Out! There are possible hazards as shown by the symbols. Fire hazard from leaking engine fuel. Fire can result from welding base non-designated areas causing a possible fuel leak. Fuel tank is located inside base.

  • Page 19: Manufacturer's Rating Labels For Ce Products

    0 − 50 h Std. 50 h Std. 3-2. Manufacturer’s Rating Labels For CE Products CC Models S-177 571 DIESEL 200A 0 − 200A API CD-MIL L 2104D, CD/SE, CD/SF Return To Table Of Contents Remove unit from shipping crate. Remove Owner’s Manual from unit.

  • Page 20: Symbols And Definitions

    3-3. Symbols And Definitions NOTE Some symbols are found only on CE products. Stop Engine Starting Aid Check Injectors/ Pump Positive Amperes Engine Stick (SMAW) Welding Time Three Phase Electrode Connection Duty Cycle Rated Idle Speed Contactor On OM-4406 Page 14 Fast (Run, Weld/ Power) Battery (Engine)

  • Page 21: Section 4 − Specifications

    SECTION 4 − SPECIFICATIONS 4-1. Weld, Power, And Engine Specifications Welding Weld Output Rated Welding Mode Range Output 45 − 500 A (CC Models) CC/DC 300 A, 40 Volts DC, 15 − 500 A 100% Duty Cycle (CC/CV Models) 400 A, 40 Volts DC, 400 A, 40 Volts DC, 60% Duty Cycle CV/DC...

  • Page 22: Volt-Ampere Curves For Cc Models

    4-3. Volt-Ampere Curves For CC Models Notes OM-4406 Page 16 Ranges 210 − Max 165 − 350 100 − 250 65 − 120 45 − 85 DC AMPERES Return To Table Of Contents The volt-ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator.

  • Page 23: Volt-Ampere Curves For Cc/Cv Models

    4-4. Volt-Ampere Curves For CC/CV Models A. Stick Mode B. MIG Mode C. TIG Mode Ranges 150 − 420 110 − 315 75 − 200 40 − 90 DC AMPERES DC AMPERES Ranges 50 − 335 40 − 240 25 − 150 15 −...

  • Page 24: Fuel Consumption

    4-5. Fuel Consumption 2.00 1.75 1.50 1.25 1.00 0.75 0.50 0.25 IDLE 0.00 DC WELD AMPERES AT 100% DUTY CYCLE 4-6. Duty Cycle And Overheating OM-4406 Page 18 100% Duty Cycle At 300 Amperes Continuous Welding % DUTY CYCLE Return To Table Of Contents The curve shows typical fuel use under weld or power loads.

  • Page 25: Ac Generator Power Curve

    4-7. AC Generator Power Curve AC AMPERES IN 240V MODE AC AMPERES IN 120V MODE 4-8. Optional Three-Phase Generator Curves A. 12 kVA/kW Single-Phase AC Output (No Weld Load) B. 15 kVA/kW Three-Phase AC Output (No Weld Load) AC AMPERES AC AMPERES Return To Table Of Contents The ac power curve shows the gen-...

  • Page 26: Volt-Ampere Curve For Cc/Cv Models In Ac Tig Mode

    4-9. Volt-Ampere Curve For CC/CV Models In AC TIG Mode Notes OM-4406 Page 20 Ranges 55 − 350 35 − 205 25 − 105 15 − 45 AC AMPERES Return To Table Of Contents AC output is only available on units equipped with optional Polarity/AC switch.

  • Page 27: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Installing Welding Generator (See Sections 5-2 And 5-3) Movement Location Grounding GND/PE Airflow Clearance 18 in (460 mm) 18 in (460 mm) Electrically bond generator frame to vehicle frame by metal-to-metal contact. Y Bed liners, shipping skids, and some running gears insulate the welding generator from the vehicle frame.

  • Page 28: Using Lifting Eye

    5-2. Using Lifting Eye Notes OM-4406 Page 22 Return To Table Of Contents Lifting Eye Carriage Bolt Raise lifting eye until 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).

  • Page 29: Mounting Welding Generator

    5-3. Mounting Welding Generator Supporting The Unit Inadequate support. Y Do not use flexible mounts. Using Mounting Brackets Tools Needed: 9/16 in Welding Unit In Place Bolting Unit In Place Return To Table Of Contents Y Do not weld on base. Weld- ing on base can cause fuel tank fire or explosion.

  • Page 30: Installing Exhaust Pipe

    5-4. Installing Exhaust Pipe Tools Needed: 1/2 in Notes OM-4406 Page 24 Return To Table Of Contents Y Stop engine and let cool. Point exhaust pipe in desired di- rection but always away from front panel and direction of travel. Ref.

  • Page 31: Activating The Dry Charge Battery (If Applicable)

    5-5. Activating The Dry Charge Battery (If Applicable) 5 A For 30 Minutes 30 A For 12 Minutes − Return To Table Of Contents Remove battery from unit. Eye Protection − Safety Glasses Or Face Shield Rubber Gloves Vent Caps Sulfuric Acid Electrolyte (1.265 Specific Gravity) Well...

  • Page 32: Connecting The Battery

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

  • Page 33: Engine Prestart Checks

    5-7. Engine Prestart Checks Full Diesel Check all engine fluids daily. Engine must be cold and on a level surface. Unit is shipped with 20W break-in oil. Automatic shutdown system stops engine if oil pressure is too low or coolant tempera- ture is too high.

  • Page 34: Connecting To Weld Output Terminals

    5-8. Connecting To Weld Output Terminals 802 311 5-9. Selecting Weld Cable Sizes* Weld Output Terminals Y Stop engine before Welding connecting to weld out- Amperes put terminals. Y Do not use worn, dam- aged, undersized, or poorly spliced cables. This chart is a general guideline and may not suit all applications.

  • Page 35: Connecting To Remote Amperage Adjust Receptacle Rc13 On Cc Models

    5-10. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models 5-11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models New! LDR-14 long distance remote distance remote (includes 120 V receptacle) *The remaining sockets are not used. 24 VOLTS AC 24 VOLTS AC REMOTE OUTPUT...

  • Page 36: Section 6 − Operating Welding Generator − Cc Models

    SECTION 6 − OPERATING WELDING GENERATOR − CC MODELS 6-1. Front Panel Controls For CC Models (See Section 6-2) 10 11 201 841 / 802 311 Return To Table Of Contents OM-4406 Page 30...

  • Page 37: Description Of Front Panel Controls For Cc Models (See Section 6-1)

    6-2. Description Of Front Panel Controls For CC Models (See Section 6-1) Engine Starting Controls Magnetic Shutdown Switch Use switch during start-up to bypass engine shutdown system. System stops engine if oil pressure is too low or coolant temperature is too high.

  • Page 38: Remote Amperage Control On Cc Models (Optional)

    6-3. Remote Amperage Control On CC Models (Optional) Example: Combination Remote Amperage Control (Stick) Set Switches Set Range 6-4. Weld Control/Arc Condition Information Label OM-4406 Page 32 Max = About 153 A DC (50% of 100 to 205) Set Control Return To Table Of Contents Remote Amperage Adjust Receptacle RC13...
  • Page 39 Notes Return To Table Of Contents OM-4406 Page 33...

  • Page 40: Section 7 − Operating Welding Generator − Cc/Cv Models

    SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS 7-1. Front Panel Controls For CC/CV Models (See Section 7-2) 10 11 201 579 / 802 311-D Return To Table Of Contents OM-4406 Page 34...

  • Page 41: Description Of Front Panel Controls For Cc/Cv Models (See Section 7-1)

    7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1) Engine Starting Controls Magnetic Shutdown Switch Use switch during start-up to bypass engine shutdown system. System stops engine if oil pressure is too low or engine temperature is too high.

  • Page 42: Process/Contactor Switch On Cc/Cv Models

    7-3. Process/Contactor Switch On CC/CV Models Switch Setting Switch Setting GTAW With HF Unit, Pulsing Remote − TIG Device, Or Remote Control Remote − Stick Stick (SMAW) With Remote On/Off Remote − MIG MIG (GMAW) Electrode Hot − MIG MIG (GMAW) Stick (SMAW), Electrode Hot −...

  • Page 43: Remote Voltage/Amperage Control On Cc/Cv Models (Optional)

    7-4. Remote Voltage/Amperage Control On CC/CV Models (Optional) Example: Combination Remote Amperage Control (Stick) Set Remote Set V/A Adjust Switch Process Example: Combination Remote Amperage Control (TIG) Set V/A Set Remote Process Adjust Switch Process = Stick (Using Remote On/Off) Set Range Control Not Used In Remote...

  • Page 44: Section 8 − Operating Auxiliary Equipment

    SECTION 8 − OPERATING AUXILIARY EQUIPMENT 8-1. 120 Volt And 240 Volt Receptacles OM-4406 Page 38 Return To Table Of Contents 120 V 20 A AC GFCI Receptacle GFCI1 240 V 30 A AC Twistlock Receptacle RC1 Receptacles supply 60 Hz single- phase power at weld/power speed.

  • Page 45: Connecting To Optional Three-Phase Generator (Cc/Cv Models Only)

    8-2. Connecting To Optional Three-Phase Generator (CC/CV Models Only) Single-Phase Power Connection Three-Phase Power Connection Y Close panel opening if no connections are made to generator. Remove plug before inserting leads. Reinstall bushing. Rear Of Panel 120V 120V Single Phase Output Volts 120/240...

  • Page 46: Optional Generator Power Receptacles

    8-3. Optional Generator Power Receptacles European Receptacle Australian Receptacle South African Receptacle OM-4406 Page 40 Return To Table Of Contents 120 V 20 A AC GFCI Receptacle GFCI1 240 V 16 A AC European Receptacle RC1 240 V 15 A AC Australian Receptacle RC1 240 V 15 A AC South African Receptacle RC1...

  • Page 47: Section 9 − Maintenance & Troubleshooting

    SECTION 9 − MAINTENANCE & TROUBLESHOOTING 9-1. Maintenance Label Return To Table Of Contents OM-4406 Page 41...

  • Page 48: Routine Maintenance

    9-2. Routine Maintenance Note Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period. Wipe Spills. Clean Air Filter. See Section 9-4. Check air cleaner hoses for cracks and loose clamps. Change Oil.

  • Page 49: Caterpillar Customer Assistance

    Check Radiator Fluid Level. See 9-3. Caterpillar Customer Assistance Every 1000 h Section 5-7. Blow Out Or Vacuum Inside. During Heavy Service, Clean Monthly. Check Valve Clearance.* SLUDGE Every 2000 h Clean/Set Injectors.* Return To Table Of Contents Change Fuel Filters.

  • Page 50: Servicing Air Cleaner

    9-4. Servicing Air Cleaner Keep nozzle 2 in (51 mm) from element. Blow OM-4406 Page 44 Optional Inspect aircleaner1 2/01− ST-153 929-B / ST-153 585 / Ref. S-0698-B / Ref. 201 841 Return To Table Of Contents Y Stop engine. Y Do not run engine without air cleaner or with dirty element.

  • Page 51: Inspecting And Cleaning Optional Spark Arrestor Muffler

    9-5. Inspecting And Cleaning Optional Spark Arrestor Muffler Tools Needed: 3/8 in Return To Table Of Contents Y Stop engine and let cool. Spark Arrestor Muffler Cleanout Plug Remove plug and remove any dirt covering cleanout hole. Exhaust Pipe Start engine and run at idle speed to blow out cleanout hole.

  • Page 52: Adjusting Engine Speed

    9-6. Adjusting Engine Speed OM-4406 Page 46 Engine Speed (No Load) 1850 rpm max (61.6 Hz) 1250 rpm (41.6 Hz) If necessary, move linkage to other hole in bracket or move cotter pin to other hole in throttle arm to set idle speed correctly.

  • Page 53: Servicing Fuel And Lubrication Systems

    9-7. Servicing Fuel And Lubrication Systems Return To Table Of Contents Y Stop engine and let cool. Y After servicing, start engine and check for fuel leaks. Stop engine, tighten connec- tions as necessary, and wipe up spilled fuel. Oil Filter Oil Drain Valve And Hose Oil Fill Cap Fuel Line...

  • Page 54: Overload Protection

    9-8. Overload Protection OM-4406 Page 48 Return To Table Of Contents Y Stop engine. When a circuit breaker or fuse opens, it usually indicates a more serious problem exists. Contact Factory Authorized Service Agent. Fuse F1 Fuse F2 F1 and F2 protect the stator exciter winding from overload.

  • Page 55: Diagnosing Causes Of Engine Fault Shutdowns

    9-9. Diagnosing Causes Of Engine Fault Shutdowns Pre-Start Diagnostic Checks Turn Engine Control Switch To Run/Idle Position While Pressing Magnetic Shutdown Switch. Diagnostic Checks While Running Start Engine (With No Load Applied). Normal Condition: Oil Pressure Light On; Battery Charging And Temperature Lights Off. If Oil Pressure Light Is Off, See Factory Authorized Service Agent.

  • Page 56: Troubleshooting

    9-10. Troubleshooting A. Welding − CC Models Trouble No weld output; generator power output Check position of Ampere Range switch. okay at ac receptacles. Check position of optional Polarity switch. Place Amperage Adjust switch in Panel position, or place switch in Remote position and connect remote control to Remote Amperage Adjust receptacle RC13 (see Sections 5-10 and 6-1).
  • Page 57 B. Welding − CC/CV Models Trouble No weld output; generator power output Place Process/Contactor switch in a Electrode Hot position, or place switch in a Remote position and okay at ac receptacles. connect remote contactor to optional Remote 14 receptacle RC14 (see Sections 5-11 and 7-1). Check position of Ampere Range switch.
  • Page 58 Trouble Min or max CV weld output only. Check position of Voltage/Amperage Adjust control and Voltage/Amperage Adjust switch. Repair or replace remote control device. Have Factory Authorized Service Agent check field current regulator board PC1. C. Standard Generator Power Trouble No generator power output at ac recep- Reset receptacle circuit breakers.
  • Page 59 Trouble Engine cranks but does not start. Press Magnetic Shutdown switch MS1 when starting engine. Check fuel level. Reset circuit breaker CB13 (see Section 9-8). Have Factory Authorized Service Agent check engine- wiring harness and components. Check battery and replace if necessary. Check engine charging system according to engine manual. Have Factory Authorized Service Agent check control relay CR2, and fuel solenoid FS1.

  • Page 60: Section 10 − Electrical Diagrams

    SECTION 10 − ELECTRICAL DIAGRAMS Figure 10-1. Circuit Diagram For CC Welding Generator Return To Table Of Contents OM-4406 Page 54...
  • Page 61 215 296-B Return To Table Of Contents OM-4406 Page 55...
  • Page 62 Figure 10-2. Circuit Diagram For CC/CV Welding Generator Return To Table Of Contents OM-4406 Page 56...
  • Page 63 215 297-B Return To Table Of Contents OM-4406 Page 57...

  • Page 64: Section 11 − Run-In Procedure

    SECTION 11 − RUN-IN PROCEDURE 11-1. Wetstacking OM-4406 Page 58 Return To Table Of Contents run_in1 8/01 Y Do perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur. Welding Generator Run diesel engines near rated volt- age and current during run-in period...

  • Page 65: Run-In Procedure Using Load Bank

    11-2. Run-In Procedure Using Load Bank Return To Table Of Contents Y Stop engine. Y Do not touch hot exhaust pipe, engine parts, or load bank/grid. Y Keep exhaust and pipe away from flammables. Y Do perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur.

  • Page 66: Run-In Procedure Using Resistance Grid

    11-3. Run-In Procedure Using Resistance Grid OM-4406 Page 60 Return To Table Of Contents Y Stop engine. Y Do not touch hot exhaust pipe, engine parts, or load bank/grid. Y Keep exhaust and pipe away from flammables. Y Do perform procedure at less than 20 volts weld output and do not exceed duty cycle or equip-...

  • Page 67: Section 12 − Generator Power Guidelines

    SECTION 12 − GENERATOR POWER GUIDELINES NOTE The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown. 12-1. Selecting Equipment 12-2. Grounding Generator To Truck Or Trailer Frame Electrically bond generator frame to vehicle frame by metal-to-metal contact.

  • Page 68: Grounding When Supplying Building Systems

    12-3. Grounding When Supplying Building Systems 12-4. How Much Power Does Equipment Require? AMPERES x VOLTS = WATTS EXAMPLE 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power requirement in watts. The load applied by the drill is 520 watts. EXAMPLE 2: If three 200 watt flood lamps are used with the drill from Example 1, add the individual loads to calculate total load.
  • Page 69 12-5. Approximate Power Requirements For Industrial Motors Industrial Motors Split Phase Capacitor Start-Induction Run Capacitor Start-Capacitor Run Fan Duty 12-6. Approximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Stock Tank De-Icer Grain Cleaner Portable Conveyor Grain Elevator Milk Cooler Milker (Vacuum Pump) FARM DUTY MOTORS Std.
  • Page 70 12-7. Approximate Power Requirements For Contractor Equipment Contractor Hand Drill Circular Saw Table Saw Band Saw Bench Grinder Air Compressor Electric Chain Saw Electric Trimmer Electric Cultivator Elec. Hedge Trimmer Flood Lights Submersible Pump Centrifugal Pump Floor Polisher High Pressure Washer 55 gal Drum Mixer Wet &...
  • Page 71 12-8. Power Required To Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code KVA/HP kVA/HP x HP x 1000 VOLTS EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4 HP motor with a motor start code of M. Volts = 230 HP = 1/4 11.2 x 1/4 x 1000...
  • Page 72 12-10. Typical Connections To Supply Standby Power Y Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes. Utility Electrical Service Y Have only qualified persons perform these connections according to all applicable codes and safety practic- Y Properly install and ground this equipment according to its Owner’s Manual and national, state, and local...
  • Page 73 12-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord. Current Load (Watts) (Amperes) 1200 1800 2400 3000 3600 4200 4800 5400 6000 *Conductor size is based on maximum 2% voltage drop Cord Lengths for 240 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord.

  • Page 74: Section 13 − Parts List

    SECTION 13 − PARTS LIST Hardware is common and not available unless listed. 111 (FIG. 13-4 OR 13-5) OM-4406 Page 68 115 (FIG 13-7) 106 (FIG 13-2 OR 13-3) 107 (CC ONLY) Figure 13-1. Main Assembly Return To Table Of Contents...
  • Page 75 85 (Fig. 13-4) Return To Table Of Contents OM-4406 Page 69 802 550-E...
  • Page 76 Item Dia. Part Mkgs....189 824 ....191 623 .
  • Page 77 Item Dia. Part Mkgs....214 658 ....*197 944 .
  • Page 78 Item Dia. Part Mkgs....Figure13-6 ....095 636 ..
  • Page 79 Figure 13-2. Control Box Assembly − CC Models Item Dia. Part Mkgs. Figure 13-2. Control Box Assembly − CC Models (Figure 13-1 Item 106) ..F1, F2 *085 874 ....046 432 .
  • Page 80 Item Dia. Part Mkgs. Figure 13-2. Control Box Assembly − CC Models (Continued) ....190 260 ..PLG3 .
  • Page 81 Item Dia. Part Mkgs. Figure 13-3. Control Box Assembly − CC/CV Models (Figure 13-1 Item 106) ..F1, F2 *085 874 ....046 432 .
  • Page 82 Hardware is common and not available unless listed. Figure 13-4. Panel, Front w/Components − CC Models Item Dia. Part Mkgs. Figure 13-4. Panel, Front w/Components − CC Models (Figure 13-1 Item 111) ....201 841 .
  • Page 83 Item Dia. Part Mkgs. Figure 13-4. Panel, Front w/Components − CC Models (Continued) ... . . 011 622 .......
  • Page 84 Hardware is common and not available unless listed. Figure 13-5. Panel, Front w/Components − CC/CV Models Item Dia. Part Mkgs. Figure 13-5. Panel, Front w/Components − CC/CV Models (Figure 13-1 Item 111) ....201 579 .
  • Page 85 Item Dia. Part Mkgs. Figure 13-5. Panel, Front w/Components − CC/CV Models (Continued) ... . . 193 118 ... . 193 234 .
  • Page 86 Item Dia. Part Mkgs. Figure 13-5. Panel, Front w/Components − CC/CV Models (Continued) ....170 391 ... 191 241 .
  • Page 87 Hardware is common and not available unless listed. Item Dia. Part Mkgs....132 053 ....183 387 .
  • Page 88 Item Dia. Part Mkgs....197 486 ....083 883 .
  • Page 89 Hardware is common and not available unless listed. 802 279-A Figure 13-7. Main Rectifier Assembly OM-4406 Page 83 Return To Table Of Contents...
  • Page 91 Warranty Questions? Call LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants 1-800-4-A-MILLER to its original retail purchaser that new Miller equipment sold for your local after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.

  • Page 92: Options And Accessories

    File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. 2004 Miller Electric Mfg. Co. 1/04 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA...

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