Miller Electric Big 40G manual From Miller to You

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Miller is the first welding equipment manufacturer in the U.S.A. to be registered to the ISO 9001 Quality System Standard.

From Miller to You

Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way.

That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy.

Today, the people that build and sell Miller products continue 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 quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there’s a Troubleshooting section that will help you figure out what the problem is. The parts list will then help you to decide which exact part you may need to fix the problem. Warranty and service information for your 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. To locate your nearest

distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web.

Working as hard as you do

–every power source from Miller is backed by the most hassle-free warranty in the business.

Miller offers a Technical Manual which provides more detailed service and parts information for your unit. To obtain a Technical Manual, contact your local distributor. Your distributor can also supply you with Welding Process Manuals such as SMAW, GTAW, GMAW, and GMAW-P.

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Contents Description OM-477Processes From Miller to You Table of Contents Page Electric Shock can kill Symbol UsageArc Welding Hazards ARC Rays can burn eyes and skinEngine Hazards Engine Exhaust Gases can kill Battery Explosion can BlindMoving Parts can cause injury Engine Heat can cause fireRadiation can cause interference Principal Safety StandardsEMF Information ARC Welding can cause interferenceUN Choc É Lectrique peut tuer Signification des symbolesConsignes DE SÉ Curité Lire Avant Utilisation LES Fumé ES ET LES GAZ peuvent ê tre dangereuxDES PIÈ CES Chaudes peuvent provoquer des brû lures graves LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux LE Bruit peut affecter l’ouïeLA Chaleur DU Moteur peut pro- voquer un incendie DES Organes Mobiles peuvent provoquer des blessures’EXPLOSION DE LA Batterie peut LA Chute DE L’APPAREIL peut blesserLE Soudage À L’ARC risque de provoquer des interfé rences Principales normes de sé curitéInformation sur les champs é lectromagné tiques Consignes relatives aux stimulateurs cardiaquesWeld, Power, And Engine Specifications SpecificationsSymbols And Definitions DefinitionsWeight Dimensions, Weights, And Operating AnglesDimensions Fuel ConsumptionMinutes Welding Minutes Resting AC Auxiliary PowerDuty Cycle And Overheating 12.5 KVA/KW Three-Phase Auxiliary Power Plant No Weld Load Optional AC Power Plant Curves5 KVA/KW Single-Phase Auxiliary Power Plant No Weld Load AC Amperes CV/DC Models with Optional CV-3 Module Volt-Ampere CurvesDC Volts CC/DC Standard 100Connecting The Battery InstallationInstalling Welding Generator Installing MufflerTop View Engine Prestart Checks13 mm Full Gasoline Capacity 9 qt 8.5 L 100 ft 30 m Or Less Connecting To Weld Output TerminalsSelecting Weld Cable Sizes 10 100% Duty CycleSocket Information Remote 14 Receptacle RC3 Information Optional, See SectionTerminal Strip 3T Connections Optional Stop engineOperating Welding Generator Front Panel Controls See SectionDescription Of Front Panel Controls See Section Ampere Range SwitchDo not switch under load Stop engine and fix trouble if either warning light goes onRemote Control Optional Example Combination remote amperage controlOperating Auxiliary Equipment Volt Duplex And Optional Gfci ReceptaclesVolt Duplex Receptacle Optional X 10 a + 120 V x 5 a = 3.0 kVA/kWConnecting Optional Auxiliary Power Plant FrontMaintenance and Troubleshooting Maintenance Label Do not clean housing with air hose Servicing Air CleanerTo Clean air filter Overload ProtectionCation makes it difficult to change Changing Engine Oil And FilterStop engine and let cool Standard Oil Filter Standard filterStop engine and let cool Inspecting And Cleaning Optional Spark Arrestor MufflerChanging Fuel Filter Adjusting Engine Weld/Power Speed 1850 rpm MaxAdjusting Engine Idle Speed Adjusting Governor SensitivityWelding Adjusting Optional High Altitude CarburetorTroubleshooting Trouble RemedyAuxiliary Power Engine Coolant temperature gets too high see SectionCheck Engine Control switch, and replace if necessary See engine manualOM-477 Electrical Diagrams Circuit Diagram For Welding Generator For Standard ModelsOM-477 193 967-A Grounding Generator To Truck Or Trailer Frame Auxiliary Power GuidelinesSelecting Equipment Earth ground if supplying Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Amperes x Volts = WattsIndustrial Motors Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsSingle-Phase Induction Motor Starting Requirements Power Required To Start MotorHow Much Power Can Generator Supply? KVA/HP x HP xTypical Connections To Supply Standby Power 240 120 GroundSelecting Extension Cord Use Shortest Cord Possible Current Load Watts AmperesOM-477 Parts List 114 113 112 111 110 109 108 107 106 105 104 103 102 101 100Includes 39 43 Dia Part Description Mkgs Quantity 025 Generator 2523Generator -1 Item 2539 IncludesCB1,2 139 Control Box w/Components -3 Item Support ServiceYour distributor also gives Owner’s Record Miller Electric Mfg. Co