Miller Electric Big 40G manual Control Box w/Components -3 Item

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Item		Dia.		Part	Description
	No.	Mkgs.		No.	Description	Quantity
					Figure 10-4. Control Box w/Components (Fig 10-3 Item 12)

. . . 1 . . . . . CR1			♦.	044 588 . . .	RELAY, encl 12VDC 3PDT	. . . 1
. . .	2 . . . .	. . R2	♦.	130 515 . . .	RESISTOR, board	. . . 1
. . . 3 . . . .		. . D1	.	189 701 . . .	DIODE/CAPACITOR BOARD	. . . 1
. . .	4 . . . .	. . 2T	.	116 005 . . .	BLOCK, term 10A 7P	. . . 1
. . .	5 . . . .	. . 1T	.	129 939 . . .	BLOCK, term 10A 19P	. . . 1
. . . 6 . . . .		. . . . . . . . . . . . .	.	130 608 . . .	MOUNTING BOX, components	. . . 1
. . .	7 . . . .	. . . . . . . . . . . . .	.	603 107 . . .	HOSE, nprn slit back .156 ID x .343 OD (order by ft)	. . . 1ft
. . . 8 . . . .		. . . . . . . . . . . . .	♦.	134 201 . . .	STAND-OFF SUPPORT, PC card	. . . 8
. . .	9 . . . . . PC1		♦.	166 205 . . .	CIRCUIT CARD, field current regulator	. . . 1
. . .	. . . . . . .	PLG1	.	135 275 . . .	CONNECTOR PLUG & SOCKETS	. . . 1
. . . 10 . . . .		. PC2	.	114 832 . . .	CIRCUIT CARD, voltage regulator	. . . 1
. . . 11 . . . .		CR99	.	090 104 . . .	RELAY, encl 12VDC SPST	. . . 1
. . . 12 . . . .		. SR2	.	097 353 . . .	DIODE/SCR, bridge integ 2scr 3 diodes	. . . 1
. . . 13 . . . .		. SR1	.	035 704 . . .	RECTIFIER, integ 40A 800V	. . . 1
. . . 14 . . .		Idle Mod	.	189 742 . . .	MODULE, pull to idle 5 pin	. . . 1
. Hardware is common and					1
. Hardware is common and
	not available unless listed.				2
					2
					3
						4

14	5

13

12

11

PC2

10

PC1

6

7

9

8

ST-109 773-C

Figure 10-4. Control Box w/Components

♦OPTIONAL

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.

OM-477 Page 54

Image 58

Contents Processes OM-477Description 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 ConsumptionDuty Cycle And Overheating AC Auxiliary PowerMinutes Welding Minutes Resting 5 KVA/KW Single-Phase Auxiliary Power Plant No Weld Load Optional AC Power Plant Curves12.5 KVA/KW Three-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 Muffler13 mm Full Gasoline Capacity 9 qt 8.5 L Engine Prestart ChecksTop View 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 filterChanging Fuel Filter Inspecting And Cleaning Optional Spark Arrestor MufflerStop engine and let cool 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 Selecting Equipment Auxiliary Power GuidelinesGrounding Generator To Truck Or Trailer Frame 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 Your distributor also gives ServiceSupport Owner’s Record Miller Electric Mfg. Co