Miller Electric Big 40G manual Moving Parts can cause injury, Battery Explosion can Blind

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MOVING PARTS can cause injury.

D Keep away from fans, belts, and rotors.

D Keep all doors, panels, covers, and guards closed and securely in place.

DStop engine before installing or connecting unit.

DHave only qualified people remove guards or covers for maint- enance and troubleshooting as necessary.

DTo prevent accidental starting during servicing, disconnect negative (–) battery cable from battery.

DKeep hands, hair, loose clothing, and tools away from moving parts.

DReinstall panels or guards and close doors when servicing is finished and before starting engine.

DBefore working on generator, remove spark plugs or injectors to keep engine from kicking back or starting.

DBlock flywheel so that it will not turn while working on generator components.

BATTERY EXPLOSION can BLIND.

DAlways wear a face shield, rubber gloves, and

protective clothing when working on a battery.

DStop engine before disconnecting or connect- ing battery cables or servicing battery.

DDo not allow tools to cause sparks when working on a battery.

DDo not use welder to charge batteries or jump start vehicles.

DObserve correct polarity (+ and –) on batteries.

DDisconnect negative (–) cable first and connect it last.

BATTERY ACID can BURN SKIN and EYES.

DDo not tip battery.

DReplace damaged battery.

DFlush eyes and skin immediately with water.

ENGINE EXHAUST GASES can kill.

DUse equipment outside in open, well-ventilated areas.

DIf used in a closed area, vent engine exhaust outside and away from any building air intakes.

ENGINE HEAT can cause fire.

DDo not locate unit on, over, or near combustible surfaces or flammables.

DKeep exhaust and exhaust pipes way from flammables.

EXHAUST SPARKS can cause fire.

DDo not let engine exhaust sparks cause fire.

DUse approved engine exhaust spark arrestor in required areas – see applicable codes.

1-4. Additional Symbols For Installation, Operation, And Maintenance

FALLING UNIT can cause injury.

DUse lifting eye to lift unit only, NOT running gear, gas cylinders, trailer, or any other accessories.

DUse equipment of adequate capacity to lift and support unit.

DIf using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.

FLYING SPARKS can cause injury.

D Wear a face shield to protect eyes and face.

D Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection.

D Sparks can cause fires — keep flammables away.

OVERUSE can cause OVERHEATING.

DAllow cooling period; follow rated duty cycle.

DReduce current or reduce duty cycle before starting to weld again.

DDo not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

DPut on grounded wrist strap BEFORE handling boards or parts.

DUse proper static-proof bags and boxes to store, move, or ship PC boards.

TILTING OF TRAILER can cause injury.

DUse tongue jack or blocks to support weight.

DProperly install welding generator onto trailer according to instructions supplied with trailer.

OVERHEATING can damage motors.

DTurn off or unplug equipment before starting or stopping engine.

DDo not let low voltage and frequency caused by low engine speed damage electric motors.

DDo not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable.

READ INSTRUCTIONS.

DUse only genuine MILLER replacement parts.

DPerform engine maintenance and service according to this manual and the engine manual.

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Contents
Processes OM-477Description From Miller to You Table of Contents Page ARC Rays can burn eyes and skin Symbol UsageArc Welding Hazards Electric Shock can killEngine Hazards Engine Heat can cause fire Battery Explosion can BlindMoving Parts can cause injury Engine Exhaust Gases can killARC Welding can cause interference Principal Safety StandardsEMF Information Radiation can cause interferenceLES Fumé ES ET LES GAZ peuvent ê tre dangereux Signification des symbolesConsignes DE SÉ Curité Lire Avant Utilisation UN Choc É Lectrique peut tuerLE Bruit peut affecter l’ouïe LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux DES PIÈ CES Chaudes peuvent provoquer des brû lures gravesLA Chute DE L’APPAREIL peut blesser DES Organes Mobiles peuvent provoquer des blessures’EXPLOSION DE LA Batterie peut LA Chaleur DU Moteur peut pro- voquer un incendieConsignes relatives aux stimulateurs cardiaques Principales normes de sé curitéInformation sur les champs é lectromagné tiques LE Soudage À L’ARC risque de provoquer des interfé rencesDefinitions SpecificationsSymbols And Definitions Weld, Power, And Engine SpecificationsFuel Consumption Dimensions, Weights, And Operating AnglesDimensions WeightDuty 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 100 Volt-Ampere CurvesDC Volts CC/DC Standard AC Amperes CV/DC Models with Optional CV-3 ModuleInstalling Muffler InstallationInstalling Welding Generator Connecting The Battery13 mm Full Gasoline Capacity 9 qt 8.5 L Engine Prestart ChecksTop View 10 100% Duty Cycle Connecting To Weld Output TerminalsSelecting Weld Cable Sizes 100 ft 30 m Or LessStop engine Remote 14 Receptacle RC3 Information Optional, See SectionTerminal Strip 3T Connections Optional Socket InformationFront Panel Controls See Section Operating Welding GeneratorStop engine and fix trouble if either warning light goes on Ampere Range SwitchDo not switch under load Description Of Front Panel Controls See SectionExample Combination remote amperage control Remote Control OptionalVolt Duplex And Optional Gfci Receptacles Operating Auxiliary EquipmentX 10 a + 120 V x 5 a = 3.0 kVA/kW Volt Duplex Receptacle OptionalFront Connecting Optional Auxiliary Power PlantMaintenance and Troubleshooting Maintenance Label Overload Protection Servicing Air CleanerTo Clean air filter Do not clean housing with air hoseStandard filter Changing Engine Oil And FilterStop engine and let cool Standard Oil Filter Cation makes it difficult to changeChanging Fuel Filter Inspecting And Cleaning Optional Spark Arrestor MufflerStop engine and let cool 1850 rpm Max Adjusting Engine Weld/Power SpeedAdjusting Governor Sensitivity Adjusting Engine Idle SpeedTrouble Remedy Adjusting Optional High Altitude CarburetorTroubleshooting WeldingAuxiliary Power See engine manual Coolant temperature gets too high see SectionCheck Engine Control switch, and replace if necessary EngineOM-477 Circuit Diagram For Welding Generator For Standard Models Electrical DiagramsOM-477 193 967-A Selecting Equipment Auxiliary Power GuidelinesGrounding Generator To Truck Or Trailer Frame Amperes x Volts = Watts Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Earth ground if supplyingFarm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Industrial Motors Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentKVA/HP x HP x Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting Requirements240 120 Ground Typical Connections To Supply Standby PowerCurrent Load Watts Amperes Selecting Extension Cord Use Shortest Cord PossibleOM-477 114 113 112 111 110 109 108 107 106 105 104 103 102 101 100 Parts ListIncludes 39 43 Dia Part Description Mkgs Quantity 025 2523 GeneratorGenerator -1 Item Includes 2539CB1,2 139 Control Box w/Components -3 Item Your distributor also gives ServiceSupport Miller Electric Mfg. Co Owner’s Record