Miller Electric Big 40 WG manual Engine Prestart Checks, Coolant Recovery Tank, Fuel, Oil

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4-7. Engine Prestart Checks

Check radiator coolant level when

fluid is low in recovery tank.

Full

Capacity: 9 qt (8.5L)

Full

Gasoline

Full

Coolant Recovery Tank

Hot Full

Cold Full

802 731

.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.

.This unit has a low oil pressure shut- down switch. However, some condi- tions may cause engine damage before the engine shuts down. Check oil level often and do not use the oil pressure shutdown system to monitor oil level.

Follow run-in procedure in engine manual.

Fuel

Add fresh fuel before starting engine the first

time (see engine maintenance label for fuel specifications).

Oil

After fueling, check oil with unit on level sur- face. If oil is not up to full mark on dipstick, add oil (see maintenance label).

Coolant

Check coolant level in radiator before start- ing unit the first time. If necessary, add cool- ant to radiator until coolant level is at bottom of filler neck.

Check coolant level in recovery tank daily. If necessary, add coolant to recovery tank until coolant level is between Cold Full and Hot Full levels. If recovery tank coolant level was low, also check coolant level in radiator. Add coolant if level is below bottom of radia- tor filler neck.

Engine coolant is a mixture of water and ethylene glycol base antifreeze. Add anti- freeze to mixture if using the unit in tempera-

tures below –34°F (–37°C).

Keep radiator and air intake clean and free of dirt.

YIncorrect engine temperature can damage engine. Do not run engine without a properly working thermo- stat and radiator cap.

.To improve cold weather starting:

Keep battery in good condition. Store battery in warm area off concrete sur- face.

Use correct grade oil for cold weather (see Section 8-1).

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Contents Processes OM-4405Description From Miller to You Table of Contents Options and Accessories Warranty 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 DefinitionsDimensions, Weights, And Operating Angles Volt-Ampere Curves For CC ModelsTIG Mode Stick ModeMIG Mode Volt-Ampere Curves for CC/CV ModelsFuel Consumption Duty Cycle And Overheating12 kVA/kW Single-Phase Auxiliary Power Plant No Weld Load AC Auxiliary Power CurveOptional AC Power Plant Curves 15 kVA/kW Three-Phase Auxiliary Power Plant No Weld LoadInstalling Welding Generator See Sections 4-2 InstallationUsing Lifting Eye Welding Unit In Place Bolting Unit In Place Installing Exhaust PipeMounting Welding Generator To Bolt Unit In PlaceRead and follow all instruc Activating The Dry Charge Battery If ApplicableDo not overfill battery cells ChargerConnecting The Battery Connect Negative Cable LastFuel Coolant Recovery TankEngine Prestart Checks OilConnecting To Weld Output Terminals Selecting Weld Cable SizesRef 862-A / 048 720-K / 802 Connecting To Remote 14 Receptacle RC14 On CC/CV Models Socket InformationOperating Welding Generator CC Models Front Panel Controls For CC Models See SectionEngine Starting Controls Engine Indicator LightsDo not switch under load To StartRemote Amperage Control On CC Models Optional OM-4405 Operating Welding Generator CC/CV Models Front Panel Controls For CC/CV Models See SectionUse switch to select weld amperage range Voltage/Amperage Adjust Switch And Remote 14 ReceptacleProcess/Contactor Switch Process/Contactor Switch On CC/CV ModelsProcess/Contactor Switch Settings RunningProcess Remote Voltage/Amperage Control On CC/CV Models OptionalSet Remote Set Range Set RemoteOperating Auxiliary Equipment Volt And 240 Volt ReceptaclesThree-Phase Power Connection Single-Phase Power Connection Single-Phase Auxiliary PowerRear Of Panel 240 V 15 a AC South African Receptacle RC1 Optional Auxiliary Power ReceptaclesCircuit Breaker CB2 Circuit Breaker CB3 Maintenance & Troubleshooting Maintenance Label100 h Routine Maintenance50 h 250 h1000 h Inspecting And Cleaning Optional Spark Arrestor Muffler500 h Stop engine and let coolServicing Air Cleaner Adjusting Engine Weld/Power Speed MaximumEngine Speed Adjusting Engine Idle SpeedNo Load Adjusting Governor Sensitivity Tools Needed 1/2Servicing Fuel And Lubrication Systems Press button to reset breaker Overload ProtectionFault Condition Diagnosing Causes Of Engine Fault ShutdownsDiagnostic Checks While Running 20s Start Engine With No Load AppliedTroubleshooting Welding CC ModelsWelding CC/CV Models Repair or replace wire feederTacle see Section Optional Auxiliary Power Plant Standard Auxiliary PowerEngine Ant temperature is too high see Sections 4-7 Wiring harness and componentsShutdown switch is released Out Or coolant temperature is too high see Sections 4-7OM-4405 Electrical Diagrams Circuit Diagram For CC Welding Generator201 991-A Circuit Diagram For CC/CV Welding Generator 201 992-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 Selecting Extension Cord Use Shortest Cord Possible Current Load Watts AmperesOM-4405 107 106 101 105 103 Parts ListCC only 104 -4 or 108 See FIGDia Part Description Dia Part Description Mkgs Quantity Control Box Assembly CC Models Control Box Assembly CC Models -1 Item Control Box Assembly CC/CV Models 177 CONN, body 5 terminal to engine control switch S1 193 Panel, Front w/Components CC Models MS1 Panel, Front w/Components CC/CV Models Panel, Front w/Components CC/CV Models -1 ItemPC6 192 Generator Generator -1 Item Main Rectifier Assembly Your distributor also gives ServiceSupport Owner’s Record Miller Electric Mfg. Co

Big 40 WG specifications

The Miller Electric Big 40 WG is a versatile and powerful welding generator designed to meet the demands of professionals in the field. Known for its reliability and robust performance, the Big 40 WG is the ideal choice for those who require both welding capabilities and a portable power source.

One of the standout features of the Big 40 WG is its ability to produce a substantial output of up to 10,000 watts of continuous power. This ensures that users have enough capacity to run various tools and equipment, making it perfect for job sites where electricity may not readily be available. The generator is powered by a Kohler Command PRO engine, renowned for its durability and efficiency, ensuring that users can depend on its performance even in the toughest conditions.

The machine offers a dual capability for electric welding and stick welding, which enables users to tackle a variety of applications, from light maintenance tasks to heavy-duty industrial jobs. The Big 40 WG features an easy-to-use control panel, equipped with clear indicators and outputs that simplify operation. Whether you need to switch between welding modes or adjust settings, the intuitive design allows for quick responses and seamless operation.

In terms of technology and innovation, the Big 40 WG includes advanced features such as an automatic idle speed adjustment, which increases fuel efficiency and reduces wear on the engine. This technology not only helps save on fuel costs but also minimizes noise levels, providing a more pleasant working environment.

Another key characteristic of the Big 40 WG is its portability. Engineered with a lightweight frame and built-in lifting hooks, it is easy to transport and maneuver, making it an excellent choice for on-site work. The rugged construction ensures that the generator can withstand the rigors of outdoor use, enhancing its lifespan and reliability.

For those in search of a welding generator that delivers on performance, functionality, and portability, the Miller Electric Big 40 WG stands out as a preferred option. Its combination of powerful output, advanced technologies, and user-friendly features makes it a valuable tool for professionals across various industries, ensuring they can complete their jobs effectively and efficiently, no matter where they are.
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