Miller Electric Big 40 WG manual Dia Part Description

Page 66

Item

Dia.

 

Part

Description

 

 

No.

 

Mkgs.

 

No.

Quantity

 

 

 

 

 

 

Figure 11-1. Main Assembly

 

 

 

 

 

 

 

 

 

. . .

1

. . . .

. . . . . .

. . .

189 824 . .

PANEL, gen LH

. . . 1

. . .

2

. . . .

. . . . . .

. . .

191 623 . .

LABEL, warning all panels must be in place while running

. . . 2

. . .

3

. . . .

. . . . . .

. . +189 828 . .

PANEL, engine side

. . . 1

. . . 4 . . . . . Z1 .

. . CC202 151 . .

REACTOR, ac

. . . 1

. . . 4 . . . . . Z1 .

. . CV201 514 . .

REACTOR, ac

. . . 1

. . .

5

. . . . . 1T .

. . .

038 621 . .

BLOCK, term 30A 4 pole frict term str

. . . 1

. . .

. . .

. . . .

. . . . . .

. . .

038 620 . .

LINK, jumper term blk 30A

. . . 2

. . .

6

. . . .

. . . . . .

. . .

081 499 . .

BRACKET, mtg strip terminal

. . . 1

. . .

7

. . . .

. . . . . .

. . .

201 701 . .

BRACE, front to center upright

. . . 2

. . .

8

. . SR4, SR5 .

035 704 . .

RECTIFIER, integ bridge 40. amp 800v

. . . 2

. . . 9 . . . . CB4

. . .

045 061 . .

CIRCUIT BREAKER, auto reset 24vdc 7 amp

. . . 1

. . . 10

. . . .

. . . . . .

. . .

201 697 . .

PAN, reactor and rectifier

. . . 1

. . . 11

. . . .

. T1 .

. . .

201 613 . .

TRANSFORMER w/bracket

. . . 1

. . . 12

. . . .

. . . . . .

. . .

173 352 . .

EXTRUSION, rubber clamp/bulb (order by ft)

. . . 3ft

. . . 13

. . . .

. . . . . .

. . .

189 708 . .

FIREWALL, top

. . . 1

. . . 14

. . . .

. . . . . .

. . .

191 307 . .

COVER, plate

. . . 1

. . . 15

. . . .

. . . . . .

. . .

200 968 . .

HOSE, elbow air cleaner

. . . 1

. . . 16

. . . .

. . . . . .

. . .

010 863 . .

CLAMP, hose 1.125 – 3.000 clp dia

. . . 4

. . . 17

. . . .

. . . . . .

. . .

189 763 . .

BRACKET, mtg air cleaner

. . . 1

. . . 18

. . . .

. . . . . .

. . .

189 764 . .

AIR CLEANER, intake

. . . 1

. . .

. . .

. . . .

. . . . . .

.. .*.♦

*192 938 . .

FILTER, air element primary

. . . 1

. . .

. . .

. . . .

. . . . . .

192 939 . .

FILTER, air element safety

. . . 1

. . . 19

. . . .

. . . . . .

. . .

198 457 . .

TUBE, air intake

. . . 1

. . . 20

. . . .

. . . . . .

. . .

200 969 . .

HOSE, air cleaner

. . . 1

. . . 21

. . . .

. . . . . .

. . .

189 464 . .

SEAL, weather lift eye

. . . 1

. . .

. . .

. . . .

. . . . . .

. . .

173 909 . .

HOSE, sae .312 id x .560 od x 24.000 (order by ft)

. . . 2

. . . 22

. . . .

. . . . . .

. . .

201 658 . .

UPRIGHT, center assembly

. . . 1

. . . 23

. . . .

. . . . . .

. . +200 999 . .

BASE

. . . 1

. . . 24

. . . .

. . . . . .

. . .

196 220 . .

BRACKET, hold down fuel tank rear

. . . 1

. . . 25

. . . .

. . . . . .

. . .

192 362 . .

BRACKET, mtg nyl 1/2 conduit

. . . 1

. . . 26

. . . .

. . . . . .

. . +200 995 . .

COVER, top

. . . 1

. . . 27

. . . .

. . . . . .

. . .

189 052 . .

GROMMET, plastic neck filler fuel

. . . 1

. . . 28

. . . .

. . . . . .

. . .

190 198 . . .

. CAP, tank screw-on 3.500 in w/vent

. . . 1

. . . 29

. . . .

. . . . . .

. . .

192 042 . .

LABEL, use gasoline fuel only

. . . 1

. . . 30

. . . .

. . . . . .

. . .

108 487 . .

LABEL, warning falling equipment

. . . 2

. . . 31

. . . .

. . . . . .

. . .

010 875 . .

CLAMP, muffler 2.000 dia

. . . 1

. . . 32

. . . .

. . . . . .

. . .

105 740 . .

PIPE, muffler exhaust engine 1.925 inlet/outlet

. . . 1

. . . 33

. . . .

. . . . . .

. . .

201 851 . .

COVER, radiator access

. . . 1

. . . 34

. . . .

. . . . . .

. . .

176 230 . .

LABEL, warning hot exhaust

. . . 1

. . . 35

. . . .

. . . . . .

. . .

191 354 . .

SUPPORT, cover

. . . 1

. . . 36

. . . .

. . . . . .

. . .

189 245 . .

TANK, fuel 23gal (consisting of)

. . . 1

. . . 37

. . . .

. . . . . .

. . .

124 253 . . .

. BUSHING, tank fuel

. . . 4

. . .

. . .

. . . .

. . . . . .

. . .

084 173 . . .

. CLAMP, hose .460 – .545clp dia slfttng

. . . 2

. . . 38

. . . .

. . . . . .

. . .

189 912 . . .

. FITTING, stl barbed elbow w/.047 in orf zinc pld

. . . 1

. . . 39

. . . .

. . . . . .

. . .

189 909 . . .

. FITTING, stand pipe hose .250 x 9.260 lg 90deg zinc

. . . 1

. . . 40

. . . .

. . . . . .

. . .

201 025 . . .

. CAP, fuel fitting

. . . 1

. . . 41

. . . .

. . . . . .

. . .

189 913 . . .

. FITTING, stl barbed elbow zinc pld

. . . 1

. . . 42

. . . .

. . . . . .

. . .

190 142 . . .

. SENDER, fuel gauge 9.7500 deep tank

. . . 1

. . . 43

. . . .

. . . . . .

. . .

189 910 . . .

. FITTING, stand pipe hose .3125 x 9.260 lg 90deg zinc

. . . 1

. . . 44

. . . .

. . . . . .

. . .

189 908 . . .

. VALVE, drain fuel 180deg

. . . 1

. . . 45

. . . .

. . . . . .

. . .

181 572 . . .

. BUSHING, tank fuel

. . . 1

. . . 46

. . . .

. . . . . .

. . .

191 446 . .

EXTRUSION, rubber w/adhesive 1.000 x 1.000 D (order by ft)

. . . 6ft

. . . 47

. . . .

. . . . . .

. . .

013 367 . .

LABEL, warning moving parts

. . . 2

. . . 48

. . . .

. . . . . .

. . .

200 984 . .

ENGINE, Wis-Con gasoline TM-20 (consisting of)

. . . 1

. . .

. . .

. . . .

. . . . . .

. . .

*025 474 . . .

. SWITCH, thermo temp 240 make 230 open

. . . 1

. . .

. . .

. . . .

. . . . . .

. . .

*025 473 . . .

. SWITCH, pressure oil 8 psi brake or make

. . . 1

. . .

. . .

. . . .

. . . . . .

. . .

201 141 . . .

. FTG, adapter oil drain 1/2-20 male x 3/8 npt female

. . . 1

. . .

. . .

. . . .

. . . . . .

. . .

*201 142 . . .

. BELT, fan

. . . 1

OM-4405 Page 62

Page 65 Page 67
Image 66
Page 65 Page 67
Contents OM-4405 ProcessesDescription 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 LoadInstallation Installing Welding Generator See Sections 4-2Using 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 ReceptaclesSingle-Phase Power Connection Single-Phase Auxiliary Power Three-Phase Power ConnectionRear Of Panel Optional Auxiliary Power Receptacles 240 V 15 a AC South African Receptacle RC1Circuit 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 MaximumAdjusting Engine Idle Speed Engine 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 ModelsRepair or replace wire feeder Welding CC/CV ModelsTacle see Section Standard Auxiliary Power Optional Auxiliary Power PlantEngine 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 Auxiliary Power Guidelines Selecting EquipmentGrounding 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 Parts List 107 106 101 105 103CC 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 Service Your distributor also givesSupport 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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