Miller Electric Big 40 WG manual Dia Part Description Mkgs Quantity

Page 67

Item

Dia.

Part

Description

 

No.

Mkgs.

No.

Quantity

 

 

 

Figure 11-1. Main Assembly (Continued)

 

 

 

 

 

 

. . . . . . . . . .

. . . . . . .

. . 172 725 . .

BOOT, starter eyelet terminal

. . . 1

. . . . . . . . . .

. . . . . . .

. . *114 559 . .

FILTER, oil

. . . 1

. . . 49 . . . .

. . . . . . .

. . *066 113 . .

FILTER, inline

. . . 1

. . . 50 . . . .

. . . . . . .

. . 200 966 . .

HOSE, radiator upper Wis-Con TM-20

. . . 1

. . . 51 . . . .

. . . . . . .

. +202 052 . .

GUARD, fan (left side)

. . . 1

. . . 52 . . . .

. . . . . . .

. . 147 923 . .

LABEL, warning moving parts

. . . 2

. . . 53 . . . .

. . . . . . .

. . 201 982 . .

RADIATOR, w/shroud and 7lb cap 3 row core

. . . 1

. . . . . . . . . .

. . . . . . .

. . 605 982 . . .

. CAP, radiator pressure 7 lb

. . . 1

. . . 54 . . . .

. . . . . . .

. . 201 749 . .

UPRIGHT, rear

. . . 1

. . . 55 . . . .

. . . . . . .

. . 190 206 . .

CABLE, bat neg 42 in lg No. 2 awg w/clamp and .375rng

. . . 1

. . . 56 . . . .

. . . . . . .

. . 108 081 . .

TERMINAL PROTECTOR, battery post mtg

. . . 2

. . . 57 . . . .

. . . . . . .

. . 190 207 . .

CABLE, bat pos 45 in lg No. 1 awg w/clamp and .406rng

. . . 1

. . . 58 . . . .

. . . . . . .

. . 203 430 . .

BRACKET, battery holddown

. . . 1

. . . 59 . . . .

. . . . . . .

. . 190 897 . .

BATTERY, stor 12V 650crk 110rsv gp 24

. . . 1

. . . 60 . . . .

. . . . . . .

. . 201 006 . .

BOLT, j stl .312–18 x 8.500 pld

. . . 2

. . . 61 . . . .

. . . . . . .

. +201 183 . .

COVER, battery access

. . . 1

. . . 62 . . . .

. . . . . . .

. . 168 385 . .

LABEL, warning battery explosion can blind

. . . 1

. . . 63 . . . .

. . . . . . .

. . 201 996 . .

LABEL, warning do not operate with guard missing

. . . 2

. . . 64 . . . .

. . . . . . .

. . 200 967 . .

HOSE, radiator lower Wis-Con TM-20

. . . 1

. . . 65 . . . .

. . . . . . .

. +200 990 . .

GUARD, fan (right side)

. . . 1

. . . 66 . . . .

. . . . . . .

. . 190 992 . .

KEEPER, latch engine access door

. . . 1

. . . 67 . . . .

. . . . . . .

. . 190 076 . .

CHANNEL, stiffener engine access

. . . 1

. . . 68 . . . .

. . . . . . .

. . 199 592 . .

LATCH, paddle series 20 (black)

. . . 1

. . . 69 . . . .

. . . . . . .

. . 201 031 . .

LABEL, gasoline engine maintenance Wis-Con TM-20

. . . 1

. . . 70 . . . .

. . . . . . .

. +200 989 . .

DOOR, engine access

. . . 1

. . . 71 . . . .

. . . . . . .

. . 189 975 . .

HINGE, door access 180deg

. . . 2

. . . 72 . . . .

. . . . . . .

. . 190 190 . .

TANK, coolant recovery

. . . 1

. . . 73 . . . .

. . . . . . .

. . 201 591 . .

STOP, door

. . . 2

. . . 74 . . . .

. . . . . . .

. . 189 826 . .

PANEL, rocker

. . . 1

. . . 75 . . . .

. . . . . . .

. . 191 626 . .

BUMPER, door engine access

. . . 2

. . . 76 . . . .

. . . . . . .

. . 189 827 . .

PANEL, gen RH

. . . 1

. . . 77 . . . .

. . . . . . .

. . 199 849 . .

SCREW, 625-11 x 4.00hexhd pln gr 5 pld

. . . 4

. . . 78 . . . .

. . . . . . .

. . 071 731 . .

WASHER, flat .656 ID x 2.250 OD x .187T stl pld

. . . 4

. . . 79 . . . .

. . . . . . .

. . 200 985 . .

BRACKET, mtg engine Wis-Con TM-20

. . . 2

. . . 80 . . . .

. . . . . . .

. . 071 890 . .

RETAINER, mount eng/gen

. . . 4

. . . 81 . . . .

. . . . . . .

. . 071 730 . .

TUBING, stl .875 OD x 12ga wall x 2.500

. . . 4

. . . 82 . . . .

. . . . . . .

. . 083 476 . .

MOUNT, eng/gen nprn .875 ID x 2.500 OD x 2.000

. . . 4

. . . 83 . . . .

. . . . . . .

. . 135 205 . .

NUT, 625-11 .94hex .76H stl pld elastic stop nut

. . . 4

. . . 84 . . . .

. . . . . . .

. . . 190757 . .

SOLENOID ASSY (consisting of)

. . . 1

. . . . . . . . . .

. . . . . . .

. . . 113658 . . .

. LINKAGE, throttle

. . . 1

. . . . . . . . . .

. . . . . . .

. . . 115857 . . .

. BRACKET, mtg solenoid idle

. . . 1

. . . . . . . . . .

. . . . . . .

. . . 005373 . . .

. SOLENOID, 14vdc .84 amp pull type cont

. . . 1

. . . . . . . . . .

. . . . . . .

. . . 010837 . . .

. PIN, spring cs .093 x .625

. . . 1

. . . . . . . . . .

. . . . . . .

. . 199 505 . .

HOSE, oil drain assy 32 in (consisting of)

. . . 1

. . . 85 . . . .

. . . . . . .

. . 165 271 . . .

. VALVE, oil drain 3/8-18NPTF

. . . 1

. . . 86 . . . .

. . . . . . .

. . 176 529 . . .

. FITTING, hose brs barbed fem 1/2tbg x 3/8NPT

. . . 1

. . . 87 . . . .

. . . . . . .

. . . 113 854 . . .

. HOSE, SAE .500 ID x .780 OD xc oil (order by ft)

. . . 3ft

. . . 88 . . . .

. . . . . . .

. . 197 448 . .

FITTING, hose brs barbed elbow m 1/2 tbg x 3/8 npt

. . . 1

. . . 89 . . . .

. . . . . . .

. . 201 141 . .

FITTING, engine adapter oil drain 12-20 x 3/8 npt female

. . . 1

. . . 90 . . . .

. . . . . . .

. . 201 362 . .

WASHER, oil drain

. . . 1

. . . 91 . . . .

. . . . . . .

Figure 11-6 . .

GENERATOR

. . . 1

. . . 92 . . . .

. . . . . . .

. . 191 897 . .

BRACKET, mtg unit

. . . 4

. . . 93 . . . .

. . . . . . .

. . 191 512 . .

BRACKET, hold down fuel tank

. . . 1

. . . 94 . . . .

. . . . . . .

. . 190 250 . .

LABEL, warning do not weld on base

. . . 2

. . . 95 . . . .

. . . . . . .

. . 190 179 . .

PANEL, mtg components

. . . 1

. . . 96 . . . .

. R2 . .

. CC189 699 . .

RESISTOR, WW tap 375W 10 ohm w/mtg bkt

. . . 1

. . . 97 . . . .

. R3 . .

. . 189 699 . .

RESISTOR, WW tap 375W 10 ohm w/mtg bkt

. . . 1

. . . 98 . . . .

. . Figure 11-2, Figure 11-3

CONTROL BOX ASSEMBLY

. . . 1

OM-4405 Page 63

Page 66 Page 68
Image 67
Page 66 Page 68
Contents Processes OM-4405Description From Miller to You Table of Contents Options and Accessories Warranty 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 SpecificationsVolt-Ampere Curves For CC Models Dimensions, Weights, And Operating AnglesVolt-Ampere Curves for CC/CV Models Stick ModeMIG Mode TIG ModeDuty Cycle And Overheating Fuel Consumption15 kVA/kW Three-Phase Auxiliary Power Plant No Weld Load AC Auxiliary Power CurveOptional AC Power Plant Curves 12 kVA/kW Single-Phase Auxiliary Power Plant No Weld LoadInstalling Welding Generator See Sections 4-2 InstallationUsing Lifting Eye To Bolt Unit In Place Installing Exhaust PipeMounting Welding Generator Welding Unit In Place Bolting Unit In PlaceCharger Activating The Dry Charge Battery If ApplicableDo not overfill battery cells Read and follow all instrucConnect Negative Cable Last Connecting The BatteryOil Coolant Recovery TankEngine Prestart Checks FuelSelecting Weld Cable Sizes Connecting To Weld Output TerminalsRef 862-A / 048 720-K / 802 Socket Information Connecting To Remote 14 Receptacle RC14 On CC/CV ModelsFront Panel Controls For CC Models See Section Operating Welding Generator CC ModelsTo Start Engine Indicator LightsDo not switch under load Engine Starting ControlsRemote Amperage Control On CC Models Optional OM-4405 Front Panel Controls For CC/CV Models See Section Operating Welding Generator CC/CV ModelsVoltage/Amperage Adjust Switch And Remote 14 Receptacle Use switch to select weld amperage rangeRunning Process/Contactor Switch On CC/CV ModelsProcess/Contactor Switch Settings Process/Contactor SwitchSet Remote Remote Voltage/Amperage Control On CC/CV Models OptionalSet Remote Set Range ProcessVolt And 240 Volt Receptacles Operating Auxiliary EquipmentThree-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 Label Maintenance & Troubleshooting250 h Routine Maintenance50 h 100 hStop engine and let cool Inspecting And Cleaning Optional Spark Arrestor Muffler500 h 1000 hServicing Air Cleaner Maximum Adjusting Engine Weld/Power SpeedEngine Speed Adjusting Engine Idle SpeedNo Load Tools Needed 1/2 Adjusting Governor SensitivityServicing Fuel And Lubrication Systems Overload Protection Press button to reset breaker20s Start Engine With No Load Applied Diagnosing Causes Of Engine Fault ShutdownsDiagnostic Checks While Running Fault ConditionWelding CC Models TroubleshootingWelding CC/CV Models Repair or replace wire feederTacle see Section Optional Auxiliary Power Plant Standard Auxiliary PowerEngine Or coolant temperature is too high see Sections 4-7 Wiring harness and componentsShutdown switch is released Out Ant temperature is too high see Sections 4-7OM-4405 Circuit Diagram For CC Welding Generator Electrical Diagrams201 991-A Circuit Diagram For CC/CV Welding Generator 201 992-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 RequirementsTypical Connections To Supply Standby Power Current Load Watts Amperes Selecting Extension Cord Use Shortest Cord PossibleOM-4405 107 106 101 105 103 Parts ListCC only 104 -4 or See FIG 108Dia 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 -1 Item Panel, Front w/Components CC/CV ModelsPC6 192 Generator Generator -1 Item Main Rectifier Assembly Your distributor also gives ServiceSupport Miller Electric Mfg. Co Owner’s Record

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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