Miller Electric Big 40 WG manual Control Box Assembly CC Models -1 Item

Page 69

Item

Dia.

 

Part

Description

 

No.

 

Mkgs.

 

No.

Quantity

 

 

 

 

Figure 11-2. Control Box Assembly – CC Models (Figure 11-1 Item 98)

 

 

 

 

 

 

 

. . .

1

. . . F1, F2

. . *085 874 . .

FUSE, mintr cer slo-blo 10A 250V

. . . 2

. . .

2

.

. . . . . . . . .

. . .

046 432 . .

HOLDER, fuse mintr .250 x 1.250

. . . 2

. . . 3

.

. . . . . . . . .

. . .

201 077 . .

CONTROL BOX, lh

. . . 1

. . . 4

.

. . . . . . . . .

. . .

201 078 . .

CONTROL BOX, rh

. . . 1

. . .

5

.

. . . . . . . . .

. . .

201 079 . .

COVER, control box

. . . 1

. . .

6

. . . . C12

. . .

191 944 . .

CAPACITOR, polyp met film 10. uf 250 vac 10%

. . . 1

. . . .

. .

. . . . . . . . . .

. . .

201 681 . .

HARNESS, control box, weld control (consisting of)

. . . 1

. . . 7 . . . . CR7

. . .

188 636 . . .

. RELAY, OCV control

. . . 1

. . . 8 . . . D1/C1

. .

189 701 . . .

. DIODE/CAPACITOR BOARD

. . . 1

. . .

9

. . SR1, SR2 .

035 704 . . .

. RECTIFIER, integ 40A 800V

. . . 2

. . . 10

.

. . . CR5 . . .

090 104 . . .

. RELAY, encl 12VDC SPST 30A/15VDC

. . . 1

. . . .

. .

.

. . . . S5 .

. . . .

011 609 . . .

. SWITCH, tgl spdt 15a 125vac on–none–on spd term chr

 

. . . .

. .

. . . . . . . . . .

. . . .

. . . . . . . . . . .

. (located on front panel, see Figure 11-4)

. . . 1

. . . .

. .

.

. . . . S6 .

. . . .

011 622 . . .

. SWITCH, tgl 3pdt 15a 125vac on–none–on spd term

 

. . . .

. .

. . . . . . . . . .

. . . .

. . . . . . . . . . .

. (located on front panel, see Figure 11-4

. . . 1

. . . .

. .

.

. . . RC4

. . .

047 483 . . .

. CONNECTOR, rect univ 084 15P/S 3 row rcpt cable/panel lkg . . . .

. . . 1

. . . .

. .

.

. . . RC3

. . .

158 466 . . .

. CONNECTOR, rect univ 084 12P/S 3 row rcpt cable/panel lkg . . . .

. . . 1

. . . .

. . . . . . RC1

. . .

135 133 . . .

. CONNECTOR, rect univ 084 9P/S 3 row rcpt cable/panel lkg

. . . 1

. . . .

. .

. . . . . . . . . .

. . .

148 850 . . .

. SOCKET, relay 5 pin

. . . 1

. . . .

. .

. . . . . . . . . .

. . .

177 859 . . .

. CONN, body 5 terminal (to engine control switch S1)

. . . 1

. . . .

. .

. . . . . . . . . .

. . .

150 316 . . .

. CONN, rect univ 039 6p/s 3row plug cable lkg

. . . 6

. . . .

. .

. . . . . . . . . .

. . .

092 670 . . .

. CONN, rect univ 084 3p/s 1row plug cable lkg

. . . 1

. . . 11

 

CB11, 12, 13

139 266 . . .

. CIRCUIT BREAKER, man reset 1P 15A 250VAC frict

. . . 3

. . . .

. .

. . . . . . . . . .

. . .

190 260 . .

HARNESS, unit weld control (consisting of)

. . . 1

. . . .

. .

.

. . . PLG3

. . . .

158465 . . .

. CONN, rect univ 084 12p/s 3row plug cable lkg

. . . 1

. . . .

. .

. . . . . . . . . .

. . . .

187654 . . .

. SEAL, wire univ 12p/s 3row

. . . 1

. . . .

. .

.

. . . PLG6

. . . .

114063 . . .

. CONN, rect univ 084 4p/s 1row plug cable lkg

. . . 1

. . . .

. .

. . . . . . . . . .

. . . .

192309 . . .

. CLIP, snap in .630 bundle .250 hole .248 thk

. . . 2

. . . 12

.

. . . . . . . . .

. . .

177 136 . .

CLAMP, capacitor 1.375dia

. . . 1

. . . 13

.

. . . . C9 .

. . . .

087 110 . .

CAPACITOR, elctlt 240uf 200VDC

. . . 1

. . . 14

.

. . . . R6 .

. . .

141 424 . .

RESISTOR, ww fxd 30 w 25 ohm faston te

. . . 1

. . . 15

.

. . . PC7

. . . . 195706 . .

MODULE, pull to idle, two output, 7 pin

. . . 1

. . . 16

.

. . . CR4

. . . . 113247 . .

RELAY, encl 12vdc dpdt 20a/120vac 8pin flange mtg

. . . 1

. . . 17

.

. . . CR6

. . . . 090104 . .

RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg

. . . 1

. . . 18

 

CR1, CR2, CR3 090 104 . .

RELAY, encl 12VDC SPST 30A/15VDC spin flange mtg

. . . 3

. . . .

. .

. . . . . . . . . .

. . .

201 357 . .

HARNESS, engine control (consisting of)

. . . 1

. . . 19

.

. . D8/C8

. .

189 701 . . .

. DIODE/CAPACITOR BOARD

. . . 1

. . . 20

.

. . . CB10

. . .

190 374 . . .

. CIRCUIT BREAKER, auto reset 12VDC 40A

. . . 1

. . . .

. .

. . . . . . . . . .

. . .

148 850 . . .

. SOCKET, relay 5 pin

. . . 3

. . . .

. .

.

. . . PLG4

. . . .

114 062 . . .

. CONNECTOR, rect univ 084 15P/S 3 row plug cable lkg

. . . 1

*Recommended Spare Parts.

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-4405 Page 65

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Contents OM-4405 ProcessesDescription From Miller to You Table of Contents Options and Accessories Warranty Arc Welding Hazards Symbol UsageElectric Shock can kill ARC Rays can burn eyes and skinEngine Hazards Moving Parts can cause injury Battery Explosion can BlindEngine Exhaust Gases can kill Engine Heat can cause fireEMF Information Principal Safety StandardsRadiation can cause interference ARC Welding can cause interferenceConsignes DE SÉ Curité Lire Avant Utilisation Signification des symbolesUN Choc É Lectrique peut tuer LES Fumé ES ET LES GAZ peuvent ê tre dangereuxDES Particules Volantes peuvent blesser les yeux LE Soudage peut provoquer un in- cendie ou une explosionDES PIÈ CES Chaudes peuvent provoquer des brû lures graves LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peut DES Organes Mobiles peuvent provoquer des blessuresLA Chaleur DU Moteur peut pro- voquer un incendie LA Chute DE L’APPAREIL peut blesserInformation sur les champs é lectromagné tiques Principales normes de sé curitéLE Soudage À L’ARC risque de provoquer des interfé rences Consignes relatives aux stimulateurs cardiaquesSymbols And Definitions SpecificationsWeld, Power, And Engine Specifications DefinitionsVolt-Ampere Curves For CC Models Dimensions, Weights, And Operating AnglesMIG Mode Stick ModeTIG Mode Volt-Ampere Curves for CC/CV ModelsDuty Cycle And Overheating Fuel ConsumptionOptional AC Power Plant Curves AC Auxiliary Power Curve12 kVA/kW Single-Phase Auxiliary Power Plant No Weld Load 15 kVA/kW Three-Phase Auxiliary Power Plant No Weld LoadInstallation Installing Welding Generator See Sections 4-2Using Lifting Eye Mounting Welding Generator Installing Exhaust PipeWelding Unit In Place Bolting Unit In Place To Bolt Unit In PlaceDo not overfill battery cells Activating The Dry Charge Battery If ApplicableRead and follow all instruc ChargerConnect Negative Cable Last Connecting The BatteryEngine Prestart Checks Coolant Recovery TankFuel OilSelecting 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 ModelsDo not switch under load Engine Indicator LightsEngine Starting Controls To StartRemote 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 rangeProcess/Contactor Switch Settings Process/Contactor Switch On CC/CV ModelsProcess/Contactor Switch RunningSet Remote Set Range Remote Voltage/Amperage Control On CC/CV Models OptionalProcess Set RemoteVolt And 240 Volt Receptacles Operating Auxiliary EquipmentSingle-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 Label Maintenance & Troubleshooting50 h Routine Maintenance100 h 250 h500 h Inspecting And Cleaning Optional Spark Arrestor Muffler1000 h Stop engine and let coolServicing Air Cleaner Maximum Adjusting Engine Weld/Power SpeedAdjusting Engine Idle Speed Engine SpeedNo Load Tools Needed 1/2 Adjusting Governor SensitivityServicing Fuel And Lubrication Systems Overload Protection Press button to reset breakerDiagnostic Checks While Running Diagnosing Causes Of Engine Fault ShutdownsFault Condition 20s Start Engine With No Load AppliedWelding CC Models TroubleshootingRepair or replace wire feeder Welding CC/CV ModelsTacle see Section Standard Auxiliary Power Optional Auxiliary Power PlantEngine Shutdown switch is released Out Wiring harness and componentsAnt temperature is too high see Sections 4-7 Or coolant 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 Auxiliary Power Guidelines Selecting EquipmentGrounding Generator To Truck Or Trailer Frame How Much Power Does Equipment Require? Grounding When Supplying Building SystemsEarth ground if supplying Amperes x Volts = WattsApproximate Power Requirements For Farm/Home Equipment Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentHow Much Power Can Generator Supply? Power Required To Start MotorSingle-Phase Induction Motor Starting Requirements KVA/HP x HP xTypical Connections To Supply Standby Power Current Load Watts Amperes Selecting Extension Cord Use Shortest Cord PossibleOM-4405 Parts List 107 106 101 105 103CC 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 Service Your distributor also givesSupport 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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