Miller Electric Big 40 WG manual Generator -1 Item

Page 77

Item

Dia.

Part

Description

 

 

No.

Mkgs.

No.

Quantity

 

 

 

 

Figure 11-6. Generator (Figure 11-1 Item 91)

 

 

 

 

 

 

 

. . .

1 . . . .

. . . . . . .

. . 132 053 . .

SCREW, .375–16x1.50 hex hd–pln gr5 pld

. . . 6

. . .

2 . . . .

. . . . . . .

. . 183 387 . .

WASHER, conical spring .406 ID x .875 OD pltd

. . . 6

. . .

3 . . . .

. . . . . . .

. . . 195 911 . .

ENDBELL, gen (consisting of)

. . . 1

. . .

4 . . . .

. . . . . . .

. . 143 220 . . .

. O-RING, 2.859 ID x .139CS

. . . 1

. . .

5 . . . .

. . . . . . .

. . 201 099 . .

STATOR, exciter/aux pwr

. . . 1

. . .

6 . . . .

. . . . . . .

. +201 110 . .

STATOR, weld assembly complete

. . . 1

. . .

6 . . . .

. . . . . . .

+♦ 201 089 . .

STATOR, weld assembly complete (full kVA option)

. . . 1

. . .

7 . . . .

. . . . . . .

. . 013 367 . .

LABEL, warning moving parts

. . . 2

. . .

8 . . . .

. . . . . . .

. . 190 197 . .

GUARD, generator wire mesh

. . . 1

. . .

9 . . . .

. . . . . . .

. . 172 674 . .

SPRING, ext .240 OD x .041 wire x 3.500pld

. . . 2

. . . 10 . . . .

. . . . . . .

. . 039 207 . .

BAFFLE, air

. . . 1

. . . 11 . . . .

. . . . . . .

. . 201 098 . .

ROTOR, gen (consisting of)

. . . 1

. . . 12 . . . .

. . . . . . .

. . 024 617 . . .

. RING, rtng ext 1.375 shaft x .050thk

. . . 1

. . . 13 . . . .

. . . . . . .

. . 053 390 . . .

. BEARING, ball rdl sgl row 1.370 x 2.830 x .6

. . . 1

. . . 14 . . . .

. . . . . . .

. . 195 547 . . .

. FAN, rotor gen

. . . 1

. . . 15 . . . .

. . . . . . .

. . 049 026 . .

SCREW, M10-1.5 x 25hexhd pln 8.8pln

. . . 6

. . . 16 . . . .

. . . . . . .

. . 083 883 . .

WASHER, lock .402 ID x 0.709 OD

. . . 10

. . . 17 . . . .

. . . . . . .

. . 202 301 . . .

. PLATE, flex

. . . 1

. . . 18 . . . .

. . . . . . .

. . 605 231 . . .

. SCREW, m10–1.5x 35 hex hd–pln 8.8 pld

. . . 4

. . . 19 . . . .

. . . . . . .

. . 194 512 . . .

. WASHER, flat 1.250 od x .406id x 7ga thk stl pld

. . . 4

. . . 20 . . . .

. . . . . . .

. . 183 387 . . .

. WASHER, cone .380idx .860odx.109t stl pld 4000lbs

. . . 6

. . . 21 . . . .

. . . . . . .

. . 198 631 . . .

. NUT, m10 hex lock nut stl pld

. . . 4

. . . 22 . . . .

. . . . . . .

. . 201 139 . .

FLYWHEEL, engine Wis-Con TM-20

. . . 1

. . . 23 . . . .

. . . . . . .

. . 201 140 . .

ADAPTER, engine Wis-Con TM-20

. . . 1

. . . 24 . . . .

. . . . . . .

. . 191 579 . .

COVER, starter hole

. . . 1

. . .

. . . . . . .

. . . . . . .

. . 200 991 . .

GUARD, starter hole Wis-Con TM-20

. . . 1

. . .

. . . . . . .

. . . . . . .

. . 191 580 . .

COVER, starter hole

. . . 1

. . . 25 . . . .

. . . . . . .

. . 172 555 . .

SCREW, M10-1.5 x 50hexhd pln 8.8pld

. . . 6

. . . 26 . . . .

. . . . . . .

. . 602 159 . .

SCREW, .312–18x .75 hexwhd.66d stl pld slffmg tap–rw

. . . 6

. . . 27 . . . .

. . . . . . .

. . 601 950 . .

SCREW, .312-18 x 2.00 hexhd pln gr 5pld

. . . 4

. . . 28 . . . .

. . . . . . .

. . . 602 211 . .

WASHER, lock .318 ID x 0.586

. . . 6

. . . 29 . . . .

. . . . . . .

. . 139 341 . .

WASHER, exciter

. . . 4

. . . 30 . . . .

. . . . . . .

. . *190 823 . .

BRUSH, contact

. . . 3

. . . 31 . . . .

. . . . . . .

. . 188 560 . .

CLIP, spring

. . . 3

. . . 32 . . . .

. . . . . . .

. . 189 142 . .

BRUSHHOLDER ASSEMBLY, gen

. . . 1

. . . 33 . . . .

. . . . . . .

. . 602 242 . .

WASHER, flat .375IDx0.875odx.083t stl pld

. . . 2

. . . 34 . . . .

. . . . . . .

. . 604 534 . .

SCREW, .312–18x1.25 hex hd–pln gr5 pld

. . . 2

. . .

. . . . . . .

. . . . . . .

. . 190 259 . .

HARNESS, brush (consisting of)

. . . 1

. . .

. . . . . . .

PLG1 .

. . 135 134 . . .

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

. . . 1

. . .

. . . . . . .

. . . . . . .

. . 187 651 . . .

. SEAL, wire univ 9P/S 3 row

. . . 1

+When ordering a component originally displaying a precautionary label, the label should also be ordered. Order label individually or as part of Label Kit 202 022.

*Recommended Spare Parts.

♦Optional

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 73

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Contents Description OM-4405Processes 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 LoadUsing Lifting Eye InstallationInstalling Welding Generator See Sections 4-2 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 EquipmentRear Of Panel Single-Phase Power Connection Single-Phase Auxiliary PowerThree-Phase Power Connection Circuit Breaker CB2 Circuit Breaker CB3 Optional Auxiliary Power Receptacles240 V 15 a AC South African Receptacle RC1 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 SpeedNo Load Adjusting Engine Idle SpeedEngine Speed 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 TroubleshootingTacle see Section Repair or replace wire feederWelding CC/CV Models Engine Standard Auxiliary PowerOptional Auxiliary Power Plant 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 Grounding Generator To Truck Or Trailer Frame Auxiliary Power GuidelinesSelecting Equipment 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 CC only 104 -4 or Parts List107 106 101 105 103 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 Support ServiceYour distributor also gives 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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