Miller Electric Big 40 WG manual Your distributor also gives, Service, Support

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Warranty Questions?

Effective January 1, 2000

(Equipment with a serial number preface of “LA” or newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other

guarantees or warranties expressed or implied.

Call

1-800-4-A-MILLER for your local Miller distributor.

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Service

You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.

Support

Need fast answers to the tough welding questions? Contact your distributor.

The expertise of the distributor and Miller is there to help you, every step of the way.

LIMITED WARRANTY – Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.

THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be followed.

Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the date that the equipment was delivered to the original retail purchaser, or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor.

1.5 Years Parts – 3 Years Labor

*Original main power rectifiers

*Inverters (input and output rectifiers only)

2.3 Years — Parts and Labor

*Transformer/Rectifier Power Sources

*Plasma Arc Cutting Power Sources

*Semi-Automatic and Automatic Wire Feeders

*Inverter Power Supplies

*Intellitig

*Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the engine manufacturer.)

3.1 Year — Parts and Labor

*DS-2 Wire Feeder

*Motor Driven Guns (w/exception of Spoolmate 185 & Spoolmate 250)

*Process Controllers

*Positioners and Controllers

*Automatic Motion Devices

*RFCS Foot Controls

*Induction Heating Power Sources

*Water Coolant Systems

*HF Units

*Grids

*Maxstar 140

*Spot Welders

*Load Banks

*Miller Cyclomatic Equipment

*Running Gear/Trailers

*Plasma Cutting Torches (except APT & SAF Models)

*Field Options

(NOTE: Field options are covered under True Bluefor the remaining warranty period of the product they are installed in, or for a minimum of one year — whichever is greater.)

4.6 Months — Batteries

5.90 Days — Parts

*MIG Guns/TIG Torches

*Induction Heating Coils and Blankets

*APT, ZIPCUT & PLAZCUT Model Plasma Cutting Torches

*Remote Controls

*Accessory Kits

*Replacement Parts (No labor)

*Spoolmate 185 & Spoolmate 250

*Canvas Covers

Miller’s True BlueLimited Warranty shall not apply to:

1.Consumable components; such as contact tips, cutting nozzles, contactors, brushes, slip rings, relays or parts that fail due to normal wear.

2.Items furnished by Miller, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturer’s warranty, if any.

3.Equipment that has been modified by any party other than Miller, or equipment that has been improperly installed, improperly operated or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of the specifications for the equipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Miller’s option: (1) repair; or (2) replacement; or, where authorized in writing by Miller in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customer’s risk and expense. Miller’s option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility as determined by Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.

Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state.

In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province.

miller_warr 7/00

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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.