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Miller Electric
Big 40 WG manual 201 991-A
Models:
Big 40 WG
1
53
80
80
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Troubleshooting
Specifications
Install
Parts list
Error messages
Electrical Diagrams
Maintenance
Connecting The Battery
Press button to reset breaker
Control Box Assembly CC Models
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201
991-A
OM-4405
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Contents
Description
OM-4405
Processes
From Miller to You
Table of Contents
Options and Accessories Warranty
Arc Welding Hazards
Symbol Usage
Electric Shock can kill
ARC Rays can burn eyes and skin
Engine Hazards
Moving Parts can cause injury
Battery Explosion can Blind
Engine Exhaust Gases can kill
Engine Heat can cause fire
EMF Information
Principal Safety Standards
Radiation can cause interference
ARC Welding can cause interference
Consignes DE SÉ Curité Lire Avant Utilisation
Signification des symboles
UN Choc É Lectrique peut tuer
LES Fumé ES ET LES GAZ peuvent ê tre dangereux
DES Particules Volantes peuvent blesser les yeux
LE Soudage peut provoquer un in- cendie ou une explosion
DES 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 blessures
LA Chaleur DU Moteur peut pro- voquer un incendie
LA Chute DE L’APPAREIL peut blesser
Information sur les champs é lectromagné tiques
Principales normes de sé curité
LE Soudage À L’ARC risque de provoquer des interfé rences
Consignes relatives aux stimulateurs cardiaques
Symbols And Definitions
Specifications
Weld, Power, And Engine Specifications
Definitions
Volt-Ampere Curves For CC Models
Dimensions, Weights, And Operating Angles
MIG Mode
Stick Mode
TIG Mode
Volt-Ampere Curves for CC/CV Models
Duty Cycle And Overheating
Fuel Consumption
Optional AC Power Plant Curves
AC Auxiliary Power Curve
12 kVA/kW Single-Phase Auxiliary Power Plant No Weld Load
15 kVA/kW Three-Phase Auxiliary Power Plant No Weld Load
Using Lifting Eye
Installation
Installing Welding Generator See Sections 4-2
Mounting Welding Generator
Installing Exhaust Pipe
Welding Unit In Place Bolting Unit In Place
To Bolt Unit In Place
Do not overfill battery cells
Activating The Dry Charge Battery If Applicable
Read and follow all instruc
Charger
Connect Negative Cable Last
Connecting The Battery
Engine Prestart Checks
Coolant Recovery Tank
Fuel
Oil
Selecting Weld Cable Sizes
Connecting To Weld Output Terminals
Ref 862-A / 048 720-K / 802
Socket Information
Connecting To Remote 14 Receptacle RC14 On CC/CV Models
Front Panel Controls For CC Models See Section
Operating Welding Generator CC Models
Do not switch under load
Engine Indicator Lights
Engine Starting Controls
To Start
Remote Amperage Control On CC Models Optional
OM-4405
Front Panel Controls For CC/CV Models See Section
Operating Welding Generator CC/CV Models
Voltage/Amperage Adjust Switch And Remote 14 Receptacle
Use switch to select weld amperage range
Process/Contactor Switch Settings
Process/Contactor Switch On CC/CV Models
Process/Contactor Switch
Running
Set Remote Set Range
Remote Voltage/Amperage Control On CC/CV Models Optional
Process
Set Remote
Volt And 240 Volt Receptacles
Operating Auxiliary Equipment
Rear Of Panel
Single-Phase Power Connection Single-Phase Auxiliary Power
Three-Phase Power Connection
Circuit Breaker CB2 Circuit Breaker CB3
Optional Auxiliary Power Receptacles
240 V 15 a AC South African Receptacle RC1
Maintenance Label
Maintenance & Troubleshooting
50 h
Routine Maintenance
100 h
250 h
500 h
Inspecting And Cleaning Optional Spark Arrestor Muffler
1000 h
Stop engine and let cool
Servicing Air Cleaner
Maximum
Adjusting Engine Weld/Power Speed
No Load
Adjusting Engine Idle Speed
Engine Speed
Tools Needed 1/2
Adjusting Governor Sensitivity
Servicing Fuel And Lubrication Systems
Overload Protection
Press button to reset breaker
Diagnostic Checks While Running
Diagnosing Causes Of Engine Fault Shutdowns
Fault Condition
20s Start Engine With No Load Applied
Welding CC Models
Troubleshooting
Tacle see Section
Repair or replace wire feeder
Welding CC/CV Models
Engine
Standard Auxiliary Power
Optional Auxiliary Power Plant
Shutdown switch is released Out
Wiring harness and components
Ant temperature is too high see Sections 4-7
Or coolant temperature is too high see Sections 4-7
OM-4405
Circuit Diagram For CC Welding Generator
Electrical Diagrams
201 991-A
Circuit Diagram For CC/CV Welding Generator
201 992-A
Grounding Generator To Truck Or Trailer Frame
Auxiliary Power Guidelines
Selecting Equipment
How Much Power Does Equipment Require?
Grounding When Supplying Building Systems
Earth ground if supplying
Amperes x Volts = Watts
Approximate Power Requirements For Farm/Home Equipment
Approximate Power Requirements For Industrial Motors
Industrial Motors Rating Starting Watts Running Watts
Farm/Home Equipment Rating Starting Watts Running Watts
Contractor Rating Starting Watts Running Watts
Approximate Power Requirements For Contractor Equipment
How Much Power Can Generator Supply?
Power Required To Start Motor
Single-Phase Induction Motor Starting Requirements
KVA/HP x HP x
Typical Connections To Supply Standby Power
Current Load Watts Amperes
Selecting Extension Cord Use Shortest Cord Possible
OM-4405
CC only 104 -4 or
Parts List
107 106 101 105 103
See FIG
108
Dia 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 Models
PC6 192
Generator
Generator -1 Item
Main Rectifier Assembly
Support
Service
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