Manuals / Miller Electric / Power Tools / Welding System

Miller Electric Big 40 WG manual Generator

Models: Big 40 WG

1 80

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Item	Dia.	Part	Description
No.	Mkgs.	No.	Description	Quantity
		Figure 11-5. Panel, Front w/Components – CC/CV Models (Continued)

. . . 53 . . . .	. . . . . . . . .	097 922 . .	KNOB, pointer .875 dia x .250 ID w/set screws plstc	. . . 1
. . . 54 . . . .	. . . . . . . . .	189 161 . .	HANDLE, switch range	. . . 1
. . . 55 . . . .	. . . . . . . . .	010 647 . .	PIN, spring CS .156 x 1.250	. . . 1
. . . 56 . . . .	. . . . . . . . .	097 924 . .	KNOB, pointer 1.625 dia x .250 ID w/set scrws plstc	. . . 1
. . . . . . . . . .	. . . . . . . . .	193 158 . .	HARNESS, unit weld control – CV (consisting of)	. . . 1
. . . . . . . . . .	PLG6 . . .	. 114 063 . . .	. CONNECTOR, rect univ 084 4p/s 1 row plug cable lkg	. . . 1
. . . . . . . . . .	PLG8 . . .	193 184 . . .	. CONNECTOR, rect cinch 30 pin	. . . 1
. . . . . . . . .	PLG13 . .	147 992 . . .	. CONNECTOR, rect univ 039 10p/s 2 row plug cable	. . . 1
. . . . . . . . . .	PLG3 . . .	158 465 . . .	. CONNECTOR, rect univ 084 12p/s 3 row plug cable	. . . 1
. . . . . . . . . .	. . . . . . . . .	088 731 . . .	. BUSHING, snap-in nyl .375 ID x .500 mtg hole	. . . 1
. . . . . . . . . .	. . . . . . . . .	135 873 . . .	. CLIP, conduit convoluted 1/2 in mtg hole	. . . 2
. . . . . . . . . .	. . . . . . . . .	187 654 . . .	. SEAL, wire univ 12p/s 3 row	. . . 1
. . . . . . . . . .	. . . . . . . . .	024 103 . .	BLANK, snap-in nyl .750 mtg hole blk	. . . 1
. . . . . . . . . .	. . . . . . . . .	120 304 . .	BLANK, snap–in nyl .250 mtg hole black	. . . 2

+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.

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.

.Hardware is common and

not available unless listed.	22

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30 31

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802 800

Figure 11-6. Generator

OM-4405 Page 72

Image 76

Miller Electric Big 40 WG manual Generator

Contents

Processes OM-4405Description From Miller to You Table of Contents Options and Accessories Warranty Symbol Usage Arc Welding HazardsElectric Shock can kill ARC Rays can burn eyes and skinEngine Hazards Battery Explosion can Blind Moving Parts can cause injuryEngine Exhaust Gases can kill Engine Heat can cause firePrincipal Safety Standards EMF InformationRadiation can cause interference ARC Welding can cause interferenceSignification des symboles Consignes DE SÉ Curité Lire Avant UtilisationUN Choc É Lectrique peut tuer LES Fumé ES ET LES GAZ peuvent ê tre dangereuxLE Soudage peut provoquer un in- cendie ou une explosion DES Particules Volantes peuvent blesser les yeuxDES PIÈ CES Chaudes peuvent provoquer des brû lures graves LE Bruit peut affecter l’ouïeDES Organes Mobiles peuvent provoquer des blessures ’EXPLOSION DE LA Batterie peutLA Chaleur DU Moteur peut pro- voquer un incendie LA Chute DE L’APPAREIL peut blesserPrincipales normes de sé curité Information sur les champs é lectromagné tiquesLE Soudage À L’ARC risque de provoquer des interfé rences Consignes relatives aux stimulateurs cardiaquesSpecifications Symbols And DefinitionsWeld, Power, And Engine Specifications DefinitionsDimensions, Weights, And Operating Angles Volt-Ampere Curves For CC ModelsStick Mode MIG ModeTIG Mode Volt-Ampere Curves for CC/CV ModelsFuel Consumption Duty Cycle And OverheatingAC Auxiliary Power Curve Optional AC Power Plant Curves12 kVA/kW Single-Phase Auxiliary Power Plant No Weld Load 15 kVA/kW Three-Phase Auxiliary Power Plant No Weld LoadInstalling Welding Generator See Sections 4-2 InstallationUsing Lifting Eye Installing Exhaust Pipe Mounting Welding GeneratorWelding Unit In Place Bolting Unit In Place To Bolt Unit In PlaceActivating The Dry Charge Battery If Applicable Do not overfill battery cellsRead and follow all instruc ChargerConnecting The Battery Connect Negative Cable LastCoolant Recovery Tank Engine Prestart ChecksFuel OilConnecting To Weld Output Terminals Selecting Weld Cable SizesRef 862-A / 048 720-K / 802 Connecting To Remote 14 Receptacle RC14 On CC/CV Models Socket InformationOperating Welding Generator CC Models Front Panel Controls For CC Models See SectionEngine Indicator Lights Do not switch under loadEngine Starting Controls To StartRemote Amperage Control On CC Models Optional OM-4405 Operating Welding Generator CC/CV Models Front Panel Controls For CC/CV Models See SectionUse switch to select weld amperage range Voltage/Amperage Adjust Switch And Remote 14 ReceptacleProcess/Contactor Switch On CC/CV Models Process/Contactor Switch SettingsProcess/Contactor Switch RunningRemote Voltage/Amperage Control On CC/CV Models Optional Set Remote Set RangeProcess Set RemoteOperating Auxiliary Equipment Volt And 240 Volt ReceptaclesThree-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 & Troubleshooting Maintenance LabelRoutine Maintenance 50 h100 h 250 hInspecting And Cleaning Optional Spark Arrestor Muffler 500 h1000 h Stop engine and let coolServicing Air Cleaner Adjusting Engine Weld/Power Speed MaximumEngine Speed Adjusting Engine Idle SpeedNo Load Adjusting Governor Sensitivity Tools Needed 1/2Servicing Fuel And Lubrication Systems Press button to reset breaker Overload ProtectionDiagnosing Causes Of Engine Fault Shutdowns Diagnostic Checks While RunningFault Condition 20s Start Engine With No Load AppliedTroubleshooting Welding CC ModelsWelding CC/CV Models Repair or replace wire feederTacle see Section Optional Auxiliary Power Plant Standard Auxiliary PowerEngine Wiring harness and components Shutdown switch is released OutAnt temperature is too high see Sections 4-7 Or coolant temperature is too high see Sections 4-7OM-4405 Electrical Diagrams Circuit Diagram For CC Welding Generator201 991-A Circuit Diagram For CC/CV Welding Generator 201 992-A Selecting Equipment Auxiliary Power GuidelinesGrounding Generator To Truck Or Trailer Frame Grounding When Supplying Building Systems How Much Power Does Equipment Require?Earth ground if supplying Amperes x Volts = WattsApproximate Power Requirements For Industrial Motors Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsPower Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements KVA/HP x HP xTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Current Load Watts AmperesOM-4405 107 106 101 105 103 Parts ListCC only 104 -4 or 108 See FIGDia 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 Panel, Front w/Components CC/CV Models -1 ItemPC6 192 Generator Generator -1 Item Main Rectifier Assembly Your distributor also gives ServiceSupport Owner’s Record Miller Electric Mfg. Co