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Welding System
Miller Electric
Big 40G
manual
OM-477
Models:
Big 40G
1
40
60
60
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60 pages
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Troubleshooting
Specs
Install
Parts list
Electrical Diagrams
Symbol Usage
Dimension
Maintenance
Battery Explosion can Blind
Adjusting Engine Idle Speed
Page 40
Image 40
Figure
8-2.
Circuit Diagram For Welding Generator With Welders And Deluxe Package Options
OM-477
Page 36
Page 39
Page 41
Page 40
Image 40
Page 39
Page 41
Contents
Processes
OM-477
Description
From Miller to You
Table of Contents
Page
Symbol Usage
Arc Welding Hazards
Electric Shock can kill
ARC Rays can burn eyes and skin
Engine Hazards
Battery Explosion can Blind
Moving Parts can cause injury
Engine Exhaust Gases can kill
Engine Heat can cause fire
Principal Safety Standards
EMF Information
Radiation can cause interference
ARC Welding can cause interference
Signification des symboles
Consignes DE SÉ Curité Lire Avant Utilisation
UN Choc É Lectrique peut tuer
LES Fumé ES ET LES GAZ peuvent ê tre dangereux
LE Soudage peut provoquer un in- cendie ou une explosion
DES Particules Volantes peuvent blesser les yeux
DES PIÈ CES Chaudes peuvent provoquer des brû lures graves
LE Bruit peut affecter l’ouïe
DES Organes Mobiles peuvent provoquer des blessures
’EXPLOSION DE LA Batterie peut
LA Chaleur DU Moteur peut pro- voquer un incendie
LA Chute DE L’APPAREIL peut blesser
Principales normes de sé curité
Information sur les champs é lectromagné tiques
LE Soudage À L’ARC risque de provoquer des interfé rences
Consignes relatives aux stimulateurs cardiaques
Specifications
Symbols And Definitions
Weld, Power, And Engine Specifications
Definitions
Dimensions, Weights, And Operating Angles
Dimensions
Weight
Fuel Consumption
Duty Cycle And Overheating
AC Auxiliary Power
Minutes Welding Minutes Resting
5 KVA/KW Single-Phase Auxiliary Power Plant No Weld Load
Optional AC Power Plant Curves
12.5 KVA/KW Three-Phase Auxiliary Power Plant No Weld Load
Volt-Ampere Curves
DC Volts CC/DC Standard
AC Amperes CV/DC Models with Optional CV-3 Module
100
Installation
Installing Welding Generator
Connecting The Battery
Installing Muffler
13 mm Full Gasoline Capacity 9 qt 8.5 L
Engine Prestart Checks
Top View
Connecting To Weld Output Terminals
Selecting Weld Cable Sizes
100 ft 30 m Or Less
10 100% Duty Cycle
Remote 14 Receptacle RC3 Information Optional, See Section
Terminal Strip 3T Connections Optional
Socket Information
Stop engine
Operating Welding Generator
Front Panel Controls See Section
Ampere Range Switch
Do not switch under load
Description Of Front Panel Controls See Section
Stop engine and fix trouble if either warning light goes on
Remote Control Optional
Example Combination remote amperage control
Operating Auxiliary Equipment
Volt Duplex And Optional Gfci Receptacles
Volt Duplex Receptacle Optional
X 10 a + 120 V x 5 a = 3.0 kVA/kW
Connecting Optional Auxiliary Power Plant
Front
Maintenance and Troubleshooting
Maintenance Label
Servicing Air Cleaner
To Clean air filter
Do not clean housing with air hose
Overload Protection
Changing Engine Oil And Filter
Stop engine and let cool Standard Oil Filter
Cation makes it difficult to change
Standard filter
Changing Fuel Filter
Inspecting And Cleaning Optional Spark Arrestor Muffler
Stop engine and let cool
Adjusting Engine Weld/Power Speed
1850 rpm Max
Adjusting Engine Idle Speed
Adjusting Governor Sensitivity
Adjusting Optional High Altitude Carburetor
Troubleshooting
Welding
Trouble Remedy
Auxiliary Power
Coolant temperature gets too high see Section
Check Engine Control switch, and replace if necessary
Engine
See engine manual
OM-477
Electrical Diagrams
Circuit Diagram For Welding Generator For Standard Models
OM-477
193 967-A
Selecting Equipment
Auxiliary Power Guidelines
Grounding Generator To Truck Or Trailer Frame
Grounding When Supplying Building Systems
How Much Power Does Equipment Require?
Earth ground if supplying
Amperes x Volts = Watts
Approximate Power Requirements For Industrial Motors
Approximate Power Requirements For Farm/Home Equipment
Industrial Motors Rating Starting Watts Running Watts
Farm/Home Equipment Rating Starting Watts Running Watts
Approximate Power Requirements For Contractor Equipment
Contractor Rating Starting Watts Running Watts
Power Required To Start Motor
How Much Power Can Generator Supply?
Single-Phase Induction Motor Starting Requirements
KVA/HP x HP x
Typical Connections To Supply Standby Power
240 120 Ground
Selecting Extension Cord Use Shortest Cord Possible
Current Load Watts Amperes
OM-477
Parts List
114 113 112 111 110 109 108 107 106 105 104 103 102 101 100
Includes 39 43
Dia Part Description Mkgs Quantity
025
Generator
2523
Generator -1 Item
2539
Includes
CB1,2 139
Control Box w/Components -3 Item
Your distributor also gives
Service
Support
Owner’s Record
Miller Electric Mfg. Co