Instruction/ maintenance manual of the product Big 40 WG Miller Electric
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Big 40 WG OM -4405 200 972A January 2001 Visit our website at www.Miller Welds .com Processes Descrip tio n Air Carbon Arc (CAC-A) Cutting and Gouging Stick (SMA W) W elding Engine Driven Welding Gene.
Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .
T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T ABLE OF CONTENTS SECTION 8 – MAINTENANCE & TROUBLESHOOTING 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. Maintenance Label 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-4405 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING rom _nd_1 1/98 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Marks a special safety message.
OM-4405 Page 2 W elding on closed containers, such as tanks, drums, o r pipes, can cause them to blow up. Sparks c a n fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire.
OM-4405 Page 3 MOVING P ARTS can cause injury . Keep away from fans, belts, and rotors. Keep all doors, panels, covers, and guards closed and securely in place. Stop engine before installing or connecting unit. Have only qualified people remove guards or covers for maint- enance and troubleshooting as necessary .
OM-4405 Page 4 H. F . RADIA TION can cause interference. High-frequency (H.F .) can interfere with radio navigation, safety services, computers, and communications equipment. Have only qualified persons familiar with electronic equipment perform this installation.
OM-4405 Page 5 SECTION 1 – CONSIGNES DE S É CURIT É – LIRE A V ANT UTILISA TION rom _nd_fre 1 1/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette proc é dure pr é sente des risques de danger ! Ceux-ci sont identifi é s par des symboles adjacents aux directives.
OM-4405 Page 6 Le soudage ef fectu é sur des conteneurs ferm é s tels que des r é servoirs, tambours ou des conduites peut provoquer leur é clatement.
OM-4405 Page 7 DES ORGANES MOBILES peuvent provoquer des blessures. Ne pas approcher les mains des ventilateurs, cour- roies et autres pi è ces en mouvement. Maintenir ferm é s et fixement en place les portes, panneaux, recouvrements et dispositifs de protection.
OM-4405 Page 8 LE RA YONNEMENT HAUTE FR É - QUENCE (H.F .) risque de provoquer des interf é rences. Le rayonnement haute fr é quence (H.F .) peut provoquer des interf é rences avec les é quipements de radio – navigation et de communication, les services de s é curit é et les ordinateurs.
OM-4405 Page 9 SECTION 2 – DEFINITIONS 2-1. Symbols And Definitions Stop Engine Fast (Run, W eld/ Power) Slow (Idle) Start Engine Air T emperature Or Engine T emperature Battery (Engine) Engine Oil .
OM-4405 Page 10 3-2. Dimensions, Weights, And Operating Angles Dimensions Height 58 in (1473 mm) (to top of muf fler) G Width 28-1/2 in (724 mm) (mtg. brackets turned in) 30-3/4 in (781 mm) (mtg. brackets turned out) Do not exceed tilt angles or engine could be damaged or unit could tip.
OM-4405 Page 1 1 3-4. V olt-Ampere Curves for CC/CV Models 202 655 / 202 656 / 202 654 The volt-ampere curves show the minimum and maximum voltage an d amperage output capabilities of th e welding generator . Curves of al l other settings fall between the curves shown.
OM-4405 Page 12 3-5. Fuel Consumption The curve shows typical fuel use under weld or power loads. 201 033 0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 2.25 2.50 05 0 100 150 200 250 300 350 400 DC WELD AMPERES A T 100% DUT Y CYCLE U.S. Ga l./Hr . IDLE Continuous Welding 3-6.
OM-4405 Page 13 3-7. AC Auxiliary Power Curve 193 018 Th e ac power curve shows the aux- iliary power in amperes available at the 120 and 240 volt receptacles. 0 50 100 150 200 250 300 0 5 10 15 20 25 30 AC AMPERES IN 240V MODE AC VOL TS 0 25 50 75 100 150 125 0 10 20 30 40 50 60 AC AMPERES IN 120V MODE 3-8.
OM-4405 Page 14 SECTION 4 – INST ALLA TION 4-1. Installing Welding Generator (See Sections 4-2 And 4-3) install2 1/01 – Ref. 800 652 / Ref. 800 477-A / 158 936-A / 0854 1 2 Electrically bond generator frame to vehicle frame by metal-to-metal contact.
OM-4405 Page 15 4-3. Mounting Welding Generator Ref. 190 250-A / Ref. 802 730 Do not weld on base. W eld - ing on base can cause fuel tank fire or explosion.
OM-4405 Page 16 4-5. Activating The Dry Charge Battery (If Applicable) Remove b attery from unit. 1 Eye Protection – Safety Glasses Or Face Shield 2 Rubber Gloves 3 V ent Caps 4 Sulfuric Acid Electrolyte (1.265 Specific Gravity) 5 W ell Fill each cell with electrolyte to bottom of well (maximum).
OM-4405 Page 17 4-6. Connecting The Battery 1/2 i n – + Connect Negative ( – ) Cable Last. T ools Needed: 802 168-B / Ref. 201 841 / 802 313 / S-0756-C Notes.
OM-4405 Page 18 4-7. Engine Prestart Checks Check all engine fluids daily . Engine must be cold and on a level surface. Unit is shipped with 20W break-in oil. Automatic shutdown system stops engine if oil pressure is too low , or coolant tempera- ture is too high.
OM-4405 Page 19 4-8. Connecting T o W eld Output T erminals 802 729 Stop engine. 1 Positive (+) Weld Output T erminal 2 Negative ( – ) W eld Output T erminal Fo r Stick and TIG welding Direct Cu.
OM-4405 Page 20 4-10. Connecting T o Remote Amperage Adjust Receptacle RC13 On CC Models Ref. 154 862-A / 048 720-K / 802 729 1 Remote Amperage Adjust Receptacle RC13 Connect optional remote control to RC13 (see Section 5-3).
OM-4405 Page 21 4-1 1. Connecting T o Remote 14 Receptacle RC14 On CC/CV Models Socket* Socket Information 24 VOL TS AC A 24 volts ac. Protected by circuit breaker CB5. 24 VOL TS AC B Contact closure to A completes 24 volt ac contactor control circuit.
OM-4405 Page 22 SECTION 5 – OPERA TING WELDING GENERA TOR – CC MODELS 5-1. Front Panel Controls For CC Models (See Section 5-2) 17 201 841 / 802 729 15 16 2 1 3 13 18 19 14 12 10 1 1 9 8 6 5 47.
OM-4405 Page 23 5-2. Description Of Front Panel Controls For CC Models (See Section 5-1) Engine Starting Controls 1 Magnetic Shutdown Switch Use switch during start-up to bypass engine shutdown system. System stops engine if oil pressure is too low or coolant temperature is too high.
OM-4405 Page 24 5-3. Remote Amperage Control On CC Models (Optional) 1 Remote Amperage Adjust Receptacle RC13 Connect optional remote control to RC13 (see Section 4-10).
OM-4405 Page 25 Notes.
OM-4405 Page 26 SECTION 6 – OPERA TING WELDING GENERA TOR – CC/CV MODELS 6-1. Front Panel Controls For CC/CV Models (See Section 6-2) 201 579 / 802 729 6 5 47 13 16 2 1 3 14 18 19 15 12 10 1 1 9 8.
OM-4405 Page 27 6-2. Description Of Front Panel Controls For CC/CV Models (See Section 6-1) Engine Starting Controls 1 Magnetic Shutdown Switch Use switch during start-up to bypass engine shutdown system. System stops engine if oil pressure is too low or engine temperature is too high.
OM-4405 Page 28 6-3. Process/Contactor Switch On CC/CV Models 1 1 Process/Contactor Switch W eld output terminals are en- ergized when Process/Con- tactor switch is in an Electrode Ho t position and the engine is running. Use switch to select weld process and weld output on/of f control (see table below and Section 6-4).
OM-4405 Page 29 6-4. Remote V oltage/Amperage Control On CC/CV Models (Optional) 1 Remote 14 Receptacle RC14 Connect optional remote control to RC14 (see Section 4-1 1 ).
OM-4405 Page 30 SECTION 7 – OPERA TING AUXILIAR Y EQUIPMENT 7-1. 120 V olt And 240 V olt Receptacles 191 624-A 2 1 120 V 20 A AC GFCI Receptacle GFCI1 2 240 V 30 A AC T wistlock Receptacle RC1 Receptacles supply 60 Hz single- phase power at weld/power speed.
OM-4405 Page 31 7-2. Connecting T o Optional Auxiliary Power Plant (CC/CV Models Only) Ref. 197 399 / 802 332-E Place Process/Contactor switch in Electrode Hot - Stick position when using auxiliary power plant (see Section 6-3).
OM-4405 Page 32 7-3. Optional Auxiliary Power Receptacles 2 1 120 V 20 A AC GFCI Receptacle GFCI1 2 240 V 16 A AC European Receptacle RC1 3 240 V 15 A AC Australian Receptacle RC1 4 240 V 15 A AC South African Receptacle RC1 Receptacles supply 60 Hz single- phase power at weld/power speed.
OM-4405 Page 33 SECTION 8 – MAINTENANCE & TROUBLESHOOTING 8-1. Maintenance Label.
OM-4405 Page 34 8-2. Routine Maintenance Follow the storage procedure in the engine owner ’ s manual if the unit will not be used for an extended period. Note Recycle engine fluids. Stop engine before maintaining. See also Engine Manual and Mainte- nance Label.
OM-4405 Page 35 500 h Repair Or Replace Damaged Cables. Check V alve Clearance.* 1000 h Blow Out Or V acuum Inside. During Heavy Service, Clean Monthly . OR Drain Sludge From Fuel T ank. See Section 8-8. FUEL SLUDGE Service Welding Generator Brushes And Slip Rings.
OM-4405 Page 36 8-4. Servicing Air Cleaner aircleaner1 9/00 – 153 929-B / 153 585 / Ref. S-0698-B Stop engine. Do not run engine without air cleaner or with dirty element. En- gine damage caused by using a damaged element is not covered by the warranty .
OM-4405 Page 37 8-5. Adjusting Engine Weld/Power Speed 802 731 / 802 780 / Ref. 801 179 / Ref. 800 161 Stop engine and let cool. Governor sensitivity may re- quire adjustment if engine speed is adjusted (see Section 8-7). Engine speed is factory set and should not require adjustment.
OM-4405 Page 38 8-6. Adjusting Engine Idle Speed 802 731 / Ref. 1 15 155-A Stop engine and let cool. Engine idle speed is factory set and normally should not require adjust- ment. After tuning engine, check engine speed with tachometer or frequency meter .
OM-4405 Page 39 8-7. Adjusting Governor Sensitivity 802 780 / Ref. 1 15 155-A Governor sensitivity may re- quire readjustment if weld speed is adjusted. W eld speed must b e readjusted if sensitivity is adjusted. Be sure carburetor and link- ages are adjusted properly be- fore adjusting sensitivity .
OM-4405 Page 40 3 1 8-8. Servicing Fuel And Lubrication Systems 802 731 / Ref. 801 434 Stop engine and let cool. After servicing, start engine and check for fuel leaks.
OM-4405 Page 41 8-9. Overload Protection Stop engine. When a circuit breaker or fuse opens, it usually indicates a more serious problem exists. Contact Factory Authorized Service Agent. 1 Fuse F1 2 Fuse F2 F1 and F2 protect the stator exciter winding from overload.
OM-4405 Page 42 8-10. Diagnosing Causes Of Engine Fault Shutdowns Ref. 201 841 Use the front panel engine lights to help determine the cause of an au- tomatic engine shutdown. Correct the cause of the shut- down before operating the welding generator .
OM-4405 Page 43 8-1 1. T roubleshooting A. Welding – CC Models T rouble Remedy No weld output; auxiliary power output okay . Check position of Ampere Range switch.
OM-4405 Page 44 B. Welding – CC/CV Models T rouble Remedy No weld output; auxiliary power output okay . Place Process/Contactor switch in a Electrode Hot position, or place switch in a R emote p osition and connect remote contactor to optional Remote 14 receptacle RC14 (see Sections 4-1 1 and 6-1).
OM-4405 Page 45 C. Standard Auxiliary Power T rouble Remedy No auxiliary power output; weld output okay . Reset receptacle circuit breakers. No auxiliary power or weld output. Disconnect equipment from auxiliary power receptacles during start-up. Check fuses F1 and F2, and replace if open (see Section 8-9).
OM-4405 Page 46 T rouble Remedy Engine cranks but does not start. Press Magnetic Shutdown switch MS1 when starting engine. Check fuel level. Reset circuit breaker CB13 (see Section 8-9). Have Factory Authorized Service Agent check engine- wiring harness and components.
OM-4405 Page 47 Notes.
OM-4405 Page 48 SECTION 9 – ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For CC Welding Generator.
OM-4405 Page 49 201 991-A.
OM-4405 Page 50 Figure 9-2. Circuit Diagram For CC/CV Welding Generator.
OM-4405 Page 51 201 992-A.
OM-4405 Page 52 SECTION 10 – AUXILIAR Y POWER GUIDELINES 10-1. Selecting Equipment aux_pwr 2/99 – Ref. ST-159 730 / ST -800 577 1 Auxiliary Power Receptacles – Neutral Bonded T o Frame 2 3-Prong Plug From Case Grounded Equipment 3 2-Prong Plug From Double Insulated Equipment OR 2 Be sure equipment has this symbol and/or wording.
OM-4405 Page 53 10-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 A WG or larger insulated copper wire. 3 Ground Device Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system.
OM-4405 Page 54 10-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting W atts Running W atts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 210.
OM-4405 Page 55 10-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting W atts Running W atts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/.
OM-4405 Page 56 10-8. Power Required T o Start Motor S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor V oltage T o find starting amperage: Step 1: Find code and use table to find kV A/HP . If code is not listed, multiply running amperage by six to find starting amperage.
OM-4405 Page 57 10-10. T ypical Connections T o Supply Standby Power S-0405-A 1 Power Company Service Meter 2 Main and Branch Overcurrent Protection 3 Double-Pole, Double-Throw T ransfer Switch Obtain and install correct switch. Switch rating must be same as or greater than the branch overcurrent protection.
OM-4405 Page 58 10-1 1. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 V olt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord.
OM-4405 Page 59 Notes.
OM-4405 Page 60 SECTION 1 1 – P ARTS LIST Hardware is common and not available unless listed. 1 2 3 4 5 6 7 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 92 93 94 95 96 (CC ONL Y ) 97 98 (FIG. 1 1 – 2 OR 1 1 – 3) 99 12 102 103 104 (FIG. 1 1 – 4 OR 1 1 – 5) 105 101 100 (Fig.
OM-4405 Page 61 802 789 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 91 (SEE FIG. 1 1 – 6) 90 89 88 87 86 85 49 83 82 81 80 79 78 77 84 50 76 74 73 72 71 70 69 68 67 66 65 64.
OM-4405 Page 62 Description Part No. Dia. Mkgs. Item No. Figure 1 1-1. Main Assembly Quantity 1 189 824 P ANEL, gen LH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-4405 Page 63 Description Part No. Dia. Mkgs. Item No. Figure 1 1-1. Main Assembly (Continued) Quantity 172 725 BOOT , starter eyelet terminal 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-4405 Page 64 Description Part No. Dia. Mkgs. Item No. Figure 1 1-1. Main Assembly (Continued) Quantity 99 189 731 FIREWALL, lower 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-4405 Page 65 Description Part No. Dia. Mkgs. Item No. Figure 1 1-2. Control Box Assembly – CC Models (Figure 1 1-1 Item 98) Quantity 1 F1, F2 *085 874 FUSE, mintr cer slo-blo 10A 250V 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-4405 Page 66 802 360 1 2 5 3 12 4 16 15 17 11 18 10 13 14 7 8 9 6 Figure 1 1-3. Control Box Assembly – CC/CV Models Description Part No. Dia. Mkgs. Item No. Figure 1 1-3. Control Box Assembly – CC/CV Models (Figure 1 1-1 Item 98) Quantity 1 F1, F2 *085 874 FUSE, mintr cer slo-blo 10A 250V 2 .
OM-4405 Page 67 Description Part No. Dia. Mkgs. Item No. Figure 1 1-3. Control Box Assembly – CC/CV Models (Continued) Quantity 177 859 CONN, body 5 terminal (to engine control switch S1) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-4405 Page 68 Hardware is common and not available unless listed. 802 799 1 3 4 5 11 14 17 22 23 25 28 31 34 35 36 37 38 39 40 16 24 29 30 15 19 2 21 26 27 12 18 13 6 7 8 9 10 20 33 32 Figure 1 1-4. Panel, Front w/Components – CC Models Description Part No.
OM-4405 Page 69 Description Part No. Dia. Mkgs. Item No. Figure 1 1-4. Panel, Front w/Components – CC Models (Continued) Quantity 5 R1 188 635 RHEOST A T , WW 300W 34 ohm 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-4405 Page 70 Hardware is common and not available unless listed. 802 732 1 2 3 4 5 6 7 9 47 49 50 51 52 53 54 55 56 12 17 18 19 20 21 22 23 24 25 26 29 27 28 14 15 33 32 31 16 34 41 42 40 39 38 37 36 35 43 46 13 10 48 11 8 30 44 45 Figure 1 1-5.
OM-4405 Page 71 Description Part No. Dia. Mkgs. Item No. Figure 1 1-5. Panel, Front w/Components – CC/CV Models (Continued) Quantity 5 R1 193 1 18 POT , cp flat 1t 2w 1k ohm linear 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-4405 Page 72 Description Part No. Dia. Mkgs. Item No. Figure 1 1-5. Panel, Front w/Components – CC/CV Models (Continued) Quantity 53 097 922 KNOB, pointer .875 dia x .250 ID w/set screws plstc 1 . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-4405 Page 73 Description Part No. Dia. Mkgs. Item No. Figure 1 1-6. Generator (Figure 1 1-1 Item 91) Quantity 1 132 053 SCREW, .375 – 16x1.50 hex hd – pln gr5 pld 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-4405 Page 74 Hardware is common and not available unless listed. 802 279-A 1 2 3 4 6 5 7 8 9 Figure 11-7. Main Rectifier Assembly Description Part No. Dia. Mkgs. Item No. Figure 1 1-7. Main Rectifier Assembly (Figure 1 1-1 Item 100) Quantity 201 747 RECTIFIER (consisting of) 1 .
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 7/00 Y our distributor also gives you ... Service Y ou 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 .
PRINTED IN USA 2001 Miller Electric Mfg. Co. 1/01 Miller Elect ric Mfg. Co. An I l li noi s T ool Works Company 1635 West Spencer St reet Applet on, WI 54914 USA International He adquarter s – U.
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If you have not bought Miller Electric Big 40 WG yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Miller Electric Big 40 WG - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Miller Electric Big 40 WG you will learn all the available features of the product, as well as information on its operation. The information that you get Miller Electric Big 40 WG will certainly help you make a decision on the purchase.
If you already are a holder of Miller Electric Big 40 WG, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Miller Electric Big 40 WG.
However, one of the most important roles played by the user manual is to help in solving problems with Miller Electric Big 40 WG. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Miller Electric Big 40 WG along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
