Miller Electric Big 40 WG Owner'S Manual Download Page 4

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TABLE OF CONTENTS

SECTION 8 – MAINTENANCE & TROUBLESHOOTING

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8-1.

Maintenance Label

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8-2.

Routine Maintenance

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8-3.

Inspecting And Cleaning Optional Spark Arrestor Muffler

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8-4.

Servicing Air Cleaner

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8-5.

Adjusting Engine Weld/Power Speed

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8-6.

Adjusting Engine Idle Speed

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8-7.

Adjusting Governor Sensitivity

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8-9.

Servicing Fuel And Lubrication Systems

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8-10. Overload Protection

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8-11. Diagnosing Causes Of Engine Fault Shutdowns

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8-12. Troubleshooting

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SECTION 9 – ELECTRICAL DIAGRAMS

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SECTION 10 – AUXILIARY POWER GUIDELINES

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SECTION 11 – PARTS LIST

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OPTIONS AND ACCESSORIES

WARRANTY

Summary of Contents for Big 40 WG

Page 1: ...January 2001 Visit our website at www MillerWelds com Processes Description Air Carbon Arc CAC A Cutting and Gouging Stick SMAW Welding Engine Driven Welding Generator TIG GTAW Welding MIG GMAW Weldi...

Page 2: ...alue established in 1929 This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They will help you protect yourself agains...

Page 3: ...ing To Remote Amperage Adjust Receptacle RC13 On CC Models 20 4 11 Connecting To Remote 14 Receptacle RC14 On CC CV Models 21 SECTION 5 OPERATING WELDING GENERATOR CC MODELS 22 5 1 Front Panel Control...

Page 4: ...36 8 5 Adjusting Engine Weld Power Speed 37 8 6 Adjusting Engine Idle Speed 38 8 7 Adjusting Governor Sensitivity 39 8 9 Servicing Fuel And Lubrication Systems 40 8 10 Overload Protection 41 8 11 Dia...

Page 5: ...en not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable Do...

Page 6: ...uch hot engine parts or just welded parts bare handed NOISE can damage hearing Noise from some processes or equipment can damage hearing Wear approved ear protection if noise level is high MAGNETIC FI...

Page 7: ...ammables Keep exhaust and exhaust pipes way from flammables EXHAUST SPARKS can cause fire Do not let engine exhaust sparks cause fire Use approved engine exhaust spark arrestor in required areas see a...

Page 8: ...une Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet...

Page 9: ...oquer une lectrocution Mettre l appareil hors tension quand on ne l utilise pas Ne pas utiliser des c bles us s endommag s de grosseur insuffisante ou mal piss s Ne pas enrouler les c bles autour du c...

Page 10: ...pour travailler sur un moteur chaud Ne pas toucher mains nues les parties chaudes du moteur ni les pi ces r cemment soud es LE BRUIT peut affecter l ou e Le bruit des processus et des quipements peut...

Page 11: ...nir distance les produits inflammables de l chappement LES TINCELLES L CHAPPEMENT peuvent provoquer un incendie Emp cher les tincelles d chappement du moteur de provoquer un incendie Utiliser uniqueme...

Page 12: ...W Lejeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 de la National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA P...

Page 13: ...nual Circuit Breaker Do Not Switch While Welding Engine Choke Contactor On Hz Hertz SECTION 3 SPECIFICATIONS 3 1 Weld Power And Engine Specifications Welding Mode Weld Output Range Rated Welding Outpu...

Page 14: ...419 mm A C 46 3 8 in 1178 B C D 9 1 2 in 241 mm E 27 1 2 in 699 mm 30 F 1 in 25 mm H 30 G 29 1 2 in 743 mm D 20 30 H 9 16 in 14 mm Dia 4 Holes Front Panel End D 20 Weight F E No fuel 1600 lb 726 kg w...

Page 15: ...other settings fall between the curves shown A Stick Mode B MIG Mode C TIG Mode 0 10 20 30 40 50 60 70 80 90 100 0 50 100 150 200 250 300 350 400 450 500 DC AMPERES DC VOLTS Ranges 50 335 40 240 25 15...

Page 16: ...25 2 50 0 50 100 150 200 250 300 350 400 DC WELD AMPERES AT 100 DUTY CYCLE U S Gal Hr IDLE Continuous Welding 3 6 Duty Cycle And Overheating Duty Cycle is percentage of 10 min utes that unit can weld...

Page 17: ...60 AC AMPERES IN 120V MODE 3 8 Optional AC Power Plant Curves 198 868 98 869 The ac power curves show the aux iliary power available in amperes at the single phase 120 240 volt re ceptacle or three p...

Page 18: ...ity hazards 1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grounding Terminal 4 Grounding Cable Use 10 AWG or larger insulated copper wire If unit does not have GFCI re ceptacles use GFCI protecte...

Page 19: ...reattach to base with original hardware Mount unit to truck or trailer with 1 2 in 12 mm hardware not supplied To Weld Unit In Place Weld unit to truck or trailer only at the four mounting brackets T...

Page 20: ...Wait ten minutes and check electro lyte level If necessary add electro lyte to raise to proper level Reins tall vent caps 6 Battery Charger Read and follow all instruc tions supplied with battery cha...

Page 21: ...OM 4405 Page 17 4 6 Connecting The Battery 1 2 in Connect Negative Cable Last Tools Needed 802 168 B Ref 201 841 802 313 S 0756 C Notes...

Page 22: ...t time If necessary add cool ant to radiator until coolant level is at bottom of filler neck Check coolant level in recovery tank daily If necessary add coolant to recovery tank until coolant level is...

Page 23: ...Exceeding 100 ft 30 m or Less 150 ft 45 m 200 ft 60 m 250 ft 70 m 300 ft 90 m 350 ft 105 m 400 ft 120 m Weld Output Terminals Stop engine before connectingto weld out put terminals Do not use worn da...

Page 24: ...age 20 4 10 Connecting To 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 Secti...

Page 25: ...New LDR 14 long distance remote includes 120 V receptacle C Output to remote control 10 volts dc in MIG or Stick mode 0 to 10 volts dc in TIG mode receptacle REMOTE OUTPUT D Remote control circuit com...

Page 26: ...OM 4405 Page 22 SECTION 5 OPERATING WELDING GENERATOR 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 11 9 8 6 5 4 7...

Page 27: ...C When equipped with gauge option engine stops if temperature exceeds 220 F 104 C 12 Engine Oil Pressure Gauge Optional Normal pressure is 30 80 psi 207 552 kPa When equipped with gauge option en gine...

Page 28: ...nal remote control to RC13 see Section 4 10 Example Combination Remote Amperage Control Stick In Example Range 100 to 205 A DC Percentage Of Range 50 Max About 153 A DC 50 of 100 to 205 Adjust Optiona...

Page 29: ...OM 4405 Page 25 Notes...

Page 30: ...OM 4405 Page 26 SECTION 6 OPERATING WELDING GENERATOR CC CV MODELS 6 1 Front Panel Controls For CC CV Models See Section 6 2 201 579 802 729 6 5 4 7 13 16 2 1 3 14 18 19 15 12 10 11 9 8 17...

Page 31: ...heck battery voltage and moni tor the engine charging system The meter should read about 14 volts dc when the en gine is running and about 12 volts dc when the engine is stopped 11 Engine Coolant Temp...

Page 32: ...l amperage during low voltage short arc length conditions to pre vent sticking electrodes The arc drive dig circuit is disabled when switch is in MIG or TIG positions Place switch in Electrode Hot Sti...

Page 33: ...10 to 315 A DC Min 110 A DC Max 315 A DC Adjust Optional Remote Control Set V A Adjust Switch Set Range Control Not Used In Remote Stick Mode Max 315 A DC Min 110 A DC Set Remote Process Example Combi...

Page 34: ...est button to verify GFCI is working properly 3 Circuit Breaker CB1 4 Circuit Breaker CB2 CB1 protects RC1 and the genera tor winding from overload If CB1 opens RC1 and GFCI1 do not work Place switch...

Page 35: ...ding Lead 7 Lead 90 Neutral 8 Isolated Neutral Terminal 9 Jumper Lead 42 10 Grounding Terminal Jumper 42 is connected to lead 90 at factory Jumper 42 may be discon nected from neutral to meet applica...

Page 36: ...s test button to verify GFCI is working properly 5 Circuit Breaker CB2 6 Circuit Breaker CB3 CB2 protects GFCI1 from overload If CB2 opens GFCI1 does not work Place button to reset breaker CB3 protect...

Page 37: ...OM 4405 Page 33 SECTION 8 MAINTENANCE TROUBLESHOOTING 8 1 Maintenance Label...

Page 38: ...e done by Factory Authorized Service Agent 8 h Check Fluid Levels See Section 4 7 Wipe Up Spills OIL Full Coolant Full 50 h Clean Air Filter See Section 8 4 Clean And Tighten Weld Terminals 1 2 in 13...

Page 39: ...Often In Dirty Conditions 8 3 Inspecting And Cleaning Optional Spark Arrestor Muffler 802 729 Ref 201 841 Stop engine and let cool 1 Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any...

Page 40: ...engine protection Never clean a safety element Re place the safety element after servic ing the primary element three times Clean or replace primary element if dirty see note above before cleaning Re...

Page 41: ...83 mm between lock nuts To adjust remove socket from arm and loos en lock nut Turn socket to adjust length Tighten nut and reattach socket to arm If linkage binds loosen socket nuts and turn sockets...

Page 42: ...dle Speed Screw 4 Throttle Stop Loosen bracket screws and move arm so screw touches stop Do not release arm Turn idle speed screw to obtain 550 rpm 5 Idle Mixture Screw Turn mixture screw counterclock...

Page 43: ...sting sensitivity Start engine Apply and remove load 1 Locking Nuts 2 Sensitivity Adjustment Screw 3 Governor Spring If engine is slow to pick up load or rpm drops under load adjust spring tension as...

Page 44: ...rks and flames away from drained fuel Dispose of drained fuel in an environmentally safe manner Do not leave unit unattended while draining fuel tank Properly lift unit and secure in a level position...

Page 45: ...e 24 volt ac output to remote receptacle RC14 and 24 volt output to field current regulator board PC1 CC CV models only If CB5 opens weld output and 24 volt output to RC14 stops On units with optional...

Page 46: ...e Factory Authorized Service Agent Check Alternator If Temperature Light Is On Correct Cause Of Overheating See Engine Manual If Engine Is Okay See Factory Authorized Service Agent If Fuel Light Is On...

Page 47: ...tions inside and outside unit Be sure connection to work piece is clean and tight Use dry properly stored electrodes Remove excessive coils from weld cables High weld output Check engine speed and adj...

Page 48: ...Check engine speed and adjust if necessary Have Factory Authorized Service Agent check field current regulator board PC1 Voltage Amperage control does not work when welding in Stick mode Place Ampere...

Page 49: ...t Trouble Remedy No or low output at optional auxiliary power plant receptacle RC5 CC CV models only Place Process Contactor switch in Electrode Hot Stick position see Section 6 3 Reset circuit breake...

Page 50: ...ee Section 8 1 Engine suddenly stops Check fuel oil and coolant levels Automatic shutdown system stops engine if oil pressure is too low or coolant temperature is too high see Sections 4 7 and 8 10 Se...

Page 51: ...OM 4405 Page 47 Notes...

Page 52: ...OM 4405 Page 48 SECTION 9 ELECTRICAL DIAGRAMS Figure 9 1 Circuit Diagram For CC Welding Generator...

Page 53: ...OM 4405 Page 49 201 991 A...

Page 54: ...OM 4405 Page 50 Figure 9 2 Circuit Diagram For CC CV Welding Generator...

Page 55: ...OM 4405 Page 51 201 992 A...

Page 56: ...le Insulated Equipment OR 2 Be sure equipment has this symbol and or wording 3 1 10 2 Grounding Generator To Truck Or Trailer Frame S 0854 1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grounding...

Page 57: ...sistive Load Equipmentwith a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when run ning see Section 10 8 3 Rating Data Rating shows vol...

Page 58: ...Home Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 M...

Page 59: ...P 6000 1500 1 1 2 HP 8200 2200 2 HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1 3...

Page 60: ...r Starting Requirements Motor Start Code G H J K L M N P KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0 EXAMPLE Calculate the starting amperage required for a 230 V 1 4 HP motor with a motor start code of...

Page 61: ...ge capacity to cord Follow all applicable codes and safety practices Turn off or unplug all equipment connected to generator before starting or stopping engine When starting or stopping the engine has...

Page 62: ...15 40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 2 voltage drop Cord Lengths for 240 Volt Loads If unit does not have GFCI receptacles use GFC...

Page 63: ...OM 4405 Page 59 Notes...

Page 64: ...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 ONLY 97 98 FIG 11 2 OR 11 3 99 12 102 103 104 FIG 11 4 OR 11 5 105 101 100 Fig...

Page 65: ...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 11 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 52 51 53 54 60 61 62 63 75...

Page 66: ...0 999 BASE 1 24 196 220 BRACKET hold down fuel tank rear 1 25 192 362 BRACKET mtg nyl 1 2 conduit 1 26 200 995 COVER top 1 27 189 052 GROMMET plastic neck filler fuel 1 28 190 198 CAP tank screw on 3...

Page 67: ...cess 180deg 2 72 190 190 TANK coolant recovery 1 73 201 591 STOP door 2 74 189 826 PANEL rocker 1 75 191 626 BUMPER door engine access 2 76 189 827 PANEL gen RH 1 77 199 849 SCREW 625 11 x 4 00hexhd p...

Page 68: ...an cause serious injury 1 190 058 NUT 250 20 u nut multi thread 19 049 525 NUT 312 18 u nut multi thread 32 202 022 KIT label includes safety and informational labels 1 When ordering a component origi...

Page 69: ...1 150 316 CONN rect univ 039 6p s 3row plug cable lkg 6 092 670 CONN rect univ 084 3p s 1row plug cable lkg 1 11 CB11 12 13 139 266 CIRCUIT BREAKER man reset 1P 15A 250VAC frict 3 190 260 HARNESS uni...

Page 70: ...CLAMP capacitor 1 375dia 1 201 495 HARNESS control box cv weld control consisting of 1 10 SR1 035 704 RECTIFIER integ 40A 800V 1 11 CR5 090 104 RELAY encl 12VDC SPST 30A 15VDC 1 RC4 047 483 CONNECTOR...

Page 71: ...a 120vac 8pin flange mtg 1 15 CR6 090104 RELAY encl 12vdc spst 30a 15vdc 5pin flange mtg 1 16 CR1 CR2 CR3 090 104 RELAY encl 12VDC SPST 30A 15VDC spin flange mtg 3 201 357 HARNESS engine control consi...

Page 72: ...Dia Mkgs Item No Figure 11 4 Panel Front w Components CC Models Figure 11 1 Item 104 Quantity 1 201 841 PLATE SCREENED ident control rating when ordering this item the nameplate should also be ordered...

Page 73: ...ABEL do not switch while welding 1 21 S12 195 825 SWITCH polarity 1 22 201 125 PANEL mtg terminal pwr output 1 23 039 046 TERMINAL pwr output black 1 180 735 WASHER output stud 2 24 181 169 SPACER out...

Page 74: ...Models Description Part No Dia Mkgs Item No Figure 11 5 Panel Front w Components CC CV Models Figure 11 1 Item 104 Quantity 1 201 579 PLATE SCREENED ident control when ordering this item the nameplat...

Page 75: ...set 3p 1 23 201 106 PANEL auxiliary power 1 23 201 107 PANEL auxiliary power full kVA option 1 24 196 781 BOOT circuit breaker 3 pole 1 25 197 508 PLUG protective 1 26 077 440 BUSHING conduit 1 in 1 2...

Page 76: ...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...

Page 77: ...9t stl pld 4000lbs 6 21 198 631 NUT m10 hex lock nut stl pld 4 22 201 139 FLYWHEEL engine Wis Con TM 20 1 23 201 140 ADAPTER engine Wis Con TM 20 1 24 191 579 COVER starter hole 1 200 991 GUARD starte...

Page 78: ...AC 1 2 188 517 BUS BAR connection board 3 3 188 135 ENCLOSURE rectifier 2 4 134 201 STAND OFF support 3 5 PC3 201 449 CIRCUIT CARD ASSEMBLY protection 1 6 188 136 INSULATOR heat sink 8 7 188 493 HEAT...

Page 79: ...ting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate 185 Spoolmate 250 Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as...

Page 80: ...complete and retain with your personal records Always provide Model Name and Serial Style Number Call 1 800 4 A Miller or see our website at www MillerWelds com to locate a DISTRIBUTOR or SERVICE AGEN...

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