Miller Electric Big 40G Page 57 Owner'S Manual Download

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OM-477 Page 53

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 10-3. Panel, Front w/Components (Fig 10-1 Item 102)
(Continued)

Quantity

Fig 10-4

CONTROL BOX w/COMPONENTS

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CB1,2

139 266

CIRCUIT BREAKER, man reset 1P 15A 250VAC

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RC1,2

170 901

RECEPTACLE, str dx grd 2P3W 15A 125V

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GFCI1,2

♦

168 068

RECEPTACLE, str dx grd 2P3W 15A 125V

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073 690

PLUG, str grd armd 2P3W 15A 125V P & S 5266DF

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♦

042 655

RECEPTACLE KIT, 240V (consisting of)

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CB1,2

139 266

CIRCUIT BREAKER, man reset 1P 15A 250VAC

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RC1

604 103

RECEPTACLE, str dx grd 2P3W 15A 250V

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RC2

039 864

RECEPTACLE, str dx grd 2P3W 15A 125V

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RC3

♦

143 976

CONNECTOR w/SOCKETS

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134 734

CONNECTOR, circ 14 pin plug Amp 213571-2

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134 731

CONNECTOR, circ pin push-in 14-18ga Amp 213603-1

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079 739

CONNECTOR, circ clamp str rlf .703 max cable OD

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Amp 206322-2 (or)

143 922

CONNECTOR, circ clamp str rlf .453 max cable OD

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Amp 206070-3

CB3,4

♦

083 432

CIRCUIT BREAKER, man reset 1P 10A 250V

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S4,5

♦

011 609

SWITCH, tgl SPDT 15A 125VAC

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011 611

SWITCH, tgl DPDT 15A 125V

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072 462

POTENTIOMETER, w/shaft lock (consisting of)

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072 590

LOCK, shaft pot .375-32 x .250dia shaft

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022 289

TUBING, stl .312 OD x .187 ID x .437

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097 926

KNOB, pointer

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♦

021 385

BOOT, tgl switch lever

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170 663

HINGE, panel front

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083 030

STUD, brs grd .250-20 x 1.750

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601 836

NUT, brs hex .250-20

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♦

046 652

METER, amp dc 50MV 0-600 scale

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♦

046 654

METER, volt dc 0-100 scale

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♦

170 391

CONNECTOR, circ protective cap Amphenol 9760-20

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♦

ENGINE METER KIT, (consisting of)

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047 842

GAUGE, pressure 5-100 lbs

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047 841

GAUGE, temperature mechanical 100/250deg

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128 829

KIT, oil line 44.000 in 1/8NPT x 10mm

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602 946

FITTING, pipe stl tee B 1/8NPT

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175 465

FITTING, pipe brs adapter

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162 380

FITTING, pipe stl adapter 3/8

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133 814

CONTROL, push/pull

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119 014

LEVER, switch black

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145 247

METER, hour 12-24VDC

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604 784

SCREW, 6-32 x .500rdh-slot brs

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601 829

NUT, brs hex 6-32

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082 788

HOLDER, light ind

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082 789

LENS, light ind red

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PL1,2

*048 155

BULB, incand flg base 12V

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118 066

GAUGE, fuel elec 12V

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189 404

SPACER, nylon

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♦

OPTIONAL

*Recommended Spare Parts.
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.

Summary of Contents for Big 40G

Page 1: ...Processes Description Air Carbon Arc CAC A Cutting and Gouging TIG GTAW Welding Stick SMAW Welding Engine Driven Welding Generator With Optional Equipment MIG GMAW Welding Flux Cored FCAW Welding Vis...

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: ...4 6 Selecting Weld Cable Sizes 16 4 7 Remote 14 Receptacle RC3 Information Optional See Section 4 8 17 4 8 Terminal Strip 3T Connections Optional 17 SECTION 5 OPERATING WELDING GENERATOR 18 5 1 Front...

Page 4: ......

Page 5: ...n 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: ...ch 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 FIE...

Page 7: ...mmables 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 ap...

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: ...quer 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 co...

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: ...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 Pa...

Page 13: ...rent Time h Hours s Seconds Stick Welding SMAW Constant Current CC MIG Welding GMAW Constant Voltage CV Do Not Switch While Welding 1 Single Phase 3 Three Phase SECTION 3 SPECIFICATIONS 3 1 Weld Power...

Page 14: ...ld tip B 59 1 8 in 1502 mm Do not move or operate unit where it could C 46 1 4 in 1175 mm tip D 34 3 4 in 883 mm B E 26 15 16 in 684 mm A C F 9 1 2 in 241 mm C 33 G 2 7 8 in 73 mm D E 33 H 7 8 in 22 m...

Page 15: ...rcentage of 10 min utes that unit can weld at rated load without overheating Exceeding duty cycle can damage unit and void warranty 60 Duty Cycle At 350 Amperes 100 Duty Cycle At 300 Amperes 3 5 AC Au...

Page 16: ...120 240 volt or three phase 240 volt terminals rsb13 1 12 94 ST 111 118 D ST 112 449 B A 8 5 KVA KW Single Phase Auxiliary Power Plant No Weld Load B 12 5 KVA KW Three Phase Auxiliary Power Plant No W...

Page 17: ...ngs fall between the curves shown rsb13 1 12 94 ST 184 477 A ST 184 475 A ST 184 480 A A CC DC Standard B CC AC Models with Optional Polarity AC Selector Switch C CV DC Models with Optional CV 3 Modul...

Page 18: ...nt Grounding Terminal 4 Grounding Cable Use 10 AWG or larger insulated copper wire If unit does not have GFCI receptacles use GFCI protected extension cord 2 OR 18 in 460 mm 18 in 460 mm 18 in 460 mm...

Page 19: ...ance label for specifications Fill fuel tank up to 1 2 in 13 mm from top to allow room for expansion Open fuel shut off valve Check fuel level on a cold engine before use each day 4 Oil After fueling...

Page 20: ...Left Side 2 1 3 4 in 4 5 Connecting To Weld Output Terminals 4 6 Selecting Weld Cable Sizes Total Cable Copper Length In Weld Circuit Not Exceeding Welding Amperes 100 ft 30 m Or Less 150 ft 45 m 200...

Page 21: ...remote control D Remote control circuit common A V E 0 to 10 volts dc input command signal from remote control Ref ST 159 730 A K Chassis common The remaining sockets are not used 4 8 Terminal Strip...

Page 22: ...OM 477 Page 18 SECTION 5 OPERATING WELDING GENERATOR 5 1 Front Panel Controls See Section 5 2 Ref ST 159 730 A Ref ST 191 898 1 2 16 17 6 7 8 15 3 4 5 12 14 13 9 10 11...

Page 23: ...terminals when remote con tactor switch is closed 5 Process Switch Optional Use switch to select Stick or MIG CV weld output Use Stick for Stick SMAW welding Use MIG CV for wire feed processes MIG FC...

Page 24: ...s On Hot and engine is running 1 Remote 14 Receptacle RC3 Connect optional remote control to RC3 see Section 4 7 Example Combination remote amperage control In Example Range 85 to 210 A DC Min 85 A DC...

Page 25: ...ot work Press but ton to reset circuit breaker If a circuit breaker continues to open contact a Factory Authorized Service Agent If a ground fault is detected the GFCI Reset button pops out and the ci...

Page 26: ...B2 protect the recep tacles from overload If CB1 or CB2 opens the 240 V receptacle and half of the 120 V receptacle does not work 120 volts may still be present at the 240 V receptacle Press button to...

Page 27: ...Circuit Grounding Lead Jumper 42 is connected to lead 90 at factory Jumper 42 may be discon nected from neutral to meet applica ble electrical codes Lead 42 connects to front panel Ground stud 9 User...

Page 28: ...ection 4 4 OIL Full 50 h Clean air filter See Section 7 3 Clean and tighten weld terminals 100 h Change oil See Section 7 5 Change oil filter See Section 7 5 Check air cleaner hoses for cracks and loo...

Page 29: ...OM 477 Page 25 7 2 Maintenance Label...

Page 30: ...t Max air pressure 100 psi 690 kPa Do not remove plastic fins Replace ele ment if it has holes or damaged gaskets Reinstall element and cap cap arrows pointing up Blow Inspect 1 2 3 5 4 7 4 Overload P...

Page 31: ...Remote Oil Filter 3 Optional Remote Oil Filter Hoses And Adapter 4 Oil Drain Plug 5 Oil Fill Cap Change filter according to engine manual Install optional remote oil filter if lo cation makes it diffi...

Page 32: ...Stop engine tighten connec tions as necessary and wipe up spilled fuel Close door Tools Needed 1 3 2 2 7 7 Inspecting And Cleaning Optional Spark Arrestor Muffler ST 800 722 Ref ST 191 898 Stop engine...

Page 33: ...n 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 6 Carburetor 7 Throttle Stop Plate 8 Throttle Stop Clearance betwe...

Page 34: ...Tighten bracket screws Release throttle arm Recheck idle speed and readjust if necessary Stop engine Close door Tools Needed 1 2 3 4 5 6 7 Right Side 1 4 in 1250 rpm 7 10 Adjusting Governor Sensitivit...

Page 35: ...12 Troubleshooting A Welding Trouble Remedy No weld output Check control settings Place optional Output Electrode Control switch in On Hot position or move switch to Remote posi tion and connect remot...

Page 36: ...mperage Voltage Adjust switch in correct position Check connections to Remote 14 receptacle RC3 and terminal strip 3T see Sections 4 7 and 4 8 Repair or replace remote control device Have Factory Auth...

Page 37: ...f necessary Check Magnetic Shutdown switch MS1 fuse F and replace if open see Section 7 4 See engine manual Have Factory Authorized Service Agent check engine charging system Battery discharges betwee...

Page 38: ...OM 477 Page 34 Notes...

Page 39: ...OM 477 Page 35 SECTION 8 ELECTRICAL DIAGRAMS 193 965 A Figure 8 1 Circuit Diagram For Welding Generator For Standard Models...

Page 40: ...OM 477 Page 36 Figure 8 2 Circuit Diagram For Welding Generator With Welders And Deluxe Package Options...

Page 41: ...OM 477 Page 37 193 967 A...

Page 42: ...e Insulated Equipment OR 2 Be sure equipment has this symbol and or wording 3 1 9 2 Grounding Generator To Truck Or Trailer Frame S 0854 1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grounding Te...

Page 43: ...istive 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 9 8 3 Rating Data Rating shows volts...

Page 44: ...me 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 Mil...

Page 45: ...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 H...

Page 46: ...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 47: ...e amperage 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 en...

Page 48: ...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 GFCI...

Page 49: ...OM 477 Page 45 Notes...

Page 50: ...is common and not available unless listed 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 49 67 66 65 68 69 70 71 72 73 74 91 92 93 94 95 96 99 98 97 103 102 Fig 10 3 115 116 114 113 111 110 109 108 107...

Page 51: ...OM 477 Page 47 ST 115 004 P 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 19 35 36 37 38 40 41 42 43 39 44 45 46 47 50 51 52 53 54 55 56 57 58 59 60 25 61 Fig 10 2 64 63 62 48 Includes Item 49...

Page 52: ...rb 1 24 000 272 CLAMP air cleaner 1 25 031 868 BRACKET mtg air cleaner 1 26 010 875 CLAMP muffler 2 000dia 1 27 105 740 MUFFLER exhaust engine 1 28 035 968 WASHER flat rbr 3 625 ID x 5 875 OD 1 195 86...

Page 53: ...R fuse box 1 77 185 000 LABEL warning auxiliary power 1 78 026 947 STAND OFF insulated 2 50 20 x 1 000 lg 1 79 134 903 FUSE box 1 80 149 541 HOLDER fuse crtg 60A 250V 3 fuses 1 81 F1 3 012 625 FUSE cr...

Page 54: ...30A 4P 1 038 620 LINK jumper term blk 30A 2 115 053 967 INSULATION rectifier 1 116 089 517 STRAP fuel tank 2 010 021 CLAMP stl cush 562dia 2 136 310 KIT label 1 Recommended Spare Parts When ordering a...

Page 55: ...E air gen 1 16 201 198 ROTOR gen consisting of 1 17 024 617 RING retaining external 1 18 053 390 BEARING ball 1 19 089 737 FAN rotor 1 035 776 KEY 375 x 375 x 2 000 1 20 044 374 STATOR excitor 1 21 17...

Page 56: ...UTDOWN consisting of 1 110 958 SWITCH automatic shutdown consisting of 1 6 MS1 011 072 SWITCH magnetic consisting of 1 7 F 048 317 FUSE mintr gl 14A 32V 1 D8 087 970 DIODE 1 8 131 999 PANEL front uppe...

Page 57: ...ng of 1 20 072 590 LOCK shaft pot 375 32 x 250dia shaft 1 21 022 289 TUBING stl 312 OD x 187 ID x 437 2 22 097 926 KNOB pointer 1 23 021 385 BOOT tgl switch lever 2 24 170 663 HINGE panel front 1 25 0...

Page 58: ...ARD field current regulator 1 PLG1 135 275 CONNECTOR PLUG SOCKETS 1 10 PC2 114 832 CIRCUIT CARD voltage regulator 1 11 CR99 090 104 RELAY encl 12VDC SPST 1 12 SR2 097 353 DIODE SCR bridge integ 2scr 3...

Page 59: ...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 60: ...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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Miller Electric Big 40G, Owner'S Manual

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