Miller Electric Big 40G Owner's Manual
  1. Manuals
  2. Brands
  3. Miller Electric Manuals
  4. Welding System
  5. Big 40G
  6. Owner's manual
Miller Electric Big 40G Owner's Manual

Miller Electric Big 40G Owner's Manual

Engine driven welding generator
Hide thumbs
Table of Contents

Advertisement

Quick Links

Visit our website at
www.MillerWelds.com
Big 40G
OM-477
116 508W
September 2000
Processes
Stick (SMAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
With Optional Equipment:
TIG (GTAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Engine Driven Welding Generator
R

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Big 40G and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Miller Electric Big 40G

Summary of Contents for Miller Electric Big 40G

  • Page 1 Visit our website at www.MillerWelds.com Big 40G OM-477 116 508W September 2000 Processes Stick (SMAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging With Optional Equipment: TIG (GTAW) Welding MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Engine Driven Welding Generator...
  • Page 2 ISO 9001 Quality System Standard. service information for your particular model are also provided. 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.

  • Page 3: Table Of Contents

    SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING WARNING This product, when used for welding or cutting, SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer.

  • Page 5: Section 1 - Safety Precautions - Read Before Using

    SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. Means “Note”; not safety related. 1-2.

  • Page 6: Engine Hazards

    WELDING can cause fire or explosion. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    MOVING PARTS can cause injury. D Keep away from fans, belts, and rotors. D Keep all doors, panels, covers, and guards closed and securely in place. D Stop engine before installing or connecting unit. D Have only qualified people remove guards or covers for maint- enance and troubleshooting as necessary.

  • Page 8: Principal Safety Standards

    H.F. RADIATION can cause interference. D High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. D Have only qualified persons familiar with electronic equipment perform this installation. D The user is responsible for having a qualified electrician prompt- ly correct any interference problem resulting from the installa- tion.

  • Page 9: Section 1 - Consignes De Sécurité - Lire Avant Utilisation

    SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Y Identifie un message de sécurité particulier. Signifie NOTA ;...

  • Page 10: Dangers Existant En Relation Avec Le Moteur

    LE SOUDAGE peut provoquer un in- cendie ou une explosion. Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    DES ORGANES MOBILES peuvent provoquer des blessures. D Ne pas approcher les mains des ventilateurs, cour- roies et autres pièces en mouvement. D Maintenir fermés et fixement en place les portes, panneaux, recouvrements protection. D Arrêter le moteur avant d’installer ou brancher l’appareil. D Demander seulement à...

  • Page 12: Principales Normes De Sécurité

    LE RAYONNEMENT HAUTE FRÉ- QUENCE (H.F.) risque de provoquer des interférences. D Le rayonnement haute fréquence (H.F.) peut provoquer des interférences avec les équipements de radio–navigation et de communication, les services de sécurité et les ordinateurs. D Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l’installation.

  • Page 13: Section 2 - Definitions

    SECTION 2 – DEFINITIONS 2-1. Symbols And Definitions Stop Engine Fast/Slow (Run/Idle) Circuit Breaker Positive Amperes Read Operator’s Manual Alternating Current Stick Welding (SMAW) Do Not Switch While Welding SECTION 3 – SPECIFICATIONS 3-1. Weld, Power, And Engine Specifications Welding Weld Output Rated Welding Mode...

  • Page 14: Dimensions, Weights, And Operating Angles

    3-2. Dimensions, Weights, And Operating Angles Dimensions Height 48-3/4 in (1238 mm) Width 24-5/8 in (625 mm) Depth 64-1/2 (1638 mm) 62 in (1575 mm) 59-1/8 in (1502 mm) 46-1/4 in (1175 mm) 34-3/4 in (883 mm) 26-15/16 in (684) mm) 9-1/2 in (241 mm) 2-7/8 in (73 mm) 7/8 in (22 mm)

  • Page 15: Duty Cycle And Overheating

    3-4. Duty Cycle And Overheating 60% Duty Cycle At 350 Amperes 6 Minutes Welding 4 Minutes Resting 3-5. AC Auxiliary Power Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. Y Exceeding duty cycle can damage warranty.

  • Page 16: Optional Ac Power Plant Curves

    3-6. Optional AC Power Plant Curves A. 8.5 KVA/KW Single-Phase Auxiliary Power Plant (No Weld Load) B. 12.5 KVA/KW Three-Phase Auxiliary Power Plant (No Weld Load) OM-477 Page 12 AC AMPERES AC AMPERES The ac power curves show the aux- iliary power in amperes available at the single-phase 120/240 volt or three-phase 240 volt terminals.

  • Page 17: Volt-Ampere Curves

    3-7. Volt-Ampere Curves A. CC/DC (Standard) B. CC/AC (Models with Optional Polarity/AC Selector Switch) C. CV/DC (Models with Optional CV-3 Module) Ranges: 190–Max 110–270 85–210 55–110 Min–65 DC Amperes AC Amperes The volt-ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator.

  • Page 18: Section 4 - Installation

    SECTION 4 – INSTALLATION 4-1. Installing Welding Generator Movement Y Do Not Lift Unit From End Grounding Electrically bond generator frame to vehicle frame by metal-to-metal contact. 4-2. Connecting The Battery 4-3. Installing Muffler Tools Needed: 1/2 in OM-477 Page 14 Airflow Clearance 18 in (460 mm)

  • Page 19: Engine Prestart Checks

    4-4. Engine Prestart Checks Full Capacity: 9 qt (8.5 L) Top View Above Below 40 F (4 C) 40 F (4 C) 1/2 in (13 mm) Full Gasoline Full ST-801 026-A / Ref. ST-159 727-C / Ref. ST-159 728-A Check all fluids daily. Engine must be cold and on a level surface.

  • Page 20: Connecting To Weld Output Terminals

    4-5. Connecting To Weld Output Terminals Tools Needed: 3/4 in 4-6. Selecting Weld Cable Sizes 100 ft (30 m) Or Less Welding Amperes Amperes 10 – 60% 60 – 100% Duty Duty Cycle Cycle *Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. Contact your distributor for the mm equivalent weld cable sizes.

  • Page 21: Remote 14 Receptacle Rc3 Information (Optional, See Section 4-8)

    4-7. Remote 14 Receptacle RC3 Information (Optional, See Section 4-8) C L N Ref. ST-159 730-A *The remaining sockets are not used. 4-8. Terminal Strip 3T Connections (Optional) Socket* Socket Information 24 volts ac. Protected by circuit breaker CB4. Contact closure to A completes 24 volts ac contactor control circuit.

  • Page 22: Section 5 - Operating Welding Generator

    SECTION 5 – OPERATING WELDING GENERATOR 5-1. Front Panel Controls (See Section 5-2) OM-477 Page 18 Ref. ST-159 730-A / Ref. ST-191 898...

  • Page 23: Description Of Front Panel Controls (See Section 5-1)

    5-2. Description Of Front Panel Controls (See Section 5-1) This unit has a max OCV control circuit that resets Amperage/Voltage Adjust Control R1 to maximum when the arc breaks. When an arc is struck, weld out- put control returns to the R1 front panel or combination front panel/remote control setting.

  • Page 24: Remote Control (Optional)

    5-3. Remote Control (Optional) Example: Combination remote amperage control Set switches Set range OM-477 Page 20 Y Weld output terminals are energized (Electrode) switch is On (Hot) and engine is running. Remote 14 Receptacle RC3 Connect optional remote control to RC3 (see Section 4-7).

  • Page 25: Section 6 - Operating Auxiliary Equipment

    SECTION 6 – OPERATING AUXILIARY EQUIPMENT 6-1. 120 Volt Duplex And Optional GFCI Receptacles Y If unit does not have GFCI re- ceptacles, use GFCI-pro- tected extension cord. 120 V 15 A AC Receptacle 120 V 15 A AC Receptacle 120 V 15 A AC GFCI Recep- tacles GFCI1 And GFCI2 (Optional)

  • Page 26: Volt Duplex Receptacle (Optional)

    6-2. 240 Volt Duplex Receptacle (Optional) OM-477 Page 22 Y If unit does not have GFCI re- ceptacles, use GFCI-pro- tected extension cord. 240 V 15 A AC Receptacle Receptacle supplies 60 Hz single- phase power at weld/power speed. Maximum output is 3 kVA/kW. Circuit Breaker CB1 Circuit Breaker CB2 CB1 and CB2 protect the recep-...

  • Page 27: Connecting Optional Auxiliary Power Plant

    6-3. Connecting Optional Auxiliary Power Plant Front Single Three Phase Phase Output Volts 120/240 Amps KVA/KW 12.5 Frequency 60 Hz Engine Speed 1850 RPM Max. Fuse Size 45 Amperes Lead 42 connects to GROUND stud on front of unit. Jumper 42 is connected to 90 at factory. Tools Needed: 240V 120V...

  • Page 28: Section 7 - Maintenance And Troubleshooting

    SECTION 7 – MAINTENANCE AND TROUBLESHOOTING NOTE Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period. 7-1. Routine Maintenance Wipe up spills. Clean air filter. See Section 7-3. Change oil. See Section 7-5.

  • Page 29: Maintenance Label

    7-2. Maintenance Label OM-477 Page 25...

  • Page 30: Servicing Air Cleaner

    7-3. Servicing Air Cleaner Blow 7-4. Overload Protection Tools Needed: OM-477 Page 26 Inspect aircleaner1 6/96 – ST-153 929-B / ST-153 585 / Ref. ST-191 898 / Ref. S-0698-B Y Stop engine. Y Do not run engine without air cleaner or with dirty element. Clean or replace element if dirty or damaged.

  • Page 31: Changing Engine Oil And Filter

    7-5. Changing Engine Oil And Filter Y Stop engine and let cool. Standard Oil Filter Optional Remote Oil Filter Optional Remote Oil Filter Hoses And Adapter Oil Drain Plug Oil Fill Cap Change filter according to engine manual. Install optional remote oil filter if lo- cation makes it difficult to change standard filter.

  • Page 32: Changing Fuel Filter

    7-6. Changing Fuel Filter Tools Needed: 7-7. Inspecting And Cleaning Optional Spark Arrestor Muffler Tools Needed: 3/8 in OM-477 Page 28 Y Stop engine and let cool. Fuel Shutoff Valve Fuel Line Fuel Filter To replace filter, close valve and re- move clamps and filter.

  • Page 33: Adjusting Engine Weld/Power Speed

    7-8. Adjusting Engine Weld/Power Speed 1/16 in (1.6 mm) 3-1/4 in (83 mm) Tools Needed: 3/8, 7/16 in 1850 rpm (max) Governor sensitivity may re- quire adjustment if engine speed is adjusted (see Section 7-10). If linkage binds, loosen socket nuts and turn sockets until link- age works smoothly.

  • Page 34: Adjusting Engine Idle Speed

    7-9. Adjusting Engine Idle Speed 7-10. Adjusting Governor Sensitivity Tools Needed: 1/2 in OM-477 Page 30 1250 rpm Right Side Tools Needed: 1/4 in Start engine. Place Engine Control Switch in Run/Idle position. Solenoid Bracket Screws Throttle Arm Idle Speed Screw Throttle Stop Loosen bracket screws and move arm so screw touches stop.

  • Page 35: Adjusting Optional High Altitude Carburetor

    7-11. Adjusting Optional High Altitude Carburetor Tools Needed: 1/2 in 7-12. Troubleshooting A. Welding Trouble 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 remote contactor to Remote 14 receptacle RC3 or terminal strip 3T (see Sections 4-7, 4-8, and 5-1).
  • Page 36 Trouble Low or high weld output. Check control settings. Place optional Process switch in correct position (see Section 5-1). Check engine weld/power speed, and adjust if necessary (see Section 7-8). Have Factory Authorized Service Agent check field current regulator board PC1. Low open-circuit voltage.
  • Page 37 Trouble Have Factory Authorized Service Agent check brushes and slip rings, and field current regulator board PC1. High or low voltage at auxiliary power Check engine weld/power speed, and adjust if necessary (see Section 7-8). ac receptacles. Have Factory Authorized Service Agent check field current resistor R3. High output at optional auxiliary power Check engine weld/power speed, and adjust if necessary (see Section 7-8).
  • Page 38 Notes OM-477 Page 34...

  • Page 39: Section 8 - Electrical Diagrams

    SECTION 8 – ELECTRICAL DIAGRAMS 193 965-A Figure 8-1. Circuit Diagram For Welding Generator For Standard Models OM-477 Page 35...
  • Page 40 Figure 8-2. Circuit Diagram For Welding Generator With Welders And Deluxe Package Options OM-477 Page 36...
  • Page 41 193 967-A OM-477 Page 37...

  • Page 42: Section 9 - Auxiliary Power Guidelines

    SECTION 9 – AUXILIARY POWER GUIDELINES 9-1. Selecting Equipment 9-2. Grounding Generator To Truck Or Trailer Frame OM-477 Page 38 Be sure equipment has this symbol and/or wording. GND/PE Electrically bond generator frame to vehicle frame by metal-to-metal contact. Auxiliary Power Receptacles –...

  • Page 43: Grounding When Supplying Building Systems

    9-3. Grounding When Supplying Building Systems 9-4. How Much Power Does Equipment Require? AMPERES x VOLTS = WATTS EXAMPLE 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power requirement in watts. The load applied by the drill is 520 watts. EXAMPLE 2: If three 200 watt flood lamps are used with the drill from Example 1, add the individual loads to calculate total load.
  • Page 44 9-5. Approximate Power Requirements For Industrial Motors Industrial Motors Split Phase Capacitor Start-Induction Run Capacitor Start-Capacitor Run Fan Duty 9-6. Approximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Stock Tank De-Icer Grain Cleaner Portable Conveyor Grain Elevator Milk Cooler Milker (Vacuum Pump) FARM DUTY MOTORS Std.
  • Page 45 9-7. Approximate Power Requirements For Contractor Equipment Contractor Hand Drill Circular Saw Table Saw Band Saw Bench Grinder Air Compressor Electric Chain Saw Electric Trimmer Electric Cultivator Elec. Hedge Trimmer Flood Lights Submersible Pump Centrifugal Pump Floor Polisher High Pressure Washer 55 gal Drum Mixer Wet &...

  • Page 46: Power Required To Start Motor

    9-8. Power Required To Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code KVA/HP kVA/HP x HP x 1000 VOLTS EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4 HP motor with a motor start code of M. Volts = 230 HP = 1/4 11.2 x 1/4 x 1000...
  • Page 47 9-10. Typical Connections To Supply Standby Power Customer-supplied equipment is required if generator is to supply standby power during emergencies or power outages. 120/240 Volt 60 Hz Three-Wire Service Load 120/240 Volt Single-Phase Three-Wire Generator Output Connection 240 V 120 V 120 V 240 V 120 V...

  • Page 48: Selecting Extension Cord (Use Shortest Cord Possible)

    9-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord. Current Load (Watts) (Amperes) 1200 1800 2400 3000 3600 4200 4800 5400 6000 *Conductor size is based on maximum 2% voltage drop Cord Lengths for 240 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord.
  • Page 49 Notes OM-477 Page 45...

  • Page 50: Section 10 - Parts List

    SECTION 10 – PARTS LIST Hardware is common and not available unless listed. Fig 10-3 OM-477 Page 46 Figure 10-1. Main Assembly...
  • Page 51 Fig 10-2 Includes Item 49 ST-115 004-P OM-477 Page 47...
  • Page 52 Item Dia. Part Mkgs..... . 134 771 ..... 184 677 .
  • Page 53 Item Dia. Part Mkgs..... . 113 658 ......
  • Page 54 Item Dia. Part Mkgs....085 551 ... . . 128 862 ....085 656 .
  • Page 55 Item Dia. Part Mkgs....106 426 INSULATOR ....106 440 BUS BAR, rectifier .
  • Page 56 Item Dia. Part Mkgs..... . 010 647 ..... 044 328 .
  • Page 57 Item Dia. Part Mkgs..... . Fig 10-4 ..CB1,2 ..139 266 .
  • Page 58 Item Dia. Part Mkgs....044 588 ....130 515 ..
  • Page 59 Warranty Questions? Call LIMITED WARRANTY – Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants 1-800-4-A-MILLER to its original retail purchaser that new Miller equipment sold for your local after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.

  • Page 60: Owner's Record

    Parts) Circuit Diagrams Welding Process Handbooks File a claim for loss or damage during shipment. 2000 Miller Electric Mfg. Co. 6/00 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters–USA USA Phone: 920-735-4505 Auto-Attended USA &...

Table of Contents

Save PDF