Miller Big 40G - Manuals

Miller Big 40G – Manual in PDF format online.

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Manual

Manual Miller Big 40G

Summary

Page 2 - From Miller to You

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local Miller distributorto receive the latest full line catalog orindividual catalog sheets. To locate your nearestdistributor or service agency call 1-800-4...

Page 3 - TABLE OF CONTENTS; WARNING

The following terms areused interchangeablythroughout this manual:TIG = GTAWStick = SMAW The engine exhaust fromthis product containschemicals known to theState of California tocause cancer, birthdefects, or otherreproductive harm. WARNING TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFO...

Page 5 - SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING; Symbol Usage; Arc Welding Hazards; ELECTRIC SHOCK can kill.

OM-477 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING rom _nd_11/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoining symbols. Marks a special safety message. Means “Note”; not safety related. This gro...

Page 6 - BUILDUP OF GAS can injure or kill.; CYLINDERS can explode if damaged.; Engine Hazards; FUEL can cause fire or explosion.

OM-477 Page 2 Welding on closed containers, such as tanks,drums, or pipes, can cause them to blow up. Sparkscan fly off from the welding arc. The flying sparks, hotworkpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can causesparks, explosion, ove...

Page 7 - Additional Symbols For Installation, Operation, And Maintenance

OM-477 Page 3 MOVING PARTS can cause injury. Keep away from fans, belts, and rotors. Keep all doors, panels, covers, and guardsclosed 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 ne...

Page 8 - Principal Safety Standards

OM-477 Page 4 H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommunications equipment. Have only qualified persons familiar withelectronic equipment perform this installation. The user is responsible for having a qualif...

Page 9 - Signification des symboles; Dangers relatifs au soudage à l’arc; UN CHOC ÉLECTRIQUE peut tuer.

OM-477 Page 5 SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION rom _nd_fre 11/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédureprésente des risques de danger ! Ceux-ci sont identifiéspar des symboles adjacents aux directives. Identifie un message ...

Page 10 - LE BRUIT peut affecter l’ouïe.; Dangers existant en relation avec le moteur

OM-477 Page 6 Le soudage effectué sur des conteneurs fermés tels quedes réservoirs, tambours ou des conduites peut provoquerleur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et deséquipements chauds peut provoquer des incendies...

Page 11 - LIRE LES INSTRUCTIONS.

OM-477 Page 7 DES ORGANES MOBILES peuventprovoquer des blessures. Ne pas approcher les mains des ventilateurs, cour-roies et autres pièces en mouvement. Maintenir fermés et fixement en place les portes,panneaux, recouvrements et dispositifs deprotection. Arrêter le moteur avant d’installer ou branch...

Page 13 - SECTION 2 – DEFINITIONS; Symbols And Definitions; SECTION 3 – SPECIFICATIONS

OM-477 Page 9 SECTION 2 – DEFINITIONS 2-1. Symbols And Definitions Stop Engine Fast (Run, Weld/ Power) Slow (Idle) Start Engine Fast/Slow (Run/Idle) Battery (Engine) Output Engine Oil Circuit Breaker Check Valve Clearance Fuel Protective Earth (Ground) Positive Negative Certified/Trained Mechanic We...

Page 14 - Dimensions, Weights, And Operating Angles; Fuel Consumption

OM-477 Page 10 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) L Engine End A 62 in (1575 mm) Do not exceed tilt angles or engine couldbe damaged or unit could tip. B 59-1/8 in (1502 mm) Do not move or operate unit ...

Page 15 - Duty Cycle And Overheating

OM-477 Page 11 6 Minutes Welding 4 Minutes Resting Continuous Welding 3-4. Duty Cycle And Overheating rduty1 5/95 – SB-111 076-A Duty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithout overheating. Exceeding duty cycle candamage unit and voidwarranty. 60% Duty Cycle At 350 Am...

Page 16 - Optional AC Power Plant Curves

OM-477 Page 12 3-6. Optional AC Power Plant Curves The ac power curves show the aux-iliary power in amperes available atthe single-phase 120/240 volt orthree-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 ...

Page 18 - SECTION 4 – INSTALLATION; Installing Welding Generator

OM-477 Page 14 SECTION 4 – INSTALLATION 4-1. Installing Welding Generator install1 12/99 – Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854 1 2 Electrically bond generator frame tovehicle frame by metal-to-metalcontact. GND/PE 3 4 Always ground generator frame to ve-hicle frame to prevent...

Page 19 - Engine Prestart Checks

OM-477 Page 15 4-4. Engine Prestart Checks Full Full 1/2 in (13 mm) Full Capacity: 9 qt (8.5 L) Above 40 ° F (4 ° C) Top View 2 Below 40 ° F (4 ° C) 1 5/16 in Gasoline ST-801 026-A / Ref. ST-159 727-C / Ref. ST-159 728-A Tools Needed: Check all fluids daily. Engine mustbe cold and on a level surface...

Page 20 - Connecting To Weld Output Terminals

OM-477 Page 16 ST-800 162-A Open left side door. 1 Bracket Route cables through bracket. 2 Positive (+) Weld OutputTerminal 3 Negative (–) Weld Output Ter-minal For Stick welding Direct CurrentElectrode Positive (DCEP), con-nect work cable to (–) terminal andelectrode holder cable to (+)terminal. Fo...

Page 22 - SECTION 5 – OPERATING WELDING GENERATOR

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 1413 9 ( ) 10 11

Page 25 - SECTION 6 – OPERATING AUXILIARY EQUIPMENT; 20 Volt Duplex And Optional GFCI Receptacles

OM-477 Page 21 SECTION 6 – OPERATING AUXILIARY EQUIPMENT 6-1. 120 Volt Duplex And Optional GFCI Receptacles Ref. ST-191 898 If unit does not have GFCI re-ceptacles, use GFCI-pro-tected extension cord. 1 120 V 15 A AC ReceptacleRC1 2 120 V 15 A AC ReceptacleRC2 3 120 V 15 A AC GFCI Recep-tacles GFCI1...

Page 27 - Connecting Optional Auxiliary Power Plant

OM-477 Page 23 6-3. Connecting Optional Auxiliary Power Plant Ref. S-185 000–A Stop engine. Power and weld outputs arelive at the same time. Discon-nect or insulate unusedcables. Have qualified person install ac-cording to circuit diagram andAuxiliary Power GuidelinesBooklet (M176 712). Place option...

Page 28 - Routine Maintenance

OM-477 Page 24 SECTION 7 – MAINTENANCE AND TROUBLESHOOTING Follow the storage procedure in the engine owner ’s manual if the unit will not beused for an extended period. NOTE 7-1. Routine Maintenance Recycle engine fluids. Stop engine before maintaining. See also Engine Manual and MaintenanceLabel. ...

Page 29 - Maintenance Label

Page 31 - Changing Engine Oil And Filter

OM-477 Page 27 7-5. Changing Engine Oil And Filter Ref. ST-159 727-B / Ref. ST-159 728-A / Ref. ST-191 898 Stop engine and let cool. 1 Standard Oil Filter 2 Optional Remote Oil Filter 3 Optional Remote Oil FilterHoses And Adapter 4 Oil Drain Plug 5 Oil Fill Cap Change filter according to enginemanua...

Page 32 - Changing Fuel Filter; Inspecting And Cleaning Optional Spark Arrestor Muffler

OM-477 Page 28 7-6. Changing Fuel Filter Ref. ST-191 898 / Ref. ST-159 727-C Stop engine and let cool. 1 Fuel Shutoff Valve 2 Fuel Line 3 Fuel Filter To replace filter, close valve and re-move clamps and filter. Install newfilter and clamps. Inspect line andreplace if cracked or worn. Wipe upany spi...

Page 33 - Adjusting Engine Weld/Power Speed

OM-477 Page 29 7-8. Adjusting Engine Weld/Power Speed Ref. ST-801 179 / Ref. ST-800 159-C / Ref. ST-800 161 Governor sensitivity may re-quire adjustment if enginespeed is adjusted (see Section7-10). If linkage binds, loosen socketnuts and turn sockets until link-age works smoothly. Tightennuts. Afte...

Page 34 - Adjusting Engine Idle Speed

OM-477 Page 30 7-9. Adjusting Engine Idle Speed Ref. ST-115 155-A Start engine. Place Engine ControlSwitch in Run/Idle position. 1 Solenoid Bracket Screws 2 Throttle Arm 3 Idle Speed Screw 4 Throttle Stop Loosen bracket screws and movearm so screw touches stop. Do notrelease arm. Turn idle speed scr...

Page 35 - -11. Adjusting Optional High Altitude Carburetor

OM-477 Page 31 7-11. Adjusting Optional High Altitude Carburetor Ref. ST-159 727-B / Ref. ST-115 155-A A too lean air-fuel mixturecan damage valves. Do notadjust main adjustmentscrew so air-fuel mixture istoo lean. Carburetor can be equipped with anadjustable main jet for operationabove 4000 ft (121...

Page 38 - Notes

Page 39 - SECTION 8 – ELECTRICAL DIAGRAMS

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

Page 42 - SECTION 9 – AUXILIARY POWER GUIDELINES; Selecting Equipment; Grounding Generator To Truck Or Trailer Frame

OM-477 Page 38 SECTION 9 – AUXILIARY POWER GUIDELINES 9-1. Selecting Equipment aux_pwr 2/99 – Ref. ST-159 730 / ST-800 577 1 Auxiliary Power Receptacles– Neutral Bonded To Frame 2 3-Prong Plug From CaseGrounded Equipment 3 2-Prong Plug From DoubleInsulated Equipment OR 2 Be sure equipmenthas this sy...

Page 43 - Grounding When Supplying Building Systems; How Much Power Does Equipment Require?

OM-477 Page 39 9-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment GroundingTerminal 2 Grounding Cable Use #10 AWG or larger insulatedcopper wire. 3 Ground Device Ground generator to systemearth ground if supplyingpower to a premises (home,shop, farm) wiring system. GND/PE 1 2 Us...

Page 45 - Approximate Power Requirements For Contractor Equipment

OM-477 Page 41 9-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/2 in 500 500 7-1/4 in 900 900 8-1/4 in 1400 1400 Table Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in...

Page 46 - Power Required To Start Motor; How Much Power Can Generator Supply?

OM-477 Page 42 9-8. Power Required To Start Motor S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor Voltage To find starting amperage: Step 1: Find code and use table tofind kVA/HP. If code is not listed,multiply running amperage by six tofind starting amperage. Step 2: Find Motor HP a...

Page 47 - -10. Typical Connections To Supply Standby Power

OM-477 Page 43 9-10. Typical Connections To Supply Standby Power S-0405-A 1 Power Company ServiceMeter 2 Main and Branch OvercurrentProtection 3 Double-Pole, Double-ThrowTransfer Switch Obtain and install correct switch.Switch rating must be same as orgreater than the branch overcurrentprotection. 4...

Page 50 - SECTION 10 – PARTS LIST

OM-477 Page 46 SECTION 10 – PARTS LIST Figure 10-1. Main Assembly Hardware is common andnot 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 10-3 115 116 114 113 111 110 109 108 107 106 101 100 104 75 76 77 ...

Page 59 - (Equipment with a serial number preface of “LA” or newer)

Warranty Questions? Call1-800-4-A-MILLERfor your localMiller distributor. miller_warr 7/00 Your distributor also givesyou ... ServiceYou always get the fast,reliable response youneed. Most replacementparts can be in yourhands in 24 hours. SupportNeed fast answers to thetough welding questions?Contac...

Page 60 - Please complete and retain with your personal records.; For Service

PRINTED IN USA  2000 Miller Electric Mfg. Co. 6/00 Miller Electric Mfg. Co. An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 USA International Headquarters–USAUSA Phone: 920-735-4505 Auto-AttendedUSA & Canada FAX: 920-735-4134International FAX: 920-735-4125 European Head...