Miller Electric Big 40G manual

Big 40G  OM-477 1 16 508W September 2000 Processes Description Air Carbon Arc (CAC-A) Cutting and Gouging TIG (GT A W ) W elding Stick (SMA W) W elding Engine Driven Welding Generator With Optional Equipment: MIG (GMA W) W elding Flux Cored (FCA W) W elding Visit our website at www.MillerWelds.com[...]

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 .MillerW eld[...]

The following terms are used interchangeably throughout this manual: TIG = GT AW Stick = SMAW The engine exhaust from this product contains chemicals known to the State of California to cause cancer , birth defects, or other reproductive harm. W ARNING T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . .[...]

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OM-477 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.  Means “Note”; not safety related. This group of symbols means W arning! W[...]

OM-477 Page 2 W elding on closed containers, such as tanks, drums, or 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. Check and b e sure the a[...]

OM-477 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 .  T o prevent acci[...]

OM-477 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.  Th e user is responsible for having a qualified electrician prompt- ly cor[...]

OM-477 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.  Identifie un message de s é curit é parti[...]

OM-477 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. Des é tincelles peuvent ê tre projet é es de l ’ arc de soudure. La projection d ’é tincelles, des pi è ces chaudes et des é quipements chauds peut provoquer des incendies et des br û l[...]

OM-477 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.  Arr ê ter le moteur avant d ’ installer ou brancher l ’ appareil. ?[...]

OM-477 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.  Demander seulement à des personnes qualifi ?[...]

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 V alve Clearance Fuel Protective Earth (Ground) Positive Negative Certified/T rained Mechanic W elding Arc A Amperes V V olts Panel/Local 14 R[...]

OM-477 Page 10 3-2. Dimensions, W eights, 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 could be damaged or unit could tip. B 59-1/8 in (1502 mm)  Do not move or operate unit where it could C 46-1/4 in ( 1 175 m[...]

OM-477 Page 1 1 6 Minutes W elding 4 Minutes Resting Continuous W elding 3-4. Duty Cycle And Overheating rduty1 5/95 – SB-1 1 1 076-A Duty Cycle is percentage of 10 mi n- 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 Ampe[...]

OM-477 Page 12 3-6. Optional AC Power Plant Curves Th e ac power curves show the aux- iliary power in amperes available at the single-phase 120/240 volt or three-phase 240 volt terminals. rsb13.1 12/94 - ST-1 1 1 1 18-D / ST -1 12 449-B A. 8.5 KV A/KW Single-Phase Auxiliary Power Plant (No Weld Load) B. 12.5 KV A/KW Three-Phase Auxiliary Power Plan[...]

OM-477 Page 13 3-7. V olt-Ampere Curves The volt-ampere curve shows the minimum and maximum voltage an d amperage output capabilities of th e welding generator . Curves of all other settings 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 Sel[...]

OM-477 Page 14 SECTION 4 – INST ALLA TION 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 to vehicle frame by metal-to-metal contact. GND/PE 3 4  Always ground generator frame to ve- hicle frame to prevent electric shock and static electrici[...]

OM-477 Page 15 4-4. Engine Prestart Checks Full Full 1/2 i n (13 mm) Full Capacity: 9 qt (8.5 L) Above 40 ° F (4 ° C) T op 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 T ools Nee d e d : Check all fluids daily . Engine must be cold and on a level surface.  This unit has a low oil pressu[...]

OM-477 Page 16 ST-800 162-A Open left side door . 1 Bracket Route cables through bracket. 2 Positive (+) Weld Output T erminal 3 Negative ( – ) W eld Output T er- minal For Stick welding Direct Current Electrode Positive (DCEP), con- nect work cable to ( – ) terminal and electrode holder cable to (+) terminal. Fo r Direct Current Electrode Nega[...]

OM-477 Page 17 4-7. Remote 14 Receptacle RC3 Information (Optional, See Section 4-8) Socket* Socket Information A 24 volts ac. Protected by circuit breaker CB4. B Contact closure to A completes 24 volts ac contactor control circuit. AJ I 1 15 volts ac. Protected by circuit breaker CB3. B K I C L NH J Contact closure to I completes 1 15 volts ac con[...]

OM-477 Page 18 SECTION 5 – OPERA TING WELDING GENERA TOR 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 34 5 12 14 13 9 () 10 11[...]

OM-477 Page 19 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- pu t control returns to the R1 front panel o r combination front panel/remote control setting. The Amperage/V oltage Adj[...]

OM-477 Page 20 5-3. Remote Control (Optional) S-0774 / Ref. ST-159 730-A / Ref. ST -191 898 1  W eld output terminals are energized when Output (Electrode) switch is 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 =[...]

OM-477 Page 21 SECTION 6 – OPERA TING AUXILIAR Y EQUIPMENT 6-1. 120 V olt 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 Receptacle RC1 2 120 V 15 A AC Receptacle RC2 3 120 V 15 A AC GFCI Recep- tacles GFCI1 And GFCI2 (Optional) Receptacles su[...]

OM-477 Page 22 6-2. 240 V olt Duplex Receptacle (Optional) Ref. ST-181 71 1-A / Ref. ST-174 408  If unit does not have GFCI re- ceptacles, use GFCI-pro- tected extension cord. 1 240 V 15 A AC Receptacle RC1 Receptacle supplies 60 Hz single- phase power at weld/power speed. Maximum output is 3 kV A/kW . 2 Circuit Breaker CB1 3 Circuit Breaker CB2[...]

OM-477 Page 23 6-3. Connecting Optional Auxiliary Power Plant Ref. S-185 000 – A  Stop engine.  Power and weld outputs are live a t the same time. Discon- nect or insulate unused cables.  Have qualified person install ac- cording to circuit diagram and Auxiliary Power Guidelines Booklet (M176 712).  Place optional Process switch in St[...]

OM-477 Page 24 SECTION 7 – MAINTENANCE AND TROUBLESHOOTING Follow the storage procedure in the engine owner ’ s manual if the unit will not be used for an extended period. NOTE 7-1. Routine Maintenance Recycle engine fluids.  Stop engine before maintaining.  Se e also Engine Manual and Maintenance Label. Service engine more often if used [...]

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

OM-477 Page 26 7-3. Servicing Air Cleaner aircleaner1 6/96 – ST -153 929-B / ST-153 585 / Ref. ST -191 898 / Ref. S-0698-B  Stop engine.  Do not run engine without air cleaner or with dirty element. Clean or replace element if dirty or damaged. Replace element yearly or after six cleanings. 1 Dust Cap 2 Baf fle 3 Element 4 Plastic Fins 5 Ho[...]

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 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[...]

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 V alve 2 Fuel Line 3 Fuel Filter T o replace filter , close valve and re- move clamps and filter . Install new filter and clamps. Inspect line and replace if cracked or worn. Wipe u p any spilled fuel. Open valve. Start engine [...]

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 engine speed is adjusted (see Section 7-10). If linkage binds, loosen socket nuts a n d t u r n s o c k e t s u n t i l l i n k - age works smoothly . Tighten nuts. After tuning engine, ch[...]

OM-477 Page 30 7-9. Adjusting Engine Idle Speed Ref. ST-1 15 155-A Start engine. Place Engine Control Switch in Run/Idle position. 1 Solenoid Bracket Screws 2 Throttle Arm 3 Idle Speed Screw 4 Throttle Stop Loosen bracket screws and move arm so screw touches stop. Do not release arm. T urn idle speed screw to obtain 550 rpm. 5 Idle Mixture Screw T [...]

OM-477 Page 31 7-1 1. Adjusting Optional High Altitude Carburetor Ref. ST-159 727-B / Ref. ST -1 15 155-A  A too lean air-fuel mixture can damage valves. Do not adjust main adjustment screw so air-fuel mixture is too lean. Carburetor can be equipped with an adjustable main jet for operation above 4000 ft (1219 m). Adjust car- buretor as follows:[...]

OM-477 Page 32 T rouble Remedy 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. Place optional Process[...]

OM-477 Page 33 T rouble Remedy Have Factory Authorized Service Agent check brushes and slip rings, and field current regulator board PC1. High or low voltage at auxiliary power ac receptacles. Check engine weld/power speed, and adjust if necessary (see Section 7-8). Have Factory Authorized Service Agent check field current resistor R3. High output [...]

OM-477 Page 34 Notes[...]

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

OM-477 Page 36 Figure 8-2. Circuit Diagram For Welding Generator With Welders And Deluxe Package Options[...]

OM-477 Page 37 193 967-A[...]

OM-477 Page 38 SECTION 9 – AUXILIAR Y POWER GUIDELINES 9-1. 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. 3 1 9-2. Groundi[...]

OM-477 Page 39 9-3. 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. GND/PE 1 2 Us e ground device as stated in electrica[...]

OM-477 Page 40 9-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running W atts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 2100 700 1/2 HP 3175 875 Capacitor Start-Induction Run 1/3 HP 2020 720 1/2 HP 3075 975 3/4 HP 4500 1400 1 HP 6100 1600 1-1/2 HP 8200 2200 2 HP 10550 2850 3 [...]

OM-477 Page 41 9-7. 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 6-1/2 in 500 500 7-1/4 in 900 900 8-1/4 in 1400 1400 T able Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in 2500 1 100 Bench Grinder 6 in 1720 720 8 in 39[...]

OM-477 Page 42 9-8. 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. Step 2 : Find Motor HP and V olts. Step 3: Determine starting amp[...]

OM-477 Page 43 9-10. 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. 4 Circuit Breakers or Fused Disconnect Swi[...]

OM-477 Page 44 9-1 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. Maximum Allowable Cord Length in ft (m) for Conductor Size (A WG)* Current (Amperes) Load (W atts) 4 6 8 10 12 14 5 600 350 (106) 225 (68) 137 (42) 100 (30) 7 840[...]

OM-477 Page 45 Notes[...]

OM-477 Page 46 SECTION 10 – P ARTS LIST Figure 10-1. Main Assembly  Hardware 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 11 5 11 6 11 4 11 3 111 11 0 109 108 107 106 101 100 104 75 76 77 78 79 80 81 82 83 84 85 86 87 89 90 1[...]

OM-477 Page 47 ST-1 15 004-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[...]

OM-477 Page 48 Description Part No. Dia. Mkgs. Item No. Figure 10-1. Main Assembly Quantity 1 134 771 PLUG, protective .640sq 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 184 677 T ANK, fuel (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

OM-477 Page 49 Description Part No. Dia. Mkgs. Item No. Figure 10-1. Main Assembly (Continued) Quantity 53 1 13 658 LINKAGE, throttle 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 FS1 CARBURETOR, (see engine parts list) 1 . . . . . . . . . . . . . . . . . . .[...]

OM-477 Page 50 Description Part No. Dia. Mkgs. Item No. Figure 10-1. Main Assembly (Continued) Quantity 106 085 551 FRAME, mtg reactor/fuel tank 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 R3 128 862 RESISTOR, WW adj 375W 50 ohm w/mtg bkt 1 . . . . . . . . . . . . . . . . . . . .[...]

OM-477 Page 51 Description Part No. Dia. Mkgs. Item No. Figure 10-2. Generator (Fig 10-1 Item 59) Quantity 1 106 426 INSULA TOR 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 106 440 BUS BAR, rectifier 2 . . . . . . . . . . . . . . . . . . . . . . . . .[...]

OM-477 Page 52 Description Part No. Dia. Mkgs. Item No. Figure 10-3. Panel, Front w/Components (Fig 10-1 Item 102) Quantity 1 010 647 PIN, spring CS .156 x 1.250 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 044 328 HANDLE, switch range 1 . . . . . . . . . . . . . . . . . . .[...]

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 12 Fig 10-4 CONTROL BOX w/COMPONENTS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 CB1,2 139 266 CIRCUIT BREAKER, man reset 1P 15A 250V AC 2 . . . . . . [...]

OM-477 Page 54 Description Part No. Dia. Mkgs. Item No. Figure 10-4. Control Box w/Components (Fig 10-3 Item 12) Quantity 1 CR1 044 588 RELA Y , encl 12VDC 3PDT 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2R 2 ♦ 130 515 RESISTOR, board 1 . . . . . . . . . . . . . . . . . . . . . . . [...]

Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 7/00 Y ou r 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 . The expertise [...]

PRINTED IN USA  2000 Miller Electric Mfg. Co. 6/00 Miller Elect ric Mfg. Co. An I l li noi s T ool Works Com pany 1635 W est S pencer St reet Applet on, WI 54914 USA International He adquarters – USA USA Phone: 920-735-4505 Auto-A t t ended USA & Canada F A X : 920-735-4134 Int ernati onal FAX: 920-735-4125 European Headqua rters – Unite[...]