Miller Electric Big 40 Diesel Owner's Manual

Big 40GOM-477 116 508WSeptember 2000ProcessesDescriptionAir Carbon Arc (CAC-A)Cutting and GougingTIG (GTAW) WeldingStick (SMAW) WeldingEngine Driven

OM-477 Page 6Le soudage effectué sur des conteneurs fermés tels quedes réservoirs, tambours ou des conduites peut provoquerleur éclatement. Des étince

OM-477 Page 7DES ORGANES MOBILES peuventprovoquer des blessures. Ne pas approcher les mains des ventilateurs, cour-roies et autres pièces en mouvemen

OM-477 Page 8LE RAYONNEMENT HAUTE FRÉ-QUENCE (H.F.) risque de provoquerdes interférences. Le rayonnement haute fréquence (H.F.) peutprovoquer des int

OM-477 Page 9SECTION 2 – DEFINITIONS2-1. Symbols And DefinitionsStop EngineFast (Run, Weld/Power)Slow (Idle) Start EngineFast/Slow(Run/Idle)Battery (E

OM-477 Page 103-2. Dimensions, Weights, And Operating AnglesDimensionsHeight 48-3/4 in (1238 mm)Width 24-5/8 in (625 mm)Depth 64-1/2 (1638 mm)LEngine

OM-477 Page 116 Minutes Welding 4 Minutes RestingContinuous Welding3-4. Duty Cycle And Overheatingrduty1 5/95 – SB-111 076-ADuty Cycle is percentage o

OM-477 Page 123-6. Optional AC Power Plant CurvesThe ac power curves show the aux-iliary power in amperes available atthe single-phase 120/240 volt or

OM-477 Page 133-7. Volt-Ampere CurvesThe volt-ampere curve shows theminimum and maximum voltageand amperage output capabilities ofthe welding generato

OM-477 Page 14SECTION 4 – INSTALLATION4-1. Installing Welding Generatorinstall1 12/99 – Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-085412E

OM-477 Page 154-4. Engine Prestart ChecksFullFull1/2 in(13 mm)FullCapacity:9 qt (8.5 L)Above40°F (4°C)Top View2Below40°F (4°C)15/16 inGasoline ST-801

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

OM-477 Page 16 ST-800 162-AOpen left side door.1 BracketRoute cables through bracket.2 Positive (+) Weld OutputTerminal3 Negative (–) Weld Output Ter-

OM-477 Page 174-7. Remote 14 Receptacle RC3 Information (Optional, See Section 4-8)Socket* Socket InformationA 24 volts ac. Protected by circuitbreake

OM-477 Page 18SECTION 5 – OPERATING WELDING GENERATOR5-1. Front Panel Controls (See Section 5-2)Ref. ST-159 730-A / Ref. ST-191 8981216176781534512141

OM-477 Page 195-2. Description Of Front Panel Controls (See Section 5-1)This unit has a max OCV control circuitthat resets Amperage/Voltage AdjustCon

OM-477 Page 205-3. Remote Control (Optional)S-0774 / Ref. ST-159 730-A / Ref. ST-191 8981 Weld output terminals areenergized when Output(Electrode) s

OM-477 Page 21SECTION 6 – OPERATING AUXILIARY EQUIPMENT6-1. 120 Volt Duplex And Optional GFCI ReceptaclesRef. ST-191 898 If unit does not have GFCI r

OM-477 Page 226-2. 240 Volt Duplex Receptacle (Optional)Ref. ST-181 711-A / Ref. ST-174 408 If unit does not have GFCI re-ceptacles, use GFCI-pro-tec

OM-477 Page 236-3. Connecting Optional Auxiliary Power Plant Ref. S-185 000–A Stop engine. Power and weld outputs arelive at the same time. Discon-n

OM-477 Page 24SECTION 7 – MAINTENANCE AND TROUBLESHOOTINGFollow the storage procedure in the engine owner’s manual if the unit will not beused for an

OM-477 Page 257-2. Maintenance Label

The following terms areused interchangeablythroughout this manual:TIG = GTAWStick = SMAWThe engine exhaust fromthis product containschemicals known to

OM-477 Page 267-3. Servicing Air Cleaneraircleaner1 6/96 – ST-153 929-B / ST-153 585 / Ref. ST-191 898 / Ref. S-0698-B Stop engine. Do not run engin

OM-477 Page 277-5. 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 Fil

OM-477 Page 287-6. Changing Fuel FilterRef. ST-191 898 / Ref. ST-159 727-C Stop engine and let cool.1 Fuel Shutoff Valve2 Fuel Line3 Fuel FilterTo re

OM-477 Page 297-8. Adjusting Engine Weld/Power SpeedRef. ST-801 179 / Ref. ST-800 159-C / Ref. ST-800 161 Governor sensitivity may re-quire adjustmen

OM-477 Page 307-9. Adjusting Engine Idle SpeedRef. ST-115 155-AStart engine. Place Engine ControlSwitch in Run/Idle position.1 Solenoid Bracket Screws

OM-477 Page 317-11. Adjusting Optional High Altitude CarburetorRef. ST-159 727-B / Ref. ST-115 155-A A too lean air-fuel mixturecan damage valves. Do

OM-477 Page 32Trouble RemedyLow or high weld output. Check control settings.Place optional Process switch in correct position (see Section 5-1).Check

OM-477 Page 33Trouble RemedyHave Factory Authorized Service Agent check brushes and slip rings, and field current regulator boardPC1.High or low volta

OM-477 Page 34Notes

OM-477 Page 35SECTION 8 – ELECTRICAL DIAGRAMS193 965-AFigure 8-1. Circuit Diagram For Welding Generator For Standard Models

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

OM-477 Page 37193 967-A

OM-477 Page 38SECTION 9 – AUXILIARY POWER GUIDELINES9-1. Selecting Equipmentaux_pwr 2/99 – Ref. ST-159 730 / ST-800 5771 Auxiliary Power Receptacles–

OM-477 Page 399-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse #10 AWG or larger insulatedc

OM-477 Page 409-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running WattsSplit Phase 1/8 HP 800 300

OM-477 Page 419-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHand Drill 1/4 in 350 3503/8 i

OM-477 Page 429-8. Power Required To Start MotorS-06241 Motor Start Code2 Running Amperage3 Motor HP4 Motor VoltageTo find starting amperage:Step 1: F

OM-477 Page 439-10. Typical Connections To Supply Standby PowerS-0405-A1 Power Company ServiceMeter2 Main and Branch OvercurrentProtection3 Double-Pol

OM-477 Page 449-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, use

OM-477 Page 45Notes

OM-477 Page 1SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USINGrom _nd_11/981-1. Symbol UsageMeans Warning! Watch Out! There are possible hazardswith

OM-477 Page 46SECTION 10 – PARTS LISTFigure 10-1. Main Assembly Hardware is common andnot available unless listed.12345678910111213141516171849676665

OM-477 Page 47ST-115 004-P2021222324252627282930 31323334193536373840414243394445464750515253545556575859602561Fig 10-264636248IncludesItem 49

OM-477 Page 48DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 10-1. Main AssemblyQuantity1 134 771 PLUG, protective .640sq 2. . . . . . . . . . . . . . . .

OM-477 Page 49DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 10-1. Main Assembly (Continued)Quantity53 113 658 LINKAGE, throttle 1. . . . . . . . . . . . .

OM-477 Page 50DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 10-1. Main Assembly (Continued)Quantity106 085 551 FRAME, mtg reactor/fuel tank 1. . . . . . .

OM-477 Page 51DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 10-2. Generator (Fig 10-1 Item 59)Quantity1 106 426 INSULATOR 4. . . . . . . . . . . . . . .

OM-477 Page 52DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 10-3. Panel, Front w/Components (Fig 10-1 Item 102)Quantity1 010 647 PIN, spring CS .156 x 1.25

OM-477 Page 53DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 10-3. Panel, Front w/Components (Fig 10-1 Item 102)(Continued)Quantity12 Fig 10-4 CONTROL BOX w

OM-477 Page 54DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 10-4. Control Box w/Components (Fig 10-3 Item 12)Quantity1 CR1 044 588 RELAY, encl 12VDC 3PDT 1

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 7/00Your distributor also givesyou ...ServiceYou always get the fa

OM-477 Page 2Welding on closed containers, such as tanks,drums, or pipes, can cause them to blow up. Sparkscan fly off from the welding arc. The flyin

PRINTED IN USA  2000 Miller Electric Mfg. Co. 6/00Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US

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

OM-477 Page 4H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommunic

OM-477 Page 5SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANTUTILISATIONrom _nd_fre 11/981-1. Signification des symbolesSignifie Mise en garde ! Soyez