Miller Electric Big 40 WG Owner's Manual Page 1

Big 40 WGOM-4405 200 972AJanuary 2001Visit our website atwww.MillerWelds.comProcessesDescriptionAir Carbon Arc (CAC-A)Cutting and GougingStick (SMAW)

OM-4405 Page 6Le soudage effectué sur des conteneurs fermés tels quedes réservoirs, tambours ou des conduites peut provoquerleur éclatement. Des étinc

OM-4405 Page 7DES ORGANES MOBILES peuventprovoquer des blessures. Ne pas approcher les mains des ventilateurs, cour-roies et autres pièces en mouveme

OM-4405 Page 8LE RAYONNEMENT HAUTE FRÉ-QUENCE (H.F.) risque de provoquerdes interférences. Le rayonnement haute fréquence (H.F.) peutprovoquer des in

OM-4405 Page 9SECTION 2 – DEFINITIONS2-1. Symbols And DefinitionsStop EngineFast (Run, Weld/Power)Slow (Idle) Start EngineAir Temperature OrEngineTemp

OM-4405 Page 103-2. Dimensions, Weights, And Operating AnglesDimensionsHeight58 in (1473 mm)(to top of muffler)GWidth28-1/2 in (724 mm)(mtg. brackets

OM-4405 Page 113-4. Volt-Ampere Curves for CC/CV Models202 655 / 202 656 / 202 654The volt-ampere curves show theminimum and maximum voltageand ampera

OM-4405 Page 123-5. Fuel ConsumptionThe curve shows typical fuel useunder weld or power loads.201 0330.000.250.500.751.001.251.501.752.002.252.5005010

OM-4405 Page 133-7. AC Auxiliary Power Curve193 018The ac power curve shows the aux-iliary power in amperes available atthe 120 and 240 volt receptacl

OM-4405 Page 14SECTION 4 – INSTALLATION4-1. Installing Welding Generator (See Sections 4-2 And 4-3)install2 1/01 – Ref. 800 652 / Ref. 800 477-A / 158

OM-4405 Page 154-3. Mounting Welding GeneratorRef. 190 250-A / Ref. 802 730 Do not weld on base. Weld-ing on base can cause fueltank fire or explosio

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

OM-4405 Page 164-5. Activating The Dry Charge Battery (If Applicable)Remove battery from unit.1 Eye Protection – SafetyGlasses Or Face Shield2 Rubber

OM-4405 Page 174-6. Connecting The Battery1/2 in–+ Connect Negative (–) Cable Last.Tools Needed:802 168-B / Ref. 201 841 / 802 313 / S-0756-CNotes

OM-4405 Page 184-7. Engine Prestart Checks Check all engine fluids daily.Engine must be cold and on a level surface.Unit is shipped with 20W break-in

OM-4405 Page 194-8. Connecting To Weld Output Terminals802 729 Stop engine.1 Positive (+) Weld Output Terminal2 Negative (–) Weld Output TerminalFor

OM-4405 Page 204-10. Connecting To Remote Amperage Adjust Receptacle RC13 On CC ModelsRef. 154 862-A / 048 720-K / 802 7291 Remote Amperage AdjustRece

OM-4405 Page 214-11. Connecting To Remote 14 Receptacle RC14 On CC/CV ModelsSocket* Socket Information24 VOLTS ACA 24 volts ac. Protected by circuitbr

OM-4405 Page 22SECTION 5 – OPERATING WELDING GENERATOR – CC MODELS5-1. Front Panel Controls For CC Models (See Section 5-2)17201 841 / 802 72915 16213

OM-4405 Page 235-2. Description Of Front Panel Controls For CC Models (See Section 5-1)Engine Starting Controls1 Magnetic Shutdown SwitchUse switch du

OM-4405 Page 245-3. Remote Amperage Control On CC Models (Optional)1 Remote Amperage AdjustReceptacle RC13Connect optional remote control toRC13 (see

OM-4405 Page 25Notes

TABLE OF CONTENTSSECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1. . . .

OM-4405 Page 26SECTION 6 – OPERATING WELDING GENERATOR – CC/CV MODELS6-1. Front Panel Controls For CC/CV Models (See Section 6-2)201 579 / 802 7296547

OM-4405 Page 276-2. Description Of Front Panel Controls For CC/CV Models (See Section 6-1)Engine Starting Controls1 Magnetic Shutdown SwitchUse switch

OM-4405 Page 286-3. Process/Contactor Switch On CC/CV Models11 Process/Contactor Switch Weld output terminals are en-ergized when Process/Con-tactor

OM-4405 Page 296-4. Remote Voltage/Amperage Control On CC/CV Models (Optional)1 Remote 14 Receptacle RC14Connect optional remote control toRC14 (see S

OM-4405 Page 30SECTION 7 – OPERATING AUXILIARY EQUIPMENT7-1. 120 Volt And 240 Volt Receptacles191 624-A21 120 V 20 A AC GFCI Receptacle GFCI12 240 V 3

OM-4405 Page 317-2. Connecting To Optional Auxiliary Power Plant (CC/CV Models Only)Ref. 197 399 / 802 332-E Place Process/Contactor switchin Electro

OM-4405 Page 327-3. Optional Auxiliary Power Receptacles21 120 V 20 A AC GFCI Receptacle GFCI12 240 V 16 A AC EuropeanReceptacle RC13 240 V 15 A AC Au

OM-4405 Page 33SECTION 8 – MAINTENANCE & TROUBLESHOOTING8-1. Maintenance Label

OM-4405 Page 348-2. Routine Maintenance Follow the storage procedure in the engine owner’s manual if the unit will not be used for anextended period.N

OM-4405 Page 35500 hRepair OrReplaceDamagedCables.CheckValveClearance.*1000 hBlow Out OrVacuum Inside.During HeavyService,Clean Monthly.ORDrain Sludge

TABLE OF CONTENTSSECTION 8 – MAINTENANCE & TROUBLESHOOTING 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. Maintena

OM-4405 Page 368-4. Servicing Air Cleaneraircleaner1 9/00 – 153 929-B / 153 585 / Ref. S-0698-B Stop engine. Do not run engine without aircleaner or

OM-4405 Page 378-5. Adjusting Engine Weld/Power Speed802 731 / 802 780 / Ref. 801 179 / Ref. 800 161 Stop engine and let cool. Governor sensitivity

OM-4405 Page 388-6. Adjusting Engine Idle Speed802 731 / Ref. 115 155-A Stop engine and let cool.Engine idle speed is factory set andnormally should

OM-4405 Page 398-7. Adjusting Governor Sensitivity802 780 / Ref. 115 155-A Governor sensitivity may re-quire readjustment if weldspeed is adjusted. W

OM-4405 Page 40318-8. Servicing Fuel And Lubrication Systems802 731 / Ref. 801 434 Stop engine and let cool. After servicing, start engine andcheck

OM-4405 Page 418-9. Overload Protection Stop engine. When a circuit breaker or fuseopens, it usually indicates amore serious problem exists.Contact

OM-4405 Page 428-10. Diagnosing Causes Of Engine Fault ShutdownsRef. 201 841Use the front panel engine lights tohelp determine the cause of an au-tom

OM-4405 Page 438-11. TroubleshootingA. Welding – CC ModelsTrouble RemedyNo weld output; auxiliary power outputokay.Check position of Ampere Range swit

OM-4405 Page 44B. Welding – CC/CV ModelsTrouble RemedyNo weld output; auxiliary power outputokay.Place Process/Contactor switch in a Electrode Hot pos

OM-4405 Page 45C. Standard Auxiliary PowerTrouble RemedyNo auxiliary power output; weld outputokay.Reset receptacle circuit breakers.No auxiliary powe

OM-4405 Page 1SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USINGrom _nd_11/981-1. Symbol UsageMeans Warning! Watch Out! There are possible hazardswit

OM-4405 Page 46Trouble RemedyEngine cranks but does not start. Press Magnetic Shutdown switch MS1 when starting engine.Check fuel level.Reset circuit

OM-4405 Page 47Notes

OM-4405 Page 48SECTION 9 – ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For CC Welding Generator

OM-4405 Page 49201 991-A

OM-4405 Page 50 Figure 9-2. Circuit Diagram For CC/CV Welding Generator

OM-4405 Page 51201 992-A

OM-4405 Page 52SECTION 10 – AUXILIARY POWER GUIDELINES10-1. Selecting Equipmentaux_pwr 2/99 – Ref. ST-159 730 / ST-800 5771 Auxiliary Power Receptacle

OM-4405 Page 5310-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse #10 AWG or larger insulate

OM-4405 Page 5410-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running WattsSplit Phase 1/8 HP 800 3

OM-4405 Page 5510-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHand Drill 1/4 in 350 3503/8

OM-4405 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 flyi

OM-4405 Page 5610-8. Power Required To Start MotorS-06241 Motor Start Code2 Running Amperage3 Motor HP4 Motor VoltageTo find starting amperage:Step 1:

OM-4405 Page 5710-10.Typical Connections To Supply Standby PowerS-0405-A1 Power Company ServiceMeter2 Main and Branch OvercurrentProtection3 Double-Po

OM-4405 Page 5810-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, u

OM-4405 Page 59Notes

OM-4405 Page 60SECTION 11 – PARTS LIST Hardware is common andnot available unless listed.12345 67101112131415161718192021222324259293949596 (CC ONLY)

OM-4405 Page 61802 789262728293031323334353637383940414243444546474891 (SEE FIG. 11–6)9089888786854983828180797877845076747372717069686766656452515354

OM-4405 Page 62DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-1. Main AssemblyQuantity1 189 824 PANEL, gen LH 1. . . . . . . . . . . . . . . . . . . .

OM-4405 Page 63DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-1. Main Assembly (Continued)Quantity172 725 BOOT, starter eyelet terminal 1. . . . . . . .

OM-4405 Page 64DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-1. Main Assembly (Continued)Quantity99 189 731 FIREWALL, lower 1. . . . . . . . . . . . .

OM-4405 Page 65DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-2. Control Box Assembly – CC Models (Figure 11-1 Item 98)Quantity1 F1, F2 *085 874 FUSE, mi

OM-4405 Page 3MOVING PARTS can cause injury. Keep away from fans, belts, and rotors. Keep all doors, panels, covers, and guardsclosed and securely i

OM-4405 Page 66802 360125312416151711181013147896Figure 11-3. Control Box Assembly – CC/CV ModelsDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-3. Contro

OM-4405 Page 67DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-3. Control Box Assembly – CC/CV Models (Continued)Quantity177 859 CONN, body 5 terminal (to

OM-4405 Page 68 Hardware is common andnot available unless listed.802 79913451114172223252831343536373839401624293015192212627121813678910203332Figur

OM-4405 Page 69DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-4. Panel, Front w/Components – CC Models (Continued)Quantity5 R1 188 635 RHEOSTAT, WW 300W

OM-4405 Page 70 Hardware is common andnot available unless listed.802 73212345679474950515253545556121718192021222324252629272814153332311634414240 3

OM-4405 Page 71DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-5. Panel, Front w/Components – CC/CV Models (Continued)Quantity5 R1 193 118 POT, cp flat 1t

OM-4405 Page 72DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-5. Panel, Front w/Components – CC/CV Models (Continued)Quantity53 097 922 KNOB, pointer .87

OM-4405 Page 73DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-6. Generator (Figure 11-1 Item 91)Quantity1 132 053 SCREW, .375–16x1.50 hex hd–pln gr5 pld

OM-4405 Page 74 Hardware is common andnot available unless listed.802 279-A123465789Figure 11-7. Main Rectifier AssemblyDescriptionPartNo.Dia.Mkgs.It

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

OM-4405 Page 4H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommuni

PRINTED IN USA  2001 Miller Electric Mfg. Co. 1/01Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US

OM-4405 Page 5SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANTUTILISATIONrom _nd_fre 11/981-1. Signification des symbolesSignifie Mise en garde ! Soyez