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Visit our website at www.MillerWelds.com Big 40 WG OM-4405 200 972A January 2001 Processes Stick (SMAW) Welding TIG (GTAW) Welding MIG (GMAW) Welding Flux Cored (FCAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging Description Engine Driven Welding Generator...
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ISO 9001 Quality System Standard. Warranty and 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.
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING WARNING This product, when used for welding or cutting, produces fumes or gases which contain SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION chemicals known to the State of California to cause birth defects and, in some cases, cancer.
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.
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.
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.
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.
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 ;...
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.
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...
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.
3-2. Dimensions, Weights, And Operating Angles Dimensions 58 in (1473 mm) Height (to top of muffler) 28-1/2 in (724 mm) (mtg. brackets turned in) Width 30-3/4 in (781 mm) (mtg. brackets turned out) Depth 64-7/16 in (1637 mm) 64-7/16 in (1637 mm) 55-7/8 in (1419 mm) 46-3/8 in (1178) 9-1/2 in (241 mm)
3-7. AC Auxiliary Power Curve AC AMPERES IN 240V MODE AC AMPERES IN 120V MODE 3-8. Optional AC Power Plant Curves A. 12 kVA/kW Single-Phase Auxiliary Power Plant (No Weld Load) B. 15 kVA/kW Three-Phase Auxiliary Power Plant (No Weld Load) AC AMPERES AC AMPERES The ac power curve shows the aux-...
4-3. Mounting Welding Generator Tools Needed: 9/16 in 4-4. Installing Exhaust Pipe Tools Needed: 1/2 in Y Do not weld on base. Weld- ing on base can cause fuel tank fire or explosion. Weld only on the four mounting brackets or bolt unit down. Mounting Bracket 1/2 in Bolt And Washer (Not Supplied)
4-5. Activating The Dry Charge Battery (If Applicable) 5 A For 30 Minutes 30 A For 12 Minutes OM-4405 Page 16 – Remove battery from unit. Eye Protection – Safety Glasses Or Face Shield Rubber Gloves Vent Caps Sulfuric Acid Electrolyte (1.265 Specific Gravity) Well Fill each cell with electrolyte to...
4-7. Engine Prestart Checks Full Gasoline Check all engine fluids daily. Engine must be cold and on a level surface. Unit is shipped with 20W break-in oil. Automatic shutdown system stops engine if oil pressure is too low, or coolant tempera- ture is too high.
4-8. Connecting To Weld Output Terminals 4-9. Selecting Weld Cable Sizes Weld Output Terminals Y Stop engine before Welding connecting to weld out- Amperes put terminals. Y Do not use worn, dam- aged, undersized, or poorly spliced cables. This chart is a general guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), use next size larger cable.
4-11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models New! LDR-14 long distance remote (includes 120 V receptacle) receptacle) *The remaining sockets are not used. Socket* 24 volts ac. Protected by circuit breaker CB5. 24 VOLTS AC 24 VOLTS AC Contact closure to A completes 24 volt ac contactor control circuit.
5-2. Description Of Front Panel Controls For CC Models (See Section 5-1) Engine Starting Controls Magnetic Shutdown Switch Use switch during start-up to bypass engine shutdown system. System stops engine if oil pressure is too low or coolant temperature is too high.
5-3. Remote Amperage Control On CC Models (Optional) Example: Combination Remote Amperage Control (Stick) Set Switches Set Range OM-4405 Page 24 Remote Amperage Adjust Receptacle RC13 Connect optional remote control to RC13 (see Section 4-10). In Example: Range = 100 to 205 A DC Percentage Of Range = 50% Max = About 153 A DC (50% of 100 to 205) Max (153 A DC)
6-2. Description Of Front Panel Controls For CC/CV Models (See Section 6-1) Engine Starting Controls Magnetic Shutdown Switch Use switch during start-up to bypass engine shutdown system. System stops engine if oil pressure is too low or engine temperature is too high.
6-4. Remote Voltage/Amperage Control On CC/CV Models (Optional) Example: Combination Remote Amperage Control (Stick) Set Remote Set V/A Adjust Switch Process Example: Combination Remote Amperage Control (TIG) Set V/A Set Remote Adjust Switch Process Process = Stick (Using Remote On/Off) Set Range Control Not Used In Remote...
SECTION 7 – OPERATING AUXILIARY EQUIPMENT 7-1. 120 Volt And 240 Volt Receptacles OM-4405 Page 30 120 V 20 A AC GFCI Receptacle GFCI1 240 V 30 A AC Twistlock Receptacle RC1 Receptacles supply 60 Hz single- phase power at weld/power speed. If a ground fault is detected, GFCI Reset button...
7-2. Connecting To Optional Auxiliary Power Plant (CC/CV Models Only) Single-Phase Power Connection Three-Phase Power Connection Y Close panel opening if no connections are made to power plant. Remove plug before inserting leads. Reinstall bushing. Rear Of Panel 120V 120V Single Phase Output...
7-3. Optional Auxiliary Power Receptacles European Receptacle Australian Receptacle South African Receptacle OM-4405 Page 32 120 V 20 A AC GFCI Receptacle GFCI1 240 V 16 A AC European Receptacle RC1 240 V 15 A AC Australian Receptacle RC1 240 V 15 A AC South African Receptacle RC1 Receptacles supply 60 Hz single- phase power at weld/power speed.
8-2. Routine Maintenance Note Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period. Coolant Full Full Clean Air Filter. See Section 8-4. Change Oil. See OM-4405 Page 34 Recycle engine Check Fluid Levels.
8-3. Inspecting And Cleaning Optional Spark Arrestor Muffler Tools Needed: 3/8 in 500 h Check Valve Clearance.* 1000 h Blow Out Or Vacuum Inside. During Heavy SLUDGE Service, Clean Monthly. Service Welding Generator Brushes And Slip Rings. Service More Often In Dirty Conditions.* Repair Or Replace Damaged...
8-4. Servicing Air Cleaner Keep nozzle 2 in (51 mm) from element. Blow OM-4405 Page 36 Inspect Y Stop engine. Y Do not run engine without air cleaner or with dirty element. En- gine damage caused by using a damaged element is not covered by the warranty.
8-5. Adjusting Engine Weld/Power Speed Engine Speed RPM (Hz) (No Load) 1850 (61.7) Weld/Power Maximum 1/16 in (1.6 mm) 3-1/4 in (83 mm) Tools Needed: 3/8, 7/16 in Y Stop engine and let cool. Governor sensitivity may re- quire adjustment if engine speed is adjusted (see Section 8-7).
8-6. Adjusting Engine Idle Speed Engine Speed (No Load) 1850 rpm max (61.6 Hz) 1250 rpm (41.6 Hz) OM-4405 Page 38 Y Stop engine and let cool. Engine idle speed is factory set and normally should not require adjust- ment. After tuning engine, check engine speed with tachometer or frequency meter.
8-7. Adjusting Governor Sensitivity Tools Needed: 1/2 in Notes Governor sensitivity may re- quire readjustment if weld speed is adjusted. Weld speed must be readjusted if sensitivity is adjusted. Be sure carburetor and link- ages are adjusted properly be- fore adjusting sensitivity. Start engine.
8-8. Servicing Fuel And Lubrication Systems Y Stop engine and let cool. Y After servicing, start engine and check for fuel leaks. Stop engine, tighten connections as necessary, and wipe up spilled fuel. Oil Filter Oil Drain Valve And Hose Oil Fill Cap/Dipstick Fuel Tank Sludge Drain Valve To change oil and filter:...
8-9. Overload Protection Y Stop engine. When a circuit breaker or fuse opens, it usually indicates a more serious problem exists. Contact Factory Authorized Service Agent. Fuse F1 Fuse F2 F1 and F2 protect the stator exciter winding from overload. If F1 opens, weld and auxiliary power is low or stops entirely.
8-10. Diagnosing Causes Of Engine Fault Shutdowns Pre-Start Diagnostic Checks Turn Engine Control Switch To Run/Idle Position While Pressing Magnetic Shut- down Switch. Diagnostic Checks While Running Start Engine (With No Load Applied). OM-4405 Page 42 Normal Condition: Oil Pressure Light On; Battery Charging, Fuel, And Temperature Lights Off.
8-11. Troubleshooting A. Welding – CC Models Trouble No weld output; auxiliary power output Check position of Ampere Range switch. okay. Check position of optional polarity switch. Place Amperage Adjust switch in Panel position, or place switch in Remote position and connect remote control to Remote Amperage Adjust receptacle RC13 (see Sections 4-10 and 5-1).
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B. Welding – CC/CV Models Trouble No weld output; auxiliary power output Place Process/Contactor switch in a Electrode Hot position, or place switch in a Remote position and okay. connect remote contactor to optional Remote 14 receptacle RC14 (see Sections 4-11 and 6-1). Check position of Ampere Range switch.
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C. Standard Auxiliary Power Trouble No auxiliary power output; weld output Reset receptacle circuit breakers. okay. No auxiliary power or weld output. Disconnect equipment from auxiliary power receptacles during start-up. Check fuses F1 and F2, and replace if open (see Section 8-9). Have Factory Authorized Service Agent check integrated rectifier SR1, capacitor C9, and the rotor.
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Trouble Engine cranks but does not start. Press Magnetic Shutdown switch MS1 when starting engine. Check fuel level. Reset circuit breaker CB13 (see Section 8-9). Have Factory Authorized Service Agent check engine- wiring harness and components. Check battery and replace if necessary. Check engine charging system according to engine manual. Have Factory Authorized Service Agent check control relay CR2, and fuel solenoid FS1.
SECTION 10 – AUXILIARY POWER GUIDELINES 10-1. Selecting Equipment 10-2. Grounding Generator To Truck Or Trailer Frame OM-4405 Page 52 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 –...
10-3. Grounding When Supplying Building Systems 10-4. 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.
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10-5. Approximate Power Requirements For Industrial Motors Industrial Motors Split Phase Capacitor Start-Induction Run Capacitor Start-Capacitor Run Fan Duty 10-6. 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.
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10-7. 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 &...
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10-8. 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...
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10-10. 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...
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10-11. 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.
Hardware is common and not available unless listed. 104 (FIG. 11–4 OR 11–5) OM-4405 Page 60 SECTION 11 – PARTS LIST 100 (Fig. 11–7) 98 (FIG. 11–2 OR 11–3) 96 (CC ONLY) Figure 11-1. Main Assembly...
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Hardware is common and not available unless listed. Figure 11-4. Panel, Front w/Components – CC Models Item Dia. Part Mkgs. Figure 11-4. Panel, Front w/Components – CC Models (Figure 11-1 Item 104) ....201 841 .
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Item Dia. Part Mkgs. Figure 11-4. Panel, Front w/Components – CC Models (Continued) ... . 188 635 ....202 209 .
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Hardware is common and not available unless listed. Figure 11-5. Panel, Front w/Components – CC/CV Models Item Dia. Part Mkgs. Figure 11-5. Panel, Front w/Components – CC/CV Models (Figure 11-1 Item 104) ....201 579 .
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Item Dia. Part Mkgs. Figure 11-5. Panel, Front w/Components – CC/CV Models (Continued) ....097 922 ....189 161 .
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Item Dia. Part Mkgs....132 053 ....183 387 .
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Hardware is common and not available unless listed. Item Dia. Part Mkgs....201 747 ....188 137 .
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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.
Parts) Circuit Diagrams Welding Process Handbooks File a claim for loss or damage during shipment. 2001 Miller Electric Mfg. Co. 1/01 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 &...