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Miller Electric Big 40G - User Manual

Miller Electric Big 40G
60 pages
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Big 40G
OM-477 116 508W
September 2000
Processes
Description
Air Carbon Arc (CAC-A)
Cutting and Gouging
TIG (GTAW) Welding
Stick (SMAW) Welding
Engine Driven Welding Generator
With Optional Equipment:
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Visit our website at
www.MillerWelds.com

Table of Contents

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Summary

SECTION 1 - SAFETY PRECAUTIONS

General Safety Warnings and Symbol Usage

Explains warning symbols and general safety precautions for hazards.

Arc Welding Hazards

Details hazards like electric shock, arc rays, fumes, and fire from welding.

Engine and Battery Hazards

Covers risks from engine exhaust, heat, battery acid, explosion, and moving parts.

Installation and Operation Safety

Discusses safety related to falling units, flying sparks, overheating, and static discharge.

Safety Standards and EMF Information

Lists key safety standards and information on electromagnetic field effects.

SECTION 2 - DEFINITIONS

Symbols and Terminology

Defines common symbols and terms used throughout the manual.

SECTION 3 - SPECIFICATIONS

Weld, Power, and Engine Specifications

Provides key specifications for welding output, auxiliary power, and engine details.

Dimensions, Weights, and Fuel Consumption

Details physical dimensions, weight, operating angles, and fuel usage.

Duty Cycle, Overheating, and AC Auxiliary Power

Explains duty cycle limits, overheating risks, and AC auxiliary power capabilities.

Volt-Ampere Curves

Shows minimum and maximum voltage/amperage output capabilities for different welding modes.

SECTION 4 - INSTALLATION

Generator Installation and Connections

Covers generator placement, airflow, grounding, battery, and muffler installation.

Engine Prestart Checks

Outlines daily checks for fluids, fuel, oil, and coolant before starting the engine.

Weld Output and Cable Sizing

Explains connecting weld cables to output terminals and selecting appropriate cable sizes.

Optional Remote Control Connections

Details connections for optional Remote 14 receptacle and terminal strip 3T.

SECTION 5 - OPERATING WELDING GENERATOR

Front Panel Controls Overview

Identifies and describes the various controls located on the front panel of the welding generator.

Detailed Front Panel Control Descriptions

Provides detailed explanations for each front panel control and indicator light.

Optional Remote Amperage Control

Explains how to use the optional remote amperage control for adjusting settings.

SECTION 6 - OPERATING AUXILIARY EQUIPMENT

120 Volt Auxiliary Receptacles

Details the 120V receptacles, GFCI protection, and circuit breakers.

240 Volt Auxiliary Receptacle

Describes the optional 240V receptacle, its protection, and output limits.

Connecting Optional Auxiliary Power Plant

Provides instructions for connecting an optional auxiliary power plant, including wiring diagrams.

SECTION 7 - MAINTENANCE AND TROUBLESHOOTING

Routine Maintenance Schedule

Outlines scheduled maintenance tasks and their intervals (e.g., oil change, filter replacement).

Maintenance Label and Service Intervals

Details the information found on the maintenance label, including fluid capacities and service intervals.

Air Cleaner Servicing and Overload Protection

Provides instructions for air filter maintenance and explains overload protection components.

Engine Oil and Filter Change

Step-by-step guide for changing the engine oil and oil filter.

Fuel Filter and Spark Arrestor Maintenance

Instructions for replacing the fuel filter and cleaning the spark arrestor muffler.

Adjusting Engine Weld;Power Speed

Details how to adjust engine speed for welding and power output.

Adjusting Engine Idle Speed and Governor Sensitivity

Explains setting idle speed and adjusting governor sensitivity for optimal performance.

High Altitude Carburetor Adjustment and Welding Troubleshooting

Instructions for high-altitude carburetor adjustment and troubleshooting welding output issues.

Troubleshooting Auxiliary Power Issues

Offers solutions for common problems related to auxiliary power output.

Troubleshooting Engine Problems

Lists common engine problems and their remedies, including starting and running issues.

SECTION 9 - AUXILIARY POWER GUIDELINES

Selecting Equipment and Grounding

Guides users on selecting auxiliary equipment and proper grounding methods.

Grounding for Building Systems and Power Calculation

Details grounding for building systems and how to calculate equipment power requirements.

Motor Power Requirements

Lists approximate starting and running watts for various industrial motors.

Farm;Home and Contractor Equipment Power Needs

Provides power requirements for common farm/home and contractor equipment.

Motor Starting Amperage and Generator Output Capacity

Explains calculating motor starting amperage and generator output limits.

Standby Power Connections

Illustrates how to connect the generator for standby power during outages.

Extension Cord Selection Guide

Provides charts for selecting appropriate extension cords based on load and length.

SECTION 10 - PARTS LIST

Main Assembly Parts

Exploded view diagram of the main assembly with numbered parts.

Generator Assembly Parts

Exploded view of the generator component with numbered parts.

Main Assembly Parts List (Continued)

Lists parts for the main assembly, continuing from previous page.

Front Panel and Control Box Parts

Lists parts for the front panel and control box assemblies.

Front Panel Components

Exploded view of the front panel with components and part numbers.

Front Panel Components (Continued)

Lists parts for the front panel, continuing from previous page.

Control Box Components

Exploded view of the control box and its components with part numbers.

Warranty Information

Contacting Distributors and Warranty Terms

Information on contacting distributors and the terms of Miller's limited warranty.

Warranty Exclusions and Limitations

Lists items and conditions not covered by the limited warranty.

Owners Record and Service Information

Service Contact and Distributor Information

Provides contact information for locating service distributors and agencies.

Miller Electric Big 40G Specifications

General IconGeneral
Welding Current Range40-400 A
Output Current Range40-400 A
Duty Cycle100% at 300 A
Welding ProcessesStick (SMAW), TIG (GTAW)
Generator Output10, 000 Watts Peak
Auxiliary Power120/240V

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