Miller Electric Big 40 User's Manual
Contents
1. Big 40 Diesel Heavy Industrial Processes Applications CC and CC CV Models Petro Chemical Piping Stick SMAW Structural Steel Work TIG GTAW Quick Maintenance and Repair Air Carbon Arc CAC A Cutting and Gouging Rated 5 16 7 9 mm carbons Capable 3 8 9 5 mm carbons Stud Welding CC CV Model Only MIG GMAW Flux Cored FCAW AC TIG Deluxe Model The Power of Blue BUILT AC TIG weld aluminum with deluxe model roves The most AC weld output on any engine drive High frequency unit required Silenced only 65 dB 90 Lwa at idle 73 8 dB at 23 ft 98 7 Lwa maximum output Improves work site communications Automatic idle saves fuel and prolongs engine life along with reducing the sound level Quick and easy maintenance with single side access to oil level check oil fill oil filter fuel filter and air cleaner Enclosed base and case protects internal components from corrosive environments and reduces sound levels Remote toolless oil drain that allows oil to be drained without getting under the engine and reduces the chance of oil spillage Hot Start provides positive Stick electrode Starts to make it easy to start all types of electrodes and works great for bead tie ins CC CV Models The Vault ultimate control board reliability See page 4 Welder generator is warranted for 3 years parts and labor The CATERPILLAR engine is warranted for 2 years by CATERPILLAR Miller Electr2. universal hitch Includes jack stand 2 in 50 mm ball hitch stand fenders and lights Hitch must be and safety chains HWY 224 also includes fenders and lights ordered separately Note Trailer is shipped unassembled Note Trailer is shipped unassembled Note Some assembly required Cable Tree 043 826 Cable Tree 043 826 Provides an area to conveniently wrap weld Provides an area to conveniently wrap weld cables and extension cords cables and extension cords Lunette Eye 2 1 2 in 64mm 043 824 Ball Hitch 2 in 50mm 043 864 Lunette Eye 3 in 76 mm 043 863 Trailer Specifications Subject to change without notice Track Center Standard Tires Gross Axle Gross Vehicle Net Height Road to center of Standard rating Weight Rating Weight Rating Payload of Bed Clearance tires or P size rating 2000 Ib axle 3000 Ib 2570 lb 21 1 4in 8in 55 1 4 in B78 13 Length 91 in 2311 mm 430 Ib 907 kg axle 1361 kg 1166 kg 540 mm 203 mm 1403 mm Width 61 1 4 in 1556 mm 195 kg HWY 224 3500 Ib 2960 Ib 2650 lb 18 1 2in 7 1 2in 52in B78 13B Length 122 1 2 in 3112 mm 355 Ib OFR 224 1588 kg 1343 kg 1202 kg 470 mm 191 mm 1321 mm Width HWY 61 in 1549 mm 161 kg OFR 58 1 2 in 1486 mm HWY 430 2200 Ib axle 4280 Ib 3750 lb 19 1 4in 8 1 2in 52in B78 13B Length 156 1 2 in 3975 mm 530 Ib 998 kg axle 1941 kg 1701 kg 489mm 216 mm 1321 mm
3. without the use of tools Deluxe model comes standard with AC DC polarity switch Installation time 35 minutes The Vault Superior Circuit Board Design Miller s critical circuit boards are engineered to carry low power and low heat to reduce thermal stress and minimize expansion and contraction In contrast our competitor s boards carry high power and high heat making them more vulnerable to failure The Vault Makes Upgrading to Miller CC CV Units Worry Free Concerns with circuit board reliability have resulted in some operators steering clear of CC CV welder generators even though they Battery Voltmeter 195 454 Field Monitors battery charging circuit Cold Weather Starting Aid Kit 195 056 Field Includes 120 V block heater Note All models come standard with glow plugs 15 000 Watt Generator Plant 12 000 Watts 1 phase 120 240 V 15 000 Watts 3 phase 240 V The panel is protected by a 50 amp on off circuit breaker It includes a 50 A 1 phase receptacle and strain relief for direct hard wiring This power is only available while NOT welding Comes standard with deluxe model Note Available as factory option See Ordering Information on back page offer a Superior arc and multiple welding processes Miller s circuit board reliability isn t a concern since all PRO 300 and Big Blue multiprocess industrial engine drives feature the Vault Created out of tw
4. 129 340 194 744 129 337 151 086 043 688 C models only hand control C CV models only amperage or voltage control CC CV models only foot control O CC CV models only momentary and maintained contact switch CC CV models only fingertip control CC CV models only fingertip control Oo Replaces the 2 in ball hitch on the HWY 224 or OFR 224 042 801 043 805 043 802 043 824 043 826 043 806 043 864 043 863 Trailer mounted cable holder for HWY 224 OFR 224 or HWY 430 Hitch required For HWY 430 only For HWY 430 only Total Quoted Price Distributed by E Miller Litho in USA Price
5. W 28 1 2 in 724 mm D 64 7 16 in 1637 mm Additional 190 Ib 86 kg when fuel tank is full exe REMOTE ON OFF SWITCH REQUIRED Process Contactor Selector Switch Engine Oil Pressure Gauge Battery Voltmeter Engine Coolant Temperature Gauge Engine Control Switch Starting Aid Switch 3 Phase Power Generator Option Strain Relief 50 A 3 Phase Circuit Breaker 50 A 120 240 V Receptacle NEMA 14 50 19 AC DC Polarity Switch Optional on select models CC CV VOLT AMP CURVES TIG MODE Ranges CC CV VOLT AMP CURVES AC TIG MODE Ranges 55 350 0 WW 500 0 50100 150 200 250 300 350 400 450 500 AC AMPERES Big 40 Diesel CC Options Weld Ammeter and Voltmeter Kit 195 131 Field Panel mounted analog meters monitor welding output Installation time 35 minutes Cold Weather Starting Aid Kit 195 056 Field Includes 120 V block heater Note All models come standard with glow plugs Battery Voltage Gauge 195 454 Field Monitors battery charging circuit DC Polarity Reversing Switch Kit 043 942 Field Changes DC polarity without the use of tools Installation time 35 minutes Big 40 Diesel CC CV Options Weld Ammeter and Voltmeter Kit 195 131 Field Panel mounted analog meters monitor welding output Deluxe model comes standard with weld meters Installation time 35 minutes AC DC Polarity Reversing Switch Kit 195 095 Field Changes DC AC DC
6. Width 61 in 1549 mm 240 kg Width at outside of fenders Does not include tongue Typical Installations Stick SMAW Basic Equipment d Flux Cored FGAW Basic Equipment SuitCase X TREME 8VS 300 093 SuitCase X TREME 12VS 195 500 MIG GMAW Basic Equipment SuitCase 8RC 194 938 SuitCase 12RC 194940 Sm Aluminum MIG GMAW Basic Equipment Spoolmatic 30A 130 831 WC 24 137 549 TIG GTAW Basic Equipment Dynasty 200 Series HF 251D 1 042 388 TIG power cable adapter required Plasma Basic Equipment Spectrum 375 X TREME 907 303 Spectrum 375 X TREME with X CASE 907 339 Spectrum 625 907 058 Spectrum 2050 903 777 01 2 Stick Electrode X TREME 8VS X TREME 12VS Feeder Work Aluminum MIG with spoolmatic 30A Gun Ordering Information Power Source and Factory Options Big 40 Diesel CC Big 40 Diesel CC CV Field Kit Accessories Weld Ammeter and Voltmeter Kit Battery Voltmeter DC Polarity Switch Kit AC DC Polarity Switch Kit Cold Weather Starting Aid Kit Lockable Fuel Cap Flame Arrestor Kit Spark Arrestor Muffler Kit Vandalism Lockout Kit Cable Holder Roll Cage Drip Pan Canvas Cover Stick Accessories Accessory Kits MIG Flux Cored Accessories Millermatic Passport Plus SuitCase X TREME 8VS SuitCase X TREME 12VS SuitCase 8RC SuitCase 12RC MIG GMAW Flux Co
7. cord RMLS 14 n 129337 RCCS 14 Remote Remote Controls CC CV models eS Fingertip Contactor aii RHC 14 Hand Control momentary and maintained contact rocker Current Control 129 340 switch for contactor control Push forward 043 688 Miniature hand control for for maintained contact and back for Up and down rotary motion fingertip control remote current and contactor Momentary contact Includes 20 ft 6 m fastens to TIG torch using two Velcro control Dimensions 4 x 4 x cord and 14 pin plug Straps Includes 28 ft 8 5 m control cord 3 1 4 in 102 x 102 x 82 mm Includes 20 ft 6 m cord and 14 pin plug Extension Cords for 14 Pin Remote Controls 122 973 25 ft 7 6 m 122 974 50 ft 15 2 m 122 975 75 ft 22 9 m Trailers and Hitches ror both models 4 West Four Wheel Steerable HWY 224 Trailer 043 805 For highway use HWY 430 Tandem Axle Trailer 043 806 Off Road Trailer 042 801 OFR 224 Trailer 043 802 For off road use Smooth riding with 3750 Ib 1701 kg capacity A heavy duty 2570 Ib 1166 kg capacity trailer A 2650 Ib 1202 kg capacity trailer Welded Includes hand operated parking brake hydraulic designed for use in mines quarries and other steel tubing frame heavy duty axle with roller brake system and a break away device to lock rough terrain Has narrow 22 ft 6 7 m turning bearing hubs and leat spring suspension brakes if the trailer comes loose Includes jack radius Includes 3 in lunette eye
8. er cannot be used with cable holder Roll Cage Drip Pan 194 918 Field Heavy duty galvanized Steel structure designed to protect the machine The roll cage 7 meets offshore oil platform POERA with a drip pan and drain plug along with a heavy duty lift eye Canvas Cover Blue 194 683 Field Attractive waterproof canvas cover resists stains and mildew and protects the finish of your welder Note Canvas cover cannot be used with cable holder Stick SMAW Welding Weld Leads 173 851 2 0 350 A 100 duty cycle 50 ft stinger 50 ft work cable 043 952 2 0 300 A 100 duty cycle 100 ft stinger 50 ft work cable Plasma Cutting Spectrum 375 X TREME 907 303 Spectrum 375 X TREME with X CASE 907 339 not shown See Lit Index No PC 9 2 Spectrum 625 907 058 See Lit Index No PC 9 5 Spectrum 2050 903 777 01 2 See Lit Index No PC 7 0 MIG GMAW or Flux Cored FCAW Millermatic Passport Plus 907 401 Portable all in one MIG package features ultimate arc performance self contained gas bottle and flexibility to plug into 115 or 230 V power with Miller exclusive Multi Voltage Plug See Lit Index No DC 12 53 SuitCase X TREME 8VS Wire Feeder 300 093 SuitCase X TREME 12VS Wire Feeder 195 500 Lightweight voltage sensing wire feeders include secondary contactor and gas valve Require drive roll kit See Lit Index No M 6 41 Q Milter Sui
9. essure Gauge Battery Voltmeter Engine Coolant Temperature Gauge Engine Control Switch Starting Aid Switch Polarity Switch FUEL CONSUMPTION CURVE 7 57 2 6 62 1 5 68 1 4 73 1 3 79 1 2 84 0 1 89 0 50 100 150 200 250 300 350 400 DC WELD AMPERES AT 100 DUTY CYCLE gt 2 US Liters Hr 2 US Gal Hr Big 40 Diesel CC CV Specifications Subject to change without notice Welding Weld Output Weld Output Rated Max Open Mode Range at 104 F 40 C Circuit Generator Power Output Rated Dimensions CC DC 20 550 A CV DC 14 40 V 100 Duty Cycle 60 Duty Cycle 40 Duty Cycle CC AC Deluxe Model 15 375 A 100 Duty Cycle 60 Duty Cycle 400 A at 36 VDC 14 4 KW 450 A at 38 VDC 17 1 KW 500 A at 34 VDC 17 kw 300 A at 32 VAC 9 6 KW 335 A at 33 V 11 1 KW 375 A at 35 V 13 1 KW 40 Duty Cycle NEMA EWI ANSI C87 1 Class 1 output ratings Additional 7 in 178 mm to top of exhaust Peak 5000 watts Continuous 4000 watts 34 17 A 120 240 VAC 60 Hz while welding Deluxe Model Additional Power Plant 1 phase 12 kW 50 A 120 240 VAC 60 Hz or 3 phase 15 kW 36 A 240 VAC 60 Hz while not welding Big 40 Diesel CC CV Control Panel Additional Features A multi colored process selector control allows quick and easy process changes without having to use multiple switches Heavy Duty Design The Vault design provides enhanced arc characteristics
10. ic Mfg Co An Illinois Tool Works Company 1635 West Spencer Street Appleton WI 54914 USA Q Miller Maintenance Displays International Headquarters Phone 920 735 4505 USA FAX 920 735 4134 Canadian FAX 920 735 4169 Issued October 2008 e Index No ED 8 5 Diesel Engine Driven Welder Generator Output Range CC DC Stick 55 500 A CC CV DC Stick 40 550A DC TIG 20 350 A AC TIG 15 375 A MIG FCAW 14 40 V Generator Output Rated at 104 F 40 C 5500 Watts Peak 4000 Watts Continuous 15 000 Watts 3 Phase 12 000 Watts 1 Phase Deluxe Model DC TIG 55 500 A Accu Rated Not Inflated Generator Power qe E CATERPILLAR industrial engine designed CAT to operate over 10 000 hours before the tai first basic overhaul Backed by worldwide CAT support and service NEW Meter maintenance displays e Hour meter function e Oil change interval e High coolant temperature and low oil pressure shutdowns e Low fuel shutdown engine Shuts downs before system runs out of fuel making restarts easy Improved Simplified control panel provides easy set up with fewer controls less training is required More welding amperage 400 amps at 100 Duty Cycle 450 amps at 60 Duty Cycle 500 amps at 40 Duty Cycle Engine gauges indicate engine oil pressure and coolant temperature standard on all models Arc Drive makes welding easy Automatically enhances Stick welding especially on pipe by focus
11. ing the arc and preventing the electrode from going out Standard GFCI receptacle required on most job sites to protect operators from electrical hazards CSA IEC and NEMA compliant for welders Degree of protection provided by enclosure IP23 MADE IN E IA A APPLETON WI WP s a Web Site www MillerWelds com 1S0 9001 2000 REGISTERED QUALITY SYSTEM International FAX 920 735 4125 Big 40 Diesel CE Specifications sunject to change without notice Welding Weld Output Weld Output Rated Max Open Generator Output Rated Mode Range at 104 F 40 C Circuit Voltage at 104 F 40 C Dimensions 400 A at 36 VDC 14 4 kW 100 Duty Cycle 60 Duty Cycle 500 A at 30 VDC 15 kW CC DC 55 500 A 40 Duty Cycle NEMA EWI ANSI C87 1 Class 1 output ratings 450 A at 38 VDC 17 1 kW Additional 7 in 178 mm to top of exhaust Peak 5500 watts Continuous 4000 watts 34 17 A 120 240 VAC 60 Hz while welding Engine Specifications Subject to change without notice Engine Engine Fuel Oil Coolant Automatic Engine Brand Type Speeds Capacity Capacity Capacity Shutdown CATERPILLAR Tier IVi C2 2 Diesel Tier IVi EPA certified indirect injected liquid cooled diesel engine Right side Service access with service intervals of 500 hours for oil and filters Run 1850 RPM Idle 1250 RPM 25 gal 95 L Four cylinder industrial liquid cooled diesel Big 40 Diesel CC Cont
12. o aluminum halves sealed with silicone as well as watertight harness connections the Vault provides a clean circuit board environment protecting the electronics and controlling output in heavy industrial applications No other competitor protects their electronics with a sealed vault leaving critical Q Milter circuit boards exposed to harsh elements that can disrupt the machine s electronics and therefore its operation Genuine Miller ACCeSSOFeS continen gt FA 1D Lockable Flame Arrestor gt FuelCap 043 947 Field Fuel cap can be padlocked to prevent vandalism A built in flame arrestor prevents flames or Sparks from entering the fuel tank Spark Arrestor Muffler Kit 195 012 Field Prevents particles from leaving the muffler that could potentially start a fire Mandatory when operating on California grasslands brush or forest covered land and in all National Forests For other areas check your state and local laws Meets US Forest Service Standard 5100 1B Vandalism Lockout Kit 195 118 Field Lockable hinged steel panels cover and protect name plate gauges and ignition switch padlock included Also includes engine compartment door lock and key Cable Holder 043 946 a Saddle bag style cable i holder Convenient wrap around storage of coiled cable for transportation Stores 100 ft of 2 0 cable on each side Note For best results do not weld when cable is coiled Canvas cov
13. red FCAW Guns Spoolmatic 30A Spool Gun WC 24 Control XR Wire Feeder Control and Guns TIG Accessories Dynasty 200 Series High Frequency Arc Starters Remote Controls RHC 3GD34A RHC 14 RFCS 14 HD RMLS 14 RCC 14 RCCS 14 Remote Control Extension Cords Trailers and Hitches 4 West Trailer HWY 224 Trailer OFR 224 Trailer Lunette Eye 2 1 2 in Cable Tree HWY 430 Trailer Ball Hitch 2 in Lunette Eye 3 in Date Stock No Description Qty 907 171 CSA model with engine gauges and automatic idle 907 170 CSA model with engine gauges and automatic idle 907 170 03 1 CSA Deluxe model w automatic idle engine gauges welding meters AC DC polarity switch and high kW option a 195131 Standard on deluxe model 195454 195012 Horizontal externally mounted 9498 S 173 851 2 0 350 A 100 duty cycle 50 ft 15 m stinger 50 ft 15 m work clamp 043 952 2 0 300 A 100 duty cycle 100 ft 30 5 m stinger 50 ft 15 m work clamp 907 401 300 093 195 500 194 938 194 940 Includes gas bottle and MVP See Lit Index No DC 12 53 See Lit Index No M 6 41 See Lit Index No M 6 41 See Lit Index No M 6 5 See Lit Index No M 6 5 See Lit Index Nos AY 15 0 AY 16 0 and AY 17 0 Requires WC 24 Control See Lit Index No M 1 73 See Lit Index No M 1 5 See Lit Index No M 1 7 M 1 71 and M 1 73 130 831 137 549 ee Lit Index No AY 4 8 ee Lit Index No AY 5 0 Ww 041 122
14. rol Panel Additional Features Proven rugged rheostat control technology that has been in Miller engine drives for over 60 years Contains no printed control boards Provisions are provided to plug a RHC3GD34A remote control that will allow precise adjustment of amperage without walking back to the machine 1 DC Ammeter 2 DC Voltmeter 3 Amperage Adjust Control 4 Amperage Range Switch 5 Amperage Adjust Switch and Remote Amperage Adjust Receptacle 6 Stick TIG Selector Switch 7 120 VAC 20 A GFCI Duplex Receptacle 8 240 VAC 30 A TwistLock Receptacle NEMA L6 30 9 Fuel Gauge Hour Meter Oil Change Interval Engine Shutdown Indicator Big 40 Diesel CC Performance Data CC DC VOLT AMP CURVES ak Oo Oo Ranges 230 Max 170 365 110 225 70 130 55 85 foe Oo DC VOLTS K 100 200 300 400 500 600 700 800 900 1000 DC AMPERES GENERATOR POWER CURVE 150 300 125 250 100 200 75 150 AC VOLTS 50 100 25 50 0 0 30 15 AC AMPERES IN 240 V MODE 0 5 10 20 25 0 10 20 30 40 50 60 AC AMPERES IN 120 V MODE Q Milter cepe Net Weight without fuel H 43 in 1092 mm W 28 i in 724 an D 64 7 16 in 1637 mm 1540 Ib 697 kg Additional 190 Ib 86 kg when fuel tank is full Oil Pressure Coolant Temperature 9 qt 9 qt 8 5 L 8 5 L 1 1 0 N aO 13 14 15 10 11 12 13 14 15 Optional on select models Engine Oil Pr
15. tCase 8RC Wire Feeder 194 938 SuitCase 12RC Wire Feeder 194 940 Lightweight and flexible enough to run a variety of wires up to 062 in diameter Comes standard with remote voltage control See Lit Index No M 6 5 MIG GMAW Flux Cored FCAW Guns Miller produces a complete line of dependable MIG guns See Lit Index Nos AY 15 0 AY 16 0 and AY 17 0 Spoolmatic 30A _ Spool Gun 130 831 Air cooled 200 amp 1 lb spool gun for aluminum MIG See Lit Index No M 1 73 WC 24 Control 137 549 Use with Spoolmatic 30A XR Wire Feeders and Guns Push pull system designed to handle difficult to feed soft alloy wires such as aluminum See Lit Index No M 1 7 M 1 71 and M 1 73 TIG GTAW Welding Dynasty 200 Series For premium portable AC DC TIG arc quality See Lit Index No AD 4 8 HF 251 Series 042 388 HF 251D 1 115 VAC 042 387 HF 251D 2 230 VAC High frequency arc Starter and stabilizer see heen Lit Index No AY 5 0 Genuine Miller ACCeSSOFES continen Remote Controls CC models only RFCS 14 HD Foot RCC 14 Remote _ eer Control 194 744 er Contactor and RHC 3GD34A Remote Foot current and Current Control Hand Control 041 122 contactor control 151 086 Allows for precise 20 ft 6m cordand 14 pin plug Rotary motion fingertip control adjustment of amperage 14 pin plug fastens to TIG torch using two Velcro straps Includes 20 ft 6 m cord Includes 28 ft 8 5 m control
16. that include more dig in the Stick mode with Smoother and lower amperage in the TIG mode Along with the superior welding performance the Vault provides the ultimate reliability in the harshest of environments A hermetically sealed vault protects Miller control boards from dust moisture and tough environmental elements Extreme conditions will not cause the output to change eliminating the need to periodically turn up the heat 15 000 watt generator option for stand by power generation adds 15 kW three phase 240 volt power to CC CV units 12 kW 120 240 volt single phase power from a 50 amp receptacle while not welding 9 DC Ammeter DC Voltmeter Amperage Voltage Adjust Control Ampere Range Switch Amperage Voltage Adjust Switch and Remote Amperage Voltage Adjust Receptacle Process Contactor Selector Switch 120 VAC 20 A GFCI Duplex Receptacle 240 VAC 30A TwistLock Receptacle NEMA L6 30 Fuel Gauge Hour Meter Oil Change Interval Engine Shutdown Indicator Big 40 Diesel CC CV Performance Data CC CV VOLT AMP CURVES STICK MODE Ranges Max 80 155 450 115 320 75 195 40 90 0 0 100 200 300 400 500 600 700 800 900 1000 DC AMPERES CC CV VOLT AMP CURVES MIG MODE DC VOLTS S 8 0 0 100 200 300 400 500 600 700 800 9001000 0 100 200 300 DC AMPERES DC AMPERES Q Milter ad Da Net Weight without fuel 1545 Ib 701 kg H 43 in 1092 mm
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