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Miller Electric Big 40 Diesel User Manual

Miller Electric Big 40 Diesel
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Processes
CC and CC/CV Models
Stick (SMAW)
TIG (GTAW)
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)
Output Range
CC: DC Stick 55 500 A DC/TIG 55 500 A
CC/CV: DC Stick 40 550 A 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)
Heavy Industrial
Applications
Petro Chemical Piping
Structural Steel Work
Maintenance and Repair
Quick
Specs
Big 40
®
Diesel
Diesel Engine-Driven
Welder/Generator
Issued April 2008 • Index No. ED/8.5
Simplified control panel provides
easy set-up with fewer controls
less training is required.
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.
Hot Start
provides positive Stick electrode
starts to make it easy to start all types of
electrodes, and works great for bead tie-ins.
Automatic idle saves fuel and prolongs
engine life along with reducing the
sound level.
Arc-Drive makes welding easy.
Automatically enhances Stick
welding, especially on pipe, by
focusing the arc and preventing
the electrode from going out.
The Power of Blue
®
.
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Web Site
www.MillerWelds.com
International Headquarters
Phone: 920-735-4505
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX: 920-735-4125
CATERPILLAR industrial engine designed
to operate over 10,000 hours before the
first basic overhaul. Backed by worldwide
CAT support and service.
Silenced only 65 dB (90 Lwa) at idle.
73.8 dB at 23 ft (98.7 Lwa) maximum
output. Improves work site communications.
Enclosed base and case protects
internal components from corrosive
environments and reduces sound levels.
Welder/generator is warranted for 3 years, parts and labor.
The CATERPILLAR engine is warranted for 2 years by CATERPILLAR.
Quick and easy maintenance with
single-side access to oil level check,
oil fill, oil filter, fuel filter and air cleaner.
Remote toolless oil drain that allows oil to
be drained without getting under the engine
and reduces the chance of oil spillage.
AC TIG weld aluminum with deluxe model.
The most AC weld output on any engine
drive. (High-frequency unit 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).
CC/CV Models: The Vault ultimate
control board reliability. See page 4.
NEW!
Meter maintenance displays.
Hour meter function
Oil change interval
High coolant temperature and
low oil pressure shutdowns
Low fuel shutdown — engine
shuts downs before system runs
out of fuel, making restarts easy.
Accu-Rated
Not Inflated
Generator Power
Improved!
Maintenance Displays!

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Miller Electric Big 40 Diesel Specifications

General IconGeneral
BrandMiller Electric
ModelBig 40 Diesel
CategoryWelding System
LanguageEnglish

Summary

Quick Specs

Heavy Industrial Applications

Lists applications like Petro Chemical Piping, Structural Steel Work, Maintenance and Repair.

Processes

Lists welding processes like Stick (SMAW), TIG (GTAW), Air Carbon Arc, Stud Welding, MIG (GMAW), Flux Cored.

Output Range

Details CC and CC/CV output ranges for Stick, TIG, MIG/FCAW.

Generator Output Rated at 104°F (40°C)

Specifies peak and continuous wattage for generator output.

Accu-Rated Generator Power

Explains the generator power rating methodology for accuracy.

Product Benefits

CATERPILLAR Industrial Engine

Features CAT engine for over 10,000 hours before overhaul, backed by worldwide support.

Meter Maintenance Displays

Includes hour meter, oil change interval, and shutdown indicators for engine monitoring.

Simplified Control Panel

Easy setup with fewer controls, requiring less training for operators.

More Welding Amperage

Provides high amperage ratings at various duty cycles for demanding applications.

Engine Gauges

Standard gauges monitor oil pressure and coolant temperature for engine health.

Arc-Drive

Enhances Stick welding, especially on pipe, by focusing the arc.

Standard GFCI Receptacle

Required on job sites to protect operators from electrical hazards.

CC Specifications

Engine Specifications

Details engine brand, features, HP, speeds, capacities, and shutdown features.

CC Control Panel Overview

Identifies and explains the functions of the various controls on the CC model's panel.

CC Performance Data

Presents graphical data for CC/DC volt/amp curves, generator power, and fuel consumption.

CC/CV Specifications

CC/CV Control Panel Overview

Identifies and explains the functions of the various controls on the CC/CV model's panel.

CC/CV Performance Data

Presents graphical data for CC/CV volt/amp curves across different welding modes.

CC Model Options

Weld Ammeter and Voltmeter Kit

Panel-mounted analog meters to monitor welding output.

Cold Weather Starting Aid Kit

Includes a 120 V block heater for cold weather operation.

DC Polarity Reversing Switch Kit

Allows changing DC polarity without tools.

CC/CV Model Options

Weld Ammeter and Voltmeter Kit

Panel-mounted analog meters for welding output monitoring.

AC/DC Polarity Reversing Switch Kit

Changes DC+/AC/DC- polarity without tools.

Battery Voltmeter

Monitors the battery charging circuit for health.

Cold Weather Starting Aid Kit

Includes a 120 V block heater for cold weather starting.

15,000 Watt Generator Plant

Provides 15 kW 3-phase or 12 kW 1-phase power while not welding.

The Vault Technology

Superior Circuit Board Design

Protects critical circuit boards from harsh elements for enhanced reliability.

Upgrading to CC/CV Units

Addresses concerns about circuit board reliability for CC/CV welder/generators.

Genuine Miller Accessories

Fuel Cap and Spark Arrestor

Lockable flame arrestor fuel cap and spark arrestor muffler kit for safety.

Vandalism Lockout Kit

Protects name plate gauges and ignition switch with lockable panels.

Cable Holder

Saddle-bag style holder for convenient wrap-around storage of coiled cable.

Roll Cage/Drip Pan

Heavy-duty galvanized steel structure for machine protection and drip containment.

Canvas Cover

Attractive, waterproof canvas cover resists stains and mildew, protecting the welder's finish.

Stick (SMAW) Welding Accessories

Includes weld leads with different amperage and length specifications.

Plasma Cutting Equipment

Lists Spectrum X-TREME and Spectrum 625 models for plasma cutting.

MIG (GMAW) Wire Feeders

Features SuitCase X-TREME and Millermatic Passport Plus wire feeders.

MIG/FCAW Guns and Spoolmatic

Details MIG guns, Spoolmatic 30A spool gun, and WC-24 control.

TIG (GTAW) Equipment

Highlights Dynasty 200 Series and HF-251 Series for TIG welding.

Remote Controls and Trailers

Remote Controls for CC Models

Includes RHC-3GD34A remote hand control for amperage adjustment.

Remote Controls for CC/CV Models

Lists RHC-14, RFCS-14 HD, RMLS-14, RCC-14, RCCS-14 for various control functions.

Extension Cords for Remotes

Provides extension cords in various lengths for 14-pin remote controls.

Trailers for Welding Units

Details 4 West, HWY-224, OFR-224, and HWY-430 trailers with specifications.

Trailer Hitches and Accessories

Includes lunette eyes, ball hitches, and cable trees for trailer setup.

Typical Installations

Stick (SMAW) Basic Equipment

Diagram showing basic Stick welding setup with electrode and work connection.

Flux-Cored (FCAW) Basic Equipment

Diagram showing FCAW setup with wire feeder and flux-cored gun.

MIG (GMAW) Basic Equipment

Diagram showing GMAW setup with wire feeder and MIG gun.

Aluminum MIG (GMAW) Basic Equipment

Diagram showing aluminum MIG setup with Spoolmatic gun and WC-24 control.

TIG (GTAW) Basic Equipment

Diagram showing TIG welding setup with TIG torch and HF-251D-1.

Plasma Basic Equipment

Diagram showing plasma cutting setup with Spectrum torch.

Ordering Information

Power Source and Factory Options

Lists stock numbers and descriptions for Big 40 Diesel CC and CC/CV power sources.

Field Kit Accessories

Details stock numbers and descriptions for various field kits and accessories.

Stick Accessories

Lists stock numbers and descriptions for stick welding accessory kits.

MIG/Flux Cored Accessories

Lists stock numbers and descriptions for MIG/Flux Cored wire feeders and guns.

TIG Accessories

Lists stock numbers for TIG accessories like Dynasty 200 Series and arc starters.

Remote Controls

Lists stock numbers and descriptions for various remote controls for CC and CC/CV models.

Trailers and Hitches

Lists stock numbers and descriptions for trailers, hitches, and related accessories.

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