Miller-electric Big 40 User Manual download pdf

Processes

CC and CC/CV Models

Stick (SMAW)

TIG (GTAW)

Air Carbon Arc (CAC-A)

(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 September 2010 • Index No. ED/8.5

Simplified control panel provides

easy set-up with fewer controls—

less training is required.

GFCI receptacle as 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

Heavy-duty low-speed industrial diesel

engine is 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.

73.2 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 standard on all

models indicate engine oil pressure

and coolant temperature.

CC/CV Models: The Vault—ultimate

control board reliability. See page 4.

Meter maintenance displays

• Fuel gauge

• Hour meter function

• Oil change interval

• High coolant temperature and

low oil pressure shutdowns

• Low fuel shutdown — engine

shuts down before system runs

out of fuel, making restarts easy.

Accu-Rated

™

–Not Inflated

Generator Power

EPA Tier 4i

Compliant

EPA Tier 4i

Compliant

EPA Tier 4i

Compliant

EPA Tier 4i

Compliant

Big 40 CC/CV Deluxe Model shown.

1 2 3 4 5 6 7 8

Summary of Contents

Page 1 - The Power of Blue

ProcessesCC and CC/CV ModelsStick (SMAW) TIG (GTAW) Air Carbon Arc (CAC-A)(Rated) 5/16 (7.9 mm) Carbons(Capable) 3/8 (9.5 mm) CarbonsStud WeldingCC/CV

Page 2 - Additional Features

2Big 40®Diesel CC Control PanelWeldingModeCC/DCBig 40®Diesel CC Specifications (Subject to change without notice.)Max. Open-Circuit Voltage95Weld Out

Page 3

3Big 40®Diesel CC/CV Control PanelWeldingModeCC/DCCV/DCCC/AC(DeluxeModel)Big 40®Diesel CC/CV Specifications (Subject to change without notice.)Max. O

Page 4 - Diesel CC/CV Options

4Big 40®Diesel CC OptionsWeld Ammeter and Voltmeter Kit#195 131 FieldPanel-mounted analog meters monitor welding output.Installation time: 35 minutesC

Page 5 - Genuine Miller Accessories

Genuine Miller Accessories (Continued)Engine Filter Kit #246 985 FieldIncludes all filters required for properengine maintenance. Oil filter, pri

Page 6 - Mounting Specifications

6Genuine Miller Accessories (Continued)Remote Controls (CC models only)RHC-3GD34A Remote Hand Control #041 122Allows for precise adjustmentof ampe

Page 7 - X-TREME 12VS

7MIG Gun Work SuitCase 8RC/12RC Work Stick Electrode Work Flux Cored Gun Aluminum MIG with Spoolmatic 30A Gun Work Cutting Torch Work Spectrum 14-Pi

Page 8 - Ordering Information

Litho in USADistributed by:Power Source and Factory Options Stock No. Description Qty. PriceBig 40®Diesel CC #907 171 CSA Model with Engine Gauges an

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Miller-electric Big 40 User Manual

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Summary of Contents

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