Miller Electric Big 40 Diesel Owner's Manual

cover 6/93 – ST-111 216-A PRINTED IN USARead and follow these instructions and allsafety blocks carefully.Have only trained and qualified personsinsta

OM-880 Page 6Rectifier SR3:Connect CV-2 Leads17 And 27 WithExisting LeadsOn SR3FRONTBIG 30 DIESEL And BIG 30A DIESELRectifier SR3Range Switch S3:Conne

OM-880 Page 718. Disconnect leads 623 and 625 at insulated fric-tion terminals, and connect these leads to thematching leads from the CV-2 panel (see

OM-880 Page 8SB-112 332-ALEFTFRONTWeldingGenerator FrameBig 40 Diesel, Big 40G, AndBig 50 Diesel TransformerMounting BracketTransformerT2RIGHTUse Swit

OM-880 Page 9the welding power source. To connect the Remote Con-tactor and/or Amperage or Voltage Control to the RE-MOTE-5 receptacle, align keyway,

OM-880 Page 10SA-112 730WeldingGeneratorConnection To CV-2 5-SocketAmphenolReceptacle RC3WorkElectrode HolderOptional RemoteContactor AndAmperage Cont

OM-880 Page 11SA-112 734WeldingGeneratorGas Supply WithFlowmeter AndRegulatorGas HoseElectrode CableConnection To CV-214-Socket AmphenolReceptacle RC4

OM-880 Page 12SA-112 734WeldingGeneratorGas Supply WithFlowmeter AndRegulatorGas HoseElectrode CableConnection To CV-214-Socket AmphenolReceptacle RC4

OM-880 Page 13SECTION 4 – OPERATOR CONTROLSSC-111 216-ACircuitBreaker CB5Remote-14Receptacle RC4Circuit Breaker CB6Output/ContactorSwitch S10Current C

OM-880 Page 14When a Remote Current or Voltage Control is beingused, the remote control functions as a fine amperageor voltage adjustment for the AMP

OM-880 Page 15SECTION 5 – SEQUENCE OF OPERATIONWARNING: ELECTRIC SHOCK can kill;MOVING PARTS can cause serious injury;IMPROPER AIRFLOW AND EXPOSURE T

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

OM-880 Page 1610. If remote contactor control is not used, place theCV-2 OUTPUT/CONTACTOR switch in the ONposition. If remote contactor control is to

OM-880 Page 175. If high frequency is desired, install and connectthe high frequency unit according the the equip-ment Owner’s Manual.6. Select and ob

OM-880 Page 18SECTION 6 – MAINTENANCE & TROUBLESHOOTING6-1. ROUTINE MAINTENANCEIMPORTANT: Every six months inspect the labels onthis unit for leg

OM-880 Page 19SC-112 013-AVoltage ControlBoard PC4Wiring Harness PlugStandoffSupport (4)Contactor ControlBoard PC3Wiring Harness PlugStandoff Support

OM-880 Page 20Table 6-2. Tungsten Electrode SizeElectrode DiameterPure Tungsten.010”.020”.040”1/16”3/32”1/8”5/32”3/16”1/4”2% Thorium Alloyed Tungsten.

OM-880 Page 21Stable ArcStraight GroundFlat(The Dia. Of ThisFlat GovernsAmperage Capacity)Arc WanderPointRadial GroundTUNGSTEN PREPARATION: IDEALTUNG

OM-880 Page 22Table 6-3. TroubleshootingTROUBLE PROBABLE REMEDYWire feeder inoperative. Circuit breaker CB5 or CB6 open. Reset CB5 or CB6 according to

OM-880 Page 23SECTION 7 – ELECTRICAL DIAGRAMCircuit Diagram No. SB-110 336-BDiagram 7-1. Circuit Diagram For CV-2Ref. D-111 326-NDiagram 7-2. Wiring D

OM-880 Page 24SECTION 8 – PARTS LIST

OM-880 Page 25SD-111 208-B123456787910111213141516171819Figure 8-1. Main Assembly

OM-880B – 7/93TABLE OF CONTENTSSection No. Page No.SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS1-1. General Information And Safety 1. . . . . . . .

OM-880 Page 26Description QuantityPartNo.Dia.Mkgs.Figure 8-1. Main AssemblyItemNo.1 S1 112 003 SWITCH, polarity 1. . . . . . . . . . . . . . . . .

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 7/00Your distributor also givesyou ...ServiceYou always get the fa

PRINTED IN USA  2000 Miller Electric Mfg. Co. 6/00Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US

OM-880 Page 1SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS1-1. GENERAL INFORMATION AND SAFETYA. GeneralInformation presented in this manual and on v

OM-880 Page 2Chart 2-1. DC Volt-Ampere Curves(CV Mode)A. BIG 30 DIESEL And BIG 30A DIESEL ModelsB. BIG 40 DIESEL And BIG 40G ModelsC. BIG 50 DIESEL

OM-880 Page 32-1. VOLT-AMPERE CURVES (Charts 2-1 And2-2)The volt-ampere curves show the output voltage andamperage of the welding generator available

OM-880 Page 4ST-145 421Transformer T2Installed OntoBase MountingStripRight Front CoverOf UnitBIG 30 DIESELAnd BIG 30A DIESELTransformer T2 Installatio

OM-880 Page 5SB-112 688-ALeft Front Upright WhenViewed From FrontOf Control PanelElectrode (Negative)Weld Output TerminalWeld OutputTerminal AssemblyW