Big 40® Diesel
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Heavy Industrial |
Processes |
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Applications |
CC and CC/CV Models |
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Petro Chemical Piping |
Stick (SMAW) |
Quick |
Structural Steel Work |
TIG (GTAW) |
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Maintenance and Repair |
Air Carbon Arc (CAC-A) |
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Cutting and Gouging |
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Specs |
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(Rated) 5/16 (7.9 mm) carbons |
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(Capable) 3/8 (9.5 mm) carbons |
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Stud Welding |
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CC/CV Model Only |
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MIG (GMAW) |
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Flux Cored (FCAW) |
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AC TIG (Deluxe Model) |
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Issued October 2008 • Index No. ED/8.5
Diesel Engine-Driven
Welder/Generator
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 |
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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)
Accu-Rated™– Not Inflated
Generator Power
The Power of Blue. |
to operate over 10,000 hours before the |
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CATERPILLAR industrial engine designed |
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AC TIG weld aluminum with deluxe model. |
first basic overhaul. Backed by worldwide |
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CAT support and service. |
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The most AC weld output on any engine |
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NEW! Meter maintenance displays. |
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drive. (High-frequency unit required.) |
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Silenced — only 65 dB (90 Lwa) at idle. |
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Hour meter function |
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Oil change interval |
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73.8 dB at 23 ft (98.7 Lwa) maximum |
Maintenance Displays! |
• High coolant temperature and |
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output. Improves work site communications. |
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low oil pressure shutdowns |
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Automatic idle saves fuel and prolongs |
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• Low fuel shutdown — engine |
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shuts downs before system runs |
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engine life along with reducing the |
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out of fuel, making restarts easy. |
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sound level. |
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Quick and easy maintenance with |
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Simplified control panel provides |
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single-side access to oil level check, |
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easy set-up with fewer controls— |
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oil fill, oil filter, fuel filter and air cleaner. |
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less training is required. |
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Enclosed base and case protects |
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More welding amperage! |
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internal components from corrosive |
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400 amps at 100% Duty Cycle |
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environments and reduces sound levels. |
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450 amps at 60% Duty Cycle |
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Remote toolless oil drain that allows oil to |
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500 amps at 40% Duty Cycle |
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Engine gauges indicate engine oil |
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be drained without getting under the engine |
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and reduces the chance of oil spillage. |
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pressure, and coolant temperature |
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Hot Start™ provides positive Stick electrode |
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(standard on all models). |
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Arc-Drive makes welding easy. |
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starts to make it easy to start all types of |
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electrodes, and works great for bead tie-ins. |
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Automatically enhances Stick |
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welding, especially on pipe, by |
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focusing the arc and preventing |
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the electrode from going out. |
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Standard GFCI receptacle required |
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on most job sites to protect |
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operators from electrical hazards. |
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CSA, IEC, and NEMA compliant for |
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welders. Degree of protection |
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CC/CV Models: The Vault — ultimate |
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provided by enclosure IP23. |
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control board reliability. See page 4. |
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Welder/generator is warranted for 3 years, parts and labor.
The CATERPILLAR engine is warranted for 2 years by CATERPILLAR.
Miller Electric Mfg. Co. |
International Headquarters |
Web Site |
An Illinois Tool Works Company |
Phone: 920-735-4505 |
www.MillerWelds.com |
1635 West Spencer Street |
USA FAX: 920-735-4134 |
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Appleton, WI 54914 USA |
Canadian FAX: 920-735-4169 |
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International FAX: 920-735-4125 |
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Big 40® Diesel CC Specifications (Subject to change without notice.)
Welding |
Weld Output |
Weld Output Rated |
Max. Open- |
Generator Output Rated |
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Net Weight |
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Mode |
Range |
at 104˚F (40˚C) |
Circuit Voltage |
at 104˚F (40˚C) |
Dimensions* |
(without fuel)** |
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CC/DC |
55 – 500 A |
400 |
A at 36 |
VDC (14.4 kW), |
95 |
Peak: 5500 watts |
H: 43 in (1092 mm) |
1540 lb (697 kg) |
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100% Duty Cycle |
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Continuous: 4000 watts, |
W: 28-1/2 in (724 mm) |
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450 |
A at 38 |
VDC (17.1 kW), |
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34/17 A, 120/ 240 VAC, 60 Hz |
D: 64-7/16 in (1637 mm) |
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60% Duty Cycle |
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while welding |
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500 |
A at 30 |
VDC (15 kW), |
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40% Duty Cycle |
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NEMA EWI (ANSI C87.1) Class (1) output ratings. *Additional 7 in (178 mm) to top of exhaust. **Additional 190 lb (86 kg) when fuel tank is full.
Engine Specifications (Subject to change without notice.)
Engine |
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Engine |
Fuel |
Oil |
Coolant |
Automatic Engine |
Brand |
Features |
HP |
Type |
Speeds |
Capacity |
Capacity |
Capacity |
Shutdown |
CATERPILLAR |
Tier IVi, EPA-certified, indirect-injected, |
32.6 |
Four-cylinder, |
Run: 1850 RPM |
25 gal |
9 qt |
9 qt |
Oil Pressure |
Tier IVi, |
liquid-cooled diesel engine. Right-side |
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industrial, |
Idle: 1250 RPM |
(95 L) |
(8.5 L) |
(8.5 L) |
Coolant Temperature |
C2.2 Diesel |
service access with service intervals of |
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liquid-cooled |
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500 hours for oil and filters. |
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diesel |
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Big 40® Diesel CC Control 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.
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9 |
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14 |
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1.DC Ammeter*
2.DC Voltmeter*
3.Amperage Adjust Control
4.Amperage Range Switch
5.Amperage Adjust Switch and Remote Amperage Adjust Receptacle
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8 |
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6. |
Stick/TIG Selector Switch |
10. Engine Oil Pressure Gauge |
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7. |
120 VAC, 20 A GFCI Duplex Receptacle |
11. Battery Voltmeter* |
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8. |
240 VAC, 30 A TwistLock Receptacle |
12. |
Engine Coolant Temperature Gauge |
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(NEMA L6-30) |
13. |
Engine Control Switch |
9. |
Fuel Gauge/Hour Meter/Oil Change Interval/ |
14. |
Starting Aid Switch |
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Engine Shutdown Indicator |
15. |
Polarity Switch* |
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*Optional on select models.
Big 40® Diesel CC Performance Data
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CC/DC VOLT/AMP CURVES |
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100 |
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Ranges |
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80 |
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230 |
– Max |
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VOLTS |
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170 |
– 365 |
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60 |
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110 |
– 225 |
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70 |
– 130 |
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55 |
– 85 |
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DC |
40 |
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20 |
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100 |
200 |
300 |
400 |
500 |
600 |
700 |
800 |
900 1000 |
DC AMPERES
GENERATOR POWER CURVE
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150 |
300 |
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125 |
250 |
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4 kW |
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5.5 kW |
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VOLTS |
100 |
200 |
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75 150 |
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AC |
50 |
100 |
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25 |
50 |
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0 |
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5 |
10 |
15 |
20 |
25 |
30 |
AC AMPERES IN 240 V MODE
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10 |
20 |
30 |
40 |
50 |
60 |
AC AMPERES IN 120 V MODE
FUEL CONSUMPTION CURVE
7.57 |
2.00 |
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6.62 |
1.75 |
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5.68 |
1.50 |
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4.73 |
1.25 |
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3.79 |
1.00 |
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2.84 |
0.75 |
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1.89 |
0.50 |
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0.95 |
0.25 |
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IDLE |
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0.00 |
0.00 |
0 |
50 |
100 |
150 |
200 |
250 |
300 |
350 |
400 |
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US Liters/Hr. |
US Gal./Hr. |
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DC WELD AMPERES |
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AT 100% DUTY CYCLE |
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2
Big 40® Diesel CC/CV Specifications (Subject to change without notice.)
Welding |
Weld Output |
Weld Output Rated |
Max. Open- |
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Net Weight |
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Mode |
Range |
at 104˚F (40˚C) |
Circuit Voltage |
Generator Power Output Rated |
Dimensions* |
(without fuel)** |
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CC/DC |
20 – 550 A |
400 |
A at 36 VDC (14.4 kW), |
95 |
Peak: 5000 watts |
H: 43 in |
1545 lb |
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100% Duty Cycle |
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Continuous: 4000 watts, 34/17 A, |
(1092 mm) |
(701 kg) |
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CV/DC |
14 – 40 V |
450 |
A at 38 VDC (17.1 kW), |
56 |
120/240 VAC, 60 Hz while welding |
W: 28-1/2 in |
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60% Duty Cycle |
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Deluxe Model Additional Power Plant: |
(724 mm) |
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500 |
A at 34 VDC (17 kw), |
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1-phase, 12 kW, 50 A, 120/240 VAC, 60 Hz; or |
D: 64-7/16 in |
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40% Duty Cycle |
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3-phase, 15 kW, 36 A, 240 VAC, 60 Hz while |
(1637 mm) |
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not welding |
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CC/AC |
15 – 375 A |
300 |
A at 32 VAC (9.6 kW), |
65 |
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(Deluxe |
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100% Duty Cycle |
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Model) |
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335 |
A at 33 V (11.1 kW), |
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60% Duty Cycle |
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375 |
A at 35 V (13.1 kW), |
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40% Duty Cycle |
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NEMA EWI (ANSI C87.1) Class (1) output ratings. *Additional 7 in (178 mm) to top of exhaust. **Additional 190 lb (86 kg) when fuel tank is full. |
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Big 40® Diesel CC/CV Control Panel |
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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 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.
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10 |
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12 |
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14 |
Process/Contactor Selector Switch |
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16 17
18
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1. |
DC Ammeter* |
10. |
Engine Oil Pressure Gauge |
2. |
DC Voltmeter* |
11. |
Battery Voltmeter* |
3. |
Amperage/Voltage Adjust Control |
12. |
Engine Coolant Temperature Gauge |
4. |
Ampere Range Switch |
13. |
Engine Control Switch |
5. |
Amperage/Voltage Adjust Switch and Remote |
14. |
Starting Aid Switch |
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Amperage/Voltage Adjust Receptacle |
15. |
3-Phase Power Generator Option* |
6. |
Process/Contactor Selector Switch |
16. |
Strain Relief* |
7. |
120 VAC, 20 A GFCI Duplex Receptacle |
17. |
50 A, 3-Phase Circuit Breaker |
8. |
240 VAC, 30A TwistLock Receptacle |
18. |
50 A, 120/240 V Receptacle |
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(NEMA L6-30) |
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(NEMA 14-50)* |
9. |
Fuel Gauge/Hour Meter/Oil Change Interval/ |
19. |
AC/DC Polarity Switch* |
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Engine Shutdown Indicator |
*Optional on select models. |
Big 40® Diesel CC/CV Performance Data
CC/CV VOLT/AMP CURVES |
CC/CV VOLT/AMP CURVES |
STICK MODE |
MIG MODE |
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100 |
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100 |
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Ranges |
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80 |
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Max |
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80 |
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155 |
– 450 |
DC VOLTS |
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DC VOLTS |
60 |
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115 – 320 |
60 |
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75 |
– 195 |
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40 |
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40 |
– 90 |
40 |
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MAX |
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20 |
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20 |
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0 |
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0 |
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0 |
100 |
200 |
300 |
400 |
500 |
600 |
700 |
800 |
900 1000 |
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0 |
100 |
200 300 400 |
500 600 700 800 |
900 1000 |
DC AMPERES |
DC AMPERES |
CC/CV VOLT/AMP CURVES |
CC/CV VOLT/AMP CURVES |
TIG MODE |
AC TIG MODE |
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100 |
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100 |
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Ranges |
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80 |
Ranges |
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80 |
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60 – 365 |
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55 |
– 350 |
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35 – 250 |
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VOLTS |
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35 |
– 205 |
VOLTS |
60 |
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25 – 155 |
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60 |
25 |
– 105 |
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15 – 75 |
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15 |
– 45 |
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40 |
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40 |
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DC |
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AC |
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20 |
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100 |
200 |
300 |
400 |
500 |
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0 |
50 100 150 200 250 300 350 400 |
450 500 |
DC AMPERES
AC AMPERES
3