®
Issued October 2008 • Index No. ED/8.5
Diesel Engine-Driven
Welder/Generator
Big 40 Diesel
Heavy Industrial
Applications
Processes
Output Range
CC:
DC Stick 55–500 A
CC/CV: DC Stick 40–550 A
AC TIG 15–375 A
DC/TIG 55–500 A
DC/TIG 20–350 A
MIG/FCAW 14–40 V
CC and CC/CV Models
Stick (SMAW)
Petro Chemical Piping
Structural Steel Work
Maintenance and Repair
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
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)
Quick
Specs
CC/CV Model Only
MIG (GMAW)
Flux Cored (FCAW)
AC TIG (Deluxe Model)
Accu-Rated™–Not Inflated
Generator Power
®
CATERPILLAR industrial engine designed
to operate over 10,000 hours before the
first basic overhaul. Backed by worldwide
CAT support and service.
The Power of Blue.
AC TIG weld aluminum with deluxe model.
The most AC weld output on any engine
drive. (High-frequency unit required.)
NEW! Meter maintenance displays.
• Hour meter function
• Oil change interval
• High coolant temperature and
Improved!
Maintenance Displays!
Silenced—only 65 dB (90 Lwa) at idle.
73.8 dB at 23 ft (98.7 Lwa) maximum
output. Improves work site communications.
low oil pressure shutdowns
• Low fuel shutdown — engine
shuts downs before system runs
out of fuel, making restarts easy.
Automatic idle saves fuel and prolongs
engine life along with reducing the
sound level.
Simplified control panel provides
easy set-up with fewer controls—
less training is required.
Quick and easy maintenance with
single-side access to oil level check,
oil fill, oil filter, fuel filter and air cleaner.
More welding amperage!
400 amps at 100% Duty Cycle
450 amps at 60% Duty Cycle
500 amps at 40% Duty Cycle
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.
Engine gauges indicate engine oil
pressure, and coolant temperature
(standard on all models).
Hot Start™ provides positive Stick electrode
starts to make it easy to start all types of
electrodes, and works great for bead tie-ins.
Arc-Drive makes welding easy.
Automatically enhances Stick
welding, especially on pipe, by
focusing 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.
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 Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters Web Site
Phone: 920-735-4505
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX: 920-735-4125
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®
Big 40 Diesel CC/CV Specifications
(Subject to change without notice.)
Welding
Weld Output
Weld Output Rated
at 104˚F (40˚C)
Max. Open-
Net Weight
(without fuel)**
Mode
Range
Circuit Voltage
Generator Power Output Rated
Dimensions*
CC/DC
20–550 A
400 A at 36 VDC (14.4 kW),
100% Duty Cycle
95
Peak: 5000 watts
Continuous: 4000 watts, 34/17 A,
120/240 VAC, 60 Hz while welding
H: 43 in
1545 lb
(701 kg)
(1092 mm)
W: 28-1/2 in
(724 mm)
D: 64-7/16 in
(1637 mm)
450 A at 38 VDC (17.1 kW),
60% Duty Cycle
56
65
CV/DC
14–40 V
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
500 A at 34 VDC (17 kw),
40% Duty Cycle
CC/AC
(Deluxe
Model)
15–375 A
300 A at 32 VAC (9.6 kW),
100% Duty Cycle
335 A at 33 V (11.1 kW),
60% Duty Cycle
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. **Additional 190 lb (86 kg) when fuel tank is full.
®
Big 40 Diesel CC/CV Control Panel
1
9
Additional Features
A multi-colored process selector control
allows quick and easy process changes
without having to use multiple switches.
2
3
4
10
11
12
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.
13
14
5
6
Process/Contactor Selector Switch
5
15
16
17
7
8
18
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.
19
1. DC Ammeter*
2. DC Voltmeter*
3. Amperage/Voltage Adjust Control
4. Ampere Range Switch
5. Amperage/Voltage Adjust Switch and Remote
Amperage/Voltage Adjust Receptacle
6. Process/Contactor Selector Switch
7. 120 VAC, 20 A GFCI Duplex Receptacle
8. 240 VAC, 30A TwistLock Receptacle
(NEMA L6-30)
10. Engine Oil Pressure Gauge
11. Battery Voltmeter*
12. Engine Coolant Temperature Gauge
13. Engine Control Switch
14. Starting Aid Switch
15. 3-Phase Power Generator Option*
16. Strain Relief*
17. 50 A, 3-Phase Circuit Breaker
18. 50 A, 120/240 V Receptacle
(NEMA 14-50)*
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. Fuel Gauge/Hour Meter/Oil Change Interval/
Engine Shutdown Indicator
19. AC/DC Polarity Switch*
*Optional on select models.
®
Big 40 Diesel CC/CV Performance Data
CC/CV VOLT/AMP CURVES
STICK MODE
CC/CV VOLT/AMP CURVES
MIG MODE
CC/CV VOLT/AMP CURVES
TIG MODE
CC/CV VOLT/AMP CURVES
AC TIG MODE
100
80
60
40
20
0
100
80
60
40
20
0
100
100
80
Ranges
Ranges
Ranges
55 – 350
35 – 205
25 – 105
15 – 45
Max
155 – 450
115 – 320
75 – 195
40 – 90
60 – 365
35 – 250
25 – 155
15 – 75
80
60
40
60
MAX
40
20
20
0
MIN
0
0
100 200 300 400 500 600 700 800 900 1000
DC AMPERES
0
100
200
300
400
500
0
100 200 300 400 500 600 700 800 9001000
DC AMPERES
0
50 100 150 200 250 300 350 400 450 500
AC AMPERES
DC AMPERES
3
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®
Big 40 Diesel CC Options
Weld Ammeter and Voltmeter Kit
#195 131 Field
Panel-mounted analog meters monitor
Battery Voltage Gauge
#195 454 Field
Monitors battery charging circuit.
welding output.
Installation time: 35 minutes
DC Polarity Reversing Switch Kit
#043 942 Field
Changes DC polarity without the use of tools.
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.
®
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
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.
AC/DC Polarity Reversing Switch Kit
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.
#195 095 Field
+
Changes DC /AC/DC- without the use
5
of tools. Deluxe model comes standard
with AC/DC polarity switch.
Installation time: 35 minutes
Note: Available as factory option.
See Ordering Information on back page.
The Vault
Superior Circuit Board Design
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.
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.
Created out of two 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
“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
circuit boards exposed to harsh elements that
can disrupt the machine’s electronics, and
therefore, its operation.
4
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Genuine Miller Accessories
(Continued)
FA-1D Lockable Flame Arrestor
Fuel Cap #043 947 Field
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
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
™
SuitCase 8RC Wire Feeder #194 938
Plasma Cutting
™
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.
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.
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.
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.
Vandalism Lockout Kit
#195 118 Field
Spoolmatic® 30A
Spool Gun
#130 831
Air-cooled, 200-amp,
1-lb spool gun for
Lockable hinged steel
panels cover and protect
name plate gauges and
ignition switch (padlock
included). Also includes
engine compartment door
lock and key.
Spectrum 2050 #903 777-01-2
See Lit. Index No. PC/7.0.
aluminum MIG. See Lit. Index No. M/1.73.
WC-24 Control #137 549
Use with Spoolmatic 30A.
MIG (GMAW) or Flux Cored (FCAW)
Millermatic®
Cable Holder #043 946
Saddle-bag-style cable
holder. Convenient wrap-
around storage of coiled
cable for transportation.
Stores 100 ft of 2/0 cable
on each side.
XR™ Wire Feeders and Guns
Passport® Plus
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.
#907 401
Portable, all-in-one
MIG package
features ultimate
arc performance,
self-contained gas
TIG (GTAW) Welding
Note: For best results do not weld when cable is coiled!
Canvas cover cannot be used with cable holder.
bottle, and flexibility to plug into 115 or 230
V power with Miller exclusive Multi-Voltage
Plug. See Lit. Index No. DC/12.53.
Dynasty® 200 Series
For premium portable
AC/DC TIG arc quality.
See Lit. Index No.
AD/4.8.
Roll Cage/Drip Pan
#194 918 Field
Heavy-duty galvanized
steel structure
designed to protect the
machine. The roll cage
meets offshore oil
platform requirements with a drip pan and
drain plug along with a heavy-duty lift eye.
HF-251 Series
#042 388
HF-251D-1, 115 VAC
#042 387
HF-251D-2, 230 VAC
High-frequency arc
™
™
SuitCase X-TREME 8VS Wire Feeder
#300 093
Canvas Cover (Blue)
#194 683 Field
Attractive, waterproof
canvas cover resists
stains and mildew,
and protects the
™
™
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.
starter and stabilizer.
See Accessory Lit. Index No. AY/5.0.
finish of your welder.
Note: Canvas cover cannot be used with cable holder.
5
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Genuine Miller Accessories
Remote Controls (CC models only)
(Continued)
RFCS-14 HD Foot
Control #194 744
Foot current and
contactor control.
20 ft (6 m) cord and 14-pin plug. Rotary-motion fingertip control
14-pin plug.
RCC-14 Remote
Contactor and
Current Control
#151 086
RHC-3GD34A Remote
Hand Control #041 122
Allows for precise
adjustment of amperage.
Includes 20 ft (6 m) cord.
®
fastens to TIG torch using two Velcro straps.
Includes 28 ft (8.5 m) control cord.
RMLS-14
#129 337
Fingertip
RCCS-14 Remote
Contactor and
Current Control
Remote Controls (CC/CV models)
momentary- and maintained-contact rocker
switch for contactor control. Push forward
for maintained contact and back for
momentary contact. Includes 20 ft (6 m)
cord and 14-pin plug.
RHC-14 Hand Control
#129 340
#043 688
Up-and-down rotary-motion fingertip control
Miniature hand control for
remote current and contactor
control. Dimensions: 4 x 4 x
3-1/4 in (102 x 102 x 82 mm). Includes 20 ft
(6 m) cord and 14-pin plug.
®
fastens to TIG torch using two Velcro
straps. Includes 28 ft (8.5 m) control cord.
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
(For both models.)
HWY-224 Trailer #043 805 For highway use.
OFR-224 Trailer #043 802 For off-road use.
A 2650 lb (1202 kg) capacity trailer. Welded
steel tubing frame, heavy-duty axle with roller
bearing hubs and leaf-spring suspension.
Includes jack stand, 2 in (50 mm) ball hitch.
HWY-224 also includes fenders and lights.
Note: Trailer is shipped unassembled.
4 West Four-Wheel Steerable
Off-Road Trailer #042 801
HWY-430 Tandem Axle Trailer #043 806
Smooth riding with 3750 lb (1701 kg) capacity.
Includes hand-operated parking brake, hydraulic
brake system, and a break-away device to lock
brakes if the trailer comes loose. Includes jack
stand, fenders and lights. (Hitch must be
ordered separately.)
A heavy-duty 2570 lb (1166 kg) capacity trailer
designed for use in mines, quarries, and other
rough terrain. Has narrow 22 ft (6.7 m) turning
radius. Includes 3 in lunette eye, universal hitch
and safety chains.
Note: Trailer is shipped unassembled.
Note: Some assembly required.
Cable Tree #043 826
Provides an area to conveniently wrap weld
cables and extension cords.
Cable Tree #043 826
Provides an area to conveniently wrap weld
cables and extension cords.
Lunette Eye 2-1/2 in (64 mm) #043 824
Ball Hitch 2 in (50 mm) #043 864
Lunette Eye 3 in (76 mm) #043 863
Trailer Specifications (Subject to change without notice.)
Track (Center Standard Tires
Gross Axle
Weight Rating Weight Rating Payload
Gross Vehicle Net
Height
of Bed
Road
Clearance tires)
8 in 55-1/4 in
to center of
(Standard rating
or P-size rating) Dimensions
Net
Weight
Model
4 West
2000 lb/axle
(907 kg/axle)
3000 lb
(1361 kg)
2570 lb
21-1/4 in
B78-13
Length: 91 in (2311 mm)**
Width: 61-1/4 in (1556 mm)
430 lb
(195 kg)
(1166 kg) (540 mm) (203 mm) (1403 mm)
2650 lb 7-1/2 in 52 in
18-1/2 in
(1202 kg) (470 mm) (191 mm) (1321 mm)
HWY-224 3500 lb
OFR-224 (1588 kg)
2960 lb
(1343 kg)
B78-13B
Length: 122-1/2 in (3112 mm) 355 lb
Width: HWY– 61 in (1549 mm)* (161 kg)
OFR–58-1/2 in (1486 mm)
HWY-430 2200 lb/axle
4280 lb
(1941 kg)
3750 lb
19-1/4 in
8-1/2 in
52 in
B78-13B
Length: 156-1/2 in (3975 mm) 530 lb
(998 kg/axle)
(1701 kg) (489 mm) (216 mm) (1321 mm)
Width: 61 in (1549 mm)*
(240 kg)
*Width at outside of fenders. **Does not include tongue.
6
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Typical Installations
Stick Electrode
Stick (SMAW) Basic Equipment
Work
Flux-Cored (FCAW) Basic Equipment
Flux Cored Gun
™
™
SuitCase X-TREME 8VS
#300 093
X-TREME 8VS/
X-TREME 12VS
Feeder
™
™
SuitCase X-TREME 12VS #195 500
Work
MIG (GMAW) Basic Equipment
14-Pin
™
MIG Gun
SuitCase 8RC
#194 938
#194 940
SuitCase
8RC/12RC
™
SuitCase 12RC
Work
Aluminum MIG with
Spoolmatic 30A Gun
Aluminum MIG (GMAW) Basic Equipment
14-Pin
14-Pin
Spoolmatic® 30A #130 831
WC-24
WC-24
#137 549
Work
TIG (GTAW) Basic Equipment
TIG
Torch
Dynasty® 200 Series
HF-251D-1
*TIG power cable adapter required
#042 388*
HF-251D-1
Work
Cutting Torch
Plasma Basic Equipment
™
®
Spectrum 375 X-TREME #907 303
™
™
®
Spectrum 375 X-TREME with X-CASE
Spectrum
#907 339
#907 058
#903 777-01-2
®
Spectrum 625
®
Spectrum 2050
Work
7
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Ordering Information
Power Source and Factory Options
Stock No.
Description
Qty.
Price
Big 40® Diesel CC
Big 40® Diesel CC/CV
#907 171
#907 170
CSA model with engine gauges and automatic idle
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
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
#195 131
#195 454
#043 942
#195 095
#195 056
#043 947
#195 012
#195 118
#043 946
#194 918
#194 683
Standard on deluxe model
Changes DC polarity positive to negative
For CC/CV models. Standard on deluxe model
120 V block heater
Padlock not included
Horizontal externally mounted
Lockable front control panel and engine compartment
Saddle-bag-style. Fastens to machine
Roll Cage/Drip Pan
Canvas Cover
Field. Cannot be used with cable holder
Stick Accessories
Accessory Kits
#173 851
#043 952
2/0, 350 A, 100% duty cycle, 50 ft (15 m) stinger, 50 ft (15 m) work clamp
2/0, 300 A, 100% duty cycle, 100 ft (30.5 m) stinger, 50 ft (15 m) work clamp
MIG/Flux Cored Accessories
Millermatic® Passport® Plus
SuitCase™ X-TREME™ 8VS
SuitCase™ X-TREME™ 12VS
SuitCase™ 8RC
#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
SuitCase™ 12RC
MIG (GMAW)/Flux Cored (FCAW) Guns
Spoolmatic® 30A Spool Gun
WC-24 Control
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
#130 831
#137 549
XR™ Wire Feeder Control and Guns
See Lit. Index No. M/1.7, M/1.71, and M/1.73
TIG Accessories
Dynasty® 200 Series
High Frequency Arc Starters
See Lit Index No. AY/4.8
See Lit. Index No. AY/5.0
Remote Controls
RHC-3GD34A
RHC-14
RFCS-14 HD
RMLS-14
RCC-14
RCCS-14
Remote Control Extension Cords
#041 122
#129 340
#194 744
#129 337
#151 086
#043 688
CC models only, hand control
CC/CV models only, amperage or voltage control
CC/CV models only, foot control
CC/CV models only, momentary and maintained contact switch
CC/CV models only, fingertip control
CC/CV models only, fingertip control
See page 6
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
#042 801
#043 805
#043 802
#043 824
#043 826
#043 806
#043 864
#043 863
4-wheel steerable implement trailer
Trailer with lights, fenders and 2 in ball hitch
Trailer with 2 in ball hitch
Replaces the 2 in ball hitch on the HWY-224 or OFR-224
Trailer mounted cable holder for HWY-224, OFR-224 or HWY-430
Hitch required
For HWY-430 only
For HWY-430 only
Date:
Total Quoted Price:
Distributed by:
Litho in USA
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