A ED8-5 Big 40 Diesel.qxd

Big 40 Diesel
Issued January 2005 • Index No. ED/8.5
®
Processes
Heavy Industrial
Applications
Quick
Specs
Diesel Engine-Driven
Welder/Generator
Petro Chemical Piping
Structural Steel Work
Maintenance and Repair
Output Range
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)
For DC Stick 55 – 500 A
For DC TIG 15 – 350 A
For AC TIG 15 – 375 A
For MIG/FCAW 14 – 40 V
Weld Output Rated at 104˚F (40˚C)
For AC TIG
400 A at 36 VDC (14.4 kW), 100% Duty Cycle
450 A at 38 VDC (17.1 kW), 60% Duty Cycle
375 A at 25 VAC (9.4 kW), 40% Duty Cycle
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)
Weight
1545 lb (701 kg)
The Power of Blue .
®
CATERPILLAR industrial engine
designed to operate over 10,000
hours before the first basic
overhaul. Backed by worldwide
CAT support and service.
NEW! Industrial-grade, sealed
marine ignition switch with
starter interlock prevents the
starter from engaging while the
engine is running. Protects ring
gear and starter from abuse.
NEW! More welding amperage!
400 amps at 100% Duty Cycle
450 amps at 60% Duty Cycle
NEW! Engine gauges are standard
on all models.
AC TIG weld aluminum with deluxe
model. The most AC weld output on
any engine drive. (High-frequency
unit required.)
Arc-Drive makes welding easy.
Automatically enhances Stick
welding, especially on pipe, by
focusing the arc and preventing
the electrode from going out.
Silenced — only 65 dB (90 Lwa)
at idle. 73.8 dB at 23 ft (98.7 Lwa)
maximum output. Improves work
site communications.
Simplified control panel provides
easy set-up with fewer controls —
less training is required.
Automatic idle saves fuel and
prolongs engine life along with
reducing the sound level.
Standard GFCI receptacle required
on most job sites to protect
operators from electrical hazards.
Enclosed base and case protects
internal components from corrosive
environments and reduces sound levels.
CSA, IEC, and NEMA compliant for
welders. Degree of protection
provided by enclosure IP23.
Quick and easy maintenance with
single-side access to oil level check, oil
fill, oil filter, fuel filter and air cleaner.
Hot Start™ provides positive Stick
electrode starts to make it easy to
start all types of electrodes, and
works great for bead tie-ins.
Remote toolless oil drain that allows oil to
be drained without getting under the engine
and reduces the chance of oil spillage.
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
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 920-735-4505
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX: 920-735-4125
www.MillerWelds.com
®
Big 40 Diesel CC Specifications
(Subject to change without notice.)
Welding
Mode
Weld Output
Range
Weld Output Rated
at 104˚F (40˚C)
Max. OpenCircuit Voltage
Generator Output Rated
at 104˚F (40˚C)
CC/DC
55 – 500 A
400 A at 36 VDC (14.4 kW),
100% Duty Cycle
450 A at 38 VDC (17.1 kW),
60% Duty Cycle
95
Peak: 5500 watts
Continuous: 4000 watts,
34/17 A, 120/ 240 VAC, 60 Hz
while welding
NEMA EWI (ANSI C87.1) Class (1) output ratings. *Additional 7 in (178 mm) to top of exhaust.
Engine Specifications
Engine
Brand
CATERPILLAR
3024C Diesel
Net Weight
(without fuel)**
Dimensions*
H: 43 in (1092 mm)
W: 28-1/2 in (724 mm)
D: 64-7/16 in (1637 mm)
1540 lb (697 kg)
**Additional 190 lb (86 kg) when fuel tank is full.
(Subject to change without notice.)
Features
HP
Type
Tier II, EPA-certified, indirect-injected,
liquid-cooled diesel engine. Right-side
service access with service intervals of
250 hours for oil and filters.
33
Four-cylinder,
industrial,
liquid-cooled
diesel
Engine
Speeds
Fuel
Capacity
Oil
Capacity
Coolant
Capacity
Automatic Engine
Shutdown
Run: 1850 RPM
Idle: 1250 RPM
25 gal
(95 L)
9 qt
(8.5 L)
9 qt
(8.5 L)
Oil Pressure
Coolant Temperature
®
Big 40 Diesel CC Control Panel
1
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.
2
3
4
9
10
11
12
13
5
6
14
15
International Model
7
7
16
8
17
1. DC Ammeter*
2. DC Voltmeter*
3. Amperage Adjust Control
4. Amperage Range Switch
5. Amperage Adjust Switch and
Remote Amperage Adjust Receptacle
6. Stick/TIG Selector Switch
7. 120 VAC, 20 A GFCI
Duplex Receptacle
8. 240 VAC, 30 A TwistLock Receptacle
(NEMA L6-30)
9. Engine Hour Meter
10. Engine Oil Pressure Gauge
11. Fuel Gauge
12. Engine Coolant Temperature Gauge
13. Battery Voltmeter*
14. Engine Control Switch
15. Starting Aid Switch
16. International Model
240 VAC, 16 A Pin and Sleeve Receptacle
17. Polarity Switch*
*Optional on select models.
®
Big 40 Diesel CC Performance Data
CC/DC VOLT/AMP CURVES
GENERATOR POWER CURVE
150 300
7.57 2.00
Ranges
60
40
20
0
0
100 200 300 400 500 600 700 800 900 1000
4 kW
5.68 1.50
100 200
4.73 1.25
75 150
3.79 1.00
50 100
2.84 0.75
25 50
1.89 0.50
0
0
0.95 0.25
0
5
10
15
20
25
30
AC AMPERES IN 240 V MODE
DC AMPERES
0
10
20
30
40
50
AC AMPERES IN 120 V MODE
2
6.62 1.75
5.5 kW
60
IDLE
0.00 0.00
US Gal./Hr.
DC VOLTS
80
125 250
AC VOLTS
230 – Max
170 – 365
110 – 225
70 – 130
55 – 85
US Liters/Hr.
100
FUEL CONSUMPTION CURVE
0
50 100 150 200 250 300 350 400
DC WELD AMPERES
AT 100% DUTY CYCLE
®
Big 40 Diesel CC/CV Specifications
(Subject to change without notice.)
Welding
Mode
Weld Output
Range
Weld Output Rated
at 104˚F (40˚C)
Max. OpenCircuit Voltage
CC/DC
45 – 500 A
400 A at 36 VDC (14.4 kW),
100% Duty Cycle
95
CV/DC
14 – 40 V
450 A at 38 VDC (17.1 kW),
60% Duty Cycle
56
CC/AC
(Deluxe
Model)
15 – 375 A
300 A at 32 VAC (9.6 kW),
100% Duty Cycle
65
Net Weight
(without fuel)**
Generator Power Output Rated
Dimensions*
Peak: 5000 watts
Continuous: 4000 watts, 34/17 A,
120/240 VAC, 60 Hz while welding
H: 43 in
(1092 mm)
W: 28-1/2 in
(724 mm)
D: 64-7/16 in
(1637 mm)
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
NEMA EWI (ANSI C87.1) Class (1) output ratings. *Additional 7 in (178 mm) to top of exhaust.
1545 lb
(701 kg)
**Additional 190 lb (86 kg) when fuel tank is full.
®
Big 40 Diesel CC/CV Control Panel
1
Additional Features
9
10
11
12
13
2
3
4
A multi-colored process selector control
allows quick and easy process changes
without having to use multiple switches.
Solid-state control provides enhanced arc
characteristics that include more dig in
the Stick mode with smoother and lower
amperage in the TIG mode. Extreme conditions will not cause the output to change,
eliminating the need to periodically turn
the heat up.
6
14
15
5
5
5
16
17
18
19
7
8
The rugged solid-state control board is
housed in a sealed vault. The vault’s sealed
connections are made through watertight
plugs that make this component impenetrable
to dust and moisture.
20
International Model
7
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.
21
1.
2.
3.
4.
5.
DC Ammeter*
DC Voltmeter*
Amperage/Voltage Adjust Control
Ampere Range Switch
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)
9. Engine Hour Meter
10. Engine Oil Pressure Gauge
11. Fuel Gauge
12. Engine Coolant Temperature Gauge
13. Battery Voltmeter*
14. Engine Control Switch
15. Starting Aid Switch
16. 3-Phase Power Generator Option*
17. Strain Relief*
18. 50 A, 3-Phase Circuit Breaker
19. 50 A, 120/240 V Receptacle
(NEMA 14-50)*
20. AC/DC Polarity Switch*
21. International Model
240 VAC, 16 A Pin and Sleeve Receptacle
*Optional on select models.
®
Big 40 Diesel CC/CV Performance Data
CC/CV VOLT/AMP CURVES
STICK MODE
100
100
80
80
100
Ranges
60
40
20
60
MAX
40
20
100 200 300 400 500 600 700 800 900 1000
DC AMPERES
80
60 – 365
35 – 250
25 – 155
15 – 75
60
40
0
100 200 300 400 500 600 700 800 900 1000
DC AMPERES
60
40
0
0
0
55 – 350
35 – 205
25 – 105
15 – 45
20
20
MIN
0
0
Ranges
Ranges
DC VOLTS
Max
155 – 450
115 – 320
75 – 195
40 – 90
DC VOLTS
DC VOLTS
80
CC/CV VOLT/AMP CURVES
AC TIG MODE
AC VOLTS
100
CC/CV VOLT/AMP CURVES
TIG MODE
CC/CV VOLT/AMP CURVES
MIG MODE
0
100
200
300
DC AMPERES
400
500
0 50 100 150 200 250 300 350 400 450 500
AC AMPERES
3
®
Big 40 Diesel CC Options
Weld Ammeter and Voltmeter Kit
#195 131 Field
Panel-mounted analog meters monitor
welding output.
Battery Voltage Gauge
#195 454 Field
Monitors battery charging circuit.
Installation time: 35 minutes
DC Polarity Reversing Switch Kit
#043 942 Field
Changes DC polarity without the use of tools.
Cold Weather Starting Aid Kit
#195 056 Field
Includes 120 V block heater.
Installation time: 35 minutes
Note: All models come standard with glow plugs.
®
Big 40 Diesel CC Genuine Miller Accessories
Remote Control
RHC-3GD34A Remote Hand Control
#041 122
Allows for precise adjustment of amperage.
Includes 20 ft (6 m) cord.
4
®
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.
Battery Voltage Gauge
#195 454 Field
Monitors battery charging circuit.
Cold Weather Starting Aid Kit
#195 056 Field
Includes 120 V block heater.
Installation time: 35 minutes
Note: All models come standard with glow plugs.
AC/DC Polarity Reversing Switch Kit
#195 095 Field
Changes DC+/AC/DC- without the use
of tools. Deluxe model comes standard
with AC/DC polarity switch.
5
Installation time: 35 minutes
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.
Note: Available as factory option.
See Ordering Information on back page.
®
Big 40 Diesel CC/CV Genuine Miller Accessories
Remote Controls
RHC-14 Hand Control
#129 340
Miniature hand control
for remote current and
contactor control.
Dimensions: 4"x4"x3-1/4"
(102 x 102 x 82 mm). Includes 20 ft (6 m)
cord and 14-pin plug.
RCCS-14 Remote Contactor and Current
Control #043 688
Up-and-down rotary-motion fingertip control
fastens to TIG torch using two Velcro®
straps. Includes 28 ft (8.5 m) control cord.
RFCS-14 HD Foot Control #194 744
Foot pedal provides remote current and
contactor control. Includes 20 ft (6 m) cord
and 14-pin plug.
MIG (GMAW)/Flux Cored (FCAW)
Welding
RMLS-14 #129 337 14-pin plug
Fingertip momentary- and maintainedcontact rocker switch for contactor control.
Push forward for maintained contact and
back for momentary contact. Includes 20 ft
(6 m) cord.
Extension Cords for 14-Pin Remote Controls
and 24 VAC Wire Feeders
#122 973 25 ft (7.6 m)
#122 974 50 ft (15.2 m)
#122 975 75 ft (22.9 m)
TIG (GTAW) Welding
HF-251 Series
#042 388
HF-251D-1, 115 VAC
#042 387
HF-251D-2, 230 VAC
High-frequency arc
starter and stabilizer.
See Accessory Lit. Index No. AY/5.0.
SuitCase™ 8VS Wire Feeder #194 890
SuitCase™ X-TREME™ 12VS Wire Feeder
#195 500
Lightweight, portable, voltage-sensing
wire feeders include secondary contactor
and gas valve. Require drive roll kit.
See Lit. Index No. M/6.4, M/6.41.
SuitCase™ 8RC Wire Feeder #194 938
SuitCase™ 12RC Wire Feeder #194 940
Lightweight, modular design and flexible
enough to run a variety of wires up to 5/64 in
diameter. Comes standard with remote
voltage control. See Lit. Index No. M/6.5.
5
Genuine Miller Accessories
Lockable Fuel Cap Flame Arrestor Kit
Green #043 947 Field
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
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.
Vandalism Lockout Kit
#195 118 Field
Lockable hinged steel panels cover and
protect name plate gauges and ignition
switch (padlock included). Also includes
engine compartment door lock and key.
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.
Note: For best results do not weld when cable is coiled!
Canvas cover cannot be used with cable holder.
Canvas Cover #194 683 Field
Attractive, blue waterproof canvas cover
resists stains and mildew, and protects
the finish of your welder. Cannot be used
with cable holder.
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.
Stick Accessory Kits
#173 851
50 ft (15 m) No. 2/0 electrode cable
with electrode holder and 50 ft (15 m)
No. 2/0 work cable with work clamp.
350 A at 100% duty cycle.
#043 952
100 ft (30.5 m) No. 2/0 electrode cable
with electrode holder and 50 ft (15 m)
No. 2/0 work cable with work clamp.
300 A at 100% duty cycle.
6
Trailers and Hitches
(For both models.)
RCT-224 Trailer #194 875
A highway trailer specifically designed for
the rental/construction site. A heavy-duty
torsion axle with a low center of gravity
provides a rugged yet smooth ride. The
RCT-224 comes with jack stand, 2-1/2 in
lunette eye, fenders, lights and safety chains.
4 West Four-Wheel Steerable Off-Road
Trailer #042 801
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.
HWY-224 Trailer #043 805
A 2650 lb (1202 kg) capacity highway
trailer. Welded steel tubing frame, heavyduty axle with roller bearing hubs and
leaf-spring suspension. The HWY-224
comes with jack stand, 2 in (50 mm)
ball hitch, fenders and lights.
OFR-224 Trailer #043 802
A 2650 lb (1202 kg) capacity off road
trailer. Welded steel tubing frame, heavyduty axle with roller bearing hubs and
leaf spring suspension. The OFR-224
comes with jack stand and 2 in (50 mm)
ball hitch.
Lunette Eye 2-1/2 in (64 mm) #043 824
For use with both 224 trailers.
Cable Tree #043 826
Provides an area to conveniently wrap weld
cables and extension cords. Works on all
224 and 430 trailers.
HWY-430 Tandem Axle Trailer #043 806
Smooth riding with 3750 lb (1701 kg)
capacity. Includes: adjustable hitch for
level operation, a hand operated parking
brake, a self-actuating hydraulic brake
system and a break-away device to lock
brakes if the trailer comes loose. It also
includes jack stand, fenders and lights.
(Hitch must be ordered separately.)
Ball Hitch 2 in (50 mm) #043 864
For use with the 430 trailer.
Lunette Eye 3 in (76 mm) #043 863
For use with the 430 trailer.
Cable Tree #043 826
Provides an area to conveniently wrap weld
cables and extension cords. Works on all
224 and 430 trailers.
Note: Trailers are shipped unassembled.
Trailer Specifications
(Subject to change without notice.)
Gross Axle
Gross Vehicle
Weight Rating Weight Rating
Net
Payload
Height
of Bed
Road
Clearance
Track (Center
to center of
tires)
Standard Tires
(Standard rating
or P-size rating)
RCT-224
2700 lb
(1225 kg)
2500 lb
(1134 kg)
2250 lb
(1021 kg)
10-1/2 in
(267 mm)
6-1/2 in
(165 mm)
49-1/2 in
(1257 mm)
4 West
2000 lb/axle
(907 kg/axle)
3000 lb
(1361 kg)
2570 lb
(1166 kg)
21-1/4 in
(540 mm)
8 in
(203 mm)
HWY-224
OFR-224
3500 lb
(1588 kg)
2960 lb
(1343 kg)
2650 lb
(1202 kg)
18-1/2 in
(470 mm)
HWY-430
2200 lb/axle
(998 kg/axle)
4280 lb
(1941 kg)
3750 lb
(1701 kg)
19-1/4 in
(489 mm)
Model
Dimensions
Net
Weight
B78-13C
Length: 98 in (2489 mm)
Width: 59 in (1499 mm)
285 lb
(129 kg)
55-1/4 in
(1403 mm)
B78-13
Length: 91 in (2311 mm)**
Width: 61-1/4 in (1556 mm)
430 lb
(195 kg)
7-1/2 in
(191 mm)
52 in
(1321 mm)
B78-13B
Length: 122-1/2 in (3112 mm)
Width: HWY– 61 in (1549 mm)*
OFR–58-1/2 in (1486 mm)
355 lb
(161 kg)
8-1/2 in
(216 mm)
52 in
(1321 mm)
B78-13B
Length: 156-1/2 in (3975 mm)
Width: 61 in (1549 mm)*
530 lb
(240 kg)
*Width at outside of fenders. **Does not include tongue.
7
Ordering Information
Power Source and Factory Options
Stock No.
Description
Big 40 Diesel CC
#907 171
#907 183
#907 170
#907 182
#907 170-03-1
CSA model with engine gauges and automatic idle
International model w/ engine gauges, automatic idle, dry battery, and international aux.
CSA model with engine gauges and automatic idle
International model w/ engine gauges, automatic idle, dry battery, and international aux.
CSA Deluxe model w/ automatic idle, engine gauges, welding meters,
AC/DC polarity switch and high kW option
#195 131
#195 454
#043 942
#195 095
#195 056
#043 947
#195 012
#195 118
#043 946
#194 683
#194 918
Standard on deluxe model
#041 122
#129 340
#043 688
#194 744
#129 337
#122 973
#122 974
#122 975
Hand control for CC models only
Hand control for CC/CV models only
Fingertip control for CC/CV models only
Foot control for CC/CV models only
Fingertip momentary- and maintained-contact switch. For CC/CV models only
25 ft, 14-pin remote controls/24 VAC wire feeders
50 ft, 14-pin remote controls/24 VAC wire feeders
75 ft, 14-pin remote controls/24 VAC wire feeders
Trailers and Hitches
RCT-224 Trailer
Ball Hitch, 2 in
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
4-West Trailer
#194 875
#189 585
#043 805
#043 802
#043 824
#043 826
#043 806
#043 864
#043 863
#042 801
Trailer with lights, fenders and 2-1/2 in lunette eye
Replaces the 2-1/2 in lunette eye on the RCT-224
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
4 wheel steerable implement trailer
Suggested TIG Accessories
HF-251D-1
HF-251-2
#042 388
#042 387
115 VAC. For CC/CV models only
230 VAC. For CC/CV models only
Wire Feeders
Suitcase 8VS
Suitcase™ X-TREME™ 12VS
#194 890
#195 500
Includes contactor and gas valve. See Lit. Index No. M/6.4
Includes contactor and gas valve. See Lit Index No. M/6.41
#194 938
#194 940
Includes remote voltage control. See Lit. Index No. M/6.5
Includes remote voltage control. See Lit. Index No. M/6.5
See Lit. Index Nos. M/10.0 and M/13.4
#173 851
#043 952
2/0, 350 A, 100% Duty Cycle, 50 ft stinger, 50 ft work clamp
2/0, 300 A, 100% Duty Cycle, 100 ft stinger, 50 ft work clamp
Big 40 Diesel CC/CV
Field Kit Accessories
Weld Ammeter and Voltmeter Kit
Battery Voltage Gauge
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
Canvas Cover
Roll Cage/Drip Pan
Remote Controls
RHC-3GD34A
RHC-14
RCCS-14
RFCS-14 HD
RMLS-14
Extension Cords
Suitcase 8RC
Suitcase 12RC
MIG Guns
Suggested Stick Accessories
No. 2/0 Stick Welding Accessory Kit
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
Field. Cannot be used with cable holder
Date:
Total Quoted Price:
Distributed by:
Litho in USA
Qty.
Price