Miller Big 40 Questions

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I recently acquired a new project in the form of a late 80's Miller Big 40 Diesel. Got a couple questions on the unit the hopefully someone on here can help with:SN is JJ4516291) There's 3 switches in a row on the lower section of the control panel and 2 circular connectors. The ID plate is too far gone to tell what these are, does anyone have this info? I've got the manual for the unit off miller but it's not specific on these. From what i can still see, both connectors are for remotes, but what's the difference between the 2? One of the switches looks like 'Process: Stick/MIG' and one seems to say something about remote control. Pictures are attached. 2) What are the positions for the polarity / AC / DC switch on the lower left corner? 3) The manual indicates that a 7.5Kw single phase power output was a factory installed option, does anyone know what changes were made for this option? Is it just a junction box or are there more changes to the windings? I would really like to get more than the 3 kW aux power out of this thing.4)What's involved in doing MIG/TIG using this unit? I know these engine driven CC/CV units are frequently used but can't seems to find a single source reference that explains how it all goes together. It looks like I have the CV option but not a CC option? There's what looks like a spot for a CC control switch and remote next to the aux power outlets. Thanks,    ~John
Reply:Photos attached. Attached Images
Reply:Welcome to the forum.  You are correct in that the manual is not very clear at all on these items but two of the switches are associated with the remote receptacles.One is for remote CONTACTOR CONTROL.  OFF for output at the weld cable terminals at all times and ON for remote ON/OFF weld output control.The other of the two is the remote CURRENT CONTROL.  OFF for control panel Fine Amperage control only and ON for remote fine amperage control from minimum up to the control panel Fine Amperage control setting.I suspect the third toggle switch is for the optional ether starting aid but I'm not 100% on that.The reason for the two different remote receptacles is the one on the left is the former 5-pin and the one on the right is the current 14-pin.  I would guess the two were provided as part of the factory remote option during Millers' transition to the current standard 14-pin.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:I don't think I've seen one of those that wasn't CC. Usually it's the CV part that's optional. As far a doing tig, take a look at Tozzi's thread on scratch start tig.www.weldingweb.com/vbb/showthread.php?t=38106That will get you the basics. With the remote hook up, you should be able to use a pedal with that machine to control your amps.  With both controller options, I'd probably look for a newer 14 pin remote as they will most likely be easier to find.From what I was told years ago when shopping for a used engine drive, the windings are different for the extra aux power. It's not a simple kit you can instal. I might be wrong on that because I can't remember the year of the big 40 I was looking at way back when..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Originally Posted by DSWI don't think I've seen one of those that wasn't CC. Usually it's the CV part that's optional. As far a doing tig, take a look at Tozzi's thread on scratch start tig.
Reply:Originally Posted by DSWFrom what I was told years ago when shopping for a used engine drive, the windings are different for the extra aux power. It's not a simple kit you can instal. I might be wrong on that . . .
Reply:Ok, so it looks like the mystery switches are a CV-2 control panel, so I've got CV & CC capabilities and a contractor installed. Thanks for the help folks. Any suggestions on a wire feeder or TIG unit that would work well with this machine? I'd be looking for older used gear, I'm on a pretty limited budget.About the only bad news is that I can't get 7.5 kW, I was hoping it would just be a matter of some connections. One of the things I want to be able to do is run my 175 Lincoln MIG off this unit as a generator and I just don't think it'll work on 3 kW.Thanks,     ~John Attached Images
Reply:For tig, any of the last 4 torches on this page would work. You'd need one with a gas valve to turn on and off the gas. You'd also need some sort of reg/flowmeter  plus a hose, and a power block for the end of the torch cable. Pedal would be optional, but recommended.http://www.arc-zone.com/index.php?ma..._907_1399_1025I'd probably suggest those 17 series compatible torches over the smaller 9 series. The 9's are smaller and lighter, but wont take as many amps.Here's the page with the power block and reg hoses.Mig I'd vote for a suitcase type feeder for that machine, though with the 14 pin connector you could use any standard Miller shop feeder also. The shop feeders aren't really designed for "field" work, but I know a few who use them that way on occasion. Often they can be found relatively inexpensively like the basic Miller S-22 feeders. With the suitcases, either a VS or RC type feeder would work. Used a Hobart Hefty, Super S32-P, LN25 or 8VS/12VS covers most of the normal VS feeders. An 8RC/12RC would work for a remote feeder with the 14 pin plug. Again you'd need a reg/flowmeter and hose if you were going to run gas or dual shield. With the RC feeders or shop feeder, you'd obviously need the 14 pin remote cable to connect to  the machine as well..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:We obviously stand corrected on the CC/CV matter.   Thanks for the follow up with photo. My vote is for the 8 or 12RC for a wire feeder - now that we all know the "rest of the story".Am I correct to suspect yours has the polarity selector switch then as well?What is in the lower right corner of your panel that we can just barely see the top of?  230V outlet?Last edited by duaneb55; 12-21-2011 at 03:49 PM.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Originally Posted by duaneb55Am I correct to suspect yours has the polarity selector switch then as well?
Reply:If you haven't already downloaded it, heres the CV-2 manual http://www.millerwelds.com/om/o880a_mil.pdf to go along with the basic unit manual http://www.millerwelds.com/om/o474c_mil.pdf based on the SN you listed in your original post.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Sorry, I guess I was mistaken, or just plain wrong! That is the first one I've seen that had CV. I wonder why Miller didn't print that under the name."Where's Stick man????????" - 7A749"SHHHHHH!! I sent him over to snag that MIC-4 while tbone wasn't looking!" - duaneb55"I have bought a few of Tbone's things unlike Stick-Man who helps himself" - TozziWelding"Stick-man"