Old Miller Big 40
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  1. #1
    Join Date
    Nov 2017
    Posts
    15

    Old Miller Big 40

    Was given this old Miller a while back as it sat I bet for 10-15 years.
    Got the old gal running, but no spark at the welding end.
    Did a bunch of contact clean up but still no success.

    I found this site by search thru Google with the above issue and
    this forum appeared.
    Somewhere posted on here is the procedure to excite/polarize/magnetize
    the welding end of this machine.

    Could this be brought back up again in real easy to use instructions?.........

    The description of the process was a tad over my head with where to put the
    postive and negative 12v battery leads...........

    Thanks folks.

  2. #2
    Join Date
    May 2008
    Location
    Orange, TX
    Posts
    16,824

    Re: Old Miller Big 40

    Let's start with a unit SN so we can determine the correct circuit diagram to be looking at for guidance.

    Even if the control panel has faded, the SN is still stamped into it so look it over carefully. It will be 2 letters followed by 6 numbers.
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  3. #3
    Join Date
    Nov 2015
    Location
    Northford, Connecticut
    Posts
    380

    Re: Old Miller Big 40

    Hey Duane, he has an intro post too! He said serial number is HH07**** Not full number but he also said a 1977 unit; if that helps!


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    1968-'70 Lincoln SA 200 code 6633
    Millermatic 200 serial#JE834063

  4. #4
    Join Date
    May 2008
    Location
    Orange, TX
    Posts
    16,824

    Re: Old Miller Big 40

    Yep. I saw that thread after I responded in this one. Thanks.
    MM200 w/Spoolmatic 1
    Syncrowave 180SD
    Bobcat 225G Plus - LP/NG
    MUTT Suitcase Wirefeeder
    WC-1S/Spoolmatic 1
    HF-251D-1
    PakMaster 100XL
    '68 Red Face Code #6633 project
    Star Jet 21-110

    Save 2nd Base!

  5. #5
    Join Date
    Jun 2016
    Location
    SE Saskatchewan, Canada
    Posts
    278

    Re: Old Miller Big 40

    I just sold my 1979 Big 40 a short while ago.

    It had been sitting for a while and when I started it up it run fine but wouldn't weld.

    I found that there is a resistor (i think) of some type that one of the contact clamps had rusted off. I could see where it had been from the wear marks so fabbed up a new clamp and it worked just fine.

    Mention this because I was researching all sorts of method to "energize" the rotor and stuff but my problem was very simple.
    Lincoln Ranger 305G
    Miller Big 40 (SOLD)
    Hypertherm 30XP
    Lincoln 210 MP
    Lincoln Square Wave TIG200
    Koike IK-12
    Evolution EVO380

  6. #6
    Join Date
    Nov 2017
    Posts
    15

    Re: Old Miller Big 40

    I'll pull the sheet metal off this gal and gett'r naked and have a better view
    of the fine details.
    Need to send the fuel tank to a rad shop for some inner descaling....
    Been using a marine tank meanwhile......................................... ......

  7. #7
    Join Date
    Nov 2017
    Posts
    51

    Re: Old Miller Big 40

    Ill be watching your progress closely. I have big 40 with same issue.

  8. #8
    Join Date
    Nov 2017
    Posts
    15

    Cool Re: Old Miller Big 40.....Update......

    Well I was reading up on the other Miller Big 40.......Evans and decided to bear
    the brunt of the cold.
    The Kubota Mini fired up and I walked it around the A-frame and grabbed onto
    the old Miller.
    Walked it up to the house garage and fired the old gal up.
    Let her warm up so my fingers wouldn't be son goll dang cold.
    I for some reason decided I was going to pick on the fine adjustment
    control rheostat.
    Found my Ohm meter and tinkered.
    No continuity so I found a piece of pot scrubber pad and scrubbed
    the face.
    Noticed a break in one of the cross bars and had continuity on one side of
    this break, but not the other............hmmmmmmmmmmmmmmmm

    So I hooked up some cables and found my helmet.
    Shazzam............I got spark and carried on a spark while adjusting the fine
    control dial.
    Once I passed the break, I lost spark..........

    At least I know where my problem lies....

    Any idea where I can find this part?

    I thank this site, mod's and members for their help.
    At least I got the gumption to try and figure this out without having to
    haul it in to a shop and pay for coffee breaks............................


  9. #9
    Join Date
    Apr 2017
    Posts
    433

    Re: Old Miller Big 40.....Update......

    List your serial number, and I will provide Miller part number, You can get them from the dealer or there online as well.

  10. #10
    Join Date
    May 2008
    Location
    Orange, TX
    Posts
    16,824

    Re: Old Miller Big 40

    Based on the HH07**** the OP posted, the rheostat should be:
    605960 RHEOSTAT, WW 300 watt 34 ohm (Eff w/HD699143)

    A bit pricey from Miller.
    http://miller4less.com/advanced_sear...14&search.y=10
    Last edited by duaneb55; 12-06-2017 at 05:01 PM.
    MM200 w/Spoolmatic 1
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    Bobcat 225G Plus - LP/NG
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    WC-1S/Spoolmatic 1
    HF-251D-1
    PakMaster 100XL
    '68 Red Face Code #6633 project
    Star Jet 21-110

    Save 2nd Base!

  11. #11
    Join Date
    Nov 2017
    Posts
    15

    Re: Old Miller Big 40

    Thanks for the updates folks.

    What year do these fit?
    Found some used parts that I will go fetch this weekend.
    The front face is of the same style/layout.
    Mine is all faded, so going to get this as well.

    Wish me luck.........

  12. #12
    Join Date
    Nov 2017
    Posts
    51

    Re: Old Miller Big 40

    Congrats on your find. Now please come help me with mine we can smokeca roast while we tinker on the welder

  13. #13
    Join Date
    Nov 2017
    Posts
    15

    Re: Old Miller Big 40

    Take your ohm meter and check each connection.
    I started at the big lead hook up and worked my way back.
    Bit of chit house luck as I was wiping the fine rheostat with
    pot scrubber material and it hooked the broken x-bar.
    Looked a bit closer and with a flash light noticed the crack.
    So I rotated the lever far one side and had continuity.
    Back the other way and no flow.
    It was enough to make me try it out.
    Welder is working.

    Continue forth Evan.
    Purrrsavere.

  14. #14
    Join Date
    Apr 2017
    Posts
    433

    Re: Old Miller Big 40

    Miller part number 605960 equivalent can be had on E-bay.
    It's a direct bolt in for the Big -40, 300 watt, 34 OHM.
    E -Bay Item number 322729133070, ships from Oceanside, ca.
    Cost is 66.50 with free freight..............

  15. #15
    Join Date
    Nov 2017
    Posts
    15

    Re: Old Miller Big 40

    Thanks Dana gear.
    Stumbled into a bunch of parts from an old welder salvage.
    Included are some new parts.
    Will be making the trip this coming Saturday to pick this lot up.
    In it is a used rheostat.
    Hopefully it will be okay.

    If not, I'll check that ebay item out.
    Up here they are pushing $400 with tax..............(12%)

  16. #16
    Join Date
    Nov 2017
    Posts
    15

    Re: Old Miller Big 40

    Did the day driving and did get all them parts..............

    Now to find the time to do the swapping.....

    One thing I did notice is the arm that makes contact with the rheostat windings
    has a carbon block that rides on the windings and I didn't notice this detail
    on the damaged part.
    Hm hmm hm hm hmmmmm...........

  17. #17
    Join Date
    May 2008
    Location
    Orange, TX
    Posts
    16,824

    Re: Old Miller Big 40

    That's the wiper contact "brush" and is vital to proper operation of the rheostat. It's possible the one on the original was defective/worn out resulting in arcing that caused the open winding you found.
    MM200 w/Spoolmatic 1
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    '68 Red Face Code #6633 project
    Star Jet 21-110

    Save 2nd Base!

  18. #18
    Join Date
    Nov 2017
    Posts
    15

    Re: Old Miller Big 40

    I'll update this thread when I get further along with this project.

    So far all this help has sure been encouraging.

    Thanks folks.

  19. #19
    Join Date
    Nov 2017
    Posts
    15

    Re: Old Miller Big 40

    Swapped the fine adjustment rheostat today and works great.
    Noticed some fumes coming off it and I guess the years of dust
    and accumulation were getting warm.
    Took the fuel tank off and sent it in to a rad shop for the dunk and
    liner.
    Pretty ugly in there.
    Need to purchase a new glass fuel bowl assembly as this one isn't looking
    great.

    Question...........what are you all using for a gas tank neck seal?
    The original rubber one is pretty deteriorated and split.
    The boot that seals the gas tank neck to the upper hood.

    She's coming along.

    Ohhhhhh, how to post photos..............

  20. #20
    Join Date
    Nov 2017
    Posts
    51

    Re: Old Miller Big 40

    Click the little tree icon thing request full site on your phone to do it.

    I got rid of fuel bowl and ran a big inline filter and new hose i think 5/16 to carb. I still need to install a fuel shut off in hose . The big automotive filter stays about half full of fuel with motor running on govenor

  21. #21
    Join Date
    Nov 2017
    Posts
    15

    Re: Old Miller Big 40

    Now you got me thinking about maybe a spin on filter with a sediment bowl on
    the bottom.
    Something like my Bobcat uses.
    Hmmmmmm.

    Going to get a new flapper cap for the exhaust too.
    What color blue paint does one purchase or go my own hot pink
    sort of color?

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