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My miller big 40 runs my power tools but will not strike an ark. What and where might my problem be?

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Not making enough electricity,get it serviced

Posted on Apr 11, 2015

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SOURCE: I have a Miller big 40 bout an 87 modle that runs and welds great but wont idle down. Any thoughts?

There is a solenoid that controls the idle speed and the run speed- it is stuck in run speed. It may be a binding linkage, it may be bypassed by a previous owner.Chances are, as the idle relay is controlled through a load sensor on the control board and it may simply be a wire is off, damaged, or the solenoid is stuck.





There were a few different engines available for that model so exact connection will vary,

This the main manual
http://www.millerwelds.com/om/o450n_mil.pdf
The manual for the engine option you can scroll down to the "Big 40" in the list and just below that are the manuals for the different engines used.

Posted on Mar 30, 2012

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1 Answer

Why will it not strike an ark but it will idle up like it is supposed to. Found a blown fuse (replaced it) and the rheostat,.same problem blew fuse again


first, make sure your brushes are making good contact at the slip rings, and the brush connectors are clean and tight.
There are two bridge rectifiers which you will see if you remove the top cover of your machine, test the rectifiers, one of them has probably failed, before testing make sure you mark the wires before you pull them off of the rectifiers you will find a wiring diagram on the inside of one of the panels, the rectifiers are connected across the fuses, they are typically 40 amp/600 volt rectifiers

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Y is my 91 miller running but won't idle up when strikes an ark and dies?


ya get both cylinders to fire and check that your idle up chain from selonoid is working to keep idle going

Sep 18, 2014 | Cars & Trucks

1 Answer

Have a 71 miller big 40 won't ark and no power out of plugs put a new ingniter on welded for an hour then shut it off when back the next day and it wooden weld ageen S\N HE802998


hi, you have 2 big resistor with ajustable tab on it,check for visual damage on it and rusted connector or tab,
replace tab at same place if you disasemble it

Feb 16, 2014 | Welding Tools

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Miller welder 330a/bp it will not weld in D/C straight or reverse no ark but will work in A/C its like there is very low volts I was welding and then could not strike a ark


It's likely that your pedal is the problem. Pull the cover and check it electrically - these have been problematic in the past. You can further troubleshoot by selecting constant output and test the output.

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I have a 125 lincoln wire feed welder. wire will feed but will not arc to weld


check you ground cable, try to strike and ark on the ground cable, if no ark test the ground circuit if the circuit is ok you will need to have the transformer tested and for that you need some specal tools.

Aug 28, 2011 | Lincoln Welding Tools

1 Answer

Voltage drop when ark


do you have enouph power available to the welder or are there other things running on the same line

Jul 26, 2011 | Miller Welding Tools

1 Answer

Welder wont strike and keep an ark


Check the output voltage of the welder (the torch and earth clamp). The voltage should be around 30 to 40 volts. If yu see the normal spark from the rod as you strike, but cannot hold an arc, have a look at your rods, they could be old, damp or incorrect for your welder or the type of work you are attempting.

Jan 19, 2011 | Hobart Welding Tools

1 Answer

I HAVE AN OLDER MILLER BIG 40 RUNS BUT NO WELD OR AC POWER


check the ground ,make sure is tight.look around the machine and see if theirs a switch or a nob to turn from mig to arcweld...

Oct 25, 2009 | Miller Welding Tools

6 Answers

Miller Big 40 will not weld and has no current at the A/C outlet


open inspection door,which also the fine tuner knob is ,there's a 2x4 size circut board that snaps out with little force to remove,this is the voltage regulator board,look for 4700 ohm resisitor burnt into,tv tech can fix or order new board at $227.00 what i paid.

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