Installing the engine in a Miller big 40 Diesel Welder that logger Wade removed what a puzzle

Shop Dirt Perfect
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logger wade removed the engine and head from his miller welder a few years ago and gave ou on the project. I decided to put a few buck into to and give it a go before it hit the scrap pile.
ran into a few problem on reassembly.
#dirtperfect
#loggerwade
#millerwelder
#engineinstsall

[@Crewsy]

When your 2 cylinders are at TDC one is at compression and the other is about to open the intake valve not the exhaust as you stated DP. Exhaust valves open at BDC. I just realized this video is nearly 2 years old and I watched it thinking it was a new one. Somehow I missed it back then. 🤔

[@steveleverett2644]

Man I love the help you had on this project. ❤❤

[@budlvr]

Makes a whole lot more sense since I've seen another video where you said you worked in a diesel shop for a few years; no way without that experience you would have gotten this far without it; AND I know you DID get it running, because I've seen it in other later videos. You are nothing, if not persistent. Great job Mike.

[@mes9260]

Thanks for posting REALITY !! Happens in my shop all the time. It is definitely a part of life and you must adapt to the challenges that are in front of you. I am very impressed with your set of skills. Thanks for the videos.

[@DirtPerfect]

Thanks and thanks for watching

[@JoelHershberger]

No reason to be sorry. Such is life. This is what life is all about. I can't wait to see the next installment, if there is one. Thanks for bringing us along for the ride. It was really interesting and fun to watch.

[@DirtPerfect]

Thanks buddy and more to come

[@Justinsr1983]

I agree no need to be sorry I learn a lot from these videos and offer input when I have it , but I’m confident you’ll get it figured out can wait for the next installment

[@tkilg7169]

Somewhere out here, there's a guy that will encounter a situation like this, and from watching your video, beforehand will figure in all the problems that you encountered, and find success. Thanks for your work.

[@gene5022]

Don’t give up don’t ever give up.😢

[@oldmanmosh6056]

I was impressed you sprayed the head gasket with copper... I use that everytime no matter if it's a gasket swap or complete rebuild... it's added protection!!

[@DirtPerfect]

Agree

[@danielpullum1907]

DP, I keep finding videos I haven't viewed. There must be a way to follow all of them. Good procedural adherence.

[@DirtPerfect]

Thanks

[@justinmills8084]

I am impressed with your shop and overheard crain. You must have done a lot of forward thinking in building your shop. Amazing setup.

[@DirtPerfect]

Yes and thanks have a video coming on it in a few weeks

[@magnificentshine1]

Pull the shut off solenoid and make sure it's getting fuel. I had kinda the same issue with my isuzu npr 4cylinder turbo diesel. The electric lift pump would pull fuel the tank and push to the injection pump, but it didn't have enough pressure to bleed the air out and forcefully prime my injection pump. I changed the pump added some motor oil with my fuel just to help lube up the entire fuel system. Turned it on, bleed the air out on the screw on the injection pump, tightened it, left the lines off and cranked it. Fuel started pushing out, put lines back on, bled the lines and SHAMWOW!!! It fired right up. Hope this helps, guaranteed you'll get it!

[@DirtPerfect]

I did think I found the problem 😁

[@magnificentshine1]

@@DirtPerfect Great! Can't wait for your vid! And also, I really like that dozer blade on your new Volvo. I use them all the time and I think they are mega handy! Only thing I've found is if your in deep mud that dam blade will be your nemesis, it acts like an anchor

[@CMDSR]

Good catch on those brushes

[@williamstentzsr.9568]

You make some fun and useful videos.👍😃

[@DirtPerfect]

Glad you think so!

[@robertpowell7672]

These problems are best slept on. When you are fresh, you will decide the way forward. Whether this means looking for another pump or having this one checked out by a specialist.

[@arthurbass1191]

Keep the video's coming love the content Long time watcher just had open heart surgery watching all them again Thanks Mike and Family

[@DirtPerfect]

Thanks buddy and hope your doing better

[@johnlemmey7698]

You are on the rite track. It can only be the pistons stuck in the injector pump. or a stuck shutoff solenoid.

[@DirtPerfect]

Yup stay tuned and for watching

[@carloskawasaki656]

Awesome,thank you,i learn a lot and thank you for shared 👍👍👍👍

[@CaptKirk1701]

Pull the shutoff solenoid completely off and see if pump primes, sometimes they stick all the way out and stop injector pump from pumping completely.

[@DirtPerfect]

👍

[@tbix1963]

Thanks for sharing your video, even if it didn’t start at least all the parts are in one spot tied together rather than exploded across the shop. Have faith that you will find the answers you seek when you least expect them. Nice companion dog. Still love the overhead gantry. Stay safe, wishing you and your family the best.

[@DirtPerfect]

Thanks Tom

[@danslawncare8594]

Hey Mike take the wire off the shut Sol and see if the Sol clicks if not the Sol is stuck. Sorry for your bad luck. Good video.

[@DirtPerfect]

It does and thanks more to come in this stay tuned

[@dennis2376]

Thank you.

[@louisianadirt2188]

Dang it, now I’m going to go pull my old welder out and get it up and running. Great video mike , thanks for taking the time to make it. Stay safe Dwayne

[@DirtPerfect]

Thanks buddy

[@codymiller2775]

I always try shoving automatic transmission fluid through pumps that dont work. It works sometimes. Worth a try. Good job getting her back together!

[@DirtPerfect]

Thanks

[@khtractors]

I’m a welding teacher and I run almost all Miller machines. When I first saw that engine setting there tore down I thought it was a Perkins. The blocks look similar.

[@DirtPerfect]

They do look very similar

[@jjknowles7348]

Putting something back together somebody else took apart takes talent. You could fix a broken heart lol. I'm all out of your videos to watch. Went back and watched them all. Some of the old ones are real good. Make some more I need content. Great channel. If it wasn't so cold up there I'd move.

[@DirtPerfect]

Thanks appreciate the feedback and post a video every other day

[@KG-yn9qi]

Good job a lot of fun know it's a good feeling taking a pile and make it work. Now I had similar situation where I was working for a company, the owner knew I have good mechanical skills. So he asked me to put a engine back together. A Ford Pu. It was a V8 dont member the size. The short black was in truck. Now thing is this engine had been put together and disable 3 times by two other persons. Parts, hardware, and everthing was scattered all over shop in bed of truck, you get it big mess. So after 8.5 hrs I sorted out cleaned and assembled it and had it running. The owner got mad said why did it take me so long to reassemble it? Well I said you wanted it to run right? I was not the one that took it apart. So did not know what hard ware went where or how the parts fitted etc. Also pointed out the other two didn't even get it assembled correctly to have it running. So if he felt I took to long, dont ask me to correct next disaster mess. I'll stick to operate equipment. And do the job he hired me for.

[@timkd5vmv583]

Simple things first... did you put fuel in it??? That’s the kind of mistake I would make lol. Great video as always!!

[@DirtPerfect]

lol yes but good ?

[@gayle4804]

🤯 mind blowing!

[@johnsmart3587]

Nice to see the dog inside with you, Thanks.

[@DirtPerfect]

😁

[@lakesideranch]

Good effort Mike, don't be depressed. You're so close, you got this! Hopefully you'll be back with a follow-up video and fire that bad boy up. Work safe, stay warm, see ya on the next 1 Doug@ the "ranch"

[@DirtPerfect]

Thanks Doug and have one coming soon

[@j.b.maxwell8300]

Keep at it mike you can’t give up now you have gone so far with it and you are just around the corner from the home straight, those pumps are very touchy with air in the system, I’m not sure but do you have to bleed the pump first then the lines and injectors, as you said mike they are a very simple fuel system but can be a mighty big pain sometimes so stick in there mate you will get it done and thank you for showing us the assembly

[@DirtPerfect]

Thanks for watching and stay tuned 😁

[@1armedguy4]

Great welder for HD gouging but still great for welding of different sorts !

[@DirtPerfect]

Yup

[@VintageFarm1086]

I didn’t read through the comments and maybe someone has already suggested this, but we had the same problem with an old IH dump truck. We couldn’t get the injections pump to prim, so we cut an valve stem off an inter tub with enough rubber to put over the filler hole on the fuel tank, put a hose clamp on real tight. Put air in the fuel tank to we thought it would explode from the pressure and forced fuel to the pump. We turned the motor over and with fuel pressure on the pump, that forced fuel through the pump and to the injectors. The motor started. Hope this helps.

[@DirtPerfect]

Good info thanks buddy

[@VintageFarm1086]

@@DirtPerfect your welcome

[@michaelowen1750]

The Miller Parts books are real good to help put it all back together...

[@DirtPerfect]

👍 where do you get one are they one line

[@michaelowen1750]

@@DirtPerfect Right on the Miller /support/manuals website.. on the right is a drop down menu, pick Big 40 Diesel.. then go by serial number for the right one.... Though the engine book was separate from the Miller stuff...

[@pauliossi2674]

I don't have much exposure to the old continental diesels in the Miller welders, but a fair amount of experience with Lincoln SA200's and other 4 cyl diesels with the VE rotary type pumps. look for bleeder screws on the pump body, 1 on the round part and 1 on top of the top of it, probably 1/4 hex head and crack them open until the pump is full of fuel and then try the crank until the injection lines fill. the throttle solenoid might be on for idle and off for run or high idle and doesn't energize unless the welder is making power. The easy way to bolt up the engine and armature is to bolt them together and then into the rear brush housing. Factory assembly is th hang the armature on the flywheel and slide the coils and housing over the armature then set it on the frame as a unit then complete assembeling the rest of the machine. the cooling system works at maximum when the fan is half way in and out of the radiator shroud. good luck with curing the problems

[@sandie062985]

What I use to do when putting new head gasket on I took 4 head bolts old one and cut the heads off . It works on all engines if you loose the guide pins . Good luck enjoy your videos.

[@DirtPerfect]

Thanks bob

[@davidwoermansr]

Going through the starter hole is an easier way to get the flywheel bolts if you ever change the engine

[@mrbakerskatz]

Can’t really stop now , about got it ! Good luck Mike

[@DirtPerfect]

Lol I know right more to come

[@dennisbroughel427]

DP, don’t get so dejected, crap happens to us all. Look at it this way, the money you spent on parts, is most likely as much as you & Mrs DP would have spent on dinner and a couple of adult beverages at a nice restaurant. Up buddy

[@amossnowdaharleyman9179]

Have the same series welder. Had the same fuel problem. If memory is right(been a while) the fuel interruption was associated with the solenoids for the auto return to idle and auto acceleration to weld system. On mine I disabled that and went with a toggle switch: up to weld,down for idle. Fixed the issue with no fuel to injection pump.There's a recent video on my channel of the unit. Another possible cause is the push to bypass button that bypasses the low oil pressure and high temp safety interlocks. If that button is not pushed when starting the fuel system is disabled by the low oil pressure safety interlock.

[@DirtPerfect]

10-4 thanks

[@amossnowdaharleyman9179]

@@DirtPerfect I don't know how to cut and paste but the video where I'm mounting a jack on a scraper tongue shows me using the interlock bypass when starting my miller welder.

[@toosavvy3504]

Well, thats something to look into.... ;

[@jackspringer9283]

I'd guess 75% of problem is low oil pressure shut down protection,good call!!

[@garywest8901]

Lol . Hang in there buddy . To make long story short , we replaced a engine similar to yours on our small skid loader. The original engine was a continental by the way. Broke two cranks lol. Any way we found a yanmar engine off a refrigerator unit for 100.00. Who knows how long since it ran.Last resort. Got it running on the floor. So we put it in with lot of fanagling. Starts , runs about 5 min and the engine runs away lol. Got fuel shut off pretty quick. Injection pump seized. Send it out for rebuild . Three years later running good. Probably your pump with high hours and been sitting. Guess you done got fixed I hope.. Thanks for showing .

[@DirtPerfect]

Thanks and thanks for watching Gary

[@davidhill4711]

Great effort, something will click in the future for you to look at. Keep your chin up.

[@DirtPerfect]

Thanks David

[@joemakowichuk3888]

If it has spin on fuel filter fill atf fluid help with lubing pump and will run on it

[@gregcothrum4045]

Great video Mike and have a great day and stay safe 👍

[@DirtPerfect]

Thanks Greg

[@NotJustaTool]

I'm guessing you got this fixed. Otherwise Kleeman loaded a similar welder into his truck bed for scrap. Nice detailed assembly. Thanks Mike. Cheers!

[@DirtPerfect]

Yes stay tuned more videos to come on this

[@rockeerockey6941]

I'm bringing all my engine work to you! Mike you're quick

[@DirtPerfect]

Lol 😝

[@danielpullum1907]

I think you were lonely and it impeded your investigative juices!!! It was one of the few times you didn't have anyone in the garage except the purty doggy. Good Luck.

[@73DiamondReo]

been into those roosamaster pumps but its been a while. Watch Wes Work channel was recently into one and might be a good refresher on the metering valve.

[@73DiamondReo]

ive bought a bunch of projects that come in 5 gallon buckets and milk crates and its always fun to figure out

[@DirtPerfect]

Thanks buddy

[@toddlasalle131]

I'm probably not the only one that has noticed that you are wearing Crocs nice job Mike

[@DirtPerfect]

Yup shop shoes 😜

[@toddlasalle131]

@@DirtPerfect The black stocks perfect pairing

[@bertrutledge4546]

Didn't start but you did a lot of work getting to that point. Hope you finish it.

[@DirtPerfect]

Yup stay tuned

[@michaelsailors7794]

It should run awhile for you Hopefully. I need to start drinking Pepsi instead of coffee. Man it makes you work fast 🤣 great video, hope you get the pump figured out

[@DirtPerfect]

Lol

[@rl3898]

Good one Mike, n My guess.... Stop Solenoid wiring or just stuck. Inside the top cover of the fuel pump is a tiny fuel valve on two long springs. I've had a John Deere and Two Perkins where this had stuck and stopped it pumping. The lightest touch and it frees. And all is ok. Good luck matey..

[@timothyball3144]

When running valves on Deere engines, I pin the flywheel which puts 1&4 (or 1&6) at TDC. Then I start at the loose valves and do int. & exh. on that cylinder, then work down the row. Do int. on the next cyl., do exh. on the next one on down to 3 or 5 depending on 4 or 6 cylinder. Then roll it over 360 and do the same thing. In my head, I just keep repeating intake, exhaust, intake, exhaust on down the line. This way you only have to turn the engine over one time to do all of the valves. I have mentioned this elsewhere, and people have said that you have to have the cylinder at TDC to adjust the valves, but this is from the Deere factory manual, and I'm guessing they kinda know what they are talking about.

[@DirtPerfect]

Thanks 👍

[@mog5858]

lost of welder will have a few of the bars cut out of the cooling fins so you can work on your bolts that you were fitting with at say 9 0r 3 o'clock. keep up the good work

[@thomasdesmond2248]

For future reference when installing brushes. You will find a tiny hole. You push the brushes all the way in then insert a paperclip to hold them. After installing remember to remove paperclips. God bless

[@DirtPerfect]

Not these

[@thomasdesmond2248]

@@DirtPerfect I never seen brushs without the retaining holes.

[@blackdogexcavator21]

I was hoping to see it run but you can't stop now. That will be a good welder for no more money than you will have invested depending on what it will cost to fix the injection pump.

[@DirtPerfect]

Agree and more to come

[@DJ2CM]

Great video . Big difference your $$$ or someone else's you can just keep throwing parts at it ! $$$ sometimes you just need to walk away and think and you know that's going to happen no one want to be defeated . You will be back at it . Have a great one and thanks for sharing 😀👍 🇨🇦 Craig

[@DirtPerfect]

I agree and thanks

[@wizard1800]

Keep after it. You will get it to run.

[@DirtPerfect]

Check out the other video

[@casycasy5199]

hope you keep working on it .need to see it run

[@DirtPerfect]

Yup stay tuned

[@stevesmith8107]

Good stuff. One thing you can do. Is if you have a head gasket that isnt destroyed. You can contact Cometic gaskets an send it to them an they will copy it an make you a MLS style gasket for a very decent price.

[@DirtPerfect]

Good info thanks steve

[@joshmaynard8231]

Awesome video Mike don't give up on her yet. Little more love and she will fire up.

[@DirtPerfect]

Thanks buddy

[@jpdavis7676]

Look up COMPANION CYLINDERS to adjust valves. It will make your engine life so much easier.

[@DirtPerfect]

👍

[@artm5294]

it must be treat to work on a nice clean engine like that on an engine stand.

[@michealmartin8565]

You can take a piece of wire and push the brushes back and put a piece of wire in it to hold the brushes back in the holder and pull it out when you put the brushes back in the weldor

[@DirtPerfect]

I have done that before but this one don’t have that little hole for the wire

[@roberttweed7854]

Love the work boots

[@DirtPerfect]

😁

[@michealmartin8565]

When I can't get a weldor to prime I put a little air to the tank and force fuel in the pump not to much air just a little pressure

[@DirtPerfect]

It has a electric pump on it

[@groundupexcavation]

Watching this makes me think of my sa200 that I really need to work on. The factory low idle is shot so I gotta put electronic idler solenoid on it. I’m scared to mess with it cause it’s a 1958 and it’s had some rigging done and I’m not to familiar with it yet and don’t know what original or factory other than someone put a dual plug on it that I’m gonna eventually take off. But it runs decent and still welds after sitting for 8 years untouched.

[@lisawest7002]

Mike,in your spare time you need to teach Captain how to run a dozer. He gets it done,but he struggles.😁😁

[@DirtPerfect]

Lol trust me I know 😜

[@MJ-vv2fr]

I could be wrong, but it almost sounds like it has a dead skip when it cranks. One cylinder has less compression than the rest and it speeds up as it cranks.

[@DirtPerfect]

Don’t believe so and that would not keep it from at least priming

[@anthonyanderson1954]

osen the fuel lines. then get a spare fuel cap and braze an air fitting on it. and put the air hose to it .thats how I used to prime Thermo kings in the winter .just make sure the supply lines are loose at the injectors.

[@DirtPerfect]

It has a electric lift pump on it

[@jerrydyke2291]

Great video DP! 😁

[@DirtPerfect]

Thanks jerry

[@stephenhunter70]

It's possible that the armature was bolted to the motor and then it was inserted in the welder alternator case.

[@DirtPerfect]

I do think so

[@sassafrasvalley1939]

Hey Mike... you have to keep going... you already spent a couple of days on it... you need space in the shop... it’s way to heavy to use as a trot line sinker! Petting your pup with greasy hands... that’s what I do. She loves it... but it puts me in the doghouse as soon as my wife sees the dog!!! Nice job shooting and editing the video too.

[@DirtPerfect]

Thanks William always look forward to your comments they make my day 😁

[@BlueDually4x4]

Stupid question but is the lift pump itself priming and pushing fuel to the injection pump? If you had to tap on it to get it to wake up that would be the first thing I would be checking.

[@DirtPerfect]

It also has a electric pump and it’s working

[@vernchaput6368]

Did you try starting fluid? That would inform you as to whether it is fuel related or some other issue.

[@DirtPerfect]

No need for that you see smoke check out the next video on this

[@dudleycornman1624]

They make little wires that are for fishing bolts into tight places... would have been nice if you had one. :)

[@geraldplender1723]

Could you attach arm, to motor and slide whole assembly in

[@shanerussell8894]

take top of pump off feul sut off to lever wit rod on stuck its a cav pump simple set up

[@DirtPerfect]

Yup not it stay tuned more to come on it

[@Farmall450]

I remember his video of it

[@kristystaats8390]

Dont give up on it

[@DirtPerfect]

Check one the next video

[@americanpatriot2.06]

I never liked those Stanadyne injection pumps. Especially the ones they put on the 6.2 and 6.5 diesel engines. They didn't last long and were excessively over priced. Their biggest issue was over heating (not good for the close tolerances) and even the external heat exchangers didn't help much.

[@DirtPerfect]

Agree on the 6.5 for sure

[@The_blindpizzaguy1300]

Knowing you you’ll probably have it fixed soon. I wish I knew more to help you but unfortunately I don’t.

[@DirtPerfect]

Thanks Alex and thanks for watching buddy

[@cameronoverfield8764]

You grew up building engines it looks like! 👍. Not me I would be lost!

[@DirtPerfect]

Built a few

[@teebugg66]

I think they bolt the armature to the flywheel then put it in the gen case. Looks like you got it tho, I wish my neighbors gave me good stuff like that! Lol

[@DirtPerfect]

Lol I thought about that after the fact

[@williamstentzsr.9568]

Now days those pumps ar not cheap. That's a bummer...

[@michealmartin8565]

Your doing a good job not to have took it apart

[@DirtPerfect]

Thanks Michael

[@michealmartin8565]

I like that crane .they come in handy

[@DirtPerfect]

Yes it does have a video coming on it in a few weeks

[@arnoldromppai5395]

the bigger puzzle is why logger wade ripped the whole engeine out of the welder, to do a head job in the first place, them millers are so easy to work on, just remove the cover off the welder and pull the head.. .. lol, i guess he thought the head was on the bottom... hhhaaa

[@TarZan49]

Did you try changing the spark plugs? They come in a set for plugs. The fifth plug goes in the auxiliary cylinder under the bolt carriage.

[@DirtPerfect]

Lol no

[@TarZan49]

Thanks for playing along. This video was one of my favorites. Keep up the good work.

[@4932gb]

you need some input fuel press. Try a cheap electric lift pump. Worked for me.

[@DirtPerfect]

Has one on it and is working

[@roydawson4882]

Try a squirt of easy start, just might give it the kick to start

[@DirtPerfect]

👍

[@LoBeau53]

I am older and lazier with bad knees. The first thing I would have done is put the welder up on stands so that I could stand or sit beside it and get off the floor.

[@richardhedrick5601]

Don't give up you will get it 😉

[@DirtPerfect]

😁

[@williamstentzsr.9568]

Slip ring is correct

[@cameronoverfield8764]

Good video man like always good

[@DirtPerfect]

Thanks buddy

[@codymcvicar]

Give it some ether. I’ve had a pump do the same thing. I gave it a little ether and than broke the lines loose than the pump started to pump fuel. Maybe that will work?

[@DirtPerfect]

👍

[@russorpcom]

I too enjoy your videos and your camera work. A shame it did not work out but I too think that you have so much money in it I would continue. You definitely could not get a Miller Welder for cheap if it was free or next to nothing.

[@DirtPerfect]

Thanks Richard and stay tuned 😁

[@anthonysimonhough9691]

Try a bit of engine start /ether

[@douglaspeck8535]

you should have pushed the brushes in farther and use nails in the small holes then pull out nails after brush holder is in place

[@DirtPerfect]

Not a hole looked

[@douglaspeck8535]

@@DirtPerfect ok in the video it looked like 3 holes for holding brushes,now i see they are not aligned

[@kdennis9115]

Hi Mike, I have a Miller big 40 welder with a gas engine installed. I want to change the gas engine to a diesel engine. What type of diesel engine did you just rebuild, Or would you recommend for my welder?

[@DirtPerfect]

To be honest I have no idea sorry