Issued July 2013 • Index No. ED/10.5

Big Blue

®

Air Pak

™

Diesel Engine-Driven Welder/

AC Generator/Air Compressor

Quick

Specs

Heavy Industrial

Applications

Railroad Maintenance

Mining Maintenance

Maintenance and Repair Rigs

Processes

DC Stick (SMAW)

AC Stick (SMAW)*

MIG (GMAW)

Flux-Cored (FCAW)

DC TIG (GTAW)

AC TIG (GTAW)*

Submerged Arc (SAW)

Stud Welding — 1/2 inch (12.7 mm)

Air Carbon Arc (CAC-A)

1/2-inch (12.7 mm) carbons

Air Plasma Cutting with Optional Spectrum Models

Battery Charging/Jump Starting*

Air Compressor

Output Range

DC Stick 45–750 A AC Stick 35–575 A*

MIG/FCAW 14–40 V

DC TIG 20–450 A AC TIG 20–375 A*

Battery Charge 12/24 V, 50–750 A*

*Deluxe model only.

Weld Output Rated at 104° F (40° C)

Stick 600 A at 44 V (26.4 kW), 40% duty cycle

Stick 550 A at 42 V (23.1 kW), 60% duty cycle

MIG/FCAW 500 A at 40 V (20 kW), 100% duty cycle

AC TIG 400 A at 26 V (10.4 kW), 100% duty cycle*

Air Compressor

100 PSI, 60 CFM, 100% duty cycle

Generator Output Rated at 104° F (40° C)

5500 watts peak, 4000 watts continuous

20,000 watts 3-phase/12,000 watts 1-phase continuous*

Accu-Rated ™ – Not Inflated

Generator Power

Welder/generator/air compressor.

One machine that will do it all. Designed and built to be the most reliable highoutput system in the world.

Ultra-reliable industrial rotary screw

air compressor. Belt-driven with automatic belt tensioner with a life expectancy of 30,000 hours.

Independent compressor controls.

On/off switch for applications not requiring compressed air. At idle

speed will produce 100 PSI at 40 CFM.

Weatherproof Lexan ® nameplate resists cracking and fading, and is color-coded for ease of operation.

Enclosed robust case design protects internal components from impact and allows air flow to cool and prolong the life of the engine. Also reduces sound levels.

GFCI receptacle as required on most jobsites to protect operators from electrical hazards.

Low maintenance with easy single-side access to engine and 500 hour oil changes for both engine and compressor.

Quiet at only 70 decibels (95 Lwa) at idle and 79 decibels (104 Lwa) at maximum output. Improves jobsite communications.

Big Blue Air Pak Deluxe model shown.

Welder/Generator/Air Compressor is warranted by Miller for 3 years, parts and labor.

Engine is warranted by Deutz for 3 years.

Miller Electric Mfg. Co.

An ITW Company

1635 West Spencer Street

P.O. Box 1079

Appleton, WI 54912-1079 USA

Equipment Sales US and Canada

Phone: 866-931-9730

FAX: 800-637-2315

International Phone: 920-735-4554

International FAX: 920-735-4125

MillerWelds.com

Heavy-duty low-speed industrial turbocharged

diesel engine provides ample power at high altitudes.

Meter maintenance displays

• Fuel gauge

• Hour meter function

• Oil change interval

• High coolant temperature and low oil pressure shutdowns

• Low fuel shutdown — engine shuts down before system runs out of fuel, making restarts easy.

Hot Start ™ provides positive stick electrode starts to make it easy to start all types of electrodes.

Arc-Drive ™ makes welding easy.

Automatically enhances Stick welding, especially on pipe, by focusing the arc and preventing the electrode from going out.

AC/DC/battery charge/jump start for AC TIG welding and 12- or 24-volt batteries. Simply select the battery voltage and connect cables to the separate battery output studs.

Included with deluxe model only.

Note: High-frequency unit required for

AC TIG.

2

9

4

5

6

7

2

3

8

Specifications

(Subject to change without notice.)

Welding

Mode

CC/DC

CV/DC

CC/AC*

Battery*

Charge

Jump Start

Weld

Output

Range

20 – 750 A

14 – 40 V

20 – 575 A

12/24 V

Weld Output Rated at 104˚ F (40˚ C)

NEMA Amperage and Voltage

600 A at 44 V (26.4 kW), 40% Duty Cycle

550 A at 42 V (23.1 kW), 60% Duty Cycle

500 A at 40 V (20 kW), 100% Duty Cycle

500 A at 40 V (20 kW), 100% Duty Cycle

400 A at 36 V (14.4 kW) 100% Duty Cycle

750 A, 12 V, Jump Start

750 A, 24 V, Jump Start

Max. Open-

Circuit

Voltage

95

56

64

14/28

Generator Output

Rated at 104˚ F (40˚ C)

Peak: 5500 watts

Continuous: 4000 watts, 34/17 A,

120/240 VAC, 60 Hz while welding

Additional Generator Power for

Deluxe Models (while NOT welding)

3-phase: 20 kW, 48 A, 240 VAC or

1-phase: 12 kW, 50 A, 120/240 VAC

Dimensions**

H: 43 in.

(1092 mm)

W: 28.5 in.

(724 mm)

D: 69.5 in.

(1765 mm)

Weight

(without fuel)***

Net: 1931 lb.

(876 kg)

Ship: 1982 lb.

(899 kg)

Deluxe Model

Net: 1956 lb.

(887 kg)

Ship: 2007 lb.

(910 kg)

*Deluxe model only. **Additional 7 in. (178 mm) to top of exhaust. ***Additional 165 lb. (75 kg) when fuel tank is full.

Certified by Canadian Standards Association to both the Canadian and U.S. Standards.

Meets NEMA and IEC output ratings.

Engine Specifications (Engines warranted separately by the engine manufacturer.)

Engine Brand

Deutz

TD2011L04o

Features

EPA Tier 4i compliant, turbocharged, direct-injected, liquid-cooled (oil) engine.

Right-side service access with service intervals of 500 hours for oil and filters. MSHA approved with purchase of certificate from Deutz dealer.

HP

63.4

Type

4-cylinder, industrial, liquid-cooled diesel

Engine Speeds

Weld: 1850 RPM

Idle: 1250 RPM

Capacities

Fuel: 25 gal. (95 L)

Oil: 11 qt. (10.4 L)

Coolant: Integrated oil

Automatic Engine

Shutdowns

Low Oil Pressure,

High Coolant

Temperature,

Low Fuel Level

Air Compressor

Compressor

Brand

Ingersoll Rand

CE55 G1

Features

Rotary screw with electric clutch for on/off.

Oil change intervals of 500 hours (same as engine). Life expectancy of 30,000 hours.

Free Air Delivery at 1850 RPM

60 CFM

(1.70 m 3 /min.)

Free Air Delivery at 1235 RPM (Idle)

40 CFM

(1.13 m 3 /min.)

Working

Pressure

Constant

100 PSIG

(7 bar)

Duty

Cycle

100%

Oil

Capacity

5 qt. (4.7 L)

Automatic

Compressor

Shutdowns

Oil Temperature

1

Control Panel

15

16

17

18

19

20

21

10

11

12

13

14

1. AC/DC Voltmeter*

2. AC/DC Ammeter*

3. Amperage Range Switch

4. Amperage/Voltage Adjust Control

5. Amperage/Voltage Adjust Switch and Remote Amperage/Voltage

Adjust 14-Pin Receptacle

6. Process/Contactor

Selector Switch

7. 120 VAC, 20 A GFCI

Duplex Receptacle

8. 240 VAC, 30 A TwistLock

Receptacle (NEMA L6-30)

9. Air Outlet Valve 3/4-inch NPT

10. Engine Oil Pressure Gauge

11. Fuel Gauge — displays engine hours and oil change intervals

International Model

12. Engine Coolant Temperature Gauge

13. Battery Voltmeter

14. Air Compressor Pressure Gauge

15. Air Compressor On/Off Switch

16. Engine Control Switch

17. Starting Aid Switch*

18. 20 kW, 3-Phase Generator*

19. Strain Relief*

20. 50 A, 3-Phase Circuit Breaker*

21. 50 A, 1-Phase 120/240 V

Receptacle (NEMA 14-50)*

22. AC/DC/Battery Charge/

Jump Start Switch*

23. International Model — 240 VAC,

16 A Pin and Sleeve Receptacle

*On Select Models

22

7 23

Performance Data

140

120

100

80

60

40

20

0

0

280

260

240

220

200

180

0

FUEL CONSUMPTION CURVE

3.00

2.75

2.50

2.25

2.00

1.75

1.50

1.25

1.00

0.75

0.50

0.25

0.00

0

IDLE

50

IDLE WITH AIR

100 150 200

WELD AND AIR

250 300 350 400

WELD ONLY

450 500 550 600

DC WELD AMPERES AT 100% DUTY CYCLE

GENERATOR POWER CURVE OPTION

12 kW

1-PHASE

10

20 kW

3-PHASE

60 70 20 30 40

AC AMPERES

50

AIR SUPPLY CURVE

10 20

IDLE

50 60 70 30

CFM

40

Ingersoll Rand Rotary Screw Air Compressor

This industrial-grade compressor, has a life expectancy of 30,000 hours, is belt driven and utilizes an electric clutch control to allow the compressor to be turned off if not needed. This design increases efficiency, reduces fuel consumption and saves you money at the pump.

An automatic belt tensioner provides proper belt tension even after years of service. The compressor is protected by a high-temperature shutdown switch.

Toolless Generator Brushes

100 percent copper-wound generator features quick and easy brush and slip ring inspection. Brushes can be removed and/or replaced in a matter of seconds.

The Vault

Superior Circuit Board Design

Our critical circuit boards are engineered to carry low power and low heat to reduce thermal stress and minimize expansion and contraction. In contrast, our competitor’s boards carry high power and high heat, making them more vulnerable to failure.

“The Vault” Makes Upgrading to Miller ®

CC/CV Units Worry-Free

Concerns with circuit board reliability have resulted in some operators steering clear of

CC/CV welder/generators — even though they offer a superior arc and multiple welding processes. Miller circuit board reliability isn’t a concern since all Big Blue multiprocess industrial engine drives feature the Vault.

Created out of two aluminum halves sealed with silicone, as well as watertight harness connections, the Vault provides a clean circuit board environment, protecting the electronics

— and controlling output — in heavy industrial applications. No other competitor protects their electronics with a sealed vault, leaving critical circuit boards exposed to harsh elements that can disrupt the machine’s electronics, and therefore, its operation.

3

4

Genuine Miller

®

Accessories

Desiccant Air Dryer System #195 117

A regenerating inline air dryer system that eliminates moisture in the air stream to prevent air tool freeze-ups in cold climates.

Internal thermostat and heating elements insure good air quality in all climates.

The system can be mounted on the side of the machine or remotely for truck mount installations.

Weld Ammeter and Voltmeter

#195 131 Field

Panel-mounted AC/DC analog meters to monitor weld output.

U.S. Model Full KVA

Plug Kit #119 172 Field

1-phase, 120/240 VAC, 50 A plug (NEMA 14-50P) to fit full KVA receptacle.

International Plug

#255 416 Field

1-Phase, 240 VAC, 16 A plug

Cold Weather Starting Kit*

#195 086 Field

120 V oil pan heater element.

Engine Filter Kit #246 988 Field

Includes all filters required for proper engine maintenance. Oil filter, primary and secondary fuel filter, and primary air filter.

Compressor Filter Kit #246 991 Field

Includes all filters required for proper compressor maintenance. Oil filter, air filter and coalescing filter.

FA-1D Lockable Flame Arrestor

Fuel Cap #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.

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 Field

Saddle-bag-style cable holder.

Convenient wraparound storage of coiled cable for transportation.

Stores 100 feet of 2/0 cable on each side.

Note: For best results do not weld when cable is coiled!

Protective cover cannot be used with cable holder.

Protective Cover

#195 159 Field

Blue water-resistant canvas cover resists stains and mildew, and protects the finish of your welder.

Note: Protective cover cannot be used with cable holder.

MIG (GMAW) or Flux-Cored (FCAW)

SuitCase ® X-TREME ™ 8VS Wire Feeder

#951 182

SuitCase ® X-TREME ™ 12VS Wire Feeder

#951 543

Lightweight, voltage-sensing wire feeders include secondary contactor, gas valve and drive roll kit. See Lit. Index No. M/6.41

and M/6.42.

SuitCase ® 8RC Wire Feeder #951 186

SuitCase ® 12RC Wire Feeder #951 188

Lightweight and flexible enough to run a variety of wires up to .062-inch diameter.

Includes remote voltage control and drive roll kit. See Lit. Index No. M/6.5.

Stick (SMAW) Welding

Weld Leads

2/0 Stick Cable Set, 50 ft. (15 m)

#173 851

Consists of 50-foot (15 m) 2/0 electrode cable with holder, and 50-foot (15 m) work cable with clamp. 350 A, 100% duty cycle.

2/0 Stick Cable Set, 100/50 ft. (30.5/15 m)

#043 952

Consists of 100-foot (30.5 m) 2/0 electrode cable with holder, and 50-foot (15 m) work cable with clamp. 300 A, 100% duty cycle.

Spoolmatic ® 30A Spool Gun #130 831

Air-cooled, 200-amp, 1-pound spool gun for aluminum MIG. See Lit. Index No. M/1.73.

WC-24 Control #137 549

Use with Spoolmatic 30A.

XR ™ Wire Feeders and Guns

Push-pull system designed to handle difficult-to-feed soft alloy wires such as aluminum. See Lit. Index No. M/1.7,

M/1.71, and M/1.73.

Genuine Miller

®

Accessories

(Continued)

TIG (GTAW) Welding

Plasma Cutting

Dynasty ® 200 Series

For premium portable AC/DC TIG arc quality. See Lit.

Index No. AD/4.8.

HF-251 Series

#042 388

HF-251D-1, 115 VAC

High-frequency arc starter and stabilizer.

See Accessory Lit.

Index No. AY/5.0.

Remote Controls

Wireless Remote

Hand Control

#300 430

For remote current, voltage and contactor control. Receiver plugs directly into the 14-pin receptacle of Miller machine.

300-foot (91.4 m) operating range.

Requires Wireless Antenna Kit #300 749.

Wireless Antenna Kit #300 749

Required for Pro Series engine drives.

Optional on other compatible Miller products where improved reception is desired.

RMLS-14 #129 337

Momentary- and maintained-contact rocker switch for contactor control. Push forward for maintained contact and back for momen tary contact. Includes 26.5-foot

(8 m) cord and 14-pin plug.

RHC-14 Hand Control #242 211 020

Miniature hand control for remote current and contactor control. Dimensions: 4 x 4 x

3.25 inches (102 x 102 x 82 mm). Includes

20-foot (6 m) cord and 14-pin plug.

RCC-14 Remote Contactor and Current

Control #151 086

Side-to-side rotary-motion fingertip control fastens to TIG torch using two Velcro ® straps. Includes 26.5-foot (8 m) cord and

14-pin plug.

Extension Cables for 14-Pin

Remote Controls or 24 VAC Wire Feeders

#242 208 025 25 ft. (7.6 m)

#242 208 050 50 ft. (15.2 m)

#242 208 080 80 ft. (24.4 m)

Spectrum 375 X-TREME and 625 X-TREME shown.

Spectrum ® 375 X-TREME

See Lit. Index No. PC/9.2.

™

Spectrum ® 625 X-TREME

See Lit. Index No. PC/9.6.

™

#907 529

#907 531

Spectrum ® 875 #907 390-01-1

See Lit. Index No. PC/9.8.

The Spectrum 375 X-TREME and 625

X-TREME come complete with protective

X-CASE ™ (not shown).

RFCS-14 HD Foot Control #194 744

Heavy-duty foot control for current and contactor control. Includes 20-foot (6 m) cord and 14-pin plug.

5

6

Trailers and Hitches

(Note: Trailers are shipped unassembled.)

Mounting Specifications

4 holes

H

4 West Four-Wheel Steerable

Off-Road Trailer #042 801

A heavy-duty 2570-pound (1166 kg) capacity trailer designed for use in mines, quarries, and other rough terrain. Has narrow 22-foot (6.7 m) turning radius.

Includes 3-inch (76 mm) lunette eye, universal hitch and safety chains.

A B

C

Front Panel

HWY-224 Trailer

#043 805 For highway use.

OFR-224 Trailer

#043 802 For off-road use.

A 2650-pound (1202 kg) capacity trailer.

Welded steel tubing frame, heavy-duty axle with roller bearing hubs and leaf-spring suspension. Includes jack stand and 2-inch

(50 mm) ball hitch. HWY-224 also includes fenders and lights.

Cable Tree #043 826

Provides an area to conveniently wrap weld cables and extension cords.

D E

F

G

A. 29.812 in. (757 mm)

B. 27.5 in. (699 mm)

C. 1 in. (25 mm)

D. 11.625 in. (295 mm)*

E. 46.375 in. (1178 mm)*

F. 58 in. (1473 mm)*

G. 69.5 in. (1765 mm)

H. .562 in. (14 mm) diameter

Height: 50 in. (1270 mm) (to top of exhaust)

Width: 28.5 in (724 mm)

(mounting brackets turned in)

30.75 in (781 mm)

(mounting brackets turned out)

Depth: 69.5 in (1765 mm)

*With mounting brackets in center position.

Dimensions vary with location of mounting brackets.

Dual Hitch #300 831

2-inch (50 mm) ball hitch and 3-inch

(76 mm) lunette eye in one reversible assembly.

Trailer Specifications (Subject to change without notice.)

Model

4 West

HWY-224

OFR-224

Gross Axle

Weight Rating

2000 lb./axle

(907 kg/axle)

3500 lb.

(1588 kg)

Gross Vehicle

Weight Rating

3000 lb.

(1361 kg)

2960 lb.

(1343 kg)

Net

Payload

2570 lb.

(1166 kg)

2650 lb.

(1202 kg)

Height of Bed

21.25 in.

(540 mm)

18.5 in.

(470 mm)

Road

Clearance

8 in.

(203 mm)

7.5 in.

(191 mm)

Track (Center to center of tires)

55.25 in.

(1403 mm)

52 in.

(1321 mm)

Standard Tires

(Standard rating or P-size rating)

B78-13

B78-13

Dimensions

Length: 91 in. (2311 mm)*

Width: 61.25 in. (1556 mm)

Length: 105 in. (2667 mm)

Width: HWY– 59.5 in. (1511 mm)**

OFR– 58.438 in. (1484 mm)

Net

Weight

430 lb.

(195 kg)

320 lb.

(145 kg)

*Does not include tongue. **Width at outside of fenders.

Typical Installations

Stick (SMAW) Basic Equipment

Flux-Cored (FCAW) Basic Equipment

SuitCase ®

SuitCase ®

X-TREME ™ 8VS

X-TREME ™ 12VS

#951 182

#951 543

MIG (GMAW) Basic Equipment

SuitCase ®

SuitCase ®

8RC #951 186

12RC #951 188

Aluminum MIG (GMAW) Basic Equipment

Spoolmatic ®

WC-24

30A #130 831

#137 549

TIG (GTAW) Basic Equipment

Dynasty ® 200 Series

HF-251D-1 #042 388*

*TIG power cable adapter required.

Plasma Basic Equipment

Spectrum ® 375 X-TREME ™

Spectrum ® 625 X-TREME ™

Spectrum ® 875

#907 529

#907 531

#907 390-01-1

Stick Electrode

Work

14-Pin

X-TREME 8VS/

X-TREME 12VS

Feeder

SuitCase

8RC/12RC

Flux-Cored Gun

Work

MIG Gun

Work

Aluminum MIG with

Spoolmatic 30A Gun

14-Pin

WC-24

14-Pin

HF-251D-1

TIG

Torch

Work

Work

Cutting Torch

Spectrum

Work

7

Ordering Information

Equipment and Factory Options

Big Blue ® Air Pak ™ CC/CV

Stock No.

#907 062

#907 062-01-1

#907 062-04-1

#907 062-07-1

Description

U.S. Base Model with Automatic Idle, Engine Gauges,

5.5 kW AC Generator, 12 V Intake Manifold Heater

International Model with 50/60 Hz, Dry Battery, Automatic Idle,

Engine Gauges, 5.5 kW AC Generator, 12 V Intake Manifold Heater

U.S. Cold Weather Model with Automatic Idle, Engine Gauges,

5.5 kW AC Generator, Weld Meters, Battery Lockout/Tagout Disconnect

Switch, 12 V Intake Manifold Heater, 120 V Oil Pan Heater

U.S. Deluxe Model with Automatic Idle, Engine Gauges, 5.5 kW AC

Generator, Weld Meters, Battery Lockout/Tagout Disconnect Switch,

12 V Intake Manifold Heater, 120 V Oil Pan Heater, Vandalism Lockout Kit,

AC/DC/Battery Charge/Jump Start Switch, 20 kW Generator,

Field Accessories

Desiccant Air Dryer System

Weld Ammeter and Voltmeter Kit

U.S. Model Full KVA Plug Kit

International Plug

Cold Weather Starting Aid

Engine Filter Kit

Compressor Filter Kit

Lockable Flame Arrestor Fuel Cap

Vandalism Lockout Kit

Cable Holder

Protective Cover

Stick Welding Leads

Plasma Cutting

Spectrum ® 375 X-TREME ™

Spectrum ® 625 X-TREME ™

Spectrum ® 875

MIG/Flux-Cored Welding

SuitCase ® X-TREME ™ 8VS

SuitCase ® X-TREME ™ 12VS

SuitCase ® 8RC

SuitCase ® 12RC

Spoolmatic ® 30A Spool Gun

WC-24 Control

XR ™ Wire Feeder Control and Guns

MIG (GMAW)/Flux-Cored (FCAW) Guns

TIG Welding

Dynasty ® 200 Series

HF-251D-1

Coolant System

Remote Controls

Trailers and Hitches

4 West Four-Wheel Steerable Trailer

HWY-224 Trailer

OFR-224 Trailer

Cable Tree

Dual Hitch

#195 117

#195 131

#119 172

#255 416

#195 086

#246 988

#246 991

#043 947

#195 118

#043 946

#195 159

#907 529

#907 531

#907 390-01-1

#951 182

#951 543

#951 186

#951 188

#130 831

#137 549

#042 388

#042 801

#043 805

#043 802

#043 826

#300 831

Date:

Removes moisture from air supply

AC/DC analog weld output meters

1-phase, 120/240 VAC, 50 A

1-phase, 240 V, 16 A

120 V oil pan heater

Includes air, oil and fuel filters

Includes air, oil and coalescing filters

Padlock not included

Lockable front control panel and engine compartment

Stores up to 200 ft. of 2/0 weld cable

Will not fit over machine with cable holder attached

See page 4

Includes X-CASE ™ . See Lit. Index No. PC/9.2

Includes X-CASE ™ . See Lit. Index No. PC/9.6

See Lit. Index No. PC/9.8

See Lit. Index No. M/6.41

See Lit. Index No. M/6.42

See Lit. Index No. M/6.5

See Lit. Index No. M/6.5

Requires WC-24 Control. See Lit. Index No. M/1.73

See Lit. Index No. M/1.5

See Lit. Index No. M/1.7, M/1.71, and M/1.73

See Lit. Index Nos. AY/15.0, AY/16.0 and AY/17.0

See Lit. Index No. AD/4.8

High-frequency unit for AC TIG welding. See Lit. Index No. AY/5.0

See Lit. Index No. AY/7.2

See page 5

Trailer with lunette eye, universal hitch and safety chains. For off-road use

Trailer with lights, fenders and 2-in. (50 mm) ball hitch. For highway use

Trailer with 2-in. (50 mm) ball hitch. For off-road use

Trailer mounted cable holder for HWY-224 or OFR-224

Combination 2-in. (50 mm) ball hitch and 3-in. (76 mm) lunette eye in one reversible assembly. For HWY-224 or OFR-224

Total Quoted Price:

Qty.

Price

Distributed by:

© 2013 Miller Electric Mfg. Co.