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Big Blue Air Pak ® Heavy Industrial Applications Railroad Maintenance Mining Maintenance Maintenance and Repair Rigs Quick Specs Processes Stick (SMAW) MIG (GMAW) Flux Cored (FCAW) Submerged Arc (SAW) AC TIG (GTAW)* DC TIG (GTAW) Issued October 2008 • Index No. ED/10.5 ™ Engine-Driven Welder/ AC Generator/Air Compressor Stud Welding — 1/2 in (12.7 mm) Air Plasma Cutting with Optional Spectrum Models Air Carbon Arc (CAC-A) 1/2 in (12.7 mm) Carbons Battery Charging/Jump-Starting* Air Compressor Weld Output Rated at 104°F (40°C) Output Range 5,500 Watts Peak — 4,000 Watts Continuous 20,000 Watts 3-Phase/12,000 Watts 1-Phase Continuous* Stick 600 A, 44 V, 26.4 kW, 40% Duty Cycle Stick 550 A, 42 V, 23.1 kW, 60% Duty Cycle MIG/FCAW 500 A, 40 V, 20 kW, 100% Duty Cycle AC TIG 400 A, 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) DC Stick 45–750 A MIG/FCAW 14–40 V DC TIG 20–450 A AC 20–575 A* Battery Charge 12/24 V, 50–750 A* *Deluxe Model Only. The Power of Blue . Accu-Rated™– Not Inflated Generator Power ® turbocharged four-cylinder diesel engine provides ample power at high altitudes. Welder/generator/air compressor. One machine that will do it all. Designed and built to be the most reliable highoutput system in the world. Improved! Maintenance Displays! ultra-reliable industrial rotary screw air compressor. Belt-driven with automatic belt tensioner with a life expectancy of 30,000 hrs. Independent compressor controls. On/off switch for applications not requiring compressed air. At idle speed will produce 100 PSI at 40 CFM. NEW! Meter maintenance display • Hour meter function • Oil Change interval • Diesel: High coolant temperature and low oil pressure shutdowns • Diesel: 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. Weatherproof Lexan® nameplate resists cracking and fading, and is color-coded for ease of operation. Arc-Drive makes welding easy. Automatically enhances Stick welding, especially on pipe, by focusing the arc and preventing the electrode from going out. 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. Optional 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. GFCI receptacle as required on most job sites 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. (High-frequency unit required for AC TIG.) Quiet at only 70 dB (95 Lwa) when idle, 79 dB (104 Lwa) at maximum output. Improves work site communications. 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. International Headquarters Web Site An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA Phone: 920-735-4505 USA FAX: 920-735-4134 Canadian FAX: 920-735-4169 International FAX: 920-735-4125 www.MillerWelds.com Specifications (Subject to change without notice.) Welding Mode Weld Output Range CC/DC 20 – 750 A 600 A, 44 V, 26.4 kW, 40% Duty Cycle 550 A, 42 V, 23.1 kW, 60% Duty Cycle 500 A, 40 V, 20 kW, 100% Duty Cycle 95 CV/DC 14 – 40 V 500 A, 40 V, 20 kW, 100% Duty Cycle 56 CC/AC* 20 – 575 A 400 A, 36 V, 14.4 kW 100% Duty Cycle 64 Battery* Charge Jump-Start 12/24 V 750 A, 12 V, Jump-Start 750 A, 24 V, Jump-Start 14/28 Weld Output Rated at 104˚ F (40˚ C) NEMA Amperage and Voltage Max. OpenCircuit Voltage Generator Output Rated at 104˚ F (40˚ C) Dimensions** Peak: 5500 watts Continuous: 4000 watts, 120/240 VAC, 34/17 A, 60 Hz while welding Optional kW 3-phase, 20 kW, 36 A, 240 VAC 1-phase, 12 kW, 50 A, 120/240 VAC while not welding H: 43 in (1092 mm) W: 28-1/2 in (724 mm) D: 67-1/2 in (1715 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) Meets NEMA and IEC output ratings. *Only available on deluxe model. **Additional 7 in (178 mm) to top of exhaust. ***Additional 190 lb (86 kg) when fuel tank is full. CSA approved. Engine Engine Brand Deutz, BF4M 2011 Diesel TD2011L04w Engine Speeds Features HP Type Tier IVi, EPA-certified, turbocharged directinjected, liquid-cooled (oil) engine. Right side service access with 500 hr intervals for oil and filters. MSHA approved with purchase of certificate from Deutz dealer. 63.4 Four-cylinder, industrial, liquidcooled engine 1850 Run 1235 Idle Fuel Capacity 25 gal (95 L) Oil Capacity Automatic Engine Shutdowns 11 qt (10.4 L) Oil pressure Oil temperature Air Compressor Compressor Brand Ingersoll-Rand CE55 G1 Features Rotary screw with electric clutch for on/off. Oil change intervals 500 hrs (same as engine). Life expectancy 30,000 hrs. Free Air Delivery at 1850 RPM Free Air Delivery at 1235 RPM Working Pressure Constant 60 cfm (1.70 m3/min) 40 cfm (1.13 m3/min) Idle 100 psig 7 bar Duty Cycle Oil Capacity Automatic Compressor Shutdowns 100% 5 qt (4.7 L) Oil temperature Control Panel 1 2 10 11 12 13 14 1. 2. 3. 4. 5. 3 15 4 5 16 6 17 7 18 19 6. 7. 8. 8 20 21 9. 10. 11. AC/DC Voltmeter* AC/DC Ammeter* Amperage Range Switch Amperage/Voltage Adjust Control Amperage/Voltage Adjust Switch and Remote Amperage/Voltage Adjust 14-Pin Receptacle Process/Contactor Selector Switch 120 VAC, 20 A GFCI Duplex Receptacle 240 VAC, 30 A TwistLock Receptacle (NEMA L6-30) Air Outlet Valve 3/4 in NPT Engine Oil Pressure Gauge Fuel Gauge—displays engine hours and oil change intervals 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. Engine Coolant Temperature Gauge Battery Voltmeter Air Compressor Pressure Gauge Air Compressor On/Off Switch Engine Control Switch Starting Aid Switch* 20 kW, 3-Phase Generator* Strain Relief* 50 A, 3-Phase Circuit Breaker* 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 International Model 22 7 9 2 23 Performance Data GENERATOR POWER CURVE OPTION 280 12 kW 1-PHASE 260 WELD AND AIR AC VOLTS US Gal./Hr. 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 WELD ONLY 240 20 kW 3-PHASE 220 200 IDLE IDLE WITH AIR 180 0 50 100 150 200 250 300 350 400 450 500 550 600 0 10 20 30 40 AC AMPERES DC WELD AMPERES AT 100% DUTY CYCLE 50 70 VOLT/AMP CURVE – STICK MODE AIR SUPPLY CURVE 100 140 120 300–Max 185–525 125–400 55–125 80 80 DC VOLTS 100 PSI 60 IDLE 60 60 40 40 20 20 0 0 10 20 30 40 50 60 0 70 0 100 200 300 CFM 600 700 800 900 1000 VOLT/AMP CURVE – DC TIG MODE 100 100 90 80 70 60 50 40 30 20 10 0 0 60–450 40–330 30–220 20–110 80 DC VOLTS DC VOLTS 500 DC AMPERES VOLT/AMP CURVE – MIG MODE MAX 60 40 20 MIN 0 100 200 300 400 500 600 700 800 900 1000 0 DC AMPERES VOLT/AMP CURVE – AC TIG MODE 100 DC VOLTS 80 AC VOLTS 400 60 40 20 0 0 100 200 300 400 AC AMPERES 500 600 700 100 200 300 400 DC AMPERES 500 600 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% copperwound generator features quick and easy brush and slip ring inspection. Brushes can be removed and/or replaced in a matter of seconds. BATTERY CHARGE OUTPUT 50 45 40 35 30 25 20 15 10 5 0 0 100 200 300 400 500 600 700 800 900 1000 DC AMPS The Vault Superior Circuit Board Design Miller’s 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’s circuit board reliability isn’t a concern since all PRO 300 and 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 Genuine Miller Accessories Field Kit 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. AC/DC/Battery Charge/Jump-Start Switch #195 148 Field AC TIG welding and 12/24 V battery charge/ jump-starting system. FA-1D Lockable Flame Arrestor Fuel Cap #043 947 Fuel cap can be padlocked to prevent vandalism. A built-in flame arrestor prevents flames or sparks from entering the fuel tank. Cold Weather Starting Aids* #043 959 Field 12 V intake manifold heater. #195 086 Field 120 V oil pan heater element. Cable Holder #043 946 Saddle-bag-style cable holder. Convenient wraparound storage of coiled cable for transportation. Stores 100 ft of 2/0 cable on each side. Note: For best results do not weld when cable is coiled! Canvas cover cannot be used with cable holder. Battery Lockout/Tagout Disconnect Switch #195 120 Field Lockable battery disconnect switch for safe routine maintenance. 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. 4 Millermatic® Passport® Plus #907 401 Portable, all-in-one MIG package features ultimate arc performance, self-contained gas bottle, and flexibility to plug into 115 or 230 V power with Miller exclusive MultiVoltage Plug. See Lit. Index No. DC/12.53. Stick (SMAW) Welding Weld Leads #173 851 2/0, 350 A, 100% duty cycle, 50 ft stinger, 50 ft work cable #043 952 2/0, 300 A, 100% duty cycle, 100 ft stinger, 50 ft work cable Plasma Cutting *Note: for extreme cold weather both starting aids can be used in conjunction. Weld Ammeter and Voltmeter #195 131 Field Panel-mounted AC/DC analog meters to monitor weld output. MIG/Flux Cored Welding Spectrum® 375 X-TREME™ #907 303 Spectrum® 375 X-TREME™ with X-CASE™ #907 339 (not shown) See Lit. Index No. PC/9.2. Spectrum® 625 #907 058 See Lit. Index No. PC/9.5. Spectrum 2050 #903 777-01-2 See Lit. Index No. PC/7.0. SuitCase™ X-TREME™ 8VS Wire Feeder #300 093 SuitCase™ X-TREME™ 12VS Wire Feeder #195 500 Lightweight, portable, voltage-sensing wire feeders include secondary contactor and gas valve. Require drive roll kit. See Lit. Index No. M/6.41. Genuine Miller Accessories MIG/Flux Cored Welding (continued) (continued) WC-24 Control #137 549 Use with Spoolmatic 30A. Remote Controls 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. RHC-14 Hand Control #129 340 Miniature hand control for remote current and contactor control. Dimensions: 4 x 4 x 3-1/4 in (102 x 102 x 82 mm). Includes 20 ft (6 m) cord and 14-pin plug. TIG (GTAW) Welding SuitCase™ 8RC Wire Feeder #194 938 SuitCase™ 12RC Wire Feeder #194 940 Lightweight, modular design and flexible enough to run a variety of wires up to 5/64 in diameter. Comes standard with remote voltage control. See Lit. Index No. M/6.5. Dynasty® 200 Series For premium portable AC/DC TIG arc quality. See Lit. Index No. AD/4.8. RFCS-14 HD Foot Control #194 744 Heavy-duty foot current and contactor control. Includes 20 ft (6 m) cord and 14-pin plug. RMLS-14 #129 337 14-pin plug Momentary- and maintainedcontact rocker switch for contactor control. Push forward for maintained contact and back for momentary contact. Includes 20 ft (6 m) cord. S-32SL Wire Feeder #109 294 Simple to use, but with all the features needed for heavy-duty applications up to 7/64 in wire diameter. See Lit. Index No. M/6.21. HF-251 Series #042 388 HF-251D-1, 115 VAC High-frequency arc starter and stabilizer. See Accessory Lit. Index No. AY/5.0. Spoolmatic® 30A Spool Gun #130 831 Air-cooled, 200-amp, 1-lb spool gun for aluminum MIG. See Lit. Index No. M/1.73. RCC-14 Remote Contactor and Current Control #151 086 14-pin plug Rotary-motion fingertip control fastens to TIG torch using two Velcro® straps. Includes 28 ft (8.5 m) control cord. Extension Cords for 14-Pin Remote Controls #122 973 25 ft (7.6 m) #122 974 50 ft (15.2 m) #122 975 75 ft (23 m) 5 Trailers and Hitches (Note: Trailers are shipped unassembled.) HWY-224 Trailer #043 805 For highway use. OFR-224 Trailer #043 802 For off-road use. A 2650 lb (1202 kg) capacity trailer. Welded steel tubing frame, heavy-duty axle with roller bearing hubs and leaf-spring suspension. Includes jack stand, 2 in (50 mm) ball hitch. HWY-224 also includes fenders and lights. HWY-430 Tandem Axle Trailer #043 806 Smooth riding with 3750 lb (1701 kg) capacity. Includes hand-operated parking brake, hydraulic brake system, and a break-away device to lock brakes if the trailer comes loose. Includes jack stand, fenders and lights. (Hitch must be ordered separately.) 4 West Four-Wheel Steerable Off-Road Trailer #042 801 A heavy-duty 2570 lb (1166 kg) capacity trailer designed for use in mines, quarries, and other rough terrain. Has narrow 22 ft (6.7 m) turning radius. Includes 3 in lunette eye, universal hitch and safety chains. Note: Trailer is shipped unassembled. Note: Some assembly required. Note: Trailer is shipped unassembled. Cable Tree #043 826 Provides an area to conveniently wrap weld cables and extension cords. Cable Tree #043 826 Provides an area to conveniently wrap weld cables and extension cords. Lunette Eye 2-1/2 in (64 mm) #043 824 Ball Hitch 2 in (50 mm) #043 864 Lunette Eye 3 in (76 mm) #043 863 Trailer Specifications (Subject to change without notice.) Gross Axle Gross Vehicle Weight Rating Weight Rating Net Payload Height of Bed Road Clearance Track (Center to center of tires) Standard Tires (Standard rating or P-size rating) 4 West 2000 lb/axle (907 kg/axle) 3000 lb (1361 kg) 2570 lb (1166 kg) 21-1/4 in (540 mm) 8 in (203 mm) 55-1/4 in (1403 mm) HWY-224 OFR-224 3500 lb (1588 kg) 2960 lb (1343 kg) 2650 lb (1202 kg) 18-1/2 in (470 mm) 7-1/2 in (191 mm) HWY-430 2200 lb/axle (998 kg/axle) 4280 lb (1941 kg) 3750 lb (1701 kg) 19-1/4 in (489 mm) 8-1/2 in (216 mm) Model *Width at outside of fenders. Dimensions Net Weight B78-13 Length: 91 in (2311 mm)** Width: 61-1/4 in (1556 mm) 430 lb (195 kg) 52 in (1321 mm) B78-13B Length: 122-1/2 in (3112 mm) Width: HWY– 61 in (1549 mm)* OFR–58-1/2 in (1486 mm) 355 lb (161 kg) 52 in (1321 mm) B78-13B Length: 156-1/2 in (3975 mm) Width: 61 in (1549 mm)* 530 lb (240 kg) **Does not include tongue. Mounting Specifications 4 Holes Engine End G A B C D E F 6 A. 20 in (508 mm) B. 16-1/2 in (419 mm) C. 1-3/4 in (44 mm) D. 6-1/16 in (154 mm) E. 32-3/4 in (832 mm) F. 45-3/8 in (1153 mm) (Gas) 52 in (1321 mm) (Diesel) G. 13/32 in (10 mm) diameter Height: (to top of exhaust) 33 in (838 mm) (Gas) 34-1/4 in (870 mm) (Diesel) Width: 20 in (508 mm) Depth: 45-7/8 in (1164 mm) (Gas) 52-1/2 in (1334 mm) (Diesel) Typical Installations Stick Electrode Stick (SMAW) Basic Equipment Work Flux-Cored (FCAW) Basic Equipment SuitCase™ X-TREME™ 8VS SuitCase™ X-TREME™ 12VS Flux Cored Gun X-TREME 8VS/ X-TREME 12VS Feeder #300 093 #195 500 Work MIG (GMAW) Basic Equipment SuitCase 8RC SuitCase™ 12RC ™ 14-Pin MIG Gun SuitCase 8RC/12RC #194 938 #194 940 Work Aluminum MIG with Spoolmatic 30A Gun Aluminum MIG (GMAW) Basic Equipment ® Spoolmatic 30A WC-24 14-Pin #130 831 #137 549 WC-24 Work TIG (GTAW) Basic Equipment Dynasty® 200 Series HF-251D-1 #042 388* *TIG power cable adapter required TIG Torch 14-Pin HF-251D-1 Work Cutting Torch Plasma Basic Equipment Spectrum® 375 X-TREME™ #907 303 Spectrum® 375 X-TREME™ with X-CASE ™ #907 339 #907 058 Spectrum® 625 Spectrum® 2050 #903 777-01-2 Spectrum Work 7 Ordering Information Equipment and Factory Options Stock No. Big Blue® Air Pak™ CC/CV Base Model #907 062 International Model #907 062-01-1 Cold Weather Model #907 062-04-1 Deluxe Model Field Kit Accessories Weld Ammeter and Voltmeter Kit Lockable Fuel Cap Flame Arrestor Cold Weather Starting Aids Desiccant Air Dryer System Vandalism Lockout Kit Battery Lockout/Tagout Disconnect Switch AC/DC/Battery Charge/Jump-Start Switch Cable Holder Protective Cover Stick Accessories Welding Leads #907 062-07-1 TIG Accessories HF-251D-1 Water Coolant System TIG Torch, Consumables Qty. Automatic Idle, Engine Gauges, 5.5 kW AC Generator 50/60 Hz, Dry Battery, Automatic Idle, Engine Gauges, 5.5 kW AC Generator 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 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, 20 kW Generator, AC/DC/Battery Charge/Jump-Start Switch #195 131 #043 947 #043 959 #195 086 #195 117 #195 118 #195 120 #195 148 #043 946 #195 159 AC/DC analog weld output meters Padlock not included 12 volt intake manifold heater 120 volt oil pan heater Removes moisture from air supply Lockable front control panel and engine compartment Allows machine battery to be disconnected and locked Field Stores up to 200 ft of 2/0 weld cable Will not fit over machine with cable holder attached #173 851 #043 952 2/0, 350 A, 100% Duty Cycle, 50 ft stinger, 50 ft work clamp 2/0, 300 A, 100% Duty Cycle, 100 ft stinger, 50 ft work clamp Plasma Cutters Spectrum® Plasma Cutter Wire Feeders SuitCase™ X-TREME™ 8VS SuitCase™ X-TREME™ 12VS SuitCase™ 8RC SuitCase™ 12RC S-32SL Wire Feeder Spoolmatic® 30A Spool Gun Guns and Consumables Description See page 4 #300 093 #195 500 #194 938 #194 940 #109 294 #130 831 Includes contactor and gas valve. See Lit. Index No. M/6.41 Includes contactor and gas valve. See Lit Index No. M/6.41 See Lit Index No. M/6.5 See Lit Index No. M/6.5 See Lit. Index No. M/6.21 Requires WC-24 Control. See Lit. Index No. M/1.73 See Lit. Index No. M/10.0 and M/13.4 #042 388 High frequency unit for AC TIG welding See Lit. Index No. AY/7.2 #129 340 #194 744 #129 337 #151 086 #122 973 #122 974 #122 975 Hand control Foot control Momentary and maintained contact switch Fingertip control 25 ft (7.6 m) 50 ft (15.2 m) 75 ft (22.9 m) #043 805 #043 802 #043 806 #042 801 #043 824 #043 863 #043 864 #043 823 #043 826 Highway trailer with 2650 lb (1202 kg) capacity Off-road trailer with 2650 lb (1202 kg) capacity Highway trailer with 3750 lb (1701 kg) capacity. Off-road steerable trailer with 2570 (1166 kg) capacity 2-1/2 in (64 mm). For 224 trailers only 3 in (76 mm). For 430 trailer only 2 in (51 mm). For 430 trailer only For 430 trailer only Works on 224 and 430 trailers Remote Controls RHC-14 RFCS-14 HD RMLS-14 RCC-14 Extension Cords Trailers and Hitches HWY-224 Trailer OFR-224 Trailer HWY-430 Tandem Axle Trailer 4-West Trailer Lunette Eye Ball Hitch Clevis Cable Tree Date: Total Quoted Price: Distributed by: Litho in USA Price
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