Big Blue Air Pak

Issued February 2003 • Index No. ED/10.5

® ™
Engine-Driven Welder/
AC Generator/Air Compressor

Heavy Industrial Applications Stud Welding — 1/2 in (12.7 mm) Weld Output Rated at 104°F (40°C)
Railroad Maintenance Air Plasma Cutting Stick 600 A, 44 V, 26.4 kW, 40% Duty Cycle
Mining Maintenance with Optional Spectrum Models Stick 550 A, 42 V, 23.1 kW, 60% Duty Cycle
Maintenance and Repair Rigs Air Carbon Arc (CAC-A) MIG/FCAW 500 A, 40 V, 20 kW, 100% Duty Cycle
1/2 in (12.7 mm) Carbons AC TIG 400 A, 26 V, 10.4 kW, 100% Duty Cycle*
Processes
Quick Stick (SMAW)
Battery Charging/Jump-Starting*
Air Compressor
Generator Output Rated at 104°F (40°C)
5,500 Watts Peak — 4,000 Watts Continuous
Specs MIG (GMAW)
Flux Cored (FCAW) Output Range 20,000 Watts 3-Phase/12,000 Watts 1-Phase
Submerged Arc (SAW) DC Stick 45–750 A MIG/FCAW 14–40 V Continuous*
AC TIG (GTAW)* DC TIG 20–450 A AC 20–575 A* Air Compressor 100 PSI, 60 CFM, 100% Duty Cycle
DC TIG (GTAW) Battery Charge 12/24 V, 50–750 A*
Weight Net: 1931 lb (876 kg)
*Deluxe Model Only. Ship: 1982 lb (899 kg)

The Power of Blue . ®

turbocharged four-cylinder diesel

engine provides ample power at high altitudes.

Welder/generator/air compressor. Low maintenance with easy

One machine that will do it all. Designed single-side access to engine and
and built to be the most reliable high- 500 hour oil changes for both
output system in the world. engine and compressor.

ultra-reliable Quiet at only 70 dB (95 Lwa)

industrial rotary screw air compressor. when idle, 79 dB (104 Lwa) at
Belt-driven with automatic belt tensioner maximum output. Improves
with a life expectancy of 30,000 hrs. work site communications.

Hot Start™ provides positive stick

Independent compressor controls. electrode starts to make it easy to
On/off switch for applications not start all types of electrodes.
requiring compressed air. At idle
speed will produce 100 PSI at 40 CFM.
Arc-Drive makes welding easy.
Automatically enhances Stick
Weatherproof Lexan® nameplate welding, especially on pipe, by
resists cracking and fading, and is focusing the arc and preventing
color-coded for ease of operation. the electrode from going out.

Enclosed robust case design protects Optional AC/DC/battery charge/

internal components from impact and jump-start for AC TIG welding
allows air flow to cool and prolong the life and 12 or 24 volt batteries. Simply
of the engine. Also reduces sound levels. 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. (High-frequency unit required for
AC TIG.)

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 Phone: 920-735-4505 www.MillerWelds.com
1635 West Spencer Street USA FAX: 920-735-4134
Appleton, WI 54914 USA Canadian FAX: 920-735-4169
International FAX: 920-735-4125
 Specifications (Subject to change without notice.)
Weld Max. Open-
Welding Output Weld Output Rated at 104˚ F (40˚ C) NEMA Circuit Generator Output Rated Weight
Mode Range Amperage and Voltage Voltage at 104˚ F (40˚ C) Dimensions** Without Fuel***
CC/DC 20 – 750 A 600 A, 44 V, 26.4 kW, 40% Duty Cycle 95 Peak: 5500 watts H: 43 in Net: 1931 lb
550 A, 42 V, 23.1 kW, 60% Duty Cycle Continuous: 4000 watts, (1092 mm) (876 kg)
500 A, 40 V, 20 kW, 100% Duty Cycle 120/240 VAC, 34/17 A, 60 Hz W: 28-1/2 in Ship: 1982 lb
while welding (724 mm) (899 kg)
CV/DC 14 – 40 V 500 A, 40 V, 20 kW, 100% Duty Cycle 56
Optional kW D: 67-1/2 in
CC/AC* 20 – 575 A 400 A, 36 V, 14.4 kW 100% Duty Cycle 64 Deluxe Model
3-phase, 20 kW, 36 A, 240 VAC (1715 mm)
Net: 1956 lb
Battery* 12/24 V 750 A, 12 V, Jump-Start 14/28 1-phase, 12 kW, 50 A, (887 kg)
Charge 750 A, 24 V, Jump-Start 120/240 VAC while not welding
Ship: 2007 lb
Jump-Start
(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 Oil Automatic Engine
Engine Brand Features HP Type Speeds Fuel Capacity Capacity Shutdowns
EPA certified, turbocharged direct-injected, 64 Four-cylinder, 1850 Run 25 gal (95 L) 11 qt Oil pressure
liquid-cooled (oil) engine. Right side service industrial, liquid- 1235 Idle (10.4 L) Oil temperature
access with 500 hr intervals for oil and filters. cooled engine
Deutz, BF4M MSHA approved with purchase of certificate
2011 Diesel from Deutz dealer.

Air Compressor
Free Air Free Air Working Automatic
Compressor Delivery at Delivery at Pressure Duty Oil Compressor
Brand Features 1850 RPM 1235 RPM Constant Cycle Capacity Shutdowns
Rotary screw with electric clutch for on/off. 60 cfm 40 cfm 100 psig 100% 5 qt (4.7 L) Oil temperature
Oil change intervals 500 hrs (same as engine). (1.70 m3/min) (1.13 m3/min) 7 bar
Ingersoll-Rand
Life expectancy 30,000 hrs. Idle
CE55 G1

Control Panel
1 10 1. AC/DC Voltmeter* 12. Engine Coolant Temperature Gauge
11 2. AC/DC Ammeter* 13. Fuel Gauge
BiG Blue Air Pak
3. Amperage Range Switch 14. Battery Voltmeter
® ™

Welder • Air Compressor • Generator

12
2 13 4. Amperage/Voltage Adjust Control 15. Air Compressor Pressure Gauge
14 5. Amperage/Voltage Adjust Switch 16. Air Compressor On/Off Switch
3 15 and Remote Amperage/Voltage 17. Starting Aid Switch*
Adjust 14-Pin Receptacle 18. Engine Control Switch
16
4 6. Process/Contactor 19. 20 kW, 3-Phase Generator*
Selector Switch 20. Strain Relief*
5 17 7. 120 VAC, 20 A GFCI 21. 50 A, 3-Phase Circuit Breaker*
6 18 Duplex Receptacle
22. 50 A, 1-Phase 120/240 V
8. 240 VAC, 30 A TwistLock Receptacle (NEMA 14-50)*
19 Receptacle (NEMA L6-30)
7 23. AC/DC/Battery Charge/
20 9. Air Outlet Valve 3/4 in NPT Jump-Start Switch*
21 10. Engine Oil Pressure Gauge 24. International Model – 240 VAC,
8 22 11. Engine Hour Meter 16 A Pin and Sleeve Receptacle
*On Select Models
International Model
23

7 24
9

2
 Performance Data
FUEL CONSUMPTION CURVE GENERATOR POWER CURVE OPTION
3.00 280 The Vault
2.75
2.50
12 kW The ultimate in
WELD AND AIR 260 1-PHASE
2.25
2.00
control board
US Gal./Hr.

AC VOLTS
1.75
1.50
240
reliability. Designed
WELD ONLY 20 kW
1.25 220 3-PHASE and built to operate
1.00
0.75
200
in the harshest
0.50
0.25
IDLE IDLE WITH AIR conditions with a 99.7% reliability rating.
0.00 180
0 50 100 150 200 250 300 350 400 450 500 550 600 0 10 20 30 40 50 60 70 This rugged solid-state control has sealed
DC WELD AMPERES AT 100% DUTY CYCLE AC AMPERES
connections made through watertight plugs
AIR SUPPLY CURVE VOLT/AMP CURVE – STICK MODE that make this component impenetrable to
100
140 dust, moisture and corrosion.
120 300–Max
80
100 185–525
125–400
IR Screw

DC VOLTS
60
PSI

80
IDLE
55–125
Compressor
60 40
40
Belt-driven
20
20 compressor with
0 0 an electric clutch
0 10 20 30 40 50 60 70 0 100 200 300 400 500 600 700 800 900 1000
CFM DC AMPERES allowing the
compressor to
VOLT/AMP CURVE – MIG MODE VOLT/AMP CURVE – DC TIG MODE
100 100 be turned off if not needed. An automatic
60–450
90
80 80
40–330 belt tensioner provides proper belt tension
30–220
70 20–110 even after years of service. The compressor
DC VOLTS

60 60
DC VOLTS

50
MAX is protected by a high-temperature
40 40 shutdown switch.
30
20 20
MIN
10 Toolless
0 0
0 100 200 300 400 500 600 700 800 900 1000 0 100 200 300 400 500 600 Generator
DC AMPERES
DC AMPERES
Brushes
VOLT/AMP CURVE – AC TIG MODE BATTERY CHARGE OUTPUT 100% copper-
100 50
45 wound
80 40
35 generator
AC VOLTS

DC VOLTS

60 30
25
features quick
40 20 and easy brush and slip ring inspection.
15
20 10 Brushes can be removed and/or replaced
5
0 0 in a matter of seconds.
0 100 200 300 400 500 600 700 0 100 200 300 400 500 600 700 800 900 1000
AC AMPERES DC AMPS

Genuine Miller Accessories

AC/DC/Battery Charge/Jump-Start Switch Vandalism
#195 148 Field Lockout Kit
AC TIG welding and 12/24 V battery charge/ #195 118 Field
jump-starting system. Lockable hinged
Lockable Fuel Cap Flame Arrestor Kit steel panels cover
#043 947 Field and protect name
Fuel cap can be padlocked to prevent plate gauges and
vandalism. A built in flame arrestor prevents ignition switch
Desiccant Air Dryer System #195 117 (padlock included).
flames or sparks from entering the fuel tank.
A regenerating inline air dryer system Also includes engine
Cold Weather Starting Aids* that eliminates moisture in the air stream compartment door
#043 959 Field 12 V intake manifold heater. to prevent air tool freeze-ups in cold lock and key.
#195 086 Field 120 V oil pan heater element. climates. Internal thermostat and heating
*Note: for extreme cold weather both starting aids elements insure good air quality in all Battery Lockout/Tagout
can be used in conjunction. climates. The system can be mounted on Disconnect Switch
Weld Ammeter and Voltmeter the side of the machine or remotely for #195 120 Field
#195 131 Field truck mount installations. Lockable battery
Panel-mounted AC/DC analog meters to disconnect switch for safe
monitor weld output. routine maintenance.
3
 Ordering Information
Equipment and Factory Options Stock No. Description Qty. Price
Big Blue Air Pak CC/CV Base Model
® ™ #907 062 Automatic Idle, Engine Gauges, 5.5 kW AC Generator
International Model #907 062-01-1 50/60 Hz, Dry Battery, Automatic Idle, Engine Gauges, 5.5 kW AC Generator
Cold Weather Model #907 062-04-1 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
Deluxe Model #907 062-07-1 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
Field Kit Accessories
Weld Ammeter and Voltmeter Kit #195 131 AC/DC analog weld output meters
Lockable Fuel Cap Flame Arrestor #043 947 Padlock not included
Cold Weather Starting Aids #043 959 12 volt intake manifold heater
#195 086 120 volt oil pan heater
Desiccant Air Dryer System #195 117 Removes moisture from air supply
Vandalism Lockout Kit #195 118 Lockable front control panel and engine compartment
Battery Lockout/Tagout Disconnect Switch #195 120 Allows machine battery to be disconnected and locked
AC/DC/Battery Charge/Jump-Start Switch #195 148 Field
Cable Holder #043 946 Stores up to 200 ft of 2/0 weld cable
Protective Cover #195 160 Will not fit over machine with cable holder attached
Remote Controls
RHC-14 #129 340 Hand control
RFCS-14 #043 554 Foot control
RMLS-14 #129 337 Momentary and maintained contact switch
RCC-14 #151 086 Fingertip control
Extension Cords #043 725 25 ft, 14-pin remote controls/24 VAC wire feeders
#043 726 50 ft, 14-pin remote controls/24 VAC wire feeders
#043 727 75 ft, 14-pin remote controls/24 VAC wire feeders
Stick Accessories
Welding Leads #173 851 2/0, 350 A, 100% Duty Cycle, 50 ft stinger, 50 ft work clamp
#043 952 2/0, 300 A, 100% Duty Cycle, 100 ft stinger, 50 ft work clamp
Wire Feeders
Suitcase 12VS Wire Feeder #194 941 Includes contactor and gas valve.See Lit. Index No. M/6.4
Suitcase 8VS Wire Feeder #194 890 Includes contactor and gas valve.See Lit. Index No. M/6.4
S-32SL Wire Feeder #109 294 See Lit. Index No. M/6.21
Guns and Consumables See Lit. Index No. M/10.0 and M/13.4
TIG Accessories
HF-251D-1 #042 388 High frequency unit for AC TIG welding
Water Coolant System See Lit. Index No. AY/7.2
TIG Torch, Consumables
Trailers and Hitches
OFR-224 Trailer #043 802 Off-road trailer with 2650 lb (1202 kg) capacity includes jack stand,
safety chains and 2 in (50 mm) ball hitch
HWY-224 Trailer #043 805 Highway trailer with 2650 lb (1202 kg) capacity includes jack stand,
safety chains, 2 in (50 mm) ball hitch, fender and lights
HWY-430 Tandem Axle Trailer #043 806 Highway trailer with 3750 lb (1701 kg) capacity.
Hitch must be ordered separately.
4-West Trailer #042 801 Off-road steerable trailer with 2570 (1166 kg) capacity
Lunette Eye #043 824 2-1/2 in (64 mm). For 224 trailers only
#043 863 3 in (76 mm). For 430 trailer only
Ball Hitch #043 864 2 in (51 mm). For 430 trailer only
Clevis #043 823 For 430 trailer only
Cable Tree #043 826 Works on 224 and 430 trailers

Date: Total Quoted Price:

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