Miller Big Blue 600 Air Pak Owner's Manual
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Miller Big Blue 600 Air Pak Owner's Manual

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Big Blue 600 Air Pak
)
Big Blue 800 Duo Pro
)
Big Blue 800 Duo Air Pak
OM-279640B
2017−10
Processes
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Stick (SMAW) Welding
TIG (GTAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
Description
Engine Driven Welder/Generator And
Air Compressor
)
)
)
File: Engine Drive

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Summary of Contents for Miller Big Blue 600 Air Pak

  • Page 1 TIG (GTAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging Description Engine Driven Welder/Generator And Air Compressor Big Blue 600 Air Pak Big Blue 800 Duo Pro Big Blue 800 Duo Air Pak File: Engine Drive For product information, Owner’s Manual translations, and more, visit www.MillerWelds.com...
  • Page 2 We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING ....... . . 1-1.
  • Page 4 TABLE OF CONTENTS 6-4. Process/Contactor Switch ............. 6-5.

  • Page 5: Section 1 − Safety Precautions − Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2015−09 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury.
  • Page 6 D Be alert that welding sparks and hot materials from welding can FLYING METAL or DIRT can injure easily go through small cracks and openings to adjacent areas. eyes. D Watch for fire, and keep a fire extinguisher nearby. D Welding, chipping, wire brushing, and grinding D Be aware that welding on a ceiling, floor, bulkhead, or partition can cause sparks and flying metal.

  • Page 7: Engine Hazards

    1-3. Engine Hazards EXHAUST SPARKS can cause fire. BATTERY EXPLOSION can injure. D Do not let engine exhaust sparks cause fire. D Always wear a face shield, rubber gloves, and D Use approved engine exhaust spark arrestor in protective clothing when working on a battery. required areas —...

  • Page 8: Additional Symbols For Installation, Operation, And Maintenance

    HOT METAL from air arc cutting and MOVING PARTS can injure. gouging can cause fire or explosion. D Keep away from moving parts such as fans, D Do not cut or gouge near flammables. belts and rotors. D Watch for fire; keep extinguisher nearby. D Keep all doors, panels, covers, and guards closed and securely in place.
  • Page 9 BATTERY CHARGING OUTPUT and BATTERY STATIC (ESD) can damage PC boards. EXPLOSION can injure. D Put on grounded wrist strap BEFORE handling Battery charging not present on all models. boards or parts. D Use proper static-proof bags and boxes to D Always wear a face shield, rubber gloves, and store, move, or ship PC boards.

  • Page 10: California Proposition 65 Warnings

    1-6. California Proposition 65 Warnings For Gasoline Engines: Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc- Health &...

  • Page 11: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 CONSIGNES DE SÉCURITÉ − LIRE AVANT − UTILISATION fre_rom_2015−09 Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
  • Page 12 D Utiliser une protection différentielle lors de l’utilisation d’un équi- LES ACCUMULATIONS DE GAZ pement auxiliaire. Ne pas tester ni réarmer les prises femelles risquent de provoquer des blessures avec différentiel au régime de ralenti/en basse tension: cela ou même la mort. endommagerait le disjoncteur différentiel, qui ne remplirait plus son rôle de protection contre une électrocution causée par un D Fermer l’alimentation du gaz comprimé...

  • Page 13: Dangers Existant En Relation Avec Le Moteur

    D Porter un équipement de protection pour le corps fait d’un matériau Si des BOUTEILLES sont endomma- résistant et ignifuge (cuir, coton robuste, laine). La protection du gées, elles pourront exploser. corps comporte des vêtements sans huile comme par ex. des gants de cuir, une chemise solide, des pantalons sans revers, des chaussures hautes et une casquette.

  • Page 14: Dangers Liés À L'air Comprimé

    D Pour empêcher tout démarrage accidentel pendant les travaux D Toujours vérifier le niveau de liquide de refroidissement dans le d’entretien, débrancher le câble négatif (−) de batterie de la borne. vase d’expansion (si présent), et non dans le radiateur (sauf si pré- cisé...

  • Page 15: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    D Pour rechercher des fuites, utiliser de l’eau savonneuse ou D Ne pas approcher les mains, cheveux, vêtements lâches et outils un détecteur à ultrasons, jamais les mains nues. En cas des organes mobiles. de détection de fuite, ne pas utiliser l’équipement. D Avant d’intervenir sur le circuit d’air comprimé, couper l’alimentation électrique, verrouiller et étiqueter l’appareil, D Remettre les portes, panneaux, recouvrements ou dispositifs...
  • Page 16 D Réduire le courant ou le facteur de marche avant de poursuivre le LA SORTIE DE RECHARGE et L’EXP- soudage. LOSION DE LA BATTERIE peuvent D Ne pas obstruer les passages d’air du poste. provoquer des blessures. LES CHARGES ÉLECTROSTATI- La recharge de batterie n’existe pas sur tous les QUES peuvent endommager les modèles.

  • Page 17: Proposition Californienne 65 Avertissements

    2-6. Proposition californienne 65 Avertissements Pour les moteurs à essence : Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques Les gaz d’échappement des moteurs contiennent des pro- dont l’État de Californie reconnaît qu’ils provoquent des mal- duits chimiques dont l’État de Californie reconnaît qu’ils formations congénitales et, dans certains cas, des cancers.
  • Page 18 OM-279640 Page 14...

  • Page 19: Section 3 − Definitions

    Complete Parts List available at www.MillerWelds.com SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbols And Definitions Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. Safe2 2017−04 Protect yourself from electric shock by insulating yourself from work and ground.
  • Page 20 Complete Parts List available at www.MillerWelds.com Do not work on unit if engine is running. Stop engine first. Safe21 2017−04 Do not smoke while fueling or if near fuel. Safe22 2017−04 Stop engine before fueling. Safe23 2017−04 Do not fuel a hot engine. Safe24 2017−04 Use lift eye to lift unit and properly installed accessories only, not gas cylinders.

  • Page 21: Miscellaneous Symbols And Definitions

    Complete Parts List available at www.MillerWelds.com Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk Become trained and read the instructions before working on the machine or welding. Safe40 2012−05 Engine fuel plus flames or sparks can cause fire. Safe45 2012−05 Remove unit from shipping crate. Remove Owner’s Manual from unit. Follow instructions to install muffler.
  • Page 22 Complete Parts List available at www.MillerWelds.com Protective Earth Engine Duty Cycle (Ground) Engine Start Single Phase Hours (Engine RPM) Engine Off Three Phase Maximum Power (Engine Stop) Consumption 1max Suitable For Welding In An Engine−Driven Idle (Slow) Environment With 3−Phase Increased Risk Of Alternator with Electric Shock...

  • Page 23: Section 4 − Specifications

    CV/DC 15−50 V 100% Duty Cycle 100% Duty Cycle 600A, 44 VDC, CC/DC 20−600A 60% Duty Cycle Big Blue 600 Air Pak — — 575A, 43 VDC, CV/DC 15−50 V 100% Duty Cycle Generator Power Rating Engine Fuel Tank Capacity...

  • Page 24: Dimensions, Weights, And Operating Angles

    Complete Parts List available at www.MillerWelds.com 4-5. Dimensions, Weights, And Operating Angles Dimensions 53.75 in. (1365 mm) Height (to top of exhaust) 28.5 in. (724 mm) (mtg. brackets turned in) Width 31.06 in. (789 mm) (mtg. brackets turned out) Depth 69.5 in.

  • Page 25: Volt-Ampere Curves (800 Models)

    Complete Parts List available at www.MillerWelds.com 4-7. Volt-Ampere Curves (800 Models) The volt-ampere curves show the A. Stick Mode minimum and maximum voltage and amperage output capabilities of the welder/generator. Curves of all other settings fall between the curves shown. Parallel Mode Dual Operator DC AMPERES...

  • Page 26: Volt-Ampere Curves (600 Models)

    Complete Parts List available at www.MillerWelds.com 4-8. Volt-Ampere Curves (600 Models) The volt-ampere curves show the A. Stick Mode minimum and maximum voltage and amperage output capabilities of the welder/generator. Curves of all other settings fall between the curves shown. DC AMPERES B.

  • Page 27: Ac Generator Power Curves

    Complete Parts List available at www.MillerWelds.com 4-9. AC Generator Power Curves The AC power curve shows the generator power in amperes. A. Single Phase 4 kW AC AMPERES B. Single Phase 12 kW AC AMPERES C. Three Phase 20 kW AC AMPERES 259679-B OM-279640 Page 23...

  • Page 28: Fuel Consumption

    Complete Parts List available at www.MillerWelds.com 4-10. Fuel Consumption The curve shows typical fuel use under weld or power loads. 800 Models 4.50 4.25 4.00 3.75 With Air Output 3.50 No Air Output 3.25 3.00 2.75 2.50 2.25 2.00 Dual Weld Mode 1.75 1.50 1.25...

  • Page 29: Section 5 − Installation

    Complete Parts List available at www.MillerWelds.com SECTION 5 − INSTALLATION 5-1. Installing Welder/Generator Airflow Clearance 18 in. Movement (460 mm) 18 in. (460 mm) 18 in. (460 mm) 18 in. 18 in. (460 mm) (460 mm) Location/Mounting Bolting Welding Unit In Unit In Place Place...

  • Page 30: Installing Exhaust Pipe

    Complete Parts List available at www.MillerWelds.com 5-2. Grounding Generator To Truck Or Trailer Frame GND/PE rot_grnd2 2014−11 − 800 652-D Always ground generator frame to frame. Always connect a ground Equipment Grounding Terminal (On vehicle frame to prevent electric wire from the generator equipment Front Panel) shock and static electricity hazards.

  • Page 31: Connecting The Battery

    Complete Parts List available at www.MillerWelds.com 5-4. Connecting The Battery − Tools Needed: 1/2 in. Conn_batt1 2014−11 802 168-E / S-0756-C NOTICE − Lead acid batteries discharge Battery is most easily accessed through Never start the engine when the when stored in any temperature. Units that the rear panel.

  • Page 32: Engine Prestart Checks

    After fueling, check oil with unit on level sur- (see engine maintenance label or en- NOTICE − Diesel engines in Miller equip- face. If oil is not up to full mark on dipstick, ment are meant to operate optimally at mod- add oil (see engine maintenance label).

  • Page 33: Connecting To Weld Output Terminals

    Complete Parts List available at www.MillerWelds.com 5-7. Connecting To Weld Output Terminals Stop engine. Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your ma- chine. Tools Needed: Do not place anything between weld 3/4 in.

  • Page 34: Making Dual Operator Cc Weld Connections W/ Separate Work Cables (800 Models)

    Complete Parts List available at www.MillerWelds.com 5-8. Making Dual Operator CC Weld Connections w/ Separate Work Cables (800 Models) Tools Needed: 3/4 in. Direct Current Electrode Positive (DCEP) connections are shown. Welder A (Left) Side Welder B (Right) Side 258 836 Stop engine.

  • Page 35: Making Dual Operator Mode Cc Weld Connections W/ Common Work Cable (800 Models)

    Complete Parts List available at www.MillerWelds.com 5-9. Making Dual Operator Mode CC Weld Connections w/ Common Work Cable (800 Models) Tools Needed: 3/4 in. Direct Current Electrode Positive (DCEP) connections are shown. Welder A (Left) Side Welder B (Right) Side 258 836 Stop engine.

  • Page 36: Making Dual Operator Cv Weld Connections W/ Separate Work Cables (800 Models)

    Complete Parts List available at www.MillerWelds.com 5-10. Making Dual Operator CV Weld Connections w/ Separate Work Cables (800 Models) Tools Needed: 3/4 in. Direct Current Electrode Positive (DCEP) connections are shown. Welder A (Left) Side Welder B (Right) Side 258 836 Stop engine.

  • Page 37: Making Dual Operator Cv Weld Connections W/ Common Work Cable (800 Models)

    Complete Parts List available at www.MillerWelds.com 5-11. Making Dual Operator CV Weld Connections w/ Common Work Cable (800 Models) Tools Needed: 3/4 in. Direct Current Electrode Positive (DCEP) connections are shown. Welder A (Left) Side Welder B (Right) Side 258 836 Stop engine.

  • Page 38: Making Dual Operator Cc And Cv Weld Connections W/ Separate Work Cables (800 Models)

    Complete Parts List available at www.MillerWelds.com 5-12. Making Dual Operator CC And CV Weld Connections w/ Separate Work Cables (800 Models) Tools Needed: 3/4 in. Direct Current Electrode Positive (DCEP) connections are shown. Welder A (Left) Side Welder B (Right) Side 258 836 Stop engine.

  • Page 39: Making Dual Operator Cc And Cv Weld Connections W/ Common Work Cable (800 Models)

    Complete Parts List available at www.MillerWelds.com 5-13. Making Dual Operator CC And CV Weld Connections w/ Common Work Cable (800 Models) Tools Needed: 3/4 in. Direct Current Electrode Positive (DCEP) connections are shown. Welder A (Left) Side Welder B (Right) Side Ref.

  • Page 40: Making Single Operator Cc Weld Connections (800 Models)

    Complete Parts List available at www.MillerWelds.com 5-14. Making Single Operator CC Weld Connections (800 Models) Direct Current Electrode Positive (DCEP) connections are shown. Welder B (right) Terminals Inactive In Single Operator Mode Welder A (Left) Side Tools Needed: 3/4 in. 258 836 Stop engine.

  • Page 41: Selecting Cable Sizes

    Complete Parts List available at www.MillerWelds.com 5-15. Selecting Cable Sizes* NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable size.

  • Page 42: Connecting To The Air Compressor (Air Pak Models)

    Complete Parts List available at www.MillerWelds.com 5-17. Connecting To The Air Compressor (Air Pak Models) Stop engine and release air pres- sure before servicing compressor. Open Position Closed Position 907752 Air pressure is present at air shutoff Be sure valve is in open position when us- The air compressor will not start if still under valve whenever Engine Display on ing air compressor.

  • Page 43: Section 6 − Operating Welder/Generator

    Complete Parts List available at www.MillerWelds.com SECTION 6 − OPERATING WELDER/GENERATOR 6-1. Front Panel Controls (See Section 6-2) 600 Air Pak Models 258 833-E / 907752 / 907750 OM-279640 Page 39...

  • Page 44: Description Of Front Panel Controls (See Section 6-1)

    To access Service Menu, push and hold Illuminates when in the Service Menu. NOTICE − Diesel engines in Miller equipment Adjust control for 5 seconds, then re- 11 In Use Light are meant to operate optimally at moderate to lease.

  • Page 45: Engine Starting Sequence

    Complete Parts List available at www.MillerWelds.com 6-3. Engine Starting Sequence Wait to Start/Preheating Service Reminder Remaining Remaining Service Reminder Engine Oil Engine Oil Compressor Oil Compressor Oil NOTICE − Do not use ether or other starting To Start: Once this message clears, the engine can fluids.

  • Page 46: Process/Contactor Switch

    Complete Parts List available at www.MillerWelds.com 6-4. Process/Contactor Switch Process/Contactor Switch Weld output terminals are energized when Process/ Contactor switch is in an Electrode Hot position and the engine is running. Use switch to select weld process and weld output on/off control (see table below).

  • Page 47: Service Menu

    Complete Parts List available at www.MillerWelds.com 6-5. Service Menu Adjust Control/Select Button Press and hold control for 5 seconds, then release to access the Service Menu. Rotate the knob to scroll through the menu items. Press and Big Blue 800 Duo Air Pak shown. release the control to access the op- tions and information within each menu item.

  • Page 48: Arc Control Settings

    6-6. Arc Control Settings Arc Control is not active when the Process/Contactor switch is in the following positions: Electrode Hot − CAC-A (Air Carbon Arc Gouging) Remote ON/OFF GTAW (Remote TIG) Miller recommends Hobart filler metals. Process/Contactor Switch Arc Control SOFT Starting point for stainless steel wire (high inductance) (−25 to −1)
  • Page 49 Complete Parts List available at www.MillerWelds.com Process/Contactor Switch Arc Control STOP Auto Crater on (see Section 6-5). More sensitive Auto-Crater (−5 to −1) initiation L (0) Starting point STOP Less sensitive Auto-Crater initiation (1 to 5) SOFT (−25 to −1) L (0) Starting point STIFF...

  • Page 50: Stick Start Procedure − Scratch Start Technique

    Auto-Crater. Arc End With Auto-Crater While welding. Lift torch slightly to start Auto-Crater end (current is reduced). Lower torch. Weld current ramps down. Shielding gas continues until shut off. Miller recommends Hobart filler metals. WM Marketing OM-279640 Page 46...

  • Page 51: Voltage/Amperage Control With 14-Pin Remote Accessory

    Complete Parts List available at www.MillerWelds.com 6-9. Voltage/Amperage Control With 14-Pin Remote Accessory Remote Receptacle Connect optional remote control to receptacle. Big Blue 800 Duo Air Pak shown. When a remote control is con- nected to the Remote recep- tacle, the Auto Remote Sense feature automatically switches voltage/amperage control to the remote control.

  • Page 52: Engine Block Heater Operation

    Complete Parts List available at www.MillerWelds.com 6-10. Engine Block Heater Operation Engine Block Heater Plug Use heater to maintain a constant engine coolant temperature. To turn on heater, connect heater Coolant Heater plug to 120 volts AC receptacle. Specifications Do not run engine while en- ±...

  • Page 53: Updating Software

    Complete Parts List available at www.MillerWelds.com 6-11. Updating Software Big Blue 800 Duo Air Pak shown. Obtain the latest firmware to be loaded When the machine has powered up, if valid During the download, the left meter display from MillerWelds.com. files exist on the flash drive, the user is indicates the active download with ALLC, prompted to confirm the start of the down-...

  • Page 54: Summary File

    Complete Parts List available at www.MillerWelds.com 6-12. Summary File Summary File, Dual Operator Units Summary File, Single Operator Units Each time a USB stick is inserted in the USB receptacle, a summa- ry file is saved to the USB stick as SummaryFile.txt.

  • Page 55: Associating Arcreach Devices (Arcreach Models Only)

    Complete Parts List available at www.MillerWelds.com 6-13. Associating ArcReach Devices (ArcReach Models Only) Stop engine. NOTICE − Do not exceed machine duty cycle. Associating ArcReach Device To Engine Driven Welder/Generator Make connections between welder/generator and ArcReach device. See Owner’s Manual for ArcReach device for typical connection diagrams.

  • Page 56: Optional Air Dryer Operation (Air Pak Models)

    Complete Parts List available at www.MillerWelds.com 6-14. Optional Air Dryer Operation (Air Pak Models) The air dryers blow out (purge) mois- ture and debris when the air compres- sor is being used. The air dryer heaters operate whenever the welder/genera- tor is running.

  • Page 57: Section 7 − Operating Auxiliary Equipment

    Complete Parts List available at www.MillerWelds.com SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. North American Auxiliary Power Receptacles 271 858-B Single-Phase Generator Power erator winding from overload. If CB6 (240 V x 13 A) + (120 V x 7 A) = opens, RC1, RC2, GFCI1 and GFCI2 do 4.0 kVA/kW Use GFCI protection when operat-...

  • Page 58: Gfci Receptacle Information, Resetting And Testing

    Complete Parts List available at www.MillerWelds.com 7-2. GFCI Receptacle Information, Resetting, And Testing Alternate location for red and green indicator LEDs. Orientation of receptacle may be different in other applications. RotGFCI1 2017-10 Use GFCI protection when operat- If a ground fault is detected, the GFCI Reset Resetting GFCI Receptacles ing auxiliary equipment.

  • Page 59: Section 8 − Maintenance

    Complete Parts List available at www.MillerWelds.com SECTION 8 − MAINTENANCE 8-1. Maintenance Label OM-279640 Page 55...

  • Page 60: Cleaning Unit

    Complete Parts List available at www.MillerWelds.com DEUTZ Service: http://www.deutzamericas.com To ensure rapid, efficient service support, you should initially contact your nearest DEUTZ service distributor or dealer. They are staffed with highly qualified parts, service and engine specialists to handle your different needs. The DEUTZ Service Desk enhances this support and can be contacted by completing and submitting the Service Support Form.

  • Page 61: Checking Generator Brushes

    Complete Parts List available at www.MillerWelds.com 8-4. Checking Generator Brushes Stop engine and let cool. Generator Brush Mark and disconnect leads at brush hold- er cap. Remove brushes. Minimum Length: Replace brushes if damaged or if brush 5/8 in. (16 mm) material is at or near minimum length.

  • Page 62: Servicing Air Cleaner

    Complete Parts List available at www.MillerWelds.com 8-6. Servicing Air Cleaner Stop engine. NOTICE − Do not run engine without air cleaner or with dirty element. Engine damage caused by using a damaged ele- ment is not covered by the warranty. The air cleaner primary element can be cleaned but the dirt holding capac- ity of the filter is reduced with each...

  • Page 63: Battery Maintenance

    Complete Parts List available at www.MillerWelds.com 8-7. Battery Maintenance Lead acid batteries discharge when stored in any temperature. Units that are stored should have the battery recharged every three months and before being put into service. To preserve optimum battery performance and life, recharge battery in storage when the open−circuit voltage drops to 12.4 volts DC when measured across the battery terminals.

  • Page 64: Servicing Fuel And Lubrication Systems

    Complete Parts List available at www.MillerWelds.com 8-10. Servicing Fuel And Lubrication Systems Tools Needed: 907752 Stop engine and let cool. To replace fuel filters: To drain sludge from fuel tank: After servicing, start engine and For primary fuel filter, disconnect water sen- check for fuel leaks.

  • Page 65: Engine/Generator Overload Protection

    Complete Parts List available at www.MillerWelds.com 8-11. Engine/Generator Overload Protection 907 535−2 / 803 229 Stop engine. F1 and F2 protect the stator exciter winding Supplementary Protector CB11 from overload. If F1 opens, weld and gen- CB11 protects the 12 volts DC supply to the When a supplementary protector, cir- erator power is low or stops entirely.

  • Page 66: Voltmeter/Ammeter Error Displays

    Complete Parts List available at www.MillerWelds.com 8-12. Voltmeter/Ammeter Error Displays IGBT TEMP Display Example Use the Voltmeter/Ammeter error displays to diagnose and correct fault conditions. When an error is displayed, normally weld output has stopped but generator power output may be okay. To reset error displays, stop unit and then restart.

  • Page 67: Removing Optional Air Dryer For Service

    Complete Parts List available at www.MillerWelds.com 8-13. Removing Optional Air Dryer For Service Follow this procedure whenev- er the air dryer must be re- moved to gain access to the battery. Air Line Timer Control Cable Air Dryer Heater Plug Solenoid LED Disconnect air line from dryer as- sembly bottom inlet.

  • Page 68: Section 9 − Air Compressor Maintenance (Air Pak Models)

    Complete Parts List available at www.MillerWelds.com SECTION 9 − AIR COMPRESSOR MAINTENANCE (AIR PAK MODELS) 9-1. Air Compressor Maintenance Label The air compressor normally requires service at the intervals listed in the maintenance schedule if used in a clean, dry environment. The compressor will require service more often if used in dirty, humid conditions.

  • Page 69: Routine Air Compressor Maintenance

    Complete Parts List available at www.MillerWelds.com 9-2. Routine Air Compressor Maintenance See Section 8 for engine/generator maintenance information. Recycle air compressor fluids. Stop engine before maintaining. Service air compressor more often if used in severe conditions. n = Check Z = Change ~ = Clean l = Replace Reference...

  • Page 70: Servicing Air Cleaner

    Complete Parts List available at www.MillerWelds.com 9-3. Servicing Air Cleaner Stop engine. NOTICE − Do not run air compressor without air cleaner or with dirty element. Compressor damage caused by using a damaged element is not covered by the warranty. Compressor Air Cleaner The air cleaner primary element can be cleaned but the dirt holding capac-...

  • Page 71: Compressor Overload Protection

    Complete Parts List available at www.MillerWelds.com 9-4. Compressor Overload Protection Stop engine. When a circuit breaker or fuse opens, it usually indicates a more serious problem exists. Contact Factory Authorized Service Agent. See Section 8-11 for engine/gener- ator overload protection. Circuit Breaker CB15 Circuit breaker CB15 protects the air compressor clutch.

  • Page 72: Servicing Air Compressor

    Complete Parts List available at www.MillerWelds.com 9-5. Servicing Air Compressor Tools Needed: 7/8, 15/16 in. Air Compressor Assembly Right Side High Full Full 907752 / 255 862-A Stop engine and let cool. Wait 60 sec- To change compressor oil and filter: Add recommended oil until oil level indicator onds for system pressure to drop be- shows system is full (see compressor mainte-...

  • Page 73: Adjusting Compressor Air Pressure

    Complete Parts List available at www.MillerWelds.com 9-6. Adjusting Compressor Air Pressure Check compressor air pressure using air pressure gauge known to be accu- rate. If necessary, adjust air pressure as follows: Tools Needed: Screw 5/16, 3/8 in. Loosen jam nut securing screw. Turn screw clockwise (increase pressure) or counterclockwise (decrease) until pressure is 125 psi (862 kPa).

  • Page 74: Section 10 − Troubleshooting

    Complete Parts List available at www.MillerWelds.com SECTION 10 − TROUBLESHOOTING 10-1. Troubleshooting Also see Voltmeter/Ammeter error displays to assist in troubleshooting weld problems (see Section 8-12). Also see Engine Information Display to assist in troubleshooting engine related problems (see Section 13). A.
  • Page 75 Complete Parts List available at www.MillerWelds.com Trouble Remedy Low CV weld output. Increase Voltage/Amperage Adjust Control setting. Min or max CV weld output only. Check position of Voltage/Amperage Adjust control and Process/Contactor switch. Repair or replace remote control device. Have Factory Authorized Service Agent check Amperage/Voltage Adjust Control and field current regulator board.
  • Page 76 Complete Parts List available at www.MillerWelds.com D. Engine Trouble Remedy Engine will not crank. Supplementary protector CB2 open. Reset CB2. Check fuel level. Check battery connections and tighten if necessary. Check battery, and replace if necessary. Circuit breaker CB10 may be open. CB10 automatically resets when fault is corrected (see Section 8-11). Have Factory Authorized Service Agent check engine wiring harness and components.

  • Page 77: Section 11 − Parts List

    Complete Parts List available at www.MillerWelds.com E. Air Compressor Trouble Remedy Air compressor does not operate; no air Place Air Compressor switch in On position. The air compressor will not start if still under pressure. If pressure at air shutoff valve. compressor is turned off, wait for air pressure to bleed off (about 60 seconds) before turning compressor on again.

  • Page 78: Section 12 − Electrical Diagrams

    SECTION 12 − ELECTRICAL DIAGRAMS Figure 12-1. Circuit Diagram For Big Blue 800 Duo Air Pak Units − Part 1 OM-279640 Page 74...
  • Page 79 279507A OM-279640 Page 75...
  • Page 80 Figure 12-2. Circuit Diagram For Big Blue 800 Duo Air Pak Units − Part 2 OM-279640 Page 76...
  • Page 81 279507A OM-279640 Page 77...
  • Page 82 Figure 12-3. Circuit Diagram For Big Blue 600 Air Pak Units − Part 1 OM-279640 Page 78...
  • Page 83 279641A OM-279640 Page 79...
  • Page 84 Figure 12-4. Circuit Diagram For Big Blue 600 Air Pak Units − Part 2 OM-279640 Page 80...
  • Page 85 279641A OM-279640 Page 81...
  • Page 86 Figure 12-5. Circuit Diagram For Big Blue 800 Duo Pro Units − Part 1 OM-279640 Page 82...
  • Page 87 279508-A OM-279640 Page 83...
  • Page 88 Figure 12-6. Circuit Diagram For Big Blue 800 Duo Pro Units − Part 2 OM-279640 Page 84...
  • Page 89 279508-A OM-279640 Page 85...
  • Page 90 SECTION 13 − ENGINE INFORMATION DISPLAY The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown. 13-1. Display Layout And Controls Engine Information Display Engine Control Switch Function Buttons Yellow LED Red LED The Engine Information Display...
  • Page 91 13-3. RPM Signal Failed Display RPM Signal Failed Display If the operator places the Engine Control switch in the Run/Idle or Run position and does not start the engine, a timer starts. If this condi- tion exists for 30 minutes or longer, the RPM signal failed message ap- pears.
  • Page 92 13-5. 6-Up Display n/min 6-Up Display With Engine RPM 6-Up Display With Air Compressor Engine Coolant Temperature Pressure (Models With Air Engine RPM Compressor) This is the default screen configuration. If Compressor Air Pressure The air compressor must be on and air the operator wants to toggle to the 1-Up Battery Voltage pressure must be available for this display...
  • Page 93 13-7. 1-Up Displays 1-Up Machine Hours Display To go to the next display, press the Next function button. To return to previous display, press the Previ- ous function button. To return to the 6-Up Display, press the View function button. Machine Hours 15 18 Battery Potential...
  • Page 94 13-8. 1-Up Compressor Displays Air Compressor Pressure 1-Up Display To increment to the next display, press the Next function button. To return to previous display, press the Previous function button. To return to the 6-Up Display, press the View function button. Air Pressure display does not appear if the air pressure input is less than 50 PSI.
  • Page 95 13-9. Fuel Level Warnings Fuel level warnings are generat- ed by sensors at the fuel tank. All engine warnings that are dis- played are generated by the en- gine controller (see Sections 13-10 and 13-11). 6-Up Display 1-Up Fuel Level Display Low Fuel Warning The low fuel warning indicator ap- pears and begins to flash when fuel...
  • Page 96 13-10. Warning or Shutdown Display Oil Pressure Display Fault Warning Indicator The warning symbol appears on the display when an engine condition approaches a shutdown condition. 45 60 Fault Shutdown Indicator The shutdown symbol appears on the display when a severe engine fault can cause shutdown.
  • Page 97 Table 13-1. Fault Descriptions This is an abbreviated list of faults. These faults can commonly be remedied by the operator. If other faults appear, contact Factory Authorized Service Agent. Description of Fault Tier 3 or Tier 4 Interim Engines Low oil pressure; warning threshold exceeded High coolant temperature;...
  • Page 98 13-12. Main Menu Access Code Access Code Display An access code is required to gain access to the main menu. This dis- play appears whenever the Menu/ Cancel function button is pressed while in the 1-Up or 6-Up display ENTER PASSWORD Access Code (Password) The factory set access code is 1000.
  • Page 99 13-14. Main Menu Options: Brightness, Contrast, And Units Main Menu Cursor Scroll Function Buttons Use scroll function buttons to move cursor. Select Function Button When the cursor is in desired posi- Brightness " tion, press Select function button to go to sub-menu. Contrast Brightness Menu Display Units...
  • Page 100 13-15. Main Menu Options − Reminders Main Menu Cursor Scroll Function Buttons Use scroll function buttons to move cursor. Select Function Button When the cursor is in desired posi- tion, press Select function button to Brightness go to sub-menu. Contrast Service Reminders Display Units English...
  • Page 101 13-16. Main Menu Options − OEM, Version, Stored Codes, And Language Main Menu Cursor Scroll Function Buttons Use scroll function buttons to move cursor. Select Function Button When the cursor is in desired posi- tion, press Select function button to go to sub-menu.

  • Page 102: Section 14 − Run-In Procedure

    2014−10 NOTICE − Diesel engines in MILLER equipment are meant to operate optimally at moderate to rated load. Using light or no load for extended periods of time may cause wetstacking or other engine damage. Do not idle engine longer than necessary.

  • Page 103: Run-In Procedure Using Load Bank Or Resistance Grid

    14-2. Run-In Procedure Using Load Bank Or Resistance Grid S-0683 / S-0684 Stop engine. Connect load bank or resistor grid to For Resistance Grid generator Side A weld output terminals Set grid switches and then adjust gen- Do not touch hot exhaust pipe, en- using proper size weld cables with correct erator A/V control so load equals rated gine parts, or load bank/grid.

  • Page 104: Section 15 − Air Compressor Tables

    SECTION 15 − AIR COMPRESSOR TABLES 15-1. Flow Of Free Air (CFM) Through Orifices Of Various Diameters Orifice Diameter (in) And Free Air Flow (CFM) Gauge Pressure (psi) 1/64 1/32 3/64 1/16 3/32 3/16 0.027 0.107 0.242 0.430 0.97 1.72 3.86 6.85 0.038...

  • Page 105: Approximate Air Consumption (Cubic Feet) To Operate Pneumatic Equipment At 70-90 P.s.i.g

    15-2. Approximate Air Consumption (Cubic Feet) To Operate Pneumatic Equipment At 70-90 P.S.I.G. Percent Use Factor And Percent Use Factor And MISCELLANEOUS MISCELLANEOUS Compressed Air Consumption (CF) Compressed Air Consumption (CF) PORTABLE PORTABLE TOOLS TOOLS 9 sec 15 sec 21 sec 1 min 9 sec 15 sec...

  • Page 106: Section 16 − Generator Power Guidelines

    SECTION 16 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welder/generators. Your unit may differ from those shown. 16-1. Selecting Equipment Generator Power Receptacles − Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment...
  • Page 107 16-3. Grounding When Supplying Building Systems Equipment Grounding Terminal Grounding Cable Use #8 AWG or larger insulated copper wire. GND/PE Ground Device Use ground device as stated in electrical codes. Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system.
  • Page 108 16-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1/8 HP 1/6 HP 1225 1/4 HP 1600 1/3 HP 2100 1/2 HP 3175 Capacitor Start-Induction Run 1/3 HP 2020 1/2 HP 3075 3/4 HP 4500 1400 1 HP...
  • Page 109 16-7. Approximate Power Requirements For Contractor Equipment Contractor Equipment Rating Starting Watts Running Watts Hand Drill 1/4 in. 3/8 in. 1/2 in. Circular Saw 6-1/2 in. 7-1/4 in. 8-1/4 in. 1400 1400 Table Saw 9 in. 4500 1500 10 in. 6300 1800 Band Saw...
  • Page 110 16-8. Power Required To Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code KVA/HP 10.0 11.2 12.5 14.0 Motor Start Code Running Amperage Motor HP Motor Voltage To find starting amperage: Step 1: Find code and use table to find kVA/HP.
  • Page 111 16-10. Typical Connections To Supply Standby Power Have only qualified persons perform these connections according to all applicable codes and safety practices. Properly install, ground, and operate this equipment ac- cording Owner’s Manual and national, state, and local codes. Customer-supplied equipment is required if generator will sup- ply standby power during Fused...
  • Page 112 16-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected exten- sion cord. Do not use GFCI receptacles to power life support equipment. Maximum Allowable Cord Length In ft (m) for Conductor Size In AWG (mm Current Load (Watts)
  • Page 113 Effective January 1, 2017 (Equipment with a serial number preface of MH or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions below, 6 Months —...
  • Page 114 Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. © ORIGINAL INSTRUCTIONS − PRINTED IN USA 2017 Miller Electric Mfg. Co. 2017−01...

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