Miller Big Blue 800 X Duo Air Pak Owner's Manual
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Miller Big Blue 800 X Duo Air Pak Owner's Manual

Miller Big Blue 800 X Duo Air Pak Owner's Manual

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Big Blue
Air Pak
OWNER'S MANUAL
OM-282374E
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Stick (SMAW) Welding
TIG (GTAW) Welding
Air Carbon Arc (CAC-A) Cutting
and Gouging
800 X Duo
®
®
Deutz
2020-07

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Summary of Contents for Miller Big Blue 800 X Duo Air Pak

  • Page 1 OM-282374E 2020-07 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Stick (SMAW) Welding TIG (GTAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging Big Blue 800 X Duo ® Air Pak ® Deutz OWNER’S MANUAL 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 Symbol Usage .
  • Page 4 TABLE OF CONTENTS 5-16 Weld Output Terminals ....................39 5-17 Connecting To Remote Receptacle .

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

    SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING 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 not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
  • Page 6 HOT PARTS can burn. WELDING can cause fire or explosion. � Do not touch hot parts bare handed. � Allow cooling period before working on equipment. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. �...

  • Page 7: Engine Hazards

    � Never weld on a pressurized cylinder — explosion will result. CYLINDERS can explode if � Use only correct compressed gas cylinders, regulators, hoses, damaged. and fittings designed for the specific application; maintain them Compressed gas cylinders contain gas under high and associated parts in good condition.

  • Page 8: Compressed Air Hazards

    1-4. Compressed Air Hazards � Reinstall doors, panels, covers, or guards when servicing is fin- COMPRESSED AIR EQUIPMENT can ished and before starting unit. injure or kill. � If ANY air is injected into the skin or body seek medical help immediately.
  • Page 9 � Follow the guidelines in the Applications Manual for the Revised HIGH PRESSURE FLUIDS can injure NIOSH Lifting Equation (Publication No. 94-110) when manually or kill. lifting heavy parts or equipment. � Engine fuel system components can be under high OVERHEATING can damage motors.

  • Page 10: California Proposition 65 Warnings

    � To reduce possible interference, keep weld cables as short as ARC WELDING can cause possible, close together, and down low, such as on the floor. interference. � Locate welding operation 100 meters from any sensitive electronic equipment. � Electromagnetic energy can interfere with sensitive electronic equipment such as microprocessors, �...

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

    SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT UTILISATION 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 � N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le- � Ne pas souder dans des endroits situés à proximité d’opérations champ les pièces endommagées. Entretenir l’appareil conformé- de dégraissage, de nettoyage ou de pulvérisation. La chaleur et ment à ce manuel. les rayons de l’arc peuvent réagir en présence de vapeurs et for- mer des gaz hautement toxiques et irritants.

  • Page 13: Dangers Existant En Relation Avec Le Moteur

    � Le soudage effectué sur un plafond, plancher, paroi ou séparation Les CHAMPS peut déclencher un incendie de l’autre côté. ÉLECTROMAGNÉTIQUES (CEM) � Ne pas couper ou souder des jantes ou des roues. Les pneus peu- peuvent affecter les implants vent exploser s’ils sont chauffés.

  • Page 14: Dangers Liés À L'air Comprimé

    � Ne pas faire le plein en fumant ou proche d’une source d’étincelles � Ne pas toucher aux pièces chaudes, utiliser les outils recomman- ou d’une flamme nue. dés et porter des gants de soudage et des vêtements épais pour éviter les brûlures.

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

    MÉTAL CHAUD provenant du Une PRESSION D’AIR RÉSIDUELLE découpage ou du gougeage à l’arc ET DES FLEXIBLES QUI FOUETTENT risque de provoquer un incendie ou risquent de provoquer des une explosion. blessures. � Détendre la pression pneumatique des outils et circuits avant �...
  • Page 16 � Suivre les consignes du Manuel des applications pour l’équation � Ne charger que des batteries plomb-acide. Ne pas utiliser le char- de levage NIOSH révisée (Publication Nº94-110) lors du levage geur de batterie pour alimenter un autre circuit électrique basse manuelle de pièces ou équipements lourds.

  • Page 17: Proposition Californienne 65 Avertissements

    � Effectuer l’installation, l’entretien et toute intervention selon les LE SOUDAGE À L’ARC risque de manuels d’utilisateurs, les normes nationales, provinciales et de provoquer des interférences. l’industrie, ainsi que les codes municipaux. � L’énergie électromagnétique risque de provoquer LE RAYONNEMENT HAUTE des interférences pour l’équipement électronique FRÉQUENCE (H.F.) risque de sensible tel que les ordinateurs et l’équipement...

  • Page 18: Informations Relatives Aux Cem

    2-8. Informations relatives aux CEM 3. Ne pas courber et ne pas entourer les câbles autour de votre Le courant électrique qui traverse tout conducteur génère des corps. champs électromagnétiques (CEM) à certains endroits. Le courant is- su d’un soudage à l’arc (et de procédés connexes, y compris le sou- 4.

  • Page 19: Section 3 - Definitions

    Some symbols are found only on CE products. facility. Some symbols are found only on CE products. Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. Contact your local recycling office or your local distributor for further information. Safe �...
  • Page 20 Turn off power before disassembling torch. � Complete Parts List is available at www.MillerWelds.com Safe19 201 Do not remove or paint over (cover) the label. Do not remove or paint over (cover) the label. Safe20 201 Do not work on unit if engine is running. Stop engine first. Do not work on unit if engine is running.
  • Page 21 Become trained and read the instructions and labels before working on machine. Hot muffler and exhaust pipe can cause severe burns. � Complete Parts List is available at www.MillerWelds.com Safe9 Safe35 2012 05 Hazardous voltage remains on input capacitors after power is turned Hazardous voltage remains on input capacitors after power is turned off.

  • Page 22: Miscellaneous Symbols And Definitions

    Connect green or green/yellow grounding conductor to ground Connect green or green/yellow grounding conductor to ground terminal. terminal. Connect input conductors (L1, L2 And L3) to line terminals. Connect input conductors (L1, L2 And L3) to line terminals. � Complete Parts List is available at www.MillerWelds.com Safe86 2012 06 Safe86 2012 06 Never use generator inside a home or garage, even if doors and win-...
  • Page 23 ne Stop Welding (FCAW) ine Stop Tungsten Inert Gas (TIG) Lift Arc Tungsten Inert � n (Fast) Complete Parts List is available at www.MillerWelds.com Gas (TIG) Lift Arc n (Fast) View Air Carbon Arc Cut- Remote Voltage Hertz ting (CAC-A) Remote Hertz Single Phase...

  • Page 24: Section 4 - Specifications

    Information About Default Weld Parameters And Settings NOTICE – Each welding application is unique. Although certain Miller Electric products are designed to determine and default to certain typical welding parameters and settings based upon specific and relatively limited application variables input by the end user, such default settings are for reference purposes only;...

  • Page 25: Dimensions, Weights, And Operating Angles

    � Complete Parts List is available at www.MillerWelds.com 4-7. Dimensions, Weights, And Operating Angles 1-1. Dimensions, Weights, And Operating Angles Dimensions Height 53.75 in. (1365 mm) to top of exhaust) Width 28.5 in. (724 mm) (mtg. brackets turned in) 30.75 in. (781 mm) Do not exceed tilt angles or engine could (mtg.

  • Page 26: Volt-Ampere Curves

    1-2. Volt-Ampere Curves 1-2. Volt-Ampere Curves � Complete Parts List is available at www.MillerWelds.com 1-2. Volt-Ampere Curves A. Stick Mode A. Stick Mode 4-9. Volt-Ampere Curves A. Stick Mode The volt-ampere curves show the minimum Stick Mode and maximum voltage and amperage output capabilities of the welder/generator.

  • Page 27: Ac Generator Power Curves

    � Complete Parts List is available at www.MillerWelds.com 4-10. AC Generator Power Curves 1-3. AC Generator Power Curves 1-3. AC Generator Power Curves 1-3. AC Generator Power Curves The AC generator power curve shows the Single Phase 4 kW A. Single Phase 4 kW generator power in amperes.

  • Page 28: Fuel Consumption

    � 1-4. Fuel Consumption Complete Parts List is available at www.MillerWelds.com 4-11. Fuel Consumption The curve shows typical fuel use under weld 4.00 or power loads. 3.75 3.50 No Air Output 3.25 3.00 With Air Output 2.75 2.50 2.25 2.00 Dual Weld Mode 1.75 1.50...

  • Page 29: Section 5 - Installation

    � Complete Parts List is available at www.MillerWelds.com SECTION 5 – INSTALLATION 5-1. Installing Welder/Generator Movement And Airflow Clearance 18 in. 18 in. (460 mm) (460 mm) 18 in. 18 in. (460 mm) 18 in. 18 in. (460 mm) (460 mm) (460 mm) 18 in.

  • Page 30: Grounding Generator To Truck Or Trailer Frame

    � Complete Parts List is available at www.MillerWelds.com 5-2. Grounding Generator to Truck or Trailer Frame 1-1. Grounding Generator To Truck Or Trailer Frame GND/PE Bed liners, shipping skids, and 1 Equipment Grounding Terminal (On Always ground generator frame to some running gear insulate the Front Panel) vehicle frame to prevent electric...

  • Page 31: Connecting The Battery

    � Complete Parts List is available at www.MillerWelds.com 5-4. Connecting The Battery 907736 / Ref. 907561 01 2-1. Connecting The Battery 1/2 in. � Never start the engine when the cables Battery is most easily accessed through the NOTICE – Lead acid batteries discharge philips head wrench crescent wrench...

  • Page 32: Using The Battery Disconnect Switch

    � Complete Parts List is available at www.MillerWelds.com 5-5. Using The Battery Disconnect Switch 2-2. Using The Battery Disconnect Switch Stop engine. 1 Battery Disconnect Switch The battery disconnect switch disconnects battery voltage from the circuit. When the switch is turned Off, the front panel controls do not work.

  • Page 33: Engine Prestart Checks

    5-6. Engine Prestart Checks 2-3. Engine Prestart Checks 907763 / 907 634 2 NOTICE – Diesel engines in Miller equip- Engine stops if fuel level is low. � Check all engine fluids daily. ment are meant to operate optimally at mod- erate to rated load.

  • Page 34: Connecting Weld Output Cables

    Complete Parts List available at www.MillerWelds.com � Complete Parts List is available at www.MillerWelds.com 5-7. Connecting Weld Output Cables Stop engine. Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your machine. � Do not place anything between weld cable terminal and copper bar.

  • Page 35: Making Dual Operator Cc Weld Connections With Separate Work Cables (800 Models)

    � Complete Parts List is available at www.MillerWelds.com 5-8. Making Dual Operator CC Weld Connections With Separate Work Cables (800 Models) 258 836 3/4 in. See Selecting Cable Size table for proper For Stick/TIG Direct Current Electrode Neg- Stop engine. philips head wrench crescent wrench...

  • Page 36: Making Dual Operator Cc Weld Connections With Common Work Cable (800 Models)

    � Complete Parts List is available at www.MillerWelds.com 5-9. Making Dual Operator CC Weld Connections With Common Work Cable (800 Models) 258 836 3/4 in. NOTICE – For common work connection, work cable and work jumper cable to Welder Stop engine. ps head wrench crescent wrench...

  • Page 37: Making Dual Operator Cv Weld Connections With Separate Work Cables (800 Models)

    � Complete Parts List is available at www.MillerWelds.com 5-10. Making Dual Operator CV Weld Connections With Separate Work Cables (800 Models) 258 836 3/4 in. See Selecting Cable Size table for proper For MIG and FCAW welding Direct Current Stop engine. philips head wrench crescent wrench...

  • Page 38: Making Dual Operator Cv Weld Connections With Common Work Cable (800 Models)

    � Complete Parts List is available at www.MillerWelds.com 5-11. Making Dual Operator CV Weld Connections With Common Work Cable (800 Models) 258 836 3/4 in. NOTICE – For common work connection, common work cable and work jumper cable Stop engine. ps head wrench crescent wrench...

  • Page 39: Making Dual Operator Cc And Cv Weld Connections With Separate Work Cables (800 Models)

    � Complete Parts List is available at www.MillerWelds.com 5-12. Making Dual Operator CC And CV Weld Connections With Separate Work Cables (800 Models) 258 836 3/4 in. 2 Wire Feeder Cable For MIG and FCAW welding Direct Current Stop engine. philips head wrench crescent wrench...

  • Page 40: Making Dual Operator Cc And Cv Weld Connections With Common Work Cable (800 Models)

    � Complete Parts List is available at www.MillerWelds.com 5-13. Making Dual Operator CC And CV Weld Connections With Common Work Cable (800 Models) Ref. 251 340-A / Ref. 802 292-A 3/4 in. NOTICE – Do not exceed machine duty Connect electrode holder cable to one Posi- Stop engine.

  • Page 41: Making Single Operator Cc Weld Connections (800 Models)

    � Complete Parts List is available at www.MillerWelds.com 5-14. Making Single Operator CC Weld Connections (800 Models) 258 836 3/4 in. to Negative (-) terminals and electrode hold- Stop engine. � philips head wrench crescent wrench Direct Current Electrode Positive er cable to Positive (+) terminals.

  • Page 42: Selecting Cable Sizes

    � Complete Parts List is 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 43: Weld Output Terminals

    � Complete Parts List is available at www.MillerWelds.com 5-16. Weld Output Terminals Weld Output Terminals Turn off power before connecting to weld output terminals. Do not use worn, damaged, under- sized, or repaired cables. 1 Positive (+) Weld Output Terminal 2 Negative (-) Weld Output Terminal 5-17.

  • Page 44: Connecting To The Air Compressor

    � Complete Parts List is available at www.MillerWelds.com 5-18. Connecting To The Air Compressor 907763 Stop engine and release air pres- Be sure valve is in open position when using The air compressor will not start if still under sure before servicing compressor. air compressor.

  • Page 45: Section 6 - Operation

    3-1. Front Panel Controls (See Section NO TAG) � Complete Parts List is available at www.MillerWelds.com SECTION 6 – OPERATION 6-1. Front Panel Controls (See Section 6-2) 907763 / 277078 OM-282374 Page 10 OM-282374 Page 41...

  • Page 46: Description Of Front Panel Controls (See Section 6-1)

    To access Service Menu, push and applied. hold Adjust control for 5 seconds, then 11 In Use Light NOTICE – Diesel engines in Miller equip- release. See Section 6-5 for Service ment are meant to operate optimally at mod- Menu operation. Service Menu will Illuminates when connected to an ArcReach erate to rated load.

  • Page 47: Engine Starting Sequence

    � Complete Parts List is available at www.MillerWelds.com 6-3. Engine Starting Sequence 2-3. Engine Starting Sequence Wait to Start/Preheating Service Reminder Remaining Service Reminder Remaining Engine Oil Engine Oil Compressor Oil Compressor Oil NOTICE – Do not use ether or other starting The Wait to Start display appears when the sequence.

  • Page 48: Process/Contactor Switch

    � Complete Parts List is available at www.MillerWelds.com 6-4. Process/Contactor Switch 1 Process/Contactor Switch Weld output terminals are energized when Process/Contactor switch is in an Electrode Hot position and the en- gine is running. Use switch to select weld process and weld output on/off control (see table below).

  • Page 49: Service Menu

    � Complete Parts List is available at www.MillerWelds.com 6-5. Service Menu 1 Adjust Control/Select Button Press and hold control for 5 seconds, then re- lease to access the Service Menu. Rotate the knob to scroll through the menu items. Press and release the control to access the options and information within each menu item.

  • Page 50: Arc Control Settings

    � Complete Parts List is available at www.MillerWelds.com 6-6. Arc Control Settings � Arc Control is not active when the Process/Contactor switch is in the following positions: Output On: CAC-A (Air Carbon Arc Gouging) Remote ON/OFF: GTAW (Remote TIG) Complete Parts List is available at w Process/Contactor Switch Arc Control Complete Parts List is available at w...

  • Page 51: Dynamic Dig Settings

    Drag electrode across workpiece like striking a match; lift electrode slightly after touching work. If arc goes out electrode was lifted too high. If electrode sticks to workpiece, use a quick twist to free it. � Miller recommends Hobart filler metals. OM-282374 Page 47...

  • Page 52: Lift-Arc™ Tig With Auto-Stop™ And Auto-Crater

    Remote control is not needed when us- ing Auto-Crater. 1. While welding. 2. Lift torch slightly to start Auto-Crater end (current is reduced). 3. Lower torch. Weld current ramps down. 4. Shielding gas continues until shut off. � Miller recommends Hobart filler metals. OM-282374 Page 48...

  • Page 53: Remote Voltage/Amperage Control

    � Complete Parts List is available at www.MillerWelds.com 6-10. Remote Voltage/Amperage Control Complete Parts List available at www.MillerWelds.com 1-1. Voltage/Amperage Control With 14-Pin Remote Accessory 277078 Remote Receptacle Connect optional remote control to 1 Remote Receptacle receptacle. Connect optional remote control to recep- When a remote control is con- Big Blue 800 Duo Air Pak shown.

  • Page 54: Updating Software

    � 3-3. Updating Software Complete Parts List is available at www.MillerWelds.com 6-11. Updating Software When the machine has powered up, if valid During the download, the left meter display Obtain the latest firmware to be loaded from files exist on the flash drive, the user is indicates the active download with ALLC, MillerWelds.com prompted to confirm the start of the down-...

  • Page 55: Summary File

    � Complete Parts List is available at www.MillerWelds.com 6-12. Summary File 3-4. Summary File 1 Summary File Each time a USB stick is inserted in the USB receptacle, a summary file is saved to the USB stick as SummaryFile.txt. "USB ACC" will display as the file is written. File is complete when display no longer shows "USB ACC."...

  • Page 56: Fuel/Hour Gauge Descriptions

    � Complete Parts List is available at www.MillerWelds.com 11-25. Fuel/Hour Gauge Descriptions 6-13. Fuel/Hour Gauge Descriptions OM-282374 Page 52...

  • Page 57: Associating Arcreach Devices (Arcreach Models Only)

    � Complete Parts List is available at www.MillerWelds.com 6-14. 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 58: Operating Oil Pan Heater

    � Complete Parts List is available at www.MillerWelds.com 6-15. Operating Oil Pan Heater 1 Oil Pan Heater Plug Use heater to maintain a constant engine oil temperature. To turn on heater, connect heater plug to 120 volts AC receptacle. Heater rated at 300 watts.

  • Page 59: Optional Air Dryer Operation

    � Complete Parts List is available at www.MillerWelds.com 6-16. Optional Air Dryer Operation 3-5. Optional Air Dryer Operation The air dryers blow out (purge) moisture and debris when the air compressor is being used. The air dryer heaters operate when- ever the welder/generator is running.

  • Page 60: Section 7 - Operating Auxiliary Equipment

    � Complete Parts List is available at www.MillerWelds.com SECTION 7 – OPERATING AUXILIARY EQUIPMENT 7-1. Export Auxiliary Power Receptacles Ref. 264 998 CB1 protects RC5 from overload. If supple- CB8 protects GFCI2 and RC2 from over- 1 110 V 16 A AC Receptacle RC1 mentary protector opens, the receptacle load.

  • Page 61: Gfci Receptacle Information, Resetting, And Testing

    � Complete Parts List is available at www.MillerWelds.com 7-2. GFCI Receptacle Information, Resetting, And Testing Use GFCI protection when operating If a ground fault is detected, the GFCI Reset Resetting GFCI Receptacles auxiliary equipment. If unit does not button pops out, and the circuit opens to dis- If a GFCI fault occurs, stop engine and dis- have GFCI receptacles, use GFCI- connect power to the faulty equipment.

  • Page 62: Section 8 - Maintenance

    � Complete Parts List is available at www.MillerWelds.com SECTION 8 – MAINTENANCE SECTION 4 MAINTENANCE 8-1. Maintenance Label 4-1. Maintenance Label NOTICE – The total initial oil fill requires approximately 18 qt (17 L). Service oil fill is 11 qt (10.4 L). Check engine dipstick as filling. Do not OM-282374 Page 16 overfill.

  • Page 63: Routine Maintenance

    WATER have no fuel to feed the engine, and the engine will not start or Hours When servicing a Miller gasoline-powered welder/generator, always perform the following basic stay running. engine checks before contacting the engine manufacturer. Trouble: Fuel level is too high. Symptom: Fuel will plug the fuel FUEL vent and flood the engine.

  • Page 64: Cleaning Unit

    � Complete Parts List is 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 65: Battery Replacement

    � Complete Parts List is available at www.MillerWelds.com allen_wrench allen_set flathead 8-5. Battery Replacement Stop engine. Larger Battery � pliers needlenose knife steelbrush Shown from top of unit. 1 Battery Locator Bracket Mounting Holes Access battery as shown in Section 5-4. Dis- tools/ connect battery.

  • Page 66: Servicing Air Cleaner

    � Complete Parts List is available at www.MillerWelds.com NOTE: This standard is now used for IED/PED models with plastic air cleaner housing. 8-7. Servicing Air Cleaner Stop engine. NOTICE – Do not run engine without air cleaner or with dirty element. Engine dam- age caused by using a damaged element is not covered by the warranty.

  • Page 67: Servicing Fuel And Lubrication Systems

    4-2. Servicing Fuel And Lubrication Systems � Complete Parts List is available at www.MillerWelds.com 8-9. Servicing Fuel And Lubrication Systems Ref. 907763 / Ref. 907 634 2 tools/ Stop engine and let cool. To replace fuel filters: Beware of fire. Do not smoke and flathead philips head wrench...

  • Page 68: Engine/Generator Overload Protection

    � Complete Parts List is available at www.MillerWelds.com 8-10. Engine/Generator Overload Protection 4-3. Engine/Generator Overload Protection 907763 3 Fuse F1 7 Supplementary Protector CB14 Stop engine. 4 Fuse F2 Air dryer overload protection, see Section 6- � When a supplementary protector, cir- cuit breaker or fuse opens, it usually F1 and F2 protect the stator exciter winding indicates a more serious problem ex-...

  • Page 69: Removing Optional Air Dryer For Service

    � Complete Parts List is available at www.MillerWelds.com 1-9. Removing Optional Air Dryer For Service 8-11. Removing Optional Air Dryer For Service � Follow this procedure whenever the air dryer must be removed to gain access to the battery. 1 Air Line 2 Timer Control Cable 3 Air Dryer Heater Plug 4 Solenoid LED...

  • Page 70: Section 9 - Air Compressor Maintenance (Air Pak Models)

    � Complete Parts List is 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 71: Routine Air Compressor Maintenance

    � Complete Parts List is available at www.MillerWelds.com 9-2. Routine Air Compressor Maintenance Stop engine before maintaining. � See Section 8-2 for engine/generator maintenance information. � Service air compressor more often if used in severe conditions. List is available at www.MillerWelds.com �...

  • Page 72: Servicing Air Cleaner

    � Complete Parts List is available at www.MillerWelds.com 9-3. Servicing Air Cleaner Stop engine. NOTICE – Do not run engine without air cleaner or with dirty element. Compressor damage caused by using a damaged ele- ment is not covered by the warranty. 1 Compressor Air Cleaner �...

  • Page 73: Compressor Overload Protection

    � Complete Parts List is 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 prob- lem exists. Contact Factory Authorized Service Agent. � See Section 8-10 for engine/generator overload protection.

  • Page 74: Servicing Air Compressor

    � Complete Parts List is available at www.MillerWelds.com 9-5. Servicing Air Compressor High Full Full 907763 / 255 862-A tools/ 7/8, 15/16 in. Stop engine and let cool. Wait 60 To replace secondary air/oil separator: � philips head wrench crescent wrench Be sure o-rings at oil drain and oil fill fit- seconds for system pressure to tings are in place before reinstalling...

  • Page 75: Adjusting Compressor Air Pressure

    � Complete Parts List is available at www.MillerWelds.com 9-6. Adjusting Compressor Air Pressure Check compressor air pressure using air Air Compressor Assembly Left Side pressure gauge known to be accurate. If necessary, adjust air pressure as follows: 1 Screw Loosen jam nut securing screw. Turn screw clockwise (increase pressure) or counter- clockwise (decrease) until pressure is 125 psi (862 kPa).

  • Page 76: Section 10 - Troubleshooting

    � Complete Parts List is available at www.MillerWelds.com SECTION 10 – TROUBLESHOOTING 10-1. Voltmeter/Ammeter Error Displays 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. �...

  • Page 77: Troubleshooting

    � Complete Parts List is available at www.MillerWelds.com 10-2. Troubleshooting � Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 10-1). Also see Engine Information Display to assist in troubleshooting engine related problems (see Section 13). A.
  • Page 78 � Complete Parts List is available at www.MillerWelds.com B. Standard Generator Power Trouble Remedy No generator power output at AC re- Reset receptacle supplementary protectors. Reset GFCI receptacle. ceptacles; weld output okay. Check fuse F1, and replace if open (see Section 8-10). Have Factory Authorized Service Agent check integrated rectifiers SR1 and SR2, resistor R3, and capacitor C6.
  • Page 79 � Complete Parts List is available at www.MillerWelds.com Trouble Remedy Check engine air and fuel filters (see Sections 8-7 and 8-9). See engine manual. Battery discharges between uses. Turn Engine Control switch off when unit is not running. Clean top of battery with baking soda and water solution; rinse with clear water. Recharge or replace battery if necessary.

  • Page 80: Section 11 - Parts List

    � Complete Parts List is available at www.MillerWelds.com SECTION 11 – PARTS LIST 11-1. Recommended Spare Parts Item No. Dia. Mkgs. Part No. Description Quantity 284184 USB Flash Drive F1, F2 085874 Fuse, Mintr Cer Slo-blo 10. Amp 250 Volt 190823 Brush, Contact Elect .250 X .500 X 1.250 Grd Ay 192939...
  • Page 81 OM-282374 Page 77...

  • Page 82: Section 12 - Electrical Diagrams

    SECTION 12 – ELECTRICAL DIAGRAMS Figure 12-1. Circuit Diagram For Welder/Generator OM-282374 Page 78...
  • Page 83 281933-C OM-282374 Page 79...

  • Page 84: Section 13 - Engine Information Display

    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 1 Engine Information Display 2 Engine Control Switch 3 Function Buttons 4 Yellow LED 5 Red LED...
  • Page 85 13-3. RPM Signal Failed Display 1 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 condition exists for 30 minutes or longer, the RPM signal failed message appears.
  • Page 86 13-5. 6–Up Display 1-1. 6-Up Display 1-1. 6-Up Display n/min 2 6-Up Display With Air Compressor Pres- 4 Engine Coolant Temperature 1 6-Up Display With Engine RPM sure (Models With Air Compressor) 5 Engine RPM This is the default screen configuration. If 6 Compressor Air Pressure The air compressor must be on and air pres- the operator wants to toggle to the 1-Up Dis-...
  • Page 87 13-7. 1–Up Displays 1-1. 1-Up Displays Machine Hours 15 18 Battery Potential Coolant Temperature Percent Load@RPM Fuel Level Engine Oil 1500 1000 2000 n/min Service Reminders 2500 Engine Speed display, press the Previous function button. To return to the 6-Up Display, press the View To go to the next display, press the Next OM-259 705 Page 1 function button.
  • Page 88 13-8. 1–Up Compressor Displays 1-1. 1-Up Compressor Displays To go 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. �...
  • Page 89 13-9. Fuel Level Warnings � Fuel level warnings are generated by sensors at the fuel tank. All engine warnings that are displayed are gener- ated by the engine controller (see Sec- tions 13-10 and 13-11). 1 6–Up Display 2 1–Up Fuel Level Display 3 Low Fuel Warning The low fuel warning indicator appears and begins to flash when fuel level reaches 10%.
  • Page 90 13-10. Warning Or Shutdown Display 1-1. Warning or Shutdown Display 1 Oil Pressure Display 2 Fault Warning Indicator 45 60 The warning symbol appears on the display when an engine condition approaches a shut- down condition. 3 Fault Shutdown Indicator Oil Pressure The shutdown symbol appears on the display when a severe engine fault can cause...
  • Page 91 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 Au- thorized Service Agent. Description of Fault Tier 3 or Tier 4 Interim Engines Low oil pressure;...
  • Page 92 13-12. Main Menu Access Code 1-2. Main Menu Access Code 1 Access Code Display An access code is required to gain access to ENTER PASSWORD the main menu. This display appears when- ever the Menu/Cancel function button is pressed while in the 1-Up or 6-Up display 0000 2 Access Code (Password) The factory set access code is 1000.
  • Page 93 13-13. Main Menu Options: Resetting Hours At Oil Change 1-1. Main Menu Options Resetting Hours At Oil Change 1 Main Menu 2 Cursor Brightness 3 Scroll Function Buttons Contrast Use scroll function buttons to move cursor. Units English 4 Select Function Button Reminders When the cursor is in desired position, press Select function button to go to sub-menu.
  • Page 94 13-14. Main Menu Options: Brightness, Contrast, And Units Brightness Brightness Contrast Units English Reminders Version Stored Codes Language English Contrast Units English Use scroll function buttons to increase or de- 7 Units Menu Display 1 Main Menu crease display brightness. When desired 2 Cursor percentage is reached, press Select function Use scroll function buttons to scroll through...
  • Page 95 13-15. Main Menu Options: Reminders 1-1. Main Menu Options Reminders Brightness Service Reminder IntervalRemaining Contrast Engine Oil Units English Compressor Oil Reminders Version Stored Codes Language English Change Engine Oil Change Engine Oil 0 0 0 0 0 0 H >...
  • Page 96 13-16. Main Menu Options: OEM, Version, Stored Codes, And Language 1-1. Main Menu Options OEM, Version, Stored Codes, And Language 1 Main Menu 2 Cursor 3 Scroll Function Buttons Use scroll function buttons to move cursor. Brightness 4 Select Function Button Contrast When the cursor is in desired position, press Units...

  • Page 97: Section 14 - Run-In Procedure

    SECTION 14 – RUN-IN PROCEDURE NOTICE – Diesel engines in Miller equipment are meant to operate optimally at moderate to rated load. Using light or no load for extended peri- ods of time may cause wetstacking or other engine damage. Do not idle engine longer than necessary.

  • Page 98: Run-In Procedure Using Load Bank Or Resistance Grid

    14-2. Run-In Procedure Using Load Bank Or Resistance Grid Stop engine. Connect load bank or resistor grid to gener- For Resistance Grid ator Side A weld output terminals using Do not touch hot exhaust pipe, en- Set grid switches and then adjust gener- proper size weld cables with correct connec- gine parts, or load bank/grid.

  • Page 99: Section 15 - Air Compressor Tables

    SECTION 15 – AIR COMPRESSOR TABLES 15-1. Flow Of Free Air (CFM) Through Orifices Of Various Diameters Gauge Orifice Diameter (in.) And Free Air Flow (CFM) Pressure 1/64 1/32 3/64 1/16 3/32 3/16 (psi) 0.027 0.107 0.242 0.430 0.97 1.72 3.86 6.85 0.038...
  • Page 100 15-2. Approximate Air Consumption (Cubic Feet) To Operate Pneumatic Equipment At 70–90 PSIG Percent Use Factor And Compressed Air Consumption (CF) Miscellaneous Portable Tools 9 seconds 15 seconds 21 seconds 1 minute Drill, 1/18” to 3/8” 3.75 6.25 8.75 Drill, 3/8” to 5/16” 5.25 8.75 12.25...

  • Page 101: 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 1 Generator Power Receptacles – Neutral Bonded To Frame 2 3-Prong Plug From Case Grounded Equipment 3 2-Prong Plug From Double Insulated...
  • Page 102 16-3. Grounding When Supplying Building Systems 1 Equipment Grounding Terminal 2 Grounding Cable GND/PE Use #8 AWG or larger insulated copper wire. 3 Ground Device � Use ground device as stated in electri- cal codes. Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wir- ing system.
  • Page 103 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 104 Farm/Home Equipment Rating Starting Watts Running Watts Refrigerator or Freezer 3100 Shallow Well Pump 1/3 HP 2150 1/2 HP 3100 1000 Sump Pump 1/3 HP 2100 1/2 HP 3200 1050 16-7. Approximate Power Requirements For Contractor Equipment Contractor Equipment Rating Starting Watts Running Watts Hand Drill...
  • Page 105 16-8. Power Required To Start Motor 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor Voltage AC MOTOR VOLTS AMPS Step 1: Find code and use table to find kVA/ CODE HP. If code is not listed, multiply running am- PHASE perage by six to find starting amperage.
  • Page 106 16-10. Typical Connections To Standby Power 1. Utility Electrical 2. Transfer Switch 3. Fused Disconnect 4. Welder/Generator Service Switch (If Required) Output 5. Essential Loads Have only qualified persons perform 1 Utility Electrical Service 4 Welder/Generator Output these connections according to all 2 Transfer Switch (Double-Throw) Generator output voltage and wiring must applicable...
  • Page 107 16-11. Selecting Extension Cord (Use Shortest Cord Possible) A. Cord Lengths For 120 Volt Loads Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected extension 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 (Amperes)
  • Page 108 Notes...

  • Page 109: Warranty

    Effective January 1, 2020 (Equipment with a serial number preface of NA or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions Supplied Air Respirator (SAR) Boxes and Panels below, Miller Electric Mfg.
  • Page 110 File a claim for loss or damage during For International Locations Visit shipment. www.MillerWelds.com For assistance in filing or settling claims, con- tact your distributor and/or equipment manu- facturer’s Transportation Department. ORIGINAL INSTRUCTIONS – PRINTED IN USA © Miller Electric Mfg. LLC 2020-07...

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