Issued October 2008 • Index No. ED/10.5
Engine-Driven Welder/
®
™
AC Generator/Air Compressor
Big Blue Air Pak
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
Heavy Industrial Applications
Railroad Maintenance
Weld Output Rated at 104°F (40°C)
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*
Mining Maintenance
Maintenance and Repair Rigs
Processes
Air Compressor 100 PSI, 60 CFM, 100% Duty Cycle
Quick
Specs
Stick (SMAW)
MIG (GMAW)
Generator Output Rated at 104°F (40°C)
5,500 Watts Peak — 4,000 Watts Continuous
20,000 Watts 3-Phase/12,000 Watts 1-Phase
Continuous*
Output Range
Flux Cored (FCAW)
Submerged Arc (SAW)
AC TIG (GTAW)*
DC TIG (GTAW)
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*
Accu-Rated™–Not Inflated
Generator Power
*Deluxe Model Only.
®
turbocharged four-cylinder diesel
engine provides ample power at high altitudes.
The Power of Blue.
Welder/generator/air compressor.
One machine that will do it all. Designed
and built to be the most reliable high-
output system in the world.
NEW! Meter maintenance display
• Hour meter function
• Oil Change interval
Improved!
• 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
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.
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.
An Illinois Tool Works Company
International Headquarters Web Site
Phone: 920-735-4505
1635 West Spencer Street
Appleton, WI 54914 USA
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX: 920-735-4125
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Performance Data
FUEL CONSUMPTION CURVE
GENERATOR POWER CURVE OPTION
280
260
240
220
200
180
3.00
2.75
2.50
12 kW
1-PHASE
WELD AND AIR
2.25
2.00
1.75
1.50
1.25
1.00
0.75
0.50
0.25
0.00
20 kW
3-PHASE
WELD ONLY
IDLE
IDLE WITH AIR
0
50 100 150 200 250 300 350 400 450 500 550 600
DC WELD AMPERES AT 100% DUTY CYCLE
0
10
20
30
40
50
60
70
AC AMPERES
Ingersoll-Rand Rotary Screw Air
Compressor
VOLT/AMP CURVE – STICK MODE
AIR SUPPLY CURVE
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.
100
80
60
40
20
0
140
120
100
80
300–Max
185–525
125–400
55–125
IDLE
60
40
20
0
0
10
20
30
40
50
60
70
0
100 200 300 400 500 600 700 800 900 1000
DC AMPERES
CFM
VOLT/AMP CURVE – MIG MODE
VOLT/AMP CURVE – DC TIG MODE
Toolless
Generator
Brushes
100% copper-
wound
generator
features quick
100
90
80
70
60
50
40
30
20
10
0
100
80
60
40
20
0
60–450
40–330
30–220
20–110
MAX
MIN
and easy brush and slip ring inspection.
Brushes can be removed and/or replaced
in a matter of seconds.
0
100 200 300 400 500 600 700 800 900 1000
DC AMPERES
0
100
200
300
400
500
600
DC AMPERES
BATTERY CHARGE OUTPUT
VOLT/AMP CURVE – AC TIG MODE
50
45
40
35
30
25
20
15
10
5
100
80
60
40
20
0
0
0
100
200
300
400
500
600
700
0
100 200 300 400 500 600 700 800 900 1000
DC AMPS
AC AMPERES
The Vault
Superior Circuit Board Design
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.
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.
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
“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
circuit boards exposed to harsh elements that
can disrupt the machine’s electronics, and
therefore, its operation.
3
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Genuine Miller Accessories
Field Kit Accessories
Cable Holder
#043 946
MIG/Flux Cored Welding
Saddle-bag-style
cable holder.
Convenient wrap-
around storage of
coiled cable for
transportation.
Stores 100 ft of
2/0 cable
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.
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
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 Multi-
Voltage Plug. See Lit. Index No. DC/12.53.
Lockable battery
disconnect switch for safe
routine maintenance.
AC/DC/Battery Charge/Jump-Start Switch
#195 148 Field
AC TIG welding and 12/24 V battery charge/
jump-starting system.
Stick (SMAW) Welding
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
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
entering the fuel tank.
Plasma Cutting
Cold Weather Starting Aids*
#043 959 Field 12 V intake manifold heater.
#195 086 Field 120 V oil pan heater element.
*Note: for extreme cold weather both starting aids
can be used in conjunction.
™
™
SuitCase X-TREME 8VS
Wire Feeder #300 093
Weld Ammeter and Voltmeter
#195 131 Field
Panel-mounted AC/DC analog meters to
monitor weld output.
™
™
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.
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.
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.
Spectrum 2050 #903 777-01-2
See Lit. Index No. PC/7.0.
4
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Genuine Miller Accessories
MIG/Flux Cored Welding (continued)
(continued)
WC-24 Control #137 549
Use with Spoolmatic 30A.
Remote Controls
RHC-14 Hand Control
#129 340
Miniature hand control for
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.
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
RFCS-14 HD Foot
Control #194 744
Heavy-duty foot current
and contactor control.
Includes 20 ft (6 m)
cord and 14-pin plug.
™
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.
RMLS-14 #129 337
®
14-pin plug Momentary- and maintained-
contact rocker switch for contactor control.
Push forward for maintained contact and
back for momentary contact. Includes 20 ft
(6 m) cord.
Dynasty 200 Series
For premium portable AC/DC TIG arc
quality. See Lit. Index No. AD/4.8.
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.
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.
HF-251 Series #042 388
HF-251D-1, 115 VAC
High-frequency arc starter and stabilizer.
See Accessory Lit. Index No. AY/5.0.
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)
Spoolmatic® 30A Spool Gun
#130 831
Air-cooled, 200-amp, 1-lb spool gun for
aluminum MIG. See Lit. Index No. M/1.73.
5
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Trailers and Hitches
(Note: Trailers are shipped unassembled.)
HWY-430 Tandem Axle Trailer #043 806
HWY-224 Trailer #043 805 For highway use.
4 West Four-Wheel Steerable
Off-Road Trailer #042 801
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.)
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.
Note: Trailer is shipped unassembled.
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: Some assembly required.
Note: Trailer is shipped unassembled.
Cable Tree #043 826
Cable Tree #043 826
Provides an area to conveniently wrap weld
cables and extension cords.
Provides an area to conveniently wrap weld
cables and extension cords.
Ball Hitch 2 in (50 mm) #043 864
Lunette Eye 3 in (76 mm) #043 863
Lunette Eye 2-1/2 in (64 mm) #043 824
Trailer Specifications (Subject to change without notice.)
Track (Center Standard Tires
Gross Axle
Weight Rating Weight Rating Payload
Gross Vehicle Net
Height
of Bed
Road
Clearance tires)
8 in 55-1/4 in
to center of
(Standard rating
or P-size rating) Dimensions
Net
Weight
Model
4 West
2000 lb/axle
(907 kg/axle)
3000 lb
(1361 kg)
2570 lb
21-1/4 in
B78-13
Length: 91 in (2311 mm)**
Width: 61-1/4 in (1556 mm)
430 lb
(195 kg)
(1166 kg) (540 mm) (203 mm) (1403 mm)
2650 lb 7-1/2 in 52 in
18-1/2 in
(1202 kg) (470 mm) (191 mm) (1321 mm)
HWY-224 3500 lb
OFR-224 (1588 kg)
2960 lb
(1343 kg)
B78-13B
Length: 122-1/2 in (3112 mm) 355 lb
Width: HWY– 61 in (1549 mm)* (161 kg)
OFR–58-1/2 in (1486 mm)
HWY-430 2200 lb/axle
4280 lb
(1941 kg)
3750 lb
19-1/4 in
8-1/2 in
52 in
B78-13B
Length: 156-1/2 in (3975 mm) 530 lb
(998 kg/axle)
(1701 kg) (489 mm) (216 mm) (1321 mm)
Width: 61 in (1549 mm)*
(240 kg)
*Width at outside of fenders.
**Does not include tongue.
Mounting Specifications
A. 20 in (508 mm)
Height: (to top of exhaust)
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)
33 in (838 mm) (Gas)
34-1/4 in (870 mm) (Diesel)
Width: 20 in (508 mm)
G
4 Holes
B
A
Depth: 45-7/8 in (1164 mm) (Gas)
52-1/2 in (1334 mm) (Diesel)
C
G. 13/32 in (10 mm) diameter
D
E
F
6
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Typical Installations
Stick Electrode
Stick (SMAW) Basic Equipment
Work
Flux Cored Gun
Flux-Cored (FCAW) Basic Equipment
X-TREME 8VS/
X-TREME 12VS
Feeder
™
™
SuitCase X-TREME 8VS
#300 093
™
™
SuitCase X-TREME 12VS #195 500
Work
14-Pin
MIG Gun
MIG (GMAW) Basic Equipment
SuitCase
8RC/12RC
™
SuitCase 8RC
#194 938
#194 940
™
SuitCase 12RC
Work
Aluminum MIG with
Spoolmatic 30A Gun
14-Pin
14-Pin
Aluminum MIG (GMAW) Basic Equipment
WC-24
Spoolmatic® 30A #130 831
WC-24
#137 549
Work
TIG (GTAW) Basic Equipment
TIG
Dynasty® 200 Series
Torch
HF-251D-1
HF-251D-1
#042 388*
*TIG power cable adapter required
Work
Cutting Torch
Plasma Basic Equipment
™
®
Spectrum 375 X-TREME #907 303
Spectrum
™
™
®
Spectrum 375 X-TREME with X-CASE
#907 339
#907 058
#903 777-01-2
®
Spectrum 625
Work
®
Spectrum 2050
7
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Ordering Information
Equipment and Factory Options
Stock No.
#907 062
Description
Qty.
Price
Big Blue® Air Pak™ CC/CV Base Model
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
Lockable Fuel Cap Flame Arrestor
Cold Weather Starting Aids
#195 131
#043 947
#043 959
#195 086
AC/DC analog weld output meters
Padlock not included
12 volt intake manifold heater
120 volt oil pan heater
Desiccant Air Dryer System
Vandalism Lockout Kit
Battery Lockout/Tagout Disconnect Switch
AC/DC/Battery Charge/Jump-Start Switch
Cable Holder
#195 117
#195 118
#195 120
#195 148
#043 946
#195 159
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
Protective Cover
Stick Accessories
Welding Leads
#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
See page 4
Wire Feeders
SuitCase™ X-TREME™ 8VS
SuitCase™ X-TREME™ 12VS
SuitCase™ 8RC
#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
SuitCase™ 12RC
S-32SL Wire Feeder
Spoolmatic® 30A Spool Gun
Guns and Consumables
Requires WC-24 Control. See Lit. Index No. M/1.73
See Lit. Index No. M/10.0 and M/13.4
TIG Accessories
HF-251D-1
Water Coolant System
TIG Torch, Consumables
#042 388
High frequency unit for AC TIG welding
See Lit. Index No. AY/7.2
Remote Controls
RHC-14
RFCS-14 HD
RMLS-14
#129 340
#194 744
#129 337
#151 086
Hand control
Foot control
Momentary and maintained contact switch
Fingertip control
RCC-14
Extension Cords
#122 973
#122 974
#122 975
25 ft (7.6 m)
50 ft (15.2 m)
75 ft (22.9 m)
Trailers and Hitches
HWY-224 Trailer
OFR-224 Trailer
HWY-430 Tandem Axle Trailer
4-West Trailer
#043 805
#043 802
#043 806
#042 801
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
Lunette Eye
#043 824
#043 863
2-1/2 in (64 mm). For 224 trailers only
3 in (76 mm). For 430 trailer only
Ball Hitch
Clevis
Cable Tree
#043 864
#043 823
#043 826
2 in (51 mm). For 430 trailer only
For 430 trailer only
Works on 224 and 430 trailers
Date:
Total Quoted Price:
Distributed by:
Litho in USA
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