Miller Big Blue 800 X Duo Air Pak User Manual

OWNER’S MANUAL
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
For product information,
Owner’s Manual translations,
and more, visit
www.MillerWelds.com
Big Blue
®
800 X Duo
Air Pak
®
Deutz

Miller Big Blue 800 X Duo Air Pak Specifications

General

Model	Big Blue 800 X Duo Air Pak
Engine Power	24.8 HP
Generator Output	12, 000 Watts
Frequency	60 Hz
Fuel Type	Diesel
Air Compressor	Yes
Rated Output	800 A
Max Output	800 A
Air Compressor Output	40 CFM
Duty Cycle	100%
Phase	Single Phase
Type	Diesel Engine Driven Welder/Generator

Summary

From Miller to You

SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING

1-2 Arc Welding Hazards

Hazards related to arc welding processes, including shock, fumes, and rays.

1-3 Engine Hazards

Hazards associated with the engine, such as battery explosion, fuel fires, and moving parts.

1-4 Compressed Air Hazards

Hazards associated with compressed air systems, including equipment failure and pressure risks.

SECTION 4 – SPECIFICATIONS

4-4 Weld, Power, And Engine Specifications

Details on welding output, power generation, and engine performance.

4-8 Duty Cycle And Overheating

Information on how to operate the unit within its limits to prevent overheating.

SECTION 5 – INSTALLATION

5-1 Installing Welder/Generator

Guidelines for physically mounting and securing the welding unit.

5-2 Grounding Generator to Truck or Trailer Frame

Procedures for safely grounding the generator to a vehicle frame.

5-6 Engine Prestart Checks

Essential checks to perform before starting the engine for safe operation.

SECTION 6 – OPERATION

6-1 Front Panel Controls (See Section 6-2)

Overview and identification of controls on the front panel.

6-2 Description Of Front Panel Controls (See Section 6-1)

Detailed explanation of each front panel control's function.

6-3 Engine Starting Sequence

Step-by-step process for starting the engine safely.

SECTION 7 – OPERATING AUXILIARY EQUIPMENT

7-2 GFCI Receptacle Information, Resetting, And Testing

Understanding GFCI protection, how to reset, and test it.

SECTION 8 – MAINTENANCE

8-1 Maintenance Label

Information on the maintenance schedule label.

8-2 Routine Maintenance

Schedule and procedures for regular maintenance tasks.

8-5 Battery Replacement

Steps for safely replacing the unit's battery.

8-7 Servicing Air Cleaner

How to clean or replace the air cleaner element for engine performance.

8-9 Servicing Fuel And Lubrication Systems

Maintenance procedures for the fuel and oil systems.

8-10 Engine/Generator Overload Protection

Understanding the protective devices for the engine and generator.

SECTION 9 – AIR COMPRESSOR MAINTENANCE (AIR PAK MODELS)

9-1 Air Compressor Maintenance Label

Information from the air compressor's maintenance schedule label.

9-2 Routine Air Compressor Maintenance

Schedule and procedures for routine air compressor maintenance.

9-5 Servicing Air Compressor

Maintenance procedures for the air compressor, including oil and filter changes.

9-6 Adjusting Compressor Air Pressure

How to adjust the air pressure output of the compressor.

SECTION 10 – TROUBLESHOOTING

10-1 Voltmeter/Ammeter Error Displays

Interpreting error codes displayed on the voltmeter/ammeter.

10-2 Troubleshooting

General troubleshooting guide for welding and generator issues.

SECTION 11 – PARTS LIST

11-1 Recommended Spare Parts

List of recommended spare parts for routine maintenance and common replacements.

SECTION 12 – ELECTRICAL DIAGRAMS

Figure 12-1. Circuit Diagram For Welder/Generator

Detailed circuit diagram for understanding the electrical system of the welder/generator.

SECTION 13 – ENGINE INFORMATION DISPLAY

13-1 Display Layout And Controls

Overview of the engine information display and its controls.

13-2 Function Buttons

Explanation of how to use the function buttons for navigation and selection.

13-5. 6–Up Display

Description of the default six-value engine information display screen.

13-9. Fuel Level Warnings

Understanding fuel level warnings and their corresponding displays.

13-10. Warning Or Shutdown Display

Information on warning and shutdown indicators and fault displays.

13-11. Engine Diagnostic Display

Accessing and interpreting engine diagnostic codes.

13-13. Main Menu Options: Resetting Hours At Oil Change

Procedure for resetting service hours after an oil change.

SECTION 14 – RUN-IN PROCEDURE

14-1. Wetstacking

Understanding and preventing wetstacking during engine run-in.

14-2. Run-In Procedure Using Load Bank Or Resistance Grid

Steps for performing the engine run-in procedure using load banks or grids.

SECTION 15 – AIR COMPRESSOR TABLES

15-1. Flow Of Free Air (CFM) Through Orifices Of Various Diameters

Table showing airflow based on orifice size and pressure.

SECTION 16 – GENERATOR POWER GUIDELINES

16-1. Selecting Equipment

Guidance on choosing appropriate electrical equipment to connect to the generator.

16-2. Grounding Generator to Truck or Trailer Frame

Procedures for safely grounding the generator when mounted on a vehicle.

16-8. Power Required To Start Motor

Calculating the power needed to start electric motors.

LIMITED WARRANTY

1. 5 Years Parts — 3 Years Labor

Warranty coverage for parts and labor on main power rectifiers.

2. 3 Years — Parts and Labor Unless Specified

Warranty coverage for various components, including engines, with specified exceptions.

Miller’s True Blue® Limited Warranty shall not apply to:

Conditions and exclusions that void the manufacturer's warranty.

For Service

Contact your Distributor for:

Information on services and resources available through your local distributor.